----------------------- Page 1----------------------- MAINTENANCE INTERVALS Operation and Maintenance Manual Excerpt ® ® © 2010 Caterpillar All Rights Reserved ----------------------- Page 2----------------------- SEBU7837-09 May 2011 Operation and Maintenance Manual 770 and 772 Off-Highway Truck RLB1-Up (Machine) BZZ1-Up (Machine) SAFETY.CAT.COM ----------------------- Page 3----------------------- 124 SEBU7837-09 Maintenance Section Maintenance Interval Schedule i04379883 Magnetic Screen (Transmission) - Clean ............ 177 Maintenance Interval Schedule Oil Filter - Inspect ................................................ 183 Rim - Inspect ....................................................... 186 Screen (Brake Oil Cooler) - Clean ...................... 188 SMCS Code: 1000; 7000 Screen (Hoist and Brake Tank) - Inspect/Clean/ Replace ............................................................. 189 Ensure that all safety information, warnings, and Traction Control System (TCS) - Test ................. 201 instructions are read and understood before any Window Washer Bottle - Fill ................................ 202 operation or any maintenance procedures are Window Wiper - Inspect/Replace ........................ 202 performed. Windows - Clean ................................................. 202 The user is responsible for the performance of Every 10 Service Hours or Daily maintenance. All adjustments, the use of proper lubricants, fluids, filters, and the replacement of Backup Alarm - Test ............................................ 127 components due to normal wear and aging are Brakes, Indicators and Gauges - Test ................. 129 included. Failure to adhere to proper maintenance Braking System - Test ......................................... 130 intervals and procedures may result in diminished Cooling System Coolant Level - Check .............. 139 performance of the product and/or accelerated wear Engine Oil Level - Check .................................... 151 of components. Fuel System Primary Filter (Water Separator) - Drain ................................................................. 164 Use mileage, fuel consumption, service hours, or Fuel Tank Water and Sediment - Drain ............... 168 calendar time, WHICH EVER OCCURS FIRST, Hoist and Brake Tank Oil Level - Check ............. 172 in order to determine the maintenance intervals. Hoist and Brake Tank Oil Level - Check ............. 173 Products that operate in severe operating conditions Seat Belt - Inspect .............................................. 191 may require more frequent maintenance. Refer to the Secondary Steering - Test .................................. 192 maintenance procedure for any other exceptions that Steering System Oil Level - Check ..................... 196 may change the maintenance intervals. Torque Converter and Transmission Oil Level - Check ................................................................ 200 Note: The aftertreatment system can be expected to function properly for the useful life of the Every 50 Service Hours or Weekly engine (emissions durability period), as defined by regulation. All prescribed maintenance requirements Body Pivot Bearings - Lubricate ......................... 129 must be followed. Central Lubrication System - Lubricate ............... 133 Differential and Final Drive Oil Level - Check ..... 146 Note: Before each consecutive interval is performed, Front Suspension Cylinder - Lubricate ............... 160 all maintenance from the previous interval must be Hoist Cylinder Bearings - Lubricate .................... 170 performed. Magnetic Plug (Wheels) - Check ........................ 175 Rear Axle A-Frame Bearing - Lubricate .............. 184 Note: If Cat HYDO Advanced hydraulic oils are used, Rear Axle Housing Lateral Control Rod Bearings - the hydraulic oil change interval is extended to 3000 Lubricate ........................................................... 184 hours. S·O·S services may extend the oil change Rear Suspension Cylinder Bearings - Lubricate .. 185 even longer. Consult your Cat dealer for details. Steering Cylinder Bearings - Lubricate ............... 193 Steering Tie Rod and Pin Bearings - Lubricate ... 197 When Required Tire Inflation - Check ........................................... 198 Air Conditioner Filter - Clean .............................. 126 Initial 500 Service Hours Automatic Lubrication Reservoir - Fill ................. 126 Battery - Recycle ................................................ 128 Electronic Unit Injector - Inspect/Adjust .............. 147 Battery or Battery Cable - Inspect/Replace ........ 128 Engine Brake Slave Piston Lash - Inspect/ Cab Air Filter - Clean/Replace ............................ 132 Adjust ................................................................ 151 Circuit Breakers - Reset ...................................... 135 Engine Valve Lash - Check/Adjust ...................... 156 Display and Camera - Clean ............................... 146 Engine Valve Rotators - Inspect ......................... 156 Engine Air Filter Primary Element - Clean/ Frame and Body Support Pads - Clean/Inspect .. 159 Replace ............................................................. 147 Engine Air Filter Secondary Element - Replace .. 149 Initial 500 Hours (for New Systems, Refilled Engine Air Precleaner - Clean ............................ 150 Systems, and Converted Systems) Ether Starting Aid Cylinder - Replace ................. 157 Fuel System - Fill ................................................ 163 Cooling System Coolant Sample (Level 2) - Fuel System - Prime ........................................... 164 Obtain ............................................................... 141 Fuses - Replace .................................................. 169 Magnetic Screen (Torque Converter Sump) - Clean ................................................................. 176 ----------------------- Page 4----------------------- SEBU7837-09 125 Maintenance Section Maintenance Interval Schedule Every 500 Service Hours Every 3000 Service Hours or 2 Years Cooling System Coolant Sample (Level 1) - Cooling System Pressure Cap - Clean/Replace .. 142 Obtain ............................................................... 140 Electronic Unit Injector - Inspect/Adjust .............. 147 Differential and Final Drive Oil Sample - Obtain .. 146 Engine Brake Slave Piston Lash - Inspect/ Engine Oil Sample - Obtain ................................ 152 Adjust ................................................................ 151 Front Wheel Oil Sample - Obtain ........................ 162 Engine Valve Lash - Check/Adjust ...................... 156 Hoist and Brake Tank Oil Sample - Obtain ......... 174 Engine Valve Rotators - Inspect ......................... 156 Steering System Oil Sample - Obtain ................. 196 Radiator Core and Aftercooler - Clean ............... 183 Torque Converter and Transmission Oil Sample - Obtain ............................................................... 200 Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture Every 500 Service Hours or 3 Months Seat Belt - Replace ............................................. 191 Belts - Inspect/Replace ....................................... 128 Breather (Hoist and Brake Tank) - Replace ........ 131 Every 4000 Service Hours or 1 Year Breather (Torque Converter and Transmission) - Replace ............................................................. 132 Differential and Final Drive Oil - Change ............ 144 Differential and Final Drive Oil - Inspect ............. 145 Engine Crankcase Breather - Clean ................... 151 Every 6000 Service Hours or 3 Years Engine Oil and Filter - Change ........................... 153 Frame - Clean/Inspect ........................................ 158 Cooling System Coolant Extender (ELC) - Add .. 138 Front Wheel Oil - Change ................................... 160 Front Wheel Oil - Inspect .................................... 161 Every 6000 Service Hours or 4 Years Front Wheel Oil Level - Check ............................ 162 Cooling System Water Temperature Regulator - Fuel System Primary Filter (Water Separator) - Replace ............................................................. 142 Replace ............................................................. 165 Engine Water Pump - Inspect ............................. 157 Fuel System Secondary Filter - Replace ............ 166 Fuel Tank Cap and Strainer - Clean ................... 168 Oil Filter (Brake, Hydraulic Fan) - Replace ......... 178 Every 10 000 Service Hours Oil Filter (Power Train) - Replace ....................... 180 Steering Ball Stud - Replace ............................... 193 Oil Filter (Steering Pump Case Drain) - Replace .. 181 Oil Filter (Steering) - Replace ............................. 182 Every 12 000 Service Hours or 6 Years Suspension Cylinder - Check ............................. 197 Cooling System Coolant (ELC) - Change ........... 136 Every 1000 Service Hours or 6 Months Every 15 000 Service Hours Engine Air Filter Primary Element - Clean/ Replace ............................................................. 147 Rim - Inspect ....................................................... 187 Frame and Body - Inspect .................................. 159 Frame and Body Support Pads - Clean/Inspect .. 159 Hoist and Brake Tank Oil - Change .................... 171 Rollover Protective Structure (ROPS) - Inspect .. 188 Seat Suspension - Inspect/Lubricate .................. 192 Service Brakes - Inspect ..................................... 193 Steering Linkage - Inspect .................................. 193 Steering System Oil - Change ............................ 194 Torque Converter and Transmission Oil - Change ............................................................. 198 Every 2000 Service Hours or 1 Year Breather (Differential and Final Drive) - Replace .. 131 Every Year Cooling System Coolant Sample (Level 2) - Obtain ............................................................... 141 Every 2 Years Receiver Dryer (Refrigerant) - Replace .............. 186 ----------------------- Page 5----------------------- 126 SEBU7837-09 Maintenance Section Air Conditioner Filter - Clean i02539367 5. Install the clean filter element and install the cover. Air Conditioner Filter - Clean Note: When a reduction of air circulation is noticed in the cab after cleaning the filter, install a new element. SMCS Code: 7320-070-FI 1. Remove screws (1) and cover (2). i02613458 Automatic Lubrication Reservoir - Fill SMCS Code: 7540-544-TNK NOTICE Check that the lines attached to all the remote grease fittings are undamaged. If the grease lines are split, grease will not reach the components that require lu- bricating. Machine damage will result. NOTICE Do not overfill the automatic lubrication reservoir. Damage to the automatic lubrication system could result. 1. Park the machine on a level surface and stop the engine. Make sure that the transmission control is in the PARK position. Illustration 129 g01271145 2. Remove screw (3) and remove air filter element (4). 3. Visually inspect the filter element before cleaning. Inspect the filter element for damage to the seal, the pleats, and the outer cover. Replace a damaged filter element with a new filter element. 4. Use low pressure compressed air in order to remove the dust from the dirty filter element. Air pressure must not exceed 207 kPa (30 psi). Take extreme care in order to avoid damage to the pleats. Note: When the filter elements are cleaned, always begin with the clean side (inside) in order to force dirt particles toward the dirty side (outside). ----------------------- Page 6----------------------- SEBU7837-09 127 Maintenance Section Backup Alarm - Test The automatic lubrication reservoir provides lubrication for many components. There are lubrication distribution valves at the following locations: rear of machine, left side of machine, and right side of machine. If the lubrication pump becomes damaged, grease can be applied directly to the fittings on the lubrication distribution valves. Refer to Operation and Maintenance Manual, “Central Lubrication System - Lubricate” for more information. For more information on the autolube system, refer to Specifications, Systems Operation, Testing and Adjusting, RENR8265, “770/772 Off-Highway Truck Automatic Lubrication System”. i03448882 Backup Alarm - Test SMCS Code: 7406-081 The backup alarm alerts the personnel behind the machine that the machine is backing up. The backup alarm is located at the rear of the machine. 1. Park the machine on a level surface and stop the engine. 2. Make sure that the area behind the machine is clear of personnel and clear of obstacles. 3. Turn the engine start switch to the ON position. Illustration 130 g01308496 Note: Do not start the engine. 2. Fill the autolube reservoir through remote fill port (1). 4. Turn the fan speed switch to the OFF position and 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 REVERSE position and listen for the backup alarm. The backup alarm should sound immediately. The backup alarm should continue to sound until the transmission control is moved out of the REVERSE position. 7. Move the transmission control to the PARK position and release the service brake. Illustration 131 g01308521 8. If the backup alarm did not function, or if the backup alarm did not function properly, contact 3. Use sight gauge (2) and sight gauge (3) to your Caterpillar dealer. determine the grease level in the reservoir. Note: The bulk capacity of the grease reservoir is 15 L (3.9 US gal). ----------------------- Page 7----------------------- 128 SEBU7837-09 Maintenance Section Battery - Recycle i00993589 4. Disconnect the negative end “−” of the battery Battery - Recycle cable from the frame near the battery disconnect switch. SMCS Code: 1401-561 Note: Do not allow the disconnected battery cable to contact the battery disconnect switch. Always recycle a battery. Never discard a battery. 5. Disconnect the negative end “−” of the battery Always return used batteries to one of the following cable from the battery. locations: 6. Disconnect the positive end “+” of the battery • A battery supplier cable from the battery. • An authorized battery collection facility 7. Replace the battery or make all necessary repairs to the battery. • Recycling facility 8. Connect the positive end “+” of the battery cable i02591828 to the battery. Battery or Battery Cable - 9. Connect the negative end “−” of the battery cable Inspect/Replace to the battery. 10. Connect the negative end “−” of the battery cable SMCS Code: 1401-040; 1401-510; 1402-040; to the frame near the battery disconnect switch. 1402-510 11. Install the battery access covers. 12. Install the key. Turn the battery disconnect switch to the ON position. i03652872 Belts - Inspect/Replace SMCS Code: 1357-040; 1357-510; 1397-040; 1397-510 The engine is equipped with a serpentine belt that drives the alternator and the a/c compressor. Note: The engine is equipped with a belt tensioner that automatically adjusts the belt to the correct tension. 1. Park the machine on a level surface and stop the Illustration 132 g01271026 engine. Make sure that the transmission control is in the PARK position. Location of the batteries Note: When you replace the batteries, always use the same type of battery. This machine requires Maintenance Free batteries or Low Maintenance High 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 OFF position. Remove the key. 3. Remove the battery access covers. ----------------------- Page 8----------------------- SEBU7837-09 129 Maintenance Section Body Pivot Bearings - Lubricate Illustration 133 g01963996 Front view of engine 2. Inspect serpentine belt (1) for the following conditions: cracks, wear, stretch, frayed areas, and missing pieces. Illustration 134 g01272953 Note: Inspect the belts through the areas that are not obstructed by the belt guard. Do not remove the Lubricate fitting (1) for the left pivot bearing for the belt guard for inspection. dump body. Lubricate fitting (2) for the right pivot bearing for the dump body. 3. Refer to Disassembly and Assembly, RENR8255, “770 and 772 Off-Highway Truck Engine Supplement” or consult your Caterpillar for i02445772 information on the replacement of the belt. Brakes, Indicators and Gauges - Test i02539862 Body Pivot Bearings - SMCS Code: 4251-081; 4267-081; 4269-081; Lubricate 7000-081; 7450-081; 7490-081 Before you operate the machine, perform the SMCS Code: 7258-086-BD following checks. Note: If the machine is equipped with central 1. Inspect the brake indicator lights in the cab. lubrication lines, refer to Operation and Maintenance Look for broken lenses on the gauges. Check Manual, “Central Lubrication System - Lubricate” for for broken indicator lights, broken switches, and lubrication points. other broken components in the cab. Look for any inoperative gauges. Wipe off the fittings before any lubricant is applied. 2. Start the engine. Check the brake system for oil leaks and for damaged brake lines. 3. Turn on all machine lights. Check for proper operation. 4. Sound the horn. Listen for proper operation. ----------------------- Page 9----------------------- 130 SEBU7837-09 Maintenance Section Braking System - Test 5. Test the parking brake. For the proper test Service Brake Holding Ability Test procedure, refer to Operation and Maintenance Manual, “Braking System - Test”. 1. Fasten the seat belt before you test the brakes. 6. Test the service brakes. For the proper test 2. Check the area around the machine. Make sure procedure, refer to Operation and Maintenance that the machine is clear of personnel and clear of Manual, “Braking System - Test”. obstacles. 7. Move the transmission control to the PARK 3. Test the brakes on a dry, level surface. position. Stop the engine. 4. Start the engine. Make any necessary repairs before machine operation. Consult your Caterpillar dealer for more 5. Depress service brake control (2) in order to apply information. the service brakes. 6. Move the transmission control lever to the D i02979612 position. Braking System - Test 7. Gradually increase the engine speed to 1200 rpm. The machine should not move. SMCS Code: 4251-081; 4267-081 8. Reduce the engine speed to low idle. Move the transmission control lever to the PARK position. Stop the engine. Personal injury can result if the machine moves during testing. If the machine begins to move dur- NOTICE ing testing, reduce the engine speed immediately If the machine moved while testing the brakes, contact and place the transmission control in the PARK your Caterpillar dealer. position in order to engage the parking brake. Have the dealer inspect and, if necessary, repair the The following tests are used to determine if the service brake before returning the machine to opera- service brake system and the secondary brake tion. system are functional. These tests are not intended to measure the maximum brake holding effort. The brake holding effort that is required to sustain a Secondary Brake Holding Ability machine at a specific engine rpm varies depending Test on the machine. The variations are the differences in the engine setting, in the power train efficiency, and 1. Fasten the seat belt before you test the brakes. in the brake holding ability, etc. 2. Check the area around the machine. Make sure During the test of the brakes, compare the previous that the machine is clear of personnel and clear of engine rpm and the recent engine rpm. This will obstacles. determine the system deterioration. 