manual de mantenimiento 773f

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MAINTENANCE INTERVALSOperation and Maintenance Manual Excerpt

SEBU7794-08May 2011

Operation andMaintenanceManual773F and 775F Off-Highway TruckEED1-Up (Machine)DLS1-Up (Machine)

SAFETY.CAT.COM

SEBU7794-08 127Maintenance Section

Maintenance Interval Schedule

i04380455

Maintenance Interval ScheduleSMCS 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. All adjustments, the use of properlubricants, fluids, filters, and the replacement ofcomponents due to normal wear and aging areincluded. Failure to adhere to proper maintenanceintervals and procedures may result in diminishedperformance of the product and/or accelerated wearof components.

Use mileage, fuel consumption, service hours, orcalendar time, WHICH EVER OCCURS FIRST,in order to determine the maintenance intervals.Products that operate in severe operating conditionsmay require more frequent maintenance. Refer to themaintenance procedure for any other exceptions thatmay change the maintenance intervals.

Note: The aftertreatment system can be expectedto function properly for the useful life of theengine (emissions durability period), as defined byregulation. All prescribed maintenance requirementsmust be followed.

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

Note: If Cat HYDO Advanced hydraulic oils are used,the hydraulic oil change interval is extended to 3000hours. S·O·S services may extend the oil changeeven longer. Consult your Cat dealer for details.

When Required

Air Conditioner Filter - Clean .............................. 129Automatic Lubrication Reservoir - Fill ................. 129Battery - Recycle ................................................ 131Battery or Battery Cable - Inspect/Replace ........ 131Cab Air Filter - Clean/Replace ............................ 136Circuit Breakers - Reset ...................................... 139Cooling System Coolant (ELC) - Change ........... 139Display and Camera - Clean ............................... 151Engine Air Filter Primary Element - Clean/Replace ............................................................. 152Engine Air Filter Secondary Element - Replace .. 154Engine Air Precleaner - Clean ............................ 155Ether Starting Aid Cylinder - Replace ................. 165Fuel System - Fill ................................................ 171Fuel System - Prime ........................................... 172Fuses - Replace .................................................. 177High Intensity Discharge Lamp (HID) - Replace .. 179

Oil Filter - Inspect ................................................ 190Rim - Inspect ....................................................... 192Screen (Brake Oil Cooler) - Clean ...................... 194Screen (Hoist and Brake Tank) - Inspect/Clean/Replace ............................................................. 195Suction Screen (Torque Converter Scavenge) -Clean ................................................................. 203Traction Control System (TCS) - Test ................. 209Window Washer Bottle - Fill ................................ 209Window Wiper - Inspect/Replace ........................ 210Windows - Clean ................................................. 210

Every 10 Service Hours or Daily

Backup Alarm - Test ............................................ 130Brakes, Indicators and Gauges - Test ................. 133Braking System - Test ......................................... 133Cooling System Coolant Level - Check .............. 143Differential and Final Drive Oil Level - Check ..... 150Engine Air Filter Service Indicator - Inspect ........ 155Engine Oil Level - Check .................................... 158Fuel System Primary Filter (Water Separator) -Drain ................................................................. 173Fuel Tank Water and Sediment - Drain ............... 176Hoist and Brake Tank Oil Level - Check ............. 182Hoist and Brake Tank Oil Level - Check ............. 183Seat Belt - Inspect .............................................. 197Secondary Steering - Test .................................. 198Steering System Oil Level - Check ..................... 202Torque Converter and Transmission Oil Level -Check ................................................................ 207

Every 50 Service Hours or Weekly

Belts - Inspect/Replace ....................................... 131Body Pivot Bearings - Lubricate ......................... 132Central Lubrication System - Lubricate ............... 137Front Suspension Cylinder Rods - Lubricate ...... 168Hoist Cylinder Bearings - Lubricate .................... 180Magnetic Plug (Wheels) - Check ........................ 184Rear Axle A-Frame Bearing - Lubricate .............. 191Rear Axle Housing Lateral Control Rod Bearings -Lubricate ........................................................... 191Rear Suspension Cylinder Bearings - Lubricate .. 191Steering Cylinder Bearings - Lubricate ............... 199Steering Tie Rod and Pin Bearings - Lubricate ... 203Tire Inflation - Check ........................................... 205

Initial 500 Service Hours

Electronic Unit Injector - Inspect/Adjust .............. 152Engine Brake Slave Piston Lash - Inspect/Adjust ................................................................ 156Engine Valve Lash - Check/Adjust ...................... 164Engine Valve Rotators - Inspect ......................... 164Frame and Body Support Pads - Clean/Inspect .. 167

Initial 500 Hours (for New Systems, RefilledSystems, and Converted Systems)

Cooling System Coolant Sample (Level 2) -Obtain ............................................................... 145

128 SEBU7794-08Maintenance SectionMaintenance Interval Schedule

Every 500 Service Hours

Cooling System Coolant Sample (Level 1) -Obtain ............................................................... 144Differential and Final Drive Oil Sample - Obtain .. 151Engine Oil Sample - Obtain ................................ 159Front Wheel Oil Sample - Obtain ........................ 170Hoist and Brake Tank Oil Sample - Obtain ......... 184Steering System Oil Sample - Obtain ................. 202Torque Converter and Transmission Oil Sample -Obtain ............................................................... 208

Every 500 Service Hours or 3 Months

Breather (Hoist and Brake Tank) - Replace ........ 135Breather (Torque Converter and Transmission) -Replace ............................................................. 135Differential and Final Drive Oil - Inspect ............. 150Engine Crankcase Breather - Clean ................... 157Engine Crankcase Breather - Clean ................... 158Engine Oil and Filter - Change ........................... 160Frame - Clean/Inspect ........................................ 166Front Wheel Oil - Change ................................... 168Front Wheel Oil - Inspect .................................... 169Front Wheel Oil Level - Check ............................ 170Fuel System Primary Filter (Water Separator) -Replace ............................................................. 173Fuel System Secondary Filter - Replace ............ 175Fuel Tank Cap and Strainer - Clean ................... 176Magnetic Screen (Transmission) - Clean ............ 185Oil Filter (Parking Brake Release) - Replace ...... 186Oil Filter (Power Train) - Replace ....................... 187Oil Filter (Steering Pump Case Drain) - Replace .. 188Oil Filter (Steering) - Replace ............................. 189Suspension Cylinder - Check ............................. 204

Every 1000 Service Hours or 6 Months

Frame and Body - Inspect .................................. 166Frame and Body Support Pads - Clean/Inspect .. 167Hoist and Brake Tank Oil - Change .................... 180Rollover Protective Structure (ROPS) - Inspect .. 194Seat Suspension - Inspect/Lubricate .................. 197Service Brakes - Inspect ..................................... 198Steering Linkage - Inspect .................................. 199Steering System Oil - Change ............................ 200Torque Converter and Transmission Oil -Change ............................................................. 205

Every 2000 Service Hours or 1 Year

Breather (Differential and Final Drive) - Replace .. 135Differential Thrust Pin Clearance - Check .......... 148

Every Year

Cooling System Coolant Sample (Level 2) -Obtain ............................................................... 145

Every 2 Years

Receiver Dryer (Refrigerant) - Replace .............. 192

Every 3000 Service Hours or 2 Years

Cooling System Pressure Cap - Clean/Replace .. 145Electronic Unit Injector - Inspect/Adjust .............. 152Engine Brake Slave Piston Lash - Inspect/Adjust ................................................................ 156Engine Valve Lash - Check/Adjust ...................... 164Engine Valve Rotators - Inspect ......................... 164Radiator Core and Aftercooler - Clean ............... 190

Every 3 Years After Date of Installation orEvery 5 Years After Date of Manufacture

Seat Belt - Replace ............................................. 197

Every 4000 Service Hours or 1 Year

Differential and Final Drive Oil - Change ............ 149


Cooling System Coolant Extender (ELC) - Add .. 141


Cooling System Water Temperature Regulator -Replace ............................................................. 146

Every 7500 Hours or 568 500 L(150 000 US gal) of Fuel

Engine Components - Rebuild/Install Reman ..... 157Engine Water Pump - Inspect ............................. 164

Every 10 000 Service Hours

Steering Ball Stud - Replace ............................... 199

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ........... 139

Every 15 000 Service Hours

Rim - Inspect ....................................................... 193

Every 15 000 Hours or 1 137 000 L(300 000 US gal) of Fuel

Engine Components - Clean/Inspect, Rebuild/InstallReman, Install New ........................................... 156


Air Conditioner Filter - Clean

i02531877

Air Conditioner Filter - CleanSMCS Code: 7320-070-FI

If a reduction in air circulation is noticed, clean theradial seal air filter for the air conditioner.

The air filter element for the air conditioner is locatedbehind the access door on the left rear of the cab.

g01266569Illustration 139

1. Open the access door and remove air filterelement (1).

2. Visually inspect the air filter element beforecleaning. Inspect the air filter element for damageto the seal, the pleats, and the outer cover.Replace a damaged air filter element with a newair filter element.

3. Use low pressure compressed air in order toremove the dust from the dirty air filter element. Airpressure must not exceed 207 kPa (30 psi). Directthe air flow up the pleats and down the pleats fromthe inside of the filter element. Take extreme carein order to avoid damage to the pleats.

4. Install the clean air filter element and close theaccess door.

i02748690

Automatic LubricationReservoir - Fill(If Equipped)SMCS Code: 7540-544-TNK

NOTICECheck that the lines attached to all the remote greasefittings are undamaged. If the grease lines are split,grease will not reach the components that require lu-bricating. Machine damage will result.

NOTICEDo not overfill the automatic lubrication reservoir.Damage to the automatic lubrication system couldresult.

1. Park the machine on a level surface and stop theengine. Make sure that the transmission controlis in the PARK position.

130 SEBU7794-08Maintenance SectionBackup Alarm - Test


2. Fill the autolube reservoir through remote fill port(1).


3. Use sight gauge (2) and sight gauge (3) todetermine the grease level in the reservoir.

Note: The bulk capacity of the grease reservoir is15 L (3.9 US gal).

The automatic lubrication reservoir provideslubrication for many components. There arelubrication distribution valves at the followinglocations: rear of machine, left side of machine, andright side of machine.

If the lubrication pump becomes damaged, greasecan be applied directly to the fittings on thelubrication distribution valves. Refer to Operation andMaintenance Manual, “Central Lubrication System -Lubricate” for more information.

For more information on the autolube system, referto Specifications, Systems Operation, Testing andAdjusting, RENR8285, “773F/775F Off-HighwayTruck Automatic Lubrication System”.

i03448882

Backup Alarm - TestSMCS Code: 7406-081

The backup alarm alerts the personnel behind themachine that the machine is backing up. The backupalarm is located at the rear of the machine.

1. Park the machine on a level surface and stop theengine.

2. Make sure that the area behind the machine isclear of personnel and clear of obstacles.

3. Turn the engine start switch to the ON position.

Note: Do not start the engine.

4. Turn the fan speed switch to the OFF positionand turn off the entertainment radio (if equipped).Open a door or a window.

5. Apply the service brakes.

6. Move the transmission control to the REVERSEposition and listen for the backup alarm. Thebackup alarm should sound immediately. Thebackup alarm should continue to sound untilthe transmission control is moved out of theREVERSE position.

7. Move the transmission control to the PARKposition and release the service brake.


Battery - Recycle

8. If the backup alarm did not function, or if thebackup alarm did not function properly, contactyour Caterpillar dealer.

i00993589

Battery - RecycleSMCS Code: 1401-561

Always recycle a battery. Never discard a battery.

Always return used batteries to one of the followinglocations:

• A battery supplier

• An authorized battery collection facility

• Recycling facility

i02424041

Battery or Battery Cable -Inspect/ReplaceSMCS Code: 1401-040; 1401-510; 1402-040;1402-510


Location of the batteries

Note: When you replace the batteries, always usethe same type of battery. This machine requiresMaintenance Free batteries or Low MaintenanceHigh Output batteries.

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

2. Turn the battery disconnect switch to the OFFposition. Remove the key.

3. Remove the battery access covers.

4. Disconnect the negative end “−” of the batterycable from the frame near the battery disconnectswitch.

Note: Do not allow the disconnected battery cable tocontact the battery disconnect switch.

5. Disconnect the negative end “−” of the batterycable from the battery.

6. Disconnect the positive end “+” of the batterycable from the battery.

7. Replace the battery or make all necessary repairsto the battery.

8. Connect the positive end “+” of the battery cableto the battery.

9. Connect the negative end “−” of the battery cableto the battery.

10.Connect the negative end “−” of the battery cableto the frame near the battery disconnect switch.

11. Install the battery access covers.

12. Install the key. Turn the battery disconnect switchto the ON position.

i03641485

Belts - Inspect/ReplaceSMCS Code: 1357-040; 1357-510; 1397-040;1397-510

Park the machine on a level surface and stop theengine. Make sure that the transmission control is inthe PARK position.

Inspection

Fan Drive Belts

This machine is equipped with a V-belt set that drivesthe radiator fan.

132 SEBU7794-08Maintenance SectionBody Pivot Bearings - Lubricate


Remove belt guard (1) and inspect V-belts (2) for thefollowing conditions: cracks, wear, stretch, frayedareas, and missing pieces.

Refrigerant Compressor and AlternatorBelt

This machine is equipped with a serpentine belt thatdrives the alternator and the refrigerant compressor.


The belt guard is removed for reference.

Inspect the belt through the areas that are notobstructed by the belt guard. Do not remove the beltguard for inspection.

Inspect serpentine belt (3) for the following conditions:cracks, wear, stretch, frayed areas, and missingpieces.

ReplacementRefer to Disassembly and Assembly, RENR8278,“773F Off-Highway Truck and 775F Off-HighwayTruck Engine Supplement ” for information onreplacing the fan drive belts and the refrigerantcompressor and the alternator belt.

i02525662

Body Pivot Bearings -LubricateSMCS Code: 7258-086-BD

Note: If the machine is equipped with centrallubrication lines, refer to Operation and MaintenanceManual, “Central Lubrication System - Lubricate” forlubrication points.

Wipe off the fittings before any lubricant is applied.


Brakes, Indicators and Gauges - Test


Lubricate two fittings (1) that are located at the rearof the machine under the body.

i02445772

Brakes, Indicators and Gauges- TestSMCS Code: 4251-081; 4267-081; 4269-081;7000-081; 7450-081; 7490-081

Before you operate the machine, perform thefollowing checks.

1. Inspect the brake indicator lights in the cab.Look for broken lenses on the gauges. Checkfor broken indicator lights, broken switches, andother broken components in the cab. Look for anyinoperative gauges.

2. Start the engine. Check the brake system for oilleaks and for damaged brake lines.

3. Turn on all machine lights. Check for properoperation.

4. Sound the horn. Listen for proper operation.

5. Test the parking brake. For the proper testprocedure, refer to Operation and MaintenanceManual, “Braking System - Test”.

6. Test the service brakes. For the proper testprocedure, refer to Operation and MaintenanceManual, “Braking System - Test”.

