lubrication & maintenance chart 222360 fig. 1 · 2011. 10. 28. · 4/23/09 3 fs222360_er15...
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4/23/09 1 FS222360_Er15
LUBRICATION & MAINTENANCE CHART 222360Fig. 1
SECTION A-A
SECTION C-CSECTION B-B
20-F
20-L20-F
22FUEL TANK VENT HOSE
A
A
B
B
C
C
20-D
20-D20-F
20-D
LEFT SIDE FUEL TANKRIGHT SIDE FUEL TANK
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LUBRICATION & MAINTENANCE CHART 222360Fig. 2
LEFT VIEW
RIGHT VIEW
4-L4-F
TRANSFER CASE COOLER
DIFFERENTIAL OIL COOLER
22
BRAKE OIL COOLER
2-A
4-D
21
2
1-D
1-F 1-L
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LUBRICATION & MAINTENANCE CHART 222360Fig. 3
DO
IN OUT
INOUT
ROTATED FORCLARITY
OUT INOUT IN
O UTININ
45
9
PUMP, BRAKECOOLING
PUMPDRIVE
PUMP,TRANSMISSION
PROPSHAFT
PUMP,ACCUMULATOR
SYSTEM
HYDRAULIC TANKMOUNTING GROUP
30
41TORQUE
CONVERTERSUCTIONSCREEN
TORQUECONVERTER
PUMP, ADDITIONALBRAKE COOLING &
HYDRAULIC SYSTEM
TRUCKBODY
FILTER,STEERING
ENGINE
FRONT
TRUCKBODY
AS VIEWEDFROM REAR
FRONT
10TORQUE
CONVERTERINLET CHARGE
FILTER 9 30
HYDRAULICCHARGEFILTER
AS VIEWEDFROM REAR
AS VIEWEDFROM LEFT
AS VIEWEDFROM TOP
FILTER,STEERING
27
27
15
12-D
12-L
12-F
77
7
7
9
9
LOCK UPCHARGE
LUBE
TRANSMISSION FILTERS
9
9
CHECKVALVE1" NPT
DIFFPUMP
TFCPUMP
TFCSUCTION
11
TFCPRESSURE
13
DIFFPRESSURE
39
FROM TFCPUMP
TO TRANSFERCASE COOLER
FROM DIFFPUMP
5 PSIPRESSURE
SWITCH(TFC LOW
PSI SWITCH)
65 PSICHECKVALVE
65 PSICHECKVALVE
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LUBRICATION & MAINTENANCE CHART 222360Fig. 4
HYDRAULIC TANK
VIEW A-A
BREATHER BOXAS VIEWED FROM REAR OF MACHINE
TRANSMISSION TANK
29
29
35
HYDRAULIC TANKFILLER CAP
19
17
17-L
28
6-F6-LSIGHT GLASS
6-LDIPSTICK
6-D
BATTERY BOX
TRANSMISSION GUARD GROUP AXLE ASSEMBLY
24-D
A
A24-L
TO BREATHER BOX
TRANSMISSION TANK
25(DIFFERENTIAL BREATHER)
TRACTION CONTROL GROUP
24-F
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LUBRICATION & MAINTENANCE CHART 222360Fig. 5
NOTE: SOME ITEMS, WHICH ARE NORMALLY HIDDEN, ARE SHOWNHERE FOR CLARITY ONLY.
LEFT SIDE VIEW
LEFT SIDE
LEFT SIDE REARAS VIEW FROM FRONT
AS VIEWED FROM REAR
AS VIEWED FROM REAR
SPINDLE
HUB
BRAKES, CAT 793
FINAL DRIVE
26-D
AIR CLEANER
MUFFLERHEAT SHIELD
PIPE
23aPRIMARYELEMENT
23bSECONDARYELEMENT
FRONT OF TRUCK
REAR SUSPENSION CYLINDER
LOWER PRESSURE GAUGE,LEFT CYLINDER
38
LOWER PRESSURE GAUGE,RIGHT CYLINDER
NITROGEN CHARGINGVALVE5
REAR AXLE ASSEMBLY
NITROGEN CHARGING VALVE
UPPER PRESSURE GAUGE,LEFT CYLINDER
UPPER PRESSURE GAUGE,RIGHT CYLINDER
37
37
LEFT REAR SUSPENSIONCYLINDER
RIGHT REARSUSPENSION CYLINDER
45ADJUST PIN TO0.002 ± 0.001 FT-LBS.
