307D Excavator-Maintenance Intervals

8/13/2019 307D Excavator-Maintenance Intervals

1/41

SAFETY.CAT.COM

307DEXCAVATOR

Maintenance Intervals

Excerpted from Operation & Maintenance Manual (SEBU8340-01-01)

2007 CaterpillarAll Rights Reserved


2/41

118 SEBU8340-01Maintenance SectionMaintenance Interval Schedule

i02894540

Maintenance Interval ScheduleSMCS Code: 7000

Ensure that all safety information, warnings andinstructions are read and understood before anyoperation or any maintenance procedures areperformed.

The user is responsible for the performance of maintenance, including all adjustments, the use of proper lubricants, uids, lters, and the replacementof components due to normal wear and aging. Failureto adhere to p roper maintenance intervals andprocedures may result in diminished performance of the product and/or accelerated wear of components.

Use mileage, fuel consumption, service hours, or

calendar time, WHICH EVER OCCURS FIRST,in order to d etermine the maintenance intervals.Products that operate in severe operating conditionsmay require more frequent maintenance.

Note: Before each consecutive interval is performed,all maintenance from the previous interval must beperformed .

When Required

Air Condit ioner/Cab Heater Filter (Recirculation) -Inspect/Replace ................................................ 120

Battery - Recycle ................................................ 120

Battery or B attery Cable - Inspect/Replace ........ 121Blade Cutting Edges - Inspect/Replace .............. 122Bucket Linkage - Inspect/Adjust ......................... 127Bucket Tips - Inspect/Replace ............................ 128Cab Air Filter (Fresh Air) - Clean/Replace .......... 130Circuit Breakers - Reset ...................................... 131Engine Air F ilter Element - Clean/Replace ......... 136Fuel System - Prime ........................................... 145Fuses - Replace .................................................. 147Hydraulic Ta nk Screen - Clean ........................... 157Oil Filter - Inspect ................................................ 159Radiator Core - Clean ......................................... 159Track Adjust ment - Adjust ................................... 163Window Washer Reservoir - Fill .......................... 166

Window Wiper - Inspect/Replace ........................ 166Windows - Clea n ................................................. 166

Every 10 Service Hours or Daily for First 100Hours

Blade Linkag e - Lubricate ................................... 123Boom and Stick Linkage - Lubricate ................... 123Bucket Linkage - Lubricate ................................. 128

Every 10 Servi ce Hours or Daily

Cooling System Coolant Level - Check .............. 134Engine Oil Lev el - Check .................................... 140

Fuel System Wat er Separator - Drain ................. 146Fuel Tank Water and Sediment - Drain ............... 147Hydraulic System Oil Level - Check ................... 155Indicators and Gauges - Test .............................. 158Seat Belt - Inspect .............................................. 161Track Adjustment - Inspect ................................. 165

Travel Alarm - T est .............................................. 165Undercarriage - Check ........................................ 166

Every 10 Service Hours or Daily for MachinesUsed in Severe Applications

Blade Linkage - Lubricate ................................... 123Bucket Linkage - Lubricate ................................. 128

Every 50 Service Hours or Weekly

Blade Linkage - Lubricate ................................... 123

Initial 100 Serv ice Hours

Engine Oil and Filter - Change ........................... 141

Every 100 Servi ce Hours or 2 Weeks

Bucket Linkage - Lubricate ................................. 128Swing Gear - Lub ricate ....................................... 162

Every 100 Service Hours or 2 Weeks for Machines Used in Severe Applications

Boom and Stick L inkage - Lubricate ................... 123

Every 100 Service Hours of Continuous

Hammer UseHydraulic Syst em Oil Filter (Pilot) - Replace ....... 153Hydraulic System Oil Filter (Return) - Replace ... 154

Initial 250 Service Hours

Engine Valve Lash - Check ................................. 143Final Drive Oil - Change ..................................... 143Hydraulic Syst em Oil Filter (Pilot) - Replace ....... 153Hydraulic System Oil Filter (Return) - Replace ... 154

Every 250 Service Hours

Cooling System Coolant Sample (Level 1) -Obtain ............................................................... 135

Engine Oil Samp le - Obtain ................................ 141Final Drive Oil Sample - Obtain .......................... 144

Every 250 Service Hours or Monthly

Belts - Inspect/Adjust/Replace ............................ 121Condenser (Refrigerant) - Clean ........................ 131Swing Bearing - L ubricate ................................... 161

Every 250 Service Hours of Partial Hammer Use (50% of Service Hours)

Hydraulic Syste m Oil Filter (Pilot) - Replace ....... 153


3/41

SEBU8340-01 119Maintenance Section

Maintenance Interval Schedule

Hydraulic Syst em Oil Filter (Return) - Replace ... 154

Initial 500 Hours (for New Systems, Re lledSystems, and Converted Systems)

Cooling System Coolant Sample (Level 2) -

Obtain ............................................................... 136

Every 500 Service Hours

Boom, Stick, and Frame - Inspect ...................... 124Hydraulic System Oil Sample - Obtain ............... 157

Every 500 Serv ice Hours or 3 Months

Engine Oil and Filter - Change ........................... 141Fuel System Pr imary Filter (Water Separator)

Element - Replace ............................................ 145Fuel Tank Cap and Strainer - Clean ................... 146Hydraulic Syst em Oil Filter (Pilot) - Replace ....... 153

Hydraulic System Oil Filter (Return) - Replace ... 154

Every 600 Service Hours of ContinuousHammer Use

Hydraulic System Oil - Change ........................... 149

Every 1000 Service Hours or 6 Months

Battery - Clean .................................................... 120Battery Hold-Down - Tighten ............................... 120Boom and Stick L inkage - Lubricate ................... 123Engine Valve Lash - Check ................................. 143Final Drive Oil Level - Check .............................. 144

Every 1000 Serv ice Hours of Partial Hammer Use (50% of Ser vice Hours)

Hydraulic System Oil - Change ........................... 149

Every 2000 Ser vice Hours or 1 Year

Final Drive Oil - Change ..................................... 143Hydraulic Syst em Oil - Change ........................... 149Receiver Dryer (Refrigerant) - Replace .............. 160Swing Gear and Bearing - Inspect ...................... 163

Every Year

Cooling System Coolant Sample (Level 2) -Obtain ............................................................... 136

Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture

Seat Belt - Rep lace ............................................. 161

Every 4000 Service Hours or 2 Years

Hydraulic Sys tem Oil - Change ........................... 149

Every 6000 Serv ice Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .. 133

Every 12 000 Ser vice Hours or 6 Years

Cooling System Coolant (ELC) - Change ........... 131


4/41

120 SEBU8340-01Maintenance Section Air Conditioner/Cab Heater Filter (Recirculation) - Inspect/Replace

i01520787

Air Conditioner/Cab Heater Filter (Recir culation) -Inspect/ReplaceSMCS Code: 105 4-040-A/C; 1054-510-A/C

NOTICE An air recirculation lter element plugged with dust willresult in decreased performance and service life to theair conditioner or cab heater.

To prevent decreased performance, clean the lter el-ement, as required.

g00685718Illustration 211

The recirculation lter is on the lower left side of the

cab.

1. To remove the lter element, slide the elementstraight up.

2. Refer to Operation and Maintenance Manual,General Hazard Information before usingpressure air to clean the air lter element.

