16G MOTOR GRADER When Required Caterpillar

(41)Air Intake System

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NOTICE
Never service air cleaner when engine is running.

Service filter elements when RED indicator locks in the visible position.

Primary Element

1. Remove cover and primary element.

2. Clean inside of body and cover.

NOTE: The primary element should be replaced after being cleaned a maximum of 6 times. Replace the element once a year even though it has not been cleaned 6 times.

3. Clean and inspect element. See CLEANING AIR CLEANER ELEMENT.

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NOTICE
Always inspect primary element before and after cleaning, with a light bulb inside the element. Discard element if any tears, rips or damage is evident.

4. Install clean element and cover. Reset filter indicator.

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NOTICE
Tighten cover retainer bolts to 3 lb. ft. (4 N·m).

NOTE: If indicator still shows RED shortly after the installation of the clean primary element, install a new secondary element.

Secondary Element

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NOTICE
Always replace the secondary element. Do not attempt to reuse the element by cleaning.

NOTE: Replace the secondary element at the time the primary element is cleaned for the third time.

1. Remove cover and primary element. Remove and discard secondary element.

2. Cover air inlet opening with tape.

3. Clean entire air cleaner, including the precleaner, if necessary.

4. Uncover the air inlet opening.

5. Inspect gasket between filter housing and air intake manifold. If gasket is damaged, or if housing was separated from manifold, remove gasket, clean mounting surface and install a new gasket.

6. Install new secondary element. Torque element nuts to 20 ± 5 lb. ft. (25 ± 7 N·m).

7. Install clean primary element and cover.

8. Reset filter indicator.

Cleaning Air Cleaner Elements

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To prevent possible personal injury when using pressure air, wear safety face shield and protective clothing. Use 30 psi (205 kPa) maximum pressure air for cleaning purposes.

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NOTICE
Do not clean element by bumping or tapping. Do not use element with damaged pleats, gaskets or seals.

NOTE: Have spare elements on hand to use while cleaning used elements.

Pressure Air - 30 psi (205 kPa) Maximum

1. Direct air inside element along length of pleats.

2. Direct air outside element along length of pleats. Direct air inside element along length of pleats. Inspect element.

Water - 40 psi (280 kPa) Maximum

1. Direct water inside element along length of pleats.

2. Direct water outside element along length of pleats. Rinse, air dry thoroughly and inspect.

Detergent

1. Wash element in warm water and non-sudsing household detergent.

2. Rinse with clean water, see above.

3. Air dry thoroughly and inspect element.

Inspecting Element

1. Insert light inside clean and dry element and inspect. Discard element if rips or tears are found.

2. Wrap and store good elements in a clean, dry place.

(42)Fuel System - Primary Fuel Filter

Change fuel filter when fuel pressure gauge registers in the RED range with engine running.

1. Close fuel supply valve.

2. Loosen nut. Remove case and element.

3. Wash element and case in clean non-flammable solvent.

4. Install element and case.

5. Open fuel supply valve. Start engine and check for leaks.

NOTE: Change final fuel filter if fuel pressure gauge still registers in the RED range with engine running.

Final Fuel Filter

1. Close fuel supply valve.

2. Remove and discard filter.

3. Clean filter base gasket surface. Be sure all of old gasket is removed.

4. Lubricate new filter gasket with clean diesel fuel. Install filter.

5. Tighten filter additional 1/2to 3/4 turn after filter gasket contacts filter base.

NOTE: The filters may have rotation index marks spaced 90° apart. These marks should be used when tightening the new filter an additional 3/4 turn more.

