MAINTENANCE INTERVALS

Operation and Maintenance

Manual Excerpt

® ®
© 2010 Caterpillar
All Rights Reserved

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 SEBU7940-06
December 2009

Operation and
Maintenance
Manual
301.6C, 301.8C and 302.5C Mini
Hydraulic Excavators
GBB1-Up (Machine)
JBB1-Up (Machine)
JSB1-Up (Machine)

SAFETY.CAT.COM

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 SEBU7940-06 107
Maintenance Section
Maintenance Interval Schedule

i03786935 Undercarriage - Check ........................................ 137

Maintenance Interval Schedule Every 50 Service Hours
SMCS Code: 7000 Blade Linkage - Lubricate ................................... 109
Boom and Stick Linkage - Lubricate .................... 110
Ensure that all safety information, warnings and Fuel System Water Separator - Drain ................. 123
instructions are read and understood before any Quick Coupler - Clean ........................................ 131
operation or any maintenance procedures are Swing Frame and Cylinder Bearings - Lubricate .. 133
performed. Swing Gear and Bearing - Lubricate ................... 134
Track Adjustment - Inspect ................................. 136
The user is responsible for the performance of
maintenance, including all adjustments, the use of Initial 100 Service Hours
proper lubricants, fluids, filters, and the replacement
of components due to normal wear and aging. Failure Final Drive Oil - Change ..................................... 121
to adhere to proper maintenance intervals and Hydraulic System Oil Filter (Return) - Replace ... 128
procedures may result in diminished performance of
the product and/or accelerated wear of components. Every 250 Service Hours

Use mileage, fuel consumption, service hours, or Engine Oil Sample - Obtain ................................ 120
calendar time, WHICH EVER OCCURS FIRST, Final Drive Oil Level - Check .............................. 122
in order to determine the maintenance intervals.
Products that operate in severe operating conditions Initial 500 Hours (for New Systems, Refilled
may require more frequent maintenance. Systems, and Converted Systems)

Note: Before each consecutive interval is performed, Cooling System Coolant Sample - Obtain ........... 117
all maintenance from the previous interval must be
performed. Every 500 Service Hours
Boom, Stick, and Frame - Inspect ....................... 110
Note: If Cat HYDO Advanced 10 hydraulic oil is
Engine Oil and Filter - Change ........................... 120
used, the hydraulic oil change interval is extended Engine Valve Lash - Check ................................. 121
to 3000 hours. S·O·S services may extend the oil
Final Drive Oil Sample - Obtain .......................... 122
change to a longer interval. Consult your Caterpillar
Fuel System Primary Filter (Water Separator)
dealer for details. Element - Replace ............................................ 123
Fuel Tank Cap and Strainer - Clean ................... 124
When Required Fuel Tank Water and Sediment - Drain ............... 124
Battery - Recycle ................................................ 109 Hydraulic System Oil Sample - Obtain ............... 130
Battery or Battery Cable - Inspect/Replace ........ 109
Bucket Tips - Inspect/Replace ............................. 112 Every 1000 Service Hours
Cab Air Filter (Fresh Air) - Clean/Replace ........... 113 Battery Hold-Down - Tighten ............................... 109
Condenser (Refrigerant) - Clean ......................... 114
Final Drive Oil - Change ..................................... 121
Engine Air Filter Element - Clean/Replace .......... 118
Hydraulic System Oil Filter (Return) - Replace ... 128
Fuses - Replace .................................................. 124 Tip-Over Protective Structure (TOPS) - Inspect .. 135
Hydraulic System Oil Cooler Core - Clean ......... 127
Oil Filter - Inspect ................................................ 130
Radiator Core - Clean ......................................... 132
Every 2000 Service Hours
Track Adjustment - Adjust ................................... 135 Hydraulic System Oil - Change ........................... 125
Window Washer Reservoir - Fill .......................... 138
Window Wiper - Inspect/Replace ........................ 138 Every 2000 Service Hours or 1 Year
Windows - Clean ................................................. 138
Receiver Dryer (Refrigerant) - Replace .............. 132
Every 10 Service Hours
Every Year
Bucket Linkage - Lubricate .................................. 112
Cooling System Coolant Level - Check ............... 116 Cooling System Coolant Sample - Obtain ........... 117
Engine Air Filter Service Indicator - Inspect ......... 119
Engine Oil Level - Check ..................................... 119 Every 3000 Service Hours
Hydraulic System Oil Level - Check ................... 129
Quick Coupler - Lubricate ................................... 131 Cooling System Coolant Extender (ELC) - Add ... 115
Seat Belt - Inspect .............................................. 133 Hydraulic System Oil - Change ........................... 125
Travel Alarm - Test .............................................. 137

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 108 SEBU7940-06
Maintenance Section
Maintenance Interval Schedule

Every 3 Years After Date of Installation or

Every 5 Years After Date of Manufacture
Seat Belt - Replace ............................................. 133

Every 6000 Service Hours

Cooling System Coolant (ELC) - Change ............ 114

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 SEBU7940-06 109
Maintenance Section
Battery - Recycle

i00993589 3. Disconnect the positive battery cable at the

battery.
Battery - Recycle
4. Perform the necessary repairs. Replace the cable
SMCS Code: 1401-561 or the battery, as needed.
Always recycle a battery. Never discard a battery. 5. Connect the positive battery cable at the battery.
Always return used batteries to one of the following 6. Connect the negative battery cable at the battery.
locations:
7. Install the engine start switch key.
• A battery supplier
• An authorized battery collection facility i02343254

• Recycling facility Blade Linkage - Lubricate

SMCS Code: 6060-086
i00934872

Battery Hold-Down - Tighten Dozer

SMCS Code: 7257 Lower all the work tools and the blade to the ground.

Tighten the hold-downs for the battery in order to

prevent the batteries from moving during machine
operation.

i02004176

Battery or Battery Cable -

Inspect/Replace
SMCS Code: 1401-040; 1401-510; 1401-561; 1401;
1402-040; 1402-510

g01169043
Illustration 120

Personal injury may occur from failure to properly

service the batteries.

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 could

cause 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 working

g01169044
with batteries. Illustration 121

Wipe all fittings before lubricating.

1. Turn the engine start switch to the OFF position.
Remove the engine start switch key from the 1. Apply lubricant to the fittings for the arms (1) that
switch. Turn all switches to the OFF position. support the blade.
2. Disconnect the negative battery cable at the
battery.

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 110 SEBU7940-06
Maintenance Section
Boom and Stick Linkage - Lubricate

2. Apply lubricant to the fitting for the rod end of the • The amount of routine servicing that has been
blade cylinder (2). Apply lubricant to the fittings for carried out
the head end of the blade cylinder (3).
If the machine has been involved in any kind of
accident, the machine must be inspected thoroughly.
i02343261
Inspect the machine regardless of the date of the last
Boom and Stick Linkage - inspection.

