Service Instructions: Cat® Self-Service Options

P00005109-01 (en-us)
July 1, 2022
CAT® SELF-SERVICE OPTIONS
SERVICE INSTRUCTIONS
PM-4
Model : 730
Prefix : B1M
Configuration : B1M00001-B1M99999
Table of Contents
Cat Self-Service Options 1
General Preventative Maintenance Information 1
Maintenance Section 3
Lubricant Viscosities 3
Capacities (Refill) 6
S O S Information 6
System Pressure Release 7
Every 2000 Service Hours 7
Refrigerant Dryer - Replace 7
Suspension System - Check 7
Hydraulic Tank Breather - Clean/Inspect/Replace 8
Frame and Body - Inspect 8
Engine Valve Lash - Check 10
Brake Accumulator (Service) - Check 11
Brake System Air - Purge 11
Engine Valve Rotators - Inspect 11
Differential and Final Drive Oil - Change 11
Cooling System Coolant Sample (Level 2) - Obtain 12
Hydraulic System Oil Filter and Screen - Clean/Inspect/Replace 13
Oscillating Hitch - Adjust 14
Rollover Protective Structure (ROPS) - Inspect 15
Torque Converter and Transmission Oil - Change 16
Transfer Gear Oil - Change 18
Transfer Gear Oil Filter - Replace 19
Transmission and Transfer Gear Breather - Clean/Replace 20
Automatic Lubrication Filler Filter - Clean 20
Axle Breathers - Clean/Replace 20
Belts - Inspect/Adjust/Replace 21
Brake Pads - Check 21
Braking System - Test 22
Differential and Final Drive Oil Level - Check 23
Differential and Final Drive Oil Sample - Obtain 23
Engine Oil and Filter - Change 24
Engine Oil Sample - Obtain 26
Fuel System - Prime 26
Fuel System Primary Filter - Clean/Inspect/Replace 27
Fuel System Secondary Filter - Replace 28
Fuel Tank Cap and Strainer - Clean 29
Hydraulic System Oil Sample - Obtain 29
Hydraulic Tank Strainer - Clean/Inspect/Replace 29
Secondary Steering - Test 30
Torque Converter and Transmission Oil Filter - Replace 30
Torque Converter and Transmission Oil Sample - Obtain 31
Transfer Gear Oil Sample - Obtain 31
Engine Crankcase Breather - Clean 32
Parking Brake - Lubricate 32
Reference Section 33
Air Conditioning Performance - Test 33
Engine Valve Lash - Inspect/Adjust 34
Heater Performance - Test 35
Identifying the Air Conditioning System 35
In-Line Refrigerant Dryer - Remove and Install 36
Machine Preparation for Disassembly and Assembly 38
Manifold Gauge Set (Refrigerant) - Install 39
Parking Brake 40
Refrigerant Accumulator - Remove and Install 40
Refrigerant Compressor - Remove and Install 40
Refrigerant Expansion Valve - Remove and Install 41
Refrigerant Leakage - Test 41
Refrigerant Oil - Test 42
Refrigerant Orifice Tube Assembly - Remove and Install 44
Refrigerant Receiver-Dryer - Remove and Install 45
Refrigerant Recovery 46
Refrigerant System - Charge 47
Refrigerant System - Evacuate 51
Refrigerant System - Flush 53
Visual Inspection 56
Cat Self-Service Options Therefore, the warnings in this publication and the warnings that
are on the product are not all inclusive. Do not use a tool, a
i08825806 procedure, a work method, or operating technique that is not
recommended by Caterpillar .
Introduction Ensure that the product will not be damaged or made unsafe by
Self-Service Options include the parts and instructions required the operation, lubrication, maintenance, or the repair
for customers to perform certain maintenance and repair work procedures.
themselves. Self-Service Options also enable the purchase of
referenced tools and products and include links to related safety WARNING
information available at Cat.com/Safety.
Do not operate or work on this machine unless you have read
CAT ® SELF-SERVICE OPTIONS INCLUDE: and understand the instructions and warnings in the Operation
and Maintenance Manuals. Failure to follow the instructions or
1. Required Genuine Cat parts heed the warnings could result in injury or death. Contact any
Caterpillar dealer for replacement manuals. Proper care is your
2. List of recommended tooling responsibility.
3. Service Instructions
For information about Self-Service Options, consult with your Cat WARNING
dealer. Contact your Cat dealer or email SelfService@Cat.Com to
share your feedback on Self-Service Options. Failure to follow all safety guidelines prescribed in this document
and by governing authorities and regulatory agencies could
Do not perform any procedure in this Service Instruction until result in severe injury or death of personnel or machine damage.
you have read and understood the information, instructions, and
warnings in the Operation and Maintenance Manual for your
product as referenced below. WARNING
General Preventative Maintenance Information Personal injury or death can result from improper maintenance
procedures. To avoid injury or death, follow the procedures
i08825809 exactly as stated below.
General Reference Section

WARNING
Reference: Operation and Maintenance Manual, SEBU7814.
Personal injury or death can result from sudden movement.
Reference: Disassembly and Assembly Manual, SENR5664.
Prevent possible injury by performing the following procedures
Reference: Non-standard torque specifications are included in before work begins:
this document. Standard torque specifications are published in
media SENR3130 which is available for download with the Move the product or equipment to a smooth, level surface.
service instructions on parts.cat.com.
When applicable, lower equipment/work tools to the ground.
Safety Section Engage the parking brake, system brakes and/or hydraulic
Reference: Operation and Maintenance Manual, SEBU7814. lockout control. When applicable, stop the engine and remove
the ignition key.
Use only proper tools and observe all precautions that pertain to
the use of those tools. Failure to follow these procedures can Release system pressure from pressurized systems.
result in personal injury. The following procedures should be If applicable, block the wheels/tracks.
observed.
Turn the battery disconnect switch to the OFF position and, if
Work safely. Most accidents that involve product operation, applicable, remove the battery disconnect key. If not equipped
maintenance, and repair are caused by failure to observe basic with a battery disconnect switch, disconnect all positive (+) and
safety rules or precautions. An accident can often be avoided by negative (−) battery cables. Install an appropriate battery cable
recognizing potentially hazardous situations before an accident lockout device and protect the battery posts to prevent
occurs. accidental contact and shorting.
A person must be alert to potential hazards. This person must Attach a “Do Not Operate” or similar warning tag at the battery
also have the necessary training, skills, and tools to perform disconnect switch location and as defined by site rules and/or
these functions properly. local regulations.
Safety precautions and warnings are provided in this instruction
and on the product. If these hazard warnings are not heeded,
bodily injury or death could occur to you or to other persons.
Caterpillar cannot anticipate every possible circumstance of a
potential hazard.
1
Illustration 1 g06276183
2
Engine SAE 5W-40 −30 50 −22 122
Maintenance Section Crankcase (1)
(2) (0) SAE 10W-30 (6) −18 40 0 104
Cat DEO-ULS SAE 10W-40 -18 50 0 122
Cat DEO
Lubricant Viscosities Multigrade
Cat DEO SYN (3)
Cat Arctic DEO
SYN (4) SAE 15W-40 −9.5 50 15 122
Operations and Maintenance Manual Cat ECF-1-a, Cat
SEBU7814 i06155211 ECF-2, Cat ECF-3
(5)
Hoist (Ejector), SAE 0W-20 (7) −40 40 −40 104
The proper lubricant viscosity grade is determined by the Steering and
Brake System,
(8)
minimum outside temperature when the machine is started. The Brake Control
Valve Damper,
proper lubricant viscosity grade is also determined by the and Suspension
maximum outside temperature while the machine is operated. Hydraulic
System SAE 10W (8) (9) −20 50 −4 122
Use the column that is designated "Min" on the table to Cat TDTO
Cat Arctic TDTO
determine the lubricant viscosity grade that is required. When commercial TO-
you start or operate a cold machine. Use the column that is 4
designated "Max" on the table to select the lubricant viscosity Torque
SAE 0W-20 (7) -40 22 -40 72
grade. For operating the machine at the highest temperature that Converter and SAE 0W-30 (10) -40 30 -40 86
Transmission
is anticipated. Use the highest SAE viscosity grade of oil that is Cat TDTO
SAE 5W-30 (10) -30 30 -22 86
allowed for the temperature when you start the machine. In Cat TDTO-TMS
Cat Arctic TDTO
SAE 10W (9) -20 22 -4 72
order to maintain the highest possible thickness of oil, machines commercial TO-
SAE 30 0 50 32 122
4
that are continuously operated should use an oil that has a Cat TDTO-TMS
(11) -10 50 14 122
higher viscosity in the final drives and in the differentials. Consult Output Transfer SAE 0W-20 (7) -40 -10 -40 14
your Caterpillar Dealer if additional information is needed. Gear (12)
Cat TDTO
Cat Arctic TDTO
commercial TO- SAE 30 -20 50 -4 122
NOTICE 4
Not following the recommendations found in these tables and Differential and SAE 0W-20 (7)
Final Drive (12) -40 -10 -40 14
associated footnotes can lead to reduced performance and Cat TDTO
SAE 50 (13) -15 40 5 104
Cat TDTO-TMS
compartment failure. Cat Arctic TDTO SAE 60 (13) -10 50 14 122
commercial TO-
4 Cat TDTO-TMS -25 22 -13 72
NOTICE
Do NOT use only the "Oil Viscosities" column when determining NOTICE
the recommended oil for a machine compartment. The "Oil Type These recommendations are subject to change without notice.
and Category" column MUST also be used. Consult your local Cat dealer for the most up to date
recommendations.
Note: The footnotes are an important part of the “Lubricant
Viscosities for Ambient Temperatures” tables. Read ALL Note: Non-Caterpillar commercial greases are as a group second
footnotes that pertain to the machine compartment that is in choice greases. Within this grouping of second choice greases
question. there are tiered levels of performance.
Note: Only use the oil type and the oil category that is NOTICE
recommended for the various machine compartments.
Cat does not warrant the quality or performance of non-Cat fluids
Note: Some machine compartments allow the use of more than and greases.
one oil type. For the best results, do not mix oil types.
Note: Different brand oils may use different additive packages to Caterpillar provides various greases that vary in performance
meet the various machine compartment performance from a moderate performance to an extremely high performance.
category/specification recommendations. For the best results, do These greases service the entire line of Caterpillar products in
not mix oil brands. the wide variety of climates throughout the world. From this
variety of Caterpillar grease products, you can find a Caterpillar
Note: The availability of the various Caterpillar oils will vary by grease that will meet or exceed the performance requirements
region. for almost every machine that is produced by any Original
Equipment Manufacturer (OEM), and for almost every machine
Note: After considering the information that is found in the application or equipment application.
associated footnotes, Caterpillar oils are the preferred oils. ALL
other oil type and categories that are listed in the applicable Before selecting a grease product, the performance
section are acceptable oils. requirements must be determined. Consult the grease
recommendations that are made by the OEM for the equipment.
Note: Do not use BIO oils as a replacement for Cat TDTO and TO- Then, consult with your Caterpillar dealer for a list of greases
4 oils. that have the performance specifications and the available
container sizes.
Table 1
Lubricant Viscosities for Ambient Temperatures Note: Always choose grease that meets or exceeds the
Compartment or System °C °F recommendations that are specified by the equipment
Oil Viscosities Min Max Min Max manufacturer for the application.
SAE 0W-20 −40 10 −40 50
SAE 0W-30 -40 30 -40 86
SAE 0W-40 -40 40 -40 104
SAE 5W-30 −30 30 −22 86
3
If it is necessary to choose a single grease to use for all of the Cat Advanced 3Moly Grease meets the NLGI certification of "GC-
equipment at one site, always choose a grease that meets or LB" . (This certification relates to extended service intervals in
exceeds the requirements of the most demanding application. automotive chassis points and in wheel bearings with disc
Remember that the products which barely meet the minimum brakes in automobiles, vans, and light trucks.)
performance requirements can be expected to barely produce
the minimum parts life. False economy is being used if a grease Note: If the application calls for a multipurpose grease with
is purchased with the lowest cost as the only consideration. molybdenum and Cat Advanced 3Moly Grease is not available,
Instead, use the grease that yields the lowest total operating consult the data sheets for the greases. Use a substitute that
cost. This cost should be based on an analysis that includes the meets or exceeds the performance characteristics of Cat
costs of parts, labor, downtime, and the cost of the amount of Advanced 3Moly Grease.
grease that is required.
Severe Applications
Note: When the grease in a joint is changed from one type of
grease to another or a grease from a different supplier is to be Caterpillar has greases which are made with a Calcium
used, it is generally recommended to purge all of the old grease Sulfonate Complex thickener. This type of grease is necessary
from the joint because some greases are not chemically for more severe applications. These greases provide more load
compatible. Consult your supplier in order to determine if the carrying (galling resistance), lower wear, longer working life,
greases are compatible. exceptional water washout, and resistance to corrosion.
If in doubt, Purge! Hammer Grease
Note: All Caterpillar brand greases are compatible with each Note: Refer to the Operation and Maintenance Manual for a
other. particular hammer for recommendations that relate to greases
for Caterpillar Hammers.
Cat Multipurpose Grease
Cat Ultra 5Moly Grease
Cat Multipurpose Grease is a National Lubricating Grease
Institute (NLGI) grade 2 grease. This grease is made with Cat Ultra 5Moly Greases are available in NLGI grades 0, 1, and 2.
petroleum base oil and a lithium complex thickener. Cat Cat Ultra 5Moly Greases are made with special blends of
Multipurpose Grease is formulated for use in applications that petroleum base oils and a Calcium Sulfonate Complex thickener.
have a low severity to a medium severity and moderate These greases also have 5% Molybdenum Disulfide (MoS 2 or
temperatures. “Moly”) and added tackifier. Cat Ultra 5Moly Greases are
specially formulated in order to protect all of the most heavily
Cat Multipurpose Grease meets the NLGI certification of "GC-LB" loaded joints in any Caterpillar machine against galling, wear,
. (This certification relates to extended service intervals in and corrosion. This protection is sustained while work is being
automotive chassis points and in wheel bearings with disc done in moderate temperatures and with wet working conditions
brakes in automobiles, vans, and light trucks.) or dry working conditions.
Note: If the application calls for a multipurpose grease and Cat Cat Ultra 5Moly Greases are formulated with special blends of
Multipurpose Grease is not available, consult the grease data naphthenic petroleum base oils that have low pour points. This
sheets. Use a substitute that meets or exceeds the performance allows the Cat Ultra 5Moly Greases to pump at lower
characteristics of Cat Multipurpose Grease. temperatures. The ability to pump Cat Ultra 5Moly Greases at
lower temperatures means added insurance that all of the
Cat White Assembly Grease grease joints in the machine will be adequately lubricated even if
the ambient temperature drops unexpectedly. This is particularly
Cat Multipurpose Grease is also available in an extra tacky important when the machine's critical lubrication points rely on
version, known as Cat White Assembly Grease. Cat White an automatic lubrication system.
Assembly Grease has the same formula and the same
performance as regular Cat Multipurpose Grease. One difference A significant challenge exists in order to get grease to pump into
between Cat Multipurpose Grease and Cat White Assembly the joints at low temperatures. Once the grease gets to the joint,
Grease is the white color. In addition, this grease has been made the grease must have extremely high resistance to galling, wear,
extra tacky in order to hold gaskets, O-rings, and needle fretting, water washout, and corrosion in order to adequately
bearings better in the assembly of engines, transmissions, and protect highly loaded joints.
other components.
Even under severely loaded conditions, the grease should
Cat Advanced 3Moly Grease preferably have a very long working life. In order to make
greases that meet these greater demands, a Calcium Sulfonate
Cat Advanced 3Moly Grease is an NLGI grade 2 grease. This Complex thickener with a properly blended naphthenic oil and/or
grease is made with petroleum base oil and a lithium complex a synthetic base oil is required. This is the reason that Caterpillar
thickener. This grease also has 3% Molybdenum Disulfide (MoS 2 uses these ingredients in Cat Ultra 5Moly Greases.
or “Moly”). Cat Advanced 3Moly Grease is formulated for use in
applications with low severity to high severity at moderate Cat Ultra 5Moly Greases also have 5% Moly, instead of the 0% to
temperatures. In addition, the molybdenum in Cat Advanced 3% that is found in most other greases. This additional Moly
3Moly Grease is a special grade that has a median particle size greatly improves the ability of the grease to protect parts from
of 3 microns in order to meet the special requirements of some damage in applications with severe impact (slamming). In
rolling element bearings. Cat Advanced 3Moly Grease is addition, the Moly in Cat Ultra 5Moly Grease is a special grade
recommended for heavily loaded pin joints, and high impact that has a median particle size of 3 microns in order to meet the
applications in machines such as track-type tractors , backhoe special requirements of some rolling element bearings.
loaders and skid steer loaders .
4
Cat Ultra 5Moly Greases are also made to be extra tacky. In Cat Desert Gold Grease has the ability to prevent galling and
some applications, the film of grease must adhere to the vertical wear at very hot temperatures under extremely severe loads and
surfaces. An example of this application is swing gears for conditions. In moderate temperatures, Cat Desert Gold Grease
excavators. Many conventional greases do not have enough of can be used in those extremely severe applications if an
the tacky characteristic in order to allow the grease to stay in improvement over Cat Ultra 5Moly Grease is desired.
place. In addition, many of these greases do not have the
performance in order to adequately protect the gear teeth in Cat Desert Gold Grease can be used in applications that require
these applications. the lubricant to last for very long periods of time because this
grease has an extremely high performance and long life.
Cat Ultra 5Moly Grease exceeds the NLGI certification of "GC-LB"
. (This certification relates to extended service intervals in Cat Desert Gold Grease exceeds the NLGI certification of "GC-LB"
automotive chassis points and in wheel bearings with disc . (This certification relates to extended service intervals in
brakes in automobiles, vans, and light trucks.) automotive chassis points and in wheel bearings with disc
brakes in automobiles, vans, and light trucks.)
Note: If the application calls for Cat Ultra 5Moly Grease and Cat
Ultra 5Moly Grease is not available, consult the data sheets for Note: If the application calls for Cat Desert Gold Grease and Cat
the grease. From these data sheets, use a substitute that meets Desert Gold Grease is not available, consult the data sheets for
the performance characteristics of Cat Ultra 5Moly Grease. the grease. From these data sheets, use a substitute that meets
the performance characteristics of Cat Desert Gold Grease. With
Cat Ultra 5Moly Grease is formulated not to contain lead, consideration given to the application, Cat Ultra 5Moly Grease ,
antimony, barium, zinc, phosphorous, or chlorine additives. Thus, or Cat Arctic Platinum Grease may perform adequately. However,
when Cat Ultra 5Moly Greases are compared to many other the use of these greases may require a different schedule for
types of grease, the Cat Ultra 5Moly Greases are more lubrication.
environmentally friendly.
Cat Desert Gold Grease is formulated not to contain lead,
Cat Desert Gold Grease antimony, barium, zinc, phosphorous, or chlorine additives. Thus,
when Cat Desert Gold Grease is compared to many other types
Cat Desert Gold Grease is formulated in order to protect the most of grease, the Cat Desert Gold Grease is more environmentally
severely loaded joints in Caterpillar machines against galling, friendly.
wear, and corrosion. This protection is sustained while work is
being done at moderate temperatures to very hot temperatures Cat Arctic Platinum
with wet conditions or dry conditions.
Cat Arctic Platinum Grease is formulated to protect the most
Cat Desert Gold Grease is an NLGI grade 2 grease. This grease is heavily loaded joints in Caterpillar machines against galling,
made with a synthetic base oil that has a very high viscosity and wear, and corrosion. With dependence on the consistency of the
a Calcium Sulfonate Complex thickener. This grease also has 5% grease, this protection is sustained, while work is being done in
Molybdenum Disulfide (MoS 2 or “Moly”) and tackifier. moderate temperatures and in temperatures that may reach a
temperature of −50 °C (−58 °F) . In addition, the conditions may
As the temperature changes, Cat Desert Gold Grease will be wet or dry. Cat Arctic Platinum Grease is available in NLGI
experience a minimal change in viscosity because the base is a grade 0.
synthetic oil. Because Cat Desert Gold Grease has a synthetic
base oil with a high viscosity, Cat Desert Gold Grease maintains Cat Arctic Platinum Grease is made with a synthetic base oil that
a thick lubricant film even at very hot temperatures. has a very low viscosity and a Calcium Sulfonate Complex
thickener. The performance is enhanced with 5% Molybdenum
Cat Desert Gold Grease is made with a Calcium Sulfonate Disulfide (MoS 2 or “Moly”) and tackifier.
Complex thickener. This provides the necessary protection
against galling, wear, fretting, water washout, and corrosion. Cat Because the base oil is synthetic, Cat Arctic Platinum Grease
Desert Gold Grease also has a very long life. This grease will has a minimal change in viscosity as the temperatures drop.
resist breakdown even when the application is under extremely Because the synthetic base oil has a very low viscosity, the Cat
heavy loads and with frequent oscillations. This protection is Arctic Platinum Grease that is made with this base oil has a
sustained while work is being done at moderate temperatures to minimal change in viscosity and flows easily as the temperature
very hot temperatures with wet conditions or dry conditions. drops. Cat Arctic Platinum Grease pumps easily at extremely low
temperatures. In fact, Cat Arctic Platinum Grease NLGI grade 0
Cat Desert Gold Grease has 5% molybdenum instead of the 0% to can be pumped through standard automatic lubrication systems
3% that is found in most other greases. This additional that are machine mounted and at temperatures down to −50 °C
molybdenum greatly improves the ability of the grease to protect (−58 °F) . This means that the grease can be pumped through
parts from damage in applications with severe impact those long unheated lines and into the required joints.
(slamming). In addition, the molybdenum in Cat Desert Gold
Grease is a special grade. This grade has a median particle size Cat Arctic Platinum Grease is made with Calcium Sulfonate
of 3 microns in order to meet the special requirements of some Complex thickener in order to provide the necessary protection
rolling element bearings. against galling, wear, fretting, water washout, and corrosion.
Cat Desert Gold Grease is made to be extra tacky. In some Cat Arctic Platinum Grease performs well for long periods of
applications, the film of grease must adhere to the vertical time. This grease resists breakdown even with extremely heavy
surfaces. An example of this application is swing gears for loads in applications with frequent oscillations. This grease
excavators. Many conventional greases do not have enough of provides protection that will be sustained in conditions that are
the tackifier to allow the grease to stay in place. In addition, wet or dry. Also, this grease will provide protection in moderate
many of these greases do not have the performance, particularly temperatures as well as extremely cold temperatures.
at high ambient temperatures, to adequately protect the gear
teeth in these applications.
5
Belt
Cat Arctic Platinum Grease has 5% of molybdenum instead of 0% Tightener,
Drive Shaft
Slip Joint,
or 3% that is found in most of the other greases. This additional Drive Shaft
Spline, Drive
molybdenum greatly improves the ability of the grease in order to Shaft
Universal
Joint, Fan
protect parts from damage in applications with severe impact Drive Pulley,
Hoist
(slamming). In addition, the molybdenum in Cat Arctic Platinum Control
Bellcrank,
Hoist
Large
amount of
Grease is a special grade. This molybdenum has a median Cylinder
Bearing,
idling. Short
to medium
hauls on
particle size of 3 microns in order to meet the special Oscillating
Hitch, Pump
Drive
Low well
maintained -30 40 -22 104 2 Multipurpose
Grease
requirements of some rolling element bearings. Universal
Joint, A-
level haul
roads.
Minimum
Frame total
Bearings, resistance
Steering
Cat Arctic Platinum Grease is made to be extra tacky. In some Cylinder
End,
applications, the film of grease must adhere to the vertical Steering
Linkage,
Steering Tie
surfaces. An example of this application is swing gears for Rod and Pin
Bearings,
excavators. Many conventional greases do not have enough Tachometer
Drive,
Tailgate
tackifier to adhere well to the vertical surfaces. This ability is Bearings
necessary in order to adequately protect the gear teeth in these