6. Open fuel supply valve. Prime fuel system (see below). Start engine and check for leaks.

Priming the Fuel System

1. Loosen fuel line nut at filter.

2. Unlock priming pump plunger and operate pump.

3. When fuel flows free of bubbles, at loose nut, close pump and lock plunger.

4. Tighten nut and start engine. Inspect for leaks.

NOTE: If engine does not start, further priming is necessary as follows:

5. Loosen fuel line nut.

6. Operate priming pump until fuel flows free of bubbles.

7. Tighten nut to 30 ± 5 lb. ft. (40.8 ± 6.8 N·m). Start engine and check for leaks.

(43)Fuel Tank

1. Open fuel tank drain valve and drain sediment and moisture. Close drain valve.

2. Remove fuel tank filler cap.

3. Disassemble cap and wash in clean non-flammable solvent. Lightly oil element and assemble cap. Install cap.

(44)Circle Drive Housing

1. Inspect oil level whenever a leak develops or is suspected. (Check with engine stopped.)

2. Maintain oil level to bottom of fill plug. Add oil if necessary.

(45)Front Wheel Spindle Bearing Housings

1. Inspect oil level whenever a leak develops or is suspected. (Check with engine stopped.)

2. Maintain oil level to bottom of fill plug opening (one each side of vehicle). Add oil if necessary.

(46)Drawbar Ball And Socket

NOTE: For Automatic Blade Control equipped machines, see your AVSpare dealer for checking and adjustment procedures.

1. With blade 90° to frame, lower blade to ground. Inch (move slowly) machine to rear. Apply parking brake and stop engine to maintain a light load between draft bolt and adapter.

2. Measure clearance between ball and insert. Clearance should be .000 to .008 inch (0.000 to 0.203 mm).

To Adjust:

1. Support drawbar and circle.

2. Remove bolts and move drawbar back or machine forward.

3. Remove two capscrews from back of adapter and remove adapter.

4. Remove the two bolts and adapter that hold the socket together and remove the .010" (.25 mm) shim.

5. Install adapter. Adapter should now be hard to rotate.

6. Assemble the drawbar to the bolster. Tighten the bolts to 300 ± 20 lb. ft. (410 ± 25 N·m).

(47)Blade Circle - Circle to Shoe Clearance

1. With machine level and blade 90° to frame, lower blade to ground and apply slight down pressure.

2. Support front of circle so that circle is touching drawbar wear strips, at a minimum of three places around the circle.

3. Measure thickness of all wear strips. Replace all wear strips if any one is .06 inch (1.5 mm) or less.

4. Make sure bolts holding shoes to drawbar are tight.

5. Measure clearance between the top of each shoe (6 shoes) and circle. Distance should be between .010 and .090 (0.25 and 2.3 mm). Adjust if necessary.

NOTE: Clearance should be measured at both ends of shoe and clearance of smallest dimension used to make adjustment. To tight of clearance may prevent circle rotation.

6. Lubricate circle guide shoes. See CIRCLE GUIDE SHOES in the EVERY 10 SERVICE HOURS OR DAILY section.

7. Clean top of circle, removing old lubricant. Apply lubricant to top of circle and inner vertical surface of circle, which the shoes bear against.

To Adjust:

1. Adjust one shoe at a time. Loosen mounting bolt (A) and remove bolts (B).

2. Remove shims to bring clearance to approximately .020 inch (0.50 mm) or to the minimum clearance which will permit circle rotation but not less than .020 inch (0.50 mm).

3. Install and tighten all mounting bolts.

4. Measure clearance between each shoe and circle.

5. Repeat Circle to Shoe Clearance inspection procedure after all shoes are adjusted.

NOTE: After all adjustments are made, circle must rotate freely without binding. Additional clearances may be required to compensate for a damaged circle.

Circle to Pinion Clearance (Circle and Pinion Mesh)

1. Park on level ground. Set blade at 90° to machine frame, lower blade to ground and apply slight down pressure.

2. Inch (move slowly) machine forward and apply parking brake to hold a light load between front shoes and circle. Stop engine.

3. Measure distance between bottom flange of pinion and inner machined surface of circle. Distance should be 2.28 to 2.40 inches (57.9 to 60.9 mm).

4. Adjust front shoes if distance between bottom flange of pinion and inner machined surface of circle is not correct. Circle tooth must not bottom in pinion tooth. See To Adjust Front Shoes.