Lubricate The machine must be clean before the machine is

inspected.
SMCS Code: 6501-086; 6502-086
Proper repair of frames and structures requires
Note: Caterpillar recommends the use of specific knowledge of the following subjects.
5% molybdenum grease for lubricating the
boom and stick linkage. Refer to Special • Materials that have been used to manufacture the
Publication, SEBU6250, “Caterpillar Machine Fluids frame members
Recommendations” for more information on grease.
• Frame member construction
Position the machine into the service position.
• Repair techniques that are recommended by the
Wipe all fittings before you apply lubricant. manufacturer.

Consult your Caterpillar dealer if repairs are

necessary. Your Caterpillar dealer is qualified to carry
out repairs on your behalf.

All repairs should be carried out by a Caterpillar

dealer. If you carry out your own repairs, contact
your Caterpillar dealer for advice about proper repair
techniques.

Particular attention should be given to all welded

structures. The following items should be thoroughly
inspected for cracks and for defects:

g01169066
• Boom
Illustration 122
• Stick
Apply lubricant to the grease fittings.
• Blade
i02860835
• Lifting points
Boom, Stick, and Frame -
• Upper frame
Inspect
• Lower frame
SMCS Code: 6501; 6502; 6506
NOTICE
All earthmoving equipment is prone to a high degree
The areas highlighted are of particular importance but
of wear. Regular inspections for structural damage
other areas must not be neglected. The entire struc-
are necessary.
ture must be carefully examined.
The interval between these inspections depends on
the factors that follow.

• The age of the machine

• The severity of the application
• The loads that have been carried on the machine

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 SEBU7940-06 111
Maintenance Section
Boom, Stick, and Frame - Inspect

Boom Check all welded joints and check the mounting

points for the cylinder.

Lifting Points

g01425291
Illustration 123

Check all welded joints and check the mounting

points for the cylinder. g01425213
Illustration 126

Stick

g00309343
Illustration 127
g01425293
Illustration 124 Check the approved lifting points carefully. Check
the welds. Check that the plates are not excessively
Check all welded joints and check the mounting bent. Check that the lifting holes are not deformed.
points for the cylinder.

Blade

g01425286
Illustration 125

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 112 SEBU7940-06
Maintenance Section
Bucket Linkage - Lubricate

Upper Frame i02016280

Bucket Linkage - Lubricate

SMCS Code: 6513-086

Note: Caterpillar recommends the use of 5%

molybdenum grease for lubricating the bucket
linkage. Refer to Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” for
more information on grease.

1. Park the machine on a level surface and lower the

work tools and the blade to the ground.

g01425289
Illustration 128

Check for damaged panels. Specifically look for any

damage to the cab or damage to the canopy that
might invalidate the certification. The cab or the
canopy is a safety device that must be maintained in
good condition. Check for loose hardware or missing g01042479
Illustration 130
hardware.
2. Wipe all fittings before you apply lubricant.
Lower Frame 3. Apply lubricant to grease fitting (1) and grease
fitting (2) for the pivot pin.

4. Apply lubricant to the grease fitting (3) for the rod

end of the bucket cylinder.

i02869831

Bucket Tips - Inspect/Replace

SMCS Code: 6805-040; 6805-510

Personal injury or death can result from bucket

falling.

Block the bucket before changing bucket tips or

side cutters.

g01425287
Illustration 129

Check the weld joints in the lower structure. Check

for loose hardware or missing hardware. Check the
ring of bolts that secure the swing gear.

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 SEBU7940-06 113
Maintenance Section
Cab Air Filter (Fresh Air) - Clean/Replace

Bucket Tips

g01183629
Illustration 133
g00101352
Illustration 131
1. Remove the bolt and remove the air filter element.
(1) Usable
(2) Replace this bucket tip.
(3) Overworn 2. Inspect the air filter element. If the air filter element
is dirty, replace the air filter element. If the air
Check the bucket tips for wear. If the bucket tip has a filter element is damaged or badly contaminated,
hole, replace the bucket tip. replace the air filter element.

3. Install the air filter element. Tighten the bolt.

302.5C
The cab air filter is located inside the engine
compartment on the right side.

g01429324
Illustration 132

1. Block the bucket.

2. Remove mounting bolts (6) and nuts (5). Remove

bucket tip (4).

3. Clean the mounting surfaces. Illustration 134

g01169003

4. Install the new bucket tip onto the adapter. 1. Open the engine access door.

i02343241 2. Inspect the air filter element. If the air filter element
is dirty, replace the air filter element. If the air
Cab Air Filter (Fresh Air) - filter element is damaged or badly contaminated,
replace the air filter element.
Clean/Replace
3. Install the air filter element. Tighten bolt (1).
SMCS Code: 7342-070; 7342-510
4. Close the engine access door.
301.6C and 301.8C
The cab air filter is located on the underside of the
frame on the right side of the machine.

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 114 SEBU7940-06
Maintenance Section
Condenser (Refrigerant) - Clean

i02375060 i02372843

Condenser (Refrigerant) - Cooling System Coolant (ELC)

Clean - Change
SMCS Code: 1805-070 SMCS Code: 1350-044
S/N: GBB1-Up

NOTICE Pressurized system: Hot coolant can cause seri-

If excessively dirty, clean condenser with a brush. To ous burn. To open cap, stop engine, wait until ra-
prevent damage or bending of the fins, do not use a diator is cool. Then loosen cap slowly to relieve
stiff brush. the pressure.
Repair the fins if found defective.
NOTICE
Mixing ELC with other products will reduce the effec-
Note: You can use compressed air, high pressure
tiveness of the coolant.
water, or steam to remove dust and other debris from
the condenser. However, the use of compressed air
This could result in damage to cooling system compo-
is preferred.
nents.
1. Open the access cover on the right side of the
If Caterpillar products are not available and com-
machine.
mercial products must be used, make sure they
have passed the Caterpillar EC-1 specification for
pre-mixed or concentrate coolants and Caterpillar
Extender.

The machine is shipped from the factory with

extended life coolant. Extended Life Coolant is
recommended when you are changing the coolant.

For information about the addition of Extender to your

cooling system, see the Operation and Maintenance
Manual, “Cooling System Extended Life Coolant
Extender - Add” or consult your Caterpillar dealer.

g01185223
Illustration 135

2. Inspect the condenser for debris.

3. Release rubber latch (1) in order to allow access

to the fan side of the condenser. Rotate the
condenser forward.

4. Clean the condenser, if necessary.

5. Close the access cover.

g01183517
Illustration 136
301.6C and 301.8C

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 SEBU7940-06 115
Maintenance Section
Cooling System Coolant Extender (ELC) - Add

3. Open drain valve (5) and allow the coolant to drain

into a suitable container.

Note: Dispose of drained fluids according to local

regulations.

4. Flush the cooling system with clean water until the

draining water is clean.

5. Close drain valve (5).

6. Add the Extended Life Coolant. See Operation

and Maintenance Manual, “Capacities (Refill)”.

g01183518
7. Start the engine. Operate the engine without the
Illustration 137 radiator cap until the thermostat opens and the
302.5C coolant level stabilizes.

