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MAINTENANCE INTERVALS

Operation and Maintenance Manual Excerpt

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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

i04149359

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, fluids, filters, 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 defined 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. S·O·S 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 Inflation - Check ........................................... 143 176 188 206

Initial 500 Hours (for New Systems, Refilled 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

SEBU7792-06

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

Every 6000 Service Hours or 3 Years
Cooling System Coolant Extender (ELC) - Add .. 150

Every 6000 Service Hours or 4 Years
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

2. Remove filter element (1).SEBU7792-06 133 Maintenance Section Air Conditioner Filter . Install the clean element. Note: Small amounts of moisture may be in the system due to condensation in the system. Illustration 146 g01167619 Air dryer (1) is located on the frame in front of the left front suspension cylinder. If there is moisture in the air tanks. Loosen the door retaining screws and open the door. The tire and the wheel have been removed for ease of viewing. 4. Drain the primary air tank and drain the secondary air tank. Park the machine on a level surface and engage the parking brake. Refer to Operation and Maintenance Manual. clean the filter element for the air conditioner. The filter element for the air conditioner is located in the compartment in the front of the cab. i02340897 Air Dryer . replace the desiccant cartridge or rebuild the desiccant cartridge. .Clean SMCS Code: 7320-070-FI If a reduction in air circulation is noticed. 5. Close the door and tighten the retaining screws. 2. Clean the element by gently tapping the element on a smooth surface. g01165826 Illustration 145 3. Release the air pressure from the air system completely before performing maintenance. Air lines to and from the air dryer must be at atmospheric pressure.Check SMCS Code: 4285-535 Air Dryer Desiccant . “Air Tank Moisture and Sediment . i02685548 3.Clean i02390098 Air Conditioner Filter .Drain” for the proper procedure. personal injury could result. Park the machine on a level surface and engage the parking brake. If the air lines are not at atmospheric pressure.Replace SMCS Code: 4285-510-DSS The air lines to and from the air dryer must be at atmospheric pressure. 1. Release the air pressure from the air system completely before performing maintenance. Consult your Caterpillar dealer for information about replacing the desiccant cartridge and for instructions for rebuilding the desiccant cartridge. 1.

797”. 7428-040 When laws in the machine's operating location require the inspection of air tanks. Illustration 147 g01167619 Air dryer (1) is located on the frame in front of the left front suspension cylinder. 1. Replace the air dryer desiccant cartridge or rebuild the air dryer desiccant cartridge if water cannot be absorbed. refer to Special Instruction.Inspect SEBU7792-06 Primary Air Tank Illustration 148 g01132606 Drain valve (1) for the primary air tank is located on the right hand side of the platform. Drain the moisture and sediment from the air tank into a suitable container. Check for moisture and sediment in the air tanks. 3. Close the drain valve for the air tank. 2.134 Maintenance Section Air Tank . Check for moisture and sediment in the air tank. Consult your Caterpillar dealer for service or for replacement parts. Drain the moisture and sediment from the air tank into a suitable container.Inspect SMCS Code: 4272-040. The tire and the wheel have been removed for ease of viewing. “Air Tank Inspection for the Off-Highway Truck 769 . i02444297 Secondary Air Tank Air Tank . REHS2398. 5505-040.Drain SMCS Code: 4272-543-MAS Park the machine on a level surface and engage the parking brake. Open drain valve (2) for the air tank. Illustration 149 g01132579 The drain valve for the secondary air tank is located on the right hand side of the cab exterior. i02602974 Air Tank Moisture and Sediment . 1. 2. . Open drain valve (1) for the air tank.

Park the machine on a level surface and engage the parking brake. i02251322 4. Check for moisture and sediment in the air tank. 3.Clean 3. Failure to properly secure the body (bed) may result in personal injury or death. Raise the dump body to the fully raised position and install the truck body retaining cable to the rear tow point pin. Install the clean breathers. 2. Wash both breathers in clean nonflammable solvent. attach the body (bed) retaining cable to the rear tow point. 2. 5. “Cable (Truck Body Retaining)”.Clean SMCS Code: 4258 When it is necessary to work under the machine with the body (bed) raised. 3. Drain the moisture and sediment from the air tank into a suitable container. Remove the truck body retaining cable and lower the body. refer to Operations and Maintenance Manual. 1. Install the rear tow point pin through the end of the retaining cable. . Primary Air Tank (If Equipped with the Sound Suppression Arrangement) Illustration 150 g01302805 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 g01133243 1. 7. Allow the breathers to dry. Remove breathers (1) and (2) for air/hydraulic cylinders (3) and (4). Close the drain valve for the air tank. For the proper procedure. Close the drain valve for the air tank. 6. Air/Hydraulic Cylinder Breather .SEBU7792-06 135 Maintenance Section Air/Hydraulic Cylinder Breather . Open drain valve (3) for the air tank. Stop the engine.

136 Maintenance Section Automatic Lubrication Reservoir . 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. Note: The bulk capacity of the grease reservoir is 27 kg (60 lb). Note: If the reservoir is not properly vented. If any of the remote lines become damaged. “Fast Fill Service Center”. If the machine is equipped with a Fast Fill Service Center. See Systems Operation. i02253468 Backup Alarm . For more information on the Fast Fill Service Center. . fittings on the right side of the machine. Also. 3. Move the transmission direction and speed control lever to the REVERSE position. Turn the engine start switch to the ON position in order to perform the test. “Automatic Lubrication System” for additional details.Fill SMCS Code: 7540-544-TNK The automatic lubrication reservoir provides lubrication for many components. pressure will cause the wiper seal on the follower assembly inside the reservoir to fail when the reservoir is filled. and fittings on the rear differential housing. Testing and Adjusting. 2. the level indicator will illuminate when the reservoir is full. SENR4724. grease on the top side of the follower assembly may cause damage to the autolube system. Lubricate the item at the fittings until the remote line can be replaced. Fill the autolube reservoir through fill port (2). Place a suitable container under the outlet for the vent port in order to collect any grease that is spilled. refer to Operation and Maintenance Manual. There are fittings on the left side of the machine. The backup alarm should sound immediately. Make sure that the area behind the machine is clear of personnel and clear of obstacles.Test SMCS Code: 7406-081 Illustration 152 g01133458 1. Remove plug (1) for the vent port if the reservoir is not equipped with a permanent vent. Fill the reservoir until grease appears at the outlet for the vent port. Illustration 153 Location of the backup alarm g01130536 Park the machine on a level surface and engage the parking brake.Fill SEBU7792-06 i03795949 Automatic Lubrication Reservoir . Grease on the top side of the follower assembly may prevent the autolube system from functioning properly. install a fitting in place of the remote line. Install the plug in the vent port if the reservoir is not equipped with a permanent vent.

8. “Belt Tension Chart”. 1. Connect the positive end “+” of the battery cable to the battery.50 to 0. Disconnect the negative end “−” of the battery cable from the battery.Recycle SMCS Code: 1401-561 Always recycle a battery. 2. Connect the negative end “−” of the battery cable to the battery. 1357-040. Note: Do not allow the disconnected battery cable to contact the battery disconnect switch. Belt slippage will decrease the life of the belt. . 7. Turn all of the switches to the OFF position. Install the key. Connect the negative end “−” of the battery cable to the frame near the battery disconnect switch. 11. Disconnect the negative end “−” of the battery cable from the frame near the battery disconnect switch. Always return used batteries to one of the following locations: • A battery supplier • An authorized battery collection facility • Recycling facility i02341243 Illustration 154 g01131766 Battery or Battery Cable Inspect/Replace SMCS Code: 1401-040. 1401-510. 6. 1402-040. 3. i02253729 Belts . Refer to Operation and Maintenance Manual.Recycle i00993589 Battery . Turn the battery disconnect switch to the OFF position. “Battery Disconnect Switch” for more information. always use the same type of battery. To maximize the engine performance. Turn the battery disconnect switch to the ON position. Park the machine on a level surface and engage the parking brake. Replace the battery or make all necessary repairs to the battery. Refer to the Engine Specifications.SEBU7792-06 137 Maintenance Section Battery .Inspect/Adjust/Replace SMCS Code: 1357-025. 4. Disconnect the positive end “+” of the battery cable from the battery.75 inch). 1402-510 Note: When you replace the batteries. Remove the key. Never discard a battery. 5. 1357-510 Inspection Park the machine on a level surface and engage the parking brake. Check the belt tension. A correctly adjusted belt will deflect 13 to 19 mm (0. inspect the belt for wear and for cracking. This machine requires Maintenance Free batteries or Low Maintenance High Output batteries. 9. 10. Turn the engine start switch to the OFF position.

If shoulder (2) of the belt tensioner is aligned with red zone (1) of the indicator. Park the machine on a level surface. 4.Inspect/Adjust/Replace SEBU7792-06 Illustration 155 g01135583 Illustration 157 g01135196 The refrigerant compressor has a belt tensioner. Refrigerant Compressor Illustration 156 g01135171 Illustration 158 g01135219 .138 Maintenance Section Belts . 8. Engage the parking brake and stop the engine. Check the belt tension on a new belt after 30 minutes of operation. 6. 3. remove the belt and replace the belt. replace the belt. Loosen mounting bolt (5) and adjusting nuts (3). If the belt guard was removed. Tighten the mounting bolt. Note: The break-in period for the belt is considered to be 30 minutes. 5. reinstall the belt guard. 2. remove belt guard (4). Adjustment and Replacement Alternator 1. 7. If necessary. If necessary. Turn adjusting nuts (3) in order to increase or decrease the belt tension. Tighten the adjusting nuts.

Brake Cooling Oil Filter Replace SMCS Code: 1366-510-FI Hot oil and hot components can cause personal injury. Refer to Engine Supplement. adjusting and repair of the product. Remove oil filler cap (1) and use a vacuum transducer and vacuum cap in order to create a vacuum to the hoist/brake tank.7 mm (0. i03536820 Illustration 160 Location of the brake cooling oil filters g01137716 1.Replace NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Engage the parking brake and stop the engine. remove the belt and replace the belt. Park the machine on a level surface.Remove and Install” for more information on replacement of the belts. Disassembly and Assembly. Shoulder (2) of the belt tensioner should be aligned with green zone (7) of the indicator. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Illustration 159 Belt tensioner for the refrigerant compressor belt g01135507 Dispose of all fluids according to local regulations and mandates. 2. Refer to Special Publication. In order to release the tension on the belt. and pry the belt tensioner in a counterclockwise direction. .50 inch) ratchet into square hole (6) in the belt tensioner. Park the machine on a level surface. 5. Attach an air supply hose to the vacuum transducer and apply 276 to 414 kPa (40 to 60 psi) of air. If necessary. “Belt Tightener . Note: The break-in period for the belt is considered to be 30 minutes. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Insert a 12. Check the belt tension on a new belt after 30 minutes of operation. 4. NENG2500. Illustration 161 g01864993 2. Do not allow hot oil or hot components to contact skin. 3. 1.SEBU7792-06 139 Maintenance Section Brake Cooling Oil Filter . Engage the parking brake and stop the engine. maintenance. testing.

RENR8332. Engage the parking brake and stop the engine. Wash the filter housings in clean nonflammable solvent. 10. For the proper procedure. refer to Operation and Maintenance Manual. 8. Do not allow hot oil or hot components to contact skin. 6. Inspect the seal in each housing base. Install the filter housings. . There are three screens that need to be cleaned. replace the seal with a new seal. After a failure in the brake circuit.Remove” for the required tooling in order to create a vacuum in the 793D hoist/brake tank. “Hoist and Brake Tank Oil Level . adjusting and repair of the product. i02320005 Brake Oil Cooler Screen Clean SMCS Code: 4257-070. “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Start the engine and operate the engine at low idle. 3. There is one screen for the front brake oil cooler and there are two screens for the rear brake oil cooler. 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 filters are removed. add oil. Check the oil level in the hoist/brake tank. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Remove filter housings (2).140 Maintenance Section Brake Oil Cooler Screen . maintenance. Remove the used filter elements and discard the used filter elements properly. NENG2500. Install the oil filler cap. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. 7.Clean SEBU7792-06 Refer to Disassembly and Assembly. 5. clean the screens for the brake oil coolers. testing. 1. Illustration 162 g01864994 The brake cooling oil filters are located behind the fuel tank. 4295-070 Hot oil and hot components can cause personal injury. Install the new filter elements in the filter housings. Make sure that the parking brake is engaged. 9. Check for leaks and make any necessary repairs. Dispose of all fluids according to local regulations and mandates. “Oil Filter (Parking Brake Release) . Refer to Special Publication. Park the machine on a level surface.Check”. 4. Remove the vacuum transducer and the vacuum cap. The fuel tank has been removed for ease of viewing. If a seal is damaged. If necessary. 11.

For the proper procedure. nonflammable solvent. Remove the front oil cooler screen. Remove cover (5) for the front oil cooler screen. (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. “Hoist and Brake Tank Oil Level . Illustration 164 Screen locations g01176679 Back side view of the housing for the rear brake oil cooler screens. Install the cover for the front brake oil cooler screen. Install the rear oil cooler screens. add oil. Install the covers for the rear brake oil cooler screens. 6. nonflammable solvent.Check”. 8. 9. Drain the oil from the front brake oil cooler screen with drain (6). 2. The tire and the rim for the front left side have been removed for ease of viewing. 11.Clean Illustration 163 g01159886 Illustration 165 g01159904 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. If necessary. Wash the oil cooler screen in a clean. Start the engine and operate the engine at low idle. 5.SEBU7792-06 141 Maintenance Section Brake Oil Cooler Screen . 12. Drain the oil from rear brake oil coolers (2) with drain (4). Remove covers (1) for the rear brake oil cooler screens. Remove the rear oil cooler screens. 3. Check the oil level in the hoist/brake tank. Make sure that the parking brake is engaged. One cover is located at the front of the screen housing and one cover is located at the rear of the screen housing. 7. 13. Wash the oil cooler screens in a clean. 10. 4. refer to Operation and Maintenance Manual. Check for leaks and make any necessary repairs. . Install the front oil cooler screen.

For the proper test procedure. Consult your Caterpillar dealer for more information. Check for proper operation. 7. Remove the truck body retaining cable and lower the body. For the proper test procedure. 4. and damaged brake lines. Start the engine. refer to Operations and Maintenance Manual. Turn the engine start switch to the ON position and monitor the self test of the VIMS.Test”. 4267-081. 2. Indicators and Gauges . Sound the horn. Look for broken lenses on the gauges. The indicator lights on the dash will illuminate for 3 seconds. Stop the engine. “Cable (Truck Body Retaining)”. Look for any inoperative gauges. 6. Clean the cover and the brake makeup oil tank in clean nonflammable solvent. Illustration 166 g01137610 The brake makeup oil tank is located on the inside rail on the left side of the machine near the center tube. 3. “Braking System . Before you operate the machine. Replace any inoperative indicator lights. 8. Inspect the cover seal and replace the cover seal if the cover seal is damaged. Remove the top cover of brake makeup oil tank (1). Turn on all machine lights. perform the following checks. 4269-081. 1. 3. attach the body (bed) retaining cable to the rear tow point.Clean SEBU7792-06 i02270875 i02381189 Brake Tank (Makeup) . 7450-081. Failure to properly secure the body (bed) may result in personal injury or death. 2.Test SMCS Code: 4251-081. 5. 4. 5. “Vital information System (VIMS) Self Test” for further information. refer to Operation and Maintenance Manual. Check the brake system for the following: oil leaks. broken switches. Install the rear tow point pin through the end of the retaining cable. Park the machine on a level surface and engage the parking brake. Test the parking brake. . Check for broken indicator lights. Stop the engine. 7000-081. 1. and other broken components in the cab. Make any necessary repairs before machine operation. “Braking System . Make sure that the parking brake is engaged. Test the service brakes. refer to Operation and Maintenance Manual. air leaks.Clean SMCS Code: 4291 Brakes. 8. 6. For the proper procedure.Test”.142 Maintenance Section Brake Tank (Makeup) . Listen for proper operation. Install the cover. Raise the truck body to the fully raised position and install the truck body retaining cable to the rear tow point pin. 7490-081 When it is necessary to work under the machine with the body (bed) raised. See Operation and Maintenance Manual. Inspect the brake indicator lights in the cab. 7. Engage the parking brake.

