Professional Documents
Culture Documents
2010 Caterpillar
All Rights Reserved
SEBU6879-06
December 2000
Operation and
Maintenance
Manual
M318 and M320 Excavators
6WL1-Up (Machine)
8AL1-Up (Machine)
6ES1-Up (Machine)
8SS1-Up (Machine)
9PS1-Up (Machine)
147
Maintenance Section
Maintenance Interval Schedule
i01462222
154
155
156
156
When Required
Battery - Recycle ................................................ 152
Battery, Battery Cable or Battery Disconnect Switch Replace ............................................................. 153
Bucket Tips - Inspect/Replace ............................ 159
Cab Air Filter - Clean/Replace ............................ 161
Drum Brakes - Inspect ........................................ 169
Engine Air Filter Primary Element Clean/Replace .................................................. 169
Engine Air Filter Secondary Element - Replace .. 171
Ether Starting Aid Cylinder - Replace ................. 179
Fuel System Priming Pump - Operate ................ 183
Fuel System Priming Pump - Operate ................ 183
Fuel System Priming Pump - Operate ................ 184
Fuses - Replace .................................................. 192
Oil Filter - Inspect ................................................ 200
Refueling Pump Strainer - Clean ........................ 202
Windows - Clean ................................................. 211
Window Washer Reservoir - Fill .......................... 211
Window Wiper - Inspect/Replace ........................ 212
154
155
156
156
154
156
156
168
206
211
149
150
151
152
158
162
176
177
180
185
186
203
207
208
157
166
173
175
189
191
199
201
203
207
210
150
151
180
207
161
168
181
182
188
190
148
Maintenance Section
Maintenance Interval Schedule
150
151
153
169
172
180
201
207
167
173
195
197
197
198
198
204
Every 3 Years
Seat Belt - Replace ............................................. 203
149
Maintenance Section
Air Conditioner - Test
i00679706
Illustration 262
g00101966
Illustration 263
g00101967
g00290119
150
Maintenance Section
Axle Bearings (Front) - Lubricate
i00060139
Illustration 265
g00242127
Illustration 264
g00102403
i00310408
151
Maintenance Section
Axle Oil (Rear) - Change
i01011566
Illustration 266
i00312048
g00102672
Illustration 267
g00333762
Illustration 268
g00102631
152
Maintenance Section
Axle Oil Level (Rear) - Check
i00703208
Illustration 270
g00102404
g00102672
Illustration 271
g00102405
i00060143
Battery - Recycle
A battery supplier
An authorized battery collection facility
Recycling facility
153
Maintenance Section
Battery, Battery Cable or Battery Disconnect Switch - Replace
i00663586
i01048535
Illustration 272
g00103933
Illustration 273
g00103934
154
Maintenance Section
Boom and Stick Linkage - Lubricate
Illustration 274
g00103935
g00291582
(1) Fitting
(2) Fitting
Material Handler
Note: For some applications of the machine, the
repeated duty cycle of the front linkage may only
require small angular movements of the boom or
stick. There might not be enough angular motion in
order to distribute the grease between the pin and
the bearing. The operator should operate the boom,
the stick and the implement in order to distribute
the grease within the joint assemblies.
Service a new machine after Every 10 Service
Hours only within the initial 100 service hours.
Illustration 276
g00293215
(3) Fitting
155
Maintenance Section
Boom and Stick Linkage - Lubricate
Illustration 277
g00354254
(4) Fitting
Illustration 278
S/N: 6WL1-Up
S/N: 6ES229-Up
(1) Fitting
(2) Fitting
S/N: 8SS1-Up
S/N: 9PS1-Up
Note: For some applications of the machine, the
repeated duty cycle of the front linkage may only
require small angular movements of the boom or
stick. There might not be enough angular motion in
order to distribute the grease between the pin and
the bearing. The operator should operate the boom,
the stick and the implement in order to distribute
the grease within the joint assemblies.
Service a new machine after Every 10 Service
Hours only within the initial 100 service hours.
Illustration 279
g00291565
(3) Fitting
156
Maintenance Section
Boom, Stick and Bucket Linkage - Lubricate
i01047178
g00354937
(4) Fittings
Illustration 282
g00102387
Illustration 281
g00354074
(1) Fittings
(2) Fittings
(3) Fitting
157
Maintenance Section
Brakes, Indicators and Gauges - Test
i00664174
Illustration 283
g00105234
(1) Fitting
(2) Fittings
(3) Fitting
Illustration 285
g00291446
Illustration 284
(4)
(5)
(6)
(7)
g00105235
Fitting
Fittings
Fittings
Fitting
158
Maintenance Section
Braking System - Test
i00767599
Personal injury can result from a sudden stop during brake test.