applications.
Table 3
Cat Arctic Platinum Grease has the ability to prevent galling and Recommended Grease for the Autolube System
wear at very cold temperatures under extremely severe loads Compartment or GreaseType NLGI Grade
°C °F
System Min Min
and conditions. In moderate temperatures, Cat Arctic Platinum
Cat 3Moly Grease NLGI Grade 2 -18 0
Grease can be used in the application if the compartment is
NLGI Grade 2 -7 20
sealed tightly in order to contain the grease.
Cat Autolube Cat Ultra 5Moly NLGI Grade 1 -18 0
System (1) (2) NLGI Grade 0 -29 -20
Cat Arctic Platinum Grease is sometimes used in applications
Cat Arctic Platinum NLGI Grade 0 -43 -45
that require the lubricant to last for very long periods of time.
Cat Desert Gold NLGI Grade 2 2 35
This is due to the fact that this grease has an extremely high
performance and this grease also has a long life.
Note: If the application calls for Cat Arctic Platinum Grease and Capacities (Refill)
no Cat Arctic Platinum Grease is available, consult the data
sheets for the grease. Use a substitute that most closely meets Operations and Maintenance Manual
the performance characteristics. SEBU7814 i03122041
Cat Arctic Platinum Grease is formulated not to contain lead, Table 1

antimony, barium, zinc, phosphorous, or chlorine additives. Thus, APPROXIMATE REFILL CAPACITIES
when Cat Arctic Platinum Grease is compared to many other Compartment or
types of grease, the Cat Arctic Platinum Grease is more Liters US Gal Imp Gal
System
environmentally friendly. Cooling System 67 17.7 14.7
Fuel Tank 355 93.8 78.1
Cat High Speed Ball Bearing Grease Engine Crankcase 41 10.8 9.0
Transmission 36 9.5 7.9
Cat High Speed Ball Bearing Grease is an NLGI grade 2 grease. Hoist, Steering, and
This grease is made with a petroleum base oil and a polyurea Brake System Tank 151 39.9 33.2
thickener. This grease is recommended for applications that Front Axle Differential 41 10.8 9.0
utilize roller bearings and ball bearings at low loads to moderate Center Axle
loads at high speed. Typical applications for this grease are 46 12.2 10.3
Differential
electric motors, alternators, and constant velocity (CV) joints for Rear Axle Differential 47 12.4 10.0
automotive products. Final Drives 5 1.3 1.1
Transfer Gear 18 4.7 4.0
Cat High Speed Ball Bearing Grease is formulated not to contain
lead, antimony, barium, zinc, phosphorous, or chlorine additives.
Thus, when Cat High Speed Ball Bearing Grease is compared to S O S Information
many other types of grease. The Cat High Speed Ball Bearing
Operations and Maintenance Manual
Grease is more environmentally friendly.
SEBU7882 i07445339
Table 2
Grease Application Chart S·O·S Services is a highly recommended process for Cat
Vehicle Application Load Factor
Typical
Application °C
Ambient Temperature Range
°F NLGI Grade Recommended
customers to use in order to minimize owning and operating cost.
Point (1) (Load and
Speed) Min Max Min Max
Grease Type
Customers provide oil samples, coolant samples, and other
Articulated
Trucks
Long haul
time with
-35 40 -31 104 1 machine information. The dealer uses the data in order to
frequent
adverse provide the customer with recommendations for management of
grades.
High
Continuous
use on Ultra 5Moly the equipment. In addition, S·O·S Services can help determine
Grease
poorly
maintained
-30 50 -22 122 2
the cause of an existing product problem.
haul roads
with high
rolling
resistance Refer to Special Publication, SEBU6250, "Caterpillar Machine
Normal load
and haul
time.
Fluid Recommendations" for detailed information concerning
Varying load
and haul S·O·S Services.
road Advanced
Medium conditions. -20 40 -4 104 2 3Moly Grease
Some (2)
adverse
grades.
The effectiveness of S·O·S Services is dependent on timely
Some high
rolling
resistance
submission of the sample to the laboratory at recommended
intervals.
6
Refer to the Operation and Maintenance Manual, "Maintenance Refrigerant Dryer - Replace
Interval Schedule" for a specific sampling location and a service
hour maintenance interval. Operations and Maintenance Manual
SEBU7498 i01836475
Consult your Cat dealer for complete information and assistance
in establishing an S·O·S program for your equipment.
WARNING
System Pressure Release
Personal injury can result from contact with refrigerant.
SEBU7814 i03711228 Contact with refrigerant can cause frost bite. Keep face and
hands away to help prevent injury.
WARNING Protective goggles must always be worn when refrigerant lines
are opened, even if the gauges indicate the system is empty of
Personal injury or death can result from sudden machine refrigerant.
movement.
Always use precaution when a fitting is removed. Slowly loosen
Sudden movement of the machine can cause injury to persons the fitting. If the system is still under pressure, release it slowly
on or near the machine. in a well ventilated area.
To prevent injury or death, make sure that the area around the Personal injury or death can result from inhaling refrigerant
machine is clear of personnel and obstructions before operating through a lit cigarette.
the machine.
Inhaling air conditioner refrigerant gas through a lit cigarette or
other smoking method or inhaling fumes released from a flame
contacting air conditioner refrigerant gas, can cause bodily harm
WARNING or death.
Personal injury can result from hydraulic oil pressure and hot oil. Do not smoke when servicing air conditioners or wherever
refrigerant gas may be present.
Hydraulic oil pressure can remain in the hydraulic system after
the engine has been stopped. Serious injury can be caused if Use a certified recovery and recycling cart to properly remove
this pressure is not released before any service is done on the the refrigerant from the air conditioning system.
hydraulic system.
Make sure all of the attachments have been lowered, oil is cool Park the machine on a level surface. Engage the parking brake.
before removing any components or lines. Remove the oil filler Lower the dump body and shut off the engine.
cap only when the engine is stopped, and the filler cap is cool
enough to touch with your bare hand.
1. Lower the dump body.

2. Shut off the engine.
3. Turn the key to the ON position before moving control levers.
4. Move the control levers through the full range of travel. This
will relieve any pressure that may be present in the implement
hydraulic system.
5. Turn steering wheel several times in both directions.
6. Depress the brake pedal repeatedly. This will relieve any
pressure that may be present in the brake hydraulic system. The in-line refrigerant dryer is located behind panel (1) on the
right side of the cab.
7. Press the breaker/relief valve release button on the tank
before loosening the cap. Remove the panel in order to gain access to the in-line
refrigerant dryer. The panel is held in place by seven bolts and
8. Slowly loosen the filler cap in order to release the pressure. washers, which should be retained.
9. Tighten the filler cap. Note: One of the bolts is located under cover (2) .
10. The pressure in the hydraulic system has been released. Refer to Service Manual, SENR5664, "In-Line Refrigerant Dryer -
Lines and components can be removed. Remove and Install" for the replacement procedure of the in-line
refrigerant dryer.
Every 2000 Service Hours Note: When you operate the machine in a climate with high
humidity, replace the in-line refrigerant dryer after every 1000
service hours or 6 months.
7
Suspension System - Check
SEBU7498 i06704466
WARNING
The suspension system may drop the machine suddenly leaving

no clearance between the axle housing, main frame, tires, and
mud guards.
Working in these areas can result in personal injury or death by
crushing.
Park the machine on level ground and block the front frame
before you go under the machine.
1. Disengage the differential locks. Bring the machine to a gentle

stop on firm level ground.
2. Release the service brake. Wait for one second before
applying the parking brake. 1. Lift the panel that covers the hydraulic tank.
3. Install suitable stands under the front frame.
Illustration 1 g01043895 2. Remove filler cap (2) . Remove the filler cap slowly in order to
gradually relieve any system pressure.
4. Measure distance (A) . Distance (A) is the distance between
the mounting pins of the suspension cylinder. Dimension (A) 3. Unscrew breather (1) . Remove the breather from the machine.
should be 700 ± 10 mm (27.6 ± 0.39 inch) .
4. Clean the breather in nonflammable solvent. Shake the
Note: Measure distance (A) when the machine is cool. breather until the breather is dry.
5. If the suspension height is not correct, consult your Caterpillar 5. Inspect the breather for damage. If the breather is damaged,
dealer. Special tools and procedures are required to adjust the replace the breather.
height of the front suspension.
6. Install the clean breather.
6. Remove the stands.
7. Install the filler cap and close cover (1) .
Hydraulic Tank Breather -
Clean/Inspect/Replace Frame and Body - Inspect
SEBU7347 i02251728
SEBU7814 i02235389
All earthmoving equipment is prone to a high degree of wear.
The tank is located on the left side of the tractor. Regular inspections for structural damage are necessary.
These inspections are particularly important for this type of
machine as the machines can experience difficult work cycles.
Regular inspections can minimize the risk of accidents. Regular
inspections can reduce down time.
The interval between these inspections depends on the factors
that follow.
8
• The age of the machine
• The severity of the application
• The loads that have been carried on the machine
• The condition of the haul road
• The amount of routine servicing that has been carried out
These inspections should be carried out at intervals no longer
than 1000 service hours or six months. Older machines, or
machines that are operating in severe applications will require
more frequent inspections.
If the machine has been involved in a collision, or if the machine
has been involved in any kind of accident, the machine must be
inspected thoroughly. Inspect the machine regardless of the date
of the last inspection.
The machine must be clean before the machine is inspected.
Proper repair of frames and structures requires specific
knowledge of the following subjects. Inspect the following areas:
• Materials that have been used to manufacture the frame • Front engine mountings (1)
members
• Steering cylinder lugs (2)
• Frame member construction
• Cab mounts (3)
• Repair techniques that are recommended by the
manufacturer. • Suspension towers (4)
Consult your Caterpillar dealer if repairs are necessary. Your • Mounting bosses (5) for the front suspension cylinders
Caterpillar dealer is qualified to carry out repairs on your behalf.
• Rear subassembly and hitch lugs (6)
All repairs should be carried out by a Caterpillar dealer. If you
carry out your own repairs, contact your Caterpillar dealer for Front Suspension Frame
advice about proper repair techniques.
Particular attention should be given to all welded structures. The
following items should be thoroughly inspected for cracks and
for defects:
• Front frame
• Front suspension frame
• Rear frame
• Oscillating hitch
• A-frames
• Dump body
Inspect the following areas:
NOTICE • Axle mountings (7)
The areas highlighted are of particular importance but other
areas must not be neglected. The entire structure must be • Pivots (8) for the A-frame
carefully examined.
• Stabilizer rod (9) and mountings
Front Frame Oscillating Hitch
9
Dump Body
The entire oscillating hitch should be thoroughly inspected. Hitch Illustration 6 g01024823
pin lugs (10) and steering cylinder lugs (11) are particularly
important, but all areas of the oscillating hitch must be checked. Inspect the following areas:
Rear Frame • The mounting brackets (19) for the hoist cylinders
• The mountings (20) for the dump body
Radiator Mounts

• Front plate (12) Illustration 7 g01134570
• Mountings (13) for the body • Radiator Mountings (21)

• Oscillating hitch tube (14) Mounts for the Suspension
• Mounting brackets (15) for the hoist cylinders
• Spindles (16) for the equalizer arms
Rear Frames
Check the mounts for cracks and for damage. If damage is

visible, contact your Caterpillar dealer for more information.
Note: Inspect the mounts for the suspension after the initial 2000
Illustration 5 g01024822 service hours and every 250 service hours thereafter.
Engine Valve Lash - Check
• Axle mountings (17) Operations and Maintenance Manual
• The pivots (18) for the A-frames SEBU7814 i02680477
10
Engine valve lash adjustments should be made at every 2000 Brake System Air - Purge
hour interval.
Note: Engine valve lash adjustment on new engines or on SEBU8345 i02239865
reconditioned engines should be made at 500 hours.
Maintenance is recommended by Caterpillar for engine valve Routine purging of the service brake lines ensures that the
lash adjustments. The maintenance for engine valve lash is part system is free of air. Purge the brake groups for the center axle
of the lubrication and preventive maintenance schedule in order and purge the brake groups for the front axle.
to provide maximum engine life. Refer to the appropriate Systems Operation, Testing and
Adjusting, "Service Brake Air - Purge" for more information.
NOTICE
Only qualified service personnel should perform this Engine Valve Rotators - Inspect
maintenance. Refer to the Service Manual or your Caterpillar
Dealer for the complete engine valve lash adjustment procedure. Operations and Maintenance Manual
SEBU7054 i00128925
WARNING
WARNING
Be sure the engine cannot be started while this maintenance is
being performed. To prevent possible injury, do not use the When inspecting the valve rotators, protective glasses or face
starting motor to turn the flywheel. shield and protective clothing must be worn, to prevent being
burned by hot oil spray.
Hot engine components can cause burns. Allow additional time
for the engine to cool before measuring/adjusting engine valve Inspect the engine valve rotators after the valve clearances have
lash clearance. been set.
NOTICE 1. Start the engine and run the engine at low idle.
Operation of Caterpillar Engines with improper engine valve lash 2. Watch the top surface of each valve rotator. When the intake
adjustments will reduce the engine efficiency. This reduced valve or the exhaust valve closes, the engine valve rotator
efficiency could result in excessive fuel usage and/or shortened should turn slightly.
engine component life.
If an intake valve or an exhaust valve fails to rotate, consult your
Measure the engine valve lash with the engine stopped. To Caterpillar Dealer.
obtain an accurate measurement, allow at least 20 minutes for
the valves to cool to engine cylinder head and block
temperature. Differential and Final Drive Oil - Change
Brake Accumulator (Service) - Check SEBU7814 i02232197
Operations and Maintenance Manual NOTICE

SEBU7347 i02253515
Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting, and
WARNING repair of the product. Be prepared to collect the fluid with
suitable containers before opening any compartment or
Personal injury or death can result from improper accumulator disassembling any component containing fluids.
charging. Refer to Special Publication, NENG2500, "Dealer Service Tool
Dry Nitrogen is the only gas approved for use in the Catalog" for tools and supplies suitable to collect and contain
accumulator. Charging the accumulator with oxygen will cause fluids on Cat ® products.
an explosion. This danger will not happen if nitrogen cylinders Dispose of all fluids according to local regulations and
with standard CGA (Compressed Gas Association, Inc.) Number mandates.
580 connections are used.
When ordering nitrogen gas, be sure that the cylinders are 1. Operate the machine until the differential oil is warm. Park the
equipped with CGA Number 580 connections. Do not use color machine on a level surface.
codes or other methods of identification to tell the difference
between nitrogen and oxygen cylinders
Never use an adapter to connect your nitrogen charging group
to a valve outlet used on both nitrogen, oxygen, or other gas
cylinders. BE SURE YOU USE DRY NITROGEN (99.8% purity).
Refer to Systems Operation, Testing and Adjusting, "Brake

Accumulator (Service) - Test and Charge" for more information.
11
Illustration 1 g01125937 Illustration 3 g01125942
2. Slowly move the machine until plug (1) is at the lowest point 10. Slowly move the machine until "Oil Level" mark (4) on the rear
on the rear left final drive. Engage the parking brake and shut off right final drive is horizontal. Engage the parking brake and shut
the engine. off the engine.
3. Wipe the area around plug (1) on the final drive. Remove plug 11. Remove plug (1) from the front right final drive and add oil to
(1) . Remove the plug slowly in order to gradually release any the final drive. Refer to Operation and Maintenance Manual,
system pressure. Allow the oil to drain into a suitable container. "Capacities (Refill)" and Operation and Maintenance Manual,
"Lubricant Viscosities" .
4. Clean plug (1) and inspect the O-ring seal for damage.
Lubricate the O-ring seal with gear oil and install the plug. Fill the final drive to the bottom of the plug hole. Allow the oil
to flow along the axle housing and settle at a common level.
Note: The plug is magnetic. Check the plug for ferrous
particles that may indicate wear of the differential and final 12. Install plug (1) .
drive components.
13. Repeat steps 9 through 12 for the rear left final drive.
5. Start the engine and disengage the parking brake.
14. Remove level plug (3) from the rear axle. Add oil to the
6. Repeat Step 2 through Step 4 for the rear right final drive. differential until the differential is full. Refer to Operation and
Maintenance Manual, "Capacities (Refill)" and Operation and
Maintenance Manual, "Lubricant Viscosities" .
15. Install the plug.
16. Repeat the procedure for the center differential and final
drives.
Repeat the procedure for the front differential and final drives.
17. Start the engine.
18. Operate the machine for a few minutes in order to circulate
the oil.
Illustration 2 g01125939 19. Shut off the engine.
7. Remove drain plug (2) and level plug (3) from the rear axle. 20. Check the oil level of the differential and final drives. Refer to
Remove the drain plug slowly in order to gradually release any Operation and Maintenance Manual, "Differential and Final Drive
system pressure. Allow the oil to drain into a suitable container. Oil Level - Check" .
8. Clean the drain plug and inspect the O-ring seal for damage.
Lubricate the O-ring seal with gear oil and install the drain plug. Cooling System Coolant Sample (Level 2) -
Obtain
Note: The drain plug is magnetic. Check the plug for ferrous
particles that may indicate wear of the differential and final Operations and Maintenance Manual
drive components. SEBU7814 i06814691
9. Start the engine and disengage the parking brake.
12
NOTICE NOTICE
Care must be taken to ensure that fluids are contained during Care must be taken to ensure that fluids are contained during
performance of inspection, maintenance, testing, adjusting, and performance of inspection, maintenance, testing, adjusting, and
repair of the product. Be prepared to collect the fluid with repair of the product. Be prepared to collect the fluid with
suitable containers before opening any compartment or suitable containers before opening any compartment or
disassembling any component containing fluids. disassembling any component containing fluids.
Refer to Special Publication, NENG2500, "Dealer Service Tool Refer to Special Publication, NENG2500, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain Catalog" for tools and supplies suitable to collect and contain
fluids on Cat ® products. fluids on Cat ® products.
Dispose of all fluids according to local regulations and Dispose of all fluids according to local regulations and
mandates. mandates.
Obtain the sample of the coolant as close as possible to the The oil filter elements and the screen are located inside tank (1) .
recommended sampling interval. Supplies for collecting samples Lift panel (2) in order to access these components. Reposition
can be obtained from your Caterpillar dealer. the panel once these components have been serviced.
Refer to Operation and Maintenance Manual, "Cooling System
Coolant Sample (Level 1) - Obtain" for the guidelines for proper
sampling of the coolant.
Submit the sample for Level 2 analysis.
Reference: For additional information about coolant analysis,
refer to Special Publication, SEBU6250, "Caterpillar Machine
Fluids Recommendations" or consult your Caterpillar dealer.
Every 1000 Service Hours

Hydraulic System Oil Filter and Screen -
Clean/Inspect/Replace Illustration 2 g01127691
Operations and Maintenance Manual 1. Remove filler cap (3) . Remove the filler cap slowly in order to
SEBU7814 i02228175
gradually relieve any system pressure.
2. Unscrew bolt (4) and lift cover (5) . The screen assembly is
fastened to the cover.
13
1. To relieve the downward force, position a hydraulic jack under
the tractor portion of the hitch and slightly raise the hitch.
2. Loosen jam nuts (1) . Turn adjusting screws (2) clockwise onto
the top of the thrust ring. Turn the adjustment screws evenly in
Illustration 3 g00686996 order to take up excessive clearance. Do not overtighten the
screws.
3. Remove cotter pin (6) and washer (7) from bolt (4) . This will
allow the removal of the filter elements from the inside of the 3. Tighten jam nuts (1) .
screen.
Adjusting the Thrust Plate
Type 1
4. There are two filter elements (8) within screen (9) . Remove
both elements and discard both filter elements.
5. Wash the screen in clean nonflammable solvent. Inspect the 1. Remove two bolts (4) and remove locking plate (5) .
screen for damage. If necessary, replace the screen. Allow the
screen to dry.
6. Install two new filter elements into the clean screen.
7. Install cotter pin (6) and washer (7) on bolt (4) .
8. Install bolt (4) and cover (5) .
9. Replace filler cap (3) .
Oscillating Hitch - Adjust

SEBU7814 i06084496
1. Relieve the tension from the oscillating hitch. Place a large
block of timber behind the rear wheels of the machine and 2. Reposition locking plate (5) against thrust flange (3) . Engage
reverse the machine against the block. both dowels (7) into two of the holes in thrust flange (3) .
2. Install the steering frame lock. Refer to Operation and 3. Insert a 3/4 inch square drive through the hole in locking plate
Maintenance Manual, "Steering Frame Lock" . (5) . The square drive will prevent locking plate (5) from rotating
clockwise.
Adjusting Hitch Pin Clearance 4. Use a suitable wrench on the square drive in order to turn
thrust flange (5) clockwise until all end play has been removed.
14
5. If necessary, turn the thrust flange counterclockwise in order 4. If necessary, turn the thrust flange counterclockwise in order
to line up the holes. Insert the square drive into the hole on to line up the holes. Insert the square drive into the hole on
locking plate (5) in order to rotate the thrust flange locking plate in order to rotate the thrust flange
counterclockwise. Rotate the thrust flange as far as the first counterclockwise. Rotate the thrust flange as far as the first
correct hole alignment. correct hole alignment.
6. Remove the square drive and reposition locking plate (5) and 5. Remove the square drive and install bolts (1) .
bolts (4) .
6. Remove the hydraulic jack.
7. Remove the hydraulic jack.
7. Remove the steering frame lock.
8. Remove the steering frame lock.
Rollover Protective Structure (ROPS) - Inspect
Type 2
SEBU7814 i01400959
NOTICE
Do not attempt to straighten the ROPS structure. Do not repair
the ROPS by welding reinforcement plates to the structure.
If there are any cracks in the welds, in the castings, or in any
metal section of the ROPS, consult your Caterpillar dealer for
repairs.
Drive shaft removed for clarity
1. Remove four bolts (1) .

