140k

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MAINTENANCE INTERVALSOperation and Maintenance Manual Excerpt

lmercadoCuadro de texto140K

SEBU8249-01November 2008

Operation andMaintenanceManual12K, 140K and 160K Motor GradersJJA1-Up (Machine)JPA1-Up (Machine)SZL1-Up (Machine)SZM1-Up (Machine)JBP1-Up (Machine)SZP1-Up (Machine)

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SEBU8249-01 81Maintenance Section

Maintenance Interval Schedule

i02943134

Maintenance Interval ScheduleSMCS Code: 1000; 7000

Ensure that all safety information, warnings, andinstructions are read and understood before anyoperation or any maintenance procedures areperformed.

The user is responsible for the performance ofmaintenance, including all adjustments, the use ofproper lubricants, fluids, filters, and the replacementof components due to normal wear and aging. Failureto adhere to proper maintenance intervals andprocedures may result in diminished performance ofthe product and/or accelerated wear of components.

Use mileage, fuel consumption, service hours, orcalendar time, WHICH EVER OCCURS FIRST,in order to determine the maintenance intervals.Products that operate in severe operating conditionsmay require more frequent maintenance.

Note: Before each consecutive interval is performed,all maintenance from the previous interval must beperformed.

When Required

Battery - Recycle .................................................. 84Belt - Replace ....................................................... 86Blade Lift Cylinder Socket - Check/Adjust/Replace ............................................................... 86Centershift Cylinder Socket - Check/Adjust/Replace ............................................................... 89Circle Clearances - Check/Adjust ......................... 90Circle Drive Oil Level - Check ............................... 94Circuit Breakers - Reset ........................................ 95Cutting Edges and End Bits - Inspect/Replace ... 102Drawbar Ball and Socket End Play -Check/Adjust ..................................................... 103Engine Air Filter Primary Element - Clean/Replace ............................................................. 104Engine Air Filter Secondary Element - Replace .. 107Engine Air Filter Service Indicator -Inspect/Replace ................................................ 107Engine Air Filter Service Indicator Screen -Check/Replace .................................................. 108Engine Air Precleaner - Clean ............................ 109Engine Crankcase Breather - Replace ............... 109Engine Overheating ............................................. 112Engine Power Loss .............................................. 113Ether Starting Aid Cylinder - Replace .................. 114Evaporator Coil and Heater Coil - Clean ............. 114Fuel System - Fill ................................................. 116Fuses - Replace .................................................. 120MoldboardWear Strip - Inspect/Adjust/Replace .. 127Radiator - Clean .................................................. 128Radiator Core - Clean ......................................... 128Ripper Tip - Inspect/Replace .............................. 129

Scarifier Teeth - Inspect/Replace ........................ 131Window Washer Reservoir - Fill .......................... 141Window Wiper - Inspect/Replace ........................ 141Windows - Clean ................................................. 141

Every 10 Service Hours or Daily

Air Tank Moisture and Sediment - Drain ............... 83Backup Alarm - Test .............................................. 84Brakes, Indicators and Gauges - Test ................... 87Circle Drive Pinion Teeth - Lubricate .................... 94Circle Top - Lubricate ............................................ 95Cooling System Coolant Level - Check ................ 99Engine Oil Level - Check .................................... 109Fuel System Water Separator - Drain .................. 119Fuel Tank Water and Sediment - Drain ............... 120Seat Belt - Inspect .............................................. 131Transmission and Differential Oil Level - Check .. 137

Initial 100 Service Hours

Transmission and Differential Oil Filter and Screens -Replace/Clean .................................................. 136

Every 100 Service Hours or 2 Weeks

Articulation Bearings - Lubricate ........................... 83Axle Oscillation Bearings - Lubricate .................... 84Belt - Inspect ......................................................... 85Blade Lift Cylinder Socket - Lubricate ................... 87Cab Air Filter - Clean/Replace .............................. 89Centershift Cylinder Socket - Lubricate ................ 90Centershift Lock Bar - Clean/Lubricate ................. 90Drawbar Ball and Socket - Lubricate .................. 103Hydraulic System Oil Level - Check ................... 125Kingpin Bearings - Lubricate ............................... 126Ripper Cylinder Bearings - Lubricate .................. 129Scarifier Lift Link Socket - Lubricate ................... 131Tandem Drive Oil Level - Check ......................... 133Tire Inflation - Check ........................................... 134Wheel Lean Bar Bearings - Lubricate ................. 140Wheel Lean Bearings - Lubricate ....................... 140Wheel Lean Cylinder Bearings - Lubricate ......... 140

Initial 500 Service Hours (or at first oilchange)

Battery or Battery Cable - Inspect/Replace .......... 84Electronic Unit Injector - Inspect/Adjust .............. 104Engine Valve Lash - Check .................................. 113

Every 500 Service Hours or 3 Months

Braking System - Test ........................................... 88Cooling System Coolant Sample (Level 1) -Obtain ................................................................. 99Engine Air Filter Service Indicator -Inspect/Replace ................................................ 107Engine Oil Sample - Obtain ................................. 110Engine Oil and Filter - Change ............................ 110Fuel System - Prime ............................................ 116

82 SEBU8249-01Maintenance SectionMaintenance Interval Schedule

Fuel System Primary Filter (Water Separator)Element - Replace ............................................. 116Fuel System Secondary Filter - Replace ............. 118Fuel Tank Cap and Strainer - Clean .................... 119Hydraulic System Oil Filter - Replace ................. 124Hydraulic System Oil Sample - Obtain ............... 126Parking Brake - Drain ......................................... 127Tandem Breather - Clean/Replace ..................... 132Tandem Drive Oil Sample - Obtain ..................... 134Transmission and Differential Oil Filter and Screens -Replace/Clean .................................................. 136Transmission and Differential Oil Sample -Obtain ............................................................... 138Wheel Bearing Oil Level (Front) - Check ............ 139Wheel Bearing Oil Sample (Front) - Obtain ........ 139

Every 1000 Service Hours or 6 Months

Blade Cushion Accumulator - Check .................... 86Rollover Protective Structure (ROPS) - Inspect .. 130Transmission and Differential Breather -Clean/Replace .................................................. 134Transmission and Differential Oil - Change ........ 135

Every 2000 Service Hours or 1 Year

Hydraulic System Oil - Change ........................... 123

Every 2000 Service Hours or 2 Years

Air Dryer Desiccant - Replace .............................. 83Battery or Battery Cable - Inspect/Replace .......... 84Circle Drive Oil - Change ...................................... 93Condenser (Refrigerant) - Clean .......................... 96Cooling System Pressure Cap - Clean/Replace .. 100Crankshaft Vibration Damper - Inspect ............... 102Electronic Unit Injector - Inspect/Adjust .............. 104Engine Valve Lash - Check .................................. 113Engine Valve Rotators - Inspect .......................... 114Evaporator Coil and Heater Coil - Clean ............. 114Final Drive Preload - Check ................................. 115Refrigerant Dryer - Replace ................................ 129Tandem Drive Oil - Change ................................ 132Wheel Bearing Oil (Front) - Change ................... 138


Cooling System Water Temperature Regulator -Replace ............................................................. 101

Every 3 Years After Date of Installation orEvery 5 Years After Date of Manufacture

Seat Belt - Replace ............................................. 132


Cooling System Coolant Extender (ELC) - Add .... 98Cooling System Water Temperature Regulator -Replace ............................................................. 101

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ............. 96


Air Dryer Desiccant - Replace

i02950140

Air Dryer Desiccant - ReplaceSMCS Code: 4285-510

The air lines to and from the air dryer must be atatmospheric pressure. If the air lines are not at at-mospheric pressure, personal injury could result.Release the air pressure from the air system com-pletely before performing maintenance.

Refer to the Operation and Maintenance Manual,Access Doors and Covers for the location of theservice points.

g01463969Illustration 78

Air dryer (1) is positioned on the right side at the frontof the machine.

1. Open the access door in order to service the airdryer.

2. Replace the air dryer desiccant cartridge whenthe water can not be absorbed. Consult yourCaterpillar dealer for service or for replacementparts.

3. Close the access door.

i02958107

Air Tank Moisture andSediment - DrainSMCS Code: 4272-543-M&S; 5505-543

Refer to the Operation and Maintenance Manual,Access Doors and Covers for the location of theaccess doors.

1. Open the access door in order to service the drainvalve for moisture and sediment.


2. The air tanks are located at the rear of themachine under the frame. Pull down the lever toopen drain valve (1) in order to drain one air tank.Pull down the lever to open drain valve (2) in orderto drain the other air tank. Close the drain valve.


Note: Small amounts of moisture may be in thesystem due to condensation in the system. Moisturemay also be in the system if an air dryer is installedon a machine that has been operating without an airdryer. Several weeks may be required in order tocompletely dry the system.

i01671010

Articulation Bearings -LubricateSMCS Code: 7057-086-BD

Wipe all the fittings before you apply lubricant throughthe fittings. The fittings for the articulation bearingsare located under the cab on the left side of themachine.