Make sure the area is clear of personnel and obstructions before testing the brakes. Fasten the
seat belt before moving the machine.
If the machine begins to move during the test,
engage the 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 brakes
are functional. This test is not intended to measure
the maximum brake holding effort. The maximum
brake holding effort that is required to hold a
machine stationary at a certain engine rpm varies
between machines. These differences are caused
by differences in the following factors:
Illustration 287
g00291447
Engine setting
Power train efficiency
Other factors
NOTICE
If the machine moved while testing the service brakes,
contact your Caterpillar dealer.
Have the dealer inspect and, if necessary, repair the
service brakes before returning the machine to operation.
g00102514
159
Maintenance Section
Bucket Tips - Inspect/Replace
Bucket Tips
Illustration 288
g00291450
Illustration 289
g00101352
(1) Usable
(2) Replace this bucket tip.
(3) Overworn
Check the bucket tips for wear. If the bucket tip has
a hole, replace the bucket tip.
1. Remove the pin from the bucket tip. The pin can
be removed by one of the following methods.
i01117817
Illustration 290
g00590670
160
Maintenance Section
Bucket Tips - Inspect/Replace
Illustration 291
g00590819
(6) Retainer
(7) Retaining washer
(8) Adapter
Illustration 293
g00590666
Side Cutters
Illustration 292
g00101359
Illustration 294
g00114738
161
Maintenance Section
Cab Air Filter - Clean/Replace
Illustration 297
g00102283
(1) Screws
(2) Cover for the cab air filter
g00291487
Illustration 296
g00105242
162
Maintenance Section
Condenser (Refrigerant) - Clean
Illustration 298
g00349372
Illustration 301
g00353312
Illustration 299
g00352012
Illustration 300
g00349232
163
Maintenance Section
Cooling System Coolant (ELC) - Change
NOTICE
Mixing Extended Life Coolant (ELC) with other
products reduces the effectiveness of the coolant
and shortens coolant life. Use only Caterpillar products or commercial products that have passed the
Caterpillar EC-1 specifications for premixed or concentrate coolants. Use only Caterpillar Extender with
Caterpillar ELC. Failure to follow these recommendations could result in the damage to cooling systems
components.
Illustration 302
g00290119
Illustration 303
g00101950
Illustration 304
NOTICE
Do not change the coolant until you read and understand the material in the Operation and Maintenance
Manual, Cooling System Specifications.
164
Maintenance Section
Cooling System Coolant (ELC) - Change
Illustration 305
g00102896
Illustration 307
g00102898
Illustration 306
g00102897
Illustration 308
g00102899
165
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
i00767761
Illustration 309
g00289939
NOTICE
Use only Caterpillar products or commercial products
that have passed Caterpillar EC-1 specification for
pre-mixed or concentrated coolants.
Use only Caterpillar Extender with Extended Life
Coolant.
Mixing Extended Life Coolant with other products reduces the Extended Life Coolant service life. Failure to
follow the recommendations can reduce cooling system components life unless appropriate corrective action is performed.
Note: Refer to Operation and Maintenance Manual,
Extended Life Coolant (ELC) for instructions
regarding contamination of the ELC Cooling System.
Note: It is acceptable to add an additive which is
intended for cooling systems that are using DEAC to
cooling systems that are using Caterpillar Extended
Life Coolant. If this is done, follow the Operation
and Maintenance Manual, Maintenance Interval
Schedule for cooling systems that are using DEAC.
Illustration 310
g00102583
166
Maintenance Section
Cooling System Level - Check
Illustration 313
g00289939
Illustration 311
g00102304
Illustration 312
g00102305
g00102309
167
Maintenance Section
Cooling System Water Temperature Regulator - Replace
Damage
Deposits
NOTICE
Failure to replace the water temperature regulators on
a regularly scheduled basis could cause severe engine damage.
Never operate the engine without the water temperature regulators installed.
Foreign material
Clean the pressure cap with a clean cloth or
replace the pressure cap if the pressure cap is
damaged.
8. Install the pressure cap. Close the access cover
to the pressure cap.
9. Close the access door on the left side of the
machine.
