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MOTOR GRADER
Maintenance Intervals
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SEBU8250-01 83
Maintenance Section
Maintenance Interval Schedule
Note: Before each consecutive interval is performed, Articulation Bearings - Lubricate ........................... 85
all maintenance from the previous interval must be Axle Oscillation Bearings - Lubricate .................... 86
performed. Belt - Inspect ......................................................... 87
Blade Lift Cylinder Socket - Lubricate ................... 89
When Required Cab Air Filter - Clean/Replace .............................. 91
Centershift Cylinder Socket - Lubricate ................ 92
Battery - Recycle .................................................. 86 Centershift Lock Bar - Clean/Lubricate ................. 92
Belt - Replace ....................................................... 88 Drawbar Ball and Socket - Lubricate .................. 105
Blade Lift Cylinder Socket - Check/Adjust/ Hydraulic System Oil Level - Check ................... 128
Replace ............................................................... 88 Kingpin Bearings - Lubricate ............................... 129
Centershift Cylinder Socket - Check/Adjust/ Ripper Cylinder Bearings - Lubricate .................. 132
Replace ............................................................... 91 Scarifier Lift Link Socket - Lubricate ................... 133
Circle Clearances - Check/Adjust ......................... 92 Tandem Drive Oil Level - Check ......................... 136
Circle Drive Oil Level - Check ............................... 96 Tire Inflation - Check ........................................... 136
Circuit Breakers - Reset ........................................ 97 Wheel Lean Bar Bearings - Lubricate ................. 142
Cutting Edges and End Bits - Inspect/Replace ... 104 Wheel Lean Bearings - Lubricate ....................... 142
Drawbar Ball and Socket End Play - Wheel Lean Cylinder Bearings - Lubricate ......... 143
Check/Adjust ..................................................... 105
Engine Air Filter Primary Element - Clean/ Initial 500 Service Hours (or at first oil
Replace ............................................................. 106 change)
Engine Air Filter Secondary Element - Replace .. 109
Engine Air Filter Service Indicator Screen - Battery or Battery Cable - Inspect/Replace .......... 86
Check/Replace ................................................... 110 Electronic Unit Injector - Inspect/Adjust .............. 106
Engine Air Precleaner - Clean ............................. 111 Engine Valve Lash - Check .................................. 116
Engine Crankcase Breather - Replace ................ 111
Engine Overheating ............................................. 115 Every 500 Service Hours or 3 Months
Engine Power Loss .............................................. 115
Ether Starting Aid Cylinder - Replace .................. 116 Braking System - Test ........................................... 90
Evaporator Coil and Heater Coil - Clean ............. 117 Cooling System Coolant Sample (Level 1) -
Fuel System - Fill ................................................. 118 Obtain ................................................................. 98
Fuses - Replace .................................................. 122 Engine Air Filter Service Indicator -
Moldboard Wear Strip - Inspect/Adjust/Replace .. 129 Inspect/Replace ................................................. 110
Radiator - Clean .................................................. 131 Engine Oil Sample - Obtain ................................. 112
Radiator Core - Clean ......................................... 131 Engine Oil and Filter - Change ............................ 112
Ripper Tip - Inspect/Replace .............................. 132 Fuel System - Prime ............................................ 119
Scarifier Teeth - Inspect/Replace ........................ 133 Fuel System Primary Filter (Water Separator)
Window Washer Reservoir - Fill .......................... 143 Element - Replace ............................................. 119
84 SEBU8250-01
Maintenance Section
Maintenance Interval Schedule
i03637299
g01705773
Refer to the Operation and Maintenance Manual, Illustration 79
“Access Doors and Covers” for the location of the
service points. 2. The air tanks are located at the rear of the
machine under the frame. Pull down the lever to
open drain valve (1) in order to drain one air tank.
Pull down the lever to open drain valve (2) in order
to drain the other air tank. Close the drain valve.
g01951911 i01671010
Illustration 78
i02958107
In order to lubricate the axle oscillation bearings, use 4. Disconnect the negative battery cable from the
183-3424 Grease Cartridge to apply lubricant to the battery.
one fitting.
5. Disconnect the positive battery cable from the
battery.
i02307698
6. Inspect the battery terminals for corrosion. Inspect
Backup Alarm - Test the battery cables for wear or damage.
SMCS Code: 7406-081 7. If necessary, make repairs. If necessary, replace
the battery cable or the battery.
Turn the engine start switch to the ON position in
order to perform the test. 8. Connect the positive battery cable at the battery.
Apply the service brake. Move the transmission 9. Connect the negative battery cable at the battery.
control (lever) to the REVERSE position.
10. Connect the battery cable at the battery
The backup alarm should sound immediately. disconnect switch.