3. Test the brakes on a dry, level surface. 4. Start the engine. 5. Depress secondary brake control (1) in order to apply the secondary brakes. 6. Move the transmission control lever to the D position. 7. Gradually increase the engine speed to 1200 rpm. The machine should not move. 8. Reduce the engine speed to low idle. Move the Illustration 135 g01271560 transmission control lever to the PARK position. Stop the engine. ----------------------- Page 10----------------------- SEBU7837-09 131 Maintenance Section Breather (Differential and Final Drive) - Replace NOTICE NOTICE If the machine moved while testing the brakes, contact If the machine moved while testing the brakes, contact your Caterpillar dealer. your Caterpillar dealer. Have the Caterpillar dealer inspect and, if necessary, Have the Caterpillar dealer inspect and, if necessary, repair the parking/secondary brakes before returning repair the parking/secondary brakes before returning the machine to operation. the machine to operation. Parking Brake Holding Ability Test i02540044 1. Fasten the seat belt before you test the brakes. Breather (Differential and Final 2. Check the area around the machine. Make sure Drive) - Replace that the machine is clear of personnel and clear of SMCS Code: 3258-510-BRE; 4050-510-BRE obstacles. 3. Test the brakes on a dry, level surface. 4. Start the engine. Illustration 137 g01271641 1. Park the machine on a level surface. Stop the engine and make sure that the transmission Illustration 136 g01519336 control is in the PARK position. 2. Remove old breather (1) and properly discard the 5. Depress button (3) for the high gear limit RAISE old breather. and depress button (4) for the high gear limit LOWER at the same time. 3. Install a new breather. 6. While both buttons are depressed, Move the transmission control lever to the D position. i02507796 Note: The buttons can now be released and the Breather (Hoist and Brake parking brake will remain on. Tank) - Replace 7. Gradually increase the engine speed to 1200 rpm. SMCS Code: 5056-510-BRE; 5057-510-BRE The machine should not move. 1. Park the machine on a level surface and stop the 8. Reduce the engine speed to low idle. Move the engine. Make sure that the transmission control transmission control lever to the PARK position. is in the PARK position. Stop the engine. ----------------------- Page 11----------------------- 132 SEBU7837-09 Maintenance Section Breather (Torque Converter and Transmission) - Replace Illustration 139 g01295227 2. Remove old breather (1) and properly discard the old breather. 3. Install a new breather. i02546692 Cab Air Filter - Clean/Replace SMCS Code: 7311-070-FI; 7311-510-FI; 7342-070; 7342-510 Illustration 138 g01255736 1. Park the machine on a level surface and stop the 2. Remove bolts (1) and breather cover (2) and wash engine. Make sure that the transmission control the cover in clean nonflammable solvent. is in the PARK position. 3. Remove old breather (3) and properly discard the old breather. 4. Install a new breather. 5. Install the clean cover. i02586980 Breather (Torque Converter and Transmission) - Replace SMCS Code: 3030-510-BRE; 3101-510-BRE 1. Park the machine on a level surface and stop the engine. Make sure that the transmission control is in the PARK position. ----------------------- Page 12----------------------- SEBU7837-09 133 Maintenance Section Central Lubrication System - Lubricate i02612816 Central Lubrication System - Lubricate (If Equipped) SMCS Code: 7510-086 Personal injury or death can occur if personnel are trapped between the wheel and the frame. The steering system is hydraulically controlled and wheels can crush personnel during move- ment. Use caution when working between the wheels and the frame. If the wheels must be turned, en- sure that all personnel are clear of the machine before any movement. NOTICE Check that the lines attached to all the remote grease fittings are undamaged. If the grease lines are split, grease will not reach the components that require lu- bricating. Machine damage will result. Wipe off the fittings before any lubricant is applied. If any of the remote lines become damaged, install a fitting in place of the remote line. Lubricate the item Illustration 140 g01274634 at the fittings until the remote line can be replaced. 2. Release latches (1) and remove cover (3). 3. Remove air filter (2). 4. Clean the inside of the air filter housing. 5. Inspect the air filter. If the pleats or the seals are damaged, replace the air filter. 6. If the air filter is not damaged, clean the air filter with pressurized air. The maximum air pressure for cleaning is 205 kPa (30 psi). Direct pressurized air along the pleats from no closer than 160 mm (6 inch) from the air filter. If the air filter is damaged, replace the air filter. 7. Install the air filter . Use the arrows on the air filter as a guide for correct installation. 8. Install the cover and fasten the latches in order to secure the air filter in position. ----------------------- Page 13----------------------- 134 SEBU7837-09 Maintenance Section Central Lubrication System - Lubricate Left Side Right Side Illustration 141 g01308059 Illustration 142 g01308094 Lubricate fitting (1) on the left front distribution valve. Lubricate fitting (2) on the right front distribution The left front distribution valve will distribute grease valve. The right front distribution valve will distribute to the following points: grease to the following points: • Left steering cylinder bearings • Right steering cylinder bearings • Left steering tie rod and pin bearings • Right steering tie rod and pin bearings • Left front suspension cylinder bearing • Right front suspension cylinder bearing • Left front suspension cylinder rod • Right front suspension cylinder rod • Left side of the center arm pivot pin. • Right side of the center arm pivot pin. ----------------------- Page 14----------------------- SEBU7837-09 135 Maintenance Section Circuit Breakers - Reset Rear i02588625 Circuit Breakers - Reset SMCS Code: 1420-529 Illustration 143 g01308108 Lubricate fitting (3) on the left rear distribution valve. The left rear distribution valve will distribute grease to the following points: • Left bearing on the lateral control rod for the rear axle housing • Left rear suspension cylinder bearings • Left pivot bearing for the dump body • Left upper hoist cylinder bearing Lubricate fitting (4) on the right rear distribution valve. The right rear distribution valve will distribute grease to the following points: Illustration 144 g01296162 • Right bearing on the lateral control rod for the rear Circuit Breaker/Reset – Push in the axle housing button in order to reset the circuit breaker. If the electrical system is working properly, the • Right rear suspension cylinder bearings button will remain depressed. If the button does not remain depressed, check the appropriate electrical • Right pivot bearing for the dump body circuit. Repair the electrical circuit, if necessary. • Right upper hoist cylinder bearing Engine ECM (1) – 15 Amp Lubricate remote fitting (5) for the A-frame bearing assembly on the rear axle support. ----------------------- Page 15----------------------- 136 SEBU7837-09 Maintenance Section Cooling System Coolant (ELC) - Change i02587680 HVAC (2) – 15 amp Cooling System Coolant (ELC) - Change SMCS Code: 1350-044-NL; 1395-510-NL Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand. Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns. Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes. NOTICE Do not change the coolant until you read and under- stand the cooling system information in Special Pub- lication, SEBU6250, “Caterpillar Machine Fluids Rec- ommendations”. Failure to do so could result in damage to the cooling system components. Illustration 145 g01296163 NOTICE Alternator (3) – 90 Amp Mixing Extended Life Coolant (ELC) with other prod- ucts reduces the effectiveness of the coolant and shortens coolant life. Use only Caterpillar products or commercial products that have passed the Cater- Starter Solenoid (4) – 90 Amp pillar EC-1 specification for premixed or concentrate coolants. Use only Caterpillar Extender with Cater- pillar ELC. Failure to follow these recommendations could result in the damage to cooling systems com- ponents. ----------------------- Page 16----------------------- SEBU7837-09 137 Maintenance Section Cooling System Coolant (ELC) - Change NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- nent containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. Whenever the coolant is dirty or whenever foaming is observed, change the coolant before the recommended interval. 1. Park the machine on a level surface and stop the engine. Make sure that the transmission control is in the PARK position. Illustration 147 g01296544 3. Open drain valve (4) and open drain valve (5). Drain the coolant into a suitable container. 4. Close both drain valves. Fill the system with clean water and a 6 to 10% concentration of cooling system cleaner. 5. Start the engine and operate the engine for 90 minutes. Stop the engine and drain the cleaning solution into a suitable container. 6. With the engine stopped, flush the system with water until the draining water is clear. Drain the water into a suitable container. 7. Close both drain valves. 8. Add the coolant solution. Refer to Special Publication, SEBU6250, “Cooling System Specifications” and Operation and Maintenance Manual, “Capacities (Refill)” for further information. 9. Start the engine. Run the engine without the Illustration 146 g01271675 radiator cap. Run the engine until the thermostat opens and the coolant level stabilizes. This should 2. Open access door (1). Remove radiator cap (2) purge the air from the system. slowly in order to gradually relieve any system pressure. . intain the coolant level between the top and 10 Ma the bottom of sight gauge (3). 1. nstall the radiator cap. 1 I ----------------------- Page 17----------------------- 138 SEBU7837-09 Maintenance Section Cooling System Coolant Extender (ELC) - Add i02540164 Cooling System Coolant NOTICE Excessive additive (greater than the recommended Extender (ELC) - Add 6% initial fill) together with concentrations of antifreeze greater than 60% cause deposits to form and can re- SMCS Code: 1352-538-NL sult in radiator tube blockage and overheating. NOTICE Mixing Extended Life Coolant (ELC) with other prod- Personal injury can result from hot coolant, steam ucts reduces the effectiveness of the coolant and and alkali. shortens coolant life. Use only Caterpillar products or commercial products that have passed the Caterpillar At operating temperature, engine coolant is hot EC-1 specifications for premixed or for concen- and under pressure. The radiator and all lines trate coolants. Use only Caterpillar Extender with to heaters or the engine contain hot coolant or Caterpillar ELC. Failure to follow these recommen- steam. Any contact can cause severe burns. dations could result in the damage to cooling system components. Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and If ELC cooling system contamination occurs, refer cooling system pressure cap is cool enough to to Operation and Maintenance Manual, SEBU6250, touch with your bare hand. “Caterpillar Machine Fluids Recommendations” under the topic of ELC Cooling System Contamination. Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing This machine was factory filled with Extended Life burns. Coolant. Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes. Refer to Operation and Maintenance Manual, SEBU6250, “Caterpillar Machine Fluids Recommendations” for the cooling system NOTICE requirements. Adding coolant to an overheated engine could result in damage to the engine. Allow the engine to cool before 1. Park the machine on a level surface and stop the adding coolant. engine. Make sure that the transmission control is in the PARK position. If the machine is to be stored in, or shipped to, an area with freezing temperatures, the cooling system must be 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 Caterpillar Antifreeze, when shipped from the factory unless special requirements are defined. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- nent containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. ----------------------- Page 18----------------------- SEBU7837-09 139 Maintenance Section Cooling System Coolant Level - Check i03792510 Cooling System Coolant Level - Check SMCS Code: 1350-535-FLV Personal injury can result from hot coolant, steam and alkali. At operating temperature, engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand. Do not attempt to tighten hose connections when the coolant is hot, the hose can come off causing burns. Cooling System Coolant Additive contains alkali. Illustration 148 g01271675 Avoid contact with skin and eyes. 2. Open access door (1). Remove radiator cap (2) NOTICE slowly in order to relieve the pressure. Adding coolant to an overheated engine could result in 3. Observe the sight gauge (3) in order to check the damage to the engine. Allow the engine to cool before coolant level. If necessary, drain enough coolant adding coolant. in order to allow the addition of the liquid coolant additive. If the machine is to be stored in, or shipped to, an area with freezing temperatures, the cooling system must Note: Make sure that the coolant is drained into a be protected to the lowest outside (ambient) temper- ature. suitable container. 4. Add 0.24 Liters (0.50 pint) of cooling system The engine cooling system is normally protect- additive for every 38 Liters (10 US Gallons) of ed to a minimum of−29°C (−20°F) with Caterpillar engine cooling capacity. Antifreeze, when shipped from the factory unless special requirements are defined. 5. Clean the radiator cap and inspect the radiator cap. Install the radiator cap. Note: If you must add coolant daily, check for leaks. 6. Start the engine and check the cooling system for 1. Park the machine on a level surface and stop the leaks. Allow the coolant level to stabilize. engine. Make sure that the transmission control is in the PARK position. 7. If necessary, add premixed coolant in order to maintain the coolant level at the full mark in the sight gauge. ----------------------- Page 19----------------------- 140 SEBU7837-09 Maintenance Section Cooling System Coolant Sample (Level 1) - Obtain i02540495 Cooling System Coolant Sample (Level 1) - Obtain SMCS Code: 1350-008; 1395-008; 7542 NOTICE Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling. Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incor- rect interpretation that could lead to concerns by both dealers and customers. Note: Level 1 results may indicate a need for Level 2 Analysis. Illustration 149 g01271675 2. Open access door (1). 3. When the coolant is cold (ambient temperature), observe sight gauge (3) in order to check the coolant level. Maintain the coolant level within the sight gauge. 4. If necessary, remove radiator cap (2) slowly in order to relieve the pressure and add coolant. Note: Always add the same coolant type that is in the machine. Do not mix coolant types. This can reduce the effectiveness of the coolant. Also, mixing coolant types can shorten the coolant life. 5. Close the access door. Illustration 150 g01271850 Sampling valve (1) for the engine coolant is located at the front right side of the engine. Obtain the sample of the coolant as close as possible to the recommended sampling interval. In order to receive the full effect of S·O·S analysis, you must establish a consistent trend of data. In order to establish a pertinent history of data, perform consistent samplings that are evenly spaced. Supplies for collecting samples can be obtained from your Caterpillar dealer. ----------------------- Page 20----------------------- SEBU7837-09 141 Maintenance Section Cooling System Coolant Sample (Level 2) - Obtain Use the following guidelines for proper sampling of the coolant: • Complete the information on the label for the sampling bottle before you begin to take the samples. • Keep the unused sampling bottles stored in plastic bags. • Obtain coolant samples directly from the coolant sample port. You should not obtain the samples from any other location. • Keep the lids on empty sampling bottles until you are ready to collect the sample. • Place the sample in the mailing tube immediately after obtaining the sample in order to avoid contamination. • Never collect samples from expansion bottles. • Never collect samples from the drain for a system. Submit the sample for Level 1 analysis. For additional information about coolant analysis, see Special Publication, SEBU6250, “Caterpillar Machine Illustration 151 g01271850 Fluids Recommendations” or consult your Caterpillar dealer. Sampling valve (1) for the engine coolant is located at the front right side of the engine. i02540516 Obtain the sample of the coolant as close as possible Cooling System Coolant to the recommended sampling interval. Supplies for collecting samples can be obtained from your Sample (Level 2) - Obtain Caterpillar dealer. SMCS Code: 1350-008; 1395-008; 7542 Refer to Operation and Maintenance Manual, “Cooling System Coolant Sample (Level 1) - Obtain” NOTICE for the guidelines for proper sampling of the coolant. Always use a designated pump for oil sampling, and Submit the sample for Level 2 analysis. use a separate designated pump for coolant sampling. Using the same pump for both types of samples may For additional information about coolant analysis, see contaminate the samples that are being drawn. This Special Publication, SEBU6250, “Caterpillar Machine contaminate may cause a false analysis and an incor- Fluids Recommendations” or consult your Caterpillar rect interpretation that could lead to concerns by both dealer. dealers and customers. ----------------------- Page 21----------------------- 142 SEBU7837-09 Maintenance Section Cooling System Pressure Cap - Clean/Replace i02540611 3. Inspect the radiator cap for damage, for foreign Cooling System Pressure Cap material, and for deposits. - Clean/Replace 4. Clean the radiator cap with a clean cloth or replace the radiator cap, if necessary. SMCS Code: 1382-070; 1382-510 5. Install the radiator cap. i02590028 Personal injury can result from hot coolant, steam Cooling System Water and alkali. Temperature Regulator - At operating temperature, engine coolant is hot Replace and under pressure. The heat exchanger and all lines to heaters or the engine contain hot coolant or steam. Any contact can cause severe burns. SMCS Code: 1355-510; 1393-510 Remove the filler cap slowly to relieve pressure only when the engine is stopped and the filler cap for the heat exchanger is cool enough to touch Pressurized system: Hot coolant can cause seri- with your bare hand. ous burn. To open cap, stop engine, wait until ra- diator is cool. Then loosen cap slowly to relieve Cooling System Conditioner contains alkali. Avoid the pressure. contact with skin and eyes. The thermostat should be replaced after the cooling 1. Park the machine on a level surface and stop the system has been cleaned. Replace the thermostat engine. Make sure that the transmission control while the cooling system is completely drained or is in the PARK position. while the cooling system coolant is drained to a level that is below the thermostat housing. NOTICE Failure to replace the engine's thermostat on a regu- larly scheduled basis could cause severe engine dam- age. Replace the thermostat on a regular basis in order to reduce the chance of unscheduled downtime and of problems with the cooling system. 