SEBU7792 MOM793D Pauta Mantenim

MAINTENANCE INTERVALS
Operation and Maintenance

Manual Excerpt
® ®
© 2010 Caterpillar
All Rights Reserved
SEBU7792-05
April 2010
Operation and
Maintenance
Manual
793D Off-Highway Truck
FDB1-Up (Machine)
SAFETY.CAT.COM
128 SEBU7792-05
Maintenance Section
Maintenance Interval Schedule
i03896670 Hoist and Brake Tank Suction Screen -

Inspect/Clean/Replace ...................................... 184
Maintenance Interval Schedule Magnetic Plug (Wheels) - Check ........................ 185
Oil Filter - Inspect ................................................ 187
SMCS Code: 1000; 7000 Rear Axle Housing End Play - Adjust ................. 188
Rim - Inspect ....................................................... 190
Ensure that all safety information, warnings and Suction Screen (Torque Converter) - Clean ........ 200
instructions are read and understood before any Traction Control System (TCS) - Test ................. 207
operation or any maintenance procedures are Window Washer Reservoir - Fill .......................... 210
performed. Window Wiper - Inspect/Replace ........................ 210
Windows - Clean .................................................. 211
The user is responsible for the performance of
maintenance, including all adjustments, the use of Every 10 Service Hours or Daily
proper lubricants, fluids, filters, and the replacement
of components due to normal wear and aging. Failure Air Tank Moisture and Sediment - Drain ............. 131
to adhere to proper maintenance intervals and Backup Alarm - Test ............................................ 133
procedures may result in diminished performance of Brakes, Indicators and Gauges - Test ................. 139
the product and/or accelerated wear of components. Cooling System Coolant Level - Check .............. 148
Differential and Final Drive Oil Level - Check ..... 156
Use mileage, fuel consumption, service hours, or Engine Oil Level - Check .................................... 164
calendar time, WHICH EVER OCCURS FIRST, Engine Oil Level - Log Additions ......................... 165
in order to determine the maintenance intervals. Hoist and Brake Tank Oil Level - Check ............. 183
Products that operate in severe operating conditions Seat Belt - Inspect .............................................. 192
may require more frequent maintenance. Refer to the Steering System Oil Level - Check ..................... 199
maintenance procedure for any other exceptions that Torque Converter Sump Oil Level - Check ......... 204
may change the maintenance intervals.
Initial 50 Service Hours
Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be Brake Cooling Oil Filter - Replace ...................... 136
performed. Oil Filter (Steering, Hydraulic Fan) - Replace ..... 186
Parking Brake Release Oil Filter - Replace ........ 187
Note: If Cat HYDO Advanced hydraulic oils are Rear Axle Oil Filter - Replace ............................. 189
used, the hydraulic oil change interval is extended Steering System Oil Filter - Replace ................... 198
to 3000 hours. S·O·S services may extend the oil Transmission Oil Filter - Replace ........................ 208
change even longer. Consult your Caterpillar dealer
for details. Initial 250 Service Hours
When Required Engine Valve Lash and Bridge - Adjust .............. 167
Air Conditioner Filter - Clean .............................. 130 Every 250 Service Hours or Monthly
Air Tank - Inspect ................................................ 131
Automatic Lubrication Reservoir - Fill ................. 133 Braking System - Test ......................................... 140
Battery - Recycle ................................................ 134 Front Wheel Oil Level - Check ............................ 173
Battery or Battery Cable - Inspect/Replace ........ 134 Magnetic Plug (Wheels) - Check ........................ 185
Brake Oil Cooler Screen - Clean ........................ 137 Tire Inflation - Check ........................................... 203
Brake Tank (Makeup) - Clean ............................. 139
Cab Air Filter - Clean/Replace ............................ 143 Initial 500 Hours (for New Systems, Refilled
Circuit Breakers - Reset ...................................... 144 Systems, and Converted Systems)
Display and Camera - Clean ............................... 157
Engine Air Filter Primary Element - Clean/ Cooling System Coolant Sample (Level 2) -
Replace ............................................................. 158 Obtain ............................................................... 149
Engine Air Filter Secondary Element - Replace .. 160
Engine Air Precleaner - Clean ............................ 161 Every 500 Service Hours
Ether Starting Aid Cylinder - Replace ................. 168
Cooling System Coolant Sample (Level 1) -
Frame and Body - Inspect .................................. 171
Obtain ............................................................... 148
Fuel System - Fill ................................................ 174
Differential and Final Drive Oil Sample - Obtain .. 157
Fuel System - Prime ........................................... 175
Engine Oil Sample - Obtain ................................ 165
Fuel System Primary Filter (Water Separator) -
Front Wheel Oil Sample - Obtain ........................ 174
Drain ................................................................. 176
Hoist and Brake Tank Oil Sample - Obtain ......... 183
Fuel System Priming Filter - Replace ................. 178
Steering System Oil Sample - Obtain ................. 199
High Intensity Discharge Lamp (HID) - Replace .. 180
Hoist Screens - Clean ......................................... 181
SEBU7792-05 129
Maintenance Section
Maintenance Interval Schedule
Torque Converter and Transmission Oil Sample - Every Year

Obtain ............................................................... 207
Cooling System Coolant Sample (Level 2) -
Every 500 Service Hours or 3 Months Obtain ............................................................... 149
Receiver Dryer (Refrigerant) - Replace .............. 190
Air Conditioner Filter - Clean .............................. 130 Sound Suppression (Covers, Panels) -
Air Dryer - Check ................................................ 130 Inspect/Replace ................................................ 195
Air/Hydraulic Cylinder Breather - Clean .............. 132
Automatic Lubrication Reservoir - Fill ................. 133 Every 3000 Service Hours or 2 Years
Belts - Inspect/Adjust/Replace ............................ 134
Brake Cooling Oil Filter - Replace ...................... 136 Cooling System Pressure Cap - Clean/Replace .. 150
Cab Air Filter - Clean/Replace ............................ 143 Cooling System Relief Valve - Clean .................. 151
Cable (Truck Body Retaining) - Inspect .............. 143 Radiator Core - Clean ......................................... 188
Differential and Final Drive Oil - Inspect ............. 156
Drive Shaft Slip Joint - Lubricate ........................ 158 Every 3 Years After Date of Installation or
Engine Crankcase Breather - Clean ................... 162 Every 5 Years After Date of Manufacture
Engine Oil Filter (Oil Renewal System) -
Change ............................................................. 163 Seat Belt - Replace ............................................. 192
Engine Oil and Filter - Change ........................... 165
Frame - Clean/Inspect ........................................ 169 Every 4000 Service Hours
Front Wheel Oil - Change ................................... 172
Engine Valve Lash and Bridge - Adjust .............. 167
Front Wheel Oil - Inspect .................................... 173
Fuel System Primary Filter (Water Separator)
Element - Replace ............................................ 176 Every 6000 Service Hours or 3 Years
Fuel System Primary Filter - Clean ..................... 177 Cooling System Coolant Extender (ELC) - Add .. 147
Fuel System Secondary Filter - Replace ............ 179
Fuel Tank Water and Sediment - Drain ............... 180 Every 6000 Service Hours or 4 Years
Hoist and Brake Tank Breather - Replace .......... 182
Oil Filter (Steering, Hydraulic Fan) - Replace ..... 186 Cooling System Water Temperature Regulator -
Parking Brake Release Oil Filter - Replace ........ 187 Replace ............................................................. 152
Rear Axle Oil Filter - Replace ............................. 189 Engine Water Pump - Inspect ............................. 167
Secondary Steering - Check ............................... 193 VIMS Module Battery - Replace ......................... 209
Steering System Oil Filter - Replace ................... 198
Suspension Cylinder - Check ............................. 202 Every 12 000 Service Hours or 6 Years
Torque Converter Outlet Screen - Replace ......... 203
Torque Converter Sump Breather - Clean .......... 204 Cooling System Coolant (ELC) - Change ........... 145
Transmission Magnetic Screen - Clean .............. 208 Steering Ball Stud - Replace ............................... 196
Transmission Oil Filter - Replace ........................ 208
Every 15 000 Service Hours
Every 1000 Service Hours or 6 Months
Rim - Inspect ....................................................... 191
Air Dryer Desiccant - Replace ............................ 130
Frame and Body Support Pads - Clean/Inspect .. 171 Every 1 393 000 L (368 000 US gal) of Fuel
Rollover Protective Structure (ROPS) - Inspect .. 192 or 8000 Service Hours
Seat Suspension - Inspect/Lubricate .................. 193
Service Brakes - Inspect ..................................... 194 Engine Components - Rebuild/Install Reman ..... 162
Steering Ball Stud - Inspect ................................ 195
Steering Linkage - Inspect .................................. 196 Every 2 786 000 L (736 000 US gal) of Fuel or
Torque Converter and Transmission Oil - 16 000 Service Hours
Change ............................................................. 205
Engine Components - Clean/Inspect, Rebuild/Install
Every 2000 Service Hours or 1 Year Reman, Install New ........................................... 161
Breather (Fuel Tank) - Replace ........................... 142

Differential Thrust Pin Clearance - Check .......... 154
Differential and Final Drive Breather - Replace .. 154
Differential and Final Drive Oil - Change ............ 154
Front Axle Breather - Replace ............................ 172
Hoist and Brake Tank Oil - Change .................... 182
Rear Axle Housing End Play - Adjust ................. 188
Steering System Oil - Change ............................ 197
Suction Screen (Rear Axle Lubrication) - Clean .. 200
130 SEBU7792-05
Maintenance Section
Air Conditioner Filter - Clean
i02390098 2. Drain the primary air tank and drain the secondary
air tank. Refer to Operation and Maintenance
Air Conditioner Filter - Clean Manual, “Air Tank Moisture and Sediment - Drain”
for the proper procedure.
SMCS Code: 7320-070-FI
If a reduction in air circulation is noticed, 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.
1. Park the machine on a level surface and engage

the parking brake.
2. Loosen the door retaining screws and open the

door.
g01167619
Illustration 134
Air dryer (1) is located on the frame in front of the left front
suspension cylinder.
The tire and the wheel have been removed for ease of viewing.
g01165826
3. If there is moisture in the air tanks, replace
Illustration 133 the desiccant cartridge or rebuild the desiccant
cartridge. Consult your Caterpillar dealer for
3. Remove filter element (1). information about replacing the desiccant cartridge
and for instructions for rebuilding the desiccant
4. Clean the element by gently tapping the element cartridge.
on a smooth surface.
Note: Small amounts of moisture may be in the
5. Install the clean element. Close the door and system due to condensation in the system.
tighten the retaining screws.
i02340897
i02685548
Air Dryer - Check Air Dryer Desiccant - Replace

SMCS Code: 4285-510-DSS
SMCS Code: 4285-535
Air lines to and from the air dryer must be at

The air lines to and from the air dryer must be at atmospheric pressure. Release the air pressure
atmospheric pressure. If the air lines are not at at- from the air system completely before performing
mospheric pressure, personal injury could result. maintenance.
Release the air pressure from the air system com-
pletely before performing maintenance.

the parking brake.
SEBU7792-05 131
Maintenance Section
Air Tank - Inspect
Primary Air Tank
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Illustration 136
Drain valve (1) for the primary air tank is located on the right hand
side of the platform.
1. Open drain valve (1) for the air tank.

g01167619
Illustration 135
2. Check for moisture and sediment in the air tanks.
Air dryer (1) is located on the frame in front of the left front
suspension cylinder.
Drain the moisture and sediment from the air tank
into a suitable container.
The tire and the wheel have been removed for ease of viewing.
3. Close the drain valve for the air tank.

Replace the air dryer desiccant cartridge or rebuild
the air dryer desiccant cartridge if water cannot be
absorbed. Consult your Caterpillar dealer for service Secondary Air Tank
or for replacement parts.
i02444297
Air Tank - Inspect

SMCS Code: 4272-040; 5505-040; 7428-040
When laws in the machine's operating location

require the inspection of air tanks, refer to Special
Instruction, REHS2398, “Air Tank Inspection for the
Off-Highway Truck 769 - 797”.
i02602974
Air Tank Moisture and

Sediment - Drain
SMCS Code: 4272-543-MAS
Park the machine on a level surface and engage the Illustration 137
g01132579
parking brake. The drain valve for the secondary air tank is located on the right
hand side of the cab exterior.
1. Open drain valve (2) for the air tank.
2. Check for moisture and sediment in the air tank.

132 SEBU7792-05
Maintenance Section
Air/Hydraulic Cylinder Breather - Clean
Primary Air Tank (If Equipped

with the Sound Suppression
Arrangement)
g01302805 g01133243
Illustration 138 Illustration 139
(1) Breather for the rear air/hydraulic cylinders
1. Open drain valve (3) for the air tank. (2) Breather for the front air/hydraulic cylinders
(3) Rear air/hydraulic cylinders
(4) Front air/hydraulic cylinders
2. Check for moisture and sediment in the air tank.
4. Remove breathers (1) and (2) for air/hydraulic
cylinders (3) and (4).
5. Wash both breathers in clean nonflammable
solvent. Allow the breathers to dry.
i02251322
6. Install the clean breathers.
Air/Hydraulic Cylinder
Breather - Clean 7. Remove the truck body retaining cable and lower
the body.
SMCS Code: 4258
When it is necessary to work under the machine

with the body (bed) raised, attach the body (bed)
retaining cable to the rear tow point. Install the
rear tow point pin through the end of the retaining
cable.
Failure to properly secure the body (bed) may re-

sult in personal injury or death.

the parking brake.
2. Raise the dump body to the fully raised position

and install the truck body retaining cable to the
rear tow point pin. For the proper procedure, refer
to Operations and Maintenance Manual, “Cable
(Truck Body Retaining)”.
3. Stop the engine.

SEBU7792-05 133
Maintenance Section
Automatic Lubrication Reservoir - Fill
i03795949 The automatic lubrication reservoir provides

lubrication for many components. There are fittings
Automatic Lubrication on the left side of the machine, fittings on the
Reservoir - Fill right side of the machine, and fittings on the rear
differential housing.
SMCS Code: 7540-544-TNK
If any of the remote lines become damaged, install a
fitting in place of the remote line. Lubricate the item
at the fittings until the remote line can be replaced.
See Systems Operation, Testing and Adjusting,

SENR4724, “Automatic Lubrication System” for
additional details.
i02253468
Backup Alarm - Test

SMCS Code: 7406-081
g01133458
Illustration 140
1. Remove plug (1) for the vent port if the reservoir is

not equipped with a permanent vent.
Note: If the reservoir is not properly vented, pressure

will cause the wiper seal on the follower assembly g01130536
Illustration 141
inside the reservoir to fail when the reservoir is filled.
Grease on the top side of the follower assembly Location of the backup alarm
may prevent the autolube system from functioning
properly. Also, grease on the top side of the follower Park the machine on a level surface and engage the
assembly may cause damage to the autolube system. parking brake.
2. Fill the autolube reservoir through fill port (2). Turn the engine start switch to the ON position in
Place a suitable container under the outlet for order to perform the test.
the vent port in order to collect any grease that
is spilled. Fill the reservoir until grease appears Make sure that the area behind the machine is clear
at the outlet for the vent port. If the machine is of personnel and clear of obstacles.
equipped with a Fast Fill Service Center, the level
indicator will illuminate when the reservoir is full. Move the transmission direction and speed control
For more information on the Fast Fill Service lever to the REVERSE position.
Center, refer to Operation and Maintenance
Manual, “Fast Fill Service Center”. The backup alarm should sound immediately. The
backup alarm should continue to sound until the
Note: The bulk capacity of the grease reservoir is transmission direction and speed control lever is
27 kg (60 lb). moved to the NEUTRAL position or to the FORWARD
position.
3. Install the plug in the vent port if the reservoir is
not equipped with a permanent vent.
134 SEBU7792-05
Maintenance Section
Battery - Recycle
i00993589
Battery - Recycle
SMCS Code: 1401-561
Always recycle a battery. Never discard a battery.
Always return used batteries to one of the following

locations:
• A battery supplier
• An authorized battery collection facility
g01131766
• Recycling facility Illustration 142
5. Disconnect the negative end “−” of the battery

i02341243
cable from the battery.
Battery or Battery Cable - 6. Disconnect the positive end “+” of the battery
Inspect/Replace cable from the battery.
SMCS Code: 1401-040; 1401-510; 1402-040; 7. Replace the battery or make all necessary repairs
1402-510 to the battery.
Note: When you replace the batteries, always use 8. Connect the positive end “+” of the battery cable
the same type of battery. This machine requires to the battery.
Maintenance Free batteries or Low Maintenance
High Output batteries. 9. Connect the negative end “−” of the battery cable
to the battery.
the parking brake. 10. Connect the negative end “−” of the battery cable
to the frame near the battery disconnect switch.
2. Turn the engine start switch to the OFF position.
Turn all of the switches to the OFF position. 11. Install the key. Turn the battery disconnect switch
to the ON position.
3. Turn the battery disconnect switch to the OFF
position. Remove the key. Refer to Operation and
Maintenance Manual, “Battery Disconnect Switch” i02253729
for more information. Belts - Inspect/Adjust/Replace

4. Disconnect the negative end “−” of the battery SMCS Code: 1357-025; 1357-040; 1357-510
cable from the frame near the battery disconnect
switch.
Inspection
Note: Do not allow the disconnected battery cable to
contact the battery disconnect switch. Park the machine on a level surface and engage the
parking brake.
To maximize the engine performance, inspect

the belt for wear and for cracking. Check the
belt tension. Belt slippage will decrease the life
of the belt. A correctly adjusted belt will deflect
13 to 19 mm (0.50 to 0.75 inch). Refer to the Engine
Specifications, “Belt Tension Chart”.
SEBU7792-05 135
Maintenance Section
Belts - Inspect/Adjust/Replace
g01135583 g01135196
The refrigerant compressor has a belt tensioner. If 2. Loosen mounting bolt (5) and adjusting nuts (3).
shoulder (2) of the belt tensioner is aligned with red
zone (1) of the indicator, replace the belt. 3. If necessary, remove belt guard (4).
Adjustment and Replacement 4. If necessary, remove the belt and replace the belt.
5. Turn adjusting nuts (3) in order to increase or

Alternator decrease the belt tension.
1. Park the machine on a level surface. Engage the 6. If the belt guard was removed, reinstall the belt
parking brake and stop the engine. guard.
7. Tighten the adjusting nuts. Tighten the mounting

bolt.
8. Check the belt tension on a new belt after 30

minutes of operation.
Note: The break-in period for the belt is considered

to be 30 minutes.
Refrigerant Compressor
g01135171
Illustration 144
g01135219
Illustration 146
136 SEBU7792-05
Maintenance Section
Brake Cooling Oil Filter - Replace
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar

Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
g01135507 Dispose of all fluids according to local regulations and

