Professional Documents
Culture Documents
2010 Caterpillar
All Rights Reserved
SEBU8249-01
November 2008
Operation and
Maintenance
Manual
12K, 140K and 160K Motor Graders
JJA1-Up (Machine)
JPA1-Up (Machine)
SZL1-Up (Machine)
SZM1-Up (Machine)
JBP1-Up (Machine)
SZP1-Up (Machine)
SAFETY.CAT.COM
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81
Maintenance Section
Maintenance Interval Schedule
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When Required
Battery - Recycle .................................................. 84
Belt - Replace ....................................................... 86
Blade Lift Cylinder Socket - Check/Adjust/
Replace ............................................................... 86
Centershift Cylinder Socket - Check/Adjust/
Replace ............................................................... 89
Circle Clearances - Check/Adjust ......................... 90
Circle Drive Oil Level - Check ............................... 94
Circuit Breakers - Reset ........................................ 95
Cutting Edges and End Bits - Inspect/Replace ... 102
Drawbar Ball and Socket End Play Check/Adjust ..................................................... 103
Engine Air Filter Primary Element - Clean/
Replace ............................................................. 104
Engine Air Filter Secondary Element - Replace .. 107
Engine Air Filter Service Indicator Inspect/Replace ................................................ 107
Engine Air Filter Service Indicator Screen Check/Replace .................................................. 108
Engine Air Precleaner - Clean ............................ 109
Engine Crankcase Breather - Replace ............... 109
Engine Overheating ............................................. 112
Engine Power Loss .............................................. 113
Ether Starting Aid Cylinder - Replace .................. 114
Evaporator Coil and Heater Coil - Clean ............. 114
Fuel System - Fill ................................................. 116
Fuses - Replace .................................................. 120
Moldboard Wear Strip - Inspect/Adjust/Replace .. 127
Radiator - Clean .................................................. 128
Radiator Core - Clean ......................................... 128
Ripper Tip - Inspect/Replace .............................. 129
131
141
141
141
82
Maintenance Section
Maintenance Interval Schedule
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Maintenance Section
Air Dryer Desiccant - Replace
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Illustration 79
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Illustration 78
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Illustration 80
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84
Maintenance Section
Axle Oscillation Bearings - Lubricate
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Battery - Recycle
SMCS Code: 1401-561
Always recycle a battery. Never discard a battery.
Always return used batteries to one of the following
locations:
A battery supplier
An authorized battery collection facility
Recycling facility
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Illustration 81
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Maintenance Section
Belt - Inspect
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Belt - Inspect
SMCS Code: 1357-040; 1397-040
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excessive cracking
excessive wear
excessive damage
Illustration 82
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Illustration 83
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Illustration 85
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86
Maintenance Section
Belt - Replace
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excessive cracking
excessive wear
excessive damage
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Belt - Replace
SMCS Code: 1357-510; 1397-510
Illustration 87
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Illustration 86
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Illustration 88
87
Maintenance Section
Blade Lift Cylinder Socket - Lubricate
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Illustration 89
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Illustration 90
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88
Maintenance Section
Braking System - Test
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Maintenance Section
Cab Air Filter - Clean/Replace
Illustration 91
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Illustration 92
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90
Maintenance Section
Centershift Cylinder Socket - Lubricate
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Maintenance Section
Circle Clearances - Check/Adjust
Illustration 95
Illustration 96
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Illustration 97
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Illustration 98
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92
Maintenance Section
Circle Clearances - Check/Adjust
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Illustration 100
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Illustration 101
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Maintenance Section
Circle Drive Oil - Change
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94
Maintenance Section
Circle Drive Oil Level - Check
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Illustration 105
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Avoid contact with a moving attachment when lubricating or maintaining the attachment.
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Maintenance Section
Circle Top - Lubricate
Illustration 106
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Illustration 108
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Illustration 107
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96
Maintenance Section
Condenser (Refrigerant) - Clean
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NOTICE
If excessively dirty, clean condenser with a brush. To
prevent damage or bending of the fins, do not use a
stiff brush.
Repair the fins if found defective.
Refer to the Operation and Maintenance Manual,
Access Doors and Covers for the location of the
service points.
Illustration 109
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NOTICE
Do not change the coolant until you read and understand the material in the Cooling System Specifications section.
