CAT M316D Maintenance

8/17/2019 CAT M316D Maintenance

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®© 2010 CaterpillarAll Rights Reserved

MAINTENANCE INTERVALSOperation and MaintenanceManual Excerpt


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SEBU8017-05

December 2009

Operation andMaintenance

ManualM313D, M315D, M316D, M318D,M322D, M318D MH and M322D MHExcavators

W6A1-4999 (Machine)W3H1-4999 (Machine)W5M1-4999 (Machine)W8P1-4999 (Machine)W8R1-4999 (Machine)W2S1-4999 (Machine)W2T1-4999 (Machine)

SAFETY.CAT.COM


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312 SEBU8017-05Maintenance SectionMaintenance Interval Schedule

i03788193

Maintenance Interval Schedule

SMCS 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, fluids, fi lters, and the replacementof components due to normal wear and aging. Failureto adhere to proper 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 determine 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.

The normal oil change interval for the engine isEvery 500 Service Hours or 3 Months. If the engineis operated under severe conditions, change theoil after Every 250 Service Hours or 1 Month.Severe conditions include the following factors: high

temperatures, continuous high loads, and extremelydusty conditions .

Refer to the results of the S·O·S oil analysis in order to determine if the oil change interval should bedecreased to 250 hours. Consult your Caterpillar Dealer for detailed information regarding the optimumoil change interval.

Refer to Operation and Maintenance Manual,“Hydraulic System Oil - Change” for information ona 4000 hour maintenance interval for the hydraulicsystem.

When Required

Air Conditioner/Cab Heater Filter (Recirculation) -Inspect/Replace ................................................ 314

Air Precleaner - Clean ........................................ 314 Air Precleaner - Clean ........................................ 315Battery - Recycle ................................................ 320Battery or Battery Cable - Inspect/Replace ........ 320Bucket Tips - Inspect/Replace ............................ 327Bucket Tips - Inspect/Replace ............................ 331Cab Air Filter (Fresh Air) - Clean/Replace .......... 334Camera - Clean/Adjust ....................................... 335Cooling System Coolant Extender (ELC) - Add .. 340

Engine Air Filter Primary Element - Clean/Replace ............................................................. 343

Engine Air Filter Secondary Element - Replace .. 345Fan Guard - Clean/Inspect ................................. 350Fuel System - Prime ........................................... 352Fuses - Replace .................................................. 356

Hydraulic System Oil Filter (Return) - Replace ... 362Oil Filter - Inspect ................................................ 366Radiator Core - Clean ......................................... 366Refueling Pump Strainer - Clean ........................ 368Stabilizer - Clean/Inspect .................................... 370Window Washer Reservoir - Fill .......................... 375Window Wiper - Inspect/Replace ........................ 375Windows - Clean ................................................. 375

Every 10 Service Hours or Daily for First 100Hours

Boom and Stick Linkage - Lubricate ................... 323Boom, Stick and Bucket Linkage - Lubricate ...... 324

Every 10 Service Hours or Daily

Cooling System Coolant Level - Check .............. 341Engine Oil Level - Check .................................... 346Hydraulic System Oil Level - Check ................... 364Seat Belt - Inspect .............................................. 369

Every 10 Service Hours or Daily for MachinesUsed in Severe Applications

Boom and Stick Linkage - Lubricate ................... 323Boom, Stick and Bucket Linkage - Lubricate ...... 324

Initial 50 Service Hours

Wheel Nut Torque - Check .................................. 374

Every 50 Service Hours or Weekly

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

Ever y 100 Service Hours or 2 Weeks

Axle Oscillation Bearings - Lubricate .................. 319Blade Linkage - Lubricate ................................... 322Stabilizer Bearings - Lubricate ............................ 370Swing Bearing - Lubricate ................................... 370

Every 250 Service Hours

Engine Oil Sample - Obtain ................................ 347

Every 250 Service Hours or Monthly

Axle Bearings (Front) - Lubricate ........................ 316 Axle Oil Level (Front) - Check ............................. 318 Axle Oil Level (Rear) - Check ............................. 318


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SEBU8017-05 313Maintenance Section

Maintenance Interval Schedule

Belts - Inspect/Adjust/Replace ............................ 321Braking System - Test ......................................... 326Condenser (Refrigerant) - Clean ........................ 336Final Drive Oil Level - Check .............................. 351Transmission Oil Level - Check .......................... 374Wheel Nut Torque - Check .................................. 374

Initial 500 Hours (for New Systems, RefilledSystems, and Converted Systems)

Cooling System Coolant Sample (Level 2) -Obtain ............................................................... 343

Engine Valve Lash - Check ................................. 350


Axle Oil Sample - Obtain .................................... 319 Axle Oil Sample - Obtain .................................... 319Cooling System Coolant Sample (Level 1) -

Obtain ............................................................... 342

Engine Crankcase Breather Filter - Replace ...... 345Engine Oil and Filter - Change ........................... 348Final Drive Oil Sample - Obtain .......................... 352Fuel System Filter - Replace .............................. 352Fuel System Water Separator Element -

Replace ............................................................. 354Hydraulic System Oil Sample - Obtain ............... 365Transmission Oil Sample - Obtain ...................... 374

Every 500 Service Hours or 3 Months

Cab Riser (Adjustable) Linkage - Lubricate ........ 334Drive Shaft - Lubricate ........................................ 343Fuel Tank Cap and Strainer - Clean ................... 355

Hydraulic Generator Brushes and Commutator -Inspect .............................................................. 359


Engine Valve Lash - Check ................................. 350

Every 1000 Service Hours or 6 Months

Battery - Clean .................................................... 320Battery Hold-Down - Tighten ............................... 320Over head Guard - Inspect .................................. 366

Every 1000 Service Hours of Partial Hammer

Use (50% of Service Hours)Hydraulic System Oil - Change ........................... 359

Every 1500 Service Hours or 1 Year (Greater than 25% Travel)

Axle Oil (Front) - Change .................................... 317 Axle Oil (Rear) - Change .................................... 317Final Drive Oil - Change ..................................... 351Tr ansmission Oil - Change ................................. 373

Every 2000 Service Hours or 1 Year

Cooling System Coolant Sample (Level 2) -Obtain ............................................................... 343

Engine Air Filter Primary Element - Clean/Replace ............................................................. 343

Engine Air Filter Secondary Element - Replace .. 345Hydraulic System Oil - Change ........................... 359Hydraulic System Oil Filter (Return) - Replace ... 363Hydraulic System Oil Filter - Replace ................. 364Swing Gear - Lubricate ....................................... 371

Every 2000 Service Hours or 1 Year (Lessthan 25% Travel)

Axle Oil (Front) - Change .................................... 317 Axle Oil (Rear) - Change .................................... 317Final Drive Oil - Change ..................................... 351Transmission Oil - Change ................................. 373

Every 3000 Service Hours or 2 YearsHydraulic System Oil - Change ........................... 359

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

Seat Belt - Replace ............................................. 369

Every 6000 Service Hours or 3 Years

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

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ........... 337


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314 SEBU8017-05Maintenance Section

Air Conditioner/Cab Heater Filter (Recirculation) - Inspect/Replace

i03769490

Air Conditioner/Cab Heater Filter (Recir culation) -Inspect/Replace

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

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

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

g01215821Illustration 289

The air fi

lter is located in the cab behind theoperator's seat.