1. Park the machine on a level surface and stop the engine. Make sure that the transmission control is in the PARK position. Illustration 152 g01271997 2. Open access door (1). Remove radiator cap (2) slowly in order to relieve the pressure. ----------------------- Page 22----------------------- SEBU7837-09 143 Maintenance Section Cooling System Water Temperature Regulator - Replace 3. If the cooling system has not been drained, make sure that the coolant level is below the thermostat housing. If necessary, open drain valve (4) and drain the coolant into a suitable container until the coolant level is below the thermostat housing. Close the drain valve. Illustration 153 g01271675 2. Open access door (1). Remove radiator cap (2) slowly in order to relieve the pressure. Illustration 155 g01296821 4. Disconnect the hose from the thermostat housing (6). 5. Remove bolts (5) from the thermostat housing and remove the thermostat housing assembly. 6. Remove the thermostat and the seals from the thermostat housing assembly. NOTICE Former thermostats may be used, if they meet test specifications and are not damaged or have excessive buildup or deposits. NOTICE Since Caterpillar engines incorporate a shunt design cooling system, it is mandatory to always operate the engine with a thermostat. Depending on load, failure to operate with a thermo- stat could result in either an overheating or an over- cooling condition. Illustration 154 g01296544 ----------------------- Page 23----------------------- 144 SEBU7837-09 Maintenance Section Differential and Final Drive Oil - Change NOTICE If the thermostat is installed incorrectly, it will cause the engine to overheat. 7. Install new seals and a new thermostat in the housing. 8. Install the thermostat housing assembly. Connect the hose assembly to the housing and tighten the hose clamps. 9. Add the coolant solution. Refer to Special Publication, SEBU6250, “Cooling System Specifications” and Operation and Maintenance Manual, “Capacities (Refill)” for further information. 10. Start the engine. Run the engine without the radiator cap. Run the engine until the thermostat opens and the coolant level stabilizes. This should purge the air from the system. Illustration 156 g01317071 11. Maintain the coolant level between the top and 1. Rotate the wheels so that final drive drain plug (1) the bottom of sight gauge (3). is in the lowest position on the rear wheel. 12. Install the radiator cap. 2. Park the machine on a level surface and stop the engine. Make sure that the transmission control i02540522 is in the PARK position. Differential and Final Drive Oil NOTICE - Change Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- SMCS Code: 3258-044-OC; 4050-044-OC ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open- The oil change interval for the differential and final ing any compartment or disassembling any compo- drives can be monitored with a S·O·S (Scheduled nent containing fluids. Oil Sampling) program. For more information on S·O·S services, refer to Operation and Maintenance Refer to Special Publication, NENG2500, “Caterpillar Manual, “S·O·S Information”. When a S·O·S Dealer Service Tool Catalog” for tools and supplies program is used, the oil change interval is based suitable to collect and contain fluids on Caterpillar on the following: products. • The condition of the oil Dispose of all fluids according to local regulations and mandates. • The S·O·S recommendation 3. Remove the final drive drain plug. Drain the oil When a S·O·S program is not used, the oil change into a suitable container. interval is based on the following: Note: Inspect the magnetic drain plug and the • 4000 service hours or 1 year if Caterpillar oil. Refer to Operation and Maintenance Manual, FDAO/FD-1 oil is used. “Differential and Final Drive Oil - Inspect” for further information. • 2000 service hours or 1 year if Caterpillar TDTO/TO-4 oil is used. 4. Clean the drain plug. Install the drain plug. 5. Repeat Step 1 through Step 4 for the other final drive. ----------------------- Page 24----------------------- SEBU7837-09 145 Maintenance Section Differential and Final Drive Oil - Inspect NOTICE If the ambient temperature at engine start-up or during operation is below −10°C (14°F), perform the procedures in Operation and Maintenance Manual, “Differential Warm-up and Break-in”. Check the differential compartment and the final drive compartment for the proper fluid level. Failure to warm up the oil or improper lubrication levels prior to operation will cause damage to the machine. 10. Clean the filler plug and install the filler plug. 11. Remove final drive filler plugs (2). Refer to illustration 156. Fill each final drive to the bottom of the filler plug opening. When the final drive drain plug is in the lowest position, the final drive filler plug will be at the correct oil level. Note: The final drives may need to be repositioned in order to place the drain plug in the lowest position. Note: Allow oil to fill all of the compartments. Correct oil levels are critical in the differential and final drives. 12. Operate the machine on level ground for a few minutes. Illustration 157 g01271903 Bottom view Note: The differential and final drive oil level needs to be checked and maintained at operating temperature. 6. Remove differential drain plug (3) and allow the oil After the oil has been changed in the differential to drain into a suitable container. and final drives, adjustment of the oil level may be necessary when the truck reaches operating 7. Clean the drain plug. Install the drain plug. temperature. 13. Stop the machine. Check the oil level. If necessary, adjust the oil level to the bottom of the opening for the differential filler plug. Note: Overfilling the differential and final drives will cause overheating and foaming of the oil in long hauling applications and high speed applications. A reduction of the life of components may be the result of overheating and foaming of the oil. i02450436 Differential and Final Drive Oil Illustration 158 g01271899 - Inspect 8. Remove differential filler plug (4) and wipe the SMCS Code: 3278-040-OC; 4050-040-OC surface around the filler plug opening . Inspect the differential and final drive oil for any of the 9. Fill the differential compartment to the bottom of following symptoms that may indicate a mechanical the filler plug opening. Refer to Operation and failure: Maintenance Manual, “Lubricant Viscosities” and Operation and Maintenance Manual, “Capacities • A high amount of metal on the magnetic plug (Refill)”. • An increased level of nickel concentration in the S·O·S sample ----------------------- Page 25----------------------- 146 SEBU7837-09 Maintenance Section Differential and Final Drive Oil Level - Check • An increase in the size of the particle count in the i02540893 S·O·S sample Differential and Final Drive Oil • Oil leaks in the area around the drive wheel Sample - Obtain bearings SMCS Code: 3278-008; 4050-008; 4070-008; 7542 The rear wheel bearings do not need to be adjusted or inspected until the scheduled overhaul. Unless a symptom of an obvious failure appears, do not adjust or inspect the rear wheel bearings. If the differential and 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. i02540884 Differential and Final Drive Oil Level - Check SMCS Code: 3258-535-FLV; 4050-535-FLV Illustration 160 g01272270 NOTICE Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling. Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incor- rect interpretation that could lead to concerns by both dealers and customers. The oil sample for the differential and for the final drives is obtained with a sampling gun through the filler plug (1). Illustration 159 g01272270 Refer to Special Publication, PEHP6001, “How To Take A Good Oil Sample”. Also, refer to Operation 1. Remove differential filler plug (1) and clean the and Maintenance Manual, “S·O·S Information” and area around the opening. Special Publication, SEBU6250, “S·O·S Oil Analysis” for additional information about obtaining an oil 2. Check the oil level. Maintain the oil level to the sample. bottom of the filler plug opening. 3. If necessary, add oil. Install the filler plug. i02449906 Display and Camera - Clean Note: The differential and final drives share a common oil compartment. When the machine is (If Equipped with Work Area parked on a level surface and when the final drive Vision System) drain plug is in the lowest position, the final drive filler plug will be at the same level as the differential SMCS Code: 7347-070; 7348-070 filler plug. Allow the oil to fill all of the compartments before rechecking the oil level. In order to maintain sufficient vision, keep the Work Area Vision System (WAVS) camera lens and the display clean. ----------------------- Page 26----------------------- SEBU7837-09 147 Maintenance Section Electronic Unit Injector - Inspect/Adjust Display i02619962 Electronic Unit Injector - Inspect/Adjust SMCS Code: 1290-025; 1290-040 Be sure the engine cannot be started while this maintenance is being performed. To prevent pos- sible injury, do not use the starting motor to turn the flywheel. Hot engine components can cause burns. Allow Illustration 161 g01223034 additional time for the engine to cool before mea- suring/adjusting the unit injectors. WAVS display Use a soft, damp cloth in order to clean the display. The electronic unit injectors use high voltage. Dis- The display has a soft plastic surface that can be connect the unit injector enable circuit connector easily damaged by an abrasive material. The display in order to prevent personal injury. Do not come is not sealed. Do not immerse the display with in contact with the injector terminals while the en- liquid. gine is running. Camera This procedure is recommended by Caterpillar as part of a lubrication and preventive maintenance schedule in order to help provide maximum engine life. Only qualified personnel should perform this procedure. For information on adjusting the electronic unit injector, refer to Systems Operation, Testing And Adjusting, SENR9832, “C15 and C18 Engines for Caterpillar Built Machines” or consult your Caterpillar dealer. i02540673 Engine Air Filter Primary Illustration 162 g01223051 Element - Clean/Replace The WAVS camera is located on the rear of the machine near the taillights. SMCS Code: 1051-070-PY; 1051-510-PY; 1054-070-PY; 1054-510-PY Use a damp cloth or water spray in order to clean the camera lens. The camera is a sealed unit. The NOTICE camera is not affected by high pressure spray. Service the air cleaner only with the engine stopped. Engine damage could result. The camera is equipped with an internal heater to help counteract the effects of condensation, snow, or ice. Service the air cleaner filter element when the engine fault indicator is activated. The engine Note: For more information on WAVS, refer to fault indicator is located inside the cab. The Operation and Maintenance Manual, SEBU8157, engine fault indicator will activate when there “Work Area Vision System”. is an inlet air restriction, and the Messenger display will provide a message regarding the specific problem. Refer to Operation and Maintenance Manual, “Monitoring System” for further information. ----------------------- Page 27----------------------- 148 SEBU7837-09 Maintenance Section Engine Air Filter Primary Element - Clean/Replace 1. Park the machine on a level surface and stop the Cleaning Primary Air Filter engine. Make sure that the transmission control Elements is in the PARK position. NOTICE Caterpillar recommends certified air filter cleaning ser- vices available at participating Caterpillar dealers. The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufficient filter life. Observe the following guidelines if you attempt to clean the filter element: Do not tap or strike the filter element in order to re- move dust. Do not wash the filter element. Illustration 163 g01217472 Use low pressure compressed air in order to remove the dust from the filter element. Air pressure must not 2. Remove cover (1) for the air filter housing. exceed 207 kPa (30 psi). Direct the air flow up the pleats and down the pleats from the inside of the filter 3. Remove primary filter element (2) from the air element. Take extreme care in order to avoid damage filter housing. to the pleats. 4. Clean the inside of the air filter housing. Do not use air filters with damaged pleats, gaskets, or seals. Dirt entering the engine will cause damage to 5. Clean the dust valve on the bottom of the air filter engine components. housing. The primary air filter element can be used up to 6. Install a clean primary air filter element. Install the six times if the element is properly cleaned and the cover for the air filter housing. element is properly inspected. When the primary air filter element is cleaned, check for rips or tears Note: Refer to “Cleaning Primary Air Filter Elements”. in the filter material. The primary air filter element should be replaced at least one time per year. This replacement should be performed regardless of the number of cleanings. NOTICE Do 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. Engine damage could result. Visually inspect the primary air filter elements before cleaning. Inspect the air filter elements for damage to the seal, the gaskets, and the outer cover. Discard any damaged air filter elements. There are two common methods that are used to clean primary air filter elements: • Pressurized air • Vacuum cleaning ----------------------- Page 28----------------------- SEBU7837-09 149 Maintenance Section Engine Air Filter Secondary Element - Replace Pressurized Air Inspecting the Primary Air Filter Elements Pressurized air can be used to clean primary air filter elements that have not been cleaned more than two times. Pressurized air will not remove deposits of carbon and oil. Use filtered, dry air with a maximum pressure of 207 kPa (30 psi). Illustration 165 g00281693 Inspect the clean, dry primary air filter element. Use a 60 watt blue light in a dark room or in a similar facility. Place the blue light in the primary air filter Illustration 164 g00281692 element. Rotate the primary air filter element. Inspect the primary air filter element for tears and/or holes. Note: When the primary air filter elements are Inspect the primary air filter element for light that may cleaned, always begin with the clean side (inside) show through the filter material. If it is necessary in in order to force dirt particles toward the dirty side order to confirm the result, compare the primary air (outside). filter element to a new primary air filter element that has the same part number. Aim the hose so that the air flows inside the element along the length of the filter in order to help prevent Do not use a primary air filter element that has any damage to the paper pleats. Do not aim the stream of tears and/or holes in the filter material. Do not use air directly at the primary air filter element. Dirt could a primary air filter element with damaged pleats, be forced further into the pleats. gaskets or seals. Discard damaged primary air filter elements. Vacuum Cleaning Vacuum cleaning is another method for cleaning i02540729 primary air filter elements which require daily cleaning Engine Air Filter Secondary because of a dry, dusty environment. Cleaning with pressurized air is recommended prior to vacuum Element - Replace cleaning. Vacuum cleaning will not remove deposits of carbon and oil. SMCS Code: 1054-510-SE NOTICE Always replace the secondary element. Do not at- tempt to reuse it by cleaning. Engine damage could result. Note: Replace the engine air filter secondary element when you service the engine air filter primary element for the third time. Replace the secondary filter element if the exhaust smoke remains black and the clean primary filter element has been installed. 1. Park the machine on a level surface and stop the engine. Make sure that the transmission control is in the PARK position. 2. Remove the air filter cover and remove the primary filter element from the air filter housing. ----------------------- Page 29----------------------- 150 SEBU7837-09 Maintenance Section Engine Air Precleaner - Clean Illustration 166 g00644798 (1) Secondary filter element 3. Remove secondary filter element (1) and properly discard the secondary element. 4. Cover the air inlet opening. Clean the inside of the air cleaner housing. 5. Uncover the air inlet opening. Install the new secondary filter element. 6. Install the primary filter element and install the air filter cover. i02540902 Engine Air Precleaner - Clean SMCS Code: 1055-070 Illustration 167 g01272292 NOTICE 1. Park the machine on a level surface and stop the Service the engine air precleaners only when the en- engine. Make sure that the transmission control gine is stopped. Engine damage could result. is in the PARK position. 2. Unlatch the clips on precleaner assembly (1). Remove the precleaner assembly. 3. Clean the precleaner and clean dust valve (2) with one of the following methods: • Air pressure • Water pressure • Detergent washing If necessary, dry the precleaner assembly completely. 4. Inspect the precleaner assembly after cleaning. Replace any damaged parts. 5. Install the precleaner assembly. ----------------------- Page 30----------------------- SEBU7837-09 151 Maintenance Section Engine Brake Slave Piston Lash - Inspect/Adjust i02610791 i02590691 Engine Brake Slave Piston Engine Crankcase Breather - Lash - Inspect/Adjust Clean (If Equipped) SMCS Code: 1317-070-ENG SMCS Code: 1129-025; 1129-040 Be sure the engine cannot be started while this maintenance is being performed. To prevent pos- sible injury, do not use the starting motor to turn the flywheel. Hot engine components can cause burns. Allow additional time for the engine to cool before mea- suring/adjusting engine valve lash clearance. NOTICE Only qualified service personnel should perform this maintenance. Refer to the Service Manual or your Caterpillar Dealer for the complete engine valve lash adjustment procedure. For proper adjustment, the engine valve lash must Illustration 168 g01297015 be adjusted before the engine brake is adjusted. For more information on engine valve lash adjustment, 1. Park the machine on a level surface and stop the refer to Operation and Maintenance Manual, “Engine engine. Make sure that the transmission control Valve Lash - Check/Adjust”. is in the PARK position. For the inspection procedure and the adjustment 2. Loosen hose clamp (2). Remove breather hose procedure for the engine brake slave piston lash, refer (3) from valve cover (1). to “Cat Compression Brake Lash - Adjust” in Systems Operation, Testing And Adjusting, SENR9832, “C15 3. Remove the valve cover. The breather is inside and C18 Engines for Caterpillar Built Machines”. the valve cover. 