NOTICE
Mixing ELC with other products reduces the effectiveness of the coolant and shortens coolant life. Use only
Caterpillar products or commercial products that have
passed the Caterpillar EC-1 specifications for premixed or concentrate coolants. Use only Caterpillar
Extender with Caterpillar ELC. Failure to follow these
recommendations could result in the damage to cooling systems components.
If ELC cooling system contamination occurs see the
topic Extended Life Coolant (ELC) in the Special Publication, SEBU6250, Caterpillar Machine Fluids Recommendations.
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Maintenance Section
Cooling System Coolant (ELC) - Change
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
If the coolant in the machine is changed to Extended
Life Coolant from another type of coolant, see Special
Publication, SEBU6250, Caterpillar Machine Fluids
Recommendations, Extended Life Coolant (ELC)
Cooling System Maintenance.
If the coolant is dirty or if you observe any foaming
in the cooling system, change the coolant before the
recommended interval.
Illustration 110
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Illustration 111
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98
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
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Maintenance Section
Cooling System Coolant Level - Check
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Illustration 114
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Illustration 113
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100
Maintenance Section
Cooling System Pressure Cap - Clean/Replace
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NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
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 incorrect interpretation that could lead to concerns by both
dealers and customers.
Note: Level 1 results may indicate a need for
Level 2 Analysis.
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Maintenance Section
Cooling System Water Temperature Regulator - Replace
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102
Maintenance Section
Crankshaft Vibration Damper - Inspect
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103
Maintenance Section
Drawbar Ball and Socket - Lubricate
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Illustration 119
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Check
Rotate the blade so that the blade is placed at an
angle of 90 degrees to the frame. Lower the blade to
the ground. While you maintain a light load between
the ball and the socket, inch the machine slowly to
the rear. Stop the machine and shut off the engine.
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Adjust
1. Support the drawbar and support the circle.
104
Maintenance Section
Electronic Unit Injector - Inspect/Adjust
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Illustration 121
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Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
Illustration 122
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Pressurized air
Vacuum cleaning
106
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
Pressurized Air
Pressurized air can be used to clean primary air filter
elements that have not been cleaned more than two
times. Pressurized air will not remove deposits of
carbon and oil. Use filtered, dry air with a maximum
pressure of 207 kPa (30 psi).
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Illustration 123
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Vacuum Cleaning
Vacuum cleaning is another method for cleaning
primary air filter elements which require daily cleaning
because of a dry, dusty environment. Cleaning with
pressurized air is recommended prior to vacuum
cleaning. Vacuum cleaning will not remove deposits
of carbon and oil.
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Illustration 125
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Maintenance Section
Engine Air Filter Secondary Element - Replace
Date of cleaning
Number of cleanings
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NOTICE
Always replace the secondary element. Do not attempt to reuse it by cleaning. Engine damage could
result.
Refer to the Operation and Maintenance Manual,
Access Doors and Covers for the location of the
service points.
Inspect
1. Start the engine.
2. Run the engine at high idle.
3. Open the access door.
Illustration 127
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108
Maintenance Section
Engine Air Filter Service Indicator Screen - Check/Replace
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Replace
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Illustration 128
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Illustration 129
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Typical Example
Check
1. Set an 8N-2694 Air Filter Service Indicator to
indicate a restricted indicator screen.
2. Screw the indicator onto a 1/8 inch NPT pipe
nipple.
3. Screw the other end of the nipple into the threaded
hole in the elbow. Normally, filter screen (1) is
located in the elbow.
4. Depress the reset button on the 8N-2694 Air
Filter Service Indicator.
5. If the indicator resets, filter screen (1) is not
plugged. If the indicator does not reset, filter
screen (1) is plugged. Filter screen (1) should
then be replaced.
Replace
1. Remove the air cleaner from the air cleaner
housing. Removing the air cleaner from the air
cleaner housing will provide access to the hole
inside the elbow. Filter screen (1) is installed
inside the elbow.
2. A 2 inch piece of 1/8 inch drill rod is needed in
order to push filter screen (1) from the inside of
the elbow to the outside.
