CAT M316D Maintenance

MAINTENANCE INTERVALS
Operation and Maintenance

Manual Excerpt
2010 Caterpillar
All Rights Reserved
SEBU8017-05
December 2009
Operation and
Maintenance
Manual
M313D, M315D, M316D, M318D,
M322D, M318D MH and M322D MH
Excavators
W6A1-4999 (Machine)
W3H1-4999 (Machine)
W5M1-4999 (Machine)
W8P1-4999 (Machine)
W8R1-4999 (Machine)
W2S1-4999 (Machine)
W2T1-4999 (Machine)
SAFETY.CAT.COM
312
Maintenance Section
Maintenance Interval Schedule
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i03788193

SMCS Code: 7000
Ensure that all safety information, warnings and
instructions are read and understood before any
operation or any maintenance procedures are
performed.
The user is responsible for the performance of
maintenance, including all adjustments, the use of
proper lubricants, fluids, filters, and the replacement
of components due to normal wear and aging. Failure
to adhere to proper maintenance intervals and
procedures may result in diminished performance of
the product and/or accelerated wear of components.
Use mileage, fuel consumption, service hours, or
calendar time, WHICH EVER OCCURS FIRST,
in order to determine the maintenance intervals.
Products that operate in severe operating conditions
may require more frequent maintenance.
Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be
performed.
The normal oil change interval for the engine is
Every 500 Service Hours or 3 Months. If the engine
is operated under severe conditions, change the
oil after Every 250 Service Hours or 1 Month.
Severe conditions include the following factors: high
temperatures, continuous high loads, and extremely
dusty conditions .
Refer to the results of the SOS oil analysis in order
to determine if the oil change interval should be
decreased to 250 hours. Consult your Caterpillar
Dealer for detailed information regarding the optimum
oil change interval.
Refer to Operation and Maintenance Manual,
Hydraulic System Oil - Change for information on
a 4000 hour maintenance interval for the hydraulic
system.
When Required
Air Conditioner/Cab Heater Filter (Recirculation) Inspect/Replace ................................................ 314
Air Precleaner - Clean ........................................ 314
Air Precleaner - Clean ........................................ 315
Battery - Recycle ................................................ 320
Battery or Battery Cable - Inspect/Replace ........ 320
Bucket Tips - Inspect/Replace ............................ 327
Bucket Tips - Inspect/Replace ............................ 331
Cab Air Filter (Fresh Air) - Clean/Replace .......... 334
Camera - Clean/Adjust ....................................... 335
Cooling System Coolant Extender (ELC) - Add .. 340
Engine Air Filter Primary Element - Clean/

Replace .............................................................
Engine Air Filter Secondary Element - Replace ..
Fan Guard - Clean/Inspect .................................
Fuel System - Prime ...........................................
Fuses - Replace ..................................................
Hydraulic System Oil Filter (Return) - Replace ...
Oil Filter - Inspect ................................................
Radiator Core - Clean .........................................
Refueling Pump Strainer - Clean ........................
Stabilizer - Clean/Inspect ....................................
Window Washer Reservoir - Fill ..........................
Window Wiper - Inspect/Replace ........................
Windows - Clean .................................................
343
345
350
352
356
362
366
366
368
370
375
375
375
Every 10 Service Hours or Daily for First 100

Hours
Boom and Stick Linkage - Lubricate ................... 323
Boom, Stick and Bucket Linkage - Lubricate ...... 324
Every 10 Service Hours or Daily

Cooling System Coolant Level - Check ..............
Engine Oil Level - Check ....................................
Hydraulic System Oil Level - Check ...................
Seat Belt - Inspect ..............................................
341
346
364
369
Every 10 Service Hours or Daily for Machines

Used in Severe Applications
Boom and Stick Linkage - Lubricate ................... 323
Boom, Stick and Bucket Linkage - Lubricate ...... 324
Initial 50 Service Hours

Wheel Nut Torque - Check .................................. 374
Every 50 Service Hours or Weekly

Automatic Lubrication Grease Tank - Fill ............
Boom and Stick Linkage - Lubricate ...................
Boom, Stick and Bucket Linkage - Lubricate ......
Fuel System Water Separator - Drain .................
Fuel Tank Water and Sediment - Drain ...............
Tire Inflation - Check ...........................................
316
323
324
354
356
373
Every 100 Service Hours or 2 Weeks

Axle Oscillation Bearings - Lubricate ..................
Blade Linkage - Lubricate ...................................
Stabilizer Bearings - Lubricate ............................
Swing Bearing - Lubricate ...................................
319
322
370
370
Every 250 Service Hours

Engine Oil Sample - Obtain ................................ 347
Every 250 Service Hours or Monthly

Axle Bearings (Front) - Lubricate ........................ 316
Axle Oil Level (Front) - Check ............................. 318
Axle Oil Level (Rear) - Check ............................. 318
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Belts - Inspect/Adjust/Replace ............................

Braking System - Test .........................................
Condenser (Refrigerant) - Clean ........................
Final Drive Oil Level - Check ..............................
Transmission Oil Level - Check ..........................
Wheel Nut Torque - Check ..................................
313
Maintenance Section
321
326
336
351
374
374
Initial 500 Hours (for New Systems, Refilled

Systems, and Converted Systems)
Cooling System Coolant Sample (Level 2) Obtain ............................................................... 343
Engine Valve Lash - Check ................................. 350

Axle Oil Sample - Obtain ....................................
Axle Oil Sample - Obtain ....................................
Cooling System Coolant Sample (Level 1) Obtain ...............................................................
Engine Crankcase Breather Filter - Replace ......
Engine Oil and Filter - Change ...........................
Final Drive Oil Sample - Obtain ..........................
Fuel System Filter - Replace ..............................
Fuel System Water Separator Element Replace .............................................................
Hydraulic System Oil Sample - Obtain ...............
Transmission Oil Sample - Obtain ......................
319
319
342
345
348
352
352
354
365
374
334
343
355
359

Engine Valve Lash - Check ................................. 350
Every 1000 Service Hours or 6 Months

Battery - Clean .................................................... 320
Battery Hold-Down - Tighten ............................... 320
Overhead Guard - Inspect .................................. 366
Every 1000 Service Hours of Partial Hammer

Use (50% of Service Hours)
Hydraulic System Oil - Change ........................... 359
Every 1500 Service Hours or 1 Year (Greater

than 25% Travel)
Axle Oil (Front) - Change ....................................
Axle Oil (Rear) - Change ....................................
Final Drive Oil - Change .....................................
Transmission Oil - Change .................................
Cooling System Coolant Sample (Level 2) Obtain ...............................................................

Engine Air Filter Primary Element - Clean/
Replace .............................................................
Engine Air Filter Secondary Element - Replace ..
Hydraulic System Oil - Change ...........................
Hydraulic System Oil Filter (Return) - Replace ...
Hydraulic System Oil Filter - Replace .................
Swing Gear - Lubricate .......................................
343
343
345
359
363
364
371
Every 2000 Service Hours or 1 Year (Less

than 25% Travel)
Axle Oil (Front) - Change ....................................
Axle Oil (Rear) - Change ....................................
Final Drive Oil - Change .....................................
Transmission Oil - Change .................................
317
317
351
373
Every 3000 Service Hours or 2 Years

Hydraulic System Oil - Change ........................... 359
Every 3 Years After Date of Installation or

Every 5 Years After Date of Manufacture
Seat Belt - Replace ............................................. 369
Every 6000 Service Hours or 3 Years
Every 500 Service Hours or 3 Months

Cab Riser (Adjustable) Linkage - Lubricate ........
Drive Shaft - Lubricate ........................................
Fuel Tank Cap and Strainer - Clean ...................
Hydraulic Generator Brushes and Commutator Inspect ..............................................................
Every 2000 Service Hours or 1 Year
317
317
351
373
Receiver Dryer (Refrigerant) - Replace .............. 368
Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ........... 337
314
Maintenance Section
Air Conditioner/Cab Heater Filter (Recirculation) - Inspect/Replace
i03769490
Air Conditioner/Cab Heater

Filter (Recirculation) Inspect/Replace
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2. Remove the scavenge hose that is attached to

the box for the air filter.
SMCS Code: 1054-040-A/C; 1054-510-A/C

NOTICE
An air recirculation filter element plugged with dust will
result in decreased performance and service life to the
air conditioner or cab heater.
To prevent decreased performance, clean the filter element, as required.
Illustration 290
g01317122
(1) scavenge hose
3. Remove the three bolts below the battery

compartment.
Illustration 289
g01215821
The air filter is located in the cab behind the

operator's seat.
1. Pull up on the air filter in order to remove the air
filter.
2. Clean the air filter with a maximum of 200 kPa
(30 psi) pressure air.
3. After you clean the filter, inspect the filter. If the
air filter is damaged or badly contaminated, use
a new air filter.
g01317127
(2) Bolt
4. Pull the box for the air filter slightly out of the
battery compartment.
5. Remove the screw in order to disassemble the
Cyclone precleaner block.
6. Remove the cover from the precleaner block.
4. Install the air filter.

i03715681
Air Precleaner - Clean

SMCS Code: 1055-070-DJ
NOTICE
Service the engine air precleaner only with the engine
stopped. Engine damage could result.
1. Open the right front access door.
Illustration 291
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Illustration 292
315
Maintenance Section
g01317146
7. Blow dust and debris out of the Cyclone precleaner

block.
8. Assemble the Cyclone precleaner block and
tighten the screw.
9. Install the box for the air filter into the battery
compartment.
10. Install the three bolts below the battery
compartment.
Illustration 293
g01181958
1. Squeeze the dust valves in order to remove any

dust. Use a suitable container in order to catch
the dust.
11. Attach the scavenge hose to the box for the air
filter.
12. Close the right front access door.
i03731370

(If Equipped)
SMCS Code: 1055-070-DJ
S/N: W6A1-4999
S/N: W8P1-4999
S/N: W8R1-4999
S/N: W2S1-4999
S/N: W2T1-4999
NOTICE
Service the engine air precleaner only with the engine
stopped. Engine damage could result.
Note: The following procedure is necessary only in
extreme conditions.
Illustration 294
g01181961
2. Loosen the clamps at the bottom of the engine

air precleaners.
3. Remove the engine air precleaners and inspect
the opening for dirt and debris. Clean the tubes, if
necessary.
4. Clean the engine air precleaner with pressure air
or wash the engine air precleaner in clean warm
water.
316
Maintenance Section
Automatic Lubrication Grease Tank - Fill
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5. Install the engine air precleaner. Tighten the

clamps.
i03716048
Automatic Lubrication Grease

Tank - Fill
(If Equipped)
SMCS Code: 7540-544; 7540-544-TNK
Caterpillar recommends the use of NLGI No. 2
grease that meets the requirements for both cold
weather conditions and hot weather conditions.
Note: NLGI No. 0 or No. 1 grease with low viscosity
should be used only in cold weather conditions.
If used in conditions other than cold weather, the
grease consumption will increase.
Note: Any foreign materials in the grease tank could
restrict the lubrication lines or damage the valves.
Before adding grease to the tank, be sure to wipe off
the tank fitting and the grease gun nozzle.
Illustration 296
g02003059
Autolub on Standard Wheeled Excavator
Note: When adding grease to the tank, never add

the grease beyond the level approximately 2 cm (0.8
inch) below the top surface of the grease tank. Adding
grease beyond that level would allow the top cover
to come off when the pump is activated. For more
information, refer to Operation and Maintenance
Manual, Capacities (Refill).
The grease level should be checked before starting
to work. If necessary, add grease to the grease tank.
Illustration 297
g01360757
i02713176
Axle Bearings (Front) Lubricate

SMCS Code: 3278-086
The front axle is the axle which steers the machine.
The rear axle is the one with the gearbox.
Illustration 295
Autolub on MH Machine
g02002374
Wipe all grease fittings before you apply grease.
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317
Maintenance Section
Axle Oil (Front) - Change
3. Remove filler plug (1).