1. Pull up on the air fi lter in order to remove the air filter.

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

3. After you clean the fi lter, inspect the filter. If theair filter is damaged or badly contaminated, usea new air filter.

4. Install the air filter.

i03715681

Air Precleaner - Clean

SMCS Code: 1055-070-DJ

NOTICEService the engine air precleaner only with the enginestopped. Engine damage could result.

1. Open the right front access door.

2. Remove the scavenge hose that is attached tothe box for the air filter.


(1) scavenge hose

3. Remove the three bolts below the batterycompartment.


(2) Bolt

4. Pull the box for the air filter slightly out of thebattery compartment.

5. Remove the screw in order to disassemble theCyclone precleaner block.

6. Remove the cover from the precleaner block.


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Air Precleaner - Clean


7. Blow dust and debris out of the Cyclone precleaner block.

8. Assemble the Cyclone precleaner block andtighten the screw.

9. Install the box for the air filter into the batterycompartment.

10. Install the three bolts below the batterycompartment.

11. Attach the scavenge hose to the box for the air filter.

12. Close the right front access door.

i03731370

Air Precleaner - Clean(If Equipped)

SMCS Code: 1055-070-DJ

S/N: W6A1-4999

S/N: W8P1-4999

S/N: W8R1-4999

S/N: W2S1-4999

S/N: W2T1-4999

NOTICEService the engine air precleaner only with the enginestopped. Engine damage could result.

Note: The following procedure is necessary only inextreme conditions.


1. Squeeze the dust valves in order to remove anydust. Use a suitable container in order to catchthe dust.


2. Loosen the clamps at the bottom of the engineair precleaners.

3. Remove the engine air precleaners and inspectthe opening for dirt and debris. Clean the tubes, if necessary.

4. Clean the engine air precleaner with pressure air or wash the engine air precleaner in clean warmwater.


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Automatic Lubrication Grease Tank - Fill

5. Install the engine air precleaner. Tighten theclamps.

i03716048

Automatic Lubrication GreaseTank - Fill(If Equipped)

SMCS Code: 7540-544; 7540-544-TNK

Caterpillar recommends the use of NLGI No. 2grease that meets the requirements for both coldweather conditions and hot weather conditions.

Note: NLGI No. 0 or No. 1 grease with low viscosityshould be used only in cold weather conditions.If used in conditions other than cold weather, the

grease consumption will increase.

Note: Any foreign materials in the grease tank couldrestrict the lubrication lines or damage the valves.Before adding grease to the tank, be sure to wipe off the tank fitting and the grease gun nozzle.

Note: When adding grease to the tank, never addthe grease beyond the level approximately 2 cm (0.8inch) below the top surface of the grease tank. Addinggrease beyond that level would allow the top cover to come off when the pump is activated. For moreinformation, refer to Operation and MaintenanceManual, “Capacities (Refill)”.

The grease level should be checked before startingto work. If necessary, add grease to the grease tank.


Autolub on MH Machine


Autolub on Standar d Wheeled Excavato r


i02713176

Axle Bearings (Front) -Lubricate

SMCS Code: 3278-086

The front axle is the axle which steers the machine.The rear axle is the one with the gearbox.

Wipe all grease fittings before you apply grease.


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Axle Oil (Front) - Change


A grease fitting is positioned on the top and on thebottom of the steering axle. Apply grease to thesefittings at each end of the steering axle.

For access to the U-joints, fully turn the wheels to theleft or to the right. The machine wheels may requirerotation in order to access the grease fittings.

i03715945

Axle Oil (Front) - Change

SMCS Code: 3278-044



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

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

2. Remove the dirt that is around filler plug (1) andaround drain plug (2).

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

3. Remove filler plug (1).

4. Remove drain plug (2). Allow the oil to drain into asuitable container.

Note: Dispose of drained fluids according to local

regulations.

5. Clean drain plug (2).

6. Inspect the O-ring seal. If damage or wear isfound, replace the O-ring seal.

7. Install drain plug (2).

8. Add oil thr ough the filler plug opening. Maintainthe oil level to the bottom of the filler plug opening.Refer to Operation and Maintenance Manual,“Capacities (Refill)”.

9. Clean filler plug (1).

10. Inspect the O-ring seal. If damage or wear isnoticed on the O-ring seal, replace the seal.

11. Install filler plug (1).

i02200350

Axle Oil (Rear) - Change

SMCS Code: 3260-044; 3278-044


(1) Filler plug(2) Drain plug

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

Filler plug (1) and drain plug (2) are located under themachine on the rear axle.

Note: Refer to the Operation and MaintenanceManual, “General Hazard Information” for informationin containing fluid spillage.


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Axle Oil Level (Front) - Check

1. Remove the dirt that is around filler plug (1) andaround drain plug (2).

2. Remove filler plug (1).

3. Remove drain plug (2). Drain the oil into a suitable

container.

Note: Dispose of any used oil according to localregulations.

4. Clean drain plug (2).


6. Install drain plug (2).

7. Fill the axle with oil to the bottom of the filler plug opening. See Operation and Maintenance

Manual, “Capacities (Refill)”.

8. Clean fi ller plug (1).



i02181845

Axle Oil Level (Front) - Check

SMCS Code: 3278-535



1. Remove the dirt that is around the fi ller plug.

2. Remove the fi ller plug.

3. Maintain the oil level to the bottom of the fi ller plugopening. Add oil through the filler plug opening,as needed.

4. Clean the filler plug.


6. Install the filler plug.

i02529374

Axle Oil Level (Rear) - Check

SMCS Code: 3260-535-FLV; 3278-535



1. Remove the dirt that is around the fi ller plug.

2. Remove the filler plug.

3. Maintain the oil level to the bottom of the filler plugopening. Add oil through the filler plug opening,as needed.

Note: The rear axle housing and the final drivehousing for the rear axle share the same oil circuit.Since the rear axle has a common oil circuit any oilthat is added will be distributed through the entirecircuit.

4. Clean the filler plug.


6. Install the filler plug.


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Axle Oil Sample - Obtain

i02182195

Axle Oil Sample - Obtain(Rear)

SMCS Code: 3260-008; 3278-008; 7542


Obtain an oil sample from the rear axle byremoving the filler plug and taking the sampledirectly from the axle housing. Refer to SpecialPublication, SEBU6250, “Caterpillar MachineFluids Recommendations”, “S·O·S Oil Analysis”for information that pertains to obtaining an oilsample from the rear axle housing. Refer to SpecialPublication, PEHP6001, “How To Take A Good OilSample” for more information about obtaining an oilsample from the rear axle housing.

i02182213

Axle Oil Sample - Obtain(Front)

SMCS Code: 3260-008; 3278-008; 7542


Obtain an oil sample from the front axle byremoving the filler plug and taking the sampledirectly from the axle housing. Refer to SpecialPublication, SEBU6250, “Caterpillar MachineFluids Recommendations”, “S·O·S Oil Analysis”for information that pertains to obtaining an oil

sample from the front axle housing. Refer to SpecialPublication, PEHP6001, “How To Take A Good OilSample” for more information about obtaining an oilsample from the front axle housing.

i02837393

Axle Oscillation Bearings -Lubricate(If Equipped)

SMCS Code: 3268-086-BD; 3278; 3282

Wipe all the grease fittings before you apply grease.