Illustration 147
mandates.
Belt tensioner for the refrigerant compressor belt
1. Park the machine on a level surface. Engage the

parking brake and stop the engine.
2. In order to release the tension on the belt, Insert a

12.7 mm (0.50 inch) ratchet into square hole (6) in
the belt tensioner, and pry the belt tensioner in a
counterclockwise direction.
3. If necessary, remove the belt and replace the belt.
4. Shoulder (2) of the belt tensioner should be

aligned with green zone (7) of the indicator.
5. Check the belt tension on a new belt after 30 g01137716

Illustration 148
minutes of operation.
Location of the brake cooling oil filters
Note: The break-in period for the belt is considered
to be 30 minutes. 1. Park the machine on a level surface. Engage the
Refer to Engine Supplement, Disassembly and
Assembly, “Belt Tightener - Remove and Install” for
more information on replacement of the belts.
i03536820
Brake Cooling Oil Filter -

Replace
SMCS Code: 1366-510-FI
Hot oil and hot components can cause personal Illustration 149
g01864993
injury. Do not allow hot oil or hot components to
contact skin. 2. Remove oil filler cap (1) and use a vacuum
transducer and vacuum cap in order to create
a vacuum to the hoist/brake tank. Attach an air
supply hose to the vacuum transducer and apply
276 to 414 kPa (40 to 60 psi) of air.
SEBU7792-05 137
Maintenance Section
Brake Oil Cooler Screen - Clean
Refer to Disassembly and Assembly, RENR8332, i02320005

“Oil Filter (Parking Brake Release) - Remove” for
the required tooling in order to create a vacuum in Brake Oil Cooler Screen -
the 793D hoist/brake tank. Clean
Note: A vacuum must exist in the hoist/brake tank in SMCS Code: 4257-070; 4295-070
order to prevent the oil from draining from the system
when the brake cooling oil filters are removed.
Hot oil and hot components can cause personal

contact skin.
NOTICE
Illustration 150
g01864994 Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies
The brake cooling oil filters are located behind the fuel tank. The
fuel tank has been removed for ease of viewing. suitable to collect and contain fluids on Caterpillar
products.
3. Remove filter housings (2).
Dispose of all fluids according to local regulations and
4. Remove the used filter elements and discard the mandates.
used filter elements properly.
After a failure in the brake circuit, clean the screens
5. Wash the filter housings in clean nonflammable for the brake oil coolers. There are three screens that
solvent. need to be cleaned. There is one screen for the front
brake oil cooler and there are two screens for the
6. Inspect the seal in each housing base. If a seal is rear brake oil cooler.
damaged, replace the seal with a new seal.
7. Install the new filter elements in the filter housings. parking brake and stop the engine.
8. Install the filter housings.
9. Remove the vacuum transducer and the vacuum

cap. Install the oil filler cap.
10. Start the engine and operate the engine at low

idle. Make sure that the parking brake is engaged.
Check for leaks and make any necessary repairs.
11. Check the oil level in the hoist/brake tank. If

necessary, add oil. For the proper procedure, refer
to Operation and Maintenance Manual, “Hoist and
Brake Tank Oil Level - Check”.
138 SEBU7792-05
Maintenance Section
Brake Oil Cooler Screen - Clean
g01159886 g01159904
The rear brake oil cooler screens are located on the right side The front brake oil cooler screen is located inside the left frame rail
behind the rear brake oil cooler and in front of the hydraulic tank. between the fuel tank and the torque converter.
(2) Rear brake oil coolers The tire and the rim for the front left side have been removed for
(3) Oil cooler for the steering/fan drive ease of viewing.
2. Drain the oil from rear brake oil coolers (2) with 7. Drain the oil from the front brake oil cooler screen
drain (4). with drain (6).
8. Remove cover (5) for the front oil cooler screen.
9. Remove the front oil cooler screen. Wash the oil

cooler screen in a clean, nonflammable solvent.
10. Install the front oil cooler screen.
11. Install the cover for the front brake oil cooler
screen.

g01176679
Illustration 152 13. Check the oil level in the hoist/brake tank. If
Screen locations necessary, add oil. For the proper procedure, refer
Back side view of the housing for the rear brake oil cooler screens. to Operation and Maintenance Manual, “Hoist and
Brake Tank Oil Level - Check”.
3. Remove covers (1) for the rear brake oil cooler
screens. One cover is located at the front of the
screen housing and one cover is located at the
rear of the screen housing.
4. Remove the rear oil cooler screens. Wash the oil

cooler screens in a clean, nonflammable solvent.
5. Install the rear oil cooler screens.
6. Install the covers for the rear brake oil cooler

screens.
SEBU7792-05 139
Maintenance Section
Brake Tank (Makeup) - Clean
i02270875 i02381189
Brake Tank (Makeup) - Clean Brakes, Indicators and Gauges

SMCS Code: 4291 - Test
SMCS Code: 4251-081; 4267-081; 4269-081;
7000-081; 7450-081; 7490-081
When it is necessary to work under the machine Before you operate the machine, perform the
with the body (bed) raised, attach the body (bed) following checks.
rear tow point pin through the end of the retaining 1. Inspect the brake indicator lights in the cab.
cable. Look for broken lenses on the gauges. Check for
broken indicator lights, broken switches, and other
Failure to properly secure the body (bed) may re- broken components in the cab.
2. Make sure that the parking brake is engaged. Turn
the engine start switch to the ON position and
monitor the self test of the VIMS. See Operation
and Maintenance Manual, “Vital information
System (VIMS) Self Test” for further information.
The indicator lights on the dash will illuminate for 3
seconds. Replace any inoperative indicator lights.
Look for any inoperative gauges.
3. Start the engine. Check the brake system for the

following: oil leaks, air leaks, and damaged brake
lines.
4. Turn on all machine lights. Check for proper

operation.
g01137610
Illustration 154
The brake makeup oil tank is located on the inside rail on the left 5. Sound the horn. Listen for proper operation.
side of the machine near the center tube.
6. Test the parking brake. For the proper test
1. Park the machine on a level surface and engage procedure, refer to Operation and Maintenance
the parking brake. Manual, “Braking System - Test”.
2. Raise the truck body to the fully raised position 7. Test the service brakes. For the proper test
and install the truck body retaining cable to the procedure, refer to Operation and Maintenance
rear tow point pin. For the proper procedure, refer Manual, “Braking System - Test”.
(Truck Body Retaining)”. 8. Engage the parking brake. Stop the engine.
3. Stop the engine. Make any necessary repairs before machine

operation. Consult your Caterpillar dealer for more
4. Remove the top cover of brake makeup oil tank information.
(1).
5. Clean the cover and the brake makeup oil tank in

clean nonflammable solvent.
6. Inspect the cover seal and replace the cover seal

if the cover seal is damaged.
7. Install the cover.
8. Remove the truck body retaining cable and lower

the body.
140 SEBU7792-05
Maintenance Section
Braking System - Test
i02934683

SMCS Code: 4251-081; 4267-081
Personal injury can result if the machine moves

while testing.
If the machine begins to move during test, reduce

the engine speed immediately and engage the
parking brake.
g01427991
Illustration 155
(1) Transmission Control Lever
(2) Parking Brake Reset Valve
(3) Parking Brake Switch
If the machine moves when testing the brakes,
contact your Caterpillar dealer. 5. Depress parking brake reset valve (2).
Have the dealer inspect and repair the brakes be- 6. Engage parking brake switch (3).
fore returning the machine to operation. Failure to
have the brakes inspected and repaired can cause 7. Move transmission control lever (1) to the FIRST
injury or death. SPEED FORWARD position.
The following tests are used to determine if the 8. Gradually increase the engine speed to 1300 rpm.
parking brake, the secondary brake, and the service The machine should not move.
brake are functional. These tests are not intended
to measure the maximum brake holding effort. The 9. Reduce the engine speed to low idle. Move
brake holding effort that is required to sustain a the transmission control lever to the NEUTRAL
machine at a specific engine rpm varies depending position. Leave the parking brake engaged. Stop
on the machine. The variations are the differences in the engine.
the engine setting, in the power train efficiency, and
in the brake holding ability, etc. NOTICE
If the machine moved while testing the brakes, contact
Note: Service personnel should perform this test your Caterpillar dealer.
monthly. Document the results of each monthly test.
Compare the engine rpm from the previous month Have the dealer inspect and, if necessary, repair the
to the current engine rpm. This will determine the parking brakes before returning the machine to oper-
system deterioration. ation.
Parking Brake Holding Ability Test Test for the Parking Brake Reset
The air control valve for the parking brake activates Valve
all the wheel brakes. The parking brakes are applied
by spring pressure and the parking brakes are 1. Fasten the seat belt before you test the brakes.
released by oil pressure.
2. Check the area around the machine. Make sure
1. Fasten the seat belt before you test the brakes. that the machine is clear of personnel and clear of
obstacles.
that the machine is clear of personnel and clear of 3. Test the brakes on a dry, level surface.
obstacles.
4. Purge the air from the air system at the air tanks.
3. Test the brakes on a dry, level surface.
5. Make sure that the parking brake reset valve is
4. Start the engine and allow the air system to build engaged. The valve will pop up to the engaged
up to the operating pressure. position.
SEBU7792-05 141
Maintenance Section
6. Start the engine and allow the air system to build

up to the operating pressure.
7. Disengage the parking brake.
8. Move the transmission control lever to the FIRST

SPEED FORWARD position.
9. Gradually increase the engine speed to 1300 rpm.

The machine should not move.
10. Reduce the engine speed to low idle. Move

the transmission control lever to the NEUTRAL
position. Engage the parking brake switch. Stop
the engine. g01167673
Illustration 156
11. In order to disengage the parking brake reset
valve , push down the knob. 5. Apply secondary brake control (4).
6. Depress the parking brake reset valve.

NOTICE
If the machine moved while testing the brakes, contact 7. Release the parking brake.
your Caterpillar dealer.
Have the dealer inspect and, if necessary, repair the SPEED FORWARD position.
parking brakes before returning the machine to oper-
ation. 9. Gradually increase the engine speed to 1300 rpm.
Secondary Brake Holding Ability 10. Reduce the engine speed to low idle. Move
Test the transmission control lever to the NEUTRAL
position. Engage the parking brake. Stop the
The secondary brake air control valve activates all engine.
the wheel brakes. The secondary brakes are applied
by spring pressure and the secondary brakes are NOTICE
released by oil pressure. If the machine moved while testing the brakes, contact
1. Fasten the seat belt before you test the brakes.
Have the Caterpillar dealer inspect and, if necessary,
2. Check the area around the machine. Make sure repair the parking/secondary brakes before returning
that the machine is clear of personnel and clear of the machine to operation.
obstacles.
3. Test the brakes on a dry, level surface. Service Brake Holding Ability Test
4. Start the engine and allow the air system to build The service brake air control valve activates all the
up to the operating pressure. wheel brakes. The service brakes are applied by oil
pressure and the service brakes are released by
spring pressure.
1. Fasten the seat belt before you test the brakes.

that the machine is clear of personnel and clear of
obstacles.
3. Test the brakes on a dry, level surface.
4. Start the engine and allow the air system to build

up to the operating pressure.
142 SEBU7792-05
Maintenance Section
Breather (Fuel Tank) - Replace

the parking brake.
2. Raise the truck body to the fully raised position

rear tow point pin. For the proper procedure for the
installation and removal of the truck body retaining
cable, refer to Operations and Maintenance
Manual, “Cable (Truck Body Retaining)”.
3. Stop the engine.
g01190530
Illustration 157
5. Apply service brake control (5).
6. Depress the parking brake reset valve.
7. Release the parking brake.

SPEED FORWARD position.
9. Gradually increase the engine speed to 1300 rpm. Illustration 158

g01172150
4. Remove fuel tank breather (1).
10. Reduce the engine speed to low idle. Move
the transmission control lever to the NEUTRAL 5. Properly discard the used breather.
position. Engage the parking brake. Stop the
engine. 6. Install a new breather.
NOTICE 7. Remove the truck body retaining cable and lower

If the machine moved while testing the brakes, contact the body.
Have the dealer inspect and, if necessary, repair the

service brake before returning the machine to opera-
tion.
i02345985
Breather (Fuel Tank) - Replace

SMCS Code: 1273-510-BRE

cable.

SEBU7792-05 143
Maintenance Section
Cab Air Filter - Clean/Replace
i01766189 i02385071
Cab Air Filter - Clean/Replace Cable (Truck Body Retaining)

SMCS Code: 7311-070-FI; 7311-510-FI; 7342-070; - Inspect
7342-510
SMCS Code: 5154-040; 7258-040-KA
A raised body (bed) may fall unexpectedly if a

damaged cable is used. Use of a damaged cable
could result in personal injury or death.
Inspect the cable for damage and do not use a

cable that is damaged.
Wear gloves when handling the cable.
1. Inspect the cable for any of the following

Illustration 159
g00903640 conditions:
Location of the filter element for the cab
(1) Cover
• Reduction in the diameter
(2) Retaining screws
• Broken wires
The filter element for the cab is located inside the
operator's compartment. • Worn wires
1. Loosen retaining screws (2). Remove cover (1) • Corroded wires

and the filter element.
• Loose strands or loose wires
2. Wash the filter element in a nonsudsing detergent.
• Loose cable ends or separation between the
3. Rinse the filter element in clean water. Allow the cable and the cable end
filter element to air dry.
• Kinks
4. Install the clean filter element and cover (1).
Tighten retaining screws (2). • Cuts
Note: When rips or tears are noticed in the filter • Flat spots
element, install a new filter element. When a
reduction of air circulation is noticed in the cab after 2. Inspect the cable ends and the cable connection
cleaning the filter element, install a new filter element. for the truck body for any of the following
conditions:
• Distortion such as bends or twists

• Wear
• Corrosion
• Cracks or gouges
If any of the above conditions exist, replace
the truck body retaining cable and the cable
connection for the truck body. Consult your
Caterpillar dealer for proper replacement parts.
144 SEBU7792-05
Maintenance Section
Circuit Breakers - Reset
i02342172
VIMS Main Module (1) – 15 Amp
Circuit Breakers - Reset
SMCS Code: 1420
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
g01167724
Illustration 160 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
g01167816
Illustration 161
Window Washer and Wiper (12) – 10

Circuit Breaker/Reset – Push in the
Amp
button in order to reset the circuit breaker. If
the electrical system is working properly, the
button will remain depressed. If the button does not
remain depressed, check the appropriate electrical Power Train Electronic Control Module
circuit. Repair the electrical circuit, if necessary. (13) – 10 Amp
Note: The circuit breakers for the low beam

Air Dryer (14) – 10 Amp
headlights, the high beam headlights, and the fog
lights are automatic reset circuit breakers.
SEBU7792-05 145
Maintenance Section
Cooling System Coolant (ELC) - Change
Heated Mirrors (15) – 25 Amp NOTICE

Power Window (16) – 10 Amp collect the fluid with suitable containers before open-

Access Lights (17) – 15 Amp
products.
Brake Electronic Control Module (18) – Dispose of all fluids according to local regulations and
10 Amp mandates.
Electronic Fuel Injection (19) – 15 Amp NOTICE

Do not change the coolant until you read and under-
stand the material in the Cooling System Specifica-
tions section.
24 to 12 Volt Converter (20) – 10 Amp
NOTICE
Mixing Cat Extended Life Coolant (ELC) with other
products reduces the effectiveness of the coolant
and shortens coolant life. Use only Caterpillar prod-
i03895691
ucts or commercial products that have passed the
Cooling System Coolant (ELC) Caterpillar EC-1 specifications for premixed or con-
centrate coolants. Use only Cat Extender with Cat
- Change ELC. Failure to follow these recommendations could
result in damage to the cooling systems components.
SMCS Code: 1350-044-NL; 1395-044-NL
If ELC cooling system contamination occurs, refer to
Operation and Maintenance, “Extended Life Coolant
(ELC)” under the topic ELC Cooling System Contam-
Personal injury can result from hot coolant, steam ination.
and alkali.
This machine was factory filled with Cat Extended Life
At operating temperature, engine coolant is hot Coolant.
and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or Drain the coolant whenever the coolant is dirty or
steam. Any contact can cause severe burns. whenever foaming is observed.
Remove cooling system pressure cap slowly to 1. Park the machine on a level surface. Engage the
relieve pressure only when engine is stopped and parking brake and stop the engine.
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.
146 SEBU7792-05
Maintenance Section
Cooling System Coolant (ELC) - Change
4. Close the drain valves. Fill the system with clean

water and a 6 to 10% concentration of cooling
system cleaner.
5. Start the engine and operate the engine for 90

minutes. Stop the engine and drain the cleaning
solution into a suitable container.
6. When the engine is stopped, flush the system with

water until the draining water is clear. Drain the
water into a suitable container.
7. Close the drain valves.
8. Add the coolant solution. Refer to Special

Publication, SEBU6250, “Cooling System
Specifications” and Operation and Maintenance
Manual, “Capacities (Refill)”.
Note: If you are using Caterpillar antifreeze, do not

add the supplemental coolant additive at this time
Illustration 162
g01159005 and/or change the element at this time.
(1) Filler cap for the aftercooler cooling system
(2) Filler cap for the jacket water cooling system 9. After the cooling system has been filled, perform
the following procedures during initial start-up:
2. Slowly loosen filler caps (1) and (2). This will
relieve system pressure. Remove the filler caps. a. Start the engine without the filler cap.
b. Run the engine at low idle for ten minutes.
c. Then, increase the engine speed to a high idle

until the thermostat is open and the coolant
level is stabilized.
d. Maintain the coolant at the proper level as the

thermostat opens and air is purged from the
system. Refer to Operation and Maintenance
Manual, “Cooling System Coolant Level -
Check”.
10. Install filler caps (1) and (2).
g01159976
Illustration 163
3. Open drain valves (3) for the jacket water cooling

system and the aftercooler cooling system. Drain
the coolant into a suitable container.
Note: When the drain valves are opened, the coolant

will drain from both systems. Opening one drain
valve will drain that system and the other system will
remain partially full.
SEBU7792-05 147
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
i02317854
NOTICE
Cooling System Coolant Excessive additive (greater than the recommended
Extender (ELC) - Add 6% initial fill) together with concentrations of antifreeze
greater than 60% cause deposits to form and can re-
SMCS Code: 1352-538-NL sult in radiator tube blockage and overheating.
NOTICE
Mixing Cat Extended Life Coolant (ELC) with other
Personal injury can result from hot coolant, steam products reduces the effectiveness of the coolant
and alkali. and shortens coolant life. Use only Caterpillar prod-
ucts or commercial products that have passed the
At operating temperature, engine coolant is hot Caterpillar EC-1 specifications for premixed or con-
and under pressure. The radiator and all lines centrate coolants. Use only Cat Extender with Cat
to heaters or the engine contain hot coolant or ELC. Failure to follow these recommendations could
steam. Any contact can cause severe burns. result in damage to the cooling systems components.
Remove cooling system pressure cap slowly to If ELC cooling system contamination occurs, refer to
relieve pressure only when engine is stopped and Operation and Maintenance, “Extended Life Coolant
cooling system pressure cap is cool enough to (ELC)” under the topic ELC Cooling System Contam-
touch with your bare hand. ination.
Do not attempt to tighten hose connections when This machine was factory filled with Cat Extended Life
the coolant is hot, the hose can come off causing Coolant.
burns.
Cooling System Coolant Additive contains alkali. Refer to Special Publication, SEBU6250, “Cooling
Avoid contact with skin and eyes. System Specification” for the cooling system
requirements.
NOTICE Use 8T-5296 Test Kit in order to check the

Adding coolant to an overheated engine could result in concentration.
damage to the engine. Allow the engine to cool before
adding coolant. 1. Park the machine on a level surface. Engage the
If the machine is to be stored in, or shipped to, an area
with freezing temperatures, the cooling system must
be protected to the lowest outside (ambient) temper-
ature.
The engine cooling system is normally protect-

ed to a minimum of−29°C (−20°F) with Caterpillar
Antifreeze, when shipped from the factory unless
special requirements are defined.
NOTICE

suitable to collect and contain fluids on Caterpillar g01159006
Illustration 164
products.
(2) Filler cap for the jacket water cooling system
Dispose of all fluids according to local regulations and (3) Level gauges
mandates.
148 SEBU7792-05
Maintenance Section
Cooling System Coolant Level - Check
2. Loosen filler caps (1) and (2) slowly in order to

relieve pressure. Remove the filler caps.
3. Check level gauges (3). If necessary, drain

enough coolant in order to allow the addition of
the liquid coolant additive.
Note: Make sure that the coolant is drained into a

suitable container.
4. Refer to the table in Special Publication,

SEBU6250, “Extended Life Coolant (ELC)”.
This table lists the correct amount of Caterpillar
Extended Life Coolant (ELC) extender that should
be added to the cooling system.
5. Clean the filler caps and inspect the filler caps.