Compare the engine rpm from the previous month to the current engine rpm. Test the brakes on a dry. Failure to have the brakes inspected and repaired can cause injury or death. contact your Caterpillar dealer. Parking Brake Holding Ability Test The air control valve for the parking brake activates all the wheel brakes. 8. Make sure that the parking brake reset valve is engaged. This will determine the system deterioration. Document the results of each monthly test. 2. Move the transmission control lever to the NEUTRAL position. The parking brakes are applied by spring pressure and the parking brakes are released by oil pressure. 2. level surface. level surface. 3. Engage parking brake switch (3). Reduce the engine speed to low idle. 1. Gradually increase the engine speed to 1300 rpm. Make sure that the machine is clear of personnel and clear of obstacles. Fasten the seat belt before you test the brakes. reduce the engine speed immediately and engage the parking brake. 9. repair the parking brakes before returning the machine to operation. NOTICE If the machine moved while testing the brakes. Stop the engine. The following tests are used to determine if the parking brake. Have the dealer inspect and. 4. Note: Service personnel should perform this test monthly. Start the engine and allow the air system to build up to the operating pressure.SEBU7792-06 143 Maintenance Section Braking System . The machine should not move. Have the dealer inspect and repair the brakes before returning the machine to operation. Illustration 167 (1) Transmission Control Lever (2) Parking Brake Reset Valve (3) Parking Brake Switch g01427991 If the machine moves when testing the brakes. 5. 5. Make sure that the machine is clear of personnel and clear of obstacles. and the service brake are functional. 7. Test the brakes on a dry. Check the area around the machine. the secondary brake. 4. Depress parking brake reset valve (2). Purge the air from the air system at the air tanks. etc. The brake holding effort that is required to sustain a machine at a specific engine rpm varies depending on the machine. Fasten the seat belt before you test the brakes. Test for the Parking Brake Reset Valve 1. If the machine begins to move during test. Check the area around the machine. Move transmission control lever (1) to the FIRST SPEED FORWARD position. in the power train efficiency.Test SMCS Code: 4251-081. and in the brake holding ability. if necessary. 6. 4267-081 Personal injury can result if the machine moves while testing. . contact your Caterpillar dealer.Test i02934683 Braking System . The valve will pop up to the engaged position. Leave the parking brake engaged. The variations are the differences in the engine setting. These tests are not intended to measure the maximum brake holding effort. 3.

Move the transmission control lever to the FIRST SPEED FORWARD position. 3. 7. NOTICE If the machine moved while testing the brakes. 1. Reduce the engine speed to low idle.Test SEBU7792-06 6. 8. Make sure that the machine is clear of personnel and clear of obstacles. Move the transmission control lever to the FIRST SPEED FORWARD position. contact your Caterpillar dealer. NOTICE If the machine moved while testing the brakes. Check the area around the machine. 2. The secondary brakes are applied by spring pressure and the secondary brakes are released by oil pressure. 1. Release the parking brake. repair the parking/secondary brakes before returning the machine to operation. Test the brakes on a dry. 9. 4. The machine should not move. Apply secondary brake control (4). Fasten the seat belt before you test the brakes. Service Brake Holding Ability Test The service brake air control valve activates all the wheel brakes. 10. . Gradually increase the engine speed to 1300 rpm. Have the dealer inspect and. if necessary. Engage the parking brake switch. Start the engine and allow the air system to build up to the operating pressure. 10. Start the engine and allow the air system to build up to the operating pressure. push down the knob. 2. Stop the engine. 4. Fasten the seat belt before you test the brakes. if necessary. Secondary Brake Holding Ability Test The secondary 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. 3. Check the area around the machine. level surface. contact your Caterpillar dealer. repair the parking brakes before returning the machine to operation. Test the brakes on a dry. Start the engine and allow the air system to build up to the operating pressure. Reduce the engine speed to low idle. 11. Make sure that the machine is clear of personnel and clear of obstacles. 6. level surface. In order to disengage the parking brake reset valve . 8. Depress the parking brake reset valve. Engage the parking brake. Disengage the parking brake. Move the transmission control lever to the NEUTRAL position.144 Maintenance Section Braking System . Move the transmission control lever to the NEUTRAL position. 7. Stop the engine. The machine should not move. Gradually increase the engine speed to 1300 rpm. Illustration 168 g01167673 5. 9. Have the Caterpillar dealer inspect and.

Install a new breather.SEBU7792-06 145 Maintenance Section Breather (Fuel Tank) . Move the transmission control lever to the NEUTRAL position. Remove fuel tank breather (1). Remove the truck body retaining cable and lower the body. Engage the parking brake. . 9. Have the dealer inspect and. 5. For the proper procedure for the installation and removal of the truck body retaining cable. 7. Illustration 169 g01190530 5. The machine should not move. 7. 3. Release the parking brake. Move the transmission control lever to the FIRST SPEED FORWARD position. Depress the parking brake reset valve. if necessary. NOTICE If the machine moved while testing the brakes. “Cable (Truck Body Retaining)”. 10. Illustration 170 g01172150 4. Failure to properly secure the body (bed) may result in personal injury or death. 6. Park the machine on a level surface and engage the parking brake. repair the service brake before returning the machine to operation. Stop the engine. attach the body (bed) retaining cable to the rear tow point.Replace 1.Replace SMCS Code: 1273-510-BRE When it is necessary to work under the machine with the body (bed) raised. 6. Raise the truck body to the fully raised position and install the truck body retaining cable to the rear tow point pin. i02345985 Breather (Fuel Tank) . 8. Install the rear tow point pin through the end of the retaining cable. refer to Operations and Maintenance Manual. Gradually increase the engine speed to 1300 rpm. contact your Caterpillar dealer. Reduce the engine speed to low idle. Apply service brake control (5). Stop the engine. Properly discard the used breather. 2.

1. When a reduction of air circulation is noticed in the cab after cleaning the filter element. 2. Rinse the filter element in clean water. Wash the filter element in a nonsudsing detergent.Clean/Replace SEBU7792-06 i01766189 i02385071 Cab Air Filter . Install the clean filter element and cover (1). Note: When rips or tears are noticed in the filter element. Remove cover (1) and the filter element. 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. 3. install a new filter element. 7342-070. 7311-510-FI. 7258-040-KA A raised body (bed) may fall unexpectedly if a damaged cable is used. . 7342-510 Cable (Truck Body Retaining) . • Kinks • Cuts • Flat spots 2. Loosen retaining screws (2). Use of a damaged cable could result in personal injury or death. Tighten retaining screws (2). Wear gloves when handling the cable. Allow the filter element to air dry.Clean/Replace SMCS Code: 7311-070-FI. 1. Inspect the cable for any of the following conditions: Illustration 171 Location of the filter element for the cab (1) Cover (2) Retaining screws g00903640 • 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 filter element for the cab is located inside the operator's compartment. Consult your Caterpillar dealer for proper replacement parts. 4.146 Maintenance Section Cab Air Filter .Inspect SMCS Code: 5154-040. replace the truck body retaining cable and the cable connection for the truck body. install a new filter element. Inspect the cable for damage and do not use a cable that is damaged.

and the fog lights are automatic reset 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 g01167724 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 g01167816 Circuit Breaker/Reset – Push in the button in order to reset the circuit breaker. the high beam headlights. Note: The circuit breakers for the low beam headlights. If the button does not remain depressed. if necessary.SEBU7792-06 147 Maintenance Section Circuit Breakers . If the electrical system is working properly. Repair the electrical circuit.Reset i02342172 Circuit Breakers . check the appropriate electrical circuit. the button will remain depressed. Window Washer and Wiper (12) – 10 Amp Power Train Electronic Control Module (13) – 10 Amp Air Dryer (14) – 10 Amp .

steam and alkali. Any contact can cause severe burns. Engage the parking brake and stop the engine. .Change SEBU7792-06 Heated Mirrors (15) – 25 Amp Power Window (16) – 10 Amp NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Dispose of all fluids according to local regulations and mandates. NOTICE Mixing Cat Extended Life Coolant (ELC) with other products reduces the effectiveness of the coolant and shortens coolant life. maintenance. Do not attempt to tighten hose connections when the coolant is hot. 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. “Extended Life Coolant (ELC)” under the topic ELC Cooling System Contamination.Change SMCS Code: 1350-044-NL. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Refer to Special Publication. Cooling System Coolant Additive contains alkali. If ELC cooling system contamination occurs. Use only Cat Extender with Cat ELC. Avoid contact with skin and eyes. 1395-044-NL Personal injury can result from hot coolant. Drain the coolant whenever the coolant is dirty or whenever foaming is observed. Park the machine on a level surface. Use only Caterpillar products or commercial products that have passed the Caterpillar EC-1 specifications for premixed or concentrate coolants.148 Maintenance Section Cooling System Coolant (ELC) . The radiator and all lines to heaters or the engine contain hot coolant or steam. Failure to follow these recommendations could result in damage to the cooling systems components. At operating temperature. testing. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. engine coolant is hot and under pressure. the hose can come off causing burns. 1. 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) . refer to Operation and Maintenance. NOTICE Do not change the coolant until you read and understand the material in the Cooling System Specifications section. adjusting and repair of the product. This machine was factory filled with Cat Extended Life Coolant. NENG2500.

“Cooling System Specifications” and Operation and Maintenance Manual. perform the following procedures during initial start-up: a. increase the engine speed to a high idle until the thermostat is open and the coolant level is stabilized. This will relieve system pressure. Drain the water into a suitable container. After the cooling system has been filled. Illustration 175 g01159976 3. Close the drain valves. Refer to Operation and Maintenance Manual. Install filler caps (1) and (2). Note: If you are using Caterpillar antifreeze. Note: When the drain valves are opened. Run the engine at low idle for ten minutes. Start the engine and operate the engine for 90 minutes. flush the system with water until the draining water is clear. . Stop the engine and drain the cleaning solution into a suitable container. Slowly loosen filler caps (1) and (2). 8. Remove the filler caps. 7. 9. Close the drain valves. do not add the supplemental coolant additive at this time and/or change the element at this time. Open drain valves (3) for the jacket water cooling system and the aftercooler cooling system. Then. 5. SEBU6250. When the engine is stopped. “Cooling System Coolant Level Check”. 6. “Capacities (Refill)”. Opening one drain valve will drain that system and the other system will remain partially full. Add the coolant solution. Drain the coolant into a suitable container. c. b. Illustration 174 (1) Filler cap for the aftercooler cooling system (2) Filler cap for the jacket water cooling system g01159005 2.SEBU7792-06 149 Maintenance Section Cooling System Coolant (ELC) . Fill the system with clean water and a 6 to 10% concentration of cooling system cleaner. Refer to Special Publication. Start the engine without the filler cap.Change 4. the coolant will drain from both systems. 10. d. Maintain the coolant at the proper level as the thermostat opens and air is purged from the system.

Refer to Special Publication. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. NENG2500. adjusting and repair of the product. If the machine is to be stored in. maintenance. refer to Operation and Maintenance. NOTICE Adding coolant to an overheated engine could result in damage to the engine. or shipped to. Do not attempt to tighten hose connections when the coolant is hot. an area with freezing temperatures. Allow the engine to cool before adding coolant. the cooling system must be protected to the lowest outside (ambient) temperature. Avoid contact with skin and eyes. Park the machine on a level surface. This machine was factory filled with Cat Extended Life Coolant. when shipped from the factory unless special requirements are defined.Add SEBU7792-06 i02317854 Cooling System Coolant Extender (ELC) .150 Maintenance Section Cooling System Coolant Extender (ELC) . Failure to follow these recommendations could result in damage to the cooling systems components.Add SMCS Code: 1352-538-NL NOTICE Excessive additive (greater than the recommended 6% initial fill) 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. Refer to Special Publication. Use 8T-5296 Test Kit in order to check the concentration. steam and alkali. engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot coolant or steam. Personal injury can result from hot coolant. 1. “Extended Life Coolant (ELC)” under the topic ELC Cooling System Contamination. “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. At operating temperature. Engage the parking brake and stop the engine. testing. Illustration 176 (1) Filler cap for the aftercooler cooling system (2) Filler cap for the jacket water cooling system (3) Level gauges g01159006 . the hose can come off causing burns. The engine cooling system is normally protected to a minimum of−29°C (−20°F) with Caterpillar Antifreeze. Use only Caterpillar products or commercial products that have passed the Caterpillar EC-1 specifications for premixed or concentrate coolants. Dispose of all fluids according to local regulations and mandates. 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. SEBU6250. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. If ELC cooling system contamination occurs. “Cooling System Specification” for the cooling system requirements. Cooling System Coolant Additive contains alkali. Use only Cat Extender with Cat ELC.

If necessary. Clean the filler caps and inspect the filler caps. Check level gauges (3). “Extended Life Coolant (ELC)”.Check 2. 1395-008. i03905010 Cooling System Coolant Sample (Level 1) . Cooling System Coolant Level . If necessary. Do not attempt to tighten hose connections when the coolant is hot. The needle should be in the green range. Personal injury can result from hot coolant. 7542 NOTICE Always use a designated pump for oil sampling. Using the same pump for both types of samples may contaminate the samples that are being drawn. allow the system to cool and add coolant. If the needle is in the red range. check for leaks. 3. Loosen filler caps (1) and (2) slowly in order to relieve pressure. Note: Level 1 results may indicate a need for Level 2 Analysis. . add premixed coolant in order to bring the coolant in the green range on the coolant level gauge. Refer to the table in Special Publication. drain enough coolant in order to allow the addition of the liquid coolant additive. At operating temperature. 5. and use a separate designated pump for coolant sampling. Any contact can cause severe burns. This table lists the correct amount of Caterpillar Extended Life Coolant (ELC) extender that should be added to the cooling system. 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.SEBU7792-06 151 Maintenance Section Cooling System Coolant Level . the hose can come off causing burns.Obtain SMCS Code: 1350-008. Allow the coolant level to stabilize. Start the engine and check for leaks. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers. Remove the filler caps. steam and alkali. Note: Make sure that the coolant is drained into a suitable container. engine coolant is hot and under pressure. 6. 4. SEBU6250. 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. The radiator and all lines to heaters or the engine contain hot coolant or steam. 7. Cooling System Coolant Additive contains alkali. Avoid contact with skin and eyes. Use level gauges (1) and (2) to check the coolant levels.Check SMCS Code: 1350-535-FLV Park the machine on a level surface and engage the parking brake. Install the filler caps.

Using the same pump for both types of samples may contaminate the samples that are being drawn. see Special Publication. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers. “Caterpillar Machine Fluids Recommendations” or consult your Caterpillar dealer. SEBU6250. perform consistent samplings that are evenly spaced. Submit the sample for Level 1 analysis. 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. • Never collect samples from expansion bottles. You should not obtain the samples from any other location. 1395-008. bags. Sampling valve (2) for the water cooled aftercooler system is located on the left side of the engine water pump. Sampling valve (1) for the jacket water cooling system is located on the right side of the engine water pump.152 Maintenance Section Cooling System Coolant Sample (Level 2) . In order to receive the full effect of S·O·S analysis. • 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.Obtain Illustration 179 Left side view of the engine g02146857 SMCS Code: 1350-008. establish a consistent trend of data. . • 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.Obtain SEBU7792-06 Obtain the sample of the coolant as close as possible to the recommended sampling interval. 7542 NOTICE Always use a designated pump for oil sampling. i03905011 Cooling System Coolant Sample (Level 2) . • Never collect samples from the drain for a system. In order to establish a pertinent history of data. For additional information about coolant analysis. are ready to collect the sample. and use a separate designated pump for coolant sampling. Supplies for collecting samples can be obtained from your Caterpillar dealer.

SEBU7792-06

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.

Illustration 182 (1) Filler cap for the aftercooler cooling system (2) Filler cap for the jacket water cooling system

g01159005

2. Remove filler caps (1) and (2) slowly in order to relieve the pressure. 3. Inspect the filler caps for damage, for foreign material, and for deposits. 4. Clean the filler caps with a clean cloth or replace the filler caps, if necessary. 5. Install the filler 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

g01172742

SEBU7792-06

155 Maintenance Section Cooling System Water Temperature Regulator - Replace

2. Slowly remove filler 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 filler 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 specifications and are not damaged or have excessive buildup or deposits. NOTICE Since Caterpillar engines incorporate a shunt design cooling system, it is mandatory to always operate the engine with a thermostat. Depending on load, failure to operate with a 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.