4. Remove drain plug (2). Allow the oil to drain into a
suitable container.
Note: Dispose of drained fluids according to local
regulations.
5. Clean drain plug (2).
6. Inspect the O-ring seal. If damage or wear is
found, replace the O-ring seal.
7. Install drain plug (2).
Illustration 298
g01362885
A grease fitting is positioned on the top and on the

bottom of the steering axle. Apply grease to these
fittings at each end of the steering axle.
For access to the U-joints, fully turn the wheels to the
left or to the right. The machine wheels may require
rotation in order to access the grease fittings.
i03715945
8. Add oil through the filler plug opening. Maintain

the oil level to the bottom of the filler plug opening.
Refer to Operation and Maintenance Manual,
Capacities (Refill).
9. Clean filler plug (1).
noticed on the O-ring seal, replace the seal.
11. Install filler plug (1).
Axle Oil (Front) - Change
i02200350
SMCS Code: 3278-044
Axle Oil (Rear) - Change

SMCS Code: 3260-044; 3278-044
Illustration 299
g01111561
Illustration 300
g01111566
(1) Filler Plug. (2) Drain Plug.
(1) Filler plug

(2) Drain plug
1. Operate the machine for an adequate amount of

time in order to warm the oil.
Operate the machine for an adequate amount of time

in order to warm the oil.
2. Remove the dirt that is around filler plug (1) and

around drain plug (2).
Filler plug (1) and drain plug (2) are located under the
machine on the rear axle.
Note: Refer to Operation and Maintenance Manual,

General Hazard Information for information in
containing fluid spillage.
Note: Refer to the Operation and Maintenance

Manual, General Hazard Information for information
in containing fluid spillage.
318
Maintenance Section
Axle Oil Level (Front) - Check
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3. Remove drain plug (2). Drain the oil into a suitable
container.
Note: Dispose of any used oil according to local
regulations.
4. Clean the filler plug.

6. Install the filler plug.
i02529374
Axle Oil Level (Rear) - Check
SMCS Code: 3260-535-FLV; 3278-535



7. Fill the axle with oil to the bottom of the filler
plug opening. See Operation and Maintenance
i02181845
Axle Oil Level (Front) - Check

SMCS Code: 3278-535
Illustration 302
g01103926
1. Remove the dirt that is around the filler plug.

2. Remove the filler plug.

3. Maintain the oil level to the bottom of the filler plug

opening. Add oil through the filler plug opening,
as needed.
Note: The rear axle housing and the final drive
housing for the rear axle share the same oil circuit.
Since the rear axle has a common oil circuit any oil
that is added will be distributed through the entire
circuit.
4. Clean the filler plug.
Illustration 301
g01103917
1. Remove the dirt that is around the filler plug.

2. Remove the filler plug.
3. Maintain the oil level to the bottom of the filler plug
opening. Add oil through the filler plug opening,
as needed.
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319
Maintenance Section
Axle Oil Sample - Obtain
i02182195

(Rear)
SMCS Code: 3260-008; 3278-008; 7542
Obtain an oil sample from the front axle by

removing the filler plug and taking the sample
directly from the axle housing. Refer to Special
Publication, SEBU6250, Caterpillar Machine
Fluids Recommendations, SOS Oil Analysis
for information that pertains to obtaining an oil
sample from the front axle housing. Refer to Special
Publication, PEHP6001, How To Take A Good Oil
Sample for more information about obtaining an oil
sample from the front axle housing.
i02837393
Axle Oscillation Bearings Lubricate

(If Equipped)
SMCS Code: 3268-086-BD; 3278; 3282
Illustration 303
g01103926
Wipe all the grease fittings before you apply grease.
Obtain an oil sample from the rear axle by

directly from the axle housing. Refer to Special
Publication, SEBU6250, Caterpillar Machine
Fluids Recommendations, SOS Oil Analysis
for information that pertains to obtaining an oil
sample from the rear axle housing. Refer to Special
sample from the rear axle housing.
i02182213

(Front)
Illustration 305
A steer axle pin is positioned at the front of the

machine. A grease fitting is positioned on the front of
the steer axle pin. Apply grease to this grease fitting.
SMCS Code: 3260-008; 3278-008; 7542
Illustration 304
g01108690
g01103917
Illustration 306
g00102405
A grease fitting is also positioned on the rear of the

steer axle pin. Apply grease to this grease fitting.
320
Maintenance Section
Battery - Clean
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Remote Grease Fittings (If

Equipped)
Battery - Recycle
Wipe remote grease fittings before you apply grease.
SMCS Code: 1401-561
i00993589
Always recycle a battery. Never discard a battery.

Always return used batteries to one of the following
locations:
A battery supplier
An authorized battery collection facility
Recycling facility
i00934872
Illustration 307
g01360647
The remote grease fittings for the steer axle pin are
located next to the right oscillating axle cylinder.
Apply grease to the remote grease fittings until
grease is visible around the steer axle pin.
Note: If the machine is equipped with a front
attachment, the front and the rear end of the
steer axle pin are lubricated by two remote grease
nipples. If the machine is not equipped with any
front attachment, then only the rear end of the pin is
lubricated by a remote grease nipple.
Battery Hold-Down - Tighten

SMCS Code: 7257
Tighten the hold-downs for the battery in order to
prevent the batteries from moving during machine
operation.
i03731373
Battery or Battery Cable Inspect/Replace

SMCS Code: 1401-510; 1402-510; 1402-510
Personal injury can result from battery fumes or

explosion.
Batteries give off flammable fumes that can explode. Electrolyte is an acid and can cause personal injury if it contacts the skin or eyes.
Illustration 308
g01360649
i00934864
Battery - Clean
SMCS Code: 1401-070
Clean the battery surface with a clean cloth. Keep the
terminals clean and keep the terminals coated with
petroleum jelly. Install the post cover after you coat
the terminal post with petroleum jelly.
Prevent sparks near the batteries. Sparks could

cause vapors to explode. Do not allow jumper cable ends to contact each other or the engine. Improper jumper cable connections can cause an explosion.
Always wear protective glasses when working
with batteries.
1. Turn the engine start switch to the OFF position.
Turn all switches to the OFF position.
2. Turn the battery disconnect switch to the OFF
position. Remove the disconnect switch key.
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321
Maintenance Section
Belts - Inspect/Adjust/Replace
3. Disconnect the battery cable at the battery

disconnect switch. The battery disconnect switch
is connected to the machine frame.
Alternator and Fan Drive Belt

Inspect the Poly V-Belt
Note: Do not allow the disconnected battery cable to

contact the battery disconnect switch.
4. Disconnect the negative battery cable at the
battery that is connected to the battery disconnect
switch.
5. Make all of the necessary repairs or replace the
battery.
6. Connect the negative battery cable at the battery.
7. Connect the negative battery cable at the battery
that is connected to the battery disconnect switch.
8. Connect the battery cable at the battery disconnect
switch.
Illustration 309
g01229454
Illustration 310
g01229884
9. Install the disconnect switch key and turn the

battery disconnect switch to the ON position.
i03717240
Belts - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510;
1358-025; 1358-510; 1359-040; 1359-510;
1361-040; 1361-510; 1397-025; 1397-040;
1397-510; 1405-025; 1405-510; 1802-025;
1802-510
All drive belts are behind the right rear access door.
Your engine is equipped with a fan drive V-belt
that also drives the alternator. The inclusion of an
automatic belt tensioner ensures the correct belt
tension during the life of the belt. For maximum
engine performance and maximum utilization of your
engine, inspect the belt for wear and for cracking.
If equipped, an additional standard belt will drive the
A/C compressor from an adapter pulley on the fan
drive.
If new belts are installed, recheck the belt adjustment
after 30 minutes of operation. If two belts or more are
required for an application, replace the belts in belt
sets. If only one belt of a matched set is replaced, the
new belt will carry more load. This is due to the fact
that the older belts are stretched. The additional load
on the new belt could cause the new belt to break.
1. Stop the engine.

2. Open the right rear access door. Secure the
access door.
3. Inspect the condition of poly V-belt (1).
4. Replace poly V-belt (1) if any of the following
conditions exist: excessive cracking, excessive
wear, and excessive damage.
Replace the Poly V-Belt

1. In order to remove poly V-belt (1), rotate automatic
belt tensioner (2) open.
2. Once automatic belt tensioner (2) has been
rotated, lock the automatic belt tensioner (2) in
place by placing pin (3) into the locking hole.
3. Replace poly V-belt (1).
4. Remove pin (3) from the locking hole and
gradually release automatic belt tensioner (2).
322
Maintenance Section
Blade Linkage - Lubricate
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Air Conditioner Belt
i03717241
NOTICE
An incorrectly tensioned V-belt could cause not only a
decrease of the compressor performance but damage
to the belt and compressor.
1. When you install a new belt, apply 420 + 20 - 10 N
(94 + 4.5 - 2.25 lb) of force.
2. When you reinstall a used belt after inspection,
apply325 10 N (73 2.25 lb) of force.
Blade Linkage - Lubricate

(If Equipped)
SMCS Code: 6060-086-KL
Note: Caterpillar recommends the use of 5%
molybdenum grease for lubricating the blade linkage.
Refer to Special Publication, SEBU6250, Lubricating
Grease for more information on the Molybdenum
Grease.
Wipe all fittings before lubricating.
1. Lower the dozer blade.
Illustration 312
g00103933
2. Raise the access cover.

Illustration 311
g01230234
(4) Mounting bolt

(5) Bracket bolt
3. If the belt tension is not correct, loosen mounting

bolt (4) and bracket bolt (5). Move the compressor
in order to attain the correct adjustment.
Note: The used belt should not need to be
tightened again. If the belt loses tension below
325 10 N (73 2.25 lb), tighten the belt again.
Make sure that the bracket bolt and the mounting bolt
are tightened correctly.
4. Tighten bracket bolt (5) and mounting bolt (4).
Illustration 313
g00103934
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323
Maintenance Section
Boom and Stick Linkage - Lubricate
4. Close the access cover (the MH dozer blade does

not have a cover).
Illustration 314
g00103935
Remote Grease Pins for the Parallel Blade

Illustration 317
g01063444
Remote grease pin for the parallel dozer blade
Note: The remote grease nipple for the radial dozer

blade is in the middle of the access cover.
Note: The arrows on Illustrations 312 through 315
show grease points without grease lines. All dozer
blades are equipped with a remote grease fitting.
Only the dozer blades on the Material Handler
machines do not offer a remote grease fitting (refer
to illustration 316).
Illustration 315
g01360718
Remote Grease Pins for the Radial Blade
i02519869
Boom and Stick Linkage Lubricate

SMCS Code: 6501-086; 6502-086
S/N: W8R1-4999
S/N: W2T1-4999
Caterpillar recommends the use of 5% molybdenum
grease. Refer to Special Publication, SEBU6250,
Caterpillar Machine Fluids Recommendations for
more information on molybdenum grease.
Note: For some applications of the machine, the
repeated duty cycle of the front linkage may only
require small angular movements of the boom or
stick. There might not be enough angular motion in
order to distribute the grease between the pin and
the bearing. The operator should operate the boom,
the stick and the work tool in order to distribute the
grease within the joint assemblies.
Illustration 316
g01360720
Grease Pins for the MH Blade
Service a new machine after Every 10 Service Hours

only within the initial 100 service hours.
3. Apply lubricant through the one remote grease

fitting, or the individual fittings on the MH dozer
blade.
After the initial 100 service hours of operation, service

the boom, the stick, and the work tool linkage after
Every 50 Service Hours.
324
Maintenance Section
Boom, Stick and Bucket Linkage - Lubricate
SEBU8017-05
Note: If the machine is operated under severe

conditions that might cause abrasive material to
enter the bearings, service the linkage after Every
10 Service Hours.
1. Wipe all fittings before you apply lubricant.
Use Steps 1.a through 1.c to ensure proper
lubrication:
a. Lower the boom and the work tool to the
ground.
3. Apply lubricant through fittings (2).

i02863963
Boom, Stick and Bucket

Linkage - Lubricate
(If Equipped)
SMCS Code: 6501-086; 6502-086; 6513-086
S/N: W6A1-4999
b. Apply a slight downward pressure on the work

tool.
S/N: W3H1-4999
c. Apply grease through the grease fitting.
S/N: W8P1-4999
S/N: W5M1-4999
S/N: W2S1-4999
Note: Caterpillar recommends the use of 5%
molybdenum grease for lubricating the boom,
stick and bucket control linkage. Refer to Special
Publication, SEBU6250, Lubricating Grease for
more information on Molybdenum Grease.
Service a new machine after Every 10 Service Hours
only within the initial 100 service hours.
Illustration 318
g01109002
Note: If the machine is operated under severe

conditions that might cause abrasive material to
enter the bearings, service the linkage after Every
10 Service Hours.
(1) Fitting
2. Apply lubricant through fitting (1).