1. Open the engine access door. 8. Check the coolant reservoir. Maintain the coolant
level between the “FULL” mark (2) and the “LOW”
2. Loosen the radiator cap (4) slowly in order to mark (3).
release pressure. Remove the radiator cap.
9. If additional coolant is necessary, remove the
coolant filler cap (1) and add the appropriate
coolant mixture. Install the filler cap.

10. Install radiator cap (4).

11. Stop the engine.

12. Close the engine access door.

i01278063

Cooling System Coolant

g01167491
Extender (ELC) - Add
Illustration 138
301.6C and 301.8C SMCS Code: 1352; 1353; 1395

Pressurized system: Hot coolant can cause seri-

ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loose the cap slowly to relieve
the pressure.

When a Caterpillar Extended Life Coolant is

used, an extender must be added to the cooling
system. See the Operation and Maintenance
Manual, “Maintenance Interval Schedule” for the
proper service interval. The amount of extender is
g01166467
determined by the cooling system capacity.
Illustration 139
302.5C

Note: Refer to Operation and Maintenance Manual,

“General Hazard Information” for information that
pertains to containing fluid spillage.

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 116 SEBU7940-06
Maintenance Section
Cooling System Coolant Level - Check

Table 45
RECOMMENDED AMOUNT OF EXTENDER BY
COOLING SYSTEM CAPACITY
Recommended Amount
Cooling System Capacity
of Extender
4 to 8 L (1.1 to 2.1 US gal) .2 L (0.19 qt)

For additional information on the addition of extender,

see Operation and Maintenance Manual, SEBU6250,
“Caterpillar Coolant Recommendations” or consult
your Caterpillar dealer.

i02337191 g01183518
Illustration 141
Cooling System Coolant Level 302.5C

- Check 1. Open the engine access door.

SMCS Code: 1350-040; 1350-535-FLV; 2. Maintain the coolant level between the “FULL”
1395-535-FLV mark (2) on the coolant reservoir and the “LOW”
mark (3) on the coolant reservoir.

Note: Refer to Operation and Maintenance Manual,

Pressurized system: Hot coolant can cause seri- “General Hazard Information” for information on
ous burn. To open cap, stop engine, wait until ra- Containing Fluid Spillage.
diator is cool. Then loosen cap slowly to relieve
the pressure. 3. If additional coolant is necessary, remove the
coolant filler cap (1) and add the appropriate
coolant mixture. Install the filler cap.

4. If the coolant reservoir is empty, remove the

cooling system pressure cap (4) slowly in order to
relieve pressure. Add coolant to the radiator.

g01183517
Illustration 140
301.6C and 301.8C

g00102170
Illustration 142

5. Inspect the condition of the cap gasket. If

necessary, replace the cap.

6. Install the cooling system pressure cap.

7. Close the engine access door.

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 SEBU7940-06 117
Maintenance Section
Cooling System Coolant Sample - Obtain

i02373374 • Place the sample in the mailing tube immediately

after obtaining the sample in order to avoid
Cooling System Coolant contamination.
Sample - Obtain
• Never collect samples from expansion bottles.
SMCS Code: 1395-008; 1395-554; 7542
• Never collect samples from the drain for a system.
Note: This machine was filled at the factory
with Caterpillar Extended Life Coolant. Cooling
systems that are filled with Cat ELC should have
a Coolant Sample (Level 2) that is obtained at
the recommended interval that is stated in the
Maintenance Interval Schedule.

NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers. Illustration 143
g00544510

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- Pressurized System: Hot coolant can cause seri-
ing, adjusting and repair of the product. Be prepared to ous burns. To open the cooling system filler cap,
collect the fluid with suitable containers before open- stop the engine and wait until the cooling system
ing any compartment or disassembling any compo- components are cool. Loosen the cooling system
nent containing fluids. pressure cap slowly in order to relieve the pres-
sure.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar 1. The machine needs to be operated in order to
products. circulate the coolant. Collect the sample after a
normal workday. Collect the samples from one to
Dispose of all fluids according to local regulations and two hours after the engine has been shut off.
mandates.
2. Start the engine momentarily in order to circulate
the coolant again.
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. In order 3. Shut off the engine.
to receive the full effect of S·O·S analysis, you
must establish a consistent trend of data. In order 4. Carefully remove the radiator cap.
to establish a pertinent history of data, perform
consistent samplings that are evenly spaced. 5. Use a vacuum pump and draw the sample. Do
Supplies for collecting samples can be obtained from not allow dirt or other contaminants to enter
your Caterpillar dealer. the sampling bottle. Fill the sampling bottle
three-fourths from the top. Do not fill the bottle
Use the following guidelines for proper sampling of completely.
the coolant:
6. Place the sampling bottle with the completed label
• Complete the information on the label for the into the mailing tube.
sampling bottle before you begin to take the
samples. 7. Install the radiator cap.
• Keep the unused sampling bottles stored in plastic 8. Submit the sample for Level 2 analysis.
bags.

• Keep the lids on empty sampling bottles until you

are ready to collect the sample.

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 118 SEBU7940-06
Maintenance Section
Engine Air Filter Element - Clean/Replace

i02331721 Vacuum Cleaning

Engine Air Filter Element - Vacuum cleaning is another method for cleaning
Clean/Replace air filter elements which require daily cleaning
because of a dry, dusty environment. Cleaning with
SMCS Code: 1054-070; 1054-510 pressurized air is recommended prior to vacuum
cleaning. Vacuum cleaning will not remove deposits
of carbon and oil.
Cleaning the Air Filter Element
Replace the air filter element after the air filter
NOTICE element has been cleaned six times. Also replace
Do not clean the air filter elements by bumping or tap- the air filter element if the air filter element has been
ping. This could damage the seals. Do not use ele- in service for 2000 hours.
ments with damaged pleats, gaskets, or seals. Dam-
aged elements will allow dirt to pass through. Engine Replacing the Air Filter Element
damage could result.
NOTICE
The air filter element can be cleaned by using the Service the air cleaner only when the engine stopped.
following methods. Engine damage could result.

• pressure air
The air filter element should be replaced immediately
• Vacuum cleaning if the element is damaged.

1. Open the engine access door.

Pressurized Air
Pressurized air can be used to clean air filter
elements. Pressurized air will not remove deposits of
carbon and oil. Use filtered, dry air with a maximum
pressure of 207 kPa (30 psi).

g01163954
Illustration 145

2. Unclamp the access cover and remove the access

cover to the air cleaner.

g00281692 3. Remove the filter element from the air cleaner

Illustration 144
housing.
Note: When the air filter element is cleaned, always
4. Cover the air inlet port in order to prevent dirt from
begin with the clean side (inside) in order to force dirt getting inside the engine.
particles toward the dirty side (outside).
5. Inspect the filter element. If the pleats, the gaskets
Aim the hose so that the air flows inside the element or the seals are damaged, discard the filter
along the length of the filter in order to help prevent
element. Replace a damaged filter element with a
damage to the paper pleats. Do not aim the stream
new filter element.
of air directly at the air filter element. Dirt could be
forced further into the pleats.
6. Wipe dust from the interior of the air cleaner
housing. Remove the cover from the air inlet port.