If the water temperature regulator is installed incorrectly, the engine may overheat, causing cylinder head
damage. Ensure that the new water temperature regulator is installed in the original position.
Note: Always discard drained fluids according to
local regulations.
Illustration 315
g00317003
168
Maintenance Section
Drive Shaft Support Bearing Lubricant - Check
i00687064
Illustration 316
g00102923
Illustration 317
g00102456
Illustration 318
g00102443
169
Maintenance Section
Drum Brakes - Inspect
g00103931
Illustration 319
g00103930
NOTICE
Never service the air cleaner with the engine running,
since this will allow dirt to enter the engine.
Check the air duct for leaks. Make all repairs to leaky
air ducts immediately, as dirt and debris could enter
the engine causing damage to the turbocharger and
engine components.
170
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
Illustration 321
g00106825
Illustration 323
g00102009
g00102010
Illustration 322
g00290071
171
Maintenance Section
Engine Air Filter Secondary Element - Replace
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.
Pressure air
Illustration 326
Pressure water
(2) Cover
(5) Baffle
Detergent washing
g00102013
Illustration 325
g00102012
NOTICE
Always replace the secondary filter element. Never attempt to reuse the secondary filter element by cleaning the element.
When the primary filter element is cleaned for the third
time, the secondary filter element should be replaced.
The secondary filter element should also be replaced
if the restricted Air Filter indicator comes on after the
installation of a clean primary filter element or if the
exhaust smoke is still black.
1. Remove the primary filter element and the
cover. See the Operation and Maintenance
Manual, Engine Air Filter Primary Element Clean/Replace.
172
Maintenance Section
Engine Crankcase Breather Valve - Replace
Illustration 327
g00102034
Illustration 328
g00289939
Illustration 329
g00102905
g00102538
Breather
Hose clamp
Hose
Rim clamp
173
Maintenance Section
Engine Governor Oil Supply Screen - Clean/Inspect/Replace
g00102906
Illustration 331
g00289939
Illustration 332
g00102905
NOTICE
Do not overfill the crankcase. Engine damage can result.
174
Maintenance Section
Engine Oil Level - Check
Illustration 336
Illustration 334
g00290071
g00102290
Illustration 335
g00102289
(1) Dipstick
(2) Oil filler plug
175
Maintenance Section
Engine Oil Level - Check
i00653127
S/N: 8AL1037-Up
S/N: 6ES228-Up
S/N: 8SS1-Up
S/N: 9PS1-Up
Illustration 339
Illustration 337
g00290071
g00102290
Illustration 338
g00289763
8. Clean oil filler plug (2). Install the oil filler plug.
176
Maintenance Section
Engine Oil and Filter - Change
i00693744
Illustration 341
g00102417
Illustration 340
g00290071
Illustration 342
g00102421
177
Maintenance Section
Engine Oil and Filter - Change
Illustration 344
Illustration 343
g00102462
g00102420
S/N: 8AL1033
S/N: 8AL1037-Up
S/N: 6ES228-Up
S/N: 8SS1-Up
S/N: 9PS1-Up
16. Start the engine. Run the engine at low idle for
two minutes. Check for oil leaks. Stop the engine.
178
Maintenance Section
Engine Oil and Filter - Change
Illustration 345
g00290071
Illustration 347
g00289774
g00102417
Illustration 348
g00102462
179
Maintenance Section
Engine Valve Lash and Fuel Injector Timing - Check
Illustration 349
i00693992
g00102420
Illustration 350
g00290071
Illustration 351
g00101991
180
Maintenance Section
Final Drive Oil - Change
i00703977
Illustration 353
g00311043
g00102722
181
Maintenance Section
Fuel System Primary Filter - Clean/Replace
i00694812
Illustration 355
(1)
(2)
(3)
(4)
g00347772
Bolt
Filter base
Case
Fuel supply valve
NOTICE
Turn the disconnect switch OFF or disconnect the battery when changing fuel filters.