Illustration 185 (1) Filler cap for the aftercooler cooling system (2) Filler cap for the jacket water cooling system

g01159005

2. Remove filler 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.

Install a new differential and final drive breather. Remove differential and final drive breather (1).Replace SMCS Code: 3258.SEBU7792-06 157 Maintenance Section Differential Thrust Pin Clearance . When a S·O·S program is used. . Engage the parking brake and stop the engine. “S·O·S Information”.Check i02320510 2. i02320548 • 4000 service hours or 1 year if Caterpillar FDAO/FD-1 oil is used.Check SMCS Code: 3258. Illustration 188 g01160212 1. For more information on S·O·S services.Change SMCS Code: 3258. This adjustment procedure is located in the Power Train Testing and Adjusting. the oil change interval is based on the following: Illustration 187 See the Adjustment Procedure For the Pin. 3. 4050 The oil change interval for the differential and final drives can be monitored with a S·O·S (Scheduled Oil Sampling) program. Differential and Final Drive Breather . Park the machine on a level surface. 3284 Differential and Final Drive Oil . refer to Operation and Maintenance Manual. the oil change interval is based on the following: g01160191 • The condition of the oil • The S·O·S recommendation When a S·O·S program is not used. TDTO/TO-4 oil is used. i02454361 Differential Thrust Pin Clearance . “Differential and Bevel Gear Adjust” for your machine. 3260. Rotate the wheels so that final drive drain plug (1) is in the lowest position on the rear wheel. 4050 • 2000 service hours or 1 year if Caterpillar Illustration 189 g01160272 1. Engage the parking brake and stop the engine. Park the machine on a level surface. 2.

perform the procedures in Operation and Maintenance Manual. NOTICE If the ambient temperature at engine start-up or during operation is below −10°C (14°F). Clean the drain plug. Note: The differential and final drive oil level needs to be checked and maintained at operating temperature. Check the differential compartment and the final drive compartment for the proper fluid level. Dispose of all fluids according to local regulations and mandates. Operate the machine on level ground for a few minutes. Fill each final drive to the bottom of the filler plug opening. 9. 14. adjusting and repair of the product. “Capacities (Refill)”. Fill the differential compartment to the bottom of the opening for the sight gauge. adjustment of the oil level may be necessary when the truck reaches operating temperature. Note: The final drives may need to be repositioned in order to place the final drive drain plug in the lowest position. Refer to Operation and Maintenance Manual. Clean the sight gauge and install the sight gauge. Wipe the surface around the opening for the sight glass. Before the differential and final drives are filled. Remove sight gauge (4). Note: Allow oil to fill all of the compartments.Change SEBU7792-06 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. After the oil has been changed in the differential and final drives. Illustration 191 g01160268 13. Remove differential drain plug (3) and allow the oil to drain into a suitable container. Correct oil levels are critical in the differential and final drives. maintenance. refer to Operation and Maintenance Manual. “Lubricant Viscosities” and Operation and Maintenance Manual. Drain the oil into a suitable container. “Differential and Final Drive Oil . Note: Inspect the magnetic drain plug and the oil. 3. Clean the drain plug. 8. Install the drain plug. Maintain the proper oil level (5) for the differential to the bottom of sight gauge (4). 7. testing. Remove the final drive drain plug. the final drive filler plug will be at the correct oil level. Repeat Step 1 through Step 4 for the other final drive. When the final drive drain plug is in the lowest position.Inspect” for further information. NENG2500. 4.158 Maintenance Section Differential and Final Drive Oil . . Illustration 190 g01160274 6. 12. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Special Publication. 5. 10. Failure to warm up the oil or improper lubrication levels prior to operation will cause damage to the machine. Install the drain plug. “Differential Warm-up and Break-in”. Remove final drive filler plugs (2). “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. 11.

Check SMCS Code: 3258. Park the machine on a level surface and engage the parking brake. Check the oil level. Differential and Final Drive Oil Level . Check the oil level prior to operation. i02450436 The differential and final drive oil level needs to be checked and maintained at operating temperature. If necessary. Maintain the proper oil level (2) at the bottom of the sight gauge. Check the oil level after repairs and after maintenance. . adjust the oil level to the bottom of the sight gauge. • A high amount of metal on the magnetic plug • An increased level of nickel concentration in the S·O·S sample S·O·S 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. A reduction of the life of components may be the result of overheating and foaming of the oil.SEBU7792-06 159 Maintenance Section Differential and Final Drive Oil . Note: If it is necessary to add oil. use final drive filler plug (2). Differential and Final Drive Oil . adjustment of the oil level may be necessary when the truck reaches operating temperature. Note: Overfilling the differential and final drives will cause overheating and foaming of the oil in long hauling applications and high speed applications.Inspect Illustration 192 g01195747 SMCS Code: 4208 Inspect the differential and final drive oil for any of the following symptoms that may indicate a mechanical failure: Location of the sight gauge for the differential and final drives 1. Stop the machine. Consult your Caterpillar dealer for more information. If the differential and final drive oil has any of the above symptoms. the rear wheel bearings may need to be inspected. i02394551 Illustration 193 g01160336 2. make sure that the filler plug is positioned above the oil level in the final drive in order to prevent any oil from draining out. Use sight gauge (1) to check the oil level for the differential and final drives. 4050 Correct oil levels are critical in the differential and final drives. 3.Inspect 15. do not adjust or inspect the rear wheel bearings. If the oil level is checked cold. Unless a symptom of an obvious failure appears.

Using the same pump for both types of samples may contaminate the samples that are being drawn. 4070-008. SEBU6250.160 Maintenance Section Differential and Final Drive Oil Sample . Sampling valve (1) for the differential and final drive oil is located on the base of the rear axle oil filter. In order to maintain sufficient vision. Allow the oil to fill all of the compartments before rechecking the oil level. “How To Take A Good Oil Sample” • Special Publication.Obtain SMCS Code: 3258-008. the filler plug will be at the correct oil level.Clean (If Equipped) SMCS Code: 7347-070. Illustration 196 WAVS display Illustration 195 g01160351 g01223034 .Obtain SEBU7792-06 NOTICE Always use a designated pump for oil sampling. i02320757 • Operation and Maintenance Manual. 4. PEDP8025. and use a separate designated pump for coolant sampling. Note: Overfilling the differential and final drives will cause overheating and foaming of the oil in long hauling applications and high speed applications. 4050-008. add oil. If necessary. PEHP6001. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers. “Fluid Analysis Interpretaion Guide” i04148950 Differential and Final Drive Oil Sample . When the drain plug is in the lowest position. 7348-070 The Work Area Vision System (WAVS) and the Cat Integrated Object Detection System both utilize multiple cameras and a display. Use filler plug (3) for the final drive in order to add oil. keep the camera lens and the display clean. “S·O·S Information” Analysis” • Special Publication. 7542 Display and Camera . Illustration 194 g01192672 Refer to the following publications for information about obtaining an oil sample. “S·O·S Oil • Special Publication. Make sure that the filler plug is positioned above the oil level in the final drive in order to prevent any oil from draining out. A reduction of the life of components may be the result of overheating and foaming of the oil.

Refer to Operation and Maintenance Manual. The display has a soft plastic surface that can be easily damaged by an abrasive material.Lubricate i02321492 Drive Shaft Slip Joint Lubricate SMCS Code: 3253-086-JT Illustration 197 Cat Integrated Object Detection System display g02217954 Use a soft. . For more information on Cat Integrated Object Detection System. Service the air cleaner filter elements when the action light is activated. Illustration 199 g01160565 Park the machine on a level surface. refer to Operation and Maintenance Manual. damp cloth in order to clean the display.Clean/Replace SMCS Code: 1051-070-PY. Park the machine on a level surface. “Vital Information Management System (VIMS)” for further information. Do not immerse the display with liquid. Engine Air Filter Primary Element . and the VIMS display will provide a message regarding the specific problem. “Camera”. The action light is located on the dash panel. The camera is not affected by high-pressure spray. For more information on WAVS. The display is not sealed. 1051-510-PY. Note: The camera is equipped with an internal heater to help counteract the effects of condensation. Engine damage could result. Engage the parking brake and stop the engine. The action light will activate when there is an inlet air restriction. 1054-510-PY NOTICE Service the air cleaner only with the engine stopped. Use a damp cloth or water spray in order to clean the camera lens. snow. Apply lubricant to the grease fitting on the drive shaft spline. 1. “Cat Integrated Object Detection System”. or ice. i02346978 Illustration 198 g01223051 The camera for WAVS and the Cat Integrated Object Detection System . 1054-070-PY. Engage the parking brake and stop the engine.SEBU7792-06 161 Maintenance Section Drive Shaft Slip Joint . The camera is a sealed unit. refer to Operation and Maintenance Manual.

Damaged elements will allow dirt to pass through.Clean/Replace SEBU7792-06 Cleaning Primary Air Filter Elements NOTICE Caterpillar recommends certified air filter cleaning services available at participating Caterpillar dealers. This replacement should be performed regardless of the number of cleanings. 6. Do not use air filters with damaged pleats. Dirt entering the engine will cause damage to engine components. or seals. Air pressure must not exceed 207 kPa (30 psi). Install clean primary air filter elements. Remove covers (1) for the air filter housings. Clean the inside of the air filter housings. 5. Do not wash the filter element. 4. gaskets. The primary air filter element can be used up to six times if the element is properly cleaned and the element is properly inspected. install new primary filter elements. Install the covers for the air filter housings. check for rips or tears in the filter material. When the primary air filter element is cleaned. or seals. Use low pressure compressed air in order to remove the dust from the filter element. If the alert indicator activates after starting the engine or the exhaust smoke is still black after installation of clean primary filter elements. 3. gaskets. the gaskets. • Pressurized air • Vacuum cleaning . Do not use elements with damaged pleats. Note: Refer to “Cleaning Primary Air Filter Elements”. If the alert indicator remains activated. Visually inspect the primary air filter elements before cleaning. and the outer cover. Engine damage could result.162 Maintenance Section Engine Air Filter Primary Element . Remove primary filter elements (2) from the air filter housings. Inspect the air filter elements for damage to the seal. The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufficient filter life. The primary air filter element should be replaced at least one time per year. Direct the air flow up the pleats and down the pleats from the inside of the filter element. Discard any damaged air filter elements. Take extreme care in order to avoid damage to the pleats. NOTICE Do not clean the air filter elements by bumping or tapping. replace the secondary elements. This could damage the seals. Observe the following guidelines if you attempt to clean the filter element: Do not tap or strike the filter element in order to remove dust. Clean the dust valves on the bottom for the air filter housings. There are two common methods that are used to clean primary air filter elements: Illustration 200 g00102316 2.

Do not aim the stream of air directly at the primary air filter element. If it is necessary in order to confirm the result. compare the primary air filter element to a new primary air filter element that has the same part number. Do not use a primary air filter element that has any tears and/or holes in the filter material.SEBU7792-06 163 Maintenance Section Engine Air Filter Secondary Element . Do not use a primary air filter element with damaged pleats. Do not attempt to reuse it by cleaning. Use filtered. dry air with a maximum pressure of 207 kPa (30 psi). gaskets or seals. Pressurized air will not remove deposits of carbon and oil. Inspect the primary air filter element for tears and/or holes. Vacuum cleaning will not remove deposits of carbon and oil. Use a 60 watt blue light in a dark room or in a similar facility. Replace the secondary elements if the exhaust smoke remains black and the clean primary elements have been installed. Cleaning with pressurized air is recommended prior to vacuum cleaning. Inspect the primary air filter element for light that may show through the filter material. Place the blue light in the primary air filter element. 1. dusty environment. Discard damaged primary air filter elements. always begin with the clean side (inside) in order to force dirt particles toward the dirty side (outside). Engine Air Filter Secondary Element . Aim the hose so that the air flows inside the element along the length of the filter in order to help prevent damage to the paper pleats. Park the machine on a level surface. Rotate the primary air filter element.Replace Pressurized Air Pressurized air can be used to clean primary air filter elements that have not been cleaned more than two times. Engine damage could result. dry primary air filter element.Replace SMCS Code: 1054-510-SE NOTICE Always replace the secondary element. Inspecting the Primary Air Filter Elements Illustration 202 g00281693 Illustration 201 g00281692 Note: When the primary air filter elements are cleaned. . Dirt could be forced further into the pleats. i02347040 Vacuum Cleaning Vacuum cleaning is another method for cleaning primary air filter elements which require daily cleaning because of a dry. Inspect the clean. Note: Replace the engine air filter secondary elements when you service the engine air filter primary elements for the third time. Engage the parking brake and stop the engine.

Install the primary elements. If the load factor is higher than 40 percent. 4. 5. The quantity of burned fuel that is shown with the service hours assumes a load factor of 40 percent. Rebuild/Install Reman. Park the machine on a level surface. i02363128 Engine Components Clean/Inspect. Paint will cause the rubber to harden and the rubber may not seal properly. If the load factor is lower than 40 percent. Install the clean lower precleaner bowl. if necessary. Gaskets and O-rings • Camshaft Bearings Illustration 204 g01180274 • Engine Mounts • Engine Software • Fuel Pressure Regulating Valve • Fuel Priming Pump • Gear Train Bushings. and the clean dust valve and tighten the clamp on the precleaner. 5. Perform the following procedure for each engine air precleaner. Engage the parking brake and stop the engine. Illustration 203 (1) Secondary element g00644798 NOTICE Do not operate the machine with the dust valves removed. Loosen clamp (1) on the precleaner and remove lower precleaner bowl (2) and dust valve (3). Cover the air inlet openings. Remove secondary elements (1) and properly discard the secondary elements. 1000-022-MC. the number of service hours for the overhaul interval will be higher. 1. 1000-571-IC Caterpillar recommends this additional maintenance for the following engine components. i02381002 3. 3. 2. Make sure that all of the tubes within the precleaner are free of dirt. Clean the lower precleaner bowl and the dust valve with air pressure. 4. Uncover the air inlet openings. Engine damage can occur. Clean the inside of the air cleaner housings. Clean the tubes. Consult your Caterpillar dealer for further information. The quantity of consumed fuel is a better indicator for the overhaul interval than service hours. the number of service hours for the overhaul interval will be lower.Clean SMCS Code: 1055-070 Install New Components • All Seals.Clean SEBU7792-06 2. Install New SMCS Code: 1000-012-IC. Bearings and Thrust Plates • Main Bearings. . Engine Air Precleaner . Install the new secondary elements. Rod Bearings and Crankshaft Thrust Plates Note: Do not paint dust valves (3).164 Maintenance Section Engine Air Precleaner .

SEBU7792-06 165 Maintenance Section Engine Components . 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. Consult your Caterpillar dealer for further information. • 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 i02381004 • Turbochargers (3516B High Displacement Engine) • Injectors • Refrigerant Compressor • Wastegate (3516B High Altitude Engine) i02322735 Engine Crankcase Breather Clean SMCS Code: 1317-070-ENG The engine in this machine is equipped with six engine crankcase breathers. If the load factor is lower than 40 percent. the number of service hours for the mid-life service interval will be lower. 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.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. Engine Components Rebuild/Install Reman SMCS Code: 1000-022-MC Caterpillar recommends this additional maintenance for the following engine components.

5. 7. Loosen clamps (4).166 Maintenance Section Engine Oil Filter (Oil Renewal System) . 6. Remove the breather assemblies from the valve covers. maintenance. The oil must be warm and the engine must be stopped. Tighten all clamps. 4. Remove hose (2) from breather assemblies (1) and from vent tube (3).Change SEBU7792-06 i02398716 Engine Oil Filter (Oil Renewal System) . testing. Install the hose on the breather assemblies and on the vent tube. Stop the engine. Install the breather assemblies on the valve covers. Park the machine on a level surface and engage the parking brake. Do not allow hot oil or hot components to contact the skin. Refer to Special Publication. Illustration 205 g01160965 1. The machine must be parked on a level surface and the parking brake must be engaged. adjusting and repair of the product. Wash the breather in clean nonflammable solvent. Illustration 206 (1) Engine oil filters (2) Oil filler cap (3) Dipstick g01162192 . Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Dispose of all fluids according to local regulations and mandates. 3. 1349 Hot oil and hot components can cause personal injury. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. 2.Change (If Equipped) SMCS Code: 1308-510. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Repeat Step 2 through Step 6 in order to clean the remaining breathers on the engine. NENG2500.