The backup alarm should continue to sound until
the transmission control (lever) is moved to the 11. Install the key for the battery disconnect switch.
NEUTRAL position or to any FORWARD position. Turn the battery disconnect switch to the ON
position.
The backup alarm is located at the rear of the
machine.
SEBU8250-01 87
Maintenance Section
Belt - Inspect
i03636021
Belt - Inspect
SMCS Code: 1357-040; 1397-040
g01464169
Illustration 84
• excessive cracking
• excessive wear
• excessive damage
Illustration 82
g01705935 5. Inspect the free arm stop of belt tensioner (5).
The free arm stop must be aligned with the green
zone which is on the decal of the belt tensioner.
If the free arm stop is in either of the red zones,
replace the belt.
g01951149
Illustration 83
g01734394
Illustration 85
3. Replace the belt if any of the following conditions Alternator and Fan Drive Belt
exist:
Refer to Operation and Maintenance Manual,
• excessive cracking “Access Doors and Covers” for the location of the
service points.
• excessive wear
• excessive damage
i02951361
Belt - Replace
SMCS Code: 1357-510; 1397-510
i01564804
6. Inspect the free arm stop of the belt tensioner. The 2. Operate the blade lift cylinders. Observe the
free arm stop must be aligned with the green zone socket. If the socket moves without blade
which is on the decal of the belt tensioner. movement, adjustment is necessary.
SEBU8250-01 89
Maintenance Section
Blade Lift Cylinder Socket - Lubricate
g00949365 g00949369
Illustration 88 Illustration 89
3. Remove two bolts (2) from each cap (1). Remove There are two blade lift cylinders (1).
the cap (1).
Each blade lift cylinder socket has one fitting (2).
4. Remove one shim from either side of the inserts in In order to lubricate the blade lift cylinder sockets,
order to reduce clearance. use 183-3424 Grease Cartridge to apply lubricant
to each fitting.
Note: If you need to remove two shims, then remove
one shim from each side of the inserts.
i02790006
i01862405
g01393751
Illustration 90
Look for inoperative gauges. Use the following test in order to determine whether
the service brake is functional. This test is not
Turn on all of the machine lights. Check for proper intended to measure the maximum holding ability of
operation. the service brake.
Sound the horn. 1. Start the engine. Raise the blade slightly. Depress
the transmission modulator control. Apply the
Move the machine forward and test the service service brake control.
brakes. If the service brakes do not function properly,
see Operation and Maintenance Manual, “Braking 2. Move the transmission control (lever) to FIFTH
System - Test” in the Maintenance Interval Schedule SPEED FORWARD. Increase the engine speed
of this manual. to high idle.
Make sure that the area around the machine is clear Test the parking brake on a hard dry surface.
of personnel and clear of obstacles.
Fasten the seat belt before you test the parking
Test the service brake on a dry level surface. brake.
Fasten your seat belt before you test the brakes. Use the following test to determine whether the
parking brake is functional. This test is not intended
to measure the maximum holding ability of the
parking brake.
SEBU8250-01 91
Maintenance Section
Cab Air Filter - Clean/Replace
1. Position the machine on a slope of 20 percent. 3. Rinse the filter elements in clean water.
Thoroughly air dry the filter elements.
2. Engage the parking brake control. Release the
service brake control. The wheels should not 4. Install the filter elements. Install the filter cover.
rotate. If the wheels rotate, engage the service
brake control.
Replace the Filters
i01829689 Note: Replace the cab air filters, as required.
SMCS Code: 7311-070-FI; 7311-510-FI; 7342-070; 2. Remove the filter elements. Discard the filter
7342-510 elements.
Note: The cab air filters are an optional attachment 3. Install the new filter elements.
on this machine.
4. Install the filter covers.
i03326788
g00933775
Illustration 91
(1) Outside filter
(2) Inside filter
The filter for the inside cab air system is positioned 3. Remove bolts (1) from cap (2). Remove cap (2).
behind the operator's seat.
4. Remove one shim from either side of the inserts in
1. Remove the filter cover. order to reduce clearance.
2. Remove the filter elements. Clean the filter Note: If you need to remove two shims, then remove
elements with pressure air or wash the filter one shim from each side of the inserts.
elements in warm water and in a nonsudsing
household detergent. 5. Install the cap and bolts and tighten the bolts.
92 SEBU8250-01
Maintenance Section
Centershift Cylinder Socket - Lubricate
i01862638
Clean the dirt, the lubricant and the rust from the
holes in the centershift lock bar.
i01865351
Circle Clearances -
Check/Adjust
SMCS Code: 6152-025; 6152-535; 6153-025;
Illustration 93
g00949526 6153-535; 6154-025; 6154-535; 6155-025;
6155-535
The centershift cylinder has one fitting on each end.
