320B, 322B and 325B Excavators-Maintenance Intervals

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320B, 322B and 325BEXCAVATORS

Maintenance Intervals

Excerpted from Operation & Maintenance Manual (SEBU6988-03-01)

®© 2007 CaterpillarAll Rights Reserved

265Maintenance Section

Maintenance Interval Schedule

i00911273

Maintenance Interval ScheduleSMCS Code: 7000

Note: All safety information, warnings, andinstructions must be read and understood beforeyou perform any operation or any maintenanceprocedure.

Before each consecutive interval is performed, allof the maintenance requirements from the previousinterval must also be performed.

When Required

Air Conditioner/Cab Heater Filter - Inspect/Replace ............................................................. 267

Battery - Recycle ................................................ 267Battery, Battery Cable or Battery Disconnect Switch -Replace ............................................................. 269

Boom Base Pins - Lubricate ............................... 269Bucket Linkage - Inspect/Adjust .......................... 275Bucket Tips - Inspect/Replace ............................ 276Cab Air Filter - Clean/Replace ............................ 277Circuit Breakers - Reset ...................................... 278Engine Air Filter Primary Element -Clean/Replace .................................................. 288

Engine Air Filter Secondary Element - Replace .. 290Engine Air Filter Service Indicator - Inspect ........ 291Ether Starting Aid Cylinder - Replace ................. 297Fuses - Replace .................................................. 308Hydraulic System Bio Filter Element - Replace .. 310Oil Filter - Inspect ................................................ 326Refueling Pump Strainer - Clean ........................ 327Track Adjustment - Adjust ................................... 334Windshield Washer Reservoir - Fill ..................... 341Windshield Wipers - Inspect/Replace ................. 342

Every 10 Service Hours or Daily for First 100Hours

Boom and Stick Linkage - Lubricate ................... 270Boom, Fore Boom and Stick Linkage -Lubricate ........................................................... 271

Boom, Stick and Bucket Linkage - Lubricate ...... 273

Every 10 Service Hours or Daily

Cooling System Level - Check ............................ 286Engine Oil Level - Check .................................... 293Fuel System Water Separator - Drain ................. 306Fuel Tank Water and Sediment - Drain ............... 308Hydraulic System Oil Level - Check .................... 318Indicators and Gauges - Test .............................. 325Radiator Core - Clean ......................................... 327Seat Belt - Inspect .............................................. 328Swing Out Hydraulic Oil Cooler - Clean .............. 333Track Adjustment - Inspect .................................. 335Travel Alarm - Test .............................................. 336

Undercarriage - Check ........................................ 337Walk-Around Inspection ...................................... 339Windows - Clean ................................................. 341

Every 10 Service Hours or Daily for MachinesUsed in Severe Applications


Boom, Stick and Bucket Linkage - Lubricate ...... 273

Every 50 Service Hours or Weekly


Boom, Stick and Bucket Linkage - Lubricate ...... 273Expandable Pin - Tighten ................................... 298Quick Coupler - Lubricate ................................... 326

Every 50 Service Hours or Weekly After Initial500 Hours

Hydraulic System Bio Filter Pressure Gauge -Inspect .............................................................. 311

Initial 250 Service Hours

Final Drive Oil - Change ..................................... 299Hydraulic System Oil Filter - Replace ................. 316Swing Drive Oil - Change ................................... 329

Every 250 Service Hours or Monthly

Condenser (Refrigerant) - Clean ........................ 278Cooling System Coolant Additive (DEAC) - Add .. 283Cooling System Coolant Sample - Obtain .......... 285Cooling System Hoses - Inspect ......................... 285Engine Oil Sample - Obtain ................................ 294Engine Oil and Filter - Change ........................... 295Final Drive Oil Level - Check ............................... 300Final Drive Oil Sample - Obtain .......................... 300Fuel System Primary Filter/Water Separator Element- Replace ........................................................... 301

Fuel System Priming Pump - Operate ................ 302Fuel System Secondary Filter Number One -Replace ............................................................. 303

Hydraulic System Oil Sample - Obtain ............... 325Swing Bearing - Lubricate .................................. 329Swing Drive Oil Level - Check ............................. 330Swing Drive Oil Sample - Obtain ........................ 331V-Belts - Inspect/Adjust/Replace ........................ 337

Every 250 Service Hours or Monthly BeforeInitial 500 Hours

Hydraulic System Bio Filter Pressure Gauge -Inspect .............................................................. 311

266Maintenance SectionMaintenance Interval Schedule

Every 500 Service Hours or 3 Months

Engine Crankcase Breather - Clean ................... 291Fuel System Secondary Filter Number Two -Replace ............................................................. 305

Fuel Tank Cap and Strainer - Clean ................... 307Hydraulic System Oil Filter - Replace ................. 316

Every 1000 Service Hours or 6 Months

Battery Electrolyte Level - Check ........................ 268Hydraulic System Oil Return Filter - Replace ..... 320Swing Drive Oil - Change ................................... 329

Every 2000 Service Hours or 1 Year

Engine Governor Oil Supply Screen -Clean/Inspect/Replace ...................................... 292

Engine Valve Lash and Fuel Injector Timing -Check ................................................................ 297

Final Drive Oil - Change ..................................... 299Hydraulic System Oil - Change ........................... 312Swing Gear - Lubricate ....................................... 331

Every 3000 Service Hours or 2 Years

Cooling System Coolant (DEAC) - Change ........ 279


Cooling System Coolant Extender (ELC) - Add .. 284

Every 3 Years

Seat Belt - Replace ............................................. 328


Cooling System Coolant (ELC) - Change ........... 281


Air Conditioner/Cab Heater Filter - Inspect/Replace

i00089621

Air Conditioner/Cab HeaterFilter - Inspect/ReplaceSMCS Code: 7309-040; 7309-510

NOTICEAn air filter element plugged with dust will result in de-creased performance and service life to the air condi-tioner or cab heater (if equipped).

To prevent decreased performance, clean the air filterelement, as required.

g00104852Illustration 159

The air conditioner filter is located behind the operator’s seat.

1. Slide the operator seat forward.

2. Loosen the bolts and remove the cover.

3. Slide the filter element outward.

4. Clean the filter element with a maximum of200 kPa (30 psi) pressure air.

5. After you clean the filter element, inspect thefilter element. If the filter element is damaged orbadly contaminated, use a new filter element.Make sure that the filter element is dry.

6. Install the filter element and the cover.

i00059329

Battery - RecycleSMCS Code: 1401-561

Always recycle a battery. Never discard a battery.

Always return used batteries to one of the followinglocations:

• A battery supplier

• An authorized battery collection facility

• Recycling facility

268Maintenance SectionBattery Electrolyte Level - Check

i00089635

Battery Electrolyte Level -CheckSMCS Code: 1401-535

Table 243

Maintenance Intervals for Batteries

Battery Interval

Conventional 100 Hours

Low Maintenance 250 Hours

Maintenance Free Maintenance Free

Tighten the battery retainers on all machines atevery 1000 hour interval.

Keep the terminals clean and coated with petroleumjelly.

Clean the top of the batteries with a clean cloth atevery 1000 hour interval or more often, if necessary.

Each battery cell should not require more than30 cc (1 oz) of water weekly. This usage of wateris typical with the proper charging rate and with amoderate climate.

When you are operating the machine in extremetemperatures, check the water in the battery cellsweekly.


1. Open the battery access covers that are on theleft side of the rear of the machine.


2. Clean the battery surface with a clean cloth.Keep the terminals clean and keep the terminalscoated with petroleum jelly. Install the post coverafter you coat the terminal post with petroleumjelly.

3. Inspect the electrolyte level in each battery cell.(A maintenance free battery does not requireinspection.) Maintain the electrolyte level tothe bottom of the filler openings. Use distilledwater. If distilled water is not available, use cleandrinking water.

4. Close the battery access covers.


Battery, Battery Cable or Battery Disconnect Switch - Replace

i00124321

Battery, Battery Cable orBattery Disconnect Switch -ReplaceSMCS Code: 1401-510; 1402-510; 1402-510

1. Turn the engine start switch key to the OFFposition. Turn all of the switches to the OFFposition.

2. Turn the battery disconnect switch to the OFFposition. Remove the disconnect switch key.

3. Disconnect the battery cable at the batterydisconnect switch. The battery disconnect switchis connected to the machine frame.

Note: Do not allow the disconnected battery cableto contact the battery disconnect switch.

4. Disconnect the negative battery cable atthe battery that is connected to the batterydisconnect switch. If the machine has four 12volt batteries, disconnect the negative batterycables of two of the batteries.

5. Make any necessary repairs or replace thebattery.

6. Reconnect the negative battery cable atthe battery that is connected to the batterydisconnect switch.

7. Reconnect the battery cable at the batterydisconnect switch.

8. Install the disconnect switch key and turn thebattery disconnect switch to the ON position.

i00112777

Boom Base Pins - LubricateSMCS Code: 6501-086

When the boom pin is replaced, lubricate the newboom pin.


1. Park the machine on a level surface and lowerthe bucket to the ground.


(1) Vent plug. (2) Fitting.

2. Vent plug (1) and fitting (2) are on the base ofthe boom. Remove vent plug (1). Apply lubricantthrough fitting (2) until lubricant comes out of theplug hole.

3. Install vent plug (1).

270Maintenance SectionBoom and Stick Linkage - Lubricate

i00915423

Boom and Stick Linkage -LubricateSMCS Code: 6501-086; 6502-086

S/N: 5BS1-Up

S/N: 9WS1-Up

S/N: 6LW1-Up

Material Handler

Note: For some applications of the machine, therepeated duty cycle of the front linkage may onlyrequire small angular movements of the boom orstick. There might not be enough angular motion inorder to distribute the grease between the pin andthe bearing. The operator should operate the boom,the stick and the implement in order to distributethe grease within the joint assemblies.

Note: Caterpillar recommends the use of 5P-0960Molybdenum Grease for lubricating the boom andstick linkage. Refer to Operation and MaintenanceManual, “Lubricating Grease” for more informationon molybdenum grease.


Wipe all fittings before you apply lubricant.


1. Apply lubricant through the fitting at the baseof each boom cylinder.


2. The fittings are at the base of the boom. Tolubricate the lower boom bearings, applylubricant through fittings (1) and (2). To lubricatethe boom cylinder rod, apply lubricant throughfittings (3) and (4). To lubricate the stick cylinderhead, apply lubricant through fitting (5).

Note: To ensure proper lubrication of the lowerboom bearings and of the boom cylinder rod endbearings, lubricant should be applied throughfittings (1), (2), (3), and (4). Apply lubricant firstwhen the boom is raised and any implement issuspended. Then apply lubricant when the boom islowered and the implement is rested on the groundwith a slight downward pressure.


