793d mantenimiento

2010 CaterpillarAll Rights Reserved

MAINTENANCE INTERVALSOperation and Maintenance Manual Excerpt

SEBU7792-06November 2010

Operation andMaintenanceManual793D Off-Highway TruckFDB1-Up (Machine)

SAFETY.CAT.COM

SEBU7792-06 131Maintenance Section

Maintenance Interval Schedule

i04149359

Maintenance Interval ScheduleSMCS Code: 1000; 7000

Ensure that all safety information, warnings, andinstructions are read and understood before anyoperation or any maintenance procedures areperformed.

The user is responsible for the performance ofmaintenance. All adjustments, the use of properlubricants, fluids, filters, and the replacement ofcomponents due to normal wear and aging areincluded. Failure to adhere to proper maintenanceintervals and procedures may result in diminishedperformance of the product and/or accelerated wearof components.

Use mileage, fuel consumption, service hours, orcalendar time, WHICH EVER OCCURS FIRST,in order to determine the maintenance intervals.Products that operate in severe operating conditionsmay require more frequent maintenance. Refer to themaintenance procedure for any other exceptions thatmay change the maintenance intervals.

Note: The aftertreatment system can be expectedto function properly for the useful life of theengine (emissions durability period), as defined byregulation. All prescribed maintenance requirementsmust be followed.

Note: Before each consecutive interval is performed,all maintenance from the previous interval must beperformed.

Note: If Cat HYDO Advanced hydraulic oils are used,the hydraulic oil change interval is extended to 3000hours. SOS services may extend the oil changeeven longer. Consult your Cat dealer for details.

When Required

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

Fuel System - Prime ........................................... 178Fuel System Primary Filter (Water Separator) -Drain ................................................................. 179Fuel System Priming Filter - Replace ................. 181High Intensity Discharge Lamp (HID) - Replace .. 183Hoist Screens - Clean ......................................... 184Hoist and Brake Tank Suction Screen -Inspect/Clean/Replace ...................................... 187Magnetic Plug (Wheels) - Check ........................ 188Oil Filter - Inspect ................................................ 190Rear Axle Housing End Play - Adjust ................. 191Rim - Inspect ....................................................... 193Suction Screen (Torque Converter) - Clean ........ 203Traction Control System (TCS) - Test ................. 210Window Washer Reservoir - Fill .......................... 213Window Wiper - Inspect/Replace ........................ 213Windows - Clean ................................................. 214

Every 10 Service Hours or Daily

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

Initial 50 Service Hours

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

Initial 250 Service Hours

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

Every 250 Service Hours or Monthly

Braking System - Test ......................................... 143Front Wheel Oil Level - Check ............................ 176Magnetic Plug (Wheels) - Check ........................ 188Tire Inflation - Check ........................................... 206

Initial 500 Hours (for New Systems, RefilledSystems, and Converted Systems)

Cooling System Coolant Sample (Level 2) -Obtain ............................................................... 152

Every 500 Service Hours

Cooling System Coolant Sample (Level 1) -Obtain ............................................................... 151

132 SEBU7792-06Maintenance SectionMaintenance Interval Schedule

Differential and Final Drive Oil Sample - Obtain .. 160Engine Oil Sample - Obtain ................................ 168Front Wheel Oil Sample - Obtain ........................ 177Hoist and Brake Tank Oil Sample - Obtain ......... 186Steering System Oil Sample - Obtain ................. 202Torque Converter and Transmission Oil Sample -Obtain ............................................................... 210

Every 500 Service Hours or 3 Months

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

Every 1000 Service Hours or 6 Months

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

Every 2000 Service Hours or 1 Year

Breather (Fuel Tank) - Replace ........................... 145Differential Thrust Pin Clearance - Check .......... 157Differential and Final Drive Breather - Replace .. 157Differential and Final Drive Oil - Change ............ 157

Front Axle Breather - Replace ............................ 175Hoist and Brake Tank Oil - Change .................... 185Rear Axle Housing End Play - Adjust ................. 191Steering System Oil - Change ............................ 200Suction Screen (Rear Axle Lubrication) - Clean .. 203

Every Year

Cooling System Coolant Sample (Level 2) -Obtain ............................................................... 152Receiver Dryer (Refrigerant) - Replace .............. 193Sound Suppression (Covers, Panels) -Inspect/Replace ................................................ 198

Every 3000 Service Hours or 2 Years

Cooling System Pressure Cap - Clean/Replace .. 153Cooling System Relief Valve - Clean .................. 154Radiator Core - Clean ......................................... 191

Every 3 Years After Date of Installation orEvery 5 Years After Date of Manufacture

Seat Belt - Replace ............................................. 195

Every 4000 Service Hours

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


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


Cooling System Water Temperature Regulator -Replace ............................................................. 155Engine Water Pump - Inspect ............................. 170VIMS Module Battery - Replace ......................... 212

Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ........... 148Steering Ball Stud - Replace ............................... 199

Every 15 000 Service Hours

Rim - Inspect ....................................................... 194

Every 1 393 000 L (368 000 US gal) of Fuelor 8000 Service Hours

Engine Components - Rebuild/Install Reman ..... 165

Every 2 786 000 L (736 000 US gal) of Fuel or16 000 Service Hours

Engine Components - Clean/Inspect, Rebuild/InstallReman, Install New ........................................... 164


Air Conditioner Filter - Clean

i02390098

Air Conditioner Filter - CleanSMCS Code: 7320-070-FI

If a reduction in air circulation is noticed, clean thefilter element for the air conditioner.

The filter element for the air conditioner is located inthe compartment in the front of the cab.

1. Park the machine on a level surface and engagethe parking brake.

2. Loosen the door retaining screws and open thedoor.

g01165826Illustration 145

3. Remove filter element (1).

4. Clean the element by gently tapping the elementon a smooth surface.

5. Install the clean element. Close the door andtighten the retaining screws.

i02685548

Air Dryer - CheckSMCS Code: 4285-535

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


2. Drain the primary air tank and drain the secondaryair tank. Refer to Operation and MaintenanceManual, Air Tank Moisture and Sediment - Drainfor the proper procedure.


Air dryer (1) is located on the frame in front of the left frontsuspension cylinder.The tire and the wheel have been removed for ease of viewing.

3. If there is moisture in the air tanks, replacethe desiccant cartridge or rebuild the desiccantcartridge. Consult your Caterpillar dealer forinformation about replacing the desiccant cartridgeand for instructions for rebuilding the desiccantcartridge.

Note: Small amounts of moisture may be in thesystem due to condensation in the system.

i02340897

Air Dryer Desiccant - ReplaceSMCS Code: 4285-510-DSS

Air lines to and from the air dryer must be atatmospheric pressure. Release the air pressurefrom the air system completely before performingmaintenance.

134 SEBU7792-06Maintenance SectionAir Tank - Inspect

g01167619Illustration 147Air dryer (1) is located on the frame in front of the left frontsuspension cylinder.

The tire and the wheel have been removed for ease of viewing.

Replace the air dryer desiccant cartridge or rebuildthe air dryer desiccant cartridge if water cannot beabsorbed. Consult your Caterpillar dealer for serviceor for replacement parts.

i02444297

Air Tank - InspectSMCS Code: 4272-040; 5505-040; 7428-040

When laws in the machine's operating locationrequire the inspection of air tanks, refer to SpecialInstruction, REHS2398, Air Tank Inspection for theOff-Highway Truck 769 - 797.

i02602974

Air Tank Moisture andSediment - DrainSMCS Code: 4272-543-MAS

Park the machine on a level surface and engage theparking brake.

Primary Air Tank

g01132606Illustration 148Drain valve (1) for the primary air tank is located on the right handside of the platform.

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

2. Check for moisture and sediment in the air tanks.Drain the moisture and sediment from the air tankinto a suitable container.