Install the filler caps.
6. Start the engine and check for leaks. Allow the

coolant level to stabilize.
g01159008
Illustration 165
7. If necessary, add premixed coolant in order to (1) Level gauge for the aftercooler cooling system
bring the coolant in the green range on the coolant (2) Level gauge for the jacket water cooling system
level gauge.
If you must add coolant daily, check for leaks.
i02317855
Park the machine on a level surface and engage the
Cooling System Coolant Level parking brake.
- Check Use level gauges (1) and (2) to check the coolant
levels. The needle should be in the green range.
SMCS Code: 1350-535-FLV
If the needle is in the red range, allow the system
to cool and add coolant.
Personal injury can result from hot coolant, steam

i03905010
and alkali.
Cooling System Coolant
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines Sample (Level 1) - Obtain
to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns. SMCS Code: 1350-008; 1395-008; 7542
Remove cooling system pressure cap slowly to NOTICE

relieve pressure only when engine is stopped and Always use a designated pump for oil sampling, and
cooling system pressure cap is cool enough to use a separate designated pump for coolant sampling.
touch with your bare hand. Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
Do not attempt to tighten hose connections when contaminate may cause a false analysis and an incor-
the coolant is hot, the hose can come off causing rect interpretation that could lead to concerns by both
burns. dealers and customers.

Avoid contact with skin and eyes. Note: Level 1 results may indicate a need for
Level 2 Analysis.
SEBU7792-05 149
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
Obtain the sample of the coolant as close as possible

to the recommended sampling interval. In order to
receive the full effect of S·O·S analysis, establish
a consistent trend of data. In order to establish
a pertinent history of data, perform consistent
samplings that are evenly spaced. Supplies for
collecting samples can be obtained from your
Caterpillar dealer.
Use the following guidelines for the proper sampling

of the coolant:
• Complete the information on the label for the

sampling bottle before you begin to take the
samples.
• Keep the unused sampling bottles stored in plastic

bags.
• Obtain coolant samples directly from the coolant

sample port. You should not obtain the samples
Illustration 166
g02146856 from any other location.
Right side view of the engine
• Keep the lids on empty sampling bottles until you
Sampling valve (1) for the jacket water cooling system are ready to collect the sample.
is located on the right side of the engine water pump.
• Place the sample in the mailing tube immediately
after you obtain the sample in order to avoid
contamination of the sample.
• Never collect samples from expansion bottles.

• Never collect samples from the drain for a system.
Submit the sample for Level 1 analysis.
For additional information about coolant analysis, see

Special Publication, SEBU6250, “Caterpillar Machine
Fluids Recommendations” or consult your Caterpillar
dealer.
i03905011
Cooling System Coolant

Sample (Level 2) - Obtain
SMCS Code: 1350-008; 1395-008; 7542
g02146857
Illustration 167
Left side view of the engine NOTICE
Always use a designated pump for oil sampling, and
Sampling valve (2) for the water cooled aftercooler use a separate designated pump for coolant sampling.
system is located on the left side of the engine water Using the same pump for both types of samples may
pump. contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.
150 SEBU7792-05
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
g02146856
Illustration 168 Personal injury can result from hot coolant, steam
Right side view of the engine and alkali.
Sampling valve (1) for the jacket water cooling system At operating temperature, engine coolant is hot
is located on the right side of the engine water pump. and under pressure. The radiator and all lines
steam. Any contact can cause severe burns.
Remove cooling system pressure cap slowly to

relieve pressure only when engine is stopped and
Do not attempt to tighten hose connections when

burns.


g02146857
Illustration 169
Left side view of the engine
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.
SEBU7792-05 151
Maintenance Section
Cooling System Relief Valve - Clean
i02347062
Cooling System Relief Valve -

Clean
SMCS Code: 1370-070

and alkali.

Remove cooling system pressure cap slowly to

g01159005 touch with your bare hand.
Illustration 170
(1) Filler cap for the aftercooler cooling system Do not attempt to tighten hose connections when
burns.
2. Remove filler caps (1) and (2) slowly in order to
relieve the pressure. Cooling System Coolant Additive contains alkali.
3. Inspect the filler caps for damage, for foreign
material, and for deposits.
If the system overheats or if coolant is leaking, clean
4. Clean the filler caps with a clean cloth or replace the relief valves or replace the relief valves.
the filler caps, if necessary.
5. Install the filler caps. parking brake and stop the motor.
g01172742
Illustration 171
(3) Cooling system relief valves
152 SEBU7792-05
Maintenance Section
Cooling System Water Temperature Regulator - Replace
2. Slowly remove filler caps (1) and (2). This will i02347151
relieve the pressure.
Cooling System Water
3. Remove the bolts from the relief valve and remove
the valve assembly.
Temperature Regulator -
Replace
SMCS Code: 1355-510; 1393-510

and alkali.

g00302286 Remove cooling system pressure cap slowly to

Illustration 172
(4) Valve cooling system pressure cap is cool enough to
(5) Valve seals
(6) Gasket
(7) Valve cover
(8) Mounting bolts Do not attempt to tighten hose connections when
4. Inspect valve (4),valve seals (5) and gasket (6). burns.
If necessary, replace the valves, the seals or the
gaskets. Cooling System Coolant Additive contains alkali.
5. Inspect valve cover (7) and mounting bolts (8).
Note: The thermostats should be replaced after
6. Assemble the relief valve. Install the relief valve.
the cooling system has been cleaned. Replace the
thermostats while the cooling system is completely
7. Install the filler caps.
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 regu-
larly scheduled basis could cause severe engine dam-
age.
Replace the four thermostats on a regular basis in

order to reduce the chance of unscheduled downtime
and of problems with the cooling system.

SEBU7792-05 153
Maintenance Section
Cooling System Water Temperature Regulator - Replace
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 thermo-

stat could result in either an overheating or an over-
g01159005
Illustration 173 cooling condition.
NOTICE
2. Remove filler caps (1) and (2) slowly in order to If the thermostat is installed incorrectly, it will cause
relieve the pressure. 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.
g01172817
Illustration 174
Note: Make sure that the coolant level is below the

thermostat housings.
154 SEBU7792-05
Maintenance Section
Differential Thrust Pin Clearance - Check
i02320510 2. Remove differential and final drive breather (1).

Differential Thrust Pin 3. Install a new differential and final drive breather.
Clearance - Check
i02454361
SMCS Code: 3258; 3260; 3284
Differential and Final Drive Oil
- Change
SMCS Code: 3258; 4050
The oil change interval for the differential and final

drives can be monitored with a S·O·S (Scheduled
Oil Sampling) program. For more information on
S·O·S services, refer to Operation and Maintenance
Manual, “S·O·S Information”. When a S·O·S
program is used, the oil change interval is based
on the following:
• The condition of the oil

g01160191
Illustration 175
• The S·O·S recommendation
See the Adjustment Procedure For the Pin. This
adjustment procedure is located in the Power Train When a S·O·S program is not used, the oil change
Testing and Adjusting, “Differential and Bevel Gear - interval is based on the following:
Adjust” for your machine.
• 4000 service hours or 1 year if Caterpillar
FDAO/FD-1 oil is used.
i02320548
Differential and Final Drive • 2000 service hours or 1 year if Caterpillar

TDTO/TO-4 oil is used.
Breather - Replace
SMCS Code: 3258; 4050
g01160272
Illustration 177
1. Rotate the wheels so that final drive drain plug (1)

is in the lowest position on the rear wheel.

g01160212
Illustration 176

SEBU7792-05 155
Maintenance Section
Differential and Final Drive Oil - Change
9. Before the differential and final drives are filled,

NOTICE refer to Operation and Maintenance Manual,
Care must be taken to ensure that fluids are contained “Lubricant Viscosities” and Operation and
during performance of inspection, maintenance, test- Maintenance Manual, “Capacities (Refill)”.
collect the fluid with suitable containers before open- NOTICE
ing any compartment or disassembling any compo- If the ambient temperature at engine start-up or
nent containing fluids. during operation is below −10°C (14°F), perform
the procedures in Operation and Maintenance
Refer to Special Publication, NENG2500, “Caterpillar Manual, “Differential Warm-up and Break-in”. Check
Dealer Service Tool Catalog” for tools and supplies the differential compartment and the final drive
suitable to collect and contain fluids on Caterpillar compartment for the proper fluid level. Failure to
products. warm up the oil or improper lubrication levels prior to
operation will cause damage to the machine.
mandates.
10. Fill the differential compartment to the bottom of
the opening for the sight gauge.
3. Remove the final drive drain plug. Drain the oil
into a suitable container. 11. Clean the sight gauge and install the sight gauge.
4. Clean the drain plug. Install the drain plug. 12. Remove final drive filler plugs (2). Fill each final
drive to the bottom of the filler plug opening. When
5. Repeat Step 1 through Step 4 for the other final the final drive drain plug is in the lowest position,
drive. the final drive filler plug will be at the correct oil
level.
Note: The final drives may need to be repositioned in

order to place the final drive drain plug in the lowest
position.
Note: Allow oil to fill all of the compartments. Correct

oil levels are critical in the differential and final drives.
g01160274
Illustration 178
g01160268
6. Remove differential drain plug (3) and allow the oil Illustration 179
to drain into a suitable container.
13. Maintain the proper oil level (5) for the differential
Note: Inspect the magnetic drain plug and the to the bottom of sight gauge (4).
oil. Refer to Operation and Maintenance Manual,
“Differential and Final Drive Oil - Inspect” for further 14. Operate the machine on level ground for a few
information. minutes.
7. Clean the drain plug. Install the drain plug. Note: The differential and final drive oil level needs to
be checked and maintained at operating temperature.
8. Remove sight gauge (4). Wipe the surface around After the oil has been changed in the differential
the opening for the sight glass. and final drives, adjustment of the oil level may
be necessary when the truck reaches operating
temperature.
156 SEBU7792-05
Maintenance Section
Differential and Final Drive Oil - Inspect
15. Stop the machine. Check the oil level. If The differential and final drive oil level needs to be
necessary, adjust the oil level to the bottom of the checked and maintained at operating temperature.
sight gauge. If the oil level is checked cold, adjustment of the
oil level may be necessary when the truck reaches
Note: If it is necessary to add oil, use final drive filler operating temperature.
plug (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.
Note: Overfilling the differential and final drives will

cause overheating and foaming of the oil in long
hauling applications and high speed applications. A
reduction of the life of components may be the result
of overheating and foaming of the oil.
i02450436

- Inspect g01195747
Illustration 180
SMCS Code: 4208 Location of the sight gauge for the differential and final drives
Inspect the differential and final drive oil for any of the 1. Park the machine on a level surface and engage
following symptoms that may indicate a mechanical the parking brake.
failure:
• A high amount of metal on the magnetic plug

• An increased level of nickel concentration in the
S·O·S sample
• An increase in the size of the particle count in the

S·O·S sample
• Oil leaks in the area around the drive wheel

bearings
The rear wheel bearings do not need to be adjusted

or inspected until the scheduled overhaul. Unless a
symptom of an obvious failure appears, do not adjust g01160336
Illustration 181
or inspect the rear wheel bearings. If the differential
and final drive oil has any of the above symptoms, 2. Use sight gauge (1) to check the oil level for the
the rear wheel bearings may need to be inspected. differential and final drives.
Consult your Caterpillar dealer for more information. 3. Maintain the proper oil level (2) at the bottom of
the sight gauge.
i02394551

Level - Check
SMCS Code: 3258; 4050
Correct oil levels are critical in the differential and

final drives. Check the oil level after repairs and after
maintenance. Check the oil level prior to operation.
SEBU7792-05 157
Maintenance Section
Differential and Final Drive Oil Sample - Obtain
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
rect interpretation that could lead to concerns by both
dealers and customers.
Sampling valve (1) for the differential and final drive

oil is located on the base of the rear axle oil filter.
Refer to the following publications for information

g01192672 about obtaining an oil sample.
Illustration 182
4. If necessary, add oil. Use filler plug (3) for the • Operation and Maintenance Manual, “S·O·S
final drive in order to add oil. When the drain Information”
plug is in the lowest position, the filler plug will be
at the correct oil level. Make sure that the filler • Special Publication, SEBU6250, “S·O·S Oil
plug is positioned above the oil level in the final Analysis”
drive in order to prevent any oil from draining out.
Allow the oil to fill all of the compartments before • Special Publication, PEHP6001, “How To Take A
rechecking the oil level. Good Oil Sample”
Note: Overfilling the differential and final drives will • Special Publication, PEDP8025, “Fluid Analysis
cause overheating and foaming of the oil in long Interpretaion Guide”
hauling applications and high speed applications. A
reduction of the life of components may be the result
i02449906
of overheating and foaming of the oil.
Display and Camera - Clean
i02320757 (If Equipped with Work Area
Differential and Final Drive Oil Vision System)
Sample - Obtain SMCS Code: 7347-070; 7348-070
SMCS Code: 3258-008; 4050-008; 4070-008; 7542 In order to maintain sufficient vision, keep the Work
Area Vision System (WAVS) camera lens and the
display clean.
Display
g01223034
Illustration 184
Illustration 183
g01160351 WAVS display
158 SEBU7792-05
Maintenance Section
Drive Shaft Slip Joint - Lubricate
Use a soft, damp cloth in order to clean the display. i02321492

The display has a soft plastic surface that can be
easily damaged by an abrasive material. The display Drive Shaft Slip Joint -
is not sealed. Do not immerse the display with
liquid.
Lubricate
SMCS Code: 3253-086-JT
Camera
g01223051
Illustration 185
The WAVS camera is located on the rear of the machine near
the taillights.
Use a damp cloth or water spray in order to clean

the camera lens. The camera is a sealed unit. The Illustration 186
g01160565
camera is not affected by high pressure spray.
Park the machine on a level surface. Engage the
The camera is equipped with an internal heater to parking brake and stop the engine.
help counteract the effects of condensation, snow,
or ice. Apply lubricant to the grease fitting on the drive shaft
spline.
Note: For more information on WAVS, refer to
Operation and Maintenance Manual, SEBU8157,
“Work Area Vision System”. i02346978
Engine Air Filter Primary

Element - Clean/Replace
SMCS Code: 1051-070-PY; 1051-510-PY;
1054-070-PY; 1054-510-PY
NOTICE
Service the air cleaner only with the engine stopped.
Engine damage could result.
Service the air cleaner filter elements when

the action light is activated. The action light
is located on the dash panel. The action
light will activate when there is an inlet air
restriction, and the VIMS display will provide a
message regarding the specific problem. Refer
to Operation and Maintenance Manual, “Vital
Information Management System (VIMS)” for
further information.

SEBU7792-05 159
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
Cleaning Primary Air Filter

Elements
NOTICE
Caterpillar recommends certified air filter cleaning ser-
vices available at participating Caterpillar dealers. The
Caterpillar cleaning process uses proven procedures
to assure consistent quality and sufficient filter life.
Observe the following guidelines if you attempt to

clean the filter element:
Do not tap or strike the filter element in order to re-

move dust.
g00102316
Illustration 187
Do not wash the filter element.
2. Remove covers (1) for the air filter housings.
Use low pressure compressed air in order to remove
3. Remove primary filter elements (2) from the air the dust from the filter element. Air pressure must not
filter housings. exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
4. Clean the inside of the air filter housings. element. Take extreme care in order to avoid damage
to the pleats.
5. Clean the dust valves on the bottom for the air
filter housings. Do not use air filters with damaged pleats, gaskets, or
seals. Dirt entering the engine will cause damage to
6. Install clean primary air filter elements. Install the engine components.
covers for the air filter housings.
Note: Refer to “Cleaning Primary Air Filter Elements”. The primary air filter element can be used up to
six times if the element is properly cleaned and the
If the alert indicator activates after starting the engine element is properly inspected. When the primary
or the exhaust smoke is still black after installation air filter element is cleaned, check for rips or tears
of clean primary filter elements, install new primary in the filter material. The primary air filter element
filter elements. If the alert indicator remains activated, should be replaced at least one time per year. This
replace the secondary elements. replacement should be performed regardless of the
number of cleanings.
NOTICE
Do not clean the air filter elements by bumping or tap-
ping. This could damage the seals. Do not use ele-
ments with damaged pleats, gaskets, or seals. Dam-
aged elements will allow dirt to pass through. Engine
damage could result.
Visually inspect the primary air filter elements before

cleaning. Inspect the air filter elements for damage
to the seal, the gaskets, and the outer cover. Discard
any damaged air filter elements.
There are two common methods that are used to

clean primary air filter elements:
• Pressurized air
• Vacuum cleaning
160 SEBU7792-05
Maintenance Section
Engine Air Filter Secondary Element - Replace
Pressurized Air Inspecting the Primary Air Filter

Pressurized air can be used to clean primary air filter
Elements
elements that have not been cleaned more than two
times. Pressurized air will not remove deposits of
carbon and oil. Use filtered, dry air with a maximum
pressure of 207 kPa (30 psi).
g00281693
Illustration 189
Inspect the clean, dry primary air filter element. Use

a 60 watt blue light in a dark room or in a similar
g00281692
facility. Place the blue light in the primary air filter
Illustration 188 element. Rotate the primary air filter element. Inspect
the primary air filter element for tears and/or holes.
Note: When the primary air filter elements are Inspect the primary air filter element for light that may
cleaned, always begin with the clean side (inside) show through the filter material. If it is necessary in
in order to force dirt particles toward the dirty side order to confirm the result, compare the primary air
(outside). filter element to a new primary air filter element that
has the same part number.
Aim the hose so that the air flows inside the element
along the length of the filter in order to help prevent Do not use a primary air filter element that has any
damage to the paper pleats. Do not aim the stream of tears and/or holes in the filter material. Do not use
air directly at the primary air filter element. Dirt could a primary air filter element with damaged pleats,
be forced further into the pleats. gaskets or seals. Discard damaged primary air filter
elements.
Vacuum Cleaning
i02347040
Vacuum cleaning is another method for cleaning
primary air filter elements which require daily cleaning
because of a dry, dusty environment. Cleaning with
Engine Air Filter Secondary
pressurized air is recommended prior to vacuum Element - Replace
cleaning. Vacuum cleaning will not remove deposits
of carbon and oil. SMCS Code: 1054-510-SE
NOTICE
Always replace the secondary element. Do not at-
tempt to reuse it by cleaning. Engine damage could
result.
Note: Replace the engine air filter secondary

elements when you service the engine air filter
primary elements for the third time. Replace the
secondary elements if the exhaust smoke remains
black and the clean primary elements have been
installed.