3. Clean the lter element with a maximum of 200 kPa (30 psi) pressure air.

4. After you clean the lter element, inspect the lter element. If the lter element is damaged or badlycontaminated, use a new lter element. Make surethat the lter element is dry.

i00934864

Battery - CleanSMCS Code: 1401-070

Clean the battery surface with a clean cloth. Keep theterminals clean and keep the terminals coated withpetroleum jelly. Install the post cover after you coatthe terminal post with petroleum jelly.

i00993589

Battery - Re cycleSMCS Code: 1401-561

Always recycle a battery. Never discard a battery.

Always retu rn used batteries to one of the followinglocations:

A battery su pplier

An authorized battery collection facility

Recycling facility

i00934872

Battery Hold-Down - TightenSMCS Code: 7257

Tighten the hold-downs for the battery in order toprevent the batteries from moving during machineoperation.


5/41


Battery or Battery Cable - Inspect/Replace

i01913589

Battery or Battery Cable -Inspect/Repl aceSMCS Code: 1401-040; 1401-510; 1401-561; 1401;

1402-040; 140 2-510

Personal injury can result from battery fumes or explosion.

Batteries give off ammable fumes that can ex-plode. Electrolyte is an acid and can cause per-sonal injury if it contacts the skin or eyes.

Prevent sparks near the batteries. Sparks couldcause vapors to explode. Do not allow jumper ca-

ble ends to contact each other or the engine. Im-proper jumper cable connections can cause an ex-plosion.

Always wear protective glasses when workingwith batteries.

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 key.

3. Disconnect the negative battery cable at thebattery.

4. Disconnect the positive battery cable at thebattery.

5. Disconnect the battery cables at the batterydisconnect switch. The battery disconnect switchis connected to the machine frame.

6. Make necessary repairs or replace the battery.

7. Connect the battery cable at the battery disconnect

switch.8. Connect the positive battery cable of the battery.

9. Connect the negative battery cable of the battery.

10. Install the key and turn the battery disconnectswitch to the ON position.

i01914481

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

1358-025; 1358-510; 1359-025; 1359-025-BE;

1359-040; 135 9-040-BE; 1359-510-BE; 1359-510;1361-025; 1361-025-BE; 1361-040-BE; 1361-040;1361-510-BE; 1361-510; 1397-025; 1397-040;1397-510; 14 05-025; 1405-025-BE; 1405-036;1405-040-BE; 1405-040; 1405-510; 1405-510-BE;1802-025; 1802-510

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.


Your engine can be equipped with a water pump,with a fan drive, and with an alternator. Your enginecan also be equipped with accessory drive belts.For maximum engine performance and maximumutilization of your engine, inspect the belts for wear and for cr acking. Check the belt tension. Adjust thebelt tension in order to minimize belt slippage. Beltslippage will decrease the belt life. Belt slippage willalso caus e poor performance of the alternator andof any driven equipment.

If new bel ts are installed, recheck the belt adjustmentafter 30 minutes of operation. If two belts or more are

required for an application, replace the belts in beltsets. If only one belt of a pair is replaced, the newbelt will carry more load. This is due to the fact thatthe older belts are stretched. The additional load onthe new belt could cause the new belt to break.


6/41

122 SEBU8340-01Maintenance SectionBlade Cutting Edges - Inspect/Replace

Water Pump Belt, Fan Drive Belt,and Alternato r Belt


(1) Alternator mounting bolt(2) Nut(3) Adjusting bolt

1. Open the engine hood.

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

3. Measure the de ection of the belt. The belt shouldde ect 8 to 11 mm (5/16 to 7/16 inch).

4. If the de ection is not correct, loosen alternator mounting bolt (1) and nut (2). Turn adjusting bolt(3) in order to adjust the belt tension.

5. When the adjustment is correct, tighten bolt (1) toa torque of 21 4 Nm (15 3 lb ft). Tighten nut(2) to a torque of 41 8 Nm (30 6 lb ft).

6. Check the de ection of the belt again.

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

Air Conditioner Belt

g00418344Illustratio n 214

(4) Collar (5) Adjusting bolt

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

2. Measure the de ection of the belt. The belt shouldde ect 7 to 10 mm (1/4 to 3/8 inch).

3. If the de ection is not correct, loosen collar (4).Turn adjusting bolt (5) in order to adjust the belttension.

4. When the adjustment is correct, tighten collar (4)to a torque o f 100 20 Nm (75 15 lb ft).

5. Check the de ection again.

Note: If a new belt is installed, recheck the beltadjustment again after 30 minutes of operation.

6. Close the engine hood.

i01914958

Blade Cutting Edges -Inspect/ReplaceSMCS Code: 6801

Personal injury or death can result from a fallingblade.

Block the blade before changing the cutting edgesand the end bits.

Check the cutting edge of the blade and the end bitsof the blade for wear. If any of the parts have signs of unusual wear or damage, replace the part.


7/41


Blade Linkage - Lubricate


1. Raise the blade and place blocking underneaththe blade.

2. Lower the blade onto the blocking.

3. Remove bolts (1), washers (4) and nuts(5).

4. Remove cutting edge (2) and end bits (3).

5. Clean the surface between the cutting edge andthe end bits.

6. Turn the cutting edge and/or the end bitsupside-down if those edges are not worn.

7. If both sides of the cutting edge and the end bitsare worn, replace the parts with new parts.

8. Install the new parts or the rotated parts with bolts(1). Tighten the bolts to a torque of 270 40 Nm(200 30 lb ft).

9. Raise the blade and remove the blocking.

10. Lower the blade to the ground.

11. After a few hours of operation, tighten bolts (1) tothe torque that is speci ed in Step 8.

i02055581

Blade Linkage - LubricateSMCS Code: 6060-086

Note: Caterpillar recommends the use of 5%molybdenum grease for lubricating the bladelinkage. Refer to Special Publication, SEBU6250,Caterpillar Machine Fluids Recommendations for more information on molybdenum grease.

Wipe all ttings before you apply lubricant.


1. Apply lubricant through tting (1). This tting islocated on the head end of the blade cylinder.

2. Apply lubricant through tting (2). This tting islocated on the rod end of the blade cylinder.


3. Apply lubr icant through tting (3) and through tting (4). These ttings are located on the bar thatsupports the blade.

i02898044

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

Note: Ca terpillar recommends the use of 5% molybdenum grease for lubricating theboom and the stick linkage. Refer to SpecialPublica tion, SEBU6250, Caterpillar Machine FluidsRecommendations for more information on grease.

Apply lu bricant through all ttings after operationunder water.

Wipe al l ttings before you apply lubricant.


8/41

124 SEBU8340-01Maintenance SectionBoom, Stick, and Frame - Inspect


1. Apply lubricant through the tting at the base of the boom.

g01443163

Illustrat ion 219

2. Apply lubricant through the ttings at the base of the boom cy linder.


3. Apply lubricant through tting (1). This tting islocated on the rod end of the boom cylinder.

4. Apply lubricant through tting (2). This tting islocated on the head end of the stick cylinder.


5. Apply lubricant through tting (3). This tting islocated at the junction of the boom and the stick.


6. Apply lubr icant through tting (4). This tting islocated on the rod end of the stick cylinder.

7. Apply lubr icant through tting (5). This tting islocated at the junction of the boom and the stick.

8. Apply lub ricant through tting (6). This tting islocated on the head end of the bucket cylinder.

i02899232

Boom, Stick, and Frame -InspectSMCS Code: 6501; 6502; 6506

All earthmoving equipment is prone to a high degreeof wear. Regular inspections for structural damageare necessary.

The interval between these inspections depends onthe factors that follow.

The age of the machine


9/41


Boom, Stick, and Frame - Inspect

The severity of the application

The loads that have been carried on the machine

The amount of routine servicing that has beencarried out

If the machine has been involved in any kind of accident, the machine must be inspected thoroughly.Inspect the ma chine regardless of the date of the lastinspection.