4. Wash the breather in clean nonflammable solvent. 5. Install the valve cover. 6. Install the breather hose. Tighten the hose clamp. i02540930 Engine Oil Level - Check SMCS Code: 1348-535-FLV NOTICE Do not under fill or overfill engine crankcase with oil. Either condition can cause engine damage. ----------------------- Page 31----------------------- 152 SEBU7837-09 Maintenance Section Engine Oil Sample - Obtain i02598975 Engine Oil Sample - Obtain SMCS Code: 1348-008; 7542 Personal injury or death can occur if personnel are trapped between the wheel and the frame. The steering system is hydraulically controlled and wheels can crush personnel during move- ment. Use caution when working between the wheels and the frame. If the wheels must be turned, en- sure that all personnel are clear of the machine before any movement. Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. Illustration 169 g01305919 1. Park the machine on a level surface. Make sure that the transmission control is in the PARK position. 2. Remove oil level gauge (2). Inspect the oil level gauge in order to determine the engine oil level. Illustration 171 g01300925 Sampling valve (1) for the engine oil is located on the engine oil filter base. Refer to Special Publication, PEHP6001, “How To Take A Good Oil Sample”. Also, refer to Operation and Maintenance Manual, “S·O·S Information” and Special Publication, SEBU6250, “Caterpillar Machine Illustration 170 g01214971 Fluids Recommendations”, “S·O·S Oil Analysis” for additional information about obtaining an oil sample. 3. Check the oil level when the engine is stopped and the oil is cold. Maintain the oil level within shaded range (X) of the oil level gauge. 4. If necessary, remove the oil filler cap (1) and add oil. Clean the filler cap and install the filler cap. ----------------------- Page 32----------------------- SEBU7837-09 153 Maintenance Section Engine Oil and Filter - Change i04380427 2. Move the engine lockout switch upward in order Engine Oil and Filter - Change to activate the engine lockout mode. Refer to Operation and Maintenance Manual, “Engine Lockout Control” for more information. SMCS Code: 1308-510; 1348-044 Personal injury or death can occur if personnel are trapped between the wheel and the frame. The steering system is hydraulically controlled and wheels can crush personnel during move- ment. Use caution when working between the wheels and the frame. If the wheels must be turned, en- sure that all personnel are clear of the machine before any movement. Illustration 172 g01300984 3. Open drain valve (1) and drain the oil into a suitable container. Close the drain valve. Hot oil and hot components can cause personal 4. Remove used oil filter (2) and discard the used injury. Do not allow hot oil or hot components to oil filter. contact the skin. Note: The filter is accessed through the right front NOTICE wheel well. Oil may be trapped in the filter housing Care must be taken to ensure that fluids are contained base. In order to avoid possible burns, remove the during performance of inspection, maintenance, test- filter when the filter is cool enough to touch with your ing, adjusting, and repair of the product. Be prepared bare hand. Drain the oil into a suitable container. to collect the fluid with suitable containers before opening any compartment or disassembling any com- 5. Clean the filter housing base. Make sure that the ponent containing fluids. former gaskets are removed. Refer to Special Publication, NENG2500, “Dealer Ser- 6. Apply a thin film of clean engine oil to the seal of vice Tool Catalog” for tools and supplies suitable to the new filter. collect and contain fluids on Cat products. 7. Install the filter by hand. Tighten the filter until Dispose of all fluids according to local regulations and the sealing surface contacts the base. Note the mandates. position of the index marks on the filter in relation to a fixed point on the filter base. Note: Some commercial oils that meet API Note: Caterpillar filters have rotation index marks specifications may require shorter oil change that are spaced 90° or 1/4 of a turn away from each intervals. The oil change intervals are determined other. When tightening the filter, use the rotation by close monitoring of the oil condition and engine index marks as a guide. wear metals. Caterpillar prefers the scheduled oil sampling as the proper method of checking engine 8. Tighten the filter according to the instructions that wear metals. are printed on the filter. Consult your Caterpillar dealer for the latest oil Note: A Caterpillar strap wrench, or another suitable recommendations. tool may be needed in order to turn the filters to the amount that is required for final installation. Make Oil Pan Drain and Engine Oil Filter sure that the installation tool does not damage the filters. 1. Park the machine on a level surface. Make sure that the transmission control is in the PARK position. The oil must be warm and the engine stopped. ----------------------- Page 33----------------------- 154 SEBU7837-09 Maintenance Section Engine Oil and Filter - Change 12. Maintain the oil level within shaded area (X) of the engine oil level gauge. QuickEvac The QuickEvac/Prelubrication system is not available on later machines. Extended operation of the QuickEvac motor could damage the motor and result in loss of emergen- cy steering capability, which could cause injury or death. The QuickEvac motor should not be used longer than 5 minutes. The motor should be allowed to cool to ambient temperatures before reuse. Table 13 Required Tools Item Part Number Description A 187-1458 QuickEvac Service Tool 1. Park the machine on a level surface. Place the transmission control lever in the PARK position. The oil must be warm and the engine must be stopped. 2. Move the engine lockout switch upward in order to activate the engine lockout mode. Refer to Operation and Maintenance Manual, “Engine Illustration 173 g01306991 Lockout Control” for more information. 9. Remove the oil filler cap (3). Fill the crankcase Note: The QuickEvac system will only evacuate the with oil. Refer to Operation and Maintenance oil when the engine lockout mode is active. Manual, “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 secondary steering switch for fifteen seconds. This switch will manually activate the prelube pump in order to fill the engine oil filter. 11. Start the engine and operate the engine at low idle for five minutes. Inspect the engine oil filter for oil leaks. Make any necessary repairs. Illustration 174 g01214971 ----------------------- Page 34----------------------- SEBU7837-09 155 Maintenance Section Engine Oil and Filter - Change Note: The filter is accessed through the right front wheel well. Oil may be trapped in the filter housing base. In order to avoid possible burns, remove the filter when the filter is cool enough to touch with your bare hand. Drain the oil into a suitable container. 8. Clean the filter housing base. Make sure that the former gasket is removed. 9. Apply a thin film of clean engine oil to the seal of the new filter. 10. Install the filter by hand. Tighten the filter until the sealing surface contacts the base. Note the position of the index marks on the filter in relation to a fixed point on the filter base. Note: Caterpillar filters have rotation index marks that are spaced 90° or 1/4 of a turn away from each other. When tightening the filters, use the rotation index marks as a guide. 11. Tighten each filter according to the instructions that are printed on the filter. Note: A Caterpillar strap wrench, or another suitable tool may be needed in order to turn the filters to the amount that is required for final installation. Make sure that the installation tool does not damage the filters. 12. Remove the oil filler cap (3). Refer to Illustration 173. Fill the crankcase with oil. Refer to Operation and Maintenance Manual, “Lubricant Viscosities” Illustration 175 g01301202 for the type of oil. Refer to Operation and Maintenance Manual, “Capacities (Refill)” for the amount of oil. 3. Detach the quick disconnect fittings. Attach QuickEvac Tool (A) to male quick disconnect fitting (6). Attach an air supply to the designated 13. Depress the brake release and secondary hose on the QuickEvac Tool. Purge the oil system steering switch for fifteen seconds. This switch will of the engine and the oil filters for 10 seconds by manually activate the prelube pump in order to fill using 620 kPa (90 psi) of air pressure. Detach the the engine oil filter. air supply. 14. Start the engine and operate the engine at low 4. Attach the designated hose from the QuickEvac idle for five minutes. Inspect the engine oil filter for Tool to female quick disconnect fitting (5) and oil leaks. Make any necessary repairs. attach the electrical connection for the QuickEvac Tool to electrical connection (7). 15. Maintain the oil level within shaded area (X) of engine oil level gauge (4). Refer to Illustration 174. 5. Use the remote operator switch on the QuickEvac Tool to evacuate the oil from the engine. Whenever a QuickEvac procedure is performed, an event will be recorded. The event will be recorded 6. Detach the QuickEvac Tool after the oil is when the pump is activated by the switch on the QuickEvac Service Tool. The event will be recorded evacuated. Attach male quick disconnect fitting (7) to female quick disconnect fitting (6). in the following manner: • The service hours of the first event 7. Remove used oil filter (2) and discard the used oil filter. Refer to Illustration 172. • The service hours of the last event • The total number of events ----------------------- Page 35----------------------- 156 SEBU7837-09 Maintenance Section Engine Valve Lash - Check/Adjust Only one event will be recorded during each power cycle to the ECM. This will prevent creating multiple NOTICE events for one Quick Evac procedure. Only qualified service personnel should perform this maintenance. Refer to the Service Manual or your For more information on the Quick Evac system, Caterpillar dealer for the complete valve lash adjust- refer to Specifications, Systems Operation, Testing ment procedure. and Adjusting, RENR8266, “770 - 772 Off-Highway Truck High Speed Oil Change (Quick Evac)”. Operation of Caterpillar engines with improper valve adjustments can reduce engine efficiency. This re- Engine Oil Fill with High Speed duced efficiency could result in excessive fuel usage and/or shortened engine component life. Arrangement (If Equipped) 1. Remove the dust cover and attach the oil fill hose This procedure is recommended by Caterpillar as to male fitting (8). Refer to Illustration 175. part of a lubrication and preventive maintenance schedule in order to help provide maximum engine 2. Fill the crankcase with oil. Refer to Operation and life. Maintenance Manual, “Lubricant Viscosities” for the correct type of oil. Refer to Operation and For information on checking the engine valve lash, Maintenance Manual, “Capacities (Refill)” for the refer to Systems Operation, Testing And Adjusting, correct amount of oil. SENR9832, “C15 and C18 Engines for Caterpillar Built Machines” or consult your Caterpillar dealer. 3. Remove the oil fill hose and install the dust cover. i01597115 4. Depress the brake release and secondary steering switch for fifteen seconds. This switch will Engine Valve Rotators - Inspect manually activate the prelube pump in order to fill the engine oil filter. SMCS Code: 1109-040-DJ 5. Start the engine and operate the engine at low idle for five minutes. Inspect the engine oil filter for oil leaks. Make any necessary repairs. When inspecting the valve rotators, protective 6. Maintain the oil level within shaded area (X) of glasses or face shield and protective clothing engine oil level gauge (3). Refer to Illustration 174 must be worn, to help prevent being burned by and Illustration 173. hot oil or spray. Engine valve rotators rotate the valves when the i02590818 engine runs. This helps to prevent deposits from Engine Valve Lash - building up on the valves and the valve seats. Check/Adjust Perform the following steps after the engine valve lash is set, but before the valve covers are installed: SMCS Code: 1102-025; 1102-535 1. Start the engine according to Operation and Maintenance Manual, “Engine Starting” (Operation Section) for the procedure. Ensure that the engine can not be started while this maintenance is being performed. To help pre- 2. Operate the engine at low idle. vent possible injury, do not use the starting motor to turn the flywheel. 3. Observe the top surface of each valve rotator. The valve rotators should turn slightly when the valves Hot engine components can cause burns. Allow close. additional time for the engine to cool before mea- suring/adjusting valve lash clearance. NOTICE A valve rotator which does not operate properly will accelerate valve face wear and valve seat wear and shorten valve life. If a damaged rotator is not replaced, valve face guttering could result and cause pieces of Electrical shock hazard. The electronic unit injec- the valve to fall into the cylinder. This can cause piston tor system uses 90-120 volts. and cylinder head damage. ----------------------- Page 36----------------------- SEBU7837-09 157 Maintenance Section Engine Water Pump - Inspect If a valve fails to rotate, consult your Caterpillar i03661501 dealer. Ether Starting Aid Cylinder - i02619880 Replace Engine Water Pump - Inspect SMCS Code: 1456-510-CD SMCS Code: 1361-040 A water pump that has failed might cause Breathing ether vapors or repeated contact of severe engine overheating problems. The engine ether with skin can cause personal injury. Person- overheating problems could result in the following al injury may occur from failure to adhere to the problems: following procedures. • Cracks in the cylinder head Use ether only in well ventilated areas. • Piston seizure Do not smoke while changing ether cylinders. • Other potential engine damage Use ether with care to avoid fires. Do not store replacement ether cylinders in living areas or in the operator's compartment. Do not store ether cylinders in direct sunlight or at temperatures above 49 °C (120 °F). Discard cylinders in a safe place. Do not puncture or burn cylinders. Keep ether cylinders out of the reach of unautho- rized personnel. 1. Park the machine on a level surface and stop the engine. Make sure that the transmission control is in the PARK position. Illustration 176 g01312416 Visually inspect water pump (1) for leaks. If leaks are found, all the seals need to be replaced. Note: For the replacement of the water pump seals, refer to Disassembly and Assembly, RENR8261, “C15 and C18 Engines For Caterpillar Built Machines”. ----------------------- Page 37----------------------- 158 SEBU7837-09 Maintenance Section Frame - Clean/Inspect i02541007 Frame - Clean/Inspect SMCS Code: 7050-571 A raised body (bed) may fall unexpectedly and without warning resulting in personal injury or death. When it is necessary to work under the truck with the body (bed) raised, install the body (bed) retain- ing pins through the pin bores in the frame and the retaining brackets on the body. 1. Park the machine on a level surface. Make sure that the transmission control is in the PARK position. 2. Raise the body to the fully raised position and install the body retaining pins. For the proper procedure, refer to Operation and Maintenance Manual, “Body Retaining Pin”. 3. Stop the engine. Illustration 177 g01272371 4. Clean the frame with a high pressure washer. 2. Open access door (1). 3. Loosen clamp (2) and unscrew ether starting aid cylinder (3). 4. Remove the used gasket. Install the new gasket that is provided with the ether starting aid cylinder. Note: Install protective cap (4) if an ether starting aid cylinder will not be in place. 5. Install a new ether starting aid cylinder. Tighten the clamp. 6. Close the access door. Illustration 178 g01272419 5. Inspect the frame for damage and for cracks. If you find cracks or damage, consult your Caterpillar dealer for specific repair procedures. Do not operate the machine until the necessary repairs have been made. 6. Remove the body retaining pins and lower the body. For the proper procedure, refer to Operation and Maintenance Manual, “Body Retaining Pin”. ----------------------- Page 38----------------------- SEBU7837-09 159 Maintenance Section Frame and Body - Inspect i02541010 6. Remove the body retaining pins and lower the Frame and Body - Inspect body. For the proper procedure, refer to Operation and Maintenance Manual, “Body Retaining Pin”. SMCS Code: 7050-040; 7258-040 i02541021 Frame and Body Support Pads A raised body (bed) may fall unexpectedly and - Clean/Inspect without warning resulting in personal injury or death. SMCS Code: 7050-571; 7258-571-S4 When it is necessary to work under the truck with the body (bed) raised, install the body (bed) retain- ing pins through the pin bores in the frame and the A raised body (bed) may fall unexpectedly and retaining brackets on the body. without warning resulting in personal injury or death. 1. Park the machine on a level surface. Make sure that the transmission control is in the PARK When it is necessary to work under the truck with position. the body (bed) raised, install the body (bed) retain- ing pins through the pin bores in the frame and the 2. Raise the body to the fully raised position and retaining brackets on the body. install the body retaining pins. For the proper procedure, refer to Operation and Maintenance 1. Park the machine on a level surface. Make sure Manual, “Body Retaining Pin”. that the transmission control is in the PARK position. 3. Stop the engine. 2. Raise the body to the fully raised position and install the body retaining pins. For the proper procedure, refer to Operation and Maintenance Manual, “Body Retaining Pin”. 3. Stop the engine. Illustration 179 g01272424 4. Clean the frame and the body with a high pressure washer. If necessary, continue to clean the frame and the body with a wire brush or a scraper. 5. Inspect the frame and the body. If you find Illustration 180 g01272442 cracks, damage or excessive wear, consult your Caterpillar dealer for specific repair procedures. 4. Clean the body support pads with high pressure Do not operate the machine until the necessary water or steam. If damage is found, consult your repairs have been made. Caterpillar dealer for specific repair procedures. ----------------------- Page 39----------------------- 160 SEBU7837-09 Maintenance Section Front Suspension Cylinder - Lubricate 5. Visually inspect each of the body support pads. Note: If the machine is equipped with central There should be no gaps between the body lubrication lines, refer to Operation and Maintenance support pads and the mating surfaces when the Manual, “Central Lubrication System - Lubricate” for body is lowered. Compare all the body support lubrication points. pads. If the inspection indicates uneven wear of the body support pads, you may need to readjust Wipe off the fittings before any lubricant is applied. the shims. Also, if the paint on the frame indicates uneven wear, you may need to readjust the shims. See the hydraulic system Testing and Adjusting, “Pad (Dump Body) - Adjust” for the procedure. If the body support pads are shimmed correctly, review your loading operation. Note: Proper installation of the body support pads will effectively balance the load weight. This will reduce the risk of possible damage to the chassis. If the body support pads indicate uneven wear, readjusting the shims may correct the problem. Also, if the paint on the frame indicates uneven wear, readjusting the shims may correct the problem. 