Boom, Fore Boom and Stick Linkage - Lubricate


3. The fittings are located at the end of the stick.Apply lubricant through fittings (6) and (8) inorder to lubricate the connection point of theboom and the stick. Apply lubricant throughfitting (7) in order to lubricate the rod end of thestick cylinder.

i00908949

Boom, Fore Boom and StickLinkage - Lubricate(If Equipped)SMCS Code: 6501-086; 6502-086; 6535-086

S/N: 4DS1-Up

Note: Caterpillar recommends the use of 5P-0960Molybdenum Grease for lubricating the boom, foreboom, stick and bucket linkage. Refer to Operationand Maintenance Manual, “Lubricating Grease” formore information on molybdenum grease.





272Maintenance SectionBoom, Fore Boom and Stick Linkage - Lubricate


2. The fittings are at the base of the boom. Thefittings can be serviced from the platform that ison the storage box. To lubricate the lower boombearings, apply lubricant through fittings (1) and(2). To lubricate the boom cylinder rod, applylubricant through fittings (3) and (4). To lubricatethe stick cylinder head, apply lubricant throughfitting (5).

Use Steps 2.a through 2.d to ensure properlubrication of the lower boom bearings and ofthe boom cylinder rod end bearings.

a. Apply grease through the grease fitting whilethe boom is raised and the implement issuspended.

b. Lower the boom and the implement to theground.

c. Apply a slight downward pressure on theimplement.

d. Apply grease through the grease fitting.


3. Apply lubricant through fittings (6), (7), (8), and(9). These fittings are on the link.

4. Apply lubricant through fittings (10), (11), and(12). These fittings are on the bucket.


5. The fittings are located at the base of thefore boom. The fitting can be serviced fromthe ground. To lubricate the connection pointbetween the boom and the fore boom, applylubricant through fittings (13). To lubricate thecylinder rod end of the fore boom, apply lubricantthrough fitting (14). To lubricate the stick cylinderhead, apply lubricant through fitting (15).


6. The fittings are located at the connection pointbetween the fore boom and the stick. To lubricatethe connection point between the fore boom andthe stick, apply lubricant through fittings (16).


Boom, Stick and Bucket Linkage - Lubricate


7. To lubricate the stick cylinder rod, apply lubricantthrough fitting (17). To lubricate the bucketcylinder head end, apply lubricant through fitting(18).

i00720346

Boom, Stick and BucketLinkage - LubricateSMCS Code: 6501-086; 6502-086; 6513-086

Note: Caterpillar recommends the use of 5P-0960Molybdenum Grease for lubricating the boom,stick and bucket linkage. Refer to Operation andMaintenance Manual, “Lubricating Grease” for moreinformation on molybdenum grease.





274Maintenance SectionBoom, Stick and Bucket Linkage - Lubricate


2. The fittings are at the base of the boom. Thefittings can be serviced from the platform that ison the storage box. To lubricate the lower boombearings, apply lubricant through fittings (1) and(2). To lubricate the boom cylinder rod, applylubricant through fittings (3) and (4). To lubricatethe stick cylinder head, apply lubricant throughfitting (5).

Use Steps 2.a through 2.d to ensure properlubrication of the lower boom bearings and ofthe boom cylinder rod end bearings.

a. Apply grease through the grease fitting whilethe boom is raised and all of the implement issuspended.

b. Lower the boom and the implement to theground.

c. Apply a slight downward pressure on theimplement.

d. Apply grease through the grease fitting.


3. Apply lubricant through fittings (6), (7), (8), and(9). These fittings are on the link.

4. Apply lubricant through fittings (10), (11), and(12). These fittings are on the bucket.


5.


6. Apply lubricant through fitting (14) on the stickcylinder rod. Apply lubricant through two fittings(13). Fittings (13) are at the connection pointof the boom and of the stick. Apply lubricantthrough fitting (15) on the bucket cylinder headend.


Bucket Linkage - Inspect/Adjust

i00142555

Bucket Linkage -Inspect/AdjustSMCS Code: 6513-025; 6513-040

When performing this adjustment, put the hy-draulic activation control lever in the LOCKEDposition and stop the engine.

NOTICEImproperly adjusted bucket clearance could causegalling on the contact surfaces of the bucket and stick,resulting in excessive noise and/or damaged O-ringseals.


(1) No gap. (2) Stick boss. (3) Bucket clearance. (4) Shims. (5)Pin. (6) Plate. (7) Bolts. (8) Washers. (9) Location. (10) Flange.(11) Bucket boss.

The clearance of the bucket linkage on this machinecan be adjusted by shimming. If the gap betweenthe bucket and the stick becomes excessive, adjustbucket clearance (3) to 0.5 to 1 mm (.02 to .04 inch).

Two shims of different thickness are used at location(9). The thicknesses of the shims are 0.5 mm(0.02 inch ) and 1.0 mm (0.04 inch).


Area for linkage adjustment

1. Position the machine on a level surface andlower the bucket to the ground.

2. Slowly operate the swing control lever until stickboss (2) and the bucket boss (11) are in full facecontact at no gap (1). This will help to determinethe total clearance of the connection point of thestick and of the bucket.

3. Place the hydraulic activation control lever in theLOCKED position and stop the engine.

4. Measure bucket clearance (3), which is theexisting total clearance.

5. Determine the number of shims that need to beremoved from shims (4) by using the followingcalculation:

Subtract 0.5 mm (0.02 inch ) or 1.0 mm(0.04 inch) from bucket clearance (3).

6. Remove the appropriate number of shims atlocation (9) in order to meet the above thickness.Make sure that you use a minimum of three0.5 mm (.02 inch) shims. To remove the shims,remove bolts (7), washers (8), and plate (6).

7. After the correct number of shims has beenremoved and pin (5) is aligned with the pinhole, install plate (6), washers (8), and bolts (7).Tighten bolts (7) to a torque of 460 ± 60 N·m(340 ± 44 lb ft).

8. After installation, make sure that bucketclearance (3) is still correct.

276Maintenance SectionBucket Tips - Inspect/Replace

i00641604

Bucket Tips - Inspect/ReplaceSMCS Code: 6805-040; 6805-510

Personal injury or death can result from bucketfalling.

Block the bucket before changing bucket tips orside cutters.

Bucket Tips


(1) This tip is usable. (2) This tip should be replaced. (3) This tiphas been overworn.

Check the bucket tips for wear. If the bucket tip hasa hole, replace the bucket tip.


1. Drive the pin out of the bucket tip from theretainer side of the bucket tip. Remove thebucket tip and the retainer.


2. Clean the adapter and the pin.

3. Fit retainer (1) into retainer washer (2). Installthis assembly into the groove that is in the sideof adapter (3).


4. Install the new bucket tip or the rotated buckettip onto the adapter. To allow greater penetrationor less penetration, the bucket tip may be rotatedby 180 degrees.

5. From the other side of the retainer, drive the pinthrough the bucket tip, through the adapter, andthrough the retainer.

6. After you drive the pin, make sure that theretainer fits snugly into the pin groove.


Cab Air Filter - Clean/Replace

Side Cutters


1. Remove the mounting bolts and the side cutters.

2. Clean the mounting surfaces.

Note: Some side cutters may be rotated foradditional wear.

3. Install the new side cutters or the rotated sidecutters.

i00059069

Cab Air Filter - Clean/ReplaceSMCS Code: 7342-070; 7342-510


The cab air filter is behind the cab.

1. Loosen two bolts (1) and remove filter cover (2)and air filter (3).

2. Clean the air filter with a maximum of 200 kPa(30 psi) pressure air.

3. After you clean the air filter, inspect the air filter. Ifthe air filter is damaged or badly contaminated,use a new air filter.

4. Install the air filter and the filter cover.

Note: Make sure that the arrow on top of the air filteris facing forward.

278Maintenance SectionCircuit Breakers - Reset

i00090104

Circuit Breakers - ResetSMCS Code: 1420-529


The circuit breakers are inside the access door on the front leftof the machine.

Alternator Circuit (1) – This circuit breakeris designed to protect the alternator. Ifthe batteries are installed with reversed

polarity, the circuit breaker would prevent thealternator from damaging the rectifier.

Main Circuit (2) – This circuit breaker isdesigned to protect the wires between thebatteries and the fuses. If the wires are

shorted to the machine’s body, this circuit breakerwould minimize the damage to the wires.

Both circuit breakers have a capacity of 60 Amp.

Circuit Breaker Reset – Push in the button in orderto reset the circuit breaker. If the electrical system isworking properly, the button will remain depressed.If the button does not remain depressed, check theappropriate electrical circuit. Repair the electricalcircuit, if necessary.

i00720211

Condenser (Refrigerant) -Clean(If Equipped)SMCS Code: 1805-070

NOTICEIf excessively dirty, clean condenser with a brush. Toprevent damage or bending of the fins, do not use astiff brush.

Repair the fins if found defective.


1. Open the access door that is on the left side ofthe machine.


2. Inspect the condenser for debris. Clean thecondenser, if necessary.

3. Use clean water to wash off all dust and dirtfrom the condenser.

4. Close the access door.


Cooling System Coolant (DEAC) - Change

i00749678

Cooling System Coolant(DEAC) - ChangeSMCS Code: 1350-044; 1352-544

NOTICEDo not change the coolant until you read and under-stand the material found in the Operation and Mainte-nance Manual, “Cooling System Specifications” sec-tion. Failure to do so could result in damage to thecooling systems components.

Note: This machine was filled at the factory withCaterpillar Extended Life Coolant. The followinginformation pertains to machines which havebeen subsequently filled with Caterpillar DieselEngine Antifreeze/Coolant (DEAC) or a commercialequivalent.

See Operation and Maintenance Manual, “CoolingSystem Specifications” for all cooling systemrequirements.

If the coolant is dirty or if you observe any foamingin the cooling system, drain the coolant before therecommended interval.


1. Unlatch the engine hood and raise the enginehood.


2. Slowly loosen the cooling system pressure capin order to relieve system pressure. Remove thepressure cap.


Note: Refer to Operation and Maintenance Manual,“General Hazard Information” for information oncontaining fluid spillage.

3. Open the drain valve that is under the radiator.Allow the coolant to drain into a suitablecontainer.

4. Close the drain valve.

5. Fill the cooling system with a solution whichconsists of clean water and cooling systemcleaner. The concentration of the cooling systemcleaner should be 6 to 10 percent.

6. Start the engine. Operate the engine withoutthe cooling system pressure cap until the watertemperature regulator opens and the coolingsystem level stabilizes.

7. Maintain the cooling system level within 13 mm(.5 inches) of the bottom of the filler pipe.

8. Install the cooling system pressure cap.

280Maintenance SectionCooling System Coolant (DEAC) - Change

9. Operate the engine for 90 minutes.

10. Stop the engine.

Pressurized System: Hot coolant can cause seri-ous burn. To open cap, stop engine, wait until ra-diator is cool. Then loosen cap slowly to relievethe pressure.


12. Drain the cleaning solution into a suitablecontainer.

Note: Dispose of drained fluids according to localregulations.

