Maintenance Intervals: Operation and Maintenance Manual Excerpt
Maintenance Intervals: Operation and Maintenance Manual Excerpt
Maintenance Intervals: Operation and Maintenance Manual Excerpt
® ®
© 2010 Caterpillar
All Rights Reserved
SEBU7162-01
February 2001
Operation and
Maintenance
Manual
318B Excavator
3LR1-Up (Machine)
7KZ1-Up (Machine)
104
Maintenance Section
Maintenance Interval Schedule
Every 3 Years
Seat Belt - Replace ............................................. 144
i01040227
NOTICE
When adding or replacing refrigerant, use only refrig-
erant recommended by Caterpillar. System damage
can result. g00537123
Illustration 196
g00102191
Illustration 195
i00062183 i00934864
• A battery supplier
• An authorized battery collection facility
• Recycling facility
i00877830
2. Turn the battery disconnect switch to the OFF 1. Park the machine on a level surface and lower
position. Remove the key. the bucket to the ground.
g00101281
Illustration 198
109
Maintenance Section
Boom, Stick and Bucket Linkage - Lubricate
g00101661
Illustration 203
g00287575
Illustration 201
5. Apply lubricant through fittings (6), (7) and (9).
2. Apply lubricant through the fitting at the base These fittings are located on the link.
of each boom cylinder.
6. Apply lubricant through fitting (8). This fitting is
located on the rod end of the bucket cylinder.
g00287577
Illustration 202
g00101687
Illustration 206
(1) No gap. (2) Stick boss. (3) Bucket clearance. (4) Shims. (5)
g00287585 Pin. (6) Plate. (7) Bolts. (8) Washers. (9) Location. (10) Flange.
Illustration 205
(11) Bucket boss.
10. Apply lubricant through fitting (14). Fitting (14) is
located on the rod end of the stick cylinder. The clearance of the bucket control linkage on
this machine can be adjusted by shimming.
11. Apply lubricant through fitting (15). Fitting (15) is If the gap between the bucket and the stick
located at the junction of the boom and the stick. becomes excessive, adjust bucket clearance (3) to
0.5 to 1 mm (0.02 to 0.04 inch).
12. Apply lubricant through fitting (16). Fitting (16) is
located on the head end of the bucket cylinder. Two shims of different thickness are used at location
(9). The thicknesses of the shims are 0.5 mm
(0.02 inch) and 1.0 mm (0.04 inch).
i01480517
Bucket Linkage -
Inspect/Adjust
SMCS Code: 6513-025; 6513-040
5. Determine the number of shims that need to be 1. Remove the pin from the bucket tip. The pin can
removed from shims (4) by using the following be removed by one of the following methods.
calculation:
• Use a hammer and a punch from the retainer
Subtract 0.5 mm (0.02 inch) or 1.0 mm (0.04 inch) side of the bucket to drive out the pin.
from bucket clearance (3).
• Use a Pin-Master. Follow Step 1.a through Step
6. Remove the appropriate number of shims at 1.c for the procedure.
location (9) in order to meet the above thickness.
Make sure that you use a minimum of three
0.5 mm (0.02 inch) shims. To remove the shims,
remove bolts (7), washers (8), and plate (6).
i01117817 g00590670
Illustration 209
Bucket Tips - Inspect/Replace (4) Back of Pin-Master
(5) Extractor
SMCS Code: 6805-040; 6805-510
a. Place the Pin-Master on the bucket tooth.
Personal injury or death can result from bucket c. Strike the Pin-Master at the back of the tool
falling. (4) and remove the pin.
Bucket Tips
g00590819
Illustration 210
(6) Retainer
(7) Retaining washer
(8) Adapter
Check the bucket tips for wear. If the bucket tip has
a hole, replace the bucket tip.