84 SEBU8249-01Maintenance SectionAxle Oscillation Bearings - Lubricate

The upper articulation bearing has one fitting (1).In order to lubricate the upper articulation bearing,use 183-3424 Grease Cartridge to apply lubricantthrough fitting (1).

The lower articulation bearing has one fitting (2).In order to lubricate the lower articulation bearing,use 183-3424 Grease Cartridge to apply lubricantthrough fitting (2).

i01671028

Axle Oscillation Bearings -LubricateSMCS Code: 3268; 4313

The lubrication fitting is located in the middle of thefront axle. Wipe the fitting before you apply lubricantto the fitting.


In order to lubricate the axle oscillation bearings, use183-3424 Grease Cartridge to apply lubricant to theone fitting.

i02307698

Backup Alarm - TestSMCS Code: 7406-081

Turn the engine start switch to the ON position inorder to perform the test.

Apply the service brake. Move the transmissioncontrol (lever) to the REVERSE position.

The backup alarm should sound immediately.The backup alarm should continue to sound untilthe transmission control (lever) is moved to theNEUTRAL position or to any FORWARD position.

The backup alarm is located at the rear of themachine.

i00993589

Battery - RecycleSMCS Code: 1401-561

Always recycle a battery. Never discard a battery.

Always return used batteries to one of the followinglocations:

A battery supplier

An authorized battery collection facility

Recycling facility

i01770781

Battery or Battery Cable -Inspect/ReplaceSMCS Code: 1401-510; 1402-510

1. Turn the engine start switch key to the OFFposition. Turn all the switches to the OFF position.

2. Turn the key for the battery disconnect switch tothe OFF position. Remove the key.

3. Disconnect the negative battery cable at thebattery disconnect switch. The battery disconnectswitch is connected to the machine frame.

Note: Do not allow the disconnected battery cable tocontact the battery disconnect switch or the machine.

4. Disconnect the negative battery cable from thebattery.

5. Disconnect the positive battery cable from thebattery.

6. Inspect the battery terminals for corrosion. Inspectthe battery cables for wear or damage.

7. If necessary, make repairs. If necessary, replacethe battery cable or the battery.

8. Connect the positive battery cable at the battery.

9. Connect the negative battery cable at the battery.

10.Connect the battery cable at the batterydisconnect switch.

11. Install the key for the battery disconnect switch.Turn the battery disconnect switch to the ONposition.


Belt - Inspect

i02950585

Belt - InspectSMCS Code: 1357-040; 1397-040

Air Conditioner BeltsRefer to Operation and Maintenance Manual,Access Doors and Covers for the location of theservice points.

1. Stop the engine.



2. Open access cover (1). Remove bolts from beltaccess cover (2). Remove the belt access cover.


3. Inspect the condition of belts (3) and (4).

4. Replace the belts if any of the following conditionsexist:

excessive cracking

excessive wear

excessive damage

5. Inspect the free arm stop of belt tensioner (5).The free arm stop must be aligned with the greenzone which is on the decal of the belt tensioner.If the free arm stop is in either of the red zones,replace the belt.

Alternator and Fan Drive BeltRefer to Operation and Maintenance Manual,Access Doors and Covers for the location of theservice points.


1. Stop the engine.

2. Inspect the condition of the belt (6).

86 SEBU8249-01Maintenance SectionBelt - Replace

3. Replace the belt if any of the following conditionsexist:

excessive cracking

excessive wear

excessive damage

i02951361

Belt - ReplaceSMCS Code: 1357-510; 1397-510

Air Conditioner BeltsRefer to Operation and Maintenance Manual,Access Doors and Covers for the location of theservice points.


1. Release the tension on belt (1) and (2). Insert a12.7 mm (0.50 inch) ratchet into the square holein belt tensioner (3) and pry the belt tensioner in aclockwise direction.

2. Remove the belts.

3. Install the new belts around the pulleys.

4. Release the belt tensioner in order to put tensionon the belts.

5. Check the belt tension after 30 minutes ofoperation.

Note: The break-in period for the belts is consideredto be 30 minutes.

6. Inspect the free arm stop of the belt tensioner. Thefree arm stop must be aligned with the green zonewhich is on the decal of the belt tensioner.

Alternator and Fan Drive BeltRefer to Operation and Maintenance Manual,Access Doors and Covers for the location of theservice points.


1. Remove the belt.

2. Install the new belt around the pulleys.

i01564804

Blade Cushion Accumulator -CheckSMCS Code: 5077-535-BG

Consult your Caterpillar dealer for the followinginformation:

The correct checking procedure

The correct filling procedures

The recommended pressure

i01862399

Blade Lift Cylinder Socket -Check/Adjust/ReplaceSMCS Code: 5102-025; 5102-510; 5102-535;5103-025; 5103-510; 5103-535

1. Rotate the blade. Position the blade at an angleof 90 degrees to the frame. Lower the blade tothe ground.

2. Operate the blade lift cylinders. Observe thesocket. If the socket moves without blademovement, adjustment is necessary.


Blade Lift Cylinder Socket - Lubricate


3. Remove two bolts (2) from each cap (1). Removethe cap (1).

4. Remove one shim from either side of the inserts inorder to reduce clearance.

Note: If you need to remove two shims, then removeone shim from each side of the inserts.

5. Install the cap. Install the bolts and tighten thebolts.

6. Check the socket for movement. If you observemovement in the socket, repeat Step 3 throughStep 5.

Note: If no shims remain, install new inserts. Installtwo shims on each side of the inserts. Add additionalshims, as needed.

i01862405

Blade Lift Cylinder Socket -LubricateSMCS Code: 5102-086; 5103-086

Wipe all the fittings before you apply lubricant to thefittings.


There are two blade lift cylinders (1).

Each blade lift cylinder socket has one fitting (2).In order to lubricate the blade lift cylinder sockets,use 183-3424 Grease Cartridge to apply lubricantto each fitting.

i02790006

Brakes, Indicators and Gauges- TestSMCS Code: 4251-081; 4267-081; 4269-081;7000-081; 7450-081; 7490-081


Look for broken lenses on the gauges, brokenindicator lights or broken switches, etc.

Start the engine. Run the engine until the gaugeshave stabilized.

88 SEBU8249-01Maintenance SectionBraking System - Test

Look for inoperative gauges.

Turn on all of the machine lights. Check for properoperation.

Sound the horn.

Move the machine forward and test the servicebrakes. If the service brakes do not function properly,see Operation and Maintenance Manual, BrakingSystem - Test in the Maintenance Interval Scheduleof this manual.

Stop the engine.

Make any needed repairs before you operate themachine.

i01998856

Braking System - TestSMCS Code: 3077-081; 4011-081; 4250-081;4251-081; 4267-081

Service Brake Holding Ability Test

Personal injury can result if the machine moveswhile testing.

If the machine begins to move during test, reducethe engine speed immediately and engage theparking brake.

NOTICEIf the machine begins to move, reduce the enginespeed immediately and engage the parking brake.

NOTICEIf the machine moved while testing the service brakeconsult your Caterpillar dealer.

Have the dealer inspect and, if necessary, repair theservice brakes before returning the machine to oper-ation.

Make sure that the area around the machine is clearof personnel and clear of obstacles.

Test the service brake on a dry level surface.

Fasten your seat belt before you test the brakes.

Use the following test in order to determine whetherthe service brake is functional. This test is notintended to measure the maximum holding ability ofthe service brake.

1. Start the engine. Raise the blade slightly. Depressthe transmission modulator control. Apply theservice brake control.

2. Move the transmission control (lever) to FIFTHSPEED FORWARD. Increase the engine speedto high idle.

3. Gradually release the transmission modulatorcontrol. The machine should not move. Theengine should stall.

4. Reduce the engine speed to low idle. Engagethe parking brake control. Lower the blade to theground. Stop the engine.

Note: The friction material for the brake may requirereplacement. The new friction material for the brakemay require burnishing for maximum performance.For the procedure to burnish the new friction materialfor the brake, consult your Caterpillar dealer.

Parking Brake Holding Ability Test

Personal injury can result if the machine moveswhile testing.

It the machine begins to move during test, reducethe engine speed immediately and engage the ser-vice brake control.

NOTICEIf the machine moved while testing the parking brake,consult your Caterpillar dealer.

Have the dealer inspect and, if necessary repair theparking brake before returning the machine to opera-tion.

Be sure that the area around the machine is clear ofpersonnel and clear of obstacles.

Test the parking brake on a hard dry surface.

Fasten the seat belt before you test the parkingbrake.

Use the following test to determine whether theparking brake is functional. This test is not intendedto measure the maximum holding ability of theparking brake.


