Professional Documents
Culture Documents
2010 Caterpillar
All Rights Reserved
Operation and
Maintenance
Manual
120K Motor Grader
SZN1-Up (Machine)
JAP1-Up (Machine)
SAFETY.CAT.COM
Use mileage, fuel consumption, service hours, or Initial 100 Service Hours
calendar time, WHICH EVER OCCURS FIRST,
in order to determine the maintenance intervals. Transmission and Differential Oil Filter and Screens -
Products that operate in severe operating conditions Replace/Clean .................................................. 141
may require more frequent maintenance.
Every 100 Service Hours or 2 Weeks
Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be Articulation Bearings - Lubricate ........................... 88
performed. Axle Oscillation Bearings - Lubricate .................... 89
Belt - Inspect ......................................................... 90
When Required Blade Lift Cylinder Socket - Lubricate ................... 92
Cab Air Filter - Clean/Replace .............................. 94
Battery - Recycle .................................................. 89 Centershift Cylinder Socket - Lubricate ................ 95
Belt - Replace ....................................................... 91 Centershift Lock Bar - Clean/Lubricate ................. 95
Blade Lift Cylinder Socket - Check/Adjust/ Drawbar Ball and Socket - Lubricate .................. 107
Replace ............................................................... 91 Hydraulic System Oil Level - Check ................... 131
Centershift Cylinder Socket - Check/Adjust/ Kingpin Bearings - Lubricate ............................... 132
Replace ............................................................... 94 Ripper Cylinder Bearings - Lubricate .................. 135
Circle Clearances - Check/Adjust ......................... 95 Scarifier Lift Link Socket - Lubricate ................... 136
Circle Drive Oil Level - Check ............................... 99 Tandem Drive Oil Level - Check ......................... 139
Circuit Breakers - Reset ...................................... 100 Tire Inflation - Check ........................................... 139
Cutting Edges and End Bits - Inspect/Replace ... 107 Wheel Lean Bar Bearings - Lubricate ................. 145
Drawbar Ball and Socket End Play - Wheel Lean Bearings - Lubricate ....................... 145
Check/Adjust ..................................................... 108 Wheel Lean Cylinder Bearings - Lubricate ......... 146
Engine Air Filter Primary Element - Clean/
Replace ............................................................. 109 Initial 500 Service Hours (or at first oil
Engine Air Filter Secondary Element - Replace .. 111 change)
Engine Air Filter Service Indicator Screen -
Check/Replace ................................................... 113 Battery or Battery Cable - Inspect/Replace .......... 89
Engine Air Precleaner - Clean ............................. 113 Electronic Unit Injector - Inspect/Adjust .............. 109
Engine Crankcase Breather - Replace ................ 114 Engine Valve Lash - Check .................................. 118
Engine Overheating ............................................. 117
Engine Power Loss .............................................. 118 Every 500 Service Hours or 3 Months
Ether Starting Aid Cylinder - Replace .................. 119
Evaporator Coil and Heater Coil - Clean ............. 119 Braking System - Test ........................................... 93
Film (Product Identification) - Clean ................... 120 Cooling System Coolant Sample (Level 1) -
Fuel System - Fill ................................................ 121 Obtain ............................................................... 101
Fuses - Replace .................................................. 125 Engine Air Filter Service Indicator -
Moldboard Wear Strip - Inspect/Adjust/Replace .. 132 Inspect/Replace ................................................. 112
Radiator - Clean .................................................. 134 Engine Oil Sample - Obtain ................................. 114
Radiator Core - Clean ......................................... 134 Engine Oil and Filter - Change ............................ 115
Ripper Tip - Inspect/Replace .............................. 135 Fuel System - Prime ........................................... 122
Scarifier Teeth - Inspect/Replace ........................ 136
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.
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.
g02220734 g02220793
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
i04031691
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.
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.
i04031736
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.
i04031832
Clean the dirt, the lubricant and the rust from the
holes in the centershift lock bar.
i04031943
Circle Clearances -
Check/Adjust
SMCS Code: 6152-025; 6152-535; 6153-025;
Illustration 93
g02220874 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
g02223593
Illustration 95
g02223695 g02223593
Illustration 96 Illustration 97
g02223717
Illustration 99
4. Shoe mounting fastener (4), shoe mounting 1. Rotate the blade. Place the blade at an angle
fastener (5), and shoe mounting fastener (6) must of 90 degrees to the frame. Lower the blade to
be tight. Make sure that the shoe wear strips (7) the ground. As you slowly inch the machine in a
are seated in the circle shoes. forward direction, apply the service brake. This
will hold a light load between the wear strips for
the front circle shoes and the circle. Engage the
parking brake. Stop the engine.
g02223714
Illustration 100
Circle Pinion and Circle 4. Loosen the shoe mounting fasteners and the
locknuts for the rear circle shoes.
