Mom Mantenimiento 140h

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2010 CaterpillarAll Rights Reserved

MAINTENANCE INTERVALSOperation and MaintenanceManual Excerpt


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SEBU7056-07

October 2007

Operation andMaintenance

Manual140H and 160H Motor Graders

XZH1-Up(Machine)XZK1-Up (Machine)2FM400-Up (Machine)5HM1150-Up (Machine)

8JM280-Up (Machine)9JM350-Up (Machine)


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98 SEBU7056-07Maintenance SectionMaintenance Interval Schedule

i02826134

Maintenance Interval Schedule

SMCS Code: 1000; 7000

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

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

Use mileage, fuel consumption, service hours, or

calendar time, WHICH EVER OCCURS FIRST,in order to determine the maintenance intervals.Products that operate in severe operating conditionsmay require more frequent maintenance.

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

When Required

Battery - Recycle ................................................ 102Blade Lift Cylinder Socket - Check/Adjust/

Replace ............................................................. 103

Centershift Cylinder Socket - Check/Adjust/Replace ............................................................. 107Circle Clearances - Check/Adjust . ...................... 108Circle Drive Oil Level - Check .............................. 112Circuit Breakers - Reset ....................................... 113Cutting Edges and End Bits - Inspect/Replace ... 120Drawbar Ball and Socket End Play -

Check/Adjust ..................................................... 121Engine Air Filter Primary Element - Clean/

Replace ............................................................. 122Engine Air Filter Secondary Element - Replace .. 123Engine Air Filter Service Indicator Screen -

Check/Replace .................................................. 125Engine Air Precleaner - Clean ............................ 125

Engine Overheating ............................................ 128Engine Power Loss ............................................. 128Ether Starting Aid Cylinder - Replace ................. 129Evaporator Coil and Heater Coil - Clean ............ 130Fuses - Replace .................................................. 134Moldboard Wear Strip - Inspect/Adjust/Replace .. 140Oil Filter - Inspect ................................................ 141Radiator Core - Clean ......................................... 143Ripper Tip - Inspect/Replace .............................. 143Scarifier Teeth - Inspect/Replace ........................ 145Seat - Inspect...................................................... 146Seat Belt - Inspect .............................................. 146Window Washer Reservoir - Fill .......................... 159Window Wiper -Inspect/Replace ........................ 160

Every 10 Service Hours or Daily

Air Tank Moisture and Sediment - Drain ............. 101Backup Alarm - Test ............................................ 102Brakes, Indicators and Gauges - Test ................. 104Circle Drive Pinion Teeth - Lubricate ................... 113

Circle Top - Lubricate ........................................... 113Cooling System Level - Check ............................. 118Engine Air Filter Service Indicator - Inspect ........ 124Engine Oil Level- Check .................................... 126Fuel Tank Water and Sediment - Drain ............... 134Walk-Around Inspection ...................................... 154Windows - Clean ................................................. 160

Every 50 Service Hours or Weekly

Articulation Bearings - Lubricate ......................... 101Axle Oscillation Bearings - Lubricate .................. 101Cab Air Filter - Clean/Replace ............................ 105Centershift LockBar - Clean/Lubricate ............... 108

Drawbar Ball and Socket - Lubricate .................. 120Hydraulic System Oil Level - Check ................... 138Kingpin Bearings- Lubricate ............................... 140Ripper Cylinder Bearings - Lubricate .................. 143Scarifier Lift Link Socket - Lubricate ................... 145Tire Inflation - Check ........................................... 148Wheel Lean Bar Bearings - Lubricate ................. 158Wheel Lean Bearings - Lubricate ....................... 158Wheel Lean Cylinder Bearings - Lubricate ......... 159

Initial 250 Service Hours

Engine Valve Lash -Check ................................. 129

Every 250 Service Hours or MonthlyBattery Electrolyte Level - Check ........................ 102Blade Lift Cylinder Socket - Lubricate ................. 104Braking System - Test ......................................... 105Centershift Cylinder Socket - Lubricate .............. 107Cooling System Coolant Additive (DEAC) - Add .. 117Engine Air Filter Service Indicator -

Inspect/Replace ................................................ 124Engine Oil Sample - Obtain ................................ 127Engine Oil and Filter - Change ........................... 127Hydraulic System Oil Sample - Obtain ............... 139Radiator - Clean .................................................. 143Tandem Drive Oil Level - Check ......................... 147Tandem Drive Oil Sample - Obtain ..................... 147Transmission and Differential Oil Level - Check .. 151Transmission and Differential Oil Sample -

Obtain ............................................................... 152V-Belts - Inspect/Adjust/Replace ........................ 152Wheel Bearing Oil Level (Front) - Check ............ 158

Every 500 Service Hours or 3 Months

Articulation Bearings - Lubricate ......................... 101Engine Crankcase Breather - Clean ................... 126Fuel System - Prime ........................................... 131Fuel System Primary Filter - Clean/Inspect/

Replace ............................................................. 132


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SEBU7056-07 99Maintenance Section

Maintenance Interval Schedule

Fuel System Secondary Filter - Replace ............ 133Fuel Tank Cap and Strainer - Clean ................... 134Hydraulic System Oil Filter - Replace ................. 137Parking Brake -Drain ......................................... 141Pump Drive Shaft - Lubricate .............................. 142Transmission and Differential Oil Filter and Screens -

Replace/Clean .................................................. 149

Every 1000 Service Hours or 6 Months

Cooling SystemPressure Cap - Clean/Replace .. 119Rollover Protective Structure (ROPS) - Inspect .. 144Transmission and Differential Oil - Change ........ 148

Every 2000 Service Hours or 1 Year

Air Conditioner - Test .......................................... 100Battery or Battery Cable - Inspect/Replace ........ 103Circle Drive Oil - Change ..................................... 111Condenser (Refrigerant) - Clean ......................... 114

Engine Valve Lash - Check ................................. 129Engine Valve Rotators - Inspect ......................... 129Evaporator Coil and Heater Coil - Clean ............ 130In-Line Refrigerant Dryer - Replace .................... 139Tandem Drive Oil - Change ................................ 146

Every 2000 Service Hours or 2 Years

Final Drive Preload - Check ................................ 130


Cooling System Coolant (DEAC) - Change ......... 114Cooling System Coolant Extender (ELC) - Add ... 118Cooling System Water Temperature Regulator -

Replace .............................................................. 119

Every 4000 Service Hours

Hydraulic System Oil - Change ........................... 136


Cooling System Coolant (ELC) - Change ............ 115


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100 SEBU7056-07Maintenance Section

Air Conditioner - Test

i01286245

Air Conditioner - Test

SMCS Code:7320-081

Inhaling air conditioner refrigerant gas through alit cigarette or other smoking method or inhalingfumes released from a flame contacting air con-ditioner refrigerant gas can cause bodily harm ordeath. Do not smoke when servicing air condition-ers or wherever refrigerant gas may be present.