The ROPS is held in position by four mounting bolts (1) , four pins
(2) and four rubber mounts (3) . One mounting bolt, one pin and
one rubber mount is located on each corner of the ROPS.
Carry out the following steps in order to inspect the ROPS:
1. Park the machine on a level surface. Engage the parking
brake. Lower the dump body and shut off the engine.
2. Install the steering frame lock. Refer to Operation and
Maintenance Manual, "Steering Frame Lock" .
3. Raise the hood in order to access the front ROPS mountings.
Refer to Operation and Maintenance Manual, "Hood Control" .
Drive shaft removed for clarity
2. Insert a 3/4 square drive through the hole (3) in locking plate
(2) . The square drive will prevent the locking plate from the
rotating clockwise.
3. Use a suitable wrench on the square drive in order to turn
thrust flange clockwise until there is not any movement.
15
4. Remove cover (4) at the left side rear of the cab by removing 10. Tighten mounting bolts (1) to a torque of 900 ± 100 N·m (664 ±
four bolts (5) and retaining the four bolts. This will enable access 74 lb ft) .
to inspect the left side rear mounting.
11. Use the bolts that were retained earlier in order to secure the
covers and panels. Secure the covers and panels in the following
order: fender panel (10) , panel (8) , cover (9) , cover (7) , tank
cover (6) and cover (4) .
12. Close the hood. Refer to Operation and Maintenance Manual,
"Hood Control" .
13. Remove the steering frame lock. Refer to Operation and
Torque Converter and Transmission Oil -

Change
Illustration 3 g00738528 Operations and Maintenance Manual
SEBU7347 i03320803
5. Remove tank cover (6) on the fuel tank and retain the bolts.
This will enable removal of fender panel (10) later. NOTICE
performance of inspection, maintenance, testing, adjusting and
repair of the product. Be prepared to collect the fluid with
disassembling any component containing fluids.
Refer to Special Publication, NENG2500, "Caterpillar Dealer
Service Tool Catalog" for tools and supplies suitable to collect
and contain fluids on Caterpillar products.
Dispose of all fluids according to local regulations and
mandates.
Illustration 4 g00738535 WARNING

6. Remove cover (7) that covers the radiator on the right side of
the machine and retain the bolts. This will enable removal of Hot oil and hot components can cause personal injury. Do not
panel (8) later. allow hot oil or hot components to contact skin.
Operate the machine until the torque converter and transmission

oil is warm. Park the machine on a level surface. Engage the
parking brake. Lower the dump body and shut off the engine.
1. Raise the hood. Refer to Operation and Maintenance Manual,
"Hood Control" .
The oil level dipstick is integral with the oil filler cap for the
torque converter and transmission oil. The oil filler cap is
located near the air cleaner housing.
7. Remove panel (8) on the right side of the cab and retain the
bolts.
Note: One of the bolts is located under cover (9) .
Remove fender panel (10) and retain the bolts.
8. Inspect the following items: mounting bolts (1) , pins (2) and
rubber mounts (3) . Replace any damaged pins, bolts or rubber
mounts with original equipment parts. Illustration 1 g01126900
9. Inspect the ROPS for bolts that are loose or damaged. Bolts 2. Clean the area around filler cap (1) and filler tube (2) . Turn the
that are loose, damaged or missing should be replaced by handle on the dipstick in order to remove the dipstick. Remove
original equipment parts only. the dipstick in order to allow the oil to drain.
16
Note: Before you change the oil, block the front frame of the 11. Ensure that the parking brake is engaged. Engage the service
machine. brakes. Slowly operate the transmission control in order to
circulate the oil.
13. Replace Plate (3) .
14. Wait for five minutes before removing dipstick (1) . Turn the
handle on the dipstick in order to remove the dipstick.
15. Clean the dipstick by wiping.
16. Install the dipstick fully.
17. Check the oil level on the COLD SAFE START side of the
dipstick. The engine can be started if the oil is anywhere within
Illustration 2 g01127725 the shaded area. If necessary, add oil.
3. Remove plate (3) in order to access the drain plug for the 18. Lower the hood.
torque converter and transmission oil.
19. Start the engine. Operate the machine until the temperature
Note: Plate (3) is located on the right side of transmission of the oil is at normal operating temperature.
guard (4) in front of the front axle.
20. Raise the hood.
21. Check the torque converter and transmission oil level on the
"FULL HOT LOW IDLE" side of the dipstick. Refer to Operation and
Maintenance Manual, "Torque Converter and Transmission Oil
Level - Check" . If necessary, add oil.
23. Close the hood.
Ecology Drain
"Hood Control" .
4. Clean the area around drain plug (5) . The oil level dipstick is integral with the oil filler cap for the
torque converter and transmission oil. The oil filler cap is
5. Remove the drain plug and the O-ring seal and retain the drain located near the air cleaner housing.
plug and the O-ring seal. Allow the oil to drain into a suitable
container. 2. Clean the area around filler cap (1) and filler tube (2) . Turn the
handle on the dipstick in order to remove the dipstick. Remove
6. Inspect the O-ring seal for the drain plug. If necessary, replace the dipstick in order to allow the oil to drain.
the O-ring seal. Lubricate the O-ring seal with transmission oil.
Install the O-ring seal and the drain plug.
7. Remove the oil filter for the torque converter and transmission
oil. Discard the oil filter. Install a new oil filter. Refer to Operation
and Maintenance Manual, "Torque Converter and Transmission
Oil Filter - Replace" .
8. Fill the transmission with new oil through filler tube (2) . Fill the
transmission to the "COLD SAFE START" range on the oil level
dipstick. Refer to the Operation and Maintenance Manual,
"Capacities (Refill)" , Operation and Maintenance Manual,
"Lubricant Viscosities" and Operation and Maintenance Manual,
"Torque Converter and Transmission Oil Level - Check" .
9. Guide the dipstick down the filler tube and turn the handle on
the dipstick in order to make the seal between the filler tube and 3. Clean the area around filler cap (1) and filler tube (2) . Turn the
the filler cap. handle on the dipstick in order to remove the dipstick. Remove
the dipstick in order to allow the oil to drain.
10. Start the engine. Run the engine at low idle. Inspect the
transmission for leaks. Note: Before you change the oil, block the front frame of the
machine.
17
15. Clean the dipstick by wiping.
16. Install the dipstick fully.
17. Check the oil level on the COLD SAFE START side of the
dipstick. The engine can be started if the oil is anywhere within
the shaded area. If necessary, add oil.
18. Lower the hood.
19. Start the engine. Operate the machine until the temperature
of the oil is at normal operating temperature.
20. Raise the hood.
21. Check the torque converter and transmission oil level on the
4. Remove plate (3) in order to access the drain plug for the "FULL HOT LOW IDLE" side of the dipstick. Refer to Operation and
torque converter and transmission oil. Maintenance Manual, "Torque Converter and Transmission Oil
Level - Check" . If necessary, add oil.
Note: Plate (3) is located on the right side of transmission
guard (4) in front of the front axle. 22. Shut off the engine.
23. Close the hood.
Transfer Gear Oil - Change

SEBU7814 i02251691
NOTICE
5. Clean the area around drain plug (5) . Refer to Special Publication, NENG2500, "Dealer Service Tool
Catalog" for tools and supplies suitable to collect and contain
6. Remove the drain plug. Install 6B-3156 Pipe Nipple in order to fluids on Cat ® products.
unseat the drain valve. Allow the oil to drain into a suitable Dispose of all fluids according to local regulations and
container. mandates.
7. Remove the pipe nipple. Inspect the drain plug and the seal for
damage. If the drain plug or the seal are damaged, replace the
damaged components. WARNING
Install the drain plug and the seal. Hot oil and hot components can cause personal injury. Do not
allow hot oil or hot components to contact skin.
8. Remove the oil filter for the torque converter and transmission
oil. Discard the oil filter. Install a new oil filter. Refer to Operation
and Maintenance Manual, "Torque Converter and Transmission Operate the machine until the oil is warm and the oil is well
Oil Filter - Replace" . circulated. Park the machine on a level surface. Ensure that the
parking brake is fully engaged. Lower the dump body and shut off
9. Guide the dipstick down the filler tube and turn the handle on the engine.
the dipstick in order to make the seal between the filler tube and
the filler cap.
10. Start the engine. Run the engine at low idle. Inspect the
transmission for leaks.
11. Ensure that the parking brake is engaged. Engage the service
brakes. Slowly operate the transmission control in order to
circulate the oil.
13. Replace Plate (3) .
14. Wait for five minutes before removing dipstick (1) . Turn the Illustration 1 g00740248
handle on the dipstick in order to remove the dipstick.
18
Drain plug (1) for the transfer gear is located on the bottom of 10. Start the engine. Operate the machine until the oil is at
the transfer gear case. operating temperature. Inspect the transfer gear case for leaks.
Note: Before you change the oil, block the front frame of the 11. Remove the oil filler cap and check the oil level on the oil
machine. level gauge.
1. Remove the drain plug and allow the oil to drain into a suitable Note: Refer to Operation and Maintenance Manual, "Transfer
container. Gear Oil Level - Check" for more information.
2. Clean the drain plug and install the drain plug. 12. Clean the oil level gauge and the oil filler cap.
13. Install the oil filler cap and tighten.
15. Clean up oil spills.
16. Lower the hood.
Transfer Gear Oil Filter - Replace

SEBU7814 i01976318
3. Remove bolts (2) and cover (3) from the machine. This will WARNING
allow access to the drain plug for the transfer gear oil tank.
The drain plug is located underneath the machine on the front Hot oil and hot components can cause personal injury. Do not
left side. allow hot oil or hot components to contact skin.
4. Remove the drain plug and allow the oil to drain into a suitable NOTICE
container.
5. Install the drain plug, cover (3) , and bolts (2) . performance of inspection, maintenance, testing, adjusting, and
6. Raise the hood. suitable containers before opening any compartment or
Refer to Special Publication, NENG2500, "Dealer Service Tool
fluids on Cat ® products.
mandates.
Park the machine on a level surface. Ensure that the parking

brake is fully engaged. Lower the dump body and shut off the
engine.
Drain the oil before removing the oil filter. Refer to Operation and
Maintenance Manual, "Transfer Gear Oil - Change" for
information on draining the oil.
Note: Before you change the filter, block the front frame of
7. Oil filler cap (4) for the transfer gear oil tank is located on the the machine.
left side of the engine compartment. The oil level gauge is
attached to the oil filler cap.
8. Unscrew and then remove the oil filler cap. Add the oil for the
transfer gear.
Refer to Operation and Maintenance Manual, "Capacities
(Refill)" and refer to Operation and Maintenance Manual,
"Lubricant Viscosities" .
9. Clean the oil level gauge and the oil filler cap. Install the oil
filler cap.
19
Every 500 Service Hours
Automatic Lubrication Filler Filter - Clean
SEBU7814 i06929014
Autolube - If Equipped
The oil filter for the transfer gear is located on the rear of the tractor on the right side of
the rear frame.
1. Clean the outside of the oil filter for the transfer gear.
2. Remove the oil filter with a strap type wrench. Discard the
used oil filter properly.
Refer to Operation and Maintenance Manual, "Oil Filter -
Inspect" .
3. Clean the oil filter base.
4. Apply a thin coat of oil to the seal of the new oil filter.
5. Install the new oil filter by hand. When the seal contacts the
oil filter base, turn the oil filter by 270° more. This will tighten the
oil filter sufficiently.
Transmission and Transfer Gear Breather - (1) Reservoir
Clean/Replace (2) Dust Cap
(3) Filler Tube Assembly
Operations and Maintenance Manual 1. Remove dust cap (2) from reservoir (1) .
SEBU7814 i02250997
2. Clean filler tube assembly (3) and the coupling on the filler
tube assembly.
WARNING
3. Remove filler tube assembly (3) and the coupling.
Install cab prop pin before working under raised cab to prevent it
from falling which could result in injury or death. 4. Remove the grease fitting from the filter and clean the filter.
5. Clean the filter with solvent and compressed air. Check the
filter for cracks. If any cracks exist, replace the filter.
6. Replace the grease fitting in the filter.
7. Fill the filter with grease.
8. Install the filter.
9. Install the filter assembly onto filler tube assembly (3) .
10. Install filler tube assembly (3) and dust cap (2) .
Axle Breathers - Clean/Replace

(1) Transfer Gear Breather Operations and Maintenance Manual
(2) Transmission Breather SEBU7814 i01981266
1. Park the machine on a level surface. Engage the parking brake Park the machine on a level surface. Move the parking brake
and shut off the engine. control to the ENGAGED position. Lower the body and shut off
2. Remove the breathers. the engine.
3. Wash the breathers in clean nonflammable solvent. Dry and Install the Steering Frame Lock. Refer to Operation and
inspect the breathers. Install the breathers. If a breather is Maintenance Manual, "Steering Frame Lock" .
damaged, install a new breather.
20
Remove the Steering Frame Lock once all the axle breathers are
installed. Refer to Operation and Maintenance Manual, "Steering
Frame Lock" .
Belts - Inspect/Adjust/Replace
SEBU7814 i02210445
The engine is equipped with a belt that drives the alternator and
the air conditioner.
Note: The engine is equipped with a belt tensioner that
Illustration 1 g00679632 automatically adjusts the belt to the correct tension.
Front axle breather (1) is mounted on the left side of the front 1. Park the machine on a level surface. Engage the parking
frame. brake. Shut off the engine.
"Hood Control" .
3. Remove the pulley guard.
4. Inspect drive belt (1) . Check the belt for wear, fraying or
cracking. If the belt is damaged, replace the belt.
Center axle breather (2) is mounted on the right side of the rear
frame.
5. If belt (1) requires replacement, insert a square drive into the

hole in tensioner (3) and turn counterclockwise in order to
release the tension from the belt.
6. Remove the belt from the engine.
7. In order to Install a new belt, insert a square drive into the
hole in tensioner (3) and turn counterclockwise.
Illustration 3 g00679629 8. Install belt (1) in the following order: tensioner (3) , idler (2) ,
drive pulleys (5) and idler (4) .
Rear axle breather (3) is mounted on the right side of the rear
frame. 9. Install the pulley guard.
Note: Before you remove the breathers, block the front frame 10. Lower the hood. Refer to Operation and Maintenance
of the machine. Manual, "Hood Control" .
1. Remove each axle breather. Brake Pads - Check
2. Wash each breather in a clean nonflammable solvent. Operations and Maintenance Manual
SEBU7814 i07945762
3. Shake each breather until the breather is dry.
4. Install each breather. A tool can be manufactured in order to facilitate measurements
by using the following information.
If any of the axle breathers are damaged, replace the damaged
breather.
21
Fabricate a tool from suitable black steel stock or suitable mild

steel bar. Refer to Illustration 1 and Table 1 .
Table 1 Illustration of the correct method of taking a measurement with the tool
Dimension The step on the tool is indicated in the Illustration with an arrow.
A 235 ± 5 mm (9.25 ± 0.20 inch)
B 82 ± 0.25 mm (3.23 ± 0.01 inch) (1)
Insert the tool into one of the holes on the caliper until the end of
the tool touches the brake lining or the step on the tool touches
C 63 ± 0.25 mm (2.48 ± 0.01 inch) (1)
the caliper. Refer to Illustration 3 and Illustration 4 .
D 5.0 ± 0.25 mm (0.20 ± 0.01 inch) diameter
E 10.0 ± 0.25 mm (0.40 ± 0.01 inch) diameter The tool has two ends of different lengths. Due to the thickness
F 0.5 mm (0.02 inch) max radius of the casting, there is approximately a 20 mm (0.80 inch)
difference between the depth of the two holes in the casting.
Ensure that the correct end of the tool is used in the correct hole
for measuring the thickness of the brake linings.
When the pads are worn, the step on the tool will touch the
caliper. When this happens, inspect the brake linings. This
indicator will show that approximately 90% of the life of the
brake lining has been reached. Individual measurements must be
recorded for rotors which have been machined or excessively
worn.
Note: The gauge needs to be used in both holes because lining
pads might not wear evenly.
Braking System - Test

SEBU7814 i04045434
WARNING
Personal injury can result if the machine moves while testing.

Illustration 2 g01145658 If the machine begins to move during test, reduce the engine
Typical example speed immediately and engage the parking brake.
In order to measure the thickness of the brake linings, locate the
two holes on the caliper for measuring the brake linings. Refer to The service brake holding ability test determines whether the
Illustration 2 . Remove any plugs from the holes and clean the service brake is functional. This test is not intended to measure
holes of any dirt. the maximum brake holding ability.
The holding ability of the service brakes at a specific engine rpm
will be different for each machine.
The results of the test should be recorded. The results should be
compared to previous test results and subsequent test results.
Use the comparison as an indication of system deterioration for a
particular machine.
1. Before you perform the test, ensure that you can test the
brakes on a surface which is level, dry, and clear of obstacles.
Fasten your seat belt. Ensure that the transmission control is in
the N position and that the parking brake control is in the
ENGAGED position.
Illustration 3 g01150338 Start the engine and wait until the brake system is fully
Illustration of the correct method of taking a measurement with the tool charged.
The step on the tool is indicated in the Illustration with an arrow.
22
2. Engage the service brakes. Move the transmission control to If the machine moved during the test, the parking brake requires
the 1 position. Move the parking brake control to the service.
DISENGAGED position.
NOTICE
3. Gradually increase the engine speed until the machine moves If the machine moved while testing the parking brake, inspect
forward. Record the engine speed when the machine moves. the parking brake components for wear or damage. Repair or
replace the worn or damaged parking brake components as
Reduce the engine speed immediately and move the parking required before returning the machine to service.
brake control to the ENGAGED position. Move the
transmission control to the N position. Shut off the engine.
4. If the machine moves at an engine speed below 1200 rpm, the
Differential and Final Drive Oil Level - Check
service brakes require service. Operations and Maintenance Manual
SEBU7814 i02582439
NOTICE
If the machine moved while testing the service brakes, contact 1. Park the machine on a level surface and stop the engine.
your Caterpillar dealer. Perform the following steps on each of the three axles:
Have the dealer inspect and, if necessary, repair the service
brakes before returning the machine to operation.
Parking Brake Check
WARNING
The parking brake holding test is a maintenance test procedure

only. The machine should never be parked on a grade with only
the parking brake engaged. If necessary to stop the machine on
a grade, block the wheels securely. Refer to Operation and
Maintenance Manual, "Jacking/Blocking Locations" for more
information. Failure to block the wheels securely could result in Illustration 1 g01293542
unintended machine movement. Personal injury or death could Typical example
result if the machine moves. Some models may have the filler plug toward the right side.
2. Remove differential filler plug (1) and clean the area around
The test for the parking brake must be carried out with the rated the opening.
load in the body.
3. Check the oil level. Maintain the oil level to the bottom of the
Test the service brakes and the secondary steering system on filler plug opening.
level ground before you carry out this procedure.
4. If necessary, add oil. Install the filler plug.
1. Drive the machine onto an incline of 15%. The machine must
be pointing down the incline.
Note: If required by local regulations, the 15% incline can be
replaced. An incline that represents the maximum grade that
the machine will be operated on at the site may be used. If the
machine moved during the maximum grade test, the parking
brake may require service. The machine operation may need
to be modified to reduce the maximum grade that the machine
is operated on in order to meet local regulatory requirements.
2. Engage the service brakes in order to stop the machine on the
incline. The area around the machine must be clear of personnel
and obstacles.
3. Move the parking brake control to the ENGAGED position. Illustration 2 g01293543
Move the transmission control to the N position. Typical Example
4. Shut off the engine. Note: The differential and final drives share a common oil
compartment. When the machine is parked on a level surface
5. Gradually disengage the service brakes. and when the final drive oil level mark (3) is horizontal, the final
drive filler plug (2) will be at the same level as the differential
6. If the machine moves forward, engage the service brakes filler plug (1) . Allow the oil to fill all of the compartments before
immediately. Start the engine. Disengage the parking brake and rechecking the oil level.
drive the machine onto level ground. Shut off the engine.
Differential and Final Drive Oil Sample - Obtain
7. Check the thickness of the brake pad linings and check the
thickness of the brake disc. Refer to Specifications, RENR6724, Operations and Maintenance Manual
"Parking Brake" . Replace parts if the specification is not met. SEBU7347 i06815502
23
Note: Use a sampling gun for obtaining the oil samples. Engine Oil and Filter - Change
SEBU7814 i03993889
Selection of the Oil Change Interval