7. Move the transmission control to the PARKposition. Stop the engine.

Make any necessary repairs before machineoperation. Consult your Caterpillar dealer for moreinformation.

i02979422

Braking System - TestSMCS Code: 4251-081; 4267-081

Personal injury can result if the machine movesduring testing. If the machine begins to move dur-ing testing, reduce the engine speed immediatelyand place the transmission control in the PARKposition in order to engage the parking brake.

The following tests are used to determine if theservice brake system and the secondary brakesystem are functional. These tests are not intendedto measure the maximum brake holding effort. Thebrake holding effort that is required to sustain amachine at a specific engine rpm varies dependingon the machine. The variations are the differences inthe engine setting, in the power train efficiency, andin the brake holding ability, etc.

During the test of the brakes, compare the previousengine rpm and the recent engine rpm. This willdetermine the system deterioration.


134 SEBU7794-08Maintenance SectionBraking System - Test

Service Brake Holding Ability Test1. Fasten the seat belt before you test the brakes.

2. Check the area around the machine. Make surethat the machine is clear of personnel and clear ofobstacles.

3. Test the brakes on a dry, level surface.

4. Start the engine.

5. Depress service brake control (1) in order to applythe service brakes.

6. Move the transmission control lever to the Dposition.

7. Gradually increase the engine speed to 1200 rpm.The machine should not move.

8. Reduce the engine speed to low idle. Move thetransmission control lever to the PARK position.Stop the engine.

NOTICEIf the machine moved while testing the brakes, contactyour Caterpillar dealer.

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

Secondary Brake Holding AbilityTest1. Fasten the seat belt before you test the brakes.




5. Depress secondary brake control (2) in order toapply the secondary brakes.

6. Move the transmission control lever to the Dposition.




Have the Caterpillar dealer inspect and, if necessary,repair the parking/secondary brakes before returningthe machine to operation.

Parking Brake Holding Ability Test1. Fasten the seat belt before you test the brakes.





5. Depress button (3) for the high gear limit RAISEand depress button (4) for the high gear limitLOWER at the same time.

6. While both buttons are depressed, Move thetransmission control lever to the D position.

Note: The buttons can now be released and theparking brake will remain on.




Breather (Differential and Final Drive) - Replace


Have the Caterpillar dealer inspect and, if necessary,repair the parking/secondary brakes before returningthe machine to operation.

i02409474

Breather (Differential and FinalDrive) - ReplaceSMCS Code: 3258-510-BRE; 4050-510-BRE

1. Park the machine on a level surface and makesure that the transmission control is in the PARKposition.


2. Remove old breather (1) and properly discard theold breather.

3. Install a new breather.

i02507796

Breather (Hoist and BrakeTank) - ReplaceSMCS Code: 5056-510-BRE; 5057-510-BRE



2. Remove bolts (1) and breather cover (2) and washthe cover in clean nonflammable solvent.



5. Install the clean cover.

i02520495

Breather (Torque Converterand Transmission) - ReplaceSMCS Code: 3030-510-BRE; 3101-510-BRE


136 SEBU7794-08Maintenance SectionCab Air Filter - Clean/Replace




i02482424

Cab Air Filter - Clean/ReplaceSMCS Code: 7311-070-FI; 7311-510-FI; 7342-070;7342-510


The filter element for the cab is located inside theoperator's compartment.

1. Loosen retaining screws (1). Remove cover (2)and filter element (3).

2. Wash the filter element in a nonsudsing detergent.

3. Rinse the filter element in clean water. Allow thefilter element to air dry.

4. Install the clean filter element and the cover.Tighten the retaining screws.

Note: When rips or tears are noticed in the filterelement, install a new filter element. When areduction of air circulation is noticed in the cab aftercleaning the filter element, install a new filter element.


Central Lubrication System - Lubricate

i02527093

Central Lubrication System -Lubricate(If Equipped)SMCS Code: 7510-086

Personal injury or death can occur if personnel aretrapped between the wheel and the frame.

The steering system is hydraulically controlledand wheels can crush personnel during move-ment.

Use caution when working between the wheelsand the frame. If the wheels must be turned, en-sure that all personnel are clear of the machinebefore any movement.

NOTICECheck that the lines attached to all the remote greasefittings are undamaged. If the grease lines are split,grease will not reach the components that require lu-bricating. Machine damage will result.


If any of the remote lines become damaged, install afitting in place of the remote line. Lubricate the itemat the fittings until the remote line can be replaced.

Left Side


Lubricate fitting (1) on the left front distribution valve.The left front distribution valve will distribute greaseto the following points:

• Left steering cylinder bearings

• Left steering tie rod and pin bearings

• Left front suspension cylinder rod

• Left side of the center arm pivot pin.

138 SEBU7794-08Maintenance SectionCentral Lubrication System - Lubricate

Right Side


Lubricate fitting (2) on the right front distributionvalve. The right front distribution valve will distributegrease to the following points:

• Right steering cylinder bearings

• Right steering tie rod and pin bearings

• Right front suspension cylinder rod

• Right side of the center arm pivot pin.

Rear


Lubricate fitting (3) on the left rear distribution valve.The left rear distribution valve will distribute grease tothe following points:

• Left hoist cylinder bearings

• Left rear suspension cylinder bearings

• Left pivot bearing for the dump body

• Right lower hoist cylinder bearing

Lubricate fitting (4) on the right rear distribution valve.The right rear distribution valve will distribute greaseto the following points:

• Bearings on the lateral control rod for the rear axlehousing

• Right rear suspension cylinder bearings

• Right pivot bearing for the dump body

• Right upper hoist cylinder bearing

Lubricate remote fitting (5) for the A-frame bearingassembly on the rear axle support.


Circuit Breakers - Reset

i02998304

Circuit Breakers - ResetSMCS Code: 1420-529


Circuit Breaker/Reset – Push in thebutton in order to reset the circuit breaker. Ifthe electrical system is working properly, the

button will remain depressed. If the button does notremain depressed, check the appropriate electricalcircuit. Repair the electrical circuit, if necessary.

Alternator (1) – 90 Amp

Engine ECM (2) – 15 Amp

Starter Solenoid (3) – 80 Amp

g01255770Illustration 156Circuit breaker (4) for the heater/air conditioner fan is located onthe panel behind the companion seat.

Heater/Air Conditioner Fan (4) – 20 Amp

i02589870

Cooling System Coolant (ELC)- ChangeSMCS Code: 1350-044-NL; 1395-044-NL

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 torelieve 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.

140 SEBU7794-08Maintenance SectionCooling System Coolant (ELC) - Change

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, “CaterpillarDealer Service Tool Catalog” for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.

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

NOTICEMixing Cat Extended Life Coolant (ELC) with otherproducts reduces the effectiveness of the coolantand shortens coolant life. Use only Caterpillar prod-ucts or commercial products that have passed theCaterpillar EC-1 specifications for premixed or con-centrate coolants. Use only Cat Extender with CatELC. Failure to follow these recommendations couldresult in damage to the cooling systems components.

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

This machine was factory filled with Cat Extended LifeCoolant.

Whenever the coolant is dirty or whenever foamingis observed, change the coolant before therecommended interval.



Top view

2. Slide open radiator cap access cover (1). Removeradiator cap (2) slowly in order to gradually relieveany system pressure.


3. Open drain valve (3) and drain the coolant into asuitable container.


Cooling System Coolant Extender (ELC) - Add

4. Close the drain valve. Fill the system with cleanwater and a 6 to 10% concentration of coolingsystem cleaner.

5. Start the engine and operate the engine for 90minutes. Stop the engine and drain the cleaningsolution into a suitable container.

6. With the engine stopped, flush the system withwater until the draining water is clear. Drain thewater into a suitable container.

7. Close the drain valve.

8. Add the coolant solution. Refer to SpecialPublication, SEBU6250, “Cooling SystemSpecifications” and Operation and MaintenanceManual, “Capacities (Refill)” for further information.

9. Start the engine. Run the engine without theradiator cap. Run the engine until the thermostatopens and the coolant level stabilizes. Thisshould purge the air from the system. Check thecoolant level. Refer to Operation and MaintenanceManual, “Cooling System Coolant Level - Check”for further information.

10. Install the radiator cap.

i02555611

Cooling System CoolantExtender (ELC) - AddSMCS Code: 1352-538-NL






NOTICEAdding coolant to an overheated engine could result indamage to the engine. Allow the engine to cool beforeadding coolant.

If the machine is to be stored in, or shipped to, an areawith freezing temperatures, the cooling system mustbe protected to the lowest outside (ambient) temper-ature.

The engine cooling system is normally protect-ed to a minimum of−29°C (−20°F) with CaterpillarAntifreeze, when shipped from the factory unlessspecial requirements are defined.




NOTICEExcessive additive (greater than the recommended6% initial fill) together with concentrations of antifreezegreater than 60% cause deposits to form and can re-sult in radiator tube blockage and overheating.

NOTICEMixing Extended Life Coolant (ELC) with other prod-ucts reduces the effectiveness of the coolant andshortens coolant life. Use only Caterpillar products orcommercial products that have passed the CaterpillarEC-1 specifications for premixed or for concen-trate coolants. Use only Caterpillar Extender withCaterpillar ELC. Failure to follow these recommen-dations could result in the damage to cooling systemcomponents.

If ELC cooling system contamination occurs, referto Operation and Maintenance Manual, SEBU6250,“Caterpillar Machine Fluids Recommendations” underthe topic of ELC Cooling System Contamination.

This machine was factory filled with Extended LifeCoolant.

142 SEBU7794-08Maintenance SectionCooling System Coolant Extender (ELC) - Add

Refer to Special Publication, SEBU6250, “CaterpillarMachine Fluids Recommendations” for the coolingsystem requirements.


g01255872Illustration 159Top view

2. Slide open radiator cap access cover (1). Removeradiator cap (2) slowly in order to relieve thepressure.


3. Observe the sight gauge (3) in order to check thecoolant level. If necessary, drain enough coolantin order to allow the addition of the liquid coolantadditive.

Note: Make sure that the coolant is drained into asuitable container.

4. Add 0.24 Liters (0.50 pint) of cooling systemadditive for every 38 Liters (10 US Gallons) ofengine cooling capacity.

5. Clean the radiator cap and inspect the radiatorcap. Install the radiator cap.

6. Start the engine and check the cooling system forleaks. Allow the coolant level to stabilize.

7. If necessary, add premixed coolant in order tomaintain the coolant level within the sight gauge.


Cooling System Coolant Level - Check

i03792511

Cooling System Coolant Level- CheckSMCS Code: 1350-535-FLV


At operating temperature, engine coolant is hotand under pressure. The heat exchanger and alllines to heaters or the engine contain hot coolantor steam. Any contact can cause severe burns.

Remove the filler cap slowly to relieve pressureonly when the engine is stopped and the filler capfor the heat exchanger is cool enough to touchwith your bare hand.

Cooling SystemConditioner contains alkali. Avoidcontact with skin and eyes.

NOTICEAdding coolant to an overheated engine could result indamage to the engine. Allow the engine to cool beforeadding coolant.

If the machine is to be stored in, or shipped to, an areawith freezing temperatures, the cooling system mustbe protected to the lowest outside (ambient) temper-ature.

The engine cooling system is normally protect-ed to a minimum of−29°C (−20°F) with CaterpillarAntifreeze, when shipped from the factory unlessspecial requirements are defined.

Refer to Special Publication, SEBU6250, “CaterpillarMachine Fluids Recommendations” for the coolingsystem requirements.


Note: If you must add coolant daily, check for leaks.


2. When the coolant is cold (ambient temperature),observe sight gauge (1) in order to check thecoolant level. Maintain the coolant level within thesight gauge.

3. If necessary, remove radiator cap (2) slowly inorder to relieve the pressure and add coolant.

Note: Always add the same coolant type that is in themachine. Do not mix coolant types. This can reducethe effectiveness of the coolant. Also, mixing coolanttypes can shorten the coolant life.

144 SEBU7794-08Maintenance SectionCooling System Coolant Sample (Level 1) - Obtain

i03646189

Cooling System CoolantSample (Level 1) - ObtainSMCS Code: 1350-008; 1395-008; 7542

NOTICEAlways use a designated pump for oil sampling, anduse a separate designated pump for coolant sampling.Using the same pump for both types of samples maycontaminate the samples that are being drawn. Thiscontaminate may cause a false analysis and an incor-rect interpretation that could lead to concerns by bothdealers and customers.

Note: Level 1 results may indicate a need forLevel 2 Analysis.

g01258196Illustration 162(1) Coolant sampling valve

Obtain the sample of the coolant as close as possibleto the recommended sampling interval. In orderto receive the full effect of S·O·S analysis, youmust establish a consistent trend of data. In orderto establish a pertinent history of data, performconsistent samplings that are evenly spaced.Supplies for collecting samples can be obtained fromyour Caterpillar dealer.

Use the following guidelines for proper sampling ofthe coolant:

• Complete the information on the label for thesampling bottle before you begin to take thesamples.

• Keep the unused sampling bottles stored in plasticbags.

• Obtain coolant samples directly from the coolantsample port. You should not obtain the samplesfrom any other location.

• Keep the lids on empty sampling bottles until youare ready to collect the sample.

• Place the sample in the mailing tube immediatelyafter you obtain the sample in order to avoidcontamination of the sample.

• Never collect samples from expansion bottles.

• Never collect samples from the drain for a system.

Submit the sample for Level 1 analysis.

Refer to the following publications for S·O·Sinformation:

• Operation and Maintenance Manual, “S·O·SInformation”

• Special Publication, SEBU6250, “CaterpillarMachine Fluids Recommendations”

• Special Instruction, PEHJ0191, “S·O·S FluidAnalysis”

• Special Publication, PEGJ0046, “S·O·S Services:Understanding Your Results”


Cooling System Coolant Sample (Level 2) - Obtain

i03646188

Cooling System CoolantSample (Level 2) - ObtainSMCS Code: 1350-008; 1395-008; 7542



(1) Coolant sampling valve

Obtain the sample of the coolant as close as possibleto the recommended sampling interval. Suppliesfor collecting samples can be obtained from yourCaterpillar dealer.

Refer to Operation and Maintenance Manual,“Cooling System Coolant Sample (Level 1) - Obtain”for the guidelines for proper sampling of the coolant.

Submit the sample for Level 2 analysis.



• Special Publication, SEBU6250, “CaterpillarMachine Fluids Recommendations”



i02510429

Cooling System Pressure Cap- Clean/ReplaceSMCS Code: 1382-070; 1382-510


At operating temperature, engine coolant is hotand under pressure. The heat exchanger and alllines to heaters or the engine contain hot coolantor steam. Any contact can cause severe burns.

Remove the filler cap slowly to relieve pressureonly when the engine is stopped and the filler capfor the heat exchanger is cool enough to touchwith your bare hand.

Cooling SystemConditioner contains alkali. Avoidcontact with skin and eyes.