3. Close the drain valve for the air tank.

Secondary Air Tank

g01132579Illustration 149The drain valve for the secondary air tank is located on the righthand side of the cab exterior.


2. Check for moisture and sediment in the air tank.Drain the moisture and sediment from the air tankinto a suitable container.


Air/Hydraulic Cylinder Breather - Clean


Primary Air Tank (If Equippedwith the Sound SuppressionArrangement)



2. Check for moisture and sediment in the air tank.Drain the moisture and sediment from the air tankinto a suitable container.


i02251322

Air/Hydraulic CylinderBreather - CleanSMCS Code: 4258

When it is necessary to work under the machinewith the body (bed) raised, attach the body (bed)retaining cable to the rear tow point. Install therear tow point pin through the end of the retainingcable.

Failure to properly secure the body (bed) may re-sult in personal injury or death.


2. Raise the dump body to the fully raised positionand install the truck body retaining cable to therear tow point pin. For the proper procedure, referto Operations and Maintenance Manual, Cable(Truck Body Retaining).

3. Stop the engine.

g01133243Illustration 151(1) Breather for the rear air/hydraulic cylinders(2) Breather for the front air/hydraulic cylinders(3) Rear air/hydraulic cylinders(4) Front air/hydraulic cylinders

4. Remove breathers (1) and (2) for air/hydrauliccylinders (3) and (4).

5. Wash both breathers in clean nonflammablesolvent. Allow the breathers to dry.

6. Install the clean breathers.

7. Remove the truck body retaining cable and lowerthe body.

136 SEBU7792-06Maintenance SectionAutomatic Lubrication Reservoir - Fill

i03795949

Automatic LubricationReservoir - FillSMCS Code: 7540-544-TNK


1. Remove plug (1) for the vent port if the reservoir isnot equipped with a permanent vent.

Note: If the reservoir is not properly vented, pressurewill cause the wiper seal on the follower assemblyinside the reservoir to fail when the reservoir is filled.Grease on the top side of the follower assemblymay prevent the autolube system from functioningproperly. Also, grease on the top side of the followerassembly may cause damage to the autolube system.

2. Fill the autolube reservoir through fill port (2).Place a suitable container under the outlet forthe vent port in order to collect any grease thatis spilled. Fill the reservoir until grease appearsat the outlet for the vent port. If the machine isequipped with a Fast Fill Service Center, the levelindicator will illuminate when the reservoir is full.For more information on the Fast Fill ServiceCenter, refer to Operation and MaintenanceManual, Fast Fill Service Center.

Note: The bulk capacity of the grease reservoir is27 kg (60 lb).

3. Install the plug in the vent port if the reservoir isnot equipped with a permanent vent.

The automatic lubrication reservoir provideslubrication for many components. There are fittingson the left side of the machine, fittings on theright side of the machine, and fittings on the reardifferential housing.

If any of the remote lines become damaged, install afitting in place of the remote line. Lubricate the itemat the fittings until the remote line can be replaced.

See Systems Operation, Testing and Adjusting,SENR4724, Automatic Lubrication System foradditional details.

i02253468

Backup Alarm - TestSMCS Code: 7406-081

g01130536Illustration 153Location of the backup alarm


Turn the engine start switch to the ON position inorder to perform the test.

Make sure that the area behind the machine is clearof personnel and clear of obstacles.

Move the transmission direction and speed controllever to the REVERSE position.

The backup alarm should sound immediately. Thebackup alarm should continue to sound until thetransmission direction and speed control lever ismoved to the NEUTRAL position or to the FORWARDposition.


Battery - Recycle

i00993589

Battery - RecycleSMCS Code: 1401-561

Always recycle a battery. Never discard a battery.

Always return used batteries to one of the followinglocations:

A battery supplier

An authorized battery collection facility

Recycling facility

i02341243

Battery or Battery Cable -Inspect/ReplaceSMCS Code: 1401-040; 1401-510; 1402-040;1402-510

Note: When you replace the batteries, always usethe same type of battery. This machine requiresMaintenance Free batteries or Low MaintenanceHigh Output batteries.


2. Turn the engine start switch to the OFF position.Turn all of the switches to the OFF position.

3. Turn the battery disconnect switch to the OFFposition. Remove the key. Refer to Operation andMaintenance Manual, Battery Disconnect Switchfor more information.

4. Disconnect the negative end of the batterycable from the frame near the battery disconnectswitch.

Note: Do not allow the disconnected battery cable tocontact the battery disconnect switch.


5. Disconnect the negative end of the batterycable from the battery.

6. Disconnect the positive end + of the batterycable from the battery.

7. Replace the battery or make all necessary repairsto the battery.

8. Connect the positive end + of the battery cableto the battery.

9. Connect the negative end of the battery cableto the battery.

10.Connect the negative end of the battery cableto the frame near the battery disconnect switch.

11. Install the key. Turn the battery disconnect switchto the ON position.

i02253729

Belts - Inspect/Adjust/ReplaceSMCS Code: 1357-025; 1357-040; 1357-510

InspectionPark the machine on a level surface and engage theparking brake.

To maximize the engine performance, inspectthe belt for wear and for cracking. Check thebelt tension. Belt slippage will decrease the lifeof the belt. A correctly adjusted belt will deflect13 to 19 mm (0.50 to 0.75 inch). Refer to the EngineSpecifications, Belt Tension Chart.

138 SEBU7792-06Maintenance SectionBelts - Inspect/Adjust/Replace


The refrigerant compressor has a belt tensioner. Ifshoulder (2) of the belt tensioner is aligned with redzone (1) of the indicator, replace the belt.

Adjustment and Replacement

Alternator

1. Park the machine on a level surface. Engage theparking brake and stop the engine.



2. Loosen mounting bolt (5) and adjusting nuts (3).

3. If necessary, remove belt guard (4).

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

5. Turn adjusting nuts (3) in order to increase ordecrease the belt tension.

6. If the belt guard was removed, reinstall the beltguard.

7. Tighten the adjusting nuts. Tighten the mountingbolt.

8. Check the belt tension on a new belt after 30minutes of operation.

Note: The break-in period for the belt is consideredto be 30 minutes.

Refrigerant Compressor



Brake Cooling Oil Filter - Replace

g01135507Illustration 159Belt tensioner for the refrigerant compressor belt


2. In order to release the tension on the belt, Insert a12.7 mm (0.50 inch) ratchet into square hole (6) inthe belt tensioner, and pry the belt tensioner in acounterclockwise direction.

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

4. Shoulder (2) of the belt tensioner should bealigned with green zone (7) of the indicator.

5. Check the belt tension on a new belt after 30minutes of operation.

Note: The break-in period for the belt is consideredto be 30 minutes.

Refer to Engine Supplement, Disassembly andAssembly, Belt Tightener - Remove and Install formore information on replacement of the belts.

i03536820

Brake Cooling Oil Filter -ReplaceSMCS Code: 1366-510-FI

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact skin.

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting and repair of the product. Be prepared tocollect the fluid with suitable containers before open-ing any compartment or disassembling any compo-nent containing fluids.

Refer to Special Publication, NENG2500, CaterpillarDealer Service Tool Catalog for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.

Dispose of all fluids according to local regulations andmandates.


Location of the brake cooling oil filters



2. Remove oil filler cap (1) and use a vacuumtransducer and vacuum cap in order to createa vacuum to the hoist/brake tank. Attach an airsupply hose to the vacuum transducer and apply276 to 414 kPa (40 to 60 psi) of air.

140 SEBU7792-06Maintenance SectionBrake Oil Cooler Screen - Clean

Refer to Disassembly and Assembly, RENR8332,Oil Filter (Parking Brake Release) - Remove forthe required tooling in order to create a vacuum inthe 793D hoist/brake tank.