In order to lubricate the centershift cylinder sockets, Blade Circle and Drawbar
use 183-3424 Grease Cartridge (5% Molybdenum
Disulfide) to apply lubricant to the fittings. 1. Rotate the blade. Place the blade at an angle of
90 degrees to the frame.
i02327869
Note: Install the C-clamps before you lower the blade
Centershift Lock Bar - to the ground.
Clean/Lubricate
SMCS Code: 5221-070; 5221-086
g00950750
Illustration 95
g00950750
Illustration 97
g00774795
Illustration 96
g00774798
Illustration 100
Note: The proper clearance will permit the blade 2. Measure the clearance (X) that is between
circle to freely rotate for 360 degrees. the bottom flange of pinion (10) and the inner
machined surface of circle (1). If the clearance is
Adjust the circle shoes (9) one at a time. less than 49.5 to 52.5 mm (1.95 to 2.07 inch), then
adjust the clearance.
6. Loosen shoe mounting fastener (6). Remove shoe
mounting fastener (4) and remove shoe mounting
fastener (5).
i03326684
g00774800
Illustration 102
3. Loosen shoe mounting fastener (4), shoe Hot oil and hot components can cause personal
mounting fastener (5), shoe mounting fastener (6) injury. Do not allow hot oil or hot components to
and locknuts (11) on the front circle shoes. contact skin.
g01704514
Illustration 104
Top view of the blade circle
g01700653
Illustration 105
Note: Clean the area around the drain plug and
clean the area around the check/fill plug before you 1. Remove check/fill plug (1).
remove the plugs.
2. Maintain the oil level to the bottom of the opening
1. Remove drain plug (1). Remove check/fill plug (2). for the check/fill plug.
Allow the oil to drain into a suitable container.
3. Install check/fill plug (1).
2. Clean the drain plug and install the drain plug.
3. Fill the circle drive housing with oil. Refer to the i02527479
4. Clean the check/fill plug and install the check/fill Contact with a moving attachment may cause in-
plug. jury or death.
5. Start the engine. Operate the machine for a few Avoid contact with a moving attachment when lu-
minutes. Check the circle drive housing for leaks. bricating or maintaining the attachment.
6. Stop the engine. Remove the check/fill plug and
check the oil level. Maintain the oil level to the Note: Caterpillar recommends the use of 5%
bottom of the filler opening. If necessary, add oil. molybdenum grease for lubricating the circle drive
pinion teeth. Refer to Special Publication, SEBU6250,
7. Install the check/fill plug. “Caterpillar Machine Fluids Recommendations” for
more information on molybdenum grease.
i03322240 The circle drive pinion teeth are located under the
Circle Drive Oil Level - Check circle drive housing.
i02795072
i03637740
2. Stop the engine. Lower the blade and any The circuit breaker resets are located in the engine
attachments to the ground. compartment on the right side of the machine.
g01952213
Illustration 107
i02793761 i03637434
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
Illustration 109
g01394849 ing any compartment or disassembling any compo-
nent containing fluids.
The refrigerant condenser (2) is located in front of the
radiator (1) at the rear of the machine. Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
1. Open the access door at the rear of the machine suitable to collect and contain fluids on Caterpillar
on the left side of the machine. products.
2. Inspect the condenser for debris. If necessary, Dispose of all fluids according to local regulations and
clean the condenser. mandates.
3. Use clean water in order to wash off all dust and NOTICE
dirt from the condenser. Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
4. Close the access door. Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
i02976205
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
If the coolant is dirty or if you observe any foaming 4. Slowly remove the cooling system pressure cap in
in the cooling system, change the coolant before the order to relieve pressure.
recommended interval.
Note: Thermostats can be reused if the thermostats 5. Open drain valve (2). The drain valves are located
meet certain test specifications. The tested at the right rear of the machine. Allow the coolant
thermostats must not be damaged and the tested to drain into a suitable container.
thermostats must not have an excessive buildup of
deposits. 6. Flush the cooling system with clean water until the
draining water is transparent.
1. Stop the engine and allow the engine to cool.
7. Close the drain valve.
10. Maintain the coolant level between the “FULL” When a Caterpillar Extended Life Coolant (ELC)
mark and the “ADD” mark on the coolant tank. is used, an extender must be added to the
cooling system. See Operation and Maintenance
11. Install the cooling system pressure cap. Close Manual, “Maintenance Interval Schedule” for the
cover (1). proper service interval. The amount of extender is
determined by the cooling system capacity.
12. Check the radiator for any external leaks. Check
for air bubbles in the radiator. 1. Stop the engine and allow the engine to cool.
i02949342
i03636207
g01951284
Illustration 114
Do not attempt to tighten hose connections when Personal injury can result from hot coolant, steam
the coolant is hot, the hose can come off causing and alkali.
burns.