The machine m ust be clean before the machine isinspected.

Proper repai r of frames and structures requiresspeci c knowledge of the following subjects.

Materials th at have been used to manufacture theframe members

Frame member construction

Repair techniques that are recommended by themanufactur er.

Consult your Caterpillar dealer if repairs arenecessary. Your Caterpillar dealer is quali ed to carryout repairs on your behalf.

All repairs should be carried out by a Caterpillar dealer. If you carry out your own repairs, contactyour Caterpillar dealer for advice about proper repair techniques .

Particular attention should be given to all weldedstructure s. The following items should be thoroughlyinspected for cracks and for defects:

Boom

Stick

Blade

Lifting po ints

Upper frame

Lower frame

NOTICEThe areas highlighted are of particular importance butother area s must not be neglected. The entire struc-ture must be carefully examined.

Boom


Typical example

Check all welded joints and check the mountingpoints for the cylinder.

Stick


Typical example

Check all w elded joints and check the mountingpoints for the cylinder.


10/41

126 SEBU8340-01Maintenance SectionBoom, Stick, and Frame - Inspect

Blade


Typical example

Check all welded joints and check the mountingpoints for the cylinder.

Lifting Points


Typical ex ample

Check the approved lifting points carefully. Checkthe welds. Check that the plates are not excessivelybent. Check that the lifting holes are not deformed.

Upper Frame


Typical example

Check for damaged panels. Speci cally look for anydamage to the cab or damage to the canopy thatmight inval idate the certi cation. The cab or thecanopy is a safety device that must be maintained ingood condition. Check for loose hardware or missinghardware.

Lower Frame


Typical example

Check the weld joints in the lower structure. Checkfor loose hardware or missing hardware. Check the

ring of bolts that secure the swing gear.


11/41


Bucket Linkage - Inspect/Adjust

i01995001

Bucket Linkage -Inspect/Adju stSMCS Code: 6513-025; 6513-040

Unexpected machine movement can cause injuryor death.

To avoid possible machine movement, move thehydraulic lockout control to the locked positionand attach a Special Instruction, SEHS7332, DoNot Operate or similar warning tag to the hy-draulic lockout control.

NOTICEImproperly adjusted bucket clearance could causegalling on the contact surfaces of the bucket andstick, resul ting in excessive noise and/or damagedO-ring seals.


(1) No gap(2) Stick bo ss(3) Bucket c learance(4) Shims(5) Pin(6) Plate(7) Bolts(8) Washers

(9) Location(10) Flange(11) Bucket b oss

The clearance of the bucket linkage on this machinecan be adjust ed 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 and lower the bucket to the ground.

2. Slowly operate the swing control lever until stickboss (2) and 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 the bucket.

3. Move the hydraulic lockout control to the LOCKEDposition. 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 have beenremoved and pin (5) is aligned with the pin hole,install plate (6), washers (8), and bolts (7). Tightenbolts (7) to a torque of 100 20 Nm (70 15 lb ft).

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


12/41

128 SEBU8340-01Maintenance SectionBucket Linkage - Lubricate

i01942324

Bucket Linkage - LubricateSMCS Code: 6513-086

Note: Caterpil lar recommends the use of 5%molybdenum grease for lubricating the bucketlinkage. Refer to Special Publication, SEBU6250,Caterpillar Machine Fluids Recommendations for more information on grease.

Wipe all ttings before you apply lubricant.


Note: Completely ll all cavities of the bucket controllinkage with grease when you initially install a bucket.

1. Apply lubricant through ttings for the linkages (1),

(2), (3), and (4).

2. Apply lubricant through ttings for the bucket (5),(6), and (7).

Note: Service the above ttings after you operatethe bucket under water.

i02420572

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

Personal injury or death can result from bucketfalling.

Block the bucket before changing bucket tips or side cutters.

Bucket Tips


(1) Usable(2) Replace this bucket tip.(3) Overworn

Check the bucket tips for wear. If the bucket tip has ahole, replace the bucket tip.

1. Remove the pin from the bucket tip. The pin canbe removed by one of the following methods.

Use a hammer and a punch from the retainer side of the bucket to drive out the pin.

Use a Pin-Master. Follow Step 1.a through Step1.c for the procedure.

g00590670Illustrat ion 233

(4) Back of Pin-Master (5) Extractor

a. Place the Pin-Master on the bucket tip.

b. Align extr actor (5) with the pin.

c. Strike the Pin-Master at the back of the tool (4)and remov e the pin.

Note: Discard the old pin and the retainer assembly.When you c hange tips, use a new pin and a newretainer assembly. Refer to the appropriate partsmanual for your machine.


13/41


Bucket Tips - Inspect/Replace


(6) Retainer assembly(7) Adapter

2. Clean the adapter and the pin.

3. Fit retainer assembly (6) into the counterbore thatis in the side of adapter (7). Make sure that theface of the retainer assembly with the markingOUTSIDE is visible.


4. Install the new bucket tip onto the adapter.

Note: The bucket tips can be rotated by 180 degreesin order to allow the tip to wear evenly. You may alsomove the t ips from the outside teeth to the insideteeth. Check the tips often. If wear is present on the

tips, rotate the tips. The outside teeth generate themost wear .

5. Drive the pin through the bucket tip. The pin canbe instal led by using one of the following methods:

From the same side of the retainer, drive the pinthrough the bucket tip, the retainer assembly,and the adapter.

Use a Pin -Master. Follow Step 5.a through Step5.e for the procedure.


(8) Pin

a. Insert pin (8) through the bucket tip.

g01209140Illustration 237(4) Back of Pin-Master (9) Pin holder (10) Pin setter

b. Place the Pi n-Master over the bucket tips sothat the pin will t into the counterbore of thepin holder (9).

c. Strike the Pin-Master with a hammer at theback of the tool (4) in order to insert the pin.

d. Slide pin holder (9) away from the pin androtate the tool slightly in order to align pin setter

(10) with t he pin.


14/41

130 SEBU8340-01Maintenance SectionCab Air Filter (Fresh Air) - Clean/Replace


Final assembly of pin into bucket tip.

e. Strike the end of the tool until the pin is fullyinserted.

Side Cutters


Bucket Wit h Side Cutters

(A) Side cutters

1. Remove the mounting bolts and the side cutters.

2. Clean the m ounting surface of the side plate onthe bucket and of the side cutter. Remove anyburrs or protrusions on the mating surfaces.

Note: Some side cutters may be rotated for additionalwear.

3. Install the side cutter.

Note: Cert ain bolts may require thread compound.

4. Hand tighten the bolts.

5. Torque the mounting bolts to the correctspeci cation.

i01996538

Cab Air Filter (Fresh Air) -Clean/Replac eSMCS Code: 7342-070; 7342-510

g00745749Illustrati on 240

(1) Bolt(2) Filter cover

The cab air lter is behind the cab.

1. Loosen bolt ( 1) and open lter cover (2) and air lter (3).


(2) Filter cover (3) Air lter

2. Remove air lter (3) from lter cover (2).

3. Clean the air lter with a maximum of 200 kPa(30 psi) pressure air.

4. After you clean the air lter, inspect the air lter.If the air lter is damaged or badly contaminated,use a new air lter.

5. Install the air lter and the lter cover.

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


15/41


Circuit Breakers - Reset

i02897449

Circuit Breakers - ResetSMCS Code: 1420-529


Open the access door on the left side of the machine.