Note: The engagement of the circle pinion and the
circle teeth is determined by the adjustment of the 5. Loosen the shoe mounting fasteners and the
circle shoes. Clean the circle and the pinion. Remove locknuts for the side circle shoes, if equipped.
any dirt and any abrasive material. Cleaning will
reduce wear to the circle pinion and to the circle 6. Adjust the front circle shoes one at a time.
teeth. Also, cleaning will improve the accuracy of the Turn the adjusting bolts (12) inward or turn the
adjustment of the circle shoes. After the adjustment, adjusting bolts (12) outward in order to attain
apply clean lubricant to the circle pinion and to the 49.5 to 52.5 mm (1.95 to 2.07 inch). Adjust the
circle teeth. other front circle shoe.
11. Tighten all shoe mounting fasteners (4), shoe Illustration 103
g02220897
mounting fasteners (5), and all shoe mounting
Bottom view of the blade circle
fasteners (6) to a torque of 475 60 Nm
(350 44 lb ft).
i04031913
SMCS Code: 5207-535-OC The circle drive pinion teeth are located under the
circle drive housing.
If a leak develops or you suspect a leak, check the
oil level.
g02220934
Illustration 106
g02220915 i03637740
Illustration 105
Circle Top - Lubricate
1. Remove check/fill plug (1).
SMCS Code: 6154-086-TP
2. Maintain the oil level to the bottom of the opening
for the check/fill plug. 1. Park the machine on a level surface and engage
the parking brake.
3. Install check/fill plug (1).
2. Stop the engine. Lower the blade and any
attachments to the ground.
g01952213
Illustration 107
i02793761
3. Apply the dry film lubricant around the entire circle.
See Special Publication, SEBU6250, Caterpillar Condenser (Refrigerant) -
Machine Fluids Recommendations, Dry Film
Lubricant for further information.
Clean
SMCS Code: 1805-070
i02795072
NOTICE
Circuit Breakers - Reset If excessively dirty, clean condenser with a brush. To
prevent damage or bending of the fins, do not use a
SMCS Code: 1417-529; 1420-529 stiff brush.
Refer to the Operation and Maintenance Manual, Repair the fins if found defective.
Access Doors and Covers for the location of the
service points.
Refer to the Operation and Maintenance Manual,
Circuit Breaker Resets Push the buttons inward Access Doors and Covers for the location of the
in order to reset the circuit breakers. If the system is service points.
working properly, the buttons will remain depressed.
If the buttons do not stay depressed, check the
appropriate electrical circuit.
g01394849
Illustration 109
The circuit breaker resets are located in the engine 1. Open the access door at the rear of the machine
compartment on the right side of the machine. on the left side of the machine.
i03637434
Note: Obtain a Coolant Sample (Level 1) if the Refer to Operation and Maintenance Manual,
cooling system is filled with any other coolant Access Doors and Covers for the location of the
instead of Cat ELC. This includes the following service points.
types of coolants:
Obtain the sample of the coolant as close as possible
Commercial long life coolants that meet the to the recommended sampling interval. In order
Caterpillar Engine Coolant Specification -1 to receive the full effect of SOS coolant analysis,
(Caterpillar EC-1) you must establish a consistent trend of data.
In order to establish a pertinent history of data,
Cat Diesel Engine Antifreeze/Coolant (DEAC) perform consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from
Commercial heavy-duty antifreeze/coolant your Caterpillar dealer.
i02976205
NOTICE
Cooling System Coolant (ELC) Care must be taken to ensure that fluids are contained
- Change during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
SMCS Code: 1350-044-NL; 1350-544-NL; collect the fluid with suitable containers before open-
1395-044-NL ing any compartment or disassembling any compo-
nent containing fluids.
Do not attempt to tighten hose connections when If the coolant is dirty or if you observe any foaming
the coolant is hot, the hose can come off causing in the cooling system, change the coolant before the
burns. recommended interval.
Cooling System Coolant Additive contains alkali. It is important to replace the thermostat in order
Avoid contact with skin and eyes. to avoid any unexpected failure of the thermostat.