SEBU7792-05 161
Maintenance Section
Engine Air Precleaner - Clean
2. Loosen clamp (1) on the precleaner and remove

lower precleaner bowl (2) and dust valve (3).
3. Clean the lower precleaner bowl and the dust

valve with air pressure.
4. Make sure that all of the tubes within the

precleaner are free of dirt. Clean the tubes, if
necessary.
5. Install the clean lower precleaner bowl, and the

clean dust valve and tighten the clamp on the
precleaner.
Illustration 190
g00644798 NOTICE
Do not operate the machine with the dust valves re-
(1) Secondary element
moved. Engine damage can occur.
2. Remove secondary elements (1) and properly
discard the secondary elements.
i02381002
3. Cover the air inlet openings. Clean the inside of
the air cleaner housings.
Engine Components -
Clean/Inspect, Rebuild/Install
4. Uncover the air inlet openings. Install the new
secondary elements. Reman, Install New
5. Install the primary elements. SMCS Code: 1000-012-IC; 1000-022-MC;
1000-571-IC
i02363128 Caterpillar recommends this additional maintenance

for the following engine components. Consult your
Engine Air Precleaner - Clean Caterpillar dealer for further information.
SMCS Code: 1055-070 The quantity of burned fuel that is shown with the
service hours assumes a load factor of 40 percent. If
the load factor is higher than 40 percent, the number
of service hours for the overhaul interval will be
lower. If the load factor is lower than 40 percent, the
number of service hours for the overhaul interval will
be higher. The quantity of consumed fuel is a better
indicator for the overhaul interval than service hours.
Install New Components

• All Seals, Gaskets and O-rings
• Camshaft Bearings
g01180274
Illustration 191 • Engine Mounts
Note: Do not paint dust valves (3). Paint will cause • Engine Software
the rubber to harden and the rubber may not seal
properly. • Fuel Pressure Regulating Valve
Perform the following procedure for each engine air • Fuel Priming Pump
precleaner.
• Gear Train Bushings, Bearings and Thrust Plates
parking brake and stop the engine. • Main Bearings, Rod Bearings and Crankshaft
Thrust Plates
162 SEBU7792-05
Maintenance Section
Engine Components - Rebuild/Install Reman
• Piston Rings The quantity of burned fuel that is shown with the
service hours assumes a load factor of 40 percent. If
• Wiring Harness the load factor is higher than 40 percent, the number
of service hours for the mid-life service interval will
be lower. If the load factor is lower than 40 percent,
Rebuild Components and/or Install the number of service hours for the mid-life service
Remanufactured Components interval will be higher. The quantity of consumed fuel
is a better indicator for the mid-life service interval
• Cylinder Heads than service hours.
• Turbochargers • Air Compressor

• Oil Coolers • Air Starter
• Oil Pump • Alternator
• Scavenge Oil Pump • Fuel Transfer Pump
• Water Pump • High Pressure Turbochargers (3516B High Altitude
Engine)
Clean Components and Inspect
• Turbochargers (3516B High Displacement Engine)
Components for Reusability
• Injectors
• Aftercooler Core
• Refrigerant Compressor
• Camshaft
• Wastegate (3516B High Altitude Engine)
• Camshaft Lifters
• Connecting Rods i02322735
• Crankshaft
Engine Crankcase Breather -
Clean
• Cylinder Block
SMCS Code: 1317-070-ENG
• Cylinder Liners
The engine in this machine is equipped with six
• Damper engine crankcase breathers. Two of the breathers
are on the valve covers on the right side and four of
• Gear Train the breathers are on the valve covers on the left side.
• Piston Crowns and Piston Skirts

• Piston Pins
• Spacer Plates
i02381004
Engine Components -
Rebuild/Install Reman
SMCS Code: 1000-022-MC
Caterpillar recommends this additional maintenance

for the following engine components. Consult your
Caterpillar dealer for further information.
SEBU7792-05 163
Maintenance Section
Engine Oil Filter (Oil Renewal System) - Change
i02398716
Engine Oil Filter (Oil Renewal

System) - Change
(If Equipped)
SMCS Code: 1308-510; 1349

contact the skin.
NOTICE

products.

mandates.
The machine must be parked on a level surface and

the parking brake must be engaged. The oil must be
g01160965
Illustration 192 warm and the engine must be stopped.

the parking brake.
2. Stop the engine. Loosen clamps (4). Remove

hose (2) from breather assemblies (1) and from
vent tube (3).
3. Remove the breather assemblies from the valve

covers.
4. Wash the breather in clean nonflammable solvent.
5. Install the breather assemblies on the valve

covers.
6. Install the hose on the breather assemblies and

on the vent tube. Tighten all clamps.
7. Repeat Step 2 through Step 6 in order to clean the

remaining breathers on the engine.
g01162192
Illustration 193
(1) Engine oil filters
(2) Oil filler cap
(3) Dipstick
164 SEBU7792-05
Maintenance Section
Engine Oil Level - Check
1. Remove used engine oil filters (1) and discard the

used engine oil filters . NOTICE
Do not under fill or overfill engine crankcase with oil.
2. Clean the oil filter base assemblies. Make sure Either condition can cause engine damage.
that all of the former gaskets are removed.
3. Apply a thin film of clean engine oil to each seal of

each new engine oil filter .
4. Install the new engine oil filters by hand. Tighten

each filter until the seal of each engine oil filter
contacts the base. Note the position of the index
marks on each filter in relation to a fixed point on
the filter base.
Note: Caterpillar filters have rotation index marks

that are spaced 90 degrees or 1/4 of a turn away
from each other. When you tighten the filters, use the
rotation index marks as a guide.
g01162246
Illustration 194
5. Tighten each filter according to the instructions
that are printed on the filter. Use the index marks Location of the dipstick for the engine oil
as a guide. The tire and the wheel have been removed for ease of viewing.
Note: You may need to use a Caterpillar strap

wrench, or another suitable tool, in order to turn
the filters to the amount that is required for final
installation. Make sure that the installation tool does
not damage the filters.
6. Start the engine and operate the engine at low idle

for five minutes. Inspect engine oil filters (1) for oil
leaks. Make any necessary repairs.
7. Maintain the oil level between the “ADD” mark and

the “FULL” mark. These marks are on the “LOW
IDLE” side of dipstick (3). Stop the engine.
g01162249
Illustration 195
i02682174
1. The machine must be on a level surface and the
Engine Oil Level - Check parking brake must be engaged.
SMCS Code: 1348-535-FLV 2. Check the oil level in the engine.
a. When the engine is running at low idle, maintain

the oil level between the “ADD” mark and the
Personal injury or death can occur if personnel are “FULL” mark. These marks are on the “LOW
trapped between the wheel and the frame. IDLE” side of dipstick (2).
The steering system is hydraulically controlled b. When the engine is stopped, maintain the oil
and wheels can crush personnel during move- level between the “ADD” mark and the “FULL”
ment. mark. These marks are on the “ENGINE
STOPPED” side of the dipstick.
Use caution when working between the wheels
and the frame. If the wheels must be turned, en- 3. If necessary, remove oil filler cap (1) and add oil.
sure that all personnel are clear of the machine
before any movement. 4. Clean the filler cap and install the filler cap.
SEBU7792-05 165
Maintenance Section
Engine Oil Level - Log Additions
i02326857 i02326499
Engine Oil Level - Log Engine Oil Sample - Obtain

Additions SMCS Code: 1348-008; 7542
(If Equipped with the Oil
Renewal System)
SMCS Code: 1348; 1349
g01162265
Illustration 197
Sampling Valve For The Engine Oil
The sampling valve for the engine oil is located above

the engine oil filters.

about obtaining an oil sample.
• Operation and Maintenance Manual, “S·O·S

Information”
g00408438
Illustration 196
• Special Publication, SEBU6250, “S·O·S Oil
The Oil Renewal System (ORS) meters engine Analysis”
oil that is blended into the fuel supply. This oil will
be consumed by the engine during the process of • Special Publication, PEHP6001, “How To Take A
combustion. Normal operation will continually lower Good Oil Sample”
the oil level in the crankcase. Continually adding new
engine oil will allow the life of the oil to be extended. • Special Publication, PEDP8025, “Fluid Analysis
An S·O·S analysis will determine if the oil needs to Interpretation Guide”
be changed.
i02454647
The graph in Illustration 196 plots the quantity of
added oil against the service hours during a 500 hour
period. This data can be used to determine if the
Engine Oil and Filter - Change
Oil Renewal System is working properly. Keeping a SMCS Code: 1308-510; 1348-044
daily maintenance log of all of the additions of oil is
necessary for the accuracy of this data. The daily Note: If your machine is equipped with the Oil
maintenance log is also necessary for adjustment of Renewal System (ORS), engine oil is blended
the metering rate. The daily maintenance log will also into the fuel supply of the machine. This oil will
indicate the total amount of oil that has been added be consumed in the engine during the process of
since the last oil change. This information is needed combustion. Normal operation will continually lower
at the time of each S·O·S analysis. the oil level in the crankcase. Continually adding
new oil will allow the life of the oil to be extended.
An S·O·S Oil Analysis will determine if the oil needs
to be changed. In order to change the engine oil
filters only, refer to Operation and Maintenance
Manual, “Engine Oil Filter (Oil Renewal System) -
Change”. For more information on the Oil Renewal
System, refer to Systems Operation, RENR2223, “Oil
Renewal System”.
166 SEBU7792-05
Maintenance Section
Engine Oil and Filter - Change
1. Open drain valve (1) and drain the oil into a

suitable container. Close the drain valve .
contact the skin.
NOTICE

products.

mandates.
g01162326
Illustration 199
Note: Some commercial oils that meet API
specifications may require shorter oil change
intervals. The oil change intervals are determined 2. Remove the used engine oil filters (2) and discard
by close monitoring of the oil condition and engine the used engine oil filters.
wear metals. Caterpillar prefers the scheduled oil
sampling as the proper method of checking engine 3. Clean the oil filter base assemblies. Make sure
wear metals. that all of the former gaskets are removed.
Consult your Caterpillar dealer for the latest oil 4. Apply a thin film of clean engine oil to the seal of
recommendations. each new engine oil filter.
The machine must be parked on a level surface and 5. Install the new engine oil filters by hand. Tighten
the parking brake must be engaged. The oil must be each engine oil filter until the seal of each engine
warm and the engine must be stopped. oil filter contacts the base of the oil filter housing.
Note the position of the index marks on each filter
in relation to a fixed point on the filter base.
Note: Caterpillar filters have rotation index marks

that are spaced 90 degrees or 1/4 of a turn away
from each other. When you tighten the filters, use the
6. Tighten each filter according to the instructions

that are printed on the filter. Use the index marks
as a guide.
Note: You may need to use a Caterpillar strap

wrench, or another suitable tool, in order to turn
the filters to the amount that is required for final
installation. Make sure that the installation tool does
not damage the filters.
7. Remove oil filler cap (3). Fill the crankcase with

oil. Refer to Operation and Maintenance Manual,
“Lubricant Viscosities” for the type of oil. Refer to
Operation and Maintenance Manual, “Capacities
g01162319
Illustration 198 (Refill)” for the amount of oil.
SEBU7792-05 167
Maintenance Section
Engine Valve Lash and Bridge - Adjust
8. Start the engine and operate the engine at low idle Table 15
for five minutes. Inspect the engine oil filter for oil VALVE CLEARANCE SETTING
leaks. Make any necessary repairs.
Inlet 0.5 mm (0.02 inch)
9. Maintain the oil level between the “ADD” mark and Exhaust 1.00 mm (0.04 inch)
the “FULL” mark. These marks are on the “LOW
IDLE” side of dipstick (4). Stop the engine.
i02342142
Engine Valve Lash and Bridge

- Adjust
SMCS Code: 1102-025
To prevent personal injury, do not use the starter

motor to turn the flywheel.
g00653920
Illustration 200
Hot engine components can cause burns. Allow
additional time for the engine to cool before mea- To check the engine valve lash, refer to System
suring valve clearance. Operation, Testing And Adjusting, SENR1123,
“3500B Engines For Caterpillar Built Machines”,
“Valve Lash and Valve Bridge Adjustment”. Consult
your Caterpillar dealer for any additional information.
Electrical shock hazard. The electronic unit injec-
tor system uses 90-120 volts. i02326985
Engine Water Pump - Inspect

Valve Bridge
SMCS Code: 1361-040
The engine in this machine is equipped with a
nonadjustable valve bridge. Proceed with the
valve lash adjustment.
Valve Lash Adjustment

NOTICE
Operation of Caterpillar Engines with improper engine
valve lash adjustments will reduce the engine efficien-
cy. This reduced efficiency could result in excessive
fuel usage and/or shortened engine component life.
Measure the engine valve lash with the engine

stopped. To obtain an accurate measurement, allow
at least 20 minutes for the valves to cool to engine
cylinder head and block temperature.
If the valve clearance is within 0.08 mm (0.0031 inch)

of the given nominal clearance, no adjustment is
required. If the clearance is not within the given limits, g01162405
Illustration 201
set the clearance to the amount that is specified in
(1) Water pump for the jacket water cooling system
the chart.
(2) Auxiliary water pump for the aftercooler cooling system
168 SEBU7792-05
Maintenance Section
Ether Starting Aid Cylinder - Replace
Water Pump for the Jacket Water i02330233
Cooling System Ether Starting Aid Cylinder -

A water pump (1) that has failed might cause Replace
severe engine overheating problems. The engine
overheating problems could result in the following SMCS Code: 1456-510-CD
problems.
• Cracks in the cylinder head

Breathing ether vapors or repeated contact of
• Piston seizure ether with skin can cause personal injury. Person-
al injury may occur from failure to adhere to the
• Other potential engine damage following procedures.
Visually inspect water pump (1) for leaks. If leaks are Use ether only in well ventilated areas.
found, all the seals need to be replaced.
Do not smoke while changing ether cylinders.
Note: See Service Manual, “Engine Disassembly
and Assembly”. Use ether with care to avoid fires.
Auxiliary Water Pump for the Do not store replacement ether cylinders in living
areas or in the operator's compartment.
Aftercooler Cooling System
Do not store ether cylinders in direct sunlight or
An auxiliary water pump (2) that has failed might at temperatures above 49 °C (120 °F).
cause severe engine overheating problems. The
engine overheating problems could result in the Discard cylinders in a safe place. Do not puncture
following problems. or burn cylinders.
• Valve failures Keep ether cylinders out of the reach of unautho-
rized personnel.
• Warped intake manifolds
To avoid possible injury, be sure the brakes are ap-
• Other potential engine damage plied and all controls are in Hold or Neutral when
starting the engine.
Visually inspect auxiliary water pump (2) for leaks. If
leaks are found, all the seals need to be replaced.
Note: See Service Manual, “Engine Disassembly

and Assembly”.
g01163382
Illustration 202
The two ether starting aid cylinders are mounted

behind the radiator.

2. Loosen the clamps and unscrew the ether starting

aid cylinders.
SEBU7792-05 169
Maintenance Section
Frame - Clean/Inspect
3. Remove the used gasket for each ether starting 4. Clean the frame with a high pressure washer.
aid cylinder and install the new gasket that is
provided for each ether starting aid cylinder. 5. Inspect the frame for damage and for cracks.
If you find cracks or damage, consult your
4. Install the new ether starting aid cylinders. Tighten Caterpillar dealer for specific repair procedures.
the clamps. Do not operate the machine until the necessary
repairs have been made.
i02340776
Note: Refer to Special instruction, REHS0541,
Frame - Clean/Inspect “Procedure for the Inspection, Repair, and
Component Replacement on the Frames of
SMCS Code: 7050-571 Off-Highway Truck/Tractor”.
Note: The graphics that are shown are for illustrative Rear Axle A-Frame and Differential
purposes. This is an in-chassis inspection.
Housing

with the body (bed) raised, attach the body (bed) When it is necessary to work under the machine
retaining cable to the rear tow point. Install the with the body (bed) raised, attach the body (bed)
rear tow point pin through the end of the retaining retaining cable to the rear tow point. Install the
cable. rear tow point pin through the end of the retaining
cable.
sult in personal injury or death. Failure to properly secure the body (bed) may re-

g01167516 g00980903
1. Park the machine on a level surface and engage 2. Clean the rear axle a-frame and the differential
the parking brake. housing with a wire brush or with a scraper.
Inspect the designated areas for cracks. If you find
2. Raise the dump body to the fully raised position cracks or damage, consult your Caterpillar dealer
and install the truck body retaining cable to the for specific repair procedures.
3. Stop the engine.