Main Breaker (1) This circuit breaker is designedto protect the electrical system. The circuit breaker has a capacity of 60 Amp.

Alternator Circuit (2) This circuit breaker isdesigned to protect the alternator. If the batteries areinstalled with reversed polarity, the circuit breaker would prevent the alternator from damaging the

recti

er. The circuit breaker has a capacity of 60 Amp.Circuit Breaker Reset Push in the button in order to 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.

i01509716

Condenser (Refrigerant) -CleanSMCS Code: 1805-070

NOTICEIf excessivel y dirty, clean condenser with a brush. Toprevent damage or bending of the ns, do not use astiff brush.

Repair the ns if found defective.

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


Typical exa mple

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

3. Use clean water to wash off all dust and dirt fromthe conden ser.

4. Close the access door.

i02897573

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

NOTICEDo not chan ge the coolant until you read and under-stand the cooling system information in Special Pub-lication, SEBU6250, Caterpillar Machine Fluids Rec-ommendati ons.

Failure to do so could result in damage to the coolingsystem com ponents.


16/41

132 SEBU8340-01Maintenance SectionCooling System Coolant (ELC) - Change

NOTICEMixing ELC with other products will reduce the effec-tiveness of the coolant.

This could resu lt in damage to cooling system compo-nents.

If Caterpilla r products are not available and com-mercial products must be used, make sure theyhave passed the Caterpillar EC-1 speci cation for pre-mixed or c oncentrate coolants and Caterpillar Extender.

Note: This machine was lled at the factory withCaterpillar Extended Life Coolant.

If the coolant in the machine is changed to ExtendedLife Coolant from another type of coolant, see Special

Publication, SEBU6250, Caterpillar Machine FluidsRecommendations.

1. Unlatch the engine hood and raise the enginehood.


2. Slowly loosen the pressure cap that is on theradiator in order to release pressure from thecooling system.

3. Remove the pressure cap.


Note: Refer to Operation and Maintenance Manual,General Hazard Information for information thatpertains to containing uid spillage.

4. Remove the access cover that is underneath theradiator.

5. Open the drain valve and allow the coolant todrain into a suitable container. The drain valve islocated on the bottom of the radiator.

6. Flush the cooling system. Follow Step 6.a throughStep 6.h in order to properly ush the coolingsystem.

a. Close the drain valve.

b. Fill the cooling system with clean water.

c. Install the pressure cap.

d. Start the engine and run the engine until theengine reaches operating temperature.

e. Stop the engine and allow the engine to cool.

f. Loosen the pressure cap slowly in order torelieve any pressure in the cooling system.

g. Open the drain valve that is underneath theradiator and allow the coolant to drain into a

suitable container.

h. Flush the radiator with clean water until thedraining water is transparent.

7. Close the drain valve and install the access cover underneath the radiator.

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

Special Publication, SEBU6250, Caterpillar Machine Fluids Recommendations


17/41


Cooling System Coolant Extender (ELC) - Add

Operation and M aintenance Manual, Capacities(Re ll)

9. Start the engi ne. Operate the engine withoutthe cooling system pressure cap until the water temperature regulator opens and the coolant level

stabilizes.

10. Maintain the coolant level within 13 mm (.5 inches)of the bottom of the ller pipe.

11. Inspect the gasket of the cooling system pressurecap. If the ga sket is damaged, replace thepressure cap.

12. Install the c ooling system pressure cap.

13. Stop the engine.

14. Open the left access door.

g0054522 6Illustration 247

(1) FULL(2) LOW

15. Check the c oolant reservoir. Maintain the coolantlevel between FULL mark (1) and LOW mark(2).

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

17. Install the reservoir cap.

18. Close the engine hood and latch the engine hood.Close the left access door.

i02586600

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

Personal injury can result from hot coolant, steamand alkali.

At operating temperature, engine coolant is hotand under pressure. The radiator and all linesto heaters or the engine contain hot coolant or steam. Any contact can cause severe burns.

Remove cooling system pressure cap slowly torelieve pressure only when engine is stopped and

cooling system pressure cap is cool enough totouch with your bare hand.

Do not attempt to tighten hose connections whenthe coolant is hot, the hose can come off causingburns.

Cooling System Coolant Additive contains alkali.Avoid contact with skin and eyes.

Use Caterpillar Extended Life Coolant (ELC) whenyou add coolant to the cooling system. See SpecialPublication, SEBU6250, Caterpillar Machine

Fluids Recommendations for all cooling systemrequirements.

Use a Coolant Conditioner Test Kit in order to checkthe concentration of the coolant.

NOTICEMixing ELC with other products will reduce the effec-tiveness of the coolant.

This could result in damage to cooling system compo-nents.

If Caterpillar products are not available and com-

mercial products must be used, make sure theyhave passed the Caterpillar EC-1 speci cation for pre-mixed or concentrate coolants and Caterpillar Extender.

Note: This machine was lled at the factory withCaterpillar Extended Life Coolant.

1. Park the machine on level ground.

2. Stop the engine.


18/41

134 SEBU8340-01Maintenance SectionCooling System Coolant Level - Check

3. Unlatch the eng ine hood and raise the enginehood.


4. Make sure that the cooling system has cooled

down. Loosen the cooling system pressurecap slowly in order to relieve system pressure.Remove the pressure cap.

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

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

Note: Always discard drained uids according tolocal regulations.

6. Add Caterpillar Extended Life Coolant (ELC) tothe cooling system. Refer to the following topicsfor the proper amount of Caterpillar Extender:


Operation and Maintenance Manual, Capacities(Re ll)

7. Inspect the gasket of the cooling system pressurecap. If the gasket is damaged, replace thepressure cap.

8. Install the cooling system pressure cap.

9. Close the engine hood and latch the engine hood.

i02580035

Cooling System Coolant Level- CheckSMCS Code: 1350-040; 1350-535-FLV;

1395-535-FLV

Personal inj ury can result from hot coolant, steamand alkali.

At operating temperature, engine coolant is hotand under pressure. The radiator and all linesto heaters or the engine contain hot coolant or steam. Any co ntact can cause severe burns.

Remove cooling system pressure cap slowly to

relieve pres sure only when engine is stopped andcooling system pressure cap is cool enough totouch with your bare hand.

Do not attempt to tighten hose connections whenthe coolant is hot, the hose can come off causingburns.

Cooling System Coolant Additive contains alkali.Avoid cont act with skin and eyes.

1. Open the left rear access door.

g00545226Illustra tion 249

(1) FULL level(2) LOW level

2. Check the coolant level of the coolant reservoir.Maintain the coolant level between the FULLmark and t he LOW mark. If the coolant reservoir is empty, follow Steps 2.a through 2.i.

a. Unlatch t he engine hood and raise the enginehood.


19/41


Cooling System Coolant Sample (Level 1) - Obtain


b. Slowly loosen the cooling system pressure capin order to relieve system pressure. Removethe pressure cap.


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


Operation and Maintenance Manual,Capacities (Re ll)

d. Start the engine. Operate the engine withoutthe cooling system pressure cap until the water temperature regulator opens and the coolantlevel stabilizes.

e. Maintain the coolant level within 13 mm(0.5 inch) of the bottom of the ller pipe.

f. Inspect the condition of the gasket on thepressure cap. If the gasket is damaged, replacethe pressure cap.

g. Install the cooling system pressure cap.

h. Stop the engine.

i. Close the engine hood and latch the enginehood.