Note: A vacuum must exist in the hoist/brake tank inorder to prevent the oil from draining from the systemwhen the brake cooling oil filters are removed.

g01864994Illustration 162The brake cooling oil filters are located behind the fuel tank. Thefuel tank has been removed for ease of viewing.

3. Remove filter housings (2).

4. Remove the used filter elements and discard theused filter elements properly.

5. Wash the filter housings in clean nonflammablesolvent.

6. Inspect the seal in each housing base. If a seal isdamaged, replace the seal with a new seal.

7. Install the new filter elements in the filter housings.

8. Install the filter housings.

9. Remove the vacuum transducer and the vacuumcap. Install the oil filler cap.

10.Start the engine and operate the engine at lowidle. Make sure that the parking brake is engaged.Check for leaks and make any necessary repairs.

11.Check the oil level in the hoist/brake tank. Ifnecessary, add oil. For the proper procedure, referto Operation and Maintenance Manual, Hoist andBrake Tank Oil Level - Check.

i02320005

Brake Oil Cooler Screen -CleanSMCS Code: 4257-070; 4295-070

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact skin.


Refer to Special Publication, NENG2500, CaterpillarTools and Shop Products Guide for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.


After a failure in the brake circuit, clean the screensfor the brake oil coolers. There are three screens thatneed to be cleaned. There is one screen for the frontbrake oil cooler and there are two screens for therear brake oil cooler.



Brake Oil Cooler Screen - Clean

g01159886Illustration 163The rear brake oil cooler screens are located on the right sidebehind the rear brake oil cooler and in front of the hydraulic tank.

(2) Rear brake oil coolers(3) Oil cooler for the steering/fan drive

2. Drain the oil from rear brake oil coolers (2) withdrain (4).

g01176679Illustration 164Screen locations

Back side view of the housing for the rear brake oil cooler screens.

3. Remove covers (1) for the rear brake oil coolerscreens. One cover is located at the front of thescreen housing and one cover is located at therear of the screen housing.

4. Remove the rear oil cooler screens. Wash the oilcooler screens in a clean, nonflammable solvent.

5. Install the rear oil cooler screens.

6. Install the covers for the rear brake oil coolerscreens.

g01159904Illustration 165The front brake oil cooler screen is located inside the left frame railbetween the fuel tank and the torque converter.

The tire and the rim for the front left side have been removed forease of viewing.

7. Drain the oil from the front brake oil cooler screenwith drain (6).

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

9. Remove the front oil cooler screen. Wash the oilcooler screen in a clean, nonflammable solvent.

10. Install the front oil cooler screen.

11. Install the cover for the front brake oil coolerscreen.

12.Start the engine and operate the engine at lowidle. Make sure that the parking brake is engaged.Check for leaks and make any necessary repairs.

13.Check the oil level in the hoist/brake tank. Ifnecessary, add oil. For the proper procedure, referto Operation and Maintenance Manual, Hoist andBrake Tank Oil Level - Check.

142 SEBU7792-06Maintenance SectionBrake Tank (Makeup) - Clean

i02270875

Brake Tank (Makeup) - CleanSMCS Code: 4291



g01137610Illustration 166The brake makeup oil tank is located on the inside rail on the leftside of the machine near the center tube.


2. Raise the truck body to the fully raised positionand install the truck body retaining cable to therear tow point pin. For the proper procedure, referto Operations and Maintenance Manual, Cable(Truck Body Retaining).

3. Stop the engine.

4. Remove the top cover of brake makeup oil tank(1).

5. Clean the cover and the brake makeup oil tank inclean nonflammable solvent.

6. Inspect the cover seal and replace the cover sealif the cover seal is damaged.

7. Install the cover.


i02381189

Brakes, Indicators and Gauges- TestSMCS Code: 4251-081; 4267-081; 4269-081;7000-081; 7450-081; 7490-081

Before you operate the machine, perform thefollowing checks.

1. Inspect the brake indicator lights in the cab.Look for broken lenses on the gauges. Check forbroken indicator lights, broken switches, and otherbroken components in the cab.

2. Make sure that the parking brake is engaged. Turnthe engine start switch to the ON position andmonitor the self test of the VIMS. See Operationand Maintenance Manual, Vital informationSystem (VIMS) Self Test for further information.The indicator lights on the dash will illuminate for 3seconds. Replace any inoperative indicator lights.Look for any inoperative gauges.

3. Start the engine. Check the brake system for thefollowing: oil leaks, air leaks, and damaged brakelines.

4. Turn on all machine lights. Check for properoperation.

5. Sound the horn. Listen for proper operation.

6. Test the parking brake. For the proper testprocedure, refer to Operation and MaintenanceManual, Braking System - Test.

7. Test the service brakes. For the proper testprocedure, refer to Operation and MaintenanceManual, Braking System - Test.

8. Engage the parking brake. Stop the engine.

Make any necessary repairs before machineoperation. Consult your Caterpillar dealer for moreinformation.

SEBU7792-06 143Maintenance SectionBraking System - Test

i02934683

Braking System - TestSMCS Code: 4251-081; 4267-081

Personal injury can result if the machine moveswhile testing.

If the machine begins to move during test, reducethe engine speed immediately and engage theparking brake.

If the machine moves when testing the brakes,contact your Caterpillar dealer.

Have the dealer inspect and repair the brakes be-fore returning the machine to operation. Failure tohave the brakes inspected and repaired can causeinjury or death.

The following tests are used to determine if theparking brake, the secondary brake, and the servicebrake are functional. These tests are not intendedto measure the maximum brake holding effort. Thebrake holding effort that is required to sustain amachine at a specific engine rpm varies dependingon the machine. The variations are the differences inthe engine setting, in the power train efficiency, andin the brake holding ability, etc.

Note: Service personnel should perform this testmonthly. Document the results of each monthly test.Compare the engine rpm from the previous monthto the current engine rpm. This will determine thesystem deterioration.

Parking Brake Holding Ability TestThe air control valve for the parking brake activatesall the wheel brakes. The parking brakes are appliedby spring pressure and the parking brakes arereleased by oil pressure.

1. Fasten the seat belt before you test the brakes.

2. Check the area around the machine. Make surethat the machine is clear of personnel and clear ofobstacles.

3. Test the brakes on a dry, level surface.

4. Start the engine and allow the air system to buildup to the operating pressure.

g01427991Illustration 167(1) Transmission Control Lever(2) Parking Brake Reset Valve(3) Parking Brake Switch

5. Depress parking brake reset valve (2).

6. Engage parking brake switch (3).

7. Move transmission control lever (1) to the FIRSTSPEED FORWARD position.

8. Gradually increase the engine speed to 1300 rpm.The machine should not move.

9. Reduce the engine speed to low idle. Movethe transmission control lever to the NEUTRALposition. Leave the parking brake engaged. Stopthe engine.

NOTICEIf the machine moved while testing the brakes, contactyour Caterpillar dealer.

Have the dealer inspect and, if necessary, repair theparking brakes before returning the machine to oper-ation.

Test for the Parking Brake ResetValve1. Fasten the seat belt before you test the brakes.



4. Purge the air from the air system at the air tanks.

5. Make sure that the parking brake reset valve isengaged. The valve will pop up to the engagedposition.

144 SEBU7792-06Maintenance SectionBraking System - Test


7. Disengage the parking brake.

8. Move the transmission control lever to the FIRSTSPEED FORWARD position.


10.Reduce the engine speed to low idle. Movethe transmission control lever to the NEUTRALposition. Engage the parking brake switch. Stopthe engine.

11. In order to disengage the parking brake resetvalve , push down the knob.


Have the dealer inspect and, if necessary, repair theparking brakes before returning the machine to oper-ation.