Check 1. Maintain the oil level between the “ADD” mark and the “FULL” mark. Illustration 207 Location of the dipstick for the engine oil g01162246 The tire and the wheel have been removed for ease of viewing. The steering system is hydraulically controlled and wheels can crush personnel during movement. Tighten each filter according to the instructions that are printed on the filter. 3. These marks are on the “LOW IDLE” side of dipstick (2). . If necessary. 4.Check SMCS Code: 1348-535-FLV 1. Install the new engine oil filters by hand. ensure that all personnel are clear of the machine before any movement. Use caution when working between the wheels and the frame. 7. remove oil filler cap (1) and add oil. The machine must be on a level surface and the parking brake must be engaged. in order to turn the filters to the amount that is required for final installation. Start the engine and operate the engine at low idle for five minutes. Note: You may need to use a Caterpillar strap wrench. Make sure that the installation tool does not damage the filters. Check the oil level in the engine. maintain the oil level between the “ADD” mark and the “FULL” mark. 5. When the engine is stopped. Make any necessary repairs. or another suitable tool. 2. use the rotation index marks as a guide. Apply a thin film of clean engine oil to each seal of each new engine oil filter . Illustration 208 i02682174 g01162249 Engine Oil Level . 2. maintain the oil level between the “ADD” mark and the “FULL” mark. Make sure that all of the former gaskets are removed. 3. Stop the engine. These marks are on the “ENGINE STOPPED” side of the dipstick. b. When you tighten the filters. 4. Personal injury or death can occur if personnel are trapped between the wheel and the frame. NOTICE Do not under fill or overfill engine crankcase with oil. If the wheels must be turned. Clean the filler cap and install the filler cap. Tighten each filter until the seal of each engine oil filter contacts the base. Remove used engine oil filters (1) and discard the used engine oil filters . 6. Inspect engine oil filters (1) for oil leaks. Clean the oil filter base assemblies. Use the index marks as a guide. These marks are on the “LOW IDLE” side of dipstick (3). Either condition can cause engine damage.SEBU7792-06 167 Maintenance Section Engine Oil Level . Note the position of the index marks on each filter in relation to a fixed point on the filter base. When the engine is running at low idle. a. Note: Caterpillar filters have rotation index marks that are spaced 90 degrees or 1/4 of a turn away from each other.

Change SMCS Code: 1308-510. This data can be used to determine if the Oil Renewal System is working properly. Normal operation will continually lower the oil level in the crankcase.Log Additions SEBU7792-06 i02326857 i02326499 Engine Oil Level . “S·O·S Oil • Special Publication. Refer to the following publications for information about obtaining an oil sample. . • Operation and Maintenance Manual. Keeping a daily maintenance log of all of the additions of oil is necessary for the accuracy of this data. “S·O·S Illustration 209 g00408438 Information” Analysis” The Oil Renewal System (ORS) meters engine oil that is blended into the fuel supply. “Engine Oil Filter (Oil Renewal System) Change”. Continually adding new engine oil will allow the life of the oil to be extended.Log Additions (If Equipped with the Oil Renewal System) SMCS Code: 1348. “Oil Renewal System”. engine oil is blended into the fuel supply of the machine. 1349 Engine Oil Sample . PEHP6001. PEDP8025. In order to change the engine oil filters only.168 Maintenance Section Engine Oil Level . Normal operation will continually lower the oil level in the crankcase. This oil will be consumed by the engine during the process of combustion. The graph in Illustration 209 plots the quantity of added oil against the service hours during a 500 hour period. Continually adding new oil will allow the life of the oil to be extended. “Fluid Analysis Interpretation Guide” i02454647 Engine Oil and Filter . 7542 Illustration 210 Sampling Valve For The Engine Oil g01162265 The sampling valve for the engine oil is located above the engine oil filters. refer to Systems Operation. This oil will be consumed in the engine during the process of combustion. An S·O·S analysis will determine if the oil needs to be changed. • Special Publication. This information is needed at the time of each S·O·S analysis. 1348-044 Note: If your machine is equipped with the Oil Renewal System (ORS). “How To Take A Good Oil Sample” • Special Publication. An S·O·S Oil Analysis will determine if the oil needs to be changed. The daily maintenance log will also indicate the total amount of oil that has been added since the last oil change. SEBU6250. refer to Operation and Maintenance Manual. For more information on the Oil Renewal System.Obtain SMCS Code: 1348-008. RENR2223. The daily maintenance log is also necessary for adjustment of the metering rate.

5. “Lubricant Viscosities” for the type of oil. Remove oil filler cap (3). The oil change intervals are determined by close monitoring of the oil condition and engine wear metals. maintenance.Change 1. Do not allow hot oil or hot components to contact the skin. in order to turn the filters to the amount that is required for final installation. Apply a thin film of clean engine oil to the seal of each new engine oil filter. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. testing. Refer to Special Publication. When you tighten the filters. Install the new engine oil filters by hand. 6. Dispose of all fluids according to local regulations and mandates. Use the index marks as a guide. Illustration 211 g01162319 . Hot oil and hot components can cause personal injury. “Capacities (Refill)” for the amount of oil. Note: Some commercial oils that meet API specifications may require shorter oil change intervals. Refer to Operation and Maintenance Manual. Make sure that all of the former gaskets are removed. adjusting and repair of the product. Close the drain valve . Note: You may need to use a Caterpillar strap wrench. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Consult your Caterpillar dealer for the latest oil recommendations. Remove the used engine oil filters (2) and discard the used engine oil filters. 4. 7.SEBU7792-06 169 Maintenance Section Engine Oil and Filter . use the rotation index marks as a guide. Fill the crankcase with oil. NENG2500. Tighten each engine oil filter until the seal of each engine oil filter contacts the base of the oil filter housing. Note: Caterpillar filters have rotation index marks that are spaced 90 degrees or 1/4 of a turn away from each other. Illustration 212 g01162326 2. Tighten each filter according to the instructions that are printed on the filter. The machine must be parked on a level surface and the parking brake must be engaged. Open drain valve (1) and drain the oil into a suitable container. or another suitable tool. Clean the oil filter base assemblies. 3. The oil must be warm and the engine must be stopped. Caterpillar prefers the scheduled oil sampling as the proper method of checking engine wear metals. Make sure that the installation tool does not damage the filters. Note the position of the index marks on each filter in relation to a fixed point on the filter base. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Refer to Operation and Maintenance Manual.

0031 inch) of the given nominal clearance.5 mm (0. Make any necessary repairs. set the clearance to the amount that is specified in the chart. Testing And Adjusting.Inspect SMCS Code: 1361-040 Valve Lash Adjustment NOTICE Operation of Caterpillar Engines with improper engine valve lash adjustments will reduce the engine efficiency. 9. Illustration 213 g00653920 To check the engine valve lash. i02342142 Table 12 VALVE CLEARANCE SETTING Inlet Exhaust 0. Illustration 214 g01162405 (1) Water pump for the jacket water cooling system (2) Auxiliary water pump for the aftercooler cooling system . do not use the starter motor to turn the flywheel. These marks are on the “LOW IDLE” side of dipstick (4). Stop the engine. “Valve Lash and Valve Bridge Adjustment”.08 mm (0. “3500B Engines For Caterpillar Built Machines”.170 Maintenance Section Engine Valve Lash and Bridge . Valve Bridge The engine in this machine is equipped with a nonadjustable valve bridge.04 inch) Engine Valve Lash and Bridge . SENR1123. no adjustment is required. Start the engine and operate the engine at low idle for five minutes. The electronic unit injector system uses 90-120 volts. Hot engine components can cause burns. refer to System Operation. Engine Water Pump . Consult your Caterpillar dealer for any additional information. i02326985 Electrical shock hazard.Adjust SEBU7792-06 8.Adjust SMCS Code: 1102-025 To prevent personal injury. Maintain the oil level between the “ADD” mark and the “FULL” mark. If the clearance is not within the given limits. Measure the engine valve lash with the engine stopped.00 mm (0. This reduced efficiency could result in excessive fuel usage and/or shortened engine component life. Inspect the engine oil filter for oil leaks. To obtain an accurate measurement.02 inch) 1. Allow additional time for the engine to cool before measuring valve clearance. If the valve clearance is within 0. Proceed with the valve lash adjustment. allow at least 20 minutes for the valves to cool to engine cylinder head and block temperature.

all the seals need to be replaced. “Engine Disassembly and Assembly”. Use ether only in well ventilated areas. Park the machine on a level surface. Note: See Service Manual. Do not smoke while changing ether cylinders. Use ether with care to avoid fires. 1. all the seals need to be replaced. Keep ether cylinders out of the reach of unauthorized personnel. Engage the parking brake and stop the engine. Do not puncture or burn cylinders. Note: See Service Manual.Replace Water Pump for the Jacket Water Cooling System A water pump (1) that has failed might cause severe engine overheating problems. be sure the brakes are applied and all controls are in Hold or Neutral when starting the engine. To avoid possible injury. Illustration 215 g01163382 The two ether starting aid cylinders are mounted behind the radiator. If leaks are found. Do not store ether cylinders in direct sunlight or at temperatures above 49 °C (120 °F). Auxiliary Water Pump for the Aftercooler Cooling System An auxiliary water pump (2) that has failed might cause severe engine overheating problems. . 2. • Valve failures • Warped intake manifolds • Other potential engine damage Visually inspect auxiliary water pump (2) for leaks. Loosen the clamps and unscrew the ether starting aid cylinders. The engine overheating problems could result in the following problems.SEBU7792-06 171 Maintenance Section Ether Starting Aid Cylinder . The engine overheating problems could result in the following problems. “Engine Disassembly and Assembly”. Discard cylinders in a safe place. i02330233 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. Do not store replacement ether cylinders in living areas or in the operator's compartment. 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.

For the proper procedure. REHS0541. Install the new ether starting aid cylinders. Repair.Clean/Inspect SMCS Code: 7050-571 Note: The graphics that are shown are for illustrative purposes. 3. “Procedure for the Inspection.172 Maintenance Section Frame . Illustration 216 g01167516 Illustration 217 g00980903 1. 4. 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. Clean the rear axle a-frame and the differential housing with a wire brush or with a scraper. i02340776 4. 1. Clean the frame with a high pressure washer. Tighten the clamps. Install the rear tow point pin through the end of the retaining cable. refer to Operations and Maintenance Manual. Failure to properly secure the body (bed) may result in personal injury or death. Do not operate the machine until the necessary repairs have been made. consult your Caterpillar dealer for specific repair procedures. . Stop the engine. Install the rear tow point pin through the end of the retaining cable. consult your Caterpillar dealer for specific repair procedures. Note: Refer to Special instruction. Failure to properly secure the body (bed) may result in personal injury or death. Inspect the designated areas for cracks. “Cable (Truck Body Retaining)”. Park the machine on a level surface and engage the parking brake. 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. If you find cracks or damage. 5. attach the body (bed) retaining cable to the rear tow point. refer to Operations and Maintenance Manual. and Component Replacement on the Frames of Off-Highway Truck/Tractor”. “Cable (Truck Body Retaining)”. Frame . 2. If you find cracks or damage.Clean/Inspect SEBU7792-06 3. This is an in-chassis inspection. Raise the dump body to the fully raised position and install the truck body retaining cable to the rear tow point pin. Inspect the frame for damage and for cracks. Remove the used gasket for each ether starting aid cylinder and install the new gasket that is provided for each ether starting aid cylinder. 2. When it is necessary to work under the machine with the body (bed) raised.

Inspect the bottom of the differential housing in the area that is indicated by shading. Inspect the welds of the rear axle a-frame. c. . Inspect the area around the bolt holes of the rear axle a-frame. Inspect the top rear sides of the differential housing in the area that is indicated by shading.Clean/Inspect Illustration 218 g00980907 Illustration 220 g00980956 a. Illustration 219 g00980933 Illustration 221 g01167529 b.SEBU7792-06 173 Maintenance Section Frame . d. Inspect the inside face of the rear axle a-frame in the area that is indicated by the shading.

. If the frame is damaged or worn. Failure to properly secure the body (bed) may result in personal injury or death. Inspect the differential housing in the area around the lower half of the differential mounting surface that is indicated by shading. Inspect the dump body. 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. If the dump body is damaged or worn. “Cable (Truck Body Retaining)”. 1. Stop the engine. attach the body (bed) retaining cable to the rear tow point. 3. consult your Caterpillar dealer for repair procedures. i02340837 When it is necessary to work under the machine with the body (bed) raised.Clean/Inspect SMCS Code: 7050-571. Inspect the dump body.174 Maintenance Section Frame and Body . Raise the dump body to the fully raised position and install the truck body retaining cable to the rear tow point pin. Park the machine on a level surface and engage the parking brake. Park the machine on a level surface and engage the parking brake. Clean the frame with a wire brush or a scraper. 1. 5. 7258-040 4. Clean the dump body with a wire brush or a scraper. attach the body (bed) retaining cable to the rear tow point. 2. For the proper procedure. i02340811 Illustration 223 g01167539 Frame and Body . consult your Caterpillar dealer for repair procedures. refer to Operations and Maintenance Manual. 7258-571-S4 When it is necessary to work under the machine with the body (bed) raised. Install the rear tow point pin through the end of the retaining cable.Inspect SMCS Code: 7050-040.Inspect SEBU7792-06 Illustration 222 g00981044 e. Frame and Body Support Pads .

The steering system is hydraulically controlled and wheels can crush personnel during movement. 2. Install a new breather on each front wheel. If the S·O·S scheduled oil sampling program is not used. i02457383 1.SEBU7792-06 175 Maintenance Section Front Axle Breather .Change SMCS Code: 4201-044-OC Note: The oil change interval for the front wheel bearing can be monitored with the S·O·S scheduled oil sampling program. 3. Engage the parking brake and stop the engine. “Cable (Truck Body Retaining)”. refer to Operations and Maintenance Manual. For the proper procedure. If problems are found.Replace SMCS Code: 4251 Personal injury or death can occur if personnel are trapped between the wheel and the frame. the oil change for the front wheel bearing should be performed at 500 service hours or 3 months. Stop the engine. Illustration 226 g01163440 . Look for damage or uneven wear of the body support pads. 5. Use caution when working between the wheels and the frame. consult your Caterpillar dealer for more information or for specific repair procedures. Remove breather (1) from each front wheel. Illustration 224 g01167566 Illustration 225 g01163437 4. 3. ensure that all personnel are clear of the machine before any movement. Visually inspect each of the body support pads. The interval is based on the condition of the oil. Raise the dump body to the fully raised position and install the truck body retaining cable to the rear tow point pin. Front Axle Breather . Clean the body support pads with high pressure water or steam. Look for gaps between the body support pads and the mating surfaces.Replace 2. i02330775 Front Wheel Oil . Park the machine on a level surface. If the wheels must be turned.

“Lubricant Viscosities”.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 S·O·S sample S·O·S sample • An increase in the size of the particle count in the • Oil leaks in the area around the front wheel spindle . i02388737 The front wheel bearings do not need to be adjusted or inspected until the scheduled overhaul. Engage the parking brake and stop the engine. Clean the filler plug and install the filler plug. Allow the oil to drain into a suitable container. adjusting and repair of the product. 4. maintenance. 3. Remove the filler plug (2). 7. use a clean cloth to wipe the area around the filler plug before you remove the filler plug. 5. Clean the filler plug and install the filler plug. Refer to Special Publication. i03025216 Front Wheel Oil Level . Dispose of all fluids according to local regulations and mandates. Front Wheel Oil .176 Maintenance Section Front Wheel Oil . Unless a symptom of an obvious failure appears. 3. Remove the drain plug. do not adjust or inspect the front wheel bearings.Inspect SEBU7792-06 1. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Stop the engine and engage the parking brake. 6. 8. Remove the filler plug. Use the same procedure for the other front wheel bearing. Clean the drain plug and install the drain plug. Illustration 227 g01180364 Note: In order to prevent dirt from entering the wheel bearing. Park the machine on a level surface. 2. If the front wheel oil has any of the above symptoms. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection.Check SMCS Code: 4201-535-FLV 1. Consult your Caterpillar dealer for more information. “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Refer to Operation and Maintenance Manual. Refer to Operation and Maintenance Manual. the front wheel bearings may need to be inspected. testing. Maintain the oil level to the bottom of the filler plug opening. “Capacities (Refill)”. 2. Fill the oil compartment to the bottom of the opening for the filler plug. Position the front wheel so that drain plug (1) is facing downward. 4. NENG2500. Park the machine on a level surface.