1. Start the engine. Operate the engine at high idle.

g00107785Illustration 170

2. Set the air conditioner control for maximumcooling. Set the fan control on HIGH FAN SPEEDposition.

3. In order to stabilize the air conditioning system,run the air conditioning system for two minutes.


4. Open the engine compartment access door on theright side of the machine.


5. Check for refrigerant in the air conditioningsystem, as follows:

Feel the suction line (1) and feel the dischargeline (2).

If the system contains refrigerant, the dischargeline is warmer than the suction line.

If the air conditioning system does not containrefrigerant or if the level of the refrigerant in theair conditioning system is very low, then you willexperience poor cooling.

6. Close the engine compartment access door onthe right side of the machine.

7. Stop the engine.

8. Consult your Caterpillar dealer for air conditionersystem service, if necessary.

Note: For the proper cooling of the air conditioner,check the temperature of the vent with a thermometer.The air temperature should be between 13 to 16 C(55 to 60 F).


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Air Tank Moisture and Sediment - Drain

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Air Tank Moisture andSediment - Drain

SMCS Code: 4272-543-M&S; 5505-543



There is one drain valve on each end of the air tank.Open the two drain valves. Drain any condensationinto a container. Close the two drain valves.

i01321864

Articulation Bearings -Lubricate

SMCS Code: 7057-086-BD

Wipe all the fittings before you apply lubricant throughthe fittings.



The upper articulation bearing has one fitting. Apply

lubricant through thefi

tting in order to lubricate theupper articulation bearing.

The lower articulation bearing has one fitting. Applylubricant through the fitting in order to lubricate thelower articulation bearing.

i01322020

Axle Oscillation Bearings -Lubricate

SMCS Code: 3268; 4313

Wipe the fitting before you apply lubricant to thefitting.


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102 SEBU7056-07Maintenance SectionBackup Alarm - Test



Apply lubricant to the one fitting in order to lubricate

the axle oscillation bearings.

i02307698

Backup Alarm - Test

SMCS Code:7406-081

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

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

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

The backup alarm is located at the rear of themachine.

i00993589

Battery - Recycle

SMCS Code: 1401-561

Always recyclea battery. Never discard a battery.

Always return used batteries to one of the followinglocations:

A battery supplier

An authorized battery collection facility

Recycling facility

i00118824

Battery Electrolyte Level -Check

SMCS Code: 1401-535-FLV

Table 10

The Chart for the Battery Electrolyte

Battery Interval

Conventional 100 Hour

Low Maintenance 250 Hours

Maintenance Free None Required

Tighten the battery retainers on all of the batteries.Tighten the battery retainers at every 1000 hours.

Check the following areas at a minimum intervalof 1000 hours. Check the following areas morefrequently during adverse conditions:

1. The battery access covers are positioned at therear of the machine on the sides. Open the batteryaccess covers.

2. Clean the battery surface with a clean cloth.

3. Maintain clean battery terminals. You may usea coating of corrosion protection. Only use thecorrosion protection after the battery cable isconnected and after the battery cable is clean.

4. Coat the terminals with corrosion protection. Then,install the post cover.

5. For conventional batteries and batteries of lowmaintenance, follow these additional instructions:

Inspect the battery electrolyte level in eachbattery cell. A maintenance free battery doesnot require inspection.


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Battery or Battery Cable - Inspect/Replace

Maintain the level of the distilled water to thebottom of the fi ller openings. If distilled water isnot available, use clean drinking water.

A battery should not require more than 30 cc(1 ounce) of water per cell per week. This

requirement should exist with the propercharging rate and with a moderate climate.

In extreme temperatures, check the water in thecells weekly. Cell water usage could be higherin extreme temperatures.

6. Close the battery access covers.

i01770781

Battery or Battery Cable -Inspect/Replace

SMCS Code:1401-510; 1402-510; 1411-510

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

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

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

Note: Do not allow the disconnected battery cable to

contact the battery disconnect switch or the machine.

4. Disconnect the negative battery cable from thebattery.

5. Disconnect the positive battery cable from thebattery.

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

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

8. Connect the positive battery cable at the battery.

9. Connect the negative battery cable at the battery.

10. Connect the battery cable at the batterydisconnect switch.

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

i01287298

Blade Lift Cylinder Socket -Check/Adjust/Replace

SMCS Code: 5102-025; 5102-510; 5102-535;

5103-025; 5103-510; 5103-535

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

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


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

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

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

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

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

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


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104 SEBU7056-07Maintenance SectionBlade Lift Cylinder Socket - Lubricate

i01322897

Blade Lift Cylinder Socket -Lubricate

SMCS Code:5102-086; 5103-086

Wipe all the fittings before you apply lubricant to thefittings.



Each blade lift cylinder socket has one fitting. Applylubricant to the fitting in order to lubricate the bladelift cylinder socket.

There is a total of two fittings.

i00185759

Brakes, Indicators and Gauges- Test

SMCS Code: 4251-081; 4267-081; 4269-081;

7000-081; 7450-081; 7490-081


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

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

Look for inoperative gauges.

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

Sound the forward horn.

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

Stop the engine.

Make any needed repairs before you operate themachine.


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Braking System - Test

i01998856

Braking System - Test

SMCS Code: 3077-081; 4011-081; 4250-081;4251-081; 4267-081

Service Brake Holding Ability Test

Personal injury can result if the machine moveswhile testing.

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

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

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

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

Make sure that the area around the machine is clear

of personnel and clear of obstacles.

Test the service brake on a dry level surface.

Fasten your seat belt before you test the brakes.

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

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

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

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

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

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

Parking Brake Holding Ability Test

Personal injury can result if the machine moveswhile testing.

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

NOTICE

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

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

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

Test the parking brake on a hard dry surface.

Fasten the seat belt before you test the parkingbrake.

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

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

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

i01288046

Cab Air Filter - Clean/Replace

SMCS Code: 7311-070-FI; 7311-510-FI; 7342-070;7342-510

Clean Filters

Note: Clean the cab airfilters more often in dustyconditions.