At operating temperature, engine coolant is hot
Cooling System Conditioner contains alkali. Avoid and under pressure. The radiator and all lines
contact with skin and eyes. to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
4. Install a new water temperature regulator and The vibration damper can be used again if none of
a new gasket. Install the water temperature the above conditions are found or if the vibration
regulator housing. damper is not damaged.
5. Install the water temperature regulator housing Note: Contact your Caterpillar dealer for further
and the hose. Tighten the hose clamp. information.
g00811262 g00949567
Illustration 118 Illustration 119
End bits (1) and/or cutting edges (2) may be Apply the appropriate lubricant through the fitting in
damaged. End bits (1) and/or cutting edges (2) may order to lubricate the drawbar ball and socket.
be worn excessively. Replace the end bits (1) and/or
the cutting edges (2), as needed.
i02528988
3. Install new end bits (1) and/or new cutting edges Check
(2).
Rotate the blade so that the blade is placed at an
4. Raise the blade and remove the blocks. angle of 90 degrees to the frame. Lower the blade to
the ground. While you maintain a light load between
i02528905 the ball and the socket, inch the machine slowly to
the rear. Stop the machine and shut off the engine.
Drawbar Ball and Socket -
Lubricate
SMCS Code: 6170-086; 6171-086
g01265355
Illustration 120
Adjust
1. Support the drawbar and support the circle.
106 SEBU8250-01
Maintenance Section
Electronic Unit Injector - Inspect/Adjust
3. Remove capscrews (7) from cap (3) that holds the The electronic unit injectors use high voltage. Dis-
drawbar and adapter (6) together. Remove the connect the unit injector enable circuit connector
adapter. in order to prevent personal injury. Do not come
in contact with the injector terminals while the en-
4. As required, remove shims (4) or install shims gine is running.
(4) in order to attain an end play of 0.6 ± 0.2 mm
(.02 ± .01 inch).
NOTICE
5. Install capscrews (7) in cap (3) and adapter (6). Only qualified service personnel should perform this
Rotate cap (3) by hand. The socket should rotate maintenance. Refer to the Service Manual or your
freely on ball (2). Caterpillar dealer for the complete valve lash adjust-
ment procedure.
6. Check the torque on bolts (5) that hold ball (2)
in place. The correct torque is 500 ± 65 N·m Operation of Caterpillar engines with improper valve
(370 ± 50 lb ft). adjustments can reduce engine efficiency. This re-
duced efficiency could result in excessive fuel usage
7. Assemble the drawbar to the bolster. Tighten bolts and/or shortened engine component life.
(1) to a torque of 950 ± 50 N·m (701 ± 37 lb ft).
The initial adjustment to the unit injector is
recommended at the initial 500 hour interval. The
unit injector adjustment should then be made at
every 2000 hour interval. The operation of Caterpillar
engines with improper adjustments of the electronic
unit injector can reduce engine efficiency. This
reduced efficiency could result in excessive fuel
usage and/or shortened engine component life.
i01631934
NOTICE
Service the air cleaner only with the engine stopped.
Engine damage could result.
SEBU8250-01 107
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
Service the air cleaner filter element when the Cleaning Primary Air Filter
yellow piston on the engine air filter service
indicator enters the red zone or the indicator
Elements
reads 63.5 cm (25 inch) of water. Refer to
Operation and Maintenance Manual, “Engine Air NOTICE
Filter Service Indicator - Inspect”. Caterpillar recommends certified air filter cleaning ser-
vices available at participating Caterpillar dealers. The
1. Open the access door for the air filter housing. Caterpillar cleaning process uses proven procedures
Refer to Operation and Maintenance Manual, to assure consistent quality and sufficient filter life.
“Access Doors and Covers”.
Observe the following guidelines if you attempt to
clean the filter element:
• Pressurized air
• Vacuum cleaning
108 SEBU8250-01
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
g00281693
Illustration 124
g00281694
Illustration 125
SEBU8250-01 109
Maintenance Section
Engine Air Filter Secondary Element - Replace
Do not use paint, a waterproof cover, or plastic as a 2. Remove the secondary element.
protective covering for storage. An airflow restriction
may result. To protect against dirt and damage, wrap 3. Cover the air inlet opening. Clean the inside of
the primary air filter elements in Volatile Corrosion the air cleaner housing.
Inhibited (VCI) paper.
4. Uncover the air inlet opening. Install a new
Place the primary air filter element into a box for secondary element.
storage. For identification, mark the outside of the
box and mark the primary air filter element. Include 5. Install the primary element and the air cleaner
the following information: cover.
