1 GENERAL

1.1 Introduction Most tables referring to the drawings contain the

following information:
This Caterpillar hydraulic excavator is a part of
the extensive range of Caterpillar mining 1. Item number
equipment.
2. Quantity
Decades of experience in the manufacture of
3. Designation
earthmoving machines, modern design and pro-
duction techniques, stringent testing procedures 4. Weight
and the highest demands on quality guarantee the
reliability and functionality of your
Caterpillar hydraulic excavator. The information on the bolts contains:

 Thread size M 20
1.1.1 Service Manual  Steel grade 10.9
 Size of wrench SW 30
This Service Manual is written with the servicing  Tightening torque MA = 630 Nm
mechanic in mind and contains important informa-  Liquid adhesive, if required Loctite
tion required to carry out repair and servicing pro-
cedures. Some drawings contain symbols and reference
numbers under them.
Read the Service Manual, but also the Operation
and Maintenance Manual for the Caterpillar hy- The symbols mean:
draulic excavator before commencing any servi-
cing or repair work. The Service Manual, as well Bolt joint with a certain
as the Operation and Maintenance Manual and tightening torque
Spare Parts Catalog should be used as a source
of reference and assistance - even when the user
is well acquainted with the range of Caterpillar ex- Component with a certain
cavators. play setting

Using the Service Manual allows the experienced

mechanic to carry out repair work correctly.
Bolt joint secured with ad-
hesive (P/No. 8432623)

Splines coated with mineral

1.1.2 How to Use the Service Manual
lubricating paste
(P/No.0244905)
The Service Manual contains information on the
main and subordinate construction elements of the
originally delivered excavator. It does not describe
The part "Sealing, Protective, Testing and Cleaning
any elements or special features introduced later.
Agents" contains comprehensive information on
adhesives and lubricating pastes.
The main table of contents allows you to find the
required information quickly.

To make it easier to understand the content, some

illustrations are simplified and therefore can slightly
differ from the actual appearance of the machine.
The item references in sectional and 3-D drawings
are mostly the same as those in the corresponding
drawings of the Spare Parts Catalog. It makes
cross referencing easier.
1.1.3 Servicing and repair
If you need some servicing and repair work, carry it
out as soon as possible. It minimizes overall servic-
ing and repair costs and increases the functionality
of the Caterpillar excavator.

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1 GENERAL
During all servicing and repair work always follow
the instructions contained in the Service Manual
and Operation and Maintenance Manual.
Caterpillar Service always performs major work
that is not described in the Service Manual.
Caterpillar has a widespread net of customer
service and spare parts depots with fully
equipped workshops and qualified personnel.
Use only original Caterpillar spare parts.
Caterpillar Global Mining HMS GmbH cannot be
held liable for any damage or injury caused by im-
proper operation of the Caterpillar hydraulic exca-
vator or by non-observance of instructions written
in this Service Manual.
This Service Manual does not supplement, in
any way whatever, the general terms of sale
and delivery of the Caterpillar Global Mining
HMS GmbH.
Please contact the Caterpillar Service for assis-
tance and advice.
When making any inquiries, please always use the
machine model and serial number.
1.1.4 Important hints
 Before carrying out any work on
the electrical system or before
welding set the red battery isola-
tor switch on the power module to
OFF and lock it.
 After finishing the work set the
battery isolator switch to ON and
unlock it (see Operation and
Maintenance Manual).
 Always provide the servicing and repair
personnel with a suitable working place.
 Before disassembling a component for
servicing or repair clean it thoroughly.
 To keep the working place clean is espe-
cially important. Never use cotton waste or
other fibrous material for cleaning pur-
poses. Use only fibreless cloths.
Page 1.1 - 2
 When components are removed, close up
all open hoses, pipes, ports and housings
to keep dirt out.
 Always use suitable tools, e.g. snub-nosed
screwdriver, when removing seals and
worn parts. Seal surfaces must not be
damaged.
 Always change all seals and O-rings to
prevent leaks at a later stage.
 Fix any leakages as soon as possible.
 Tighten up leaking fittings only after de-
pressurization. Do not repair damaged
pipes. Change them. Change hoses im-
mediately if you see damages or "sweat-
ing".
 Ensure that all changed consumables and
worn components, such as oil filters, hy-
draulic hoses and drained fluids are dis-
posed of safely and with minimal environ-
mental impact.
 Ensure that all national and local regula-
tions regarding environment protection are
carefully followed.
 Check all mechanical connections and
locks, e.g. screws, nuts, bolts, lock wash-
ers, before inserting them again. Change
them if necessary.
 All seating surfaces must be even and free
of paint, grease, acid, dirt and rust.
 Prepare suitable containers to catch all es-
caping fluids, e.g. cleaning fluid, hydraulic
oil, brake fluid, fuel, water, battery electro-
lyte. Dispose of the fluids in accordance
with the requirements on environmental
protection.
 Dispose of used filter cartridges, old batter-
ies and irreparable parts, such as hydraulic
hoses, in accordance with environmental
protection requirements as well.
 Connect the weld earth clamp as near to
the weld area as possible. Do not allow the
welding current to run through swing bear-
ings, hydraulic cylinders, pins or bearing
points.
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