PEHP6001. NOTICE Use only a Caterpillar approved fast fill system to fuel machines. Over pressurization may cause tank deformation and fuel spillage. Turn the disconnect switch OFF or disconnect the battery when changing fuel filters. testing. Illustration 228 Filler plug for the front wheel g01180364 NOTICE Always use a designated pump for oil sampling. 7542 Fuel System . Contact your Cat dealer for fast fill system availability. “Fluid Analysis Interpretaion Guide” . Refer to Operation and Maintenance Manual.Obtain i02330789 i03315684 Front Wheel Oil Sample Obtain SMCS Code: 4201-008-OC. Refer to the following publications for information about obtaining an oil sample.Fill (Fast Fill Fuel Adapter) SMCS Code: 1250-544 Personal injury or death may result from failure to adhere to the following procedures. • Operation and Maintenance Manual. “S·O·S Oil Analysis” • Special Publication. Do not smoke while working on the fuel system. PEDP8025. Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Dispose of all fluids according to local regulations and mandates. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. and repair of the machine.SEBU7792-06 177 Maintenance Section Front Wheel Oil Sample . 1. adjusting. Using the same pump for both types of samples may contaminate the samples that are being drawn. maintenance. and use a separate designated pump for coolant sampling. “S·O·S Information” • Special Publication. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers. SEBU6250. Clean up all leaked or spilled fuel. “Capacities (Refill)” for the fuel tank capacity of your machine. The oil sample for the front wheel is obtained with a sampling gun through the filler plug. “How To Take A Good Oil Sample” • Special Publication. Park the machine on a level surface and engage the parking brake.

fuel pressure will increase. Clean up fuel spills immediately.Prime SEBU7792-06 Illustration 229 g01695333 Illustration 230 g01167459 2. Park the machine on a level surface. If the button does not remain depressed. If the engine starts but the engine runs rough. Hold the switch upward in order to activate the electric fuel priming pump. Clean the fast fill fuel adapter and the dust cover. Note: The maximum fuel flow rate for the fast fill fuel adapter group is 375 L/min (100 US gpm). As the air is purged from the fuel system. 3. 3.Prime SMCS Code: 1250-548 Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. 6. Start the engine.178 Maintenance Section Fuel System . SEHS9586. “3500 Electronic Unit Injection (EUI) Fuel Priming Procedure” or consult your Caterpillar dealer. The priming pump will fill the engine fuel lines and the fuel filters with fuel. . 4. continue to run the engine at low idle until the engine runs smoothly. Note: The engine start switch must be in the OFF position in order to prime the fuel system. 4. 1. if necessary. Fuel System . Push in the button in order to reset the circuit breaker. Observe fuel level sight gauge (2) in order to prevent overfilling. Install the dust cover on the adapter. 5. If the electrical system is working properly. Pull out on switch (1) in order to release the switch. check the electrical circuit for the priming pump. i02435121 2. Note: Button (2) is the circuit breaker reset for the electric fuel priming pump. 7. Do not continue priming the fuel system after the priming pump is under load. the button will remain depressed. refer to Special instruction. Do not operate the priming pump for more than two minutes. Repair the electrical circuit. If the engine does not start after several attempts. Fill the fuel tank through the fast fill fuel adapter. Engage the parking brake and stop the engine. 5. Remove dust cover (1) and clean the fast fill fuel adapter. Listen for the electric fuel priming pump to come under load.

Open drain valves (1) on the bottom of the fuel/water separator elements in order to drain the water into an approved container. Dispose of all fluids according to local regulations and mandates. Refer to Special Publication. . “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. maintenance.SEBU7792-06 179 Maintenance Section Fuel System Primary Filter (Water Separator) . adjusting and repair of the product. The fuel will not be filtered and could be contaminated. testing. Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. turn the battery disconnect switch to the OFF position when changing fuel filters or water separator elements. NENG2500. “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. 1263-543 Park the machine on a level surface. Refer to Special Publication. Dispose of all fluids according to local regulations and mandates. NENG2500. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Personal injury or death can result if spilled fuel ignites. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Engage the parking brake and stop the engine. Illustration 231 g01167092 The fuel/water separators are located on the right inside frame rail in front of the front axle. NOTICE Do not fill fuel filters with fuel before installing them. testing. Clean up fuel spills immediately. adjusting and repair of the product. Close the drain valves when all of the water has been drained. maintenance. Contaminated fuel will cause accelerated wear to fuel system parts. 1263-510-FQ Replace the fuel/water separator elements when the engine has a loss of power or when the exhaust smoke is black. Park the machine on a level surface and engage the parking brake. Fuel System Primary Filter (Water Separator) Element Replace (If Equipped) SMCS Code: 1260-510. The fuel system should be primed prior to starting the engine. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. 1. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection.Drain (If Equipped) SMCS Code: 1261-543. To help prevent possible injury.Drain i02338162 i02338293 Fuel System Primary Filter (Water Separator) .

3. When you tighten the elements. “Fuel System . NENG2500. testing. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Discard the used elements properly. Open the fuel shutoff valve. use the rotation index marks as a guide. maintenance. 11. Remove the fuel/water separator elements (2) with a strap type wrench. Prime the fuel system. Tighten all filters according to the instructions that are printed on the filter. For information on priming the fuel system. Note: You may need to use a strap type wrench or a suitable tool in order to turn the filters to the amount that is required for final installation. Note the position of the index marks on the elements in relation to a fixed point on the mounting base.180 Maintenance Section Fuel System Primary Filter . 12. Make sure that the installation tool does not damage the filters.Prime”. Lubricate the seals of the new elements with clean diesel fuel. Install the drain tube assembly to the bottom of the new elements. Make any necessary repairs. i02891403 Illustration 232 View of the back side of the fuel tank g01167276 2. 10. If the engine has a loss of power or the exhaust smoke is still black. Clean the mounting base. Illustration 233 g01167178 Fuel System Primary Filter Clean (If Equipped) SMCS Code: 1260-070. 8. refer to the Operation and Maintenance Manual. replace the secondary filters. The fuel/water separator is located on the right inside frame rail in front of the front axle. 6. Refer to Special Publication. Make sure that both of the old seals are removed. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products.Clean SEBU7792-06 7. Start the engine and inspect the filter for leaks. Dispose of all fluids according to local regulations and mandates. 4. 5. 1261-070 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. adjusting and repair of the product. . Remove drain tube assembly (3) from the bottom of the drain valves for the fuel/water separator elements. 9. Install the new elements by hand until the seal contacts the mounting base. Note: There are rotation index marks on each filter that is spaced 90 degrees (1/4 turn) away from each other. Stop the engine and close fuel shutoff valve (1).

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. . Install the filter element and the filter housing.SEBU7792-06 181 Maintenance Section Fuel System Priming Filter . Dispose of all fluids according to local regulations and mandates. Clean the primary element when the engine has a loss of power or when the exhaust smoke is black. Start the engine and inspect the filter for leaks. Make any necessary repairs.Prime”. Under normal circumstances. 6. use the procedure that follows. Park the machine on a level surface and engage the parking brake. for tools and supplies suitable to collect and contain fluids. Illustration 234 View of the back side of the fuel tank g01167019 2. If the engine has a loss of power or the exhaust smoke is still black. 5. Stop the engine and close fuel shutoff valve (1). adjusting and repair of the machine. 9. Stop the engine and close fuel shutoff valve (1). change the secondary filters. “Caterpillar Tools and Shop Products Guide”. Loosen bolt (2). If the filter base gasket is damaged. Prime the fuel system. Contaminated fuel will cause accelerated wear to fuel system parts. 7. Open the fuel shutoff valve. Fuel only flows through the filter when you activate the priming pumps. 4. Illustration 235 g01167276 2. Refer to Special Publication. Tighten bolt (2) to a torque of 25 ± 7 N·m (18 ± 5 lb ft). nonflammable solvent. Wash the base and the element in clean. Refer to Operation and Maintenance Manual. 1. 1. testing. 8. Fuel System Priming Filter Replace SMCS Code: 1258-510-FI. If the filter must be replaced. “Fuel System . the original fuel priming filter should last for the entire service life of the machine. replace the filter base gasket. 3. Park the machine on a level surface and engage the parking brake. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. 1261-510 The fuel priming filter is located on the right side of the engine directly below the electric fuel priming pump. Remove filter housing (3) and the filter element. NENG2500. maintenance.Replace i02345997 NOTICE Do not fill fuel filters with fuel before installing them.

Prime”. Clean the filter mounting base. Make sure that the old filter seals are removed. Clean the filter mounting bases.Replace SEBU7792-06 i02327025 Fuel System Secondary Filter Replace SMCS Code: 1261-510-SE 1. . 8. Make sure that the installation tool does not damage the filter. Tighten all filters according to the instructions that are printed on the filter. Remove fuel priming filter (2) with a strap type wrench. “Fuel System . use the rotation index marks as a guide. Park the machine on a level surface. Contaminated fuel will cause accelerated wear to fuel system parts. Tighten the filter for an additional 3/4 of a turn. Note the position of the index marks on the filter in relation to a fixed point on the mounting base. 6. 4. Engage the parking brake and stop the engine. Illustration 237 g01162420 2. Install the new filter by hand. Tighten all filters according to the instructions that are printed on the filter. Remove secondary fuel filters (1) with a strap type wrench. Install the new filter by hand until the seal contacts the mounting base. 7. Discard the used filters properly. Make sure that the former seal is removed. The fuel would not be filtered and could be contaminated. Lubricate the seals of the new filters with clean diesel fuel.182 Maintenance Section Fuel System Secondary Filter . Install the new filters by hand until the seal contacts the mounting base. Note: You may need to use a strap type wrench or a suitable tool in order to turn the filter to the amount that is required for final installation. When you tighten the filters. Note: There are rotation index marks on each filter that is spaced 90 degrees (1/4 turn) away from each other. Note the position of the index marks on the filters in relation to a fixed point on the mounting base. 4. use the rotation index marks as a guide. Discard the used filter properly. 6. Open the fuel shutoff valve. 3. 10. 5. Illustration 236 g01172157 3. When you tighten the filter. Tighten the filter until the sealing surface contacts the base. Prime the fuel system. 5. Lubricate the seal of the new filter with clean diesel fuel. Refer to Operation and Maintenance Manual. 9. Note: There are rotation index marks on each filter that is spaced 90 degrees (1/4 turn) away from each other. NOTICE Do not fill the secondary fuel filter with fuel before installing.

Reassemble the housing for the HID lamp. Disassemble the housing for the HID lamp in order to have access to the bulb. Engage the parking brake and stop the engine. Note: In order to avoid failure to the bulb that is premature. Replace the entire lens assembly on these HID lamps. Open fuel tank drain valve (1) and allow the moisture and the sediment to drain into a suitable container. 8. in order to ensure that the bulb is cool. Check for leaks and make any necessary repairs. Illustration 238 View of the back side of the fuel tank g01167012 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Remove the bulb from the HID lamp. the bulb is an integral part of the lens assembly.Prime”. i02338067 i02245859 High Intensity Discharge Lamp (HID) . Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Drain Note: You may need to use a strap type wrench or a suitable tool in order to turn the filters to the amount that is required for final installation. . or any waste that contains mercury. adjusting and repair of the product. The electrical power must be removed from the HID lamp for at least five minutes. Refer to Special Publication. testing. Start the engine and operate the engine at low idle. disconnect power before servicing HID lamps. Remove the electrical power from the high intensity discharge lamp (HID). “Fuel System . 1. Clean any fingerprints from the bulb with alcohol prior to operation. maintenance. Refer to the Operation and Maintenance Manual. Park the machine on a level surface. 3. 2. “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. The bulb is not removed separately from the lens assembly. 7. avoid touching the bulb's surface with your bare hands. Make sure that the installation tool does not damage the filters. Make sure that the parking brake is engaged. 4. Note: On some HID lamps. Before servicing.SEBU7792-06 183 Maintenance Section Fuel Tank Water and Sediment . 5.Drain SMCS Code: 1273-543-MAS HID lamps operate at very high voltages. NENG2500. install the replacement lens assembly in the HID lamp. Install the replacement bulb in the HID lamp. NOTICE Although HID bulb materials may change over time. When disposing of this component. please use caution and comply with any applicable laws. remove power from lamp for at least five minutes to ensure lamp is cool. Ensure that any printing on the lens is oriented correctly with respect to the HID lamp's mounting position on the machine. Dispose of all fluids according to local regulations and mandates.Replace (If Equipped) SMCS Code: 1434-510 Fuel Tank Water and Sediment . Close the drain valve. HID bulbs become very hot during operation. To avoid electrical shock and personal injury. Prime the fuel system. If the bulb is an integral part of the lens assembly. HID bulbs produced at the time of the printing of this manual contain mercury.

5. Tighten the bolts. or hoist pumps. Remove the bolts that attach hoses (1) to housings (2) for the hoist screen. 7. “Hoist and Brake Tank Oil Level . NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Note: Consult your Caterpillar dealer for additional information on HID lamps. Do not allow hot oil or hot components to contact the skin.Clean SMCS Code: 5057-070-Z3 g01440260 Illustration 239 When it is necessary to work under the machine with the body (bed) raised. 4. Check for leaks and make any necessary repairs. Drain the oil from the lines into a suitable container. 7. 2. 3. Stop the engine. Park the machine on a level surface and engage the parking brake. i02892963 Hoist Screens . Remove the hoist screens from the housings. If necessary. Clean the screens whenever there is a failure of the brakes. Start the engine and operate the engine at low idle. adjusting and repair of the product. Raise the truck body to the fully raised position and install the truck body retaining cable to the rear tow point pin. Check the HID lamp for proper operation. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. 8. The hoist screens are located on the right rear of the center tube. refer to Operation and Maintenance Manual. Hot oil and hot components can cause personal injury.Check”. Clean the hoist screens in clean nonflammable solvent. hoist cylinders. NENG2500. Install the clean hoist screens and the hoses. Check the oil level in the hoist/brake tank. Refer to Special Publication. 1. . testing. Dispose of all fluids according to local regulations and mandates. Use new seals. Install the rear tow point pin through the end of the retaining cable. refer to Operations and Maintenance Manual. “Cable (Truck Body Retaining)”. For the proper procedure for the installation and removal of the truck body retaining cable. 6. Failure to properly secure the body (bed) may result in personal injury or death. add oil. Remove the truck body retaining cable and lower the body.184 Maintenance Section Hoist Screens . For the proper procedure. 9. Reattach the electrical power to the HID lamp.Clean SEBU7792-06 6. attach the body (bed) retaining cable to the rear tow point. Make sure that the parking brake is engaged. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. maintenance.

Stop the engine. Install the rear tow point pin through the end of the retaining cable. 3. Clean the drain plug and install the drain plug. 1. 5057 Hoist and Brake Tank Oil Change SMCS Code: 5056 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Remove the truck body retaining cable and lower the body. 3. 4. 6.Replace SMCS Code: 5056. The parking brake must be engaged and the engine must be stopped.0 mm (3. Failure to properly secure the body (bed) may result in personal injury or death. The outer diameter of the NPT pipe nipple should be 25 mm (1 inch). The machine must be level. The truck body must be in the DOWN position.Replace i02340012 i02685600 Hoist and Brake Tank Breather . adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. This will prevent dirt from entering the system. Refer to Special Publication. refer to Operations and Maintenance Manual. . “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Drain the oil into a suitable container. Dispose of all fluids according to local regulations and mandates. Do not use tools. Illustration 241 g01172912 1. Remove the filler cap. 5. Illustration 240 g01172423 4. Note: Hand tighten the NPT pipe nipple.50 inch) long NPT pipe nipple in order to open the internal drain valve. Remove filler cap (1) in order to prevent a vacuum in the tank. testing. Install a 88. “Cable (Truck Body Retaining)”. Park the machine on a level surface and engage the parking brake. Raise the truck body to the fully raised position and install the truck body retaining cable to the rear tow point pin. Remove breather (1) and discard the breather properly. maintenance. 2. Remove tank drain valve plug (3). attach the body (bed) retaining cable to the rear tow point. When it is necessary to work under the machine with the body (bed) raised. For the proper procedure for the installation and removal of the truck body retaining cable. NENG2500. 2. Install a new breather. Remove the pipe nipple. Install the filler cap after the tank has been drained.SEBU7792-06 185 Maintenance Section Hoist and Brake Tank Breather .

if necessary.Check SMCS Code: 5056 1. “Lubricant Viscosities”. Crank the engine for approximately 15 seconds. Lower the truck body and add oil. Remove the retaining ring on the filler screen.186 Maintenance Section Hoist and Brake Tank Oil Level . Illustration 243 g01172846 Illustration 242 g01349223 2. Start the engine and operate the engine at low idle. 7. i02399492 Hoist and Brake Tank Oil Level . Remove the screen. Refer to Operation and Maintenance Manual. Raise the truck body until the hoist cylinders are fully extended. 16. Wash the cap and the filler screen in clean. Use engine shutdown control (4) to prevent the engine from starting.Obtain SMCS Code: 5056-008. Fill the hoist/brake tank. 14. 8. i02336350 9. g01188933 . Repeat Step 13 and Step 14 until the oil level stabilizes in the “FULL” mark in the upper sight gauge. Use a new seal if the used seal is damaged. If necessary. “Capacities (Refill)”. Add oil to the tank in order to raise the oil level to the “FULL” mark in upper sight gauge (2).Check SEBU7792-06 5. nonflammable solvent. 11. 13. Install the filler screen and the retaining ring. 7542 Illustration 244 The fuel tank is removed for ease of viewing. Hoist and Brake Tank Oil Sample . 10. The oil level will decrease as oil fills the system. Lower the truck body and add oil. remove filler cap (1) and add oil. Repeat Step 9 and Step 10 until the oil stabilizes in the “FULL” mark in the upper sight gauge. Check for leaks and make necessary repairs. 12. Install the filler cap. Inspect the cap seal. Park the machine on a level surface with the truck body in the DOWN position and engage the parking brake. 15. 6. Lower the guard on the engine shutdown control. Refer to Operation and Maintenance Manual. if necessary. Maintain the oil level to the “FULL” mark on sight gauge (2). Allow the cap and the filler screen to dry. Raise the truck body until the hoist cylinders are extended halfway.