This is a good preventive maintenance practice that
reduces the chances of unscheduled downtime.
NOTICE Failure to replace the thermostat on a regularly
Do not change the coolant until you read and under- scheduled basis could cause severe engine damage.
stand the material in the Cooling System Specifica-
tions section. Note: If you are only replacing the thermostat, drain
the coolant from the cooling system so that the level
of the coolant is below the thermostat housing.
NOTICE
Mixing ELC with other products reduces the effective-
Always operate Caterpillar engines with a thermostat
ness of the coolant and shortens coolant life. Use only
because these engines have a shunt design cooling
Caterpillar products or commercial products that have
system.
passed the Caterpillar EC-1 specifications for pre-
mixed or concentrate coolants. Use only Caterpillar
Note: Thermostats can be reused if the thermostats
Extender with Caterpillar ELC. Failure to follow these
meet certain test specifications. The tested
recommendations could result in the damage to cool-
thermostats must not be damaged and the tested
ing systems components.
thermostats must not have an excessive buildup of
deposits.
If ELC cooling system contamination occurs see the
topic Extended Life Coolant (ELC) in the Special Pub-
1. Stop the engine and allow the engine to cool.
lication, SEBU6250, Caterpillar Machine Fluids Rec-
ommendations.
i02949342
8. Add the Extended Life Coolant. Refer to Operation Refer to Special Publication, NENG2500, Caterpillar
and Maintenance Manual, Capacities (Refill). Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
Note: Make sure that the cooling system pressure products.
cap is removed for Steps 9 through 10.
Dispose of all fluids according to local regulations and
9. Start the engine and run the engine until the mandates.
thermostat opens and the coolant level stabilizes.
g01951284
Illustration 114
i02949519
5. Remove the cooling system pressure cap slowly Cooling System Conditioner contains alkali. Avoid
in order to relieve pressure. contact with skin and eyes.
g01463648
Illustration 116
4. Inspect the cooling system pressure cap and Note: If you are only replacing the water temperature
the cap seal for damage, deposits, and foreign regulator, drain the cooling system coolant to a level
material. Clean the cooling system pressure cap that is below the water temperature regulator housing
with a clean cloth. Replace the cooling system assembly.
pressure cap if the cap is damaged.
1. Loosen the hose clamp and remove the hose from
5. Install the cooling system pressure cap. the water temperature regulator housing.
6. Close the cover. 2. Remove the bolts from the water temperature
regulator housing and remove the water
temperature regulator housing.
i00350379
Cooling System Water 3. Remove the gasket and remove the water
temperature regulator from the water temperature
Temperature Regulator - regulator housing.
Replace
NOTICE
SMCS Code: 1355-070; 1355-510; 1393-010 Former water temperature regulators may be used, if
they meet test specifications and are not damaged or
have excessive buildup or deposits.
g01466327 g00811262
Illustration 117 Illustration 118
Caterpillar recommends replacing vibration damper End bits (1) and/or cutting edges (2) may be
(1) for any of the following reasons: damaged. End bits (1) and/or cutting edges (2) may
be worn excessively. Replace the end bits (1) and/or
The engine has had a failure because of a broken the cutting edges (2), as needed.
crankshaft.
1. Place blocks under the blade. Lower the blade
The SOS analysis detected a worn crankshaft onto the blocks. Do not block up the blade too
front bearing. high. Just use enough blocks so that end bits (1)
and cutting edges (2) can be removed.
The SOS analysis detected a large amount of
gear train wear that is not caused by a lack of oil. 2. Remove end bits (1) and/or cutting edges (2).
Fluid leakage is detected during inspection. 3. Install new end bits (1) and/or new cutting edges
(2).
The housing is damaged.
4. Raise the blade and remove the blocks.
Refer to Disassembly and Assembly, Damper &
Crankshaft Pulley for the procedure to remove the
i02528905
damper and the procedure to install the damper.
g00949567
Illustration 119
g01265355
Illustration 120
Adjust
1. Support the drawbar and support the circle.
The initial adjustment to the unit injector is 6. Install a clean primary air filter element. Install the
recommended at the initial 500 hour interval. The cover for the air filter housing.
unit injector adjustment should then be made at
every 2000 hour interval. The operation of Caterpillar Note: Refer to Cleaning Primary Air Filter Elements.
engines with improper adjustments of the electronic
unit injector can reduce engine efficiency. This 7. Reset the engine air filter service indicator.
reduced efficiency could result in excessive fuel
usage and/or shortened engine component life. 8. Close the access door.