146 SEBU7794-08Maintenance SectionCooling System Water Temperature Regulator - Replace


Top view


3. Inspect the radiator cap for damage, for foreignmaterial, and for deposits.

4. Clean the radiator cap with a clean cloth or replacethe radiator cap, if necessary.


i03639786

Cooling System WaterTemperature Regulator -ReplaceSMCS Code: 1355-510; 1393-510









NOTICEFailure to replace the engine's thermostat on a regu-larly scheduled basis could cause severe engine dam-age.

Note: The thermostats should be replaced afterthe cooling system has been cleaned. Replace thethermostats while the cooling system is completelydrained or while the cooling system coolant is drainedto a level that is below the thermostat housing.


Cooling System Water Temperature Regulator - Replace

Replace the two thermostats on a regular basis inorder to reduce the chance of unscheduled downtimeand of problems with the cooling system.


g01255872Illustration 165Top view



3. If the cooling system has not been drained, makesure that the coolant level is below the thermostathousing. If necessary, open drain valve (3) anddrain the coolant into a suitable container untilthe coolant level is below the thermostat housing.Close the drain valve.

148 SEBU7794-08Maintenance SectionDifferential Thrust Pin Clearance - Check


4. Disconnect the hose assembly from elbow (A).Remove bolts (4) from the elbow (B) and removebolts (5) from the thermostat housing (6).

5. Remove the thermostat housing assembly.

6. Remove the thermostats and the seals from thethermostat housing assembly.

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

Depending on load, failure to operate with a thermo-stat could result in either an overheating or an over-cooling condition.

NOTICEIf the thermostat is installed incorrectly, it will causethe engine to overheat.

7. Install new seals and new thermostats in thehousing.

8. Install the thermostat housing assembly. Installthe bolts for the thermostat housing and install thebolts for the elbow (B).

9. Connect the hose assembly to elbow (A). Tightenthe hose clamps.

10.Add the coolant solution. Refer to SpecialPublication, SEBU6250, “Cooling SystemSpecifications” and Operation and MaintenanceManual, “Capacities (Refill)” for further information.

11.Start the engine. Run the engine without theradiator cap. Run the engine until the thermostatopens and the coolant level stabilizes. Thisshould purge the air from the system. Check thecoolant level. Refer to Operation and MaintenanceManual, “Cooling System Coolant Level - Check”for further information.


i02510601

Differential Thrust PinClearance - CheckSMCS Code: 3258-535-T9


For the proper adjustment procedure for the thrustpin, refer to Testing and Adjusting, RENR8283,“773F and 775F Off Highway Truck Power Train”,“Differential and Bevel Gear - Adjust”.


Differential and Final Drive Oil - Change

i02510630

Differential and Final Drive Oil- ChangeSMCS Code: 3258-044-OC; 4050-044-OC

The oil change interval for the differential and finaldrives can be monitored with a S·O·S (ScheduledOil Sampling) program. For more information onS·O·S services, refer to Operation and MaintenanceManual, “S·O·S Information”. When a S·O·Sprogram is used, the oil change interval is basedon the following:

• The condition of the oil

• The S·O·S recommendation

When a S·O·S program is not used, the oil changeinterval is based on the following:

• 4000 service hours or 1 year if CaterpillarFDAO/FD-1 oil is used.

• 2000 service hours or 1 year if CaterpillarTDTO/TO-4 oil is used.


1. Rotate the wheels so that final drive drain plug (1)is in the lowest position on the rear wheel.





3. Remove the final drive drain plug. Drain the oilinto a suitable container.

Note: Inspect the magnetic drain plug and theoil. Refer to Operation and Maintenance Manual,“Differential and Final Drive Oil - Inspect” for furtherinformation.

4. Clean the drain plug. Install the drain plug.

5. Repeat Step 1 through Step 4 for the other finaldrive.


6. Remove differential drain plug (4) and allow the oilto drain into a suitable container.

Note: Inspect the magnetic drain plug and theoil. Refer to Operation and Maintenance Manual,“Differential and Final Drive Oil - Inspect” for furtherinformation.

7. Clean the drain plug. Install the drain plug.

8. Remove differential filler plug (3) and wipe thesurface around the filler plug opening .

150 SEBU7794-08Maintenance SectionDifferential and Final Drive Oil - Inspect

9. Fill the differential compartment to the bottom ofthe filler plug opening. Refer to Operation andMaintenance Manual, “Lubricant Viscosities” andOperation and Maintenance Manual, “Capacities(Refill)”.

NOTICEIf the ambient temperature at engine start-up orduring operation is below −10°C (14°F), performthe procedures in Operation and MaintenanceManual, “Differential Warm-up and Break-in”. Checkthe differential compartment and the final drivecompartment for the proper fluid level. Failure towarm up the oil or improper lubrication levels prior tooperation will cause damage to the machine.

10.Clean the filler plug and install the filler plug.

11.Remove final drive filler plugs (2). Fill each finaldrive to the bottom of the filler plug opening. Whenthe final drive drain plug is in the lowest position,the final drive filler plug will be at the correct oillevel.

Note: The final drives may need to be repositioned inorder to place the drain plug in the lowest position.

Note: Allow oil to fill all of the compartments. Correctoil levels are critical in the differential and final drives.

12.Operate the machine on level ground for a fewminutes.

Note: The differential and final drive oil level needs tobe checked and maintained at operating temperature.After the oil has been changed in the differentialand final drives, adjustment of the oil level maybe necessary when the truck reaches operatingtemperature.

13.Stop the machine. Check the oil level. Ifnecessary, adjust the oil level to the bottom of theopening for the differential filler plug.

Note: Overfilling the differential and final drives willcause overheating and foaming of the oil in longhauling applications and high speed applications. Areduction of the life of components may be the resultof overheating and foaming of the oil.

i02450436

Differential and Final Drive Oil- InspectSMCS Code: 3278-040-OC; 4050-040-OC

Inspect the differential and final drive oil for any of thefollowing symptoms that may indicate a mechanicalfailure:

• A high amount of metal on the magnetic plug

• An increased level of nickel concentration in theS·O·S sample

• An increase in the size of the particle count in theS·O·S sample

• Oil leaks in the area around the drive wheelbearings

The rear wheel bearings do not need to be adjustedor inspected until the scheduled overhaul. Unless asymptom of an obvious failure appears, do not adjustor inspect the rear wheel bearings. If the differentialand final drive oil has any of the above symptoms,the rear wheel bearings may need to be inspected.

Consult your Caterpillar dealer for more information.

i02582653

Differential and Final Drive OilLevel - CheckSMCS Code: 3258-535-FLV; 4050-535-FLV



2. Remove differential filler plug (1) and clean thearea around the opening.

3. Check the oil level. Maintain the oil level to thebottom of the filler plug opening.

4. If necessary, add oil. Install the filler plug.


Differential and Final Drive Oil Sample - Obtain

Note: The differential and final drives share acommon oil compartment. When the machine isparked on a level surface and when the final drivedrain plug is in the lowest position, the final drivefiller plug will be at the same level as the differentialfiller plug. Allow the oil to fill all of the compartmentsbefore rechecking the oil level.

i03646160

Differential and Final Drive OilSample - ObtainSMCS Code: 3278-008; 4050-008; 4070-008; 7542



The oil sample for the differential and for the finaldrives is obtained with a sampling gun through thefiller plug (1).



• Special Publication, SEBU6250, “S·O·S ServicesOil Analysis”


• Special Publication, PEGJ0047, “How to Take aGood Oil Sample”


i02449906

Display and Camera - Clean(If Equipped with Work AreaVision System)SMCS Code: 7347-070; 7348-070

In order to maintain sufficient vision, keep the WorkArea Vision System (WAVS) camera lens and thedisplay clean.

Display


WAVS display

Use a soft, damp cloth in order to clean the display.The display has a soft plastic surface that can beeasily damaged by an abrasive material. The displayis not sealed. Do not immerse the display withliquid.

Camera

g01223051Illustration 174The WAVS camera is located on the rear of the machine nearthe taillights.

152 SEBU7794-08Maintenance SectionElectronic Unit Injector - Inspect/Adjust

Use a damp cloth or water spray in order to cleanthe camera lens. The camera is a sealed unit. Thecamera is not affected by high pressure spray.

The camera is equipped with an internal heater tohelp counteract the effects of condensation, snow,or ice.

Note: For more information on WAVS, refer toOperation and Maintenance Manual, SEBU8157,“Work Area Vision System”.

i02549084

Electronic Unit Injector -Inspect/AdjustSMCS Code: 1290-025; 1290-040

Be sure the engine cannot be started while thismaintenance is being performed. To prevent pos-sible injury, do not use the starting motor to turnthe flywheel.

Hot engine components can cause burns. Allowadditional time for the engine to cool before mea-suring/adjusting the unit injectors.

The electronic unit injectors use high voltage. Dis-connect the unit injector enable circuit connectorin order to prevent personal injury. Do not comein contact with the injector terminals while the en-gine is running.

This procedure is recommended by Caterpillar aspart of a lubrication and preventive maintenanceschedule in order to help provide maximum enginelife. Only qualified personnel should perform thisprocedure.

For information on adjusting the electronic unitinjector, refer to Systems Operation, Testing AndAdjusting, SENR9937, “C27 and C32 Engines forCaterpillar Built Machines” or consult your Caterpillardealer.

i02436954

Engine Air Filter PrimaryElement - Clean/ReplaceSMCS Code: 1051-070-PY; 1051-510-PY;1054-070-PY; 1054-510-PY

NOTICEService the air cleaner only with the engine stopped.Engine damage could result.

Service the air cleaner filter elements when the airfilter service indicator detects an inlet air restriction.Refer to Operation and Maintenance Manual,“Engine Air Filter Service Indicator - Inspect” for moreinformation.



2. Remove covers (1) for the air filter housings.

3. Remove primary filter elements (2) from the airfilter housings.

4. Clean the inside of the air filter housings.

5. Clean the dust valves on the bottom for the airfilter housings.

6. Install clean primary air filter elements. Install thecovers for the air filter housings.

Note: Refer to “Cleaning Primary Air Filter Elements”.


Engine Air Filter Primary Element - Clean/Replace

Cleaning Primary Air FilterElements

NOTICECaterpillar recommends certified air filter cleaning ser-vices available at participating Caterpillar dealers. TheCaterpillar cleaning process uses proven proceduresto assure consistent quality and sufficient filter life.

Observe the following guidelines if you attempt toclean the filter element:

Do not tap or strike the filter element in order to re-move dust.

Do not wash the filter element.

Use low pressure compressed air in order to removethe dust from the filter element. Air pressure must notexceed 207 kPa (30 psi). Direct the air flow up thepleats and down the pleats from the inside of the filterelement. Take extreme care in order to avoid damageto the pleats.

Do not use air filters with damaged pleats, gaskets, orseals. Dirt entering the engine will cause damage toengine components.

The primary air filter element can be used up tosix times if the element is properly cleaned and theelement is properly inspected. When the primaryair filter element is cleaned, check for rips or tearsin the filter material. The primary air filter elementshould be replaced at least one time per year. Thisreplacement should be performed regardless of thenumber of cleanings.

NOTICEDo not clean the air filter elements by bumping or tap-ping. This could damage the seals. Do not use ele-ments with damaged pleats, gaskets, or seals. Dam-aged elements will allow dirt to pass through. Enginedamage could result.

Visually inspect the primary air filter elements beforecleaning. Inspect the air filter elements for damageto the seal, the gaskets, and the outer cover. Discardany damaged air filter elements.

There are two common methods that are used toclean primary air filter elements:

• Pressurized air

• Vacuum cleaning

Pressurized Air

Pressurized air can be used to clean primary air filterelements that have not been cleaned more than twotimes. Pressurized air will not remove deposits ofcarbon and oil. Use filtered, dry air with a maximumpressure of 207 kPa (30 psi).


Note: When the primary air filter elements arecleaned, always begin with the clean side (inside)in order to force dirt particles toward the dirty side(outside).

Aim the hose so that the air flows inside the elementalong the length of the filter in order to help preventdamage to the paper pleats. Do not aim the stream ofair directly at the primary air filter element. Dirt couldbe forced further into the pleats.

Vacuum Cleaning

Vacuum cleaning is another method for cleaningprimary air filter elements which require daily cleaningbecause of a dry, dusty environment. Cleaning withpressurized air is recommended prior to vacuumcleaning. Vacuum cleaning will not remove depositsof carbon and oil.

154 SEBU7794-08Maintenance SectionEngine Air Filter Secondary Element - Replace

Inspecting the Primary Air FilterElements


Inspect the clean, dry primary air filter element. Usea 60 watt blue light in a dark room or in a similarfacility. Place the blue light in the primary air filterelement. Rotate the primary air filter element. Inspectthe primary air filter element for tears and/or holes.Inspect the primary air filter element for light that mayshow through the filter material. If it is necessary inorder to confirm the result, compare the primary airfilter element to a new primary air filter element thathas the same part number.

Do not use a primary air filter element that has anytears and/or holes in the filter material. Do not usea primary air filter element with damaged pleats,gaskets or seals. Discard damaged primary air filterelements.

i02437040

Engine Air Filter SecondaryElement - ReplaceSMCS Code: 1054-510-SE

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

Note: Replace the engine air filter secondaryelements when you service the engine air filterprimary elements for the third time. Replace thesecondary filter elements if the exhaust smokeremains black and the clean primary filter elementshave been installed.


2. Remove the air filter covers and remove theprimary filter elements from the air filter housings.

g00644798Illustration 178(1) Secondary filter element

3. Remove secondary filter elements (1) and properlydiscard the secondary elements.

4. Cover the air inlet openings. Clean the inside ofthe air cleaner housings.

5. Uncover the air inlet openings. Install the newsecondary filter elements.

6. Install the primary filter elements and install theair filter covers.


Engine Air Filter Service Indicator - Inspect

i02516078

Engine Air Filter ServiceIndicator - InspectSMCS Code: 7452-040-DJ


The air filter service indicators will detect an inlet airrestriction. Examine the air filter service indicators. Ifthe yellow piston in the indicator (2) enters the redzone, service the designated air cleaner.

Note: The yellow piston in the indicator will remain atthe maximum position that was reached during theprevious operation. Depress reset button (1) in orderto reset the position of the yellow piston.

NOTICEService the engine air filters with the engine stopped.Engine damage could result.

In order to service the engine air filters, referto Operation and Maintenance Manual, “EngineAir Filter Primary Element - Clean/Replace” andOperation and Maintenance Manual, “Engine AirFilter Secondary Element - Replace”.

i02513550

Engine Air Precleaner - CleanSMCS Code: 1055-070

NOTICEService the engine air precleaners only when the en-gine is stopped. Engine damage could result.



2. Unlatch the clips on each precleaner assembly(1). Remove the precleaner assemblies.

3. Clean the precleaners and clean dust valves (2)with one of the following methods:

• Air pressure

• Water pressure

• Detergent washing

156 SEBU7794-08Maintenance SectionEngine Brake Slave Piston Lash - Inspect/Adjust

If necessary, dry the precleaner assembliescompletely.