112
Maintenance Section
Cab Air Filter - Clean/Replace
Side Cutters
g00101359
Illustration 211
i00061455
g00590666
Illustration 212
(4) Back of Pin-Master
(9) Pin setter
(10) Pin holder
i01041005
i00936381
NOTICE
If excessively dirty, clean condenser with a brush. To
prevent damage or bending of the fins, do not use a
stiff brush.
g00393008
Illustration 215
g00102191
Illustration 217
g00601077
Illustration 216
114
Maintenance Section
Cooling System Coolant (ELC) - Change
g00537515 g00101813
Illustration 218 Illustration 219
Typical example
1. Open the left access door.
2. Inspect the condenser for debris. Clean the
condenser, if necessary.
i01502733
NOTICE
Mixing ELC with other products reduces the effec-
tiveness of the coolant and shortens coolant life.
Use only Caterpillar products or commercial products
that have passed the Caterpillar EC-1 specifications
for pre-mixed or concentrate coolants. Use only
Caterpillar Extender with Caterpillar ELC. Failure to
follow these recommendations could result in the
damage to cooling systems components.
g00544510
Illustration 221
If ELC cooling system contamination occurs see the
topic ELC Cooling System Contamination of this op-
3. Slowly loosen the pressure cap that is on the
eration and maintenance manual.
radiator in order to release pressure from the
cooling system.
If the coolant in the machine is changed to
Extended Life Coolant from another type of 4. Remove the pressure cap.
coolant, see Operation and Maintenance Manual,
SEBU6250, “Extended Life Coolant Cooling System
Maintenance”.
115
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
• Operation and Maintenance Manual, When a Caterpillar Extended Life Coolant (ELC) is
SEBU6250, “Cooling System Specifications” used, an Extender must be added to the cooling
system. See Special Publication, SEBU6250,
• Operation and Maintenance Manual, “Refill “Cooling Recommendations” for all cooling system
Capacities” requirements.
116
Maintenance Section
Cooling System Hoses - Inspect
Use a 8T-5296 Coolant Conditioner Test Kit to Note: Refer to Operation and Maintenance Manual,
check the concentration of the coolant. “General Hazard Information” for information on
containing fluid spillage.
NOTICE
Mixing Extended Life Coolant (ELC) with other prod- 3. It may be necessary to drain some coolant from
ucts reduces the effectiveness of the coolant and the radiator so that Caterpillar Extender can be
shortens coolant life. Use only Caterpillar products added to the cooling system.
or commercial products that have passed the Cater-
pillar EC-1 specification for premixed or concentrate Note: Always discard drained fluids according to
coolants. Use only Caterpillar Extender with Cater- local regulations.
pillar ELC. Failure to follow these recommendations
could result in the damage to cooling systems com- 4. Add Extender to the cooling system. Refer to
ponents. the following topics for the proper amount of
Caterpillar Extender:
If ELC cooling system contamination occurs refer
to Operation and Maintenance Manual, SEBU6250, • Special Publication, SEBU6250, “Extended
“ELC Cooling System Contamination”. Life Coolant (ELC)”
This machine was factory filled with Extended Life • Operation and Maintenance Manual, “Refill
Coolant. Capacities”
i00826806
g00359072
Illustration 226
i01052571
g00101557
Illustration 229
g00288136
Illustration 228
g00101561 g00102170
Illustration 231 Illustration 233
a. Unlatch the engine hood and raise the engine f. Inspect the condition of the gasket on the
hood. pressure cap. If the gasket is damaged,
replace the pressure cap.
g00101415
Illustration 237
NOTICE
Do not clean the filter elements by bumping or tapping
them. Do not use filter elements with damaged pleats,
gaskets or seals. Engine damage can result.
2. Squeeze the outlet tube slightly in order to purge Primary filter elements can be cleaned with
the dirt from the outlet tube. pressure air, pressure water or a detergent
washing. When pressure water is used the
maximum pressure should not exceed 280 kPa
(40 psi).
g00289172
Illustration 236
120
Maintenance Section
Engine Air Filter Secondary Element - Replace
i00702568
Illustration 238
g00102970 Engine Air Filter Secondary
Element - Replace
8. Direct air or water along the pleats inside the
primary filter element and outside the primary SMCS Code: 1054-510
filter element.