Wash the suction screens in clean. 3. The truck body must be in the DOWN position. 7. Install the clean suction screens and install the hoses and flanges. Drain the oil into a suitable container. If the gasket is damaged. There are three suction screens on the hoist/brake tank. Remove tank drain plug (1).4 mm (1. hoist cylinders or hoist pumps. maintenance. Note: Hand tighten the NPT pipe nipple. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. “S·O·S Information” Analysis” • Special Publication. PEDP8025.00 inch). 8. Remove the flanges and three hoses (3). “Fluid Analysis Interpretaion Guide” Illustration 245 g01165906 i02685621 Hoist and Brake Tank Suction Screen .50 inch) long NPT pipe nipple in order to open the internal drain valve. Do not use tools. 2. adjusting and repair of the product. testing. 6. PEHP6001. Clean the cover for the front of hoist and brake tank in clean. SEBU6250. The machine must be level. “How To Take A Good Oil Sample” • Special Publication. NENG2500. 1. “S·O·S Oil • Special Publication. Dispose of all fluids according to local regulations and mandates. Refer to Special Publication.Inspect/Clean/Replace SMCS Code: 5056 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Remove the bolts from cover (2) on the front of the hoist and brake tank. Install a 88. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Inspect/Clean/Replace Sampling valve (1) for the hoist and brake oil is located at the base of the brake cooling oil filters. Refer to the following publications for information about obtaining an oil sample. replace the gasket. . Clean the debris from the bottom of the tank. Clean all of the screens whenever there is a failure of brakes. Illustration 246 View of the back side of the hoist and brake tank g01165914 4.SEBU7792-06 187 Maintenance Section Hoist and Brake Tank Suction Screen . The outer diameter of the NPT pipe nipple should be 25. Inspect the cover gasket. Remove the cover.0 mm (3. nonflammable solvent. • Operation and Maintenance Manual. nonflammable solvent. 5. The parking brake must be engaged and the engine must be stopped. Remove the suction screens from the tank.

“Capacities (Refill)”. consult your Caterpillar dealer. The oil level will decrease as oil fills the system. 17. if necessary. Install the cover to the front of the tank. Illustration 249 (1) Magnetic plug on the front wheel g01172641 Illustration 248 g01165956 12. Crank the engine for approximately 15 seconds. Repeat Step 15 and Step 16until the oil level stabilizes in the “FULL” mark in the upper sight gauge. Clean the filler cap and install the filler cap. Run the engine at low idle. Start the engine. Illustration 247 g01349223 11. if necessary. Inspect the machine for oil leaks and make necessary repairs. 16. “Lubricant Viscosities”. Refer to Operation and Maintenance Manual. . Raise the truck body until the hoist cylinders are extended halfway.188 Maintenance Section Magnetic Plug (Wheels) . Add oil to the tank in order to raise the oil level to the “FULL” mark in upper sight gauge (5). Lower the truck body and add oil. i02346919 Magnetic Plug (Wheels) Check SMCS Code: 0663 Note: A weekly inspection of the magnetic plugs is strongly recommended. Repeat Step 11 and Step 12 until the oil stabilizes in the “FULL” mark in the upper sight gauge. 13. Raise the truck body until the hoist cylinders are fully extended. 14. Illustration 250 (2) Magnetic plug on the rear wheel g01172642 All of the wheels have a magnetic plug. Refer to Operation and Maintenance Manual.Check SEBU7792-06 9. 10. Lower the guard on the ground level shutdown control. Use ground level shutdown switch (4) to prevent the engine from starting. A bearing failure is indicated by an increased amount of metal on the magnetic plug. 15. If excessive particles or abnormal particles are found. Lower the truck body and add oil. Fill the hoist/brake tank. The magnetic plug (1) and (2) will attract metal from the oil. 18.

Engage the parking brake and stop the engine. Park the machine on a level surface. 5068-510-HFN 3. Remove case drain filter (3) for the hydraulic fan and remove case drain filter (4) for the steering system from the mounting bases with a strap type wrench.Replace (Hydraulic Pump Case Drain) SMCS Code: 5068-510-ZH. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. NENG2500. Check for leaks and make any necessary repairs. Hydraulic Fan) . 8. Discard the used filters properly. Illustration 251 g01163566 2. adjusting and repair of the product. Lubricate the seals of the new filters with clean oil. use the rotation index marks as a guide. Start the engine and operate the engine at low idle. Tighten all filters according to the instructions that are printed on the filter. Make sure that the installation tool does not damage the filters. Install the new filters by hand until the seal contacts the mounting base. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Push button (1) on the breaker relief valve. Make sure that all of the old filter seals are removed. Do not allow hot oil or hot components to contact skin. Note the position of the index marks on the filters in relation to a fixed point on the mounting base. Dispose of all fluids according to local regulations and mandates. 5. Refer to Special Publication.SEBU7792-06 189 Maintenance Section Oil Filter (Steering. When you tighten the filters. add oil. Hot oil and hot components can cause personal injury. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Refer to Operation and Maintenance Manual. Hydraulic Fan) .Replace i02398678 Oil Filter (Steering. 6. maintenance. Note: There are rotation index marks on each filter that is spaced 90 degrees (1/4 turn) away from each other. 9. Make sure that the parking brake is engaged. “Steering System Oil Level . testing. 7. Note: You may need to use a strap type wrench or a suitable tool in order to turn the filters to the amount that is required for final installation. Check the oil level. If necessary. 10. 1. . 4.Check”. Slowly remove cap (2) on the steering hydraulic tank in order to relieve the pressure. Clean the mounting bases.

Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Small amounts of debris may be found in the filter element. 1. Do not allow hot oil or hot components to contact the skin. Drain the oil into a suitable container. Spread apart the pleats and inspect the element for metal and for other debris. This could be caused by friction and by normal wear.190 Maintenance Section Oil Filter . This can result in larger particles in unfiltered oil. If metals are found in the filter element. testing. maintenance. g00100013 Use a filter cutter to cut the filter element open. Park the machine on a level surface. Ferrous metals can indicate wear on steel parts and on cast iron parts. Clean the drain plug and install the drain plug.Inspect SMCS Code: 5068-040 Parking Brake Release Oil Filter . 4295 Inspect a Used Filter for Debris Hot oil and hot components can cause personal injury. NENG2500. An excessive amount of debris in the filter element can indicate a possible failure. Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount of debris is found. Dispose of all fluids according to local regulations and mandates.Replace SMCS Code: 4257. “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Illustration 252 The element is shown with debris.Inspect SEBU7792-06 i02106227 i02320227 Oil Filter . Refer to Special Publication. Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings. Engage the parking brake and stop the engine. Remove drain plug (2) from the bottom of filter housing (1). Using an oil filter element that is not recommended by Caterpillar can result in severe engine damage to engine bearings. or turbocharger bearings. rod bearings. to the crankshaft. . The particles could enter the lubricating system and the particles could cause damage. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Illustration 253 g01160070 2. a magnet can be used to differentiate between ferrous metals and nonferrous metals. adjusting and repair of the product. and to other parts.

9. “Know Your Cooling System” for the complete procedure for cleaning the radiator core. Discard the used filter element. However. Install the new element in the filter housing. 6. 5. refer to Operation and Maintenance Manual. Use a water spray nozzle that will disperse the water. Wash the filter housing in clean. Start the engine and operate the engine at low idle. the use of compressed air is preferred. See Special Publication. .SEBU7792-06 191 Maintenance Section Radiator Core . refer to Testing and Adjusting. nonflammable solvent. If necessary. 3. Remove filter housing (1) and the filter element. Install the filter housing. “Rear Axle Housing End Play .Clean SMCS Code: 1353 Illustration 254 g01167490 You can use compressed air. Inspect the seal in the housing base. 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. RENR8327. Make sure that the parking brake is engaged. 8. 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. If the seal is damaged. Consult your Caterpillar dealer for any additional information. add oil. SEBD0518. 4. “Hoist and Brake Tank Oil Level . i02340749 NOTICE High water pressure water and high water volume can damage the radiator. Check the oil level in the hoist/brake tank. 7. or steam to remove dust and other debris from the air side of the radiator core.Adjust”. “793D Power Train Testing and Adjusting”. high pressure water. For the proper procedure. To adjust the end play of the rear axle housing.Clean Note: Removing the drain plug from the bottom of the filter housing may not drain all of the oil from the filter. Check for leaks and make any necessary repairs. Radiator Core .Check”. replace the seal with a new seal.

“Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. consult your Caterpillar dealer. Install the new filter element in the filter housing.Replace SEBU7792-06 i02783212 Rear Axle Oil Filter . Discard the used filter element. If the 6 micron element becomes plugged before the initial 50 service hours. 4. Check the oil level after repairs and after maintenance.192 Maintenance Section Rear Axle Oil Filter . Check for leaks and make any necessary repairs. For the proper procedure. maintenance. Refer to Special Publication. replace seals with new seals. Start the engine and operate the engine at low idle. Note: The machine is shipped with a 6 micron filter element for the rear axle. Note: Correct oil levels are critical in the differential and final drives. 8. If the seals are damaged. Remove the drain plug from filter housing (1). add oil. Make sure that the parking brake is engaged. Caterpillar recommends the use of a 6 micron element for the initial 50 service hours. NENG2500. Wash the filter housing in clean nonflammable solvent. Install the filter housing. If the oil level is checked cold. replace the 6 micron element with another 6 micron element. Drain the oil into a suitable container. replace the 6 micron element with a 20 micron element. Do not allow hot oil or hot components to contact the skin. 3.Replace SMCS Code: 5068-510 1. Engage the parking brake and stop the engine. 6. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Check”. Clean the drain plug and install the drain plug. Illustration 255 g01162468 Note: The lubrication pump for the rear axle will not operate with the oil temperature below 15 °C (59 °F). testing. Inspect the seals in the filter base. If the element continues to become plugged after 50 service hours. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. When the machine reaches 50 service hours. Note: The differential and final drive oil level needs to be checked and maintained at operating temperature. 5. adjustment of the oil level may be necessary when the truck reaches operating temperature. If necessary. refer to Operation and Maintenance Manual. 7. Note: Removing the drain plug from the bottom of the filter housing may not drain all of the oil from the filter. Check the oil level in the rear axle. “Differential and Final Drive Oil . . adjusting and repair of the product. Hot oil and hot components can cause personal injury. Park the machine on a level surface. Dispose of all fluids according to local regulations and mandates. Remove the filter housing and the filter element. 2.

Slowly loosen the fitting. NOTICE If the refrigerant system has been open to the outside air (without being plugged) for more than 30 minutes. Do not smoke when servicing air conditioners or wherever refrigerant gas may be present. even if the gauges indicate the system is empty of refrigerant. the receiver-dryer must be replaced. “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.SEBU7792-06 193 Maintenance Section Receiver Dryer (Refrigerant) .Replace i02656745 Receiver Dryer (Refrigerant) Replace SMCS Code: 7322-510 Personal injury can result from contact with refrigerant. Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system. i02650497 Rim . Personal injury or death can result from inhaling refrigerant through a lit cigarette. Always use precaution when a fitting is removed.Inspect SMCS Code: 4209-040 Inspect the rim whenever a tire is dismounted. Illustration 256 g01159180 Protective goggles must always be worn when refrigerant lines are opened. Moisture will enter an open refrigerant system and cause corrosion which will lead to component failure. release it slowly in a well ventilated area. Inhaling air conditioner refrigerant gas through a lit cigarette or other smoking method or inhaling fumes released from a flame contacting air conditioner refrigerant gas. . SENR5664. Refer to Service Manual. If the system is still under pressure. Contact with refrigerant can cause frost bite. can cause bodily harm or death. Keep face and hands away to help prevent injury. The refrigerant dryer is located in the refrigerant lines underneath the cab.

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 flanges • (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 . corrosion. Lock Ring (2) – Inspect the lock ring for the following: wear. worn. Do not reuse rim components that are cracked. or pitted from corrosion. corrosion. Flanges (4) – Inspect the flanges for the following: wear. damaged. and warping. cracks. consult your Caterpillar dealer. The tires must be dismounted from the rim in order to perform a magnetic particle inspection.Inspect SEBU7792-06 i03808474 Rim . Consult your tire dealer for dismounting the tires from the rims. and cracks. the two ends of the lock ring must overlap each other. For more information on the reusability of the rim components. and fretting. and fretting. flat spots.Inspect SMCS Code: 4209-040 If regulatory agencies require a rim inspection. cracks. cracks. this documentation can be used as a guideline.194 Maintenance Section Rim . 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. When the lock ring is not assembled. corrosion. Rim Base (3) – Inspect the rim base for the following: wear. corrosion.

replace the seat belt. Note: Within three years of the date of installation or within five years of the date of manufacture. “Inspection. Do not weld reinforcement plates to the ROPS in order to repair the ROPS. A date label for determining the age of the seat belt is attached to the 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. Refer to Special Instruction. or cracks in any metal section. the seat belt buckle. and Repair of ROPS and Attachment Installation Guidelines” or consult your Caterpillar dealer for more information. refer to Guideline For Reusable Parts And Salvage Operations. SEHS6929. Inspect the ROPS for any cracks in the welds. If the buckle is worn or damaged. . Replace the seat belt at the date which occurs first. Do not weld reinforcement plates to the ROPS in order to straighten the ROPS.Inspect For more information on magnetic particle inspection. cracks in the castings. Check buckle (2) for wear or for damage. Seat Belt . Inspect the seat belt (3) for webbing that is worn or frayed. Replace any damaged bolts and any missing bolts with original replacement parts only. Improper bolt torque can result if you do not apply oil to the threads. Make sure that the mounting bolts are tight. or pitted from corrosion. damaged. replace the seat belt. Replace any parts that are damaged or worn before you operate the machine. and the seat belt retractor. replace the seat belt . worn. i02429594 Seat Belt . Maintenance.Inspect SMCS Code: 7325-040 Inspect the Rollover Protective Structure (ROPS) for bolts that are loose or damaged. Replace any mounting hardware that is worn or damaged.Replace SMCS Code: 7327-510 Within three years of the date of installation or within five years of the date of manufacture. If your machine is equipped with a seat belt extension. and the seat belt retractor. the seat belt buckle. Note: Apply oil to all bolt threads for the ROPS before you install the bolts. A date label for determining the age of the seat belt is attached to the seat belt. i02381197 Rollover Protective Structure (ROPS) . SEBF8148. Replace the seat belt if the seat belt is worn or frayed.SEBU7792-06 195 Maintenance Section Rollover Protective Structure (ROPS) . consult your Caterpillar dealer. i02429589 Illustration 259 Typical example g00932801 Check the seat belt mounting hardware (1) for wear or for damage. Do not reuse rim components that are cracked. Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware. “General Salvage and Reconditioning Techniques” or consult your Caterpillar dealer. Replace the seat belt at the date which occurs first. Tighten the bolts to a torque of 1904 ± 68 N·m (1400 ± 50 lb ft). For more information on the reusability of the rim components. also perform this inspection procedure for the seat belt extension.