Cab Air Filter - Clean/Replace

1. Position the machine on a slope of 20 percent.

2. Engage the parking brake control. Release theservice brake control. The wheels should notrotate. If the wheels rotate, engage the servicebrake control.

i01829689

Cab Air Filter - Clean/ReplaceSMCS Code: 7311-070-FI; 7311-510-FI; 7342-070;7342-510

Note: The cab air filters are an optional attachmenton this machine.

g00933775Illustration 91(1) Outside filter(2) Inside filter

Clean the FiltersNote: Clean the cab air filters more often in dustyconditions.

The cab air system has two outside filters. There isone outside filter above each cab door.

The filter for the inside cab air system is positionedbehind the operator's seat.

1. Remove the filter cover.

2. Remove the filter elements. Clean the filterelements with pressure air or wash the filterelements in warm water and in a nonsudsinghousehold detergent.

3. Rinse the filter elements in clean water.Thoroughly air dry the filter elements.

4. Install the filter elements. Install the filter cover.

Replace the FiltersNote: Replace the cab air filters, as required.

1. Remove the filter covers.

2. Remove the filter elements. Discard the filterelements.

3. Install the new filter elements.

4. Install the filter covers.

i03326788

Centershift Cylinder Socket -Check/Adjust/ReplaceSMCS Code: 5223-023; 5223-025; 5223-535

1. Rotate the blade. Place the blade at an angle of90 degrees to the frame. Lower the blade to theground.

2. Operate the centershift cylinder. Observe thesocket. If the socket moves without movement ofthe drawbar, adjustment is necessary.


3. Remove bolts (1) from cap (2). Remove cap (2).

4. Remove one shim from either side of the inserts inorder to reduce clearance.

Note: If you need to remove two shims, then removeone shim from each side of the inserts.

5. Install the cap and bolts and tighten the bolts.

90 SEBU8249-01Maintenance SectionCentershift Cylinder Socket - Lubricate

6. Check the socket for movement. If you observemovement in the socket, repeat Step 3 throughStep 5.

Note: If no shims remain, install new inserts. Installtwo shims on each side of the socket. Add additionalshims, as needed.

i01862638

Centershift Cylinder Socket -LubricateSMCS Code: 5223-086

Wipe all the fittings before you apply lubricant to thefittings.


The centershift cylinder has one fitting on each end.In order to lubricate the centershift cylinder sockets,use 183-3424 Grease Cartridge (5% MolybdenumDisulfide) to apply lubricant to the fittings.

i02327869

Centershift Lock Bar -Clean/LubricateSMCS Code: 5221-070; 5221-086

Note: Caterpillar recommends the use of 5%molybdenum grease for lubricating the centershiftlock bar. Refer to Special Publication, SEBU6250,Caterpillar Machine Fluids Recommendations formore information on molybdenum grease.


Centershift lock bar (1) is located under the frontframe and above the circle.

Clean the dirt, the lubricant and the rust from theholes in the centershift lock bar.

Apply the appropriate lubricant to the holes in thecentershift lock bar.

i01865351

Circle Clearances -Check/AdjustSMCS Code: 6152-025; 6152-535; 6153-025;6153-535; 6154-025; 6154-535; 6155-025;6155-535

Blade Circle and Drawbar1. Rotate the blade. Place the blade at an angle of90 degrees to the frame.

Note: Install the C-clamps before you lower the bladeto the ground.


Circle Clearances - Check/Adjust



2. Clamp two C-clamps onto the front of the bladecircle (1) and the drawbar (2). This will fasten theblade circle and the drawbar together. Tightenthe two C-clamps until the wear strips (3) are incontact with the top of the blade circle and thewear strips (3) are in contact with the bottom ofthe drawbar.

3. Lower the blade to the ground. Stop the engine.

4. Measure the distance (A) that is between the topsurface of the blade circle and the bottom surfaceof the drawbar. Replace the wear strip (3), if thedistance between the top surface of the bladecircle and the bottom surface of the drawbar isless than 1.5 mm (0.06 inch).

5. Inspect the wear strip (3). Inspect the drawbar.The wear strip (3) should be in complete contactat all points with the blade circle. If the wear strip(3) is not in complete contact with the blade circle,replace the wear strip (3).

Blade Circle to Shoe Clearance1. Rotate the blade. Place the blade at an angle of90 degrees to the frame.

Note: Install the C-clamps before you lower the bladeto the ground.



2. Clamp two C-clamps onto the front of the bladecircle (1) and the drawbar (2). Tighten bothC-clamps until the wear strips (3) contact the topof the circle and the bottom of the drawbar.

3. Lower the blade to the ground. Stop the engine.

Note: Check the wear strips (3) around the entirecircumference of the blade circle. The wear strips (3)should be in complete contact with the blade circleand the drawbar.

92 SEBU8249-01Maintenance SectionCircle Clearances - Check/Adjust


4. Shoe mounting fastener (4), shoe mountingfastener (5) and shoe mounting fastener (6) mustbe tight. Make sure that the shoe wear strips (3)are completely seated in the circle shoes.


5. Measure the clearance (B) between the bottom ofthe circle (1) and the top of the shoe wear strip(7). Maintain a maximum clearance of 0.5 mm(0.02 inch). Maintain the proper clearance byadding shims (8) or by removing shims (8).

Note: The proper clearance will permit the bladecircle to freely rotate for 360 degrees.

Adjust the circle shoes (9) one at a time.

6. Loosen shoe mounting fastener (6). Remove shoemounting fastener (4) and remove shoe mountingfastener (5).

7. Add shims or remove shims, as required.

8. Install shoe mounting fastener (4) and install shoemounting fastener (5). Tighten the shoe mountingfasteners.

9. After all the circle shoes (9) have been adjusted,check the circle shoes (9) for proper clearance.If necessary, perform adjustments to the circleshoes (9).

Note: After all the adjustments have been performed,the blade circle (1) must rotate freely without binding .

Circle Pinion and CircleNote: The engagement of the circle pinion and thecircle teeth is determined by the adjustment of thecircle shoes. Clean the circle and the pinion. Removeany dirt and any abrasive material. This will reducewear to the circle pinion and to the circle teeth. Also,this will improve the accuracy of the adjustment ofthe circle shoes. After the adjustment, apply cleanlubricant to the circle pinion and to the circle teeth.

1. Rotate the blade. Place the blade at an angleof 90 degrees to the frame. Lower the blade tothe ground. As you slowly inch the machine in aforward direction, apply the service brake. Thiswill hold a light load between the wear strips forthe front circle shoes and the circle. Engage theparking brake. Stop the engine.


2. Measure the clearance (X) that is betweenthe bottom flange of pinion (10) and the innermachined surface of circle (1). If the clearance isless than 49.5 to 52.5 mm (1.95 to 2.07 inch), thenadjust the clearance.


Circle Drive Oil - Change


3. Loosen shoe mounting fastener (4), shoemounting fastener (5), shoe mounting fastener (6)and locknuts (11) on the front circle shoes.

4. Loosen the shoe mounting fasteners and thelocknuts for the rear circle shoes.

5. Loosen the shoe mounting fasteners and thelocknuts for the side circle shoes, if equipped.

6. Adjust the front circle shoes one at a time.Turn the adjusting bolts (12) inward or turn theadjusting bolts (12) outward in order to attain49.5 to 52.5 mm (1.95 to 2.07 inch). Adjust theother front circle shoe.

Note: If the circle shoes are moved outward, it maybe necessary to slowly inch the machine in a forwarddirection in order to place a light load between thewear strips for the front circle shoes and the circle.

Note: Adjust the front shoes so that the front circleshoes have the same clearance measurement.

7. If you cannot attain the correct clearancemeasurement due to worn front shoe wear strips(7), replace the worn shoe wear strips (7). Then,repeat Step 6.

8. Tighten the shoe mounting fasteners and locknutsfor the front circle shoes.

Note: The adjusting bolts must be tight againstthe circle shoes before you tighten the mountingfasteners and the locknuts.

9. Set all of the circle shoes (front, side and rear)to contact the circle. There will be no clearancebetween the circle shoes and the circle.

10.When the pinion clearance is set and the frontcircle shoes are in contact with the blade circle,measure the distance (C) between each wear strip(7) and the blade circle. The clearance should bea maximum of 0.8 mm (0.03 inch).

11. Tighten all shoe mounting fasteners (4), shoemounting fasteners (5) and all shoe mountingfasteners (6) to a torque of 475 60 Nm(350 44 lb ft).

12. Tighten all locknuts (11) to a torque of200 30 Nm (150 22 lb ft).

i03326684

Circle Drive Oil - ChangeSMCS Code: 5207-510-OC

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact skin.

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.

Refer to Special Publication, NENG2500, CaterpillarDealer Service Tool Catalog for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.


Bottom view of the blade circle

94 SEBU8249-01Maintenance SectionCircle Drive Oil Level - Check

g01704514Illustration 104Top view of the blade circle

Note: Clean the area around the drain plug andclean the area around the check/fill plug before youremove the plugs.