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

4. Install the reservoir cap.

5. Close the left a ccess door.

i02425978

Cooling System Coolant

Sample (Level 1) - ObtainSMCS Code: 139 5-008; 1395-554; 7542

Note: It is not necessary to obtain a CoolantSample (Level 1) if the cooling system is lledwith Cat ELC (Extended Life Coolant). Coolingsystems that are lled with Cat ELC should havea Coolant Sam ple (Level 2) that is obtained atthe recommended interval that is stated in theMaintenance Interval Schedule.

Note: Obtain a Coolant Sample (Level 1) if thecooling system is lled with any other coolant

instead of C at ELC. This includes the followingtypes of coolants.

Commercial long life coolants that meet theCaterpillar Engine Coolant Speci cation -1(Caterpillar EC-1)

Cat Diesel Engine Antifreeze/Coolant (DEAC)

Commercial heavy-duty antifreeze/coolant solution

NOTICE Always use a designated pump for oil sampling, anduse a separa te designated pump for coolant sampling.Using the same pump for both types of samples maycontaminate the samples that are being drawn. Thiscontamina te may cause a false analysis and an incor-rect interpretation that could lead to concerns by bothdealers and customers.

Note: Leve l 1 results may indicate a need for Level 2 Analysis.

NOTICECare must b e taken to ensure that uids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect t he uid with suitable containers before open-ing any compartment or disassembling any compo-nent containing uids.

Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and suppliessuitabl e to collect and contain uids on Caterpillar products.

Dispose of all uids according to local regulations andmandates.


20/41

136 SEBU8340-01Maintenance SectionCooling System Coolant Sample (Level 2) - Obtain

Obtain the samp le of the coolant as close aspossible to the recommended sampling interval.The recommended sampling interval for Level 1Coolant Analy sis is every 250 service hours. Inorder to receive the full effect of SOS analysis,you must establish a consistent trend of data.

In order to es tablish a pertinent history of data,perform consistent samplings that are evenly spaced.Supplies for collecting samples can be obtained fromyour Caterp illar dealer.

Use the following guidelines for proper sampling of the coolant :

Complete the information on the label for thesampling bo ttle before you begin to take thesamples.

Keep the unu sed sampling bottles stored in plasticbags.

Keep the li ds on empty sampling bottles until youare ready to collect the sample.

Place the s ample in the mailing tube immediatelyafter obtaining the sample in order to avoidcontamination.

Never collect samples from expansion bottles.

Never coll ect samples from the drain for a system.


Pressurized System: Hot coolant can cause seri-ous burn s. To open the cooling system ller cap,stop the engine and wait until the cooling systemcomponents are cool. Loosen the cooling systempressur e cap slowly in order to relieve the pres-sure.

1. The mach ine needs to be operated in order tocirculate the coolant. Collect the sample after anormal workday. Collect the samples from one totwo hou rs after the engine has been shut off.

2. Start the engin e momentarily in order to circulatethe coolant again.

3. Shut off the en gine.

4. Carefully remove the radiator cap.

5. Use a vacuum pump and draw the sample. Donot allow dirt or other contaminants to enter the sampling b ottle. Fill the sampling bottlethree-fourths from the top. Do not ll the bottlecompletely.

6. Place the sampling bottle with the completed labelinto the mailing tube.

7. Install the radiator cap.

i02049802

Cooling Sys tem CoolantSample (Level 2) - ObtainSMCS Code: 1395-008; 1395-554; 7542

Reference: Refer to Operation and MaintenanceManual, Co oling System Coolant Sample (Level 1)- Obtain for the guidelines for proper sampling of the coolant.

Obtain the sample of the coolant as close as possibleto the recommended sampling interval. Suppliesfor collec ting samples can be obtained from your Caterpillar dealer.

Submit the sample for Level 2 analysis.

Reference: For additional information about coolantanalysis , refer to Special Publication, SEBU6250,Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer.

i02197700

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

NOTICEService t he air cleaner only with the engine stopped.Engine damage could result.

1. Open the e ngine hood.

2. Start the engine.


21/41


Engine Air Filter Element - Clean/Replace


3. Service the air cleaner if the yellow piston in the lter element indicator moves into the red zone.

4. Stop the engine.


5. Squeeze the outlet tube slightly in order to purgethe dirt fr om the outlet tube.


6. Loosen the three cover latches and remove theair cleaner cover.


7. Remove the primary lter element from the air cleaner housing.

8. Clean the air cleaner cover.

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


10. Cover the opening of the air inlet to the engine.

11. Clean the inside of the air cleaner housing.

12. Clean the primary lter element and inspect the lter element.

Note: Refer to Cleaning Primary Air Filter Elements.

13. Install t he clean primary lter element.


22/41

138 SEBU8340-01Maintenance SectionEngine Air Filter Element - Clean/Replace


14. Install the air cleaner cover. The arrows onthe front must point upward. Close the latchessecurely.


15. Reset the lter indicator by pushing in the resetbutton on top of the indicator.

16. Install a new primary lter element if one of the following problems occurs after starting theengine.

The piston of the air lter indicator moves intothe red zo ne.

The color of the exhaust smoke is black.

Note: The primary lter can be cleaned up to sixtimes. Replace the lter after one year.


Cleaning Primary Air Filter Elements

NOTICECaterpillar recommends certi ed air lter cleaning ser-

vices available at participating Caterpillar dealers. TheCaterpillar cleaning process uses proven proceduresto assure consistent quality and suf cient lter life.

Observe the following guidelines if you attempt toclean the lter element:

Do not tap or strike the lter element in order to re-move dust.

Do not wash the lter element.

Use low pressure compressed air in order to removethe dust from the lter element. Air pressure must not

exceed 207 kPa (30 psi). Direct the air ow up thepleats and down the pleats from the inside of the lter element. Take extreme care in order to avoid damageto the pleats.

Do not use air lters with damaged pleats, gaskets, or seals. Dirt entering the engine will cause damage toengine components.

The primary air lter element can be used up to sixtimes if the element is properly cleaned and if theelement is properly inspected. When the primaryair lter element is cleaned, check for rips or tearsin the lter material. The primary air lter elementshould be replaced at least one time per year. Thisreplacement should be performed regardless of thenumber of cleanings.

NOTICEDo not clean the air lter elements by bumping or tap-ping. This could damage the seals. Do not use ele-ments with damaged pleats, gaskets, or seals. Dam-aged elements will allow dirt to pass through. Enginedamage could result.

Visually inspect the primary air lter elements before

cleaning. Inspect the air

lter elements for damageto the seal, the gaskets, and the outer cover. Discardany damaged air lter elements.

There are two common methods that are used toclean primary air lter elements:

Pressurized air

Vacuum cleaning


23/41


Engine Air Filter Element - Clean/Replace

Pressurized Ai r

Pressurized air can be used to clean primary air lter elements that have not been cleaned more than twotimes. Pressurized air will not remove deposits of carbon and oil. Use ltered, dry air with a maximum

pressure of 2 07 kPa (30 psi).


Note: When the primary air lter elements arecleaned, always begin with the clean side (inside)in order to force dirt particles toward the dirty side(outside).

Aim the hose so that the air ows inside the elementalong the length of the lter in order to help preventdamage to the paper pleats. Do not aim the stream of air directly at the primary air lter element. Dirt couldbe forced further into the pleats.

Vacuum Cleaning

Vacuum cleaning is another method for cleaningprimary air lter elements which require daily cleaningbecause of a dry, dusty environment. Cleaning withpressurized air is recommended prior to vacuumcleaning. Vacuum cleaning will not remove depositsof carbon and oil.