Note: This fitting supplies grease to all other bearings
except the bearings on the stick end through a
distribution valve. The distribution valve is designed
to give the proper amount of grease to all bearings. If
the distribution valve will not accept grease, one of
the lines is blocked.
Illustration 319
(2) Fittings
After the initial 100 service hours of operation, service

the boom, the stick, and the work tool linkage after
Every 50 Service Hours.
g01109000
1. Open the access door for the engine compartment

on the right side of the machine.
SEBU8017-05
Illustration 320
325
Maintenance Section
Boom, Stick and Bucket Linkage - Lubricate
Illustration 321
g01066936
Illustration 322
g01426604
g00794926
3. Apply lubricant through the lowest grease fitting

that is located in the engine compartment.
Note: This fitting supplies grease to all linkage
bearings from the frame to the nose of the boom.
The valve is designed to give the proper amount of
grease to all bearings. If the valve will not accept
grease, one of the lines is blocked.
Use Steps 3.a through 3.d to ensure proper
lubrication.
a. Apply grease through the grease fitting while
the boom is raised and the work tool is
suspended.
b. Lower the boom and the work tool to the
ground.
c. Apply a slight downward pressure on the work
tool.
5. Apply lubricant through the grease fittings.
Ditch Cleaning Bucket (If Equipped)

d. Apply grease through the grease fitting.

4. Lower the boom and the stick to ground level.
Illustration 323
g01066935
326
Maintenance Section
Braking System - Test
SEBU8017-05
2. Apply lubricant through the grease fittings.
Offset Boom (If Equipped)

1. Wipe the remote grease fittings (1) before you
apply lubricant.
The following test determines if the service brakes

are functional. This test is not intended to measure
the maximum brake holding effort. The maximum
brake holding effort that is required to hold a
machine stationary at a certain engine rpm varies
between machines. These differences are caused by
differences in the following factors:
Engine setting
Power train efficiency
Brake holding ability
Other factors
Illustration 324
g01072199
2. Apply lubricant through the remote grease fittings

(1) until grease is visible around pins and bearings.
i03731386
Braking System - Test

Illustration 325
SMCS Code: 4250-081
Service Brake Holding Ability Test
g01361688
(1) Service brake pedal

(2) Travel speed pedal
1. Start the engine. Keep the engine speed at low

idle.
2. Slightly raise all work tools.
Personal injury can result from a sudden stop during brake test.
3. Depress service brake pedal (1).
Make sure the area is clear of personnel and obstructions before testing the brakes. Fasten the
seat belt before moving the machine.
If the machine begins to move during the test, engage
the parking brake immediately.
Make sure that the area around the machine is clear
of personnel and of obstacles.
Test the service brakes on a dry, level surface.
Fasten the seat belt before you test the brakes.
Illustration 326
g01215873
The soft switch panel is located on the right console.

(3) Parking brake control
(4) Transmission control
4. Release the parking brake by pushing down on

the button for the parking brake control (3).
SEBU8017-05
5. Push the button for the transmission control (4)

once in order to select FIRST GEAR. The first
LED light will illuminate.
6. Without releasing the service brake pedal,
depress the front of travel speed pedal (2) to the
FORWARD position. The machine should not
move. Release the travel speed pedal.
327
Maintenance Section
Bucket Tips - Inspect/Replace
i03450548

(Drive-through System)
SMCS Code: 6805-040; 6805-510
S/N: W6A1-4999
7. Engage parking brake (3). This is the end of the

test of the service brakes.
S/N: W3H1-4999
8. Lower all the work tools to the ground.
S/N: W8P1-4999
9. Stop the engine.
S/N: W2S1-4999
NOTICE
If the machine moved while testing the service brakes,
contact your Caterpillar dealer.
S/N: W5M1-4999
Personal injury or death can result from bucket

falling.
Have the dealer inspect and, if necessary, repair the

service brakes before returning the machine to operation.
Block the bucket before changing bucket tips or

side cutters.
Testing the Brake Accumulator
Bucket Tips
1. Move the engine start switch key to the ON

position.
Note: In order to maximize the life of the bucket tip

and the penetration of the bucket tip, the bucket tip
can be rotated.
2. If the accumulator is not at normal operating

pressure, the monitor will display a BRAKE
PRESSURE LOW warning.
3. Start the engine.
4. Run the engine for 30 seconds in order to increase
the accumulator pressure. The warning message
on the monitor should turn off.
5. Stop the engine.
6. While the engine is stopped, turn the engine start
switch to the ON position. Apply the service brakes
for two times. If the warning message on the
monitor comes on, consult your Caterpillar dealer.
Illustration 327
Acceptable wear
g01055179
328
Maintenance Section
Illustration 328
SEBU8017-05
g01055196
Illustration 330
g01054386
Replace this bucket tip.
Internal view
Check the bucket tips for wear. If the bucket tip has a
hole, replace the bucket tip.
1. Use a hammer and a punch in order to drive out

the retainer. The retainer can be removed from
the top of the bucket tip or from the bottom of the
bucket tip.
Removal Procedure
2. Remove the bucket tip from the adapter with a

slight counterclockwise rotation.
Retainer pin, when struck with force, can fly out
and cause injury to nearby people.
Installation Procedure
Make sure the area is clear of people when driving

retainer pins.
1. Clean the adapter, if necessary.
To avoid injury to your eyes, wear protective

glasses when striking a retainer pin.
2. Install the new bucket tip or the rotated bucket tip

onto the adapter with a slight clockwise rotation.
Illustration 331
Illustration 329
g01053737
(1) Bucket tip

(2) Retainer
(3) Adapter
Note: Retainers are often damaged during the

removal process. Caterpillar recommends the
installation of a new retainer when bucket tips are
rotated or replaced.
g01498093
Proper location for installing the retainer
3. The retainer can be installed from the top of the

bucket tip or from the bottom of the bucket tip. Use
a hammer and a 1 inch X 1 inch X 8 inch steel bar
stock in order to drive retainer (2) into adapter (3).
SEBU8017-05
329
Maintenance Section
Side Cutters (If Equipped)
Illustration 332
g01492733
Internal View
Illustration 334
The latch of the retainer is properly seated in the recess of the

bucket tip.
Bucket with side cutters
g01092808
(A) Side cutters
1. Remove the mounting bolts and the side cutters.

2. Clean the mounting surface of the side plate on
the bucket and of the side cutter. Remove any
burrs or protrusions on the mating surfaces.
Illustration 333
g01054753
A properly installed retainer does not extend beyond the ear of

the bucket tip.
4. The retainer is properly seated if the retainer can

be moved slightly by the technician's hand. If the
retainer cannot be moved, adjust the retainer,
as needed. The ends of the retainer should not
extend beyond the ear of the bucket tip.
Illustration 335
g01389435
(4) Side cutter
Note: Some side cutters may be rotated for additional

wear.
3. Install the side cutter.
Note: Certain bolts may require thread compound.
4. Hand tighten the bolts.
330
Maintenance Section
Illustration 336
SEBU8017-05
g01389433
Section B-B From Illustration 335

(4)
(5)
(6)
(7)
Illustration 338
g01389453
(8) Side plate

(9) Retainer
(10) Side protector
(11) Pin
Side cutter
Side plate on a bucket
0.0 mm (0.0 inch)
Shear ledge on a side cutter
5. Make sure that there is not a gap between the

side plate on the bucket and the shear ledge on
the side cutter.
6. Torque the mounting bolts to the correct
specification.
Side Protectors (If Equipped)

Inspect the wear of the side protector. When too
much wear is present, replace the protector.
1. Hit pin (11) from the retainer side of the bucket

in order to remove side protector (10) from side
plate (8).
2. Clean side protector (10), pin (11), retainer (9) and
side plate (8) before installation.
Note: Lateral clearance between the side plate
and the side protector should not exceed 1 mm
(0.04 inch). Shims may be required in order to
decrease the lateral clearance which will decrease
movement. Install the shims between the side plate
and the side protector on the opposite side of the
retainer.
3. Put retainer (9) in side plate (8).
4. Align two pin holes of the new protector and the
side plate. Hit the pin from the side of the bucket
without the retainer.
Note: If the pin and/or the retainer are worn, replace
the pin and/or the retainer.
Illustration 337
g01389452
SEBU8017-05
331
Maintenance Section
i03574842

SMCS Code: 6805-040; 6805-510
S/N: W6A1-4999
S/N: W3H1-4999
S/N: W5M1-4999
S/N: W8P1-4999
S/N: W2S1-4999
Block the bucket before changing the bucket

teeth.
To prevent possible injury to the eyes, wear a protective face shield when striking the pin.
The pin, when struck, can fly out and cause injury
to nearby personnel.
Illustration 340
g01577993
(4) Back of Pin-Master

(5) Extractor
a. Place the Pin-Master on the bucket tip.
Bucket Tips
b. Align extractor (5) with the pin.

c. Strike the Pin-Master at the back of the tool (4)
and remove the pin.
Note: Discard the old pin and the retainer assembly.
When you change tips, use a new pin and a new
retainer assembly. Refer to the appropriate parts
manual for your machine.
Illustration 339
g01577934
(1) Usable tip

(2) Replaceable bucket tip
(3) Overworn tip
Check the bucket tips for wear. If the bucket tip has a
hole, replace the bucket tip.
1. Remove the pin from the bucket tip. The pin can
be removed by one of the following methods.
Use a hammer and a punch from the retainer

side of the bucket to drive out the pin.
Use a Pin-Master. Follow Step 1.a through Step
1.c for the procedure.
Illustration 341
g01577913
(6) Retainer assembly

(7) Adapter
2. Clean the adapter and the pin.

3. Fit retainer assembly (6) into the counterbore that
is in the side of adapter (7). Make sure that the
face of the retainer assembly with the marking
OUTSIDE is visible.
332
Maintenance Section
Illustration 342
SEBU8017-05
g00101359
4. Install the new bucket tip onto the adapter.

Note: The bucket tips can be rotated by 180 degrees
in order to allow the tip to wear evenly. You may also
move the tips from the outside teeth to the inside
teeth. Check the tips often. If wear is present on the
tips, rotate the tips. The outside teeth generate the
most wear.
5. Drive the pin through the bucket tip. The pin can
be installed by using one of the following methods:
Illustration 344
g01578342
b. Place the Pin-Master over the bucket tips so

that the pin will fit into the counterbore of the
pin holder (9).
c. Strike the Pin-Master with a hammer at the
back of the tool (4) in order to insert the pin.
d. Slide pin holder (9) away from the pin and
rotate the tool slightly in order to align pin setter
(10) with the pin.
From the same side of the retainer, drive the pin

through the bucket tip, the retainer assembly,
and the adapter.
Use a Pin-Master. Follow Step 5.a through Step

5.e for the procedure.
Illustration 345
g01209159
Final assembly of pin into bucket tip
e. Strike the end of the tool until the pin is fully

inserted.
Illustration 343
(8) Pin
a. Insert pin (8) through the bucket tip.
g01578233
SEBU8017-05
333
Maintenance Section
Side Cutters
Note: Certain bolts may require thread compound.

4. Hand tighten the bolts.
5. Make sure that there is not a gap between the
side plate on the bucket and the shear ledge on
the side cutter.
6. Torque the mounting bolts to the correct
specification.
Side Protectors (If Equipped)

Inspect the wear of the side protector. When too
much wear is present, replace the protector.
Illustration 346
g01579693
Bucket With Side Cutters
1. Remove the mounting bolts and the side cutters

(11).
2. Clean the mounting surface of the side plate on
the bucket and of the side cutter. Remove any
burrs or protrusions on the mating surfaces.
Illustration 347
g01579713
(12) Shear ledge on a side cutter

(13) Side plate on a bucket
(B) 0.0 mm (0.0 inch)
Note: Some side cutters may be rotated for additional

wear.
3. Install the side cutter.
Illustration 348
g01592996
Illustration 349
g01903678
(14)
(15)
(16)
(17)
(18)
Side plate
Retainer
Side protector
Pin
Shim
334
Maintenance Section
Cab Air Filter (Fresh Air) - Clean/Replace
SEBU8017-05
1. Hit pin (17) from the side of the bucket without

the retainer in order to remove side protector (16)
from side plate (14).
2. Clean side protector (16), pin (17), retainer (15)
and side plate (14) before installation.
Note: Lateral clearance between the side plate
and the side protector should not exceed 1 mm
(0.04 inch). Shims (18) may be required in order to
decrease the lateral clearance which will decrease
movement. Install the shims (18) between the side
plate and the side protector on the opposite side of
the retainer.
Illustration 351
3. Put retainer (15) in side plate (14).