13. Flush the cooling system with water until thedraining water is transparent.


15. Add the appropriate coolant solution to thecooling system. Refer to the following topics:

• Operation and Maintenance Manual, “CoolingSystem Specifications”

• Operation and Maintenance Manual, “RefillCapacities”

Note: If you are using Caterpillar antifreeze, donot add the supplemental coolant additive at thistime. Also, do not replace the supplemental coolantadditive element at this time.

16. Start the engine. Operate the engine withoutthe cooling system pressure cap until the watertemperature regulator opens and the coolantlevel stabilizes.

17. Maintain the coolant level within 13 mm(.5 inches) of the bottom of the filler pipe.

18. Inspect the gasket of the cooling systempressure cap. If the gasket is damaged, replacethe pressure cap.




21. Open the access door on the left side of themachine.


(A) “FULL” level(B) “LOW” level

22. Check the coolant level of the coolant reservoir.Maintain the coolant level between the “FULL”mark and the “LOW” mark.

23. If additional coolant is necessary, remove thereservoir cap and add the appropriate coolantsolution.

24. Install the reservoir cap.

25. Close the engine hood and latch the enginehood.



Cooling System Coolant (ELC) - Change

i00750704

Cooling System Coolant (ELC)- ChangeSMCS Code: 1350-044

NOTICEDo not change the coolant until you read and under-stand the material found in the Operation and Mainte-nance Manual, “Cooling System Specifications” sec-tion. Failure to do so could result in damage to thecooling systems components.

NOTICEMixing ELC with other products reduces the effec-tiveness of the coolant and shortens coolant life.Use only Caterpillar products or commercial productsthat have passed the Caterpillar EC-1 specificationsfor pre-mixed or concentrate coolants. Use onlyCaterpillar Extender with Caterpillar ELC. Failure tofollow these recommendations could result in thedamage to cooling systems components.

If ELC cooling system contamination occurs see thetopic ELC Cooling System Contamination of this op-eration and maintenance manual.

If the coolant in the machine is changed toExtended Life Coolant from another type of coolant,see Operation and Maintenance Manual, “ExtendedLife Coolant Cooling System Maintenance”.







3. Open the drain valve that is under the radiator.Allow the coolant to drain into a suitablecontainer.

4. Flush the cooling system with clean water untilthe draining water is transparent.


6. Add the Extended Life Coolant. Refer to thefollowing topics:

• Operation and Maintenance Manual, “CoolingSystem Specifications”


282Maintenance SectionCooling System Coolant (ELC) - Change

7. Start the engine. Operate the engine withoutthe cooling system pressure cap until the watertemperature regulator opens and the coolantlevel stabilizes.

8. Maintain the coolant level within 13 mm(.5 inches) of the bottom of the filler pipe.







(A) “FULL” level(B) “LOW” level







Cooling System Coolant Additive (DEAC) - Add

i00747524

Cooling System CoolantAdditive (DEAC) - AddSMCS Code: 1352; 1353; 1395

Note: This machine was filled at the factory withCaterpillar Extended Life Coolant. The followinginformation pertains to machines which havebeen subsequently filled with Caterpillar DieselEngine Antifreeze/Coolant (DEAC) or a commercialequivalent.

See the Cooling System Specifications in theOperation and Maintenance Manual for all coolingsystem requirements.

Check the concentration of the coolant. Use8T-5296 Coolant Conditioner Test Kit to check theconcentration.

If necessary, add Caterpillar Supplemental CoolantAdditive (SCA).

NOTICEExcessive additive (greater than the recommended6% initial fill) together with concentrations of antifreezegreater than 60% cause deposits to form and can re-sult in radiator tube blockage and overheating.

Liquid Supplemental CoolantAdditive


1. Unlatch the engine hood. Raise the engine hood.




3. It may be necessary to drain some coolant fromthe radiator so that Caterpillar SupplementalCoolant Additive can be added to the coolingsystem.

Note: Always discard drained fluids according tolocal regulations.

4. Add the Supplemental Coolant Additive to thecooling system. Refer to the following topics forthe proper amount of Caterpillar SupplementalCoolant Additive:

• Operation and Maintenance Manual,“Supplemental Coolant Additive (SCA)”




7. Close the engine hood. Latch the engine hood.

284Maintenance SectionCooling System Coolant Extender (ELC) - Add

i00747688

Cooling System CoolantExtender (ELC) - AddSMCS Code: 1352; 1353; 1395

When a Caterpillar Extended Life Coolant (ELC) isused, an Extender must be added to the coolingsystem. See the Operation and MaintenanceManual, “Cooling Recommendations” for all coolingsystem requirements.

Use a 8T-5296 Coolant Conditioner Test Kit tocheck the concentration of the coolant.

NOTICEMixing Extended Life Coolant (ELC) with other prod-ucts reduces the effectiveness of the coolant andshortens coolant life. Use only Caterpillar productsor commercial products that have passed the Cater-pillar EC-1 specification for premixed or concentratecoolants. Use only Caterpillar Extender with Cater-pillar ELC. Failure to follow these recommendationscould result in the damage to cooling systems com-ponents.

If ELC cooling system contamination occurs refer toOperation and Maintenance Manual, “ELC CoolingSystem Contamination”.

This machine was factory filled with Extended LifeCoolant.




2. Loosen the cooling system pressure cap slowlyin order to relieve system pressure. Remove thepressure cap.


3. It may be necessary to drain some coolant fromthe radiator so that Caterpillar Extender can beadded to the cooling system.

Note: Always discard drained fluids according tolocal regulations.

4. Add Extender to the cooling system. Refer tothe following topics for the proper amount ofCaterpillar Extender:

• Operation and Maintenance Manual,“Extended Life Coolant (ELC)”


5. Inspect the gasket of the pressure cap. Replacethe pressure cap if the cap gasket is damaged.Install the pressure cap.



Cooling System Coolant Sample - Obtain

i00917739

Cooling System CoolantSample - ObtainSMCS Code: 1350-554-SM


Pressurized system: Hot coolant can cause seri-ous burn. To open cap, stop engine, wait until ra-diator is cool. Then loosen cap slowly to relievethe pressure.


3. Obtain a sample of the coolant through the fillerpipe of the radiator.

Note: Refer to Operation and Maintenance Manual,“S·O·S Oil Analysis” for information that pertains toobtaining a sample of the coolant.

i00752444

Cooling System Hoses -InspectSMCS Code: 1380-040




2. Inspect all hoses for leaks due to cracking,for softness next to the clamps, and for looseclamps.

3. Replace hoses that are cracked or soft andtighten any loose clamps.

Use Steps 3.a through 3.f to replace the hoses.

286Maintenance SectionCooling System Level - Check


a. Slowly loosen the cooling system pressurecap in order to relieve system pressure.Remove the pressure cap.


b. Drain the coolant from the cooling system toa level that is below the hose that is beingreplaced.

Note: Dispose of the drained fluids according tolocal regulations.

c. Loosen the hose clamps and disconnect thedamaged hose.

d. Replace the damaged hose with a new hose.

e. Replace the hose clamps and tighten thehose clamps.

f. Add the appropriate coolant solution to thecooling system. Refer to the Operation andMaintenance Manual, “Cooling System Level- Check”.


i00752510

Cooling System Level - CheckSMCS Code: 1350-535




(A) “FULL” Level(B) “LOW” Level


If the reservoir is empty, use steps 2.a through2.i.


Cooling System Level - Check


a. Unlatch the engine hood and raise the enginehood.


b. Slowly loosen the cooling system pressurecap in order to relieve system pressure.Remove the pressure cap.


c. Add the appropriate coolant solution to thecooling system. Refer to the following topics:

• Operation and Maintenance Manual,“Cooling System Specifications”


d. Start the engine. Operate the engine withoutthe cooling system pressure cap until thewater temperature regulator opens and thecoolant level stabilizes.

e. Maintain the coolant level within 13 mm(0.5 inch) of the bottom of the radiator fillerpipe.


f. Inspect the gasket of the cooling systempressure cap. If the gasket is damaged,replace the pressure cap.

g. Install the cooling system pressure cap.

h. Stop the engine.

i. Close the engine hood and latch the enginehood.





288Maintenance SectionEngine Air Filter Primary Element - Clean/Replace

i00174147

Engine Air Filter PrimaryElement - Clean/ReplaceSMCS Code: 1054-070; 1054-510




2. Open the front access door on the left side ofthe machine.


3. Loosen the four cover latches and remove theair cleaner cover.


4. Remove the primary filter element from the aircleaner housing.

5. Clean the air cleaner cover and the inside of theair cleaner housing.

6. Inspect the O-ring seal on the air cleaner cover.Replace the O-ring seal if the O-ring seal is wornor damaged.

NOTICEDo not clean the filter elements by bumping or tappingthem. Do not use filter elements with damaged pleats,gaskets or seals. Engine damage can result.

Make sure the cleaned filter elements are completelydry before installing into the filter housing. Water re-maining in the elements can cause false indications ofcontamination in Scheduled Oil Sampling test results.

7. Clean the primary filter. Inspect the primary filter.

Primary filter elements can be cleaned withpressure air, pressure water or a detergentwashing. When pressure water is used themaximum pressure should not exceed 280 kPa(40 psi).

Refer to Operation and Maintenance, “GeneralHazard Information” before you use pressure airin order to clean the primary filter element.


Engine Air Filter Primary Element - Clean/Replace


8. Direct air or water along the pleats inside theprimary filter element and outside the primaryfilter element.

The primary filter element can be washedin warm water and nonsudsing householddetergent. Rinse inside the pleats and outsidethe pleats. Allow the primary filter element to airdry fully.

9. Inspect the primary filter element after cleaning.Do not use a primary filter element with damagedpleats, damaged gaskets or damaged seals.

10. Encase the clean primary filter element andstore the clean primary filter element in a clean,dry place.

11. Install the clean primary filter.

12. Install the air cleaner cover and close thelatches securely.


Note: Install the air cleaner cover properly. Thearrows must point upward.

13. Change the filter if any of the following conditionsoccurs:

• Restricted Air Filter indicator on the monitorpanel still comes on.

• Exhaust smoke is still black after the installationof a primary filter.

Note: The primary filter can be cleaned up to sixtimes. Replace the primary filter if the primary filterhas been in service for one year.

14. Close the access doors.

290Maintenance SectionEngine Air Filter Secondary Element - Replace

i00693889

Engine Air Filter SecondaryElement - ReplaceSMCS Code: 1054-510

NOTICEAlways replace the secondary filter element. Never at-tempt to reuse the secondary filter element by clean-ing the element.

When the primary filter element is replaced, the sec-ondary filter element should be replaced.

The secondary filter element should also be replacedif the restricted Air Filter indicator comes on after theinstallation of a clean primary filter element or if theexhaust smoke is still black.

Note: See Operation and Maintenance Manual,“Engine Air Filter Primary Element - Clean/Replace”for information that pertains to the removal of theair cleaner cover and the removal of the primaryfilter element.