A steer axle pin is positioned at the front of themachine. A grease fitting is positioned on the front of the steer axle pin. Apply grease to this grease fitting.


A grease fitting is also positioned on the rear of thesteer axle pin. Apply grease to this grease fitting.


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320 SEBU8017-05Maintenance SectionBattery - Clean

Remote Grease Fittings (If Equipped)

Wipe remote grease fittings before you apply grease.


The remote grease fittings for the steer axle pin arelocated next to the right oscillating axle cylinder.

Apply grease to the remote grease fittings untilgrease is visible around the steer axle pin.

Note: If the machine is equipped with a frontattachment, the front and the rear end of thesteer axle pin are lubricated by two remote greasenipples. If the machine is not equipped with anyfront attachment, then only the rear end of the pin islubricated by a remote grease nipple.

g01360649

Illustration 308

i00934864

Battery - Clean

SMCS 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 - Recycle

SMCS 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

i00934872

Battery Hold-Down - Tighten

SMCS Code: 7257

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

i03731373

Battery or Battery Cable -Inspect/Replace

SMCS Code: 1401-510; 1402-510; 1402-510

Personal injury can result from battery fumes or explosion.

Batteries give off flammable fumes that can 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-

pr oper jumper cable connections can cause an ex-plosion.

Always wear protective glasses when workingwith batteries.

1. Turn the engine start switch to the OFF position.Turn all switches to the OFF position.

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


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Belts - Inspect/Adjust/Replace

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 cable tocontact the battery disconnect switch.

4. Disconnect the negative battery cable at thebattery that is connected to the battery disconnectswitch.

5. Make all of the necessary repairs or replace thebattery.

6. Connect the negative battery cable at the battery.

7. Connect the negative battery cable at the batterythat is connected to the battery disconnect switch.

8. Connect the battery cable at the battery disconnect

switch.

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

i03717240

Belts - Inspect/Adjust/Replace

SMCS Code: 1357-025; 1357-040; 1357-510;1358-025; 1358-510; 1359-040; 1359-510;1361-040; 1361-510; 1397-025; 1397-040;1397-510; 1405-025; 1405-510; 1802-025;

1802-510

All drive belts are behind the right rear access door.

Your engine is equipped with a fan drive V-beltthat also drives the alternator. The inclusion of anautomatic belt tensioner ensures the correct belttension during the life of the belt. For maximumengine performance and maximum utilization of your engine, inspect the belt for wear and for cracking.

If equipped, an additional standard belt will drive the A/C compressor from an adapter pulley on the fandrive.

If new belts are installed, recheck the belt adjustmentafter 30 minutes of operation. If two belts or more arerequired for an application, replace the belts in beltsets. If only one belt of a matched set is replaced, thenew belt will carry more load. This is due to the factthat the older belts are stretched. The additional loadon the new belt could cause the new belt to break.

Alternator and Fan Drive Belt

Inspect the Poly V-Belt



1. Stop the engine.

2. Open the right rear access door. Secure theaccess door.

3. Inspect the condition of poly V-belt (1).

4. Replace poly V-belt (1) if any of the followingconditions exist: excessive cracking, excessivewear, and excessive damage.

Replace the Poly V-Belt1. In order to remove poly V-belt (1), rotate automatic

belt tensioner (2) open.

2. Once automatic belt tensioner (2) has beenrotated, lock the automatic belt tensioner (2) inplace by placing pin (3) into the locking hole.

3. Replace poly V-belt (1).

4. Remove pin (3) from the locking hole andgradually release automatic belt tensioner (2).


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322 SEBU8017-05Maintenance SectionBlade Linkage - Lubricate

Air Conditioner Belt

NOTICE An incorrectly tensioned V-belt could cause not only adecrease of the compressor performance but damageto the belt and compressor.

1. When you install a new belt, apply 420 + 20 - 10 N(94 + 4.5 - 2.25 lb) of force.

2. When you reinstall a used belt after inspection,apply325 ± 10 N (73 ± 2.25 lb) of force.


(4) Mounting bolt(5) Bracket bolt

3. If the belt tension is not correct, loosen mountingbolt (4) and bracket bolt (5). Move the compressor in order to attain the correct adjustment.

Note: The used belt should not need to betightened again. If the belt loses tension below325 ± 10 N (73 ± 2.25 lb), tighten the belt again.Make sure that the bracket bolt and the mounting boltare tightened correctly.

4. Tighten bracket bolt (5) and mounting bolt (4).

i03717241

Blade Linkage - Lubricate(If Equipped)

SMCS Code: 6060-086-KL

Note: Caterpillar recommends the use of 5%molybdenum grease for lubricating the blade linkage.Refer to Special Publication, SEBU6250, “LubricatingGrease” for more information on the MolybdenumGrease.

Wipe all fittings before lubricating.

1. Lower the dozer blade.


2. Raise the access cover.



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Boom and Stick Linkage - Lubricate


Remote Grease Pins for the Parallel Blade


Remote Grease Pins for the Radial Blade


Grease Pins for the MH Blade

3. Apply lubricant through the one remote greasefitting, or the individual fittings on the MH dozer blade.

4. Close the access cover (the MH dozer blade doesnot have a cover).


Remote grease pin for the parallel dozer blade

Note: The remote grease nipple for the radial dozer blade is in the middle of the access cover.

Note: The arrows on Illustrations 312 through 315show grease points without grease lines. All dozer blades are equipped with a remote grease fitting.Only the dozer blades on the Material Handler machines do not offer a remote grease fitting (refer to illustration 316).

i02519869

Boom and Stick Linkage -

LubricateSMCS Code: 6501-086; 6502-086

S/N: W8R1-4999

S/N: W2T1-4999

Caterpillar recommends the use of 5% molybdenumgrease. Refer to Special Publication, SEBU6250,“Caterpillar Machine Fluids Recommendations” for more information on molybdenum grease.

Note: For some applications of the machine, the

repeated duty cycle of the front linkage may onlyrequire small angular movements of the boom or stick. 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 work tool in order to distribute thegrease within the joint assemblies.

Service a new machine after Every 10 Service Hoursonly within the initial 100 service hours.

After the initial 100 service hours of operation, servicethe boom, the stick, and the work tool linkage after Every 50 Service Hours.


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324 SEBU8017-05Maintenance SectionBoom, Stick and Bucket Linkage - Lubricate

Note: If the machine is operated under severeconditions that might cause abrasive material toenter the bearings, service the linkage after Every10 Service Hours.

1. Wipe all fittings before you apply lubricant.

Use Steps 1.a through 1.c to ensure proper lubrication:

a. Lower the boom and the work tool to theground.

b. Apply a slight downward pressure on the worktool.

c. Apply grease through the grease fitting.


(1) Fitting

2. Apply lubricant through fitting (1).

Note: This fitting supplies grease to all other bearingsexcept the bearings on the stick end through adistribution valve. The distribution valve is designedto give the proper amount of grease to all bearings. If the distribution valve will not accept grease, one of the lines is blocked.


(2) Fittings

3. Apply lubricant through fittings (2).

i02863963

Boom, Stick and Bucket

Linkage - Lubricate(If Equipped)

SMCS Code: 6501-086; 6502-086; 6513-086

S/N: W6A1-4999

S/N: W3H1-4999

S/N: W5M1-4999

S/N: W8P1-4999

S/N: W2S1-4999

Note: Caterpillar recommends the use of 5%molybdenum grease for lubricating the boom,stick and bucket control linkage. Refer to SpecialPublication, SEBU6250, “Lubricating Grease” for more information on Molybdenum Grease.