NOTICE
A 500 hour engine oil change interval is available, provided that
the operating conditions and recommended multigrade oil types
are met. When these requirements are not met, shorten the oil
change interval to 250 hours, or use an S·O·S Services oil
sampling and analysis program to determine an acceptable oil
change interval.
If you select an interval for oil and filter change that is too long,
1. Park the machine on level ground. Slowly move the machine you may damage the engine.
until "Oil Level" mark (1) on the front right final drive is horizontal.
Engage the parking brake and shut off the engine. Caterpillar oil filters are strongly recommended.
2. Wipe the area around plug (2) on the final drive. Remove the Recommended multigrade oil types are listed in Table 1 . Do not
plug and the O-ring seal. Remove the plug slow to relieve any use single grade oils.
system pressure.
Abnormally harsh operating cycles or harsh environments can
3. Obtain an oil sample through the plug hole in the final drive. shorten the service life of the engine oil. Operating with high
load factors or with fuel sulfur levels above 0.3% may require
4. Clean the plug and check the plug for ferrous particles that reduced oil drain intervals. Corrosive environments or extremely
may indicate wear of the final drive and differential components. dusty conditions may require a reduction in engine oil change
intervals from the recommendations in Table 1 .
5. Lubricate the O-ring seal with gear oil. Install the plug and the
O-ring seal. Operating the engine in the following conditions will shorten the
service life of the engine oil which will require reduced oil drain
6. Start the engine. intervals:
7. Repeat Steps 1 through 6 to obtain oil samples from the final • Low ambient temperatures
drives on the remaining five wheels.
• Short operating durations
• Long idle times
• Altitudes above 1830 m (6000 ft)
• Poor maintenance of air filters or of fuel filters
See your Caterpillar dealer for more information if this product
will experience abnormally harsh operating cycles or harsh
environments.
Refer to Special Publication, SEBU6250, "Caterpillar Machine
Fluid Recommendations" for more information.
NOTICE
8. Wipe the area around plug (3) on the rear axle housing.
Remove the plug and the O-ring seal. Remove the plug slow to The oil drain intervals specified in table 1 are based on the use
relieve any system pressure. of premium diesel engine oils.
9. Obtain an oil sample through the plug hole in the front axle The preferred oil for attaining the specified intervals is Cat DEO
housing. Multigrade.
10. Clean the plug and check the plug for ferrous particles that Premium oils that meet the Cat ECF-1 (Engine Crankcase Fluid
may indicate wear of the differential and final drive components. specification - 1) are second choice oils.
11. Lubricate the O-ring seal with gear oil. Install the plug and Table 1
the O-ring seal. 725 and 730 Articulated Trucks
Oil Change Interval (1)
12. Repeat steps 8 through 11 for the center axle and the front Operating Conditions
axle. Severe
Multigrade Oil Type High Load Factor Fuel Sulfur from
above 41 L (10.8 US 0.3% to 0.5% Altitude above 1830
13. Use S·O·S Oil Analysis to monitor the condition of the Normal (2) gal) per hour m (6000 ft)
(3) (4)
differential and final drive components.
24
Cat DEO 500 hr 500 hr 500 hr 250 hr (0)
Preferred NOTICE
ECF-1
11.0 minimum TBN Care must be taken to ensure that fluids are contained during
500 hr 500 hr 500 hr 250 hr (0)
(4)
Preferred
performance of inspection, maintenance, testing, adjusting and
ECF-1
500 hr 500 hr 250 hr (5) 250 hr (6)
TBN (4) below 11.0 suitable containers before opening any compartment or
Adjustment of the Oil Change Interval Refer to Special Publication, NENG2500, "Cat dealer Service Tool
Catalog" , and to Special Publication, GECJ0001, "Cat Shop
Note: Your Caterpillar dealer has additional information on these Supplies and Tools" guide for tools and supplies suitable to
programs. collect and contain fluids on Caterpillar products.
Program A Dispose of all fluids according to local regulations and

mandates.
Verification for an Oil Change Interval of 500 Hours
This program consists of three oil change intervals of 500 hours. brake is fully engaged. Lower the dump body and shut off the
Oil sampling and analysis is done at 250 hours and 500 hours for engine.
each of the three intervals for a total of six oil samples. The
analysis includes oil viscosity and infrared (IR) analysis of the oil. Note: Drain the crankcase while the oil is warm and while the oil
If all of the results are satisfactory, the 500 hour oil change is well circulated. This ensures that waste particles will be
interval is acceptable for the engine in that application. Repeat suspended in the oil and that these particles will be removed as
Program A if you change the application of the engine. the oil is drained.
If a sample does not pass the oil analysis, take one of these
actions:
• Shorten the oil change interval to 250 hours.
• Proceed to Program B.
• Change to a preferred oil type in Table 1 .
Program B
Optimizing Oil Change Intervals
Begin with a 250 hour oil change interval. The oil change
intervals are adjusted by increments. Each interval is adjusted an Illustration 1 g01126944
additional 50 hours. Periodic oil sampling and analysis is done
during each interval. The analysis includes oil viscosity and 1. Remove the cover from the crankcase guard.
infrared (IR) analysis of the oil. Repeat Program B if you change
the application of the engine.
If an oil sample does not pass the analysis, shorten the oil
change interval, or change to a preferred multigrade oil type in
the listing above.
References
Reference: Special Publication, PEDP7036, "S·O·S Services"
Reference: Special Publication, PEDP7076, "Understanding the
S·O·S Oil Analysis Tests"
Reference: Special Publication, PEHP7052, "Making the Most of Illustration 2 g01126945
S·O·S Services"
2. Attach a suitable hose to the drain valve.
Procedure for Changing Engine Oil and Filter
3. Open the oil drain valve until oil flows from the hole. Allow the
oil to drain into a suitable container.
4. Remove the hose from the drain valve. Clean the oil drain valve
and close the oil drain valve.
"Hood Control" .
25
Engine Oil Sample - Obtain
SEBU7814 i02210439
Note: The engine oil filter is remotely mounted on the right

side of the engine.
6. Remove the oil filter with a strap type wrench. Discard the
used oil filter properly. Illustration 1 g01134568
Refer to the Operation and Maintenance Manual, "Oil Filter - The sampling valve for the engine oil is located on the right side
Inspect" . of the engine on the engine oil filter base.
7. Clean the oil filter base. Refer to Special Publication, SEBU6250, "S·O·S Oil Analysis" for
information that pertains to obtaining a sample of the engine oil.
8. Apply a thin coat of engine oil to the seal of the new oil filter. Refer to Special Publication, PEHP6001, "How To Take A Good Oil
Sample" for more information about obtaining a sample of the
9. Install the new oil filter by hand. engine oil.
Instructions for the installation of the filter are printed on the Fuel System - Prime
side of each Caterpillar spin-on filter. For non-Caterpillar
filters, refer to the installation instructions that are provided Operations and Maintenance Manual
by the supplier of the filter. SEBU7814 i02883746
WARNING
Fuel leaked or spilled onto hot surfaces or electrical components

can cause a fire. Clean up fuel spills immediately.
NOTICE
Illustration 4 g01125742 Refer to Special Publication, NENG2500, "Dealer Service Tool
10. Remove oil filler cap (2) . Fill the crankcase with new oil fluids on Cat ® products.
through the filler tube.
Refer to Operation and Maintenance Manual, "Lubricant mandates.
Viscosities" and Operation and Maintenance Manual,
"Capacities (Refill)" .
Prime the fuel system in order to fill the fuel filter with fuel. It is
11. Remove dipstick (1) and then clean the dipstick. Reinstall the necessary to prime the fuel system after the fuel filters have
dipstick. been changed.
12. Remove the dipstick and check the oil level. The oil level Park the machine on a level surface and engage the parking
should be between the "ADD" and "FULL" marks on the dipstick. brake. Lower the dump body and stop the engine.
Add oil, if necessary.
Raise the hood. Refer to Operation and Maintenance Manual,
13. Start the engine and run the engine at low idle for 1 minute. "Hood Control" .
14. Repeat steps 11 and 12 . Type 1

15. Close the hood and shut off the engine.
26
1. Open purge screw (2) . Note: The engine start switch must be in the OFF position in
order to prime the fuel system.
2. Turn the priming pump plunger (1) counterclockwise in order
to unlock the plunger. Manually pump the plunger. This will fill 1. Open purge screw (4) .
the engine fuel lines and the fuel filters with fuel.
2. Hold switch (3) upward in order to operate the electric fuel
3. Operate the priming pump until the flow of fuel is free of air priming pump. This will fill the engine fuel lines and the fuel
bubbles. filters with fuel.
4. Close the purge screw. 3. Operate the priming pump until the flow of fuel is free of air
bubbles. Do not operate the pump for more than two minutes.
5. Continue to operate the priming pump in order to build fuel
pressure. This will create resistance in the plunger. Operate the 4. Close the purge screw.
priming pump until resistance is felt.
5. Continue to operate the priming pump in order to build fuel
Note: Resistance will not be felt until the purge screw has pressure. As the fuel pressure increases, the priming pump will
been tightened. come under load. Listen for the priming pump to come under
load. Do not continue priming the fuel system after the priming
6. Push in the plunger. Turn the plunger clockwise in order to pump is under load. Do not operate the pump for more than two
lock the plunger. minutes.
7. Start the engine. If the engine starts but the engine runs Note: The priming pump will not come under load until the
rough, continue to run the engine at low idle until the engine purge screw has been tightened.
runs smoothly. If the engine will not start after several attempts,
consult your Caterpillar dealer. 6. Start the engine. If the engine starts but the engine runs
rough, continue to run the engine at low idle until the engine
Type 2 runs smoothly. If the engine will not start after several attempts,
consult your Caterpillar dealer.
Fuel System Primary Filter -

Clean/Inspect/Replace
SEBU7814 i02565212
NOTICE
Do not fill fuel filter with fuel before installing the fuel filter.
Contaminated fuel causes accelerated wear to fuel system parts.
27
NOTICE Refer to the Operation and Maintenance Manual, "Fuel System
- Prime" .
performance of inspection, maintenance, testing, adjusting, and 13. Start the engine and check for leaks.
suitable containers before opening any compartment or 14. Close the hood.
Fuel System Secondary Filter - Replace
Catalog" for tools and supplies suitable to collect and contain Operations and Maintenance Manual
fluids on Cat ® products. SEBU7814 i02235586
Dispose of all fluids according to local regulations and NOTICE

mandates.
Do not fill the secondary fuel filter with fuel before installing. The
fuel would not be filtered and could be contaminated.
1. Park the machine on a level surface. Ensure that the parking Contaminated fuel will cause accelerated wear to fuel system
brake is fully engaged. Lower the dump body and stop the parts.
engine.
2. Raise the hood. Refer to Operation and Maintenance Manual, NOTICE
"Hood Control" .
3. Clean the outside of the primary fuel filter element. performance of inspection, maintenance, testing, adjusting, and
mandates.
Note: Before you replace the secondary fuel filter, the primary
fuel filter must be replaced. Refer to the Operation and
Maintenance Manual, "Fuel System Primary Filter -
Clean/Inspect/Replace" .
1. Park the machine on a level surface. Ensure that the parking
engine.
Illustration 1 g01296268 "Hood Control" .
4. Insert drain hose (5) into a suitable container. Open valve (3) in
order to drain the fuel from the filter. Close the valve.
5. Use a strap wrench to remove filter element (1) from the filter
base assembly.
6. Detach bowl (2) from the filter element. Properly discard the
used filter.
7. Clean the filter base assembly.
8. Coat the new seal with clean diesel fuel prior to installation.
9. Attach the bowlto the new filter element.
10. Install the new filter element by hand. When the seal
contacts the filter base assembly, tighten the filter by 270 3. Use a strap wrench and remove the secondary fuel filter.
degrees more. Discard the secondary fuel filter properly.
Note: The filter element has indicator marks at every 90 4. Clean the fuel filter base.
degrees.
5. Coat the seal for the new secondary fuel filter with clean
11. Ensure that the drain hose is routed through hole (4) . diesel fuel prior to installation.
12. Prime the fuel system.
28
6. Install the new secondary fuel filter by hand. Do not use a tool Hydraulic System Oil Sample - Obtain
for installation of the secondary fuel filter. When the new filter
base gasket contacts the fuel filter base, tighten the secondary Operations and Maintenance Manual
fuel filter by an additional 270°. SEBU7814 i02228019
7. Prime the fuel system. Park the machine on a level surface. Ensure that the parking
Refer to the Operation and Maintenance Manual, "Fuel System brake is fully engaged. Lower the dump body and shut off the
- Prime" . engine.
8. Start the engine and check for leaks. Install the steering frame lock. Refer to Operation and
9. Lower the hood.
Fuel Tank Cap and Strainer - Clean

SEBU7347 i02235442

engine.
The sampling valve for the hydraulic system oil is located on the
left side of the machine behind the cab.
Refer to Special Publication, SEBU6250, "S·O·S Oil Analysis" for
information that pertains to obtaining a sample of oil. Refer to
Special Publication, PEHP6001, "How To Take A Good Oil Sample"
for more information about obtaining a sample of oil.
Hydraulic Tank Strainer -

Clean/Inspect/Replace
1. Remove the fuel tank cap.
SEBU7814 i02228026
NOTICE
Illustration 2 g01127259 Dispose of all fluids according to local regulations and

mandates.
2. Remove fuel strainer (1) .
3. Inspect O-ring seal (2) for damage. Replace the O-ring seal if Park the machine on a level surface. Ensure that the parking
the O-ring seal is damaged. brake is fully engaged. Lower the dump body and shut off the
engine.
4. Clean the fuel strainer in clean, nonflammable solvent. If the
fuel strainer is damaged, replace the fuel strainer.
5. Clean the fuel tank cap in nonflammable solvent. If the fuel
tank cap is damaged, replace the fuel tank cap.
6. Allow the fuel strainer and the fuel tank cap to dry.
7. Reinstall the fuel strainer.
8. Reinstall the fuel tank cap.
29
2. Press and hold the top of the test switch for the secondary
steering. This will activate the secondary steering motor.
3. Turn the steering wheel fully from left to right. If the machine
responds to the steering input the secondary steering is
Illustration 1 g01133381 operating. If the machine does not respond to the steering input
the secondary steering is not working.
The strainer is located inside the filler tube for the tank. The filler
tube is located on top of the tank on the left side of the machine. 4. Release the test switch for the secondary steering. Spring
Lift the panelthat covers the hydraulic tank in order to access the force will return the test switch for the secondary steering to the
filler tube. Reposition this panel once the strainer has been OFF position. This will deactivate the secondary steering motor.
cleaned. Do not run the secondary steering motor longer than 12 seconds
while you are testing the secondary steering.
Do not operate the machine if the secondary steering is not
operating correctly.
Torque Converter and Transmission Oil Filter -

Replace
SEBU7814 i02228027
NOTICE
Illustration 2 g01127485 performance of inspection, maintenance, testing, adjusting, and
1. Remove filler cap (1) . suitable containers before opening any compartment or
2. Remove retaining ring (2) and remove strainer (3) from the
hydraulic filler tube. Refer to Special Publication, NENG2500, "Dealer Service Tool
3. Wash the strainer in nonflammable solvent. Allow the strainer fluids on Cat ® products.
to dry before the strainer is reinstalled.
If the strainer is damaged, replace the strainer. mandates.
4. Inspect the filler cap and the gasket which is inside of the
filler cap. Replace any damaged components. WARNING
5. Install the strainer and the retaining ring. Hot oil and hot components can cause personal injury. Do not
6. Install the filler cap. allow hot oil or hot components to contact skin.
Secondary Steering - Test Park the machine on a level surface. Engage the parking brake.
Lower the dump body and shut off the engine.
SEBU7814 i02210447 Note: Before you remove the filter, block the front frame of
the machine.
Test the secondary steering by using the following procedure:
1. Park the machine on a hard level surface. Lower the dump
body and shut off the engine. Leave the engine start switch in
the ON position.
30
Torque Converter and Transmission Oil Sample
- Obtain
SEBU7814 i02228028
NOTICE
1. Remove the cover in order to access the oil filter cover. Catalog" for tools and supplies suitable to collect and contain
mandates.
WARNING
Hot oil and hot components can cause personal injury. Do not
2. Clean the area around drain plug (3) . Remove the drain plug
and the O-ring seal and retain the drain plug and the O-ring seal.
Allow the oil to drain into a suitable clean container.
Note: Approximately 4.5 L (1.2 US gal) will drain from the
transmission when drain plug (3) is removed.
3. Remove oil filter cover (2) . Remove the O-ring seal and retain
the O-ring seal.
Note: Note the orientation of cover (2) . The cover must be
installed in the position. Remove the plate on the left side of the transmission guard in
order to access the sampling port.
4. Remove the nut and the washer that secures the oil filter to
the transmission. Remove the oil filter and discard the oil filter.
5. Fit a new oil filter. Fit the washer and the nut in order to
secure the oil filter to the transmission.
6. Inspect the O-ring seal for the oil filter cover. If necessary,
replace the O-ring seal. Lubricate the O-ring seal with
transmission oil. Install the O-ring seal and oil filter cover (2) .
7. Inspect the O-ring seal for drain plug (3) . If necessary, replace
the O-ring seal. Lubricate the O-ring seal with transmission oil.
Install the O-ring seal and install the drain plug.
8. Top up the torque converter and transmission oil level with the
correct oil. Refer to Operation and Maintenance Manual, "Torque
Converter and Transmission Oil Level - Check" and Operation and The sampling valve is located on the left side of the transmission.
Maintenance Manual, "Lubricant Viscosities" .
Refer to Special Publication, SEBU6250, "S·O·S Oil Analysis" for
9. Check oil filter cover (2) and drain plug (3) for leaks. If oil information that pertains to obtaining a sample of the engine oil.
leakage is evident, repeat the replacement procedure. Refer to Special Publication, PEHP6001, "How To Take A Good Oil
Sample" for more information about obtaining a sample of the
10. Replace the cover on the transmission guard. engine oil.
31
Transfer Gear Oil Sample - Obtain Engine Crankcase Breather - Clean
Operations and Maintenance Manual Operations and Maintenance Manual
SEBU7814 i01980902 SEBU7814 i02210945
NOTICE Park the machine on a level surface. Ensure that the parking
Care must be taken to ensure that fluids are contained during engine.
repair of the product. Be prepared to collect the fluid with 1. Raise the hood.
disassembling any component containing fluids. Refer to Operation and Maintenance Manual, "Hood Control" .
mandates.
WARNING
Hot oil and hot components can cause personal injury. Do not
2. Loosen hose clamp (1) in order to detach the hose from the
breather. Remove breather (2) .
3. Wash the breather in a clean, nonflammable solvent. Wipe the
breather with a clean, dry cloth. Replace the breather if the
breather is damaged.
4. Inspect the breather seal. If necessary, install a new seal.
5. Ensure that the breather is dry.
6. Reposition the breather. Fasten the breather to the top of the
Illustration 1 g00847341 engine. Tighten hose clamp (1) in order to fasten the hose to the
Location of the sampling valve for the transfer gear breather.
1. Operate the machine until the oil reaches operating 7. Lower the hood.
temperature.
2. Park the machine on a level surface. Lower the dump body Every 250 Service Hours
and engage the parking brake.
Parking Brake - Lubricate
4. Install the steering frame lock. Refer to Operation and SEBU7347 i07939133
1. Park the machine on flat, level ground.
Note: Before you obtain a sample of the oil, block the front
frame of the machine. 2. Engage the parking brake. Shut off the engine.
5. Install the oil drain tube assembly to the sampling valve. 3. Install steering frame locks.
6. Start the engine. 4. Install body support (if equipped).
7. Drain an oil sample from the sampling valve. 5. Shut off the engine.
9. Remove oil drain tube assembly from the sampling valve.
Use S·O·S oil analysis in order to monitor the condition of the
transfer gear.
32
or death.
Do not smoke when servicing air conditioners or wherever
Before any checks of the air conditioning and heating system are
made, move the machine to a smooth horizontal surface. Lower
all implements to the ground. Make sure the transmission is in
NEUTRAL or PARK and that the parking brake is engaged. Keep
all other personnel away from the machine or where they can be
seen.
WARNING
Personal injury can result from hot coolant. Any contact with hot
coolant or with steam can cause severe burns. Allow cooling
system components to cool before the cooling system is drained.
Note: A grease fitting is located above the center axle NOTICE

differential casing.
Never weld or solder any charged components.
6. Grease the parking brake grease fitting using a hand grease
gun until fresh grease is seen. If regular lubrication is performed Note: A performance check of the air conditioning system must
at the recommended interval, only one or two shots of grease be made with a manifold gauge set. Refer to the Testing and
will be required at the fitting. Adjusting, "Manifold Gauge Set - Install" .
Note: Not all hand operated grease guns deliver the same Note: Before you conduct a performance test, refer to the
amount of grease per stroke. Check with the manufacturer of Troubleshooting, "Visual Inspection" .
your grease gun to determine the proper number of pumps
needed. Note: The ambient temperature must be at least 21 °C (70 °F) in
order to conduct the following test.
Note: Do not use automatic/pneumatic grease guns.
1. Install the manifold gauge set. Refer to the Testing and
Note: Not following the Caterpillar service recommendation Adjusting, "Manifold Gauge Set (Refrigerant) - Install" .
for greasing the parking brake debris barrier compartments
can result in reduced service life and improper functioning of 2. Start the engine and operate the engine at 1000 rpm (Low idle).
the parking brake.
3. Move the temperature control knob to the maximum cool
Reference Section position. Put the fan switch in the HIGH position on the side that
is for air conditioning.
Air Conditioning Performance - Test 4. In order to stabilize the system, continue to operate the system
Testing and Adjusting
at 1000 rpm for a minimum of 10 minutes.
UENR4125 i05907572 5. Adjust the engine speed to approximately 1300 to 1400 rpm.
Record the readings on the gauge for discharge (high pressure),
WARNING and on the gauge for suction (low pressure).
6. Compare the discharge and suction pressures on the manifold
Personal injury can result from contact with refrigerant. gauge set to the pressure ranges in Table 1 in order to determine
This system is under pressure at all times, even if the engine is if the system is functioning correctly for the current ambient
not running. Heat should never be applied to a charged system. temperature.
Contact with refrigerant can cause frost bite. Keep face and Table 1
hands away to help prevent injury. Pressure Range (1)
Ambient Air Temperature High Pressure Test Fitting Low Pressure Test Fitting
Protective goggles must always be worn when refrigerant lines C° (F°) kPa (psi) (2) (3) kPa (psi) (4) (5) (6)
are opened, even if the gauges indicate the system is empty of 21°C (70°F) 820 to 1300 kPa (120 to 190 70 to 138 kPa (10 to 20 psi)
psi)
refrigerant.
950 to 1450 kPa (140 to 210
27°C (80°F) 70 to 173 kPa (10 to 25 psi)
psi)
Always use caution when a fitting is removed. Slowly loosen the
1175 to 1650 kPa (170 to 240
fitting. If the system is still under pressure, evacuate the system 32°C (90°F) psi) 105 to 210 kPa (15 to 30 psi)
recovering the refrigerant before removing the fitting. 1300 to 1850 kPa (190 to 270
38°C (100°F) 105 to 210 kPa (15 to 30 psi)
psi)
Personal injury or death can result from inhaling refrigerant 1450 to 2075 kPa (210 to 300
43°C (110°F) 105 to 210 kPa (15 to 30 psi)
through a lit cigarette. psi)
33
7. If the suction and the discharge pressures are not within the
normal operating range, refer to the Troubleshooting, "Air
Conditioning System Troubleshooting" .
During normal operation of the air conditioning system in 21 °C
(70 °F) weather, the discharge pressure will be 820 kPa (120 psi)
to 1300 kPa (190 psi) . The suction side pressure will be 70 kPa
(10 psi) to 130 kPa (20 psi) .
The outside temperature and humidity will have an effect on the
pressures. If the outside temperature is high, the discharge
pressure will be high. In hot weather, the suction and the
discharge pressures will be high. In cooler weather, the suction
and the discharge pressure will be normal or the pressure can
be lower. Illustration 1 g01193938
Cylinder and Valve location
(A) Exhaust valves
Engine Valve Lash - Inspect/Adjust (B) Inlet valves
Testing and Adjusting Valve Lash and Valve Bridge Adjustment

KENR9888 i02793330
WARNING
To prevent possible injury, do not use the starter to turn the

flywheel.
Hot engine components can cause burns. Allow additional time
for the engine to cool before measuring valve clearance.
WARNING
This engine uses high voltage to control the fuel injectors.