4. Inspect the precleaner assemblies after cleaning.Replace any damaged parts.

5. Install the precleaner assemblies.

i02502656

Engine Brake Slave PistonLash - Inspect/Adjust(If Equipped)SMCS Code: 1129-025; 1129-040

Be sure the engine cannot be started while thismaintenance is being performed. To prevent pos-sible injury, do not use the starting motor to turnthe flywheel.

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

NOTICEOnly qualified service personnel should perform thismaintenance. Refer to the Service Manual or yourCaterpillar Dealer for the complete engine valve lashadjustment procedure.

For proper adjustment, the engine valve lash mustbe adjusted before the engine brake is adjusted. Formore information on engine valve lash adjustment,refer to Operation and Maintenance Manual, “EngineValve Lash - Check/Adjust”.

For the inspection procedure and the adjustmentprocedure for the engine brake slave piston lash,refer to the “Cat Compression Brake Valve Lash -Adjust” in Systems Operation, Testing and Adjusting,SENR9937, “C27 and C32 Engines For CaterpillarBuilt Machines”.

i03997266

Engine Components -Clean/Inspect, Rebuild/InstallReman, Install NewSMCS Code: 1000-012-IC; 1000-022-MC;1000-571-IC

Caterpillar recommends this additional maintenancefor the following engine components. Consult yourCaterpillar dealer for further information.

The quantity of burned fuel that is shown with theservice hours assumes a load factor of 40 percent. Ifthe load factor is higher than 40 percent, the numberof service hours for the overhaul interval will belower. If the load factor is lower than 40 percent, thenumber of service hours for the overhaul interval willbe higher. The quantity of consumed fuel is a betterindicator for the overhaul interval than service hours.

Install New Components• All seals, gaskets, and O-rings

• Camshaft bearings

• Crankshaft seals

• Gear train bushings, bearings, and thrust plates

• Main bearings, rod bearings, and crankshaft thrustplates

• Piston rings

Rebuild Components and/or InstallRemanufactured Components• Cylinder heads

• Oil pump

• Scavenge oil pump

• Variable speed fan clutch (if equipped)

Clean Components and InspectComponents for Reusability• Aftercooler core

• Camshaft

• Camshaft lifters

• Connecting rods


Engine Components - Rebuild/Install Reman

• Crankshaft

• Cylinder block

• Cylinder liners

• Damper

• Gear train

• Oil coolers

• Piston crowns and piston skirts

• Piston pins

• Spacer plates

i02574644

Engine Components -Rebuild/Install RemanSMCS Code: 1000-022-MC

Caterpillar recommends this additional maintenancefor the following engine components. Consult yourCaterpillar dealer for further information.

The quantity of burned fuel that is shown with theservice hours assumes a load factor of 40 percent. Ifthe load factor is higher than 40 percent, the numberof service hours for the mid-life service interval willbe lower. If the load factor is lower than 40 percent,the number of service hours for the mid-life serviceinterval will be higher. The quantity of consumedfuel is a better indicator for the mid-life serviceinterval than service hours. The following list containscomponents that should be rebuilt or replaced with aremanufactured product.

• Alternator

• Electric Starter

• Turbochargers

• Injectors

• Refrigerant Compressor

• Water Pump

i03130918

Engine Crankcase Breather -CleanSMCS Code: 1317-070-ENG

S/N: EED1-376

S/N: DLS1-382


g01222705Illustration 181The crankcase breather is located on the back of the engine.

2. Remove hose (1) from the outlet of breatherassembly (2).

3. Remove the four bolts and remove the breatherassembly from the engine.

4. Remove the breather element. Wash the breatherelement and the breather in a clean nonflammablesolvent. Allow the breather element to dry beforeinstallation.

158 SEBU7794-08Maintenance SectionEngine Crankcase Breather - Clean

5. Check the condition of the hose. Replace the hoseif the hose is damaged. Check the condition of thebreather assembly seal. Replace the seal if theseal is damaged.

6. Install the breather element and install thebreather assembly.

7. Install the hose onto the outlet of the breatherassembly and tighten the clamp.

i03130910

Engine Crankcase Breather -CleanSMCS Code: 1317-070-ENG

S/N: EED377-Up

S/N: DLS383-Up


The engine in this machine is equipped with twoengine crankcase breathers (1). One breather is onthe valve cover on the right side and one breather ison the valve cover on the left side.


2. Loosen the clamps.

3. Remove the hoses from the breathers. Removethe breathers from the valve covers.

4. Wash the breathers in clean nonflammablesolvent.

5. Install the breathers on the valve covers. Installthe hoses and clamps on the breathers.

6. Tighten all of the clamps.

i02612771

Engine Oil Level - CheckSMCS Code: 1348-535-FLV

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


1. Park the machine on a level surface. Make surethat the transmission control is in the PARKposition.

2. Remove engine oil level gauge (1). Inspect theoil level gauge in order to determine the engineoil level.


Engine Oil Sample - Obtain


3. Check the oil level when the engine is stoppedand the oil is cold. Maintain the oil level withinshaded range (X) of the oil level gauge.

4. If necessary, remove the oil filler cap (2) and addoil. Clean the filler cap and install the filler cap.

i03646162

Engine Oil Sample - ObtainSMCS Code: 1348-008; 7542




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


Sampling valve (1) for the engine oil is located onthe engine oil filter base.







160 SEBU7794-08Maintenance SectionEngine Oil and Filter - Change

i04380516

Engine Oil and Filter - ChangeSMCS Code: 1308-510; 1348-044





NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting, and repair of the product. Be preparedto collect the fluid with suitable containers beforeopening any compartment or disassembling any com-ponent containing fluids.

Refer to Special Publication, NENG2500, “Dealer Ser-vice Tool Catalog” for tools and supplies suitable tocollect and contain fluids on Cat products.


Note: Some commercial oils that meet APIspecifications may require shorter oil changeintervals. The oil change intervals are determinedby close monitoring of the oil condition and enginewear metals. Caterpillar prefers the scheduled oilsampling as the proper method of checking enginewear metals.

Consult your Caterpillar dealer for the latest oilrecommendations.

Oil Change Interval

NOTICEA 500 hour engine oil change interval is available, pro-vided that the operating conditions and recommend-ed multigrade oil types are met. When these require-ments are not met, shorten the oil change intervalto 250 hours, or use an S·O·S Services oil samplingand analysis program to determine an acceptable oilchange interval.

If you select an interval for oil and filter change that istoo long, you may damage the engine.

Operating the engine in the following conditions willshorten the service life of the engine oil which willrequire reduced oil change intervals:

• Low ambient temperatures

• Short operating durations

• Long idle times

• Altitudes above 1830 m (6000 ft)

• Poor maintenance of air filters or of fuel filters

See your Caterpillar dealer for more information if thisproduct will experience abnormally harsh operatingcycles or harsh environments.

Oil Pan Drain and Engine Oil Filters1. Park the machine on a level surface. Make surethat the transmission control is in the PARKposition. The oil must be warm and the enginestopped.

2. Move the engine lockout switch upward in orderto activate the engine lockout mode. Refer toOperation and Maintenance Manual, “EngineLockout Control” for more information.


Engine Oil and Filter - Change


3. Open drain valve (1) and drain the oil into asuitable container. Close the drain valve.


4. Remove used oil filters (2) and discard the usedoil filters.

Note: The filters are accessed through the right frontwheel well. Oil may be trapped in the filter housingbases. In order to avoid possible burns, remove thefilters when the filters are cool enough to touch withyour bare hand. Drain the oil into a suitable container.

5. Clean the filter housing base. Make sure that theformer gaskets are removed.

6. Apply a thin film of clean engine oil to the seal ofeach new filter.

7. Install the filters by hand. Tighten each filter untilthe sealing surface contacts the base. Note theposition of the index marks on each filter in relationto a fixed point on the filter base.

Note: Caterpillar filters have rotation index marksthat are spaced 90° or 1/4 of a turn away from eachother. When tightening the filters, use the rotationindex marks as a guide.

8. Tighten each filter according to the instructionsthat are printed on the filter.

Note: A Caterpillar strap wrench, or another suitabletool may be needed in order to turn the filters to theamount that is required for final installation. Makesure that the installation tool does not damage thefilters.


9. Remove the oil filler cap (4). Fill the crankcasewith oil. Refer to Operation and MaintenanceManual, “Lubricant Viscosities” for the type of oil.Refer to Operation and Maintenance Manual,“Capacities (Refill)” for the amount of oil.

10.Depress the brake release and secondarysteering switch for thirty seconds. This switch willmanually activate the prelube pump in order tofill the engine oil filters.

162 SEBU7794-08Maintenance SectionEngine Oil and Filter - Change

11.Start the engine and operate the engine at lowidle for five minutes. Inspect the engine oil filtersfor oil leaks. Make any necessary repairs.


12.Maintain the oil level within shaded area (X) ofthe engine oil level gauge.

QuickEvacThe QuickEvac/Prelubrication system is notavailable on later machines.

Extended operation of the QuickEvac motor coulddamage the motor and result in loss of emergen-cy steering capability, which could cause injuryor death. The QuickEvac motor should not beused longer than 5 minutes. The motor should beallowed to cool to ambient temperatures beforereuse.

Table 6

Required Tools

Item Part Number Description

A 187-1458 QuickEvac Service Tool

1. Park the machine on a level surface. Place thetransmission control lever in the PARK position.The oil must be warm and the engine must bestopped.

2. Move the engine lockout switch upward in orderto activate the engine lockout mode. Refer toOperation and Maintenance Manual, “EngineLockout Control” for more information.

Note: The QuickEvac system will only evacuate theoil when the engine lockout mode is active.


3. Detach the quick disconnect fittings. AttachQuickEvac Tool (A) to male quick disconnectfitting (7). Attach an air supply to the designatedhose on the QuickEvac Tool. Purge the oil systemof the engine and the oil filters for 10 seconds byusing 620 kPa (90 psi) of air pressure. Detach theair supply.

4. Attach the designated hose from the QuickEvacTool to female quick disconnect fitting (6) andattach the electrical connection for the QuickEvacTool to electrical connection (5).

5. Use the remote operator switch on the QuickEvacTool to evacuate the oil from the engine.

6. Detach the QuickEvac Tool after the oil isevacuated. Attach male quick disconnect fitting (7)to female quick disconnect fitting (6).

7. Remove used oil filters (2) and discard the usedoil filters. Refer to Illustration 187.

Note: The filters are accessed through the right frontwheel well. Oil may be trapped in the filter housingbases. In order to avoid possible burns, remove thefilters when the filters are cool enough to touch withyour bare hand. Drain the oil into a suitable container.

8. Clean the filter housing base. Make sure that theformer gaskets are removed.


Engine Oil and Filter - Change

9. Apply a thin film of clean engine oil to the seal ofeach new filter.

10. Install the filters by hand. Tighten each filter untilthe sealing surface contacts the base. Note theposition of the index marks on each filter in relationto a fixed point on the filter base.

Note: Caterpillar filters have rotation index marksthat are spaced 90° or 1/4 of a turn away from eachother. When tightening the filters, use the rotationindex marks as a guide.

11.Tighten each filter according to the instructionsthat are printed on the filter.

Note: A Caterpillar strap wrench, or another suitabletool may be needed in order to turn the filters to theamount that is required for final installation. Makesure that the installation tool does not damage thefilters.

12.Remove the oil filler cap (4). Refer to Illustration188. Fill the crankcase with oil. Refer to Operationand Maintenance Manual, “Lubricant Viscosities”for the type of oil. Refer to Operation andMaintenance Manual, “Capacities (Refill)” for theamount of oil.

13.Depress the brake release and secondarysteering switch for thirty seconds. This switch willmanually activate the prelube pump in order tofill the engine oil filters.

14.Start the engine and operate the engine at lowidle for five minutes. Inspect the engine oil filtersfor oil leaks. Make any necessary repairs.

15.Maintain the oil level within shaded area (X) ofengine oil level gauge (3).

Whenever a QuickEvac procedure is performed, anevent will be recorded. The event will be recordedwhen the pump is activated by the switch on theQuickEvac Service Tool. The event will be recordedin the following manner:

• The service hours of the first event

• The service hours of the last event

• The total number of events

Only one event will be recorded during each powercycle to the ECM. This will prevent creating multipleevents for one Quick Evac procedure.

For more information on the Quick Evac system, referto Specifications, Systems Operation, Testing andAdjusting, RENR8395, “773F - 777F Off-HighwayTruck Prelubrication and High Speed Oil Change(Quick Evac)”.

Engine Oil Fill with High SpeedArrangement (If Equipped)


1. Remove the dust cover and attach the oil fill hoseto male fitting (8).

2. Fill the crankcase with oil. Refer to Operation andMaintenance Manual, “Lubricant Viscosities” forthe correct type of oil. Refer to Operation andMaintenance Manual, “Capacities (Refill)” for thecorrect amount of oil.

3. Remove the oil fill hose and install the dust cover.

4. Depress the brake release and secondary steeringswitch for thirty seconds. This switch will manuallyactivate the prelube pump in order to fill the engineoil filters.

5. Start the engine and operate the engine at low idlefor five minutes. Inspect the engine oil filters for oilleaks. Make any necessary repairs.

6. Maintain the oil level within shaded area (X) ofengine oil level gauge (3). Refer to Illustration 189and Illustration 188.

164 SEBU7794-08Maintenance SectionEngine Valve Lash - Check/Adjust

i02548994

Engine Valve Lash -Check/AdjustSMCS Code: 1102-025; 1102-535

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.

Electrical shock hazard. The electronic unit injec-tor system uses 90-120 volts.

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.

This procedure is recommended by Caterpillar aspart of a lubrication and preventive maintenanceschedule in order to help provide maximum enginelife.

For information on checking the engine valve lash,refer to Systems Operation, Testing And Adjusting,SENR9937, “C27 and C32 Engines for CaterpillarBuilt Machines” or consult your Caterpillar dealer.

i01597115

Engine Valve Rotators - InspectSMCS Code: 1109-040-DJ

When inspecting the valve rotators, protectiveglasses or face shield and protective clothingmust be worn, to help prevent being burned byhot oil or spray.

Engine valve rotators rotate the valves when theengine runs. This helps to prevent deposits frombuilding up on the valves and the valve seats.

Perform the following steps after the engine valvelash is set, but before the valve covers are installed:

1. Start the engine according to Operation andMaintenance Manual, “Engine Starting” (OperationSection) for the procedure.

2. Operate the engine at low idle.

3. Observe the top surface of each valve rotator. Thevalve rotators should turn slightly when the valvesclose.

NOTICEA valve rotator which does not operate properly willaccelerate valve face wear and valve seat wear andshorten valve life. If a damaged rotator is not replaced,valve face guttering could result and cause pieces ofthe valve to fall into the cylinder. This can cause pistonand cylinder head damage.

If a valve fails to rotate, consult your Caterpillardealer.

i02445963

Engine Water Pump - InspectSMCS Code: 1361-040

A water pump that has failed might causesevere engine overheating problems. The engineoverheating problems could result in the followingproblems:

• Cracks in the cylinder head

• Piston seizure

• Other potential engine damage


Ether Starting Aid Cylinder - Replace


Visually inspect water pump (1) for leaks. If leaks arefound, all the seals need to be replaced.