Illustration 354
g00290071
182
Maintenance Section
Fuel System Water Separator Element - Replace
i01462342
g00306068
Illustration 358
(2)
(3)
(4)
(5)
Illustration 356
g00290071
g00326643
183
Maintenance Section
Fuel System Priming Pump - Operate
Illustration 360
g00106756
i00694981
S/N: 8AL1-805
SMCS Code: 1258
S/N: 6WL1-96
S/N: 8AL806-1032
S/N: 8AL1034-1036
S/N: 6ES1-227
Illustration 359
g00290071
Illustration 361
g00290071
184
Maintenance Section
Fuel System Priming Pump - Operate
i00653135
Illustration 362
g00102558
Illustration 363
g00290071
Illustration 364
g00290420
185
Maintenance Section
Fuel System Secondary Filter - Replace
Illustration 365
g00290071
S/N: 6WL1-96
S/N: 8AL1-1032
S/N: 8AL1034-1036
S/N: 6ES1-227
g00305704
186
Maintenance Section
Fuel System Secondary Filter Number One - Replace
i00694975
g00102534
S/N: 6ES228-Up
S/N: 8SS1-Up
S/N: 9PS1-Up
Illustration 368
g00290071
187
Maintenance Section
Fuel System Secondary Filter Number One - Replace
Illustration 370
g00102044
g00347792
188
Maintenance Section
Fuel System Secondary Filter Number Two - Replace
i00730770
Illustration 372
g00290278
(1) Valves
(2) Upper secondary filter (Secondary filter number two)
Illustration 371
g00290071
189
Maintenance Section
Fuel System Water Separator - Drain
i00695057
g00102534
S/N: 9PS1-Up
Illustration 374
g00290071
190
Maintenance Section
Fuel Tank Cap and Strainer - Clean
Illustration 375
g00104785
Illustration 376
g00289939
Illustration 377
g00102604
191
Maintenance Section
Fuel Tank Water and Sediment - Drain
Illustration 379
g00294897
g00102605
Screws
Filter Assembly
Valve
Seal
Illustration 380
g00102343
192
Maintenance Section
Fuses - Replace
Illustration 383
Illustration 381
g00102346
g00289939
Fuses - Replace
SMCS Code: 1417-510
Fuses The fuses protect the electrical
system from damage that is caused
by overloads. If the element separates,
change the fuse. If the element of the new fuse
separates, check the circuit and repair the circuit.
NOTICE
Always replace fuses with the same type and capacity
fuse that was removed. Otherwise, electrical damage
could result.
Illustration 382
g00102345
NOTICE
If it is necessary to replace fuses frequently, an electrical problem may exist.
Contact your Caterpillar dealer.
193
Maintenance Section
Fuses - Replace
Illustration 384
g00294897
Illustration 386
g00102040
g00102039
Illustration 387
194
Maintenance Section
Fuses - Replace
Additional Fuses
Fuse for Main Power
Illustration 389
g00102043
g00102041
Illustration 390
g00290071
This fuse is located behind the access cover that is on the right
side of the machine.
Illustration 391
g00102045
195
Maintenance Section
Hydraulic System Oil - Change
i00767627
Illustration 392
g00289939
Illustration 393
g00102936
Illustration 394
g00123374
Illustration 395
g00102939
196
Maintenance Section
Hydraulic System Oil - Change
g00102960
g00102968
197
Maintenance Section
Hydraulic System Oil Filter - Clean
i00763691
Illustration 398
g00347812
In-line filter (1) is positioned at the right rear of hydraulic tank (2).
Illustration 400
g00102975
The pilot filter is located under the top access cover, and below
the pilot manifold.
Illustration 399
g00347813
g00130794
198
Maintenance Section
Hydraulic System Oil Filter - Replace
Illustration 402
g00290071
g00102971
(1) Nuts
(2) Filter cover
g00102976
199
Maintenance Section
Hydraulic System Oil Filter - Replace
g00101502
S/N: 6ES229-Up
6. Install the new filter by hand. When the gasket
contacts the filter base, tighten the filter by an
additional 3/4 turn.
S/N: 8SS1-Up
S/N: 9PS1-Up
Note: The hydraulic oil system must be empty when
the filter is being serviced. Refer to Operation
and Maintenance Manual, Hydraulic System Oil
- Change.
i00699726
Illustration 405
g00290375
Illustration 407
g00290071
200
Maintenance Section
Oil Filter - Inspect
Illustration 408
g00102300
Illustration 410
g00102302
(3) Breather
(4) Filler plug
g00290119
Illustration 411
g00100013
201
Maintenance Section
Overhead Guard - Inspect
i01220682
Illustration 413
g00379606
Illustration 412
g00102876
Illustration 414
(3) Baffles
g00652861
202
Maintenance Section
Refueling Pump Strainer - Clean
Illustration 415
g00652838
Illustration 417
g00294897
Illustration 418
g00102274
(1) Screen
(2) Coupling
Illustration 416
g00378632
203
Maintenance Section
Seat Belt - Inspect
i00060103
i00699946
Illustration 419
g00102359
Illustration 421
g00102409
Illustration 420
g00037721
Illustration 422
g00102507
204
Maintenance Section
Swing Gear - Lubricate
Illustration 424
g00102746
Illustration 425
g00102747
g00289939
205
Maintenance Section
Swing Gear - Lubricate
i00995226
g00309143
NOTICE
Improper lubrication can cause damage to machine
components.