1. Remove drain plug (1). Remove check/fill plug (2).Allow the oil to drain into a suitable container.

2. Clean the drain plug and install the drain plug.

3. Fill the circle drive housing with oil. Refer to thefollowing topics:

Operation and Maintenance Manual, LubricantViscosities

Operation andMaintenance Manual, Capacities(Refill)

4. Clean the check/fill plug and install the check/fillplug.

5. Start the engine. Operate the machine for a fewminutes. Check the circle drive housing for leaks.

6. Stop the engine. Remove the check/fill plug andcheck the oil level. Maintain the oil level to thebottom of the filler opening. If necessary, add oil.

7. Install the check/fill plug.

i03322240

Circle Drive Oil Level - CheckSMCS Code: 5207-535-OC

If a leak develops or you suspect a leak, check theoil level.

Wipe the surfaces around the opening for thecheck/fill plug before you check the oil and beforeyou add oil.

The check/fill plug is located on top of the circle drivehousing at the front of the circle.


1. Remove check/fill plug (1).

2. Maintain the oil level to the bottom of the openingfor the check/fill plug.

3. Install check/fill plug (1).

i02527479

Circle Drive Pinion Teeth -LubricateSMCS Code: 5207-086-PI

Contact with a moving attachment may cause in-jury or death.

Avoid contact with a moving attachment when lu-bricating or maintaining the attachment.

Note: Caterpillar recommends the use of 5%molybdenum grease for lubricating the circle drivepinion teeth. Refer to Special Publication, SEBU6250,Caterpillar Machine Fluids Recommendations formore information on molybdenum grease.

The circle drive pinion teeth are located under thecircle drive housing.

SEBU8249-01 95Maintenance SectionCircle Top - Lubricate


1. Clean the dirt and the old lubricant from circledrive pinion teeth (1) and from blade circle (2).

2. Apply the appropriate lubricant to circle drivepinion teeth (1) and blade circle (2).

i01863885

Circle Top - LubricateSMCS Code: 6154-086-TP

1. Park the machine on a level surface and engagethe parking brake.

2. Stop the engine. Lower the blade and anyattachments to the ground.


3. Apply a dry film lubricant to the 5 mm (0.2 inch)gap between the circle and the drawbar yoke.Apply the dry film lubricant around the entire circle.See Special Publication, SEBU6250, CaterpillarMachine Fluids Recommendations, Dry FilmLubricant for further information.

i02795072

Circuit Breakers - ResetSMCS Code: 1417-529; 1420-529


Circuit Breaker Resets Push the buttons inwardin order to reset the circuit breakers. If the system isworking properly, the buttons will remain depressed.If the buttons do not stay depressed, check theappropriate electrical circuit.


The circuit breaker resets are located in the enginecompartment on the right side of the machine.

Alternator (1) The circuit breaker for thealternator is 80 amp.

Main Circuit Breaker (2) The maincircuit breaker is 80 amp.

96 SEBU8249-01Maintenance SectionCondenser (Refrigerant) - Clean

i02793761

Condenser (Refrigerant) -CleanSMCS Code: 1805-070

NOTICEIf excessively dirty, clean condenser with a brush. Toprevent damage or bending of the fins, do not use astiff brush.

Repair the fins if found defective.



The refrigerant condenser (2) is located in front of theradiator (1) at the rear of the machine.

1. Open the access door at the rear of the machineon the left side of the machine.

2. Inspect the condenser for debris. If necessary,clean the condenser.

3. Use clean water in order to wash off all dust anddirt from the condenser.


i02976205

Cooling System Coolant (ELC)- ChangeSMCS Code: 1350-044-NL; 1350-544-NL;1395-044-NL

Personal injury can result from hot coolant, steamand alkali.

At operating temperature, engine coolant is hotand under pressure. The radiator and all linesto heaters or the engine contain hot coolant orsteam. Any contact can cause severe burns.

Remove cooling system pressure cap slowly torelieve pressure only when engine is stopped andcooling system pressure cap is cool enough totouch with your bare hand.

Do not attempt to tighten hose connections whenthe coolant is hot, the hose can come off causingburns.

Cooling System Coolant Additive contains alkali.Avoid contact with skin and eyes.

NOTICEDo not change the coolant until you read and under-stand the material in the Cooling System Specifica-tions section.

NOTICEMixing ELC with other products reduces the effective-ness of the coolant and shortens coolant life. Use onlyCaterpillar products or commercial products that havepassed the Caterpillar EC-1 specifications for pre-mixed or concentrate coolants. Use only CaterpillarExtender with Caterpillar ELC. Failure to follow theserecommendations could result in the damage to cool-ing systems components.

If ELC cooling system contamination occurs see thetopic Extended Life Coolant (ELC) in the Special Pub-lication, SEBU6250, Caterpillar Machine Fluids Rec-ommendations.


Cooling System Coolant (ELC) - Change




If the coolant in the machine is changed to ExtendedLife Coolant from another type of coolant, see SpecialPublication, SEBU6250, Caterpillar Machine FluidsRecommendations, Extended Life Coolant (ELC)Cooling System Maintenance.

If the coolant is dirty or if you observe any foamingin the cooling system, change the coolant before therecommended interval.

It is important to replace the thermostat in orderto avoid any unexpected failure of the thermostat.This is a good preventive maintenance practice thatreduces the chances of unscheduled downtime.Failure to replace the thermostat on a regularlyscheduled basis could cause severe engine damage.

Note: If you are only replacing the thermostat, drainthe coolant from the cooling system so that the levelof the coolant is below the thermostat housing.

Always operate Caterpillar engines with a thermostatbecause these engines have a shunt design coolingsystem.

Note: Thermostats can be reused if the thermostatsmeet certain test specifications. The testedthermostats must not be damaged and the testedthermostats must not have an excessive buildup ofdeposits.

1. Stop the engine and allow the engine to cool.


2. Open cover (1).

3. Clean the area around the cooling systempressure cap of any dirt or debris. This must bedone before the cooling system pressure cap canbe removed.

4. Slowly remove the cooling system pressure cap inorder to relieve pressure.


5. Open drain valve (2). The drain valves are locatedat the right rear of the machine. Allow the coolantto drain into a suitable container.

6. Flush the cooling system with clean water until thedraining water is transparent.

7. Close the drain valve.

8. Add the Extended Life Coolant. Refer to Operationand Maintenance Manual, Capacities (Refill).

Note: Make sure that the cooling system pressurecap is removed for Steps 9 through 10.

9. Start the engine and run the engine until thethermostat opens and the coolant level stabilizes.

98 SEBU8249-01Maintenance SectionCooling System Coolant Extender (ELC) - Add

10.Maintain the coolant level between the FULLmark and the ADD mark on the coolant tank.

11. Install the cooling system pressure cap. Closecover (1).

12.Check the radiator for any external leaks. Checkfor air bubbles in the radiator.

13.Stop the engine.

i02949342

Cooling System CoolantExtender (ELC) - AddSMCS Code: 1352-045; 1352-535; 1352-544-NL;1352-544; 1395-081



Remove cooling system pressure cap slowly torelieve pressure only when engine is stopped andcooling system pressure cap is cool enough totouch with your bare hand.


Cooling System Coolant Additive contains alkali.Avoid contact with skin and eyes.




When a Caterpillar Extended Life Coolant (ELC)is used, an extender must be added to thecooling system. See Operation and MaintenanceManual, Maintenance Interval Schedule for theproper service interval. The amount of extender isdetermined by the cooling system capacity.

1. Stop the engine and allow the engine to cool.


2. Open cover (1).


4. Remove the cooling system pressure cap slowlyin order to relieve the pressure.

5. Drain some coolant from the radiator into asuitable container. This will allow space foradditional cooling system coolant extender.

6. In order to add cooling system coolant extender,refer to Special Publication, SEBU6250,Extended Life Coolant (ELC). Refer to the tablefor the correct amount of Caterpillar ExtendedLife Coolant (ELC) Extender that is needed to beadded to the cooling system.

7. Install the cooling system pressure cap. Closethe cover.


Cooling System Coolant Level - Check

i02951626

Cooling System Coolant Level- CheckSMCS Code: 1350-040-HX; 1350-040;1350-535-FLV; 1350-535; 1353-535-FLV;1354-535; 1395-082; 1395-535; 1395-535-FLV



Remove filler cap slowly to relieve pressure onlywhen engine is stopped and radiator cap is coolenough to touch with your bare hand.


Cooling SystemConditioner contains alkali. Avoidcontact with skin and eyes.

Refer to Operation and Maintenance Manual,Access Doors and Covers for the location of theservice points.