4. Align two pin holes of the new protector and the
side plate. Hit the pin from the retainer side of the
bucket.
Note: If the pin and/or the retainer are worn, replace
the pin and/or the retainer.
i02520019
Cab Air Filter (Fresh Air) Clean/Replace
g01261373
(2) Filter cover

(3) Air filter
2. Remove air filter (3) from filter cover (2).

3. Clean the air filter with a maximum of 200 kPa
(30 psi) pressure air.
4. After you clean the air filter, inspect the air filter.
If the air filter is damaged or badly contaminated,
use a new air filter.
5. Install the air filter and the filter cover.
Note: Make sure that the arrow on top of the air filter
is facing forward.
SMCS Code: 7342-070; 7342-510
i01871602
Cab Riser (Adjustable) Linkage

- Lubricate
(If Equipped)
SMCS Code: 7260-086-KL
S/N: W8R1-4999
S/N: W2T1-4999
Illustration 350
g01261325
(1) Wing bolt

(2) Filter cover
The cab air filter is behind the cab.

1. Loosen wing bolt (1) and open filter cover (2).
Service the linkage after Every 500 Service Hours

while the cab is in the lowered position.
SEBU8017-05
Illustration 352
335
Maintenance Section
Camera - Clean/Adjust
g00349372
2. Apply lubricant through fittings (1) and (2) on both

sides of the linkage.
Illustration 355
g00353312
5. Apply lubricant through fittings (5) on the right side

of the linkage.
i03126933
Camera - Clean/Adjust
SMCS Code: 7348
Illustration 353
g00352012
3. Apply lubricant through fitting (3) on each side of

the linkage.
Failure to use an appropriate external ladder or an

appropriate platform for direct access to the rear
view camera could result in slipping and falling
which could result in personal injury or death. Be
sure to use an appropriate external ladder or an
appropriate platform for direct access to the rear
view camera.
The machine's counterweight and the engine
hood are not approved as a maintenance platforms.
Unexpected machine movement can cause injury

or death.
In order to avoid possible machine movement, move the hydraulic lockout control to the
LOCKED position and attach a Special Instruction, SEHS7332, Do Not Operate or similar
warning tag to the hydraulic lockout control.
Illustration 354
g00349232
4. Apply lubricant through fittings (4) on the left side

of the linkage.
When maintenance or servicing of the rear view

camera is required follow these steps.
1. Park the machine on a level surface.
2. Place the work tool on the level surface.
3. Move the hydraulic lockout control to the Locked
position.
336
Maintenance Section
Condenser (Refrigerant) - Clean
SEBU8017-05
4. Turn the engine start switch to the OFF position

and remove the engine start switch key.
5. Turn the battery disconnect switch to theOFF
position and remove the battery disconnect switch
key.
Clean Camera Lens

If necessary, clean the camera lens before you
operate the machine. Use a soft cloth for cleaning.
Adjust the Area of Visibility

If the camera displays an undesired view, adjust the
area of the visibility.
Illustration 358
g01598234
3. Adjust the area of the visibility of the camera so

that a 1.5 m (5 ft 11 inch) tall obstacle which is 1 m
(3 ft) behind the counterweight can be seen.
4. Tighten the 2 bolts (3) to a torque of 0.5 0.05 Nm
(4 0.4 lb in).
Illustration 356
g01598213
5. Tighten the 2 bolts (2) to a torque of 55 10 Nm

(40 7 lb ft) in order to fix the cover (1).
(1) Cover
(2) Bolt
i02617968
Condenser (Refrigerant) Clean

SMCS Code: 1805-070
NOTICE
If excessively dirty, clean condenser with a brush. To
prevent damage or bending of the fins, do not use a
stiff brush.
Repair the fins if found defective.
Illustration 357
g01598214
(3) Bolt
1. Remove the 2 bolts (2) in order to remove the

cover (1).
2. Unfasten the 2 bolts (3).

access door.
SEBU8017-05
Illustration 359
337
Maintenance Section
Cooling System Coolant (ELC) - Change
g01217572
Door latch for the right front access door
2. Pull the door latch for the right front access

door. The door latch is located in the engine
compartment. This will unlatch the right front
access door.
3. Open the right front access door. Secure the
access door.
Illustration 361
g01217574
a. Loosen bolts (1) in order to release the

condenser.
b. Swing the condenser open.
5. Use clean water to wash off all dust and dirt from
the condenser.
6. Swing the condenser back into position, and
secure the condenser with the bolts (1).
7. Close the access doors.
i02709297
Cooling System Coolant (ELC)

- Change
SMCS Code: 1350-044
Illustration 360
g01217573
4. Inspect the condenser for debris. Clean the

condenser, if necessary.
Note: Open the condenser in order to clean both
sides of the condenser.
NOTICE
Do not change the coolant until you read and understand the cooling system information in Special Publication, SEBU6250, Caterpillar Machine Fluids Recommendations.
Failure to do so could result in damage to the cooling
system components.
338
Maintenance Section
SEBU8017-05
NOTICE
Mixing ELC with other products will reduce the effectiveness of the coolant.
This could result in damage to cooling system components.
If Caterpillar products are not available and commercial products must be used, make sure they
have passed the Caterpillar EC-1 specification for
pre-mixed or concentrate coolants and Caterpillar
Extender.
Illustration 362
Steam or hot coolant can cause severe burns.

Do not loosen the filler cap or the pressure cap on
a hot engine.
g01311235
2. In order to open the top access door for the engine

compartment, the quick locks should be turned
90 degrees counter clockwise. Secure the access
door.
Allow the engine to cool before removing the filler

cap or the pressure cap.
This machine was filled with Extended Life Coolant
at the factory.
If the coolant is dirty or if you observe any foaming
in the cooling system, drain the coolant before the
recommended interval.
If the coolant in the machine is changed to Extended
Life Coolant from another type of coolant, see Special
Publication, SEBU6250, Caterpillar Machine Fluids
Recommendations.
Illustration 363
g01217622
3. Slowly loosen the pressure cap in order to relieve

the system pressure. Remove the pressure cap.
Bodily injury can occur from unexpected contact
with open cab doors on machines equipped with
a fixed cab riser.
To avoid injury, close the cab door before climbing
onto the rear of the machine.
1. Open the left front access door. Secure the access
door.

access door.
SEBU8017-05
339
Maintenance Section
Illustration 366
g01311237
Drain valve
Illustration 364
g01217623
Drain valve
5. There is a cover under the engine compartment.

Remove the cover in order to expose the drain
valve.
9. A drain valve is located at the side of the cylinder

block. Open this drain valve in order to allow
coolant to drain from the internal passages in the
cylinder block.
10. Flush the cooling system with clean water until
the draining water is clean.
11. Close the drain valves. Install the access cover
under the rear center part of the upper frame. Use
two bolts to secure the access cover.
12. Install the drain plug on the engine cylinder block.
regulations.
13. Add the Extended Life Coolant. Refer to the
Operation and Maintenance Manual, Capacities
(Refill) for the capacity of the cooling system.
Note: The maximum fill rate is 6-7 L/min
(1.6-1.9 US gpm).
Illustration 365
g00903010
6. The second drain valve is located under the center

of the rear frame. The access cover is held by
two bolts. Remove the access cover in order to
expose the drain valve.
7. Attach suitable hoses to the drain valves.
8. Open the drain valves, and allow the coolant to
drain into a suitable container.
14. Close the pressure cap and run the engine at

speed dial 1 for 2 to 5 minutes.
15. Stop the engine.
16. Open the pressure cap slowly and carefully.
340
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
SEBU8017-05
NOTICE
Use only Caterpillar products or commercial products
that have passed Caterpillar EC-1 specification for
pre-mixed or concentrated coolants.
Use only Caterpillar Extender with Extended Life
Coolant.
Mixing Extended Life Coolant with other products reduces the Extended Life Coolant service life. Failure to
follow the recommendations can reduce cooling system components life unless appropriate corrective action is performed.
Illustration 367
g01217624
17. Fill up the coolant as required to main coolant

level at the center of the expansion tank gauge.
18. Close the pressure cap and run the engine until
the temperature reaches its normal operating
temperature.
19. Allow the machine to cool down. Check coolant
level again. Fill up coolant if required.
20. Close all access doors and secure all doors.

a fixed cab riser.
door.
i02617987
Cooling System Coolant

Extender (ELC) - Add
SMCS Code: 1352; 1353; 1395
Note: This machine was filled with Caterpillar
Extended Life Coolant at the factory.
When Caterpillar Extended Life Coolant (ELC) is
used, Caterpillar Extender must be added to the
cooling system. See Special Publication, SEBU6250,
Caterpillar Machine Fluids Recommendations for all
the cooling system requirements.
Use an coolant conditioner test kit to check the
concentration of the coolant.
Illustration 368
g01217625
2. Open the top access door for the engine

compartment by turning the quick locks
counterclockwise for 90 degrees. Secure the
access door.
SEBU8017-05
Illustration 369
341
Maintenance Section
Cooling System Coolant Level - Check
g01217622

the system pressure. Remove the pressure cap.
4. You may be required to drain enough coolant from
the radiator in order to allow the addition of the
Caterpillar ELC Extender. If this is necessary, refer
to Operation and Maintenance Manual, Cooling
System Coolant (ELC) - Change for the location
of the radiator drain valves.
Illustration 370
g01217572
Door latch for the right front access door
2. Pull the door latch for the right front access

door. The door latch is located in the engine
compartment. This will unlatch the right front
access door.
3. Open the right front access door. Secure the
access door.

regulations.
5. Add the proper amount of Caterpillar ELC
Extender to the cooling system. Refer to Operation
and Maintenance Manual, Capacities (Refill) and
Operation and Maintenance Manual, Extended
Life Coolant (ELC) for the proper quantity.
6. Replace the pressure cap if the gasket is
damaged. Install the pressure cap. Close the
cover over the pressure cap.
7. Close all access doors.
Illustration 371
i02618000
Cooling System Coolant Level

- Check
SMCS Code: 1350-535
access door.
g01217624
4. Maintain the coolant level to the center of the sight

gauge.
General Hazard Information on containing fluid
spillage.
5. If additional coolant is needed, open the left front
access door. Secure the access door.

a fixed cab riser.
342
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
SEBU8017-05
11. Install the pressure cap. Close the top access

door for the engine compartment.
12. Inspect the radiator core for debris. Clean the
radiator core, as needed. See Operation and
Maintenance Manual, Radiator Core - Clean.
i03717304

Sample (Level 1) - Obtain
Illustration 372
g01217625
6. Open the top access door for the engine

compartment by turning the quick locks by 90
degrees counterclockwise. Secure the access
door.
SMCS Code: 1350-008; 1395-008; 1395-554;

7542-008; 7542
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
Illustration 373
g01217622
Note: Level 1 results may indicate a need for

Level 2 Analysis.

the system pressure.
If you must add coolant daily, check the coolant
system for leaks.
8. Remove the pressure cap.
9. Add the coolant.
10. Inspect the pressure cap and the cap seal for the
following defects:
Damage
Deposits
Foreign material
Clean the pressure cap with a clean cloth or
replace the pressure cap if the pressure cap is
damaged.
Illustration 374
A typical example is shown.
g00544510
SEBU8017-05
343
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
Pressurized System: Hot coolant can cause serious burns. To open the cooling system filler cap,
stop the engine and wait until the cooling system
components are cool. Loosen the cooling system
pressure cap slowly in order to relieve the pressure.
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. In order
to receive the full effect of SOS analysis, you
must establish a consistent trend of data. In order
to establish a pertinent history of data, perform
consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from
your Caterpillar dealer.
Obtain the sample of the coolant as close as possible

to the recommended sampling interval. Supplies
for collecting samples can be obtained from your
Caterpillar dealer.
Submit the sample for Level 2 analysis.
Reference: For additional information about coolant
analysis, refer to Special Publication, SEBU6250,
Caterpillar Machine Fluids Recommendations or
consult your Caterpillar dealer.
i03717305
Drive Shaft - Lubricate

SMCS Code: 3253-086
Use the following guidelines for proper sampling of

the coolant:
Complete the information on the label for the

sampling bottle before you begin to take the
samples.
Keep the unused sampling bottles stored in plastic

bags.
Obtain coolant samples directly from the coolant

sample port, when possible.
Keep the lids on empty sampling bottles until you
Illustration 375
Place the sample in the mailing tube immediately
The grease fittings are located below the center of

the machine.
are ready to collect the sample.
after obtaining the sample in order to avoid

contamination.
Never collect samples from expansion bottles.