NOTICE
Service the air cleaner only with the engine stopped.
Engine damage could result.
The primary air filter element can be used up to Aim the hose so that the air flows inside the element
six times if the element is properly cleaned and along the length of the filter in order to help prevent
inspected. When the primary air filter element is damage to the paper pleats. Do not aim the stream of
cleaned, check for rips or tears in the filter material. air directly at the primary air filter element. Dirt could
The primary air filter element should be replaced at be forced further into the pleats.
least one time per year. This replacement should be
performed regardless of the number of cleanings. Vacuum Cleaning
Vacuum cleaning is another method for cleaning
NOTICE
primary air filter elements which require daily cleaning
Do not clean the air filter elements by bumping or tap-
because of a dry, dusty environment. Cleaning with
ping. This could damage the seals. Do not use ele-
pressurized air is recommended prior to vacuum
ments with damaged pleats, gaskets, or seals. Dam-
cleaning. Vacuum cleaning will not remove deposits
aged elements will allow dirt to pass through. Engine
of carbon and oil.
damage could result.
Pressurized air
Vacuum cleaning
Inspecting the Primary Air Filter Do not use paint, a waterproof cover, or plastic as a
protective covering for storage. An airflow restriction
Elements may result. To protect against dirt and damage, wrap
the primary air filter elements in Volatile Corrosion
Inhibited (VCI) paper.
Date of cleaning
Number of cleanings
Store the box in a dry location.
g00281693
Illustration 124
i01562943
Inspect the clean, dry primary air filter element. Use Engine Air Filter Secondary
a 60 watt blue light in a dark room or in a similar
facility. Place the blue light in the primary air filter Element - Replace
element. Rotate the primary air filter element. Inspect
the primary air filter element for tears and/or holes. SMCS Code: 1051-510-SE; 1054-510-SE
Inspect the primary air filter element for light that may
show through the filter material. If it is necessary in NOTICE
order to confirm the result, compare the primary air Always replace the secondary element. Do not at-
filter element to a new primary air filter element that tempt to reuse it by cleaning. Engine damage could
has the same part number. result.
g00281694
Illustration 125
g00039214
Illustration 126
2. Remove the secondary element. Note: See the Operation and Maintenance Manual,
Engine Air Filter Primary Element - Clean/Replace.
3. Cover the air inlet opening. Clean the inside of See the Operation and Maintenance Manual, Engine
the air cleaner housing. Air Filter Secondary Element - Replace.
4. Uncover the air inlet opening. Install a new Note: Refer to Operation and Maintenance Manual,
secondary element. Engine Air Filter Service Indicator - Inspect/Replace
in order to check an engine air filter service indicator
5. Install the primary element and the air cleaner that is faulty.
cover.
i03636214
6. Close the left side engine compartment door.
g01951289
Illustration 128
4. If the yellow piston in the engine air filter service Note: The air filter indicator should be replaced
indicator enters the red zone, service the air during engine overhauls. The air filter indicator should
cleaner. also be replaced during replacement of any major
engine component . Replace the air filter indicator at
5. Stop the engine. least one time per year.
4. If the indicator will not reset easily, replace the 5. If the indicator resets, filter screen (1) is not
service indicator. If the yellow piston of the plugged. If the indicator does not reset, filter
indicator will not latch at the highest vacuum that is screen (1) is plugged. Filter screen (1) should
attained, replace the service indicator. Tighten the then be replaced.
indicator to a torque of 2 Nm (18 lb in). Excessive
tightening force may crack the top of the indicator.
For more information on the air filter indicator,
Replace
refer to Video Tape, PEVN1736, Caterpillar Air
1. Remove the air cleaner from the air cleaner
Filter Service Indicator.
housing. Removing the air cleaner from the air
cleaner housing will provide access to the hole
Note: If you still believe that the service indicator
inside the elbow. Filter screen (1) is installed
is working improperly, refer to Operation and
inside the elbow.
Maintenance Manual, Engine Air Filter Service
Indicator Screen - Check/Replace.
