215 EXCAVATOR Every 10 Service Hours or Daily Caterpillar

(1)Cooling System-Check coolant level

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At operating temperature, engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only when the engine is stopped and the radiator cap is cool enough to touch with your hand. Remove the fill cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with skin and eyes to prevent personal injury.

1. Open the radiator cap access door on the left rear upper panel. Remove the radiator cap slowly to relieve pressure.

2. Maintain the coolant level to within 1 cm (1/2in.) of the bottom of the fill pipe. If it is necessary to add coolant daily, check for leaks.

3. Replace the cap if the seal is damaged. Install the cap and close the access door.

(2)Air Cleaner Precleaner-Inspect and clean

1. Inspect for accumulation of dust in the precleaner cup.

2. If dust is to the FULL mark, loosen the wingnut and remove the cap.

3. Empty the cup. Wipe the cap and cup with a clean rag.

4. Install the precleaner cup, cap and wingnut.

Periodically wash the entire precleaner with clean, warm water.

(3)Engine Crankcase-Check oil level

The machine must be level. The equipment must be lowered.

1. Unlatch and open the left rear access door.

2. Measure the oil level. The level can be measured ...

a. ... with the engine stopped. The level must be in the SAFE STARTING RANGE on the ENGINE STOPPED side of the dipstick. The level can be measured ...

b. ... with the engine running. The level must be between the ADD and FULL marks on the ENGINE RUNNING side of the dipstick.

3. Remove the fill plug and add oil if necessary.

4. Clean and install the fill plug.

(4)Fuel Tank-Drain moisture and sedment

Fill the fuel tank at the end of each day to drive out moisture laden air. Fill it with at least enough fuel for a shift.

Drain moisture and sediment from the fuel tank at the start of each shift or after the tank has been filled and allowed to stand for 5 to 10 minutes.

Open the drain valve at the bottom of the tank. Allow the moisture and sediment to drain. Close the valve.

(5)Warning System-Test

Turn on the battery disconnect switch. Move and hold the system's test switch to TEST position.

The large malfunction warning flasher (1) and Air and Hydraulic Oil Filter Indicators (2) should go on.

(6)Travel Alarm (if equipped)-Test

The machine must be moved to test the alarm.

1. Start the engine. Raise the boom high enough to clear obstacles. Watch the overhead clearance.

2. Depress the right-hand travel pedal to move the machine toward the idlers.

3. The travel alarm, located under the upper structure, should sound.

4. Release the right-hand pedal. Depress the left-hand pedal to move toward the sprockets. The alarm should sound.

5. Push in the button on top of the steering control while moving. The alarm should stop after 10 seconds when moving in either direction.

6. Stop the machine. Lower the equipment. Engage the hydraulic and anti-travel lock lever. Stop the engine.

(1) HIGH

(2) LOW

(3) MEDIUM

7. The sound level can be adjusted to meet operating requirements.

The level is usually set at (1) HIGH when the machine is shipped from the factory.

Every 50 Service Hours or Weekly

(7)Pump Drive-Check oil level

The machine must be level. The equipment must be lowered. The hydraulic and anti-travel lock must be engaged. The engine must be stopped.

1. Unlatch and open the right rear access door.

2. Remove the oil level plug. The oil level should be to the bottom of the plug opening.

3. If necessary, remove the fill plug and add oil.

4. Clean and install the plugs. Close the access doors.

(8)Hydraulic System-Check oil level

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At operating temperature, the hydraulic oil is hot and under pressure. Hot oil can cause personal injury. Remove the hydraulic tank cap only when it is cool enough to touch with your hand. Remove the cap slowly to relieve pressure.

1. The machine must be level. Lower and position all equipment as follows:

BACKHOE-Position the bucket flat on the ground, with the stick cylinder fully extended.

CLAMSHELL-Position the clamshell open on the ground, with the stick cylinder fully extended.

2. The engine must be stopped and the hydraulic oil cool. The hydraulic and antitravel lock must be engaged.

3. Unlatch and open the right side front access door.

4. Maintain the oil level to the FULL mark on sight gauge.

5. To add oil, remove the fill cap slowly to relieve pressure. Add oil to the FULL mark on the sight gauge.

6. Replace the cap gasket if it is damaged. Install the fill cap. Close and secure the access door.

(9)Batteries-Check electrolyte

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Batteries give off flammable fumes that can explode. Do not smoke when observing electrolyte levels. Electrolyte is an acid. It can cause personal injury if it contacts skin or eyes.

At the proper charging rate, in a moderate climate, a battery should not require more than 30 cc (1 ounce) of water per cell per week.

1. Unlatch and open the left rear access door.

2. Clean the top of the batteries with a clean cloth. Keep the terminals clean and coated with petroleum jelly.

3. Inspect the electrolyte level in each battery cell. Maintain the level to the bottom of the fill openings with distilled water. If distilled water is not available, use clean drinking water. Close and secure the box cover and the access door.

(10)Swing Gear-Lubricate

Lubricate the swing gear through the left-hand fitting, located on the cab floor.

Swing the upper structure 720° (two full rotations). Stop at each 90° (1/4 turn) and lubricate the bearing through the right-hand grease fitting, located on the cab floor.

(11)Swing Bearing-Lubricate

Swing the upper structure 720° (two full rotations). Stop at each 90° (1/4 turn) and lubricate the gear through the fitting.

Lubricate at each position until grease is visible (flowing from behind the bearing seal).

(12)Boom and Stick-Lubricate 11 fittings

Lubricate 2 fittings at the head end of the boom cylinders.

Lubricate 3 fittings for the lower boom bearings

One Piece Boom

Two Piece Boom

Lubricate 2 fittings (1) at the rod ends of the boom cylinders and 1 fitting (2) at the head end of the stick cylinder.

Lubricate 1 fitting (1) at the rod end of the stick cylinder, and 1 fitting (2) at the boom to stick bearing.

Lubricate 1 fitting at the end of the stick.

(13)Backhoe Bucket and Linkage-Lubricate 6 fittings

Lubricate 1 fitting at each end of the bucket cylinder.

Lubricate 1 fitting (1) at the stick and 3 fittings (2) on the power link.

(14)Clamshell Bucket and Linkage-Lubricate 15 fittings

Lubricate 2 fittings on the swivel.

Lubricate 2 fittings on the rotator.

Lubricate 2 fittings at each side of the clamshell links.

Lubricate 3 fittings at each side of the bucket.

Lubricate 1 fitting on the rod end of the bucket cylinder.

(15)Clamshell Rotator Gear Drive-Check oil level

1. Remove the fill plug at the top of the rotator.

2. Maintain the oil level to the bottom of the fill opening.

3. Clean and install the plug.