793D Mantenimiento

MAINTENANCE INTERVALS
Operation and Maintenance Manual Excerpt
2010 Caterpillar All Rights Reserved
SEBU7792-06 November 2010
Operation and Maintenance Manual

793D Off-Highway Truck
FDB1-Up (Machine)
SAFETY.CAT.COM
SEBU7792-06
131 Maintenance Section Maintenance Interval Schedule
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Maintenance Interval Schedule

SMCS Code: 1000; 7000 Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. The user is responsible for the performance of maintenance. All adjustments, the use of proper lubricants, uids, lters, and the replacement of components due to normal wear and aging are included. Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and/or accelerated wear of components. Use mileage, fuel consumption, service hours, or calendar time, WHICH EVER OCCURS FIRST, in order to determine the maintenance intervals. Products that operate in severe operating conditions may require more frequent maintenance. Refer to the maintenance procedure for any other exceptions that may change the maintenance intervals. Note: The aftertreatment system can be expected to function properly for the useful life of the engine (emissions durability period), as dened by regulation. All prescribed maintenance requirements must be followed. Note: Before each consecutive interval is performed, all maintenance from the previous interval must be performed. Note: If Cat HYDO Advanced hydraulic oils are used, the hydraulic oil change interval is extended to 3000 hours. SOS services may extend the oil change even longer. Consult your Cat dealer for details.
Fuel System - Prime ........................................... Fuel System Primary Filter (Water Separator) Drain ................................................................. Fuel System Priming Filter - Replace ................. High Intensity Discharge Lamp (HID) - Replace .. Hoist Screens - Clean ......................................... Hoist and Brake Tank Suction Screen Inspect/Clean/Replace ...................................... Magnetic Plug (Wheels) - Check ........................ Oil Filter - Inspect ................................................ Rear Axle Housing End Play - Adjust ................. Rim - Inspect ....................................................... Suction Screen (Torque Converter) - Clean ........ Traction Control System (TCS) - Test ................. Window Washer Reservoir - Fill .......................... Window Wiper - Inspect/Replace ........................ Windows - Clean .................................................
178 179 181 183 184 187 188 190 191 193 203 210 213 213 214
Every 10 Service Hours or Daily

Air Tank Moisture and Sediment - Drain ............. Backup Alarm - Test ............................................ Brakes, Indicators and Gauges - Test ................. Cooling System Coolant Level - Check .............. Differential and Final Drive Oil Level - Check ..... Engine Oil Level - Check .................................... Engine Oil Level - Log Additions ......................... Hoist and Brake Tank Oil Level - Check ............. Seat Belt - Inspect .............................................. Steering System Oil Level - Check ..................... Torque Converter Sump Oil Level - Check ......... 134 136 142 151 159 167 168 186 195 202 207
Initial 50 Service Hours

Brake Cooling Oil Filter - Replace ...................... 139 Oil Filter (Steering, Hydraulic Fan) - Replace ..... 189 Parking Brake Release Oil Filter - Replace ........ 190 Rear Axle Oil Filter - Replace ............................. 192 Steering System Oil Filter - Replace ................... 201 Transmission Oil Filter - Replace ......................... 211
Initial 250 Service Hours

Engine Valve Lash and Bridge - Adjust .............. 170
When Required
Air Conditioner Filter - Clean .............................. Air Tank - Inspect ................................................ Automatic Lubrication Reservoir - Fill ................. Battery - Recycle ................................................ Battery or Battery Cable - Inspect/Replace ........ Brake Oil Cooler Screen - Clean ........................ Brake Tank (Makeup) - Clean ............................. Cab Air Filter - Clean/Replace ............................ Circuit Breakers - Reset ...................................... Display and Camera - Clean ............................... Engine Air Filter Primary Element - Clean/ Replace ............................................................. Engine Air Filter Secondary Element - Replace .. Engine Air Precleaner - Clean ............................ Ether Starting Aid Cylinder - Replace ................. Frame and Body - Inspect .................................. Fuel System - Fill ................................................ 133 134 136 137 137 140 142 146 147 160 161 163 164 171 174 177
Every 250 Service Hours or Monthly

Braking System - Test ......................................... Front Wheel Oil Level - Check ............................ Magnetic Plug (Wheels) - Check ........................ Tire Ination - Check ........................................... 143 176 188 206
Initial 500 Hours (for New Systems, Relled Systems, and Converted Systems)
Cooling System Coolant Sample (Level 2) Obtain ............................................................... 152
Every 500 Service Hours

Cooling System Coolant Sample (Level 1) Obtain ............................................................... 151
132 Maintenance Section Maintenance Interval Schedule
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Differential and Final Drive Oil Sample - Obtain .. 160 Engine Oil Sample - Obtain ................................ 168 Front Wheel Oil Sample - Obtain ........................ 177 Hoist and Brake Tank Oil Sample - Obtain ......... 186 Steering System Oil Sample - Obtain ................. 202 Torque Converter and Transmission Oil Sample Obtain ............................................................... 210
Front Axle Breather - Replace ............................ Hoist and Brake Tank Oil - Change .................... Rear Axle Housing End Play - Adjust ................. Steering System Oil - Change ............................ Suction Screen (Rear Axle Lubrication) - Clean ..
175 185 191 200 203
Every Year
Cooling System Coolant Sample (Level 2) Obtain ............................................................... 152 Receiver Dryer (Refrigerant) - Replace .............. 193 Sound Suppression (Covers, Panels) Inspect/Replace ................................................ 198
Every 500 Service Hours or 3 Months

Air Conditioner Filter - Clean .............................. 133 Air Dryer - Check ................................................ 133 Air/Hydraulic Cylinder Breather - Clean .............. 135 Automatic Lubrication Reservoir - Fill ................. 136 Belts - Inspect/Adjust/Replace ............................ 137 Brake Cooling Oil Filter - Replace ...................... 139 Cab Air Filter - Clean/Replace ............................ 146 Cable (Truck Body Retaining) - Inspect .............. 146 Differential and Final Drive Oil - Inspect ............. 159 Drive Shaft Slip Joint - Lubricate ........................ 161 Engine Crankcase Breather - Clean ................... 165 Engine Oil Filter (Oil Renewal System) Change ............................................................. 166 Engine Oil and Filter - Change ........................... 168 Frame - Clean/Inspect ........................................ 172 Front Wheel Oil - Change ................................... 175 Front Wheel Oil - Inspect .................................... 176 Fuel System Primary Filter (Water Separator) Element - Replace ............................................ 179 Fuel System Primary Filter - Clean ..................... 180 Fuel System Secondary Filter - Replace ............ 182 Fuel Tank Water and Sediment - Drain ............... 183 Hoist and Brake Tank Breather - Replace .......... 185 Oil Filter (Steering, Hydraulic Fan) - Replace ..... 189 Parking Brake Release Oil Filter - Replace ........ 190 Rear Axle Oil Filter - Replace ............................. 192 Secondary Steering - Check ............................... 196 Steering System Oil Filter - Replace ................... 201 Suspension Cylinder - Check ............................. 205 Torque Converter Outlet Screen - Replace ......... 206 Torque Converter Sump Breather - Clean .......... 207 Transmission Magnetic Screen - Clean ............... 211 Transmission Oil Filter - Replace ......................... 211
Every 3000 Service Hours or 2 Years

Cooling System Pressure Cap - Clean/Replace .. 153 Cooling System Relief Valve - Clean .................. 154 Radiator Core - Clean ......................................... 191
Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture
Seat Belt - Replace ............................................. 195
Every 4000 Service Hours

Engine Valve Lash and Bridge - Adjust .............. 170

Cooling System Coolant Extender (ELC) - Add .. 150

Cooling System Water Temperature Regulator Replace ............................................................. 155 Engine Water Pump - Inspect ............................. 170 VIMS Module Battery - Replace ......................... 212
Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ........... 148 Steering Ball Stud - Replace ............................... 199
Every 1000 Service Hours or 6 Months

Air Dryer Desiccant - Replace ............................ Frame and Body Support Pads - Clean/Inspect .. Rollover Protective Structure (ROPS) - Inspect .. Seat Suspension - Inspect/Lubricate .................. Service Brakes - Inspect ..................................... Steering Ball Stud - Inspect ................................ Steering Linkage - Inspect .................................. Torque Converter and Transmission Oil Change ............................................................. 133 174 195 196 197 198 199 208
Every 15 000 Service Hours

Rim - Inspect ....................................................... 194
Every 1 393 000 L (368 000 US gal) of Fuel or 8000 Service Hours
Engine Components - Rebuild/Install Reman ..... 165
Every 2 786 000 L (736 000 US gal) of Fuel or 16 000 Service Hours
Engine Components - Clean/Inspect, Rebuild/Install Reman, Install New ........................................... 164
Every 2000 Service Hours or 1 Year

Breather (Fuel Tank) - Replace ........................... Differential Thrust Pin Clearance - Check .......... Differential and Final Drive Breather - Replace .. Differential and Final Drive Oil - Change ............ 145 157 157 157
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133 Maintenance Section Air Conditioner Filter - Clean
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Air Conditioner Filter - Clean

SMCS Code: 7320-070-FI If a reduction in air circulation is noticed, clean the lter element for the air conditioner. The lter element for the air conditioner is located in the compartment in the front of the cab. 1. Park the machine on a level surface and engage the parking brake. 2. Loosen the door retaining screws and open the door.
2. Drain the primary air tank and drain the secondary air tank. Refer to Operation and Maintenance Manual, Air Tank Moisture and Sediment - Drain for the proper procedure.
Illustration 146
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Air dryer (1) is located on the frame in front of the left front suspension cylinder. The tire and the wheel have been removed for ease of viewing.
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Illustration 145
3. Remove lter element (1). 4. Clean the element by gently tapping the element on a smooth surface. 5. Install the clean element. Close the door and tighten the retaining screws.
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3. If there is moisture in the air tanks, replace the desiccant cartridge or rebuild the desiccant cartridge. Consult your Caterpillar dealer for information about replacing the desiccant cartridge and for instructions for rebuilding the desiccant cartridge. Note: Small amounts of moisture may be in the system due to condensation in the system.
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Air Dryer - Check

SMCS Code: 4285-535
Air Dryer Desiccant - Replace

SMCS Code: 4285-510-DSS
The air lines to and from the air dryer must be at atmospheric pressure. If the air lines are not at atmospheric pressure, personal injury could result. Release the air pressure from the air system completely before performing maintenance. 1. Park the machine on a level surface and engage the parking brake.
Air lines to and from the air dryer must be at atmospheric pressure. Release the air pressure from the air system completely before performing maintenance.
134 Maintenance Section Air Tank - Inspect
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Primary Air Tank
Illustration 148
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Drain valve (1) for the primary air tank is located on the right hand side of the platform.
1. Open drain valve (1) for the air tank.

Illustration 147
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Air dryer (1) is located on the frame in front of the left front suspension cylinder. The tire and the wheel have been removed for ease of viewing.
2. Check for moisture and sediment in the air tanks. Drain the moisture and sediment from the air tank into a suitable container. 3. Close the drain valve for the air tank.
Replace the air dryer desiccant cartridge or rebuild the air dryer desiccant cartridge if water cannot be absorbed. Consult your Caterpillar dealer for service or for replacement parts.
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Secondary Air Tank
Air Tank - Inspect

SMCS Code: 4272-040; 5505-040; 7428-040 When laws in the machine's operating location require the inspection of air tanks, refer to Special Instruction, REHS2398, Air Tank Inspection for the Off-Highway Truck 769 - 797.
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Air Tank Moisture and Sediment - Drain

SMCS Code: 4272-543-MAS Park the machine on a level surface and engage the parking brake.
Illustration 149
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The drain valve for the secondary air tank is located on the right hand side of the cab exterior.
1. Open drain valve (2) for the air tank. 2. Check for moisture and sediment in the air tank. Drain the moisture and sediment from the air tank into a suitable container.
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135 Maintenance Section Air/Hydraulic Cylinder Breather - Clean
3. Close the drain valve for the air tank.
Primary Air Tank (If Equipped with the Sound Suppression Arrangement)
Illustration 150
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Illustration 151 (1) (2) (3) (4) Breather for the rear air/hydraulic cylinders Breather for the front air/hydraulic cylinders Rear air/hydraulic cylinders Front air/hydraulic cylinders
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1. Open drain valve (3) for the air tank. 2. Check for moisture and sediment in the air tank. Drain the moisture and sediment from the air tank into a suitable container. 3. Close the drain valve for the air tank.
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4. Remove breathers (1) and (2) for air/hydraulic cylinders (3) and (4). 5. Wash both breathers in clean nonammable solvent. Allow the breathers to dry. 6. Install the clean breathers. 7. Remove the truck body retaining cable and lower the body.
Air/Hydraulic Cylinder Breather - Clean

SMCS Code: 4258
When it is necessary to work under the machine with the body (bed) raised, attach the body (bed) retaining cable to the rear tow point. Install the rear tow point pin through the end of the retaining cable. Failure to properly secure the body (bed) may result in personal injury or death. 1. Park the machine on a level surface and engage the parking brake. 2. Raise the dump body to the fully raised position and install the truck body retaining cable to the rear tow point pin. For the proper procedure, refer to Operations and Maintenance Manual, Cable (Truck Body Retaining). 3. Stop the engine.
136 Maintenance Section Automatic Lubrication Reservoir - Fill
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Automatic Lubrication Reservoir - Fill

SMCS Code: 7540-544-TNK
The automatic lubrication reservoir provides lubrication for many components. There are ttings on the left side of the machine, ttings on the right side of the machine, and ttings on the rear differential housing. If any of the remote lines become damaged, install a tting in place of the remote line. Lubricate the item at the ttings until the remote line can be replaced. See Systems Operation, Testing and Adjusting, SENR4724, Automatic Lubrication System for additional details.
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Backup Alarm - Test

SMCS Code: 7406-081
Illustration 152
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1. Remove plug (1) for the vent port if the reservoir is not equipped with a permanent vent. Note: If the reservoir is not properly vented, pressure will cause the wiper seal on the follower assembly inside the reservoir to fail when the reservoir is lled. Grease on the top side of the follower assembly may prevent the autolube system from functioning properly. Also, grease on the top side of the follower assembly may cause damage to the autolube system. 2. Fill the autolube reservoir through ll port (2). Place a suitable container under the outlet for the vent port in order to collect any grease that is spilled. Fill the reservoir until grease appears at the outlet for the vent port. If the machine is equipped with a Fast Fill Service Center, the level indicator will illuminate when the reservoir is full. For more information on the Fast Fill Service Center, refer to Operation and Maintenance Manual, Fast Fill Service Center. Note: The bulk capacity of the grease reservoir is 27 kg (60 lb). 3. Install the plug in the vent port if the reservoir is not equipped with a permanent vent.
Illustration 153 Location of the backup alarm
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Park the machine on a level surface and engage the parking brake. Turn the engine start switch to the ON position in order to perform the test. Make sure that the area behind the machine is clear of personnel and clear of obstacles. Move the transmission direction and speed control lever to the REVERSE position. The backup alarm should sound immediately. The backup alarm should continue to sound until the transmission direction and speed control lever is moved to the NEUTRAL position or to the FORWARD position.
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137 Maintenance Section Battery - Recycle
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Battery - Recycle
SMCS Code: 1401-561 Always recycle a battery. Never discard a battery. Always return used batteries to one of the following locations:
A battery supplier An authorized battery collection facility Recycling facility

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Illustration 154
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Battery or Battery Cable Inspect/Replace

SMCS Code: 1401-040; 1401-510; 1402-040; 1402-510 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. Park the machine on a level surface and engage the parking brake. 2. Turn the engine start switch to the OFF position. Turn all of the switches to the OFF position. 3. Turn the battery disconnect switch to the OFF position. Remove the key. Refer to Operation and Maintenance Manual, Battery Disconnect Switch for more information. 4. Disconnect the negative end of the battery cable from the frame near the battery disconnect switch. Note: Do not allow the disconnected battery cable to contact the battery disconnect switch.
5. Disconnect the negative end of the battery cable from the battery. 6. Disconnect the positive end + of the battery cable from the battery. 7. Replace the battery or make all necessary repairs to the battery. 8. Connect the positive end + of the battery cable to the battery. 9. Connect the negative end of the battery cable to the battery. 10. Connect the negative end of the battery cable to the frame near the battery disconnect switch. 11. Install the key. Turn the battery disconnect switch to the ON position.
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Belts - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510
Inspection
Park the machine on a level surface and engage the parking brake. To maximize the engine performance, inspect the belt for wear and for cracking. Check the belt tension. Belt slippage will decrease the life of the belt. A correctly adjusted belt will deect 13 to 19 mm (0.50 to 0.75 inch). Refer to the Engine Specications, Belt Tension Chart.
138 Maintenance Section Belts - Inspect/Adjust/Replace
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Illustration 155
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Illustration 157
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The refrigerant compressor has a belt tensioner. If shoulder (2) of the belt tensioner is aligned with red zone (1) of the indicator, replace the belt.
2. Loosen mounting bolt (5) and adjusting nuts (3). 3. If necessary, remove belt guard (4). 4. If necessary, remove the belt and replace the belt. 5. Turn adjusting nuts (3) in order to increase or decrease the belt tension. 6. If the belt guard was removed, reinstall the belt guard. 7. Tighten the adjusting nuts. Tighten the mounting bolt. 8. Check the belt tension on a new belt after 30 minutes of operation. Note: The break-in period for the belt is considered to be 30 minutes.
Adjustment and Replacement