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106 SEBU7056-07Maintenance SectionCab Air Filter - Clean/Replace

Outside Filters


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


1. Remove the fi lter cover.

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

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

4. Install the filter elements. Install the fi lter cover.

Inside Filter


The filter for the inside cab air system is positionedbehind the operators seat.


1. Remove the filter cover.

2. Remove the filter element. Clean the fi lter elementwith pressure air or wash the filter element in warmwater and in a nonsudsing household detergent.

3. Rinse the filter element in clean water. Thoroughlyair dry the filter element.

4. Install the fi lter element. Install the fi lter cover.

Replace the Filters

Note: Replace the cab airfilters, as required.


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Centershift Cylinder Socket - Check/Adjust/Replace

Outside Filters



2. Remove the filter elements. Discard the filterelements.

3. Install the new filter elements.

4. Install the filter cover.

Inside Filter



2. Remove the filter element. Discard the filter

element.

3. Install the new filter element.

4. Install the filter cover.

i00173892

Centershift Cylinder Socket -Check/Adjust/Replace

SMCS Code: 5223-023; 5223-025; 5223-535

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

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


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

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

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

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

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

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

i00177746

Centershift Cylinder Socket -Lubricate

SMCS Code: 5223-086

Wipe all the fittings before you apply lubricant to thefittings.


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108 SEBU7056-07Maintenance SectionCentershift Lock Bar - Clean/Lubricate



The centershift cylinder has one fitting on each end.

Apply lubricant to thefi

ttings in order to lubricate thecentershift cylinder socket.

There is a total of two fittings.

i01323659

Centershift Lock Bar -Clean/Lubricate

SMCS Code:5221-070; 5221-086



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

Apply lubricant to the holes in the centershift lock bar.

i01865351

Circle Clearances -Check/Adjust

SMCS Code: 6152-025; 6152-535; 6153-025;6153-535; 6154-025; 6154-535; 6155-025;6155-535

Blade Circle and Drawbar

1. Rotate the blade. Place the blade at an angle of90 degreesto the frame.

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



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Circle Clearances - Check/Adjust


2. Clamp two C-clamps onto the front of the bladecircle (1) and the drawbar (2). This will fasten theblade circle and the drawbar together. Tighten

the two C-clamps until the wear strips (3) are incontact with the top of the blade circle and thewear strips (3) are in contact with the bottom ofthe drawbar.

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

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

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

Blade Circle to Shoe Clearance

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

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



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

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

Note: Check the wear strips (3) around the entirecircumference of the blade circle. The wear strips (3)

should be in complete contact with the blade circleand the drawbar.


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110 SEBU7056-07Maintenance SectionCircle Clearances - Check/Adjust


4. Shoe mounting fastener (4), shoe mountingfastener (5) and shoe mounting fastener (6) mustbe tight. Make sure that the shoe wear strips (3)

are completely seated in the circle shoes.


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

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

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

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

7. Add shims or remove shims, as required.

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

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

Note:After all the adjustments have been performed,

the blade circle (1) must rotate freely without binding .

Circle Pinion and Circle

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

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


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

adjust the clearance.


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Circle Drive Oil - Change


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

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

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

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

Note: If the circle shoes are moved outward, it may

be necessary to slowly inch the machine in a forwarddirection in order to place a light load between thewear strips for the front circle shoes and the circle.

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

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

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

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

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

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

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

12. Tighten all locknuts (11) to a torque of

200 30 Nm (150 22 lb ft).

i01862702

Circle Drive Oil - Change

SMCS Code: 5207-510-OC

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

ing any compartment or disassembling any compo-nent containing fluids.

Refer to Special Publication, NENG2500, CaterpillarTools and Shop Products Guide for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

Clean the area around the drain plug and clean thearea around the check/fill plug before you removethe plugs.


Bottom view of the blade circle.


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112 SEBU7056-07Maintenance SectionCircle Drive Oil Level - Check


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

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

3. Fill the circle drive housing with oil. See Operationand Maintenance Manual, Capacities (Refill).

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

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

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

7. Install the check/fill plug.

i01325743

Circle Drive Oil Level - Check

SMCS Code: 5207-535-OC

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

Wipe the surfaces around the check/fill plug openingbefore youcheck the oil and before you add oil.



1. Remove the check/fill plug.

2. Maintain the oil level to the bottom of the check/fillplug opening.

3. Install the check/fill plug.


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Circle Drive Pinion Teeth - Lubricate

i01446316

Circle Drive Pinion Teeth -Lubricate

SMCS Code: 5207-086-PI



1. Clean the dirt and the old lubricant from the bladecircle and from the circle drive pinion teeth.

2. Apply molybdenum disulfide grease to theblade circle and to the circle drive pinion teeth.Caterpillar Auto Lube 2 is recommended.

i01459100

Circle Top - LubricateSMCS Code: 6154-086-TP

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

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


3. Apply a dryfilm lubricant to the 5 mm (0.2 inch) gapbetween the circle and the drawbar yoke. Applythe dry fi lm lubricant around the entire circle. See

Operation and Maintenance Manual, SEBU6250,Dry fi lm Lubricant for further information.

i00178485

Circuit Breakers - Reset

SMCS Code: 1417-529; 1420-529

Circuit Breaker Reset Push the button inward inorder to reset the circuit breakers. If the system isworking properly, the button will remain depressed.If the button does not stay depressed, check theappropriate electrical circuit.


The main circuit breaker for the alternatoris positioned at the right rear of the enginecompartment.

Alternator The main circuit breaker forthe alternator is 60 amp.


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114 SEBU7056-07Maintenance SectionCondenser (Refrigerant) - Clean

i01355464

Condenser (Refrigerant) -Clean

SMCS Code:1805-070

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

Repair the fins if found defective.


The refrigerant condenser is located behind theradiator at the rear of the machine.

1. Remove the access panel for the radiator at therear of the machine.

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

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

4. Replace the access panel.

i01326615

Cooling System Coolant(DEAC) - Change

SMCS Code: 1350-044; 1350-070; 1395-044;

1395-544

Personal injury can result from hot coolant, steamand alkali.

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

Remove cooling system pressure cap slowly to

relieve pressure only when engine is stopped andcooling system pressure cap is cool enough totouch with your bare hand.

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

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

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

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

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

Always operate Caterpillar engines with a thermostat

because these engines have a shunt design coolingsystem.