2. A 2 inch piece of 1/8 inch drill rod is needed in
order to push filter screen (1) from the inside of
5. Close the left side engine compartment door. the elbow to the outside.
NOTICE
Service the engine air precleaner only with the engine
stopped. Engine damage could result.
g00713605
Illustration 129
Typical Example
Check
1. Set an 8N-2694 Air Filter Service Indicator to
indicate a restricted indicator screen.
i01632265
Table 9
References
Reference: Form, PEDP7035, Optimizing Oil
Change Intervals
g01265545
Illustration 133
g01951448
Illustration 135
10. Clean the area around oil filler cap (3) before you
remove the oil filler cap. Clean the area around oil
Illustration 134
g01951336 level gauge (4) before you remove the oil level
gauge. Remove the oil filler cap. Fill the crankcase
3. Open the right side access door. with new oil. Refer to the following topics:
4. Clean the area around engine oil filter (2) before Operation and Maintenance Manual, Lubricant
you remove the engine oil filter. Remove the Viscosities
engine oil filter with a strap type wrench. Refer
to Operation and Maintenance Manual, Oil Filter Operation and Maintenance Manual, Capacities
- Inspect. (Refill)
5. Clean the base of the engine oil filter housing. 11. Clean the filler cap and install the filler cap.
Make sure that all of the old filter gasket is
removed. 12. Start the engine and allow the oil to warm. Check
the engine for leaks.
6. Apply a thin film of engine oil to the gasket of the
new filter. 13. Check the oil level. If necessary, add oil. Refer to
Operation and Maintenance Manual, Engine Oil
7. Install the new filter by hand until the seal of the Level - Check for more information.
filter contacts the base. Note the position of the
index marks on the filter in relation to a fixed point 14. Stop the engine. Close all access doors.
on the filter base.
i01900293
Note: There are rotation index marks on the filter
that are spaced 90 degrees or 1/4 of a turn away Engine Overheating
from each other. When you tighten the filter, use the
rotation index marks as a guide. SMCS Code: 1000; 1350; 1353
8. Tighten the filter according to the instructions If your machine experiences an engine overheating
that are printed on the filter. Use the index marks problem, do the following maintenance procedures
as a guide. For non-Caterpillar filters, use the in the order that is listed:
instructions that are provided with the filter.
1. Operation and Maintenance Manual, Cooling
Note: You may need to use a Caterpillar strap System Coolant Level Check
wrench, or another suitable tool, in order to turn
the filter to the amount that is required for final 2. Operation and Maintenance Manual, Radiator -
installation. Make sure that the installation tool does Clean
not damage the filter.
3. Operation and Maintenance Manual, Belt -
9. Open the left side access door. Inspect
SMCS Code: 1000; 1051; 1250 Hot engine components can cause burns. Allow
additional time for the engine to cool before mea-
If your machine experiences an engine power loss, suring/adjusting valve lash clearance.
perform the following maintenance procedures in the
order that is listed:
NOTICE
Only qualified service personnel should perform this
1. Operation and Maintenance Manual, Engine Air
maintenance. Refer to the Service Manual or your
Filter Service Indicator - Inspect
Caterpillar dealer for the complete valve lash adjust-
ment procedure.
2. Operation and Maintenance Manual, Engine Air
Precleaner - Clean
Operation of Caterpillar engines with improper valve
adjustments can reduce engine efficiency. This re-
3. Operation and Maintenance Manual, Engine Air
duced efficiency could result in excessive fuel usage
Filter Primary Element - Clean/Replace
and/or shortened engine component life.
4. Operation and Maintenance Manual, Engine Air
Filter Secondary Element - Replace NOTICE
Do not use the yoke that comes out of the front of the
5. Operation and Maintenance Manual, Fuel Tank engine in order to turn over the engine. Damage to the
Water and Sediment - Drain crankshaft vibration damper can occur.
6. Operation and Maintenance Manual, Fuel Tank
Cap and Strainer - Clean The adjustment is necessary due to the initial wear of
the valve train components and to the seating of the
7. Operation and Maintenance Manual, Fuel System valve train components.
Water Separator Element - Replace
This maintenance is recommended by Caterpillar
8. Operation and Maintenance Manual, Fuel System as part of a lubrication and preventive maintenance
Secondary Filter - Replace schedule in order to help provide maximum engine
life.
If the power loss is not corrected, consult your
Caterpillar dealer. Ensure that the engine is stopped before you
measure the valve lash. To obtain an accurate
measurement, allow the valves to cool before you
perform this maintenance.