Secondary Brake Holding AbilityTestThe secondary brake air control valve activates allthe wheel brakes. The secondary brakes are appliedby spring pressure and the secondary brakes arereleased by oil pressure.






5. Apply secondary brake control (4).

6. Depress the parking brake reset valve.

7. Release the parking brake.



10.Reduce the engine speed to low idle. Movethe transmission control lever to the NEUTRALposition. Engage the parking brake. Stop theengine.


Have the Caterpillar dealer inspect and, if necessary,repair the parking/secondary brakes before returningthe machine to operation.

Service Brake Holding Ability TestThe service brake air control valve activates all thewheel brakes. The service brakes are applied by oilpressure and the service brakes are released byspring pressure.






Breather (Fuel Tank) - Replace


5. Apply service brake control (5).

6. Depress the parking brake reset valve.

7. Release the parking brake.



10.Reduce the engine speed to low idle. Movethe transmission control lever to the NEUTRALposition. Engage the parking brake. Stop theengine.


Have the dealer inspect and, if necessary, repair theservice brake before returning the machine to opera-tion.

i02345985

Breather (Fuel Tank) - ReplaceSMCS Code: 1273-510-BRE




2. Raise the truck body to the fully raised positionand install the truck body retaining cable to therear tow point pin. For the proper procedure for theinstallation and removal of the truck body retainingcable, refer to Operations and MaintenanceManual, Cable (Truck Body Retaining).

3. Stop the engine.


4. Remove fuel tank breather (1).

5. Properly discard the used breather.

6. Install a new breather.


146 SEBU7792-06Maintenance SectionCab Air Filter - Clean/Replace

i01766189

Cab Air Filter - Clean/ReplaceSMCS Code: 7311-070-FI; 7311-510-FI; 7342-070;7342-510

g00903640Illustration 171Location of the filter element for the cab(1) Cover(2) Retaining screws

The filter element for the cab is located inside theoperator's compartment.

1. Loosen retaining screws (2). Remove cover (1)and the filter element.

2. Wash the filter element in a nonsudsing detergent.

3. Rinse the filter element in clean water. Allow thefilter element to air dry.

4. Install the clean filter element and cover (1).Tighten retaining screws (2).

Note: When rips or tears are noticed in the filterelement, install a new filter element. When areduction of air circulation is noticed in the cab aftercleaning the filter element, install a new filter element.

i02385071

Cable (Truck Body Retaining)- InspectSMCS Code: 5154-040; 7258-040-KA

A raised body (bed) may fall unexpectedly if adamaged cable is used. Use of a damaged cablecould result in personal injury or death.

Inspect the cable for damage and do not use acable that is damaged.

Wear gloves when handling the cable.

1. Inspect the cable for any of the followingconditions:

Reduction in the diameter

Broken wires

Worn wires

Corroded wires

Loose strands or loose wires

Loose cable ends or separation between thecable and the cable end

Kinks

Cuts

Flat spots

2. Inspect the cable ends and the cable connectionfor the truck body for any of the followingconditions:

Distortion such as bends or twists

Wear

Corrosion

Cracks or gouges

If any of the above conditions exist, replacethe truck body retaining cable and the cableconnection for the truck body. Consult yourCaterpillar dealer for proper replacement parts.


Circuit Breakers - Reset

i02342172

Circuit Breakers - ResetSMCS Code: 1420



Circuit Breaker/Reset Push in thebutton in order to reset the circuit breaker. Ifthe electrical system is working properly, the

button will remain depressed. If the button does notremain depressed, check the appropriate electricalcircuit. Repair the electrical circuit, if necessary.

Note: The circuit breakers for the low beamheadlights, the high beam headlights, and the foglights are automatic reset circuit breakers.

VIMS Main Module (1) 15 Amp

Gauges (2) 10 Amp

Backup Alarm (3) 10 Amp

Engine Starting Aid (4) 20 Amp

Steering Accumulator Pressure (5) 10Amp

Keyswitch (6) 10 Amp

Stop Lights and Dome light (7) 10 Amp

Brake Retraction Motor (8) 20 Amp

Air Conditioner (9) 15 Amp

Alternator (10) 105 Amp

VIMS Message Center (11) 10 Amp

Window Washer and Wiper (12) 10Amp

Power Train Electronic Control Module(13) 10 Amp

Air Dryer (14) 10 Amp

148 SEBU7792-06Maintenance SectionCooling System Coolant (ELC) - Change

Heated Mirrors (15) 25 Amp

Power Window (16) 10 Amp

Access Lights (17) 15 Amp

Brake Electronic Control Module (18) 10 Amp

Electronic Fuel Injection (19) 15 Amp

24 to 12 Volt Converter (20) 10 Amp

i03895691

Cooling System Coolant (ELC)- ChangeSMCS Code: 1350-044-NL; 1395-044-NL

Personal injury can result from hot coolant, steamand alkali.

At operating temperature, engine coolant is hotand under pressure. The radiator and all linesto heaters or the engine contain hot coolant orsteam. Any contact can cause severe burns.

Remove cooling system pressure cap slowly torelieve pressure only when engine is stopped andcooling system pressure cap is cool enough totouch with your bare hand.

Do not attempt to tighten hose connections whenthe coolant is hot, the hose can come off causingburns.

Cooling System Coolant Additive contains alkali.Avoid contact with skin and eyes.




NOTICEDo not change the coolant until you read and under-stand the material in the Cooling System Specifica-tions section.

NOTICEMixing Cat Extended Life Coolant (ELC) with otherproducts reduces the effectiveness of the coolantand shortens coolant life. Use only Caterpillar prod-ucts or commercial products that have passed theCaterpillar EC-1 specifications for premixed or con-centrate coolants. Use only Cat Extender with CatELC. Failure to follow these recommendations couldresult in damage to the cooling systems components.

If ELC cooling system contamination occurs, refer toOperation and Maintenance, Extended Life Coolant(ELC) under the topic ELC Cooling System Contam-ination.

This machine was factory filled with Cat Extended LifeCoolant.

Drain the coolant whenever the coolant is dirty orwhenever foaming is observed.



Cooling System Coolant (ELC) - Change

g01159005Illustration 174(1) Filler cap for the aftercooler cooling system(2) Filler cap for the jacket water cooling system

2. Slowly loosen filler caps (1) and (2). This willrelieve system pressure. Remove the filler caps.


3. Open drain valves (3) for the jacket water coolingsystem and the aftercooler cooling system. Drainthe coolant into a suitable container.

Note:When the drain valves are opened, the coolantwill drain from both systems. Opening one drainvalve will drain that system and the other system willremain partially full.

4. Close the drain valves. Fill the system with cleanwater and a 6 to 10% concentration of coolingsystem cleaner.

5. Start the engine and operate the engine for 90minutes. Stop the engine and drain the cleaningsolution into a suitable container.

6. When the engine is stopped, flush the system withwater until the draining water is clear. Drain thewater into a suitable container.

7. Close the drain valves.

8. Add the coolant solution. Refer to SpecialPublication, SEBU6250, Cooling SystemSpecifications and Operation and MaintenanceManual, Capacities (Refill).

Note: If you are using Caterpillar antifreeze, do notadd the supplemental coolant additive at this timeand/or change the element at this time.

9. After the cooling system has been filled, performthe following procedures during initial start-up:

a. Start the engine without the filler cap.

b. Run the engine at low idle for ten minutes.

c. Then, increase the engine speed to a high idleuntil the thermostat is open and the coolantlevel is stabilized.

d. Maintain the coolant at the proper level as thethermostat opens and air is purged from thesystem. Refer to Operation and MaintenanceManual, Cooling System Coolant Level -Check.