1. Maintain the coolant level between the FULLmark and the ADD mark on coolant tank (1).


2. If necessary, add the appropriate coolant mixture.

3. Open cover (2).


5. Remove the cooling system pressure cap slowlyin order to relieve pressure.

6. Add coolant through the filler tube.

7. Clean the cooling system pressure cap and installthe cooling system pressure cap.

8. Close the cover.

i02951574

Cooling System CoolantSample (Level 1) - ObtainSMCS Code: 1395-554

Note: Obtaining a Coolant Sample (Level 1) isoptional if the cooling system is filled with CatELC (Extended Life Coolant). Cooling systems thatare filled with Cat ELC should have a Coolant Sample(Level 2) that is obtained at the recommended intervalthat is stated in the Maintenance Interval Schedule.

Note: Obtain a Coolant Sample (Level 1) if thecooling system is filled with any other coolantinstead of Cat ELC. This includes the followingtypes of coolants:

Commercial long life coolants that meet theCaterpillar Engine Coolant Specification -1(Caterpillar EC-1)

Cat Diesel Engine Antifreeze/Coolant (DEAC)

100 SEBU8249-01Maintenance SectionCooling System Pressure Cap - Clean/Replace

Commercial heavy-duty antifreeze/coolant




NOTICEAlways use a designated pump for oil sampling, anduse a separate designated pump for coolant sampling.Using the same pump for both types of samples maycontaminate the samples that are being drawn. Thiscontaminate may cause a false analysis and an incor-rect interpretation that could lead to concerns by bothdealers and customers.

Note: Level 1 results may indicate a need forLevel 2 Analysis.



Obtain the sample of the coolant as close as possibleto the recommended sampling interval. In orderto receive the full effect of SOS coolant analysis,you must establish a consistent trend of data.In order to establish a pertinent history of data,perform consistent samplings that are evenly spaced.Supplies for collecting samples can be obtained fromyour Caterpillar dealer.

Use the following guidelines for proper sampling ofthe coolant:

Complete the information on the label for thesampling bottle before you begin to take thesamples.

Keep the unused sampling bottles stored in plasticbags.

Obtain coolant samples directly from the coolantsample port. You should not obtain the samplesfrom any other location.

Keep the lids on empty sampling bottles until youare ready to collect the sample.

Place the sample in the mailing tube immediatelyafter obtaining the sample in order to avoidcontamination.

Never collect samples from expansion bottles.

Never collect samples from the drain for a system.

Submit the sample for Level 1 analysis.

For additional information about coolant analysis, seeSpecial Publication, SEBU6250, Caterpillar MachineFluids Recommendations or consult your Caterpillardealer.

i02949519

Cooling System Pressure Cap- Clean/ReplaceSMCS Code: 1382-070; 1382-510







Cooling System Water Temperature Regulator - Replace


The cooling system pressure cap is located on top ofthe engine compartment.

1. Open cover (1).


3. Remove the cooling system pressure cap slowlyin order to relieve pressure.

4. Inspect the cooling system pressure cap andthe cap seal for damage, deposits, and foreignmaterial. Clean the cooling system pressure capwith a clean cloth. Replace the cooling systempressure cap if the cap is damaged.

5. Install the cooling system pressure cap.

6. Close the cover.

i00350379

Cooling System WaterTemperature Regulator -ReplaceSMCS Code: 1355-070; 1355-510; 1393-010






Replace the cooling system water temperatureregulator on a regular basis in order to reduce thechance of unscheduled downtime and of problemswith the cooling system.

The water temperature regulator should be replacedafter the cooling system has been cleaned. Replacethe water temperature regulator while the coolingsystem is completely drained or while the coolingsystem coolant is drained to a level that is below thewater temperature regulator housing assembly.

NOTICEFailure to replace the engine's water temperature reg-ulator on a regularly scheduled basis could cause se-vere engine damage.

Note: If you are only replacing the water temperatureregulator, drain the cooling system coolant to a levelthat is below the water temperature regulator housingassembly.

1. Loosen the hose clamp and remove the hose fromthe water temperature regulator housing.

2. Remove the bolts from the water temperatureregulator housing and remove the watertemperature regulator housing.

102 SEBU8249-01Maintenance SectionCrankshaft Vibration Damper - Inspect

3. Remove the gasket and remove the watertemperature regulator from the water temperatureregulator housing.

NOTICEFormer water temperature regulators may be used, ifthey meet test specifications and are not damaged orhave excessive buildup or deposits.

NOTICESince Caterpillar engines incorporate a shunt designcooling system, it is mandatory to always operate theengine with a water temperature regulator.

Depending on load, failure to operate with a watertemperature regulator could result in either an over-heating or an overcooling condition.

NOTICEIf the water temperature regulator is installed incor-rectly, it will cause the engine to overheat.

4. Install a new water temperature regulator anda new gasket. Install the water temperatureregulator housing.

5. Install the water temperature regulator housingand the hose. Tighten the hose clamp.

6. Add the cooling system coolant. Maintain thecoolant level within 13 mm (.5 inch) of the bottomof the filler tube.

i02951706

Crankshaft Vibration Damper- InspectSMCS Code: 1205-040

Damage to the vibration damper or failure of thevibration damper will increase torsional vibrations.These vibrations will result in damage to thecrankshaft and to the other engine components. Adeteriorating vibration damper will cause excessivegear train noise at variable points in the speed range.


Caterpillar recommends replacing vibration damper(1) for any of the following reasons:

The engine has had a failure because of a brokencrankshaft.

The SOS analysis detected a worn crankshaftfront bearing.

The SOS analysis detected a large amount ofgear train wear that is not caused by a lack of oil.

Fluid leakage is detected during inspection.

The housing is damaged.

Refer to Disassembly and Assembly, Damper &Crankshaft Pulley for the procedure to remove thedamper and the procedure to install the damper.

The vibration damper can be used again if none ofthe above conditions are found or if the vibrationdamper is not damaged.

Note: Contact your Caterpillar dealer for furtherinformation.

i01569254

Cutting Edges and End Bits -Inspect/ReplaceSMCS Code: 6801-040; 6801-510; 6804-040;6804-510

Personal injury or death can result from the bladefalling.

Block the blade before changing blade tips.


Drawbar Ball and Socket - Lubricate


End bits (1) and/or cutting edges (2) may bedamaged. End bits (1) and/or cutting edges (2) maybe worn excessively. Replace the end bits (1) and/orthe cutting edges (2), as needed.

1. Place blocks under the blade. Lower the bladeonto the blocks. Do not block up the blade toohigh. Just use enough blocks so that end bits (1)and cutting edges (2) can be removed.

2. Remove end bits (1) and/or cutting edges (2).

3. Install new end bits (1) and/or new cutting edges(2).

4. Raise the blade and remove the blocks.

i02528905

Drawbar Ball and Socket -LubricateSMCS Code: 6170-086; 6171-086

Note: Caterpillar recommends the use of 5%molybdenum grease for lubricating the drawbar balland socket. Refer to Special Publication, SEBU6250,Caterpillar Machine Fluids Recommendations formore information on molybdenum grease.

Wipe the fitting before you apply lubricant throughthe fitting.


Apply the appropriate lubricant through the fitting inorder to lubricate the drawbar ball and socket.

i02528988

Drawbar Ball and Socket EndPlay - Check/AdjustSMCS Code: 6170-025; 6170-535; 6171-025;6171-535

CheckRotate the blade so that the blade is placed at anangle of 90 degrees to the frame. Lower the blade tothe ground. While you maintain a light load betweenthe ball and the socket, inch the machine slowly tothe rear. Stop the machine and shut off the engine.


Measure the end play that is between ball (2) andcap (3). The end play should be 0.6 0.2 mm(.02 .01 inch). Adjust the end play, if necessary.

Adjust1. Support the drawbar and support the circle.

104 SEBU8249-01Maintenance SectionElectronic Unit Injector - Inspect/Adjust

2. Remove bolts (1) that hold the drawbar to thebolster. Move the drawbar backward or move themachine forward.


3. Remove capscrews (7) from cap (3) that holds thedrawbar and adapter (6) together. Remove theadapter.

4. As required, remove shims (4) or install shims(4) in order to attain an end play of 0.6 0.2 mm(.02 .01 inch).

5. Install capscrews (7) in cap (3) and adapter (6).Rotate cap (3) by hand. The socket should rotatefreely on ball (2).

6. Check the torque on bolts (5) that hold ball (2)in place. The correct torque is 500 65 Nm(370 50 lb ft).

7. Assemble the drawbar to the bolster. Tighten bolts(1) to a torque of 950 50 Nm (701 37 lb ft).

i01649392

Electronic Unit Injector -Inspect/AdjustSMCS Code: 1251-025; 1251-040; 1290-025;1290-040

Be sure the engine cannot be started while thismaintenance is being performed. To prevent pos-sible injury, do not use the starting motor to turnthe flywheel.

Hot engine components can cause burns. Allowadditional time for the engine to cool before mea-suring/adjusting the unit injectors.

The electronic unit injectors use high voltage. Dis-connect the unit injector enable circuit connectorin order to prevent personal injury. Do not comein contact with the injector terminals while the en-gine is running.