Submit the sample for Level 1 analysis.
For additional information about coolant analysis, see
Special Publication, SEBU6250, Caterpillar Machine
Fluids Recommendations or consult your Caterpillar
dealer.
i02049802

Sample (Level 2) - Obtain
g00102443
Apply grease to the fitting on the universal joint

at both ends of the drive shaft. This machine is
equipped with a two-piece drive shaft. There is a total
of four grease fittings per drive shaft.
i03717306
Engine Air Filter Primary

Element - Clean/Replace
SMCS Code: 1054-070; 1054-510
Table 184
SMCS Code: 1350-008; 1395-008; 1395-554; 7542

Reference: Refer to Operation and Maintenance
Manual, Cooling System Coolant Sample (Level 1)
- Obtain for the guidelines for proper sampling of
the coolant.
AIR FILTER
PLUGGED
344
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
SEBU8017-05
Service the air filter if the AIR FILTER PLUGGED

warning appears on the monitor. Stop the engine.
A primary filter element may be cleaned for a
maximum of five times. Also replace the primary
element if the primary element has been used for two
years.
The secondary filter element should also be replaced
when the primary filter element is replaced.
See Operation and Maintenance Manual, Engine Air
Filter Secondary Element - Replace.
1. In order to access the filter elements, open the
right front access door.
Illustration 377
g02003304
(3) Primary filter element

(4) Handle
5. Pull up on handle (4) in order to remove primary

filter element (3).
6. Clean the inside of the air cleaner housing.
7. Inspect the primary element. If the pleats, the
gaskets, or the seals are damaged, discard the
element. Replace a damaged primary element
with a clean primary element.
Illustration 376
g01217976
(1) Latch
(2) Cover
2. Open four latches (1) in order to unlock cover (2).

3. Remove the cover.
4. Clean cover (2).
A primary element may be cleaned for a maximum

of five times. Also replace the primary element if
the primary element has been used for two years.
NOTICE
Do not clean the filter elements by bumping or tapping
them. Do not use filter elements with damaged pleats,
gaskets, or seals. Do not wash the filter elements.
8. If the primary element is not damaged, clean the
primary element.
The filter elements can be cleaned with
pressurized air.
If you use pressurized air, use a maximum air
pressure of 205 kPa (30 psi).
SEBU8017-05
345
Maintenance Section
Engine Air Filter Secondary Element - Replace
1. Remove the cover and the primary filter

element. See the Operation and Maintenance
Manual, Engine Air Filter Primary Element Clean/Replace.
Illustration 378
g02003305
9. When you clean the inside pleats and the outside

pleats, direct the air along the pleats.
10. Inspect the filter elements after you clean the
filter elements. Do not use a filter if the pleats, the
gaskets or the seals are damaged.
11. Cover the clean filter elements. Store the
elements in a clean, dry location.
Illustration 379
g01229520
12. Install a clean primary filter element. Lower the

handle in order to secure the new primary filter in
the air cleaner housing.
2. Pull up on the secondary filter element in order to

remove the secondary filter element.
13. Install cover (2).
3. Cover the air inlet opening. Clean the inside of

the air cleaner housing.
14. Close four latches (1) in order to lock cover (2)

in place.
15. Close the access door.
i02618005
Engine Air Filter Secondary

Element - Replace
SMCS Code: 1054-510
NOTICE
Always replace the secondary filter element. Never attempt to reuse the secondary filter element by cleaning the element.
When the primary filter element is replaced, the secondary filter element should be replaced.
The secondary filter element should also be replaced
if the restricted Air Filter indicator comes on after the
installation of a clean primary filter element or if the
exhaust smoke is still black.
4. Uncover the air inlet opening. Install a new

secondary filter element.
5. Install the primary filter element and the cover.
See Operation and Maintenance Manual, Engine
Air Filter Primary Element - Clean/Replace for
the necessary steps.
i03027620
Engine Crankcase Breather

Filter - Replace
SMCS Code: 1317-510; 1317-510-FI; 1317
1. Open the engine access door that is located on
the top of the machine. Secure the access door.
Hot engine components can cause injury from

burns. Before performing maintenance on the
engine, allow the engine and the components to
cool.
346
Maintenance Section
Engine Oil Level - Check
SEBU8017-05
6. You may need to use a Caterpillar strap wrench or

another suitable tool in order to tighten the filter.
Use the instructions that are printed on the filter in
order to tighten the filter. Use the rotation index
marks as a guide. Do not damage the filter with
the installation tool.
Note: If you install a filter that has not been provided
by Caterpillar, use the instructions that were provided
with the filter.
7. Close all access covers.
i02522182
Engine Oil Level - Check

SMCS Code: 1000-535
Illustration 380
g01532096
2. Remove the filter with a strap type wrench. See

Operation and Maintenance Manual, Oil Filter Inspect. Dispose of the used filter according to
local regulations.
Note: Maintain the vertical position of the filter until
you can dispose of the filter and oil properly. Tilting
the filter will allow oil to run out of the filter.
NOTICE
Do not overfill the crankcase. Engine damage can result.
Check the engine oil level while the machine is
parked on a level surface and the engine has been
stopped for a minimum of 10 minutes.
access door.
3. Clean the housing base for the filter. Remove all

of the remaining filter gasket from the housing.
Illustration 381
g00102462
4. Apply a thin coat of oil to the gasket of the new

filter seal.
5. Place the new filter onto the base. Rotate the filter
until the filter seal contacts the base. Note the
position of the index marks on the filter relative to
a fixed point on the filter base.
Note: Index marks on the filter are separated by 90
degrees or 1/4 of a rotation.
Illustration 382
(S/N: W3H1-UP; W5M1-UP)
g01262193
SEBU8017-05
347
Maintenance Section
Engine Oil Sample - Obtain
5. Maintain the oil level below the FULL RANGE

mark on the dipstick and above the ADD on the
dipstick. If the oil level is low, add oil.
Note: If the oil level is above the FULL RANGE
mark, operating the engine could cause the
crankshaft to dip into the oil. This could lead to
excessively high oil temperatures. Excessively
high oil temperatures can reduce the lubricating
characteristics of the oil. The reduction of lubricating
characteristics of the oil causes bearing damage.
Bearing damage leads to loss of engine power.
General Hazard Information for information on
6. Remove oil filler plug (2) in order to add oil.
7. Add oil, if necessary.
Illustration 383
g01217627
(S/N: W6A1-UP; W8P1-UP; W8R1-UP; W2S1-UP; W2T1-UP)
Note: Refer to Operation and Maintenance

Manual, Lubricant Viscosities for information on
recommended engine oil.
8. Clean oil filler plug (2). Install the oil filler plug.

cool.
2. Remove dipstick (1) in order to measure the oil
level.
Oil which is badly contaminated or badly
deteriorated should be replaced early. Replace
the oil regardless of the time interval.
9. Close the right rear access door.

i02522209
Engine Oil Sample - Obtain

SMCS Code: 1000-008; 1000; 1300; 1318;
1348-008; 1348-554-SM; 1348-554; 7000;
7542-008; 7542-554-OC, SM; 7542
3. Remove the oil from dipstick (1).

4. Insert dipstick (1). Remove the dipstick again.
Illustration 385
Illustration 384
g00102290
g01262213
348
Maintenance Section
Engine Oil and Filter - Change
Illustration 386
SEBU8017-05
g01217628
Obtain a sample of the engine oil from the engine oil

sampling valve that is located on the engine oil filter
housing. Refer to Special Publication, SEBU6250,
Caterpillar Machine Fluids Recommendations,
SOS Oil Analysis for information that pertains to
obtaining a sample of the engine oil. Refer to Special
Sample for more information about obtaining a
sample of the engine oil.
Illustration 387
g01262675
i03731387

SMCS Code: 1318-510
2. Engage the parking brake.
3. Lower the work tools to the ground.
4. Stop the engine.
Note: Drain the crankcase while the oil is warm. This
allows waste particles that are suspended in the oil to
drain. As the oil cools, the waste particles will settle
to the bottom of the crankcase. The particles will not
be removed by draining the oil and the particles will
recirculate in the engine lubrication system with the
new oil.
access door.
Illustration 388
g01262688
6. Remove oil filler plug (1).
SEBU8017-05
Illustration 389
349
Maintenance Section
g01262686
(3) Crankcase drain valve
Illustration 391
g01217630
7. Remove the cover under crankcase drain valve

(3).
8. Open crankcase drain valve (3). Allow the oil to
drain into a suitable container. Close crankcase
drain valve (3).
regulations.

cool.
9. Remove used oil filter (4). See Operation and
Maintenance Manual, Oil Filter - Inspect.
Note: Maintain the vertical position of the filter until
you can dispose of the filter and oil properly. Tilting
the filter will allow oil to run out of the filter.
10. Clean the housing base for the filter. Remove all
of the old filter gasket.
Illustration 392
Illustration 390
g01262681
g00102462
11. Apply a thin coat of engine oil to the gasket of

the new filter.
350
Maintenance Section
Engine Valve Lash - Check
SEBU8017-05
Note: Every new oil filter has rotation index marks

that are spaced at increments of 1/4 turn. Use the
rotation index marks as a guide for tightening the
oil filter.
12. Install the engine oil filter hand tight until the
gasket of the engine oil filter contact the filter
base. Note the position of the index marks on the
filter in relation to a fixed point on the filter base.
13. Tighten the filter according to the instructions that
are printed on the filter. Use the index marks as
a guide.
Note: Do not use a strap wrench on the filter.
NOTICE
Do not overfill the crankcase. Engine damage can result.
i01747875
Engine Valve Lash - Check

SMCS Code: 1102-082; 1102-535; 1102; 1105-025;
1105-535; 1121-535; 1209-082; 1209-535; 1209;
7527
Refer to Engine Systems Operation/Testing and
Adjusting in order to perform the complete procedure
for the valve lash adjustment.
i02357513
Fan Guard - Clean/Inspect

(If Equipped)
SMCS Code: 1360
S/N: W6A1-4999
14. Fill the crankcase with new oil.
S/N: W8P1-4999

S/N: W8R1-4999
S/N: W2T1-4999

17. Start the engine. Run the engine at low idle for
two minutes. Check for oil leaks. Stop the engine.
Illustration 393
NOTICE
Inspect the fan motor and the fan shaft for any obstructions. Failure to remove any debris from the fan motor
or the fan shaft could result in damage to the machine.
g00102420
18. Wait for ten minutes in order to allow the oil to

drain back into the crankcase. Check the oil level.
Maintain the oil level between the ADD mark and
FULL mark on dipstick (2).
19. Install the cover under crankcase drain valve (3).
S/N: W2S1-4999
Illustration 394
g01177535
1. Lift the fan guard in order to inspect the fan and

the radiator grill for dirt accumulation or debris
accumulation.
2. If there is debris on the fan or the radiator grill,
clean the fan or the radiator grill.
SEBU8017-05
351
Maintenance Section
Final Drive Oil - Change
i01827771
i02437239
Final Drive Oil - Change
Final Drive Oil Level - Check
SMCS Code: 4050-044-FLV
Illustration 395
g00102722
1. Turn the hub until the fill/drain plug is at the lowest

position.
2. Remove the dirt that is around the fill/drain plug.
3. Remove the fill/drain plug. Drain the oil into a
suitable container.
Note: Dispose of used oil according to local
regulations.
4. Turn the hub until the opening of the fill/drain plug
is horizontal.
5. Fill the final drive with lubricant to the bottom of
the opening of the fill/drain plug. See Operation
and Maintenance Manual, Capacities (Refill).
7. Install the O-ring seal. Install the fill/drain plug.
8. Repeat Steps 1 through 7 for the remaining three
axle hubs.
Illustration 396
g00311043