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 SEBU7940-06 119
Maintenance Section
Engine Air Filter Service Indicator - Inspect

7. Put the clean air filter element into the air cleaner 4. If the piston in the engine air filter service indicator
housing and push the air filter element into enters the red zone, service the air cleaner.
position.
5. Stop the engine.
8. Install the access cover and clamp the access
cover. Note: See the Operation and Maintenance Manual,
“Engine Air Filter Element - Clean/Replace”.
9. Close the engine access door.
6. Close the engine access door.
i02373198

Engine Air Filter Service i02331424

Indicator - Inspect Engine Oil Level - Check

SMCS Code: 1000-535
SMCS Code: 7452-040-DJ
NOTICE
NOTICE
Do not overfill the crankcase. Engine damage can re-
Service the air cleaner only with the engine stopped.
sult.
Engine damage could result if the air cleaner is ser-
viced while the engine is running.
1. Open the engine access door.

g01183886
Illustration 146 g01163811
Illustration 148
301.6C and 301.8C
301.6C and 301.8C

g01163949
Illustration 147 g01163810
Illustration 149
302.5C
302.5C

1. Open the engine access door.

2. While the engine is stopped, maintain the oil level
in the crosshatched area on the dipstick (2).
2. Start the engine.

3. Run the engine at high idle.

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 120 SEBU7940-06
Maintenance Section
Engine Oil Sample - Obtain

3. If necessary, remove the oil filler cap (1) and add

oil. Allow the oil to drain into the crankcase before
you check the oil level.

4. Close the engine access door.

i02331668

Engine Oil Sample - Obtain

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

g01166478
Illustration 151
Location for the drain plug on the 301.6C and on the 301.8C

g01163905
Illustration 150

Obtain a sample of the engine oil through the dipstick

tube. Refer to Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations”, g01166480
Illustration 152
“S·O·S Oil Analysis” for information that pertains to
obtaining a sample of the engine oil. Refer to Special Location for the drain plug on the 302.5C
Publication, PEHP6001, “How To Take A Good Oil
Sample” for more information about obtaining a 2. Remove the crankcase drain plug and allow the oil
sample of the engine oil. to drain into a suitable container. After you drain
the oil, clean the drain plug and clean the plug
hole. Install the drain plug.
i02336591

Engine Oil and Filter - Change

SMCS Code: 1318-510

Note: If the sulfur content in the fuel is greater than

1.5% by weight, use an oil with a TBN of 30. With the
high sulfur fuel, change the oil and the filter element
after every 125 hours. Otherwise, change the oil and
the filter element after every 500 hours.

Change the oil while the machine is parked on flat

ground. Lower all attachments to the ground.

1. Open the engine access door. Illustration 153

g01166481

The oil filter location for the 302.5C is shown. The oil filter location
Note: Refer to Operation and Maintenance Manual, for the 301.6C and for the 301.8C is similar.
“General Hazard Information” for information on
Containing Fluid Spillage. 3. Remove the filter element with a filter wrench.

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 SEBU7940-06 121
Maintenance Section
Engine Valve Lash - Check

4. Install the new filter element by hand. When the

gasket contacts the filter base, tighten the filter for NOTICE
an additional three quarters of a turn. Only qualified service personnel should perform this
maintenance. Refer to the Systems Operation/Testing
and Adjusting Manual, “Valve Lash and Valve Bridge
Adjustment” article or consult your Caterpillar dealer
for the complete valve lash adjustment procedure.

Operation of Caterpillar engines with improper valve

adjustments can reduce engine efficiency. This re-
duced efficiency could result in excessive fuel usage
and/or shortened engine component life.

For the serial number GBB1-up, refer to Service

Manual, RENR5578, “S3L2/S4L2 MHI Engine
Manual” in order to perform the complete procedure
for the valve lash adjustment.
g01163810
Illustration 154
The location for the oil filler cap for the 302.5C is shown. The For the serial number JBB1-up and JSB1-up, refer to
location for the oil filler cap for the 301.6C and for the 301.8C is Service Manual, RENR9981, “MHI L-Series Engine
similar. Service Manual.” in order to perform the complete
procedure for the valve lash adjustment.
5. Remove the oil filler cap (1) and add the
appropriate amount of oil.
i02360062

6. Start the engine and operate the engine at low idle

for several minutes. While the engine is running,
Final Drive Oil - Change
check the filter base for oil leaks. SMCS Code: 4050-044-FLV
7. Stop the engine and allow the oil to drain back Note: At the time of changing oil, observe the oil
into the crankcase. Maintain the oil level in the for presence of metallic particles or other foreign
crosshatched area on the dipstick (2). matters. If you find something that needs attention,
consult your Caterpillar dealer.
8. Close the engine access door.
1. Warm up the oil by roading the tracks.
i02858287
2. Move the machine to level ground.
Engine Valve Lash - Check
SMCS Code: 1102-082; 1102-535; 1102; 1105-025;
1105-535; 1121-535; 1209-082; 1209-535; 1209;
7527

Ensure that the engine can not be started while

this maintenance is being performed. To help pre-
vent possible injury, do not use the starting motor
to turn the flywheel.

Hot engine components can cause burns. Allow

additional time for the engine to cool before mea- g01045493
Illustration 155
suring/adjusting valve lash clearance.
(1) Oil drain plug
(2) Oil level plug

3. Position one final drive so that the drain plug is

at the bottom.

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 122 SEBU7940-06
Maintenance Section
Final Drive Oil Level - Check

Note: Refer to Operation and Maintenance Manual, 1. Position one final drive so that the oil drain plug
“General Hazard Information” for information on (1) is on the bottom. Oil level plug (2) is in position
Containing Fluid Spillage. ready to check the oil level.

4. Remove the oil level plug (2). Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information on
5. Remove the oil drain plug (1). Allow the oil to drain Containing Fluid Spillage.
into a suitable container.
2. Remove the oil level plug (2).
6. Clean the drain plug. Apply pipe sealant on the
threads in order to prevent leakage. Reinstall the 3. Check the oil level. The oil level should be near
oil drain plug. the bottom of the opening for the oil level plug (2).

7. Add oil to the final drive through the opening 4. If necessary, add oil through the opening for the
for the oil level plug until the oil is level with the oil level plug (2).
plug threads. See Operation and Maintenance
Manual, “Lubricant Viscosities” and Operation and Note: Do not overfill the final drive compartment.
Maintenance Manual, “ Capacities (Refill)”.
5. Clean the oil level plug. Reinstall the plug. Apply
8. Clean the oil level plug. pipe sealant on the threads in order to prevent
leakage.
9. Repeat the procedure for the other final drive.
6. Repeat the procedure for the other final drive.
10. Start the engine and allow the final drives to run
through several cycles.
i02024989

11. Stop the engine. Check the oil level in both final
drives.
Final Drive Oil Sample - Obtain
SMCS Code: 4011-008; 4050-008; 4050-SM;
12. Apply pipe sealant on the threads of the oil level 7542-008
plug. Reinstall the oil level plug.