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

1. Stop theengine and allow the engine to cool.


20/65


Cooling System Coolant (ELC) - Change


2. Open the cover. Slowly remove the cooling systempressure cap in order to relieve pressure.

g00701954

Illustration 212

3. Remove the drain plug (1). The drain plug (1) islocated on the water line at the lower left side ofthe engine. Open the drain valve (2). The drainvalve is located under the radiator. Allow thecoolant to drain into a suitable container.

Note: Discard any drained fluids according to localregulations.

4. Close the drain valve. Clean the drain plug andinstall the drain plug. Fill the cooling system withclean water and with a 6 to 10% concentration of

cooling system cleaner.

5. Start the engine. Run the engine for 90 minutes.

6. Stop the engine. Drain the cleaning solution.

7. Flush the cooling system with water until thedraining water is transparent.

8. Close the drain valve and install the drain plug.

9. Add the coolant solution. Refer to Operation andMaintenance Manual, Refill Capacities.

10. Remove the cooling system pressure cap. Startthe engine and run the engine. Leave the cap offuntil the thermostat opens and the coolant levelstabilizes.

11. Maintain the coolant level within 13 mm (.5 inch)

of the bottomof the fi ller tube.

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

13. Stop the engine.

i01327874

Cooling System Coolant (ELC)- Change

SMCS Code: 1350-044-NL; 1350-544-NL;

1395-044-NL







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


21/65

116 SEBU7056-07Maintenance SectionCooling System Coolant (ELC) - Change

NOTICEMixing Extended Life Coolant (ELC) with other prod-ucts reduces the effectiveness of the coolant andshortens coolant life. Use only Caterpillar prod-ucts or commercial products that have passed the

Caterpillar EC-1 specifications for premixed or con-centrate coolants. Use only Caterpillar Extender withCaterpillarELC. Failure to follow these recommenda-tions could result in the damage to cooling systemscomponents.

If ELC cooling system contamination occurs, refer toOperation and Maintenance, Extended Life Coolant(ELC) underthe topic ELC Cooling System Contam-ination.

This machine was factory filled with Extended LifeCoolant.

If the coolant in the machine is changed to ExtendedLife Coolant from another type of coolant, seeOperation and Maintenance Manual, SEBU6250,Extended Life Coolant (ELC) Cooling SystemMaintenance.

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

It is important to replace the thermostat in orderto avoid any unexpected failure of the thermostat.This is a good preventive maintenance practice that

reduces the chances of unscheduled downtime.Failure to replace the thermostat on a regularlyscheduled basis could cause severe engine damage.

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

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

Note: Thermostats can be reused if the thermostatsmeet certain test specifications. The tested

thermostats must not be damaged and the testedthermostats must not have an excessive buildup ofdeposits.

1. Stop theengine and allow the engine to cool.


2. Open the cover. Slowly remove the cooling systempressure cap in order to relieve pressure.

g00701954

Illustration 214

3. Remove the drain plug (1). The drain plug (1) islocated on the water line at the lower left side ofthe engine. Open the drain valve (2). The drainvalve is located under the radiator. Allow thecoolant to drain into a suitable container.


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

5. Close the drain valve. Clean the drain plug andinstall the drain plug.

6. Add the Extended Life Coolant. See Operationand Maintenance Manual, Refill Capacities.

Note: Make sure that the cooling system pressurecap is removed for the following Steps 7 through 8.

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

8. Maintain the coolant level within 13 mm (.5 inch)of the bottom of the fi ller tube.


22/65


Cooling System Coolant Additive (DEAC) - Add



i00155934

Cooling System CoolantAdditive (DEAC) - Add

SMCS Code: 1352-045; 1352-535; 1352-544;1395-081



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



See the appropriate topics in your machinesOperation and Maintenance Manual for all coolingsystem requirements.

Use 8T-5296Test Group to check the concentrationof the Diesel Engine Antifreeze/Coolant DEAC.

If necessary, add cooling system coolant additive.

NOTICEDo not exceed the recommended six percent coolingsystem coolant additive concentration. Excessivecooling system coolant additive concentration canform deposits on the higher temperature surfaces

of the cooling system, reducing the engines heattransfer characteristics. Reduced heat transfer couldcause cracking of the cylinder head and other hightemperature components. Excessive cooling systemcoolant additive concentration could also result in ra-diator tube blockage, overheating, and/or acceleratedwater pump seal wear. Never use both liquid coolingsystem coolant additive and the spin-on element (ifequipped) at the same time. The use of those addi-tives together could result in cooling system coolantadditive concentration exceeding the recommendedsix percentmaximum.

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


2. Open the cover. Remove the cooling systempressure cap slowly in order to relieve thepressure.

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

Note: Always discard drained fluids according tolocal regulations.

4. Add 0.24 L (.50 pint) of cooling system coolantadditive for every 38 L (10 US gal) of enginecooling capacity.



23/65

118 SEBU7056-07Maintenance SectionCooling System Coolant Extender (ELC) - Add

i01292446

Cooling System CoolantExtender (ELC) - Add

SMCS Code: 1352-045; 1352-535; 1352-544;

1352-544-NL;1395-081







When a Caterpillar Extended Life Coolant (ELC)is used, an extender must be added to the cooling

system. See the Operation and MaintenanceManual, Maintenance Interval Schedule for theproper service interval. The amount of extender isdetermined by the cooling system capacity.

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


2. Open the cover. Remove the cooling systempressure cap slowly in order to relieve thepressure.

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

Note: Discard drained fluids according to localregulations.

4. In order to add cooling system coolant extender,refer to the Operation and Maintenance Manual,SEBU6250, Extended Life Coolant (ELC). Referto the table for the correct amount of CaterpillarExtended Life Coolant (ELC) Extender that isneeded to be added to the cooling system.


i00120056

Cooling System Level - CheckSMCS Code: 1350-040-HX; 1350-040;

1350-535-FLV; 1350-535; 1353-535-FLV;1354-535; 1395-082; 1395-535-FLV; 1395-535

The coolingsystem pressure cap is positioned in theleft rear of the hood.


1. Open the cover. Remove the cap slowly in orderto relieve pressure.

2. Maintain the coolant level within 13 mm (.5 inch)of the bottom of the fi ller pipe. If it is necessary toadd coolant daily, check for leaks.