Disconnect electronic fuel injector enable circuit connector to
prevent personal injury.
Do not come in contact with the fuel injector terminals while the
engine is running.
Note: Valve lash is measured between the rocker arm and the (1) Exhaust rocker arm
bridge for the inlet valves. Valve lash is measured between the (2) Inlet valve bridge
(3) Rocker arm adjustment screw locknut for the exhaust rocker arm
rocker arm and the valve stem for the exhaust valve. All of the (4) Rocker arm adjustment screw for the exhaust rocker arm
clearance measurements and the adjustments must be made
with the engine stopped. The valves must be fully closed. Table 2
Valve Lash
Valve Lash Check Valves Dimension of Gauge
Inlet 0.38 ± 0.08 mm (0.0150 ± 0.0031 inch)
Table 1
Exhaust 0.64 ± 0.08 mm (0.0252 ± 0.0031 inch)
Inlet Valves Exhaust Valves
Valve Lash Check (Stopped 0.38 ± 0.08 mm (0.0150 ± 0.64 ± 0.08 mm (0.0252 ± Adjust the valve lash while the engine is stopped. Use the
Engine) 0.0031 inch) 0.0031 inch)
following procedure to adjust the valves:
TC Compression Stroke 1-2-4 1-3-5
TC Exhaust Stroke (1) 3-5-6 2-4-6 1. Put the No. 1 piston at the top center position on the
Firing Order 1-5-3-6-2-4 (2) compression stroke. Refer to Testing and Adjusting, "Finding Top
Center Position for No. 1 Piston" .
An adjustment is not necessary if the measurement of the valve Table 3
lash is in the acceptable range. Adjust the valve lash while the TC Compression Stroke Inlet Valves Exhaust Valves
engine is stopped. The range is specified in Table 1 . 0.38 ± 0.08 mm (0.0150 ± 0.64 ± 0.08 mm (0.0252 ±
Valve Lash 0.0031 inch) 0.0031 inch)
If the measurement is not within this range adjustment is Cylinders 1-2-4 1-3-5
necessary. See Testing And Adjusting, "Valve Lash And Valve
Bridge Adjustment" . 2. Adjust the valve lash according to Table 3 .
a. Lightly tap the rocker arm at the top of the adjustment
screw with a soft mallet. This will ensure that the lifter
roller seats against the camshaft's base circle.
34
b. Loosen the adjustment locknut. Always use caution when a fitting is removed. Slowly loosen the
fitting. If the system is still under pressure, evacuate the system
c. Place the appropriate feeler gauge between rocker arm recovering the refrigerant before removing the fitting.
and the valve bridge. Then, turn the adjustment screw in a
clockwise direction. Slide the feeler gauge between the Personal injury or death can result from inhaling refrigerant
rocker arm and the valve bridge. Continue turning the through a lit cigarette.
adjustment screw until a slight drag is felt on the feeler
gauge. Remove the feeler gauge. Inhaling air conditioner refrigerant gas through a lit cigarette or
d. Tighten the adjustment locknut to a torque of 30 ± 7 N·m contacting air conditioner refrigerant gas, can cause bodily harm
(22 ± 5 lb ft) . Do not allow the adjustment screw to turn or death.
while you are tightening the adjustment locknut. Recheck Do not smoke when servicing air conditioners or wherever
the valve lash after tightening the adjustment locknut. refrigerant gas may be present.
3. Remove the timing bolt and turn the flywheel by 360 degrees in Before any checks of the air conditioning and heating system are
the direction of engine rotation. This will put the No. 6 piston at made, move the machine to a smooth horizontal surface. Lower
the top center position on the compression stroke. Install the all implements to the ground. Make sure the transmission is in
timing bolt in the flywheel. NEUTRAL or PARK and that the parking brake is engaged. Keep
Table 4
seen.
TC Exhaust Stroke (1) Inlet Valves Exhaust Valves
0.38 ± 0.08 mm (0.0150 ± 0.64 ± 0.08 mm (0.0252 ±
Valve Lash 0.0031 inch) 0.0031 inch)
Cylinders 3-5-6 2-4-6
WARNING
4. Adjust the valve lash according to Table 4 . coolant or with steam can cause severe burns. Allow cooling
a. Lightly tap the rocker arm at the top of the adjustment
screw with a soft mallet. This will ensure that the lifter In order to conduct a performance of the heating system,
roller seats against the camshaft's base circle. perform the following procedure.
b. Loosen the adjustment locknut. 1. Run the engine at 1000 rpm (low idle speed) until the engine
c. Place the appropriate feeler gauge between rocker arm coolant temperature is in the normal operating range.
and the valve bridge. Then, turn the adjustment screw in a 2. Adjust the temperature control knob to the hottest position.
clockwise direction. Slide the feeler gauge between the
rocker arm and the valve bridge. Continue turning the 3. Put the fan switch in the HIGH position on heat.
adjustment screw until a slight drag is felt on the feeler
gauge. Remove the feeler gauge. 4. Check the system for normal operating conditions.
d. Tighten the adjustment locknut to a torque of 30 ± 7 N·m • The temperature of the air that is flowing from the louvers
(22 ± 5 lb ft) . Do not allow the adjustment screw to turn (air ducts) should be warm.
while you are tightening the adjustment locknut. Recheck
the valve lash after tightening the adjustment locknut. • The temperature of the air should be easily controllable by
the control panel in the dash.
5. Remove the timing bolt from the flywheel after all adjustments
to the valve lash have been made. Reinstall the timing cover. • There should not be a smell of coolant that is present in the
cab.
Heater Performance - Test
If any of the three items are not working properly, refer to
Testing and Adjusting Troubleshooting section of this manual.
UENR4125 i05907615
Identifying the Air Conditioning System
WARNING Systems Operation
SENR5664 i02979466
This system is under pressure at all times, even if the engine is The R-134a air conditioning system can be identified as an orifice
not running. Heat should never be applied to a charged system. tube system or an expansion valve system.
Contact with refrigerant can cause frost bite. Keep face and
Protective goggles must always be worn when refrigerant lines
refrigerant.
35
(1) In-line dryer (3) Block expansion valve
(4) 90° expansion valve
One identifies the orifice tube system by locating either an in-line
dryer (1) or an accumulator (2) in the system. The orifice tube is
located within the in-line dryer or within the evaporator inlet tube
and the orifice tube cannot be seen.
(5) Receiver-dryers
The following components are the five components of the

expansion valve system:
(2) Accumulators
• Compressor
The following components are the six components of the orifice
tube system: • Condenser coil
• Compressor • Receiver-dryer
• Condenser coil • Expansion valve
• Dryer • Evaporator coil
• Orifice tube In-Line Refrigerant Dryer - Remove and Install

• Evaporator Coil Disassembly and Assembly
UENR4125 i05907627
• Accumulator
The expansion valve system can be identified by locating a Dryer Installation
Thermostatic Expansion Valve (TXV) in the system. The two main
types of TXV's are block (3) and 90° expansion valves (4) . WARNING
Expansion valve systems also contain a receiver-dryer (5) .
This system is under pressure at all times, even if the engine is
not running. Heat should never be applied to a charged system.
refrigerant.
Always use caution when a fitting is removed. Slowly loosen the
recovering the refrigerant before removing the fitting.
36
Personal injury or death can result from inhaling refrigerant
through a lit cigarette.
or death.
seen.
WARNING
coolant or with steam can cause severe burns. Allow cooling Illustration 2 g01520434
system components to cool before the cooling system is drained. In-line dryer without quick disconnects
(4) Inlet hose without air conditioner quick disconnect
(5) Dryer
NOTICE (6) Outlet hose without air conditioner quick disconnects
Never weld of solder any charged components.
320-0562 Refrigerant Dryer As
Illustration 1 g01520430 (7) Dryer
Typical In-Line Dryer with quick disconnects (8) Air conditioner orifice assembly
(1) Inlet hose with air conditioner quick disconnect
(2) Dryer Note: Every 2 years replace dryer (5) and (7) . Dryer (5) and (7)
(3) Outlet hose with air conditioner quick disconnect should also be replaced whenever the system is opened.
Note: Replace dryer (2) annually. Dryer (2) should also be Before removing the dryer, perform the following
replaced whenever the system is opened.
steps in order to diagnose the problem
Disassembly and Assembly 1. Check the following components for blockages:
• Condenser
• Evaporator
• Fresh air filters
2. Check the condition and the tension of the compressor drive
belt.
37
3. Connect a manifold gauge set to the compressor. Refer to 11. Recharge the refrigerant. Refer to Testing and Adjusting,
Testing and Adjusting, "Manifold Gauge Set (Refrigerant) - Install" "Refrigerant System - Charge" Section.
.
12. Retest the system with the engine at 1400 rpm and check for
4. Operate the Air conditioning. frost at the dryer outlet.
• Operate the engine at 1400 rpm. 13. Ensure that the pressures are normal for the current ambient
temperature.
• Place the air conditioning switch in the ON position.
14. Refer to Table 1 for the pressures which are normal for the
• Set the blower switch to the HIGH position. current ambient air temperature.
• Open all of the louvers in the cab. 15. If a component is leaking, bill the claim against the leaking
component and provide details in the description.
• Close the cab doors and close all of the cab windows.
Dryer Removal
5. Compare the pressures for the manifold gauge to the pressure
ranges in Table 1 in order to ensure that the pressures are If the dryer does not have air conditioner quick Disconnects, the
normal for the current ambient air temperature. refrigerant that is in the system must be recovered. Refer to the
Testing and Adjusting, "Refrigerant System Recovery" section
Table 1
before you remove the dryer.
Pressure Range (1)
Ambient Air Temperature High Pressure Test Fitting Low Pressure Test Fitting If the dryer has air conditioner quick disconnects, use the
C° (F°) kPa (psi) (2) (3) kPa (psi) (4) (5)
procedure that follows.
820 to 1300 kPa (120 to 190
21°C (70°F) 70 to 138 kPa (10 to 20 psi)
psi)
950 to 1450 kPa (140 to 210
Refer to Disassembly and Assembly, "Machine Preparation for
27°C (80°F) psi) 70 to 173 kPa (10 to 25 psi) Disassembly and Assembly" before service is performed on the
1175 to 1650 kPa (170 to 240 air conditioning system.
32°C (90°F) 105 to 210 kPa (15 to 30 psi)
psi)
38°C (100°F) 1300 to 1850 kPa (190 to 270 105 to 210 kPa (15 to 30 psi)
1. Stop the engine for 5 minutes to allow the air conditioning
psi) system to equalize the pressure.
1450 to 2075 kPa (210 to 300
43°C (110°F) 105 to 210 kPa (15 to 30 psi)
psi) 2. Disconnect the inlet hose from the old dryer.
3. Connect the hose that was disconnected in Step 2 to the inlet
6. Check for frost at the dryer outlet. on the new dryer.
Note: Moisture on the drier outlet tube after the orifice is Note: For a dryer that has air conditioner quick disconnects,
normal and this moisture does not indicate a failure with the do not add additional oil or refrigerant to the system.
dryer. Frost on the drier outlet tube after the orifice is an
indicator of a low refrigerant charge. 4. Start the engine. Operate the air conditioning system for 1
minute.
7. If frost is indicated at the dryer outlet or if pressures are low,
proceed to Step 8 . Otherwise, proceed to Step 15 . 5. With the air conditioning system in operation, disconnect the
outlet hose from the old dryer. Disconnect the old dryer.
8. Recover the refrigerant charge from the machine. Refer to
Disassembly and Assembly, "Refrigerant System Recovery" . 6. Stop the engine for 5 minutes to allow the air conditioning
system to equalize pressure.
9. Record the amount of refrigerant and oil that is recovered from
the Air Conditioner system. 7. Connect the outlet hose that was disconnected in Step 6 to the
new dryer.
These values will be needed in order to calculate the amount
of oil that is needed. Refer to Testing and Adjusting, 8. Mark the new dryer in permanent marker Installed mm/dd/yy
"Refrigerant Compressor Oil - Test" Section. to assist in future maintenance of the in-line dryer.
10. If the charge was low, check the system for leaks.
Machine Preparation for Disassembly and
a. Use an Ultraviolet light and use an electronic leak Assembly
detector. Ensure that the following items are checked:
Disassembly and Assembly
• Quick disconnects which are on the dryer UENR4125 i05907618
• Check the drier swivel nut and tighten the nut to 27 ± 4

N·m (20 ± 3 lb ft) . WARNING
• All the connections in the circuit that are O-ring Personal injury can result from contact with refrigerant.
• Hoses for rubbing, bulging, and wet spots (oil leaks) This system is under pressure at all times, even if the engine is
Note: In order to help reveal leaks, simulate the vibrations
which are made by the machine by moving the Contact with refrigerant can cause frost bite. Keep face and
connections. hands away to help prevent injury.
38
Protective goggles must always be worn when refrigerant lines 2. Remove the component or remove the hose that is being
are opened, even if the gauges indicate the system is empty of repaired or replaced. Install protective plugs on components or
refrigerant. hoses that are left exposed to the air.
Always use caution when a fitting is removed. Slowly loosen the 3. Replace any damaged component or hose.
recovering the refrigerant before removing the fitting. 4. Use the following table in order to determine the amount of oil
that is lost during individual replacements of components. Follow
Personal injury or death can result from inhaling refrigerant the process provided in Testing and Adjusting, "Refrigerant Oil -
through a lit cigarette. Test" to calculate the correct amount of oil needed for the
Inhaling air conditioner refrigerant gas through a lit cigarette or system.
other smoking method or inhaling fumes released from a flame Table 1
Oil Capacities for Component Replacements
or death.
Accumulator 30 mL (1 fl oz)
Do not smoke when servicing air conditioners or wherever Refer to the Testing and Adjusting,
Compressor "Refrigerant Compressor Oil - Check"
refrigerant gas may be present. section.
Condenser 30 mL (1 fl oz)
Evaporator 90 mL (3 fl oz)
all implements to the ground. Make sure the transmission is in In-Line Dryer (1) before any oil is installed 30 mL (1 fl oz)
NEUTRAL or PARK and that the parking brake is engaged. Keep Receiver-Dryer 30 mL (1 fl oz)
seen.
5. Refer to the Testing and Adjusting, "Refrigerant System -
Evacuate" section.
WARNING 6. Refer to the Testing and Adjusting, "Refrigerant System -
Charge" section.
system components to cool before the cooling system is drained. Manifold Gauge Set (Refrigerant) - Install
NOTICE SENR5664 i03862454
Never weld or solder any charged components.
WARNING
Note: Before you conduct a performance check, refer to the
Troubleshooting, "Visual Inspection (Troubleshooting)" section. Personal injury can result from contact with refrigerant.
Note: Refer to the Troubleshooting, "Machine Preparation for This system is under pressure at all times, even if the engine is
Troubleshooting" section before service work is performed on not running. Heat should never be applied to a charged system.
the air conditioning system.
When the service work is done on the air conditioning system, hands away to help prevent injury.
the service work must keep the system clean and free from Protective goggles must always be worn when refrigerant lines
contamination. Plugs and caps must be used in order to close are opened, even if the gauges indicate the system is empty of
the components and hoses when the components and hoses are refrigerant.
open. The plugs and caps protect the system from dirt and air
(moisture). Only new refrigerant oil of the correct viscosity and Always use caution when a fitting is removed. Slowly loosen the
new refrigerant can be added to the system. For the correct oil, fitting. If the system is still under pressure, evacuate the system
refer to the Specifications section of this manual. Any other recovering the refrigerant before removing the fitting.
material or any other substance is considered non-condensable
and the material will contaminate the system. Keep the work Personal injury or death can result from inhaling refrigerant
area clean. through a lit cigarette.
• Dust caps on the refrigerant compressor block fitting are the Inhaling air conditioner refrigerant gas through a lit cigarette or
primary seal on the air conditioning system. other smoking method or inhaling fumes released from a flame
• All machines should have an identification tag in the cab or death.
that specifies the proper refrigerant charge for the machine.
When replacement or repair of components and hoses are refrigerant gas may be present.
required, perform the following procedure:
1. Remove the refrigerant charge. Measure the amount of oil made, move the machine to a smooth horizontal surface. Lower
recovered. Refer to the Testing and Adjusting, "Refrigerant all implements to the ground. Make sure the transmission is in
Recovery" and Testing and Adjusting, "Refrigerant Oil - Test" NEUTRAL or PARK and that the parking brake is engaged. Keep
section, for proper procedures. all other personnel away from the machine or where they can be
seen.
39
WARNING
1. Use the 138-6629 Refrigerant Identifier in order to verify that

the refrigerant that is in the air conditioning system is R134a.
2. Connect the manifold gauge set to the service ports near the
refrigerant compressor. The service ports for charging are
located on the refrigerant lines. Connect the low pressure hose
to the service port on the suction side of the compressor. Illustration 2 g01108038
Connect the high pressure hose to the service port on the (18g) Chamber
discharge side of the compressor. Make sure that the valved (18h) Actuator piston
couplings are turned counterclockwise for installation. Then, turn (18i) Spring
the valved couplings clockwise in order to open the valves.
The parking brake is located in front of the center axle. Disc
3. Turn the pressure valves clockwise and make sure that both (18e) is part of the drive line.
pressure valves on the manifold gauge set are closed.
The parking brake is engaged by spring force and the parking
4. Place a clean rag over the charging hose fitting that is brake is disengaged by oil pressure.
loosened at the manifold gauge set. This will prevent the
spraying of compressor oil. Open the low pressure valve on the The parking brake is controlled by the parking brake control in
gauge set about 1/2 turn. Keep the valve open for 2 to 3 seconds the cab. The parking brake engages automatically when the
in order to flush air from the low pressure hose. This will also engine is shut off.
flush air from the gauge set. Close the low pressure valve on the When the parking brake control is moved to the DISENGAGED
gauge set. Repeat this process for the high pressure valve. position, oil flows through line (18d) and into chamber (18g) . The
Tighten the charging hose fitting at the manifold gauge set. oil moves actuator piston (18h) against spring (18i) and rod (18b)
Note: Use the refrigerant identifier. The refrigerant identifier will moves forward. Motion of the rod rotates lever (18f) in the
prevent refrigerants that are not R134a from contaminating the counterclockwise direction which relieves the clamping force
recovery and charging tools. between brake shoes (18a) and disc (18e) .
When the parking brake control is moved to the ENGAGED
Parking Brake position, pressure is relieved from line (18d) and chamber (18g) .
This allows spring (18i) to extend and the spring moves piston
Systems Operation (18h) and rod (18b) . Motion of the rod rotates lever (18f) in the
RENR6725 i02308857 clockwise direction which produces a clamping force between
brake shoes (18a) and disc (18e) . The clamping force opposes
the motion of the disc.
Refrigerant Accumulator - Remove and Install

UENR4125 i05907623
The refrigerant must be recovered before the accumulator is

removed. Refer to the Testing and Adjusting, "Refrigerant
Recovery" section.
Remove the accumulator. The accumulator has an internal oil
drain hole which could become plugged. The oil could be
Illustration 1 g01108037 trapped inside the accumulator. It is necessary to check for
Typical example excessive oil when the accumulator is changed. Add the same
(18a) Brake shoes amount of oil that was drained from the old accumulator. Add an
(18b) Rod
(18c) Actuator
additional 30 mL (1 fl oz) to the new accumulator before the new
(18d) Line accumulator is installed. Do not add oil if the compressor was
(18e) Disc changed also. Evacuate the system and recharge the system.
(18f) Lever Refer to the Testing and Adjusting, "Refrigerant System -
Evacuate" section. Refer to the Testing and Adjusting,
"Refrigerant System - Charge" section.
Note: If the accumulator has frost on the outside, the air
conditioning system still contains refrigerant.
Refrigerant Compressor - Remove and Install

SENR5664 i05907622
40
Removal Refrigerant Expansion Valve - Remove and
Install
UENR4125 i05907624
To replace the expansion valve, use the procedure that follows.