1. Remove the air cleaner cover from the air cleanerhousing.

2. Remove the primary filter element from the aircleaner housing.


3. Remove the secondary filter element.

4. Cover the air inlet opening.

5. Clean the inside of the air cleaner housing.

6. Remove the covering from the air inlet opening.

7. Install the new secondary filter element.

8. Install the primary filter element.

9. Install the air cleaner cover and close the latchessecurely.



Engine Air Filter Service Indicator - Inspect

i00091440

Engine Air Filter ServiceIndicator - InspectSMCS Code: 7452-040-DJ

NOTICEService the air cleaner only when the engine stopped.Engine damage could result.


Check the air filter indicator while the engine isrunning under a full load. Service the air cleaner ifthe restricted air filter indicator on the monitor panelcomes on. Stop the engine before you service theair cleaner.

i00093744

Engine Crankcase Breather -CleanSMCS Code: 1317-070-DJ




2. Loosen hose clamp (1) and disconnect outlethose (2) from breather (3).

3. Loosen bolt (4). Remove breather (3) and seal.


4. Wash breather (3) in a clean, nonflammablesolvent.

5. Inspect the seal. If the seal is damaged, install anew seal.

6. Install the O-ring seal and clean breather (3).Tighten bolt (4) to 14 ± 3 N·m (10 ± 2 lb ft).

7. Slide hose on breather (3). Tighten hose clamp(1).

292Maintenance SectionEngine Governor Oil Supply Screen - Clean/Inspect/Replace


i00093745

Engine Governor Oil SupplyScreen - Clean/Inspect/ReplaceSMCS Code: 1264-040; 1264-070; 1264-510





2. Remove oil supply tube (1) from the cylinderhead. Remove fitting (2) and seal (3) from thegovernor housing.

3. Use a 6 mm hexagon wrench in order to removeoil screen (4).

4. Wash the oil screen in a clean, nonflammablesolvent in order to remove any debris. Inspectthe oil screen and the seals for damage. Ifnecessary, replace the oil screen.

5. Install the oil screen into the governor housing.The oil screen should be far enough into thegovernor housing in order to allow clearance forthe seals and for the fitting.


Engine Oil Level - Check

6. Install the seal, the fitting, and the oil supply tube.


i00093751

Engine Oil Level - CheckSMCS Code: 1000-535

NOTICEDo not overfill the crankcase. Engine damage can re-sult.

Note: This machine is equipped with a function forchecking fluid levels. However, if the machine ison an incline or the engine has been stopped onlyfor a short time, the engine oil does not return tothe crankcase. The fluid level cannot be properlychecked. Park the machine on level ground andcheck the oil level after the engine has beenstopped for at least 15 minutes.

Check the oil level while the engine is stopped. Donot check the oil level while the engine is running.




2. Remove dipstick (2). Wipe the oil off the dipstickand reinsert the dipstick.

294Maintenance SectionEngine Oil Sample - Obtain


3. Check the dipstick. The oil level should bebetween the “FULL” mark and the “ADD” mark.

NOTICEDo not fill above the “FULL” mark on the dipstick.

If the oil level is above the “FULL” Mark, the crankshaftmight dip into the oil during engine operation. This willlead to excessively high oil temperatures. High oil tem-peratures can reduce the lubricating characteristics ofoil.


4. Remove oil filler plug (1) in order to add oil,if necessary. See Operation and MaintenanceManual, “Refill Capacities”.

Note: If the oil is deteriorated or badly contaminated,change the oil regardless of the maintenanceinterval.

5. Clean oil filler plug (1). Install oil filler plug (1).

6. Close the engine hood. Latch the engine hood.

i00914083

Engine Oil Sample - ObtainSMCS Code: 1000-008; 7542-008


Open the access door on the right side of themachine in order to access the sampling valve.


The sampling valve for the engine oil is located onthe top of the engine oil filter.

Refer to Operation and Maintenance Manual, “S·O·SOil Analysis” for more information on obtaining asample of the engine oil.


Engine Oil and Filter - Change

i00093754

Engine Oil and Filter - ChangeSMCS Code: 1318-510

Note: If the sulfur content in the fuel is greater than1.5 percent by weight, use an oil that has a TBN of30 and reduce the oil change interval by one-half.

Park the machine on a level surface. Stop theengine.

Note: Drain the crankcase while the oil is warm. Thisallows waste particles that are suspended in the oilto drain. As the oil cools, the waste particles willsettle to the bottom of the crankcase. The particleswill not be removed by draining the oil and theparticles will recirculate in the engine lubricationsystem with the new oil.


1. Open the crankcase access cover.



2. Open the crankcase drain valve. Allow the oil todrain into a suitable container.



4. Close the crankcase access cover.


5. Open the access door at the right side of themachine.


6. Remove the oil filter with a strap type wrench.See Operation and Maintenance Manual, “OilFilter - Inspect”. Dispose of the used filteraccording to local regulations.

7. Clean the filter housing base. Make sure that allof the old filter gasket is removed.

296Maintenance SectionEngine Oil and Filter - Change


8. Apply a thin coat of engine oil to the gasket ofthe new filter.

9. Install the new filter by hand. When the gasketcontacts the filter base, turn the filter by270 degrees more. This will tighten the filtersufficiently.

Every new oil filter has rotation index marks thatare spaced at 90 degree increments. Use therotation index marks as a guide for tighteningthe oil filter.





12. Remove oil filler plug (1). Fill the crankcase withnew oil. See Operation and Maintenance Manual,“Refill Capacities”. Clean the oil filler plug andinstall the oil filler plug.

NOTICEDo not under fill or overfill engine crankcase with oil.Either condition can cause engine damage.

13. Start the engine and allow the oil to warm.Check the engine for leaks.

14. Run the engine and check dipstick (2) after theengine has been running for fifteen minutes.Maintain the oil between the marks on thedipstick. If necessary, add oil.



Engine Valve Lash and Fuel Injector Timing - Check

i00707053

Engine Valve Lash and FuelInjector Timing - CheckSMCS Code: 1102; 1105-025; 1105; 1290-531-FT;

1290

Refer to the Service Manual for the completeprocedure for checking the engine valve lash. Thisprocedure lists the steps for the engine valve lashadjustment and the steps in order to check theengine valve lash.

Note: Make sure that a qualified mechanic works onthe injector fuel timing. Special tools and trainingare required.

Refer to the Service Manual for the completeprocedure for checking the injector fuel timing or foradjusting the injector fuel timing.

Note: The correct fuel timing specification isgiven on the Engine Information Plate. Fueltiming specifications may differ for distinct engineapplications and/or power ratings.

i00719603

Ether Starting Aid Cylinder -Replace(If Equipped)SMCS Code: 1456-510-CD


The ether cylinder is located in the radiator compartment.

1. Open the access door at the back left side ofthe machine.


2. Loosen the cylinder retaining clamp.

3. Unscrew the empty ether starting aid cylinderand remove the empty ether starting aid cylinder.

298Maintenance SectionExpandable Pin - Tighten


4. Remove the used gasket.

5. Install a new gasket.

Note: A new gasket is provided with each new etherstarting aid cylinder.

6. Install the new ether starting aid cylinder.

7. Tighten the ether starting aid cylinder hand tight.

8. Tighten the cylinder retaining clamp securely.


i00909473

Expandable Pin - Tighten(If Equipped)SMCS Code: 6501-527-PN; 6535-527-PN

S/N: 4DS1-Up


(1) Expandable pins

Expandable pins (1) are located at the junctionbetween the boom foot and the boom nose.

Check the torque on expandable pins (1). Referto Operation and Maintenance Manual, “Torquefor Expandable Pins” for the proper torquespecification.

Note: If the pins must be replaced, grease the pinbores, the pins, and the sleeves with CaterpillarTO-2 oil or an equivalent before installing the pins.


Final Drive Oil - Change

i00337108

Final Drive Oil - ChangeSMCS Code: 4050-044-FLV


(1) Drain plug. (2) Level plug.

1. Position one final drive so that oil drain plug (1)is at the bottom.


2. Remove drain plug (1) and level plug (2). Allowthe oil to drain into a suitable container.


3. Clean the plugs and inspect the O-ring seals. Ifwear or damage is evident, replace the drainplug, the level plug, and/or the O-ring seals.

4. Install drain plug (1).

5. Fill the final drive to the bottom of the opening onlevel plug (2). See Operation and MaintenanceManual, “Lubricant Viscosities” and Operationand Maintenance Manual, “Refill Capacities”.

6. Install level plug (2).

7. Perform Step 1 to Step 6 on the other final drive.Use a different container for the oil so that the oilsamples from the final drives will be separate.

8. Completely remove the oil that has spilled ontosurfaces.

9. Start the engine and allow the final drives to runthrough several cycles.

10. Stop the engine. Check the oil level.

11. Check the drained oil for metal chips or forparticles. If there are any chips or particles,consult your Caterpillar dealer.

300Maintenance SectionFinal Drive Oil Level - Check

i00337373

Final Drive Oil Level - CheckSMCS Code: 4050-535-FLV


(1) Drain plug. (2) Level plug.

1. Position one final drive so that oil drain plug (1)is at the bottom.


2. Remove oil level plug (2).

3. Check the oil level. The oil should be near thebottom of the level plug opening.

4. Add oil through the level plug opening, ifnecessary.

Note: Overfilling the final drive will cause the sealson the travel motor to allow hydraulic oil or waterto enter the final drive. This may contaminate thefinal drive.

5. Clean oil level plug (2). Inspect the O-ring seal.Replace the O-ring seal if the O-ring seal is wornor damaged.

6. Install oil level plug (2).

7. Repeat Steps 1 through 6 for the other final drive.

i00877870

Final Drive Oil Sample - ObtainSMCS Code: 4050-008


(1) Oil drain plug(2) Oil level plug

1. Position the final drive so that oil drain plug (1)is at the bottom.

2. Remove oil level plug (2).

3. Obtain a sample of the final drive oil through thehole for the oil level plug.

4. Install oil level plug (2).

Refer to Operation and Maintenance Manual, “S·O·SOil Analysis” for more information on obtaining asample of the final drive oil.


Fuel System Primary Filter/Water Separator Element - Replace

i00913103

Fuel System PrimaryFilter/Water Separator Element- ReplaceSMCS Code: 1260-510; 1263-510

Personal injury or death can result from a fire.

Fuel leaked or spilled onto hot surfaces or electri-cal components can cause a fire.

Clean up all leaked or spilled fuel. Do not smokewhile working on the fuel system.

Turn the disconnect switch OFF or disconnect thebattery when changing fuel filters.

NOTICEDo not fill fuel filters with fuel before installing them.Contaminated fuel will cause accelerated wear to fuelsystem parts.


The fuel shutoff valve is located under the fuel tank.

1. Turn the fuel supply valve clockwise in order toshut off the fuel supply.




(1) Collar(2) Primary filter/water separator(3) Collar(4) Drain valve(5) Bowl

3. Turn drain valve (4) counterclockwise in orderto open.

4. Drain the water and the sediment into a suitablecontainer.

Note: Dispose of drained fluids and used filtersaccording to local regulations.