170 SEBU7792-05
Maintenance Section
Frame - Clean/Inspect
g00980907 g00980956
a. Inspect the inside face of the rear axle a-frame c. Inspect the bottom of the differential housing in
in the area that is indicated by the shading. the area that is indicated by shading.
Inspect the welds of the rear axle a-frame.
g01167529
Illustration 208
g00980933
Illustration 206
d. Inspect the top rear sides of the differential
b. Inspect the area around the bolt holes of the housing in the area that is indicated by shading.
rear axle a-frame.
SEBU7792-05 171
Maintenance Section
Frame and Body - Inspect
g00981044
Illustration 209
e. Inspect the differential housing in the area

around the lower half of the differential
mounting surface that is indicated by shading.
g01167539
i02340811 Illustration 210
Frame and Body - Inspect 4. Clean the frame with a wire brush or a scraper.
Inspect the dump body. If the frame is damaged
SMCS Code: 7050-040; 7258-040 or worn, consult your Caterpillar dealer for repair
procedures.
5. Clean the dump body with a wire brush or a

When it is necessary to work under the machine scraper. Inspect the dump body. If the dump body
with the body (bed) raised, attach the body (bed) is damaged or worn, consult your Caterpillar
retaining cable to the rear tow point. Install the dealer for repair procedures.
cable. i02340837
Failure to properly secure the body (bed) may re- Frame and Body Support Pads
- Clean/Inspect
1. Park the machine on a level surface and engage SMCS Code: 7050-571; 7258-571-S4
the parking brake.

rear tow point pin. For the proper procedure, refer When it is necessary to work under the machine
to Operations and Maintenance Manual, “Cable with the body (bed) raised, attach the body (bed)
(Truck Body Retaining)”. retaining cable to the rear tow point. Install the
3. Stop the engine. cable.


the parking brake.
172 SEBU7792-05
Maintenance Section
Front Axle Breather - Replace

3. Stop the engine.
g01163437
g01167566 Illustration 212
Illustration 211

4. Clean the body support pads with high pressure parking brake and stop the engine.
water or steam.
2. Remove breather (1) from each front wheel.
5. Visually inspect each of the body support pads.
Look for damage or uneven wear of the body 3. Install a new breather on each front wheel.
support pads. Look for gaps between the body
support pads and the mating surfaces. If problems
are found, consult your Caterpillar dealer for more i02330775
information or for specific repair procedures.
Front Wheel Oil - Change
i02457383 SMCS Code: 4201-044-OC
Front Axle Breather - Replace Note: The oil change interval for the front wheel
bearing can be monitored with the S·O·S scheduled
SMCS Code: 4251 oil sampling program. The interval is based on
the condition of the oil. If the S·O·S scheduled oil
sampling program is not used, the oil change for
the front wheel bearing should be performed at 500
Personal injury or death can occur if personnel are service hours or 3 months.
trapped between the wheel and the frame.
The steering system is hydraulically controlled

and wheels can crush personnel during move-
ment.

and the frame. If the wheels must be turned, en-
before any movement.
g01163440
Illustration 213
SEBU7792-05 173
Maintenance Section
Front Wheel Oil - Inspect
1. Position the front wheel so that drain plug (1) is The front wheel bearings do not need to be adjusted
facing downward. or inspected until the scheduled overhaul. Unless a
symptom of an obvious failure appears, do not adjust
2. Park the machine on a level surface. Engage the or inspect the front wheel bearings. If the front wheel
parking brake and stop the engine. oil has any of the above symptoms, the front wheel
bearings may need to be inspected. Consult your
NOTICE Caterpillar dealer for more information.
during performance of inspection, maintenance, test- i03025216
collect the fluid with suitable containers before open- Front Wheel Oil Level - Check
nent containing fluids. SMCS Code: 4201-535-FLV
Refer to Special Publication, NENG2500, “Caterpillar 1. Park the machine on a level surface. Stop the
Tools and Shop Products Guide” for tools and supplies engine and engage the parking brake.
products.

mandates.
3. Remove the drain plug.
4. Allow the oil to drain into a suitable container.
5. Clean the drain plug and install the drain plug.
6. Remove the filler plug (2).
7. Fill the oil compartment to the bottom of the g01180364

Illustration 214
opening for the filler plug. Refer to Operation
and Maintenance Manual, “Lubricant Viscosities”. Note: In order to prevent dirt from entering the wheel
bearing, use a clean cloth to wipe the area around
“Capacities (Refill)”. the filler plug before you remove the filler plug.
8. Clean the filler plug and install the filler plug. Use
2. Remove the filler plug.
the same procedure for the other front wheel
bearing. 3. Maintain the oil level to the bottom of the filler plug
opening.
i02388737
4. Clean the filler plug and install the filler plug.
Front Wheel Oil - Inspect
SMCS Code: 4201-040-OC
Inspect the front wheel oil for any of the following

symptoms that may indicate a failure of the wheel
bearings:
• A high amount of metal on the magnetic plug

• An increased level of nickel concentration in the
S·O·S sample
• An increase in the size of the particle count in the

S·O·S sample
• Oil leaks in the area around the front wheel spindle

174 SEBU7792-05
Maintenance Section
Front Wheel Oil Sample - Obtain
i02330789 i03315684
Front Wheel Oil Sample - Fuel System - Fill

Obtain (Fast Fill Fuel Adapter)
SMCS Code: 4201-008-OC; 7542 SMCS Code: 1250-544
Personal injury or death may result from failure to

adhere to the following procedures.
Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire.
Clean up all leaked or spilled fuel. Do not smoke

while working on the fuel system.
Turn the disconnect switch OFF or disconnect the

battery when changing fuel filters.
g01180364
Illustration 215
Filler plug for the front wheel NOTICE
NOTICE during performance of inspection, maintenance, test-
Always use a designated pump for oil sampling, and ing, adjusting, and repair of the machine. Be prepared
use a separate designated pump for coolant sampling. to collect the fluid with suitable containers before
Using the same pump for both types of samples may opening any compartment or disassembling any com-
contaminate the samples that are being drawn. This ponent containing fluids.
rect interpretation that could lead to concerns by both Dispose of all fluids according to local regulations and
dealers and customers. mandates.
The oil sample for the front wheel is obtained with a NOTICE
sampling gun through the filler plug. Use only a Caterpillar approved fast fill system to fuel
machines. Over pressurization may cause tank defor-
Refer to the following publications for information mation and fuel spillage.
Contact your Cat dealer for fast fill system availability.
Information”
“Capacities (Refill)” for the fuel tank capacity of your
• Special Publication, SEBU6250, “S·O·S Oil machine.
Analysis”
• Special Publication, PEHP6001, “How To Take A the parking brake.
Good Oil Sample”
• Special Publication, PEDP8025, “Fluid Analysis

Interpretaion Guide”
SEBU7792-05 175
Maintenance Section
Fuel System - Prime
g01695333 g01167459
2. Remove dust cover (1) and clean the fast fill fuel 2. Pull out on switch (1) in order to release the switch.
adapter.
3. Hold the switch upward in order to activate the
Note: The maximum fuel flow rate for the fast fill fuel electric fuel priming pump. The priming pump will
adapter group is 375 L/min (100 US gpm). fill the engine fuel lines and the fuel filters with fuel.
3. Fill the fuel tank through the fast fill fuel adapter. Note: Button (2) is the circuit breaker reset for the
electric fuel priming pump. Push in the button in order
4. Observe fuel level sight gauge (2) in order to to reset the circuit breaker. If the electrical system is
prevent overfilling. working properly, the button will remain depressed.
If the button does not remain depressed, check the
5. Clean the fast fill fuel adapter and the dust cover. electrical circuit for the priming pump. Repair the
Install the dust cover on the adapter. electrical circuit, if necessary.
4. As the air is purged from the fuel system, fuel

i02435121
pressure will increase. Listen for the electric fuel
Fuel System - Prime priming pump to come under load. Do not continue
priming the fuel system after the priming pump is
SMCS Code: 1250-548 under load. Do not operate the priming pump for
more than two minutes.
5. Start the engine.

Fuel leaked or spilled onto hot surfaces or elec- 6. If the engine starts but the engine runs rough,
trical components can cause a fire. Clean up fuel continue to run the engine at low idle until the
spills immediately. engine runs smoothly.
Note: The engine start switch must be in the OFF 7. If the engine does not start after several attempts,
position in order to prime the fuel system. refer to Special instruction, SEHS9586, “3500
Electronic Unit Injection (EUI) Fuel Priming
1. Park the machine on a level surface. Engage the Procedure” or consult your Caterpillar dealer.
176 SEBU7792-05
Maintenance Section
Fuel System Primary Filter (Water Separator) - Drain
i02338162 i02338293
Fuel System Primary Filter Fuel System Primary Filter

(Water Separator) - Drain (Water Separator) Element -
(If Equipped) Replace
SMCS Code: 1261-543; 1263-543
(If Equipped)
SMCS Code: 1260-510; 1263-510-FQ
Park the machine on a level surface. Engage the
Replace the fuel/water separator elements when the
engine has a loss of power or when the exhaust
smoke is black.
Personal injury or death can result if spilled fuel

ignites. Fuel leaked or spilled onto hot surfaces
or electrical components can cause a fire.
To help prevent possible injury, turn the battery

disconnect switch to the OFF position when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
NOTICE
g01167092
Illustration 218 nent containing fluids.
The fuel/water separators are located on the right inside frame rail
in front of the front axle. Refer to Special Publication, NENG2500, “Caterpillar
NOTICE suitable to collect and contain fluids on Caterpillar
Care must be taken to ensure that fluids are contained products.
ing, adjusting and repair of the product. Be prepared to Dispose of all fluids according to local regulations and
collect the fluid with suitable containers before open- mandates.
NOTICE
Refer to Special Publication, NENG2500, “Caterpillar Do not fill fuel filters with fuel before installing them.
Tools and Shop Products Guide” for tools and supplies The fuel will not be filtered and could be contaminated.
suitable to collect and contain fluids on Caterpillar Contaminated fuel will cause accelerated wear to fuel
products. system parts. The fuel system should be primed prior
to starting the engine.
mandates. 1. Park the machine on a level surface and engage
the parking brake.
Open drain valves (1) on the bottom of the fuel/water
separator elements in order to drain the water into an
approved container. Close the drain valves when all
of the water has been drained.
SEBU7792-05 177
Maintenance Section
Fuel System Primary Filter - Clean
7. Install the new elements by hand until the seal

contacts the mounting base. Note the position of
the index marks on the elements in relation to a
fixed point on the mounting base.
Note: There are rotation index marks on each filter

that is spaced 90 degrees (1/4 turn) away from
each other. When you tighten the elements, use the
8. Tighten all filters according to the instructions that

are printed on the filter.
Note: You may need to use a strap type wrench or a

g01167276
suitable tool in order to turn the filters to the amount
Illustration 219 that is required for final installation. Make sure that
View of the back side of the fuel tank the installation tool does not damage the filters.
2. Stop the engine and close fuel shutoff valve (1). 9. Install the drain tube assembly to the bottom of
the new elements.
10. Open the fuel shutoff valve.
11. Prime the fuel system.
For information on priming the fuel system, refer

to the Operation and Maintenance Manual, “Fuel
System - Prime”.
12. Start the engine and inspect the filter for leaks.
Make any necessary repairs. If the engine has a
loss of power or the exhaust smoke is still black,
replace the secondary filters.
i02891403
Fuel System Primary Filter -

Clean
g01167178
(If Equipped)
Illustration 220
The fuel/water separator is located on the right inside frame rail SMCS Code: 1260-070; 1261-070
in front of the front axle.
NOTICE
3. Remove drain tube assembly (3) from the bottom
of the drain valves for the fuel/water separator
elements.
4. Remove the fuel/water separator elements (2) with
a strap type wrench. Discard the used elements
properly.
5. Clean the mounting base. Make sure that both of
the old seals are removed.
products.
6. Lubricate the seals of the new elements with clean
diesel fuel.
mandates.
178 SEBU7792-05
Maintenance Section
Fuel System Priming Filter - Replace
i02345997
NOTICE
Do not fill fuel filters with fuel before installing them.
Fuel System Priming Filter -
Contaminated fuel will cause accelerated wear to fuel Replace
system parts.
SMCS Code: 1258-510-FI; 1261-510
Clean the primary element when the engine has a
The fuel priming filter is located on the right side of the
loss of power or when the exhaust smoke is black.
engine directly below the electric fuel priming pump.
Fuel only flows through the filter when you activate
the priming pumps. Under normal circumstances,
the parking brake.
the original fuel priming filter should last for the
entire service life of the machine. If the filter must be
replaced, use the procedure that follows.

the parking brake.
g01167019
Illustration 221
View of the back side of the fuel tank
2. Stop the engine and close fuel shutoff valve (1).
3. Loosen bolt (2). Illustration 222

g01167276
4. Remove filter housing (3) and the filter element. 2. Stop the engine and close fuel shutoff valve (1).
5. Wash the base and the element in clean,
nonflammable solvent. NOTICE
6. If the filter base gasket is damaged, replace the during performance of inspection, maintenance, test-
filter base gasket. ing, adjusting and repair of the machine. Be prepared
to collect the fluid with suitable containers before
7. Install the filter element and the filter housing. opening any compartment or disassembling any com-
Tighten bolt (2) to a torque of 25 ± 7 N·m ponent containing fluids.
(18 ± 5 lb ft).
8. Open the fuel shutoff valve. Prime the fuel system. Tools and Shop Products Guide”, for tools and sup-
Refer to Operation and Maintenance Manual, plies suitable to collect and contain fluids.
“Fuel System - Prime”.
9. Start the engine and inspect the filter for leaks. mandates.
Make any necessary repairs. If the engine has a
loss of power or the exhaust smoke is still black,
change the secondary filters.
SEBU7792-05 179
Maintenance Section
Fuel System Secondary Filter - Replace
i02327025
Fuel System Secondary Filter -

Replace
SMCS Code: 1261-510-SE

g01172157
Illustration 223
3. Remove fuel priming filter (2) with a strap type

wrench. Discard the used filter properly.
4. Clean the filter mounting base. Make sure that the

former seal is removed.
5. Lubricate the seal of the new filter with clean

diesel fuel. g01162420
Illustration 224
6. Install the new filter by hand. Tighten the filter until

2. Remove secondary fuel filters (1) with a strap type
the sealing surface contacts the base. Tighten the
wrench. Discard the used filters properly.
filter for an additional 3/4 of a turn.
3. Clean the filter mounting bases. Make sure that
7. Install the new filter by hand until the seal contacts
the old filter seals are removed.
the mounting base. Note the position of the index
marks on the filter in relation to a fixed point on
the mounting base. NOTICE
Do not fill the secondary fuel filter with fuel before in-
Note: There are rotation index marks on each filter stalling. The fuel would not be filtered and could be
that is spaced 90 degrees (1/4 turn) away from each contaminated. Contaminated fuel will cause acceler-
other. When you tighten the filter, use the rotation ated wear to fuel system parts.
index marks as a guide.
4. Lubricate the seals of the new filters with clean
8. Tighten all filters according to the instructions that diesel fuel.
5. Install the new filters by hand until the seal
Note: You may need to use a strap type wrench or a contacts the mounting base. Note the position of
suitable tool in order to turn the filter to the amount the index marks on the filters in relation to a fixed
that is required for final installation. Make sure that point on the mounting base.
the installation tool does not damage the filter.
Note: There are rotation index marks on each filter
9. Open the fuel shutoff valve. that is spaced 90 degrees (1/4 turn) away from each
other. When you tighten the filters, use the rotation
10. Prime the fuel system. Refer to Operation and index marks as a guide.
Maintenance Manual, “Fuel System - Prime”.
180 SEBU7792-05
Maintenance Section
Fuel Tank Water and Sediment - Drain
Note: You may need to use a strap type wrench or a i02245859

suitable tool in order to turn the filters to the amount
that is required for final installation. Make sure that High Intensity Discharge Lamp
the installation tool does not damage the filters. (HID) - Replace
7. Prime the fuel system. Refer to the Operation and (If Equipped)
Maintenance Manual, “Fuel System - Prime”.
SMCS Code: 1434-510
HID lamps operate at very high voltages. To avoid
i02338067
electrical shock and personal injury, disconnect
power before servicing HID lamps.
Fuel Tank Water and Sediment
- Drain
SMCS Code: 1273-543-MAS HID bulbs become very hot during operation.
Before servicing, remove power from lamp for at
least five minutes to ensure lamp is cool.
NOTICE
Although HID bulb materials may change over time,
HID bulbs produced at the time of the printing of this
manual contain mercury. When disposing of this com-
ponent, or any waste that contains mercury, please
use caution and comply with any applicable laws.
1. Remove the electrical power from the high

intensity discharge lamp (HID). The electrical
power must be removed from the HID lamp for
g01167012 at least five minutes, in order to ensure that the
Illustration 225
View of the back side of the fuel tank bulb is cool.
2. Disassemble the housing for the HID lamp in order

NOTICE
to have access to the bulb.
Note: On some HID lamps, the bulb is an integral
part of the lens assembly. The bulb is not removed
separately from the lens assembly. Replace the
entire lens assembly on these HID lamps.
3. Remove the bulb from the HID lamp.
4. Install the replacement bulb in the HID lamp.
products.
If the bulb is an integral part of the lens assembly,
install the replacement lens assembly in the HID
lamp.
mandates.
Note: In order to avoid failure to the bulb that is
Park the machine on a level surface. Engage the premature, avoid touching the bulb's surface with
parking brake and stop the engine. your bare hands. Clean any fingerprints from the bulb
with alcohol prior to operation.
Open fuel tank drain valve (1) and allow the moisture
and the sediment to drain into a suitable container. 5. Reassemble the housing for the HID lamp. Ensure
Close the drain valve. that any printing on the lens is oriented correctly
with respect to the HID lamp's mounting position
on the machine.
SEBU7792-05 181
Maintenance Section
Hoist Screens - Clean
6. Reattach the electrical power to the HID lamp.
7. Check the HID lamp for proper operation.
Note: Consult your Caterpillar dealer for additional

information on HID lamps.
i02892963
Hoist Screens - Clean

SMCS Code: 5057-070-Z3
g01440260
Illustration 226
When it is necessary to work under the machine The hoist screens are located on the right rear of the center tube.
cable.
Failure to properly secure the body (bed) may re- injury. Do not allow hot oil or hot components to
sult in personal injury or death. contact the skin.
4. Remove the bolts that attach hoses (1) to housings

NOTICE (2) for the hoist screen. Drain the oil from the lines
Care must be taken to ensure that fluids are contained into a suitable container.
ing, adjusting and repair of the product. Be prepared to 5. Remove the hoist screens from the housings.
collect the fluid with suitable containers before open- Clean the hoist screens in clean nonflammable
ing any compartment or disassembling any compo- solvent.
6. Install the clean hoist screens and the hoses. Use
Refer to Special Publication, NENG2500, “Caterpillar new seals. Tighten the bolts.
suitable to collect and contain fluids on Caterpillar 7. Start the engine and operate the engine at low
products. idle. Make sure that the parking brake is engaged.
mandates. 8. Remove the truck body retaining cable and lower
the body.
Clean the screens whenever there is a failure of the
brakes, hoist cylinders, or hoist pumps. 9. Check the oil level in the hoist/brake tank. If
1. Park the machine on a level surface and engage to Operation and Maintenance Manual, “Hoist and
the parking brake. Brake Tank Oil Level - Check”.

installation and removal of the truck body retaining
cable, refer to Operations and Maintenance
3. Stop the engine.