6. Remove the body retaining pins and lower the body. For the proper procedure, refer to Operation and Maintenance Manual, “Body Retaining Pin”. i02541040 Front Suspension Cylinder - Illustration 181 g01272469 Lubricate Right front suspension cylinder SMCS Code: 7201-086 Lubricate fitting (1) for the front suspension cylinder bearing. Lubricate fitting (2) for the front suspension cylinder rod. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could NOTICE result in injury or death. Excessive grease could damage the rod seals. Do not operate or perform any lubrication, main- tenance or repair on this product, until you have read and understood the operation, lubrication, i03041269 maintenance and repair information. Front Wheel Oil - Change SMCS Code: 4201-044-OC Note: The oil change interval for the front wheel Personal injury or death can occur if personnel are can be determined with the S·O·S scheduled oil trapped between the wheel and the frame. sampling program. The oil change interval is based on the condition of the oil. If the S·O·S scheduled oil The steering system is hydraulically controlled and wheels can crush personnel during move- sampling program is not used, the oil change should ment. be performed at 500 service hours. Use caution when working between the wheels and the frame. If the wheels must be turned, en- sure that all personnel are clear of the machine before any movement. ----------------------- Page 40----------------------- SEBU7837-09 161 Maintenance Section Front Wheel Oil - Inspect Illustration 182 g01250756 Illustration 183 g01250751 1. Position the front wheel so that the drain plug is 6. Remove the filler plug. facing downward. 7. Fill the oil compartment to the bottom of the filler 2. Park the machine on a level surface and stop the plug opening. Refer to Operation and Maintenance engine. Make sure that the transmission control Manual, “Capacities (Refill)”. is in the PARK position. 8. Clean the filler plug and install the filler plug. Use NOTICE the same procedure for the other front wheel Care must be taken to ensure that fluids are contained bearing. during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to i02388737 collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- Front Wheel Oil - Inspect nent containing fluids. SMCS Code: 4201-040-OC Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies Inspect the front wheel oil for any of the following suitable to collect and contain fluids on Caterpillar symptoms that may indicate a failure of the wheel products. bearings: Dispose of all fluids according to local regulations and • A high amount of metal on the magnetic plug mandates. • An increased level of nickel concentration in the S·O·S sample 3. Remove the drain plug slowly in order to relieve any pressure. • An increase in the size of the particle count in the 4. Allow the oil to drain into a suitable container. S·O·S sample • Oil leaks in the area around the front wheel spindle 5. Clean the drain plug and install the drain plug. The front wheel bearings do not need to be adjusted or inspected until the scheduled overhaul. Unless a symptom of an obvious failure appears, do not adjust or inspect the front wheel bearings. If the front wheel oil has any of the above symptoms, the front wheel bearings may need to be inspected. Consult your Caterpillar dealer for more information. ----------------------- Page 41----------------------- 162 SEBU7837-09 Maintenance Section Front Wheel Oil Level - Check i03041270 i03646165 Front Wheel Oil Level - Check Front Wheel Oil Sample - Obtain SMCS Code: 4201-535-FLV SMCS Code: 4201-008-OC; 7542 1. Park the machine on a level surface and stop the engine. Make sure that the transmission control is in the PARK position. Illustration 185 g01250751 Illustration 184 g01250751 NOTICE Always use a designated pump for oil sampling, and Note: In order to prevent dirt from entering the wheel use a separate designated pump for coolant sampling. bearing, use a clean cloth to wipe the area around Using the same pump for both types of samples may the filler plug before you remove the filler plug. contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incor- 2. Remove the filler plug slowly in order to relieve rect interpretation that could lead to concerns by both dealers and customers. any pressure. 3. Maintain the oil level to the bottom of the filler plug Use a sampling gun in order to obtain an oil sample opening. for the front wheel through the filler plug. Remove the filler plug slowly in order to relieve any pressure. 4. Clean the filler plug and install the filler plug. Refer to the following publications for S·O·S information: • Operation and Maintenance Manual, “S·O·S Information” • Special Publication, SEBU6250, “S·O·S Services Oil Analysis” • Special Instruction, PEHJ0191, “S·O·S Fluid Analysis” • Special Publication, PEGJ0047, “How to Take a Good Oil Sample” • Special Publication, PEGJ0046, “S·O·S Services: Understanding Your Results” ----------------------- Page 42----------------------- SEBU7837-09 163 Maintenance Section Fuel System - Fill i02648833 Fuel System - Fill NOTICE Failure to install a vented fuel cap on a nonpressurized fuel tank could create a vacuum in the fuel system. SMCS Code: 1250-544 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- Personal injury or death may result from failure to ized fast fill fuel adapter group could cause the fuel adhere to the following procedures. tank to be overfilled during refueling. Fuel leaked or spilled onto hot surfaces or electri- cal components can cause a fire. Refer to Operation and Maintenance Manual, “Capacities (Refill)” for the fuel tank capacity of your machine. Clean up all leaked or spilled fuel. Do not smoke while working on the fuel system. Park the machine on a level surface. Make sure that Turn the disconnect switch OFF or disconnect the the transmission control is in the PARK position. battery when changing fuel filters. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, adjusting, and repair of the machine. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any com- ponent containing fluids. Dispose of all fluids according to local regulations and mandates. Illustration 187 g01329275 Fuel Tank Filler Neck 1. Clean fuel cap (3) and the filler neck. Remove the fuel cap. 2. Fill the fuel tank with fuel through the filler neck and install the fuel cap. Fast Fill Fuel Adapter (If Equipped) Illustration 186 g01329147 NOTICE (1) Vented Fuel Cap Use only a Caterpillar approved fast fill system to fuel (2) Non-Vented Fuel Cap machines. Over pressurization may cause tank defor- mation and fuel spillage. Note: Machines that are not equipped with a fast fill fuel adapter group require a vented fuel cap. Contact your Cat dealer for fast fill system availability. Machines that are equipped with the nonpressurized fast fill fuel adapter group require a vented fuel cap. 1. Remove dust cover (4) and clean the fast fill fuel Machines that are equipped with the pressurized fast adapter. fill fuel adapter group require a non-vented fuel cap. Note: The maximum fuel flow rate for the fast fill fuel adapter group is 375 L/min (100 US gpm). 2. Fill the fuel tank through the fast fill fuel adapter and install the dust cover. ----------------------- Page 43----------------------- 164 SEBU7837-09 Maintenance Section Fuel System - Prime i02601453 3. As the air is purged from the fuel system, fuel Fuel System - Prime pressure will increase. Listen for the electric fuel priming pump to come under load. Do not continue priming the fuel system after the priming pump is SMCS Code: 1250-548 under load. Do not operate the priming pump for more than two minutes. 4. Start the engine. Fuel leaked or spilled onto hot surfaces or elec- trical components can cause a fire. Clean up fuel 5. If the engine starts but the engine runs rough, spills immediately. continue to run the engine at low idle until the engine runs smoothly. Note: The engine start switch must be in the OFF 6. If the engine does not start after several attempts, position in order to prime the fuel system. consult your Caterpillar dealer. 1. Park the machine on a level surface and stop the engine. Make sure that the transmission control i02601819 is in the PARK position. Fuel System Primary Filter (Water Separator) - Drain SMCS Code: 1261-543; 1263-543 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- nent containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. Park the machine on a level surface and stop the engine. Make sure that the transmission control is in the PARK position. Illustration 188 g01302109 (1) Switch for the Electric Fuel Priming Pump 2. Hold switch (1) upward in order to activate the electric fuel priming pump. The priming pump will fill the engine fuel lines and the fuel filters with fuel. ----------------------- Page 44----------------------- SEBU7837-09 165 Maintenance Section Fuel System Primary Filter (Water Separator) - Replace NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- nent containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. NOTICE Do 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 fuel system parts. The fuel system should be primed prior to starting the engine. 1. Park the machine on a level surface and stop the engine. Make sure that the transmission control Illustration 189 g01302190 is in the PARK position. Open drain valve (1) on the bottom of the fuel/water separator element in order to drain the water into an approved container. Close the drain valve when all of the water has been drained. i02601215 Fuel System Primary Filter (Water Separator) - Replace SMCS Code: 1261-510; 1263-070 Replace the fuel/water separator elements when the Illustration 190 g01301832 engine has a loss of power or when the exhaust smoke is black. View of the back side of the fuel tank 2. Close fuel shutoff valve (1). Personal injury or death can result if spilled fuel ignites. Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. To help prevent possible injury, turn the battery disconnect switch to the OFF position when changing fuel filters or water separator elements. Clean up fuel spills immediately. ----------------------- Page 45----------------------- 166 SEBU7837-09 Maintenance Section Fuel System Secondary Filter - Replace Note: There are rotation index marks on the fuel filter that are spaced 90 degrees or 1/4 of a turn away from each other. When you tighten the fuel filter, use the rotation index marks as a guide. 10. Tighten the filter according to the instructions that are printed on the filter. Use the index marks as a guide. For non-Caterpillar filters, use the instructions that are provided with the filter. Note: You may need to use a Caterpillar strap wrench, or another suitable tool, in order to turn the filter to the amount that is required for final installation. Make sure that the installation tool does not damage the filter. 11. Tighten the drain valve on the water separator bowl. Note: The water separator element is under suction during normal engine operation. The drain valve must be tightened in order to prevent air leakage into the fuel system. 12. Open the fuel shutoff valve. 13. Prime the fuel system. Illustration 191 g01301834 For information on priming the fuel system, refer to the Operation and Maintenance Manual, “Fuel 3. The water separator bowl (3) is located on the System - Prime”. bottom of the primary fuel filter (2). Open the drain valve (4) on the water separator bowl. Allow the 14. Start the engine and inspect the filter for leaks. water and the fuel to drain into a suitable container. Make any necessary repairs. If the engine has a loss of power or the exhaust smoke is still black, 4. Use a strap type wrench to remove the filter from replace the secondary filters. the filter mounting base. 5. Remove the water separator bowl from the filter i03661502 element. Clean the water separator bowl and the Fuel System Secondary Filter - O-ring groove. Replace Note: The water separator bowl is reusable. Do not discard the water separator bowl. SMCS Code: 1261-510-SE 6. Inspect the O-ring seal in the water separator bowl for damage. Replace the O-ring seal, if necessary. Personal injury or death can result if spilled fuel 7. Lubricate the O-ring seal with clean diesel fuel or ignites. Fuel leaked or spilled onto hot surfaces with engine oil. Place the O-ring seal in the water or electrical components can cause a fire. separator bowl. To help prevent possible injury, turn the battery 8. Install the water separator bowl onto the new filter disconnect switch to the OFF position when element by hand. Do not use tools to tighten the changing fuel filters or water separator elements. water separator bowl. Clean up fuel spills immediately. 9. Lubricate the gasket of the new filter element with clean diesel fuel. Install the new filter hand tight until the seal of the fuel filter contacts the base. Note the position of the index marks on the filter in relation to a fixed point on the filter base. ----------------------- Page 46----------------------- SEBU7837-09 167 Maintenance Section Fuel System Secondary Filter - Replace NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- nent containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. NOTICE Do 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 fuel Illustration 193 g01302139 system parts. The fuel system should be primed prior to starting the engine. 3. Secondary fuel filter (2) is located on the left side of the engine. Remove the filter elements from the 1. Park the machine on a level surface and stop the base. Discard the used element. engine. Make sure that the transmission control is in the PARK position. 4. Clean the filter mounting base. Make sure that all of the former seal is removed. 5. Lubricate the sealing surfaces of the new filter elements with clean diesel fuel. 6. Install the filters by hand. Tighten the filter elements until the sealing surfaces contact the base. Tighten the filter elements for an additional 3/4 of a turn. There are rotation index marks on each filter element. These marks are spaced 90° or 1/4 turn from each other. Use the marks as a guide when you tighten the filter elements. Illustration 192 g01301832 7. Open the fuel shutoff valve. View of the back side of the fuel tank 8. Prime the fuel system. Refer to the Operation and 2. Close fuel shutoff valve (1). Maintenance Manual, “Fuel System - Prime”. 9. Start the engine and inspect the filter for leaks. Make any necessary repairs. ----------------------- Page 47----------------------- 168 SEBU7837-09 Maintenance Section Fuel Tank Cap and Strainer - Clean i02517264 i02519799 Fuel Tank Cap and Strainer - Fuel Tank Water and Sediment Clean - Drain SMCS Code: 1273-070-STR; 1273-070-Z2 SMCS Code: 1273-543-MAS 1. Park the machine on a level surface and stop the engine. Make sure that the transmission control is in the PARK position. Illustration 195 g01204673 The fuel tank is located on the left side of the machine. NOTICE Illustration 194 g01259408 Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- 2. Remove fuel tank cap (1). ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open- 3. Inspect the cap gasket. Replace the gasket if the ing any compartment or disassembling any compo- gasket is damaged. nent containing fluids. 4. Remove the retaining snap ring. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies 5. Remove the screen. suitable to collect and contain fluids on Caterpillar products. 6. Disassemble the cap. Dispose of all fluids according to local regulations and 7. Wash all the parts in clean, nonflammable solvent. mandates. 8. Lightly oil the element. Assemble the cap. 1. Park the machine on a level surface and stop the 9. Install the screen, the retaining snap ring and the engine. Make sure that the transmission control cap. is in the PARK position. 2. Open fuel tank drain valve (1) and allow the moisture and the sediment to drain into a suitable container. 3. Close the drain valve. ----------------------- Page 48----------------------- SEBU7837-09 169 Maintenance Section Fuses - Replace i02590828 Fuses - Replace SMCS Code: 1417-510 NOTICE If it is necessary to replace fuses frequently, an elec- trical problem may exist. Contact your Caterpillar dealer. NOTICE Always replace fuses with the same type and capacity fuse that was removed. Otherwise, electrical damage could result. Fuses protect the electrical system from damage that is caused by overloaded electrical circuits. Replace a fuse if the element separates. If the fuse of a particular electrical system requires frequent replacement, check the electrical circuit. Repair the electrical circuit, if necessary. Illustration 196 g01297084 (1) 24 Volt to 12 Volt Converter and Ether Starting Aid – 15 Amp (2) Front Brake – 10 Amp (3) Heated Seat – 15 Amp ----------------------- Page 49----------------------- 170 SEBU7837-09 Maintenance Section Hoist Cylinder Bearings - Lubricate (4) Brake Retarder – 10 Amp (17) Panel Light and Tail Light – 10 Amp (5) Engine Lockout – 10 Amp (18) Spare Fuse – 10 Amp (6) Windshield Washer and Wiper – 10 Amp (19) Transmission ECM – 15 Amp (7) Autolube System – 10 Amp (20) Interior Light and Brake Light – 10 (8) Secondary Steering, Brake Release, Amp Prelube, and QuickEvac – 10 Amp (9) Exhaust Diverter – 10 Amp (21) Messenger – 10 Amp (10) Heated Mirror – 10 Amp (22) Horn – 20 Amp (11) Strut Pressure Sensor – 10 Amp (23) Spare Fuse – 10 Amp (12) Spare Fuse – 15 Amp (24) Backup Alarm – 10 Amp (13) TPMS – 15 Amp i02624239 (14) Spare Fuse – 20 Amp Hoist Cylinder Bearings - Lubricate SMCS Code: 5102-086-BD (15) Keyswitch – 15 Amp Note: If the machine is equipped with central lubrication lines, refer to Operation and Maintenance Manual, “Central Lubrication System - Lubricate” for lubrication points. (16) Fuel Priming Pump – 20 Amp Wipe off the fittings before any lubricant is applied. ----------------------- Page 50----------------------- SEBU7837-09 171 Maintenance Section Hoist and Brake Tank Oil - Change Upper i02916668 Hoist and Brake Tank Oil - Change SMCS Code: 5056-044 1. Park the machine on a level surface and stop the engine. Make sure that the transmission control is in the PARK position and make sure that the truck body is in the DOWN position. Illustration 197 g01315270 Lubricate fitting (1) for the left upper hoist cylinder bearing. Lubricate fitting (2) for the right upper hoist cylinder bearing. Lower Illustration 199 g01272580 2. Remove filler cap (1) in order to prevent a vacuum in the tank. Install the cap after the tank has been drained. This will prevent dirt from entering the system. Illustration 198 g0 1315286 Fitting (3) is located on each lower hoist cylinder bearing. Lubricate the lower bearing on each hoist cylinder. ----------------------- Page 51----------------------- 172 SEBU7837-09 Maintenance Section Hoist and Brake Tank Oil Level - Check 13. Start the engine and operate the engine at low NOTICE idle. Check the hydraulic system for leaks and Care must be taken to ensure that fluids are contained make necessary repairs. during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to 14. Raise the dump body until the hoist cylinders are collect the fluid with suitable containers before open- extended halfway. Lower the dump body and add ing any compartment or disassembling any compo- oil, if necessary. nent containing fluids. 