Alternator
1. Park the machine on a level surface. Engage the parking brake and stop the engine.
Refrigerant Compressor
Illustration 156
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Illustration 158
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139 Maintenance Section Brake Cooling Oil Filter - Replace
NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products.
Illustration 159 Belt tensioner for the refrigerant compressor belt
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Dispose of all uids according to local regulations and mandates.
1. Park the machine on a level surface. Engage the parking brake and stop the engine. 2. In order to release the tension on the belt, Insert a 12.7 mm (0.50 inch) ratchet into square hole (6) in the belt tensioner, and pry the belt tensioner in a counterclockwise direction. 3. If necessary, remove the belt and replace the belt. 4. Shoulder (2) of the belt tensioner should be aligned with green zone (7) of the indicator. 5. Check the belt tension on a new belt after 30 minutes of operation. Note: The break-in period for the belt is considered to be 30 minutes. Refer to Engine Supplement, Disassembly and Assembly, Belt Tightener - Remove and Install for more information on replacement of the belts.
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Illustration 160 Location of the brake cooling oil lters
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Brake Cooling Oil Filter Replace

SMCS Code: 1366-510-FI
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin.
Illustration 161
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2. Remove oil ller cap (1) and use a vacuum transducer and vacuum cap in order to create a vacuum to the hoist/brake tank. Attach an air supply hose to the vacuum transducer and apply 276 to 414 kPa (40 to 60 psi) of air.
140 Maintenance Section Brake Oil Cooler Screen - Clean
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Refer to Disassembly and Assembly, RENR8332, Oil Filter (Parking Brake Release) - Remove for the required tooling in order to create a vacuum in the 793D hoist/brake tank. Note: A vacuum must exist in the hoist/brake tank in order to prevent the oil from draining from the system when the brake cooling oil lters are removed.
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Brake Oil Cooler Screen Clean

SMCS Code: 4257-070; 4295-070
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids.
Illustration 162
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The brake cooling oil lters are located behind the fuel tank. The fuel tank has been removed for ease of viewing.
Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. After a failure in the brake circuit, clean the screens for the brake oil coolers. There are three screens that need to be cleaned. There is one screen for the front brake oil cooler and there are two screens for the rear brake oil cooler. 1. Park the machine on a level surface. Engage the parking brake and stop the engine.
3. Remove lter housings (2). 4. Remove the used lter elements and discard the used lter elements properly. 5. Wash the lter housings in clean nonammable solvent. 6. Inspect the seal in each housing base. If a seal is damaged, replace the seal with a new seal. 7. Install the new lter elements in the lter housings. 8. Install the lter housings. 9. Remove the vacuum transducer and the vacuum cap. Install the oil ller cap. 10. Start the engine and operate the engine at low idle. Make sure that the parking brake is engaged. Check for leaks and make any necessary repairs. 11. 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.
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141 Maintenance Section Brake Oil Cooler Screen - Clean
Illustration 163
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Illustration 165
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The rear brake oil cooler screens are located on the right side behind the rear brake oil cooler and in front of the hydraulic tank. (2) Rear brake oil coolers (3) Oil cooler for the steering/fan drive
The front brake oil cooler screen is located inside the left frame rail between the fuel tank and the torque converter. The tire and the rim for the front left side have been removed for ease of viewing.
2. Drain the oil from rear brake oil coolers (2) with drain (4).
7. Drain the oil from the front brake oil cooler screen with drain (6). 8. Remove cover (5) for the front oil cooler screen. 9. Remove the front oil cooler screen. Wash the oil cooler screen in a clean, nonammable solvent. 10. Install the front oil cooler screen. 11. Install the cover for the front brake oil cooler screen. 12. Start the engine and operate the engine at low idle. Make sure that the parking brake is engaged. Check for leaks and make any necessary repairs.
Illustration 164 Screen locations
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Back side view of the housing for the rear brake oil cooler screens.
13. 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.
3. Remove covers (1) for the rear brake oil cooler screens. One cover is located at the front of the screen housing and one cover is located at the rear of the screen housing. 4. Remove the rear oil cooler screens. Wash the oil cooler screens in a clean, nonammable solvent. 5. Install the rear oil cooler screens. 6. Install the covers for the rear brake oil cooler screens.
142 Maintenance Section Brake Tank (Makeup) - Clean
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Brake Tank (Makeup) - Clean

SMCS Code: 4291
Brakes, Indicators and Gauges - Test

SMCS Code: 4251-081; 4267-081; 4269-081; 7000-081; 7450-081; 7490-081
When it is necessary to work under the machine with the body (bed) raised, attach the body (bed) retaining cable to the rear tow point. Install the rear tow point pin through the end of the retaining cable. Failure to properly secure the body (bed) may result in personal injury or death.
Before you operate the machine, perform the following checks. 1. Inspect the brake indicator lights in the cab. Look for broken lenses on the gauges. Check for broken indicator lights, broken switches, and other broken components in the cab. 2. Make sure that the parking brake is engaged. Turn the engine start switch to the ON position and monitor the self test of the VIMS. See Operation and Maintenance Manual, Vital information System (VIMS) Self Test for further information. The indicator lights on the dash will illuminate for 3 seconds. Replace any inoperative indicator lights. Look for any inoperative gauges. 3. Start the engine. Check the brake system for the following: oil leaks, air leaks, and damaged brake lines. 4. Turn on all machine lights. Check for proper operation.
Illustration 166
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The brake makeup oil tank is located on the inside rail on the left side of the machine near the center tube.
5. Sound the horn. Listen for proper operation. 6. Test the parking brake. For the proper test procedure, refer to Operation and Maintenance Manual, Braking System - Test. 7. Test the service brakes. For the proper test procedure, refer to Operation and Maintenance Manual, Braking System - Test. 8. Engage the parking brake. Stop the engine. Make any necessary repairs before machine operation. Consult your Caterpillar dealer for more information.
1. Park the machine on a level surface and engage the parking brake. 2. Raise the truck body to the fully raised position and install the truck body retaining cable to the rear tow point pin. For the proper procedure, refer to Operations and Maintenance Manual, Cable (Truck Body Retaining). 3. Stop the engine. 4. Remove the top cover of brake makeup oil tank (1). 5. Clean the cover and the brake makeup oil tank in clean nonammable solvent. 6. Inspect the cover seal and replace the cover seal if the cover seal is damaged. 7. Install the cover. 8. Remove the truck body retaining cable and lower the body.
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143 Maintenance Section Braking System - Test
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Braking System - Test

SMCS Code: 4251-081; 4267-081
Personal injury can result if the machine moves while testing. If the machine begins to move during test, reduce the engine speed immediately and engage the parking brake.
Illustration 167 (1) Transmission Control Lever (2) Parking Brake Reset Valve (3) Parking Brake Switch
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If the machine moves when testing the brakes, contact your Caterpillar dealer. Have the dealer inspect and repair the brakes before returning the machine to operation. Failure to have the brakes inspected and repaired can cause injury or death. The following tests are used to determine if the parking brake, the secondary brake, and the service brake are functional. These tests are not intended to measure the maximum brake holding effort. The brake holding effort that is required to sustain a machine at a specic engine rpm varies depending on the machine. The variations are the differences in the engine setting, in the power train efciency, and in the brake holding ability, etc. Note: Service personnel should perform this test monthly. Document the results of each monthly test. Compare the engine rpm from the previous month to the current engine rpm. This will determine the system deterioration.
5. Depress parking brake reset valve (2). 6. Engage parking brake switch (3). 7. Move transmission control lever (1) to the FIRST SPEED FORWARD position. 8. Gradually increase the engine speed to 1300 rpm. The machine should not move. 9. Reduce the engine speed to low idle. Move the transmission control lever to the NEUTRAL position. Leave the parking brake engaged. Stop the engine. NOTICE If the machine moved while testing the brakes, contact your Caterpillar dealer. Have the dealer inspect and, if necessary, repair the parking brakes before returning the machine to operation.
Parking Brake Holding Ability Test

The air control valve for the parking brake activates all the wheel brakes. The parking brakes are applied by spring pressure and the parking brakes are released by oil pressure. 1. Fasten the seat belt before you test the brakes. 2. Check the area around the machine. Make sure that the machine is clear of personnel and clear of obstacles. 3. Test the brakes on a dry, level surface. 4. Start the engine and allow the air system to build up to the operating pressure.
Test for the Parking Brake Reset Valve

1. Fasten the seat belt before you test the brakes. 2. Check the area around the machine. Make sure that the machine is clear of personnel and clear of obstacles. 3. Test the brakes on a dry, level surface. 4. Purge the air from the air system at the air tanks. 5. Make sure that the parking brake reset valve is engaged. The valve will pop up to the engaged position.
144 Maintenance Section Braking System - Test
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6. Start the engine and allow the air system to build up to the operating pressure. 7. Disengage the parking brake. 8. Move the transmission control lever to the FIRST SPEED FORWARD position. 9. Gradually increase the engine speed to 1300 rpm. The machine should not move. 10. Reduce the engine speed to low idle. Move the transmission control lever to the NEUTRAL position. Engage the parking brake switch. Stop the engine. 11. In order to disengage the parking brake reset valve , push down the knob. NOTICE If the machine moved while testing the brakes, contact your Caterpillar dealer. Have the dealer inspect and, if necessary, repair the parking brakes before returning the machine to operation.
Illustration 168
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5. Apply secondary brake control (4). 6. Depress the parking brake reset valve. 7. Release the parking brake. 8. Move the transmission control lever to the FIRST SPEED FORWARD position. 9. Gradually increase the engine speed to 1300 rpm. The machine should not move. 10. Reduce the engine speed to low idle. Move the transmission control lever to the NEUTRAL position. Engage the parking brake. Stop the engine. NOTICE If the machine moved while testing the brakes, contact your Caterpillar dealer. Have the Caterpillar dealer inspect and, if necessary, repair the parking/secondary brakes before returning the machine to operation.
Secondary Brake Holding Ability Test

The secondary brake air control valve activates all the wheel brakes. The secondary brakes are applied by spring pressure and the secondary brakes are released by oil pressure. 1. Fasten the seat belt before you test the brakes. 2. Check the area around the machine. Make sure that the machine is clear of personnel and clear of obstacles. 3. Test the brakes on a dry, level surface. 4. Start the engine and allow the air system to build up to the operating pressure.
Service Brake Holding Ability Test

The service brake air control valve activates all the wheel brakes. The service brakes are applied by oil pressure and the service brakes are released by spring pressure. 1. Fasten the seat belt before you test the brakes. 2. Check the area around the machine. Make sure that the machine is clear of personnel and clear of obstacles. 3. Test the brakes on a dry, level surface. 4. Start the engine and allow the air system to build up to the operating pressure.
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145 Maintenance Section Breather (Fuel Tank) - Replace
1. Park the machine on a level surface and engage the parking brake. 2. Raise the truck body to the fully raised position and install the truck body retaining cable to the rear tow point pin. For the proper procedure for the installation and removal of the truck body retaining cable, refer to Operations and Maintenance Manual, Cable (Truck Body Retaining). 3. Stop the engine.
Illustration 169
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5. Apply service brake control (5). 6. Depress the parking brake reset valve. 7. Release the parking brake. 8. Move the transmission control lever to the FIRST SPEED FORWARD position. 9. Gradually increase the engine speed to 1300 rpm. The machine should not move. 10. Reduce the engine speed to low idle. Move the transmission control lever to the NEUTRAL position. Engage the parking brake. Stop the engine. NOTICE If the machine moved while testing the brakes, contact your Caterpillar dealer. Have the dealer inspect and, if necessary, repair the service brake before returning the machine to operation.
Illustration 170
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4. Remove fuel tank breather (1). 5. Properly discard the used breather. 6. Install a new breather. 7. Remove the truck body retaining cable and lower the body.
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Breather (Fuel Tank) - Replace

SMCS Code: 1273-510-BRE
146 Maintenance Section Cab Air Filter - Clean/Replace
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i01766189
i02385071
Cab Air Filter - Clean/Replace

SMCS Code: 7311-070-FI; 7311-510-FI; 7342-070; 7342-510
Cable (Truck Body Retaining) - Inspect

SMCS Code: 5154-040; 7258-040-KA
A raised body (bed) may fall unexpectedly if a damaged cable is used. Use of a damaged cable could result in personal injury or death. Inspect the cable for damage and do not use a cable that is damaged. Wear gloves when handling the cable. 1. Inspect the cable for any of the following conditions:
Illustration 171 Location of the lter element for the cab (1) Cover (2) Retaining screws
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Reduction in the diameter Broken wires Worn wires Corroded wires Loose strands or loose wires Loose cable ends or separation between the
cable and the cable end
The lter element for the cab is located inside the operator's compartment. 1. Loosen retaining screws (2). Remove cover (1) and the lter element. 2. Wash the lter element in a nonsudsing detergent. 3. Rinse the lter element in clean water. Allow the lter element to air dry. 4. Install the clean lter element and cover (1). Tighten retaining screws (2). Note: When rips or tears are noticed in the lter element, install a new lter element. When a reduction of air circulation is noticed in the cab after cleaning the lter element, install a new lter element.
Kinks Cuts Flat spots

2. Inspect the cable ends and the cable connection for the truck body for any of the following conditions:
Distortion such as bends or twists Wear Corrosion Cracks or gouges

If any of the above conditions exist, replace the truck body retaining cable and the cable connection for the truck body. Consult your Caterpillar dealer for proper replacement parts.
SEBU7792-06
147 Maintenance Section Circuit Breakers - Reset
i02342172
Circuit Breakers - Reset

SMCS Code: 1420
VIMS Main Module (1) 15 Amp
Gauges (2) 10 Amp
Backup Alarm (3) 10 Amp
Engine Starting Aid (4) 20 Amp
Steering Accumulator Pressure (5) 10 Amp Keyswitch (6) 10 Amp
Illustration 172
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Stop Lights and Dome light (7) 10 Amp
Brake Retraction Motor (8) 20 Amp
Air Conditioner (9) 15 Amp
Alternator (10) 105 Amp
VIMS Message Center (11) 10 Amp

Illustration 173
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Circuit Breaker/Reset Push in the button in order to reset the circuit breaker. If the electrical system is working properly, the button will remain depressed. If the button does not remain depressed, check the appropriate electrical circuit. Repair the electrical circuit, if necessary. Note: The circuit breakers for the low beam headlights, the high beam headlights, and the fog lights are automatic reset circuit breakers.
Window Washer and Wiper (12) 10 Amp Power Train Electronic Control Module (13) 10 Amp Air Dryer (14) 10 Amp
148 Maintenance Section Cooling System Coolant (ELC) - Change
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Heated Mirrors (15) 25 Amp
Power Window (16) 10 Amp
NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. NOTICE Do not change the coolant until you read and understand the material in the Cooling System Specications section. NOTICE Mixing Cat Extended Life Coolant (ELC) with other products reduces the effectiveness of the coolant and shortens coolant life. Use only Caterpillar products or commercial products that have passed the Caterpillar EC-1 specications for premixed or concentrate coolants. Use only Cat Extender with Cat ELC. Failure to follow these recommendations could result in damage to the cooling systems components. If ELC cooling system contamination occurs, refer to Operation and Maintenance, Extended Life Coolant (ELC) under the topic ELC Cooling System Contamination. This machine was factory lled with Cat Extended Life Coolant. Drain the coolant whenever the coolant is dirty or whenever foaming is observed. 1. Park the machine on a level surface. Engage the parking brake and stop the engine.
Access Lights (17) 15 Amp
Brake Electronic Control Module (18) 10 Amp Electronic Fuel Injection (19) 15 Amp
24 to 12 Volt Converter (20) 10 Amp
i03895691
Cooling System Coolant (ELC) - Change