182 SEBU7792-05
Maintenance Section
Hoist and Brake Tank Breather - Replace
i02340012 i02685600
Hoist and Brake Tank Breather Hoist and Brake Tank Oil -
- Replace Change
SMCS Code: 5056; 5057 SMCS Code: 5056
NOTICE
When it is necessary to work under the machine during performance of inspection, maintenance, test-
with the body (bed) raised, attach the body (bed) ing, adjusting and repair of the product. Be prepared to
retaining cable to the rear tow point. Install the collect the fluid with suitable containers before open-
rear tow point pin through the end of the retaining ing any compartment or disassembling any compo-
cable. nent containing fluids.
Failure to properly secure the body (bed) may re- Refer to Special Publication, NENG2500, “Caterpillar
sult in personal injury or death. Dealer Service Tool Catalog” for tools and supplies
products.
the parking brake. Dispose of all fluids according to local regulations and
mandates.
rear tow point pin. For the proper procedure for the The machine must be level. The truck body must be
installation and removal of the truck body retaining in the DOWN position. The parking brake must be
cable, refer to Operations and Maintenance engaged and the engine must be stopped.
3. Stop the engine.
g01172912
Illustration 228
1. Remove filler cap (1) in order to prevent a vacuum

in the tank. Install the filler cap after the tank has
been drained. This will prevent dirt from entering
the system.
2. Remove tank drain valve plug (3). Install a

88.0 mm (3.50 inch) long NPT pipe nipple in
order to open the internal drain valve. The outer
g01172423
Illustration 227 diameter of the NPT pipe nipple should be 25 mm
(1 inch). Drain the oil into a suitable container.
4. Remove breather (1) and discard the breather
properly. Note: Hand tighten the NPT pipe nipple. Do not use
tools.
5. Install a new breather.
3. Remove the pipe nipple. Clean the drain plug and
6. Remove the truck body retaining cable and lower install the drain plug.
the body.
4. Remove the filler cap.
SEBU7792-05 183
Maintenance Section
Hoist and Brake Tank Oil Level - Check
5. Remove the retaining ring on the filler screen. i02399492

Remove the screen.
Hoist and Brake Tank Oil Level
6. Wash the cap and the filler screen in clean,
nonflammable solvent. Allow the cap and the filler
- Check
screen to dry. SMCS Code: 5056
7. Inspect the cap seal. Use a new seal if the used 1. Park the machine on a level surface with the
seal is damaged. Install the filler screen and the truck body in the DOWN position and engage the
retaining ring. parking brake.
8. Fill the hoist/brake tank. Refer to Operation and
Maintenance Manual, “Lubricant Viscosities”.
“Capacities (Refill)”.
g01172846
Illustration 230
2. Maintain the oil level to the “FULL” mark on sight

gauge (2). If necessary, remove filler cap (1) and
g01349223
add oil.
Illustration 229
9. Use engine shutdown control (4) to prevent i02336350

the engine from starting. Crank the engine for
approximately 15 seconds. The oil level will Hoist and Brake Tank Oil
decrease as oil fills the system. Sample - Obtain
10. Add oil to the tank in order to raise the oil level to SMCS Code: 5056-008; 7542
the “FULL” mark in upper sight gauge (2).
11. Repeat Step 9 and Step 10 until the oil stabilizes

in the “FULL” mark in the upper sight gauge.
12. Lower the guard on the engine shutdown control.

Start the engine and operate the engine at low
idle. Check for leaks and make necessary repairs.
13. Raise the truck body until the hoist cylinders are
extended halfway. Lower the truck body and add
oil, if necessary.
fully extended. Lower the truck body and add oil, if
necessary.
15. Repeat Step 13 and Step 14 until the oil level

stabilizes in the “FULL” mark in the upper sight
gauge.
16. Install the filler cap. g01188933

Illustration 231
The fuel tank is removed for ease of viewing.
184 SEBU7792-05
Maintenance Section
Hoist and Brake Tank Suction Screen - Inspect/Clean/Replace
Sampling valve (1) for the hoist and brake oil is

located at the base of the brake cooling oil filters.


Information”
• Special Publication, SEBU6250, “S·O·S Oil

Analysis”
• Special Publication, PEHP6001, “How To Take A

Good Oil Sample”
g01165906
Illustration 232
• Special Publication, PEDP8025, “Fluid Analysis
1. Remove tank drain plug (1). Install a 88.0 mm
(3.50 inch) long NPT pipe nipple in order to open
i02685621 the internal drain valve. The outer diameter of the
NPT pipe nipple should be 25.4 mm (1.00 inch).
Hoist and Brake Tank Suction Drain the oil into a suitable container.
Screen - Inspect/Clean/Replace
Note: Hand tighten the NPT pipe nipple. Do not use
SMCS Code: 5056 tools.
2. Remove the bolts from cover (2) on the front of

NOTICE
the hoist and brake tank. Remove the cover.
3. Clean the debris from the bottom of the tank.

products.

mandates.
The machine must be level. The truck body must be

in the DOWN position. The parking brake must be
g01165914
engaged and the engine must be stopped. Illustration 233
View of the back side of the hoist and brake tank
There are three suction screens on the hoist/brake
tank. Clean all of the screens whenever there is a 4. Remove the flanges and three hoses (3).
failure of brakes, hoist cylinders or hoist pumps.
5. Remove the suction screens from the tank.
6. Wash the suction screens in clean, nonflammable

solvent.
7. Install the clean suction screens and install the

hoses and flanges.
8. Clean the cover for the front of hoist and brake

tank in clean, nonflammable solvent. Inspect the
cover gasket. If the gasket is damaged, replace
the gasket.
SEBU7792-05 185
Maintenance Section
Magnetic Plug (Wheels) - Check
9. Install the cover to the front of the tank. 17. Repeat Step 15 and Step 16until the oil level
stabilizes in the “FULL” mark in the upper sight
10. Fill the hoist/brake tank. Refer to Operation and gauge.
Maintenance Manual, “Lubricant Viscosities”.
Refer to Operation and Maintenance Manual, 18. Clean the filler cap and install the filler cap.
i02346919
Magnetic Plug (Wheels) -

Check
SMCS Code: 0663
Note: A weekly inspection of the magnetic plugs is

strongly recommended.
g01349223
Illustration 234
11. Use ground level shutdown switch (4) to prevent

the engine from starting. Crank the engine for
approximately 15 seconds. The oil level will
decrease as oil fills the system.
g01172641
Illustration 236
(1) Magnetic plug on the front wheel
g01165956
Illustration 235
12. Add oil to the tank in order to raise the oil level to
the “FULL” mark in upper sight gauge (5).
13. Repeat Step 11 and Step 12 until the oil stabilizes

in the “FULL” mark in the upper sight gauge. g01172642
Illustration 237
(2) Magnetic plug on the rear wheel
14. Lower the guard on the ground level shutdown
control. Start the engine. Run the engine at low All of the wheels have a magnetic plug. The magnetic
idle. Inspect the machine for oil leaks and make plug (1) and (2) will attract metal from the oil. A
necessary repairs. bearing failure is indicated by an increased amount
of metal on the magnetic plug.
extended halfway. Lower the truck body and add If excessive particles or abnormal particles are found,
oil, if necessary. consult your Caterpillar dealer.
fully extended. Lower the truck body and add oil, if
necessary.
186 SEBU7792-05
Maintenance Section
Oil Filter (Steering, Hydraulic Fan) - Replace
i02398678 3. Slowly remove cap (2) on the steering hydraulic

tank in order to relieve the pressure.
Oil Filter (Steering, Hydraulic
Fan) - Replace 4. Remove case drain filter (3) for the hydraulic fan
and remove case drain filter (4) for the steering
(Hydraulic Pump Case Drain) system from the mounting bases with a strap type
wrench. Discard the used filters properly.
SMCS Code: 5068-510-ZH; 5068-510-HFN
5. Clean the mounting bases. Make sure that all of
the old filter seals are removed.
Hot oil and hot components can cause personal 6. Lubricate the seals of the new filters with clean oil.
contact skin. 7. Install the new filters by hand until the seal
contacts the mounting base. Note the position of
the index marks on the filters in relation to a fixed
NOTICE point on the mounting base.
during performance of inspection, maintenance, test- Note: There are rotation index marks on each filter
ing, adjusting and repair of the product. Be prepared to that is spaced 90 degrees (1/4 turn) away from each
collect the fluid with suitable containers before open- other. When you tighten the filters, use the rotation
ing any compartment or disassembling any compo- index marks as a guide.
Refer to Special Publication, NENG2500, “Caterpillar are printed on the filter.
suitable to collect and contain fluids on Caterpillar Note: You may need to use a strap type wrench or a
products. suitable tool in order to turn the filters to the amount
that is required for final installation. Make sure that
Dispose of all fluids according to local regulations and the installation tool does not damage the filters.
mandates.
10. Check the oil level. If necessary, add oil. Refer
to Operation and Maintenance Manual, “Steering
System Oil Level - Check”.
g01163566
Illustration 238
2. Push button (1) on the breaker relief valve.

SEBU7792-05 187
Maintenance Section
Oil Filter - Inspect
i02106227 i02320227
Oil Filter - Inspect Parking Brake Release Oil

SMCS Code: 5068-040 Filter - Replace
SMCS Code: 4257; 4295
Inspect a Used Filter for Debris

contact the skin.
NOTICE
g00100013
Illustration 239
The element is shown with debris. Tools and Shop Products Guide” for tools and supplies
Use a filter cutter to cut the filter element open. products.
Spread apart the pleats and inspect the element for
metal and for other debris. An excessive amount of Dispose of all fluids according to local regulations and
debris in the filter element can indicate a possible mandates.
failure.
If metals are found in the filter element, a magnet can 1. Park the machine on a level surface. Engage the
be used to differentiate between ferrous metals and parking brake and stop the engine.
nonferrous metals.
Ferrous metals can indicate wear on steel parts and

on cast iron parts.
Nonferrous metals can indicate wear on the

aluminum parts of the engine such as main bearings,
rod bearings, or turbocharger bearings.
Small amounts of debris may be found in the filter

element. This could be caused by friction and by
normal wear. Consult your Caterpillar dealer in order
to arrange for further analysis if an excessive amount
of debris is found.
Using an oil filter element that is not recommended

by Caterpillar can result in severe engine damage
to engine bearings, to the crankshaft, and to other
parts. This can result in larger particles in unfiltered
oil. The particles could enter the lubricating system
and the particles could cause damage.
g01160070
Illustration 240
2. Remove drain plug (2) from the bottom of filter

housing (1). Drain the oil into a suitable container.
Clean the drain plug and install the drain plug.
188 SEBU7792-05
Maintenance Section
Radiator Core - Clean
Note: Removing the drain plug from the bottom of the

filter housing may not drain all of the oil from the filter. NOTICE
High water pressure water and high water volume can
3. Remove filter housing (1) and the filter element. damage the radiator.
Discard the used filter element.
Use a water spray nozzle that will disperse the water.
4. Wash the filter housing in clean, nonflammable
solvent.
See Special Publication, SEBD0518, “Know Your
5. Inspect the seal in the housing base. If the seal is Cooling System” for the complete procedure for
damaged, replace the seal with a new seal. cleaning the radiator core.
6. Install the new element in the filter housing. i02346912
7. Install the filter housing. Rear Axle Housing End Play -

8. Start the engine and operate the engine at low Adjust
Check for leaks and make any necessary repairs. SMCS Code: 3282-025-EP
9. Check the oil level in the hoist/brake tank. If The end play adjustment of the rear axle housing
necessary, add oil. For the proper procedure, refer is recommended at the initial 2000 service hours.
to Operation and Maintenance Manual, “Hoist and Yearly inspection and maintenance of the end play of
Brake Tank Oil Level - Check”. the rear axle housing will maximize service life.
Note: The end play adjustment of the rear axle

i02340749 housing is recommended at every 6 months in severe
applications.
Radiator Core - Clean
To adjust the end play of the rear axle housing, refer
SMCS Code: 1353 to Testing and Adjusting, RENR8327, “793D Power
Train Testing and Adjusting”, “Rear Axle Housing End
Play - Adjust”. Consult your Caterpillar dealer for any
additional information.
g01167490
Illustration 241
You can use compressed air, high pressure water,

or steam to remove dust and other debris from the
air side of the radiator core. However, the use of
compressed air is preferred.
SEBU7792-05 189
Maintenance Section
Rear Axle Oil Filter - Replace
i02783212 1. Park the machine on a level surface. Engage the

Rear Axle Oil Filter - Replace
2. Remove the drain plug from filter housing (1).
SMCS Code: 5068-510 Drain the oil into a suitable container. Clean the
drain plug and install the drain plug.
Note: Removing the drain plug from the bottom of the

filter housing may not drain all of the oil from the filter.
3. Remove the filter housing and the filter element.

Discard the used filter element.
4. Wash the filter housing in clean nonflammable

solvent.
5. Inspect the seals in the filter base. If the seals are

damaged, replace seals with new seals.
6. Install the new filter element in the filter housing.

Install the filter housing.

g01162468
Illustration 242 Note: The lubrication pump for the rear axle will not
operate with the oil temperature below 15 °C (59 °F).
8. Check the oil level in the rear axle. If necessary,

Hot oil and hot components can cause personal add oil. For the proper procedure, refer to
Operation and Maintenance Manual, “Differential
contact the skin. and Final Drive Oil - Check”.
Note: Correct oil levels are critical in the differential

NOTICE and final drives. Check the oil level after repairs and
Care must be taken to ensure that fluids are contained after maintenance.
ing, adjusting and repair of the product. Be prepared to Note: The differential and final drive oil level needs to
collect the fluid with suitable containers before open- be checked and maintained at operating temperature.
ing any compartment or disassembling any compo- If the oil level is checked cold, adjustment of the
nent containing fluids. oil level may be necessary when the truck reaches
operating temperature.
products.

mandates.
Note: The machine is shipped with a 6 micron filter

element for the rear axle. Caterpillar recommends
the use of a 6 micron element for the initial 50 service
hours. If the 6 micron element becomes plugged
before the initial 50 service hours, replace the 6
micron element with another 6 micron element.
When the machine reaches 50 service hours, replace
the 6 micron element with a 20 micron element. If
the element continues to become plugged after 50
service hours, consult your Caterpillar dealer.
190 SEBU7792-05
Maintenance Section
Receiver Dryer (Refrigerant) - Replace
i02656745
Receiver Dryer (Refrigerant) -

Replace
SMCS Code: 7322-510
Personal injury can result from contact with refrig-

erant.
Contact with refrigerant can cause frost bite. Keep

face and hands away to help prevent injury.
g01159180
Illustration 243
Protective goggles must always be worn when re- The refrigerant dryer is located in the refrigerant lines underneath
frigerant lines are opened, even if the gauges in- the cab.
dicate the system is empty of refrigerant.
Refer to Service Manual, SENR5664, “Air
Always use precaution when a fitting is removed. Conditioning and Heating R-134a for All Caterpillar
Slowly loosen the fitting. If the system is still un- Machines” for the proper procedure to change the
der pressure, release it slowly in a well ventilated receiver-dryer assembly and for the procedure to
area. reclaim the refrigerant gas.
Personal injury or death can result from inhaling

i02650497
refrigerant through a lit cigarette.
Inhaling air conditioner refrigerant gas through a

Rim - Inspect
lit cigarette or other smoking method or inhaling SMCS Code: 4209-040
fumes released from a flame contacting air con-
ditioner refrigerant gas, can cause bodily harm or Inspect the rim whenever a tire is dismounted.
death.
Do not smoke when servicing air conditioners or

wherever refrigerant gas may be present.
Use a certified recovery and recycling cart to prop-

erly remove the refrigerant from the air condition-
ing system.
NOTICE
If the refrigerant system has been open to the outside
air (without being plugged) for more than 30 minutes,
the receiver-dryer must be replaced. Moisture will en-
ter an open refrigerant system and cause corrosion
which will lead to component failure.
SEBU7792-05 191
Maintenance Section
Rim - Inspect
i03808474
Rim - Inspect
SMCS Code: 4209-040
If regulatory agencies require a rim inspection, this

documentation can be used as a guideline.
The tires must be dismounted from the rim in order to

perform a magnetic particle inspection. Consult your
tire dealer for dismounting the tires from the rims.
g01330970
Illustration 244
Typical example
Cutaway view of the rim assembly
Inspect the following components of the rim

assembly:
Bead Seat Band (1) – Inspect the bead seat band

for the following: wear, corrosion, and cracks.
Lock Ring (2) – Inspect the lock ring for the

following: wear, corrosion, cracks, flat spots, and g01331173
Illustration 245
warping. When the lock ring is not assembled, the
two ends of the lock ring must overlap each other. Typical example
Cutaway view of the rim assembly
Rim Base (3) – Inspect the rim base for the following:
wear, corrosion, cracks, and fretting. Perform a magnetic particle inspection of the
following high stress areas of the rim:
Flanges (4) – Inspect the flanges for the following:
wear, corrosion, cracks, and fretting. • (1) Areas of contact with flanges
Do not reuse rim components that are cracked, • (2) Contact areas with the lock ring and the groove
worn, damaged, or pitted from corrosion. For more for the lock ring
information on the reusability of the rim components,
consult your Caterpillar dealer. • (3) Welds on the rim disc
• (4) Welds around the circumference of the rim base
• (5) Butt welds
192 SEBU7792-05
Maintenance Section
Rollover Protective Structure (ROPS) - Inspect
For more information on magnetic particle inspection,

refer to Guideline For Reusable Parts And Salvage
Operations, SEBF8148, “General Salvage and
Reconditioning Techniques” or consult your
Caterpillar dealer.
Do not reuse rim components that are cracked,

worn, damaged, or pitted from corrosion. For more
information on the reusability of the rim components,
consult your Caterpillar dealer.
i02381197
Rollover Protective Structure