Note: For the replacement of the water pump seals,refer to Disassembly and Assembly, RENR9217,“C27 and C32 Engines For Caterpillar BuiltMachines”.

i02513607

Ether Starting Aid Cylinder -ReplaceSMCS Code: 1456-510-CD

Breathing ether vapors or repeated contact ofether with skin can cause personal injury. Person-al injury may occur from failure to adhere to thefollowing procedures.

Use ether only in well ventilated areas.

Do not smoke while changing ether cylinders.

Use ether with care to avoid fires.

Do not store replacement ether cylinders in livingareas or in the operator's compartment.

Do not store ether cylinders in direct sunlight orat temperatures above 49 °C (120 °F).

Discard cylinders in a safe place. Do not punctureor burn cylinders.

Keep ether cylinders out of the reach of unautho-rized personnel.

To avoid possible injury, be sure the brakes are ap-plied and all controls are in Hold or Neutral whenstarting the engine.

166 SEBU7794-08Maintenance SectionFrame - Clean/Inspect


1. Loosen clamp (1) and unscrew ether starting aidcylinder (2).

2. Remove the used gasket. Install the new gasketthat is provided with the ether starting aid cylinder.Install the new ether starting aid cylinder. Tightenthe clamp.

Note: Install protective cap (3) if an ether starting aidcylinder will not be in place.

i02516682

Frame - Clean/InspectSMCS Code: 7050-571

A raised body (bed) may fall unexpectedly andwithout warning resulting in personal injury ordeath.

When it is necessary to work under the truck withthe body (bed) raised, install the body (bed) retain-ing pins through the pin bores in the frame and theretaining brackets on the body.


2. Raise the body to the fully raised position andinstall the body retaining pins. For the properprocedure, refer to Operation and MaintenanceManual, “Body Retaining Pin”.

3. Stop the engine.

4. Clean the frame with a high pressure washer.


5. Inspect the frame for damage and for cracks.If you find cracks or damage, consult yourCaterpillar dealer for specific repair procedures.Do not operate the machine until the necessaryrepairs have been made.

6. Remove the body retaining pins and lower thebody. For the proper procedure, refer to Operationand Maintenance Manual, “Body Retaining Pin”.

i02516834

Frame and Body - InspectSMCS Code: 7050-040; 7258-040





Frame and Body Support Pads - Clean/Inspect


3. Stop the engine.


4. Clean the frame and the body with a high pressurewasher. If necessary, continue to clean the frameand the body with a wire brush or a scraper.

5. Inspect the frame and the body. If you findcracks, damage or excessive wear, consult yourCaterpillar dealer for specific repair procedures.Do not operate the machine until the necessaryrepairs have been made.


i03645004

Frame and Body Support Pads- Clean/InspectSMCS Code: 7050-571; 7258-571-S4





3. Stop the engine.


4. Clean the body support pads with high pressurewater or steam. If damage is found, consult yourCaterpillar dealer for specific repair procedures.

168 SEBU7794-08Maintenance SectionFront Suspension Cylinder Rods - Lubricate

5. Visually inspect each of the body support pads.Compare all the body support pads. If theinspection indicates uneven wear of the bodysupport pads, you may need to readjust the shims.Also, if the paint on the frame indicates unevenwear, you may need to readjust the shims. If thebody support pads are shimmed correctly, reviewyour loading operation.

Note: Proper installation of the body support padswill effectively balance the load weight. If the bodysupport pads indicate uneven wear, readjusting theshims may correct the problem. Also, if the paint onthe frame indicates uneven wear, readjusting theshims may correct the problem.


i03646222

Front Suspension CylinderRods - LubricateSMCS Code: 7201-086-RO

Improper operation, lubrication, maintenance orrepair of this product can be dangerous and couldresult in injury or death.

Do not operate or perform any lubrication, main-tenance or repair on this product, until you haveread and understood the operation, lubrication,maintenance and repair information.




NOTICEExcessive grease could damage the seals.



g01956633Illustration 197Right front suspension cylinder

Fitting (1) is located on each front suspensioncylinder. Lubricate the fitting on each front suspensioncylinder.

i03041269

Front Wheel Oil - ChangeSMCS Code: 4201-044-OC

Note: The oil change interval for the front wheelcan be determined with the S·O·S scheduled oilsampling program. The oil change interval is basedon the condition of the oil. If the S·O·S scheduled oilsampling program is not used, the oil change shouldbe performed at 500 service hours.


Front Wheel Oil - Inspect


1. Position the front wheel so that the drain plug isfacing downward.





3. Remove the drain plug slowly in order to relieveany pressure.

4. Allow the oil to drain into a suitable container.

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


6. Remove the filler plug.

7. Fill the oil compartment to the bottom of the fillerplug opening. Refer to Operation and MaintenanceManual, “Capacities (Refill)”.

8. Clean the filler plug and install the filler plug. Usethe same procedure for the other front wheelbearing.

i02388737

Front Wheel Oil - InspectSMCS Code: 4201-040-OC

Inspect the front wheel oil for any of the followingsymptoms that may indicate a failure of the wheelbearings:

• A high amount of metal on the magnetic plug

• An increased level of nickel concentration in theS·O·S sample

• An increase in the size of the particle count in theS·O·S sample

• Oil leaks in the area around the front wheel spindle

The front wheel bearings do not need to be adjustedor inspected until the scheduled overhaul. Unless asymptom of an obvious failure appears, do not adjustor inspect the front wheel bearings. If the front wheeloil has any of the above symptoms, the front wheelbearings may need to be inspected. Consult yourCaterpillar dealer for more information.

170 SEBU7794-08Maintenance SectionFront Wheel Oil Level - Check

i03041270

Front Wheel Oil Level - CheckSMCS Code: 4201-535-FLV



Note: In order to prevent dirt from entering the wheelbearing, use a clean cloth to wipe the area aroundthe filler plug before you remove the filler plug.

2. Remove the filler plug slowly in order to relieveany pressure.

3. Maintain the oil level to the bottom of the filler plugopening.

4. Clean the filler plug and install the filler plug.

i03646165

Front Wheel Oil Sample -ObtainSMCS Code: 4201-008-OC; 7542



Use a sampling gun in order to obtain an oil samplefor the front wheel through the filler plug. Remove thefiller plug slowly in order to relieve any pressure.







SEBU7794-08 171Maintenance SectionFuel System - Fill

i02648692

Fuel System - FillSMCS Code: 1250-544

Personal injury or death may result from failure toadhere to the following procedures.

Fuel leaked or spilled onto hot surfaces or electri-cal components can cause a fire.

Clean up all leaked or spilled fuel. Do not smokewhile working on the fuel system.

Turn the disconnect switch OFF or disconnect thebattery when changing fuel filters.

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting, and repair of the machine. Be preparedto collect the fluid with suitable containers beforeopening any compartment or disassembling any com-ponent containing fluids.



(1) Vented Fuel Cap(2) Non-Vented Fuel Cap

Note: Machines that are not equipped with a fastfill fuel adapter group require a vented fuel cap.Machines that are equipped with the nonpressurizedfast fill fuel adapter group require a vented fuel cap.Machines that are equipped with the pressurized fastfill fuel adapter group require a non-vented fuel cap.

NOTICEFailure to install a vented fuel cap on a nonpressurizedfuel tank could create a vacuum in the fuel system.This could cause damage to the fuel system compo-nents and/or inefficient engine operation.

Failure to install a non-vented fuel cap on a pressur-ized fast fill fuel adapter group could cause the fueltank to be overfilled during refueling.

Refer to Operation and Maintenance Manual,“Capacities (Refill)” for the fuel tank capacity of yourmachine.

Park the machine on a level surface. Make sure thatthe transmission control is in the PARK position.


Fuel Tank Filler Neck1. Clean fuel cap (3) and the filler neck. Remove thefuel cap.

2. Fill the fuel tank with fuel through the filler neckand install the fuel cap.

Fast Fill Fuel Adapter (If Equipped)

NOTICEUse only a Caterpillar approved fast fill system to fuelmachines. Over pressurization may cause tank defor-mation and fuel spillage.

Contact your Cat dealer for fast fill system availability.

172 SEBU7794-08Maintenance SectionFuel System - Prime

1. Remove dust cover (4) and clean the fast fill fueladapter.

Note: The maximum fuel flow rate for the fast fill fueladapter group is 375 L/min (100 US gpm).

2. Fill the fuel tank through the fast fill fuel adapterand install the dust cover.

i02434474

Fuel System - PrimeSMCS Code: 1250-548

Fuel leaked or spilled onto hot surfaces or elec-trical components can cause a fire. Clean up fuelspills immediately.

Note: The engine start switch must be in the OFFposition in order to prime the fuel system.



The tire and the wheel are removed for ease of viewing.

(1) Switch for the Electric Fuel PrimingPump

2. Hold switch (1) upward in order to activate theelectric fuel priming pump. The priming pump willfill the engine fuel lines and the fuel filters with fuel.

3. As the air is purged from the fuel system, fuelpressure will increase. Listen for the electric fuelpriming pump to come under load. Do not continuepriming the fuel system after the priming pump isunder load. Do not operate the priming pump formore than two minutes.


5. If the engine starts but the engine runs rough,continue to run the engine at low idle until theengine runs smoothly.

6. If the engine does not start after several attempts,consult your Caterpillar dealer.


Fuel System Primary Filter (Water Separator) - Drain

i02612728

Fuel System Primary Filter(Water Separator) - DrainSMCS Code: 1261-543; 1263-543







Open drain valve (1) on the bottom of the fuel/waterseparator element in order to drain the water into anapproved container. Close the drain valve when all ofthe water has been drained.

i02517121

Fuel System Primary Filter(Water Separator) - ReplaceSMCS Code: 1261-510; 1263-070

Replace the fuel/water separator elements when theengine has a loss of power or when the exhaustsmoke is black.

Personal injury or death can result if spilled fuelignites. Fuel leaked or spilled onto hot surfacesor electrical components can cause a fire.

To help prevent possible injury, turn the batterydisconnect switch to the OFF position whenchanging fuel filters or water separator elements.Clean up fuel spills immediately.




NOTICEDo not fill fuel filters with fuel before installing them.The fuel will not be filtered and could be contaminated.Contaminated fuel will cause accelerated wear to fuelsystem parts. The fuel system should be primed priorto starting the engine.


174 SEBU7794-08Maintenance SectionFuel System Primary Filter (Water Separator) - Replace

g01259298Illustration 206View of the back side of the fuel tank

2. Close fuel shutoff valve (1).



3. The water separator bowl (3) is located on thebottom of the primary fuel filter (2). Open the drainvalve (4) on the water separator bowl. Allow thewater and the fuel to drain into a suitable container.

4. Use a strap type wrench to remove the filter fromthe filter mounting base.

5. Remove the water separator bowl from the filterelement. Clean the water separator bowl and theO-ring groove.

Note: The water separator bowl is reusable. Do notdiscard the water separator bowl.

6. Inspect the O-ring seal in the water separator bowlfor damage. Replace the O-ring seal, if necessary.

7. Lubricate the O-ring seal with clean diesel fuel orwith engine oil. Place the O-ring seal in the waterseparator bowl.

8. Install the water separator bowl onto the new filterelement by hand. Do not use tools to tighten thewater separator bowl.

9. Lubricate the gasket of the new filter element withclean diesel fuel. Install the new filter hand tightuntil the seal of the fuel filter contacts the base.Note the position of the index marks on the filter inrelation to a fixed point on the filter base.

Note: There are rotation index marks on the fuel filterthat are spaced 90 degrees or 1/4 of a turn awayfrom each other. When you tighten the fuel filter, usethe rotation index marks as a guide.

10. Tighten the filter according to the instructionsthat are printed on the filter. Use the index marksas a guide. For non-Caterpillar filters, use theinstructions that are provided with the filter.

Note: You may need to use a Caterpillar strapwrench, or another suitable tool, in order to turnthe filter to the amount that is required for finalinstallation. Make sure that the installation tool doesnot damage the filter.

11. Tighten the drain valve on the water separatorbowl.

Note: The water separator element is under suctionduring normal engine operation. The drain valve mustbe tightened in order to prevent air leakage into thefuel system.

12.Open the fuel shutoff valve.

13.Prime the fuel system.

For information on priming the fuel system, referto the Operation and Maintenance Manual, “FuelSystem - Prime”.

14.Start the engine and inspect the filter for leaks.Make any necessary repairs. If the engine has aloss of power or the exhaust smoke is still black,replace the secondary filters.


Fuel System Secondary Filter - Replace

i02612676

Fuel System Secondary Filter -ReplaceSMCS Code: 1261-510-SE

Personal injury or death can result if spilled fuelignites. Fuel leaked or spilled onto hot surfacesor electrical components can cause a fire.

To help prevent possible injury, turn the batterydisconnect switch to the OFF position whenchanging fuel filters or water separator elements.Clean up fuel spills immediately.




NOTICEDo not fill fuel filters with fuel before installing them.The fuel will not be filtered and could be contaminated.Contaminated fuel will cause accelerated wear to fuelsystem parts. The fuel system should be primed priorto starting the engine.


g01259298Illustration 208View of the back side of the fuel tank

2. Close fuel shutoff valve (1).


3. Secondary fuel filter (2) is located on the right sideof the engine. Remove the filter elements from thebase. Discard the used element.

4. Clean the filter mounting base. Make sure that allof the former seal is removed.

5. Lubricate the sealing surfaces of the new filterelements with clean diesel fuel.

6. Install the filters by hand. Tighten the filterelements until the sealing surfaces contact thebase. Tighten the filter elements for an additional3/4 of a turn.

There are rotation index marks on each filterelement. These marks are spaced 90° or 1/4 turnfrom each other. Use the marks as a guide whenyou tighten the filter elements.

176 SEBU7794-08Maintenance SectionFuel Tank Cap and Strainer - Clean

7. Open the fuel shutoff valve.

8. Prime the fuel system. Refer to the Operation andMaintenance Manual, “Fuel System - Prime”.

9. Start the engine and inspect the filter for leaks.Make any necessary repairs.

i02517264

Fuel Tank Cap and Strainer -CleanSMCS Code: 1273-070-STR; 1273-070-Z2



2. Remove fuel tank cap (1).

3. Inspect the cap gasket. Replace the gasket if thegasket is damaged.

4. Remove the retaining snap ring.

5. Remove the screen.

6. Disassemble the cap.

7. Wash all the parts in clean, nonflammable solvent.

8. Lightly oil the element. Assemble the cap.

9. Install the screen, the retaining snap ring and thecap.

i02519799

Fuel Tank Water and Sediment- DrainSMCS Code: 1273-543-MAS

g01204673Illustration 211The fuel tank is located on the left side of the machine.





2. Open fuel tank drain valve (1) and allow themoisture and the sediment to drain into a suitablecontainer.

3. Close the drain valve.


Fuses - Replace

i02500085

Fuses - ReplaceSMCS Code: 1417-510

NOTICEIf it is necessary to replace fuses frequently, an elec-trical problem may exist.