3. If additional coolant is necessary, add theappropriate coolant mixture.

4. Install the cap. Close the cover.


24/65


Cooling System Pressure Cap - Clean/Replace

i00135951

Cooling System Pressure Cap- Clean/Replace

SMCS Code:1382-070; 1382-510



Remove filler cap slowly to relieve pressure onlywhen engine is stopped and radiator cap is cool

enough to touch with your bare hand.


Cooling System Conditioner contains alkali. Avoidcontact with skin and eyes.

The cooling system pressure cap is positioned in theleft rear of the hood.


1. Open the cover. Remove the cap slowly in orderto relieve pressure.

2. Inspect the cap and the cap seal for damage,deposits, and foreign material. Clean the capwith a clean cloth. Replace the cap if the cap isdamaged.

3. Install the cap. Close the cover.

i00350379

Cooling System WaterTemperature Regulator -Replace

SMCS Code: 1355-070; 1355-510; 1393-010



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


Cooling System Conditioner contains alkali. Avoidcontact with skin and eyes.

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

with the cooling system.

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

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

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

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

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


25/65

120 SEBU7056-07Maintenance SectionCutting Edges and End Bits - Inspect/Replace

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

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

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

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

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

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

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

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

of the filler tube.

i01328429

Cutting Edges and End Bits -Inspect/Replace

SMCS Code: 6801-040; 6801-510; 6804-040;6804-510

Personal injury or death can result from the blade

falling.

Block the blade before changing blade tips.

The cutting edges and/or the end bits may bedamaged or the cutting edges and/or the end bitsmay be worn excessively. Replace the cutting edgesand/or the end bits, as needed.

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


2. Remove the cutting edges and/or the end bits.

3. Install the new cutting edges and/or the end bits.

4. Raise the blade and remove the blocks.

i01328517

Drawbar Ball and Socket -Lubricate

SMCS Code: 6170-086; 6171-086

Wipe the fitting before you apply lubricant to thefitting.

g00702974

Illustration 220


26/65


Drawbar Ball and Socket End Play - Check/Adjust


The drawbar ball and socket has one fitting. Applylubricant to thefitting in order to lubricate the drawbarball and socket.

i00347316

Drawbar Ball and Socket EndPlay - Check/Adjust

SMCS Code: 6170-025; 6170-535; 6171-025;6171-535

Check

Rotate the blade so that the blade is placed at anangle of 90 degrees to the frame. Lower the blade to

the ground. While you maintain a light load betweenthe drawbar ball and the socket, inch the machineslowly to the rear. Stop the machine and shut off theengine.


Measurethe end play that is between the drawbarball (6) and the drawbar cap (4). The end play shouldbe 0.6 0.2 mm (.02 .01 inch). Adjust the end play,if necessary.

Adjust

1. Support the drawbar and support the circle.

2. Remove the four bolts that hold the drawbar to thebolster. Move the drawbar backward or move the

machine forward.


3. Remove the two capscrews (1) from the drawbarcap (4) that holds the drawbar and the adapter (2)together. Remove the adapter.

4. As required, remove the shims (3) or installthe shims (3) in order to attain an end play of0.6 0.2 mm (.02 .01 inch).

5. Install the two capscrews (1) in the drawbar cap(4) and adapter (2). Rotate the drawbar cap (4)

by hand. The socket should rotate freely on thedrawbar ball (6).


6. Check the torque on the five bolts (5) that holdthe drawbar ball (6) in place. The correct torqueis 500 20 Nm (370 15 lb ft).

7. Assemble the drawbar to the bolster. Tightenthe four bolts to a torque of 700 40 Nm(515 29lb ft).


27/65

122 SEBU7056-07Maintenance SectionEngine Air Filter Primary Element - Clean/Replace

i01328707

Engine Air Filter PrimaryElement - Clean/Replace

SMCS Code: 1051-070-PY; 1051-510-PY;

1054-070-PY;1054-510-PY


The engine airfi lter primary element is located on theleft side of the machine at the rear of the machine.

1. Open the left side engine compartment accessdoor, if the machine is equipped with enginecompartment access doors.


2. Remove air cleaner cover (1).

3. Remove the engine airfilter primary element (2)from the air cleaner housing.


4. Clean the inside of the air cleaner housing.

5. Inspect the primary element. If the pleats, the

gaskets, or the seals are damaged, discard theprimary element. Replace a damaged primaryelement with a clean primary element.

NOTICEDo not clean the primary element by bumping or tap-ping them. Do not use primary element with damagedpleats, gaskets or seals. Engine damage can result.

Make sure the cleaned primary element is completelydry before installing into the air cleaner housing. Waterremaining in the primary element can cause false in-dications of contamination in Scheduled Oil Samplingtest results.

6. If the primary element is not damaged, clean theprimary element.

The primary element can be cleaned by using thefollowing methods:

Air pressure

Water pressure

Detergent washing

When you use air pressure, the maximum airpressure is 205 kPa (30 psi). When you use waterpressure, the maximum water pressure is 280 kPa(40 psi).


28/65


Engine Air Filter Secondary Element - Replace


7. When you clean the inside pleats and the outsidepleats, direct the air along the pleats or direct thewater along the pleats.

The primary element can be washed in a solutionthat consists of warm water and of nonsudsinghousehold detergent. Fully rinse the pleats. Allowthe primary element to air dry completely.

8. Inspect the primary element after you clean theprimary element. Do not use a primary element ifthe pleats, the gaskets or the seals are damaged.

9. Cover the clean primary element. Store theprimary element in a clean, dry location.

A primary element may be cleaned for a maximum

of six times. Also replace the primary element ifthe primary element has been in service for oneyear.

10. Install a clean primary element.

11. Clean the cover and install the cover.

12. Reset the engine airfi lter service indicator.

Start the engine. If the yellow piston in the engineairfilter service indicator moves into the red zone,install a new primary element. Also if the exhaustsmoke is black, install a new primary element. If

the piston remains in the red zone after resettingand installing a new primaryfilter element, replacethe engine airfilter secondary element. See theOperation and Maintenance Manual, Engine AirFilter Secondary Element - Replace.