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Maintenance Section
Engine Air Precleaner - Clean
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Illustration 130
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Illustration 131
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110
Maintenance Section
Engine Oil Sample - Obtain
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Illustration 132
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Multigrade
Oil Type
Fuel
Sulfur
from
0.3%
to
0.5%(4)
Altitude
above
1830 m
(6000 ft)
Normal(2)
High
Load
Factor(3)
Cat DEO
Preferred
500 hr
500 hr
500 hr
250 hr(6)
Cat ECF-1
11.0
minimum
TBN(4)
Preferred
500 hr
500 hr
500 hr
250 hr(6)
Cat ECF-1
TBN(4)
below 11.0
500 hr
500 hr
250
hr(5)
250 hr(6)
API CG-4
500 hr
250 hr(5)
250
hr(5)
250 hr(6)
(1)
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Maintenance Section
Engine Oil and Filter - Change
Program A
Verification for an Oil Change Interval of 500
Hours
This program consists of three oil change intervals of
500 hours. Oil sampling and analysis is done at 250
hours and 500 hours for each of the three intervals
for a total of six oil samples. The analysis includes
oil viscosity and infrared (IR) analysis of the oil. If
all of the results are satisfactory, the 500 hour oil
change interval is acceptable for the machine in that
application. Repeat Program A if you change the
application of the machine.
If a sample does not pass the oil analysis, take one
of these actions:
References
Reference: Form, PEDP7035, Optimizing Oil
Change Intervals
Reference: Form, PEDP7036, SOS Fluid Analysis
Reference: Special Publication, PEHP7076,
Understanding the SOS Services Tests
Illustration 133
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112
Maintenance Section
Engine Overheating
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Illustration 135
Illustration 134
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10. Clean the area around oil filler cap (3) before you
remove the oil filler cap. Clean the area around oil
level gauge (4) before you remove the oil level
gauge. Remove the oil filler cap. Fill the crankcase
with new oil. Refer to the following topics:
11. Clean the filler cap and install the filler cap.
12. Start the engine and allow the oil to warm. Check
the engine for leaks.
13. Check the oil level. If necessary, add oil. Refer to
Operation and Maintenance Manual, Engine Oil
Level - Check for more information.
14. Stop the engine. Close all access doors.
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Engine Overheating
SMCS Code: 1000; 1350; 1353
If your machine experiences an engine overheating
problem, do the following maintenance procedures
in the order that is listed:
1. Operation and Maintenance Manual, Cooling
System Coolant Level Check
2. Operation and Maintenance Manual, Radiator Clean
3. Operation and Maintenance Manual, Belt Inspect
4. Operation and Maintenance Manual, Cooling
System Pressure Cap - Clean/Replace
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Maintenance Section
Engine Power Loss
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114
Maintenance Section
Engine Valve Rotators - Inspect
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Illustration 137
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Maintenance Section
Final Drive Preload - Check
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Required Tools
Part Number
Description
Wrench for 140K
6V-4074
9U-5015
Quantity
1
1
Illustration 139
Table 13
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Final Torque
102 Nm (75 lb ft)
Illustration 140
Illustration 138
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116
Maintenance Section
Fuel System - Fill
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Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over disconnected fuel system component.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting, and repair of the machine. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any component containing fluids.
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire.
Illustration 141
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Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
NOTICE
Do not fill the fuel filters with fuel before installing the
fuel filters. The fuel will not be filtered and could be
contaminated. Contaminated fuel will cause accelerated wear to fuel system parts.
Refer to Operation and Maintenance Manual,
Access Doors and Covers for the location of the
service points.
Illustration 143
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Illustration 142
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118
Maintenance Section
Fuel System Secondary Filter - Replace
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Illustration 144
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Maintenance Section
Fuel System Water Separator - Drain
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NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
Illustration 147
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Typical example
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Maintenance Section
Fuel Tank Water and Sediment - Drain
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Illustration 149
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Illustration 148
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Fuses - Replace
SMCS Code: 1417-510
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Maintenance Section
Fuses - Replace
Illustration 152
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Blank (11)
122
Maintenance Section
Fuses - Replace
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Blank (29)
Blank (31)
Blank (32)
Blank (33)
Blank (44)
Blank (45)
Blank (35)
Blank (46)
Blank (47)
Blank (48)
Blank (49)
Illustration 153
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Blank (50)
Blank (51)
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Maintenance Section
Hydraulic System Oil - Change
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NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
Note: The normal hydraulic oil change interval
is at every 2000 Service Hours or 1 Year. By
performing SOS oil analysis, the hydraulic
oil change interval may be extended to 4000
Service Hours or 2 Years. SOS oil analysis
must be performed at every 500 Service Hours
or 3 Months in order to extend the hydraulic oil
change interval. The results from the SOS oil
analysis will determine if the hydraulic oil change
interval may be extended. If SOS oil analysis is
not available, the hydraulic oil change interval
must remain at every 2000 Service Hours or 1
Year . Refer to the Operation and Maintenance
Manual, SOS Information.