Service a new machine after Every 10 Service Hoursonly within the initial 100 service hours.

After the initial 100 service hours of operation, servicethe boom, the stick, and the work tool linkage after Every 50 Service Hours.

Note: If the machine is operated under severe

conditions that might cause abrasive material toenter the bearings, service the linkage after Every10 Service Hours.

1. Open the access door for the engine compartmenton the right side of the machine.



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Boom, Stick and Bucket Linkage - Lubricate


3. Apply lubricant through the lowest grease fittingthat is located in the engine compartment.

Note: This fitting supplies grease to all linkagebearings from the frame to the nose of the boom.The valve is designed to give the proper amount of grease to all bearings. If the valve will not acceptgrease, one of the lines is blocked.

Use Steps 3.a through 3.d to ensure proper lubrication.

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

b. Lower the boom and the work tool to theground.

c. Apply a slight downward pressure on the worktool.

d. Apply grease through the grease fitting.

4. Lower the boom and the stick to ground level.



5. Apply lubricant through the grease fittings.

Ditch Cleaning Bucket (If Equipped)




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326 SEBU8017-05Maintenance SectionBraking System - Test

2. Apply lubricant through the grease fittings.

Offset Boom (If Equipped)

1. Wipe the remote grease fittings (1) before youapply lubricant.


2. Apply lubricant through the remote grease fittings(1) until grease is visible around pins and bearings.

i03731386

Braking System - Test

SMCS Code: 4250-081

Service Brake Holding Ability Test

Personal injury can result from a sudden stop dur-ing brake test.

Make sure the area is clear of personnel and ob-structions before testing the brakes. Fasten theseat belt before moving the machine.

If the machine begins to move during the test, engagethe parking brake immediately.

Make sure that the area around the machine is clear of personnel and of obstacles.

Test the service brakes on a dry, level surface.

Fasten the seat belt before you test the brakes.

The following test determines if the service brakesare functional. This test is not intended to measurethe maximum brake holding effort. The maximumbrake holding effort that is required to hold amachine stationary at a certain engine rpm variesbetween machines. These differences are caused by

differences in the following factors:

• Engine setting

• Power train ef ficiency

• Brake holding ability

• Other factors


(1) Service brake pedal(2) Travel speed pedal

1. Start the engine. Keep the engine speed at lowidle.

2. Slightly raise all work tools.

3. Depress service brake pedal (1).


The soft switch panel is located on the right console.

(3) Parking brake control(4) Transmission control

4. Release the parking brake by pushing down onthe button for the parking brake control (3).


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Bucket Tips - Inspect/Replace

5. Push the button for the transmission control (4)once in order to select FIRST GEAR. The firstLED light will illuminate.

6. Without releasing the service brake pedal,depress the front of travel speed pedal (2) to the

FORWARD position. The machine should notmove. Release the travel speed pedal.

7. Engage parking brake (3). This is the end of thetest of the service brakes.

8. Lower all the work tools to the ground.

9. Stop the engine.

NOTICEIf the machine moved while testing the service brakes,contact your Caterpillar dealer.

Have the dealer inspect and, if necessary, repair theservice brakes before returning the machine to oper-ation.

Testing the Brake Accumulator

1. Move the engine start switch key to the ONposition.

2. If the accumulator is not at normal operatingpressure, the monitor will display a “BRAKEPRESSURE LOW” warning.

3. Start the engine.

4. Run the engine for 30 seconds in order to increasethe accumulator pressure. The warning messageon the monitor should turn off.

5. Stop the engine.

6. While the engine is stopped, turn the engine startswitch to the ON position. Apply the service brakesfor two times. If the warning message on themonitor comes on, consult your Caterpillar dealer.

i03450548

Bucket Tips - Inspect/Replace(Drive-through System)

SMCS Code: 6805-040; 6805-510

S/N: W6A1-4999

S/N: W3H1-4999

S/N: W5M1-4999

S/N: W8P1-4999

S/N: W2S1-4999

Personal injury or death can result from bucketfalling.

Block the bucket before changing bucket tips or side cutters.

Bucket Tips

Note: In order to maximize the life of the bucket tipand the penetration of the bucket tip, the bucket tipcan be rotated.


Acceptab le wear


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328 SEBU8017-05Maintenance SectionBucket Tips - Inspect/Replace


Replace this bucket tip.

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

Removal Procedure

Retainer pin, when struck with force, can fly outand cause injury to nearby people.

Make sure the area is clear of people when drivingretainer pins.

To avoid injury to your eyes, wear protectiveglasses when striking a retainer pin.


(1) Bucket tip(2) Retainer (3) Adapter

Note: Retainers are often damaged during theremoval process. Caterpillar recommends theinstallation of a new retainer when bucket tips arerotated or replaced.


Internal view

1. Use a hammer and a punch in order to drive outthe retainer. The retainer can be removed from

the top of the bucket tip or from the bottom of thebucket tip.

2. Remove the bucket tip from the adapter with aslight counterclockwise rotation.

Installation Procedure

1. Clean the adapter, if necessary.

2. Install the new bucket tip or the rotated bucket tiponto the adapter with a slight clockwise rotation.


Proper location for installing the retainer

3. The retainer can be installed from the top of thebucket tip or from the bottom of the bucket tip. Usea hammer and a 1 inch X 1 inch X 8 inch steel bar stock in order to drive retainer (2) into adapter (3).


20/66




Internal View

The latch of the retainer is properly seated in the recess of thebucket tip.


A properly installed retainer does not extend beyond the ear of the bucket tip.

4. The retainer is properly seated if the retainer canbe moved slightly by the technician's hand. If theretainer cannot be moved, adjust the retainer,as needed. The ends of the retainer should notextend beyond the ear of the bucket tip.

Side Cutters (If Equipped)


Bucket with side cutters

(A) Side cutters

1. Remove the mounting bolts and the side cutters.

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


(4) Side cutter

Note: Some side cutters may be rotated for additionalwear.

3. Install the side cutter.

Note: Certain bolts may require thread compound.

4. Hand tighten the bolts.


21/66



Section B-B From Illustration 335

(4) Side cutter (5) Side plate on a bucket(6) 0.0 mm (0.0 inch)

(7) Shear ledge on a side cutter

5. Make sure that there is not a gap between theside plate on the bucket and the shear ledge onthe side cutter.

6. Torque the mounting bolts to the correctspecification.

Side Protectors (If Equipped)

Inspect the wear of the side protector. When toomuch wear is present, replace the protector.



(8) Side plate(9) Retainer (10) Side protector (11) Pin

1. Hit pin (11) from the retainer side of the bucketin order to remove side protector (10) from sideplate (8).

2. Clean side protector (10), pin (11), retainer (9) andside plate (8) before installation.

Note: Lateral clearance between the side plateand the side protector should not exceed 1 mm(0.04 inch). Shims may be required in order todecrease the lateral clearance which will decreasemovement. Install the shims between the side plateand the side protector on the opposite side of theretainer.

3. Put retainer (9) in side plate (8).

4. Align two pin holes of the new protector and theside plate. Hit the pin from the side of the bucketwithout the retainer.