10. Install filler caps (1) and (2).

150 SEBU7792-06Maintenance SectionCooling System Coolant Extender (ELC) - Add

i02317854

Cooling System CoolantExtender (ELC) - AddSMCS Code: 1352-538-NL






NOTICEAdding coolant to an overheated engine could result indamage to the engine. Allow the engine to cool beforeadding coolant.

If the machine is to be stored in, or shipped to, an areawith freezing temperatures, the cooling system mustbe protected to the lowest outside (ambient) temper-ature.

The engine cooling system is normally protect-ed to a minimum of29C (20F) with CaterpillarAntifreeze, when shipped from the factory unlessspecial requirements are defined.


Refer to Special Publication, NENG2500, CaterpillarTools and Shop Products Guide for tools and suppliessuitable to collect and contain fluids on Caterpillarproducts.


NOTICEExcessive additive (greater than the recommended6% initial fill) together with concentrations of antifreezegreater than 60% cause deposits to form and can re-sult in radiator tube blockage and overheating.

NOTICEMixing Cat Extended Life Coolant (ELC) with otherproducts reduces the effectiveness of the coolantand shortens coolant life. Use only Caterpillar prod-ucts or commercial products that have passed theCaterpillar EC-1 specifications for premixed or con-centrate coolants. Use only Cat Extender with CatELC. Failure to follow these recommendations couldresult in damage to the cooling systems components.

If ELC cooling system contamination occurs, refer toOperation and Maintenance, Extended Life Coolant(ELC) under the topic ELC Cooling System Contam-ination.

This machine was factory filled with Cat Extended LifeCoolant.

Refer to Special Publication, SEBU6250, CoolingSystem Specification for the cooling systemrequirements.

Use 8T-5296 Test Kit in order to check theconcentration.


g01159006Illustration 176(1) Filler cap for the aftercooler cooling system(2) Filler cap for the jacket water cooling system(3) Level gauges


Cooling System Coolant Level - Check

2. Loosen filler caps (1) and (2) slowly in order torelieve pressure. Remove the filler caps.

3. Check level gauges (3). If necessary, drainenough coolant in order to allow the addition ofthe liquid coolant additive.

Note: Make sure that the coolant is drained into asuitable container.

4. Refer to the table in Special Publication,SEBU6250, Extended Life Coolant (ELC).This table lists the correct amount of CaterpillarExtended Life Coolant (ELC) extender that shouldbe added to the cooling system.

5. Clean the filler caps and inspect the filler caps.Install the filler caps.

6. Start the engine and check for leaks. Allow thecoolant level to stabilize.

7. If necessary, add premixed coolant in order tobring the coolant in the green range on the coolantlevel gauge.

i02317855

Cooling System Coolant Level- CheckSMCS Code: 1350-535-FLV






g01159008Illustration 177(1) Level gauge for the aftercooler cooling system(2) Level gauge for the jacket water cooling system

If you must add coolant daily, check for leaks.


Use level gauges (1) and (2) to check the coolantlevels. The needle should be in the green range.

If the needle is in the red range, allow the systemto cool and add coolant.

i03905010

Cooling System CoolantSample (Level 1) - ObtainSMCS Code: 1350-008; 1395-008; 7542

NOTICEAlways use a designated pump for oil sampling, anduse a separate designated pump for coolant sampling.Using the same pump for both types of samples maycontaminate the samples that are being drawn. Thiscontaminate may cause a false analysis and an incor-rect interpretation that could lead to concerns by bothdealers and customers.

Note: Level 1 results may indicate a need forLevel 2 Analysis.

152 SEBU7792-06Maintenance SectionCooling System Coolant Sample (Level 2) - Obtain

g02146856Illustration 178Right side view of the engine

Sampling valve (1) for the jacket water cooling systemis located on the right side of the engine water pump.

g02146857Illustration 179Left side view of the engine

Sampling valve (2) for the water cooled aftercoolersystem is located on the left side of the engine waterpump.

Obtain the sample of the coolant as close as possibleto the recommended sampling interval. In order toreceive the full effect of SOS analysis, establisha consistent trend of data. In order to establisha pertinent history of data, perform consistentsamplings that are evenly spaced. Supplies forcollecting samples can be obtained from yourCaterpillar dealer.

Use the following guidelines for the proper samplingof the coolant:

Complete the information on the label for thesampling bottle before you begin to take thesamples.

Keep the unused sampling bottles stored in plasticbags.

Obtain coolant samples directly from the coolantsample port. You should not obtain the samplesfrom any other location.

Keep the lids on empty sampling bottles until youare ready to collect the sample.

Place the sample in the mailing tube immediatelyafter you obtain the sample in order to avoidcontamination of the sample.

Never collect samples from expansion bottles.

Never collect samples from the drain for a system.

Submit the sample for Level 1 analysis.

For additional information about coolant analysis, seeSpecial Publication, SEBU6250, Caterpillar MachineFluids Recommendations or consult your Caterpillardealer.

i03905011

Cooling System CoolantSample (Level 2) - ObtainSMCS Code: 1350-008; 1395-008; 7542



Cooling System Pressure Cap - Clean/Replace

g02146856Illustration 180Right side view of the engine

Sampling valve (1) for the jacket water cooling systemis located on the right side of the engine water pump.

g02146857Illustration 181Left side view of the engine

Sampling valve (2) for the water cooled aftercoolersystem is located on the left side of the engine waterpump.

Obtain the sample of the coolant as close as possibleto the recommended sampling interval. Suppliesfor collecting samples can be obtained from yourCaterpillar dealer.

Refer to Operation and Maintenance Manual,Cooling System Coolant Sample (Level 1) - Obtainfor guidelines on the proper sampling of the coolant.

Submit the sample for Level 2 analysis.

For additional information about coolant analysis, seeSpecial Publication, SEBU6250, Caterpillar MachineFluids Recommendations or consult your Caterpillardealer.

i02347060

Cooling System Pressure Cap- Clean/ReplaceSMCS Code: 1382-070; 1382-510







154 SEBU7792-06Maintenance SectionCooling System Relief Valve - Clean


2. Remove filler caps (1) and (2) slowly in order torelieve the pressure.

3. Inspect the filler caps for damage, for foreignmaterial, and for deposits.

4. Clean the filler caps with a clean cloth or replacethe filler caps, if necessary.

5. Install the filler caps.

i02347062

Cooling System Relief Valve -CleanSMCS Code: 1370-070






If the system overheats or if coolant is leaking, cleanthe relief valves or replace the relief valves.

1. Park the machine on a level surface. Engage theparking brake and stop the motor.

g01172742Illustration 183(1) Filler cap for the aftercooler cooling system(2) Filler cap for the jacket water cooling system(3) Cooling system relief valves


Cooling System Water Temperature Regulator - Replace

2. Slowly remove filler caps (1) and (2). This willrelieve the pressure.

3. Remove the bolts from the relief valve and removethe valve assembly.

g00302286Illustration 184(4) Valve(5) Valve seals(6) Gasket(7) Valve cover(8) Mounting bolts

4. Inspect valve (4),valve seals (5) and gasket (6).If necessary, replace the valves, the seals or thegaskets.

5. Inspect valve cover (7) and mounting bolts (8).

6. Assemble the relief valve. Install the relief valve.

7. Install the filler caps.

i02347151

Cooling System WaterTemperature Regulator -ReplaceSMCS Code: 1355-510; 1393-510






Note: The thermostats should be replaced afterthe cooling system has been cleaned. Replace thethermostats while the cooling system is completelydrained or while the cooling system coolant is drainedto a level that is below the thermostat housing.

NOTICEFailure to replace the engine's thermostat on a regu-larly scheduled basis could cause severe engine dam-age.

Replace the four thermostats on a regular basis inorder to reduce the chance of unscheduled downtimeand of problems with the cooling system.