Move the seat rearward and forward several times in order to distribute the lubricant. . If your machine is equipped with a seat belt extension. Personal injury or death can occur if steering is lost completely during operation. refer to Systems Operation. Testing and Adjusting. “Operator Controls” for more information on the secondary steering system. Inspect the machine and correct the condition which made the use of the secondary steering necessary. Disassembly and Assembly. Do not continue to operate the machine using the secondary steering. 7324-086 Inspect Seat Suspension Inspect the seat suspension for excessive looseness and wear. Apply dry lubricant or silicone lubricant between the parts in the mechanism for the armrest assembly.196 Maintenance Section Seat Suspension . Use caution when working between the wheels and the frame.Inspect/Lubricate SEBU7792-06 Armrest (Seat) Pivot the armrest to the vertical position. “Caterpillar Comfort Series Seat with three point operator restraint”. ensure that all personnel are clear of the machine before any movement. Seat Suspension Inspect/Lubricate SMCS Code: 7324-040. This machine is equipped with a secondary steering system. If the secondary steering activates during operation. RENR8391. i03327080 Secondary Steering . Refer to Operation and Maintenance Manual . If excessive looseness or wear is detected. The secondary steering system will only provide steering until the stored hydraulic pressure is exhausted. Adjust the seat fully forward and apply a dry lubricant to the rear of the seat slide mechanism. The steering system is hydraulically controlled and wheels can crush personnel during movement. 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. Personal injury or death can occur if personnel are trapped between the wheel and the frame. If the wheels must be turned. i02302909 Gas under pressure. the machine must be safely shut down immediately. Rapid discharge from disconnecting or disassembly could cause personal injury or death. also perform this replacement procedure for the seat belt extension.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) g01152685 Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware. Lubricate Seat Suspension Adjust the seat fully rearward and apply a dry lubricant to the front of the seat slide mechanism. “Troubleshooting Chart”. See service manual before relieving pressure or charging.

Verify that the front wheels turn left as the steering wheel is turned left. Steering accumulators (1) is located on the outside right frame rail near the front of the machine. check the oil level. Illustration 263 g01349223 The engine shutdown switch is located on the front bumper. When the engine is stopped with the engine start switch.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. . If the secondary steering system is unable to comply with any portion of this field test. 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. b. b. Visually confirm the following: a. “793D Off-Highway Truck Steering System” or consult your Caterpillar dealer. Illustration 261 g01163448 There are two steering accumulators on the machine. Refer to System Operation. 7. check accumulator charge before proceeding to the next step. Empty the truck body and park the machine on a level surface. Compare subsequent measurements to the initial measurement in order to determine the amount of wear. If the oil level registers below the full mark in the lower sight gauge.Inspect 4. If the oil level registers at the full mark in lower sight gauge (3). 5. Verify that the front wheels turn right as the steering wheel is turned right. 2. check the steering hydraulic oil level. After engine start-up. Turn the front wheels to the straight ahead position. 3. i02346399 Illustration 262 g01163447 Perform the following field test in order to verify that the secondary steering system is functional: 1. RENR8336. the accumulators are properly charged. Inspect the rear brakes for wear and inspect the rear brakes for system leakage.SEBU7792-06 197 Maintenance Section Service Brakes . 6. Chock the rear wheels and release the parking brake. Inspect the front brakes for wear and inspect the brake system for leakage. Maintain the oil to the full mark in upper sight gauge (2). Place the transmission control in the NEUTRAL position and engage the parking brake. consult your Caterpillar dealer. a. Testing and Adjusting. Service Brakes .

“Service Brake Discs .Inspect SMCS Code: 4305-040-SD The inspection procedure for the ball studs uses a straight beam examination. The louver assembly is on the front of the radiator. final drives. 7076-510.Inspect/Replace (If Equipped with the Sound Suppression Arrangement) SMCS Code: 1801-040. “793D Air System and Brakes”. SEBF8095.198 Maintenance Section Sound Suppression (Covers. Testing and Adjusting. perform the necessary repairs and/or replace any damaged sound suppression liners. 7261-040. “Steering Ball Stud Inspection for Off. The ball studs can develop cracks that may cause the ball stud to fail. perform the necessary repairs and/or replace any damaged sound suppression covers. and lead to the loss of steering. The sound suppression panels are bolted on the front portion of the machine in order to enclose the engine compartment. Panels) . Inspect the panels for the following damage: • Broken fasteners or missing fasteners • Burnt insulation material • Compressed insulation material • Insulation material with fluid 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. 7261-510 • Bent steel mesh or broken steel mesh • Burnt insulation material • Compressed insulation material • Insulation material with fluid saturation • Loose insulation material • Missing pieces of insulation material • Tears in the insulation material If any of these conditions exist. RENR8330. torque converter. Panels) .Inspect/Replace SEBU7792-06 For more information on the proper procedures. The inspection procedure does not require the ball studs to be removed from the machine. perform the necessary repairs and/or replace any damaged louvers. Louvers Inspect the louver assembly. The sound suppression covers are fastened to the following components: engine. The inspection procedure references ASTM E114-95 and ASTM E1901-97. Inspect the covers for the following damage: • Broken fasteners or missing fasteners • Broken pieces . 7076-040.Highway Trucks” in order to perform the proper inspection procedure for the ball studs. Sound Covers Inspect the sound suppression covers. 1801-510. and differential. i02602002 • Cracks • Loose covers • Missing pieces If any of these conditions exist. refer to Systems Operation. The inspection procedure is used to identify any damage that has developed during the operation of the machine. Note: Refer to Guideline for Reusable Parts and Salvage Operations. i03572122 Sound Panels Inspect the sound suppression panels.Check”. REHS4420. “Service Brakes for Off-Highway Trucks and Tractors” when you rebuild the brakes. Refer to Special Instruction. Steering Ball Stud . Inspect the louvers for the following damage: Sound Suppression (Covers.

either the steering arm or the steering box must be scrapped and replaced. number of turns per cycle. inspect the grease fittings and the seals. The replacement interval may vary and the replacement interval is heavily dependent on the haul cycle conditions. and grade of the haul road. 5. Replace any worn components and any damaged components.SEBU7792-06 199 Maintenance Section Steering Ball Stud . To measure the horizontal wear of the ball studs and of the outer bearing races on the steering cylinders. If the taper is too far out of the specification. Set the dial indicator to zero. Record the amount of horizontal play on the indicator dial. 4. The steering linkage must be free of contaminants in order to ensure the durability of components. Attach the magnetic base of a 8T-5096 Dial Indicator Group to steering link (2).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. length of hauls. Set the dial indicator to zero. The maximum amount of horizontal wear is 1. place the dial indicator against the side of center arm (3). Steer the front wheels in both directions. Record the amount of horizontal play on the indicator dial. Inspect all of the covers for the ball studs. Park the machine on a level surface.Inspect SMCS Code: 4305-040 Inspect the horizontal wear limits for the ball studs in the steering linkage. 793. “Salvage of Steering Arm and Steering Arm (T-Bar) Tapers on 785. At the same time. “Off-Highway Truck Machine Systems” manual for your machine or consult your Caterpillar dealer. Also. 10. replace the worn ball studs and the outer bearing races. then an oversize ball stud may be used. Inspect all grease fittings and seals.Replace i02387439 Steering Ball Stud . 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. place the dial indicator against the side of steering arm (1). Steering Linkage . Inspect the condition of the tapered steering bore whenever a ball stud is replaced. load. SEBF8271. For the replacement procedure. Refer to Reuse and Salvage Guidelines. Note: Properly lubricate the steering linkage in order to ensure the durability of components. Steer the front wheels in both directions.02 mm (0. This indicates the amount of wear in the ball studs and the outer bearing races. inspect the outer bearing race.040 inch). 6. If any of the measurements exceed this limit. 7. In this case. 1. Note: Repeat this procedure in order to measure all of the ball studs and outer bearing races. i03370162 Illustration 264 Typical example (1) Steering arm (2) Steering link assembly (3) Center arm g01442892 2. This will allow the horizontal movement of the ball stud to be measured. 3. then an oversize ball stud cannot be used. These conditions include the following considerations: haul road condition. 8. refer to the Disassembly and Assembly. . To measure the horizontal wear of the ball studs and of the outer bearing races on the other ball studs and outer bearing races. If the tapered bore is out of the specification and the tapered bore is able to be salvaged. 9. 789.

Refer to Special Publication. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. nonflammable solvent. Allow the oil to drain into a suitable container. 3. Install the strainer and the retaining ring for the strainer. 7. Allow the cap and the strainer to dry. Park the machine on a level surface and engage the parking brake.200 Maintenance Section Steering System Oil . Stop the engine. Remove filler strainer (7). 6. maintenance. Illustration 265 g01163770 4. Open drain valve (1). Inspect cap seal (5). NENG2500. 1. NOTICE Do not fill the steering hydraulic tank when the engine is running.Change SMCS Code: 4300-044-OC Hot oil and hot components can cause personal injury. Close the drain valve. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. Use a new seal if the used seal is damaged. Do not allow hot oil or hot components to contact the skin. . Operate the engine until the steering hydraulic oil is warm. Wash the cap and the strainer in clean. remove filler cap (4) on the steering hydraulic tank in order to relieve the pressure. Slowly. Remove retaining ring (6) for the filler strainer.Change SEBU7792-06 i02331342 Steering System Oil . 2. 5. Push button (3) on the breaker relief valve. “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. 8. 9. Dispose of all fluids according to local regulations and mandates. adjusting and repair of the product. Discharge from the secondary steering accumulators could overfill the tank when the engine is stopped. testing.

Remove spring pin (7) and spacer (8). 1. If necessary. Inspect the machine for leaks and make any necessary repairs. 3. 4. Push button (3) on the breaker relief valve. 5. 15. Use the reading from the upper sight gauge to maintain the steering oil level. Stop the engine. add oil.SEBU7792-06 201 Maintenance Section Steering System Oil Filter . 13. 12. “Lubricant Viscosities”. Remove four nuts (1) from the filter cover. 11. Operate the engine until the steering hydraulic oil is warm.Replace 10. Refer to Operation And Maintenance Manual. Remove filter cover (5) from stud (10). Remove used filter elements (9) and discard the used filter elements. Hot oil and hot components can cause personal injury. Fill the steering hydraulic tank. Illustration 267 g01163878 6. Install the filler cap. Stop the engine. 7. Use the reading from the upper sight gauge to maintain the steering oil level. When the engine is not running. i02331551 Steering System Oil Filter Replace SMCS Code: 431F-510 Illustration 266 g01163863 2. . Install the filler cap after the pressure is relieved. “Capacities (Refill)”. Allow the steering accumulators to completely discharge and check the oil level. Do not allow hot oil or hot components to contact the skin. When the engine is stopped. Slowly remove filler cap (4) on the steering hydraulic tank in order to relieve any pressure. Pull filter assembly (2) out of the tank. Park the machine on level ground and engage the parking brake. the oil level should be at the “FULL” mark in upper sight gauge (2). Refer to Operation And Maintenance Manual. 8. 14. the oil level should be at the “FULL” mark in the upper sight gauge.

Sampling port (1) for the steering oil is located on the steering solenoid and relief valve. 12. Discharge from the secondary steering accumulators could overfill the tank when the engine is stopped. “Secondary Steering . 4. Maintain the oil level to the full mark in upper sight gauge (1). 2. Install the new filter elements. See Operation And Maintenance Manual. If necessary. add oil. If the oil level in the lower sight gauge is low. “Steering System Oil Level .202 Maintenance Section Steering System Oil Level .Check”. 7542 Steering System Oil Level Check SMCS Code: 4332-535-FLV Illustration 269 Illustration 268 g01726834 g01163967 1. Park the machine on a level surface and engage the parking brake. 13. PEHP6001. 15. If necessary. Install the nuts for the filter cover. Note: After the engine start-up. i02331813 Steering System Oil Sample Obtain SMCS Code: 4300-008-OC. 10. Check the steering system oil level. Check for leaks and make any necessary repairs. Inspect seal (12) for retainer assembly (11). 11. Stop the engine and allow the secondary steering accumulators to completely discharge before the oil level is observed. refer to Operation and Maintenance Manual. • Operation and Maintenance Manual. Make sure that the parking brake is engaged. Start the engine and operate the engine at low idle. “S·O·S Information” Analysis” • Special Publication. For the proper procedure. 3. Refer to the following publications for information about obtaining an oil sample.Check SEBU7792-06 9. “S·O·S Oil • Special Publication. add oil. Inspect seal (6) for the filter cover. Install the spring pin and the spacer. the oil level should be within the operating range of lower sight gauge (2). Replace any seals that are damaged.Check” for additional information. Tighten the filter cover by hand. i03352042 NOTICE Do not fill the steering hydraulic tank when the engine is running. 14. SEBU6250. “How To Take A Good Oil Sample” . check the secondary steering. Install the filter assembly into the tank. Install the filter cover on the stud.

If the oil level is checked cold. Check the oil level in the rear axle. If the seal is damaged.Clean SMCS Code: 3016. nonflammable solvent. 3291 Hot oil and hot components can cause personal injury. 6. Make sure that the parking brake is engaged. “Fluid Analysis Interpretaion Guide” i02337440 4. a stiff bristle brush or air pressure. Remove screen cover plate (1 ). Illustration 271 g01166878 3. Note: The lubrication pump for the rear axle will not operate with the oil temperature below 15 °C (59 °F). Note: Correct oil levels are critical in the differential and final drives. Wash the screen and the magnetic tube assembly in clean. . Suction Screen (Rear Axle Lubrication) . Note: The differential and final drive oil level needs to be checked and maintained at operating temperature. Do not allow hot oil or hot components to contact the skin. Check the oil level after repairs and after maintenance. Inspect seal (4).SEBU7792-06 203 Maintenance Section Suction Screen (Rear Axle Lubrication) . 3278-070-Z3.Clean • Special Publication. Replace any damaged magnets. Install the screen cover plate. 7. 9. 8. Engage the parking brake and stop the engine. Illustration 270 g01166714 i02682176 2. Suction Screen (Torque Converter) . Check for leaks and make any necessary repairs. replace the seal. “Differential and Final Drive Oil . Install the magnetic tube assembly and the screen. If necessary. refer to Operation and Maintenance Manual. For the proper procedure. Do not allow hot oil or hot components to contact the skin. Remove screen (2) and magnetic tube assembly (3). Park the machine on a level surface. PEDP8025.Check”. add oil. 1. adjustment of the oil level may be necessary when the truck reaches operating temperature. NOTICE Do not drop or rap the magnets against any hard objects. Start the engine and operate the engine at low idle. 5.Clean SMCS Code: 3101-070-Z3 Hot oil and hot components can cause personal injury. Clean the magnets with a cloth.

Remove the filler cap and fill the torque converter to the top of upper sight gauge (4). The oil level will decrease as oil fills the system. If the cover gasket is damaged. See Operation And Maintenance Manual. Park the machine on a level surface. 8. Illustration 272 g01164290 2. “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Install the cover assembly. 6. . add oil in order to raise the oil level to the “FULL” mark of the upper sight gauge. Refer to Special Publication. Engage the parking brake and stop the engine. Remove drain valve plug (2) in the torque converter sump. Illustration 274 g01164452 9. 4. testing. Remove filler cap (1) in order to prevent a vacuum in the torque converter sump. 7. maintenance. Dispose of all fluids according to local regulations and mandates. Install the screen. Drain the oil into a suitable container. The screen cover is located at the lower left rear corner of the sump. 1. Remove the cover and the screen assembly. Check the oil level in the torque converter sump. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. If necessary. 10. Do not crush the screen assembly.Clean SEBU7792-06 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. Wash the screen assembly and the cover in a clean. “Lubricant Viscosities”. adjusting and repair of the product. Illustration 273 g01164303 5. Do not use tools. Install the filler cap after the torque converter sump is drained. Inspect the cover gasket for damage. Clean the drain plug and install the drain plug. NENG2500. use a new gasket. 3.204 Maintenance Section Suction Screen (Torque Converter) . “Capacities (Refill)”. Remove the pipe nipple. See Operation And Maintenance Manual. Remove the bolts from screen cover (3). Install a 100 mm (4 inch) long NPT pipe nipple in order to open the internal drain valve. Operate the engine for ten seconds and then turn off the engine. The outer diameter of the NPT pipe nipple should be 25 mm (1 inch). This will prevent dirt from entering the system. 11. nonflammable solvent. Note: Hand tighten the NPT pipe nipple.