5. Close drain valve (4).

6. Hold the bottom of primary filter/water separator(2) while you loosen collar (3).

7. Remove bowl (5).

8. Loosen collar (1).

9. Remove primary filter/water separator (2).

10. Discard primary filter/water separator (2).

302Maintenance SectionFuel System Priming Pump - Operate

11. Clean the inside surfaces of the filter head andof bowl (5).

Note: Dispose of drained fluids and used filtersaccording to local regulations.

Note: The primary filter/water separator is acartridge type filter. The filter cannot be reused.

12. Inspect the O-ring on bowl (5). Also inspect theseal on the filter head. Replace these seals if theseals are worn or damaged.

13. Install a new primary filter/water separator.Tighten collar (1) in order to secure the primaryfilter/water separator.

14. Install bowl (5). Tighten collar (3).

Note: Do not start the engine until all service tothe fuel system is complete. For instructions aboutpriming the fuel system, refer to Operation andMaintenance Manual, “Fuel System Priming Pump- Operate”.


16. Turn the fuel shutoff valve counterclockwise inorder to open the fuel supply.

i00059065

Fuel System Priming Pump -OperateSMCS Code: 1258


1. Turn the fuel drain valve counterclockwise to theON position.


2. Unlock the priming pump plunger and operatethe priming pump plunger until fuel flows out ofthe drain hose.

3. Turn the fuel drain valve clockwise to the OFFposition.

4. Operate the priming pump plunger for anotherten strokes.

5. Push in the priming pump plunger and tightenthe priming pump plunger by hand.

6. Crank the engine. If the engine does not startor the engine misfires, additional priming isrequired. Also if the engine emits smoke,additional priming is required.


Fuel System Secondary Filter Number One - Replace

7. If the engine starts but the engine runs rough,continue to run the engine at low idle. Run theengine at low idle until the engine runs properly.

8. Check the fuel system for leaks. Stop the engine.

i00728372

Fuel System Secondary FilterNumber One - Replace(Lower Filter)SMCS Code: 1261-510-SE








304Maintenance SectionFuel System Secondary Filter Number One - Replace


(1) Secondary filter(2) Secondary filter(3) Drain valve(4) Drain valve

Note: Drain upper secondary filter (2) before youremove lower secondary filter (1).


2. Open drain valve (4) and immediately open drainvalve (3). Allow the fuel to drain into a suitablecontainer.

Note: Make sure that the drain valves are opened inthe proper order. If you open the wrong drain valvefirst, an air lock in the fuel system may occur. Thiswill not allow fuel to drain from the upper filter.

3. Slowly loosen upper secondary filter (2) for 1/4turn. Allow any remaining fuel in the valves todrain into a suitable container. When the fuelstops draining, loosen upper secondary filter (2)for an additional 1/4 turn. Repeat this processuntil the upper filter is completely drained.

4. Close drain valves (3) and (4).

Note: Dispose of used fluids according to localregulations.

5. Remove lower secondary filter (1).

Note: The lower secondary filter has not beendrained. The filter contains fuel. When you removethe lower filter, use caution in order to avoid spillingthe fuel.

6. Inspect the fuel filter for debris by cutting thefuel filter open.

Note: This fuel filter is a cartridge type filter. Thistype of filter cannot be reused.

Note: Dispose of used filters according to localregulations.

7. Clean the mounting base of the fuel filter. Makesure that all of the old seal is removed from themounting base.


8. Apply a thin coat of clean diesel fuel to thesealing surface of the new fuel filter.

9. Install the new fuel filter by hand. When the sealcontacts the filter mounting base, tighten thefilter by an additional 3/4 turn.

The filter has rotation index marks that arespaced by increments of 1/4 turn. Use theserotation index marks as a guide for propertightening.

10. Tighten upper secondary filter (2) in the samemanner that is described in Step 9.

11. Prime the fuel system. See Operation andMaintenance Manual, “Fuel System PrimingPump - Operate” for instructions.



Fuel System Secondary Filter Number Two - Replace

i00913140

Fuel System Secondary FilterNumber Two - Replace(Upper Filter)SMCS Code: 1261-510-SE









(1) Drain valve(2) Secondary filter(3) Drain valve


2. Open drain valve (3) and immediately open drainvalve (1). Allow the fuel to drain into a suitablecontainer.

Note: Make sure that the drain valves are opened inthe proper order. If you open the wrong drain valvefirst, an air lock in the fuel system may occur. Thiswill not allow fuel to drain from the upper filter.

3. Slowly loosen upper secondary filter (2) for 1/4turn. Allow any remaining fuel in the valves todrain into a suitable container. When the fuelstops draining, loosen upper secondary filter (2)for an additional 1/4 turn. Repeat this processuntil the upper filter is completely drained.

4. Close drain valves (3) and (1).

Note: Dispose of used fluids according to localregulations.

5. Remove upper secondary filter (2).

6. Inspect the fuel filter for debris by cutting thefuel filter open.

Note: This fuel filter is a cartridge type filter. Thistype of filter cannot be reused.

Note: Dispose of used filters according to localregulations.

7. Clean the mounting base of the fuel filter. Makesure that all of the old seal is removed from themounting base.

306Maintenance SectionFuel System Water Separator - Drain


8. Apply a thin coat of clean diesel fuel to thesealing surface of the new fuel filter.

9. Install the new fuel filter by hand. When the sealcontacts the filter mounting base, tighten thefilter by an additional 3/4 turn.

The filter has rotation index marks that arespaced by increments of 1/4 turn. Use theserotation index marks as a guide for propertightening.

10. Prime the fuel system. See Operation andMaintenance Manual, “Fuel System PrimingPump - Operate” for instructions.


i00796424

Fuel System Water Separator- DrainSMCS Code: 1263




The water separator is located behind the left side access door atthe back of the machine.

The drain valve is located on the bottom of the water separator.

2. Turn the drain valve counterclockwise in orderto open.


3. Drain the water and drain the sediment into asuitable container.





Fuel Tank Cap and Strainer - Clean

i00076547

Fuel Tank Cap and Strainer -CleanSMCS Code: 1273-070-STR


1. Remove the fuel cap.

2. Inspect seal (4) for damage. Replace the seal,if necessary.

3. Remove screws (1), filter assembly (2), drainvalve (3) and the gaskets.


Note: Refer to Operation and Maintenance Manual,“General Hazard Information” for information onContaining Fluid Spillage.

4. Remove the strainer that is located in the filleropening.

5. Wash the strainer and the fuel tank cap in aclean, nonflammable solvent.

6. Install a new cap filter kit. Install the gaskets,drain valve (3), filter assembly (2), and screws(1).

7. Install the strainer into the filler opening.

8. Install the fuel tank cap.

308Maintenance SectionFuel Tank Water and Sediment - Drain

i00118500

Fuel Tank Water and Sediment- DrainSMCS Code: 1273-543



1. Open the drain valve that is located under thefuel tank. Allow the water and the sediment todrain into a suitable container.



Fill the Fuel Tank

You can now add fuel to the fuel tank, if necessary.Remove the fuel tank cap and pump fuel throughthe opening.

Make sure that you lock the fuel tank cap after therefueling is complete.

Certain machines are equipped with electricrefueling pumps. For more information, seeOperation and Maintenance Manual, “ElectricRefueling Pump”.

i00095100

Fuses - ReplaceSMCS Code: 1417-510


The fuse panel is located on the left console. Openthe access cover in order to access the fuses.

Fuses – Fuses protect the electricalsystem from damage that is caused byoverloaded circuits. Change a fuse if the

element separates. If the element of a new fuseseparates, check the circuit and/or repair the circuit.

NOTICEAlways replace fuses with the same type and capacityfuse that was removed. Otherwise, electrical damagecould result.

NOTICEIf it is necessary to replace fuses frequently, a electri-cal problem may exist.

Contact your Caterpillar dealer.

To replace a fuse, use the puller that is stored inthe fuse panel. Two fuses of 10 Amperes, one fuseof 15 Amperes, and one fuse of 30 Amperes arecontained in the fuse panel as spare fuses.

The following list identifies the circuits that areprotected by each fuse. The amperage for eachfuse is included with each circuit.


Fuses - Replace



Spare (1) – 10 Amp

Auxiliary Circuit (2) – 10 Amp

Auxiliary Circuit (3) – 10 Amp

Backup (4) – 10 Amp

Inspection Lamp (If Equipped) (5) – 10 Amp

Hydraulic Lock Limit Switch or Hydraulic LockSolenoid (6) – 10 Amp

Engine Governor (7) – 10 Amp

Engine Controller or Pump Controller (8) – 15 Amp

Horn (9) – 10 Amp

Cab Dome Light(10) – 10 Amp

Engine Shutdown (11) – 10 Amp

Engine Start Switch (12) – 10 Amp

Electric Refueling Pump (If Equipped) (13) – 30 Amp

Fine Swing Control (14) – 10 Amp

Boom Lamp (15) – 10 Amp

Auto Lubricator (If Equipped) (16) – 10 Amp

Switch Panel (17) – 10 Amp

Cigar Lighter (18) – 10 Amp

Heater and Air Conditioner (19) – 15 Amp

Windshield Washer and Windshield Wiper (20) –10 Amp

Auxiliary Circuit (Attachment) (21) – 10 Amp

Radio (If Equipped) (22) – 10 Amp

Cab and Chassis Lamp (23) – 15

Auxiliary Hydraulic (Attachment) (24) – 15 Amp




310Maintenance SectionHydraulic System Bio Filter Element - Replace

i00731715

Hydraulic System Bio FilterElement - Replace(If Equipped)SMCS Code: 5068-510


(1) Bolts(2) Cover

1. Remove seven bolts (1) and cover (2) from themachine.


(3) Bolts(4) Cover

2. Remove four bolts (3) and cover (4) from the BIOfilter.


(5) BIO filter element

3. Remove BIO filter element (5) from the filterassembly.

4. Install a new filter element.

5. Place cover (4) in place and secure four bolts (3).

6. Place cover (2) in place and secure seven bolts(1).


Hydraulic System Bio Filter Pressure Gauge - Inspect

i00731972

Hydraulic System Bio FilterPressure Gauge - Inspect(If Equipped)SMCS Code: 5068-040


1. Slowly loosen the filler plug in order to relieveany pressure.

2. Tighten the filler plug after the pressure isrelieved.


3. Place the machine in the servicing position, asshown.

4. Move the hydraulic activation control lever to theLOCKED position.

5. Turn the engine speed dial to the high idleposition “10”.


6. Open the rear access door on the left side ofthe machine.


7. Open the front access door on the left side ofthe machine.


The BIO filter is located behind the front access door on the leftside of the machine.

312Maintenance SectionHydraulic System Oil - Change

8. Read the value of the pressure gauge that is ontop of the BIO filter.

If the pressure is between “1 ± 0.2 bars” and “3± 0.2 bars”, the BIO filter element is clean.