NOTICE
The primary filter element can be washed
Always replace the secondary filter element. Never at-
in warm water and nonsudsing household
tempt to reuse the secondary filter element by clean-
detergent. Rinse inside the pleats and outside
ing the element.
the pleats. Allow the primary filter element to air
dry fully.
When the primary filter element is replaced, the sec-
ondary filter element should be replaced.
9. Inspect the primary filter element after cleaning.
Do not use a primary filter element with damaged
The secondary filter element should also be replaced
pleats, damaged gaskets or damaged seals.
if the restricted Air Filter indicator comes on after the
installation of a clean primary filter element or if the
10. Encase the clean primary filter element and
exhaust smoke is still black.
store the clean primary filter element in a clean,
dry place.
g00101721
Illustration 240
g00101451 g00359072
Illustration 241 Illustration 242
3. Remove the secondary filter element. 1. Unlatch the engine hood and raise the engine
hood.
4. Cover the air inlet opening. Clean the inside of
the air cleaner housing.
i00902996 g00288174
Illustration 243
Engine Oil Level - Check 2. Remove the dipstick. Wipe the oil off the dipstick
and reinsert the dipstick.
SMCS Code: 1000-535
NOTICE
Do not overfill the crankcase. Engine damage can re-
sult.
NOTICE
Operating your engine when the oil level is above the
“H” mark could cause the crankshaft to dip into the oil.
This could lead to excessively high oil temperatures
which can reduce the lubricating characteristics of the
oil, lead to bearing damage, and could result in loss of
engine power.
g00101627
Illustration 246
5. Clean the oil filler plug. Install the oil filler plug. g00288304
Illustration 247
6. Close the engine hood. Latch the engine hood. 2. Open the crankcase drain valve. Allow the oil to
drain into a suitable container.
i00931799
Note: Discard any drained fluids according to local
Engine Oil and Filter - Change regulations.
Note: If the sulfur content in the fuel is greater than 4. Install the crankcase access cover.
1.5% by weight, use an oil that has a TBN of 30 and
reduce the oil change interval by one-half.
g00101449 g00101634
Illustration 248 Illustration 250
The engine oil filter is located behind the right side door.
8. Apply a light coat of engine oil to the gasket of
5. Open the access door on the right side of the the new filter.
machine.
9. Install the new filter by hand. When the gasket
contacts the filter base, turn the filter by 3/4 of a
turn more. This will tighten the filter sufficiently.
g00288305
Illustration 249
g00288310
Illustration 252
(1) Dipstick. (2) Oil filler plug.
124
Maintenance Section
Engine Valve Lash - Check
11. Remove oil filler plug (2). Fill the crankcase with i01041923
new oil. Refer to Operation and Maintenance
Manual, “Refill Capacities” and Operation and Final Drive Oil - Change
Maintenance Manual, “Lubricant Viscosities”.
Clean the oil filler plug and install the oil filler SMCS Code: 4050-044-FLV
plug.
NOTICE
Do not under fill or overfill engine crankcase with oil.
Either condition can cause engine damage.
g00538194
Illustration 254
(1) Oil drain plug
(2) Oil level plug
g00538194
Illustration 255
(1) Oil drain plug
(2) Oil level plug
Note: Refer to Operation and Maintenance Manual, 1. Unlatch the engine hood and raise the engine
“General Hazard Information” for information on hood.
Containing Fluid Spillage.
Note: Refer to Operation and Maintenance Manual,
2. Remove oil level plug (2). “General Hazard Information” for information on
Containing Fluid Spillage.
3. Check the oil level. The oil should be near the
bottom of the level plug opening.
7. Repeat the procedure for the other final drive. 2. Remove the filter.
3. Clean the filter mounting base. Make sure that all 3. When the above procedure has been performed,
of the used seal is removed. the engine will be ready to start. If the engine
does not start, prime the fuel system. For more
details, refer to the next section of this Operation
and Maintenance Manual, “Fuel System Priming
Pump - Operate”.
i00645608
g00288425
Illustration 260
1. Place engine speed dial (1) at the low idle 4. Tighten air vent (1).
position.