13. Properly dispose of the drained material. Obey

local regulations for the disposal of the material.

i02015871

Final Drive Oil Level - Check

SMCS Code: 4050-535-FLV

g01045493
Illustration 157
(1) Oil drain plug
(2) Oil level plug

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

at the bottom.

2. Remove oil level plug (2).

3. Obtain a sample of the final drive oil through the

g01045493
Illustration 156 hole for the oil level plug.
(1) Oil drain plug
(2) Oil level plug 4. Install oil level plug (2).

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 SEBU7940-06 123
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace

Refer to Special Publication, SEBU6250, “S·O·S Oil 3. Support the water separator element and rotate
Analysis” for more information on obtaining a sample the locking ring (2) counterclockwise. Remove the
of the final drive oil. For additional information about primary filter/water separator.
taking an oil sample, refer to Special Publication,
PEHP6001, “How To Take A Good Oil Sample”. 4. Remove the water separator bowl (3) from the
bottom of the fuel filter/water separator.
i02331839
Note: The water separator bowl is reusable. Do not
Fuel System Primary Filter discard the water separator bowl.

(Water Separator) Element - 5. Inspect the O-ring seal of the water separator bowl
Replace for damage. Replace the O-ring seal, if necessary.

6. Lubricate the O-ring seal with clean diesel fuel or

SMCS Code: 1263-510-FQ
lubricate the O-ring seal with motor oil. Place the
seal in the water separator bowl.

7. Spin the water separator bowl onto the new

element by hand until the fuel filter/water separator
is snug. Do not use tools to tighten the fuel
filter/water separator element to the bowl.

8. Clean the filter mounting base.

9. Install the new element. Rotate the locking ring

clockwise in order to fasten the filter to the
mounting base.

10. Close the engine access door.

g01183469
Illustration 158
i02331817
The fuel system filter/water separator element is
located on the engine access door on the 301.6C Fuel System Water Separator
and on the 301.8C.
- Drain
SMCS Code: 1263

g01183470
Illustration 159

The fuel system filter/water separator element is g01183502

located in the engine compartment on the 302.5C. Illustration 160

1. Open the engine access door. The water separator is located on the engine access
door on the 301.6C and on the 301.8C.
2. Open the drain on the water separator bowl (1).
Allow the water and fuel to drain into a suitable
container.

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 124 SEBU7940-06
Maintenance Section
Fuel Tank Cap and Strainer - Clean

g01183503 g00104238
Illustration 161 Illustration 163

The water separator is located in the engine 2. Inspect the cap. Replace the cap if the cap is
compartment on the 302.5C. damaged.

1. Open the engine access door. 3. Wash fuel fill screen (2) in a clean, nonflammable
solvent and dry the fuel fill screen.
2. Loosen the drain valve on the bottom of the water
separator. Allow the water and the sediment to 4. Install fuel fill screen (2).
drain into a suitable container.
5. Put a light coating of fuel on the cap gasket.
3. Tighten the drain valve.
6. Install fuel cap (1).
4. Close the engine access door.
i02015865

Fuel Tank Water and Sediment

i02338406

Fuel Tank Cap and Strainer - - Drain

Clean
SMCS Code: 1273-543
SMCS Code: 1273-070-STR
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information on
Containing Fluid Spillage.

1. Open the drain valve that is located under the fuel

tank. Allow the water and the sediment to drain
into a suitable container.

Note: Discard the drained fluids according to local

regulations.

2. Close the drain valve.

i02327084
g01167205
Illustration 162
Fuses - Replace
1. Remove fuel cap (1) and fuel fill screen (2).
SMCS Code: 1417-510

Fuses – Fuses protect the electrical system from

damage that is caused by overloaded circuits.
Replace the fuse if the element separates. If the
element of a new fuse separates, check the circuit. If
necessary, repair the circuit.

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 SEBU7940-06 125
Maintenance Section
Hydraulic System Oil - Change

NOTICE
Replace the fuses with the same type and size only.
If the type and size is changed, electrical damage can
result.

If it is necessary to replace fuses frequently, an electri-

cal problem may exist. Contact your Caterpillar dealer.

The fuse panel is located in the storage box under

the operator seat.

g01124518
Illustration 165
Side view inside storage compartment

(17) Main Fuse – 60 amp

(18) Alternator – 30 amp

i03653015

Hydraulic System Oil - Change

g01162478 SMCS Code: 5056-044
Illustration 164

(1) Spare – 5 Amp Cat HYDO Oil Change Interval

(2) Spare – 10 Amp The standard Cat HYDO oil change interval is every
2000 service hours.
(3) Spare – 15 Amp
A maintenance interval of 4000 service hours for
(4) Spare – 20 Amp changing the hydraulic oil is available. The extended
interval requires S·O·S monitoring of the hydraulic
(5) Radio – 5 amp oil. The interval for S·O·S monitoring is every 500
hours. The maintenance interval for the hydraulic oil
(6) Window Wiper and Window Washer – 10 amp filter is not changed.

(7) Heater – 15 amp Machines with hammers are not included in

the maintenance interval of 4000 service hours.
(8) Air conditioning – 20 amp Machines with hammers must use the intervals that
are listed in the Maintenance Interval Schedule.
(9) Start – 10 amp Machines that are used in severe conditions are not
included in the maintenance interval 4000 service
(10) Engine Start Switch – 15 amp hours. Machines that are used in severe conditions
must use the interval in the Maintenance Interval
(11) Cab Dome Light – 10 amp Schedule.

(12) Horn – 5 amp

Cat HYDO Advanced 10 Oil Change
(13) Fuel Pump – 5 amp Interval
(14) Accessory – 10 amp The standard Cat HYDO Advanced 10 oil change
interval is every 3000 service hours.
(15) Beacon – 10 amp

(16) Chassis Lights – 15 amp

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 126 SEBU7940-06
Maintenance Section
Hydraulic System Oil - Change

A maintenance interval of 6000 service hours for

changing the hydraulic oil is available. The extended
interval requires S·O·S monitoring of the hydraulic
oil. The interval for S·O·S monitoring is every 500
hours. The maintenance interval for the hydraulic oil
filter is not changed.

Machines with hammers are not included in the

maintenance interval of 6000 service hours .
Machines with hammers must use the intervals that
are listed in the Maintenance Interval Schedule.
Machines that are used in severe conditions are not
included in the maintenance interval 6000 service
hours. Machines that are used in severe conditions
must use the interval in the Maintenance Interval g01168803
Schedule. Illustration 167
301.6C and 301.8C

Procedure to Change the Hydraulic

Oil

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact skin.

1. Park the machine on level ground. Position the

machine so that the right rear corner of the
machine is located outside the tracks.
g01168804
Illustration 168
302.5C

3. Open the access door to the hydraulic tank. Clean

the area thoroughly around the hydraulic oil filler
cap in order to prevent dirt from entering the
hydraulic tank.