If the pressure is “3 ± 0.2 bars” or more, theBIO filter element is clogged. If this occurs,replace the BIO filter element. Refer to Operationand Maintenance Manual, “Hydraulic SystemBio Filter Element - Replace” for information onreplacing the BIO filter element.

i00722935

Hydraulic System Oil - ChangeSMCS Code: 5056-044



1. Park the machine on level ground. Lower thebucket to the ground so that the stick is vertical.


(1) Bolts(2) Washers(3) Cover

2. Remove bolts (1), washers (2) and cover (3) fromthe top of the hydraulic tank.


Hydraulic System Oil - Change


3. Clean the area thoroughly in order to keep dirt outof the screen cover. Clean the area thoroughly inorder to keep dirt out of the fill/vent plug.

4. Relieve the internal pressure from the hydraulictank by loosening the fill/vent plug. After thepressure is relieved, remove the fill/vent plug.


5. The oil drain valve is located under the hydraulictank.

6. Remove the hydraulic tank access cover that islocated under the upper structure. This will allowaccess to the drain valve.



7. Remove the oil drain valve plug.


8. Install a Swivel Hose with clear plastic tubing inorder to open the drain valve. Drain the oil into asuitable container.

9. Remove the Swivel Hose in order to close thedrain valve.

10. Inspect the O-ring. Replace the O-ring if wearor damage is evident.

11. Clean the drain plug. Install the drain plug.


12. Open the access door on the right side of themachine.

13. Clean the pump. Clean the hydraulic lines.Clean the hydraulic tank.

314Maintenance SectionHydraulic System Oil - Change


14. Remove the plug from the tube. Allow the oil todrain into a container.

15. Inspect the O-ring. Replace the O-ring if wearor damage is evident.

16. Clean the plug. Install the plug and the O-ringinto the drain port.


(4) Bolt(5) Washers(6) Cover(7) Spring(8) Screen

17. Remove bolts (4), washers (5), and cover (6).

Note: Used filters and used fluids should alwaysbe disposed of according to established localregulations.

Note: Do not allow spring (7) to fall into the tank.

18. Remove spring (7) and screen (8).



(9) O-ring seal(10) O-ring seal

19. Remove O-ring seal (9) from the old screen.

20. Inspect O-ring seal (9) and O-ring seal (10).Replace the O-ring seals if wear or damage isevident.

21. Install O-ring seal (9) on new screen (8).

22. Install screen (8) and spring (7). Then, installcover (6), washers (5), and bolts (4).

Note: Make sure that the O-ring seals and the springare properly positioned during installation.

Note: Perform the following five steps only if yourmachine is equipped with an auxiliary gear pump.


(11) Bolts(12) Washers(13) Plate

23. Remove four bolts (11) and four washers (12).


Hydraulic System Oil - Change

24. Pull plate (13) away from the hydraulic tank.Inspect the seal on plate (13). Replace the sealif wear or damage is evident.

25. Remove the screen.

Note: Used filters and used fluids should alwaysbe disposed of according to established localregulations.

26. Install a new screen.

27. Install four bolts (11) and four washers (12) inorder to attach plate (13) to the hydraulic tank.

28. Fill the hydraulic system oil tank. Refer toOperation and Maintenance Manual, “RefillCapacities”.

29. Inspect the O-ring on the filler plug for damage.Replace the O-ring, if necessary. Clean the fillerplug. Install the filler plug.


30. Remove the pressure cap.


31. Inspect the pressure cap. Clean the pressurecap. Replace the pressure cap if damage isevident.

32. Install the pressure cap.


Note: Make no attempt to start the engine until thepump has been filled with hydraulic oil. Seriousdamage to the hydraulic components can result.

33. When the hydraulic oil has been replaced,the airmust be removed from the hydraulic oil system.Use the following procedure to remove the airfrom the hydraulic oil system.

a. While the engine is stopped, remove the ventplug which is on the top of the pump. Do notinstall the vent plug until the pump is filledwith hydraulic oil. After the pump is filled withhydraulic oil, tighten the vent plug. Start theengine. When the engine is at low idle, fullyraise the boom. Hold the boom in this position.

b. Stop the engine. Slowly lower the boom untilthe bucket is on the ground. This pressurizesthe hydraulic tank.

c. Slowly loosen the vent plug for several turnsuntil the hydraulic oil flows out of the openingfor the vent plug. This indicates that the airhas been released from the pump. Tightenthe plug.


35. Start the engine. Operate the engine at idlingspeed for five minutes.

316Maintenance SectionHydraulic System Oil Filter - Replace


36. Operate the control levers in order to circulatethe hydraulic oil. Lower the bucket to the groundso that the stick is vertical to the ground. Stopthe engine.


(A) High Temperature Range(B) Low Temperature Range

37. Maintain the oil level between the marks onthe sight gauge in the appropriate temperaturerange.

i00095013

Hydraulic System Oil Filter -ReplaceSMCS Code: 5068-510

Replace the Pilot Filter




2. Clean the area in order to keep dirt out of thefilter base.

3. Remove the used pilot filter element from thefilter base.

Note: This element is a cartridge type filter. Theelement cannot be reused.

Note: Used filters should always be disposed ofaccording to local regulations.

4. Clean the filter base.


Hydraulic System Oil Filter - Replace


5. Coat the seal of a new pilot filter with cleanhydraulic oil. Install the new pilot filter in the filterbase. Tighten the pilot filter hand tight.


Replace the Case Drain Filter


The case drain filter is located on the side of the fuel tank.


1. Clean the area in order to keep dirt out of thefilter base.

2. Remove the used case drain filter from the filterbase.

Note: This element is a cartridge type filter. Theelement cannot be reused.

Note: Used filters should always be disposed ofaccording to local regulations.

3. Clean the filter base.


4. Coat the seal of a new case drain filter with cleanhydraulic oil. Install the new case drain filter inthe filter base. Tighten the case drain filter handtight.

5. Drive the machine slowly for 10 to 15 minutes.Move each cylinder evenly through severalcycles.


6. Return the machine to the position that is shownabove. Check the machine for oil leaks.

7. Stop the engine.

8. Open the access door on the right side of themachine in order to access the sight gauge.

318Maintenance SectionHydraulic System Oil Level - Check

Note: On the 320B Excavator, the sight gauge ison the side of the machine. The access door doesnot need to be opened.


(A) High Temperature Range. (B) Low Temperature Range.

9. Maintain the oil level in the low temperaturerange for a cold machine. Maintain the oil levelin the high temperature range for a machine thatis at a normal operating temperature.


10. Slowly loosen the filler plug in order to relieveany pressure. Remove the filler plug in order toadd oil, if necessary.

11. Clean the filler plug. Install the filler plug.


i00790351

Hydraulic System Oil Level -CheckSMCS Code: 5050-535

NOTICENever remove the fill/vent plug from the hydraulic tankif the oil is hot.

Air can enter the system and cause pump damage.

Note: The hydraulic oil tank is on the right side ofthe machine.

1. Park the machine on level ground.


Excavator

Position the machine with the stick in the vertical position and theimplement on the ground.


Excavator with VA boom

Retract the stick cylinder. Extend the boom cylinders. Place thebucket on the ground.


Hydraulic System Oil Level - Check


Super long demolition

Completely raise the boom and position the tool as close aspossible to the machine.


Material handler

Completely raise the boom and fully retract the stick cylinder.


Coal shovel

Position the bucket on the ground and position the bucket as closeas possible to the machine.

2. Position the machine in a position that is shownin illustration 297, 298, 299, 300, or 301.




(A) High temperature range(B) Low temperature range

320Maintenance SectionHydraulic System Oil Return Filter - Replace

Note: On the 320B Excavator, the sight gauge ison the side of the machine. The access door doesnot need to be opened.

4. For a cold machine, maintain the hydraulic oillevel in the low temperature range. For a machinethat is at normal operating temperature, maintainthe hydraulic oil level in the high temperaturerange.


Note: Refer to Operation and Maintenance Manual,“General Hazard Information” for information aboutcontaining fluid spillage.

Note: Perform Step 5 through Step 7 if the oil levelis low.

5. Slowly loosen the filler plug in order to relieveany pressure. Add oil, if necessary.

6. Check the O-ring seal on the filler plug. Replacethe O-ring seal if the O-ring seal is damaged.

7. Clean the filler plug and install the filler plug.


i00693713

Hydraulic System Oil ReturnFilter - ReplaceSMCS Code: 5068-510-RJ

Remove the Filter Cartridge

The return filter is a cartridge type filter. The returnfilter reduces the amount of foreign material thatenters the hydraulic system when the filter elementis replaced.


Note: If the indicator for a Restricted HydraulicReturn Filter comes on, push the reset switch atthe filter case. Run the machine on level groundfor approximately 10 minutes. If the indicator stillcomes on, inspect the filter and replace the filter, ifnecessary.


1. Loosen the filler plug in order to relieve thehydraulic tank pressure. Tighten the filler plugafter the hydraulic tank pressure is relieved.

Note: The return filter is located behind the fillerplug.


Hydraulic System Oil Return Filter - Replace


(1) Bolts(2) Washers(3) Cover(4) Plug(5) Filter cartridge

2. Remove bolts (1), washers (2), and cover (3).


3. Remove plug (4) in order to release the pressurein filter cartridge (5).


(5) Filter cartridge(6) Filter case(A) Guide

4. Pull up the handle at the top of filter cartridge(5) until the filter cartridge contacts guide (A)on filter case (6).


5. Turn the filter cartridge counterclockwise by 1/2turn in order to align the projection of the filtercartridge with the notch of the filter case. Pullout the filter cartridge.


(7) O-ring.

6. Inspect the cover and O-ring (7). If either part isdamaged, replace the part.

7. Inspect the filter cartridge for debris and fordamage. If necessary, replace the filter cartridge.


Remove the Filter Element


(4) Plug(8) Plate(18) O-ring

1. Make sure that plug (4) is removed. Make surethat all of O-ring (18) is removed from plate (8).


(8) Plate(9) Spiral retaining ring

2. Use a flat screwdriver in order to remove spiralretaining ring (9).


(8) Plate(10) Shell(11) O-ring(12) Filter element

3. Hold the filter cartridge with one hand. Graspthe grip of plate (8) with your other hand. Liftplate (8) in order to separate plate (8) from thefilter cartridge.

4. Remove O-ring (11) from plate (8).

5. Lift filter element (12) from shell (10).

6. Pour the remaining oil into a suitable container.

Clean Shell of Filter Cartridge


(13) Slide plate(14) Pads(15) Screws(19) Port

1. Turn shell (10) upside-down.

2. Remove screws (15).

3. Remove Pads (14) from slide plate (13).

4. Wash the following parts in a clean nonflammablesolvent: plug (4), plate (8), spiral retaining ring(9), shell (10), and Pads (14). Dry the parts.


Hydraulic System Oil Return Filter - Replace

Install the Filter Element

Note: Consult a Caterpillar dealer for the ServiceKit that is needed to install the filter element andthe filter cartridge.