Note: Lock the priming pump before the vent plug
2. Turn engine start switch (2) to the ON position is tightened. Pressure in the fuel system could make
and allow the engine to crank for ten to fifteen locking the plunger in place difficult. Wipe away
seconds. This will remove the air from the fuel any spilled fuel.
system.
127
Maintenance Section
Fuel System Priming Pump Strainer - Clean
g00393008
Illustration 262
g00288503
Illustration 261
g00288393
Illustration 264
g00535969
Illustration 267
2. Inspect the cap. Replace the cap if the cap is Note: Dispose of drained fluids according to local
damaged. regulations.
Make sure that you lock the fuel tank cap after the
refueling is complete.
g00104239
Illustration 266
i00925326
Fuses - Replace
SMCS Code: 1417-510
g00293681
Illustration 268
NOTICE
Always replace fuses with the same type and capacity
fuse that was removed. Otherwise, electrical damage
could result. Illustration 269
g00485892
Contact your Caterpillar dealer. Cab and Chassis Lamp (3) – 15 Amp
(1) Bolts
Auxiliary Circuit (Attachment) (23) – 10 Amp (2) Washers
(3) Cover
Power Window (If Equipped) (24) – 15 Amp
2. Remove bolts (1), washers (2) and the cover (3)
Spare (25) – 5 Amp from the top of the hydraulic tank.
i01125805
g00104289
Illustration 272
g00101446
Illustration 273
g00101449
Illustration 276
g00104295
Illustration 274
g00101490
Illustration 277
(4) Bolt
(5) Washer
(6) Cover
(7) Spring
g00293719 (8) Screen
Illustration 275
g00101492
Illustration 278
(9) O-ring seal g00101462
(10) O-ring seal Illustration 280
17. Inspect O-ring seals (9) and (10). Replace the 22. Inspect the pressure cap. Clean the pressure
O-ring seals if wear or damage is evident. cap. Replace the pressure cap if damage is
evident.
18. Install a new screen and spring (7). Then install
cover (6), washers (5), and bolts (4). 23. Install the pressure cap.
Note: Make sure that the O-ring seals and the spring
are properly positioned during installation.
g00287566
Illustration 281
26. Start the engine. Operate the engine at idling Hydraulic System Oil Filter -
speed for five minutes.
Replace
SMCS Code: 5068-510
g00101435
Illustration 282
g00400487
Illustration 285
g00101449
Illustration 287
2. Clean the area in order to keep dirt out of the
filter base. 1. Open the access door on the right side of the
machine.
3. Remove the used pilot filter element from the
filter base.
g00400489
Illustration 288
g00101502 g00400491
Illustration 289 Illustration 291
(A) High temperature range
5. Coat the seal of a new case drain filter with clean (B) Low temperature range
hydraulic oil. Install the new case drain filter in
the filter base. Tighten the case drain filter hand 11. Maintain the oil level in the low temperature
tight. range for a cold machine. Maintain the oil level
in the high temperature range for a machine that
6. Close the access door. is at a normal operating temperature.
g00103996
Illustration 292
8. Return the machine to the position that is shown 13. Clean the filler plug. Install the filler plug.
above. Check the machine for oil leaks.
14. Close the access door.
9. Stop the engine.
i00818967
10. Open the access door on the right side of the
machine in order to access the sight gauge. Hydraulic System Oil Level -
Check
SMCS Code: 5050-535
NOTICE
Never remove the fill/vent plug from the hydraulic tank
if the oil is hot.
g00102817
Illustration 293
The hydraulic oil tank is on the right side of the machine.
g00400491
Illustration 295
(A) High temperature range
(B) Low temperature range
137
Maintenance Section
Hydraulic System Oil Return Filter - Replace
g00102209 g00102211
Illustration 297 Illustration 299
(1) Bolts. (2) Washers. (3) Cover. (4) Plug. (5) Filter cartridge.