SMCS Code: 1350-044-NL; 1395-044-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.
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149 Maintenance Section Cooling System Coolant (ELC) - Change
4. Close the 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. When the engine is stopped, ush the system with water until the draining water is clear. Drain the water into a suitable container. 7. Close the drain valves. 8. Add the coolant solution. Refer to Special Publication, SEBU6250, Cooling System Specications and Operation and Maintenance Manual, Capacities (Rell). Note: If you are using Caterpillar antifreeze, do not add the supplemental coolant additive at this time and/or change the element at this time. 9. After the cooling system has been lled, perform the following procedures during initial start-up: a. Start the engine without the ller cap. b. Run the engine at low idle for ten minutes. c. Then, increase the engine speed to a high idle until the thermostat is open and the coolant level is stabilized. d. Maintain the coolant at the proper level as the thermostat opens and air is purged from the system. Refer to Operation and Maintenance Manual, Cooling System Coolant Level Check. 10. Install ller caps (1) and (2).
Illustration 174 (1) Filler cap for the aftercooler cooling system (2) Filler cap for the jacket water cooling system
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2. Slowly loosen ller caps (1) and (2). This will relieve system pressure. Remove the ller caps.
Illustration 175
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3. Open drain valves (3) for the jacket water cooling system and the aftercooler cooling system. Drain the coolant into a suitable container. Note: When the drain valves are opened, the coolant will drain from both systems. Opening one drain valve will drain that system and the other system will remain partially full.
150 Maintenance Section Cooling System Coolant Extender (ELC) - Add
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Cooling System Coolant Extender (ELC) - Add

SMCS Code: 1352-538-NL
NOTICE Excessive additive (greater than the recommended 6% initial ll) together with concentrations of antifreeze greater than 60% cause deposits to form and can result in radiator tube blockage and overheating. NOTICE Mixing Cat Extended Life Coolant (ELC) with other products reduces the effectiveness of the coolant and shortens coolant life. Use only Caterpillar products or commercial products that have passed the Caterpillar EC-1 specications for premixed or concentrate coolants. Use only Cat Extender with Cat ELC. Failure to follow these recommendations could result in damage to the cooling systems components. If ELC cooling system contamination occurs, refer to Operation and Maintenance, Extended Life Coolant (ELC) under the topic ELC Cooling System Contamination. This machine was factory lled with Cat Extended Life Coolant. Refer to Special Publication, SEBU6250, Cooling System Specication for the cooling system requirements. Use 8T-5296 Test Kit in order to check the concentration. 1. Park the machine on a level surface. Engage the parking brake and stop the engine.
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 Adding coolant to an overheated engine could result in damage to the engine. Allow the engine to cool before adding coolant. 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) temperature. The engine cooling system is normally protected to a minimum of29C (20F) with Caterpillar Antifreeze, when shipped from the factory unless special requirements are dened. NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates.
Illustration 176 (1) Filler cap for the aftercooler cooling system (2) Filler cap for the jacket water cooling system (3) Level gauges
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151 Maintenance Section Cooling System Coolant Level - Check
2. Loosen ller caps (1) and (2) slowly in order to relieve pressure. Remove the ller caps. 3. Check level gauges (3). If necessary, drain enough coolant in order to allow the addition of the liquid coolant additive. Note: Make sure that the coolant is drained into a suitable container. 4. Refer to the table in Special Publication, SEBU6250, Extended Life Coolant (ELC). This table lists the correct amount of Caterpillar Extended Life Coolant (ELC) extender that should be added to the cooling system. 5. Clean the ller caps and inspect the ller caps. Install the ller caps. 6. Start the engine and check for leaks. Allow the coolant level to stabilize. 7. If necessary, add premixed coolant in order to bring the coolant in the green range on the coolant level gauge.
i02317855
Illustration 177 (1) Level gauge for the aftercooler cooling system (2) Level gauge for the jacket water cooling system
g01159008
If you must add coolant daily, check for leaks.
Cooling System Coolant Level - Check

SMCS Code: 1350-535-FLV
Park the machine on a level surface and engage the parking brake. Use level gauges (1) and (2) to check the coolant levels. The needle should be in the green range. If the needle is in the red range, allow the system to cool and add coolant.
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.
i03905010
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 incorrect interpretation that could lead to concerns by both dealers and customers. Note: Level 1 results may indicate a need for Level 2 Analysis.
152 Maintenance Section Cooling System Coolant Sample (Level 2) - Obtain
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Obtain the sample of the coolant as close as possible to the recommended sampling interval. In order to receive the full effect of SOS analysis, 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. Use the following guidelines for the proper sampling of the coolant:
Complete the information on the label for the

sampling bottle before you begin to take the samples. bags.
Keep the unused sampling bottles stored in plastic Obtain coolant samples directly from the coolant
Illustration 178 Right side view of the engine
g02146856
sample port. You should not obtain the samples from any other location. are ready to collect the sample.
Keep the lids on empty sampling bottles until you Place the sample in the mailing tube immediately
after you obtain the sample in order to avoid contamination of the sample.
Sampling valve (1) for the jacket water cooling system is located on the right side of the engine water pump.
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 Fluids Recommendations or consult your Caterpillar dealer.
i03905011
Cooling System Coolant Sample (Level 2) - Obtain

Illustration 179 Left side view of the engine
g02146857
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 incorrect interpretation that could lead to concerns by both dealers and customers.
Sampling valve (2) for the water cooled aftercooler system is located on the left side of the engine water pump.
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153 Maintenance Section Cooling System Pressure Cap - Clean/Replace
Refer to Operation and Maintenance Manual, Cooling System Coolant Sample (Level 1) - Obtain for guidelines on the proper sampling of the coolant. Submit the sample for Level 2 analysis. For additional information about coolant analysis, see Special Publication, SEBU6250, Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer.
i02347060
Cooling System Pressure Cap - Clean/Replace

SMCS Code: 1382-070; 1382-510
Illustration 180 Right side view of the engine
g02146856
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. 1. Park the machine on a level surface. Engage the parking brake and stop the engine.
Sampling valve (1) for the jacket water cooling system is located on the right side of the engine water pump.
Illustration 181 Left side view of the engine
g02146857
Sampling valve (2) for the water cooled aftercooler system is located on the left side of the engine water pump. Obtain the sample of the coolant as close as possible to the recommended sampling interval. Supplies for collecting samples can be obtained from your Caterpillar dealer.
154 Maintenance Section Cooling System Relief Valve - Clean
SEBU7792-06
i02347062
Cooling System Relief Valve Clean

SMCS Code: 1370-070
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. If the system overheats or if coolant is leaking, clean the relief valves or replace the relief valves. 1. Park the machine on a level surface. Engage the parking brake and stop the motor.
g01159005
2. Remove ller caps (1) and (2) slowly in order to relieve the pressure. 3. Inspect the ller caps for damage, for foreign material, and for deposits. 4. Clean the ller caps with a clean cloth or replace the ller caps, if necessary. 5. Install the ller caps.
Illustration 183 (1) Filler cap for the aftercooler cooling system (2) Filler cap for the jacket water cooling system (3) Cooling system relief valves
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SEBU7792-06
155 Maintenance Section Cooling System Water Temperature Regulator - Replace
2. Slowly remove ller caps (1) and (2). This will relieve the pressure. 3. Remove the bolts from the relief valve and remove the valve assembly.
i02347151
Cooling System Water Temperature Regulator Replace

SMCS Code: 1355-510; 1393-510
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.
Illustration 184 (4) (5) (6) (7) (8) Valve Valve seals Gasket Valve cover Mounting bolts
g00302286
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. Note: The thermostats should be replaced after the cooling system has been cleaned. Replace the thermostats while the cooling system is completely drained or 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 regularly scheduled basis could cause severe engine damage. Replace the four thermostats 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. Engage the parking brake and stop the engine.
4. Inspect valve (4),valve seals (5) and gasket (6). If necessary, replace the valves, the seals or the gaskets. 5. Inspect valve cover (7) and mounting bolts (8). 6. Assemble the relief valve. Install the relief valve. 7. Install the ller caps.
156 Maintenance Section Cooling System Water Temperature Regulator - Replace
SEBU7792-06
3. Disconnect the hose assemblies from thermostat housing assemblies (3). 4. Remove the thermostat housing assemblies. 5. Remove the gasket, the thermostat, and the seal from the thermostat housing assembly. NOTICE Former thermostats may be used, if they meet test specications 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 thermostat could result in either an overheating or an overcooling condition. NOTICE If the thermostat is installed incorrectly, it will cause the engine to overheat. 6. Install a new seal in the thermostat housing. Install a new thermostat and a new gasket. Repeat Steps 5 and 6 for the three remaining thermostats. 7. Install the thermostat housing assemblies on the engine cylinder head. Connect the hose assemblies to the thermostat housing assemblies. 8. Tighten the hose clamps.
g01159005
2. Remove ller caps (1) and (2) slowly in order to relieve the pressure.
Illustration 186
g01172817
Note: Make sure that the coolant level is below the thermostat housings.
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157 Maintenance Section Differential Thrust Pin Clearance - Check
i02320510
2. Remove differential and nal drive breather (1). 3. Install a new differential and nal drive breather.
i02454361
Differential Thrust Pin Clearance - Check

SMCS Code: 3258; 3260; 3284
Differential and Final Drive Oil - Change

SMCS Code: 3258; 4050 The oil change interval for the differential and nal drives can be monitored with a SOS (Scheduled Oil Sampling) program. For more information on SOS services, refer to Operation and Maintenance Manual, SOS Information. When a SOS program is used, the oil change interval is based on the following:
g01160191
The condition of the oil The SOS recommendation

When a SOS program is not used, the oil change interval is based on the following:
Illustration 187
See the Adjustment Procedure For the Pin. This adjustment procedure is located in the Power Train Testing and Adjusting, Differential and Bevel Gear Adjust for your machine.
i02320548
4000 service hours or 1 year if Caterpillar

FDAO/FD-1 oil is used. TDTO/TO-4 oil is used.
Differential and Final Drive Breather - Replace

SMCS Code: 3258; 4050
2000 service hours or 1 year if Caterpillar
Illustration 189
g01160272
1. Rotate the wheels so that nal drive drain plug (1) is in the lowest position on the rear wheel. 2. Park the machine on a level surface. Engage the parking brake and stop the engine.
Illustration 188
g01160212
158 Maintenance Section Differential and Final Drive Oil - Change
SEBU7792-06
NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. 3. Remove the nal drive drain plug. Drain the oil into a suitable container. 4. Clean the drain plug. Install the drain plug. 5. Repeat Step 1 through Step 4 for the other nal drive.
9. Before the differential and nal drives are lled, refer to Operation and Maintenance Manual, Lubricant Viscosities and Operation and Maintenance Manual, Capacities (Rell). NOTICE If the ambient temperature at engine start-up or during operation is below 10C (14F), perform the procedures in Operation and Maintenance Manual, Differential Warm-up and Break-in. Check the differential compartment and the nal drive compartment for the proper uid level. Failure to warm up the oil or improper lubrication levels prior to operation will cause damage to the machine. 10. Fill the differential compartment to the bottom of the opening for the sight gauge. 11. Clean the sight gauge and install the sight gauge. 12. Remove nal drive ller plugs (2). Fill each nal drive to the bottom of the ller plug opening. When the nal drive drain plug is in the lowest position, the nal drive ller plug will be at the correct oil level. Note: The nal drives may need to be repositioned in order to place the nal drive drain plug in the lowest position. Note: Allow oil to ll all of the compartments. Correct oil levels are critical in the differential and nal drives.
Illustration 190
g01160274
6. Remove differential drain plug (3) and allow the oil to drain into a suitable container. Note: Inspect the magnetic drain plug and the oil. Refer to Operation and Maintenance Manual, Differential and Final Drive Oil - Inspect for further information. 7. Clean the drain plug. Install the drain plug. 8. Remove sight gauge (4). Wipe the surface around the opening for the sight glass.
Illustration 191
g01160268
13. Maintain the proper oil level (5) for the differential to the bottom of sight gauge (4). 14. Operate the machine on level ground for a few minutes. Note: The differential and nal drive oil level needs to be checked and maintained at operating temperature. After the oil has been changed in the differential and nal drives, adjustment of the oil level may be necessary when the truck reaches operating temperature.
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159 Maintenance Section Differential and Final Drive Oil - Inspect
15. Stop the machine. Check the oil level. If necessary, adjust the oil level to the bottom of the sight gauge. Note: If it is necessary to add oil, use nal drive ller plug (2). make sure that the ller plug is positioned above the oil level in the nal drive in order to prevent any oil from draining out. Note: Overlling the differential and nal 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
The differential and nal drive oil level needs to be checked and maintained at operating temperature. If the oil level is checked cold, adjustment of the oil level may be necessary when the truck reaches operating temperature.
Differential and Final Drive Oil - Inspect

Illustration 192
g01195747
SMCS Code: 4208 Inspect the differential and nal drive oil for any of the following symptoms that may indicate a mechanical failure:
Location of the sight gauge for the differential and nal drives
1. Park the machine on a level surface and engage the parking brake.
A high amount of metal on the magnetic plug An increased level of nickel concentration in the
SOS sample SOS sample bearings
An increase in the size of the particle count in the Oil leaks in the area around the drive wheel
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 nal drive oil has any of the above symptoms, the rear wheel bearings may need to be inspected. Consult your Caterpillar dealer for more information.
i02394551
Illustration 193
g01160336
2. Use sight gauge (1) to check the oil level for the differential and nal drives. 3. Maintain the proper oil level (2) at the bottom of the sight gauge.
Differential and Final Drive Oil Level - Check

SMCS Code: 3258; 4050 Correct oil levels are critical in the differential and nal drives. Check the oil level after repairs and after maintenance. Check the oil level prior to operation.
160 Maintenance Section Differential and Final Drive Oil Sample - Obtain
SEBU7792-06
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 incorrect interpretation that could lead to concerns by both dealers and customers. Sampling valve (1) for the differential and nal drive oil is located on the base of the rear axle oil lter.
Illustration 194
g01192672
Refer to the following publications for information about obtaining an oil sample.
4. If necessary, add oil. Use ller plug (3) for the nal drive in order to add oil. When the drain plug is in the lowest position, the ller plug will be at the correct oil level. Make sure that the ller plug is positioned above the oil level in the nal drive in order to prevent any oil from draining out. Allow the oil to ll all of the compartments before rechecking the oil level. Note: Overlling the differential and nal 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.
i02320757
Operation and Maintenance Manual, SOS

Information Analysis
Special Publication, SEBU6250, SOS Oil Special Publication, PEHP6001, How To Take A
Good Oil Sample
Special Publication, PEDP8025, Fluid Analysis

Interpretaion Guide
i04148950
Differential and Final Drive Oil Sample - Obtain

SMCS Code: 3258-008; 4050-008; 4070-008; 7542
Display and Camera - Clean (If Equipped)

SMCS Code: 7347-070; 7348-070 The Work Area Vision System (WAVS) and the Cat Integrated Object Detection System both utilize multiple cameras and a display. In order to maintain sufcient vision, keep the camera lens and the display clean.
Illustration 196 WAVS display Illustration 195

g01160351
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SEBU7792-06
161 Maintenance Section Drive Shaft Slip Joint - Lubricate
i02321492
Drive Shaft Slip Joint Lubricate

SMCS Code: 3253-086-JT
Illustration 197 Cat Integrated Object Detection System display
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Use a soft, damp cloth in order to clean the display. The display has a soft plastic surface that can be easily damaged by an abrasive material. The display is not sealed. Do not immerse the display with liquid.
Illustration 199
g01160565
Park the machine on a level surface. Engage the parking brake and stop the engine. Apply lubricant to the grease tting on the drive shaft spline.
i02346978
Illustration 198
g01223051
The camera for WAVS and the Cat Integrated Object Detection System .
Engine Air Filter Primary Element - Clean/Replace

SMCS Code: 1051-070-PY; 1051-510-PY; 1054-070-PY; 1054-510-PY NOTICE Service the air cleaner only with the engine stopped. Engine damage could result. Service the air cleaner lter elements when the action light is activated. The action light is located on the dash panel. The action light will activate when there is an inlet air restriction, and the VIMS display will provide a message regarding the specic problem. Refer to Operation and Maintenance Manual, Vital Information Management System (VIMS) for further information. 1. Park the machine on a level surface. Engage the parking brake and stop the engine.
Use a damp cloth or water spray in order to clean the camera lens. The camera is a sealed unit. The camera is not affected by high-pressure spray. Note: The camera is equipped with an internal heater to help counteract the effects of condensation, snow, or ice. For more information on WAVS, refer to Operation and Maintenance Manual, Camera. For more information on Cat Integrated Object Detection System, refer to Operation and Maintenance Manual, Cat Integrated Object Detection System.
162 Maintenance Section Engine Air Filter Primary Element - Clean/Replace
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Cleaning Primary Air Filter Elements