To avoid damage, make sure that the proper amount
of grease is applied to the swing drive.
When the amount of grease in the compartment becomes too large, the agitation loss becomes large,
thereby accelerating grease deterioration.
Grease deterioration can cause damage to the pinion
gear of the swing drive and swing internal gear.
Not enough grease will result in poor gear lubrication.
Illustration 427
g00519844
206
Maintenance Section
Tire Inflation - Check
g00290391
Bolts
Bumper springs
Cover
Gasket
g00102393
Illustration 429
(5) Plug
(6) O-ring seal
g00309463
207
Maintenance Section
Transmission Oil - Change
i01011331
i01225442
Illustration 431
g00102674
Illustration 432
g00655082
Illustration 433
g00102374
208
Maintenance Section
V-Belts - Inspect/Adjust/Replace
i00708237
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;
1405-510; 7320-025; 7320-040; 7320-510
Illustration 434
g00102376
g00290071
Illustration 435
g00102377
209
Maintenance Section
V-Belts - Inspect/Adjust/Replace
Illustration 437
g00328628
Illustration 438
g00102478
Mounting bolt
Bracket bolt
Idler pulley
Square hold in mounting bracket
Illustration 439
g00328628
Illustration 440
g00102479
NOTICE
An incorrectly tensioned V-belt could cause not only a
decrease of the compressor performance but damage
to the belt and compressor.
210
Maintenance Section
Walk-Around Inspection
g00102480
Tank
Hoses
i00995282
Tubes
Walk-Around Inspection
Plugs
Assembled joints
NOTICE
Accumulated grease and oil on a machine is a fire hazard. Remove this debris with steam cleaning or high
pressure water, at least every 1000 hours or each time
any significant quantity of oil is spilled on a machine.
NOTICE
Spray cleaning the machine with the engine access
cover open and engine running could result in engine
damage.
To avoid engine damage, always shut the engine down
and cover the engine air inlet opening before spray
cleaning with the hood open.
Note: Watch closely for leaks. If you observe a leak,
find the source of the leak and correct the leak. If
you suspect a leak or you observe a leak, check
the fluid levels more frequently. Refer to Operation
and Maintenance Manual, Maintenance Interval
Schedule for the correct intervals.
Check the implement cylinders and the linkage.
Repair these components if these components are
damaged or excessively worn.
Fittings
Inspect the swing drive. Repair all leaks.
Inspect the steering axle, the axle hubs, and the
axle gearbox. Correct any leaks.
Inspect the wheel brakes for oil leaks. Repair any
leaks.
Inspect the transmission for leaks. Correct any
leaks.
Inspect all tires for damage and for proper inflation.
Replace any missing valve caps.
Inspect the covers for damage and the guards for
damage. Also make sure that these components
are securely attached.
Inspect the following components for condition and
for cleanliness. Repair the components or clean the
components, as needed.
Steps
Walkways
211
Maintenance Section
Wheel Nut Torque - Check
Handholds
Inspect the Falling Objects Protective Structure (if
equipped) for damage. Tighten any loose bolts.
Make any necessary repairs.
Inspect the operators compartment for cleanliness.
Keep the operators compartment clean.
Adjust the rearview mirrors for best visibility.
i00124062
g00566124
Typical example
Cleaning Methods
Aircraft Windshield Cleaner
Apply the cleaner with a soft cloth. Rub the window
with moderate pressure until all the dirt is removed.
Allow the cleaner to dry. Wipe off the cleaner with
a clean soft cloth.
Illustration 442
g00102965
Windows - Clean
SMCS Code: 7310-070; 7340-070
Use commercially available window cleaning
solutions in order to clean the windows. Clean the
outside of the windows from the ground, unless
handholds are available.
212
Maintenance Section
Window Wiper - Inspect/Replace
i01221005
Illustration 444
g00290119
Illustration 445
g00102266