1. Turn the hub until the opening of the fill/drain plug
is horizontal, as shown.
2. Remove the dirt that is around the fill/drain plug.
3. Remove the fill/drain plug.
4. Fill the final drive with lubricant to the bottom
of the opening of the fill/drain plug. Add oil, if
necessary. See Operation and Maintenance
Manual, Lubricant Viscosities.
6. Install the O-ring seal. Install the fill/drain plug.
7. Repeat Steps 1 through 6 for the remaining three
axle hubs.
352
Maintenance Section
Final Drive Oil Sample - Obtain
SEBU8017-05
i01905883
Final Drive Oil Sample - Obtain

SMCS Code: 4011-008; 4050-008; 4050-SM;
7542-008; 7542
Illustration 399
g01217631
2. Press the button and release. Repeat this process

approximately 10 times to 15 times.
Illustration 397
g00311043
Obtain an oil sample of the final drive oil by removing

the filler plug and taking the sample directly from
the final drive housing. Refer to Special Publication,
SEBU6250, SOS Oil Analysis for information
that pertains to obtaining an oil sample from the
final drive housing. Refer to Special Publication,
PEHP6001, How To Take A Good Oil Sample for
more information about obtaining an oil sample from
the final drive housing.
i02618303
Fuel System - Prime

SMCS Code: 1250-548
access door.
3. Crank the engine. If the engine does not start, or

the engine misfires, or the engine emits smoke,
then prime the engine again.
4. If the engine starts but the engine runs rough,
continue to run the engine at low idle. Run the
engine at low idle until the engine runs properly.
5. Check the fuel system for leaks. Stop the engine.
NOTICE
Do not touch the high pressure fuel injection lines.
Touching the fuel injection lines could cause the fuel
injection lines to break.
Note: Do not fill the fuel filter with fuel before installing
the filter on the machine.
i03731390
Fuel System Filter - Replace

SMCS Code: 1261-510
Personal injury or death can result from a fire.

Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.
Illustration 398
g01262710
Clean up all leaked or spilled fuel. Do not smoke

while working on the fuel system.
Turn the disconnect switch OFF or disconnect the
battery when changing fuel filters.
SEBU8017-05
353
Maintenance Section
Fuel System Filter - Replace
NOTICE
Do not pre-fill new fuel filters during fuel filter changes.
Engine damage can result.
NOTICE
Turn the disconnect switch OFF or disconnect the battery when changing fuel filters.
NOTICE
Do not touch the high pressure fuel injection lines.
Touching the fuel injection lines could cause the fuel
injection lines to break.
Illustration 402

access door.
g01217824
3. Remove the fuel filter.

Containing Fluid Spillage.
4. Clean the base for the filter housing.
5. Install the new filter by hand.
6. Open the fuel supply valve.
7. Refer to Operation and Maintenance Manual,
Fuel System - Prime for the engine starting
procedure to be used after servicing the fuel
system.
Illustration 400
g01215468
2. Close the fuel supply valve. The valve is closed

when the lever is horizontal.
Illustration 401
g01262965
Note: Do not fill the fuel filter with fuel before installing
the filter on the machine. Dirt or debris might enter
the system which could cause damage to the fuel
injection equipment.
354
Maintenance Section
Fuel System Water Separator - Drain
SEBU8017-05
i02709634
Fuel System Water Separator

- Drain
Note: Drained fluids should always be disposed of

according to local regulations.
4. Close the drain valve.
SMCS Code: 1263
i03734080

Fuel System Water Separator

Element - Replace
SMCS Code: 1263-510-FQ; 1263

NOTICE
Do not pre-fill new fuel filters during fuel filter changes.
Engine damage can result.
access door.

access door.
Illustration 403
g01262996
2. Turn the drain valve counterclockwise in order to

open. The drain valve is located on the bottom of
the water separator and bowl.
Containing Fluid Spillage.
3. Drain the water and the sediment into a suitable
container.
Illustration 404
g01215468
2. Close the fuel supply valve. The valve is closed

when the lever is horizontal.
SEBU8017-05
355
Maintenance Section
Fuel Tank Cap and Strainer - Clean

Note: Do not start the engine until all service to
the fuel system is complete. For instructions about
priming the fuel system, refer to Operation and
Maintenance Manual, Fuel System - Prime.
i01606934
Fuel Tank Cap and Strainer Clean

SMCS Code: 1273-070-STR
Illustration 405
g01263129
3. Turn drain valve (4) counterclockwise in order to

open. The drain valve is located at the bottom of
the fuel filter/water separator.
in Containing Fluid Spillage.
door.
4. Drain the water and the sediment into a suitable

container.
Note: Obey all local regulations when you discard
drained fluids and filters.
5. Close drain valve (4).
6. Hold bowl (3). Remove bowl (3) from the fuel
filter/water separator.
7. Remove fuel filter/water separator (2). Discard
fuel filter/water separator (2).
8. Clean the inside surfaces of the filter base and
of bowl (4).
9. Inspect the bowl (4). If damage is found, replace
the bowl.
10. Inspect the O-ring on the bowl (4). Replace the
seal if the O-ring seal is worn or damaged.
11. Install a new fuel filter/water separator by hand.
Tighten the collar in order to secure the filter
element.
12. Install bowl (4).
13. Open the fuel supply valve.

a fixed cab riser.
2. Remove the fuel tank cap and the fuel fill screen.
3. Wash the fuel fill screen and wash the fuel tank
cap in a clean, nonflammable solvent.
4. Inspect the seal for damage. Replace the seal if
the seal is damaged.
5. Install the fuel tank cap.
6. Close the left front access door.
356
Maintenance Section
Fuel Tank Water and Sediment - Drain
SEBU8017-05
i01546211
Fuel Tank Water and Sediment

- Drain
SMCS Code: 1273-543

1. Remove the cap that is on the bottom of the fuel
tank drain valve.
2. Install a drain hose onto the drain valve in order to
drain the water and the sediment. Drain the water
and the sediment into a suitable container.
3. Remove the drain hose. Install the cap.
i03688014
Fuses - Replace
SMCS Code: 1417-510
Illustration 406
The fuse panel is located behind the operator seat

in the cab.
Left Fuse Panel (+24V Ignition)
Fuses Fuses protect the electrical

system from damage that is caused by
overloaded circuits. Change a fuse if the
element separates. If the element of a new fuse
separates, check the circuit and/or repair the circuit.
NOTICE
Always replace fuses with the same type and capacity
fuse that was removed. Otherwise, electrical damage
could result.
g01983398
(1) Soft Switch Panel, Monitor, Machine Security

System, Service Connector 5 Amp
(2) Hydraulic Lockout Control, Working Lights for
the Rear of the Cab Working Lights Front Relays
and Travel Alarm 5 Amp
(3)24V Sensors, Product Link, Travel Alarm Relay
and Auto Lubrication Relay 5 Amp
(4) Low Beam and High Beam Relays 15 Amp
(5) Turn Signals 5 Amp
NOTICE
If it is necessary to replace fuses frequently, an electrical problem may exist.
Contact your Caterpillar dealer.
(6) Brake Lights 5 Amp

(7) Working Lights for the Front of the Cab 15
Amp
(8) Working Lights for the Boom 15 Amp
The following list identifies the circuits that are

protected by each fuse. The amperage for each fuse
is included with each circuit.
(9) Rotating Beacons and 24 Volt Plug at the Rear

of the Cab 10 Amp
SEBU8017-05
(10) Individual Stabilizers, Dozer Blade and

Material Handler Dozer Front Blade 5 Amp
(11) Horn, Wiper Motor and Window Washer
Pump 15 Amp
(12) Air Suspension Seat and Deluxe Seat 15
Amp
(13) Heater Fan and Air Conditioner 10 Amp
(14) Mirror Heater, Automatic Lubrication and
Reverse Fan 10 Amp
357
Maintenance Section
Fuses - Replace
(34) Cab Heater and Air Conditioner 15 Amp

(35) Spare 30 Amp
(36) Spare 10 Amp
(37) Spare 10 Amp
(38) Spare 15 Amp
(39) Spare 15 Amp
(40) Spare 20 Amp
(15) Electric Fuel Pump 15 Amp

(16) 12.5 kW Generator, 15 kW Generator Control
1 15 Amp
(17) Converter (Rear Camera, Cab Socket 12V15A,
12V Radio) 5 Amp
(18) 15 kW Generator Control 2 30 Amp
(19) Spare 5 Amp
(20) Spare 5 Amp
Right Fuse Panel (+24V Battery)
(21) Electronic Machine Controller (Master) and
Hydraulic Lockout Control Relay 20 Amp
(22) Electronic Machine Controller (Slave) and
Product Link 20 Amp
(23) Monitor 5 Amp
(24) Engine Start Switch and Main Power Relay
5 Amp
(25) Warning Lights (Hazards) 10 Amp
(26) Position Light Relays 5 Amp
(27) Left Side Position Lights and 24 Volt Plug
(Front Socket) 10 Amp
(28) Right Side Position Lights, Switch Locating
Lights and License Plate Lights 10 Amp
(29) Left Side Low Beams 5 Amp
(30) Right Side Low Beams 5 Amp
(31) Left Side High Beams 5 Amp
(32) Right Side High Beams 5 Amp
(33) Converter (Rear Camera, Cab Socket 12V5A,
12V Radio), Cigar Lighter, Dome Light 15 Amp
Illustration 407
(41) Boom Lights Relay

(42) Front Cab Lights - Relay Relay
(43) Horn Relay
(44) Hydraulic Lockout Relay
(45) Brake Lights Relay
(46) Travel Alarm Relay
g02013973
358
Maintenance Section
Fuses - Replace
SEBU8017-05
(48) Automatic Lubrication Relay
Additional Fuses for 4 Cylinder

Engine
Additional Fuses for 6 Cylinder

Engine
Fuses for the Main Power, for the

Alternator, and for the Thermal Starting
Aid
(47) Window Wiper Cut Off - Relay Relay
Fuses for the Main Power, for the

Alternator, and for the Thermal Starting
Aid
Illustration 409
g01433101
These fuses are located behind the right rear access door.
Alternator (55) 80 Amp

Illustration 408
g01229562
These fuses are located behind the right rear access door.
Glow Plug (56) 60 Amp
Alternator (49) 80 Amp
Starter Relay (57) 60 Amp
Main Power (50) 80 Amp
Spare (58) 80 Amp
Glow Plug (51) 60 Amp
Main Power (59) 80 Amp
Starter Relay (52) 60 Amp
Electronic Control Module (60) 30 Amp
Electronic Control Module (53) 30 Amp

Spare (54) 80 Amp
SEBU8017-05
359
Maintenance Section
Hydraulic Generator Brushes and Commutator - Inspect
i02618010
Hydraulic Generator Brushes

and Commutator - Inspect
SMCS Code: 1404-040-BQ
S/N: W8R1-4999
S/N: W2T1-4999
Machines with hammers are not included in the

4000 service hour or 2 year maintenance interval.
Machines with hammers must use the intervals that
are listed in the Maintenance Interval Schedule.
Machines that are used in severe conditions are
not included in the 4000 service hour or 2 year
maintenance interval. Machines that are used
in severe conditions must use the interval in the
Maintenance Interval Schedule.
Cat HYDO Advanced 10 Oil Change

Interval
The standard Cat HYDO Advanced 10 oil change
interval is every 3000 service hours or 18 months.
A 6000 service hour or 3 year maintenance interval
for hydraulic oil (change) is available. The extended
interval requires SOS monitoring of the hydraulic
oil. The interval for SOS monitoring is every 500
hours. The maintenance interval for the hydraulic oil
filter is not changed.
Illustration 410
g00987570
1. Remove the access cover in order to gain access

to the brushes on the generator. The generator
is located on the rear right corner of the upper
structure above the hydraulic tank.
2. Inspect the brushes for wear and the ability to
move in the brush holder.
Note: The brushes should be no shorter than a
length of 20 mm (0.79 inch).
3. The brushes should be replaced in order to
prevent any damage to the generator if the
brushes are less than 20 mm (0.79 inch) in length.
i03738740
Machines with hammers are not included in the

6000 service hour or 3 year maintenance interval.
Machines with hammers must use the intervals that
are listed in the Maintenance Interval Schedule.
Machines that are used in severe conditions are
not included in the 6000 service hour or 3 year
maintenance interval. Machines that are used
in severe conditions must use the interval in the
Maintenance Interval Schedule.
Drain the Oil

1. Operate the machine for an adequate period of
time in order to warm the oil.
Hydraulic System Oil - Change

SMCS Code: 5056-044
Cat HYDO Oil Change Interval

The standard Cat HYDO oil change interval is every
2000 service hours or 1 year.
A 4000 service hour or 2 year maintenance interval
for hydraulic oil (change) is available. The extended
interval requires SOS monitoring of the hydraulic
oil. The interval for SOS monitoring is every 500
hours. The maintenance interval for the hydraulic oil
filter is not changed.
Illustration 411
g01362926
360
Maintenance Section
SEBU8017-05
Note: In order to loosen the breather, a clip must be

attached to the breather. The clip is located in the
literature compartment with the machines Operation
and Maintenance Manual.
7. Slowly loosen the breather in order to relieve
system pressure.
Illustration 412
g01404462
Illustration 415
Illustration 413
g01362927
g00803527
The drain valve is under the middle of the machine.
4. Place the machine in the service position, as

shown.