1. Spray oil to the inside of shell (10) in order toprevent rust.

2. Apply grease to a new O-ring (11).

3. Plate (8) will contact the inside of shell (10).Apply grease to this point.

4. Apply grease to O-rings inside ports (19) at thebottom of shell (10).

5. Install new Pads (14). Tighten the screws to atorque of 0.4 N·m (3.5 lb in).

6. Spray oil into the clearance between shell (10)and slide plate (13).


(8) Plate(10) Shell(16) Boss(17) Notch

7. Turn over shell (10). Apply grease to the twoO-rings on new element (12). Install element (12)into shell (10).

8. Move boss (16) in alignment with notch (17).Install plate (8) into shell (10).

9. Install spiral retaining ring (9) into the groove inshell (10).

10. Apply grease to new O-ring (18). Install O-ring(18) on plug (4).

11. Install plug (4) into plate (8).

Install the Filter Cartridge


(B) Port(C) Slide plate

1. Check that ports (B) at the bottom of the filtercase are closed.

Note: If the ports are open, rotate slide plate (C)counterclockwise to the stopper in order to fullyclose the ports. When the ports are fully closed, anyremaining oil in the filter case should be completelyremoved.


(E) Slide plate(D) Port

2. Check that ports (D) of the filter cartridge arefully closed.

Note: The filter cartridge cannot be installed unlessthe ports are fully closed. If the ports are open,rotate slide plate (E) counterclockwise to thestopper in order to fully close the ports.



(F) O-rings

3. Check that O-rings (F) have been installed andthat oil has been applied to O-rings (F).


(1) Bolts

4. Install the filter cartridge into the filter case. Turnthe filter cartridge clockwise by 1/2 turn andpush down the filter cartridge when the filtercartridge contacts guide (A).

5. Install plug (4), cover (3), washers (2), and bolts(1). Tighten bolts (1) to a torque of 29 ± 5 N·m(22 ± 4 lb ft).


6. To turn off the indicator for a Restricted HydraulicReturn Filter, push the reset switch on the filtercase while the engine start switch is in the ONposition.


Hydraulic System Oil Sample - Obtain

i00914176

Hydraulic System Oil Sample- ObtainSMCS Code: 5050-008; 7542-008


Open the access door on the right side of themachine in order to access the sampling valve.


The hydraulic oil sampling valve is located nearthe pilot filter.

Refer to Operation and Maintenance Manual, “S·O·SOil Analysis” for more information on obtaining ahydraulic oil sample.

i00107754

Indicators and Gauges - TestSMCS Code: 7450-081; 7490-081


1. Look for broken lenses on the gauges, brokenindicator lights, broken switches, and otherbroken components in the cab.

2. Start the engine.

3. Look for inoperative gauges.

4. Turn on all machine lights. Check for properoperation.

5. Move the machine forward. Release the travellevers and the travel pedals. The machine shouldstop.

6. Stop the engine.

7. Make any repairs that are required beforeoperating the machine.

326Maintenance SectionOil Filter - Inspect

i00052234

Oil Filter - InspectSMCS Code: 1308-507; 5068-507

Inspect A Used Filter for Debris


The element is shown with debris.

Use a 4C-5084 Filter Cutter to cut the filter elementopen. Spread apart the pleats and inspect theelement for metal and for other debris. An excessiveamount of debris in the filter element can indicatea possible failure.

If metals are found in the filter element, a magnetcan be used to differentiate between ferrous metalsand nonferrous metals.

Ferrous metals can indicate wear on steel parts andon cast iron parts.

Nonferrous metals can indicate wear on thealuminum parts of the engine such as mainbearings, rod bearings, or turbocharger bearings.

Small amounts of debris may be found in the filterelement. This could be caused by friction and bynormal wear. Consult your Caterpillar dealer inorder to arrange for further analysis if an excessiveamount of debris is found.

Using an oil filter element that is not recommendedby Caterpillar can result in severe engine damageto engine bearings, to the crankshaft, and to otherparts. This can result in larger particles in unfilteredoil. The particles could enter the lubricating systemand the particles could cause damage.

i00094899

Quick Coupler - LubricateSMCS Code: 6129-086



Apply lubricant through the four fittings on the quickcoupler. The quick coupler has two fittings on eachside.

Note: Do not lubricate the wedge and the wearplates. Friction is needed in order to hold the wedgein place during backfilling.


Radiator Core - Clean

i00118496

Radiator Core - CleanSMCS Code: 1353-070


(1) Wing bolt(2) Radiator screen

1. Loosen wing bolts (1) on the front of the radiator.Remove radiator screen (2) from the radiator.


2. Check the radiator fins for debris.

3. Remove dust and debris from the radiator finsand from the radiator screen.

Compressed air is preferred, but high pressurewater or steam can be used to remove dustand general debris from the radiator. Clean theradiator according to the condition of the radiator.

See Special Publication, SEBD0518, “Know YourCooling System” for more detailed informationabout cleaning radiator fins.

4. Install radiator screen (2) to the radiator, andtighten wing bolts (1).

i00734932

Refueling Pump Strainer -Clean(If Equipped)SMCS Code: 1295-070-STR


(1) Suction hose(2) Clamp(3) Strainer(4) Bar(5) Strip

1. Open the cover for the storage box on the frontof the machine.

2. Remove suction hose (1) from the holder.

3. Loosen clamp (2) and disconnect strainer (3)from hose (1).

4. Wash strainer (3) in a clean, nonflammablesolvent. Allow the strainer to dry.

5. Mount strainer (3) on suction hose (1).

6. Secure the strainer and the hose with clamp (2).

NOTICETo prevent hose damage, do not coil the hose in a tightradius.

7. When suction hose (1) is stored, wind the suctionhose on bar (4) that is provided in the storagebox. Hold the hose end with strip (5), as shown.

8. Close the cover for the storage box.

328Maintenance SectionSeat Belt - Inspect

i00112638

Seat Belt - InspectSMCS Code: 7327-040


When this machine was shipped from Caterpillar,Inc., this machine was equipped with a seatbelt and with a seat belt installation. At the timeof installation, the seat belt and the seat beltinstallation met “SAE J386 JUN85” for an industrialmachine and “SAE J386 JUN93”. Consult yourCaterpillar dealer for all replacement parts.

Regardless of appearance, replace the seat beltafter every three years of use. A date label fordetermining the age of the seat belt is attached toeach seat belt.

Always check the condition of the seat belt andthe condition of the seat belt mounting hardwarebefore you operate the machine. If damage or wearis found, replace either the seat belt or the seat beltmounting hardware before operating the machine.

i00731002

Seat Belt - ReplaceSMCS Code: 7327-510


Regardless of the appearance, replace the seat beltonce during every three year interval.


Swing Bearing - Lubricate

i00059356

Swing Bearing - LubricateSMCS Code: 7063-086

Wipe the fittings before you lubricate the swingbearings.


The swing bearings are under the base of the boom.


Apply lubricant through the fittings until the lubricantoverflows the bearing seals.

i00093759

Swing Drive Oil - ChangeSMCS Code: 5459-044


The oil drain hose is under the center of the upperstructure.



1. Remove drain hose (2) from holder (1) on theupper frame. Face the end of the hose towardthe container.

2. Use a universal joint with a socket extension toloosen the drain valve in hole (3). Drain the oilinto a suitable container.

Note: Drained fluids should always be disposed ofaccording to local regulations.

330Maintenance SectionSwing Drive Oil Level - Check


3. Tighten the drain valve. Hook drain hose (2) toholder (1). Make sure that the end of the hoseis facing upward.


4. Remove dipstick (4).

5. Add the specified quantity of oil through thedipstick tube. See Operation and MaintenanceManual, “Refill Capacities”.

6. Make sure that the oil level is maintained to the“FULL” mark on dipstick (4).

7. Check the oil that has been drained for metalchips or for metal particles. Consult yourCaterpillar dealer if any metal chips or metalparticles are found.

Note: Drained materials should always be disposedof according to local regulations.

i00093757

Swing Drive Oil Level - CheckSMCS Code: 5459-535-FLV


The dipstick for the swing drive oil is on the swingdrive at the rear base of the boom.


1. Remove the dipstick.


2. Check the dipstick. Maintain the oil level to the“FULL” mark on the dipstick. Add oil through thedipstick tube, if necessary.

3. Insert the dipstick.


Swing Drive Oil Sample - Obtain

i00858525

Swing Drive Oil Sample -ObtainSMCS Code: 5459-008

Refer to Operation and Maintenance Manual,“S·O·S Oil Analysis” for information that pertains toobtaining a sample of the swing drive oil.

Obtain a sample of the swing drive oil through theopening of the dipstick.

i00093750

Swing Gear - LubricateSMCS Code: 7063-086

NOTICEWhen the amount of grease in the compartment be-comes too large, the agitation loss becomes large,thereby accelerating grease deterioration.

Grease deterioration can cause damage to the piniongear of the swing drive and swing internal gear. Notenough grease will result in poor gear lubrication.


Remove the inspection cover that is located nearthe boom base. Inspect the grease.


1. Remove bolts (1) and washers (2). Removecover (3) and gasket (4).

332Maintenance SectionSwing Gear - Lubricate


2. Inspect gasket (4). Replace the gasket if damageis evident.

3. Check the level of the grease. The grease shouldbe evenly distributed on the floor of the pan.

The depth of the grease should be 13 to 19 mm(0.50 to 0.75 inch). The capacity of the pan is21.2 L (5.6 US gal) or 19.3 kg (42.5 lb).

Add grease, as needed. Remove grease, asneeded. Too much grease will result in thedeterioration of the grease because of excessivemovement of the grease. Too little grease willresult in poor lubrication of the swing gear.


4. Check for contamination and for discoloredgrease.

5. If the grease is contaminated or discolored withwater, change the grease. Remove plug (5) inorder to allow the water to drain. When youreinstall plug (5), inspect O-ring seal (6). Replacethe O-ring seal if damage is evident.


6. Raise the boom and turn the upper structure by30 degrees. Lower the bucket to the ground.

7. Repeat Step 3 at every 30 degrees in 12 places.Add grease, as needed.

8. Install gasket (4), cover (3), washers (2), andbolts (1).


Swing Out Hydraulic Oil Cooler - Clean

i00724203

Swing Out Hydraulic Oil Cooler- Clean(If Equipped)SMCS Code: 1374-070

The swing out hydraulic oil cooler makes cleaningthe radiator and the hydraulic oil cooler easier.


(1) Bolts(2) Washers(3) Support

1. Open the engine hood and open the accessdoor on the left side of the machine.

2. Remove bolts (1) and washers (2) (4 positions),and open support (3).


(4) Bolts(5) Washers(6) Hydraulic oil cooler

3. Remove bolts (4) and washers (5) (4 positions),and tilt hydraulic oil cooler (6) outward.


(6) Hydraulic oil cooler(7) Radiator

4. Check for accumulated dust in the fins ofhydraulic oil cooler (6) and radiator (7).

5. Clean the fins of the hydraulic oil cooler andradiator with compressed air, pressurized wateror steam. At the same time, clean the screenthat is attached to the radiator.