24-L
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LUBRICATION & MAINTENANCE CHART 222360Fig. 6
TOP VIEW
VIEW A-A
FRONT OF TRUCK
AS VIEWED FROM THEREAR OF THE MACHINE
VIEWED FROM LEFTSECTION B-BLH SUSPENSION MODULE
VIEWED FROM REAR
HYDRAULIC MODULE
16
16
14
1616
14148
A A
18MAIN HYDRAULIC FILTER
CONNECTS TO RHCYLINDER STR PIVOT
CONNECTS TO FRONTBULKHEAD FITTING RH
WHIFFLETREE
CONNECTS TO REAR BULKHEAD FITTING RH WHIFFLETREE
CONNECTS TO FRONT BULKHEADFITTING LH WHIFFLETREE
CONNECTS TO BOTTOM PORTWHIFFLETREE TUBE PORT
CONNECTS TO LH CYLINDER STR PIVOT
CONNECTS TO REAR BULKHEAD FITTINGLH WHIFFLETREE
CONNECTS TO TOP PORT WHIFFLETREETUBE PIVOT
CONNECTS TO RH CYLINDER ROD STR PIVOT
CONNECTS TO LH CYLINDER ROD STR PIVOT
B
B
LIMIT SWITCH
ADJUSTMENTLINK
STRUT
34
STEERING HOUSING
SCISSOR LINKS
UPPER TAPER POPPER
STEERING HOUSING
34
LOWER TAPER POPPER
LOWER BEARING
3
UPPER BEARING
SEAL
32-F
32-L
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LUBRICATION & MAINTENANCE CHART 222360Fig. 7
A
A
19
25
6
33
10a
15
TO HYDRAULIC TANK
TO DIFFERENTIAL
TO TRANSMISSION TANK
TO TORQUE CONVERTER
TO TRANSFER CASE
TOP OF TRANSFER CASE
24-F
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LUBRICATION & MAINTENANCE CHART 222360Fig. 8
VIEW B-B
VIEW A-A
B B
HYDRAULIC TANKTO 19
TRANSFER CASE
TO 15
ELBOW TO TORQUE CONVERTER FILTER
PUMP DRIVE
TORQUE CONVERTER
FLYWHEEL HOUSING
TO DIFFERENTIAL BREATHERTO TRANSMISSION TANKBREATHER
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CH240C & 200C SERIES II LUBRICATION INFORMATIONThe service points shown in the preceding illustrations are called out in the Lubrication Chart below. This informa-tion includes lubrication points, filters, breathers and fill points for various liquids. The service points are identified with a number, some of which are followed by a letter (F, D, or L). The letter “F” signifies a fill point, the letter “D” signifies a drain point, and the letter “L” signifies a level checkpoint. This can be a sight glass, a plug, a dipstick, or a standpipe. The information in the lubrication chart is intended to supplement the original manufacturer's recommen-dations. Refer to the equipment manufacturer's manual for additional recommendations. If a conflict exists between this lubrication chart and the manufacturer's manual, the equipment manufacturer's manual takes precedence.
Use the “Maintenance Interval Schedule” found in the Caterpillar 789C Off-Highway Truck docu-ment SEBU7174. Insert the additional Kress components listed in the charts on the following pages into the appropri-ate interval section for your site’s maintenance schedule. If you have any questions about sampling or maintenance intervals, contact your local Caterpillar dealer.