• Number of cleanings Note: When you replace the air filter element, you
must replace the filter screen. Refer to Operation
Store the box in a dry location. and Maintenance Manual, “Engine Air Filter Service
Indicator Screen - Check/Replace”.
i01562943
i02794241
Engine Air Filter Secondary
Element - Replace Engine Air Filter Service
Indicator - Inspect
SMCS Code: 1051-510-SE; 1054-510-SE
SMCS Code: 7452-040; 7452-040-DJ;
NOTICE 7452-040-ENG
Always replace the secondary element. Do not at-
tempt to reuse it by cleaning. Engine damage could Refer to the Operation and Maintenance Manual,
result. “Access Doors and Covers” for the location of the
service points.
Refer to the Operation and Maintenance Manual,
“Access Doors and Covers” for the location of the
service points.
g00039214
Illustration 126
110 SEBU8250-01
Maintenance Section
Engine Air Filter Service Indicator - Inspect/Replace
Note: See the Operation and Maintenance Manual, 4. If the indicator will not reset easily, replace the
“Engine Air Filter Primary Element - Clean/Replace”. service indicator. If the yellow piston of the
See the Operation and Maintenance Manual, “Engine indicator will not latch at the highest vacuum that is
Air Filter Secondary Element - Replace”. attained, replace the service indicator. Tighten the
indicator to a torque of 2 N·m (18 lb in). Excessive
Note: Refer to Operation and Maintenance Manual, tightening force may crack the top of the indicator.
“Engine Air Filter Service Indicator - Inspect/Replace” For more information on the air filter indicator,
in order to check an engine air filter service indicator refer to Video Tape, PEVN1736, “Caterpillar Air
that is faulty. Filter Service Indicator”.
g01951289
Illustration 128
5. If the indicator resets, filter screen (1) is not 3. Clean engine air precleaner (2) with pressure air
plugged. If the indicator does not reset, filter or wash the engine air precleaner (2) in clean
screen (1) is plugged. Filter screen (1) should warm water.
then be replaced.
4. Install engine air precleaner (2). Tighten clamp (1).
Replace
i01632265
1. Remove the air cleaner from the air cleaner
housing. Removing the air cleaner from the air Engine Crankcase Breather -
cleaner housing will provide access to the hole
inside the elbow. Filter screen (1) is installed
Replace
inside the elbow.
SMCS Code: 1317-510
2. A 2 inch piece of 1/8 inch drill rod is needed in
Only replace the engine crankcase breather when
order to push filter screen (1) from the inside of
you rebuild the engine.
the elbow to the outside.
Clean the area around the oil level gauge and clean
the area around the oil filler cap before you remove
the oil level gauge and before you remove the oil
filler cap.
g00805907
Illustration 130
g01469847 g01951294
Illustration 131 Illustration 132
2. Before starting the engine, check oil level gauge The sampling valve for the engine oil is located on
(2). Maintain the oil level between the marks on the right side of the engine compartment.
the oil level gauge.
Refer to Special Publication, SEBU6250, “Caterpillar
3. If necessary, remove oil filler cap (1) in order to Machine Fluids Recommendations”, “S·O·S Services
add oil. Oil Analysis” for information that pertains to obtaining
a sample of the engine oil. Refer to Special
4. Clean the oil filler cap and install the oil filler cap. Publication, PEHP6001, “How To Take A Good Oil
Sample” for more information about obtaining a
5. Close the access door. sample of the engine oil.
i03636222 i03636246
Refer to Special Publication, NENG2500, “Caterpillar Caterpillar oil filters are recommended.
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar Recommended multigrade oil types are listed in
products. Table 9. Do not use single grade oils.
Dispose of all fluids according to local regulations and
mandates.
Procedure for Changing the Engine 1. Open crankcase drain valve (1). Allow the oil to
drain into a suitable container.
Oil and Filter
2. Close crankcase drain valve (1).
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Park the machine on a level surface and engage the 7. Install the new filter by hand until the seal of the
parking brake. Stop the engine. filter contacts the base. Note the position of the
index marks on the filter in relation to a fixed point
Note: Drain the crankcase while the oil is warm. This on the filter base.
allows waste particles that are suspended in the oil to
drain. As the oil cools, the waste particles will settle Note: There are rotation index marks on the filter
to the bottom of the crankcase. The particles will not that are spaced 90 degrees or 1/4 of a turn away
be removed by draining the oil and the particles will from each other. When you tighten the filter, use the
recirculate in the engine lubrication system with the rotation index marks as a guide.
new oil.