NOTICE Caterpillar recommends certied air lter cleaning services available at participating Caterpillar dealers. The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufcient lter life. Observe the following guidelines if you attempt to clean the lter element: Do not tap or strike the lter element in order to remove dust. Do not wash the lter element. Use low pressure compressed air in order to remove the dust from the lter element. Air pressure must not exceed 207 kPa (30 psi). Direct the air ow up the pleats and down the pleats from the inside of the lter element. Take extreme care in order to avoid damage to the pleats. Do not use air lters with damaged pleats, gaskets, or seals. Dirt entering the engine will cause damage to engine components. The primary air lter element can be used up to six times if the element is properly cleaned and the element is properly inspected. When the primary air lter element is cleaned, check for rips or tears in the lter material. The primary air lter 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 lter elements by bumping or tapping. This could damage the seals. Do not use elements with damaged pleats, gaskets, or seals. Damaged elements will allow dirt to pass through. Engine damage could result. Visually inspect the primary air lter elements before cleaning. Inspect the air lter elements for damage to the seal, the gaskets, and the outer cover. Discard any damaged air lter elements. There are two common methods that are used to clean primary air lter elements:
Illustration 200
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2. Remove covers (1) for the air lter housings. 3. Remove primary lter elements (2) from the air lter housings. 4. Clean the inside of the air lter housings. 5. Clean the dust valves on the bottom for the air lter housings. 6. Install clean primary air lter elements. Install the covers for the air lter housings. Note: Refer to Cleaning Primary Air Filter Elements. If the alert indicator activates after starting the engine or the exhaust smoke is still black after installation of clean primary lter elements, install new primary lter elements. If the alert indicator remains activated, replace the secondary elements.
Pressurized air Vacuum cleaning
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163 Maintenance Section Engine Air Filter Secondary Element - Replace
Pressurized Air
Pressurized air can be used to clean primary air lter elements that have not been cleaned more than two times. Pressurized air will not remove deposits of carbon and oil. Use ltered, dry air with a maximum pressure of 207 kPa (30 psi).
Inspecting the Primary Air Filter Elements
Illustration 202
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Illustration 201
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Note: When the primary air lter elements are cleaned, always begin with the clean side (inside) in order to force dirt particles toward the dirty side (outside). Aim the hose so that the air ows inside the element along the length of the lter in order to help prevent damage to the paper pleats. Do not aim the stream of air directly at the primary air lter element. Dirt could be forced further into the pleats.
Inspect the clean, dry primary air lter element. Use a 60 watt blue light in a dark room or in a similar facility. Place the blue light in the primary air lter element. Rotate the primary air lter element. Inspect the primary air lter element for tears and/or holes. Inspect the primary air lter element for light that may show through the lter material. If it is necessary in order to conrm the result, compare the primary air lter element to a new primary air lter element that has the same part number. Do not use a primary air lter element that has any tears and/or holes in the lter material. Do not use a primary air lter element with damaged pleats, gaskets or seals. Discard damaged primary air lter elements.
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Vacuum Cleaning
Vacuum cleaning is another method for cleaning primary air lter elements which require daily cleaning because of a dry, dusty environment. Cleaning with pressurized air is recommended prior to vacuum cleaning. Vacuum cleaning will not remove deposits of carbon and oil.
Engine Air Filter Secondary Element - Replace

SMCS Code: 1054-510-SE NOTICE Always replace the secondary element. Do not attempt to reuse it by cleaning. Engine damage could result. Note: Replace the engine air lter secondary elements when you service the engine air lter primary elements for the third time. Replace the secondary elements if the exhaust smoke remains black and the clean primary elements have been installed. 1. Park the machine on a level surface. Engage the parking brake and stop the engine.
164 Maintenance Section Engine Air Precleaner - Clean
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2. Loosen clamp (1) on the precleaner and remove lower precleaner bowl (2) and dust valve (3). 3. Clean the lower precleaner bowl and the dust valve with air pressure. 4. Make sure that all of the tubes within the precleaner are free of dirt. Clean the tubes, if necessary. 5. Install the clean lower precleaner bowl, and the clean dust valve and tighten the clamp on the precleaner.
Illustration 203 (1) Secondary element
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NOTICE Do not operate the machine with the dust valves removed. Engine damage can occur.
2. Remove secondary elements (1) and properly discard the secondary elements.
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3. Cover the air inlet openings. Clean the inside of the air cleaner housings. 4. Uncover the air inlet openings. Install the new secondary elements. 5. Install the primary elements.
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Engine Components Clean/Inspect, Rebuild/Install Reman, Install New

SMCS Code: 1000-012-IC; 1000-022-MC; 1000-571-IC Caterpillar recommends this additional maintenance for the following engine components. Consult your Caterpillar dealer for further information. The quantity of burned fuel that is shown with the service hours assumes a load factor of 40 percent. If the load factor is higher than 40 percent, the number of service hours for the overhaul interval will be lower. If the load factor is lower than 40 percent, the number of service hours for the overhaul interval will be higher. The quantity of consumed fuel is a better indicator for the overhaul interval than service hours.
Engine Air Precleaner - Clean

SMCS Code: 1055-070
Install New Components

All Seals, Gaskets and O-rings Camshaft Bearings
Illustration 204
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Engine Mounts Engine Software Fuel Pressure Regulating Valve Fuel Priming Pump Gear Train Bushings, Bearings and Thrust Plates Main Bearings, Rod Bearings and Crankshaft
Thrust Plates
Note: Do not paint dust valves (3). Paint will cause the rubber to harden and the rubber may not seal properly. Perform the following procedure for each engine air precleaner. 1. Park the machine on a level surface. Engage the parking brake and stop the engine.
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165 Maintenance Section Engine Components - Rebuild/Install Reman
Piston Rings Wiring Harness
Rebuild Components and/or Install Remanufactured Components

Cylinder Heads Turbochargers Oil Coolers Oil Pump Scavenge Oil Pump Water Pump
The quantity of burned fuel that is shown with the service hours assumes a load factor of 40 percent. If the load factor is higher than 40 percent, the number of service hours for the mid-life service interval will be lower. If the load factor is lower than 40 percent, the number of service hours for the mid-life service interval will be higher. The quantity of consumed fuel is a better indicator for the mid-life service interval than service hours.
Air Compressor Air Starter Alternator Fuel Transfer Pump High Pressure Turbochargers (3516B High Altitude
Engine)
Clean Components and Inspect Components for Reusability

Aftercooler Core Camshaft Camshaft Lifters Connecting Rods Crankshaft Cylinder Block Cylinder Liners Damper Gear Train Piston Crowns and Piston Skirts Piston Pins Spacer Plates
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Turbochargers (3516B High Displacement Engine) Injectors Refrigerant Compressor Wastegate (3516B High Altitude Engine)
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Engine Crankcase Breather Clean

SMCS Code: 1317-070-ENG The engine in this machine is equipped with six engine crankcase breathers. Two of the breathers are on the valve covers on the right side and four of the breathers are on the valve covers on the left side.
Engine Components Rebuild/Install Reman

SMCS Code: 1000-022-MC Caterpillar recommends this additional maintenance for the following engine components. Consult your Caterpillar dealer for further information.
166 Maintenance Section Engine Oil Filter (Oil Renewal System) - Change
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Engine Oil Filter (Oil Renewal System) - Change (If Equipped)

SMCS Code: 1308-510; 1349
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 uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. The machine must be parked on a level surface and the parking brake must be engaged. The oil must be warm and the engine must be stopped.
Illustration 205
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1. Park the machine on a level surface and engage the parking brake. 2. Stop the engine. Loosen clamps (4). Remove hose (2) from breather assemblies (1) and from vent tube (3). 3. Remove the breather assemblies from the valve covers. 4. Wash the breather in clean nonammable solvent. 5. Install the breather assemblies on the valve covers. 6. Install the hose on the breather assemblies and on the vent tube. Tighten all clamps. 7. Repeat Step 2 through Step 6 in order to clean the remaining breathers on the engine.
Illustration 206 (1) Engine oil lters (2) Oil ller cap (3) Dipstick
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167 Maintenance Section Engine Oil Level - Check
1. Remove used engine oil lters (1) and discard the used engine oil lters . 2. Clean the oil lter base assemblies. Make sure that all of the former gaskets are removed. 3. Apply a thin lm of clean engine oil to each seal of each new engine oil lter . 4. Install the new engine oil lters by hand. Tighten each lter until the seal of each engine oil lter contacts the base. Note the position of the index marks on each lter in relation to a xed point on the lter base. Note: Caterpillar lters have rotation index marks that are spaced 90 degrees or 1/4 of a turn away from each other. When you tighten the lters, use the rotation index marks as a guide. 5. Tighten each lter according to the instructions that are printed on the lter. Use the index marks as a guide. Note: You may need to use a Caterpillar strap wrench, or another suitable tool, in order to turn the lters to the amount that is required for nal installation. Make sure that the installation tool does not damage the lters. 6. Start the engine and operate the engine at low idle for ve minutes. Inspect engine oil lters (1) for oil leaks. Make any necessary repairs. 7. Maintain the oil level between the ADD mark and the FULL mark. These marks are on the LOW IDLE side of dipstick (3). Stop the engine.
NOTICE Do not under ll or overll engine crankcase with oil. Either condition can cause engine damage.
Illustration 207 Location of the dipstick for the engine oil
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The tire and the wheel have been removed for ease of viewing.
Illustration 208
i02682174
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Engine Oil Level - Check

1. The machine must be on a level surface and the parking brake must be engaged. 2. Check the oil level in the engine. a. When the engine is running at low idle, maintain the oil level between the ADD mark and the FULL mark. These marks are on the LOW IDLE side of dipstick (2). b. When the engine is stopped, maintain the oil level between the ADD mark and the FULL mark. These marks are on the ENGINE STOPPED side of the dipstick. 3. If necessary, remove oil ller cap (1) and add oil. 4. Clean the ller cap and install the ller cap.
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 movement. Use caution when working between the wheels and the frame. If the wheels must be turned, ensure that all personnel are clear of the machine before any movement.
168 Maintenance Section Engine Oil Level - Log Additions
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Engine Oil Level - Log Additions (If Equipped with the Oil Renewal System)
SMCS Code: 1348; 1349
Engine Oil Sample - Obtain

SMCS Code: 1348-008; 7542
Illustration 210 Sampling Valve For The Engine Oil
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The sampling valve for the engine oil is located above the engine oil lters. Refer to the following publications for information about obtaining an oil sample.

Illustration 209
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The Oil Renewal System (ORS) meters engine oil that is blended into the fuel supply. This oil will be consumed by the engine during the process of combustion. Normal operation will continually lower the oil level in the crankcase. Continually adding new engine oil will allow the life of the oil to be extended. An SOS analysis will determine if the oil needs to be changed. The graph in Illustration 209 plots the quantity of added oil against the service hours during a 500 hour period. This data can be used to determine if the Oil Renewal System is working properly. Keeping a daily maintenance log of all of the additions of oil is necessary for the accuracy of this data. The daily maintenance log is also necessary for adjustment of the metering rate. The daily maintenance log will also indicate the total amount of oil that has been added since the last oil change. This information is needed at the time of each SOS analysis.
Good Oil Sample

Interpretation Guide
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Engine Oil and Filter - Change

SMCS Code: 1308-510; 1348-044 Note: If your machine is equipped with the Oil Renewal System (ORS), engine oil is blended into the fuel supply of the machine. This oil will be consumed in the engine during the process of combustion. Normal operation will continually lower the oil level in the crankcase. Continually adding new oil will allow the life of the oil to be extended. An SOS Oil Analysis will determine if the oil needs to be changed. In order to change the engine oil lters only, refer to Operation and Maintenance Manual, Engine Oil Filter (Oil Renewal System) Change. For more information on the Oil Renewal System, refer to Systems Operation, RENR2223, Oil Renewal System.
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169 Maintenance Section Engine Oil and Filter - Change
1. Open drain valve (1) and drain the oil into a suitable container. Close the drain valve . 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 uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. Note: Some commercial oils that meet API specications may require shorter oil change intervals. The oil change intervals are determined by close monitoring of the oil condition and engine wear metals. Caterpillar prefers the scheduled oil sampling as the proper method of checking engine wear metals. Consult your Caterpillar dealer for the latest oil recommendations. The machine must be parked on a level surface and the parking brake must be engaged. The oil must be warm and the engine must be stopped.
Illustration 212
g01162326
2. Remove the used engine oil lters (2) and discard the used engine oil lters. 3. Clean the oil lter base assemblies. Make sure that all of the former gaskets are removed. 4. Apply a thin lm of clean engine oil to the seal of each new engine oil lter. 5. Install the new engine oil lters by hand. Tighten each engine oil lter until the seal of each engine oil lter contacts the base of the oil lter housing. Note the position of the index marks on each lter in relation to a xed point on the lter base. Note: Caterpillar lters have rotation index marks that are spaced 90 degrees or 1/4 of a turn away from each other. When you tighten the lters, use the rotation index marks as a guide. 6. Tighten each lter according to the instructions that are printed on the lter. Use the index marks as a guide. Note: You may need to use a Caterpillar strap wrench, or another suitable tool, in order to turn the lters to the amount that is required for nal installation. Make sure that the installation tool does not damage the lters. 7. Remove oil ller cap (3). Fill the crankcase with oil. Refer to Operation and Maintenance Manual, Lubricant Viscosities for the type of oil. Refer to Operation and Maintenance Manual, Capacities (Rell) for the amount of oil.
Illustration 211
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170 Maintenance Section Engine Valve Lash and Bridge - Adjust
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8. Start the engine and operate the engine at low idle for ve minutes. Inspect the engine oil lter for oil leaks. Make any necessary repairs. 9. Maintain the oil level between the ADD mark and the FULL mark. These marks are on the LOW IDLE side of dipstick (4). Stop the engine.
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Table 12
VALVE CLEARANCE SETTING Inlet Exhaust 0.5 mm (0.02 inch) 1.00 mm (0.04 inch)
Engine Valve Lash and Bridge - Adjust

SMCS Code: 1102-025
To prevent personal injury, do not use the starter motor to turn the ywheel. Hot engine components can cause burns. Allow additional time for the engine to cool before measuring valve clearance.
Illustration 213
g00653920
To check the engine valve lash, refer to System Operation, Testing And Adjusting, SENR1123, 3500B Engines For Caterpillar Built Machines, Valve Lash and Valve Bridge Adjustment. Consult your Caterpillar dealer for any additional information.
i02326985
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
Valve Bridge
The engine in this machine is equipped with a nonadjustable valve bridge. Proceed with the valve lash adjustment.
Engine Water Pump - Inspect

SMCS Code: 1361-040
Valve Lash Adjustment

NOTICE Operation of Caterpillar Engines with improper engine valve lash adjustments will reduce the engine efciency. This reduced efciency could result in excessive fuel usage and/or shortened engine component life. Measure the engine valve lash with the engine stopped. To obtain an accurate measurement, allow at least 20 minutes for the valves to cool to engine cylinder head and block temperature. If the valve clearance is within 0.08 mm (0.0031 inch) of the given nominal clearance, no adjustment is required. If the clearance is not within the given limits, set the clearance to the amount that is specied in the chart.
Illustration 214
g01162405
(1) Water pump for the jacket water cooling system (2) Auxiliary water pump for the aftercooler cooling system
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171 Maintenance Section Ether Starting Aid Cylinder - Replace
Water Pump for the Jacket Water Cooling System

A water pump (1) that has failed might cause severe engine overheating problems. The engine overheating problems could result in the following problems.
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Ether Starting Aid Cylinder Replace

SMCS Code: 1456-510-CD
Cracks in the cylinder head Piston seizure Other potential engine damage
Visually inspect water pump (1) for leaks. If leaks are found, all the seals need to be replaced. Note: See Service Manual, Engine Disassembly and Assembly. Breathing ether vapors or repeated contact of ether with skin can cause personal injury. Personal injury may occur from failure to adhere to the following procedures. Use ether only in well ventilated areas. Do not smoke while changing ether cylinders. Use ether with care to avoid res. 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 unauthorized personnel. To avoid possible injury, be sure the brakes are applied and all controls are in Hold or Neutral when starting the engine.
Auxiliary Water Pump for the Aftercooler Cooling System

An auxiliary water pump (2) that has failed might cause severe engine overheating problems. The engine overheating problems could result in the following problems.
Valve failures Warped intake manifolds Other potential engine damage