TIME INTERVAL
SERVICEPOINT FIG.# SERVICE POINT DESCRIPTION REQUIRED SERVICE LUBE
# OFFITTINGS
8 HOURS 1-L 2 Engine Crankcase Oil Check level EO 1 dipstick4-L 2 Engine Coolant Check level GLY 1 cap6-L 4 Transmission Fluid Check level TDTO 1 dipstick
6-L 4 Transmission Fluid Check levelQuick Check ONLY TDTO 1 sight glass
The Transmission Tank has a Dipstick and a Sight Gauge. The Sight Gauge is to be used as a Quick visual check only. The Dipstick is for accurate measuring of the fluid level. The vehicle needs to be set at the ride height with the engine off. Check the dipstick for fluid level and fill, if needed, to the “Full” mark,
12-L 3 Transfer Case Oil Check level TFCO sight glass17-L 4 Hydraulic Tank Check level HO sight glass20-L 1 Fuel Tank Check level DF sight tube23a 5 Primary Engine Air Filters Check indicators 4 filters
23b 5 Secondary Engine Air Filter Change every 4th primary change 4 filters
24-L 4 Axle/differential Check level GO sight glass29 4, 7 Accumulator Precharge Check Pressure DRY N2 5 gauges35 4 Front Strut(Top) Nitrogen Charge Check Pressure DRY N2 2 gauges36 2 Front Strut(Bottom) Nitrogen Fitting Check Pressure DRY N2 2 fittings37 4 Rear Suspension Upper Nitrogen Gauge Check Pressure DRY N2 2 gauges38 4 Rear Suspension Lower Nitrogen Gauge Check Pressure DRY N2 2 gauges
Tire Valve Check Air Pressure 8 valvesService & Park Brakes Check for Proper FunctionSeat Belts Inspect
50 HOURSOr Auto
Lube
5 4 Rear Axle Pivot Pin & Rear Suspension Cylinder Pivots Grease MPG 4 fitting
8 6 Whiffletree Pivot Grease MPG 1 fitting14 6 Steering Cylinder Rod & Head Grease MPG 4 fittings16 6 Steering Draglink Connections Grease MPG 4 fitting44 1 Cab Air Filter Clean or Replace 1 filter
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250HOURS
4-L 2 Coolant Check Condition GLY cap33 7 Breather Box Filter Check and/or Clean 2 filters
34 Front Suspension Bearings Lube, Pump till grease is expelled from Dust seal at top. MPG 2 fittings
27 3 Prop Shaft, Pump Drive Lube MPG 2 fittings32-L 6 Front Wheel Bearings Check Level GO 4 plugs32-F 6 Front Wheel Bearings Add to Check Level GO 4 plugs
500HOURS
9 3 Transmission Filter Change 3 filters40 2 Secondary Fuel Filter Clean 2 filters10 3 Torque Converter Filter Change 1 filter21 2 Primary Fuel Filter (Water Separator) Change 1 filter28 4 Tranmission Tank Strainer Clean 1 strainer18 6 Main Psi Hydraulic Filter Change 1 filter
12-D 3 Transfer Gear Case Drain 1 plug12-F 3 Transfer Gear Case Refill TFCO 1 plug13 3 Transfer Case Filter Psi Change 1 filter11 3 Transfer Case Filter (Suction) Change 1 filter2a 2 Oil Renewal Filter Change 1 filter
1-D 2 Engine Oil Drain 1 plug1-F 2 Engine Oil Refill EO cap2 2 Engine Oil Filter Change 3 filters30 3 Hydraulic Charge Filter (Brake Cooling Change 1 filter42 1 Suspension Filter, Front Change 2 filters43 3 Steering Filter, Inlet Change 1 filter33 7 Breather Box Filter Clean or Replace as needed 2 filters
1000HOURS
6-D 5 Transmission & Cooler Drain Fluids plugs6-F 4 Transmission & Cooler Refill Fluids TDTO cap
7 3 Grease Zerks On Transfer Case Bushing Housing
Pump Lube till grease expells from around bushing. MPG 4 fittings
39 3 Differential Case Filter Psi Change 1 filter15 3 Transfer Case Breather Clean or Replace as needed 1 breather19 4 Hydraulic Tank Breather Clean or Replace as needed 1 breather22 1 Fuel Tank Vent Hose Inspect - Clean Drain Hose End 2 hoses25 4 Differential Breather Clean or Replace as needed 1 breather6 7 Transmission Tank Breather Clean or Replace as needed 1 breather
10a 7 Torque Converter Breather Clean or Replace as needed 1 breather2000
HOURS26-D 5 Final Drive Drain 2 plugs
24-D 4 Axle/differential Drain 1 plug24-F 7 Axle/differential/Final Drive Refill GO 1 plug
17 4 Hydraulic Tank
Change fluid or as fluid sam-pling dictates. Also check tank cleanliness & all interior tank parts for proper serviceability
HO 1 tank
41 3 Torque Converter Screen Change 1 screen5000
HOURS22 2 Upper Drive Shaft Slip Joint Grease ULTRA 1 fitting
TIME INTERVAL
SERVICEPOINT FIG.# SERVICE POINT DESCRIPTION REQUIRED SERVICE LUBE
# OFFITTINGS
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6000HOURS
4-D 1 Engine Coolant Drain plug4-F 1 Engine Coolant Refill GLY cap3 6 Front Suspension Scissors Lube MPG 4 fittings
LIQUIDS LISTPART # LUBRICANT TYPE ABBR.105031 Electrical Sealer -203394 Freon: Air conditioner refrigerant R-134a -033162 Diesel Fuel, meeting ASTM D-975 (Grade 2-D)/cetane No.40 DF
147862 Engine Oil 10w30 A.P.I. Classification: CG4/CF4 per Caterpillar document SEBU6385; Meeting Military Spec. Mil-l-2104-d; 0 Deg. F. And Below Use Fluid Heaters E040
147803Antifreeze/Coolant, extended Life. Ethylene glycol base containing approximately 90-97% ethylene glycol; 1.5-3% corrosion inhibitors; up to 5% water and anti-foam agents. Mixture should be approxi-mately 50/50 water and antifreeze.