Refer to Service Manual, "Troubleshooting Heating and Air
Conditioning Control System" before service work is performed
on the air conditioning system.
1. Recover the refrigerant.
Note: Cap all disconnected lines and hoses.
Illustration 1 g00742981 2. Remove the insulation and the clip. The insulation and the clip
(1) Bolt hold the sensing bulb to the evaporator outlet pipe.
(2) Drive belt
(3) Suction and discharge hoses 3. Disconnect the sensing line for pressure from the evaporator
(4) Compressor
outlet pipe.
1. Remove the refrigerant charge. Refer to the Testing and
Adjusting, "Refrigerant Recovery" section. 4. Loosen and remove the two connections at the expansion
valve. Remove the expansion valve.
2. Disconnect electrical wires from the magnetic clutch.
Note: Check the O-ring seals. The seals must be in good
3. Loosen all the mounting bolts and loosen the belt tightener (if condition and the seals must be properly lubricated with the
equipped). Remove drive belt (2) . correct refrigerant oil before assembly.
4. Disconnect hoses (3) and put plugs or caps on the hoses. Put 5. Install the expansion valve for replacement and tighten the
plugs or caps on the fittings of the compressor. Put identification two connections.
marks on the hoses. The marks will ensure that the hoses will be
connected correctly at a later time. 6. Tighten the pressure sensing connection on the evaporator
outlet pipe.
5. Remove all the mounting bolts and remove the compressor (4) .
The weight of the compressor is approximately 18 kg (40 lb) . 7. Use a 8P-6355 Clip to hold the sensing bulb onto the
evaporator outlet pipe. The sensing bulb should be as close to
Installation the coil as possible. The bulb should be upstream of the pressure
sensing connection on the evaporator outlet pipe. The 5P-7070
1. Check the amount and condition of the oil in the compressor Insulation should be wrapped tightly around the clip, the sensing
(4) . Refer to the Testing and Adjusting, "Refrigerant Compressor bulb, and the outlet pipe. There should be no insulation between
Oil-Test" section. the bulb and the outlet pipe.
2. Inspect the drive belt (2) . If the drive belt (2) is damaged or 8. Tighten all the connections correctly.
worn replace the belt. 9. Evacuate the system. Refer to the Testing and Adjusting,
3. Install the compressor (4) . Do not tighten the mounting bolts "Refrigerant System - Evacuate" section.
until drive belt (2) is installed and adjusted. 10. Charge the system with the correct amount of refrigerant by
4. Connect the discharge and the suction hoses (3) to the weight. Refer to the Testing and Adjusting, "Refrigerant System -
discharge and suction ports on the compressor. Charge" section.
5. Connect the electrical wires to the magnetic clutch. Refrigerant Leakage - Test
6. Evacuate the system. Refer to the Testing and Adjusting, Testing and Adjusting
"Refrigerant System - Evacuate" section. UENR4125 i05907592
7. Charge the system. Refer to the Testing and Adjusting, Dye

"Refrigerant System - Charge" section.
8. For the correct system operation, refer to the Troubleshooting WARNING
Section in this manual.
Note: Refer to the Specifications, "Refrigerant Compressor" in
the Section for the correct belt tension. This system is under pressure at all times, even if the engine is
9. For the oil level in the system, refer to Service Manual,
"Refrigerant Compressor Oil - Check" . Contact with refrigerant can cause frost bite. Keep face and
41
Protective goggles must always be worn when refrigerant lines 2. If a leak is found in the air conditioning system, use a 4C-2964
are opened, even if the gauges indicate the system is empty of Refrigerant Leak Detector in order to confirm the leak that was
refrigerant. detected by the use of the black light.
Always use caution when a fitting is removed. Slowly loosen the 3. Repair the leak In the air conditioning system and clean the
fitting. If the system is still under pressure, evacuate the system area with 192-4727 Dye Cleaning Solution .
Personal injury or death can result from inhaling refrigerant Leak Detector
The 208-1374 Refrigerant Leak Detectors are designed in order to
Inhaling air conditioner refrigerant gas through a lit cigarette or detect leaks as small as 7.4 mL (.25 oz) per year of refrigerant in
other smoking method or inhaling fumes released from a flame the air conditioning system. Perform the following procedure in
contacting air conditioner refrigerant gas, can cause bodily harm order to determine if the system has a leak.
or death.
The system must contain at least 0.4 kg (.88 lb) of refrigerant.
Do not smoke when servicing air conditioners or wherever Install the manifold gauge set. The manifold gauge set can
refrigerant gas may be present. determine if pressure exists in the system. A leak test can be
performed if the system indicates pressure.
made, move the machine to a smooth horizontal surface. Lower Note: Refrigerant vapor is heavier than air. For best results,
all implements to the ground. Make sure the transmission is in place the sensor tip directly below possible leaks.
all other personnel away from the machine or where they can be Note: Leaks in the high-pressure side of the system are more
seen. easily found if the air conditioner is operated for a few minutes.
The leak test must be performed immediately after the unit is
turned OFF . The leak test for the high-pressure side is performed
WARNING before the pressures in the system equalize. Leaks in the low-
pressure side of the system are more easily found if the air
Personal injury can result from hot coolant. Any contact with hot conditioner has been turned OFF for several minutes. The leak
coolant or with steam can cause severe burns. Allow cooling test for the low-pressure side is performed after the pressures in
system components to cool before the cooling system is drained. the system equalize.
1. Move the sensor tip along possible leak points at a rate of 1
Table 1 inch per second.
Required Tools
Part Number Part Description Quantity 2. It may not be necessary to recover refrigerant if a loose fitting
192-2331 Leak Detection Lamp Gp 1 or a loose connection is causing a leak. Tighten the loose
connection and perform the performance check procedure. If
In the middle of , Caterpillar began installing dye in the necessary, add refrigerant to the air conditioning system. Refer
refrigeration systems of Caterpillar machines. The dye is used in to the Testing and Adjusting, "Refrigerant System - Charge"
order to assist in identifying points of leakage in the refrigeration section for the proper procedure.
system.
3. If the repair of a leak calls for the removal or the replacement
Finding leaks and repairing leaks from refrigerant is important of a component, refer to the Disassembly and Assembly,
since the air conditioner is a closed circuit system. "Machine Preparation for Disassembly and Assembly" within this
manual.
The system must contain at least 0.4 kg (.88 lb) of refrigerant.
Install the manifold gauge set. The manifold gauge set can Note: Refrigerants that are not approved by Caterpillar may have
determine if pressure exists in the system. A leak test can be higher leakage rates.
performed if the system indicates pressure.
Refrigerant Oil - Test
Note: Refrigerant vapor is heavier than air. For best results,
place the black light directly below possible leaks. Testing and Adjusting
SENR5664 i05907605
Note: Leaks that are in the high-pressure side of the system are
more easily found if the air conditioner is operated for 5 to 10
minutes. The leak test must be performed immediately after the WARNING
unit is turned OFF . The leak test for the high-pressure side is
performed before the pressures in the system equalize. Leaks Personal injury can result from contact with refrigerant.
that are in the low-pressure side of the system are more easily
found if the air conditioner has been turned OFF for 5 to 10 This system is under pressure at all times, even if the engine is
minutes. The leak test for the low-pressure side is performed not running. Heat should never be applied to a charged system.
after the pressures in the system equalize. Contact with refrigerant can cause frost bite. Keep face and
1. Move the black light along possible leak points. When a leak is hands away to help prevent injury.
present, the black light will illuminate the dye that is in the Protective goggles must always be worn when refrigerant lines
refrigerant. are opened, even if the gauges indicate the system is empty of
refrigerant.
Note: Leaks that are indicated by the presence of dye should
always be confirmed with an electronic leak detector.
42
Always use caution when a fitting is removed. Slowly loosen the • (A) Oil that is removed from the system during refrigerant
fitting. If the system is still under pressure, evacuate the system recovery. Refer to Testing and Adjusting, "Refrigerant
recovering the refrigerant before removing the fitting. Recovery" in order to see the correct procedure for
recovering refrigerant. Record the amount of oil that is
Personal injury or death can result from inhaling refrigerant collected during the recovery.
• (B) Oil that is removed from the system due to component
Inhaling air conditioner refrigerant gas through a lit cigarette or replacement, other than the A/C compressor . Refer to "Oil
other smoking method or inhaling fumes released from a flame Capacities for Component Replacements" . Refer to Table 1 .
or death. • (C) Oil is removed due to replacing the A/C compressor.
Do not smoke when servicing air conditioners or wherever Refer to Check of A/C System Oil .
Replacing a Component
made, move the machine to a smooth horizontal surface. Lower When the replacement of a component is necessary, follow the
all implements to the ground. Make sure the transmission is in procedures below.
all other personnel away from the machine or where they can be Note: If the failure of a component, causes particles of metal or
seen. other foreign material to be introduced into the system. flushing
the system will be necessary. Refer to Troubleshooting,
"Refrigerant System Flush" to make sure of proper diagnostics.
Replacing both the orifice tube and receiver dryer is
WARNING recommended in the event of A/C system contamination. Flushing
of the A/C lines, condenser, and evaporator components will be
Personal injury can result from hot coolant. Any contact with hot necessary to safe guard installation of a new compressor.
coolant or with steam can cause severe burns. Allow cooling Failure to do so could void component warranties.
1. If, the A/C system is operable operate the engine at 1000 rpm.
Specifications Set the temperature on maximum cooling setting. Move the fan
speed switch to HIGH . The system will stabilize in a minimum of
Table 1 10 minutes.
Oil Capacities for Component Replacements
Accumulator 30 mL (1 fl. oz)
2. Stop the engine. Remove the refrigerant charge from the
system. Refer to Testing and Adjusting, "Refrigerant Recovery" .
Refer to the Testing and Adjusting,
Compressor "Refrigerant Compressor Oil-Check" section.
Condenser 30 mL (1 fl. oz)
3. Remove any components as needed. Install a plug in all open
lines as necessary.
Evaporator 90 mL (3 fl. oz)
In-Liner Dryer (1) 30 mL (1 fl. oz) 4. Replaced any damaged components
Receiver - Dryer 30 mL (1 fl. oz)
5. Refer to table 1 to determine amount of oil volume of replaced
components.
Introduction
6. Add the amount of oil from recovery plus the amount for each
Oil supplies the necessary lubrication in the refrigerant circuit replaced component back to the system.
for the compressor. Too little oil in the circuit can cause the
compressor to seize. Too much oil decreases the amount of 7. Perform refrigerant system evacuation procedures. Refer to
cooling that is supplied to the operator. Testing and Adjusting, "Refrigerant System Evacuate" .
The procedures outlined in this publication describe a process Replacing the A/C Compressor
for ensuring the appropriate concentration of oil in the
refrigerant circuit when oil has been removed from the circuit. If the A/C compressor is being replaced, the refrigerant oil (PAG,
All systems are charged with oil from the factory. This process POE) must be adjusted by using the procedure that is outlined
assumes that the factory fill oil amount is still in the system. This below. If refrigerant is still contained within the air conditioning
process assumes that a minimal amount of oil has been lost due system, then follow the steps for recovery.
to leakage of pressure relief.
1. Perform the procedures outlined in Testing and Adjusting,
Check of A/C System Oil "Refrigerant Recovery" .
Whenever the refrigerant or a component for the air conditioning
unit is removed, some of the refrigerant oil is also removed. The
correct amount of oil must be replaced. The following three
examples are conditions refrigerant oil must be replaced.
Note: If oil has leaked from the system prior to service, then the
system oil charge cannot be accurately determined. Proper oil
charge can now only be determined by flushing and using
method for oil charge after system flush. refer to Testing and
Adjusting, "Refrigerant System Flush" "Oil Charge After System
Flush" .
43
6. Determine the amount of oil required by the A/C system (A/C
System Oil) . Add the oil from recovery (A) , plus the amount of oil
for other components being replaced (B) per Table 1 , plus the
amount of oil removed from the old compressor (C) . The sum of
the following: A+B+C = A/C System Oil.
7. Finally, take the value for New Compressor Oil and subtract
A/C System Oil to determine the amount of oil that must be
drained. The oil must be drained from the new compressor prior
to installation to prevent an oil overcharge. New Compressor Oil
- A/C System Oil = Oil amount to drain from new compressor.
Example:
• Amount of oil from recovery (A) equals 60 mL (2 oz) .
(1) Pulley
(2) Hose (low pressure)
• If the dryer was replaced, the amount of oil due to
(3) Hose (high pressure) component replacement (B) equals 30 mL (1 oz) .
(4) Electrical harness
(5) Service valve (low pressure) • Oil drained from the old compressor (C) equals 90 mL (3 oz) .
(6) Service valve (high pressure)
(7) Plug (oil change) • Amount of oil contained inside new compressor as read from
(8) Belt
the label (New Compressor Oil) equals 300 mL (10.2 oz) .
2. Remove the old compressor from the air conditioning system.
Place protective caps on all fittings and hoses. Then A/C System Oil = A + B+ C = 60 + 30 + 90 = 180 mL (6.1
oz) .
3. Place the compressor in a horizontal position on a bench or
suitable work surface so oil plug (7) is facing downward. Remove Finally, New Compressor Oil - A/C System Oil = 300 – 180 = 120
oil plug (7) from the compressor. Drain the oil into a clean mL (4.1 oz) .
metered container. Rock the compressor back and forth in order In the above example, 120 mL (4.1 oz) of oil should be drained
to remove all of the oil. Also, rotate the compressor shaft in order from the new compressor.
to drain the rest of the oil that is in the oil sump. Record the
volume of drained refrigerant. Inspect the oil for the following Note: In some instances the above calculation could yield a
items: negative value. In these instances the amount of oil should
NOT be drained from the compressor, but rather the oil should
• Contaminants be ADDED to the A/C system.
• Metal chips 8. Install the new A/C compressor.
• Rubber particles 9. Perform refrigerant system evacuation procedures. Refer to
• Foreign material Testing and Adjusting, "Refrigerant System Evacuate" .
Note: If, the failure of a compressor causes particles of metal Refrigerant Orifice Tube Assembly - Remove
or other foreign material to be introduced into the system. and Install
flushing the system will be necessary. Refer to
Troubleshooting, "Refrigerant System Flush" for the proper Disassembly and Assembly
diagnostics. Replacing both the orifice tube and accumulator UENR4125 i05907628
/receiver dryer is recommended in the event of A/C system
contamination. Flushing of the A/C lines, condenser, and The orifice tube may be located in the refrigerant line near the
evaporator components will be necessary to safe guard evaporator inlet, or in the in-line dryer.
installation of a new compressor. Failure to do so could void
component warranties. If the orifice tube is located in the refrigerant line near the
evaporator inlet, use the procedure that follows. If the orifice
4. Record the amount of oil from old compressor. tube is located in the in-line dryer, refer to Dryer Replacement.
5. Refer to specifications for new compressor to determine type
oil and compressor volume. Removing the Orifice Tube
Note: Do not use Polyalkylene Glycol (PAG) oil (134A) in 294- Refer to Safety Requirements before service work is performed
8140 Compressor Assembly . Use Polyol Ester (POE) oil. The on the air conditioning system.
use of any other will cause rapid dielectric failure of the The refrigerant must be recovered before removing the
compressor. accumulator. Refer to the Testing and Adjusting, "Refrigerant
Note: The new A/C compressor will already contain oil inside. Recovery" section.
Certain new compressors will contain a volume of oil of 180
ml, while other new compressors contain a volume of 300 ml. NOTICE
Do not attempt to remove the orifice tube with pliers. Do not
twist or rotate the orifice tube in the tube assembly.
44
2. Place the orifice tube into the 1U-9890 Orifice Removal Tool .
Insert the orifice tube straight into the evaporator inlet tube
without twisting until the tube is seated.
3. Disengage the removal tool from the orifice tube.
4. Use a new O-Ring that is lubricated with clean refrigerant oil.
Reconnect the high side line at the enlarged section of the
evaporator inlet port.
5. Do a leak test. Evacuate the system and recharge the system.
Refer to the Testing and Adjusting, "Refrigerant Systems-
Evacuate" section. Also, refer to the Testing and Adjusting,
"Refrigerant Systems-Charge" section.
Orifice tube
(1) O-Ring seals Refrigerant Receiver-Dryer - Remove and
(2) Lugs
(3) Body
Install
(4) Drive screw
(5) Finger lock Operations and Maintenance Manual
M0107500 i05907625
1. Disconnect the high side line at the enlarged section of the
evaporator inlet port. This will expose the orifice tube for
removal.
2. Align the short fingers of the 1U-9890 Orifice Removal Tool
with the ribs of the orifice tube. Insert the tool onto the tube until
the tool bottoms out.
3. Turn drive screw (4) clockwise. Turn far enough to engage the
lugs (2) on the orifice tube in the finger lock (5) . The finger lock
(5) is part of the removal tool.
4. Hold the drive screw (4) stationary. Thread the body (3)
forward until the body makes contact with the inlet port.
5. Continue holding the drive screw stationary, and thread the Illustration 1 g01257459
body forward until the orifice tube becomes free. Top View of Receiver-Dryer
(1) Inlet
(2) Quick Disconnect Fittings
(3) Moisture Indicator
(4) Outlet
NOTICE
If the receiver-dryer does not have air conditioner quick
disconnects, the system must be recovered, evacuated, and
recharged after the receiver-dryer has been replaced.
The refrigerant that is in the system must be recovered if the

receiver-dryer does not have air conditioner quick disconnects
(2) . Refer to the Testing and Adjusting, "Refrigerant Recovery"
section before you remove the receiver-dryer. If the receiver-
dryer has air conditioner quick disconnects (2) , use the
Removing the broken orifice tube procedure that follows.
(3) Body
(4) Drive screw Refer to Safety Requirements before service is performed on the
(6) Extractor tip air conditioning system.
6. For the removal of the orifice tube assembly, use the extractor 1. Stop the engine for 5 minutes to allow the air conditioning
tip (6) on 1U-9890 Orifice Removal Tool . Insert the tool into the system to equalize the pressure.
evaporator inlet tube and thread the tool into the brass center of
the orifice tube. 2. Disconnect the inlet hose (1) from the old receiver-dryer at the
air conditioner quick disconnects.
7. Repeat steps 3 and 4.
3. Connect the hose that was disconnected in Step 2 to the inlet
8. If only the brass center of the orifice tube is removed, thread on the new receiver-dryer.
the tool into the plastic body and repeat step 3 and 4.
4. Disconnect the electrical connections on the old receiver-
Orifice Tube Installation dryer. Connect the electrical connections to the new receiver-
dryer.
1. Lubricate the O-Ring on the orifice tube with the proper clean
refrigerant oil.
45
Note: If the receiver-dryer has quick disconnects, do not add If service work is required on an air conditioning system, the
additional oil or refrigerant to the system. refrigerant must be recovered first before components are
removed or installed. Use the following procedure:
5. Start the engine. Operate the air conditioning system for 1
minute. 1. Use the refrigerant identifier. The refrigerant identifier will
detect refrigerants that are not R134a . The refrigerant identifier
6. With the air conditioning system in operation, disconnect the will prevent the refrigerants from contaminating the tools for
outlet hose (4) from the old receiver-dryer. Disconnect the old recovery and the tools for charging. The refrigerant identifier will
receiver-dryer at the air conditioner quick disconnects. also detect the percentage of air that may be in the system.
7. Stop the engine for 5 minutes to allow the air conditioning
system to equalize pressure.
8. Connect the outlet hose (4) that was disconnected in step 6 to
the new receiver-dryer.
Note: The receiver-dryer must be replaced annually. The
receiver-dryer must also be replaced whenever the system is
opened. The receiver-dryer should be replaced if moisture
indicator (3) is filled with moisture. Moisture indicator (3) will
display a pink color or white color if the receiver-dryer is full of
moisture.
Refrigerant Recovery
UENR4125 i05907596
WARNING Illustration 1 g00389232