NOTICEOnly qualified service personnel should perform thismaintenance. Refer to the Service Manual or yourCaterpillar dealer for the complete valve lash adjust-ment procedure.

Operation of Caterpillar engines with improper valveadjustments can reduce engine efficiency. This re-duced efficiency could result in excessive fuel usageand/or shortened engine component life.

The initial adjustment to the unit injector isrecommended at the initial 500 hour interval. Theunit injector adjustment should then be made atevery 2000 hour interval. The operation of Caterpillarengines with improper adjustments of the electronicunit injector can reduce engine efficiency. Thisreduced efficiency could result in excessive fuelusage and/or shortened engine component life.

i01631934

Engine Air Filter PrimaryElement - Clean/ReplaceSMCS Code: 1051-070-PY; 1051-510-PY;1054-070-PY; 1054-510-PY

NOTICEService the air cleaner only with the engine stopped.Engine damage could result.


Engine Air Filter Primary Element - Clean/Replace

Service the air cleaner filter element when theyellow piston on the engine air filter serviceindicator enters the red zone or the indicatorreads 63.5 cm (25 inch) of water. Refer toOperation and Maintenance Manual, Engine AirFilter Service Indicator - Inspect.

1. Open the access door for the air filter housing.Refer to Operation and Maintenance Manual,Access Doors and Covers.


2. Remove cover (1) for the air filter housing .

3. Remove primary filter element (2) from the airfilter housing.

4. Clean the inside of the air filter housing.

5. If the machine is equipped with a vacuator valve,clean the vacuator valve on the cover for the airfilter housing.

6. Install a clean primary air filter element. Install thecover for the air filter housing.

Note: Refer to Cleaning Primary Air Filter Elements.

7. Reset the engine air filter service indicator.


If the yellow piston in the indicator moves into the redzone after starting the engine or the exhaust smokeis still black after installation of a clean primary filterelement, install a new primary filter element. If thepiston remains in the red zone replace the secondaryelement.

Cleaning Primary Air FilterElements

NOTICECaterpillar recommends certified air filter cleaning ser-vices available at participating Caterpillar dealers. TheCaterpillar cleaning process uses proven proceduresto assure consistent quality and sufficient filter life.

Observe the following guidelines if you attempt toclean the filter element:

Do not tap or strike the filter element in order to re-move dust.

Do not wash the filter element.

Use low pressure compressed air in order to removethe dust from the filter element. Air pressure must notexceed 207 kPa (30 psi). Direct the air flow up thepleats and down the pleats from the inside of the filterelement. Take extreme care in order to avoid damageto the pleats.

Do not use air filters with damaged pleats, gaskets, orseals. Dirt entering the engine will cause damage toengine components.

The primary air filter element can be used up tosix times if the element is properly cleaned andinspected. When the primary air filter element iscleaned, check for rips or tears in the filter material.The primary air filter element should be replaced atleast one time per year. This replacement should beperformed regardless of the number of cleanings.

NOTICEDo not clean the air filter elements by bumping or tap-ping. This could damage the seals. Do not use ele-ments with damaged pleats, gaskets, or seals. Dam-aged elements will allow dirt to pass through. Enginedamage could result.

Visually inspect the primary air filter elements beforecleaning. Inspect the air filter elements for damageto the seal, the gaskets, and the outer cover. Discardany damaged air filter elements.

There are two common methods that are used toclean primary air filter elements:

Pressurized air

Vacuum cleaning

106 SEBU8249-01Maintenance SectionEngine Air Filter Primary Element - Clean/Replace

Pressurized Air

Pressurized air can be used to clean primary air filterelements that have not been cleaned more than twotimes. Pressurized air will not remove deposits ofcarbon and oil. Use filtered, dry air with a maximumpressure of 207 kPa (30 psi).


Note: When the primary air filter elements arecleaned, always begin with the clean side (inside)in order to force dirt particles toward the dirty side(outside).

Aim the hose so that the air flows inside the elementalong the length of the filter in order to help preventdamage to the paper pleats. Do not aim the stream ofair directly at the primary air filter element. Dirt couldbe forced further into the pleats.

Vacuum Cleaning

Vacuum cleaning is another method for cleaningprimary air filter elements which require daily cleaningbecause of a dry, dusty environment. Cleaning withpressurized air is recommended prior to vacuumcleaning. Vacuum cleaning will not remove depositsof carbon and oil.

Inspecting the Primary Air FilterElements


Inspect the clean, dry primary air filter element. Usea 60 watt blue light in a dark room or in a similarfacility. Place the blue light in the primary air filterelement. Rotate the primary air filter element. Inspectthe primary air filter element for tears and/or holes.Inspect the primary air filter element for light that mayshow through the filter material. If it is necessary inorder to confirm the result, compare the primary airfilter element to a new primary air filter element thathas the same part number.

Do not use a primary air filter element that has anytears and/or holes in the filter material. Do not usea primary air filter element with damaged pleats,gaskets or seals. Discard damaged primary air filterelements.

Storing Primary Air Filter Elements

If a primary air filter element that passes inspectionwill not be used, the primary air filter element canbe stored for future use.



Engine Air Filter Secondary Element - Replace

Do not use paint, a waterproof cover, or plastic as aprotective covering for storage. An airflow restrictionmay result. To protect against dirt and damage, wrapthe primary air filter elements in Volatile CorrosionInhibited (VCI) paper.

Place the primary air filter element into a box forstorage. For identification, mark the outside of thebox and mark the primary air filter element. Includethe following information:

Date of cleaning

Number of cleanings

Store the box in a dry location.

i01562943

Engine Air Filter SecondaryElement - ReplaceSMCS Code: 1051-510-SE; 1054-510-SE

NOTICEAlways replace the secondary element. Do not at-tempt to reuse it by cleaning. Engine damage couldresult.


Note: Replace the engine air filter secondary elementwhen you service the engine air filter primary elementfor the third time. Replace the secondary elementif the exhaust smoke remains black and a cleanprimary element has been installed. Also, replacethe secondary element if the element has been inservice for one year.

1. Open the access door on the left side of theengine compartment. Remove the air cleanercover and the primary element.


2. Remove the secondary element.

3. Cover the air inlet opening. Clean the inside ofthe air cleaner housing.

4. Uncover the air inlet opening. Install a newsecondary element.

5. Install the primary element and the air cleanercover.

6. Close the left side engine compartment door.

Note: When you replace the air filter element, youmust replace the filter screen. Refer to Operationand Maintenance Manual, Engine Air Filter ServiceIndicator Screen - Check/Replace.

i03351840

Engine Air Filter ServiceIndicator - Inspect/ReplaceSMCS Code: 7452-040; 7452-510

Inspect1. Start the engine.

2. Run the engine at high idle.

3. Open the access door.


4. If the yellow piston in the engine air filter serviceindicator enters the red zone, service the aircleaner.

5. Stop the engine.

Note: See the Operation and Maintenance Manual,Engine Air Filter Primary Element - Clean/Replace.See the Operation and Maintenance Manual, EngineAir Filter Secondary Element - Replace.

108 SEBU8249-01Maintenance SectionEngine Air Filter Service Indicator Screen - Check/Replace

ReplaceRefer to the Operation and Maintenance Manual,Access Doors and Covers for the location of theservice points.

1. Open the access door.


2. Stop the engine. Check the operation of theservice indicator by pressing the reset button onthe bottom of the service indicator. This shouldrequire three pushes or less of the reset button.

3. Next, check the movement of the yellow pistonin the service indicator. Start the engine andaccelerate the engine to high idle for a fewseconds. After the accelerator control (pedal)is released, the yellow piston should remain atthe highest position that was achieved duringacceleration.

Note: The air filter indicator should be replacedduring engine overhauls. The air filter indicator shouldalso be replaced during replacement of any majorengine component . Replace the air filter indicator atleast one time per year.

4. If the indicator will not reset easily, replace theservice indicator. If the yellow piston of theindicator will not latch at the highest vacuum that isattained, replace the service indicator. Tighten theindicator to a torque of 2 Nm (18 lb in). Excessivetightening force may crack the top of the indicator.For more information on the air filter indicator,refer to Video Tape, PEVN1736, Caterpillar AirFilter Service Indicator.

Note: If you still believe that the service indicatoris working improperly, refer to Operation andMaintenance Manual, Engine Air Filter ServiceIndicator Screen - Check/Replace.

5. Close the left side engine compartment door.

i01360098

Engine Air Filter ServiceIndicator Screen -Check/ReplaceSMCS Code: 7452-510-Z3; 7452-535-Z3


Typical Example

Check1. Set an 8N-2694 Air Filter Service Indicator toindicate a restricted indicator screen.

2. Screw the indicator onto a 1/8 inch NPT pipenipple.

3. Screw the other end of the nipple into the threadedhole in the elbow. Normally, filter screen (1) islocated in the elbow.