156 SEBU7792-06Maintenance SectionCooling System Water Temperature Regulator - Replace


2. Remove filler caps (1) and (2) slowly in order torelieve the pressure.


Note: Make sure that the coolant level is below thethermostat housings.

3. Disconnect the hose assemblies from thermostathousing assemblies (3).

4. Remove the thermostat housing assemblies.

5. Remove the gasket, the thermostat, and the sealfrom the thermostat housing assembly.

NOTICEFormer thermostats may be used, if they meet testspecifications and are not damaged or have excessivebuildup or deposits.

NOTICESince Caterpillar engines incorporate a shunt designcooling system, it is mandatory to always operate theengine with a thermostat.

Depending on load, failure to operate with a thermo-stat could result in either an overheating or an over-cooling condition.

NOTICEIf the thermostat is installed incorrectly, it will causethe engine to overheat.

6. Install a new seal in the thermostat housing. Installa new thermostat and a new gasket.

Repeat Steps 5 and 6 for the three remainingthermostats.

7. Install the thermostat housing assemblies onthe engine cylinder head. Connect the hoseassemblies to the thermostat housing assemblies.

8. Tighten the hose clamps.


Differential Thrust Pin Clearance - Check

i02320510

Differential Thrust PinClearance - CheckSMCS Code: 3258; 3260; 3284


See the Adjustment Procedure For the Pin. Thisadjustment procedure is located in the Power TrainTesting and Adjusting, Differential and Bevel Gear -Adjust for your machine.

i02320548

Differential and Final DriveBreather - ReplaceSMCS Code: 3258; 4050



2. Remove differential and final drive breather (1).

3. Install a new differential and final drive breather.

i02454361

Differential and Final Drive Oil- ChangeSMCS Code: 3258; 4050

The oil change interval for the differential and finaldrives can be monitored with a SOS (ScheduledOil Sampling) program. For more information onSOS services, refer to Operation and MaintenanceManual, SOS Information. When a SOSprogram is used, the oil change interval is basedon the following:

The condition of the oil

The SOS recommendation

When a SOS program is not used, the oil changeinterval is based on the following:

4000 service hours or 1 year if CaterpillarFDAO/FD-1 oil is used.

2000 service hours or 1 year if CaterpillarTDTO/TO-4 oil is used.


1. Rotate the wheels so that final drive drain plug (1)is in the lowest position on the rear wheel.


158 SEBU7792-06Maintenance SectionDifferential and Final Drive Oil - Change




3. Remove the final drive drain plug. Drain the oilinto a suitable container.

4. Clean the drain plug. Install the drain plug.

5. Repeat Step 1 through Step 4 for the other finaldrive.


6. Remove differential drain plug (3) and allow the oilto drain into a suitable container.

Note: Inspect the magnetic drain plug and theoil. Refer to Operation and Maintenance Manual,Differential and Final Drive Oil - Inspect for furtherinformation.

7. Clean the drain plug. Install the drain plug.

8. Remove sight gauge (4). Wipe the surface aroundthe opening for the sight glass.

9. Before the differential and final drives are filled,refer to Operation and Maintenance Manual,Lubricant Viscosities and Operation andMaintenance Manual, Capacities (Refill).

NOTICEIf the ambient temperature at engine start-up orduring operation is below 10C (14F), performthe procedures in Operation and MaintenanceManual, Differential Warm-up and Break-in. Checkthe differential compartment and the final drivecompartment for the proper fluid level. Failure towarm up the oil or improper lubrication levels prior tooperation will cause damage to the machine.

10. Fill the differential compartment to the bottom ofthe opening for the sight gauge.

11.Clean the sight gauge and install the sight gauge.

12.Remove final drive filler plugs (2). Fill each finaldrive to the bottom of the filler plug opening. Whenthe final drive drain plug is in the lowest position,the final drive filler plug will be at the correct oillevel.

Note: The final drives may need to be repositioned inorder to place the final drive drain plug in the lowestposition.

Note: Allow oil to fill all of the compartments. Correctoil levels are critical in the differential and final drives.


13.Maintain the proper oil level (5) for the differentialto the bottom of sight gauge (4).

14.Operate the machine on level ground for a fewminutes.

Note: The differential and final drive oil level needs tobe checked and maintained at operating temperature.After the oil has been changed in the differentialand final drives, adjustment of the oil level maybe necessary when the truck reaches operatingtemperature.


Differential and Final Drive Oil - Inspect

15.Stop the machine. Check the oil level. Ifnecessary, adjust the oil level to the bottom of thesight gauge.

Note: If it is necessary to add oil, use final drive fillerplug (2). make sure that the filler plug is positionedabove the oil level in the final drive in order to preventany oil from draining out.

Note: Overfilling the differential and final drives willcause overheating and foaming of the oil in longhauling applications and high speed applications. Areduction of the life of components may be the resultof overheating and foaming of the oil.

i02450436

Differential and Final Drive Oil- InspectSMCS Code: 4208

Inspect the differential and final drive oil for any of thefollowing symptoms that may indicate a mechanicalfailure:

A high amount of metal on the magnetic plug

An increased level of nickel concentration in theSOS sample

An increase in the size of the particle count in theSOS sample

Oil leaks in the area around the drive wheelbearings

The rear wheel bearings do not need to be adjustedor inspected until the scheduled overhaul. Unless asymptom of an obvious failure appears, do not adjustor inspect the rear wheel bearings. If the differentialand final drive oil has any of the above symptoms,the rear wheel bearings may need to be inspected.

Consult your Caterpillar dealer for more information.

i02394551

Differential and Final Drive OilLevel - CheckSMCS Code: 3258; 4050

Correct oil levels are critical in the differential andfinal drives. Check the oil level after repairs and aftermaintenance. Check the oil level prior to operation.

The differential and final drive oil level needs to bechecked and maintained at operating temperature.If the oil level is checked cold, adjustment of theoil level may be necessary when the truck reachesoperating temperature.

g01195747Illustration 192Location of the sight gauge for the differential and final drives



2. Use sight gauge (1) to check the oil level for thedifferential and final drives.

3. Maintain the proper oil level (2) at the bottom ofthe sight gauge.

160 SEBU7792-06Maintenance SectionDifferential and Final Drive Oil Sample - Obtain


4. If necessary, add oil. Use filler plug (3) for thefinal drive in order to add oil. When the drainplug is in the lowest position, the filler plug will beat the correct oil level. Make sure that the fillerplug is positioned above the oil level in the finaldrive in order to prevent any oil from draining out.Allow the oil to fill all of the compartments beforerechecking the oil level.

Note: Overfilling the differential and final drives willcause overheating and foaming of the oil in longhauling applications and high speed applications. Areduction of the life of components may be the resultof overheating and foaming of the oil.

i02320757

Differential and Final Drive OilSample - ObtainSMCS Code: 3258-008; 4050-008; 4070-008; 7542



Sampling valve (1) for the differential and final driveoil is located on the base of the rear axle oil filter.

Refer to the following publications for informationabout obtaining an oil sample.

Operation and Maintenance Manual, SOSInformation

Special Publication, SEBU6250, SOS OilAnalysis

Special Publication, PEHP6001, How To Take AGood Oil Sample

Special Publication, PEDP8025, Fluid AnalysisInterpretaion Guide

i04148950

Display and Camera - Clean(If Equipped)SMCS Code: 7347-070; 7348-070

The Work Area Vision System (WAVS) and the CatIntegrated Object Detection System both utilizemultiple cameras and a display.

In order to maintain sufficient vision, keep the cameralens and the display clean.


WAVS display


Drive Shaft Slip Joint - Lubricate

g02217954Illustration 197Cat Integrated Object Detection System display

Use a soft, damp cloth in order to clean the display.The display has a soft plastic surface that can beeasily damaged by an abrasive material. The displayis not sealed. Do not immerse the display withliquid.

g01223051Illustration 198The camera for WAVS and the Cat Integrated Object DetectionSystem .