Contact your Caterpillar dealer.

Fuses protect the electrical system from damagethat is caused by overloaded electrical circuits.Replace a fuse if the element separates. If the fuseof a particular electrical system requires frequentreplacement, check the electrical circuit. Repair theelectrical circuit, if necessary. The fuse panel ispositioned in the operator's compartment behind theoperator's seat.

NOTICEAlways replace fuses with the same type and capacityfuse that was removed. Otherwise, electrical damagecould result.

24 Volt Fuses


Spare Fuse (1)

Spare Fuse (2)

Spare Fuse (3)

Spare Fuse (4)

178 SEBU7794-08Maintenance SectionFuses - Replace

Spare Fuse (5)

HVAC (6) – 15 Amp

Spare Fuse (7)

Spare Fuse (8)

Backup Alarm (9) – 10 Amp

MineStar (10) – 10 Amp

Autolube System (11) – 10 Amp

Accessories (12) – 10 Amp

WAVS (13) – 10 Amp

Spare Fuse (14)

Spare Fuse (15)

Secondary Steering, Prelube, and OilEvac (16) – 10 Amp

Spare Fuse (17)

Spare Fuse (18)

Heated Mirror (Upper) (19) – 10 Amp

Heated Mirror (Lower) (20) – 10 Amp

Horn (21) – 10 Amp

Chassis ECM (22) – 15 Amp

Directional Signal/Hazard Light (23) – 10Amp

Product Link (24) – 10 Amp

Windshield Washer and Wiper (25) – 15Amp

Instrument Cluster (26) – 10 Amp

VIMS or TPMS (27) – 10 Amp

Brake ECM (28) – 15 Amp

Keyswitch (29) – 10 Amp

Stop Lamps (30) – 15 Amp

MineStar (31) – 15 Amp


High Intensity Discharge Lamp (HID) - Replace

24 Volt to 12 Volt Converter (32) – 20Amp

12 Volt Fuses


Spare Fuse (33)

Spare Fuse (34)

Entertainment Radio (35) – 10 Amp

12 Volt Power Port (Console Panel)(36) – 10 Amp

12 Volt Power Port (Rear Panel) (37) – 10Amp

Spare Fuse (38)

Cigar Lighter (39) – 10 Amp

Communication Radio (40) – 20 Amp

HVAC Control (41) – 10 Amp

Spare Fuse (42)

Spare Fuse (43)

Spare Fuse (44)

Entertainment Radio (45) – 10 Amp

Spare Fuse (46)

Spare Fuse (47)

Spare Fuse (48)

i02245859

High Intensity Discharge Lamp(HID) - Replace(If Equipped)SMCS Code: 1434-510

HID lamps operate at very high voltages. To avoidelectrical shock and personal injury, disconnectpower before servicing HID lamps.

180 SEBU7794-08Maintenance SectionHoist Cylinder Bearings - Lubricate

HID bulbs become very hot during operation.Before servicing, remove power from lamp for atleast five minutes to ensure lamp is cool.

NOTICEAlthough HID bulb materials may change over time,HID bulbs produced at the time of the printing of thismanual contain mercury. When disposing of this com-ponent, or any waste that contains mercury, pleaseuse caution and comply with any applicable laws.

1. Remove the electrical power from the highintensity discharge lamp (HID). The electricalpower must be removed from the HID lamp forat least five minutes, in order to ensure that thebulb is cool.

2. Disassemble the housing for the HID lamp in orderto have access to the bulb.

Note: On some HID lamps, the bulb is an integralpart of the lens assembly. The bulb is not removedseparately from the lens assembly. Replace theentire lens assembly on these HID lamps.

3. Remove the bulb from the HID lamp.

4. Install the replacement bulb in the HID lamp.

If the bulb is an integral part of the lens assembly,install the replacement lens assembly in the HIDlamp.

Note: In order to avoid failure to the bulb that ispremature, avoid touching the bulb's surface withyour bare hands. Clean any fingerprints from the bulbwith alcohol prior to operation.

5. Reassemble the housing for the HID lamp. Ensurethat any printing on the lens is oriented correctlywith respect to the HID lamp's mounting positionon the machine.

6. Reattach the electrical power to the HID lamp.

7. Check the HID lamp for proper operation.

Note: Consult your Caterpillar dealer for additionalinformation on HID lamps.

i02525926

Hoist Cylinder Bearings -LubricateSMCS Code: 5102-086-BD




Cutaway view of the upper hoist cylinder bracket

Two fittings (1) are located on each hoist cylinderbearing. Lubricate the upper bearing and the lowerbearing on each hoist cylinder.

i02916668

Hoist and Brake Tank Oil -ChangeSMCS Code: 5056-044

1. Park the machine on a level surface and stop theengine. Make sure that the transmission control isin the PARK position and make sure that the truckbody is in the DOWN position.


Hoist and Brake Tank Oil - Change


2. Remove filler cap (1) in order to prevent a vacuumin the tank. Install the cap after the tank has beendrained. This will prevent dirt from entering thesystem.




Note: Hand tighten the NPT pipe nipple. Do not usetools.

3. Remove drain plug (3) from the hoist/brake tank.Install a 88 mm (3.50 inch) long NPT pipe nipplein order to open the internal drain valve. Theouter diameter of the NPT pipe nipple should be25.4 mm (1 inch). Drain the oil into a suitablecontainer.

4. Remove the pipe nipple. Clean the drain plug andinstall the drain plug.

5. Remove the tank filler cap.

6. Remove the retaining ring on the filler screen.Remove the screen.

7. Wash the cap and the filler screen in clean,nonflammable solvent. Allow the cap and the fillerscreen to dry.

8. Inspect the cap seal. Use a new seal if the usedseal is damaged. Install the filler screen and theretaining ring.

9. Fill the hoist/brake tank. Refer to Operation andMaintenance Manual, “Lubricant Viscosities”.Refer to Operation and Maintenance Manual,“Capacities (Refill)”.

10.Start the engine and run the engine forapproximately 15 seconds. The oil level willdecrease as oil fills the system.

11.Stop the engine.

12.Add oil to the tank in order to raise the oil to theproper level in upper sight gauge (2). Refer toOperation and Maintenance Manual, “Hoist andBrake Tank Oil Level - Check” for the proper oillevel within the sight gauge.

13.Start the engine and operate the engine at lowidle. Check the hydraulic system for leaks andmake necessary repairs.

14.Raise the dump body until the hoist cylinders areextended halfway. Lower the dump body and addoil, if necessary.

15.Raise the dump body until the hoist cylinders arefully extended. Lower the dump body and add oil,if necessary.

16.Repeat Step 14 and Step 15 until the proper oillevel stabilizes in the upper sight gauge. Installthe filler cap.

182 SEBU7794-08Maintenance SectionHoist and Brake Tank Oil Level - Check

i03194840

Hoist and Brake Tank Oil Level- Check(Type 1)SMCS Code: 5056-535-OC

S/N: EED1-844

S/N: DLS1-807

The type 1 tank was factory installed on machines inthis serial number range. All type 1 tanks should beupdated to a type 2 tank. Contact your Caterpillardealer in order to update the hoist/brake tank.


The hoist/brake tanks can be identified by the height of the uppersight gauge and filler neck. The upper sight gauge and the fillerneck on a type 1 tank (A) is lower than the upper sight gauge andthe filler neck on a type 2 tank (B).

Note: The type 1 tank and the type 2 tank have thesame oil capacity. The upper sight gauge is raised onthe type 2 tank in order to display the proper levelwithin the sight gauge.

1. Park the machine on a level surface with the truckbody in the DOWN position. Stop the engineand allow the oil to cool. Make sure that thetransmission control is in the PARK position.

g01629753Illustration 217The hoist/brake tank is located on the right side of the machine.

2. Check the oil level in sight gauge (2). The oil levelmust be checked when the oil is cold (ambienttemperature). The oil level must be within uppergreen range (4) on the sight gauge.

Note: As the oil approaches operating temperature,the oil level will rise above the top of the sight gauge.

NOTICEDo not use the lower green range in order to check tooil level of the hoist, torque converter, and brake tank.The lower green range will not provide enough oil tothe system and machine damage could result.


Hoist and Brake Tank Oil Level - Check

3. If necessary, remove filler cap (1) and add oil. Ifthe system has been drained, see this Operationand Maintenance Manual, “Hoist and Brake TankOil - Change” for the proper filling procedure.

Note: If the oil level must be checked with the truckbody in the RAISED position, the minimum oil levelmust be within sight gauge (3) with the engine on.

i03196138

Hoist and Brake Tank Oil Level- Check(Type 2)SMCS Code: 5056-535-OC

S/N: EED845-Up

S/N: DLS808-Up

The type 2 tank was factory installed on machinesin this serial number range. All machines with aprevious serial number should be converted to a type2 tank.

g01627915Illustration 218The hoist/brake tanks can be identified by the height of the uppersight gauge and filler neck. The upper sight gauge and the fillerneck on a type 2 tank (B) is higher than the upper sight gauge andthe filler neck on a type 1 tank (A).

Note: The type 1 tank and the type 2 tank have thesame oil capacity. The upper sight gauge is raised onthe type 2 tank in order to display the proper levelwithin the sight gauge.

1. Park the machine on a level surface with the truckbody in the DOWN position. Stop the engine andmake sure that the transmission control is in thePARK position.

g01628256Illustration 219The hoist/brake tank is located on the right side of the machine.

2. Check the oil level in sight gauge (2).

a. When the oil is hot (operating temperature),maintain the oil level within upper green range(4).

b. When the oil is cold (ambient temperature),maintain the oil level within lower green range(5).

3. If necessary, remove filler cap (1) and add oil. Ifthe system has been drained, see this Operationand Maintenance Manual, “Hoist and Brake TankOil - Change” for the proper filling procedure.

184 SEBU7794-08Maintenance SectionHoist and Brake Tank Oil Sample - Obtain

Note: If the oil level must be checked with the truckbody in the RAISED position, the minimum oil levelmust be within sight gauge (3) with the engine on.

i03646172

Hoist and Brake Tank OilSample - ObtainSMCS Code: 5050-008; 5056-008; 7542






Oil sampling valve (1) for the hoist/brake system islocated on the front of the hoist/brake oil cooler onthe right side of the engine.







i02518144

Magnetic Plug (Wheels) -CheckSMCS Code: 0663-535

g01259881Illustration 221Magnetic plug on the rear wheel


Magnetic Screen (Transmission) - Clean

g01250751Illustration 222Magnetic plug on the front wheel

All of the wheels have a magnetic plug. The magneticplugs will attract metal from the oil. A bearing failureis indicated by an increased amount of metal on themagnetic plug.

If any abnormal particles are found, consult yourCaterpillar dealer.

After you correct a failure that produces debris, cleanthe compartments before you add any oil.

i02521748

Magnetic Screen(Transmission) - CleanSMCS Code: 3030-070-MGS



Location of the magnetic screen for the transmission


2. Remove cover assembly (1), screen (2) andmagnetic tube assembly (3).

3. Inspect the screen and the magnets for debris. Anexcessive amount of debris may be an indicationof possible failure. Also, oil contamination mayrequire you to change the transmission oil. If largeparticles are found, consult your Caterpillar dealerfor further analysis and additional guidance.

NOTICEDo not drop or rap the magnets against any hard ob-jects. Replace any damaged magnets.

186 SEBU7794-08Maintenance SectionOil Filter (Parking Brake Release) - Replace

4. Wash the screen and the magnetic tube assemblyin clean, nonflammable solvent. Clean themagnets with a cloth, a stiff bristle brush or airpressure.

5. Install the magnetic tube assembly and the screen.

6. Inspect seal (4). If the seal is damaged, replacethe seal.

7. Install the cover assembly.

8. Start the engine and operate the engine at lowidle. Inspect the area for leaks and make anynecessary repairs.

9. Check the oil level in the transmission and torqueconverter system. If necessary, add oil. Referto Operation and Maintenance Manual, “TorqueConverter and Transmission Oil Level - Check”for the proper procedure.

i03652875

Oil Filter (Parking BrakeRelease) - ReplaceSMCS Code: 5068-510-BRK









g01960224Illustration 225The parking brake release oil filters are located on the inside leftframe rail between the front axle and the fuel tank.

2. Remove drain plugs (2) from filter housings (1).Drain the oil into a suitable container.


Oil Filter (Power Train) - Replace

Note: Removing the bottom drain plugs may notallow all of the oil to drain from the filter housings.When you remove the filter housings and the filterelements, be careful to avoid contact with hot oil.

3. Clean the drain plugs and inspect the seals in thedrain plugs. If a seal is damaged, replace the sealwith a new seal. Install the drain plugs.

4. Remove the filter housings and the filter elements.Properly discard the used filter elements.

5. Wash the filter housings in clean nonflammablesolvent.

6. Inspect the seal in the filter bases. If a seal isdamaged, replace the seal with a new seal.

7. Install the new filter elements in the housings.Install the housings.

8. Start the engine and operate the engine at lowidle. Check for any leaks and make the necessaryrepairs.

9. Check the oil level in the hoist/brake tank. Ifnecessary, add oil. For the proper procedure, referto Operation and Maintenance Manual, “Hoist andBrake Tank Oil Level - Check”.

i02518734

Oil Filter (Power Train) -ReplaceSMCS Code: 3067-510; 3101-510-FI





Note: The power train oil filter is the oil filter for thetransmission/torque converter.






2. Remove drain plug (2) from filter housing (1).Drain the oil into a suitable container. Clean thedrain plug and install the drain plug.

188 SEBU7794-08Maintenance SectionOil Filter (Steering Pump Case Drain) - Replace

Note: Removing the drain plug from the bottom ofthe power train oil filter may not allow all of the oilto drain from the filter housings. When you removethe filter housing and the filter element, be careful toavoid contact with hot oil.

3. Remove the filter housing and the filter element.Properly discard the used filter element.

4. Wash the filter housing in clean nonflammablesolvent.

5. Inspect the seal in the filter base. If the seal isdamaged, replace the seal with a new seal.

6. Install the new filter element in the housing. Installthe housing.

7. Start the engine and operate the engine at lowidle. Check for any leaks and make the necessaryrepairs.

8. Check the oil level in the transmission and torqueconverter system. If necessary, add oil. Referto Operation and Maintenance Manual, “TorqueConverter and Transmission Oil Level - Check”for the proper procedure.

i02550132

Oil Filter (Steering Pump CaseDrain) - ReplaceSMCS Code: 5068-510; 5091-510-ZH

Park the machine on level ground and stop theengine. Make sure that the transmission control is inthe PARK position.


1. Push the button on breaker relief valve (2).

2. Slowly, loosen filler cap (1) on the steeringhydraulic tank in order to relieve the pressure.


3. Remove case drain oil filter (3).

4. Clean the filter mounting base. Make sure that theold filter seal is removed.

5. Lubricate the seal of the new filter with clean oil.

6. Install the new filter by hand until the seal contactsthe filter mounting base. Note the position of theindex marks on the filter in relation to a fixed pointon the mounting base.