13. Close the engine compartment access door, if themachine is equipped with engine compartmentaccess doors.

i01341132

Engine Air Filter SecondaryElement - Replace

SMCS Code: 1051-510-SE; 1054-510-SE

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

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

1. Open the left side engine compartment accessdoor, if equipped. Remove the air cleaner coverand the primary element.


2. Remove the secondary element.

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

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

5. Install the primary element and the air cleanercover.

6. Close the left side engine compartment door, ifequipped.

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


29/65

124 SEBU7056-07Maintenance SectionEngine Air Filter Service Indicator - Inspect

i01340969

Engine Air Filter ServiceIndicator - Inspect

SMCS Code: 7452-040; 7452-040-DJ;

7452-040-ENG


1. Start the engine.

2. Run the engine at high idle.

3. If the yellow piston in the engine airfilter serviceindicator enters the red zone, service the aircleaner.

4. Stop the engine.

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

Air Filter Secondary Element - Replace.

Note: Refer to Operation and Maintenance Manual,Engine Air Filter Service Indicator - Inspect/Replacein order to check an engine airfilter service indicatorthat is faulty.

i01360141

Engine Air Filter ServiceIndicator - Inspect/Replace

SMCS Code: 7452-040; 7452-510


1. Open the left side engine compartment door.

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

3. Next, checkthe movement of the yellow pistonin the service indicator. Start the engine andaccelerate the engine to high idle for a fewseconds. After the governor control pedal isreleased, the yellow piston should remain atthe highest position that was achieved duringacceleration.

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

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

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

5. Close the left side engine compartment door.


30/65


Engine Air Filter Service Indicator Screen - Check/Replace

i01360098

Engine Air Filter ServiceIndicator Screen -Check/Replace

SMCS Code:7452-510-Z3; 7452-535-Z3


Typical Example

Check

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

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

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

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

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

Replace

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

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

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

i00186095

Engine Air Precleaner - Clean

SMCS Code: 1055-070; 1055-070-DJ

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


The engine air precleaner is positioned at the center

rear of the machine.


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

2. Remove the engine air precleaner screen (2) andinspect the engine air precleaner tube openingsfor dirt and debris. Clean the tubes, if necessary.

3. Clean theengine air precleaner screen (2) withpressure air or wash the engine air precleanerscreen (2) in clean warm water.


31/65

126 SEBU7056-07Maintenance SectionEngine Crankcase Breather - Clean

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

i01329959

Engine Crankcase Breather -Clean

SMCS Code: 1000-070-BRE; 1317-070;1317-070-DJ

The engine crankcase breather is positioned on thetop of the engine at the front of the engine.


1. Open the left side engine compartment accessdoor, if the machine is equipped with enginecompartment access doors.


2. Loosen the outlet hose clamp on the cover of theengine crankcase breather. Remove the outlethose from the cover of the engine crankcasebreather.


3. Remove the bolt. Remove the washer and removethe cover from the engine crankcase breather.

4. Check the condition of the seal on the cover. Ifthe seal is damaged, replace the old seal with anew seal.

5. Remove the engine crankcase breather. Wash theengine crankcase breather and the cover in cleannonflammable solvent.

6. Shake the engine crankcase breather or usepressure air to dry the engine crankcase breather.

7. Inspect the hose for damage. If the hose isdamaged, replace the hose.

8. Install the engine crankcase breather. Install thecover. Install the washer and install the bolt for theengine crankcase breather.

9. Install the hose and the clamp.

10. Close the left side engine compartment accessdoor, if the machine is equipped with enginecompartment access doors.

i01330176

Engine Oil Level - Check

SMCS Code: 1000-535-FLV; 1302-535-FLV;1326-535-OC; 1326-535-FLV; 1348-535-FLV

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

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


32/65


Engine Oil Sample - Obtain

Clean the area around the dipstick and clean thearea around the oil fi ller cap before you remove thedipstick and the oil fi ller cap.


1. Open the left side engine compartment accessdoor, if themachine is equipped with enginecompartment access doors.


2. Before starting the engine, check the ENGINESTOPPED side of dipstick (1) while the engine isstopped. Maintain the oil level between the ADDmark and the FULL mark.

Start the engine and check the ENGINERUNNING side of dipstick (1) while the engine isrunning. Maintain the oil level between the ADD

mark andthe FULL mark.

3. Remove oil fi ller cap (2). If necessary, add oil.

4. Clean the oil fi ller cap and install the oil fi ller cap.

5. Close the left side engine compartment accessdoor, if the machine is equipped with enginecompartment access doors.

i01312992

Engine Oil Sample - Obtain

SMCS Code: 1348-008; 1348-554-SM; 7542-008;7542-554-OC, SM


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

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

i01330276

Engine Oil and Filter - Change

SMCS Code: 1302-044-OC; 1308-510; 1318-510;1326-535-OC; 1348-044


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

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

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


33/65

128 SEBU7056-07Maintenance SectionEngine Overheating

Note:Articulate the machine to the left in order to getbetter access to the crankcase drain valve.


1. Open the crankcase drain valve. Allow the oil to

drain into a suitable container.

Note: Discard any drained fluids and discard anyfilter elements according to local regulations.

2. Close the crankcase drain valve.

3. Open the engine compartment access door on theleft side of the machine.

4. Clean the area around the engine oil fi lter beforeremoving the engine oil fi lter. Remove the engineoil fi lter with a strap type wrench. See Operationand Maintenance Manual, Oil Filter - Inspect.

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

6. Apply a light coat of engine oil to the gasket of thenew engine oil fi lter.

7. Install the new engine oil filter by hand. Additionallytighten the engine oil filter by 3/4 of a turn, afterthe gasket contacts the filter base.


8. Clean the area around the dipstick beforeremoving the dipstick. Clean the area aroundthe oil filler cap before removing the oil fi ller cap.Remove the oil fi ller cap (1). Fill the crankcasewith new oil. See Operation and MaintenanceManual, Refill Capacities. Clean the filler cap

and install the fi ller cap.

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

10. Run the engine. Check the ENGINE RUNNINGside of dipstick (2) while the engine is running.Maintain the oil level between the ADD mark andthe FULL mark. If necessary, add oil .