5. Measure clearance between each rear shoe and circle. Distance should be approximately .030 inch (0.76 mm) when front shoe adjustment is correct. Adjust rear shoes if necessary. See To Adjust Rear Shoes.

6. Measure clearance between each intermediate shoe and circle. Distance should be approximately .030 inch (0.76 mm). If measurement is greater than 0.60 inch (0.25 mm) adjust shoes.

NOTE: After all adjustments are made, circle must rotate freely without binding. Clearances may have to be increased if worn or damaged circle is being adjusted.

To Adjust Front Shoes

1. Loosen mounting bolts of front and rear shoes.

2. Loosen front shoe adjusting screw locknuts.

3. Turn adjusting screws in or out to obtain 2.40 inch (60.9 mm) between botton flange of pinion and inner machined surface of circle. Front shoes must be adjusted uniformly.

4. Tighten adjusting screw locknuts and shoe mounting bolts.

5. measure distance between bottom flange of pinion and inner machined surface of circle.

6. If correct measurement cannot be obtained and front shoes are worn, install new shoes and repeat adjustment procedure.

To Adjust Rear Shoes

1. Loosen mounting bolts (A) and adjusting screw lock nuts (B).

2. Turn adjusting screws in or out to obtain .030 inch (0.76 mm) clearance between shoe and circle.

NOTE: .030 (0.76 mm) clearance may have to be increased on machines which have worn or damaged circles to permit free rotation of the circle.

3. Tighten locknuts and mounting bolts.

4. Measure clearance. If correct measurement cannot be obtained, install new shoes and repeat adjustment procedure.

To Adjust Intermediate Shoes

1. Loosen mounting bolts (A) and adjusting screw locknuts.

2. Turn adjusting screws in or out to obtain .030 inch (0.76 mm) clearance between shoe and circle.

3. Tighten locknuts and mounting bolts.

4. Measure clearance. If correct measurement cannot be obtained install new shoes and repeat adjustment procedure.

NOTE: If measurement is greater than .12 inch (3.1 mm) on both intermediate shoes, replace them. Otherwise, center circle by adjusting rear shoes to equalize clearance.

(48)Cutting Edge And End Bits - Cutting Edge

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NOTICE
To prevent damage to moldboard, replace cutting edge when moldboard can contact ground with blade tipped fully back.

1. Lower moldboard onto blocks. Stop engine.

2. Remove cutting edge bolts.

3. Remove cutting edge.

4. Install new cutting edge. Use new bolts if old ones are damaged.

End Bits

1. Remove end bit bolts. Remove end bit.

2. Install new narrow end bits if old ones are worn or damaged.

3. Install new end bits. Use new bolts if old ones are damaged.

(49)Ripper Teeth

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To avoid possible injury to eyes, wear protective glasses when striking pins. The pin when struck, can fly out and cause injury to nearby personel.

Replace ripper tip when worn to near the shanks. This will prevent shank damage.

1. Drive pin out from washer side of shank and remove old tip.

2. Clean pin, washer and shank assembly.

3. Install washer and new tip.

4. Install pin from the side opposite washer.

(50)Blade Accumulator

If lift cylinder movement becomes stiff, measure nitrogen precharge. Your AVSpare dealer is equipped to perform this measurement.

(51)Top Of Circle

1. Clean top of circle to remove old grease and dirt. Apply grease to top of circle.

(52)Service Brakes

Test stopping ability of service brakes whenever a deficiency is suspected.

To Test Service Brakes:

1. Drain moisture and sediment from both sections of the air reservoir.

2. Start engine and let the air pressure go up to cutout pressure, 115 to 125 PSI (795 to 860 kPa).

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When testing service brakes, fasten seat belt, and be ready for the sudden stop.

3. Operate the machine in 4th speed forward, at high idle, on a clay-type surface.

4. Push the service brake pedal down fully. Rear wheels must slide and stall the engine.

5. If rear wheels do not slide, and the engine does not stall, see your AVSpare dealer.

(53)Parking/Emergency Brake

Test holding ability of parking/emergency brake whenever a deficiency is suspected.