16. Make sure that the parking brake is engaged. Compare the present distance to the distance from the previous time. During field assembly. The transmission direction and speed control MUST be left in NEUTRAL until the system is full. Follow the procedure that is described above. . Use caution when working between the wheels and the frame. Check the oil level with the engine at low idle and the transmission in neutral. Stop the machine gradually on a level surface without using the brakes. add oil. 13.Check 12. These relief valves are located 180 degrees from the lubrication fitting. “Suspension Cylinder (Front) . Illustration 275 (X) Distance of exposed chrome g01163979 Measure the distance of exposed chrome (X) for the front suspension cylinders.SEBU7792-06 205 Maintenance Section Suspension Cylinder . If necessary. See Testing And Adjusting. i02331858 Suspension Cylinder . 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. Do not plug the grease passage of the relief valves. perform the charging procedure. Check for leaks and make any necessary repairs.Purge and Charge” for the charging procedure. NOTICE Failure to properly fill the torque converter sump after an oil change may cause damage to the power train system. Note: There are two relief valves for the grease on the forward side of the front suspension cylinder. ensure that all personnel are clear of the machine before any movement. Front Suspension Cylinder Personal injury or death can occur if personnel are trapped between the wheel and the frame. Torque converter stalls may be performed in order to bring the torque converter oil up to operating temperature. Maintain the oil level until the oil level stabilizes in the “FULL” mark of the upper sight gauge.Check SMCS Code: 7201-535 Make sure that the dump body is empty. Operate the engine until the torque converter oil reaches operating temperature. The steering system is hydraulically controlled and wheels can crush personnel during movement. 14. Start the engine and operate the engine at low idle. 15. If the wheels must be turned. If you do not have those dimensions. Clean the filler cap and install the filler cap on the filler tube. the suspension cylinders must be charged with nitrogen.

If the seal is damaged.Check SMCS Code: 4203-535-AI. replace the seal with a new seal. the left rear suspension cylinder will not show as much chrome as the right rear suspension cylinder.Check SEBU7792-06 Rear Suspension Cylinder NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. 3. 4203-535-PX Measure the tire pressure on each tire. Remove the screen. Illustration 276 (Y) Distance between the pins g01163990 Measure distance (Y) for the rear suspension cylinders. Engage the parking brake and stop the engine. Wash the screen housing in clean. Dispose of all fluids according to local regulations and mandates. adjusting and repair of the product. This is due to the rigid frame and to the weight of the cab. perform the charging procedure.Replace SMCS Code: 3103 Hot oil and hot components can cause personal injury. Remove drain plug (2) from the bottom of screen housing (1) and drain the oil into a suitable container. Do not allow hot oil or hot components to contact skin. 1. Torque Converter Outlet Screen . Adjust the tire pressure. testing. “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. . Park the machine on a level surface. i02332019 Illustration 277 g01164086 2. Note: When the rear suspension cylinders are properly charged. See Operation and Maintenance Manual. 4. nonflammable solvent. “Suspension Cylinder (Rear) . Inspect the seal in the base of the screen housing. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. If you do not have those dimensions. 5. Note: Removing the drain plug from the bottom of the screen housing may not drain all of the oil from the screen. Consult your tire supplier for the correct tire operating pressures and load ratings. maintenance. See Testing And Adjusting. Compare the present distance to the distance from the previous time. if necessary. Refer to Special Publication.206 Maintenance Section Tire Inflation .Purge and Charge” for the charging procedure. “Tire Inflation Information” for more tire information. NENG2500. Clean the drain plug and install the drain plug. Discard the used screen. i02416817 Tire Inflation . Remove the screen housing.

7. refer to Operations and Maintenance Manual. Start the engine and operate the engine at low idle.Check”. . refer to Operation and Maintenance Manual. 2. 5. Wash the breather in a clean. “Torque Converter Sump Oil Level . i02335501 Torque Converter Sump Breather . Make sure that the parking brake is engaged. nonflammable solvent. Note: The breather for the torque converter sump also vents the transmission case. Note: The engine should be on in order to check the cold oil (oil at ambient temperature) level of the torque converter. 1. Failure to properly secure the body (bed) may result in personal injury or death.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. For the proper procedure. 7. 2. Raise the truck body to the fully raised position and install the truck body retaining cable to the rear tow point pin. Allow the breather to air dry. For the proper procedure for the installation and removal of the truck body retaining cable. “Cable (Truck Body Retaining)”. Operate the engine at low idle with the transmission in neutral and with the parking brake engaged. add oil. Install the breather. 4. 6. Check for leaks and make any necessary repairs.Check SMCS Code: 3101-535-FLV Note: The oil level in the transmission is supplied by the torque converter sump. Install the new screen in the screen housing. 3. Remove breather (1). 8. Park the machine on a level surface.SEBU7792-06 207 Maintenance Section Torque Converter Sump Breather . i02682170 Torque Converter Sump Oil Level . Stop the engine. Install the screen housing. and the engine should be on in order to check the hot oil (oil at operating temperature) level of the torque converter. Park the machine on a level surface and engage the parking brake. If necessary. Check the oil level in the torque converter sump. 1.Clean 6. Remove the truck body retaining cable and lower the body. Install the rear tow point pin through the end of the retaining cable.

maintenance. The torque converter oil and transmission oil is added at filler cap (1). b. Dispose of all fluids according to local regulations and mandates. Clean the drain valve plug and install the drain valve plug. use upper sight gauge (2) in order to check the oil level. Note: If the system has been drained. 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. testing. If necessary. Engage the parking brake and stop the engine. a. If the torque converter oil is in the operating temperature range. The outer diameter of the NPT pipe nipple should be 25 mm (1 inch).Change” for the proper procedure. Remove the pipe nipple. Check the oil level in the torque converter sump. . Drain the oil into a suitable container. Torque Converter and Transmission Oil . “Caterpillar Dealer Service Tool Catalog” for tools and supplies suitable to collect and contain fluids on Caterpillar products. Park the machine on a level surface. 4. 4.208 Maintenance Section Torque Converter and Transmission Oil . refer to Operation and Maintenance Manual. “Torque Converter and Transmission Oil . 3. add oil.Change SEBU7792-06 Illustration 279 g01347318 Illustration 280 g01164290 3. If the torque converter oil is cold. Install the filler cap after the torque converter sump is drained. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. NENG2500. NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. 1. Do not allow hot oil or hot components to contact the skin. Note: Hand tighten the NPT pipe nipple. Do not use tools. i02682180 2. This will prevent dirt from entering the system. adjusting and repair of the product.Change SMCS Code: 3030-044-OC. Refer to Special Publication. Remove filler cap (1) in order to prevent a vacuum in the torque converter sump. use lower sight gauge (3) in order to check the oil level. 3101-044-OC Hot oil and hot components can cause personal injury.

Drain the oil into a suitable container. . Clean the filler cap and install the filler cap on the filler tube. Illustration 282 g01164452 10. Follow the procedure that is described above. Torque converter stalls may be performed in order to bring the torque converter oil up to operating temperature. 7. See Operation And Maintenance Manual. Start the engine and operate the engine at low idle.Change 12. Illustration 281 g01164714 5. Add oil in order to raise the oil level to the “FULL” mark of the upper sight gauge. 14. Allow the cap and the filler screen to dry. 8. nonflammable solvent. Wash the cap and the filler screen in clean. 9. Make sure that the parking brake is engaged. Fill the torque converter to the top of upper sight gauge (4). Remove the screen. Maintain the oil level until the oil level stabilizes in the “FULL” mark of the upper sight gauge. Remove drain plugs (3) from the transmission extension housing. Remove the retaining ring on the filler screen.SEBU7792-06 209 Maintenance Section Torque Converter and Transmission Oil . 16. If necessary. 6. 13. The oil level will decrease as oil fills the system. add oil. Check the oil level in the torque converter sump. 15. Check the oil level with the engine at low idle and the transmission in neutral. Install the filler screen and the retaining ring. Clean the drain plugs and install drain plugs. Use a new seal if the used seal is damaged. See Operation And Maintenance Manual. Remove the filler cap. Operate the engine until the torque converter oil reaches operating temperature. “Lubricant Viscosities”. Inspect the cap seal. NOTICE Failure to properly fill the torque converter sump after an oil change may cause damage to the power train system. 11. Check for leaks and make any necessary repairs. 17. Operate the engine for ten seconds and then turn off the engine. The transmission direction and speed control MUST be left in NEUTRAL until the system is full. “Capacities (Refill)”.

Refer to the following publications for information about obtaining an oil sample. Hold the test switch down. The machine will gradually slow down. drive the machine in a complete circle. 7. Illustration 284 g01444054 • Operation and Maintenance Manual. 8. Release the test switch. 10. Find a clear area and a level area.Test SMCS Code: 3288-081. PEDP8025. 4. “S·O·S Oil Analysis” Good Oil Sample” • Special Publication. Turn the steering wheel all the way to the right. 3101-008. “Fluid Analysis Interpretaion Guide” . Hold the test switch down. Start the machine and move the transmission direction and speed control lever to the first gear Forward. • Special Publication. 4801-081 Note: This procedure determines if the Traction Control System (TCS) is functioning. 5. Continue to turn the machine and push the top half of the test switch for the TCS. Release the test switch. The test will end and the machine will increase speed. In this area. SEBU6250. The machine will gradually slow down. “How To Take A • Special Publication. This procedure also determines if the left rear brake and the right rear brake activate at the correct time. 6. 9. This will begin the test. 1.210 Maintenance Section Torque Converter and Transmission Oil Sample . The test will end and the machine will increase speed. Turn the steering wheel all the way to the left. PEHP6001. With the engine at low idle. If the TCS did not function properly. Continue to turn the machine and push the top half of test switch (1) for the TCS. Illustration 283 g01251142 The sampling valve for the transmission and torque converter oil is located on the oil filter housing for the torque converter in front of the hoist/brake tank. With the engine at low idle. drive the machine in a complete circle. consult your Caterpillar dealer for information and service. turn the machine in a complete circle. “S·O·S Information” 3. “Caterpillar Machine Fluids Recommendations”. This will begin the test. 2.Obtain SEBU7792-06 i02501245 i02900768 Torque Converter and Transmission Oil Sample Obtain SMCS Code: 3030-008. 7542 Traction Control System (TCS) .

nonflammable solvent. add oil. Engage the parking brake and stop the engine. Inspect seal (5). Check for leaks and make any necessary repairs.Clean i02335439 Transmission Magnetic Screen .Clean SMCS Code: 3030-070-MGS 4. replace the seal. NOTICE Do not drop or rap the magnets against any hard objects.Check”. screen (3). For the proper procedure. . Engage the parking brake and stop the engine. 9. If the seal is damaged. the screen. a stiff bristle brush or air pressure. Illustration 286 g01166968 2. Install the magnetic tube assembly. Do not allow hot oil or hot components to contact the skin. If necessary. 8. Clean the magnets with a cloth. Remove wave washer (2). and the wave washer. Do not allow hot oil or hot components to contact the skin. 7. and magnetic tube assembly (4). 6. Start the engine and operate the engine at low idle. i02335442 Hot oil and hot components can cause personal injury. Check the oil level in the torque converter sump. refer to Operation and Maintenance Manual. Replace any damaged magnets. Install the screen cover plate. 5. Illustration 285 Location of the transmission magnetic screen g01165690 Transmission Oil Filter Replace SMCS Code: 3067-510 1. “Torque Converter Sump Oil Level . Make sure that the parking brake is engaged. Park the machine on a level surface. Illustration 287 g01165699 1. 3. Remove screen cover plate (1).SEBU7792-06 211 Maintenance Section Transmission Magnetic Screen . Park the machine on a level surface. Wash the screen and the magnetic tube assembly in clean. Hot oil and hot components can cause personal injury. Note: The oil level in the transmission is supplied by the torque converter sump.

The lithium battery fails quickly. Start the engine and operate the engine at low idle. Leave the battery disconnect switch in the ON position. “Caterpillar Tools and Shop Products Guide” for tools and supplies suitable to collect and contain fluids on Caterpillar products. testing.Replace SEBU7792-06 i03010045 NOTICE Care must be taken to ensure that fluids are contained during performance of inspection. 5. Discard the used filter element. cut the service interval in half. 7601-510-B11 Illustration 288 (1) Plate g01043143 A lithium battery is contained inside the main module of the VIMS. adjusting and repair of the product. 6. a fault code will indicate that the battery needs a replacement. Refer to Special Publication. add oil. Remove the filter housing and the filter element. This will occur regardless of the position of the battery disconnect switch. do NOT turn the engine start switch to the OFF position. The internal battery prevents the loss of stored information. 8. immediately download the stored data. . Note: All of the oil from the filter may not drain when the drain plug from the bottom of the filter housing is removed. 2. Note: The oil level in the transmission is supplied by the torque converter sump. Clean the drain plug and install the drain plug. Note: If the Vital Information Management System (VIMS) detects a failed battery. Make sure that the parking brake is engaged.212 Maintenance Section VIMS Module Battery . If necessary. Note: If ECM BKUP BATT ERR is displayed in the message area of the VIMS. replace the internal battery at the service interval. 7. 3. Check for leaks and make any necessary repairs. 4. For the proper procedure. Note: To prevent the loss of stored information. Drain the oil into a suitable container. maintenance. Then replace the internal battery without turning off the engine start switch or the battery disconnect switch. When the fault code is present. If the seals are damaged.Check”. Wash the filter housing in clean nonflammable solvent. Check the oil level in the torque converter sump. replace seals with new seals. If power is removed from the main module of the VIMS during this fault code. refer to Operation and Maintenance Manual. An example of the stored information is the payload data. Remove drain plug (2) for filter housing (1). The internal battery also retains the time and the date. Go to Step 3. The internal battery retains the time and the date when the engine start switch is in the OFF position. If power is removed from the main module of the VIMS. loss of the stored data can occur within several hours. Stop the machine and turn off the engine. Install the new filter element in the housing. the internal battery will begin to retain the stored data. “Torque Converter Sump Oil Level . Power is removed from the main module of the VIMS when the battery disconnect switch is in the OFF position. Dispose of all fluids according to local regulations and mandates. Inspect the seals in the filter base. NENG2500. Install the housing. If the ambient temperature is continuously in the range of 0 to −40°C (32 to −40°F). Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids. VIMS Module Battery . 1.Replace SMCS Code: 7490-510-B11.

the time will default to “00:00:00”.SEBU7792-06 213 Maintenance Section Window Washer Reservoir . Check the O-ring seal. 8. Install the cap. Leave the engine start switch in the ON position or leave the keyswitch for the VIMS in the ON position. The service tool for the VIMS is not part of the machine. use Caterpillar nonfreezing window washer solvent or equivalent. Replace any windshield wiper blade that streaks the windshield. i02346847 Illustration 289 g01139822 Window washer reservoir (1) is located in the compartment in the front of the cab. Use the service tool for the VIMS to download all of the stored information. 3. System damage can result from freezing. The O-ring seal is located under the cap. The battery is located behind plate (1). After the battery has been replaced. 7305-510 Illustration 290 g01165832 Window Washer Reservoir Fill SMCS Code: 7306-544-KE NOTICE When operating in freezing temperatures. . Replace the windshield wiper blade if the wiper blade is worn or damaged. RENR2631. 5. Be careful to align the pins of the new battery with the sockets. A dead battery will cause the date to be lost and a dead battery will cause the time to be lost. Remove the battery from the back of the VIMS module. Make sure that the O-ring seal is not damaged. the date will default to “01/01/00”. The real time clock format in the main module is powered by this battery. Tighten the cap securely against the housing. 7. Keep the area clean. Note: Do not allow dirt or water into the opening. Install a new internal battery. Testing and Adjusting. Turn the engine start switch to the ON position or turn the keyswitch for the VIMS to the ON position. If necessary. Refer to Troubleshooting. Inspect windshield wiper blade (1). Failure to perform this step may result in the loss of stored data.Fill 2. 4. 6. Note: If these switches remain in the ON position during replacement. Fill the reservoir with windshield washer fluid. “Vital Information Management System (VIMS)”. use the service tool for the VIMS to set the time and the date. Leave the battery disconnect switch in the ON position. i02335763 Window Wiper Inspect/Replace SMCS Code: 7305-040. Also. Make sure that the O-ring seal is in the proper place. the date and the time of day are less likely to require programming.

Clean SMCS Code: 7310.214 Maintenance Section Windows .Clean SEBU7792-06 i02680928 Windows . Only clean the windows. when handholds are available. 7340 Illustration 291 g01346892 Use commercially available window cleaning solutions to clean the windows. .