15. Raise the dump body until the hoist cylinders are Refer to Special Publication, NENG2500, “Caterpillar fully extended. Lower the dump body and add oil, Dealer Service Tool Catalog” for tools and supplies if necessary. suitable to collect and contain fluids on Caterpillar products. 16. Repeat Step 14 and Step 15 until the proper oil level stabilizes in the upper sight gauge. Install Dispose of all fluids according to local regulations and the filler cap. mandates. i03194840 Note: Hand tighten the NPT pipe nipple. Do not use Hoist and Brake Tank Oil Level tools. - Check 3. Remove drain plug (3) from the hoist/brake tank. Install a 88 mm (3.50 inch) long NPT pipe nipple (Type 1) in order to open the internal drain valve. The outer diameter of the NPT pipe nipple should be SMCS Code: 5056-535-OC 25.4 mm ( 1 inch). Drain the oil into a suitable S/N: RLB1-485 container. S/N: BZZ1-395 4. Remove the pipe nipple. Clean the drain plug and install the drain plug. The type 1 tank was factory installed on machines in this serial number range. All type 1 tanks should be 5. Remove the tank filler cap. updated to a type 2 tank. Contact your Caterpillar dealer in order to update the hoist/brake tank. 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 filler screen to dry. 8. Inspect the cap seal. Use a new seal if the used seal is damaged. Install the filler screen and the retaining ring. 9. Fill the hoist/brake tank. Refer to Operation and Maintenance Manual, “Lubricant Viscosities”. Refer to Operation and Maintenance Manual, “Capacities (Refill)”. 10. Start the engine and run the engine for approximately 15 seconds. The oil level will decrease as oil fills the system. 11. Stop the engine. . d oil to the tank in order to raise the oil to the Illustration 200 g01627915 12 Ad proper level in upper sight gauge (2). Refer to The hoist/brake tanks can be identified by the height of the upper Operation and Maintenance Manual, “Hoist and sight gauge and filler neck. The upper sight gauge and the filler Brake Tank Oil Level - Check” for the proper oil neck on a type 1 tank (A) is lower than the upper sight gauge and the filler neck on a type 2 tank (B). level within the sight gauge. ----------------------- Page 52----------------------- SEBU7837-09 173 Maintenance Section Hoist and Brake Tank Oil Level - Check Note: The type 1 tank and the type 2 tank have the same oil capacity. The upper sight gauge is raised on NOTICE the type 2 tank in order to display the proper level Do not use the lower green range in order to check to within the sight gauge. oil level of the hoist, torque converter, and brake tank. The lower green range will not provide enough oil to 1. Park the machine on a level surface with the truck the system and machine damage could result. body in the DOWN position. Stop the engine and allow the oil to cool. Make sure that the transmission control is in the PARK position. 3. If necessary, remove filler cap (1) and add oil. If the system has been drained, see this Operation and Maintenance Manual, “Hoist and Brake Tank Oil - Change” for the proper filling procedure. Note: If the oil level must be checked with the truck body in the RAISED position, the minimum oil level must 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: RLB486-Up S/N: BZZ396-Up The type 2 tank was factory installed on machines in this serial number range. All machines with a previous serial number should be converted to a type 2 tank. Illustration 201 g01629753 The hoist/brake tank is located on the right side of the machine. 2. Check the oil level in sight gauge (2). The oil level must be checked when the oil is cold (ambient Illustration 202 g01627915 temperature). The oil level must be within upper green range (4) on the sight gauge. The hoist/brake tanks can be identified by the height of the upper sight gauge and filler neck. The upper sight gauge and the filler neck on a type 2 tank (B) is higher than the upper sight gauge and Note: As the oil approaches operating temperature, the filler neck on a type 1 tank (A). the oil level will rise above the top of the sight gauge. ----------------------- Page 53----------------------- 174 SEBU7837-09 Maintenance Section Hoist and Brake Tank Oil Sample - Obtain Note: The type 1 tank and the type 2 tank have the b. When the oil is cold (ambient temperature), same oil capacity. The upper sight gauge is raised on maintain the oil level within lower green range the type 2 tank in order to display the proper level (5). within the sight gauge. 3. If necessary, remove filler cap (1) and add oil. If 1. Park the machine on a level surface with the truck the system has been drained, see this Operation body in the DOWN position. Stop the engine and and Maintenance Manual, “Hoist and Brake Tank make sure that the transmission control is in the Oil - Change” for the proper filling procedure. PARK position. Note: If the oil level must be checked with the truck body in the RAISED position, the minimum oil level must be within sight gauge (3) with the engine on. i02605155 Hoist and Brake Tank Oil Sample - Obtain SMCS Code: 5050-008; 5056-008; 7542 Personal injury or death can occur if personnel are trapped between the wheel and the frame. The steering system is hydraulically controlled and wheels can crush personnel during move- ment. Use caution when working between the wheels and the frame. If the wheels must be turned, en- sure that all personnel are clear of the machine before any movement. Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. Illustration 203 g01628256 The 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). ----------------------- Page 54----------------------- SEBU7837-09 175 Maintenance Section Magnetic Plug (Wheels) - Check i02546124 Magnetic Plug (Wheels) - Check SMCS Code: 0663-535 Illustration 205 g01274177 Magnetic plug on the rear wheel Illustration 204 g01304009 Sampling valve (1) for the hoist and brake oil is located on the screen housing for the brake oil cooler. Refer to Special Publication, PEHP6001, “How To Take A Good Oil Sample”. Also, refer to Operation and Maintenance Manual, “SOS Information” and Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations”, “SOS Oil Analysis” for additional information about obtaining an oil sample. Illustration 206 g01250751 Magnetic plug on the front wheel All of the wheels have a magnetic plug. The magnetic plugs will attract metal from the oil. A bearing failure is indicated by an increased amount of metal on the magnetic plug. If any abnormal particles are found, consult your Caterpillar dealer. ----------------------- Page 55----------------------- 176 SEBU7837-09 Maintenance Section Magnetic Screen (Torque Converter Sump) - Clean After you correct a failure that produces debris, clean the compartments before you add any oil. i02607426 Magnetic Screen (Torque Converter Sump) - Clean SMCS Code: 3101-070-MGS NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- nent containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. 1. Park the machine on a level surface and stop the engine. Make sure that the transmission control is in the PARK position. Illustration 207 g01305487 Location of the magnetic screen for the torque converter sump Illustration 208 g01262121 2. Remove cover assembly (1), screen (2) and magnetic tube assembly (3). ----------------------- Page 56----------------------- SEBU7837-09 177 Maintenance Section Magnetic Screen (Transmission) - Clean 3. Inspect the screen and the magnets for debris. An 1. Park the machine on a level surface and stop the excessive amount of debris may be an indication engine. Make sure that the transmission control of possible failure. Also, oil contamination may is in the PARK position. require you to change the oil in the transmission and torque converter system. If large particles are found, consult your Caterpillar dealer for further analysis and additional guidance. NOTICE Do not drop or rap the magnets against any hard ob- jects. Repl ace any damaged magnets. 4. Wash the screen and the magnetic tube assembly in clean, nonflammable solvent. Clean the magnets with a cloth, a stiff bristle brush or air pressure. 5. Install the magnetic tube assembly and the screen. 6. Inspect seal (4). If the seal is damaged, replace the seal. 7. Install the cover assembly. 8. Start the engine and operate the engine at low idle. Inspect the area for leaks and make any necessary repairs. 9. Check the oil level in the transmission and torque converter system. If necessary, add oil. Refer to Operation and Maintenance Manual, “Torque Converter and Transmission Oil Level - Check” for the proper procedure. i02606196 Magnetic Screen Illustration 209 g01304774 (Transmission) - Clean Location of the magnetic screen for the transmission SMCS Code: 3030-070-MGS NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- nent containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Illustration 210 g01262121 Dispose of all fluids according to local regulations and mandates. 2. Remove cover assembly (1), screen (2) and magnetic tube assembly (3). ----------------------- Page 57----------------------- 178 SEBU7837-09 Maintenance Section Oil Filter (Brake, Hydraulic Fan) - Replace 3. Inspect the screen and the magnets for debris. An excessive amount of debris may be an indication of possible failure. Also, oil contamination may Hot oil and hot components can cause personal require you to change the oil in the transmission injury. Do not allow hot oil or hot components to and torque converter system. If large particles are contact the skin. found, consult your Caterpillar dealer for further analysis and additional guidance. NOTICE NOTICE Care must be taken to ensure that fluids are contained Do not drop or rap the magnets against any hard ob- during performance of inspection, maintenance, test- jects. Repl ace any damaged magnets. ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- 4. Wash the screen and the magnetic tube assembly nent containing fluids. in clean, nonflammable solvent. Clean the magnets with a cloth, a stiff bristle brush or air Refer to Special Publication, NENG2500, “Caterpillar pressure. Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar 5. Install the magnetic tube assembly and the screen. products. 6. Inspect seal (4). If the seal is damaged, replace Dispose of all fluids according to local regulations and the seal. mandates. 7. Install the cover assembly. Park the machine on a level surface and stop the 8. Start the engine and operate the engine at low engine. Make sure that the transmission control is in idle. Inspect the area for leaks and make any the PARK position. necessary repairs. 9. Check the oil level in the transmission and torque converter system. If necessary, add oil. Refer to Operation and Maintenance Manual, “Torque Converter and Transmission Oil Level - Check” for the proper procedure. i02605535 Oil Filter (Brake, Hydraulic Fan) - Replace SMCS Code: 5068-510-BRK; 5068-510-HFN Personal injury or death can occur if personnel are trapped between the wheel and the frame. The steering system is hydraulically controlled and wheels can crush personnel during move- ment. Use caution when working between the wheels and the frame. If the wheels must be turned, en- sure that all personnel are clear of the machine before any movement. ----------------------- Page 58----------------------- SEBU7837-09 179 Maintenance Section Oil Filter (Brake, Hydraulic Fan) - Replace 770 7. Start the engine and operate the engine at low idle. Check for any leaks and make the necessary repairs. 8. Check the oil level in the hoist/brake tank. If necessary, add oil. For the proper procedure, refer to Operation and Maintenance Manual, “Hoist and Brake Tank Oil Level - Check”. 772 Illustration 211 g01304415 1. Remove drain plug (2) from filter housing (1). Drain the oil into a suitable container. Note: Removing the drain plug from the bottom of the oil filter may not allow all of the oil to drain from the filter housings. When you remove the filter housing and the filter element, be careful to avoid contact with hot oil. Illustration 212 g01304451 2. Clean the drain plug and inspect the seal in the 1. Remove drain plugs (2) from filter housings (1). drain plug. If the seal is damaged, replace the seal Drain the oil into a suitable container. with a new seal. Install the drain plug. Note: Removing the drain plug from the bottom of the 3. Remove the filter housing and the filter element. oil filter may not allow all of the oil to drain from the Properly discard the used filter element. filter housings. When you remove the filter housing and the filter element, be careful to avoid contact 4. Wash the filter housing in clean nonflammable with hot oil. solvent. 2. Clean the drain plugs and inspect the seal in the 5. Inspect the seal in the filter base. If the seal is drain plugs. If the seals are damaged, replace the damaged, replace the seal with a new seal. seals with new seals. Install the drain plugs. 6. Install the new filter element in the housing. Install 3. Remove the filter housings and the filter elements. the housing. Properly discard the used filter elements. ----------------------- Page 59----------------------- 180 SEBU7837-09 Maintenance Section Oil Filter (Power Train) - Replace 4. Wash the filter housings in clean nonflammable solvent. 5. Inspect the seal in each filter base. If a seal is damaged, replace the seal with a new seal. 6. Install a new filter element in each housing. Install the housings. 7. Start the engine and operate the engine at low idle. Check for any leaks and make the necessary repairs. 8. Check the oil level in the hoist/brake tank. If necessary, add oil. For the proper procedure, refer to Operation and Maintenance Manual, “Hoist and Brake Tank Oil Level - Check”. i02605058 Oil Filter (Power Train) - Replace SMCS Code: 3067-510; 3101-510-FI Personal injury or death can occur if personnel are trapped between the wheel and the frame. The steering system is hydraulically controlled and wheels can crush personnel during move- ment. Illustration 213 g01304162 Use caution when working between the wheels and the frame. If the wheels must be turned, en- NOTICE sure that all personnel are clear of the machine Care must be taken to ensure that fluids are contained before any movement. during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- nent containing fluids. Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to Refer to Special Publication, NENG2500, “Caterpillar contact the skin. Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar Note: The power train oil filter is the oil filter for the products. transmission/torque converter. Dispose of all fluids according to local regulations and 1. Park the machine on a level surface and stop the mandates. engine. Make sure that the transmission control is in the PARK position. 2. Remove drain plug (2) from filter housing (1). Drain the oil into a suitable container. Clean the drain plug and install the drain plug. ----------------------- Page 60----------------------- SEBU7837-09 181 Maintenance Section Oil Filter (Steering Pump Case Drain) - Replace Note: Removing the drain plug from the bottom of the power train oil filter may not allow all of the oil to drain from the filter housings. When you remove the filter housing and the filter element, be careful to avoid 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 nonflammable solvent. 5. Inspect the seal in the filter base. If the seal is damaged, replace the seal with a new seal. 6. Install the new filter element in the housing. Install the housing. 7. Start the engine and operate the engine at low idle. Check for any leaks and make the necessary repairs. 8. Check the oil level in the transmission and torque converter system. If necessary, add oil. Refer to Operation and Maintenance Manual, “Torque Converter and Transmission Oil Level - Check” for the proper procedure. i02541312 Oil Filter (Steering Pump Case Drain) - Replace SMCS Code: 5068-510; 5091-510-ZH Illustration 214 g01306228 Park the machine on level ground and stop the engine. Make sure that the transmission control is in 1. Push the button on breaker relief valve (1). the PARK position. 2. Slowly, loosen filler cap (2) on the steering Note: In order to gain improved access to the case hydraulic tank in order to relieve the pressure. drain oil filter for the steering pump, first remove the steering oil filter. For more information on the steering oil filter, refer to Operation and Maintenance Manual, “Oil Filter (Steering) - Replace”. Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. 3. Remove case drain oil filter (3). 4. Clean the filter mounting base. Make sure that the old 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 contacts the filter mounting base. Note the position of the index marks on the filter in relation to a fixed point on the mounting base. ----------------------- Page 61----------------------- 182 SEBU7837-09 Maintenance Section Oil Filter (Steering) - Replace Note: There are rotation index marks on each filter that is spaced 90 degrees (1/4 turn) away from each other. When you tighten the filter, use the rotation index marks as a guide. 7. Tighten all filters according to the instructions that are 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 a suitable tool in order to turn the filter to the amount that is required for final installation. Make sure that the installation tool does not damage the filter. 8. Start the engine and operate the engine at low idle. Check the machine for leaks and make any necessary repairs. Install the filler cap. 9. Check the oil level. Maintain the oil level within the green range of sight gauge (4). If necessary, add oil. i02541381 Oil Filter (Steering) - Replace SMCS Code: 5068-510-ZH Park the machine on level ground and stop the engine. Make sure that the transmission control is in the PARK position. Illustration 215 g01306232 1. Push the button on breaker relief valve (1). 2. Slowly, loosen filler cap (2) on the steering hydraulic tank in order to relieve the pressure. Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. 3. Remove steering oil filter (3). Note: For improved access to the case drain oil filter for the steering pump, change the case drain oil filter when the steering oil filter is removed. For more information on the case drain oil filter, refer to Operation and Maintenance Manual , “Oil Filter (Steering Pump Case Drain) - Replace”. 4. Clean the filter mounting base. Make sure that the old filter seal is removed. 