Note: If the indicator for a Restricted Hydraulic
Return Filter comes on, push the reset switch at 2. Remove bolts (1), washers (2), and cover (3).
the filter case. Run the machine on level ground
for approximately 10 minutes. If the indicator still Note: Refer to Operation and Maintenance Manual,
comes on, inspect the filter and replace the filter, if “General Hazard Information” for information on
necessary. Containing Fluid Spillage.
g00104227
Illustration 298
Note: The return filter is located behind the filler 4. Pull up the handle at the top of filter cartridge
plug. (5) until the filter cartridge contacts guide (A)
on filter case (6).
138
Maintenance Section
Hydraulic System Oil Return Filter - Replace
g00102214
Illustration 301
g00104507
Illustration 303
5. Turn the filter cartridge counterclockwise by 1/2 (4) Plug. (8) Plate. (18) O-ring.
turn in order to align the projection of the filter
cartridge with the notch of the filter case. Pull 1. Make sure that plug (4) is removed. Make sure
out the filter cartridge. that all of O-ring (18) is removed from plate (8).
g00102219 g00104508
Illustration 302 Illustration 304
(7) O-ring. (8) Plate. (9) Spiral retaining ring.
6. Inspect the cover and O-ring (7). If either part is 2. Use a flat screwdriver in order to remove spiral
damaged, replace the part. retaining ring (9).
7. Inspect the filter cartridge for debris and for
damage. If necessary, replace the filter cartridge.
g00104510
Illustration 305
(8) Plate. (10) Shell. (11) O-ring. (12) Filter element.
139
Maintenance Section
Hydraulic System Oil Return Filter - Replace
3. Hold the filter cartridge with one hand. Grasp 6. Spray oil into the clearance between shell (10)
the grip of plate (8) with your other hand. Lift and slide plate (13).
plate (8) in order to separate plate (8) from the
filter cartridge.
g00104512
Illustration 307
(8) Plate. (10) Shell. (16) Boss. (17) Notch.
Illustration 306
g00104511 9. Install spiral retaining ring (9) into the groove in
shell (10).
(13) Slide plate. (14) Blotter Pads. (15) Screws. (19) Port.
10. Apply grease to new O-ring (18). Install O-ring
1. Turn shell (10) upside-down. (18) on plug (4).
2. Remove screws (15).
11. Install plug (4) into plate (8).
3. Remove Blotter Pads (14) from slide plate (13).
Install the Filter Cartridge
4. Wash the following parts in a clean nonflammable
solvent: plug (4), plate (8), spiral retaining ring
(9), shell (10), and Blotter Pads (14). Dry the
parts.
3. Plate (8) will contact the inside of shell (10). (B) Port. (C) Slide plate.
Apply grease to this point.
1. Check that ports (B) at the bottom of the filter
4. Apply grease to O-rings inside ports (19) at the case are closed.
bottom of shell (10).
g00102225
Illustration 311
(1) Bolts.
2. Check that ports (D) of the filter cartridge are 5. Install plug (4), cover (3), washers (2), and bolts
fully closed. (1). Tighten bolts (1) to a torque of 29 ± 5 N·m
(22 ± 4 lb ft).
Note: The filter cartridge cannot be installed unless
the ports are fully closed. If the ports are open,
rotate slide plate (E) counterclockwise to the
stopper in order to fully close the ports.
g00104319
Illustration 312
i00107754 i01479169
g00106777
Illustration 313
7. Make any repairs that are required before Nonferrous metals can indicate wear on the
operating the machine. aluminum parts of the engine such as main
bearings, rod bearings, or turbocharger bearings.
i01491316 i01503128
g00287672
Illustration 316 Replacement Procedure
2. Check the radiator fins for debris. (Receiver-Dryer with Quick
Couplers)
3. Remove dust and debris from the radiator fins
and from the screen of the radiator.
g00393008
Illustration 317
143
Maintenance Section
Refrigerant Receiver-Dryer - Replace
1. Open the access door on the left side of the Replacement Procedure
machine. The receiver-dryer is located behind
this access door.