Visually inspect auxiliary water pump (2) for leaks. If leaks are found, all the seals need to be replaced. Note: See Service Manual, Engine Disassembly and Assembly.
Illustration 215
g01163382
The two ether starting aid cylinders are mounted behind the radiator. 1. Park the machine on a level surface. Engage the parking brake and stop the engine. 2. Loosen the clamps and unscrew the ether starting aid cylinders.
172 Maintenance Section Frame - Clean/Inspect
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3. Remove the used gasket for each ether starting aid cylinder and install the new gasket that is provided for each ether starting aid cylinder. 4. Install the new ether starting aid cylinders. Tighten the clamps.
i02340776
4. Clean the frame with a high pressure washer. 5. Inspect the frame for damage and for cracks. If you nd cracks or damage, consult your Caterpillar dealer for specic repair procedures. Do not operate the machine until the necessary repairs have been made. Note: Refer to Special instruction, REHS0541, Procedure for the Inspection, Repair, and Component Replacement on the Frames of Off-Highway Truck/Tractor.
Frame - Clean/Inspect
SMCS Code: 7050-571 Note: The graphics that are shown are for illustrative purposes. This is an in-chassis inspection.
Rear Axle A-Frame and Differential Housing
When it is necessary to work under the machine with the body (bed) raised, attach the body (bed) retaining cable to the rear tow point. Install the rear tow point pin through the end of the retaining cable. Failure to properly secure the body (bed) may result in personal injury or death. 1. Raise the dump body to the fully raised position and install the truck body retaining cable to the rear tow point pin. For the proper procedure, refer to Operations and Maintenance Manual, Cable (Truck Body Retaining).
Illustration 216
g01167516
Illustration 217
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1. Park the machine on a level surface and engage the parking brake. 2. Raise the dump body to the fully raised position and install the truck body retaining cable to the rear tow point pin. For the proper procedure, refer to Operations and Maintenance Manual, Cable (Truck Body Retaining). 3. Stop the engine.
2. Clean the rear axle a-frame and the differential housing with a wire brush or with a scraper. Inspect the designated areas for cracks. If you nd cracks or damage, consult your Caterpillar dealer for specic repair procedures.
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173 Maintenance Section Frame - Clean/Inspect
Illustration 218
g00980907
Illustration 220
g00980956
a. Inspect the inside face of the rear axle a-frame in the area that is indicated by the shading. Inspect the welds of the rear axle a-frame.
c. Inspect the bottom of the differential housing in the area that is indicated by shading.
Illustration 219
g00980933
Illustration 221
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b. Inspect the area around the bolt holes of the rear axle a-frame.
d. Inspect the top rear sides of the differential housing in the area that is indicated by shading.
174 Maintenance Section Frame and Body - Inspect
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Illustration 222
g00981044
e. Inspect the differential housing in the area around the lower half of the differential mounting surface that is indicated by shading.
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Illustration 223
g01167539
Frame and Body - Inspect

SMCS Code: 7050-040; 7258-040
4. Clean the frame with a wire brush or a scraper. Inspect the dump body. If the frame is damaged or worn, consult your Caterpillar dealer for repair procedures. 5. Clean the dump body with a wire brush or a scraper. Inspect the dump body. If the dump body is damaged or worn, consult your Caterpillar dealer for repair procedures.
i02340837
When it is necessary to work under the machine with the body (bed) raised, attach the body (bed) retaining cable to the rear tow point. Install the rear tow point pin through the end of the retaining cable. Failure to properly secure the body (bed) may result in personal injury or death. 1. Park the machine on a level surface and engage the parking brake. 2. Raise the dump body to the fully raised position and install the truck body retaining cable to the rear tow point pin. For the proper procedure, refer to Operations and Maintenance Manual, Cable (Truck Body Retaining). 3. Stop the engine.
Frame and Body Support Pads - Clean/Inspect

SMCS Code: 7050-571; 7258-571-S4
When it is necessary to work under the machine with the body (bed) raised, attach the body (bed) retaining cable to the rear tow point. Install the rear tow point pin through the end of the retaining cable. Failure to properly secure the body (bed) may result in personal injury or death. 1. Park the machine on a level surface and engage the parking brake.
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175 Maintenance Section Front Axle Breather - Replace
2. Raise the dump body to the fully raised position and install the truck body retaining cable to the rear tow point pin. For the proper procedure, refer to Operations and Maintenance Manual, Cable (Truck Body Retaining). 3. Stop the engine.
Illustration 224
g01167566
Illustration 225
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4. Clean the body support pads with high pressure water or steam. 5. Visually inspect each of the body support pads. Look for damage or uneven wear of the body support pads. Look for gaps between the body support pads and the mating surfaces. If problems are found, consult your Caterpillar dealer for more information or for specic repair procedures.
i02457383
1. Park the machine on a level surface. Engage the parking brake and stop the engine. 2. Remove breather (1) from each front wheel. 3. Install a new breather on each front wheel.
i02330775
Front Wheel Oil - Change

SMCS Code: 4201-044-OC Note: The oil change interval for the front wheel bearing can be monitored with the SOS scheduled oil sampling program. The interval is based on the condition of the oil. If the SOS scheduled oil sampling program is not used, the oil change for the front wheel bearing should be performed at 500 service hours or 3 months.
Front Axle Breather - Replace

SMCS Code: 4251
Illustration 226
g01163440
176 Maintenance Section Front Wheel Oil - Inspect
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1. Position the front wheel so that drain plug (1) is facing downward. 2. Park the machine on a level surface. Engage the parking brake and stop the engine. NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. 3. Remove the drain plug. 4. Allow the oil to drain into a suitable container. 5. Clean the drain plug and install the drain plug. 6. Remove the ller plug (2). 7. Fill the oil compartment to the bottom of the opening for the ller plug. Refer to Operation and Maintenance Manual, Lubricant Viscosities. Refer to Operation and Maintenance Manual, Capacities (Rell). 8. Clean the ller plug and install the ller plug. Use the same procedure for the other front wheel bearing.
i02388737
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.
i03025216
Front Wheel Oil Level - Check

SMCS Code: 4201-535-FLV 1. Park the machine on a level surface. Stop the engine and engage the parking brake.
Illustration 227
g01180364
Note: In order to prevent dirt from entering the wheel bearing, use a clean cloth to wipe the area around the ller plug before you remove the ller plug. 2. Remove the ller plug. 3. Maintain the oil level to the bottom of the ller plug opening. 4. Clean the ller plug and install the ller plug.
Front Wheel Oil - Inspect

SMCS Code: 4201-040-OC Inspect the front wheel oil for any of the following symptoms that may indicate a failure of the wheel bearings:
A high amount of metal on the magnetic plug An increased level of nickel concentration in the
SOS sample SOS sample
An increase in the size of the particle count in the Oil leaks in the area around the front wheel spindle
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177 Maintenance Section Front Wheel Oil Sample - Obtain
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i03315684
Front Wheel Oil Sample Obtain

SMCS Code: 4201-008-OC; 7542
Fuel System - Fill (Fast Fill Fuel Adapter)

SMCS Code: 1250-544
Personal injury or death may result from failure to adhere to the following procedures. Fuel leaked or spilled onto hot surfaces or electrical components can cause a re. Clean up all leaked or spilled fuel. Do not smoke while working on the fuel system. Turn the disconnect switch OFF or disconnect the battery when changing fuel lters.
Illustration 228 Filler plug for the front wheel
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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 incorrect interpretation that could lead to concerns by both dealers and customers. The oil sample for the front wheel is obtained with a sampling gun through the ller plug. Refer to the following publications for information about obtaining an oil sample.
NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the machine. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Dispose of all uids according to local regulations and mandates. NOTICE Use only a Caterpillar approved fast ll system to fuel machines. Over pressurization may cause tank deformation and fuel spillage. Contact your Cat dealer for fast ll system availability. Refer to Operation and Maintenance Manual, Capacities (Rell) for the fuel tank capacity of your machine. 1. Park the machine on a level surface and engage the parking brake.
Operation and Maintenance Manual, SOS Information Special Publication, SEBU6250, SOS Oil Analysis Special Publication, PEHP6001, How To Take A
Good Oil Sample

Interpretaion Guide
178 Maintenance Section Fuel System - Prime
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Illustration 229
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Illustration 230
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2. Remove dust cover (1) and clean the fast ll fuel adapter. Note: The maximum fuel ow rate for the fast ll fuel adapter group is 375 L/min (100 US gpm). 3. Fill the fuel tank through the fast ll fuel adapter. 4. Observe fuel level sight gauge (2) in order to prevent overlling. 5. Clean the fast ll fuel adapter and the dust cover. Install the dust cover on the adapter.
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2. Pull out on switch (1) in order to release the switch. 3. Hold the switch upward in order to activate the electric fuel priming pump. The priming pump will ll the engine fuel lines and the fuel lters with fuel. Note: Button (2) is the circuit breaker reset for the electric fuel priming pump. Push in the button in order to reset the circuit breaker. If the electrical system is working properly, the button will remain depressed. If the button does not remain depressed, check the electrical circuit for the priming pump. Repair the electrical circuit, if necessary. 4. As the air is purged from the fuel system, fuel 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 under load. Do not operate the priming pump for more than two minutes. 5. Start the engine.
Fuel System - Prime

SMCS Code: 1250-548
Fuel leaked or spilled onto hot surfaces or electrical components can cause a re. Clean up fuel spills immediately. Note: The engine start switch must be in the OFF position in order to prime the fuel system. 1. Park the machine on a level surface. Engage the parking brake and stop the engine.
6. If the engine starts but the engine runs rough, continue to run the engine at low idle until the engine runs smoothly. 7. If the engine does not start after several attempts, refer to Special instruction, SEHS9586, 3500 Electronic Unit Injection (EUI) Fuel Priming Procedure or consult your Caterpillar dealer.
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179 Maintenance Section Fuel System Primary Filter (Water Separator) - Drain
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i02338293
Fuel System Primary Filter (Water Separator) - Drain (If Equipped)

SMCS Code: 1261-543; 1263-543 Park the machine on a level surface. Engage the parking brake and stop the engine.
Fuel System Primary Filter (Water Separator) Element Replace (If Equipped)
SMCS Code: 1260-510; 1263-510-FQ Replace the fuel/water separator elements when the engine has a loss of power or when the exhaust smoke is black.
Personal injury or death can result if spilled fuel ignites. Fuel leaked or spilled onto hot surfaces or electrical components can cause a re. To help prevent possible injury, turn the battery disconnect switch to the OFF position when changing fuel lters or water separator elements. Clean up fuel spills immediately. NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. NOTICE Do not ll fuel lters with fuel before installing them. The fuel will not be ltered 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 engage the parking brake.
Illustration 231
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The fuel/water separators are located on the right inside frame rail in front of the front axle.
NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. Open drain valves (1) on the bottom of the fuel/water separator elements in order to drain the water into an approved container. Close the drain valves when all of the water has been drained.
180 Maintenance Section Fuel System Primary Filter - Clean
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7. Install the new elements by hand until the seal contacts the mounting base. Note the position of the index marks on the elements in relation to a xed point on the mounting base. Note: There are rotation index marks on each lter that is spaced 90 degrees (1/4 turn) away from each other. When you tighten the elements, use the rotation index marks as a guide. 8. Tighten all lters according to the instructions that are printed on the lter. Note: You may need to use a strap type wrench or a suitable tool in order to turn the lters to the amount that is required for nal installation. Make sure that the installation tool does not damage the lters. 9. Install the drain tube assembly to the bottom of the new elements. 10. Open the fuel shutoff valve. 11. Prime the fuel system. For information on priming the fuel system, refer to the Operation and Maintenance Manual, Fuel System - Prime. 12. Start the engine and inspect the lter for leaks. Make any necessary repairs. If the engine has a loss of power or the exhaust smoke is still black, replace the secondary lters.
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Illustration 232 View of the back side of the fuel tank
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2. Stop the engine and close fuel shutoff valve (1).
Illustration 233
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Fuel System Primary Filter Clean (If Equipped)

SMCS Code: 1260-070; 1261-070 NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates.
The fuel/water separator is located on the right inside frame rail in front of the front axle.
3. Remove drain tube assembly (3) from the bottom of the drain valves for the fuel/water separator elements. 4. Remove the fuel/water separator elements (2) with a strap type wrench. Discard the used elements properly. 5. Clean the mounting base. Make sure that both of the old seals are removed. 6. Lubricate the seals of the new elements with clean diesel fuel.
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181 Maintenance Section Fuel System Priming Filter - Replace
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NOTICE Do not ll fuel lters with fuel before installing them. Contaminated fuel will cause accelerated wear to fuel system parts. Clean the primary element when the engine has a loss of power or when the exhaust smoke is black. 1. Park the machine on a level surface and engage the parking brake.
Fuel System Priming Filter Replace

SMCS Code: 1258-510-FI; 1261-510 The fuel priming lter is located on the right side of the engine directly below the electric fuel priming pump. Fuel only ows through the lter when you activate the priming pumps. Under normal circumstances, the original fuel priming lter should last for the entire service life of the machine. If the lter must be replaced, use the procedure that follows. 1. Park the machine on a level surface and engage the parking brake.
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2. Stop the engine and close fuel shutoff valve (1). 3. Loosen bolt (2). 4. Remove lter housing (3) and the lter element. 5. Wash the base and the element in clean, nonammable solvent. 6. If the lter base gasket is damaged, replace the lter base gasket. 7. Install the lter element and the lter housing. Tighten bolt (2) to a torque of 25 7 Nm (18 5 lb ft). 8. Open the fuel shutoff valve. Prime the fuel system. Refer to Operation and Maintenance Manual, Fuel System - Prime. 9. Start the engine and inspect the lter for leaks. Make any necessary repairs. If the engine has a loss of power or the exhaust smoke is still black, change the secondary lters.
Illustration 235
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2. Stop the engine and close fuel shutoff valve (1). NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide, for tools and supplies suitable to collect and contain uids. Dispose of all uids according to local regulations and mandates.
182 Maintenance Section Fuel System Secondary Filter - Replace
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Fuel System Secondary Filter Replace

SMCS Code: 1261-510-SE 1. Park the machine on a level surface. Engage the parking brake and stop the engine.
Illustration 236
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3. Remove fuel priming lter (2) with a strap type wrench. Discard the used lter properly. 4. Clean the lter mounting base. Make sure that the former seal is removed. 5. Lubricate the seal of the new lter with clean diesel fuel. 6. Install the new lter by hand. Tighten the lter until the sealing surface contacts the base. Tighten the lter for an additional 3/4 of a turn. 7. Install the new lter by hand until the seal contacts the mounting base. Note the position of the index marks on the lter in relation to a xed point on the mounting base. Note: There are rotation index marks on each lter that is spaced 90 degrees (1/4 turn) away from each other. When you tighten the lter, use the rotation index marks as a guide. 8. Tighten all lters according to the instructions that are printed on the lter. Note: You may need to use a strap type wrench or a suitable tool in order to turn the lter to the amount that is required for nal installation. Make sure that the installation tool does not damage the lter. 9. Open the fuel shutoff valve. 10. Prime the fuel system. Refer to Operation and Maintenance Manual, Fuel System - Prime.
Illustration 237
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2. Remove secondary fuel lters (1) with a strap type wrench. Discard the used lters properly. 3. Clean the lter mounting bases. Make sure that the old lter seals are removed. NOTICE Do not ll the secondary fuel lter with fuel before installing. The fuel would not be ltered and could be contaminated. Contaminated fuel will cause accelerated wear to fuel system parts. 4. Lubricate the seals of the new lters with clean diesel fuel. 5. Install the new lters by hand until the seal contacts the mounting base. Note the position of the index marks on the lters in relation to a xed point on the mounting base. Note: There are rotation index marks on each lter that is spaced 90 degrees (1/4 turn) away from each other. When you tighten the lters, use the rotation index marks as a guide. 6. Tighten all lters according to the instructions that are printed on the lter.
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183 Maintenance Section Fuel Tank Water and Sediment - Drain
Note: You may need to use a strap type wrench or a suitable tool in order to turn the lters to the amount that is required for nal installation. Make sure that the installation tool does not damage the lters. 7. Prime the fuel system. Refer to the Operation and Maintenance Manual, Fuel System - Prime. 8. Start the engine and operate the engine at low idle. Make sure that the parking brake is engaged. Check for leaks and make any necessary repairs.
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i02245859
High Intensity Discharge Lamp (HID) - Replace (If Equipped)

SMCS Code: 1434-510
Fuel Tank Water and Sediment - Drain

SMCS Code: 1273-543-MAS
HID lamps operate at very high voltages. To avoid electrical shock and personal injury, disconnect power before servicing HID lamps.
HID bulbs become very hot during operation. Before servicing, remove power from lamp for at least ve minutes to ensure lamp is cool. NOTICE Although HID bulb materials may change over time, HID bulbs produced at the time of the printing of this manual contain mercury. When disposing of this component, or any waste that contains mercury, please use caution and comply with any applicable laws. 1. Remove the electrical power from the high intensity discharge lamp (HID). The electrical power must be removed from the HID lamp for at least ve minutes, in order to ensure that the bulb is cool. 2. Disassemble the housing for the HID lamp in order to have access to the bulb. Note: On some HID lamps, the bulb is an integral part of the lens assembly. The bulb is not removed separately from the lens assembly. Replace the entire lens assembly on these HID lamps. 3. Remove the bulb from the HID lamp. 4. Install the replacement bulb in the HID lamp. If the bulb is an integral part of the lens assembly, install the replacement lens assembly in the HID lamp. Note: In order to avoid failure to the bulb that is premature, avoid touching the bulb's surface with your bare hands. Clean any ngerprints from the bulb with alcohol prior to operation. 5. Reassemble the housing for the HID lamp. Ensure that any printing on the lens is oriented correctly with respect to the HID lamp's mounting position on the machine.
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NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. Park the machine on a level surface. Engage the parking brake and stop the engine. Open fuel tank drain valve (1) and allow the moisture and the sediment to drain into a suitable container. Close the drain valve.
184 Maintenance Section Hoist Screens - Clean
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6. Reattach the electrical power to the HID lamp. 7. Check the HID lamp for proper operation. Note: Consult your Caterpillar dealer for additional information on HID lamps.
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Hoist Screens - Clean