(ROPS) - Inspect Illustration 246
g00932801
Typical example
SMCS Code: 7325-040
Check the seat belt mounting hardware (1) for wear
Inspect the Rollover Protective Structure (ROPS) or for damage. Replace any mounting hardware that
for bolts that are loose or damaged. Replace any is worn or damaged. Make sure that the mounting
damaged bolts and any missing bolts with original bolts are tight.
replacement parts only. Tighten the bolts to a torque
of 1904 ± 68 N·m (1400 ± 50 lb ft). Check buckle (2) for wear or for damage. If the buckle
is worn or damaged, replace the seat belt.
Note: Apply oil to all bolt threads for the ROPS before
you install the bolts. Improper bolt torque can result if Inspect the seat belt (3) for webbing that is worn or
you do not apply oil to the threads. frayed. Replace the seat belt if the seat belt is worn
or frayed.
Do not weld reinforcement plates to the ROPS
in order to straighten the ROPS. Do not weld Consult your Caterpillar dealer for the replacement of
reinforcement plates to the ROPS in order to repair the seat belt and the mounting hardware.
the ROPS.
Note: Within three years of the date of installation or
Inspect the ROPS for any cracks in the welds, cracks within five years of the date of manufacture, replace
in the castings, or cracks in any metal section. the seat belt. Replace the seat belt at the date which
occurs first. A date label for determining the age of
Refer to Special Instruction, SEHS6929, “Inspection, the seat belt is attached to the seat belt, the seat belt
Maintenance, and Repair of ROPS and Attachment buckle, and the seat belt retractor.
Installation Guidelines” or consult your Caterpillar
dealer for more information. If your machine is equipped with a seat belt
extension, also perform this inspection procedure for
the seat belt extension.
i02429589
Seat Belt - Inspect i02429594
SMCS Code: 7327-040 Seat Belt - Replace

Always check the condition of the seat belt and the SMCS Code: 7327-510
condition of the seat belt mounting hardware before
you operate the machine. Replace any parts that are Within three years of the date of installation or within
damaged or worn before you operate the machine. five years of the date of manufacture, replace the
seat belt . Replace the seat belt at the date which
occurs first. A date label for determining the age of
the seat belt is attached to the seat belt, the seat belt
buckle, and the seat belt retractor.
SEBU7792-05 193
Maintenance Section
Seat Suspension - Inspect/Lubricate
Armrest (Seat)
Pivot the armrest to the vertical position. Apply dry
lubricant or silicone lubricant between the parts in the
mechanism for the armrest assembly.
i03327080
Secondary Steering - Check

SMCS Code: 4300-535-SST
g01152685
Illustration 247
(1) Date of installation (retractor)
(2) Date of installation (buckle)
Gas under pressure. Rapid discharge from dis-
(3) Date of manufacture (tag) (fully extended web) connecting or disassembly could cause personal
(4) Date of manufacture (underside) (buckle) injury or death. See service manual before reliev-
ing pressure or charging.
Consult your Caterpillar dealer for the replacement of
the seat belt and the mounting hardware.
If your machine is equipped with a seat belt

extension, also perform this replacement procedure Personal injury or death can occur if steering is
for the seat belt extension. lost completely during operation.
Do not continue to operate the machine using the

i02302909
secondary steering.
Seat Suspension - If the secondary steering activates during opera-
Inspect/Lubricate tion, the machine must be safely shut down imme-
diately. Inspect the machine and correct the condi-
SMCS Code: 7324-040; 7324-086 tion which made the use of the secondary steering
necessary.
Inspect
Seat Suspension
Personal injury or death can occur if personnel are
Inspect the seat suspension for excessive looseness trapped between the wheel and the frame.
and wear. If excessive looseness or wear is detected,
refer to Systems Operation, Testing and Adjusting, The steering system is hydraulically controlled
Disassembly and Assembly, RENR8391, “Caterpillar and wheels can crush personnel during move-
Comfort Series Seat with three point operator ment.
restraint”, “Troubleshooting Chart”.
Lubricate and the frame. If the wheels must be turned, en-
Seat Suspension
Adjust the seat fully rearward and apply a dry This machine is equipped with a secondary steering
lubricant to the front of the seat slide mechanism. system. The steering system accumulators provide
Adjust the seat fully forward and apply a dry lubricant a limited amount of stored hydraulic pressure for
to the rear of the seat slide mechanism. Move the steering if the power source for the normal steering
seat rearward and forward several times in order to system fails or the engine stops. The secondary
distribute the lubricant. steering system will only provide steering until the
stored hydraulic pressure is exhausted. Refer to
Operation and Maintenance Manual , “Operator
Controls” for more information on the secondary
steering system.
194 SEBU7792-05
Maintenance Section
Service Brakes - Inspect
4. Turn the front wheels to the straight ahead

position.
5. Chock the rear wheels and release the parking

brake.
g01163448
Illustration 248
There are two steering accumulators on the machine.

Steering accumulators (1) is located on the outside
right frame rail near the front of the machine.
g01349223
Illustration 250
The engine shutdown switch is located on the front bumper.
6. Stop the engine with ground level shutdown switch

(4). This permits the accumulators to stay charged
in order to provide stored energy for the secondary
steering system when the engine is stopped.
7. Visually confirm the following:
a. Verify that the front wheels turn left as the

steering wheel is turned left.
b. Verify that the front wheels turn right as the

g01163447
steering wheel is turned right.
Illustration 249
If the secondary steering system is unable to comply
Perform the following field test in order to verify that with any portion of this field test, consult your
the secondary steering system is functional: Caterpillar dealer.
1. Empty the truck body and park the machine on a
level surface. Place the transmission control in the i02346399
NEUTRAL position and engage the parking brake.
Service Brakes - Inspect
2. When the engine is stopped with the engine start
switch, check the steering hydraulic oil level. SMCS Code: 4251-040
Maintain the oil to the full mark in upper sight
gauge (2). Record the initial measurement of the service
brake disc thickness when the machine is new or
3. After engine start-up, check the oil level. when the brakes are rebuilt. Compare subsequent
measurements to the initial measurement in order to
a. If the oil level registers at the full mark in lower determine the amount of wear.
sight gauge (3), the accumulators are properly
charged. Inspect the front brakes for wear and inspect the
brake system for leakage.
b. If the oil level registers below the full mark in the
lower sight gauge, check accumulator charge Inspect the rear brakes for wear and inspect the rear
before proceeding to the next step. Refer to brakes for system leakage.
System Operation, Testing and Adjusting,
RENR8336, “793D Off-Highway Truck Steering
System” or consult your Caterpillar dealer.
SEBU7792-05 195
Maintenance Section
Sound Suppression (Covers, Panels) - Inspect/Replace
For more information on the proper procedures, • Cracks

refer to Systems Operation, Testing and Adjusting,
RENR8330, “793D Air System and Brakes”, “Service • Loose covers
Brake Discs - Check”.
• Missing pieces
Note: Refer to Guideline for Reusable Parts and
Salvage Operations, SEBF8095, “Service Brakes for If any of these conditions exist, perform the
Off-Highway Trucks and Tractors” when you rebuild necessary repairs and/or replace any damaged
the brakes. sound suppression covers.
i02602002 Louvers
Sound Suppression (Covers, Inspect the louver assembly. The louver assembly is
Panels) - Inspect/Replace on the front of the radiator. Inspect the louvers for the
following damage:
(If Equipped with the Sound
Suppression Arrangement) • Bent steel mesh or broken steel mesh
SMCS Code: 1801-040; 1801-510; 7076-040; • Burnt insulation material

7076-510; 7261-040; 7261-510
• Compressed insulation material
Sound Panels • Insulation material with fluid saturation
Inspect the sound suppression panels. The sound • Loose insulation material
suppression panels are bolted on the front portion
of the machine in order to enclose the engine • Missing pieces of insulation material
compartment. Inspect the panels for the following
damage: • Tears in the insulation material
• Broken fasteners or missing fasteners If any of these conditions exist, perform the necessary
repairs and/or replace any damaged louvers.
• Burnt insulation material
i03572122
• Compressed insulation material
Steering Ball Stud - Inspect
• Insulation material with fluid saturation
SMCS Code: 4305-040-SD
• Loose insulation material
The inspection procedure for the ball studs uses a
• Missing pieces of insulation material straight beam examination. The inspection procedure
does not require the ball studs to be removed from
• Tears in the insulation material the machine. The inspection procedure is used to
identify any damage that has developed during the
• Bent steel panels or broken steel panels operation of the machine. The ball studs can develop
cracks that may cause the ball stud to fail, and lead
If any of these conditions exist, perform the to the loss of steering. The inspection procedure
necessary repairs and/or replace any damaged references ASTM E114-95 and ASTM E1901-97.
sound suppression liners.
Refer to Special Instruction, REHS4420, “Steering
Sound Covers Ball Stud Inspection for Off- Highway Trucks” in order
to perform the proper inspection procedure for the
Inspect the sound suppression covers. The sound ball studs.
suppression covers are fastened to the following
components: engine, torque converter, final drives,
and differential. Inspect the covers for the following
damage:
• Broken fasteners or missing fasteners

• Broken pieces
196 SEBU7792-05
Maintenance Section
Steering Ball Stud - Replace
i02387439
Steering Ball Stud - Replace

SMCS Code: 4305-510-SD
The recommended replacement interval for the

steering cylinder and steering linkage ball studs is
between 12000 operating hours and 15000 operating Illustration 251
g01442892
hours or at the planned component rebuild of the
Typical example
steering cylinder. For the replacement procedure,
refer to the Disassembly and Assembly, “Off-Highway (1) Steering arm
(2) Steering link assembly
Truck Machine Systems” manual for your machine or (3) Center arm
consult your Caterpillar dealer.
2. Attach the magnetic base of a 8T-5096 Dial
The replacement interval may vary and the Indicator Group to steering link (2). This will allow
replacement interval is heavily dependent on the the horizontal movement of the ball stud to be
haul cycle conditions. These conditions include the measured.
following considerations: haul road condition, length
of hauls, number of turns per cycle, load, and grade 3. To measure the horizontal wear of the ball studs
of the haul road. and of the outer bearing races on the steering
cylinders, place the dial indicator against the side
Inspect the condition of the tapered steering bore of steering arm (1).
whenever a ball stud is replaced. Refer to Reuse and
Salvage Guidelines, SEBF8271, “Salvage of Steering 4. Set the dial indicator to zero.
Arm and Steering Arm (T-Bar) Tapers on 785, 789,
793, and 797 Off-Highway Trucks” or consult your 5. Steer the front wheels in both directions. Record
Caterpillar dealer in order to determine whether the amount of horizontal play on the indicator dial.
the tapered bore can be reused or machined to an This indicates the amount of wear in the ball studs
oversized dimension. and the outer bearing races.
If the tapered bore is out of the specification and the 6. To measure the horizontal wear of the ball studs
tapered bore is able to be salvaged, then an oversize and of the outer bearing races on the other ball
ball stud may be used. If the taper is too far out of studs and outer bearing races, place the dial
the specification, then an oversize ball stud cannot indicator against the side of center arm (3).
be used. In this case, either the steering arm or the
steering box must be scrapped and replaced. 7. Set the dial indicator to zero.
i03370162 8. Steer the front wheels in both directions. Record

the amount of horizontal play on the indicator dial.
Steering Linkage - Inspect
Note: Repeat this procedure in order to measure all
SMCS Code: 4305-040 of the ball studs and outer bearing races.
Inspect the horizontal wear limits for the ball studs in 9. The maximum amount of horizontal wear is
the steering linkage. At the same time, inspect the 1.02 mm (0.040 inch). If any of the measurements
outer bearing race. Also, inspect the grease fittings exceed this limit, replace the worn ball studs and
and the seals. the outer bearing races.
1. Park the machine on a level surface. 10. Inspect all of the covers for the ball studs. Inspect
all grease fittings and seals. Replace any worn
components and any damaged components.
Note: Properly lubricate the steering linkage in order

to ensure the durability of components. The steering
linkage must be free of contaminants in order to
ensure the durability of components.
SEBU7792-05 197
Maintenance Section
Steering System Oil - Change
i02331342
Steering System Oil - Change

SMCS Code: 4300-044-OC

contact the skin.
1. Operate the engine until the steering hydraulic oil

is warm. Park the machine on a level surface and
engage the parking brake. Stop the engine.
3. Slowly, remove filler cap (4) on the steering

hydraulic tank in order to relieve the pressure.
NOTICE

products.
g01163770
Illustration 252
mandates. 4. Open drain valve (1).
5. Allow the oil to drain into a suitable container.

Close the drain valve.
6. Remove retaining ring (6) for the filler strainer.
7. Remove filler strainer (7). Wash the cap and the

strainer in clean, nonflammable solvent. Allow the
cap and the strainer to dry.
8. Inspect cap seal (5). Use a new seal if the used

seal is damaged.
9. Install the strainer and the retaining ring for the

strainer.
NOTICE
Do not fill the steering hydraulic tank when the engine
is running. Discharge from the secondary steering ac-
cumulators could overfill the tank when the engine is
stopped.
198 SEBU7792-05
Maintenance Section
Steering System Oil Filter - Replace
10. Fill the steering hydraulic tank. Refer to Operation

And Maintenance Manual, “Lubricant Viscosities”.
Refer to Operation And Maintenance Manual,
11. Use the reading from the upper sight gauge to

maintain the steering oil level. When the engine is
not running, the oil level should be at the “FULL”
mark in upper sight gauge (2).
12. Install the filler cap.
13. Operate the engine until the steering hydraulic oil

is warm. Inspect the machine for leaks and make
any necessary repairs.
14. Stop the engine. Allow the steering accumulators

to completely discharge and check the oil level.
Use the reading from the upper sight gauge to
maintain the steering oil level.
15. When the engine is stopped, the oil level should

be at the “FULL” mark in the upper sight gauge. If
necessary, add oil.
i02331551
Steering System Oil Filter - Illustration 253

g01163863
Replace
SMCS Code: 431F-510
3. Slowly remove filler cap (4) on the steering
hydraulic tank in order to relieve any pressure.
Install the filler cap after the pressure is relieved.
4. Remove four nuts (1) from the filter cover.
contact the skin.
5. Pull filter assembly (2) out of the tank.
1. Park the machine on level ground and engage the

parking brake. Stop the engine.
g01163878
Illustration 254
6. Remove filter cover (5) from stud (10).
7. Remove spring pin (7) and spacer (8).
8. Remove used filter elements (9) and discard the

used filter elements.
SEBU7792-05 199
Maintenance Section
Steering System Oil Level - Check
9. Install the new filter elements.

NOTICE
10. Install the spring pin and the spacer. Do not fill the steering hydraulic tank when the engine
is running. Discharge from the secondary steering ac-
11. Inspect seal (6) for the filter cover. Inspect seal cumulators could overfill the tank when the engine is
(12) for retainer assembly (11). Replace any seals stopped.
that are damaged.
12. Install the filter cover on the stud. Tighten the filter Note: After the engine start-up, the oil level should
cover by hand. be within the operating range of lower sight gauge
(2). If the oil level in the lower sight gauge is low,
13. Install the filter assembly into the tank. Install the check the secondary steering. See Operation And
nuts for the filter cover. Maintenance Manual, “Secondary Steering - Check”
for additional information.
idle. Make sure that the parking brake is engaged. i02331813
Steering System Oil Sample -
15. Check the steering system oil level. If necessary,
add oil. For the proper procedure, refer to Obtain
Operation and Maintenance Manual, “Steering
System Oil Level - Check”. SMCS Code: 4300-008-OC; 7542
i03352042
Steering System Oil Level -

Check
SMCS Code: 4332-535-FLV
g01163967
Illustration 256
g01726834
Illustration 255
Sampling port (1) for the steering oil is located on the
steering solenoid and relief valve.
the parking brake. Refer to the following publications for information
2. Stop the engine and allow the secondary steering
accumulators to completely discharge before the
oil level is observed. • Operation and Maintenance Manual, “S·O·S
Information”
3. Maintain the oil level to the full mark in upper sight
gauge (1). • Special Publication, SEBU6250, “S·O·S Oil
Analysis”
4. If necessary, add oil.
Good Oil Sample”
200 SEBU7792-05
Maintenance Section
Suction Screen (Rear Axle Lubrication) - Clean
• Special Publication, PEDP8025, “Fluid Analysis 4. Wash the screen and the magnetic tube assembly
Interpretaion Guide” in clean, nonflammable solvent. Clean the
magnets with a cloth, a stiff bristle brush or air
pressure.
i02337440
Suction Screen (Rear Axle 5. Install the magnetic tube assembly and the screen.
Lubrication) - Clean 6. Inspect seal (4). If the seal is damaged, replace

the seal.
SMCS Code: 3016; 3278-070-Z3; 3291
7. Install the screen cover plate.

Hot oil and hot components can cause personal idle. Make sure that the parking brake is engaged.
injury. Do not allow hot oil or hot components to Check for leaks and make any necessary repairs.
contact the skin.
Note: The lubrication pump for the rear axle will not
operate with the oil temperature below 15 °C (59 °F).
parking brake and stop the engine. 9. Check the oil level in the rear axle. If necessary,
add oil. For the proper procedure, refer to
Operation and Maintenance Manual, “Differential
and Final Drive Oil - Check”.
Note: Correct oil levels are critical in the differential

and final drives. Check the oil level after repairs and
after maintenance.
Note: The differential and final drive oil level needs to

be checked and maintained at operating temperature.
If the oil level is checked cold, adjustment of the
oil level may be necessary when the truck reaches
operating temperature.
g01166714 i02682176
Illustration 257
2. Remove screen cover plate (1 ).

Suction Screen (Torque
Converter) - Clean
SMCS Code: 3101-070-Z3

contact the skin.
g01166878
Illustration 258
3. Remove screen (2) and magnetic tube assembly

(3).
NOTICE
Do not drop or rap the magnets against any hard ob-
jects. Replace any damaged magnets.
SEBU7792-05 201
Maintenance Section
Suction Screen (Torque Converter) - Clean
NOTICE

products.
Dispose of all fluids according to local regulations and g01164303

Illustration 260
mandates.
5. Remove the bolts from screen cover (3). The
1. Park the machine on a level surface. Engage the screen cover is located at the lower left rear corner
parking brake and stop the engine. of the sump. Remove the cover and the screen
assembly.
6. Wash the screen assembly and the cover in a

clean, nonflammable solvent. Do not crush the
screen assembly.
7. Inspect the cover gasket for damage. If the cover

gasket is damaged, use a new gasket.
8. Install the screen. Install the cover assembly.
g01164290
Illustration 259
2. Remove filler cap (1) in order to prevent a vacuum

in the torque converter sump. Install the filler cap
after the torque converter sump is drained. This
will prevent dirt from entering the system.
3. Remove drain valve plug (2) in the torque

converter sump. Install a 100 mm (4 inch) long
NPT pipe nipple in order to open the internal drain
valve. The outer diameter of the NPT pipe nipple g01164452
Illustration 261
should be 25 mm (1 inch). Drain the oil into a
suitable container. 9. Remove the filler cap and fill the torque converter
to the top of upper sight gauge (4). See Operation
Note: Hand tighten the NPT pipe nipple. Do not use And Maintenance Manual, “Lubricant Viscosities”.
tools. See Operation And Maintenance Manual,
4. Remove the pipe nipple. Clean the drain plug and
install the drain plug. 10. Operate the engine for ten seconds and then turn
off the engine. The oil level will decrease as oil
fills the system.
11. Check the oil level in the torque converter sump.