NOTICE
Hot oil can cause personal injury. Remove the hy-
draulic oil filler cap only when the engine is stopped.
Allow time for the hydraulic system to cool. Remove
hydraulic oil filler cap slowly in order to relieve pres-
Illustration 166
g01167770 sure.

2. Extend the stick and the bucket fully. Lower the 4. The hydraulic oil drain plug is located on the
boom so that the bucket is rested on the ground. bottom of the hydraulic oil tank.
Lower the blade to the ground.
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information on
Containing Fluid Spillage.

5. Remove the hydraulic oil drain plug. Allow the oil

to drain into a suitable container.

6. Clean the drain plug and reinstall the plug.

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 SEBU7940-06 127
Maintenance Section
Hydraulic System Oil Cooler Core - Clean

7. Remove the hose from the hydraulic tank strainer. 15. Maintain the hydraulic oil level between the top
Inspect the hose. Replace the hose if the hose is mark and the bottom mark on the decal next to
damaged. the sight gauge, if a decal is installed. This is
particularly important on early 301.6c and 301.8c
8. Remove the hydraulic tank strainer. Inspect the models. The correct oil level is important to avoid
strainer and clean the strainer. Replace the pump cavitation. If your machine has no decal
strainer if the strainer is worn. next to the sight gauge, the oil level must be
visible in the sight gauge. Any position on the sight
9. Install the strainer. Install the hose. gauge is acceptable level.

10. Change the hydraulic oil filter. Refer to Operation Note: The oil must be free of bubbles. If bubbles are
and Maintenance Manual, “Hydraulic System Oil present in the oil, air is entering the hydraulic system.
Filter (Return) - Replace”. Inspect the suction hoses, the hose clamps and the
hydraulic oil return filter.
11. Fill the hydraulic system oil tank. Refer to
Operation and Maintenance Manual, “Lubricant 16. Stop the engine.
Viscosities” and Operation and Maintenance
Manual, “ Capacities (Refill)”. 17. If necessary, tighten any loose clamps and any
loose connections. Replace any damaged hoses.
12. Inspect the gasket on the hydraulic tank filler cap
for damage. Replace the gasket, if necessary. 18. Close the access door.

13. Install the hydraulic tank filler cap.

i02342268

14. Start the engine and run the engine for a few
minutes. Operate the control levers in order to
Hydraulic System Oil Cooler
cause the hydraulic oil to flow through the circuits. Core - Clean
SMCS Code: 1374-070-KO

Note: Certain work environments may encourage

plugging and more frequent cleaning may be
required.

g01167771
Illustration 169
301.8C is shown.

g01167841
Illustration 171
301.6C and 301.8C

g01621721
Illustration 170
302.5C is shown.

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 128 SEBU7940-06
Maintenance Section
Hydraulic System Oil Filter (Return) - Replace

g01167843 g01168349
Illustration 172 Illustration 173
302.5C 301.6C and 301.8C

1. Open the engine access door.

2. Remove the access panel on the right rear corner

on the 301.6C and on the 301.8C.

The hydraulic oil cooler core is bolted to the

outside edge of the radiator.

3. Check for accumulation of dust in the fins of the

hydraulic oil cooler.

4. Clean the fins of the hydraulic oil cooler with

compressed air, pressurized water or steam.
g01168353
Note: Clean the area between the fins of the oil Illustration 174
cooler and the radiator. 302.5C

5. Replace the access panel on the corner. 1. Open the access door in order to gain access to
the hydraulic oil tank. Clean the area thoroughly in
6. Close the engine access door. order to prevent dirt from entering the filter.

2. Slowly remove the hydraulic oil filler cap (1) in

i02342279 order to relieve the pressure in the hydraulic oil
Hydraulic System Oil Filter tank.

(Return) - Replace Note: Refer to Operation and Maintenance Manual,

“General Hazard Information” for information on
SMCS Code: 5068-510-RJ Containing Fluid Spillage.

NOTICE 3. Remove the used filter (2).

Hot oil can cause personal injury. Remove the hy-
draulic oil filler cap only when the engine is stopped. 4. Install the new filter.
Allow time for the hydraulic system to cool. Remove
hydraulic oil filler cap slowly in order to relieve pres- 5. Reinstall the hydraulic oil filler cap.
sure.
6. Close the access door.

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 SEBU7940-06 129
Maintenance Section
Hydraulic System Oil Level - Check

i02342208

Hydraulic System Oil Level -

Check
SMCS Code: 5050-535

Note: Check the hydraulic system oil level with the

machine on a level surface.

g01167778
Illustration 177
Location for the 302.5C

3. The sight gauge is located on the hydraulic tank.

4. Maintain the hydraulic system oil level between

the top mark and the bottom mark on the sight
gauge.
g01167770
Illustration 175 NOTICE
Hot oil can cause personal injury. Remove the hy-
1. Extend the stick and the bucket fully. Lower the draulic oil filler cap only when the engine is stopped.
boom so that the bucket is rested on the ground. Allow time for the hydraulic system to cool. Remove
Lower the blade to the ground. hydraulic oil filler cap slowly in order to relieve pres-
sure.
2. Open the access door for the hydraulic tank on
the 301.6C and the 301.8C.
5. Remove the hydraulic tank filler cap slowly in
order to relieve any pressure and add hydraulic
oil, if necessary.

6. Clean the hydraulic tank filler cap. Install the

hydraulic tank filler cap.

g01167771
Illustration 176
Location for the 301.6C and the 301.8C

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 130 SEBU7940-06
Maintenance Section
Hydraulic System Oil Sample - Obtain

i02340736 i02106227

Hydraulic System Oil Sample Oil Filter - Inspect

- Obtain SMCS Code: 1308-507; 5068-507
SMCS Code: 5050-008-OC; 5095-008; 5095-SM;
7542-008; 7542 Inspect a Used Filter for Debris

g01183311 g00100013
Illustration 178 Illustration 180
301.6C and 301.8C The element is shown with debris.

Use a filter cutter to cut the filter element open.

Spread apart the pleats and inspect the element for
metal and for other debris. An excessive amount of
debris in the filter element can indicate a possible
failure.

If metals are found in the filter element, a magnet can

be used to differentiate between ferrous metals and
nonferrous metals.

Ferrous metals can indicate wear on steel parts and

on cast iron parts.

g01183314
Nonferrous metals can indicate wear on the
Illustration 179 aluminum parts of the engine such as main bearings,
302.5C rod bearings, or turbocharger bearings.

Obtain a sample of the hydraulic oil from the hydraulic Small amounts of debris may be found in the filter
oil sampling valve. The hydraulic oil sampling valve element. This could be caused by friction and by
is located on the hydraulic oil tank. Refer to Special normal wear. Consult your Caterpillar dealer in order
Publication, SEBU6250, “S·O·S Oil Analysis” for to arrange for further analysis if an excessive amount
information that pertains to obtaining a sample of debris is found.
of the hydraulic oil. Refer to Special Publication,
PEHP6001, “How To Take A Good Oil Sample” for Using an oil filter element that is not recommended
more information about obtaining a sample of the by Caterpillar can result in severe engine damage
hydraulic oil. to engine bearings, to the crankshaft, and to other
parts. This can result in larger particles in unfiltered
oil. The particles could enter the lubricating system
and the particles could cause damage.