8. Tighten the filter according to the instructions
that are printed on the filter. Use the index marks
as a guide. For non-Caterpillar filters, use the
instructions that are provided with the filter.
g01265545
Illustration 133
SEBU8250-01 115
Maintenance Section
Engine Overheating
i01900299
• Operation and Maintenance Manual, “Lubricant 2. Operation and Maintenance Manual, “Engine Air
Viscosities” Precleaner - Clean”
• Operation and Maintenance Manual, “Capacities 3. Operation and Maintenance Manual, “Engine Air
(Refill)” Filter Primary Element - Clean/Replace”
11. Clean the filler cap and install the filler cap. 4. Operation and Maintenance Manual, “Engine Air
Filter Secondary Element - Replace”
12. Start the engine and allow the oil to warm. Check
the engine for leaks. 5. Operation and Maintenance Manual, “Fuel Tank
Water and Sediment - Drain”
13. Check the oil level. If necessary, add oil. Refer to
Operation and Maintenance Manual, “Engine Oil 6. Operation and Maintenance Manual, “Fuel Tank
Level - Check” for more information. Cap and Strainer - Clean”
14. Stop the engine. Close all access doors. 7. Operation and Maintenance Manual, “Fuel System
Water Separator Element - Replace”
i01498587 i00128925
Ensure that the engine can not be started while When inspecting the valve rotators, protective
this maintenance is being performed. To help pre- glasses or face shield and protective clothing
vent possible injury, do not use the starting motor must be worn, to prevent being burned by hot oil
to turn the flywheel. spray.
g00931904
Illustration 137
i02794509
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting, and repair of the machine. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.
Illustration 140
g00985487 Reference: Refer to Operation and Maintenance
Manual, “Capacities (Refill)” for the fuel tank capacity
8. Install the wrench for your machine to the of your machine.
appropriate torque wrench.
g01395489
Illustration 141
i03636427
9. Install the new filter hand tight until the seal of the
filter contacts the filter mounting base. Note the
position of the index marks on the filter in relation
to a fixed point on the filter mounting base.
2. Close the fuel supply valve. The fuel supply valve i03339624
is positioned in the engine compartment on the
left side of the machine. Fuel System Water Separator
- Drain
SMCS Code: 1263-543
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Use the rotation index marks on the new Fuel system water separator (1) is mounted on the
secondary fuel filter as a guide for tightening the left side of the machine. Refer to Operation and
filter. These rotation index marks are spaced at Maintenance Manual, “Access Doors and Covers”
intervals of 1/4 turn. for the location.
8. Open the fuel supply valve. 1. Open the rear access door.
9. Prime the fuel system. See the Operation and 2. Open drain (2) on water separator bowl (1).
Maintenance Manual, “Fuel System - Prime” for
more information. 3. Drain the water from the water separator bowl.
10. Close the engine compartment access door on 4. Close the drain.
the left side of the machine.
5. Close the access door.
122 SEBU8250-01
Maintenance Section
Fuel Tank Cap and Strainer - Clean
i02794517 i03329409
Fuel Tank Cap and Strainer - Fuel Tank Water and Sediment
Clean - Drain
SMCS Code: 1273-070-STR; 1273-070-Z2 SMCS Code: 1273-543-M&S
g01395494 g01707876
Illustration 147 Illustration 148
1. Clean fuel tank cap (1) and the surrounding area. Refer to Operation and Maintenance Manual,
“Access Doors and Covers” for the location of the
2. Remove the fuel tank cap and disassemble the service points.
fuel tank cap.
1. Open drain valve (1). Drain the water and
3. Inspect the seal on the fuel tank cap for damage. sediment into a suitable container.
If the seal is damaged, replace the seal. Lubricate
the seal on the fuel tank cap. Note: Discard any drained fluids according to local
regulations.
4. Replace the element on the fuel tank cap.
2. Close the drain valve.
5. Remove the strainer from the filler opening.
i03336504
6. Wash the strainer in clean nonflammable solvent.
Fuses - Replace
7. Install the strainer.
SMCS Code: 1417-510
8. Install the fuel tank cap.
Fuses – Fuses protect the electrical system from
damage that is caused by overloaded circuits.
Replace the fuse if the element is separated. Check
the circuit if the element is separated in a new fuse.
Repair the circuit.
NOTICE
Replace the fuses with the same type and size only.
Blank (11)
g00935093
Illustration 150
(3) Overhead fuse panel
Radio (13) (If Equipped) – 10 amp
There are three fuse panels. Two fuse panels are
positioned in the base of the steering column. The
other fuse panel is near the top of the cab at the right
side of the operator. Dome Lamp (14) – 10 amp
g01713777
Illustration 151
Fuse panel on the steering console (unswitched power) (1)
AccuGrade(18) (If Equipped) – 20 amp
Blank (31)
Blank (32)
Blank (33)
g01713781
Illustration 152
Fuse panel on the steering console (switched power) (2)
i03322061
Snow Wing Light (39) (If Equipped) – 10
amp Hydraulic System Oil - Change
SMCS Code: 5050-044; 5056-044; 5095-044
Front Windshield Defroster (40) – 10
amp
NOTICE
Rear Window Defroster (42) – 10 amp
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
Exterior Heated Mirrors (43) (If ing any compartment or disassembling any compo-
Equipped) – 10 amp nent containing fluids.