Inspect the engine valve rotators after the valve Evaporator Coil and Heater
clearances have been set. Coil - Clean
1. Start the engine and run the engine at low idle. SMCS Code: 7309-070; 7343-070
2. Watch the top surface of each valve rotator. When The evaporator coil and the heater coil are located
the intake valve or the exhaust valve closes, the under the seat in the cab.
engine valve rotator should turn slightly.
1. Remove the seat.
If an intake valve or an exhaust valve fails to rotate,
consult your Caterpillar Dealer. 2. Remove both of the covers.
i02954154
g00931904
Illustration 137
Illustration 136
g01469857 4. Replace both of the covers and replace the seat.
1. Open the right side access door. Note: If you are operating the machine under harsh
conditions or with the cab door open, it may be
2. Loosen the retaining clamp on ether starting aid necessary to clean the coils more often.
cylinder (1). Remove the empty ether starting aid
cylinder. Properly discard the empty ether starting
aid cylinder.
i02796944
Make sure that all of the product identification Part Number Description Quantity
films are legible. Make sure that the recommended Wrench for 120K
procedures are used in order to clean the product 6V-4074 1
identification films. Ensure that all the product Wrench for 12K
identification films are not damaged or missing. Clean Torque Wrench Gp
9U-5015 1
the product identification films or replace the films. (3/4 Inch Drive)
g00985487
Illustration 142
i02794509
6. Remove outer cover (1).
Fuel System - Fill
SMCS Code: 1250-544
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.
Reference: Refer to Operation and Maintenance 4. When the water separator is full of fuel, attempt
Manual, Capacities (Refill) for the fuel tank capacity to start the engine. If the engine starts and the
of your machine. engine runs rough or the engine misfires, operate
at low idle until the engine is running smoothly.
If the engine cannot be started, or if the engine
continues to misfire or smoke, repeat Step 1.
i03636427
g01395489
Illustration 143
Fuel leaked or spilled onto hot surfaces or electri-
1. Clean filler cap (1) and the surrounding area. cal components can cause a fire.
2. Remove the filler cap. Turn the disconnect switch OFF when draining
and/or removing any fuel system components.
3. Fill fuel tank (2) with fuel.
2. Verify that the water separator is full of fuel. Refer to Operation and Maintenance Manual,
Access Doors and Covers for the location of the
3. If the water separator is not full of fuel, turn the service points.
engine start switch OFF and then turn the engine
start switch ON. This will cycle the fuel priming
pump again.
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.
g01951468
Note: There are rotation index marks on the filter
Illustration 144 that are spaced 90 degrees or 1/4 of a turn away
from each other. When you tighten the filter, use the
The primary fuel filter is located inside the engine rotation index marks as a guide.
compartment on the left side of the machine.
10. Tighten the filter according to the instructions that
are printed on the filter. Use the index marks as a
guide for tightening the filter. For non-Caterpillar
filters, use the instructions that are provided with
the filter.
1. Open the engine compartment access door on the Use the rotation index marks on the new
left side of the machine. secondary fuel filter as a guide for tightening the
filter. These rotation index marks are spaced at
intervals of 1/4 turn.
i03339624
Illustration 146
g01951470 Fuel System Water Separator
- Drain
2. Close the fuel supply valve. The fuel supply valve
is positioned in the engine compartment on the SMCS Code: 1263-543
left side of the machine.
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.
3. Drain the water from the water separator bowl. Fuel Tank Water and Sediment
4. Close the drain.
- Drain
SMCS Code: 1273-543-M&S
5. Close the access door.
i02794517
g01707876
Illustration 150
Blank (11)
g00935093
Illustration 152
(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 153
Fuse panel on the steering console (unswitched power) (1)
AccuGrade(18) (If Equipped) 20 amp
Blank (31)
Blank (32)
Blank (33)
g01713781
Illustration 154
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 156
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 157
i03326582
g00932336
Illustration 158
g01707235
Illustration 159
i01863714
g00950101
Illustration 162
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 165
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 167
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 169
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.
g01152685
Illustration 172
(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 173
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 176
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, SOS 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 175
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 181 Illustration 183
Illustration 182
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 185
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, SOS 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 187
2. Maintain the oil level to the bottom of the opening Refer to Special Publication, SEBU6250, SOS
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 189
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.
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 192
The wheel has been removed for ease of viewing.
i03326131
Window Wiper -
Inspect/Replace
SMCS Code: 7305-040; 7305-510
g01703833
Illustration 194
i03326104
Windows - Clean
SMCS Code: 7310-070; 7340-070
g01703793
Illustration 195