5. Lubricate the seal of the new filter with clean oil. ----------------------- Page 62----------------------- SEBU7837-09 183 Maintenance Section Oil Filter - Inspect 6. Install the new filter by hand until the seal contacts Ferrous metals can indicate wear on steel parts and the filter mounting base. Note the position of the on cast iron parts. index marks on the filter in relation to a fixed point on the mounting base. Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings, Note: There are rotation index marks on each filter rod bearings, or turbocharger bearings. that is spaced 90 degrees (1/4 turn) away from each other. When you tighten the filter, use the rotation Small amounts of debris may be found in the filter index marks as a guide. element. This could be caused by friction and by normal wear. Consult your Caterpillar dealer in order 7. Tighten all filters according to the instructions that to arrange for further analysis if an excessive amount are printed on the filter. For non-Caterpillar filters, of debris is found. use the instructions that are provided with the filter. Using an oil filter element that is not recommended Note: You may need to use a strap type wrench or a by Caterpillar can result in severe engine damage suitable tool in order to turn the filter to the amount to engine bearings, to the crankshaft, and to other that is required for final installation. Make sure that parts. This can result in larger particles in unfiltered the installation tool does not damage the filter. oil. The particles could enter the lubricating system and the particles could cause damage. 8. Start the engine and operate the engine at low idle. Check the machine for leaks and make any necessary repairs. Install the filler cap. i02541458 Radiator Core and Aftercooler 9. Check the oil level. Maintain the oil level within the green range of sight gauge (4). If necessary, - Clean add oil. SMCS Code: 1064-070; 1353-070-KO i02106227 NOTICE Oil Filter - Inspect High water pressure water and high water volume can damage the radiator. SMCS Code: 5068-040 Use a water spray nozzle that will disperse the water. Inspect a Used Filter for Debris 1. Park the machine on a level surface and stop the engine. Make sure that the transmission control is in the PARK position. Illustration 216 g00100013 The element is shown with debris. Use a filter cutter to cut the filter element open. Spread apart the pleats and inspect the element for metal and for other debris. An excessive amount of debris in the filter element can indicate a possible failure. If metals are found in the filter element, a magnet can Illustration 217 g01272925 be used to differentiate between ferrous metals and nonferrous metals. ----------------------- Page 63----------------------- 184 SEBU7837-09 Maintenance Section Rear Axle A-Frame Bearing - Lubricate 2. Remove two-piece grill (2). 3. Swing air conditioner condenser (1) away from the radiator. 4. Clean the radiator core and clean the aftercooler. You can use compressed air, high pressure water, or steam to remove dust and other debris from the radiator core and the aftercooler. However, the use of compressed air is preferred. 5. Swing the air conditioner condenser next to the radiator and secure the air conditioner condenser in position. 6. install both pieces of the grill. See Special Publication, SEBD0518, “Know Your Cooling System” for the complete procedure for cleaning the radiator core and the aftercooler. i02544077 Rear Axle A-Frame Bearing - Lubricate SMCS Code: 7551-086-ZX Illustration 218 g01316306 Note: If the machine is equipped with central Lubricate fitting (1) for the A-frame bearing assembly. lubrication lines, refer to Operation and Maintenance Manual, “Central Lubrication System - Lubricate” for i02543944 lubrication points. Rear Axle Housing Lateral Wipe off the fitting before any lubricant is applied. Control Rod Bearings - Lubricate SMCS Code: 7551-086-RO Note: If the machine is equipped with central lubrication lines, refer to Operation and Maintenance Manual, “Central Lubrication System - Lubricate” for lubrication points. Wipe off the fittings before any lubricant is applied. ----------------------- Page 64----------------------- SEBU7837-09 185 Maintenance Section Rear Suspension Cylinder Bearings - Lubricate Upper Illustration 219 g01316095 Illustration 220 g01316108 Lubricate fitting (1) and fitting (2) for the bearings in the lateral control rod. Lubricate fitting (1) for the upper bearing on the left rear suspension cylinder. Lubricate fitting (2) for the i02543889 upper bearing on the right rear suspension cylinder. Rear Suspension Cylinder Lower Bearings - Lubricate SMCS Code: 7213-086-BD Note: If the machine is equipped with central lubrication lines, refer to Operation and Maintenance Manual, “Central Lubrication System - Lubricate” for lubrication points. Wipe off the fittings before any lubricant is applied. Illustration 221 g01316142 Fitting (3) is located on the lower bearings for the rear suspension cylinders. Lubricate the lower bearing on each rear suspension cylinder. ----------------------- Page 65----------------------- 186 SEBU7837-09 Maintenance Section Receiver Dryer (Refrigerant) - Replace i02544244 Receiver Dryer (Refrigerant) - Replace SMCS Code: 7322-510 Personal injury can result from contact with refrig- erant. Contact with refrigerant can cause frost bite. Keep face 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- Illustration 222 g01273249 der pressure, release it slowly in a well ventilated area. Refrigerant dryer (1) is located on the right side of the cab. Remove the panel in order to access the Personal injury or death can result from inhaling refrigerant dryer. refrigerant through a lit cigarette. Refer to Service Manual, SENR5664, “Air Inhaling air conditioner refrigerant gas through a Conditioning and Heating R-134a for All Caterpillar lit cigarette or other smoking method or inhaling Machines” for the proper procedure to change the fumes released from a flame contacting air con- refrigerant dryer and for the proper procedure to ditioner refrigerant gas, can cause bodily harm or death. reclaim the refrigerant gas. Do not smoke when servicing air conditioners or i02650056 wherever refrigerant gas may be present. Rim - Inspect Use a certified recovery and recycling cart to prop- erly remove the refrigerant from the air condition- SMCS Code: 4209-040 ing system. Inspect the rim whenever a tire is dismounted. NOTICE If the refrigerant system has been open to the outside air (without being plugged) for more than 30 minutes, the receiver-dryer must be replaced. Moisture will en- ter an open refrigerant system and cause corrosion which will lead to component failure. ----------------------- Page 66----------------------- SEBU7837-09 187 Maintenance Section Rim - Inspect i02650089 Rim - Inspect SMCS Code: 4209-040 The tires must be dismounted from the rim in order to perform a magnetic particle inspection. Illustration 223 g01329962 Typical example Cutaway view of the rim assembly Inspect the following components of the rim assembly: Bead Seat Band (1) – Inspect the bead seat band Illustration 224 g01330544 for the following: wear, corrosion, and cracks. Typical example Lock Ring (2) – Inspect the lock ring for the Cutaway view of the rim assembly following: wear, corrosion, cracks, flat spots, and warping. When the lock ring is not assembled, the The following high stress areas of the rim should be two ends of the lock ring must overlap each other. checked: Rim Base (3) – Inspect the rim base for the following: • (1) Areas of contact with flanges wear, corrosion, cracks, and fretting. • (2) Contact areas with the lock ring and the groove Flanges (4) – Inspect the flanges for the following: for the lock ring wear, corrosion, cracks, and fretting. • (3) Welds on the rim disc Do not reuse rim components that are cracked, worn, damaged, or pitted from corrosion. For more • (4) Welds around the circumference of the rim base information on the reusability of the rim components, consult your Caterpillar dealer. • (5) Butt welds For more information on magnetic particle inspection, refer to Guideline For Reusable Parts And Salvage Operations, SEBF8148, “General Salvage and Reconditioning Techniques” or consult your Caterpillar dealer. . ----------------------- Page 67----------------------- 188 SEBU7837-09 Maintenance Section Rollover Protective Structure (ROPS) - Inspect Do not reuse rim components that are cracked, worn, damaged, or pitted from corrosion. For more information on the reusability of the rim components, Hot oil and hot components can cause personal consult your Caterpillar dealer. injury. Do not allow hot oil or hot components to contact skin. i02623990 Rollover Protective Structure NOTICE (ROPS) - Inspect Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to SMCS Code: 7325-040 collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- Inspect the Rollover Protective Structure (ROPS) nent containing fluids. for bolts that are loose or damaged. Replace any damaged bolts and any missing bolts with original Refer to Special Publication, NENG2500, “Caterpillar replacement parts only. Refer to Specifications, Dealer Service Tool Catalog” for tools and supplies SENR3130, “Torque Specifications” for the suitable to collect and contain fluids on Caterpillar recommended torque. products. Note: Apply oil to all bolt threads for the ROPS before Dispose of all fluids according to local regulations and you install the bolts. Improper bolt torque can result if mandates. you do not apply oil to the threads. Do not weld reinforcement plates to the ROPS After a failure in the brake circuit, clean the screen for in order to straighten the ROPS. Do not weld the brake oil cooler. The oil cooler screen is located reinforcement plates to the ROPS in order to repair on the right side of the engine. the ROPS. 1. Park the machine on a level surface and stop the Inspect the ROPS for any cracks in the welds, cracks engine. Make sure that the transmission control in the castings, or cracks in any metal section. is in the PARK position. Refer to Special Instruction, SEHS6929, “Inspection, 2. Remove bottom guard (1). Maintenance, and Repair of ROPS and Attachment Installation Guidelines” or consult your Caterpillar dealer for more information. i02609230 Screen (Brake Oil Cooler) - Clean SMCS Code: 4295-070; 5068-070-Z3 Personal injury or death can occur if personnel are trapped between the wheel and the frame. The steering system is hydraulically controlled and wheels can crush personnel during move- ment. Use caution when working between the wheels and the frame. If the wheels must be turned, en- sure that all personnel are clear of the machine before any movement. ----------------------- Page 68----------------------- SEBU7837-09 189 Maintenance Section Screen (Hoist and Brake Tank) - Inspect/Clean/Replace i02916417 Screen (Hoist and Brake Tank) - Inspect/Clean/Replace SMCS Code: 5056-040-Z3 There is one suction screen inside the hoist/brake tank. There is also one return screen. Clean both screens whenever there is a failure of brakes, hoist cylinders or hoist pumps. The machine must be level. The transmission control must be in the PARK position and the engine must be stopped. Illustration 225 g01306345 3. Remove drain plug (2) and drain the oil from the screen housing into a suitable container. Clean the drain plug and install the drain plug. Note: Inspect all seals that are removed during this procedure. Replace any damaged seals. 4. Remove screen plug (4) and oil cooler screen (3). Illustration 226 g01273302 Note: The oil cooler screens are fragile. 1. Remove filler cap (1) in order to prevent a vacuum in the tank. 5. Wash the screen and the screen plug in clean, nonflammable solvent. 6. Install the screen and the screen plug. 7. Install the bottom guard. 8. Start the engine and run the engine at low idle. Check for leaks and make any necessary repairs. 9. Check the oil level in the hoist/brake tank. If necessary, add oil. Refer to Operation and Maintenance Manual, “Hoist and Brake Tank Oil Level - Check” for more information. ----------------------- Page 69----------------------- 190 SEBU7837-09 Maintenance Section Screen (Hoist and Brake Tank) - Inspect/Clean/Replace NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- nent containing fluids. Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Dispose of all fluids according to local regulations and mandates. Note: Hand tighten the NPT pipe nipple. Do not use tools. 2. Remove tank drain plug (2). Install a 88 mm (3.50 inch) long NPT pipe nipple in order to open the internal drain valve. The outer diameter of the NPT pipe nipple should be 25.4 mm (1 inch). Drain the oil into a suitable container. Illustration 228 g01262924 Cutaway view 6. Remove suction screen (5) from the tank. 7. Wash the suction screen in clean, nonflammable solvent. 8. Install the clean suction screen. 9. Remove return screen (6) and properly discard the return screen. 10. Install a new return screen. 11. Clean the cover for the front of the hoist/brake tank in clean, nonflammable solvent. Inspect the cover gasket. If the gasket is damaged, replace the gasket. Illustration 227 g01262829 12. Install the front cover to the tank. 3. Remove return line (3). 13. Install the return line. 4. Remove front cover (4) from the tank. 14. Fill the hoist/brake tank. Refer to Operation and 5. Clean any debris from the inside of the tank. Maintenance Manual, “Lubricant Viscosities”. Refer to Operation and Maintenance Manual, “Capacities (Refill)”. 15. Start the engine and run the engine for approximately 15 seconds. The oil level will decrease as oil fills the system. ----------------------- Page 70----------------------- SEBU7837-09 191 Maintenance Section Seat Belt - Inspect 16. Stop the engine. Illustration 230 g01212078 Illustration 229 g01273419 Typical example 17. Add oil to the tank in order to raise the oil to the Inspect seat belt (1) for webbing that is worn or proper level in upper sight gauge (7). Refer to frayed. Replace the seat belt if the seat belt is worn Operation and Maintenance Manual, “Hoist and or frayed. Brake Tank Oil Level - Check” for the proper oil level within the sight gauge. Check buckle (2) for wear or for damage. If the buckle is worn or damaged, replace the seat belt. 18. Start the engine and operate the engine at low idle. Check the hydraulic system for leaks and Check all seat belt mounting hardware (3) for wear make necessary repairs. or for damage. Replace any mounting hardware that is worn or damaged. Make sure that the mounting 19. Raise the dump body until the hoist cylinders are bolts are tight. extended halfway. Lower the dump body and add oil, if necessary. Contact your Caterpillar dealer for the replacement of the seat belt and the mounting hardware. 20. Raise the dump body until the hoist cylinders are fully extended. Lower the dump body and add oil, Note: Within three years of the date of installation or if necessary. within five years of the date of manufacture, replace the seat belt. Replace the seat belt at the date which 21. Repeat Step 19 and Step 20 until the proper oil occurs first. A date label for determining the age of level stabilizes in the upper sight gauge. Install the seat belt is attached to the seat belt, the seat belt the filler cap. buckle, and the seat belt retractor. If your machine is equipped with a seat belt i02425004 extension, also perform this inspection procedure for Seat Belt - Inspect the seat belt extension. SMCS Code: 7327-040 i04270251 Always check the condition of the seat belt and the Seat Belt - Replace condition of the seat belt mounting hardware before you operate the machine. Replace any parts that are SMCS Code: 7327-510 damaged or worn before you operate the machine. Within 3 years of the date of installation or within 5 years of the date of manufacture, Caterpillar recommends replacing the seat belt. Replace the seat belt at the date which occurs first. A date label for determining the age of the seat belt is attached to the seat belt, the seat belt buckle, and the seat belt retractor. ----------------------- Page 71----------------------- 192 SEBU7837-09 Maintenance Section Seat Suspension - Inspect/Lubricate Armrest (Seat) Pivot the armrest to the vertical position. Apply dry lubricant or silicone lubricant between the parts in the mechanism for the armrest assembly. i02545100 Secondary Steering - Test SMCS Code: 4300-081-SST Illustration 231 g01152685 (1) Date of installation (retractor) Personal injury or death can occur if steering is (2) Date of installation (buckle) (3) Date of manufacture (tag) (fully extended Web) lost completely during operation. (4) Date of manufacture (underside) (buckle) Do not continue to operate the machine using the Consult your Cat dealer for the replacement of the secondary steering. seat belt and the mounting hardware. If the secondary steering activates during opera- If your machine is equipped with a seat belt tion, immediately park the machine in a safe loca- extension, also perform this replacement procedure tion. Inspect the machine and correct the condi- for the seat belt extension. tion which made the use of the secondary steer- ing necessary. i02302909 Seat Suspension - NOTICE The secondary steering switch should always be in the Inspect/Lubricate AUTO position during normal operation. This will en- sure that secondary steering capability is immediately SMCS Code: 7324-040; 7324-086 available if the primary steering system fails. Inspect NOTICE To minimize battery drain, leave the switch in the Seat Suspension MANUAL position only long enough to test the sec- ondary steering. Return the switch to the AUTO Inspect the seat suspension for excessive looseness position immediately after testing. and wear. If excessive looseness or wear is detected, refer to Systems Operation, Testing and Adjusting, Disassembly and Assembly, RENR8391, “Caterpillar Comfort Series Seat with three point operator restraint”, “Troubleshooting Chart”. Lubricate Seat Suspension Adjust the seat fully rearward and apply a dry lubricant to the front of the seat slide mechanism. Adjust the seat fully forward and apply a dry lubricant to the rear of the seat slide mechanism. Move the seat rearward and forward several times in order to Illustration 232 g01273655 distribute the lubricant. 