11. Stop the engine. Close the engine compartmentaccess door on the left side of the machine.

i01485299

Engine Overheating

SMCS Code: 1000; 1350; 1353

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

1. Operation and Maintenance Manual, CoolingSystem Level Check

2. Operation and Maintenance Manual, Radiator -

Clean

3. Operation and Maintenance Manual, Belts -Inspect/Adjust/Replace

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

5. Operation and Maintenance Manual, RadiatorCore - Clean

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

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

i00357039

Engine Power Loss

SMCS Code: 1000; 1051; 1250

If your machine experiences an engine power loss,do the following maintenance procedures in the orderlisted:


34/65


Engine Valve Lash - Check

See Operation and Maintenance Manual for thefollowing topics:

1. Engine Air Filter Service Indicator - Inspect

2. Engine Air Precleaner - Clean

3. Engine Air Filter Primary Element - Clean/Replace

4. Engine Air Filter Secondary Element - Replace

5. Fuel Tank Water and Sediment - Drain

6. Fuel Tank Cap and Strainer - Clean

7. Fuel System Primary Filter - Clean/Inspect/Replace

8. Fuel System Secondary Filter - Replace

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

i01714628

Engine Valve Lash - Check

SMCS Code: 1105-535

Ensure that the engine can not be started whilethis maintenance is being performed. To help pre-

vent possible injury, do not use the starting motorto turn the flywheel.

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

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

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

The initial valve lash adjustment is recommendedat the first scheduled oil change. The valve lashadjustment should then be made at every 2000 hourinterval. The adjustment is necessary due to theinitial wear of the valve train components and to theseating of the valve train components.

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

Ensure that the engine is stopped before measuring

the valve lash. To obtain an accurate measurement,allow the valves to cool before this maintenance isperformed.

Refer to the Service Manual for more information.

i00128925

Engine Valve Rotators - Inspect

SMCS Code: 1109-040

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

Inspect the engine valve rotators after the valveclearanceshave been set.

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

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

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

i01330698

Ether Starting Aid Cylinder -Replace

SMCS Code: 1456-510-CD



35/65

130 SEBU7056-07Maintenance SectionEvaporator Coil and Heater Coil - Clean

1. Open the fan access door on the left side rearof the machine. The ether starting aid cylinder ismounted on the left side of the compartment.


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

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

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

5. Close the left side fan access door.

i01827363

Evaporator Coil and HeaterCoil - Clean

SMCS Code:7309-070; 7343-070

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

1. Remove the seat.

2. Remove both of the covers.


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

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

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

i01863059

Final Drive Preload - Check

SMCS Code: 4050-535-ZP

Table 11

Required Tools

Part Number Description Quantity

Wrench for 140H5P-4204

Wrench for 160H1

9U-5015 Torque Wrench Gp

(3/4 Inch Drive) 1

Table 12

Bearing Preload for the Final Drive

Sales Model Final Torque

140H

160H136 Nm (100 lb ft)

1. Park the machine on a level surface.


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SEBU7056-07 131Maintenance SectionFuel System - Prime

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

3. Unlock the differential.

4. Stop the engine.

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


6. Remove outer cover (1).


7. Remove lock (2).


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

9. Check the torque. Refer to Table 12.

10. Refer to the adjustment procedure in SystemsOperation, Testing and Adjusting, Final DriveBearings - Adjust if the torque is incorrect.

i00130623

Fuel System - Prime

SMCS Code: 1250-548; 1258-548

The primingpump for the fuel system is positionedin the engine compartment at the right rear of the

machine.

1. Open the engine access door on the right side ofthe machine.


2. Check that the fuel supply valve is open. Thefuel supply valve is positioned in the enginecompartment on the right side of the engine.


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132 SEBU7056-07Maintenance SectionFuel System Primary Filter - Clean/Inspect/Replace


3. Unlock the priming pump plunger by turning thepriming pump plunger counterclockwise and pullout the priming pump plunger.

4. Operate the priming pump in order to fill the newprimary fuel filter and the new secondary fuel filter.Continue to operate the priming pump until thepump resists operation. This indicates that the fuelfilters are full of fuel.

5. Lock the priming pump plunger by turning thepriming pump plunger clockwise.

6. Start the engine. Look for leaks around theprimary fuel filter and the secondary fuel fi lter. Ifthe engine will not start, air is trapped in the fuelinjection lines to the engine.

7. Loosen all the fuel injection lines at the cylinderhead of the engine. Use two wrenches to avoidbreaking the fuel injection lines.

8. Move the throttle control to the LOW IDLE position.

9. Turn and hold the engine start switch to theSTART position until the fuel flows free of airbubbles from all fuel injector lines. Allow the fuelto flow into a suitable container.


10. Stop the engine. Tighten the nuts on the fuelinjector lines to a torque of 40 7 Nm (30 5 lb ft).

11. Close the engine access door on the right side ofthe machine.

i00130694

Fuel System Primary Filter -Clean/Inspect/Replace

SMCS Code: 1260-040; 1260-070; 1260-510;

1260-571

NOTICEDo not fill fuel filters with fuel before installing them.Contaminated fuel will cause accelerated wear to fuelsystem parts.

Wipe the area around the primary fi lter for the fuelsystem beforeyou remove the primary fi lter.

The primary filter for the fuel system is positionedin the enginecompartment at the right rear of themachine.

1. Open the engine compartment access door onthe right side of the machine, if the machine isequipped with engine compartment access doors.


2. Close the fuel supply valve. The fuel supply valveis positioned in the engine compartment on theright side of the machine.


3. Loosen the fi lter housing retaining bolt.


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Fuel System Secondary Filter - Replace

4. Remove the fi lter housing and the primary fi lter.

5. Drain the fuel from the filter housing and theprimary fi lterinto a suitable container.

Note: Discard any drained fluids according to local

regulations.

6. Remove the primary fi lter from the fi lter housing.

7. Wash the primary fi lter and the filter housing in aclean, nonflammable solvent.

8. Inspect the primary filter. If the primary filter isdamaged, replace the primary fi lter.

9. Use pressure air to dry the primary fi lter.

10. Clean the filter housing base.

11. Inspect the seal in the fi lter housing base. Inspectthe gasket inthe filter housing base. If the sealis damaged, replace the seal. If the gasket isdamaged, replace the gasket.

12. Install the clean primaryfi lter in the filter housing.

13. Install the clean primary filter and the filter housinginto the fi lter housing base.

14. Tighten the retaining bolt to a torque of 24 4 Nm(17 3 lb ft).

15. Open the fuel supply valve.

16. Prime the fuel system. See the Operation andMaintenance Manual, Fuel System - Prime formore information.

17. Close the engine access door on the right sideof the machine, if the machine is equipped withengine compartment access doors.

i01331041

Fuel System Secondary Filter -Replace

SMCS Code: 1261-510-SE

NOTICEDo not fill fuel filters with fuel before installing them.Contaminated fuel will cause accelerated wear to fuelsystem parts.

The secondary fi lter for the fuel system is positionedin the engine compartment at the right rear of themachine.