To Test Parking/Emergency Brake:

1. Drain moisture and sediment from both sections of the air reservoir.

2. Start engine and let the air pressure go up to cutout pressure, 115 to 125 PSI (795 to 860 kPa).

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When testing parking/emergency brake, fasten seat belt, and be ready for the sudden stop.

3. Operate the machine in 4th speed forward, at high idle, on a clay-type surface.

4. Move transmission shift lever to NEUTRAL and the parking/emergency brake lever to PARK. The rear wheels must stop turning immediately (slide).

5. If the wheels do not slide, see your AVSpare dealer.

(54)Cooling System - Cleaning

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Always inspect cooling system with engine stopped. Remove radiator cap slowly to relieve pressure. Steam can cause personal injury. Inhibitor contains alkali, avoid contact with skin and eyes to prevent personal injury.

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NOTICE
Never add coolant to an overheated engine, allow engine to cool first.

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NOTICE
If machine is to be stored in, or shipped to, an area with below freezing temperatures, the cooling system must either be protected to the lowest expected ambient temperature, or drained completely. Do not use AVSpare Cooling System Inhibitor with Dowtherm 209.

NOTE: Add 1 pint (.5 litre) of AVSpare Cooling System Inhibitor, or equivalent, per 4 U.S. gallons (15 litres) of coolant to give a 3% concentration of cooling system inhibitor to the cooling system.

Machine level, engine stopped and cool.

1. Loosen radiator cap slowly to relieve pressure.

2. Open cooling system drain valve and drain coolant.

3. Remove coolant drain plug from bottom of oil cooler and drain coolant.

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Use all cleaning solutions with care.

NOTE: Most commercial cooling system cleaners may be used.

4. Close drain valve and install oil cooler drain plug. Fill system with cleaning solution. ⁽¹⁾

5. Start and run engine for 1/2 hour. Stop engine and drain cleaning solution.

6. Flush system with clean water until draining water is clean. Do not run engine while flushing.

7. Close drain valve and install oil cooler drain plug. Fill system with neutralizing solution. ⁽²⁾

8. Start and run engine for 10 minutes. Stop engine and drain neutralizing solution.

9. Flush system with clean water, until draining water is clean. Do not run engine while flushing.

10. Close drain valve and install oil cooler drain plug.

11. Mix antifreeze solution to provide protection to the lowest expected ambient temperature.

NOTE: Do not completely fill cooling system. Allow for addition of AVSpare Corrosion Inhibitor, or equivalent.

12. To help avoid air locks, add coolant slowly, at 5 U.S. gallons (19 litres) per minute or less.

13. Add antifreeze solution. See REFILL CAPACITIES.

14. Start and run engine with radiator cap removed. Allow coolant to warm and level to stabilize.

15. Add coolant, if necessary, to bring level to within 1 to 1-1/2 inches (2.5 to 3.8 cm) below top of fill pipe.

16. Observe condition of filler cap gasket. Replace if damaged. Install filler cap.

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⁽¹⁾2 lb. Sodium Bisulfate (NaHSO₄) per 10 U.S. gallons (1 kilogram per 40 litres) water.

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⁽²⁾1/2 lb. Sodium Carbonate Crystals (Na₂CO₃ · 10 H₂O) per 10 U.S. gallons (250 grams per 40 litres) water.

(55)Cooling System Relief Valve

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Always inspect cooling system with engine stopped. Remove radiator cap slowly to relieve pressure. Steam can cause personal injury. Inhibitor contains alkali, avoid contact with skin and eyes to prevent personal injury.

Clean or replace valve if system overheats or loss of coolant is observed.

(56)Seat Belts

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Replace seat belt every 3 years regardless of appearance.

Inspect seat belt and mounting hardware. Replace any damaged components.

(57)Fuses

When electrical circuits do not function, remove and inspect fuses. Replace any fuse which has a broken element.

(58)Air Conditioner

Wash filter elements when a reduction of air circulation in cab is noted.

1. Open cover and remove filter elements.

2. Clean elements by using pressure air or by tapping element on a smooth object.

3. Install element.