4. Depress the reset button on the 8N-2694 AirFilter Service Indicator.

5. If the indicator resets, filter screen (1) is notplugged. If the indicator does not reset, filterscreen (1) is plugged. Filter screen (1) shouldthen be replaced.

Replace1. Remove the air cleaner from the air cleanerhousing. Removing the air cleaner from the aircleaner housing will provide access to the holeinside the elbow. Filter screen (1) is installedinside the elbow.

2. A 2 inch piece of 1/8 inch drill rod is needed inorder to push filter screen (1) from the inside ofthe elbow to the outside.


Engine Air Precleaner - Clean

3. After the plugged filter screen (1) has beenremoved, install a new filter screen (1) in the holeon the outside of the elbow. Use a piece of 1/4inch drill rod to lightly seat the filter element in thebottom of the bore.

i01550089

Engine Air Precleaner - CleanSMCS Code: 1055-070; 1055-070-DJ

NOTICEService the engine air precleaner only with the enginestopped. Engine damage could result.

The engine air precleaner is positioned on top of theengine compartment.


1. Loosen clamp (1) at the bottom of engine airprecleaner (2).

2. Remove engine air precleaner (2) and inspect theopening for dirt and debris. Clean the tubes, ifnecessary.

3. Clean engine air precleaner (2) with pressure airor wash the engine air precleaner (2) in cleanwarm water.

4. Install engine air precleaner (2). Tighten clamp (1).

i01632265

Engine Crankcase Breather -ReplaceSMCS Code: 1317-510

Only replace the engine crankcase breather whenyou rebuild the engine.

i02954148

Engine Oil Level - CheckSMCS Code: 1000-535-FLV; 1302-535-FLV;1326-535-OC; 1326-535-FLV; 1348-535-FLV


NOTICEDo not under fill or overfill engine crankcase with oil.Either condition can cause engine damage.


Clean the area around the oil level gauge and cleanthe area around the oil filler cap before you removethe oil level gauge and before you remove the oilfiller cap.

1. Open the front left access door.


2. Before starting the engine, check oil level gauge(2). Maintain the oil level between the marks onthe oil level gauge.

3. If necessary, remove oil filler cap (1) in order toadd oil.

4. Clean the oil filler cap and install the oil filler cap.


110 SEBU8249-01Maintenance SectionEngine Oil Sample - Obtain

i03330561

Engine Oil Sample - ObtainSMCS Code: 1348-008; 1348-554-SM; 7542-008;7542-554-OC, SM


The sampling valve for the engine oil is located onthe right side of the engine compartment to the leftof the oil filter.

Refer to Operation and Maintenance Manual,SEBU6250, SOS Oil Analysis for information thatpertains to obtaining a sample of the engine oil.Refer to Special Publication, PEHP6001, How ToTake A Good Oil Sample for more information aboutobtaining a sample of the engine oil.

i02977642

Engine Oil and Filter - ChangeSMCS Code: 1302-044-OC; 1308-510; 1318-510;1326-535-OC; 1348-044

Selection of the Oil Change Interval

NOTICEA 500 hour engine oil change interval is available, pro-vided that the operating conditions and recommend-ed multigrade oil types are met. When these require-ments are not met, shorten the oil change intervalto 250 hours, or use an SOS Services oil samplingand analysis program to determine an acceptable oilchange interval.

If you select an interval for oil and filter change that istoo long, you may damage the engine.

Caterpillar oil filters are recommended.

Recommended multigrade oil types are listed inTable 11. Do not use single grade oils.

Abnormally harsh operating cycles or harshenvironments can shorten the service life ofthe engine oil. Arctic temperatures, corrosiveenvironments, or extremely dusty conditions mayrequire a reduction in engine oil change intervalsfrom the recommendations in Table 11. Also referto Special Publication, SEBU5898, Cold WeatherRecommendations. Poor maintenance of air filtersor of fuel filters requires reduced oil change intervals.See your Caterpillar dealer for more information if thisproduct will experience abnormally harsh operatingcycles or harsh environments.

Table 11

Engine Oil Change Interval(1)

Operating Conditions

Severe

MultigradeOil Type Normal(2)

HighLoadFactor(3)

FuelSulfurfrom0.3%to

0.5%(4)

Altitudeabove1830 m(6000 ft)

Cat DEOPreferred 500 hr 500 hr 500 hr 250 hr

(6)

Cat ECF-111.0

minimumTBN(4)Preferred

500 hr 500 hr 500 hr 250 hr(6)

Cat ECF-1TBN(4)

below 11.0500 hr 500 hr 250hr(5) 250 hr

(6)

API CG-4 500 hr 250 hr(5) 250hr(5) 250 hr(6)

(1) The traditional oil change interval for engines is 250 hours.The standard oil change interval in this machine is 500 hours, ifthe operating conditions and recommended oil types that arelisted in this table are met. Improvements in the engine allowthis engine oil change interval. This new standard interval is notpermitted for other machines. Refer to the applicable Operationand Maintenance Manuals for the other machines.

(2) Normal conditions include these factors: Fuel sulfur below0.3%, altitude below 1830 m (6000 ft), and good air filter andfuel filter maintenance. Normal conditions do not include highload factor, harsh operating cycles, or harsh environments.

(3) High load factors can shorten the service life of your engineoil. Continuous heavy load cycles and very little idle time resultin increased fuel consumption and oil contamination. Thesefactors deplete the oil additives more rapidly. If the averagefuel consumption of your machine exceeds 24 L (6.4 US gal)per hour, follow the High Load Factor recommendations inTable 11. To determine average fuel consumption, measureaverage fuel consumption for a period of 50 to 100 hours. Ifthe application of the machine is changed, the average fuelconsumption may change.

(4) For sulfur content above 0.5%, refer to Special Publication,SEBU6250, Total Base Number (TBN) and Fuel Sulfur Levelsfor Direct Injection (DI) Diesel Engines.

(5) In order to verify an oil change interval of 500 hours, refer toProgram A below.

(6) Use Program B below to determine an appropriate interval.


Engine Oil and Filter - Change

Adjustment of the Oil ChangeIntervalNote: Your Caterpillar dealer has additionalinformation on these programs.

Program A

Verification for an Oil Change Interval of 500Hours

This program consists of three oil change intervals of500 hours. Oil sampling and analysis is done at 250hours and 500 hours for each of the three intervalsfor a total of six oil samples. The analysis includesoil viscosity and infrared (IR) analysis of the oil. Ifall of the results are satisfactory, the 500 hour oilchange interval is acceptable for the machine in thatapplication. Repeat Program A if you change theapplication of the machine.

If a sample does not pass the oil analysis, take oneof these actions:

Shorten the oil change interval to 250 hours.

Proceed to Program B.

Change to a preferred oil type in Table 11.

Program B

Optimizing Oil Change Intervals

Begin with a 250 hour oil change interval. The oilchange intervals are adjusted by increments. Eachinterval is adjusted an additional 50 hours. Periodic oilsampling and analysis is done during each interval.The analysis includes oil viscosity and infrared (IR)analysis of the oil. Repeat Program B if you changethe application of the machine.

If an oil sample does not pass the analysis, shortenthe oil change interval, or change to a preferredmultigrade oil type in the listing above.

References

Reference: Form, PEDP7035, Optimizing OilChange Intervals

Reference: Form, PEDP7036, SOS Fluid Analysis

Reference: Special Publication, PEHP7076,Understanding the SOS Services Tests

Procedure for Changing the EngineOil and Filter





NOTICEDo not under fill or overfill engine crankcase with oil.Either condition can cause engine damage.


Park the machine on a level surface and engage theparking brake. Stop the engine.

Note: Drain the crankcase while the oil is warm. Thisallows waste particles that are suspended in the oil todrain. As the oil cools, the waste particles will settleto the bottom of the crankcase. The particles will notbe removed by draining the oil and the particles willrecirculate in the engine lubrication system with thenew oil.


112 SEBU8249-01Maintenance SectionEngine Overheating

1. Open crankcase drain valve (1). Allow the oil todrain into a suitable container.

2. Close crankcase drain valve (1).


3. Open the right side access door.

4. Open the left side access door.

5. Clean the area around engine oil filter (2) beforeyou remove the engine oil filter. Remove theengine oil filter with a strap type wrench. Referto Operation and Maintenance Manual, Oil Filter- Inspect.

6. Clean the base of the engine oil filter housing.Make sure that all of the old filter gasket isremoved.

7. Apply a thin film of engine oil to the gasket of thenew filter.

8. Install the new filter by hand until the seal of thefilter contacts the base. Note the position of theindex marks on the filter in relation to a fixed pointon the filter base.

Note: There are rotation index marks on the filterthat are spaced 90 degrees or 1/4 of a turn awayfrom each other. When you tighten the filter, use therotation index marks as a guide.