Note: If the pin and/or the retainer are worn, replacethe pin and/or the retainer.


22/66



i03574842


SMCS Code: 6805-040; 6805-510

S/N: W6A1-4999

S/N: W3H1-4999

S/N: W5M1-4999

S/N: W8P1-4999

S/N: W2S1-4999

Block the bucket before changing the bucketteeth.

To prevent possible injury to the eyes, wear a pro-tective f ace shield when striking the pin.

The pin, when struck, can fly out and cause injuryto nearby personnel.

Bucket Tips


(1) Usable tip(2) Replaceable bucket tip(3) Overworn tip

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.


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

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

b. Align extractor (5) with the pin.

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

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


(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 marking“OUTSIDE” is visible.


23/66



4. Install the new bucket tip onto the adapter.

Note: The bucket tips can be rotated by 180 degrees

in order to allow the tip to wear evenly. You may alsomove the tips from the outside teeth to the insideteeth. Check the tips often. If wear is present on thetips, rotate the tips. The outside teeth generate themost wear.

5. Drive the pin through the bucket tip. The pin canbe installed 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 Step

5.e for the procedure.


(8) Pin

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


b. Place the Pin-Master over the bucket tips sothat the pin will fit 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 the pin.


Final assembly of pin into bucket tip

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


24/66



Side Cutters


Bucket With Side Cutters

1. Remove the mounting bolts and the side cutters

(11).

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


(12) Shear ledge on a side cutter (13) Side plate on a bucket(B) 0.0 mm (0.0 inch)

Note: Some side cutters may be rotated for additionalwear.

3. Install the side cutter.

Note: Certain bolts may require thread compound.

4. Hand tighten the bolts.

5. Make sure that there is not a gap between theside plate on the bucket and the shear ledge on

the side cutter.

6. Torque the mounting bolts to the correctspecification.

Side Protectors (If Equipped)

Inspect the wear of the side protector. When toomuch wear is present, replace the protector.



(14) Side plate(15) Retainer (16) Side protector (17) Pin(18) Shim


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334 SEBU8017-05Maintenance SectionCab Air Filter (Fresh Air) - Clean/Replace

1. Hit pin (17) from the side of the bucket withoutthe retainer in order to remove side protector (16)from side plate (14).

2. Clean side protector (16), pin (17), retainer (15)and side plate (14) before installation.

Note: Lateral clearance between the side plateand the side protector should not exceed 1 mm(0.04 inch). Shims (18) may be required in order todecrease the lateral clearance which will decreasemovement. Install the shims (18) between the sideplate and the side protector on the opposite side of the retainer.

3. Put retainer (15) in side plate (14).

4. Align two pin holes of the new protector and theside plate. Hit the pin from the retainer side of thebucket.

Note: If the pin and/or the retainer are worn, replacethe pin and/or the retainer.

i02520019

Cab Air Filter (Fresh Air) -Clean/Replace

SMCS Code: 7342-070; 7342-510


(1) Wing bolt

(2) Filter cover

The cab air filter is behind the cab.

1. Loosen wing bolt (1) and open fi lter cover (2).


(2) Filter cover (3) Air filter

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

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

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

5. Install the air filter and the fi lter cover.

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

i01871602

Cab Riser (Adjustable) Linkage- Lubricate(If Equipped)

SMCS Code: 7260-086-KL

S/N: W8R1-4999

S/N: W2T1-4999

Service the linkage after Every 500 Service Hourswhile the cab is in the lowered position.



26/66


Camera - Clean/Adjust


2. Apply lubricant through fittings (1) and (2) on bothsides of the linkage.

g00352012

Illustration 353

3. Apply lubricant through fitting (3) on each side of the linkage.


4. Apply lubricant through fittings (4) on the left sideof the linkage.


5. Apply lubricant through fittings (5) on the right sideof the linkage.

i03126933

Camera - Clean/Adjust

SMCS Code: 7348

Failure to use an appropriate external ladder or anappropriate platform for direct access to the rear view camera could result in slipping and fallingwhich could result in personal injury or death. Besure to use an appropriate external ladder or an

appropriate platform for direct access to the rear view camera.

The machine's counterweight and the enginehood are not approved as a maintenance plat-forms.

Unexpected machine movement can cause injuryor death.

In order to avoid possible machine move-

ment, move the hydraulic lockout control to theLOCKED position and attach a Special Instruc-tion, SEHS7332, “Do Not Operate” or similar warning tag to the hydraulic lockout control.

When maintenance or servicing of the rear viewcamera is required follow these steps.

1. Park the machine on a level surface.

2. Place the work tool on the level surface.

3. Move the hydraulic lockout control to the Lockedposition.


27/66

336 SEBU8017-05Maintenance SectionCondenser (Refrigerant) - Clean

4. Turn the engine start switch to the OFF positionand remove the engine start switch key.

5. Turn the battery disconnect switch to theOFFposition and remove the battery disconnect switchkey.

Clean Camera Lens

If necessary, clean the camera lens before youoperate the machine. Use a soft cloth for cleaning.

Adjust the Area of Visibility

If the camera displays an undesired view, adjust thearea of the visibility.


(1) Cover

(2) Bolt


(3) Bolt

1. Remove the 2 bolts (2) in order to remove thecover (1).

2. Unfasten the 2 bolts (3).


3. Adjust the area of the visibility of the camera sothat a 1.5 m (5 ft 11 inch) tall obstacle which is 1 m(3 ft) behind the counterweight can be seen.

4. Tighten the 2 bolts (3) to a torque of 0.5 ± 0.05 N·m(4 ± 0.4 lb in).

5. Tighten the 2 bolts (2) to a torque of 55 ± 10 N·m(40 ± 7 lb ft) in order to fix the cover (1).

i02617968

Condenser (Refrigerant) -Clean

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.



28/66


Cooling System Coolant (ELC) - Change


Door latch for the right front access door

2. Pull the door latch for the right front accessdoor. The door latch is located in the engine

compartment. This will unlatch the right frontaccess door.

3. Open the right front access door. Secure theaccess door.


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

Note: Open the condenser in order to clean bothsides of the condenser.


a. Loosen bolts (1) in order to release thecondenser.

b. Swing the condenser open.

5. Use clean water to wash off all dust and dirt fromthe condenser.

6. Swing the condenser back into position, andsecure the condenser with the bolts (1).

7. Close the access doors.

i02709297

Cooling System Coolant (ELC)- Change

SMCS Code: 1350-044

NOTICEDo not change the coolant until you read and under-stand the cooling system information in Special Pub-

lication, SEBU6250, “Caterpillar Machine Fluids Rec-ommendations”.

Failure to do so could result in damage to the coolingsystem components.


29/66

338 SEBU8017-05Maintenance SectionCooling System Coolant (ELC) - Change

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 specification for pre-mixed or concentrate coolants and Caterpillar Extender.

Steam or hot coolant can cause severe burns.

Do not loosen the filler cap or the pressure cap on

a hot engine.

Allow the engine to cool before removing the filler cap or the pressure cap.

This machine was fi lled with Extended Life Coolantat the factory.

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

If the coolant in the machine is changed to Extended

Life Coolant from another type of coolant, see SpecialPublication, SEBU6250, “Caterpillar Machine FluidsRecommendations”.