(1) Low-pressure valve. (2) High-pressure valve. (3) Charging hose. (4) Low-pressure hose.
Personal injury can result from contact with refrigerant. (5) High-pressure hose. (6) Manifold gauge set. (7) Control panel. (8) Inlet on recovery
station. (9) Accumulator/oil separator. (10) Drain valve. (11) Pressure valve on accumulator.
(12) Compressor. (13) Refrigerant tank. (14) Hose (liquid). (15) Hose (vapor). (16) Refrigerant
This system is under pressure at all times, even if the engine is pump. (17) Filter dryer. (18) Scale. (A) Refrigerant compressor. (B) Low-pressure side
not running. Heat should never be applied to a charged system. (suction). (C) High-pressure side (discharge).
Contact with refrigerant can cause frost bite. Keep face and 2. Install the manifold gauge set (6) . Make sure that both valves
hands away to help prevent injury. are closed. Turn the valves clockwise in order to close the
valves. Refer to the Testing and Adjusting, "Manifold Gauge Set
Protective goggles must always be worn when refrigerant lines (Refrigerant) - Install" section.
refrigerant. Note: Do not operate the engine.
Always use caution when a fitting is removed. Slowly loosen the 3. Attach charging hose (3) of the Manifold gauge set to the inlet
fitting. If the system is still under pressure, evacuate the system (8) on the refrigerant service unit.
4. Slowly open valves (1) and (2) in order to release the air from
Personal injury or death can result from inhaling refrigerant the charging hose. Ensure that the valves on the refrigerant tank
through a lit cigarette. (13) are open. One valve is for vapor and the other valve is for
liquid.
other smoking method or inhaling fumes released from a flame 5. Plug the recovery station into an electrical outlet and turn the
contacting air conditioner refrigerant gas, can cause bodily harm power switch ON . This switch is located on the control panel (7)
or death. .
Do not smoke when servicing air conditioners or wherever 6. Press the "Compressor Start" . The amber "Compressor On"
refrigerant gas may be present. light will come on and compressor (12) will start. The compressor
Before any checks of the air conditioning and heating system are will automatically shut off when the recovery of refrigerant is
made, move the machine to a smooth horizontal surface. Lower complete.
NEUTRAL or PARK and that the parking brake is engaged. Keep 7. Drain accumulator (9) of refrigerant oil. Open accumulator
all other personnel away from the machine or where they can be pressurizing valve (11) long enough so that some discharge from
seen. the compressor can flow back to the accumulator. Open oil drain
valve (10) slowly and drain the oil into a measuring cup. Do not
allow a complete loss of pressure in the accumulator/oil
separator. When the oil stops draining, close oil drain valve (10) .
WARNING
8. If 15.0 mL (.50 fl oz) of compressor oil was lost during the
Personal injury can result from hot coolant. Any contact with hot recovery process, new oil must be added to the system. Refer to
coolant or with steam can cause severe burns. Allow cooling the Testing and Adjusting, "Refrigerant Compressor Oil - Check"
system components to cool before the cooling system is drained. section.
46
9. The system must be cleaned and the system must be flushed if Table 2 contains the recommended charges for the compressors
any particles of metal or other foreign material from a component that are listed below:
failure have circulated through the system. Debris in the system
can cause the compressor to fail . Refer to Testing and • 3E-1906 Refrigerant Compressor Gp
Adjusting, "Refrigerant System - Flush" .
• 3E-1908 Refrigerant Compressor Gp
Oil and Refrigerant Charge for the Air Conditioning
• 106-5122 Refrigerant Compressor Gp
System
NOTICE
The addition of oil to the air conditioning system is applicable • 178-9570 Refrigerant Compressor Gp
only after the flush of the entire air conditioning system. If an air
conditioning system is overcharged with oil, the result is a • 183-5106 Refrigerant Compressor Gp
decrease of the cooling performance and damage to the
compressor may occur. • 218-0324 Refrigerant Compressor Gp
Note: Refer to one of the tables below for your particular
application. Note: The new compressors that are listed above contain 300 ml
of oil. The total charge for the air conditioning system must equal
Table 1 contains the recommended charges for the compressors the total amount from Table 2 and the oil that is already added in
that are listed below : a new compressor.
• 214-4302 Refrigerant Compressor Gp Table 2
Recommended Charges for the Air Conditioning System
• 217-4448 Refrigerant Compressor Gp Refrigerant Oil (1)
1.1 kg (2.5 lb) 0
1.2 kg (2.75 lb) 0
• 272-5767 Refrigerant Compressor Gp 1.4 kg (3 lb) 0
1.5 kg (3.25 lb) 0
Note: The new compressors that are listed above contain 180 ml 1.6 kg (3.5 lb) 0
of oil. The total charge for the air conditioning system must equal 1.7 kg (3.75 lb) 30
the total amount from Table 1 and the oil that is already added in 1.8 kg (4 lb) 50
a new compressor. 1.9 kg (4.25 lb) 70
2.0 kg (4.5 lb) 90
Table 1
2.2 kg (4.75 lb) 110
2.3 kg (5.0 lb) 130
Refrigerant Oil (1) (2)
2.4 kg (5.25 lb) 150
1.1 kg (2.5 lb) 30
2.5 kg (5.5 lb) 170
1.2 kg (2.75 lb) 60
2.6 kg (5.75 lb) 190
1.4 kg (3 lb) 80
2.7 kg (6.0 lb) 210
1.5 kg (3.25 lb) 100
2.8 kg (6.25 lb) 230
1.6 kg (3.5 lb) 120
2.9 kg (6.5 lb) 260
1.7 kg (3.75 lb) 140
3.1 kg (6.75 lb) 280
1.8 kg (4 lb) 160
3.2 kg (7.0 lb) 300
1.9 kg (4.25 lb) 190
3.3 kg (7.25 lb) 330
2.0 kg (4.5 lb) 210
3.4 kg (7.5 lb) 350
2.2 kg (4.75 lb) 230
3.5 kg (7.75 lb) 370
2.3 kg (5.0 lb) 250
3.6 kg (8.0 lb) 390
2.4 kg (5.25 lb) 270
3.7 kg (8.25 lb) 410
2.5 kg (5.5 lb) 290
3.9 kg (8.5 lb) 430
2.6 kg (5.75 lb) 320
4.0 kg (8.75 lb) 450
2.7 kg (6.0 lb) 340
4.1 kg (9.0 lb) 480
2.8 kg (6.25 lb) 360
2.9 kg (6.5 lb) 380
3.1 kg (6.75 lb)
3.2 kg (7.0 lb)
400
420
Refrigerant System - Charge
3.3 kg (7.25 lb) 440 Operations and Maintenance Manual
3.4 kg (7.5 lb) 470 M0107500 i05907609
3.5 kg (7.75 lb) 490
3.6 kg (8.0 lb) 510
3.7 kg (8.25 lb) 530 WARNING
3.9 kg (8.5 lb) 550
4.0 kg (8.75 lb) 570
4.1 kg (9.0 lb) 600
This system is under pressure at all times, even if the engine is
47
Contact with refrigerant can cause frost bite. Keep face and • Incorrect refrigerant
• Incorrect refrigerant charge
are opened, even if the gauges indicate the system is empty of Table 2
refrigerant. Relationship Between Temperature and Pressure ( R-134a Refrigerant)
Always use caution when a fitting is removed. Slowly loosen the Temperature °C (°F) Pressure kPa (psi) (1)
fitting. If the system is still under pressure, evacuate the system −18 °C (0.0 °F) 44 kPa (6.4 psi)
recovering the refrigerant before removing the fitting. −17° C (2.0 °F) 51 kPa (7.4 psi)
−16 °C (4.0 °F) 59 kPa (8.5 psi)
Personal injury or death can result from inhaling refrigerant −14 °C (6.0 °F) 66 kPa (9.6 psi)
through a lit cigarette. −13 °C (8.0 °F) 74 kPa (10.7 psi)
−12 °C (10.0 °F) 82 kPa (11.9 psi)
other smoking method or inhaling fumes released from a flame −11 °C (12.0 °F) 90 kPa (13.1 psi)
contacting air conditioner refrigerant gas, can cause bodily harm −10 °C (14.0 °F) 99 kPa (14.3 psi)
or death. −9 °C (16.0 °F) 108 kPa (15.6 psi)
−8 °C (18.0 °F) 117 kPa (17.0 psi)
Do not smoke when servicing air conditioners or wherever −7 °C (20.0 °F) 127 kPa (18.4 psi)
refrigerant gas may be present. −6 °C (21.0 °F) 132 kPa (19.1 psi)
−6 °C (22.0 °F) 137 kPa (19.8 psi)
−5 °C (23.0 °F) 141 kPa (20.5 psi)
all implements to the ground. Make sure the transmission is in −4 °C (24.0 °F) 147 kPa (21.3 psi)
NEUTRAL or PARK and that the parking brake is engaged. Keep −4 °C (25.0 °F) 152 kPa (22.0 psi)
all other personnel away from the machine or where they can be −3 °C (26.0 °F) 157 kPa (22.8 psi)
seen. −3 °C (27.0 °F) 163 kPa (23.6 psi)
−2 °C (28.0 °F) 168 kPa (24.4 psi)
−2 °C (29.0 °F) 174 kPa (25.2 psi)
WARNING −1 °C (30.0 °F) 179 kPa (26.0 psi)
−1 °C (31.0 °F) 185 kPa (26.8 psi)
Personal injury can result from hot coolant. Any contact with hot 0 °C (32.0 °F) 191 kPa (27.7 psi)
coolant or with steam can cause severe burns. Allow cooling 1 °C (33.0 °F) 197 kPa (28.5 psi)
system components to cool before the cooling system is drained. 1 °C (34.0 °F) 203 kPa (29.4 psi)
2 °C (35.0 °F) 209 kPa (30.3 psi)
Note: To avoid cross contamination of Polyalkylene Glycol (PAG) 2 °C (36.0 °F) 215 kPa (31.2 psi)
oil and Polyol Ester (POE) electric drive compressor oil: 3 °C (37.0 °F) 221 kPa (32.1 psi)
3 °C (38.0 °F) 228 kPa (33.0 psi)
• Flush the service hoses (red, blue, and yellow) and R-134a 4 °C (39.0 °F) 234 kPa (34.0 psi)
Couplers (high and low side) with an approved solvent for R- 4 °C (40.0 °F) 241 kPa (34.9 psi)
134a air conditioning systems before servicing the air 5 °C (41.0 °F) 248 kPa (35.9 psi)
conditioning system 6 °C (42.0 °F) 254 kPa (36.9 psi)
• Or use new service hoses and couplers on D7E machines. 6 °C (43.0 °F) 261 kPa (37.9 psi)
Reference service hose part numbers 272-3091 red, 208-1335 7 °C (44.0 °F) 263 kPa (38.9 psi)
blue, 208-1334 yellow hoses, and 208-1339 coupler (low side), 7 °C (45.0 °F) 275 kPa (39.9 psi)
208-1340 coupler (high side). 8 °C (46.0 °F) 283 kPa (41.0 psi)
8 °C (47.0 °F) 290 kPa (42.0 psi)
Table 1 9 °C (48.0 °F) 297 kPa (43.1 psi)
Required Tools 9 °C (49.0 °F) 305 kPa (44.2 psi)
Part Number Part Description Quantity 10 °C (50.0 °F) 312 kPa (45.3 psi)
4C-4874 Heater Blanket As 1 11 °C (51.0 °F) 320 kPa (46.4 psi)
11 °C (52.0 °F) 328 kPa (47.5 psi)
Relationship Between Temperature and Pressure ( R- 12 °C (53.0 °F) 336 kPa (48.7 psi)
134a Refrigerant) 12 °C (54.0 °F) 344 kPa (49.9 psi)
13 °C (55.0 °F) 352 kPa (51.0 psi)
Table 2 can be used in order to determine the pressure level and 13 °C (56.0 °F) 360 kPa (52.2 psi)
contamination level of a container of refrigerant. Table 2 can 14 °C (57.0 °F) 369 kPa (53.5 psi)
also be used for an air conditioning system that is not operating. 14 °C (58.0 °F) 377 kPa (54.7 psi)
This same system must be stabilized to the ambient temperature. 15 °C (59.0 °F) 385 kPa (55.9 psi)
In order to stabilize an air conditioning system at the ambient 16 °C (60.0 °F) 394 kPa (57.2 psi)
temperature, the machine must not operate for 10 to 12 hours. 16 °C (61.0 °F) 403 kPa (58.2 psi)
The machine must not be stored in direct sunlight.
17 °C (62.0 °F) 412 kPa (59.8 psi)
If the measured pressure at any specific temperature does not 17 °C (63.0 °F) 421 kPa (61.1 psi)
match the pressure that is given in the chart, the following 18 °C (64.0 °F) 430 kPa (62.4 psi)
problems may exist: 18 °C (65.0 °F) 440 kPa (63.8 psi)
19 °C (66.0 °F) 450 kPa (65.2 psi)
• Contaminants in the system 19 °C (67.0 °F) 459 kPa (66.8 psi)
48
20 °C (68.0 °F) 469 kPa (68.0 psi) 56 °C (133.0 °F) 1422 kPa (206.3 psi)
21 °C (69.0 °F) 478 kPa (69.4 psi) 57 °C (134.0 °F) 1443 kPa (209.3 psi)
21 °C (70.0 °F) 488 kPa (70.8 psi)
22 °C (71.0 °F) 498 kPa (72.3 psi)
22 °C (72.0 °F) 509 kPa (73.8 psi) Procedure for Labeling
23 °C (73.0 °F) 519 kPa (75.3 psi)
23 °C (74.0 °F) 530 kPa (76.8 psi)
Attach a label to the air conditioning system that indicates the
system charge. Attaching a label to the system will allow easy
24 °C (75.0 °F) 540 kPa (78.3 psi)
identification of the system. Refer to Table 3 for the part number
24 °C (76.0 °F) 551 kPa (79.9 psi)
of the appropriate label. A 8L-8413 Cable Strap may be used in
25 °C (77.0 °F) 562 kPa (81.5 psi) order to secure the tag to the air conditioning system.
26 °C (78.0 °F) 573 kPa (83.1 psi)
26 °C (79.0 °F) 584 kPa (84.7 psi) Table 3
27 °C (80.0 °F) 595 kPa (86.3 psi) System Capacity Part Number for Label
27 °C (81.0 °F) 607 kPa (88.0 psi) 9U-7551 Air Conditioner Oil
28 °C (82.0 °F) 618 kPa (89.7 psi) 1.5 kg (3.31 lb) 130-4677
28 °C (83.0 °F) 630 kPa (91.4 psi) 1.8 kg (3.97 lb) 114-0050
29 °C (84.0 °F) 642 kPa (93.1 psi) 1.9 kg (4.19 lb) 114-0051
29 °C (85.0 °F) 654 kPa (94.8 psi) 2.0 kg (4.41 lb) 114-0052
30 °C (86.0 °F) 666 kPa (96.6 psi) 2.1 kg (4.63 lb) 114-0053
31 °C (87.0 °F) 678 kPa (98.4 psi) 2.2 kg (4.85 lb) 114-0054
31 °C (88.0 °F) 691 kPa (100.2 psi) 2.3 kg (5.07 lb) 114-0055
32 °C (89.0 °F) 703 kPa (102.0 psi) 2.5 kg (5.51 lb) 114-0056
32 °C (90.0 °F) 716 kPa (103.8 psi) 2.7 kg (5.95 lb) 114-0057
33 °C (91.0 °F) 729 kPa (105.7 psi) 3.0 kg (6.61 lb) 114-0058
33 °C (92.0 °F) 742 kPa (107.6 psi) 3.1 kg (6.83 lb) 140-7484
34 °C (93.0 °F) 755 kPa (109.5 psi) 4C-2959 Air Conditioner Oil
34 °C (94.0 °F) 768 kPa (111.4 psi) 1.6 kg (3.54 lb) 114-0059
35 °C (95.0 °F) 782 kPa (113.4 psi) 1.7 kg (3.75 lb) 114-0060
36 °C (96.0 °F) 796 kPa (115.4 psi) 1.8 kg (3.97 lb) 114-0061
36 °C (97.0 °F) 809 kPa (117.4 psi) 1.9 kg (4.19 lb) 114-0062
37 °C (98.0 °F) 823 kPa (119.4 psi) 2.0 kg (4.41 lb) 114-0063
37 °C (99.0 °F) 838 kPa (121.5 psi) 2.1 kg (4.63 lb) 114-0064
38 °C (100.0 °F) 852 kPa (123.5 psi) 2.2 kg (4.85 lb) 114-0065
38 °C (101.0 °F) 866 kPa (125.6 psi) 2.3 kg (5.07 lb) 114-0066
39 °C (102.0 °F) 881 kPa (127.8 psi) 2.4 kg (5.29 lb) 114-0067
39 °C (103.0 °F) 896 kPa (129.9 psi) 2.5 kg (5.51 lb) 114-0068
40 °C (104.0 °F) 911 kPa (132.1 psi) 2.6 kg (5.73 lb) 114-0048
41 °C (105.0 °F) 926 kPa (134.3 psi) 2.7 kg (5.95 lb) 114-0069
41 °C (106.0 °F) 941 kPa (136.5 psi) 3.0 kg (6.61 lb) 114-0070
42 °C (107.0 °F) 956 kPa (138.7 psi) 3.8 kg (8.38 lb) 114-0071
42 °C (108.0 °F) 972 kPa (141.0 psi) 4C-2960 Air Conditioner Oil
43 °C (109.0 °F) 988 kPa (143.3 psi) 1.1 kg (2.42 lb) 122-3300
43 °C (110.0 °F) 1004 kPa (145.6 psi) 1.4 kg (3.09 lb) 114-0072
44 °C (111.0 °F) 1020 kPa (147.9 psi) 1.5 kg (3.31 lb) 114-0073
44 °C (112.0 °F) 1036 kPa (150.3 psi) 1.6 kg (3.53 lb) 114-0074
45 °C (113.0 °F) 1053 kPa (152.7 psi) 1.7 kg (3.75 lb) 114-0075
46 °C (114.0 °F) 1069 kPa (155.1 psi) 1.8 kg (3.97 lb) 114-0076
46 °C (115.0 °F) 1087 kPa (157.6 psi) 1.9 kg (4.19 lb) 114-0077
47 °C (116.0 °F) 1103 kPa (160.0 psi) 2.0 kg (4.41 lb) 114-0078
47 °C (117.0 °F) 1120 kPa (162.5 psi) 2.1 kg (4.63 lb) 114-0079
48 °C (118.0 °F) 1138 kPa (165.1 psi) 2.2 kg (4.85 lb) 114-0080
48 °C (119.0 °F) 1156 kPa (167.6 psi) 2.3 kg (5.07 lb) 114-0081
49 °C (120.0 °F) 1173 kPa (170.2 psi) 2.4 kg (5.29 lb) 114-0082
49 °C (121.0 °F) 1191 kPa (172.8 psi) 2.5 kg (5.51 lb) 114-0083
50 °C (122.0 °F) 1209 kPa (175.4 psi) 2.6 kg (5.73 lb) 114-0084
51 °C (123.0 °F) 1228 kPa (178.1 psi) 2.7 kg (5.95 lb) 122-3301
51 °C (124.0 °F) 1247 kPa (180.8 psi) 2.8 kg (6.17 lb) 114-0085
52 °C (125.0 °F) 1265 kPa (183.5 psi) 3.0 kg (6.61 lb) 122-3302
52 °C (126.0 °F) 1285 kPa (186.3 psi)
53 °C (127.0 °F) 1304 kPa (189.1 psi) Charging the System
53 °C (128.0 °F) 1323 kPa (191.9 psi)
54 °C (129.0 °F) 1342 kPa (194.7 psi) Pressure cannot accurately be used to charge the air
54 °C (130.0 °F) 1362 kPa (197.6 psi) conditioning system
55 °C (131.0 °F) 1382 kPa (200.5 psi)
56 °C (132.0 °F) 1402 kPa (203.4 psi)
49
An accurate refrigerant charge may only be determined by • With condensers that are mounted on the roof and with
weight. Several variables affect the pressure and the variables remote mounted condensers, always check that both fan
cause the system to be incorrectly charged. motors are running. Check for restrictions. A clean condenser
will lead to improved life for the compressor.
Compressor Speed - :
2. Check for a loose belt on the compressor.
• The rate of refrigerant that is pumped by the compressor will
affect the pressure that is built by the compressor. 3. Clean the fresh air filter and clean the recirculation filter.
Air Flow and Air Temperatures Through the Condenser and 4. Check the moisture indicator on either the receiver-dryer or
Evaporator - : the in-line dryer. If the moisture indicator is pink or white, there
is moisture in the system. Replace the receiver-dryer or the in-
• The amount of air flow and the temperature of the air that is line dryer. Refer to the Disassembly and Assembly, "Machine
moving through the condenser or evaporator will affect the Preparation for Disassembly and Assembly" section. If the
pressures that are seen at the compressor. Blockages in the moisture indicator is blue, the system is normal.
stream of air flow will affect the amount of heat that is
rejected from the refrigerant or absorbed into the refrigerant. 5. Check the condensate tube on the evaporator. Make sure that
This process affects the working pressures. the tube is not plugged and that the valve is properly in place.
Ambient Temperature - : Note: Before an accurate reading for moisture can be
attained, a new receiver-dryer requires 2 to 3 hours of
• Pressures are affected by ambient air temperature and solar operation.
load to the cab.
Note: The preferred method for charging the air conditioning
• Temperature that is around hoses and other components system is listed below.
affect the ambient temperature. As the engine heats up, some
of the heat is absorbed into the refrigerant during the • Recover the refrigerant.
refrigerant ride through the hoses and components. The
pressure in the compressor can be greatly affected by the • Evacuate the system.
heat that is absorbed in many locations.
• Charge the system with the correct amount of refrigerant.
• Ambient temperatures will change throughout the operation Measure the refrigerant by weight.
of the AC, resulting in constant pressure fluctuations.
Note: After the system has been recovered and the system
Internal Blockages - : has been evacuated, charge the system with the correct
amount of refrigerant. Measure the refrigerant by weight.
• Blockages that are at different locations in the refrigerant Refer to the Specifications, "System Capacities for
circuit will affect the pressures and the blockages will cause Refrigerant" section for the proper capacity. Also, refer to the
various concerns with pressure and fluctuations. Systems Operation, "Identifying the Air Conditioning System"
section.
Note: Do not add or remove part of the refrigerant.
Complete Charge of the System from a Refrigerant
Note: Never charge liquid or gas through the discharge side Tank with a Scale
(high side) of the system when the engine is in operation.
The use of a refrigerant tank, heat blanket, and a scale is
NOTICE necessary in order to charge the system. Use the procedure that
In an expansion valve system which uses poly alkaline glycol follows to charge the system.
(PAG), the sight glass is not a reliable way to determine the
system charge. Note: Ensure that you have enough refrigerant in the tank for a
complete charge. Do not use multiple cans of refrigerant, using
multiple cans of refrigerant leads to incorrect charge amounts.
Note: For expansion valve systems that contain PAG oil, the sight
glass cannot be used for charging the system. In order to
achieve a full charge for the system, the refrigerant must be NOTICE
recovered from the system and the system must be evacuated.
After the system has been recovered and the system has been Evacuate the system before charging any Refrigerant system.
evacuated, charge the system with the correct amount of Refer to Testing and Adjusting, "Refrigerant System - Evacuate" .
refrigerant. This process is the only procedure that is
recommended. Refer to the Specifications, "System Capacities In order to find the refrigerant capacity for the system that needs
for Refrigerant" section for the proper capacity. Also, refer to the a refrigerant charge, refer to the Specifications, "System
Systems Operation, "Identifying the Air Conditioning System" Capacities for Refrigerant" section. Also, refer to the Systems
section. Operation, "Identifying the Air Conditioning System" section.
Note: Before you charge the system, these important items Engine OFF
should be checked.
1. Condenser and evaporator
• Inspect the condenser and inspect the evaporator for
foreign material such as dirt, insects, plastic bags, and so on,
that would inhibit air flow.
50
• Record the amount of refrigerant you recovered from the
"HVAC" system.
• Record the amount of oil that you recovered from the "HVAC"
system or removed from the "HVAC" components.
• Record the amount of refrigerant you charged back into the
system.
• Record the amount of oil you replenished into the system.
Refer to Testing and Adjusting, "Refrigerant Oil - Test" to
determine the correct amount of oil to replace.
7. In order to ensure correct system operation, disconnect
charging hose (5) and conduct a performance check. Refer to the
Testing and Adjusting, "Air Conditioning Performance - Test"
section.
Refrigerant System - Evacuate