SMCS Code: 5057-070-Z3
g01440260
Illustration 239
When it is necessary to work under the machine with the body (bed) raised, attach the body (bed) retaining cable to the rear tow point. Install the rear tow point pin through the end of the retaining cable. Failure to properly secure the body (bed) may result in personal injury or death. NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. Clean the screens whenever there is a failure of the brakes, hoist cylinders, or hoist pumps. 1. Park the machine on a level surface and engage the parking brake. 2. Raise the truck body to the fully raised position and install the truck body retaining cable to the rear tow point pin. For the proper procedure for the installation and removal of the truck body retaining cable, refer to Operations and Maintenance Manual, Cable (Truck Body Retaining). 3. Stop the engine.
The hoist screens are located on the right rear of the center tube.
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. 4. Remove the bolts that attach hoses (1) to housings (2) for the hoist screen. Drain the oil from the lines into a suitable container. 5. Remove the hoist screens from the housings. Clean the hoist screens in clean nonammable solvent. 6. Install the clean hoist screens and the hoses. Use new seals. Tighten the bolts. 7. Start the engine and operate the engine at low idle. Make sure that the parking brake is engaged. Check for leaks and make any necessary repairs. 8. Remove the truck body retaining cable and lower the body. 9. 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.
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185 Maintenance Section Hoist and Brake Tank Breather - Replace
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i02685600
Hoist and Brake Tank Breather - Replace

SMCS Code: 5056; 5057
Hoist and Brake Tank Oil Change

SMCS Code: 5056 NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. The machine must be level. The truck body must be in the DOWN position. The parking brake must be engaged and the engine must be stopped.
When it is necessary to work under the machine with the body (bed) raised, attach the body (bed) retaining cable to the rear tow point. Install the rear tow point pin through the end of the retaining cable. Failure to properly secure the body (bed) may result in personal injury or death. 1. Park the machine on a level surface and engage the parking brake. 2. Raise the truck body to the fully raised position and install the truck body retaining cable to the rear tow point pin. For the proper procedure for the installation and removal of the truck body retaining cable, refer to Operations and Maintenance Manual, Cable (Truck Body Retaining). 3. Stop the engine.
Illustration 241
g01172912
1. Remove ller cap (1) in order to prevent a vacuum in the tank. Install the ller cap after the tank has been drained. This will prevent dirt from entering the system. 2. Remove tank drain valve plug (3). Install a 88.0 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 mm (1 inch). Drain the oil into a suitable container. Note: Hand tighten the NPT pipe nipple. Do not use tools. 3. Remove the pipe nipple. Clean the drain plug and install the drain plug. 4. Remove the ller cap.
Illustration 240
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4. Remove breather (1) and discard the breather properly. 5. Install a new breather. 6. Remove the truck body retaining cable and lower the body.
186 Maintenance Section Hoist and Brake Tank Oil Level - Check
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5. Remove the retaining ring on the ller screen. Remove the screen. 6. Wash the cap and the ller screen in clean, nonammable solvent. Allow the cap and the ller screen to dry. 7. Inspect the cap seal. Use a new seal if the used seal is damaged. Install the ller screen and the retaining ring. 8. Fill the hoist/brake tank. Refer to Operation and Maintenance Manual, Lubricant Viscosities. Refer to Operation and Maintenance Manual, Capacities (Rell).
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Hoist and Brake Tank Oil Level - Check

SMCS Code: 5056 1. Park the machine on a level surface with the truck body in the DOWN position and engage the parking brake.
Illustration 243
g01172846
Illustration 242
g01349223
2. Maintain the oil level to the FULL mark on sight gauge (2). If necessary, remove ller cap (1) and add oil.
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9. Use engine shutdown control (4) to prevent the engine from starting. Crank the engine for approximately 15 seconds. The oil level will decrease as oil lls the system. 10. Add oil to the tank in order to raise the oil level to the FULL mark in upper sight gauge (2). 11. Repeat Step 9 and Step 10 until the oil stabilizes in the FULL mark in the upper sight gauge. 12. Lower the guard on the engine shutdown control. Start the engine and operate the engine at low idle. Check for leaks and make necessary repairs. 13. Raise the truck body until the hoist cylinders are extended halfway. Lower the truck body and add oil, if necessary. 14. Raise the truck body until the hoist cylinders are fully extended. Lower the truck body and add oil, if necessary. 15. Repeat Step 13 and Step 14 until the oil level stabilizes in the FULL mark in the upper sight gauge. 16. Install the ller cap.
Hoist and Brake Tank Oil Sample - Obtain

SMCS Code: 5056-008; 7542
Illustration 244 The fuel tank is removed for ease of viewing.
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187 Maintenance Section Hoist and Brake Tank Suction Screen - Inspect/Clean/Replace
Sampling valve (1) for the hoist and brake oil is located at the base of the brake cooling oil lters. Refer to the following publications for information about obtaining an oil sample.

Good Oil Sample

Interpretaion Guide
Illustration 245
g01165906
i02685621
Hoist and Brake Tank Suction Screen - Inspect/Clean/Replace

SMCS Code: 5056 NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. The machine must be level. The truck body must be in the DOWN position. The parking brake must be engaged and the engine must be stopped. There are three suction screens on the hoist/brake tank. Clean all of the screens whenever there is a failure of brakes, hoist cylinders or hoist pumps.
1. Remove tank drain plug (1). Install a 88.0 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 (1.00 inch). Drain the oil into a suitable container. Note: Hand tighten the NPT pipe nipple. Do not use tools. 2. Remove the bolts from cover (2) on the front of the hoist and brake tank. Remove the cover. 3. Clean the debris from the bottom of the tank.
Illustration 246 View of the back side of the hoist and brake tank
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4. Remove the anges and three hoses (3). 5. Remove the suction screens from the tank. 6. Wash the suction screens in clean, nonammable solvent. 7. Install the clean suction screens and install the hoses and anges. 8. Clean the cover for the front of hoist and brake tank in clean, nonammable solvent. Inspect the cover gasket. If the gasket is damaged, replace the gasket.
188 Maintenance Section Magnetic Plug (Wheels) - Check
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9. Install the cover to the front of the tank. 10. Fill the hoist/brake tank. Refer to Operation and Maintenance Manual, Lubricant Viscosities. Refer to Operation and Maintenance Manual, Capacities (Rell).
17. Repeat Step 15 and Step 16until the oil level stabilizes in the FULL mark in the upper sight gauge. 18. Clean the ller cap and install the ller cap.
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Magnetic Plug (Wheels) Check

SMCS Code: 0663 Note: A weekly inspection of the magnetic plugs is strongly recommended.
Illustration 247
g01349223
11. Use ground level shutdown switch (4) to prevent the engine from starting. Crank the engine for approximately 15 seconds. The oil level will decrease as oil lls the system.
Illustration 249 (1) Magnetic plug on the front wheel
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Illustration 248
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12. Add oil to the tank in order to raise the oil level to the FULL mark in upper sight gauge (5). 13. Repeat Step 11 and Step 12 until the oil stabilizes in the FULL mark in the upper sight gauge. 14. Lower the guard on the ground level shutdown control. Start the engine. Run the engine at low idle. Inspect the machine for oil leaks and make necessary repairs. 15. Raise the truck body until the hoist cylinders are extended halfway. Lower the truck body and add oil, if necessary. 16. Raise the truck body until the hoist cylinders are fully extended. Lower the truck body and add oil, if necessary.
Illustration 250 (2) Magnetic plug on the rear wheel
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All of the wheels have a magnetic plug. The magnetic plug (1) and (2) will attract metal from the oil. A bearing failure is indicated by an increased amount of metal on the magnetic plug. If excessive particles or abnormal particles are found, consult your Caterpillar dealer.
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189 Maintenance Section Oil Filter (Steering, Hydraulic Fan) - Replace
i02398678
Oil Filter (Steering, Hydraulic Fan) - Replace (Hydraulic Pump Case Drain)
SMCS Code: 5068-510-ZH; 5068-510-HFN
3. Slowly remove cap (2) on the steering hydraulic tank in order to relieve the pressure. 4. Remove case drain lter (3) for the hydraulic fan and remove case drain lter (4) for the steering system from the mounting bases with a strap type wrench. Discard the used lters properly. 5. Clean the mounting bases. Make sure that all of the old lter seals are removed.
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. 1. Park the machine on a level surface. Engage the parking brake and stop the engine.
6. Lubricate the seals of the new lters with clean oil. 7. Install the new lters by hand until the seal contacts the mounting base. Note the position of the index marks on the lters in relation to a xed point on the mounting base. Note: There are rotation index marks on each lter that is spaced 90 degrees (1/4 turn) away from each other. When you tighten the lters, use the rotation index marks as a guide. 8. Tighten all lters according to the instructions that are printed on the lter. Note: You may need to use a strap type wrench or a suitable tool in order to turn the lters to the amount that is required for nal installation. Make sure that the installation tool does not damage the lters. 9. Start the engine and operate the engine at low idle. Make sure that the parking brake is engaged. Check for leaks and make any necessary repairs. 10. Check the oil level. If necessary, add oil. Refer to Operation and Maintenance Manual, Steering System Oil Level - Check.
Illustration 251
g01163566
2. Push button (1) on the breaker relief valve.
190 Maintenance Section Oil Filter - Inspect
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i02320227
Oil Filter - Inspect

SMCS Code: 5068-040
Parking Brake Release Oil Filter - Replace

SMCS Code: 4257; 4295
Inspect a Used Filter for Debris
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 uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids.
Illustration 252 The element is shown with debris.
g00100013
Use a lter cutter to cut the lter element open. Spread apart the pleats and inspect the element for metal and for other debris. An excessive amount of debris in the lter element can indicate a possible failure. If metals are found in the lter element, a magnet can be used to differentiate between ferrous metals and nonferrous metals. Ferrous metals can indicate wear on steel parts and on cast iron parts. Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings, rod bearings, or turbocharger bearings. Small amounts of debris may be found in the lter element. This could be caused by friction and by normal wear. Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount of debris is found. Using an oil lter element that is not recommended by Caterpillar can result in severe engine damage to engine bearings, to the crankshaft, and to other parts. This can result in larger particles in unltered oil. The particles could enter the lubricating system and the particles could cause damage.
Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. 1. Park the machine on a level surface. Engage the parking brake and stop the engine.
Illustration 253
g01160070
2. Remove drain plug (2) from the bottom of lter housing (1). Drain the oil into a suitable container. Clean the drain plug and install the drain plug.
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191 Maintenance Section Radiator Core - Clean
Note: Removing the drain plug from the bottom of the lter housing may not drain all of the oil from the lter. 3. Remove lter housing (1) and the lter element. Discard the used lter element. 4. Wash the lter housing in clean, nonammable solvent. 5. Inspect the seal in the housing base. If the seal is damaged, replace the seal with a new seal. 6. Install the new element in the lter housing. 7. Install the lter housing. 8. Start the engine and operate the engine at low idle. Make sure that the parking brake is engaged. Check for leaks and make any necessary repairs. 9. 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.
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NOTICE High water pressure water and high water volume can damage the radiator. Use a water spray nozzle that will disperse the water. See Special Publication, SEBD0518, Know Your Cooling System for the complete procedure for cleaning the radiator core.
i02346912
Rear Axle Housing End Play Adjust

SMCS Code: 3282-025-EP The end play adjustment of the rear axle housing is recommended at the initial 2000 service hours. Yearly inspection and maintenance of the end play of the rear axle housing will maximize service life. Note: The end play adjustment of the rear axle housing is recommended at every 6 months in severe applications. To adjust the end play of the rear axle housing, refer to Testing and Adjusting, RENR8327, 793D Power Train Testing and Adjusting, Rear Axle Housing End Play - Adjust. Consult your Caterpillar dealer for any additional information.
Radiator Core - Clean

SMCS Code: 1353
Illustration 254
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You can use compressed air, high pressure water, or steam to remove dust and other debris from the air side of the radiator core. However, the use of compressed air is preferred.
192 Maintenance Section Rear Axle Oil Filter - Replace
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i02783212
Rear Axle Oil Filter - Replace

SMCS Code: 5068-510
1. Park the machine on a level surface. Engage the parking brake and stop the engine. 2. Remove the drain plug from lter housing (1). Drain the oil into a suitable container. Clean the drain plug and install the drain plug. Note: Removing the drain plug from the bottom of the lter housing may not drain all of the oil from the lter. 3. Remove the lter housing and the lter element. Discard the used lter element. 4. Wash the lter housing in clean nonammable solvent. 5. Inspect the seals in the lter base. If the seals are damaged, replace seals with new seals. 6. Install the new lter element in the lter housing. Install the lter housing. 7. Start the engine and operate the engine at low idle. Make sure that the parking brake is engaged. Check for leaks and make any necessary repairs.
Illustration 255
g01162468
Note: The lubrication pump for the rear axle will not operate with the oil temperature below 15 C (59 F). 8. Check the oil level in the rear axle. If necessary, add oil. For the proper procedure, refer to Operation and Maintenance Manual, Differential and Final Drive Oil - Check. Note: Correct oil levels are critical in the differential and nal drives. Check the oil level after repairs and after maintenance. Note: The differential and nal drive oil level needs to be checked and maintained at operating temperature. If the oil level is checked cold, adjustment of the oil level may be necessary when the truck reaches operating temperature.
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 uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. Note: The machine is shipped with a 6 micron lter element for the rear axle. Caterpillar recommends the use of a 6 micron element for the initial 50 service hours. If the 6 micron element becomes plugged before the initial 50 service hours, replace the 6 micron element with another 6 micron element. When the machine reaches 50 service hours, replace the 6 micron element with a 20 micron element. If the element continues to become plugged after 50 service hours, consult your Caterpillar dealer.
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193 Maintenance Section Receiver Dryer (Refrigerant) - Replace
i02656745
Receiver Dryer (Refrigerant) Replace

SMCS Code: 7322-510
Personal injury can result from contact with refrigerant. Contact with refrigerant can cause frost bite. Keep face and hands away to help prevent injury.
Illustration 256
g01159180
Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant. Always use precaution when a tting is removed. Slowly loosen the tting. If the system is still under pressure, release it slowly in a well ventilated area. Personal injury or death can result from inhaling refrigerant through a lit cigarette. Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a ame contacting air conditioner refrigerant gas, can cause bodily harm or death. Do not smoke when servicing air conditioners or wherever refrigerant gas may be present. Use a certied recovery and recycling cart to properly remove the refrigerant from the air conditioning system. 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 enter an open refrigerant system and cause corrosion which will lead to component failure.
The refrigerant dryer is located in the refrigerant lines underneath the cab.
Refer to Service Manual, SENR5664, Air Conditioning and Heating R-134a for All Caterpillar Machines for the proper procedure to change the receiver-dryer assembly and for the procedure to reclaim the refrigerant gas.
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Rim - Inspect
SMCS Code: 4209-040 Inspect the rim whenever a tire is dismounted.
194 Maintenance Section Rim - Inspect
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Rim - Inspect
SMCS Code: 4209-040 If regulatory agencies require a rim inspection, this documentation can be used as a guideline. The tires must be dismounted from the rim in order to perform a magnetic particle inspection. Consult your tire dealer for dismounting the tires from the rims.
Illustration 257 Typical example Cutaway view of the rim assembly
g01330970
Inspect the following components of the rim assembly: Bead Seat Band (1) Inspect the bead seat band for the following: wear, corrosion, and cracks. Lock Ring (2) Inspect the lock ring for the following: wear, corrosion, cracks, at spots, and warping. When the lock ring is not assembled, the two ends of the lock ring must overlap each other. Rim Base (3) Inspect the rim base for the following: wear, corrosion, cracks, and fretting. Flanges (4) Inspect the anges for the following: wear, corrosion, cracks, and fretting. Do not reuse rim components that are cracked, worn, damaged, or pitted from corrosion. For more information on the reusability of the rim components, consult your Caterpillar dealer.
Illustration 258 Typical example Cutaway view of the rim assembly
g01331173
Perform a magnetic particle inspection of the following high stress areas of the rim:
(1) Areas of contact with anges (2) Contact areas with the lock ring and the groove
for the lock ring
(3) Welds on the rim disc (4) Welds around the circumference of the rim base (5) Butt welds
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195 Maintenance Section Rollover Protective Structure (ROPS) - Inspect
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. Do not reuse rim components that are cracked, worn, damaged, or pitted from corrosion. For more information on the reusability of the rim components, consult your Caterpillar dealer.
i02381197
Rollover Protective Structure (ROPS) - Inspect