6. After cleaning, tilt hydraulic oil cooler (6) andsupport (3) upward. When hydraulic oil cooler (6)and support (3) are back into position, tighten thebolts to a torque of 100 ± 20 N·m (75 ± 15 lb ft).

Note: Refer to Operation and Maintenance Manual,“Radiator Core - Clean” for information on cleaningthe radiator core.

334Maintenance SectionTrack Adjustment - Adjust

i00093743

Track Adjustment - AdjustSMCS Code: 4170-025

Personal injury or death can result from greaseunder pressure.

Grease coming out of the relief valve under pres-sure can penetrate the body causing injury ordeath.

Do not watch the relief valve to see if grease is es-caping. Watch the track or track adjustment cylin-der to see if the track is being loosened.

Loosen the relief valve one turn only.

If track does not loosen, close the relief valve andcontact your Caterpillar dealer.

NOTICEKeeping the track properly adjusted will increase theservice life of the track and drive components.

Note: The track tension must be set according tothe current operating conditions. Keep the track asslack as possible if the soil is heavy.

Measuring Track Tension


1. Place a straight edge on the tracks. The straightedge should be long enough to extend from theidler to the carrier roller.

2. Measure the maximum amount of sag in thetrack. The sag is measured from the highestpoint of the track grouser to the bottom of theedge. A track that is properly adjusted will havea slack of 40 to 55 mm (1 5/8 to 2 1/8 inch ).

Tightening the Track


The track adjuster is located on the track frame.

Wipe the fitting before you add grease.


1. Add grease through valve fitting (1) until thecorrect track tension is reached.

2. Operate the machine back and forth in order toequalize the pressure.

3. Check the amount of sag. Adjust the track, asneeded.


Track Adjustment - Inspect

Loosening the Track


The track adjuster is located on the track frame.


1. Loosen relief valve (2) carefully until the trackbegins to loosen. One turn should be themaximum.

2. Tighten relief valve (2) to 34 N·m (25 lb ft) whenthe desired track tension is reached.

3. Operate the machine back and forth in order toequalize the pressure.

4. Check the amount of sag. Adjust the track, asneeded.

If the correct adjustment cannot be achieved,consult your Caterpillar dealer.

i00091417

Track Adjustment - InspectSMCS Code: 4170-040


Check the track adjustment. Check the track forwear and for excessive dirt buildup.

If the track appears to be too tight or too loose,see Operation and Maintenance Manual, “TrackAdjustment - Adjust”.

336Maintenance SectionTravel Alarm - Test

i00674980

Travel Alarm - TestSMCS Code: 7429-081

You must move the machine in order to test thetravel alarm.

1. Start the engine. Move the hydraulic activationcontrol lever to the UNLOCKED position.

2. Raise the attachments in order to avoid anyobstacles. Make sure that there is adequateoverhead clearance.


3. Use the travel levers or the travel pedals to movethe machine forward. The travel alarm shouldsound.

4. Release the travel levers and the travel pedals inorder to stop the machine.

5. Use the travel levers and the travel pedals tomove the machine backward. The travel alarmshould sound.


6. Push the alarm cancel switch that is located onthe electronic monitor panel. The travel alarmshould shut off.

7. Stop the machine. Lower the attachments. Movethe hydraulic activation control lever to theLOCKED position. Stop the engine.


Undercarriage - Check

i00059401

Undercarriage - CheckSMCS Code: 4150-535


1. Check the carrier rollers, the track rollers, andthe idler wheels for possible leakage.

2. Check the surface of the track, the carrier rollers,the track rollers, the idler wheels, the trackshoes, and the drive sprockets. Look for signs ofwear and loose mounting bolts.

3. Listen for any abnormal noises while you aremoving slowly in an open area.

4. If abnormal wear exists or abnormal noises orleaks are found, consult your Caterpillar dealer.

i00725155

V-Belts - Inspect/Adjust/ReplaceSMCS Code: 1357-025; 1357-040; 1357-510;

1359-025; 1359-040; 1359-510; 1361-025;1361-040; 1361-510; 1405-025; 1405-040;1405-510; 7320-025; 7320-040; 7320-510

Your engine can be equipped with a water pumpbelt, with a fan drive belt and with accessory drivebelts. Your engine can also be equipped with analternator belt. For maximum engine performanceand maximum utilization of your engine, inspectthe belts for wear and for cracking. Check the belttension. Adjust the belt tension in order to minimizebelt slippage. Belt slippage will decrease the beltlife. Belt slippage will also cause poor performanceof the alternator and of any driven equipment.

If new belts are installed, recheck the beltadjustment after 30 minutes of operation. If two beltsor more are required for an application, replace thebelts in belt sets. If only one belt of a matched setis replaced, the new belt will carry more load. Thisis due to the fact that the older belts are stretched.The additional load on the new belt could cause thenew belt to break.

Water Pump Belt


1. To check the belt tension, apply 110 N (25 lb)of force midway between the pulleys. Correctlyadjusted belts will deflect 13 to 19 mm(1/2 to 3/4 inch).

338Maintenance SectionV-Belts - Inspect/Adjust/Replace


Typical example

(1) Mounting bolt(2) Bracket bolt(3) Idler pulley(4) Square hole

2. To adjust the water pump drive belt, loosenmounting bolt (1) and bracket bolt (2).

3. Move idler pulley (3) in order to achieve thecorrect adjustment.

4. If necessary, use a pry bar in square hole (4) inthe mounting bracket.

5. Tighten mounting bolt (1) and bracket bolt (2).

6. If a new belt is installed, run the engine at ratedspeed for thirty minutes. Check the bolt torque.Readjust the belt, if necessary.

Alternator Belt and Fan Belt


1. To check the belt tension, apply 110 N (25 lb)of force midway between the pulleys. Correctlyadjusted belts will deflect 13 to 19 mm(1/2 to 3/4 inch).


(1) Bracket bolt(2) Mounting bolt(3) Hole

2. To adjust the alternator belt and the fan belt,loosen bracket bolt (1) and mounting bolt (2) onthe alternator bracket.

3. To achieve the correct adjustment, move thealternator inward or move the alternator outward,as required.

4. If necessary, use a pry bar in hole (3) in thealternator bracket.

5. Tighten mounting bolt (2) and bracket bolt (1).

Note: The alternator shaft nut must be tightened toa torque of 50 ± 5 N·m (37 ± 4 lb ft).

6. If new belts are installed, check the beltadjustment again after 30 minutes of engineoperation at the rated speed.

Air Conditioner Belt

NOTICEThe V-belt must be tensioned correctly. Failure to ten-sion the belt properly could cause damage to the beltand/or to the air conditioner compressor.


Walk-Around Inspection


1. Apply approximately 98 N (22 lb) force midwaybetween the pulleys.


(1) Nut(2) Bolt(3) Bolt

2. Measure the deflection of the belt. The beltshould deflect 7 to 10 mm (5/16 to 7/16 inch).

3. If the deflection is not correct, loosen nut (1) andtwo bolts (2). Turn bolt (3) in order to adjust thebelt tension.

4. When the adjustment is correct, tighten nut (1)and two bolts (2) to a torque of 100 ± 20 N·m(70 ± 15 lb ft).

5. Check the deflection again.

Note: If a new belt is installed, check the beltadjustment again after 30 minutes of engineoperation at the rated speed.

i00553473

Walk-Around InspectionSMCS Code: 7000

NOTICEAccumulated grease and oil on a machine is a firehazard.

Remove debris with steam cleaning or high pressurewater, at the specified interval in the Maintenance In-terval Schedule or each time any significant quantityof oil is spilled on the machine.

Note: Watch closely for leaks. If you observe a leak,find the source of the leak and correct the leak. Ifyou suspect a leak or you observe a leak, checkthe fluid levels more frequently.


Inspect the hydraulic cylinders for damage orfor excessive wear. Inspect the linkage and thebucket for damage or for excessive wear. Make anynecessary repairs.

Inspect the lights for broken bulbs and for brokenlenses. Replace any broken bulbs and any brokenlenses.

Inspect the engine compartment for any trashbuildup. Remove any trash buildup from the enginecompartment.

Inspect the cooling system for any leaks, for faultyhoses and for any trash buildup. Correct any leaks.Remove any trash from the radiator.

Inspect all of the belts for the engine attachments.Replace any belts that are worn, frayed, or broken.

340Maintenance SectionWalk-Around Inspection


Inspect the hydraulic system for leaks. Inspect thetank, the cylinder rod seals, the hoses, the tubes,the plugs, the connections, and the fittings. Correctany leaks in the hydraulic system.

Inspect the final drives for leaks. Make anynecessary repairs. Check the oil level if leakage isnoticed.

Inspect the swing drive for leaks. Make anynecessary repairs.

Make sure that all covers and guards are securelyattached. Inspect the covers and the guards fordamage.


Inspect the steps, the walkways, and the handholds.Clean the steps, the walkways, and the handholds.Make any necessary repairs.

Inspect the Falling Objects Protective Structurefor damage. If repair is necessary, consult yourCaterpillar dealer. Tighten any loose bolts.

Inspect the operator compartment for trash buildup.Check for trash buildup under the floorplate. Keepthese areas clean.

Adjust the rearview mirrors for the best operatorvision.


Windows - Clean

i00059418

Windows - CleanSMCS Code: 7310-070; 7340-070

Use commercially available window cleaningsolutions in order to clean the windows. Clean theoutside of the windows from the ground, unlesshandholds are available.

Cleaning Methods

Aircraft Windshield Cleaner

Apply the cleaner with a soft cloth. Rub the windowwith moderate pressure until all the dirt is removed.Allow the cleaner to dry. Wipe off the cleaner witha clean soft cloth.

Soap and Water

Use a clean sponge or a soft cloth. Wash thewindows with a mild soap or with a mild detergent.Also use plenty of lukewarm water. Rinse thewindows thoroughly. Dry the windows with a moistchamois or with a moist cellulose sponge.

Stubborn Dirt and Grease

Wash the windows with a good grade of naphtha,or isopropyl alcohol, or of Butyl Cellosolve. Then,wash the windows with soap and with water.

i00762526

Windshield Washer Reservoir -FillSMCS Code: 7306-544-KE

NOTICEWhen operating in freezing temperatures, useCaterpillar or any commercially available nonfreezingwindow washer solvent.


The windshield washer reservoir is located behindthe cab.



Typical example

342Maintenance SectionWindshield Wipers - Inspect/Replace


Demolition configuration

2. Remove the filler cap.

3. Fill the windshield washer reservoir with washerfluid through the filler opening.

4. Install the filler cap.


Note: The windshield washer nozzles can beadjusted so that the washer fluid will be sprayedin the desired direction.

i00058886

Windshield Wipers -Inspect/ReplaceSMCS Code: 7305-040; 7305-510

Inspect the condition of the windshield wiperblades. Replace the windshield wiper blades if thewindshield wiper blades are worn or damaged. Ifthe windshield wiper blades streak the windshield,replace the windshield wiper blades .

320B, 322B and 325B Excavators-Maintenance Intervals

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Transcript of 320B, 322B and 325B Excavators-Maintenance Intervals