Inspecting the Primary Air Filter Elements


Inspect the clean, dry primary air lter element. Usea 60 watt blue light in a dark room or in a similar facility. Place the blue light in the primary air lter element. Rotate the primary air lter element. Inspectthe primary air lter element for tears and/or holes.Inspect the primary air lter element for light that mayshow through the lter material. If it is necessary inorder to con rm the result, compare the primary air lter element to a new primary air lter element thathas the same part number.

Do not use a primary air lter element that has anytears and/or holes in the lter material. Do not usea primary air lter element with damaged pleats,gaskets or seals. Discard damaged primary air lter elements.

Storing Primary Air Filter Elements

If a primary air lter element that passes inspectionwill not be used, the primary air lter element canbe stored for future use.



24/41

140 SEBU8340-01Maintenance SectionEngine Oil Level - Check

Do not use paint , a waterproof cover, or plastic as aprotective covering for storage. An air ow restrictionmay result. To protect against dirt and damage, wrapthe primary ai r lter elements in Volatile CorrosionInhibited (VCI) paper.

Place the pri mary air lter element into a box for storage. For identi cation, mark the outside of thebox and mark the primary air lter element. Includethe followin g information:

Date of cleaning

Number of cleanings

Store the box in a dry location.

i02897584

Engine Oil Level - CheckSMCS Code: 1000-535

NOTICEDo not over ll the crankcase. Engine damage can re-sult.

Park the machine on level ground. The oil levelshould only be checked after the engine has beenstopped for at least 30 minutes.

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




2. Remove the dipstick and wipe off the oil.

3. Reinsert the dipstick.

4. Remove the dipstick and check the oil level onthe dipstick.


5. Maintain the oil level between the L and the Fmarks on the dipstick.


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


25/41


Engine Oil Sample - Obtain

6. Remove the oil ller plug in order to add oil, if necessary. Refer to Operation and MaintenanceManual, Capacities (Re ll), and Operation andMaintenance M anual, Lubricant Viscosities for more information.

Note: If the o il is deteriorated or badly contaminated,change the oil regardless of the maintenance interval.

7. Clean the oil ller plug.

8. Install the oil ller plug.


i02768461

Engine Oil Sample - ObtainSMCS Code: 1000-008; 1000; 1348-008;

1348-554-SM; 7542-008; 7542-554-OC, SM


Obtain a sample of the engine oil through theopening for the dipstick. Refer to Special Publication,SEBU6250, SOS Oil Analysis for information thatpertains to obtaining a sample of the engine oil.Refer to Special Publication, PEHP6001, How ToTake A Good Oil Sample for more information aboutobtaining a sample of the engine oil.

i02897588

Engine Oil and Filter - ChangeSMCS Code: 1318-510

Note: If the sulfur content in the fuel is greater than1.5% by weight, use an oil that has a TBN of 30 andreduce t he oil change interval by one-half.

Park the machine on a level surface. Stop the engine.

Note: Drain the crankcase while the oil is warm. Thisallows waste particles that are suspended in the oil todrain. As the oil cools, the waste particles will settleto the bottom o f the crankcase. The particles will notbe removed by draining the oil and the particles willrecirculate in the engine lubrication system with the

new oil.


1. Open the crankcase access cover that is under the rear of the machine. Remove the bolts thatsecure the access cover.



2. Remove t he crankcase drain plug. Allow the oil todrain into a suitable container.

Note: Discard any drained uids according to localregulations.

3. Clean th e drain plug and install the drain plug.

4. Install the crankcase access cover.


26/41

142 SEBU8340-01Maintenance SectionEngine Oil and Filter - Change




6. Remove the oil lter. Refer to Operation andMaintenan ce Manual, Oil Filter - Inspect. Discardthe used oil lter properly.

7. Clean the lter housing base. Make sure that all of the former lter gasket is removed.


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

9. Install the new lter by hand. When the gasketcontacts the lter base, turn the lter by 270degrees more. This will tighten the lter suf ciently.


10. Remove the oil ller plug.

11. Fill the crankcase with new oil. Refer to Operationand Maintenance Manual, Capacities (Re ll) andOperation and Maintenance Manual, LubricantViscosities.

NOTICEDo not under ll or over ll engine crankcase with oil.Either condition can cause engine damage.

12. Clean the oil ller plug and install the oil ller plug.

13. Start the engine and allow the oil to warm.

14. Check the engine for leaks.

15. Stop the engine.

16. Wait for thirty minutes in order to allow the oil todrain back into the crankcase.


17. Remove the dipstick and wipe off the oil.

18. Reinsert the dipstick.


27/41


Engine Valve Lash - Check

19. Remove the dips tick and check the oil level onthe dipstick.


20. Maintain the oil between the L and F marks

on the dipstick.


i01747875

Engine Valve Lash - CheckSMCS Code: 1102-082; 1102-535; 1102; 1105-025;

1105-535; 1121-535; 1209-082; 1209-535; 1209;7527

Refer to Engine Systems Operation/Testing and Adjusting in order to perform the complete procedurefor the valve lash adjustment.

i0199956 5

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


(1) Oil drain plug(2) Oil level plug(3) Oil ller plug

1. Position one nal drive so that oil drain plug (1) isat the bottom.


2. Remove oil drain plug (1), level plug (2) and ller plug (3). Allow the oil to drain into a suitablecontainer.

3. Clean the plugs and inspect the plugs. Replace aworn plug or a damaged plug.

4. Apply pipe sealant to oil drain plug (1), level plug(2) and ller plug (3).

5. Install drain plug (1).

6. Add oil through the opening of ller plug (3).

7. Fill the nal drive to the bottom of the opening for level plug (2). Refer to Operation and MaintenanceManual, Lubricant Viscosities and Operation andMaintenanc e Manual, Capacities (Re ll).

8. Install level plug (2) and ller plug (3).

9. Perform Step 1 to Step 8 on the other nal drive.Do not combine the oil for the nal drives in thesame contai ner. The oil from the nal drives mustbe kept separate for the check that is performedin Step 15.

10. Completely remove any oil that has spilled.

11. Start the e ngine and allow the nal drives tooperate through several cycles.

12. Stop the en gine.

13. Check the oil level.

14. Maintain the oil level to the bottom of the openingfor level plug (2).

15. Check the drained oil for metal chips or for particles. If there are any chips or particles, consultyour Cater pillar dealer.

Note: Dispose of drained uids according to localregulati ons.


28/41

144 SEBU8340-01Maintenance SectionFinal Drive Oil Level - Check

i01407687

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



1. Position one nal drive so that oil drain plug (1) isat the bottom.


2. Remove oil level plug (2).

3. Check the oil level. The oil should be near thebottom of the opening of level plug (2).

4. Add oil through the opening of ller plug (3), if necessary.

Note: Over lling the nal drive will cause the seals onthe travel motor to allow hydraulic oil or water to enter the nal drive. This may contaminate the nal drive.

5. Clean oil level plug (2) and ller plug (3).

6. Apply pipe sealant to oil level plug (2) and ller plug (3).

7. Install oil level plug (2).

8. Install oil ller plug (3).

9. Repeat the procedure for the other nal drive.

i01996577

Final Drive Oil Sample - ObtainSMCS Code: 4011-008; 4050-008; 4050-SM;

7542-008



1. Position the nal drive so that oil drain plug (1) isat the bottom.

2. Remove oil level plug (2).

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

4. Install oil level plug (2).

Refer to Special Publication, SEBU6250, SOS Oil Analysis for more information on obtaining a sampleof the nal drive oil. For additional information abouttaking an oil sample, refer to Special Publication,PEHP6001, How To Take A Good Oil Sample.