Bodily injury can occur from unexpected contactwith open cab doors on machines equipped witha fixed cab riser.

To avoid injury, close the cab door before climbingonto the rear of the machine.

1. Open the left front access door. Secure the accessdoor.


2. In order to open the top access door for the enginecompartment, the quick locks should be turned90 degrees counter clockwise. Secure the access

door.


3. Slowly loosen the pressure cap in order to relievethe system pressure. Remove the pressure cap.



30/66


Cooling System Coolant (ELC) - Change


Drain valve

5. There is a cover under the engine compartment.Remove the cover in order to expose the drainvalve.


6. The second drain valve is located under the center of the rear frame. The access cover is held bytwo bolts. Remove the access cover in order toexpose the drain valve.


7. Attach suitable hoses to the drain valves.

8. Open the drain valves, and allow the coolant todrain into a suitable container.


Drain valve

9. A drain valve is located at the side of the cylinder block. Open this drain valve in order to allow

coolant to drain from the internal passages in thecylinder block.

10. Flush the cooling system with clean water untilthe draining water is clean.

11. Close the drain valves. Install the access cover under the rear center part of the upper frame. Usetwo bolts to secure the access cover.

12. Install the drain plug on the engine cylinder block.

Note: Dispose of drained fluids according to localregulations.

13. Add the Extended Life Coolant. Refer to theOperation and Maintenance Manual, “Capacities(Refill)” for the capacity of the cooling system.

Note: The maximum fill rate is 6-7 L/min(1.6-1.9 US gpm).

14. Close the pressure cap and run the engine atspeed dial 1 for 2 to 5 minutes.

15. Stop the engine.

16. Open the pressure cap slowly and carefully.


31/66

340 SEBU8017-05Maintenance SectionCooling System Coolant Extender (ELC) - Add


17. Fill up the coolant as required to main coolantlevel at the center of the expansion tank gauge.

18. Close the pressure cap and run the engine untilthe temperature reaches its normal operatingtemperature.

19. Allow the machine to cool down. Check coolantlevel again. Fill up coolant if required.

20. Close all access doors and secure all doors.

i02617987

Cooling System CoolantExtender (ELC) - Add

SMCS Code: 1352; 1353; 1395

Note: This machine was filled with Caterpillar Extended Life Coolant at the factory.

When Caterpillar Extended Life Coolant (ELC) isused, Caterpillar Extender must be added to thecooling system. See Special Publication, SEBU6250,“Caterpillar Machine Fluids Recommendations” for allthe cooling system requirements.

Use an coolant conditioner test kit to check theconcentration of the coolant.

NOTICEUse only Cater pillar products or commercial productsthat have passed Caterpillar EC-1 specification for pre-mixed or concentrated coolants.

Use only Caterpillar Extender with Extended LifeCoolant.

Mixing Extended Life Coolant with other products re-duces the ExtendedLife Coolant service life. Failure tofollow the r ecommendations can reduce cooling sys-tem components life unless appropriate corrective ac-tion is performed.

Bodily injury can occur from unexpected contactwith open cab doors on machines equipped with

a fixed cab riser.




2. Open the top access door for the enginecompartment by turning the quick lockscounterclockwise for 90 degrees. Secure the

access door.


32/66


Cooling System Coolant Level - Check


3. Slowly loosen the pressure cap in order to relievethe system pressure. Remove the pressure cap.

4. You may be required to drain enough coolant fromthe radiator in order to allow the addition of theCaterpillar ELC Extender. If this is necessary, refer to Operation and Maintenance Manual, “CoolingSystem Coolant (ELC) - Change” for the locationof the radiator drain valves.


5. Add the proper amount of Caterpillar ELCExtender to the cooling system. Refer to Operationand Maintenance Manual, “Capacities (Refill)” andOperation and Maintenance Manual, “Extended

Life Coolant (ELC)” for the proper quantity.

6. Replace the pressure cap if the gasket isdamaged. Install the pressure cap. Close thecover over the pressure cap.

7. Close all access doors.

i02618000

Cooling System Coolant Level- Check

SMCS Code: 1350-535



Door latch for the right front access door

2. Pull the door latch for the right front accessdoor. The door latch is located in the engine

compartment. This will unlatch the right frontaccess door.

3. Open the right front access door. Secure theaccess door.


4. Maintain the coolant level to the center of the sightgauge.

Note: Refer to Operation and Maintenance Manual,“General Hazard Information” on containing fluidspillage.

5. If additional coolant is needed, open the left frontaccess door. Secure the access door.




33/66

342 SEBU8017-05Maintenance SectionCooling System Coolant Sample (Level 1) - Obtain


6. Open the top access door for the enginecompartment by turning the quick locks by 90degrees counterclockwise. Secure the access

door.


7. Slowly loosen the pressure cap in order to relievethe system pressure.

If you must add coolant daily, check the coolantsystem for leaks.

8. Remove the pressure cap.

9. Add the coolant.

10. Inspect the pressure cap and the cap seal for thefollowing defects:

• Damage

• Deposits

• Foreign material

Clean the pressure cap with a clean cloth or r eplace the pressure cap if the pressure cap isdamaged.

11. Install the pressure cap. Close the top accessdoor for the engine compartment.

12. Inspect the radiator core for debris. Clean theradiator core, as needed. See Operation andMaintenance Manual, “Radiator Core - Clean”.

13. Close all access doors.

i03717304

Cooling System CoolantSample (Level 1) - Obtain

SMCS Code: 1350-008; 1395-008; 1395-554;7542-008; 7542

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

Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations andmandates.

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


A typical example is shown.


34/66


Cooling System Coolant Sample (Level 2) - Obtain

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

Obtain the sample of the coolant as close as possibleto the recommended sampling interval. In order to receive the full effect of S·O·S analysis, youmust establish a consistent trend of data. In order to establish a pertinent history of data, performconsistent samplings that are evenly spaced.Supplies for collecting samples can be obtained fromyour Caterpillar dealer.

Use the following guidelines for proper sampling of

the coolant:

• Complete the information on the label for thesampling bottle before you begin to take thesamples.

• Keep the unused sampling bottles stored in plasticbags.

• Obtain coolant samples directly from the coolantsample port, when possible.

• Keep the lids on empty sampling bottles until youare ready to collect the sample.

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

• Never collect samples from expansion bottles.

Submit the sample for Level 1 analysis.

For additional information about coolant analysis, seeSpecial Publication, SEBU6250, “Caterpillar MachineFluids Recommendations” or consult your Caterpillar dealer.

i02049802

Cooling System CoolantSample (Level 2) - Obtain

SMCS Code: 1350-008; 1395-008; 1395-554; 7542

Reference: Refer to Operation and MaintenanceManual, “Cooling 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 collecting 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.

i03717305

Drive Shaft - Lubricate

SMCS Code: 3253-086


The grease fittings are located below the center of the machine.

Apply grease to the fitting on the universal jointat both ends of the drive shaft. This machine isequipped with a two-piece drive shaft. There is a totalof four grease fittings per drive shaft.

i03717306

Engine Air Filter PrimaryElement - Clean/Replace

SMCS Code: 1054-070; 1054-510

Table 184

AIR FILTER

PLUGGED


35/66

344 SEBU8017-05Maintenance SectionEngine Air Filter Primary Element - Clean/Replace

Service the air fi lter if the “AIR FILTER PLUGGED”warning appears on the monitor. Stop the engine.