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 SEBU7940-06 131
Maintenance Section
Quick Coupler - Clean

i02973191

Quick Coupler - Clean

SMCS Code: 6129-070

g01167510
Illustration 182
Typical example

3. Apply grease to the fittings of the quick coupler.

g01155173
Illustration 181
Typical example

1. Remove pin (1).

2. Remove safety pin (2) from the quick coupler. The

pin may be located on the right side or located on
the rear of the quick coupler.

3. Clean safety pin (2).

4. Clean out bore (3) on either side of the coupler.

5. Remove any trash or buildup from the quick

coupler. Illustration 183
g01167518

Typical example
6. Apply grease to safety pin (2).
4. Apply grease to the external surface of the pin in
Refer to Special Publication, SEBU6250, the lock assembly.
“Caterpillar Machine Fliud Recommendations” for
more information about the selection of grease. Note: The lock assembly may be located on the side
of the coupler or located on the rear of the coupler.
7. Insert safety pin (2) into bore (3)on the right side.
5. Check the overall condition of the quick coupler.
8. Insert pin (1) into safety pin (2) on the left side of Look for the following conditions: loose bolts, worn
the quick coupler. parts, broken parts, missing parts, and damaged
parts. Make any necessary repairs.
i02973110

Quick Coupler - Lubricate

(If Equipped)
SMCS Code: 6129-086

1. Lower all work tools to the ground.

2. Wipe off the fittings before you lubricate the fitting.

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 132 SEBU7940-06
Maintenance Section
Radiator Core - Clean

i02326214 i02723802

Radiator Core - Clean Receiver Dryer (Refrigerant) -

SMCS Code: 1353-070 Replace
SMCS Code: 7322-510; 7322-710

Personal injury can result from contact with refrig-

erant.

Contact with refrigerant can cause frost bite. Keep

face and hands away to help prevent injury.

Protective goggles must always be worn when re-

frigerant lines are opened, even if the gauges in-
dicate the system is empty of refrigerant.
g01167841
Illustration 184 Always use precaution when a fitting is removed.
301.6C and 301.8C Slowly loosen the fitting. If the system is still un-
der pressure, release it slowly in a well ventilated
area.

Personal injury or death can result from inhaling

refrigerant through a lit cigarette.

Inhaling air conditioner refrigerant gas through a

lit cigarette or other smoking method or inhaling
fumes released from a flame contacting air con-
ditioner refrigerant gas, can cause bodily harm or
death.

Do not smoke when servicing air conditioners or

wherever refrigerant gas may be present.
g01162208
Illustration 185
Use a certified recovery and recycling cart to prop-
302.5C erly remove the refrigerant from the air condition-
ing system.
1. Open the engine access doors.

2. Remove the access panel on the right rear corner NOTICE

on the 301.6C and on the 301.8C. If the refrigerant system has been open to the outside
air (without being plugged) for more than 30 minutes,
3. You can use compressed air, high pressure water, the receiver-dryer must be replaced. Moisture will en-
or steam to remove dust and other debris from ter an open refrigerant system and cause corrosion
the radiator fins. However, the use of compressed which will lead to component failure.
air is preferred.

4. Replace the access panel on the corner. Refer to Service Manual, SENR5664, “Air
Conditioning and Heating System with R-134a
5. Close the engine access doors. Refrigerant for All Caterpillar Machines” for the proper
procedure to change the receiver-dryer assembly
and for the procedure to reclaim the refrigerant gas.

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 SEBU7940-06 133
Maintenance Section
Seat Belt - Inspect

i02429589 i02429594

Seat Belt - Inspect Seat Belt - Replace

SMCS Code: 7327-040 SMCS Code: 7327-510

Always check the condition of the seat belt and the Within three years of the date of installation or within
condition of the seat belt mounting hardware before five years of the date of manufacture, replace the
you operate the machine. Replace any parts that are seat belt . Replace the seat belt at the date which
damaged or worn before you operate the machine. occurs first. A date label for determining the age of
the seat belt is attached to the seat belt, the seat belt
buckle, and the seat belt retractor.

g00932801
Illustration 186 g01152685
Illustration 187
Typical example
(1) Date of installation (retractor)
(2) Date of installation (buckle)
Check the seat belt mounting hardware (1) for wear (3) Date of manufacture (tag) (fully extended web)
or for damage. Replace any mounting hardware that (4) Date of manufacture (underside) (buckle)
is worn or damaged. Make sure that the mounting
bolts are tight. Consult your Caterpillar dealer for the replacement of
the seat belt and the mounting hardware.
Check buckle (2) for wear or for damage. If the buckle
is worn or damaged, replace the seat belt. If your machine is equipped with a seat belt
extension, also perform this replacement procedure
Inspect the seat belt (3) for webbing that is worn or for the seat belt extension.
frayed. Replace the seat belt if the seat belt is worn
or frayed.
i02476957

Consult your Caterpillar dealer for the replacement of Swing Frame and Cylinder
the seat belt and the mounting hardware.
Bearings - Lubricate
Note: Within three years of the date of installation or
within five years of the date of manufacture, replace SMCS Code: 5105-086-BD; 6506-086-BD;
the seat belt. Replace the seat belt at the date which 6507-086-BD
occurs first. A date label for determining the age of
the seat belt is attached to the seat belt, the seat belt Wipe the fittings before you lubricate the fittings.
buckle, and the seat belt retractor.

If your machine is equipped with a seat belt

extension, also perform this inspection procedure for
the seat belt extension.

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 134 SEBU7940-06
Maintenance Section
Swing Gear and Bearing - Lubricate

g01171787 g01171789
Illustration 188 Illustration 191
301.6C and 301.8C
Apply lubricant to the grease fitting for the bearing on
the head end of the swing cylinder.

i02326498

Swing Gear and Bearing -

Lubricate
SMCS Code: 7063-086

1. Lower all work tools to the ground.

g01171713
Illustration 189
301.6C and 301.8C

g01162263
Illustration 192

2. Wipe all fittings before you lubricate the fittings.

3. The fittings for the swing gear and bearing are

g01236788
Illustration 190 located under the boom base on the front side of
302.5C the upper structure.

Apply lubricant to the fittings. 4. Rotate the upper structure for 90°.

5. Apply grease to the fittings for the swing gear and

bearing.

6. Repeat Step 4 and Step 5 until the upper structure

has rotated 360°.

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 SEBU7940-06 135
Maintenance Section
Tip-Over Protective Structure (TOPS) - Inspect

i02345179 i02050907

Tip-Over Protective Structure Track Adjustment - Adjust

(TOPS) - Inspect SMCS Code: 4170-025
SMCS Code: 7325-040
Tightening the Tracks

g01171594
Illustration 193
g00523702
Illustration 194
Inspect the Tip Over Protection Structure (TOPS) for
bolts that are loose, damaged or missing. Replace 1. Remove the cover plate for the track adjustment
any bolts that are loose, damaged, or missing with valve.
original replacement parts only. Torque the M14 bolts
to 80 ± 15 N·m (60 ± 10 lb ft).