5. Stop the engine.
8. Remove the cap at the bottom of the drain valve.

door.
9. Install a drain hose in order to drain the hydraulic

tank. Open the drain valve. Allow the oil to drain
into a suitable container.
regulations.
10. Close the drain valve and remove the drain hose.
Install the cap at the drain valve.
11. Tighten the breather in Step 7.
Service the Hydraulic System

Filters
Note: The pressure must be removed from the
hydraulic oil system before the filter can be serviced.
Refer to Testing and Adjusting, Hydraulic System
Pressure - Release.
Refer to the following topics in order to service the
hydraulic system filters:
Illustration 414
g01217959
SEBU8017-05
361
Maintenance Section
Operation and Maintenance Manual, Hydraulic
System Oil Filter - Replace (Return In-line Filter)

System Oil Filter - Replace (Hydraulic Demand
Fan In-Line Filter)
Note: Air may become trapped in the hydraulic

system. The pump may cavitate or the machine may
move in jerks for several seconds. If these symptoms
continue then air is trapped in the hydraulic system.
Pressure - Release for instructions on releasing the
air.
System Oil Filter - Replace (Hydraulic Swing

Circuit Filter)

System Oil Filter - Replace (Pilot Filter)

System Oil Filter - Replace (Return Filter)
Note: All machines have all these filters.
Fill the Hydraulic Tank

Illustration 417
g01362926
Illustration 418
g01404462
Illustration 419
g01362927
5. Start the engine. Operate the engine at idling

speed for a few minutes.
7. Place the machine in the service position, as

shown.
6. Operate the control levers in order to allow the

hydraulic oil to circulate through all hydraulic
circuits.
8. Stop the engine.
Illustration 416
g01217962
1. Remove the filler plug from the hydraulic tank.

2. Fill the hydraulic oil tank. See Operation and
Maintenance Manual, Capacities (Refill).
3. Clean the filler plug. Inspect the O-ring seal.
Replace the O-ring seal if the seal is worn or
damaged.
362
Maintenance Section
Hydraulic System Oil Filter (Return) - Replace
Illustration 420
SEBU8017-05
g01217964
The sight gauge is located in the engine compartment on the right

side of the machine.
Illustration 422
g01969938
Typical example of the sight gauge when the hydraulic oil is warm.
9. The sight gauge contains three red rings for level

markers. Maintain the oil level between the bottom
ring and the center ring for a cold machine, and
between the center ring and the top ring for a
machine at normal operating temperature.
i03737701
Illustration 421
g01969937
Typical example of the sight gauge when the hydraulic oil is cold.
Hydraulic System Oil Filter

(Return) - Replace
(In-line Filters)
SMCS Code: 5068-510-RJ
Pressure - Release.
SEBU8017-05
363
Maintenance Section
Hydraulic System Oil Filter (Return) - Replace
5. Install new in-line filters. Install the in-line filters

into the holders.
6. Connect the hydraulic lines.
i02437695
Hydraulic System Oil Filter

(Return) - Replace
SMCS Code: 5068-510-RJ
Pressure - Release.
Illustration 423
g00804045
In-line filter (1) is positioned at the right rear of hydraulic tank (2).
Illustration 425
g01217968
(1) Nuts
(2) Filter cover
1. Remove four nuts (1) and lock washers. Remove

filter cover (2).
Illustration 424
g00804053
In-line filter (3) is positioned at the front of hydraulic tank (2).
2. Remove the filter element. Discard the filter

element.
1. Separate the hydraulic lines at in-line filter (1) and

at in-line filter (3).
Note: Dispose of used filter elements according to

local regulations.
2. Remove the in-line filter from the holders.
3. Install a new filter element.
3. Discard the filter.
4. Clean filter cover (2). Inspect the cover seal. If

damage or wear is found, replace the cover seal.
Note: Dispose of used filters according to local

regulations.
4. Clean the holders. Inspect the O-ring seals of the
holders. If damage or wear is found, replace the
O-ring seals.
5. Install filter cover (2). Install four lock washers and

nuts (1).
364
Maintenance Section
Hydraulic System Oil Filter - Replace
SEBU8017-05
i01983461
Hydraulic System Oil Filter Replace

(Pilot Filter)
2. Remove the filter element. Discard the filter

element.
Note: Dispose of used filter elements according to
local regulations.
3. Clean the filter housing.
SMCS Code: 5068-510

Pressure - Release.
4. Install a new filter element in the filter housing.

5. Install the filter housing.
i03668728
Hydraulic System Oil Level Check

SMCS Code: 5050-535
1. Park the machine on ground that is stable and
level. Place the machine in the service position.
Illustration 426
g00804473
The pilot filter is located under the cab of the machine.
Illustration 427
1. Remove the filter housing.
g00804075
Illustration 428
g01362926
Illustration 429
g01404462
SEBU8017-05
365
Maintenance Section
Hydraulic System Oil Sample - Obtain
8. If the level is low, please read the introduction Fill

the hydraulic tank.
i03668700
Hydraulic System Oil Sample

- Obtain
SMCS Code: 5050-008; 7542-008
Illustration 430
g01362927

3. Refer to the illustrations 428, 429, and 430 in
order to place the machine in the service position.
4. Refer to the illustrations 428, 429, and 430 in order
to make sure that the stabilizers and the dozer
blade (if equipped) are in the fully raised position.
5. Stop the engine and remove the key.
6. Wait for 5 minutes in order to allow the hydraulic
oil to stabilize before checking hydraulic oil level.
7. Open the right rear access cover that is located
in the engine compartment on the right side of
the machine.
Illustration 432
g01217962
Obtain a sample of the hydraulic oil from the

hydraulic tank opening. Refer to Special Publication,
SEBU6250, SOS Oil Analysis or contact your
dealer for information that pertains to obtaining
a sample of the hydraulic oil. Refer to Special
Sample for more information about obtaining a
sample of the hydraulic oil.
Illustration 431
g00803536
Note: The glass gauge contains three rings for

level markers. Maintain the oil level between the
bottom ring and the center ring for a cold machine,
and between the center ring and the top ring for a
machine at normal operating temperature.
366
Maintenance Section
Oil Filter - Inspect
SEBU8017-05
i02106227
Oil Filter - Inspect
i00699883
Overhead Guard - Inspect

(If Equipped)
SMCS Code: 1308-507; 5068-507
Inspect a Used Filter for Debris
SMCS Code: 7159-040
Illustration 434
Illustration 433
g00102876
g00100013
The element is shown with debris.
Use a filter cutter to cut the filter element open.

Spread apart the pleats and inspect the element for
metal and for other debris. An excessive amount of
debris in the filter element can indicate a possible
failure.
If metals are found in the filter element, a magnet can
be used to differentiate between ferrous metals and
nonferrous metals.
Ferrous metals can indicate wear on steel parts and
on cast iron parts.
Nonferrous metals can indicate wear on the
aluminum parts of the engine such as main bearings,
rod bearings, or turbocharger bearings.
Small amounts of debris may be found in the filter
element. This could be caused by friction and by
normal wear. Consult your Caterpillar dealer in order
to arrange for further analysis if an excessive amount
of debris is found.
Using an oil filter element that is not recommended
by Caterpillar can result in severe engine damage
to engine bearings, to the crankshaft, and to other
parts. This can result in larger particles in unfiltered
oil. The particles could enter the lubricating system
and the particles could cause damage.
1. Inspect the overhead guard for any bolts that

are loose or damaged. Replace bolts that are
damaged or missing. Use original equipment parts
only. Tighten the bolts.
Note: Apply oil to all the bolt threads before you
install the bolts. Failure to oil the threads can cause
improper bolt torque.
2. If the overhead guard rattles during machine
operation or if the overhead guard makes noises
during machine operation, replace the mounting
supports for the overhead guard.
Do not repair the overhead guard by welding
reinforcement plates to the overhead guard.
Consult your Caterpillar dealer for repair of cracks
in the welds on the overhead guard. Consult your
Caterpillar dealer for repair of cracks in any metal
section of the overhead guard.
i03667941
Radiator Core - Clean

SMCS Code: 1353-070
Note: Observe the following guidelines when you
perform the procedure:
Park the machine on a level surface.

Stop the engine before you perform the procedure.
Make sure that the radiator fan comes to a
complete stop before you open the radiator access

door.
SEBU8017-05
Illustration 435
367
Maintenance Section
Radiator Core - Clean
g01968803
1. Loosen bolts (1) on the radiator access door.
Illustration 437
g00820764
3. Check the radiator fins for debris.

4. Remove foreign material from the radiator fins.
Note: In order to remove dust from a radiator and
debris from a radiator, compressed air is preferred.
High pressure water can be used and steam can also
be used.
5. Close the radiator access door and tighten bolts
(1).
Refer to Special Publication, SEBD0518, Know Your
Cooling System for more information on cleaning
the radiator fins.
Illustration 436
g01311495
2. Open the radiator access door and secure the

access door.
368
Maintenance Section
Receiver Dryer (Refrigerant) - Replace
SEBU8017-05
i02723802
Receiver Dryer (Refrigerant) Replace

SMCS Code: 7322-510; 7322-710
i02618651
Refueling Pump Strainer Clean

(If Equipped)
SMCS Code: 1295-070-STR
Personal injury can result from contact with refrigerant.

Contact with refrigerant can cause frost bite. Keep
face and hands away to help prevent injury.
Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant.
Always use precaution when a fitting is removed.
Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated
area.
Illustration 438
g01263831
A typical example is located in the figure above.
Personal injury or death can result from inhaling

refrigerant through a lit cigarette.
1. Open the tool box on the left side of the machine.
Inhaling air conditioner refrigerant gas through a

lit cigarette or other smoking method or inhaling
fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or
death.
Do not smoke when servicing air conditioners or
wherever refrigerant gas may be present.
Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system.
NOTICE
If the refrigerant system has been open to the outside
air (without being plugged) for more than 30 minutes,
the receiver-dryer must be replaced. Moisture will enter an open refrigerant system and cause corrosion
which will lead to component failure.
Refer to Service Manual, SENR5664, Air
Conditioning and Heating System with R-134a
Refrigerant for All Caterpillar Machines for the proper
procedure to change the receiver-dryer assembly
and for the procedure to reclaim the refrigerant gas.
Illustration 439
g01311513
(1) Screen
(2) Coupling
2. Remove screen (1) from coupling (2).