1. Open the enginecompartment access door onthe right side of the machine, if the machine isequipped with engine compartment access doors.


2. Close the fuel supply valve. The fuel supply valveis positioned in the engine compartment on theright side of the machine.


3. Remove the secondary fuel filter.

4. Drain the fuel from the secondary fuel fi lter into asuitable container.


5. Clean the mounting base for the secondary fuelfilter. Make sure that you removed all of the oldseal.

6. Coat the seal of the new secondary fuel filter withclean diesel fuel.

7. Install the new secondary fuel filter by hand.Tightenthe new secondary fuel fi lter until the sealcontacts the mounting base. Then tighten the newsecondary fuel filter for an additional turn of 3/4of a turn.


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134 SEBU7056-07Maintenance SectionFuel Tank Cap and Strainer - Clean

Use the rotation index marks on the newsecondary fuel fi lter as a guide for tightening thefilter. These rotation index marks are spaced atintervals of 1/4 turn.

8. Open the fuel supply valve.

9. Prime the fuel system. See the Operation andMaintenance Manual, Fuel System - Prime formore information.

10. Close the engine compartment access door onthe right side of the machine, if the machine isequipped with engine compartment access doors.

i00130705

Fuel Tank Cap and Strainer -Clean

SMCS Code:1273-070-STR; 1273-070-Z2

The fuel tank cap is positioned on the left side rearof the machine.


1. Remove the fuel tank cap and disassemble thefuel tank cap.

2. Inspect the seal on the fuel tank cap for damage.If the seal is damaged, replace the seal.

3. Remove the strainer from the fi ller opening.

4. Wash the strainer and the fuel tank cap in cleannonflammable solvent.

5. Disassemble the vent assembly. Wash the ventassembly in clean nonflammable solvent.

6. Inspect the vent assembly for damage. If the ventassembly is damaged, replace the vent assembly.

7. Apply a light coat of oil to the vent assembly.Assemble the fuel tank cap.

8. Install the strainer.

9. Install the fuel tank cap.

i01331178

Fuel Tank Water and Sediment- Drain

SMCS Code: 1273-543-M&S

The drain valve is positioned at the left side of themachine under the fuel tank.


1. Open the drain valve. Drain the water and thesediment into a suitable container.


2. Close the drain valve.

i00259472

Fuses - Replace

SMCS Code: 1417-510



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Fuses - Replace

Fuses Fuses protect the electrical system fromdamage that is caused by overloaded circuits.Replace the fuse if the element is separated. Checkthe circuit ifthe element is separated in a new fuse.Repair the circuit.

NOTICEReplace the fuses with the same type and size only.

If it is necessary to replace fuses frequently, an electri-cal problem may exist. Consult your Caterpillar dealer.

There are two fuse panels. One fuse panel ispositioned in the base of the steering column.The other fuse panel is on the control box for thewindshield wipers at the right side of the operator.


Tail Lights (1) 10 amp

Key Switch (2) 10 amp

Gauges (3) 10 amp

Horn (4) 10 amp

Rear Floodlights (5) 10 amp

Heating (6) 15 amp

Stop Lights (7) 10 amp

Floodlights for the Blade (8) 10 amp

Centershift Lock (9) 10 amp


Dome Lamp (10) 10 amp

Upper Front Windshield Wiper/Washer(11) 10 amp

Lower Front Windshield Wiper/Washer(12) 10 amp

Rear Windshield Wiper/Washer (13) 10amp


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Hydraulic System Oil Filter - Replace

3. Replace the filter for the hydraulic system oil. SeeOperation and Maintenance Manual, HydraulicSystem Oil Filter - Replace in the MaintenanceInterval Schedule.

4. Remove the fi ller screen from the fi ller tube in the

hydraulic oil tank. Wash the filler screen in cleannonflammable solvent. Allow the filler screen todry.

5. Clean the drain plug and install the drain plug.

6. Install the filler screen.

7. Fill the hydraulic system oil tank. See Operationand Maintenance Manual, Refill Capacities.

8. Inspect the fi ller cap gasket. If the fi ller cap gasketis damaged, replace the fi ller cap gasket.

9. Install the hydraulic oil fi ller cap.

10. Start the engine. Run the engine for a fewminutes.



11. Maintain the oil level above the ADD mark insight gauge (1). If necessary, add oil through thefiller tube (2).

Note: The oil must be free from bubbles. If there arebubbles in the oil, then air is entering the hydraulicsystem. Inspect the suction hoses and inspect theclamps.


13. If necessary, tighten any loose clamps and anyloose connections. Replace any damaged hoses.

i00457463

Hydraulic System Oil Filter -Replace

SMCS Code: 5056-510-FI; 5068-510


Park the machine on a level surface with front wheelsstraight ahead. Lower all attachments to the ground.

Apply a slight downward pressure to the attachments.Center the articulation of the machine and install theframe lock pin. The frame lock pin must move freelyin the frame. Move the front wheels to vertical andinstall the wheel lean bolt. Engage the parking brake.Stop the engine.

Clean the area around the fi ller cap before removingthe filler cap. Clean the area around the filter coverbefore removing the fi lter cover.


1. Slowly remove the hydraulic oil filler cap in orderto relieve the tank pressure.


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138 SEBU7056-07Maintenance SectionHydraulic System Oil Level - Check


2. Remove the filter cover from the hydraulic systemoil tank.

3. Inspect the seal for the cover. If necessary, replacethe seal.

4. Remove the fi lter element and discard the fi lterelement.

Note: Discard any drained fluids and discard anyfilter elements according to local regulations.

5. Install a new filter element.

6. Install the cover.


7. Maintainthe hydraulic oil level above the ADDmark in the sight gauge.

8. Inspect the fi ller cap gasket. If the fi ller cap gasketis damaged, replace the filler cap gasket. Installthe oil filler cap.

i01331619

Hydraulic System Oil Level -Check

SMCS Code: 5050-535-FLV; 5056-535-FLV;

5095-535-FLV; 7479-535


Operate the machine until the oil is warm.

Park the machine on a level surface with front wheelsstraight ahead. Lower all attachments to the ground.

Apply a slight downward pressure to the attachments.Center the articulation of the machine and install theframe lock pin. The frame lock pin must move freelyin the frame. Move the front wheels to vertical andinstall the wheel lean bolt. Engage the parking brake.Stop the engine.


The hydraulic tank sight gauge

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Mom Mantenimiento 140h