Oil Filter (Steering) - Replace

Note: There are rotation index marks on each filterthat is spaced 90 degrees (1/4 turn) away from eachother. When you tighten the filter, use the rotationindex marks as a guide.

7. Tighten all filters according to the instructions thatare printed on the filter. For non-Caterpillar filters,use the instructions that are provided with the filter.

Note: You may need to use a strap type wrench or asuitable tool in order to turn the filter to the amountthat is required for final installation. Make sure thatthe installation tool does not damage the filter.

8. Start the engine and operate the engine at lowidle. Check the machine for leaks and make anynecessary repairs. Install the filler cap.

9. Check the oil level. Maintain the oil level withinthe green range of sight gauge (4). If necessary,add oil.

i02550137

Oil Filter (Steering) - ReplaceSMCS Code: 5068-510-ZH

Park the machine on level ground and stop theengine. Make sure that the transmission control is inthe PARK position.


1. Push the button on breaker relief valve (2).

2. Slowly, loosen filler cap (1) on the steeringhydraulic tank in order to relieve the pressure.


3. Remove steering oil filter (3).

4. Clean the filter mounting base. Make sure that theold filter seal is removed.

5. Lubricate the seal of the new filter with clean oil.

6. Install the new filter by hand until the seal contactsthe filter mounting base. Note the position of theindex marks on the filter in relation to a fixed pointon the mounting base.

190 SEBU7794-08Maintenance SectionOil Filter - Inspect

Note: There are rotation index marks on each filterthat is spaced 90 degrees (1/4 turn) away from eachother. When you tighten the filter, use the rotationindex marks as a guide.

7. Tighten all filters according to the instructions thatare printed on the filter. For non-Caterpillar filters,use the instructions that are provided with the filter.

Note: You may need to use a strap type wrench or asuitable tool in order to turn the filter to the amountthat is required for final installation. Make sure thatthe installation tool does not damage the filter.

8. Start the engine and operate the engine at lowidle. Check the machine for leaks and make anynecessary repairs. Install the filler cap.

9. Check the oil level. Maintain the oil level withinthe green range of sight gauge (4). If necessary,add oil.

i02106227

Oil Filter - InspectSMCS Code: 5068-040

Inspect a Used Filter for Debris


The element is shown with debris.

Use a filter cutter to cut the filter element open.Spread apart the pleats and inspect the element formetal and for other debris. An excessive amount ofdebris in the filter element can indicate a possiblefailure.

If metals are found in the filter element, a magnet canbe used to differentiate between ferrous metals andnonferrous metals.

Ferrous metals can indicate wear on steel parts andon cast iron parts.

Nonferrous metals can indicate wear on thealuminum parts of the engine such as main bearings,rod bearings, or turbocharger bearings.

Small amounts of debris may be found in the filterelement. This could be caused by friction and bynormal wear. Consult your Caterpillar dealer in orderto arrange for further analysis if an excessive amountof debris is found.

Using an oil filter element that is not recommendedby Caterpillar can result in severe engine damageto engine bearings, to the crankshaft, and to otherparts. This can result in larger particles in unfilteredoil. The particles could enter the lubricating systemand the particles could cause damage.

i02612604

Radiator Core and Aftercooler- CleanSMCS Code: 1064-070; 1353-070-KO

NOTICEHigh water pressure water and high water volume candamage the radiator.

Use a water spray nozzle that will disperse the water.


Typical example


2. Remove the two-piece grill.


Rear Axle A-Frame Bearing - Lubricate

3. Clean the radiator core and clean the aftercooler.

Use compressed air, high pressure water, orsteam to remove dust and other debris from theradiator core and the aftercooler. However, theuse of compressed air is preferred.

4. install both pieces of the grill.

See Special Publication, SEBD0518, “Know YourCooling System” for the complete procedure forcleaning the radiator core.

i02526632

Rear Axle A-Frame Bearing -LubricateSMCS Code: 7551-086-ZX


Wipe off the fitting before any lubricant is applied.


Lubricate fitting (1) that is located on the pin for therear axle support.

i02525735

Rear Axle Housing LateralControl Rod Bearings -LubricateSMCS Code: 7551-086-RO



g01263428Illustration 232This rear view is cutaway in order to show the fittings for the lateralcontrol rod.

Lubricate two fittings (1) that are located at the rear ofthe machine between the frame and the differential.

i02525682

Rear Suspension CylinderBearings - LubricateSMCS Code: 7213-086-BD


192 SEBU7794-08Maintenance SectionReceiver Dryer (Refrigerant) - Replace


Lubricate four fittings (1) that are located at the rear ofthe machine between the frame and the differential.

i02656717

Receiver Dryer (Refrigerant) -ReplaceSMCS Code: 7322-510

Personal injury can result from contact with refrig-erant.

Contact with refrigerant can cause frost bite. Keepface and hands away to help prevent injury.

Protective goggles must always be worn when re-frigerant lines are opened, even if the gauges in-dicate the system is empty of refrigerant.

Always use precaution when a fitting is removed.Slowly loosen the fitting. If the system is still un-der pressure, release it slowly in a well ventilatedarea.

Personal injury or death can result from inhalingrefrigerant through a lit cigarette.

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 conditioners orwherever refrigerant gas may be present.

Use a certified recovery and recycling cart to prop-erly remove the refrigerant from the air condition-ing system.

NOTICEIf the refrigerant system has been open to the outsideair (without being plugged) for more than 30 minutes,the receiver-dryer must be replaced. Moisture will en-ter an open refrigerant system and cause corrosionwhich will lead to component failure.

g01217368Illustration 234(1) Refrigerant dryer

Refer to Service Manual, SENR5664, “AirConditioning and Heating R-134a for All CaterpillarMachines” for the proper procedure to change therefrigerant dryer and for the proper procedure toreclaim the refrigerant gas.

i02650056

Rim - InspectSMCS Code: 4209-040

Inspect the rim whenever a tire is dismounted.


Rim - Inspect


Typical example

Cutaway view of the rim assembly

Inspect the following components of the rimassembly:

Bead Seat Band (1) – Inspect the bead seat bandfor the following: wear, corrosion, and cracks.

Lock Ring (2) – Inspect the lock ring for thefollowing: wear, corrosion, cracks, flat spots, andwarping. When the lock ring is not assembled, thetwo ends of the lock ring must overlap each other.

Rim Base (3) – Inspect the rim base for the following:wear, corrosion, cracks, and fretting.

Flanges (4) – Inspect the flanges for the following:wear, corrosion, cracks, and fretting.

Do not reuse rim components that are cracked,worn, damaged, or pitted from corrosion. For moreinformation on the reusability of the rim components,consult your Caterpillar dealer.

i02650089

Rim - InspectSMCS Code: 4209-040

The tires must be dismounted from the rim in order toperform a magnetic particle inspection.


Typical example

Cutaway view of the rim assembly

The following high stress areas of the rim should bechecked:

• (1) Areas of contact with flanges

• (2) Contact areas with the lock ring and the groovefor the lock ring

• (3) Welds on the rim disc

• (4) Welds around the circumference of the rim base

• (5) Butt welds

For more information on magnetic particle inspection,refer to Guideline For Reusable Parts And SalvageOperations, SEBF8148, “General Salvage andReconditioning Techniques” or consult yourCaterpillar dealer.

.

194 SEBU7794-08Maintenance SectionRollover Protective Structure (ROPS) - Inspect

Do not reuse rim components that are cracked,worn, damaged, or pitted from corrosion. For moreinformation on the reusability of the rim components,consult your Caterpillar dealer.

i02623990

Rollover Protective Structure(ROPS) - InspectSMCS Code: 7325-040

Inspect the Rollover Protective Structure (ROPS)for bolts that are loose or damaged. Replace anydamaged bolts and any missing bolts with originalreplacement parts only. Refer to Specifications,SENR3130, “Torque Specifications” for therecommended torque.

Note: Apply oil to all bolt threads for the ROPS beforeyou install the bolts. Improper bolt torque can result ifyou do not apply oil to the threads.

Do not weld reinforcement plates to the ROPSin order to straighten the ROPS. Do not weldreinforcement plates to the ROPS in order to repairthe ROPS.

Inspect the ROPS for any cracks in the welds, cracksin the castings, or cracks in any metal section.

Refer to Special Instruction, SEHS6929, “Inspection,Maintenance, and Repair of ROPS and AttachmentInstallation Guidelines” or consult your Caterpillardealer for more information.

i02524321

Screen (Brake Oil Cooler) -CleanSMCS Code: 4295-070; 5068-070-Z3

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




After a failure in the brake circuit, clean the screen forthe brake oil cooler. The oil cooler screen is locatedon the right side of the engine.



2. Remove drain plug (1) and drain the oil from theoil cooler into a suitable container. Clean the drainplug and install the drain plug.

Note: Inspect all seals that are removed during thisprocedure. Replace any damaged seals.


Screen (Hoist and Brake Tank) - Inspect/Clean/Replace


3. Remove screen plug (3) and oil cooler screen (2).

Note: The oil cooler screens are fragile.

4. Wash the screen and the screen plug in clean,nonflammable solvent.

5. Install the screen and the screen plug. Orient thescreen so that the end with the holes is closer tothe screen plug.

6. Start the engine and run the engine at low idle.Check for leaks and make any necessary repairs.

7. Check the oil level in the hoist/brake tank. Ifnecessary, add oil. Refer to Operation andMaintenance Manual, “Hoist and Brake Tank OilLevel - Check” for more information.

i02916417

Screen (Hoist and Brake Tank)- Inspect/Clean/ReplaceSMCS Code: 5056-040-Z3

There is one suction screen inside the hoist/braketank. There is also one return screen. Clean bothscreens whenever there is a failure of brakes, hoistcylinders or hoist pumps.

The machine must be level. The transmission controlmust be in the PARK position and the engine mustbe stopped.


1. Remove filler cap (1) in order to prevent a vacuumin the tank.





2. Remove tank drain plug (2). Install a 88 mm(3.50 inch) long NPT pipe nipple in order to openthe internal drain valve. The outer diameter ofthe NPT pipe nipple should be 25.4 mm (1 inch).Drain the oil into a suitable container.

196 SEBU7794-08Maintenance SectionScreen (Hoist and Brake Tank) - Inspect/Clean/Replace


3. Remove return line (3).

4. Remove front cover (4) from the tank.

5. Clean any debris from the inside of the tank.

g01262924Illustration 241Cutaway view

6. Remove suction screen (5) from the tank.

7. Wash the suction screen in clean, nonflammablesolvent.

8. Install the clean suction screen.

9. Remove return screen (6) and properly discardthe return screen.

10. Install a new return screen.

11.Clean the cover for the front of the hoist/braketank in clean, nonflammable solvent. Inspect thecover gasket. If the gasket is damaged, replacethe gasket.

12. Install the front cover to the tank.

13. Install the return line.

14. Fill the hoist/brake tank. Refer to Operation andMaintenance Manual, “Lubricant Viscosities”.Refer to Operation and Maintenance Manual,“Capacities (Refill)”.

15.Start the engine and run the engine forapproximately 15 seconds. The oil level willdecrease as oil fills the system.

16.Stop the engine.


17.Add oil to the tank in order to raise the oil to theproper level in upper sight gauge (7). Refer toOperation and Maintenance Manual, “Hoist andBrake Tank Oil Level - Check” for the proper oillevel within the sight gauge.

18.Start the engine and operate the engine at lowidle. Check the hydraulic system for leaks andmake necessary repairs.

19.Raise the dump body until the hoist cylinders areextended halfway. Lower the dump body and addoil, if necessary.

SEBU7794-08 197Maintenance SectionSeat Belt - Inspect

20.Raise the dump body until the hoist cylinders arefully extended. Lower the dump body and add oil,if necessary.

21.Repeat Step 19 and Step 20 until the proper oillevel stabilizes in the upper sight gauge. Installthe filler cap.

i02425004

Seat Belt - InspectSMCS Code: 7327-040

Always check the condition of the seat belt and thecondition of the seat belt mounting hardware beforeyou operate the machine. Replace any parts that aredamaged or worn before you operate the machine.

g01212078Illustration 243Typical example

Inspect seat belt (1) for webbing that is worn orfrayed. Replace the seat belt if the seat belt is wornor frayed.

Check buckle (2) for wear or for damage. If the buckleis worn or damaged, replace the seat belt.

Check all seat belt mounting hardware (3) for wearor for damage. Replace any mounting hardware thatis worn or damaged. Make sure that the mountingbolts are tight.

Contact your Caterpillar dealer for the replacement ofthe seat belt and the mounting hardware.

Note:Within three years of the date of installation orwithin five years of the date of manufacture, replacethe seat belt. Replace the seat belt at the date whichoccurs first. A date label for determining the age ofthe seat belt is attached to the seat belt, the seat beltbuckle, and the seat belt retractor.

If your machine is equipped with a seat beltextension, also perform this inspection procedure forthe seat belt extension.

i04270251

Seat Belt - ReplaceSMCS Code: 7327-510

Within 3 years of the date of installation or within5 years of the date of manufacture, Caterpillarrecommends replacing the seat belt. Replace theseat belt at the date which occurs first. A date labelfor determining the age of the seat belt is attached tothe seat belt, the seat belt buckle, and the seat beltretractor.

g01152685Illustration 244(1) Date of installation (retractor)(2) Date of installation (buckle)(3) Date of manufacture (tag) (fully extended Web)(4) Date of manufacture (underside) (buckle)

Consult your Cat dealer for the replacement of theseat belt and the mounting hardware.

If your machine is equipped with a seat beltextension, also perform this replacement procedurefor the seat belt extension.

i02302909

Seat Suspension -Inspect/LubricateSMCS Code: 7324-040; 7324-086

Inspect

Seat Suspension

Inspect the seat suspension for excessive loosenessand wear. If excessive looseness or wear is detected,refer to Systems Operation, Testing and Adjusting,Disassembly and Assembly, RENR8391, “CaterpillarComfort Series Seat with three point operatorrestraint”, “Troubleshooting Chart”.

198 SEBU7794-08Maintenance SectionSecondary Steering - Test

Lubricate

Seat Suspension

Adjust the seat fully rearward and apply a drylubricant to the front of the seat slide mechanism.Adjust the seat fully forward and apply a dry lubricantto the rear of the seat slide mechanism. Move theseat rearward and forward several times in order todistribute the lubricant.

Armrest (Seat)

Pivot the armrest to the vertical position. Apply drylubricant or silicone lubricant between the parts in themechanism for the armrest assembly.

i02559990

Secondary Steering - TestSMCS Code: 4300-081-SST

Personal injury or death can occur if steering islost completely during operation.

Do not continue to operate the machine using thesecondary steering.

If the secondary steering activates during opera-tion, immediately park the machine in a safe loca-tion. Inspect the machine and correct the condi-tion which made the use of the secondary steer-ing necessary.

Extended operation of the secondary steeringmo-tor could damage the motor and result in loss ofemergency steering capability, which could causeinjury or death. The Secondary Steering Systemshould not be used for towing the machine or forother service procedures lasting longer than 5minutes. The motor should be allowed to cool toambient temperatures before reuse.