Use a damp cloth or water spray in order to cleanthe camera lens. The camera is a sealed unit. Thecamera is not affected by high-pressure spray.

Note: The camera is equipped with an internal heaterto help counteract the effects of condensation, snow,or ice.

For more information on WAVS, refer to Operationand Maintenance Manual, Camera.

For more information on Cat Integrated ObjectDetection System, refer to Operation andMaintenance Manual, Cat Integrated ObjectDetection System.

i02321492

Drive Shaft Slip Joint -LubricateSMCS Code: 3253-086-JT


Park the machine on a level surface. Engage theparking brake and stop the engine.

Apply lubricant to the grease fitting on the drive shaftspline.

i02346978

Engine Air Filter PrimaryElement - Clean/ReplaceSMCS Code: 1051-070-PY; 1051-510-PY;1054-070-PY; 1054-510-PY

NOTICEService the air cleaner only with the engine stopped.Engine damage could result.

Service the air cleaner filter elements whenthe action light is activated. The action lightis located on the dash panel. The actionlight will activate when there is an inlet airrestriction, and the VIMS display will provide amessage regarding the specific problem. Referto Operation and Maintenance Manual, VitalInformation Management System (VIMS) forfurther information.


162 SEBU7792-06Maintenance SectionEngine Air Filter Primary Element - Clean/Replace


2. Remove covers (1) for the air filter housings.

3. Remove primary filter elements (2) from the airfilter housings.

4. Clean the inside of the air filter housings.

5. Clean the dust valves on the bottom for the airfilter housings.

6. Install clean primary air filter elements. Install thecovers for the air filter housings.

Note: Refer to Cleaning Primary Air Filter Elements.

If the alert indicator activates after starting the engineor the exhaust smoke is still black after installationof clean primary filter elements, install new primaryfilter elements. If the alert indicator remains activated,replace the secondary elements.

Cleaning Primary Air FilterElements

NOTICECaterpillar recommends certified air filter cleaning ser-vices available at participating Caterpillar dealers. TheCaterpillar cleaning process uses proven proceduresto assure consistent quality and sufficient filter life.

Observe the following guidelines if you attempt toclean the filter element:

Do not tap or strike the filter element in order to re-move dust.

Do not wash the filter element.

Use low pressure compressed air in order to removethe dust from the filter element. Air pressure must notexceed 207 kPa (30 psi). Direct the air flow up thepleats and down the pleats from the inside of the filterelement. Take extreme care in order to avoid damageto the pleats.

Do not use air filters with damaged pleats, gaskets, orseals. Dirt entering the engine will cause damage toengine components.

The primary air filter element can be used up tosix times if the element is properly cleaned and theelement is properly inspected. When the primaryair filter element is cleaned, check for rips or tearsin the filter material. The primary air filter elementshould be replaced at least one time per year. Thisreplacement should be performed regardless of thenumber of cleanings.

NOTICEDo not clean the air filter elements by bumping or tap-ping. This could damage the seals. Do not use ele-ments with damaged pleats, gaskets, or seals. Dam-aged elements will allow dirt to pass through. Enginedamage could result.

Visually inspect the primary air filter elements beforecleaning. Inspect the air filter elements for damageto the seal, the gaskets, and the outer cover. Discardany damaged air filter elements.

There are two common methods that are used toclean primary air filter elements:

Pressurized air

Vacuum cleaning


Engine Air Filter Secondary Element - Replace

Pressurized Air

Pressurized air can be used to clean primary air filterelements that have not been cleaned more than twotimes. Pressurized air will not remove deposits ofcarbon and oil. Use filtered, dry air with a maximumpressure of 207 kPa (30 psi).


Note: When the primary air filter elements arecleaned, always begin with the clean side (inside)in order to force dirt particles toward the dirty side(outside).

Aim the hose so that the air flows inside the elementalong the length of the filter in order to help preventdamage to the paper pleats. Do not aim the stream ofair directly at the primary air filter element. Dirt couldbe forced further into the pleats.

Vacuum Cleaning

Vacuum cleaning is another method for cleaningprimary air filter elements which require daily cleaningbecause of a dry, dusty environment. Cleaning withpressurized air is recommended prior to vacuumcleaning. Vacuum cleaning will not remove depositsof carbon and oil.

Inspecting the Primary Air FilterElements


Inspect the clean, dry primary air filter element. Usea 60 watt blue light in a dark room or in a similarfacility. Place the blue light in the primary air filterelement. Rotate the primary air filter element. Inspectthe primary air filter element for tears and/or holes.Inspect the primary air filter element for light that mayshow through the filter material. If it is necessary inorder to confirm the result, compare the primary airfilter element to a new primary air filter element thathas the same part number.

Do not use a primary air filter element that has anytears and/or holes in the filter material. Do not usea primary air filter element with damaged pleats,gaskets or seals. Discard damaged primary air filterelements.

i02347040

Engine Air Filter SecondaryElement - ReplaceSMCS Code: 1054-510-SE

NOTICEAlways replace the secondary element. Do not at-tempt to reuse it by cleaning. Engine damage couldresult.

Note: Replace the engine air filter secondaryelements when you service the engine air filterprimary elements for the third time. Replace thesecondary elements if the exhaust smoke remainsblack and the clean primary elements have beeninstalled.


164 SEBU7792-06Maintenance SectionEngine Air Precleaner - Clean

g00644798Illustration 203(1) Secondary element

2. Remove secondary elements (1) and properlydiscard the secondary elements.

3. Cover the air inlet openings. Clean the inside ofthe air cleaner housings.

4. Uncover the air inlet openings. Install the newsecondary elements.

5. Install the primary elements.

i02363128

Engine Air Precleaner - CleanSMCS Code: 1055-070


Note: Do not paint dust valves (3). Paint will causethe rubber to harden and the rubber may not sealproperly.

Perform the following procedure for each engine airprecleaner.


2. Loosen clamp (1) on the precleaner and removelower precleaner bowl (2) and dust valve (3).

3. Clean the lower precleaner bowl and the dustvalve with air pressure.

4. Make sure that all of the tubes within theprecleaner are free of dirt. Clean the tubes, ifnecessary.

5. Install the clean lower precleaner bowl, and theclean dust valve and tighten the clamp on theprecleaner.

NOTICEDo not operate the machine with the dust valves re-moved. Engine damage can occur.

i02381002

Engine Components -Clean/Inspect, Rebuild/InstallReman, Install NewSMCS Code: 1000-012-IC; 1000-022-MC;1000-571-IC

Caterpillar recommends this additional maintenancefor the following engine components. Consult yourCaterpillar dealer for further information.

The quantity of burned fuel that is shown with theservice hours assumes a load factor of 40 percent. Ifthe load factor is higher than 40 percent, the numberof service hours for the overhaul interval will belower. If the load factor is lower than 40 percent, thenumber of service hours for the overhaul interval willbe higher. The quantity of consumed fuel is a betterindicator for the overhaul interval than service hours.

Install New Components All Seals, Gaskets and O-rings

Camshaft Bearings

Engine Mounts

Engine Software

Fuel Pressure Regulating Valve

Fuel Priming Pump

Gear Train Bushings, Bearings and Thrust Plates

Main Bearings, Rod Bearings and CrankshaftThrust Plates


Engine Components - Rebuild/Install Reman

Piston Rings

Wiring Harness

Rebuild Components and/or InstallRemanufactured Components Cylinder Heads

Turbochargers

Oil Coolers

Oil Pump

Scavenge Oil Pump

Water Pump

Clean Components and InspectComponents for Reusability Aftercooler Core

Camshaft

Camshaft Lifters

Connecting Rods

Crankshaft

Cylinder Block

Cylinder Liners

Damper

Gear Train

Piston Crowns and Piston Skirts

Piston Pins

Spacer Plates

i02381004

Engine Components -Rebuild/Install RemanSMCS Code: 1000-022-MC

Caterpillar recommends this additional maintenancefor the following engine components. Consult yourCaterpillar dealer for further information.