If necessary, add oil in order to raise the oil level
to the “FULL” mark of the upper sight gauge.
202 SEBU7792-05
Maintenance Section
Suspension Cylinder - Check
12. Start the engine and operate the engine at low Front Suspension Cylinder
13. Operate the engine until the torque converter oil

reaches operating temperature. Torque converter Personal injury or death can occur if personnel are
stalls may be performed in order to bring the trapped between the wheel and the frame.
torque converter oil up to operating temperature.
The steering system is hydraulically controlled
14. Check the oil level with the engine at low idle and and wheels can crush personnel during move-
the transmission in neutral. ment.
15. Maintain the oil level until the oil level stabilizes Use caution when working between the wheels
in the “FULL” mark of the upper sight gauge. If and the frame. If the wheels must be turned, en-
necessary, add oil. sure that all personnel are clear of the machine
16. Clean the filler cap and install the filler cap on the
filler tube.
NOTICE
Failure to properly fill the torque converter sump after
an oil change may cause damage to the power train
system. Follow the procedure that is described above.
The transmission direction and speed control MUST

be left in NEUTRAL until the system is full.
i02331858
Suspension Cylinder - Check g01163979

Illustration 262
SMCS Code: 7201-535 (X) Distance of exposed chrome
Make sure that the dump body is empty. Measure the distance of exposed chrome (X) for the
front suspension cylinders. Compare the present
Stop the machine gradually on a level surface without distance to the distance from the previous time. If you
using the brakes. do not have those dimensions, perform the charging
procedure. See Testing And Adjusting, “Suspension
Engage the parking brake and stop the engine. Cylinder (Front) - Purge and Charge” for the charging
procedure.
Note: All of the suspension cylinders that are shipped
from the factory receive a preliminary charge of Note: There are two relief valves for the grease on
nitrogen and a preliminary charge of oil. During field the forward side of the front suspension cylinder.
assembly, the suspension cylinders must be charged These relief valves are located 180 degrees from the
with nitrogen. lubrication fitting. Do not plug the grease passage
of the relief valves.
SEBU7792-05 203
Maintenance Section
Tire Inflation - Check
Rear Suspension Cylinder

NOTICE

products.

mandates.
g01163990
Illustration 263
(Y) Distance between the pins
Measure distance (Y) for the rear suspension
cylinders. Compare the present distance to the
distance from the previous time. If you do not have
those dimensions, perform the charging procedure.
See Testing And Adjusting, “Suspension Cylinder
(Rear) - Purge and Charge” for the charging
procedure.
Note: When the rear suspension cylinders are

properly charged, the left rear suspension cylinder
will not show as much chrome as the right rear
suspension cylinder. This is due to the rigid frame
and to the weight of the cab.
i02416817
Tire Inflation - Check

SMCS Code: 4203-535-AI; 4203-535-PX
Measure the tire pressure on each tire. Adjust the tire

pressure, if necessary. Consult your tire supplier for g01164086
Illustration 264
the correct tire operating pressures and load ratings.
2. Remove drain plug (2) from the bottom of screen
See Operation and Maintenance Manual, “Tire
housing (1) and drain the oil into a suitable
Inflation Information” for more tire information.
container. Clean the drain plug and install the
drain plug.
i02332019
Note: Removing the drain plug from the bottom of
Torque Converter Outlet the screen housing may not drain all of the oil from
Screen - Replace the screen.
SMCS Code: 3103 3. Remove the screen housing. Remove the screen.
Discard the used screen.
4. Wash the screen housing in clean, nonflammable

solvent.
injury. Do not allow hot oil or hot components to 5. Inspect the seal in the base of the screen housing.
contact skin. If the seal is damaged, replace the seal with a
new seal.
204 SEBU7792-05
Maintenance Section
Torque Converter Sump Breather - Clean
6. Install the new screen in the screen housing.

Install the screen housing.

8. Check the oil level in the torque converter sump. If

to Operation and Maintenance Manual, “Torque
Converter Sump Oil Level - Check”.
i02335501
Torque Converter Sump

Breather - Clean
SMCS Code: 3101
g01167449
Illustration 265
with the body (bed) raised, attach the body (bed) 4. Remove breather (1).
rear tow point pin through the end of the retaining 5. Wash the breather in a clean, nonflammable
cable. solvent. Allow the breather to air dry.
Failure to properly secure the body (bed) may re- 6. Install the breather.
7. Remove the truck body retaining cable and lower
the body.
Note: The breather for the torque converter sump
also vents the transmission case.
i02682170
the parking brake. Torque Converter Sump Oil
Level - Check
and install the truck body retaining cable to the SMCS Code: 3101-535-FLV
installation and removal of the truck body retaining Note: The oil level in the transmission is supplied by
cable, refer to Operations and Maintenance the torque converter sump.
1. Park the machine on a level surface.
3. Stop the engine.
2. Operate the engine at low idle with the
transmission in neutral and with the parking brake
engaged.
Note: The engine should be on in order to check the

cold oil (oil at ambient temperature) level of the torque
converter, and the engine should be on in order to
check the hot oil (oil at operating temperature) level
of the torque converter.
SEBU7792-05 205
Maintenance Section
Torque Converter and Transmission Oil - Change
g01347318 g01164290
3. Check the oil level in the torque converter sump. 2. Remove filler cap (1) in order to prevent a vacuum
in the torque converter sump. Install the filler cap
a. If the torque converter oil is cold, use lower after the torque converter sump is drained. This
sight gauge (3) in order to check the oil level. will prevent dirt from entering the system.
b. If the torque converter oil is in the operating NOTICE

temperature range, use upper sight gauge (2) Care must be taken to ensure that fluids are contained
in order to check the oil level. during performance of inspection, maintenance, test-
4. If necessary, add oil. The torque converter oil and collect the fluid with suitable containers before open-
transmission oil is added at filler cap (1). ing any compartment or disassembling any compo-
Note: If the system has been drained, refer to
Operation and Maintenance Manual, “Torque Refer to Special Publication, NENG2500, “Caterpillar
Converter and Transmission Oil - Change” for the Dealer Service Tool Catalog” for tools and supplies
proper procedure. suitable to collect and contain fluids on Caterpillar
products.
i02682180
Torque Converter and mandates.
Transmission Oil - Change
3. Remove drain valve plug (2) in the torque
SMCS Code: 3030-044-OC; 3101-044-OC converter sump. Install a 100 mm (4 inch) long
NPT pipe nipple in order to open the internal drain
valve. The outer diameter of the NPT pipe nipple
should be 25 mm (1 inch). Drain the oil into a
suitable container.
injury. Do not allow hot oil or hot components to Note: Hand tighten the NPT pipe nipple. Do not use
contact the skin. tools.
1. Park the machine on a level surface. Engage the 4. Remove the pipe nipple. Clean the drain valve
parking brake and stop the engine. plug and install the drain valve plug.
206 SEBU7792-05
Maintenance Section
Torque Converter and Transmission Oil - Change
12. Check the oil level in the torque converter sump.

Add oil in order to raise the oil level to the “FULL”
mark of the upper sight gauge.

14. Operate the engine until the torque converter oil

reaches operating temperature. Torque converter
stalls may be performed in order to bring the
torque converter oil up to operating temperature.
15. Check the oil level with the engine at low idle and
g01164714
the transmission in neutral.
Illustration 268
16. Maintain the oil level until the oil level stabilizes
5. Remove drain plugs (3) from the transmission in the “FULL” mark of the upper sight gauge. If
extension housing. Drain the oil into a suitable necessary, add oil.
container. Clean the drain plugs and install drain
plugs. 17. Clean the filler cap and install the filler cap on the
filler tube.
6. Remove the filler cap.
7. Remove the retaining ring on the filler screen. NOTICE

Remove the screen. Failure to properly fill the torque converter sump after
an oil change may cause damage to the power train
8. Wash the cap and the filler screen in clean, system. Follow the procedure that is described above.
nonflammable solvent. Allow the cap and the filler
screen to dry. The transmission direction and speed control MUST
be left in NEUTRAL until the system is full.
9. Inspect the cap seal. Use a new seal if the used
seal is damaged. Install the filler screen and the
retaining ring.
g01164452
Illustration 269
10. Fill the torque converter to the top of upper sight

gauge (4). See Operation And Maintenance
Manual, “Lubricant Viscosities”. See Operation
And Maintenance Manual, “Capacities (Refill)”.
11. Operate the engine for ten seconds and then turn
off the engine. The oil level will decrease as oil
fills the system.
SEBU7792-05 207
Maintenance Section
Torque Converter and Transmission Oil Sample - Obtain
i02501245 i02900768
Torque Converter and Traction Control System (TCS)

Transmission Oil Sample - - Test
Obtain SMCS Code: 3288-081; 4801-081
SMCS Code: 3030-008; 3101-008; 7542 Note: This procedure determines if the Traction
Control System (TCS) is functioning. This procedure
also determines if the left rear brake and the right
rear brake activate at the correct time.
1. Find a clear area and a level area. In this area,

turn the machine in a complete circle. Start the
machine and move the transmission direction and
speed control lever to the first gear Forward.
2. Turn the steering wheel all the way to the left.

With the engine at low idle, drive the machine in
a complete circle.
g01251142
Illustration 270
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.
g01444054
Refer to the following publications for information Illustration 271
3. Continue to turn the machine and push the top
• Operation and Maintenance Manual, “S·O·S half of test switch (1) for the TCS. Hold the test
Information” switch down. This will begin the test.
• Special Publication, SEBU6250, “Caterpillar 4. The machine will gradually slow down.
Machine Fluids Recommendations”, “S·O·S Oil
Analysis” 5. Release the test switch. The test will end and the
machine will increase speed.
Good Oil Sample” 6. Turn the steering wheel all the way to the right.
With the engine at low idle, drive the machine in
• Special Publication, PEDP8025, “Fluid Analysis a complete circle.
7. Continue to turn the machine and push the top
half of the test switch for the TCS. Hold the test
switch down. This will begin the test.
8. The machine will gradually slow down.
9. Release the test switch. The test will end and the
machine will increase speed.
10. If the TCS did not function properly, consult your

Caterpillar dealer for information and service.
208 SEBU7792-05
Maintenance Section
Transmission Magnetic Screen - Clean
i02335439 4. Wash the screen and the magnetic tube assembly

in clean, nonflammable solvent. Clean the
Transmission Magnetic Screen magnets with a cloth, a stiff bristle brush or air
- Clean pressure.
SMCS Code: 3030-070-MGS 5. Install the magnetic tube assembly, the screen,
and the wave washer.
6. Inspect seal (5). If the seal is damaged, replace

the seal.
injury. Do not allow hot oil or hot components to 7. Install the screen cover plate.
contact the skin.
Note: The oil level in the transmission is supplied by

the torque converter sump.
9. Check the oil level in the torque converter sump. If

to Operation and Maintenance Manual, “Torque
Converter Sump Oil Level - Check”.
i02335442
Illustration 272
g01165690 Transmission Oil Filter -
Location of the transmission magnetic screen Replace
1. Park the machine on a level surface. Engage the SMCS Code: 3067-510

contact the skin.
g01166968
Illustration 273
2. Remove screen cover plate (1).
3. Remove wave washer (2), screen (3), and

magnetic tube assembly (4). g01165699
Illustration 274
NOTICE 1. Park the machine on a level surface. Engage the

Do not drop or rap the magnets against any hard ob- parking brake and stop the engine.
jects. Replace any damaged magnets.
SEBU7792-05 209
Maintenance Section
VIMS Module Battery - Replace
i03010045
NOTICE
VIMS Module Battery - Replace
SMCS Code: 7490-510-B11; 7601-510-B11

products.

mandates.
2. Remove drain plug (2) for filter housing (1). Drain

the oil into a suitable container. Clean the drain
g01043143
plug and install the drain plug. Illustration 275
(1) Plate
Note: All of the oil from the filter may not drain when
the drain plug from the bottom of the filter housing A lithium battery is contained inside the main module
is removed. of the VIMS. The internal battery prevents the loss
of stored information. An example of the stored
3. Remove the filter housing and the filter element. information is the payload data. The internal battery
Discard the used filter element. also retains the time and the date.
4. Wash the filter housing in clean nonflammable If power is removed from the main module of the
solvent. VIMS, the internal battery will begin to retain the
stored data. Power is removed from the main module
5. Inspect the seals in the filter base. If the seals are of the VIMS when the battery disconnect switch is
damaged, replace seals with new seals. in the OFF position. The internal battery retains the
time and the date when the engine start switch is in
6. Install the new filter element in the housing. Install the OFF position. This will occur regardless of the
the housing. position of the battery disconnect switch.
7. Start the engine and operate the engine at low Note: To prevent the loss of stored information,
idle. Make sure that the parking brake is engaged. replace the internal battery at the service interval. If
Check for leaks and make any necessary repairs. the ambient temperature is continuously in the range
of 0 to −40°C (32 to −40°F), cut the service interval
Note: The oil level in the transmission is supplied by in half.
the torque converter sump.
Note: If the Vital Information Management System
8. Check the oil level in the torque converter sump. If (VIMS) detects a failed battery, a fault code will
necessary, add oil. For the proper procedure, refer indicate that the battery needs a replacement. If
to Operation and Maintenance Manual, “Torque power is removed from the main module of the VIMS
Converter Sump Oil Level - Check”. during this fault code, loss of the stored data can
occur within several hours. The lithium battery fails
quickly. When the fault code is present, immediately
download the stored data. Then replace the internal
battery without turning off the engine start switch or
the battery disconnect switch.
Note: If ECM BKUP BATT ERR is displayed in the

message area of the VIMS, do NOT turn the engine
start switch to the OFF position. Go to Step 3.
1. Stop the machine and turn off the engine. Leave

the battery disconnect switch in the ON position.
210 SEBU7792-05
Maintenance Section
Window Washer Reservoir - Fill
2. Turn the engine start switch to the ON position or

turn the keyswitch for the VIMS to the ON position.
3. Use the service tool for the VIMS to download all

of the stored information. The service tool for the
VIMS is not part of the machine. Failure to perform
this step may result in the loss of stored data.
4. Leave the engine start switch in the ON position

or leave the keyswitch for the VIMS in the ON
position. Leave the battery disconnect switch in
the ON position.
Note: If these switches remain in the ON position

during replacement, the date and the time of day are g01139822
less likely to require programming. Illustration 276
5. Remove the battery from the back of the VIMS Window washer reservoir (1) is located in the
module. The battery is located behind plate (1). compartment in the front of the cab.
Note: Do not allow dirt or water into the opening. Fill the reservoir with windshield washer fluid.
Keep the area clean.
i02335763
6. Install a new internal battery. Be careful to align
the pins of the new battery with the sockets. Window Wiper -
7. Check the O-ring seal. The O-ring seal is located Inspect/Replace
under the cap. Make sure that the O-ring seal is in
the proper place. Make sure that the O-ring seal SMCS Code: 7305-040; 7305-510
is not damaged. Install the cap. Tighten the cap
securely against the housing.
8. The real time clock format in the main module is

powered by this battery. A dead battery will cause
the date to be lost and a dead battery will cause
the time to be lost. After the battery has been
replaced, the date will default to “01/01/00”. Also,
the time will default to “00:00:00”. If necessary,
use the service tool for the VIMS to set the time
and the date. Refer to Troubleshooting, Testing
and Adjusting, RENR2631, “Vital Information
Management System (VIMS)”.
g01165832
i02346847 Illustration 277
Window Washer Reservoir - Inspect windshield wiper blade (1). Replace the
Fill windshield wiper blade if the wiper blade is worn or
damaged. Replace any windshield wiper blade that
streaks the windshield.
SMCS Code: 7306-544-KE
NOTICE
When operating in freezing temperatures, use
Caterpillar nonfreezing window washer solvent or
equivalent. System damage can result from freezing.
SEBU7792-05 211
Maintenance Section
Windows - Clean
i02680928
Windows - Clean
SMCS Code: 7310; 7340
g01346892
Illustration 278
Use commercially available window cleaning

solutions to clean the windows. Only clean the
windows, when handholds are available.

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MAINTENANCE INTERVALS

Operation and Maintenance

i03896670 Hoist and Brake Tank Suction Screen -

Torque Converter and Transmission Oil Sample - Every Year

Breather (Fuel Tank) - Replace ........................... 142

If a reduction in air circulation is noticed, clean the

The filter element for the air conditioner is located in

1. Park the machine on a level surface and engage

2. Loosen the door retaining screws and open the

Air Dryer - Check Air Dryer Desiccant - Replace

Air lines to and from the air dryer must be at

1. Park the machine on a level surface and engage

Primary Air Tank

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

3. Close the drain valve for the air tank.

Air Tank - Inspect

When laws in the machine's operating location

Air Tank Moisture and

1. Open drain valve (2) for the air tank.

2. Check for moisture and sediment in the air tank.

3. Close the drain valve for the air tank.

Primary Air Tank (If Equipped

When it is necessary to work under the machine

Failure to properly secure the body (bed) may re-

1. Park the machine on a level surface and engage

2. Raise the dump body to the fully raised position

3. Stop the engine.

i03795949 The automatic lubrication reservoir provides

See Systems Operation, Testing and Adjusting,

Backup Alarm - Test

1. Remove plug (1) for the vent port if the reservoir is

Note: If the reservoir is not properly vented, pressure

Always recycle a battery. Never discard a battery.

Always return used batteries to one of the following

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

for more information. Belts - Inspect/Adjust/Replace

To maximize the engine performance, inspect

5. Turn adjusting nuts (3) in order to increase or

7. Tighten the adjusting nuts. Tighten the mounting

8. Check the belt tension on a new belt after 30

Note: The break-in period for the belt is considered

Refer to Special Publication, NENG2500, “Caterpillar

g01135507 Dispose of all fluids according to local regulations and

1. Park the machine on a level surface. Engage the

2. In order to release the tension on the belt, Insert a

3. If necessary, remove the belt and replace the belt.

4. Shoulder (2) of the belt tensioner should be

5. Check the belt tension on a new belt after 30 g01137716

Brake Cooling Oil Filter -

Refer to Disassembly and Assembly, RENR8332, i02320005

Hot oil and hot components can cause personal

8. Install the filter housings.

9. Remove the vacuum transducer and the vacuum

10. Start the engine and operate the engine at low

11. Check the oil level in the hoist/brake tank. If

8. Remove cover (5) for the front oil cooler screen.

9. Remove the front oil cooler screen. Wash the oil

10. Install the front oil cooler screen.

12. Start the engine and operate the engine at low

4. Remove the rear oil cooler screens. Wash the oil

5. Install the rear oil cooler screens.

6. Install the covers for the rear brake oil cooler

Brake Tank (Makeup) - Clean Brakes, Indicators and Gauges