(Receiver-Dryer without Quick
Couplers)
2. Stop the engine. Allow the air conditioning
system to remain inactive for five minutes in
order to equalize the pressure.
g00101563
Illustration 321
145
Maintenance Section
Swing Drive Oil - Change
g00101569 g00104281
Illustration 323 Illustration 326
The swing bearings are under the base of the boom. Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information on
Containing Fluid Spillage.
g00287576
Illustration 324
i00822248
g00101586
Illustration 325
g00104248 g00287629
Illustration 328 Illustration 330
6. Make sure that the oil level is maintained 1. Remove the dipstick.
between the marks on dipstick (2).
i00826799
g00101622
Illustration 329
i00998900
NOTICE
Improper lubrication can cause damage to machine
components.
Grease deterioration can cause damage to the pinion 2. Inspect gasket (4). Replace the gasket if damage
gear of the swing drive and swing internal gear. is evident.
Not enough grease will result in poor gear lubrication. 3. Check the level of the grease. The grease should
be evenly distributed on the floor of the pan.
g00287633
Illustration 332
g00101653
Illustration 335
g00101644
Illustration 336
g00101752
Illustration 337
6. Raise the boom and turn the upper structure by
90 degrees. Lower the bucket to the ground. 1. Place a straight edge on the tracks. The straight
edge should be long enough to reach from the
7. Repeat Step 3 through Step 6 for one complete idler to the carrier roller.
revolution.
2. Measure the maximum amount of sag in the
8. Install gasket (4), cover (3), washers (2), and track. The sag is measured from the highest
bolts (1). point of the track grouser to the bottom of the
edge. A track that is properly adjusted will have
i00059427 a slack of 40 to 55 mm (1 5/8 to 2 1/8 inch ).
If track does not loosen, close the relief valve and Wipe the fitting before you add grease.
contact your Caterpillar dealer.
NOTICE
Keeping the track properly adjusted will increase the
service life of the track and drive components.
g00397520
Illustration 342
i01077733
g00560313
Illustration 343
g00101898
3. Use the travel levers or the travel pedals to move Illustration 345
the machine forward. The travel alarm should
sound. 1. Check the carrier rollers, the track rollers, and
the idler wheels for possible leakage.
4. Release the travel levers and the travel pedals in
order to stop the machine. 2. Check the surface of the track, the carrier rollers,
the track rollers, the idler wheels, the track
5. Use the travel levers and the travel pedals to shoes, and the drive sprockets. Look for signs of
move the machine backward. The travel alarm wear and loose mounting bolts.
should sound.
3. Listen for any abnormal noises while you are
moving slowly in an open area.
i00925362
V-Belts - Inspect/Adjust/
Replace
SMCS Code: 1357-025; 1357-040; 1357-510;
1359-025; 1359-040; 1359-510; 1361-025;
1361-040; 1361-510; 1405-025; 1405-040;
g00101993 1405-510; 7320-025; 7320-040; 7320-510
Illustration 344
g00287539
Illustration 348
(4) Nut
(5) Adjusting bolt
Note: If a new belt is installed, operate the engine Inspect the cooling system for any leaks, for faulty
at the rated engine speed for 30 minutes. hoses and for any trash buildup. Correct any leaks.
Remove any trash from the radiator.
6. Check the deflection again. Readjust the belt,
if necessary. Inspect all of the belts for the engine attachments.
Replace any belts that are worn, frayed, or broken.
7. Close the engine hood and latch the engine
hood.
i00729594
Walk-Around Inspection
SMCS Code: 7000
NOTICE
Accumulated grease and oil on a machine is a fire
hazard.
g00101867
Illustration 349
Inspect the engine compartment for any trash Inspect the steps, the walkways, and the handholds.
buildup. Remove any trash buildup from the engine Clean the steps, the walkways, and the handholds.
compartment. Make any necessary repairs.
g00566124
Illustration 354
Typical example
i00936923 i01258249
g00393008
Illustration 355
g00287841
Illustration 356