A primary filter element may be cleaned for amaximum of five times. Also replace the primaryelement if the primary element has been used for two

years.

The secondary fi lter element should also be replacedwhen the primary fi lter element is replaced.

See Operation and Maintenance Manual, “Engine Air Filter Secondary Element - Replace”.

1. In order to access the filter elements, open theright front access door.


(1) Latch(2) Cover

2. Open four latches (1) in order to unlock cover (2).

3. Remove the cover.

4. Clean cover (2).


(3) Primary fi lter element(4) Handle

5. Pull up on handle (4) in order to remove primaryfilter element (3).

6. Clean the inside of the air cleaner housing.

7. Inspect the primary element. If the pleats, thegaskets, or the seals are damaged, discard theelement. Replace a damaged primary elementwith a clean primary element.

A primary element may be cleaned for a maximumof five times. Also replace the primary element if the primary element has been used for two years.

NOTICEDo not clean the filter elements by bumping or tappingthem. Do not use filter elements with damaged pleats,gaskets, or seals. Do not wash the fi lter elements.

8. If the primary element is not damaged, clean theprimary element.

The filter elements can be cleaned withpressurized air.

If you use pressurized air, use a maximum air pressure of 205 kPa (30 psi).


36/66


Engine Air Filter Secondary Element - Replace


9. When you clean the inside pleats and the outsidepleats, direct the air along the pleats.

10. Inspect the filter elements after you clean thefilter elements. Do not use a fi lter if the pleats, thegaskets or the seals are damaged.

11. Cover the clean filter elements. Store theelements in a clean, dry location.

12. Install a clean primary filter element. Lower thehandle in order to secure the new primary fi lter inthe air cleaner housing.

13. Install cover (2).

14. Close four latches (1) in order to lock cover (2)

in place.

15. Close the access door.

i02618005

Engine Air Filter SecondaryElement - Replace

SMCS Code: 1054-510

NOTICE Always 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.

1. Remove the cover and the primary filter element. See the Operation and MaintenanceManual, “Engine Air Filter Primary Element -Clean/Replace”.


2. Pull up on the secondary fi lter element in order toremove the secondary fi lter element.

3. Cover the air inlet opening. Clean the inside of the air cleaner housing.

4. Uncover the air inlet opening. Install a newsecondary filter element.

5. Install the primary filter element and the cover.See Operation and Maintenance Manual, “Engine

Air Filter Primary Element - Clean/Replace” for the necessary steps.

i03027620

Engine Crankcase Breather Filter - Replace

SMCS Code: 1317-510; 1317-510-FI; 1317

1. Open the engine access door that is located onthe top of the machine. Secure the access door.

Hot engine components can cause injury fromburns. Before performing maintenance on theengine, allow the engine and the components tocool.


37/66

346 SEBU8017-05Maintenance SectionEngine Oil Level - Check


2. Remove the filter with a strap type wrench. SeeOperation and Maintenance Manual, “Oil Filter -Inspect”. Dispose of the used filter according tolocal regulations.

Note: Maintain the vertical position of the filter untilyou can dispose of the fi lter and oil properly. Tiltingthe fi lter will allow oil to run out of the fi lter.

3. Clean the housing base for the filter. Remove allof the remaining fi lter gasket from the housing.


4. Apply a thin coat of oil to the gasket of the newfilter seal.

5. Place the new fi lter onto the base. Rotate the fi lter until the filter seal contacts the base. Note theposition of the index marks on the filter relative toa fixed point on the fi lter base.

Note: Index marks on the filter are separated by 90degrees or 1/4 of a rotation.

6. You may need to use a Caterpillar strap wrench or another suitable tool in order to tighten the filter.Use the instructions that are printed on the fi lter inorder to tighten the filter. Use the rotation indexmarks as a guide. Do not damage the filter withthe installation tool.

Note: If you install a filter that has not been providedby Caterpillar, use the instructions that were providedwith the filter.

7. Close all access covers.

i02522182

Engine Oil Level - Check

SMCS Code: 1000-535

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

Check the engine oil level while the machine isparked on a level surface and the engine has beenstopped for a minimum of 10 minutes.



(S/N: W3H1-UP; W5M1-UP)


38/66


Engine Oil Sample - Obtain


(S/N: W6A1-UP; W8P1-UP; W8R1-UP; W2S1-UP; W2T1-UP)


2. Remove dipstick (1) in order to measure the oil

level.

Oil which is badly contaminated or badlydeteriorated should be replaced early. Replacethe oil regardless of the time interval.

3. Remove the oil from dipstick (1).

4. Insert dipstick (1). Remove the dipstick again.


5. Maintain the oil level below the “FULL RANGE”mark on the dipstick and above the “ADD” on thedipstick. If the oil level is low, add oil.

Note: If the oil level is above the “FULL RANGE”mark, operating the engine could cause the

crankshaft to dip into the oil. This could lead toexcessively high oil temperatures. Excessivelyhigh oil temperatures can reduce the lubricatingcharacteristics of the oil. The reduction of lubricatingcharacteristics of the oil causes bearing damage.Bearing damage leads to loss of engine power.

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

6. Remove oil fi ller plug (2) in order to add oil.

7. Add oil, if necessary.

Note: Ref er to Operation and MaintenanceManual, “Lubricant Viscosities” for information onrecommended engine oil.

8. Clean oil filler plug (2). Install the oil fi ller plug.

9. Close the right rear access door.

i02522209

Engine Oil Sample - Obtain

SMCS Code: 1000-008; 1000; 1300; 1318;1348-008; 1348-554-SM; 1348-554; 7000;7542-008; 7542-554-OC, SM; 7542




39/66

348 SEBU8017-05Maintenance SectionEngine Oil and Filter - Change



Obtain a sample of the engine oil from the engine oilsampling valve that is located on the engine oil fi lter

housing. Refer to Special Publication, SEBU6250,“Caterpillar Machine Fluids Recommendations”,“S·O·S Oil Analysis” for information that pertains toobtaining a sample of the engine oil. Refer to SpecialPublication, PEHP6001, “How To Take A Good OilSample” for more information about obtaining asample of the engine oil.

i03731387

Engine Oil and Filter - Change

SMCS Code: 1318-510

1. Park the machine on a level surface.

2. Engage the parking brake.

3. Lower the work tools to the ground.

4. Stop the engine.

Note: Drain the crankcase while the oil is warm. Thisallows waste particles that are suspended in the oil todrain. As the oil cools, the waste particles will settleto the bottom of the crankcase. The particles will notbe r emoved by draining the oil and the particles will

recirculate in the engine lubrication system with thenew oil.






6. Remove oil filler plug (1).


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Engine Oil and Filter - Change


(3) Crankcase drain valve

7. Remove the cover under crankcase drain valve(3).


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

drain valve (3).







9. Remove used oil filter (4). See Operation and

Maintenance Manual, “Oil Filter - Inspect”.

Note: Maintain the vertical position of the filter untilyou can dispose of the filter and oil properly. Tiltingthe fi lter will allow oil to run out of the filter.

10. Clean the housing base for the fi lter. Remove allof the old filter gasket.


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


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350 SEBU8017-05Maintenance SectionEngine Valve Lash - Check

Note: Every new oil fi lter has rotation index marksthat are spaced at increments of 1/4 turn. Use therotation index marks as a guide for tightening theoil filter.