The quantity of burned fuel that is shown with theservice hours assumes a load factor of 40 percent. Ifthe load factor is higher than 40 percent, the numberof service hours for the mid-life service interval willbe lower. If the load factor is lower than 40 percent,the number of service hours for the mid-life serviceinterval will be higher. The quantity of consumed fuelis a better indicator for the mid-life service intervalthan service hours.

Air Compressor

Air Starter

Alternator

Fuel Transfer Pump

High Pressure Turbochargers (3516B High AltitudeEngine)

Turbochargers (3516B High Displacement Engine)

Injectors

Refrigerant Compressor

Wastegate (3516B High Altitude Engine)

i02322735

Engine Crankcase Breather -CleanSMCS Code: 1317-070-ENG

The engine in this machine is equipped with sixengine crankcase breathers. Two of the breathersare on the valve covers on the right side and four ofthe breathers are on the valve covers on the left side.

166 SEBU7792-06Maintenance SectionEngine Oil Filter (Oil Renewal System) - Change



2. Stop the engine. Loosen clamps (4). Removehose (2) from breather assemblies (1) and fromvent tube (3).

3. Remove the breather assemblies from the valvecovers.

4. Wash the breather in clean nonflammable solvent.

5. Install the breather assemblies on the valvecovers.

6. Install the hose on the breather assemblies andon the vent tube. Tighten all clamps.

7. Repeat Step 2 through Step 6 in order to clean theremaining breathers on the engine.

i02398716

Engine Oil Filter (Oil RenewalSystem) - Change(If Equipped)SMCS Code: 1308-510; 1349

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact the skin.




The machine must be parked on a level surface andthe parking brake must be engaged. The oil must bewarm and the engine must be stopped.

g01162192Illustration 206(1) Engine oil filters(2) Oil filler cap(3) Dipstick


Engine Oil Level - Check

1. Remove used engine oil filters (1) and discard theused engine oil filters .

2. Clean the oil filter base assemblies. Make surethat all of the former gaskets are removed.

3. Apply a thin film of clean engine oil to each seal ofeach new engine oil filter .

4. Install the new engine oil filters by hand. Tighteneach filter until the seal of each engine oil filtercontacts the base. Note the position of the indexmarks on each filter in relation to a fixed point onthe filter base.

Note: Caterpillar filters have rotation index marksthat are spaced 90 degrees or 1/4 of a turn awayfrom each other. When you tighten the filters, use therotation index marks as a guide.

5. Tighten each filter according to the instructionsthat are printed on the filter. Use the index marksas a guide.

Note: You may need to use a Caterpillar strapwrench, or another suitable tool, in order to turnthe filters to the amount that is required for finalinstallation. Make sure that the installation tool doesnot damage the filters.

6. Start the engine and operate the engine at low idlefor five minutes. Inspect engine oil filters (1) for oilleaks. Make any necessary repairs.

7. Maintain the oil level between the ADD mark andthe FULL mark. These marks are on the LOWIDLE side of dipstick (3). Stop the engine.

i02682174

Engine Oil Level - CheckSMCS Code: 1348-535-FLV

Personal injury or death can occur if personnel aretrapped between the wheel and the frame.

The steering system is hydraulically controlledand wheels can crush personnel during move-ment.

Use caution when working between the wheelsand the frame. If the wheels must be turned, en-sure that all personnel are clear of the machinebefore any movement.

NOTICEDo not under fill or overfill engine crankcase with oil.Either condition can cause engine damage.


Location of the dipstick for the engine oil

The tire and the wheel have been removed for ease of viewing.


1. The machine must be on a level surface and theparking brake must be engaged.

2. Check the oil level in the engine.

a. When the engine is running at low idle, maintainthe oil level between the ADD mark and theFULL mark. These marks are on the LOWIDLE side of dipstick (2).

b. When the engine is stopped, maintain the oillevel between the ADD mark and the FULLmark. These marks are on the ENGINESTOPPED side of the dipstick.

3. If necessary, remove oil filler cap (1) and add oil.

4. Clean the filler cap and install the filler cap.

168 SEBU7792-06Maintenance SectionEngine Oil Level - Log Additions

i02326857

Engine Oil Level - LogAdditions(If Equipped with the OilRenewal System)SMCS Code: 1348; 1349


The Oil Renewal System (ORS) meters engineoil that is blended into the fuel supply. This oil willbe consumed by the engine during the process ofcombustion. Normal operation will continually lowerthe oil level in the crankcase. Continually adding newengine oil will allow the life of the oil to be extended.An SOS analysis will determine if the oil needs tobe changed.

The graph in Illustration 209 plots the quantity ofadded oil against the service hours during a 500 hourperiod. This data can be used to determine if theOil Renewal System is working properly. Keeping adaily maintenance log of all of the additions of oil isnecessary for the accuracy of this data. The dailymaintenance log is also necessary for adjustment ofthe metering rate. The daily maintenance log will alsoindicate the total amount of oil that has been addedsince the last oil change. This information is neededat the time of each SOS analysis.

i02326499

Engine Oil Sample - ObtainSMCS Code: 1348-008; 7542

g01162265Illustration 210Sampling Valve For The Engine Oil

The sampling valve for the engine oil is located abovethe engine oil filters.

Refer to the following publications for informationabout obtaining an oil sample.

Operation and Maintenance Manual, SOSInformation

Special Publication, SEBU6250, SOS OilAnalysis

Special Publication, PEHP6001, How To Take AGood Oil Sample

Special Publication, PEDP8025, Fluid AnalysisInterpretation Guide

i02454647

Engine Oil and Filter - ChangeSMCS Code: 1308-510; 1348-044

Note: If your machine is equipped with the OilRenewal System (ORS), engine oil is blendedinto the fuel supply of the machine. This oil willbe consumed in the engine during the process ofcombustion. Normal operation will continually lowerthe oil level in the crankcase. Continually addingnew oil will allow the life of the oil to be extended.An SOS Oil Analysis will determine if the oil needsto be changed. In order to change the engine oilfilters only, refer to Operation and MaintenanceManual, Engine Oil Filter (Oil Renewal System) -Change. For more information on the Oil RenewalSystem, refer to Systems Operation, RENR2223, OilRenewal System.


Engine Oil and Filter - Change

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact the skin.




Note: Some commercial oils that meet APIspecifications may require shorter oil changeintervals. The oil change intervals are determinedby close monitoring of the oil condition and enginewear metals. Caterpillar prefers the scheduled oilsampling as the proper method of checking enginewear metals.

Consult your Caterpillar dealer for the latest oilrecommendations.

The machine must be parked on a level surface andthe parking brake must be engaged. The oil must bewarm and the engine must be stopped.


1. Open drain valve (1) and drain the oil into asuitable container. Close the drain valve .


2. Remove the used engine oil filters (2) and discardthe used engine oil filters.

3. Clean the oil filter base assemblies. Make surethat all of the former gaskets are removed.

4. Apply a thin film of clean engine oil to the seal ofeach new engine oil filter.

5. Install the new engine oil filters by hand. Tighteneach engine oil filter until the seal of each engineoil filter contacts the base of the oil filter housing.Note the position of the index marks on each filterin relation to a fixed point on the filter base.

793d mantenimiento

Documents

maintenance procedures

frequent maintenance

prescribed maintenance

fuel system priming

air tank

engine air precleaner

fuel system prime

cab air filter cleanreplace