9. Tighten the filter according to the instructionsthat are printed on the filter. Use the index marksas a guide. For non-Caterpillar filters, use theinstructions that are provided with the filter.

Note: You may need to use a Caterpillar strapwrench, or another suitable tool, in order to turnthe filter to the amount that is required for finalinstallation. Make sure that the installation tool doesnot damage the filter.


10.Clean the area around oil filler cap (3) before youremove the oil filler cap. Clean the area around oillevel gauge (4) before you remove the oil levelgauge. Remove the oil filler cap. Fill the crankcasewith new oil. Refer to the following topics:

Operation and Maintenance Manual, LubricantViscosities

Operation andMaintenanceManual, Capacities(Refill)

11.Clean the filler cap and install the filler cap.

12.Start the engine and allow the oil to warm. Checkthe engine for leaks.

13.Check the oil level. If necessary, add oil. Refer toOperation and Maintenance Manual, Engine OilLevel - Check for more information.

14.Stop the engine. Close all access doors.

i01900293

Engine OverheatingSMCS Code: 1000; 1350; 1353

If your machine experiences an engine overheatingproblem, do the following maintenance proceduresin the order that is listed:

1. Operation and Maintenance Manual, CoolingSystem Coolant Level Check

2. Operation and Maintenance Manual, Radiator -Clean

3. Operation and Maintenance Manual, Belt -Inspect

4. Operation and Maintenance Manual, CoolingSystem Pressure Cap - Clean/Replace

SEBU8249-01 113Maintenance SectionEngine Power Loss

5. Operation and Maintenance Manual, RadiatorCore - Clean

6. Operation and Maintenance Manual, CoolingSystem Water Temperature Regulator - Replace

If the engine overheating problem is not corrected,consult your Caterpillar dealer.

i01900299

Engine Power LossSMCS Code: 1000; 1051; 1250

If your machine experiences an engine power loss,perform the following maintenance procedures in theorder that is listed:

1. Operation and Maintenance Manual, Engine AirFilter Service Indicator - Inspect

2. Operation and Maintenance Manual, Engine AirPrecleaner - Clean

3. Operation and Maintenance Manual, Engine AirFilter Primary Element - Clean/Replace

4. Operation and Maintenance Manual, Engine AirFilter Secondary Element - Replace

5. Operation and Maintenance Manual, Fuel TankWater and Sediment - Drain

6. Operation and Maintenance Manual, Fuel TankCap and Strainer - Clean

7. Operation and Maintenance Manual, Fuel SystemWater Separator Element - Replace

8. Operation and Maintenance Manual, Fuel SystemSecondary Filter - Replace

If the power loss is not corrected, consult yourCaterpillar dealer.

i01498587

Engine Valve Lash - CheckSMCS Code: 1105-535

Ensure that the engine can not be started whilethis maintenance is being performed. To help pre-vent possible injury, do not use the starting motorto turn the flywheel.

Hot engine components can cause burns. Allowadditional time for the engine to cool before mea-suring/adjusting valve lash clearance.

NOTICEOnly qualified service personnel should perform thismaintenance. Refer to the Service Manual or yourCaterpillar dealer for the complete valve lash adjust-ment procedure.

Operation of Caterpillar engines with improper valveadjustments can reduce engine efficiency. This re-duced efficiency could result in excessive fuel usageand/or shortened engine component life.

NOTICEDo not use the yoke that comes out of the front of theengine in order to turn over the engine. Damage to thecrankshaft vibration damper can occur.

The adjustment is necessary due to the initial wear ofthe valve train components and to the seating of thevalve train components.

This maintenance is recommended by Caterpillaras part of a lubrication and preventive maintenanceschedule in order to help provide maximum enginelife.

Ensure that the engine is stopped before youmeasure the valve lash. To obtain an accuratemeasurement, allow the valves to cool before youperform this maintenance.

Remove the cover in order to access the rear ofthe engine. Check the valve lash. For the correctadjustment procedure, refer to Systems Operation,Testing and Adjusting, Engine Valve Lash -Inspect/Adjust.

114 SEBU8249-01Maintenance SectionEngine Valve Rotators - Inspect

i00128925

Engine Valve Rotators - InspectSMCS Code: 1109-040

When inspecting the valve rotators, protectiveglasses or face shield and protective clothingmust be worn, to prevent being burned by hot oilspray.

Inspect the engine valve rotators after the valveclearances have been set.

1. Start the engine and run the engine at low idle.

2. Watch the top surface of each valve rotator. Whenthe intake valve or the exhaust valve closes, theengine valve rotator should turn slightly.

If an intake valve or an exhaust valve fails to rotate,consult your Caterpillar Dealer.

i02954154

Ether Starting Aid Cylinder -ReplaceSMCS Code: 1456-510-CD



1. Open the right side access door.

2. Loosen the retaining clamp on ether starting aidcylinder (1). Remove the empty ether starting aidcylinder. Properly discard the empty ether startingaid cylinder.

3. Remove the used gasket. Install the new gasketthat is provided with each new ether starting aidcylinder.

4. Install the new ether starting aid cylinder. Tightenthe ether starting aid cylinder hand tight. Tightenthe retaining clamp on the ether starting aidcylinder securely.


i01827363

Evaporator Coil and HeaterCoil - CleanSMCS Code: 7309-070; 7343-070

The evaporator coil and the heater coil are locatedunder the seat in the cab.

1. Remove the seat.

2. Remove both of the covers.


3. Clean evaporator coil (1) and clean heater coil (2).Replace both coils.

4. Replace both of the covers and replace the seat.

Note: If you are operating the machine under harshconditions or with the cab door open, it may benecessary to clean the coils more often.


Final Drive Preload - Check

i02954165

Final Drive Preload - CheckSMCS Code: 4050-535-ZP

Table 12

Required Tools

Part Number Description Quantity

Wrench for 140K6V-4074

Wrench for 160K1

9U-5015 Torque Wrench Gp(3/4 Inch Drive) 1

Table 13

Bearing Preload for the Final Drive

Sales Model Final Torque

140K

160K102 Nm (75 lb ft)

1. Park the machine on a level surface.

2. Refer to the Operation and Maintenance Manual,Jacking Locations for the proper lifting points.Support the machine so that the rear tires areoff the ground. The machine must be in a stableposition in order to be able to turn the rear tires.

3. Unlock the differential.

4. Stop the engine.

5. Drain the oil below the level of the outer cover.


6. Remove outer cover (1).


7. Remove lock (2).


8. Install the wrench for your machine to theappropriate torque wrench.

9. Check the torque. Refer to Table 13.

10.Refer to the adjustment procedure inthe PowerTrain Systems Operation, Testing and Adjusting,Final Drive Bearings - Adjust if the torque isincorrect.

116 SEBU8249-01Maintenance SectionFuel System - Fill

i02794509

Fuel System - FillSMCS Code: 1250-544

Personal injury or death may result from failure toadhere to the following procedures.

Fuel leaked or spilled onto hot surfaces or electri-cal components can cause a fire.

Clean up all leaked or spilled fuel. Do not smokewhile working on the fuel system.

Turn the disconnect switch OFF or disconnect thebattery when changing fuel filters.

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting, and repair of the machine. Be preparedto collect the fluid with suitable containers beforeopening any compartment or disassembling any com-ponent containing fluids.


Reference: Refer to Operation and MaintenanceManual, Capacities (Refill) for the fuel tank capacityof your machine.


1. Clean filler cap (1) and the surrounding area.

2. Remove the filler cap.

3. Fill fuel tank (2) with fuel.

4. Install the filler cap.

Note: Prime the fuel system. Refer to Operation andMaintenance Manual, Fuel System - Prime for moreinformation.

i02096133

Fuel System - PrimeSMCS Code: 1250-548; 1258-548

NOTICEDo not allow dirt to enter the fuel system. Thoroughlyclean the area around a fuel system component thatwill be disconnected. Fit a suitable cover over discon-nected fuel system component.

1. Turn the engine start switch to the ON position.Leave the engine start switch in the ON positionfor two minutes.

2. Verify that the water separator is full of fuel.

3. If the water separator is not full of fuel, turn theengine start switch OFF and then turn the enginestart switch ON. This will cycle the fuel primingpump again.

4. When the water separator is full of fuel, attemptto start the engine. If the engine starts and theengine runs rough or the engine misfires, operateat low idle until the engine is running smoothly.If the engine cannot be started, or if the enginecontinues to misfire or smoke, repeat Step 1.

i03351320

Fuel System Primary Filter(Water Separator) Element -ReplaceSMCS Code: 1263-510-FQ

Fuel leaked or spilled onto hot surfaces or electri-cal components can cause a fire.

Turn the disconnect switch OFF when drainingand/or removing any fuel system components.


Fuel System Primary Filter (Water Separator) Element - Replace

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers b

140k

Documents

engine air precleaner

engine overheating

frequent maintenance

maintenance procedures

engine crankcase breather

engine power loss

radiator clean

consecutive interval