NOTICEThe secondary steering switch should always be in theAUTO position during normal operation. This will en-sure that secondary steering capability is immediatelyavailable if the primary steering system fails.

NOTICETo minimize battery drain, leave the switch in theMANUAL position only long enough to test the sec-ondary steering. Return the switch to the AUTOposition immediately after testing.


1. Stop the machine on a level surface. Place thetransmission control in the PARK position andstop the engine.

2. Push the top half of brake release and secondarysteering switch (1) and hold the switch in orderto manually activate the brake release andsecondary steering pump. The switch is locatedon the overhead switch panel.

3. Turn the steering wheel completely to the right.Then, turn the steering wheel completely to theleft.

4. Release the switch in order to return the switch tothe AUTO position.

The secondary steering response should be similarto the primary steering response. If the secondarysteering does not function properly, consult yourCaterpillar dealer.

i02519758

Service Brakes - InspectSMCS Code: 4251-040

Record the initial measurement of the servicebrake disc thickness when the machine is new orwhen the brakes are rebuilt. Compare subsequentmeasurements to the initial measurement in order todetermine the amount of wear.

Inspect the front brakes for wear and inspect thebrake system for leakage.


Steering Ball Stud - Replace

Inspect the rear brakes for wear and inspect the rearbrakes for system leakage.

For more information on the proper procedures,refer to Systems Operation, Testing and Adjusting,RENR8294, “773F and 775F Hydraulic System”,“Service Brake Discs - Check”.

Note: Refer to Guideline for Reusable Parts andSalvage Operations, SEBF8095, “Service Brakes forOff-Highway Trucks and Tractors” when you rebuildthe brakes.

i03646309

Steering Ball Stud - ReplaceSMCS Code: 4305-510-SD

For instructions on replacement of the ball studs,refer to the Disassembly and Assembly, “Off-HighwayTruck Machine Systems” manual for your machine orconsult your Caterpillar dealer.

The replacement interval may vary and thereplacement interval is heavily dependent on theconditions of the haul cycle. These conditions includethe following considerations: haul road condition,length of hauls, number of turns per cycle, load, andgrade of the haul road.

Inspect the condition of the tapered steering bores inthe steering assembly whenever the ball studs arereplaced. Refer to Reuse and Salvage Guidelines,SEBF9054, “Reusability of Tapered SteeringBores” or consult your Caterpillar dealer in order todetermine whether the tapered bore can be reused.

i02545225

Steering Cylinder Bearings -LubricateSMCS Code: 4303-086-BD



g01273737Illustration 246Top view of steering cylinders

Lubricate fittings (1) on the steering cylinders.

i03206342

Steering Linkage - InspectSMCS Code: 4305-040

Inspect the horizontal wear limits for the ball studs inthe steering linkage. At the same time, inspect theouter bearing race. Also, inspect the grease fittingsand the seals.

1. Stop the machine on a level surface and place thetransmission control in the PARK position.

g01416360Illustration 247(1) Link(2) Steering arm(3) Center arm

2. Attach the magnetic base of a dial indicator to link(1). This will allow the horizontal movement of theball stud to be measured.

3. To measure the horizontal wear of the ball studsand of the outer bearing races on the steeringcylinders, place the dial indicator against the sideof steering arm (2).

4. Set the dial indicator to zero.

5. Steer the front wheels in both directions. Recordthe amount of horizontal play on the indicator dial.This indicates the amount of wear in the ball studsand the outer bearing races.

200 SEBU7794-08Maintenance SectionSteering System Oil - Change

6. To measure the horizontal wear of the ball studsand of the outer bearing races on the other ballstuds and outer bearing races, place the dialindicator against the side of center arm (3).

7. Set the dial indicator to zero.

8. Steer the front wheels in both directions. Recordthe amount of horizontal play on the indicator dial.

Note: Repeat this procedure in order to measure allof the ball studs and outer bearing races.

9. The maximum amount of horizontal wear is1.02 mm (0.040 inch). If any of the measurementsexceed this limit, replace the worn ball studs andthe outer bearing races.

10. Inspect all of the covers for the ball studs. Inspectall grease fittings and seals. Replace any worncomponents and any damaged components.

Note: Properly lubricate the steering linkage in orderto ensure the durability of components. The steeringlinkage must be free of contaminants in order toensure the durability of components.

i03639847

Steering System Oil - ChangeSMCS Code: 4300-044-OC


Operate the engine in order to warm the steeringsystem oil. Park the machine on a level surface andplace the transmission control lever in the PARKposition. Stop the engine.


1. Push the button on the breaker relief valve (1).The breaker relief valve is located on top of thesteering hydraulic tank.

2. Slowly, remove filler cap (2) on the steeringhydraulic tank in order to relieve the pressure.Install the filler cap after the tank has beendrained. This will prevent dirt from entering thesystem.


Steering System Oil - Change





3. Remove cap plug (3) and drain the oil into asuitable container.

4. Clean the cap plug and install the cap plug.

5. Remove the filler cap and the retaining ring on thescreen.

6. Remove the filler screen. Wash the cap and thescreen in clean, nonflammable solvent. Allow thecap and the screen to dry.

7. Inspect the cap seal. Use a new seal if the usedseal is damaged.

8. Install the screen and the retaining ring.


9. Fill the steering hydraulic tank and install thefiller cap. The oil level must be within the greenrange of sight gauge (4). Refer to Operation andMaintenance Manual, “Lubricant Viscosities”.Refer to Operation and Maintenance Manual,“Capacities (Refill)”.

10.Start the engine. Observe the oil level and inspectthe machine for leaks. Stop the machine andmake any necessary repairs.

11.Check the oil level in the steering hydraulic tank.When the engine is running and the oil is atoperating temperature, maintain the oil level withinthe green range of the sight gauge. If necessary,add oil.

202 SEBU7794-08Maintenance SectionSteering System Oil Level - Check

i03126943

Steering System Oil Level -CheckSMCS Code: 4332-535-OC

g01604534Illustration 251The steering hydraulic tank is mounted on the right hand platform.


Check the oil level in the steering hydraulic tank.Maintain the oil level within green range (A) of sightgauge (1). If necessary, add oil in order to bring theoil level into the green range.

i03646176

Steering System Oil Sample -ObtainSMCS Code: 4300-008-OC; 7542






Sampling valve (1) for the steering hydraulic oil

Activate the machine lockout control. Make sure thatthe transmission control is in the PARK position.Refer to Operation and Maintenance Manual,“Machine Lockout Control” for more information.

Take the oil sample when the engine is operating atlow idle.







Steering Tie Rod and Pin Bearings - Lubricate


i02545438

Steering Tie Rod and PinBearings - LubricateSMCS Code: 4300-086-BD; 4318-086; 7551-086-PN



g01273755Illustration 253Top view of the steering linkage

Lubricate fittings (1) on the center arm pivot pinbearing.

Lubricate fittings (2) on the steering tie rods.

i04388579

Suction Screen (TorqueConverter Scavenge) - CleanSMCS Code: 3101-070-Z3


NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting, and repair of the product. Be preparedto collect the fluid with suitable containers beforeopening any compartment or disassembling any com-ponent containing fluids.

Refer to Special Publication, NENG2500, “Dealer Ser-vice Tool Catalog” for tools and supplies suitable tocollect and contain fluids on Cat products.




204 SEBU7794-08Maintenance SectionSuspension Cylinder - Check

2. Remove cover assembly (1) and the torqueconverter screen.

3. Wash the screen and the cover assembly in aclean, nonflammable solvent. Do not crush thescreen.

4. Inspect the seal on the cover assembly. If the sealis damaged, replace the seal with a new seal.

5. Install the screen and the cover assembly.

6. Start the engine and operate the engine at lowidle. Inspect the area for leaks and make anynecessary repairs.

7. Check the oil level in the transmission/torqueconverter. Refer to Operation and MaintenanceManual, “Transmission and Torque ConverterOil Level - Check” for the proper procedure. Ifnecessary, add oil.

i02331858

Suspension Cylinder - CheckSMCS Code: 7201-535

Make sure that the dump body is empty.

Stop the machine gradually on a level surface withoutusing the brakes.

Engage the parking brake and stop the engine.

Note: All of the suspension cylinders that are shippedfrom the factory receive a preliminary charge ofnitrogen and a preliminary charge of oil. During fieldassembly, the suspension cylinders must be chargedwith nitrogen.

Front Suspension Cylinder




g01163979Illustration 255(X) Distance of exposed chrome

Measure the distance of exposed chrome (X) for thefront suspension cylinders. Compare the presentdistance to the distance from the previous time. If youdo not have those dimensions, perform the chargingprocedure. See Testing And Adjusting, “SuspensionCylinder (Front) - Purge and Charge” for the chargingprocedure.

Note: There are two relief valves for the grease onthe forward side of the front suspension cylinder.These relief valves are located 180 degrees from thelubrication fitting. Do not plug the grease passageof the relief valves.

Rear Suspension Cylinder

g01163990Illustration 256(Y) Distance between the pins

Measure distance (Y) for the rear suspensioncylinders. Compare the present distance to thedistance from the previous time. If you do not havethose dimensions, perform the charging procedure.See Testing And Adjusting, “Suspension Cylinder(Rear) - Purge and Charge” for the chargingprocedure.

SEBU7794-08 205Maintenance SectionTire Inflation - Check

Note: When the rear suspension cylinders areproperly charged, the left rear suspension cylinderwill not show as much chrome as the right rearsuspension cylinder. This is due to the rigid frameand to the weight of the cab.

i02416817

Tire Inflation - CheckSMCS Code: 4203-535-PX; 4203-535-AI

Measure the tire pressure on each tire. Adjust the tirepressure, if necessary. Consult your tire supplier forthe correct tire operating pressures and load ratings.

See Operation and Maintenance Manual, “TireInflation Information” for more tire information.

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Torque Converter andTransmission Oil - ChangeSMCS Code: 3030-044-OC; 3101-044-OC



2. Remove filler cap (1) in order to prevent a vacuumin the torque converter sump.

206 SEBU7794-08Maintenance SectionTorque Converter and Transmission Oil - Change






3. Remove drain valve plug (4) from the torqueconverter sump. Install a 100 mm (4.0 inch) longNPT pipe nipple in order to open the internal drainvalve. The outer diameter of the NPT pipe nippleshould be 25 mm (1.0 inch). Drain the oil into asuitable container.


4. Remove the pipe nipple. Clean the drain plug andinstall the drain plug.


5. Remove drain plug (5) from the transmissionhousing. The drain plug is located on the right sideof the transmission housing. Drain the oil into asuitable container. Clean the drain plug and installthe drain plug.

6. Fill the torque converter sump. Refer to OperationAnd Maintenance Manual, “Lubricant Viscosities”.Refer to Operation And Maintenance Manual,“Capacities (Refill)”.


Torque Converter and Transmission Oil Level - Check

7. Fill the torque converter sump to top of the greenrange in lower sight gauge (3). Clean the filler capand install the filler cap.

8. Start the engine and run the engine forapproximately 15 seconds. The oil level willdecrease as oil fills the system.

9. Stop the engine.

10.Remove filler cap. Add oil to the torque convertersump in order to raise the oil level within the greenrange of the lower sight gauge. Install filler cap.

11.Start the engine and run the engine at low idle.Check for leaks and make necessary repairs.

12.Operate the machine until the oil stabilizes. Parkthe machine on a level surface.

13.Check the oil level in the transmission and torqueconverter system. When the engine is runningand the oil is at operating temperature, maintainthe oil level within the green range in upper sightgauge (2).

NOTICEFailure to properly fill the torque converter sump afteran oil change may cause damage to the power trainsystem. Follow the procedure that is described above.

The transmission direction and speed control MUSTbe left in NEUTRAL until the system is full.

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Torque Converter andTransmission Oil Level -CheckSMCS Code: 3030-535-FLV; 3101-535-FLV



2. If the oil is at operating temperature, the oil levelmust be within the green range in upper sightgauge (2).

3. If the oil is cold, the oil level must be within thegreen range in lower sight gauge (3).

4. If necessary, add oil. The torque converter oiland transmission oil is added at filler tube (1).If the system has been drained, see OperationAnd Maintenance Manual, “Torque Converterand Transmission Oil - Change” for the properprocedure.

208 SEBU7794-08Maintenance SectionTorque Converter and Transmission Oil Sample - Obtain

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Torque Converter andTransmission Oil Sample -ObtainSMCSCode: 3080-008; 3101-008-OC; 7542-008-OC






Sampling valve (1) for the transmission and torqueconverter oil is located on the power train oil filter.








Traction Control System (TCS) - Test

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Traction Control System (TCS)- TestSMCS Code: 3288-081; 4801-081

Note: This procedure determines whether theTraction Control System (TCS) is functioning. Thisprocedure also determines if the left rear brake andthe right rear brake engage at the correct time.

1. Find an area that is clear and level. Also, the areamust be large enough in order to safely drive themachine in a complete circle. Start the machineand move the transmission control lever to theFIRST GEAR FORWARD.

2. Position the machine for a counterclockwise circle.Turn the steering wheel all the way to the left.With the engine at low idle, drive the machine ina complete circle.


TCS test switch (1) is located on the overhead switch panel.

3. During the turn, press TCS test switch (1) andhold the switch in the ON position.

4. The machine will gradually come to a stop. Theright brake will then disengage and the machinewill accelerate. This sequence will repeat as themachine drives in a circle.

5. Release the test switch.

6. Position the machine for a clockwise circle. Turnthe steering wheel all the way to the right. Withthe engine at low idle, drive the machine in acomplete circle.

7. During the turn, press the TCS test switch andhold the switch in the ON position.

8. The machine will gradually come to a stop. Theleft brake will then disengage and the machinewill accelerate. This sequence will repeat as themachine drives in a circle.

9. Release the test switch.

10. For information on the TCS, refer toSpecifications, Systems Operation, Testingand Adjusting, SENR2986, “Off-HighwayTrucks/Tractors Automatic Electronic Traction Aid(AETA)/Traction Control System (TCS)” or consultyour Caterpillar dealer.

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Window Washer Bottle - FillSMCS Code: 7306-544-KE

NOTICEWhen operating in freezing temperatures, useCaterpillar nonfreezing window washer solvent orequivalent. System damage can result from freezing.


The filler spout for the washer fluid bottle is locatedon the left rear of the cab. Remove filler cap (1) inorder to fill the bottle with window washer solvent.

210 SEBU7794-08Maintenance SectionWindow Wiper - Inspect/Replace

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Window Wiper -Inspect/ReplaceSMCS Code: 7305-040; 7305-510


Inspect the windshield wiper blade. Replace thewindshield wiper blade if the windshield wiper bladeis worn or damaged. Replace any windshield wiperblade that streaks the windshield.

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Windows - CleanSMCS Code: 7310-070; 7340-070

g01207547Illustration 265Cab window group

Use commercially available window cleaningsolutions to clean the windows. Only clean thewindows when handholds are available.

manual de mantenimiento 773f

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