SMCS Code: 7325-040 Inspect the Rollover Protective Structure (ROPS) for bolts that are loose or damaged. Replace any damaged bolts and any missing bolts with original replacement parts only. Tighten the bolts to a torque of 1904 68 Nm (1400 50 lb ft). Note: Apply oil to all bolt threads for the ROPS before you install the bolts. Improper bolt torque can result if you do not apply oil to the threads. Do not weld reinforcement plates to the ROPS in order to straighten the ROPS. Do not weld reinforcement plates to the ROPS in order to repair the ROPS. Inspect the ROPS for any cracks in the welds, cracks in the castings, or cracks in any metal section. Refer to Special Instruction, SEHS6929, Inspection, Maintenance, and Repair of ROPS and Attachment Installation Guidelines or consult your Caterpillar dealer for more information.
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Illustration 259 Typical example
g00932801
Check the seat belt mounting hardware (1) for wear or for damage. Replace any mounting hardware that is worn or damaged. Make sure that the mounting bolts are tight. Check buckle (2) for wear or for damage. If the buckle is worn or damaged, replace the seat belt. Inspect the seat belt (3) for webbing that is worn or frayed. Replace the seat belt if the seat belt is worn or frayed. Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware. Note: Within three years of the date of installation or within ve years of the date of manufacture, replace the seat belt. Replace the seat belt at the date which occurs rst. 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. If your machine is equipped with a seat belt extension, also perform this inspection procedure for the seat belt extension.
i02429594
Seat Belt - Inspect

SMCS Code: 7327-040 Always check the condition of the seat belt and the condition of the seat belt mounting hardware before you operate the machine. Replace any parts that are damaged or worn before you operate the machine.
Seat Belt - Replace

SMCS Code: 7327-510 Within three years of the date of installation or within ve years of the date of manufacture, replace the seat belt . Replace the seat belt at the date which occurs rst. 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.
196 Maintenance Section Seat Suspension - Inspect/Lubricate
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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.
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Secondary Steering - Check

SMCS Code: 4300-535-SST
Illustration 260 (1) Date (2) Date (3) Date (4) Date of installation (retractor) of installation (buckle) of manufacture (tag) (fully extended web) of manufacture (underside) (buckle)
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Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware. If your machine is equipped with a seat belt extension, also perform this replacement procedure for the seat belt extension.
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Gas under pressure. Rapid discharge from disconnecting or disassembly could cause personal injury or death. See service manual before relieving pressure or charging.
Personal injury or death can occur if steering is lost completely during operation. Do not continue to operate the machine using the secondary steering. If the secondary steering activates during operation, the machine must be safely shut down immediately. Inspect the machine and correct the condition which made the use of the secondary steering necessary.
Seat Suspension Inspect/Lubricate

SMCS Code: 7324-040; 7324-086
Inspect
Seat Suspension
Inspect the seat suspension for excessive looseness 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. 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 movement. Use caution when working between the wheels and the frame. If the wheels must be turned, ensure that all personnel are clear of the machine before any movement. This machine is equipped with a secondary steering system. The steering system accumulators provide a limited amount of stored hydraulic pressure for steering if the power source for the normal steering system fails or the engine stops. The secondary steering system will only provide steering until the stored hydraulic pressure is exhausted. Refer to Operation and Maintenance Manual , Operator Controls for more information on the secondary steering system.
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 distribute the lubricant.
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197 Maintenance Section Service Brakes - Inspect
4. Turn the front wheels to the straight ahead position. 5. Chock the rear wheels and release the parking brake.
Illustration 261
g01163448
There are two steering accumulators on the machine. Steering accumulators (1) is located on the outside right frame rail near the front of the machine.
Illustration 263
g01349223
The engine shutdown switch is located on the front bumper.
6. Stop the engine with ground level shutdown switch (4). This permits the accumulators to stay charged in order to provide stored energy for the secondary steering system when the engine is stopped. 7. Visually conrm the following: a. Verify that the front wheels turn left as the steering wheel is turned left. b. Verify that the front wheels turn right as the steering wheel is turned right. If the secondary steering system is unable to comply with any portion of this eld test, consult your Caterpillar dealer.
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Illustration 262
g01163447
Perform the following eld test in order to verify that the secondary steering system is functional: 1. Empty the truck body and park the machine on a level surface. Place the transmission control in the NEUTRAL position and engage the parking brake. 2. When the engine is stopped with the engine start switch, check the steering hydraulic oil level. Maintain the oil to the full mark in upper sight gauge (2). 3. After engine start-up, check the oil level. a. If the oil level registers at the full mark in lower sight gauge (3), the accumulators are properly charged. b. If the oil level registers below the full mark in the lower sight gauge, check accumulator charge before proceeding to the next step. Refer to System Operation, Testing and Adjusting, RENR8336, 793D Off-Highway Truck Steering System or consult your Caterpillar dealer.
Service Brakes - Inspect

SMCS Code: 4251-040 Record the initial measurement of the service brake disc thickness when the machine is new or when the brakes are rebuilt. Compare subsequent measurements to the initial measurement in order to determine the amount of wear. 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.
198 Maintenance Section Sound Suppression (Covers, Panels) - Inspect/Replace
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For more information on the proper procedures, refer to Systems Operation, Testing and Adjusting, RENR8330, 793D Air System and Brakes, 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 the brakes.
i02602002
Cracks Loose covers Missing pieces

If any of these conditions exist, perform the necessary repairs and/or replace any damaged sound suppression covers.
Louvers
Inspect the louver assembly. The louver assembly is on the front of the radiator. Inspect the louvers for the following damage:
Sound Suppression (Covers, Panels) - Inspect/Replace (If Equipped with the Sound Suppression Arrangement)
SMCS Code: 1801-040; 1801-510; 7076-040; 7076-510; 7261-040; 7261-510
Bent steel mesh or broken steel mesh Burnt insulation material Compressed insulation material Insulation material with uid saturation Loose insulation material Missing pieces of insulation material Tears in the insulation material
If any of these conditions exist, perform the necessary repairs and/or replace any damaged louvers.
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Sound Panels
Inspect the sound suppression panels. The sound suppression panels are bolted on the front portion of the machine in order to enclose the engine compartment. Inspect the panels for the following damage:
Broken fasteners or missing fasteners Burnt insulation material Compressed insulation material Insulation material with uid saturation Loose insulation material Missing pieces of insulation material Tears in the insulation material Bent steel panels or broken steel panels
If any of these conditions exist, perform the necessary repairs and/or replace any damaged sound suppression liners.
Steering Ball Stud - Inspect

SMCS Code: 4305-040-SD The inspection procedure for the ball studs uses a straight beam examination. The inspection procedure does not require the ball studs to be removed from the machine. The inspection procedure is used to identify any damage that has developed during the operation of the machine. The ball studs can develop cracks that may cause the ball stud to fail, and lead to the loss of steering. The inspection procedure references ASTM E114-95 and ASTM E1901-97. Refer to Special Instruction, REHS4420, Steering Ball Stud Inspection for Off- Highway Trucks in order to perform the proper inspection procedure for the ball studs.
Sound Covers
Inspect the sound suppression covers. The sound suppression covers are fastened to the following components: engine, torque converter, nal drives, and differential. Inspect the covers for the following damage:
Broken fasteners or missing fasteners Broken pieces
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199 Maintenance Section Steering Ball Stud - Replace
i02387439
Steering Ball Stud - Replace

SMCS Code: 4305-510-SD The recommended replacement interval for the steering cylinder and steering linkage ball studs is between 12000 operating hours and 15000 operating hours or at the planned component rebuild of the steering cylinder. For the replacement procedure, refer to the Disassembly and Assembly, Off-Highway Truck Machine Systems manual for your machine or consult your Caterpillar dealer. The replacement interval may vary and the replacement interval is heavily dependent on the haul cycle conditions. These conditions include the following considerations: haul road condition, length of hauls, number of turns per cycle, load, and grade of the haul road. Inspect the condition of the tapered steering bore whenever a ball stud is replaced. Refer to Reuse and Salvage Guidelines, SEBF8271, Salvage of Steering Arm and Steering Arm (T-Bar) Tapers on 785, 789, 793, and 797 Off-Highway Trucks or consult your Caterpillar dealer in order to determine whether the tapered bore can be reused or machined to an oversized dimension. If the tapered bore is out of the specication and the tapered bore is able to be salvaged, then an oversize ball stud may be used. If the taper is too far out of the specication, then an oversize ball stud cannot be used. In this case, either the steering arm or the steering box must be scrapped and replaced.
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Illustration 264 Typical example (1) Steering arm (2) Steering link assembly (3) Center arm
g01442892
2. Attach the magnetic base of a 8T-5096 Dial Indicator Group to steering link (2). This will allow the horizontal movement of the ball stud to be measured. 3. To measure the horizontal wear of the ball studs and of the outer bearing races on the steering cylinders, place the dial indicator against the side of steering arm (1). 4. Set the dial indicator to zero. 5. Steer the front wheels in both directions. Record the amount of horizontal play on the indicator dial. This indicates the amount of wear in the ball studs and the outer bearing races. 6. To measure the horizontal wear of the ball studs and of the outer bearing races on the other ball studs and outer bearing races, place the dial 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 ttings 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.
Steering Linkage - Inspect

SMCS Code: 4305-040 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 ttings and the seals. 1. Park the machine on a level surface.
200 Maintenance Section Steering System Oil - Change
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i02331342
Steering System Oil - Change

SMCS Code: 4300-044-OC
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. 1. Operate the engine until the steering hydraulic oil is warm. Park the machine on a level surface and engage the parking brake. Stop the engine. 2. Push button (3) on the breaker relief valve. 3. Slowly, remove ller cap (4) on the steering hydraulic tank in order to relieve the pressure. NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates.
Illustration 265
g01163770
4. Open drain valve (1). 5. Allow the oil to drain into a suitable container. Close the drain valve. 6. Remove retaining ring (6) for the ller strainer. 7. Remove ller strainer (7). Wash the cap and the strainer in clean, nonammable solvent. Allow the cap and the strainer to dry. 8. Inspect cap seal (5). Use a new seal if the used seal is damaged. 9. Install the strainer and the retaining ring for the strainer. NOTICE Do not ll the steering hydraulic tank when the engine is running. Discharge from the secondary steering accumulators could overll the tank when the engine is stopped.
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201 Maintenance Section Steering System Oil Filter - Replace
10. Fill the steering hydraulic tank. Refer to Operation And Maintenance Manual, Lubricant Viscosities. Refer to Operation And Maintenance Manual, Capacities (Rell). 11. Use the reading from the upper sight gauge to maintain the steering oil level. When the engine is not running, the oil level should be at the FULL mark in upper sight gauge (2). 12. Install the ller cap. 13. Operate the engine until the steering hydraulic oil is warm. Inspect the machine for leaks and make any necessary repairs. 14. Stop the engine. Allow the steering accumulators to completely discharge and check the oil level. Use the reading from the upper sight gauge to maintain the steering oil level. 15. When the engine is stopped, the oil level should be at the FULL mark in the upper sight gauge. If necessary, add oil.
i02331551
Steering System Oil Filter Replace

SMCS Code: 431F-510
Illustration 266
g01163863
2. Push button (3) on the breaker relief valve. 3. Slowly remove ller cap (4) on the steering hydraulic tank in order to relieve any pressure. Install the ller cap after the pressure is relieved. 4. Remove four nuts (1) from the lter cover. 5. Pull lter assembly (2) out of the tank.
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. 1. Park the machine on level ground and engage the parking brake. Stop the engine.
Illustration 267
g01163878
6. Remove lter cover (5) from stud (10). 7. Remove spring pin (7) and spacer (8). 8. Remove used lter elements (9) and discard the used lter elements.
202 Maintenance Section Steering System Oil Level - Check
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9. Install the new lter elements. 10. Install the spring pin and the spacer. 11. Inspect seal (6) for the lter cover. Inspect seal (12) for retainer assembly (11). Replace any seals that are damaged. 12. Install the lter cover on the stud. Tighten the lter cover by hand. 13. Install the lter assembly into the tank. Install the nuts for the lter cover. 14. Start the engine and operate the engine at low idle. Make sure that the parking brake is engaged. Check for leaks and make any necessary repairs. 15. Check the steering system oil level. If necessary, add oil. For the proper procedure, refer to Operation and Maintenance Manual, Steering System Oil Level - Check.
i03352042
NOTICE Do not ll the steering hydraulic tank when the engine is running. Discharge from the secondary steering accumulators could overll the tank when the engine is stopped. Note: After the engine start-up, the oil level should be within the operating range of lower sight gauge (2). If the oil level in the lower sight gauge is low, check the secondary steering. See Operation And Maintenance Manual, Secondary Steering - Check for additional information.
i02331813
Steering System Oil Sample Obtain

SMCS Code: 4300-008-OC; 7542
Steering System Oil Level Check

Illustration 269 Illustration 268

g01726834
g01163967
1. Park the machine on a level surface and engage the parking brake. 2. Stop the engine and allow the secondary steering accumulators to completely discharge before the oil level is observed. 3. Maintain the oil level to the full mark in upper sight gauge (1). 4. If necessary, add oil.
Sampling port (1) for the steering oil is located on the steering solenoid and relief valve. Refer to the following publications for information about obtaining an oil sample.

Good Oil Sample
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203 Maintenance Section Suction Screen (Rear Axle Lubrication) - Clean

Interpretaion Guide
i02337440
4. Wash the screen and the magnetic tube assembly in clean, nonammable 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 screen cover plate. 8. Start the engine and operate the engine at low idle. Make sure that the parking brake is engaged. Check for leaks and make any necessary repairs. Note: The lubrication pump for the rear axle will not operate with the oil temperature below 15 C (59 F). 9. Check the oil level in the rear axle. If necessary, add oil. For the proper procedure, refer to Operation and Maintenance Manual, Differential and Final Drive Oil - Check. Note: Correct oil levels are critical in the differential and nal drives. Check the oil level after repairs and after maintenance. Note: The differential and nal drive oil level needs to be checked and maintained at operating temperature. If the oil level is checked cold, adjustment of the oil level may be necessary when the truck reaches operating temperature.
Suction Screen (Rear Axle Lubrication) - Clean

SMCS Code: 3016; 3278-070-Z3; 3291
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin. 1. Park the machine on a level surface. Engage the parking brake and stop the engine.
Illustration 270
g01166714
i02682176
2. Remove screen cover plate (1 ).
Suction Screen (Torque Converter) - Clean

SMCS Code: 3101-070-Z3
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.
Illustration 271
g01166878
3. Remove screen (2) and magnetic tube assembly (3). NOTICE Do not drop or rap the magnets against any hard objects. Replace any damaged magnets.
204 Maintenance Section Suction Screen (Torque Converter) - Clean
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NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. 1. Park the machine on a level surface. Engage the parking brake and stop the engine.
Illustration 273
g01164303
5. Remove the bolts from screen cover (3). The screen cover is located at the lower left rear corner of the sump. Remove the cover and the screen assembly. 6. Wash the screen assembly and the cover in a clean, nonammable solvent. Do not crush the screen assembly. 7. Inspect the cover gasket for damage. If the cover gasket is damaged, use a new gasket. 8. Install the screen. Install the cover assembly.
Illustration 272
g01164290
2. Remove ller cap (1) in order to prevent a vacuum in the torque converter sump. Install the ller cap after the torque converter sump is drained. This will prevent dirt from entering the system. 3. Remove drain valve plug (2) in the torque converter sump. Install a 100 mm (4 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 inch). Drain the oil into a suitable container. Note: Hand tighten the NPT pipe nipple. Do not use tools. 4. Remove the pipe nipple. Clean the drain plug and install the drain plug.
Illustration 274
g01164452
9. Remove the ller cap and ll the torque converter to the top of upper sight gauge (4). See Operation And Maintenance Manual, Lubricant Viscosities. See Operation And Maintenance Manual, Capacities (Rell). 10. Operate the engine for ten seconds and then turn off the engine. The oil level will decrease as oil lls the system. 11. Check the oil level in the torque converter sump. If necessary, add oil in order to raise the oil level to the FULL mark of the upper sight gauge.
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205 Maintenance Section Suspension Cylinder - Check
12. Start the engine and operate the engine at low idle. Make sure that the parking brake is engaged. Check for leaks and make any necessary repairs. 13. Operate the engine until the torque converter oil reaches operating temperature. Torque converter stalls may be performed in order to bring the torque converter oil up to operating temperature. 14. Check the oil level with the engine at low idle and the transmission in neutral. 15. Maintain the oil level until the oil level stabilizes in the FULL mark of the upper sight gauge. If necessary, add oil. 16. Clean the ller cap and install the ller cap on the ller tube. NOTICE Failure to properly ll the torque converter sump after an oil change may cause damage to the power train system. Follow the procedure that is described above. The transmission direction and speed control MUST be left in NEUTRAL until the system is full.
Front Suspension Cylinder
i02331858
Suspension Cylinder - Check