Park the machine on a level surface with the front 4. Remove the filler screen from the filler tube in the
wheel straight ahead. Lower all attachments to the hydraulic oil tank. Wash the filler screen in clean
ground. Apply a slight downward pressure to the nonflammable solvent. Allow the filler screen to
attachments. Center the articulation of the machine dry.
and install the frame lock pin. The frame lock pin
must move freely in the frame. Move the front wheels 5. Clean the drain plug and install the drain plug.
to vertical and install the wheel lean bolt. Engage the
parking brake. Stop the engine. 6. Install the filler screen.
The hydraulic system oil tank is positioned behind 7. Fill the hydraulic system oil tank. See Operation
the operator station at the center of the machine. and Maintenance Manual, “Capacities (Refill)”.
i01827858
Illustration 154
g00932315 Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
1. Slowly remove hydraulic oil filler cap (1). contact skin.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g00932333
Illustration 155
i03326582
g00932336
Illustration 156
g01707235
Illustration 157
i01863714
g00950101
Illustration 160
Parking Brake - Drain (1) Parking brake
(2) Outer plug
SMCS Code: 4267-543-M&S
1. Remove outer plug (2) and an inner plug (not
shown) behind outer plug (2).
Sudden movement of the machine or release of 2. Start the engine. Make sure that the air system
air under pressure can cause injury to persons on pressure reaches 965 ± 34 kPa (140 ± 5 psi).
or near the machine. To prevent possible injury,
perform the procedure that follows before testing
and adjusting the air system and brakes.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Dispose of all fluids according to local regulations and 3. Make sure that the service brake control (pedal)
mandates. is down. Move lever (3) from PARKING BRAKE
ENGAGED position to the NEUTRAL position
1. Move the machine to a smooth horizontal location. and back to the PARKING BRAKE ENGAGED
Move away from operating machines and move position.
away from personnel. Lower all implements to the
ground. 4. Continue to move lever (3) from PARKING BRAKE
ENGAGED position to the NEUTRAL position
2. Install the wheel lean locking bolt in the front axle. and back to the PARKING BRAKE ENGAGED
Install the frame lock pin. Engage the parking position. This will drain the moisture from parking
brake and stop the engine. brake (1).
3. Permit only one operator on the machine. Keep all 5. Stop the engine and allow the air to escape from
other personnel away from the machine. Also, all the system. Replace the inner plug and outer plug
personnel should be visible to the operator. (2).
i02793379 i01827882
g00812585
Illustration 163
Note: Caterpillar recommends the use of 5% Inspect the ripper tips. Replace the ripper tips if the
molybdenum grease for lubricating the ripper cylinder tips are damaged or the tips are worn excessively.
bearings. Refer to Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” for 1. Block up the ripper to a height that is adequate for
more information on molybdenum grease. the removal of the tips.
g00110460
Illustration 165
Fitting (2) is mounted on the left side rod end of 4. Install the new ripper tip over the retainer.
the ripper cylinder. Apply the appropriate lubricant
through the fitting in order to lubricate the rod end of 5. Drive the retainer pin through the retainer, through
the ripper cylinder. the adapter, and through the ripper tip from the
opposite side of the retainer.
i01563909
6. Repeat Step 2 through Step 5 in order to replace
Ripper Tip - Inspect/Replace additional ripper tips.
SMCS Code: 6808-040; 6808-510 7. Raise the ripper. Remove the block. Lower the
ripper to the ground.
i01831248 i01863262
NOTICE Wipe all the fittings before you apply lubricant to the
Do not attempt to straighten the ROPS structure. Do fittings.
not repair the ROPS by welding reinforcement plates
to the structure.
g00949846
Illustration 167
1. There are two retaining pins for the ROPS. One i01863797
retaining pin is located on each side of the cab.
Remove the access covers (1) from the retaining Scarifier Teeth -
pin locations. Inspect/Replace
2. Inspect the retaining pins. Inspect the keeper bolt. SMCS Code: 6807-040; 6807-510
Replace any damaged keeper bolts or any missing
keeper bolts with only original equipment parts.
5. When you operate the machine on a rough To avoid injury to your eyes, wear protective
surface, the ROPS may rattle or the ROPS may glasses when removing/installing scarifier teeth.
make a noise. If the ROPS rattles or if the ROPS
makes a noise, replace the ROPS mounting If the scarifier teeth are damaged or worn excessively,
supports . then change the scarifier teeth.