GLY
223472 Gear Lube: SAE 60 gear lubricant meets CAT FD-1 Spec. GO221257 Hydraulic Oil 10 Wt.; CAT TO-4 Spec or equivalent HO
035620 741 EP multi-purpose lithium soap grease (for components other than high-temperature areas and drive shafts) MPG
150587 Transfer Case Oil SAE 30 TDTO oil or approved equivalent. Meeting military specs Mil-l-46152; +5 Deg. F. To -30 Deg. F. Use SAE 10 Wt.: -30 Deg. F. -54 Deg. F. Use SAE 5W20 TFCO
202887 Grease: B-51 Ultra-blue Lubricant (for upper & lower drive shafts) ULTRA
REPLACEMENT FILTERS LIST
PART NO. QTY DESCRIPTIONSERVICE
POINT CATERPILLAR NO.3 Engine Oil Filters 2 2P4005
212314 3 Transmission Filter Elements 9 1R07733 O-ring (For Installing 212314) 2S8439
040411 1 Strainer, Transmission Tank 28 3D6678212313 2 Torque Converter Filter Element 10 1R0741
2 O-ring (For Installing 212313 Filter) 8T6444212315 1 Torque Converter Screen 41 6E1473027602 3 Hydraulic Oil Filters 18, 42061322 3 O-ring (For Installing 027602 Filter)211606 1 Filter, Hydraulic Charge (Brake Cooling) 30
1 O-ring (Supplied With 211606 Filter)1 Fuel Filter, Primary (Water Seperator) 21 111-07161 O-Ring (For Installing 111-0716 Filter) 3J-1907
Gasket (2)(For Installing 111-0716 Filter) 4P-73832 Fuel Filter (Secondary) 40 1R07551 Oil Renewal Filter (Part of 222362) 2a 1R0750
050388 4 Primary Air Cleaner Element 23a017267 4 Secondary Air Cleaner Element 23b
1 Heater/AC Air Filter 44 1193355221642 1 Steering Filter Element 43 4T6915203608 1 TFC Suction Filter 11
TIME INTERVAL
SERVICEPOINT FIG.# SERVICE POINT DESCRIPTION REQUIRED SERVICE LUBE
# OFFITTINGS
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When replacing the Front Suspension filters ensure that “ALL” pressure has been discharged before proceeding. See Kress document FS222775 in the Service Manual for more details.
129530 1 TFC Pressure Filter 13 1R0719212314 1 Diff Pressure Filter Element 39 1R0773223552 2 Filter, Breather Box 33125427 1 Breather, Transfer Case 15 6G0078065934 1 Breather, Hydraulic Tank 19125427 1 Breather, Differential 25 6G0078065934 1 Breather, Transmission Tank 6014159 1 Breather, Torque Converter 10a
REPLACEMENT FILTERS LIST (Continued)
PART NO. QTY DESCRIPTIONSERVICE
POINT CATERPILLAR NO.
FILTER CANISTER SPRAYED SAFETY RED
MOUNTING PLATEWARNING PLATE ATTACHED
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The Transmission Tank has a Dipstick and a Sight Gauge. The Sight Gauge is to be used as aQuick visual check only. The Dipstick is for accurate measuring of the fluid level.
FLUID CAPACITY CHART
DESCRIPTION IMPERIAL UNITS METRIC UNITSA/C R-134a Refrigerant 5 lbs. 2.27 kgEngine Crankcase Oil 56 gal. 212 L
Engine Coolant 134 gal. 511.0 LTransmission Fluid 70 265
Transfer Case 6 22.7Hydraulic Oil 241 gal. 912.3 LDiesel Fuel 874 gal. (both tanks) 3308.5 L
Rear Axle & Differential 80 gal. 302.8 LFinal Drive 35 gal. per side 132.5 L
Front Wheel Bearings 12 gal. (6 per axle) 45.4 L (22.7 per axle)Front Suspension 35 lbs. (per module) 15.9 kg
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