3. Wash screen (2) in a clean, nonflammable solvent.
Dry the screen.
4. Install the screen to coupling (2).
5. Close the tool box.
SEBU8017-05
369
Maintenance Section
Seat Belt - Inspect
i02429589
i02429594
Seat Belt - Inspect
Seat Belt - Replace
SMCS Code: 7327-040
SMCS Code: 7327-510
Always check the condition of the seat belt and the

condition of the seat belt mounting hardware before
you operate the machine. Replace any parts that are
damaged or worn before you operate the machine.
Within three years of the date of installation or within

five years of the date of manufacture, replace the
seat belt . Replace the seat belt at the date which
occurs first. A date label for determining the age of
the seat belt is attached to the seat belt, the seat belt
buckle, and the seat belt retractor.
Illustration 440
g00932801
Typical example
Check the seat belt mounting hardware (1) for wear

or for damage. Replace any mounting hardware that
is worn or damaged. Make sure that the mounting
bolts are tight.
Check buckle (2) for wear or for damage. If the buckle
is worn or damaged, replace the seat belt.
Inspect the seat belt (3) for webbing that is worn or
frayed. Replace the seat belt if the seat belt is worn
or frayed.
Consult your Caterpillar dealer for the replacement of
the seat belt and the mounting hardware.
Note: Within three years of the date of installation or
within five years of the date of manufacture, replace
the seat belt. Replace the seat belt at the date which
occurs first. A date label for determining the age of
the seat belt is attached to the seat belt, the seat belt
buckle, and the seat belt retractor.
If your machine is equipped with a seat belt
extension, also perform this inspection procedure for
the seat belt extension.
Illustration 441
(1)
(2)
(3)
(4)
g01152685
Date of installation (retractor)

Date of installation (buckle)
Date of manufacture (tag) (fully extended web)
Date of manufacture (underside) (buckle)
Consult your Caterpillar dealer for the replacement of

the seat belt and the mounting hardware.
If your machine is equipped with a seat belt
extension, also perform this replacement procedure
for the seat belt extension.
370
Maintenance Section
Stabilizer - Clean/Inspect
SEBU8017-05
i03731388
Stabilizer - Clean/Inspect
(If Equipped)
SMCS Code: 7222-040; 7222-070
Illustration 443
g00102409
Apply lubricant to the one fitting that is on the pin for

the stabilizer pad.
Apply lubricant to one fitting that is on the pin for the
stabilizer arm.
Apply lubricant to the fitting that is on the rod end
of the stabilizer cylinder.
Illustration 442
g01060126
1. Lift the stabilizer cover in order to inspect the

stabilizer cylinder for dirt accumulation.
2. If there is dirt on the stabilizer cylinder, clean
the stabilizer cylinder and that area around the
stabilizer cylinder.
Apply lubricant to the fitting on the pin at the head

end of the stabilizer cylinder.
i01829671
Swing Bearing - Lubricate

SMCS Code: 7063-086
i00699946
Stabilizer Bearings - Lubricate

(If Equipped)
SMCS Code: 7222-086-BD; 7222
Wipe all fittings before you apply the grease.
Note: Perform the following procedure for each
stabilizer.
Illustration 444
g00797153
Apply grease to the two upper grease fittings that are

located in the engine compartment.
SEBU8017-05
371
Maintenance Section
Swing Gear - Lubricate
Apply an appropriate amount of grease according to

the severity of the application. Requirements for the
swing bearing lubrication increase with frequency of
the swing and higher load factors.
i03167110

SMCS Code: 7063-086
Table 185
Recommended Lubrication and Service Period

Based on the Load Factor
Swing Drive Actuation/Load Factor
Recommended
Greasing
Frequency
NOTICE
Improper lubrication can cause damage to machine
components.
Low
(<30%)
Medium
(30 - 40%)
High
(>40%)
To avoid damage, make sure that the proper amount

of grease is applied to the swing drive.
Every two
weeks
Once a
week
Once
every 10
service
hours
When the amount of grease in the compartment becomes too large, the agitation loss becomes large,
thereby accelerating grease deterioration.
Recommended
Amount
of Grease
per Service
(Grams)
100
Total Amount
of Grease to
be applied
(Grams)
400
400
400
Per Machine
Operating
Hours
400
250
135
80
30
Grease deterioration can cause damage to the pinion

gear of the swing drive and swing internal gear.
Not enough grease will result in poor gear lubrication.
The swing gear should be checked after a long period
of stationary, especially under the cold weather
conditions.
Note: The lubrication requirements may exceed these

recommendations for some severe applications. The
lubrication frequency may increase in some severe
applications.
Check the collar of grease for overflow. When the
new grease is overflowed, additional greasing is not
required. Reduce the amount of grease that is applied
to the bearing if the grease overflows excessively
on the outer bearing seal. Reducing grease to the
bearing seal will avoid damage to the bearing seal.
Illustration 445
g01426848
1. Remove the inspection cover that is located near

the boom base. Inspect the grease.
372
Maintenance Section
Illustration 446
(1)
(2)
(3)
(4)
SEBU8017-05
g00290391
Bolts
Bumper springs
Cover
Gasket
Illustration 448
g01624721
VisibleWaveless area indicates lack of grease.
4. Check the level of grease. The grease should be

evenly distributed on the floor of the pan.
2. Remove bolts (1) and bumper springs (2). Remove

cover (3) and gasket (4).
3. Inspect gasket (4). Replace the gasket if damage
is evident.
The level of grease is correct when waves of

grease, as shown in illustration447, from the
rotating swing drive pinion are present along the
entire swing gear.
Smeared or waveless areas as shown in
Illustration 448 are evidence for a lack of grease.
Note: Add grease, as needed. Remove grease,
as needed. Too much grease will result in the
deterioration of the grease because of excessive
movement of the grease. Too little grease will result
in poor lubrication of the swing gear.
5. Check for contamination and for discolored
grease.
Illustration 447
g01624697
Waves of grease from rotating pinion are present.
Illustration 449
g00309463
(5) Plug
(6) O-ring seal
6. If the grease is contaminated or if the grease is

discolored with water, change the grease. Remove
plug (5) in order to allow the water to drain. When
you reinstall plug (5), inspect the O-ring seal (6).
Replace the O-ring seal if damage is evident.
SEBU8017-05
373
Maintenance Section
Tire Inflation - Check
7. Raise the boom. Turn the upper structure by 1/12

of a turn. This is the same angle as the angle
between the hours of an analog clock. Lower the
work tool to the ground.
8. Repeat Step 4 to Step 7 twelve times. Add grease,
as needed.
9. Install gasket (4), cover (3), bumper springs (2)
and bolts (1).
i00735307
Tire Inflation - Check

Illustration 451
SMCS Code: 4203-535-PX; 4203-535-AI
g00102674
(1) Filler plug

(2) Drain plug
Operate the machine for an adequate amount of time

in order to warm the oil.
3. Remove drain plug (2). Drain the oil into a suitable
container.
Illustration 450
g00102393
Measure the air pressure on each tire. Consult your

Caterpillar dealer for the correct load rating and for
the correct operating pressures.
If necessary, inflate the tires. See Operation and
Maintenance Manual, Tire Inflation Information.
i02837406
Transmission Oil - Change

SMCS Code: 3080-044
Note: Do not grease the transmission. The grease
fitting is used only under towing conditions for
activating and deactivating the parking brake
manually. For more information, refer to Operation
and Maintenance Manual, Towing Information.
Note: Dispose of any used oils according to local

regulations.
7. Fill the gearbox with oil to the bottom of the filler
plug opening. See Operation and Maintenance
374
Maintenance Section
Transmission Oil Level - Check
SEBU8017-05
i03667882
Transmission Oil Level - Check

Note: Do not grease the transmission. The grease
fitting is used only under towing conditions for
activating and deactivating the parking brake
manually. For more information, refer to Operation
and Maintenance Manual, Towing Information.
i01871854
Transmission Oil Sample Obtain

SMCS Code: 3030-008; 3080; 7542-008; 7542
Illustration 453
Illustration 452
g00655082
(1) Filler plug
1. Clean the dirt and debris from filler plug (1).

Remove filler plug (1).
2. Check the oil level. The oil level should be at the
bottom of the opening for filler plug (1).
3. If necessary, fill the gearbox with oil to the bottom
of the opening for filler plug (1).
g00947765
Obtain an oil sample from the transmission by

directly from the transmission housing. Refer to
Special Publication, SEBU6250, Caterpillar Machine
Fluids Recommendations, SOS Oil Analysis for
information that pertains to obtaining an oil sample
from the transmission housing. Refer to Special
sample from the transmission housing.
i02525605
Wheel Nut Torque - Check

SMCS Code: 4210-535

Illustration 454
g00102965
Check the torque on all wheel nuts on each of the

four wheels. The torque needs to be 450 50 Nm
(332 37 lb ft). If necessary, tighten the wheel nuts.
SEBU8017-05
375
Maintenance Section
Window Washer Reservoir - Fill
i02437701
i01077829
Window Washer Reservoir Fill
Windows - Clean
SMCS Code: 7306-544-KE
Use commercially available window cleaning

solutions in order to clean the windows. Clean the
outside of the windows from the ground, unless
handholds are available.
NOTICE
When operating in freezing temperatures, use
Caterpillar or any commercially available nonfreezing
window washer solvent.
SMCS Code: 7310-070; 7340-070

door.
2. Open the top access cover.

a fixed cab riser.
Illustration 456
g00566124
Typical example
Use a pole with a squeegee in order to reach the high

areas of the window.
Cleaning Methods
Aircraft Windshield Cleaner
Apply the cleaner with a soft cloth. Rub the window
with moderate pressure until all the dirt is removed.
Allow the cleaner to dry. Wipe off the cleaner with a
clean soft cloth.
Illustration 455
g01217973
Typical location
3. Fill the fluid reservoir through the filler opening on

the top of the reservoir.
Soap and Water

Use a clean sponge or a soft cloth. Wash the windows
with a mild soap or with a mild detergent. Also
use plenty of lukewarm water. Rinse the windows
thoroughly. Dry the windows with a moist chamois or
with a moist cellulose sponge.
Stubborn Dirt and Grease

i01258249
Window Wiper Inspect/Replace

SMCS Code: 7305-040; 7305-510
Inspect the condition of the wiper blades. Replace
the wiper blades if the wiper blades are worn or
damaged or if streaking occurs.
Wash the windows with a good grade of naphtha, of

isopropyl alcohol, or of Butyl Cellosolve. Then, wash
the windows with soap and with water.

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MAINTENANCE INTERVALS

Operation and Maintenance

Maintenance Interval Schedule

Engine Air Filter Primary Element - Clean/

Every 10 Service Hours or Daily for First 100

Every 10 Service Hours or Daily

Every 10 Service Hours or Daily for Machines

Initial 50 Service Hours

Every 50 Service Hours or Weekly

Every 100 Service Hours or 2 Weeks

Every 250 Service Hours

Every 250 Service Hours or Monthly

Belts - Inspect/Adjust/Replace ............................

Initial 500 Hours (for New Systems, Refilled

Every 500 Service Hours

Every 1000 Service Hours

Every 1000 Service Hours or 6 Months

Every 1000 Service Hours of Partial Hammer

Every 1500 Service Hours or 1 Year (Greater

Cooling System Coolant Sample (Level 2) Obtain ...............................................................

Every 2000 Service Hours or 1 Year (Less

Every 3000 Service Hours or 2 Years

Every 3 Years After Date of Installation or

Every 6000 Service Hours or 3 Years

Every 500 Service Hours or 3 Months

Every 2000 Service Hours or 1 Year

Receiver Dryer (Refrigerant) - Replace .............. 368

Every 12 000 Service Hours or 6 Years

Air Conditioner/Cab Heater

2. Remove the scavenge hose that is attached to

SMCS Code: 1054-040-A/C; 1054-510-A/C

(1) scavenge hose

3. Remove the three bolts below the battery

The air filter is located in the cab behind the

4. Install the air filter.

Air Precleaner - Clean

7. Blow dust and debris out of the Cyclone precleaner

1. Squeeze the dust valves in order to remove any

Air Precleaner - Clean

2. Loosen the clamps at the bottom of the engine

5. Install the engine air precleaner. Tighten the

Automatic Lubrication Grease

Autolub on Standard Wheeled Excavator

Note: When adding grease to the tank, never add

Axle Bearings (Front) Lubricate

Wipe all grease fittings before you apply grease.

3. Remove filler plug (1).

A grease fitting is positioned on the top and on the

8. Add oil through the filler plug opening. Maintain

Axle Oil (Front) - Change

SMCS Code: 3278-044

Axle Oil (Rear) - Change

The front axle is the axle which steers the machine.

SMCS Code: 3260-044; 3278-044

(1) Filler Plug. (2) Drain Plug.

(1) Filler plug