134 SEBU8250-01
Maintenance Section
Seat Belt - Inspect
g01152685
Illustration 170
(1) Date of installation (retractor)
(2) Date of installation (buckle)
(3) Date of manufacture (tag) (fully extended web)
(4) Date of manufacture (underside) (buckle)
g01393785
Illustration 171
The tandem breathers are located on the top of each tandem.
9. Clean the oil check plug and install the oil check
plug.
12. Check the oil level. Maintain the oil level to the
bottom of the opening for the oil check plug. Add
oil, if necessary.
g01395434
13. Install the oil check plug. Illustration 174
14. Repeat Step 1 through Step 13 for the other side The oil sample for the tandem drive should be taken
of the machine. from the housing by removing one of the plates that
are located on the top of the tandem housing.
i02794271
Refer to Special Publication, SEBU6250, “Caterpillar
Tandem Drive Oil Level - Check Machine Fluids Recommendations”, “S·O·S Oil
Analysis” for information that pertains to obtaining
SMCS Code: 4071-535 a sample of the tandem drive oil. Refer to Special
Publication, PEHP6001, “How To Take A Good Oil
Clean the surface area around the oil check plug Sample” for more information about obtaining a
before you check the oil level. sample of the tandem drive oil.
i00149440
g01395433
Illustration 173
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g01504633 g01707177
Illustration 179 Illustration 181
Illustration 180
g01504634 NOTICE
Do not drop or rap magnets on hard objects, or dam-
1. Remove drain plug (3) on transmission oil filter age can result. Replace damaged magnets.
housing (2). Allow the oil to drain into a suitable
container. 14. Clean the magnet with a cloth or clean the magnet
with a firm brush. Allow the magnet to dry.
2. Loosen oil sampling valve (1) in order to vent the
transmission oil filter housing. 15. Install the magnet and the tube assembly into the
screen.
3. Remove the transmission oil filter housing.
16. Install the screen.
4. Remove the used element and discard the used
element. 17. Inspect the cover seals. If the cover seals are
damaged, replace the cover seals.
5. Clean the transmission oil filter housing with a
clean, nonflammable solvent. 18. Install the covers and tighten the bolts.
6. Clean the base of the transmission oil filter 19. Start the engine.
housing.
20. With the parking brake engaged, run the engine
7. Insert a new filter element into the transmission oil at low idle in order to circulate the transmission oil.
filter housing.
21. Inspect all of the transmission components for
8. Replace the filter housing base seal. leaks.
9. Install the transmission oil filter housing.
g01951114
Illustration 183
SEBU8250-01 141
Maintenance Section
Wheel Bearing Oil (Front) - Change
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, SEBU6250, “S·O·S 2. Use a 1U-7683 Suction Gun in order to remove
Services Oil Analysis” for information that pertains to the oil from the housing for the wheel bearing.
obtaining a sample of the transmission and differential
oil. Refer to Special Publication, PEHP6001, “How 3. Add oil to the housing for the wheel bearing until
To Take A Good Oil Sample” for more information the oil level is at the bottom of the opening for
about obtaining a sample of the transmission and check/fill plug (1).
differential oil.
4. Install check/fill plug (1).
i01829992 5. Repeat Step 1 through Step 4 for the other wheel
Wheel Bearing Oil (Front) - bearing.
Change i01830000
g00934106
Illustration 185
2. Maintain the oil level to the bottom of the opening Refer to Special Publication, SEBU6250, “S·O·S
for the check/fill plug. If necessary, add oil. Services Oil Analysis” for information that pertains
to obtaining a sample of the oil. Refer to Special
3. Install plug (1). Publication, PEHP6001, “How To Take A Good Oil
Sample” for more information about obtaining a
4. Repeat Step 1 through Step 3 for the other wheel sample of the hydraulic oil.
bearing.
i02793110
i02793125
Illustration 187
g01271804 Note: Caterpillar recommends the use of 5%
molybdenum grease for lubricating the wheel lean
The wheel has been removed for ease of viewing.
bearings. Refer to Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” for
The wheel bearing sample plug (1) is located on the more information on molybdenum grease.
inner side of each front wheel of the machine.
Wipe the fittings before you apply lubricant through
the fittings.
SEBU8250-01 143
Maintenance Section
Wheel Lean Cylinder Bearings - Lubricate
i01834467
NOTICE
Use Caterpillar nonfreezing window washer solvent
or a commercially available windshield washer fluid
in order to prevent freezing of the windshield washer
system.
i02793132
g01394696
Illustration 190
The wheel has been removed for ease of viewing.
i03326131
Window Wiper -
Inspect/Replace
SMCS Code: 7305-040; 7305-510
g01703833
Illustration 192
i03326104
Windows - Clean
SMCS Code: 7310-070; 7340-070
g01703793
Illustration 193