Note: Apply thread lock to all bolt threads for the

TOPS before you install the bolts.

Do not weld reinforcement plates to the TOPS

in order to straighten the TOPS. Do not weld
reinforcement plates to the TOPS in order to repair
the TOPS.

Consult your Caterpillar dealer for repairs of any

cracks in the TOPS.

Consult your Caterpillar dealer for an inspection of

g00523707
the TOPS if an incident occurs. Illustration 195

2. Wipe the fitting before you add grease.

3. Add grease through the valve fitting until the

correct tension is reached.

4. Operate the track back and forth in order to

equalize the pressure.

5. Check the amount of sag. Adjust the track, as

needed. Refer to Operation and Maintenance,
“Track Adjustment - Inspect”.

6. Replace the cover plate for the track adjustment

valve.

7. Repeat the same procedure for the other track.

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 136 SEBU7940-06
Maintenance Section
Track Adjustment - Inspect

Loosening the Track i02345604

Track Adjustment - Inspect

SMCS Code: 4170-040
Personal injury or death can result from grease
under pressure. Note: Keeping the track properly adjusted will
increase the service life of the track components and
Grease coming out of the relief valve under pres- the drive components.
sure can penetrate the body causing injury or
death. Check the rubber tracks for the following conditions:

Do not watch the relief valve to see if grease is es- • Steel cords that are cut
caping. Watch the track or track adjustment cylin-
der to see if the track is being loosened. • Core irons that are fractured
Loosen the relief valve one turn only. • Rubber flaking off to the point of showing steel
cords or core irons
If track does not loosen, close the relief valve and
contact your Caterpillar dealer. • Loss of traction or grousers are worn down to
approximately 5 mm (0.2 inch) in height.

If any of the above conditions or a combination of the

above conditions are observed, replace the belt.

Measuring Rubber Track Tension

1. Park the machine on a level surface.

2. Position the upper frame over the tracks at a 90°

angle.

3. Lower the bucket to the ground with the stick in

a vertical position.
g00523707
Illustration 196 4. Chock the track that is not being lifted off the
ground.
1. Loosen the filler valve carefully until the track
begins to loosen. One turn should be the 5. Apply boom down pressure until the track that is
maximum. on the same side as the bucket has cleared the
ground.
2. Tighten the filler valve to 34 N·m (25 lb ft) when
the desired track tension is reached. 6. Chock the lower frame of the machine in this
position.
3. Operate the track back and forth in order to
equalize pressure. 7. Clean the track rollers and the area around the
skid plate.
4. Check the amount of sag in the track. Adjust
the track, as needed. Refer to Operation and
Maintenance, “Track Adjustment - Inspect”.

5. Repeat the same procedure for the other track.

If the correct adjustment cannot be achieved consult

your Caterpillar dealer.

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 SEBU7940-06 137
Maintenance Section
Travel Alarm - Test

i02345060

Travel Alarm - Test

SMCS Code: 7429-081

You must move the machine in order to test the travel

alarm.

1. Start the engine. Lower the hydraulic lockout

control to the UNLOCKED position.

2. Raise the work tool. Make sure that there is

adequate overhead clearance.
g00484245
Illustration 197

8. For a machine that is equipped with the rubber

tracks, locate the “omega” mark on the inside flat
of the track.

9. Locate the “omega” mark under the center track

roller.

g01171530
Illustration 199

3. Use the travel levers to move the machine

forward. The travel alarm should sound.

4. Release the travel levers in order to stop the

machine.

g00522663
5. Use the travel levers to move the machine
Illustration 198 backward. The travel alarm should sound.
The distance (B) should be 10 to 15 mm (0.4 to 0.6 inch).
6. Release the travel levers in order to stop the
10. Measure the sag in the track. The sag is machine. Lower the work tool to the ground.
measured from the bottom of the roller to the Deactivate the hydraulic controls by placing the
surface on the top of the track. A properly adjusted hydraulic control console in the RAISED position.
track will have 10 to 15 mm (0.4 to 0.6 inch) of sag. Stop the engine.

Measuring Steel Track Tension i01725177

Note: The track tension must be set according to the Undercarriage - Check
current operating conditions. Keep the track as slack
as possible if the soil is heavy. SMCS Code: 4150-535

Follow the same procedures for measuring rubber 1. Check the track rollers and the idler wheels for
track tension. There is not an “omega” mark on possible leakage.
the steel tracks. You do not need to align the steel
tracks. The proper amount of sag for steel tracks is 2. Check the surface of the track, the carrier rollers,
25 to 35 mm (1.0 to 1.4 inch). the track rollers, the idler wheels, the track shoes,
and the drive sprockets. Look for signs of wear
If the correct adjustment cannot be achieved consult and loose mounting bolts.
your Caterpillar dealer.

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 138 SEBU7940-06
Maintenance Section
Window Washer Reservoir - Fill

3. Listen for any abnormal noises while you are

moving slowly in an open area.
Wash polycarbonate windows with a mild soap
4. If abnormal wear exists or abnormal noises or
and water. Never use a cleaning solvent on poly-
leaks are found, consult your Caterpillar dealer.
carbonate windows.

i01021011
Cleaning Methods
Window Washer Reservoir -
Fill Aircraft Windshield Cleaner
SMCS Code: 7306-544-KE Apply the cleaner with a soft cloth. Rub the window
with moderate pressure until all the dirt is removed.
NOTICE Allow the cleaner to dry. Wipe off the cleaner with a
When operating in freezing temperatures, use clean soft cloth.
Caterpillar or any commercially available nonfreezing
window washer solvent. Soap and Water
Use a clean sponge or a soft cloth. Wash the windows
The washer fluid bottle is located in the engine
with a mild soap or with a mild detergent. Also
compartment.
use plenty of lukewarm water. Rinse the windows
thoroughly. Dry the windows with a moist chamois or
1. Open the engine access door.
with a moist cellulose sponge.
2. Remove the filler cap.
Stubborn Dirt and Grease
3. Fill the washer fluid bottle with washer fluid
through the filler opening. Wash the windows with a good grade of naphtha, or
isopropyl alcohol, or of Butyl Cellosolve. Then, wash
4. Replace the filler cap. the windows with soap and with water.

5. Close the engine access door.

i01048717

Window Wiper -
Inspect/Replace
SMCS Code: 7305-040; 7305-510

Inspect the wiper blade on the front window. Replace

the window wiper blade if the window wiper blade is
worn or damaged. Replace the front window wiper
blade if the front window is streaked after use.

i01592019

Windows - Clean
SMCS Code: 7310-070; 7340-070

Use commercially available window cleaning

solutions in order to clean the windows.

Note: When you are cleaning the window above the

front window, you should use a soft cloth that is not
abrasive. This window can be easily scratched.

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