1. Stop the machine on a level surface. Place the transmission control in the PARK position and stop the engine. ----------------------- Page 72----------------------- SEBU7837-09 193 Maintenance Section Service Brakes - Inspect 2. Push the top half of brake release/secondary The replacement interval may vary and the steering switch (1) and hold the switch in order replacement interval is heavily dependent on the to manually activate the brake release and conditions of the haul cycle. These conditions include secondary steering pump. the following considerations: haul road condition, length of hauls, number of turns per cycle, load, and 3. Turn the steering wheel completely to the right. grade of the haul road. Then, turn the steering wheel completely to the left. Inspect the condition of the tapered steering bores in the steering assembly whenever the ball studs are 4. Release the switch in order to return the switch to replaced. Refer to Reuse and Salvage Guidelines, the AUTO position. SEBF9054, “Reusability of Tapered Steering Bores” or consult your Caterpillar dealer in order to The secondary steering response should be similar determine whether the tapered bore can be reused. to the primary steering response. If the secondary steering does not function properly, consult your Caterpillar dealer. i02545225 Steering Cylinder Bearings - i02545186 Lubricate Service Brakes - Inspect SMCS Code: 4303-086-BD SMCS Code: 4251-040 Note: If the machine is equipped with central Record the initial measurement of the service lubrication lines, refer to Operation and Maintenance brake disc thickness when the machine is new or Manual, “Central Lubrication System - Lubricate” for lubrication points. when the brakes are rebuilt. Compare subsequent measurements to the initial measurement in order to determine the amount of wear. Wipe off the fittings before any lubricant is applied. Inspect the front brakes for wear and inspect the brake system for leakage. Inspect the rear brakes for wear and inspect the rear brakes for system leakage. For more information on the proper procedures, refer to Systems Operation, Testing and Adjusting, RENR8272, “770 and 772 Hydraulic System”, “Service Brake Discs - Check”. Note: Refer to Guideline for Reusable Parts and Salvage Operations, SEBF8095, “Service Brakes for Off-Highway Trucks and Tractors” when you rebuild Illustration 233 g01273737 the brakes. Top view of steering cylinders i03646309 Lubricate fittings (1) on the steering cylinders. Steering Ball Stud - Replace i03206342 SMCS Code: 4305-510-SD Steering Linkage - Inspect For instructions on replacement of the ball studs, SMCS Code: 4305-040 refer to the Disassembly and Assembly, “Off-Highway Truck Machine Systems” manual for your machine or consult your Caterpillar dealer. Inspect the horizontal wear limits for the ball studs in the steering linkage. At the same time, inspect the outer bearing race. Also, inspect the grease fittings and the seals. 1. Stop the machine on a level surface and place the transmission control in the PARK position. ----------------------- Page 73----------------------- 194 SEBU7837-09 Maintenance Section Steering System Oil - Change i02608552 Steering System Oil - Change SMCS Code: 4300-044-OC Illustration 234 g01416360 Hot oil and hot components can cause personal (1) Link injury. Do not allow hot oil or hot components to (2) Steering arm contact the skin. (3) Center arm 2. Attach the magnetic base of a dial indicator to link (1). This will allow the horizontal movement of the ball stud to be measured. Personal injury or death can occur if personnel are trapped between the wheel and the frame. 3. To measure the horizontal wear of the ball studs and of the outer bearing races on the steering The steering system is hydraulically controlled cylinders, place the dial indicator against the side and wheels can crush personnel during move- of steering arm (2). ment. 4. Set the dial indicator to zero. Use caution when working between the wheels and the frame. If the wheels must be turned, en- 5. Steer the front wheels in both directions. Record sure that all personnel are clear of the machine the amount of horizontal play on the indicator dial. before any movement. This indicates the amount of wear in the ball studs and the outer bearing races. Operate the engine in order to warm the steering 6. To measure the horizontal wear of the ball studs system oil. Park the machine on a level surface and and of the outer bearing races on the other ball place the transmission control lever in the PARK studs and outer bearing races, place the dial position. Stop the engine. indicator against the side of center arm (3). 7. Set the dial indicator to zero. 8. Steer the front wheels in both directions. Record the amount of horizontal play on the indicator dial. Note: Repeat this procedure in order to measure all of the ball studs and outer bearing races. 9. The maximum amount of horizontal wear is 1.02 mm (0.040 inch). If any of the measurements exceed this limit, replace the worn ball studs and the outer bearing races. 10. Inspect all of the covers for the ball studs. Inspect all grease fittings and seals. Replace any worn components and any damaged components. Note: Properly lubricate the steering linkage in order to ensure the durability of components. The steering linkage must be free of contaminants in order to ensure the durability of components. ----------------------- Page 74----------------------- SEBU7837-09 195 Maintenance Section Steering System Oil - Change Illustration 236 g01306018 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to Illustration 235 g01306137 collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- nent containing fluids. 1. Push the button on the breaker relief valve (1). The breaker relief valve is located on top of the Refer to Special Publication, NENG2500, “Caterpillar steering hydraulic tank. Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar 2. Slowly, remove filler cap (2) on the steering products. hydraulic tank in order to relieve the pressure. Install the filler cap after the tank has been Dispose of all fluids according to local regulations and drained. This will prevent dirt from entering the mandates. system. 3. Remove cap plug (4) and drain the oil into a suitable container. 4. Clean the cap plug and install the cap plug. 5. Remove the filler cap and the retaining ring on the screen. 6. Remove the filler screen. Wash the cap and the screen in clean, nonflammable solvent. Allow the cap and the screen to dry. 7. Inspect the cap seal. Use a new seal if the used seal is damaged. ----------------------- Page 75----------------------- 196 SEBU7837-09 Maintenance Section Steering System Oil Level - Check 8. Install the screen and the retaining ring. Park the machine on a level surface and stop the engine. Make sure that the transmission control is in 9. Fill the steering hydraulic tank and install the the PARK position. filler cap. The oil level must be within the green range of sight gauge (3). Refer to Operation and Check the oil level in the steering hydraulic tank. Maintenance Manual, “Lubricant Viscosities”. The oil level must be within the green range of sight Refer to Operation and Maintenance Manual, gauge (1). If necessary, add oil. “Capacities (Refill)”. 10. Start the engine. Observe the oil level and inspect i02608884 the machine for leaks. Stop the machine and Steering System Oil Sample - make any necessary repairs. Obtain 11. Check the oil level in the steering hydraulic tank. When the engine is stopped and the oil is warm, SMCS Code: 4300-008-OC; 7542 the oil must be within the green range of the sight gauge. If necessary, add oil. i02545424 Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to Steering System Oil Level - contact the skin. Check SMCS Code: 4332-535-OC Illustration 238 g01316783 Sampling valve (1) for the steering oil is located Illustration 237 g01306208 above the left frame rail on the back of the left rear pedestal. ----------------------- Page 76----------------------- SEBU7837-09 197 Maintenance Section Steering Tie Rod and Pin Bearings - Lubricate Note: The sample should be taken when the engine i02545537 is operating at low idle. Suspension Cylinder - Check Refer to the following publications for additional information about obtaining an oil sample. SMCS Code: 7201-535 • Special Publication, PEHP6001, “How To Take A Make sure that the dump body is empty. Good Oil Sample” Stop the machine gradually on a level surface without • Operation and Maintenance Manual, “S·O·S using the brakes. Information” Place the transmission control lever in the PARK • Special Publication, SEBU6250, “Caterpillar position and stop the engine. Machine Fluids Recommendations”, “S·O·S Oil Analysis” Note: All of the suspension cylinders that are shipped from the factory receive a preliminary charge of nitrogen and a preliminary charge of oil. During field i02545438 assembly, the suspension cylinders must be charged Steering Tie Rod and Pin with nitrogen. Bearings - Lubricate Front Suspension Cylinder SMCS Code: 4300-086-BD; 4318-086; 7551-086-PN Note: If the machine is equipped with central lubrication lines, refer to Operation and Maintenance Personal injury or death can occur if personnel are Manual, “Central Lubrication System - Lubricate” for trapped between the wheel and the frame. lubrication points. The steering system is hydraulically controlled Wipe off the fittings before any lubricant is applied. and wheels can crush personnel during move- ment. Use caution when working between the wheels and the frame. If the wheels must be turned, en- sure that all personnel are clear of the machine before any movement. Illustration 239 g01273755 Top view of the steering linkage Lubricate fittings (1) on the center arm pivot pin bearing. Lubricate fittings (2) on the steering tie rods. Illustration 240 g01273811 Right front suspension cylinder (X) Distance of exposed chrome ----------------------- Page 77----------------------- 198 SEBU7837-09 Maintenance Section Tire Inflation - Check Measure the distance of the exposed chrome Note: If the present distance is not equal to the (X) on the suspension cylinders. Compare the previous distance, perform the charging procedure present distance to the previous distance. If you or the purge procedure so the two dimensions are do not have the previous dimensions, perform the equal. See Testing And Adjusting, “Suspension charging procedure. See Testing And Adjusting, Cylinder (Rear) - Purge and Charge” for the charging “Suspension Cylinder (Front) - Purge and Charge” procedure. for the charging procedure. Record the dimensions for future reference. i02416817 Note: If the present distance is not equal to the Tire Inflation - Check previous distance, perform the charging procedure or the purge procedure so the two dimensions are SMCS Code: 4203-535-PX; 4203-535-AI equal. See Testing And Adjusting, “Suspension Cylinder (Front) - Purge and Charge” for the charging Measure the tire pressure on each tire. Adjust the tire procedure. pressure, if necessary. Consult your tire supplier for the correct tire operating pressures and load ratings. Note: There is a relief valve on the forward side of the front suspension cylinder. This relief valve is See Operation and Maintenance Manual, “Tire located 180 degrees from the lubrication fitting. Do Inflation Information” for more tire information. not plug the grease passage of the relief valve. Rear Suspension Cylinder i02608088 Torque Converter and Transmission Oil - Change SMCS Code: 3030-044-OC; 3101-044-OC Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, test- ing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before open- ing any compartment or disassembling any compo- nent containing fluids. Illustration 241 g01273813 Refer to Special Publication, NENG2500, “Caterpillar Dealer Service Tool Catalog” for tools and supplies Right rear suspension cylinder suitable to collect and contain fluids on Caterpillar (Y) Distance between the pins products. Measure distance (Y) for the rear suspension Dispose of all fluids according to local regulations and cylinders. Compare the present distance to the mandates. distance from the previous time. If you do not have those dimensions, perform the charging procedure. See Testing And Adjusting, “Suspension Cylinder 1. Park the machine on a level surface and stop the (Rear) - Purge and Charge” for the charging engine. Make sure that the transmission control procedure. Record the dimensions for future is in the PARK position. reference. ----------------------- Page 78----------------------- SEBU7837-09 199 Maintenance Section Torque Converter and Transmission Oil - Change 3. Remove drain plug (3) from the transmission housing. The drain plug is located on the front right side of the transmission housing. Drain the oil into a suitable container. Clean the drain plug and install the drain plug. 4. Remove drain valve plug (4) from the torque converter sump. Install a 100 mm (4.0 inch) long NPT pipe nipple in order to open the internal drain valve. The outer diameter of the NPT pipe nipple should be 25 mm (1.0 inch). Drain the oil into a suitable container. Note: Hand tighten the NPT pipe nipple. Do not use tools. 5. Remove the pipe nipple. Clean the drain plug and install the drain plug. 6. Fill the transmission and torque converter system through filler tube (2). Refer to Operation And Maintenance Manual, “Lubricant Viscosities”. Refer to Operation And Maintenance Manual, “Capacities (Refill)”. Illustration 244 g01305717 Illustration 242 g01305588 7. Make sure that the oil level is within “COLD OIL - SAFE TO START” shaded range (Y) of the oil 2. Remove oil level gauge assembly (1) for the level gauge. transmission and torque converter system in order to prevent a vacuum in the torque converter sump. 8. Start the engine and run the engine for approximately 15 seconds. The oil level will decrease as oil fills the system. 9. Add more oil through the filler tube in order to raise the oil level within the “COLD OIL - SAFE TO START” shaded range of the oil level gauge. 10. Repeat Step 8 and Step 9 until the oil level stabilizes within the “COLD OIL - SAFE TO START” shaded range of the oil level gauge. 11. Start the engine and operate the engine at low idle. Check for leaks and make necessary repairs. 12. Observe the oil level again when the following conditions exist: • The oil is at operating temperature. • The transmission control is in the PARK position. Illustration 243 g01305675 • The engine is running at low idle. ----------------------- Page 79----------------------- 200 SEBU7837-09 Maintenance Section Torque Converter and Transmission Oil Level - Check 13. Maintain the oil level to “HOT LOW IDLE” shaded range (X) of the oil level gauge. If necessary, add oil. 14. Clean the oil level gauge assembly and install the oil level gauge assembly on the filler tube. NOTICE Illustration 246 g01305717 Failure to properly fill the torque converter sump after an oil change may cause damage to the power train system. Follow the procedure that is described above. Maintain the oil level within the “HOT LOW IDLE” shaded range (X) of oil level gauge (1) when the The transmission control lever MUST be left in PARK following conditions exist: until the system is full. • The transmission control is in the PARK position. • The engine is running at low idle. i02608428 Torque Converter and • The transmission and torque converter oil is at Transmission Oil Level - operating temperature. Check Maintain the oil level within the “COLD OIL - SAFE TO START” shaded range (Y) of oil level gauge (1) SMCS Code: 3030-535-FLV; 3101-535-FLV when the following conditions exist: • The engine is stopped. • The transmission control is in the PARK position. • The transmission and torque converter oil is cold. If necessary, add oil. The transmission and torque converter oil is added at filler tube (2). If the system has been drained, see Operation And Maintenance Manual, “Torque Converter and Transmission Oil - Change” for the proper procedure. i02605481 Torque Converter and Transmission Oil Sample - Obtain SMCS Code: 3080-008; 3101-008-OC; 7542-008-OC Personal injury or death can occur if personnel are trapped between the wheel and the frame. The steering system is hydraulically controlled and wheels can crush personnel during move- ment. Use caution when working between the wheels and the frame. If the wheels must be turned, en- sure that all personnel are clear of the machine Illustration 245 g01305588 before any movement. ----------------------- Page 80----------------------- SEBU7837-09 201 Maintenance Section Traction Control System (TCS) - Test i02546898 Traction Control System (TCS) Hot oil and hot components can cause personal - Test injury. Do not allow hot oil or hot components to contact the skin. (If Equipped) SMCS Code: 3288-081; 4801-081 Note: This procedure determines whether the Traction Control System (TCS) is functioning. This procedure also determines if the left rear brake and the right rear brake engage at the correct time. 1. Find an area that is clear and level. Also, the area must be large enough in order to safely drive the machine in a complete circle. Start the machine and move the transmission control lever to the FIRST 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 in a complete circle. Illustration 248 g01274780 Illustration 247 g01304285 3. During the turn, press TCS test switch (1) and hold the switch in the ON position. Sampling valve (1) for the transmission and torque converter oil is located on the right outside frame rail 4. The machine will gradually come to a stop. The between the right front tire and the hoist/brake tank. right brake will then disengage and the machine will accelerate. This sequence will repeat as the Refer to Special Publication, PEHP6001, “How To machine drives in a circle. Take A Good Oil Sample”. Also, refer to Operation and Maintenance Manual, “S·O·S Information” and 5. Release the test switch. Special Publication, SEBU6250, “S·O·S Oil Analysis” for additional information about obtaining an oil 6. Position the machine for a clockwise circle. Turn sample. the steering wheel all the way to the right. With the engine at low idle, drive the machine in a complete circle. 7. During the turn, press the TCS test switch and hold the switch in the ON position. ----------------------- Page 81----------------------- 202 SEBU7837-09 Maintenance Section Window Washer Bottle - Fill 8. The machine will gradually come to a stop. The i02545057 left brake will then disengage and the machine Window Wiper - will accelerate. This sequence will repeat as the machine drives in a circle. Inspect/Replace 9. Release the test switch. SMCS Code: 7305-040; 7305-510 10. For information on the TCS, refer to Specifications, Systems Operation, Testing and Adjusting, SENR2986, “Off-Highway Trucks/Tractors Automatic Electronic Traction Aid (AETA)/Traction Control System (TCS)” or consult your Caterpillar dealer. i02544846 Window Washer Bottle - Fill SMCS Code: 7306-544-KE NOTICE Illustration 250 g01273638 When operating in freezing temperatures, use Caterpillar nonfreezing window washer solvent or Inspect the windshield wiper blade. Replace the equivalent. System damage can result from freezing. windshield wiper blade if the windshield wiper blade is worn or damaged. Replace any windshield wiper blade that streaks the windshield. i02545928 Windows - Clean SMCS Code: 7310-070; 7340-070 Clean the windows or the windshield from a se- cure location. Clean the windows from the ground if there is not a safe location on the machine. If the windows can not be reached from the ground, use a squeegee with an extension handle. Failure to work from a secure location may result in injury or death from a slip or a fall. Illustration 249 g01273507 The window washer reservoir is located behind access door (1). Remove cap (2) in order to fill the reservoir with window washer solvent. ----------------------- Page 82----------------------- SEBU7837-09 203 Maintenance Section Windows - Clean Illustration 251 g01274053 Use commercially available window cleaning solutions to clean the windows. Clean the windows from the ground when a secure location on the machine is not available.