UENR4125 i03862991
Refrigerant tank inverted for liquid charging
(1) Low-pressure valve WARNING
(2) High-pressure valve
(3) Manifold gauge set
(4) Valve on top of refrigerant tank
(5) Charging hose
(6) Low-pressure hose This system is under pressure at all times, even if the engine is
(7) High-pressure hose not running. Heat should never be applied to a charged system.
(8) Service valve (discharge)
(9) Service valve (suction) Contact with refrigerant can cause frost bite. Keep face and
(10) Refrigerant tank hands away to help prevent injury.
(11) Scale
(12) Compressor
(13) Heat blanket
(V) Vapor are opened, even if the gauges indicate the system is empty of
(L) Liquid refrigerant.
1. Hand tighten charging hose (5) from the manifold gauge set Always use caution when a fitting is removed. Slowly loosen the
directly to the valve (4) on refrigerant tank (10) . Open the valve fitting. If the system is still under pressure, evacuate the system
(4) on top side of refrigerant tank (10) . recovering the refrigerant before removing the fitting.
2. Turn the tank over so that the tank is resting on handles of Personal injury or death can result from inhaling refrigerant
tank. This procedure allows the flow of liquid refrigerant through through a lit cigarette.
the charging hose (5) to the manifold gauge set (3) .
Place the refrigerant tank (10) on the scale (11) so that the other smoking method or inhaling fumes released from a flame
valve (4) is at the bottom. Check and record the weight of the contacting air conditioner refrigerant gas, can cause bodily harm
tank. or death.
3. Loosen the hose (5) at the manifold gauge set (3) for 2 to 3 Do not smoke when servicing air conditioners or wherever
seconds. Then tighten the connection. This procedure will purge refrigerant gas may be present.
the air from the line. Before any checks of the air conditioning and heating system are
4. Open the high-pressure valve (2) on the manifold gauge set (3) made, move the machine to a smooth horizontal surface. Lower
. This action allows the refrigerant liquid to charge the system all implements to the ground. Make sure the transmission is in
through the high-pressure side of the compressor. NEUTRAL or PARK and that the parking brake is engaged. Keep
5. Check the weight of the refrigerant tank (10) often. The weight seen.
will decrease as the refrigerant leaves the tank and the
refrigerant enters the system. When the required amount of
refrigerant (system capacity) has entered the system, close the WARNING
valve (4) on the tank and close the high-pressure valve (2) .
Closing the valves stops the flow of the refrigerant. For example, Personal injury can result from hot coolant. Any contact with hot
1.8 kg (4 lb) of refrigerant has entered a system with 1.8 kg (4 lb) coolant or with steam can cause severe burns. Allow cooling
capacity. system components to cool before the cooling system is drained.
Note: Heater blanket (13) is required when you charge an air

conditioning system.
6. Record the following information in the "SIMSi" ticket.
51
If replacement of a component is necessary or repair to a
component is necessary, the refrigerant in the system must be
recovered. Also, if the system has lost any charge after a long
period of time, the refrigerant in the system must be recovered. It
is necessary to perform the evacuating procedure in order to
delete the system of all air and moisture. A complete charge
must never be given to a system without first performing the
evacuating procedure. Before evacuating the system, refer to the
following manual.
• Testing and Adjusting, "Refrigerant Leakage - Test"
• Testing and Adjusting, "Refrigerant Recovery"
• Testing and Adjusting, "Refrigerant Compressor Oil - Check"
If the system has been left open for more than 1/2 hour, the
system has been exposed to air or moisture and a new receiver-
dryer, an in-line dryer or a desiccant accumulator needs to be
installed. Moisture will combine with metals in the refrigerant
system and this will produce highly corrosive by-products. The
by-products are oxides, iron hydroxide, and aluminum hydroxide.
Moisture can freeze the expansion valve and moisture can Illustration 1 g00452649
freeze the orifice tube. If there is water in the system the water (1) Low pressure valve
must be removed. Remove the water by pumping the system with (2) High pressure valve
a vacuum pump and boiling the water. Refer to Table 1 that is (3) Charging hose
(4) Compressor block fitting (discharge)
shown below. (5) Compressor block fitting (suction)
(6) Service valve (discharge)
The time for the evacuation process will increase under the (7) Service valve (suction)
following conditions: (8) Vented exhaust valve
(9) Line from condenser
• The air conditioning system has been rebuilt. (10) Line from evaporator
• The air conditioning system has been flushed. 1. After the refrigerant is recovered from the system, make sure
that the low pressure valve (1) and the high pressure valve (2)
• The air conditioning system has new components. are closed. Disconnect the charging hose (3) of the manifold
gauge set from the refrigerant service unit.
• The air conditioning system has been retrofitted.
2. Check the oil level in the vacuum pump. Refer to the Testing
Table 1 and Adjusting, "Refrigerant Compressor Oil - Check" for the
Boiling Point of Water Under Vacuum correct procedure. Add oil if oil is needed. If contamination of
the system is indicated, change the oil.
Vacuum That Is Required In Order To
Temperature of Work Area (°C (°F)) Boil Water In An Air Conditioning
System (m bar (Hg)) 3. Connect the electrical plug from the vacuum pump to an
38 °C (100 °F) 95 kPa (28 in Hg) approved electrical outlet.
32 °C (89.6000 °F) 96.5 kPa (28.50 in Hg)
4. Connect the charging hose (3) to the inlet fitting on the
27 °C (81 °F) 97.5 kPa (28.80 in Hg)
vacuum pump. Refer to Illustration 1 .
21 °C (70 °F) 98.8 kPa (29.20 in Hg)
5. Open low pressure valve (1) and open high pressure valve (2)
Note: After the leak test is completed, the system must be on the manifold gauge set completely. Turn the valves
evacuated for a minimum of 30 minutes. In order to correctly counterclockwise.
evacuate the system, the vacuum gauge must be less than three
inches away from the system port. If the gauge is more than 6. In order to start the pump motor, turn the power switch to the
three inches away from the system port, pull a vacuum and allow ON position.
the system to equalize for ten minutes. This will ensure an
accurate gauge reading. 7. In order to open the vented exhaust valve (8) , turn the valve
counterclockwise.
NOTICE
All refrigerant must be recovered before the evacuating Note: The vented exhaust valve (8) must be closed until the
procedure is started. Never discharge the refrigerant through the vacuum pump has started.
vacuum pump. Never discharge the refrigerant into the
atmosphere. Always use the Refrigerant Identifier tool in order to 8. Operate the vacuum pump until the low pressure gauge
ensure that contamination of the system does not occur. indicates a pressure that is between 95 kPa (28 in hg) and 98 kPa
(29 in hg) . After the vacuum in the system reaches a value that
is between 95 kPa (28 in hg) and 98 kPa (29 in hg) , close the
vented exhaust valve (8) . Operate the vacuum pump for a
minimum of 90 minutes after the vented exhaust valve is closed.
Use a 113 L/min (4 cfm) pump. Make allowances for pumps that
are smaller than 113 L/min (4 cfm) cfm.
52
Note: 95 kPa (28 in hg) to 98 kPa (29 in hg) is the required Before any checks of the air conditioning and heating system are
specification at sea level. For every 305 m (1000 ft) above sea made, move the machine to a smooth horizontal surface. Lower
level, decrease the required specification by 3 kPa (1 in hg) . all implements to the ground. Make sure the transmission is in
At high elevations, less vacuum is required. NEUTRAL or PARK and that the parking brake is engaged. Keep
9. If the specific vacuum cannot be reached, the system may seen.
have a leak. Refer to the Testing and Adjusting, "Refrigerant
Leakage - Test" section. Perform the procedures that are
indicated. Repair all leaks and repeat Step 1 of the evacuating WARNING
procedure.
Note: The evacuating procedure removes air and moisture coolant or with steam can cause severe burns. Allow cooling
from the system. Do not use the vacuum pump primarily to system components to cool before the cooling system is drained.
indicate a system leak.
10. After 95 kPa (28 in hg) to 98 kPa (29 in hg) vacuum has been System Contamination and Flush Procedure
reached and held for an additional 90 minutes, close valve (1)
and close valve (2) completely. Turn the power switch on the NOTICE
vacuum pump to the OFF position. The maximum amount of Debris in the air conditioning refrigerant circuit can cause the
vacuum loss in five minutes must not be more than 7 kPa (2 in compressor to fail. Use the following procedure for cleaning and
hg) . Excessive vacuum loss is an indication of a possible leak in flushing the system.
the system. Refer to the Testing and Adjusting, "Refrigerant
Leakage - Test" section. Perform the procedures that are This procedure provides a method and instructions to remove
indicated. Repair all leaks and repeat Step 1 of the evacuating contamination from the air conditioning system refrigeration
procedure. circuit and individual components. A primary instance where a
system flush is necessary is any time a refrigerant compressor
11. If the vacuum loss does not exceed 7 kPa (2 in hg) in five has had an internal failure, indicated by a locked or seized
minutes, the system is then ready for a complete charge. Refer to condition. The air conditioning system refrigeration circuit and
the Testing and Adjusting, "Refrigerant System - Charge" section. components must be cleaned and flushed to remove any
Perform the procedures that are indicated. particles of metal or other foreign material. Failure to properly
flush the air conditioning circuit will damage or shorten the
Refrigerant System - Flush operating life of the replacement compressor.
UENR4125 i05907599 A general flow chart of the flush procedure is shown in
Illustration 2 . The detailed procedure is shown in Step 1 through
Step 19 below.
WARNING
1. Identify the refrigerant and then recover the refrigerant. Refer
Personal injury can result from contact with refrigerant. to the Testing and Adjusting, "Refrigerant Recovery" section.
This system is under pressure at all times, even if the engine is 2. Remove the compressor. Refer to the Disassembly and
not running. Heat should never be applied to a charged system. Assembly, "Refrigerant Compressor - Remove and Install"
section.
hands away to help prevent injury. 3. Remove the receiver-dryer or the in-line dryer. Refer to the
Disassembly and Assembly, "Receiver-Dryer - Remove and
Protective goggles must always be worn when refrigerant lines Install" section. For in-line dryers, refer to the Disassembly and
are opened, even if the gauges indicate the system is empty of Assembly, "In-Line Refrigerant Dryer - Remove and Install"
refrigerant. section.
Always use caution when a fitting is removed. Slowly loosen the 4. Remove the accumulator. Refer to the Disassembly and
fitting. If the system is still under pressure, evacuate the system Assembly, "Air Conditioner Accumulator - Remove and Install"
recovering the refrigerant before removing the fitting. section.
Personal injury or death can result from inhaling refrigerant 5. Remove the expansion valve or the orifice tube. Refer to the
through a lit cigarette. Disassembly and Assembly, "Expansion Valve - (Air Conditioner)
Remove and Install" section. Refer to the Disassembly and
Inhaling air conditioner refrigerant gas through a lit cigarette or Assembly, "Orifice Tube (Air Conditioner) - Remove and Install"
other smoking method or inhaling fumes released from a flame section.
or death. 6. If necessary, remove the quick disconnect fittings from the
Do not smoke when servicing air conditioners or wherever dryer refrigerant lines.
NOTICE
In order to avoid component damage, do not flush system
components with anything other than 153-8538 Refrigerant
Flushing Solution .
53
7. Replace any other failed component such as coils, fittings, etc. 14. Install new quick couplers to the dryer inlet and outlet lines, if
. necessary.
15. Install a new compressor.
Evacuate" section.
17. Add additional oil to the air conditioning system, if necessary.
Refer to Oil Charge After System Flush .
Note: New compressors are shipped with oil in the
compressors. In many instances, it is not necessary to add
extra oil to the air conditioning system.
Charge" section.
Note: Also, Refer to Specifications, "System Capacities for
Refrigerant" .
19. In order to ensure proper operation of the system, refer to the
Testing and Adjusting, "Performance Test" section.
(1) Multichannel Extruded Tube
(2) Manifold
(3) Manifold Baffle
8. Replace condenser coils that are parallel flow or multiple flow.

Refer to Illustration 1 for a reference example. Condenser coils
that are parallel flow or multiple flow have small passages. The
proper flushing out of the passages will be difficult. Failure to
replace the condenser coils may reduce the cooling
performance of the air conditioner and premature failure of the
compressor.
9. Flush the remainder of the system. Flush the air conditioning
system with a 153-8537 Air Conditioner Flushing Unit . Also, a
153-8537 Air Conditioner Flushing Unit can be used in order to
flush the system. Refer to the information that is provided with
the flushing unit. Flush the system with 153-8538 Refrigerant
Flushing Solution .
10. Blow out the air conditioning system with clean dry shop air
for 5 to 10 minutes. Follow the instructions that are provided with
the flushing unit.
NOTICE
Oil Charge After System Flush
It is important that all of the flushing solvent is purged from the
Air Conditioning System. Failure to purge all of the solvent will NOTICE
result in premature compressor failure. Components should be
positioned in order to ensure that no solvent is trapped in the The addition of oil to the air conditioning system is applicable
system. only after the flush of the entire air conditioning system. If an air
conditioning system is overcharged with oil, the result is a
11. Install a new receiver-dryer or an in-line dryer. Refer to the decrease of the cooling performance and damage to the
Disassembly and Assembly, "Receiver-Dryer - Remove and compressor may occur.
Install" section. For in-line dryers, refer to the Disassembly and
Assembly, "In-Line Refrigerant Dryer - Remove and Install" 1. Locate the correct refrigerant charge for the machine that is
section. being serviced. Refrigerant charge can be found on a tag inside
the cab or by referencing the Specifications, "System Capacities
12. Install a new accumulator, if necessary. Refer to the for Refrigerant" section.
Disassembly and Assembly, "Air Conditioner Accumulator -
Remove and Install" section. 2. Locate the part number for the a/c compressor that is being
serviced in the flush procedure.
13. Install a new expansion valve or an orifice tube. Clean the
original quick couplers or replace the original quick couplers. 3. Refer to table 1 or table 2 below for your particular application.
Note: If the Air Conditioning System has an in-line dryer, then
the new orifice tube is already contained inside the dryer.
54
4.0 kg (8.75 lb) 517
4. Use proper oil charging equipment. Usually, oil charge is a
4.1 kg (9.0 lb) 541
function that is provided by the refrigerant service unit. Refer to
208-1316 Refrigerant Service Unit for an example. A portable
injection tool such as 9U-6494 Refrigerant Oil Injector can also Table 2 contains the recommended charges for the a/c
provide the oil charge function. compressors that are listed below:
Table 1 contains the recommended charges for the a/c • 3E-1906 Refrigerant Compressor Gp
compressors that are listed below :
• 3E-1908 Refrigerant Compressor Gp
Note: The new a/c compressors that are listed above contain 300
Note: The new a/c compressors that are listed above contain 150 mL (10.2 oz) of oil. Table 2 is applicable only for new
mL (5.1 oz) to 180 mL (6.1 oz) of oil. Table 1 is only applicable for compressors that contain 300 mL (10.2 oz) of oil. The total oil
new compressors that contain 150 mL (5.1 oz) to 180 mL (6.1 oz) charge for the air conditioning system must equal the total
of oil. The total oil charge for the air conditioning system must amount from Table 2 and the oil that is already contained inside
equal the amount from Table 1 and the oil that is already the new compressor.
contained inside the new compressor.
Table 2
Table 1
Refrigerant Oil (1)
Refrigerant Oil (1) (2)
0.9 kg (2.0 lb) -100
0.5 kg (1.0 lb) -80
1.0 kg (2.25 lb) -80
0.6 kg (1.25 lb) -60
1.1 kg (2.5 lb) -50
0.7 kg (1.5 lb) -30
1.2 kg (2.75 lb) -30
0.8 kg (1.75 lb) 0
1.4 kg (3 lb) 0
0.9 kg (2.0 lb) 0
1.5 kg (3.25 lb) 0
1.0 kg (2.25 lb) 0
1.6 kg (3.5 lb) 0
1.1 kg (2.5 lb) 0
1.7 kg (3.75 lb) 0
1.2 kg (2.75 lb) 15
1.8 kg (4 lb) 0
1.4 kg (3 lb) 33
1.9 kg (4.25 lb) 0
1.5 kg (3.25 lb) 51
2.0 kg (4.5 lb) 11
1.6 kg (3.5 lb) 69
2.2 kg (4.75 lb) 30
1.7 kg (3.75 lb) 88
2.3 kg (5.0 lb) 50
1.8 kg (4 lb) 107
2.4 kg (5.25 lb) 71
1.9 kg (4.25 lb) 126
2.5 kg (5.5 lb) 91
2.0 kg (4.5 lb) 146
2.6 kg (5.75 lb) 112
2.2 kg (4.75 lb) 165
2.7 kg (6.0 lb) 133
2.3 kg (5.0 lb) 185
2.8 kg (6.25 lb) 154
2.4 kg (5.25 lb) 206
2.9 kg (6.5 lb) 176
2.5 kg (5.5 lb) 226
3.1 kg (6.75 lb) 198
2.6 kg (5.75 lb) 247
3.2 kg (7.0 lb) 220
2.7 kg (6.0 lb) 268
3.3 kg (7.25 lb) 242
2.8 kg (6.25 lb) 289
3.4 kg (7.5 lb) 265
2.9 kg (6.5 lb) 311
3.5 kg (7.75 lb) 287
3.1 kg (6.75 lb) 333
3.6 kg (8.0 lb) 311
3.2 kg (7.0 lb) 355
3.7 kg (8.25 lb) 334
3.3 kg (7.25 lb) 377
3.9 kg (8.5 lb) 358
3.4 kg (7.5 lb) 400
4.0 kg (8.75 lb) 382
3.5 kg (7.75 lb) 422
4.1 kg (9.0 lb) 406
3.6 kg (8.0 lb) 446
3.7 kg (8.25 lb) 469
3.9 kg (8.5 lb) 493
55
Note: Always use new refrigerant oil and clean equipment to
avoid contamination inside the air conditioning system.
Note: Make sure that the equipment for oil injection does not
contain air in the supply line to the air conditioning system. This
prevents air from being injected into the system which can lead
to poor cooling performance and possible system damage.
Note: Oil should only be charged into the discharge service port.
Failure to charge the oil correctly can cause damage to the
compressor from liquid slugging with oil.
Visual Inspection
RENR6739 i02303778
When you are identifying a problem, visually inspect the

automatic lubrication system. As follows, visually inspect the
complete automatic lubrication system.
1. Inspect the lubrication pump, the lubrication distribution
valves, the metering units, the primary grease lines and the
secondary grease lines for lubrication leaks.
2. Inspect the electrical system for worn wiring or frayed wiring.
Also, inspect the electrical system for damaged connectors or a
bad fuse.
56
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CAT, CATERPILLAR, LET’S DO THE WORK, their respective logos, “Caterpillar Yellow,” the “Power Edge” and Cat “Modern Hex“
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General Reference Section

necessary in order to adequately protect the gear teeth in these

Cat Arctic Platinum Grease is formulated not to contain lead, Table 1

1. Lower the dump body.

The suspension system may drop the machine suddenly leaving

1. Disengage the differential locks. Bring the machine to a gentle

3. Install suitable stands under the front frame.

Inspect the following areas:

• Mountings (13) for the body • Radiator Mountings (21)

Check the mounts for cracks and for damage. If damage is

Operations and Maintenance Manual NOTICE

Refer to Systems Operation, Testing and Adjusting, "Brake

9. Start the engine and disengage the parking brake.

Illustration 1 g03486336 Illustration 1 g01133448

Every 1000 Service Hours

Oscillating Hitch - Adjust

1. Remove four bolts (1) .

Torque Converter and Transmission Oil -

Illustration 4 g00738535 WARNING

Operate the machine until the torque converter and transmission

Transfer Gear Oil - Change

Transfer Gear Oil Filter - Replace

Park the machine on a level surface. Ensure that the parking

Axle Breathers - Clean/Replace

5. If belt (1) requires replacement, insert a square drive into the

Fabricate a tool from suitable black steel stock or suitable mild

Braking System - Test

Personal injury can result if the machine moves while testing.

Parking Brake Check

The parking brake holding test is a maintenance test procedure

Selection of the Oil Change Interval

Program A Dispose of all fluids according to local regulations and

Note: The engine oil filter is remotely mounted on the right

Fuel leaked or spilled onto hot surfaces or electrical components

14. Repeat steps 11 and 12 . Type 1

Fuel System Primary Filter -

Dispose of all fluids according to local regulations and NOTICE

Fuel Tank Cap and Strainer - Clean

Park the machine on a level surface. Ensure that the parking

Hydraulic Tank Strainer -

Illustration 2 g01127259 Dispose of all fluids according to local regulations and

Torque Converter and Transmission Oil Filter -

Note: A grease fitting is located above the center axle NOTICE

Testing and Adjusting Valve Lash and Valve Bridge Adjustment

To prevent possible injury, do not use the starter to turn the

This engine uses high voltage to control the fuel injectors.

The following components are the five components of the

• Condenser coil • Expansion valve

• Dryer • Evaporator coil

• Orifice tube In-Line Refrigerant Dryer - Remove and Install

• Check the drier swivel nut and tighten the nut to 27 ± 4

1. Use the 138-6629 Refrigerant Identifier in order to verify that

Refrigerant Accumulator - Remove and Install

The refrigerant must be recovered before the accumulator is

Refrigerant Compressor - Remove and Install

To replace the expansion valve, use the procedure that follows.

7. Charge the system. Refer to the Testing and Adjusting, Dye

The refrigerant that is in the system must be recovered if the

WARNING Illustration 1 g00389232

Refrigerant System - Evacuate

Note: Heater blanket (13) is required when you charge an air

8. Replace condenser coils that are parallel flow or multiple flow.