Note: Cat HYDO Advanced 10 has a 50% increase
in the standard oil drain interval for machine
hydraulic systems (3000 hours versus 2000
hours) over second and third choice oils - when
following the maintenance interval schedule for
oil filter changes and for oil sampling that is
stated in the Operation and Maintenance Manual
for your particular machine. 6000 hour oil drain
intervals are possible when using SOS Services
oil analysis. Contact your Cat dealer for details.
Operate the machine until the oil is warm.
Illustration 154
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Maintenance Section
Hydraulic System Oil Filter - Replace
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NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
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Maintenance Section
Hydraulic System Oil Level - Check
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Illustration 155
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Maintenance Section
Hydraulic System Oil Sample - Obtain
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Illustration 157
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Illustration 158
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Maintenance Section
Moldboard Wear Strip - Inspect/Adjust/Replace
Illustration 159
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NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
1. Move the machine to a smooth horizontal location.
Move away from operating machines and move
away from personnel. Lower all implements to the
ground.
2. Install the wheel lean locking bolt in the front axle.
Install the frame lock pin. Engage the parking
brake and stop the engine.
3. Permit only one operator on the machine. Keep all
other personnel away from the machine. Also, all
personnel should be visible to the operator.
4. Place chocks in front of the wheels and behind
the wheels.
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Maintenance Section
Radiator - Clean
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Radiator - Clean
SMCS Code: 1353-070; 1805-070; 1810-070
Illustration 160
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Illustration 162
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Maintenance Section
Refrigerant Dryer - Replace
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Illustration 164
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Illustration 163
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Maintenance Section
Rollover Protective Structure (ROPS) - Inspect
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Illustration 165
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Illustration 166
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Maintenance Section
Scarifier Lift Link Socket - Lubricate
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Illustration 168
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Illustration 169
Typical example
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Maintenance Section
Seat Belt - Replace
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Illustration 170
(1) Date
(2) Date
(3) Date
(4) Date
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of installation (retractor)
of installation (buckle)
of manufacture (tag) (fully extended web)
of manufacture (underside) (buckle)
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Maintenance Section
Tandem Drive Oil Level - Check
(Refill)
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Illustration 173
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Maintenance Section
Tandem Drive Oil Sample - Obtain
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Illustration 175
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Maintenance Section
Transmission and Differential Oil - Change
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Illustration 177
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Bottom View
Illustration 178
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136
Maintenance Section
Transmission and Differential Oil Filter and Screens - Replace/Clean
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Illustration 180
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Maintenance Section
Transmission and Differential Oil Level - Check
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Illustration 182
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22. Clean the area around oil level gauge/fill cap (6).
23. With the engine at low idle, maintain the oil level
between the marks on the oil level gauge. If
necessary, add oil through oil level gauge/fill cap
(6).
24. Stop the engine.
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Illustration 183
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Maintenance Section
Transmission and Differential Oil Sample - Obtain
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Illustration 185
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Maintenance Section
Wheel Bearing Oil Level (Front) - Check
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
1. Remove check/fill plug (1).
2. Use a 1U-7683 Suction Gun in order to remove
the oil from the housing for the wheel bearing.
3. Add oil to the housing for the wheel bearing until
the oil level is at the bottom of the opening for
check/fill plug (1).
4. Install check/fill plug (1).
5. Repeat Step 1 through Step 4 for the other wheel
bearing.
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Illustration 187
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Illustration 186
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Maintenance Section
Wheel Lean Bar Bearings - Lubricate
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Illustration 190
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Maintenance Section
Window Washer Reservoir - Fill
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NOTICE
Use Caterpillar nonfreezing window washer solvent
or a commercially available windshield washer fluid
in order to prevent freezing of the windshield washer
system.
The windshield washer reservoir is positioned in the
seat support to the left of the operator's seat.
1. Remove the access cover for the windshield
washer reservoir.
Illustration 192
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Illustration 191
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Windows - Clean
SMCS Code: 7310-070; 7340-070
Illustration 193
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