29/41

SEBU8340-01 145Maintenance SectionFuel System - Prime

i02166043

Fuel System - PrimeSMCS Code: 1250-548

NOTICECare must be taken to ensure that uids are containedduring perfor mance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the uid with suitable containers before open-ing any compar tment or disassembling any compo-nent containing uids.

Refer to Speci al Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and suppliessuitable to collect and contain uids on Caterpillar products.

Dispose of all uids according to local regulations andmandates.


1. Operate the fuel priming pump plunger in order to ll the new lter element with fuel. Continue topump until a resistance is felt. This resistance will

indicate that the lter element is full of fuel.

2. Start the engine. If the engine will not start, further priming is necessary. If the engine starts but theengine continues to mis re, further priming isnecessary. If the engine starts but the enginecontinues to emit smoke, further priming isnecessary.

3. If the engine starts but the engine runs rough,continue to run the engine at low idle. Continueto run the engine at low idle until the engine runssmoothly.

i02897671

Fuel System Primary Filter (Water Separa tor) Element -ReplaceSMCS Code: 126 3-510-FQ

Personal injury or death may result from failure toadhere to the following procedures.

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

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 lters.

NOTICEDo not ll the fuel lters with fuel before installing thefuel lters. The fuel will not be ltered and could becontaminate d. Contaminated fuel will cause acceler-ated wear to fuel system parts.

1. Open the acce ss door on the right side of themachine.

g01442846Illustration 279(1) Locking Ring(2) Water Separator Bowl(3) Drain Hose

2. Open the drain on the water separator bowl (1). Allow the water and fuel to drain into a suitablecontainer.

3. Support the water separator element and rotatethe locking ring (2) counterclockwise. Remove thelocking ring.


30/41

146 SEBU8340-01Maintenance SectionFuel System Water Separator - Drain

4. Remove the wate r separator bowl from the bottomof the fuel lter/water separator element.

Note: The wate r separator bowl is reusable. Do notdiscard the water separator bowl.

5. Inspect the O- ring seal of the water separator bowlfor damage. Replace the O-ring seal, if necessary.

6. Lubricate the O-ring seal with clean diesel fuel or lubricate the O-ring seal with motor oil. Place theseal in the water separator bowl.

7. Spin the water separator bowl onto the new lter element by hand until the fuel lter/water separator is snug. Do not use tools to tighten thefuel lter/water separator element to the bowl.

8. Clean the lter mounting base.

9. Install the new element. Rotate the locking ringclockwise i n order to fasten the lter to themounting base.

10. Prime the fu el system. See Operation andMaintenance Manual, Fuel System - Prime for instructions.


i02897701

Fuel System Water Separator

- DrainSMCS Code: 1263

1. Open the ac cess door on the right side of themachine.


2. Turn the drain valve counterclockwise in order toopen the drain valve.

Note: Refer to O peration and Maintenance Manual,General Hazard Information for information oncontaining uid spillage.

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

Note: Dispose of drained uids according to localregulations.

4. Close the drain valve.

5. Close the acc ess door.

i01407838

Fuel Tank Cap and Strainer -Clean

SMCS Code: 12 73-070-STR


1. Remove the fuel cap and the fuel ll screen.


2. Inspect the cap. Replace the cap if the cap isdamaged.


31/41


Fuel Tank Water and Sediment - Drain


3. Wash the fuel ll screen in a clean, non ammablesolvent and dry the fuel ll screen.

4. Install the fuel ll screen.

5. Put a light coating of fuel oil on the cap gasket.

6. Install the fuel cap.

i02897718

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

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


Note: Refer to Operation and Maintenance Manual,General Hazard Information for information oncontain ing uid spillage.

2. Open the drain valve and allow the water and thesedimen t to drain into a suitable container.

Note: Dispose of drained uids according to localregulat ions.

3. Close the drain valve.


Fill the Fuel Tank

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

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

i02897743

Fuses - ReplaceSMCS Code: 1417-510

The fuse panel is located on the inside of the cabbehind the seat.

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.

NOTICE Always replace fuses with the same type and capacityfuse that was removed. Otherwise, electrical damagecould resul t.

NOTICEIf it is necessary to replace fuses frequently, an elec-trical problem may exist.

Contact your Caterpillar dealer.

To replace a fuse, use the puller that is stored inthe fuse panel. Two fuses of 5 Amperes, six fusesof 10 Amperes, and three fuses of 15 Amperes arecontained in the fuse panel as spare fuses.

The following list identi es the circuits that are

protected by each fuse. The amperage for each fuseis included with each circuit.


32/41

148 SEBU8340-01Maintenance SectionFuses - Replace


(1) Spare 5 Amp

(2) Spare 10 Amp

(3) Spare 15 Amp

(4) Spare 20 Amp

(5) Spare 25 Amp

(6) Spare 30 Amp

(7) Auxiliary Circuit 10 Amp

(8) Product Link 5 Amp

(9) Horn 10 Amp

(10) Engine Start Switch 10 Amp

(11) Interior Light 10 Amp

(12) Machine Lockout Control 10 Amp

(13) Blower Fan 20 Amp

(14) Machine Co ntrol Module 25 Amp

(15) Electric Fuel Pump 15 Amp

(16) Starter Relay 30 Amp

(17) Fuel Shut off Solenoid 5 Amp

(18) Electrical Relay 5 Amp

(19) Electrical Solenoid 10 Amp

(20) Radio and Display 5 Amp

(21) Automatic Engine Speed Control 5 Amp

(22) Bucket System Failure or Malfunction 5 Amp

(23) Alarm 5 Amp

(24) Alarm 5 Amp

(25) Machine Speed 5 Amp

(26) Seat Heater 10 Amp

(27) Coupler W edge 10 Amp

(28) 12 Volt 5 Amp Converter 10 Amp

(29)Air Suspension 10 Amp

(30) Window Wi per and Window Washer Relay 5 Amp

(31) Engine S peed Control 10 Amp

(32) Boom Light 15 Amp

(33)Cigar Lighter 10 Amp

(34) Cab Ligh t 15 Amp

(35) Heater and Air Conditioner 20 Amp


33/41


Hydraulic System Oil - Change

Relays


(36) Neutral Start Relay

(37) Horn Relay

(38) Lights Relay

(39) Travel Alarm Relay

(40) Travel Alarm Relay

(41) Lights Relay

(42) Engine Control Module Relay

i02897886

Hydraulic System Oil - ChangeSMCS Code: 5056-044

4000 Hour Oil Change Interval A 4000 hour mai ntenance interval for a hydraulicoil change is available. The extended intervalrequires SOS monitoring of the hydraulic oil. Theinterval for S OS monitoring is every 500 hours. Themaintenance interval for the hydraulic oil lter is notchanged. If SOS monitoring is not performed, the2000 hour mai ntenance interval must be used.

Machines with hammers are not included in the4000 hour mai ntenance interval. Machines withhammers must use the intervals that are listed inthe Maintenance Interval Schedule. Machines thatare used in s evere conditions are not included in the4000 hour maintenance interval. Machines that areused in severe conditions must use the interval in theMaintenan ce Interval Schedule.

Lubricants

Approved hydraulic oil must be used to obtain the4000 hour hydraulic oil change. Refer to the list thatfollows fo r approved oils.

Caterpillar Hydraulic Oils

Cat HYDO TDTO

TDTO (TMS)

DEO

Biodegrad able Hydraulic Oil (HEES)

MTO

Commercial Oils

Heavy-dut y diesel engine oils with a minimumzinc content of 900 ppm can be used. Acceptablecommercial oils are identi ed by the AmericanPetroleu m Institute trademark (API) . Refer to the listthat follows for acceptable types of hydraulic oils.