SMCS Code: 7201-535 Make sure that the dump body is empty. Stop the machine gradually on a level surface without using the brakes. Engage the parking brake and stop the engine. 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 eld assembly, the suspension cylinders must be charged with nitrogen.
Illustration 275 (X) Distance of exposed chrome
g01163979
Measure the distance of exposed chrome (X) for the front suspension cylinders. Compare the present distance to the distance from the previous time. If you do not have those dimensions, perform the charging procedure. See Testing And Adjusting, Suspension Cylinder (Front) - Purge and Charge for the charging procedure. Note: There are two relief valves for the grease on the forward side of the front suspension cylinder. These relief valves are located 180 degrees from the lubrication tting. Do not plug the grease passage of the relief valves.
206 Maintenance Section Tire Ination - Check
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Rear Suspension Cylinder

NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. 1. Park the machine on a level surface. Engage the parking brake and stop the engine.
Illustration 276 (Y) Distance between the pins
g01163990
Measure distance (Y) for the rear suspension cylinders. Compare the present distance to the distance from the previous time. If you do not have those dimensions, perform the charging procedure. See Testing And Adjusting, Suspension Cylinder (Rear) - Purge and Charge for the charging procedure. Note: When the rear suspension cylinders are properly charged, the left rear suspension cylinder will not show as much chrome as the right rear suspension cylinder. This is due to the rigid frame and to the weight of the cab.
i02416817
Tire Ination - Check

SMCS Code: 4203-535-AI; 4203-535-PX Measure the tire pressure on each tire. Adjust the tire pressure, if necessary. Consult your tire supplier for the correct tire operating pressures and load ratings. See Operation and Maintenance Manual, Tire Ination Information for more tire information.
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Illustration 277
g01164086
2. Remove drain plug (2) from the bottom of screen housing (1) and drain the oil into a suitable container. Clean the drain plug and install the drain plug. Note: Removing the drain plug from the bottom of the screen housing may not drain all of the oil from the screen. 3. Remove the screen housing. Remove the screen. Discard the used screen. 4. Wash the screen housing in clean, nonammable solvent. 5. Inspect the seal in the base of the screen housing. If the seal is damaged, replace the seal with a new seal.
Torque Converter Outlet Screen - Replace

SMCS Code: 3103
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin.
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207 Maintenance Section Torque Converter Sump Breather - Clean
6. Install the new screen in the screen housing. Install the screen housing. 7. Start the engine and operate the engine at low idle. Make sure that the parking brake is engaged. Check for leaks and make any necessary repairs. 8. Check the oil level in the torque converter sump. If necessary, add oil. For the proper procedure, refer to Operation and Maintenance Manual, Torque Converter Sump Oil Level - Check.
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Torque Converter Sump Breather - Clean

SMCS Code: 3101
g01167449
Illustration 278
When it is necessary to work under the machine with the body (bed) raised, attach the body (bed) retaining cable to the rear tow point. Install the rear tow point pin through the end of the retaining cable. Failure to properly secure the body (bed) may result in personal injury or death. Note: The breather for the torque converter sump also vents the transmission case. 1. Park the machine on a level surface and engage the parking brake. 2. Raise the truck body to the fully raised position and install the truck body retaining cable to the rear tow point pin. For the proper procedure for the installation and removal of the truck body retaining cable, refer to Operations and Maintenance Manual, Cable (Truck Body Retaining). 3. Stop the engine.
4. Remove breather (1). 5. Wash the breather in a clean, nonammable solvent. Allow the breather to air dry. 6. Install the breather. 7. Remove the truck body retaining cable and lower the body.
i02682170
Torque Converter Sump Oil Level - Check

SMCS Code: 3101-535-FLV Note: The oil level in the transmission is supplied by the torque converter sump. 1. Park the machine on a level surface. 2. Operate the engine at low idle with the transmission in neutral and with the parking brake engaged. Note: The engine should be on in order to check the cold oil (oil at ambient temperature) level of the torque converter, and the engine should be on in order to check the hot oil (oil at operating temperature) level of the torque converter.
208 Maintenance Section Torque Converter and Transmission Oil - Change
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Illustration 279
g01347318
Illustration 280
g01164290
3. Check the oil level in the torque converter sump. a. If the torque converter oil is cold, use lower sight gauge (3) in order to check the oil level. b. If the torque converter oil is in the operating temperature range, use upper sight gauge (2) in order to check the oil level. 4. If necessary, add oil. The torque converter oil and transmission oil is added at ller cap (1). Note: If the system has been drained, refer to Operation and Maintenance Manual, Torque Converter and Transmission Oil - Change for the proper procedure.
i02682180
2. Remove ller cap (1) in order to prevent a vacuum in the torque converter sump. Install the ller cap after the torque converter sump is drained. This will prevent dirt from entering the system. NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. 3. Remove drain valve plug (2) in the torque converter sump. Install a 100 mm (4 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 inch). Drain the oil into a suitable container. Note: Hand tighten the NPT pipe nipple. Do not use tools. 4. Remove the pipe nipple. Clean the drain valve plug and install the drain valve plug.
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. 1. Park the machine on a level surface. Engage the parking brake and stop the engine.
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209 Maintenance Section Torque Converter and Transmission Oil - Change
12. Check the oil level in the torque converter sump. Add oil in order to raise the oil level to the FULL mark of the upper sight gauge. 13. Start the engine and operate the engine at low idle. Make sure that the parking brake is engaged. Check for leaks and make any necessary repairs. 14. Operate the engine until the torque converter oil reaches operating temperature. Torque converter stalls may be performed in order to bring the torque converter oil up to operating temperature. 15. Check the oil level with the engine at low idle and the transmission in neutral. 16. Maintain the oil level until the oil level stabilizes in the FULL mark of the upper sight gauge. If necessary, add oil. 17. Clean the ller cap and install the ller cap on the ller tube. NOTICE Failure to properly ll the torque converter sump after an oil change may cause damage to the power train system. Follow the procedure that is described above. The transmission direction and speed control MUST be left in NEUTRAL until the system is full.
Illustration 281
g01164714
5. Remove drain plugs (3) from the transmission extension housing. Drain the oil into a suitable container. Clean the drain plugs and install drain plugs. 6. Remove the ller cap. 7. Remove the retaining ring on the ller screen. Remove the screen. 8. Wash the cap and the ller screen in clean, nonammable solvent. Allow the cap and the ller screen to dry. 9. Inspect the cap seal. Use a new seal if the used seal is damaged. Install the ller screen and the retaining ring.
Illustration 282
g01164452
10. Fill the torque converter to the top of upper sight gauge (4). See Operation And Maintenance Manual, Lubricant Viscosities. See Operation And Maintenance Manual, Capacities (Rell). 11. Operate the engine for ten seconds and then turn off the engine. The oil level will decrease as oil lls the system.
210 Maintenance Section Torque Converter and Transmission Oil Sample - Obtain
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i02501245
i02900768
Torque Converter and Transmission Oil Sample Obtain

SMCS Code: 3030-008; 3101-008; 7542
Traction Control System (TCS) - Test

SMCS Code: 3288-081; 4801-081 Note: This procedure determines if the Traction Control System (TCS) is functioning. This procedure also determines if the left rear brake and the right rear brake activate at the correct time. 1. Find a clear area and a level area. In this area, turn the machine in a complete circle. Start the machine and move the transmission direction and speed control lever to the rst gear Forward. 2. Turn the steering wheel all the way to the left. With the engine at low idle, drive the machine in a complete circle.
Illustration 283
g01251142
The sampling valve for the transmission and torque converter oil is located on the oil lter housing for the torque converter in front of the hoist/brake tank. Refer to the following publications for information about obtaining an oil sample.
Illustration 284
g01444054

Information
3. Continue to turn the machine and push the top half of test switch (1) for the TCS. Hold the test switch down. This will begin the test. 4. The machine will gradually slow down. 5. Release the test switch. The test will end and the machine will increase speed. 6. Turn the steering wheel all the way to the right. With the engine at low idle, drive the machine in a complete circle. 7. Continue to turn the machine and push the top half of the test switch for the TCS. Hold the test switch down. This will begin the test. 8. The machine will gradually slow down. 9. Release the test switch. The test will end and the machine will increase speed. 10. If the TCS did not function properly, consult your Caterpillar dealer for information and service.
Special Publication, SEBU6250, Caterpillar
Machine Fluids Recommendations, SOS Oil Analysis Good Oil Sample
Special Publication, PEHP6001, How To Take A Special Publication, PEDP8025, Fluid Analysis
Interpretaion Guide
SEBU7792-06
211 Maintenance Section Transmission Magnetic Screen - Clean
i02335439
Transmission Magnetic Screen - Clean

SMCS Code: 3030-070-MGS
4. Wash the screen and the magnetic tube assembly in clean, nonammable solvent. Clean the magnets with a cloth, a stiff bristle brush or air pressure. 5. Install the magnetic tube assembly, the screen, and the wave washer. 6. Inspect seal (5). If the seal is damaged, replace the seal. 7. Install the screen cover plate. 8. Start the engine and operate the engine at low idle. Make sure that the parking brake is engaged. Check for leaks and make any necessary repairs. Note: The oil level in the transmission is supplied by the torque converter sump. 9. Check the oil level in the torque converter sump. If necessary, add oil. For the proper procedure, refer to Operation and Maintenance Manual, Torque Converter Sump Oil Level - Check.
i02335442
Illustration 285 Location of the transmission magnetic screen
g01165690
Transmission Oil Filter Replace

SMCS Code: 3067-510
Illustration 286
g01166968
2. Remove screen cover plate (1). 3. Remove wave washer (2), screen (3), and magnetic tube assembly (4). NOTICE Do not drop or rap the magnets against any hard objects. Replace any damaged magnets.
Illustration 287
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212 Maintenance Section VIMS Module Battery - Replace
SEBU7792-06
i03010045
NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. 2. Remove drain plug (2) for lter housing (1). Drain the oil into a suitable container. Clean the drain plug and install the drain plug. Note: All of the oil from the lter may not drain when the drain plug from the bottom of the lter housing is removed. 3. Remove the lter housing and the lter element. Discard the used lter element. 4. Wash the lter housing in clean nonammable solvent. 5. Inspect the seals in the lter base. If the seals are damaged, replace seals with new seals. 6. Install the new lter element in the housing. Install the housing. 7. Start the engine and operate the engine at low idle. Make sure that the parking brake is engaged. Check for leaks and make any necessary repairs. Note: The oil level in the transmission is supplied by the torque converter sump. 8. Check the oil level in the torque converter sump. If necessary, add oil. For the proper procedure, refer to Operation and Maintenance Manual, Torque Converter Sump Oil Level - Check.
VIMS Module Battery - Replace

SMCS Code: 7490-510-B11; 7601-510-B11
Illustration 288 (1) Plate
g01043143
A lithium battery is contained inside the main module of the VIMS. The internal battery prevents the loss of stored information. An example of the stored information is the payload data. The internal battery also retains the time and the date. If power is removed from the main module of the VIMS, the internal battery will begin to retain the stored data. Power is removed from the main module of the VIMS when the battery disconnect switch is in the OFF position. The internal battery retains the time and the date when the engine start switch is in the OFF position. This will occur regardless of the position of the battery disconnect switch. Note: To prevent the loss of stored information, replace the internal battery at the service interval. If the ambient temperature is continuously in the range of 0 to 40C (32 to 40F), cut the service interval in half. Note: If the Vital Information Management System (VIMS) detects a failed battery, a fault code will indicate that the battery needs a replacement. If power is removed from the main module of the VIMS during this fault code, loss of the stored data can occur within several hours. The lithium battery fails quickly. When the fault code is present, immediately download the stored data. Then replace the internal battery without turning off the engine start switch or the battery disconnect switch. Note: If ECM BKUP BATT ERR is displayed in the message area of the VIMS, do NOT turn the engine start switch to the OFF position. Go to Step 3. 1. Stop the machine and turn off the engine. Leave the battery disconnect switch in the ON position.
SEBU7792-06
213 Maintenance Section Window Washer Reservoir - Fill
2. Turn the engine start switch to the ON position or turn the keyswitch for the VIMS to the ON position. 3. Use the service tool for the VIMS to download all of the stored information. The service tool for the VIMS is not part of the machine. Failure to perform this step may result in the loss of stored data. 4. Leave the engine start switch in the ON position or leave the keyswitch for the VIMS in the ON position. Leave the battery disconnect switch in the ON position. Note: If these switches remain in the ON position during replacement, the date and the time of day are less likely to require programming. 5. Remove the battery from the back of the VIMS module. The battery is located behind plate (1). Note: Do not allow dirt or water into the opening. Keep the area clean. 6. Install a new internal battery. Be careful to align the pins of the new battery with the sockets. 7. Check the O-ring seal. The O-ring seal is located under the cap. Make sure that the O-ring seal is in the proper place. Make sure that the O-ring seal is not damaged. Install the cap. Tighten the cap securely against the housing. 8. The real time clock format in the main module is powered by this battery. A dead battery will cause the date to be lost and a dead battery will cause the time to be lost. After the battery has been replaced, the date will default to 01/01/00. Also, the time will default to 00:00:00. If necessary, use the service tool for the VIMS to set the time and the date. Refer to Troubleshooting, Testing and Adjusting, RENR2631, Vital Information Management System (VIMS).
i02346847
Illustration 289
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Window washer reservoir (1) is located in the compartment in the front of the cab. Fill the reservoir with windshield washer uid.
i02335763
Window Wiper Inspect/Replace

SMCS Code: 7305-040; 7305-510
Illustration 290
g01165832
Window Washer Reservoir Fill

SMCS Code: 7306-544-KE NOTICE When operating in freezing temperatures, use Caterpillar nonfreezing window washer solvent or equivalent. System damage can result from freezing.
Inspect windshield wiper blade (1). Replace the windshield wiper blade if the wiper blade is worn or damaged. Replace any windshield wiper blade that streaks the windshield.
214 Maintenance Section Windows - Clean
SEBU7792-06
i02680928
Windows - Clean
SMCS Code: 7310; 7340
Illustration 291
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Use commercially available window cleaning solutions to clean the windows. Only clean the windows, when handholds are available.

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MAINTENANCE INTERVALS

Operation and Maintenance Manual Excerpt

2010 Caterpillar All Rights Reserved

SEBU7792-06 November 2010

Operation and Maintenance Manual

131 Maintenance Section Maintenance Interval Schedule

Maintenance Interval Schedule

Every 10 Service Hours or Daily

Initial 50 Service Hours

Initial 250 Service Hours

Every 250 Service Hours or Monthly

Every 500 Service Hours

132 Maintenance Section Maintenance Interval Schedule

175 185 191 200 203

Every 500 Service Hours or 3 Months

Every 3000 Service Hours or 2 Years

Every 4000 Service Hours

Every 6000 Service Hours or 3 Years

Every 6000 Service Hours or 4 Years

Every 12 000 Service Hours or 6 Years

Every 1000 Service Hours or 6 Months

Every 15 000 Service Hours

Every 2000 Service Hours or 1 Year

133 Maintenance Section Air Conditioner Filter - Clean

Air Conditioner Filter - Clean

Air Dryer - Check

Air Dryer Desiccant - Replace

134 Maintenance Section Air Tank - Inspect

Primary Air Tank

1. Open drain valve (1) for the air tank.

Secondary Air Tank

Air Tank - Inspect

Air Tank Moisture and Sediment - Drain

135 Maintenance Section Air/Hydraulic Cylinder Breather - Clean

3. Close the drain valve for the air tank.

Air/Hydraulic Cylinder Breather - Clean

136 Maintenance Section Automatic Lubrication Reservoir - Fill

Automatic Lubrication Reservoir - Fill

Backup Alarm - Test

Illustration 153 Location of the backup alarm

137 Maintenance Section Battery - Recycle

A battery supplier An authorized battery collection facility Recycling facility

Battery or Battery Cable Inspect/Replace

138 Maintenance Section Belts - Inspect/Adjust/Replace

Adjustment and Replacement

139 Maintenance Section Brake Cooling Oil Filter - Replace

Dispose of all uids according to local regulations and mandates.

Illustration 160 Location of the brake cooling oil lters

Brake Cooling Oil Filter Replace

140 Maintenance Section Brake Oil Cooler Screen - Clean

Brake Oil Cooler Screen Clean

141 Maintenance Section Brake Oil Cooler Screen - Clean

Illustration 164 Screen locations

142 Maintenance Section Brake Tank (Makeup) - Clean

Brake Tank (Makeup) - Clean

Brakes, Indicators and Gauges - Test

143 Maintenance Section Braking System - Test

Braking System - Test

Parking Brake Holding Ability Test

Test for the Parking Brake Reset Valve