12. Install the engine oil filter hand tight until the

gasket of the engine oil filter contact the filter base. Note the position of the index marks on thefilter in relation to a fixed point on the fi lter base.

13. Tighten the fi lter according to the instructions thatare printed on the fi lter. Use the index marks asa guide.

Note: Do not use a strap wrench on the fi lter.

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

14. Fill the crankcase with new oil.

Note: Refer to the Operation and MaintenanceManual, “Capacities (Refill)”.

15. Clean filler plug (1).


17. Start the engine. Run the engine at low idle for two minutes. Check for oil leaks. Stop the engine.


18. Wait for ten minutes in order to allow the oil todrain back into the crankcase. Check the oil level.Maintain the oil level between the “ADD” mark and“FULL” mark on dipstick (2).

19. Install the cover under crankcase drain valve (3).


i01747875

Engine Valve Lash - Check

SMCS Code: 1102-082; 1102-535; 1102; 1105-025;1105-535; 1121-535; 1209-082; 1209-535; 1209;

7527

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

i02357513

Fan Guard - Clean/Inspect(If Equipped)

SMCS Code: 1360

S/N: W6A1-4999

S/N: W8P1-4999

S/N: W8R1-4999

S/N: W2S1-4999

S/N: W2T1-4999

NOTICEInspect the fan motor and the fan shaft for any obstruc-tions. Failure to remove any debris from the fan motor or the fan shaft could result in damage to the machine.


1. Lift the fan guard in order to inspect the fan andthe radiator grill for dirt accumulation or debrisaccumulation.

2. If there is debris on the fan or the radiator grill,clean the fan or the radiator grill.


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Final Drive Oil - Change

i01827771

Final Drive Oil - Change

SMCS Code: 4050-044-FLV


1. Turn the hub until the fi ll/drain plug is at the lowestposition.

2. Remove the dirt that is around the fi ll/drain plug.


3. Remove the fill/drain plug. Drain the oil into asuitable container.

Note: Dispose of used oil according to localregulations.

4. Turn the hub until the opening of the fill/drain plugis horizontal.

5. Fill the final drive with lubricant to the bottom of the opening of the fill/drain plug. See Operationand Maintenance Manual, “Capacities (Refill)”.


7. Install the O-ring seal. Install the fi ll/drain plug.

8. Repeat Steps 1 through 7 for the remaining threeaxle hubs.

i02437239

Final Drive Oil Level - Check

SMCS Code: 4050-535-FLV



1. Turn the hub until the opening of the fi ll/drain plugis horizontal, as shown.

2. Remove the dirt that is around the fi ll/drain plug.

3. Remove the fill/drain plug.

4. Fill the final drive with lubricant to the bottom

of the opening of the fi

ll/drain plug. Add oil, if necessary. See Operation and MaintenanceManual, “Lubricant Viscosities”.


6. Install the O-ring seal. Install the fi ll/drain plug.

7. Repeat Steps 1 through 6 for the remaining threeaxle hubs.


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352 SEBU8017-05Maintenance SectionFinal Drive Oil Sample - Obtain

i01905883

Final Drive Oil Sample - Obtain

SMCS Code: 4011-008; 4050-008; 4050-SM;7542-008; 7542


Obtain an oil sample of the final drive oil by removingthe filler plug and taking the sample directly fromthe final drive housing. Refer to Special Publication,SEBU6250, “S·O·S Oil Analysis” for informationthat per tains to obtaining an oil sample from thefinal drive housing. Refer to Special Publication,PEHP6001, “How To Take A Good Oil Sample” for more information about obtaining an oil sample fromthe final drive housing.

i02618303

Fuel System - Prime

SMCS Code: 1250-548






2. Press the button and release. Repeat this processapproximately 10 times to 15 times.

3. Crank the engine. If the engine does not start, or the engine misfires, or the engine emits smoke,then prime the engine again.

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

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


NOTICEDo not touch the high pressure fuel injection lines.Touching the fuel injection lines could cause the fuelinjection lines to break.

Note: Do not fill the fuel filter with fuel before installingthe filter on the machine.

i03731390

Fuel System Filter - Replace

SMCS Code: 1261-510

Personal injury or death can result from a fire.

Fuel leaked or spilled onto hot surfaces or 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.


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Fuel System Filter - Replace

NOTICEDo not pre-fill new fuel filters during fuel filter changes.Engine damage can result.

NOTICETurn the disconnect switch OFF or disconnect the bat-tery when changing fuel filters.

NOTICEDo not touch the high pressure fuel injection lines.Touching the fuel injection lines could cause the fuelinjection lines to break.



2. Close the fuel supply valve. The valve is closedwhen the lever is horizontal.





3. Remove the fuel filter.

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

4. Clean the base for the filter housing.

5. Install the new fi lter by hand.

6. Open the fuel supply valve.

7. Refer to Operation and Maintenance Manual,“Fuel System - Prime” for the engine startingprocedure to be used after servicing the fuelsystem.


Note: Do not fill the fuel filter with fuel before installingthe filter on the machine. Dirt or debris might enter the system which could cause damage to the fuelinjection equipment.


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354 SEBU8017-05Maintenance SectionFuel System Water Separator - Drain

i02709634

Fuel System Water Separator - Drain

SMCS Code: 1263





NOTICEDo not pre-fill new fuel filters during fuel filter changes.Engine damage can result.



2. Turn the drain valve counterclockwise in order toopen. The drain valve is located on the bottom of the water separator and bowl.

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

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

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

4. Close the drain valve.


i03734080

Fuel System Water Separator Element - Replace

SMCS Code: 1263-510-FQ; 1263







2. Close the fuel supply valve. The valve is closedwhen the lever is horizontal.


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Fuel Tank Cap and Strainer - Clean


3. Turn drain valve (4) counterclockwise in order toopen. The drain valve is located at the bottom of the fuel filter/water separator.

Note: Refer to the Operation and MaintenanceManual, “General Hazard Information” for informationin Containing Fluid Spillage.

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

Note: Obey all local regulations when you discarddrained fluids and filters.

5. Close drain valve (4).

6. Hold bowl (3). Remove bowl (3) from the fuelfilter/water separator.

7. Remove fuel filter/water separator (2). Discardfuel fi lter/water separator (2).

8. Clean the inside surfaces of the filter base andof bowl (4).

9. Inspect the bowl (4). If damage is found, replacethe bowl.

10. Inspect the O-ring on the bowl (4). Replace theseal if the O-ring seal is worn or damaged.

11. Install a new fuel filter/water separator by hand.Tighten the collar in order to secure the filter element.

12. Install bowl (4).

13. Open the fuel supply valve.


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 - Prime”.

i01606934

Fuel Tank Cap and Strainer -Clean

SMCS Code: 1273-070-STR








2. Remove the fuel tank cap and the fuel fill screen.

3. Wash the fuel fi ll screen and wash the fuel tankcap in a clean, nonflammable solvent.

4. Inspect the seal for damage. Replace the seal if

the seal is damaged.

5. Install the fuel tank cap.

6. Close the left front access door.


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356 SEBU8017-05Maintenance SectionFuel Tank Water and Sediment - Drain

i01546211

Fuel Tank Water and Sediment- Drain

SMCS Code: 1273-543




Turn the dis

Documents

CAT M316D Maintenance