CF

CF-4

CG-4

CH-4


34/41

150 SEBU8340-01Maintenance SectionHydraulic System Oil - Change

Note: Industri al hydraulic oils are not recommendedfor the hydraulic systems of Caterpillar machines.Industrial hydraulic oils are more likely to allowcorrosion and Industrial hydraulic oils are more likelyto allow excessive wear.

Changing the Hydraulic Oil


1. Park the machine on level ground. Lower the worktool to the ground with the stick in the verticalposition.


(1) Bolt(2) Washer (3) Cover

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


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 pressure cap.

4. Relieve the internal pressure from the hydraulictank by loosening the pressure cap. After thepressure is relieved, remove the pressure cap.


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.


35/41


Hydraulic System Oil - Change



7. Remove the oil drain valve plug.


8. Install a s wivel 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 wear or damage is evident.

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


12. Open the access door that is located on the rightside of the machine.

13. Clean the pump, the hydraulic lines and thehydraulic tank.


(4) Bolts(5) Washers(6) Cover (7) Spring

(8) Screen

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

Note: Dispose of used lters and used uidsaccording to local regulations.

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

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

Note: Refer to Operation and Maintenance, GeneralHazard Information for information on containinguid spillage.


36/41

152 SEBU8340-01Maintenance SectionHydraulic System Oil - Change

16. Wash the screen in a clean non ammable solvent. Allow the screen to dry. Inspect the screen.Replace the screen, if the screen is damaged.


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

17. Remove O-ring seals (9) from the old screen.

18. Inspect O-ring seals (9) and (10). Replace theO-ring seals if wear or damage is evident.

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

20. 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.

21. Fill the hydraulic system oil tank. Refer toOperation and Maintenance Manual, Capacities(Re ll).


22. Inspect the pressure cap. Clean the pressure cap.Replace t he pressure cap if damage is evident.

23. Install the pressure cap.


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

24. When the hydraulic oil has been replaced, the air must be removed from the hydraulic oil system.Use the following procedure to remove the air from the hydraulic oil system.

a. Stop the engine.

b. Slowly loosen the pressure cap on the top of the hydraulic tank.

c. Slowly loosen the vent plug on the top of thehydraulic pump.

d. Leave the plug loose until hydraulic oil starts toows out of the plug. This indicates that the air has been released from the hydraulic system.

e. Install the vent plug to a torque of 19 to 23 Nm(14 to 17 lb ft).

f. If necessary, add hydraulic oil through theopening for the pressure cap.

g. Tighten the pressure cap securely.

25. Install the access cover that is located on the rightside of the machine.

26. Install the hydraulic tank access cover that islocated under the upper structure.

27. Install the access cover that is located on the topof the hydraulic tank.

28. Start the engine. Operate the engine at idlingspeed for ve minutes.


37/41


Hydraulic System Oil Filter (Pilot) - Replace


29. Operate the joysticks in order to circulate thehydraulic oil. Lower the work tool to the ground sothat the stick is vertical to the ground. Stop the

engine.


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

30. Maintain the oil level between the marks on thesight gauge in the appropriate temperature range.

i02897904

Hydraulic System Oil Filter (Pilot) - Repl aceSMCS Code: 5068-510; 5068-510-PS; 5092-510

g01442431Illustrati on 300

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


2. Clean the area around the lter in order to keepdirt out of the lter base.

3. Remove the used pilot lter element from the lter base.

Note: Used lters should always be disposed of according to local regulations.

4. Clean the lter base.


38/41

154 SEBU8340-01Maintenance SectionHydraulic System Oil Filter (Return) - Replace


5. Coat the seal of the new pilot lter with cleanhydraulic oil. Install the new pilot lter in the lter base. Tighten the pilot lter hand tight.

6. Drive the machine slowly for 10 minutes to 15minutes. Move each cylinder evenly throughseveral cycles.


7. Return the machine to the service position. Checkthe machi ne for oil leaks.

8. Stop the engine.



9. Maintain the oil level in the low temperature range

for a cold machine. Maintain the oil level in thehigh temperature range for a machine that is at anormal operating temperature.

10. Slowly loosen the pressure cap in order to relieveany pressure. Remove the pressure cap in order to add oil, if necessary.

11. Clean the pressure cap and install the pressurecap.


i02897912

Hydraulic System Oil Filter (Return) - ReplaceSMCS Code: 5068-510-RJ


1. Park the m achine on level ground. Lower thebucket to the ground with the stick in a verticalposition.


39/41


Hydraulic System Oil Level - Check


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

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


3. Clean the area thoroughly in order to keep dirt outof the retu rn lter cover and the pressure cap.

4. Relieve the internal pressure from the hydraulictank by loo sening the pressure cap. After thepressure is relieved, remove the pressure cap.


(4) Bolts(5) Washers(6) Cover (7) Spring(8) Valve(9) Element(10) O-ring seal

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

6. Remove spring (7), valve (8) and element (9) from

the tank.7. Inspect O-ring seal (10). Replace the O-ring seal

if wear or damage is evident.

8. Install a new element (9) into the tank. Install valve(8) and spring (7) onto the tank also.

9. Clean the pressure cap and install the pressurecap.

10. Install access cover (3) with bolts (1) and washers(2).

i02897914

Hydraulic System Oil Level -CheckSMCS Code: 5050-535

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

Air can enter the system and cause pump damage.


40/41

156 SEBU8340-01Maintenance SectionHydraulic System Oil Level - Check


1. Park the machine on level ground. Lower the worktool to the ground with the stick in the verticalposition.



2. For a cold machine, maintain the hydraulic oil levelin the low temperature range. For a machine thatis at normal operating temperature, maintain thehydraulic oil level in the high temperature range.

3. Perform Step 3.a through Step 3.f if the oil levelis low.

Note: Refer to Operation and Maintenance Manual,

General Hazard Information for information onContaining Fluid Spillage.


a. Remove bolts (1), washers (2) and accesscover (3) from the top of the hydraulic tank.


b. Relieve th e internal pressure from the hydraulictank by loosening the pressure cap. After thepressure is relieved, remove the pressure cap.

c. Add hydraulic oil to the tank through theopening for the pressure cap.


d. Inspect the pressure cap. Replace the cap if damage is evident.


41/41


Hydraulic System Oil Sample - Obtain

e. Clean the press ure cap and install the cap.

f. Install access cover (3), washers (2) and bolts(1).

i01995757

Hydraulic System Oil Sample- ObtainSMCS Code: 5050-008-OC; 5095-008; 5095-SM;

7542-008; 7542


The hydraulic oil sampling valve is near the pilot lter.Obtain a sample of the hydraulic oil from the hydraulicoil sampling valve that is located on the hydraulicoil lter housing. Refer to Special Publication,

SEBU6250, SOS Oil Analysis for information thatpertains to obtaining a sample of the hydraulic oil.Refer to Special Publication, PEHP6001, How ToTake A Good Oil Sample for more information aboutobtaining a sample of the hydraulic oil.

i028979 19

Hydraulic Tank Screen - CleanSMCS Code: 5056-070-Z3

1. Park the machin e on level ground. Lower the worktool 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.


3. Clean the area thoroughly in order to keep dirt outof the scre en cover. Clean the area thoroughly inorder to keep dirt out of the pressure cap.

4. Relieve th e internal pressure from the hydraulictank by loosening the pressure cap. After thepressure is relieved, remove the pressure cap.

Documents

307D Excavator-Maintenance Intervals