793D Off-Highway Truck - Maintenance Intervals

SAFETY.CAT.
COM
793D OFF-HIGHWAY
TRUCKS
Maintenance Intervals
Excerpted from Operation & Maintenance Manual (SEBU7792-02-01)
2007 Caterpillar
All Rights Reserved
SEBU7792-02
107
Maintenance Section
Maintenance Interval Schedule
i02573890

SMCS Code: 1000; 7000
Ensure that all safety information, warnings and
instructions are read and understood before any
operation or any maintenance procedures are
performed.
The user is responsible for the performance of
maintenance, including all adjustments, the use of
proper lubricants, fluids, filters, and the replacement
of components due to normal wear and aging. Failure
to adhere to proper maintenance intervals and
procedures may result in diminished performance of
the product and/or accelerated wear of components.
Use mileage, fuel consumption, service hours, or
calendar time, WHICH EVER OCCURS FIRST,
in order to determine the maintenance intervals.
Products that operate in severe operating conditions
may require more frequent maintenance.
Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be
performed.
When Required
Air Conditioner Filter - Clean .............................. 109
Automatic Lubrication Reservoir - Fill .................. 112
Battery - Recycle ................................................. 112
Battery or Battery Cable - Inspect/Replace ......... 113
Brake Oil Cooler Screen - Clean ......................... 115
Brake Tank (Makeup) - Clean .............................. 117
Cab Air Filter - Clean/Replace ............................ 120
Circuit Breakers - Reset ...................................... 121
Engine Air Filter Primary Element - Clean/
Replace ............................................................. 135
Engine Air Filter Secondary Element - Replace .. 137
Engine Air Precleaner - Clean ............................ 137
Ether Starting Aid Cylinder - Replace ................. 145
Frame and Body - Inspect .................................. 147
Fuel System - Prime ........................................... 150
Fuel System Primary Filter (Water Separator) Drain ................................................................. 151
Fuel System Priming Filter - Replace ................. 153
High Intensity Discharge Lamp (HID) - Replace .. 155
Hoist Screens - Clean ......................................... 156
Hoist and Brake Tank Suction Screen Inspect/Clean/Replace ...................................... 159
Magnetic Plug (Wheels) - Check ........................ 161
Oil Filter - Inspect ................................................ 162
Rear Axle Housing End Play - Adjust ................. 163
Rim - Inspect ....................................................... 165
Suction Screen (Torque Converter) - Clean ........ 179
Traction Control System (TCS) - Test ................. 187
Windows - Clean ................................................. 190
Window Washer Reservoir - Fill .......................... 190
Window Wiper - Inspect/Replace ........................ 190
Every 10 Service Hours or Daily

Air Tank Moisture and Sediment - Drain .............. 110
Backup Alarm - Test ............................................. 112
Brakes, Indicators and Gauges - Test .................. 117
Cooling System Coolant Level - Check .............. 126
Differential and Final Drive Oil Level - Check ..... 133
Engine Oil Level - Check .................................... 140
Engine Oil Level - Log Additions ......................... 141
Hoist and Brake Tank Oil Level - Check ............. 158
Seat Belt - Inspect .............................................. 167
Steering System Oil Level - Check ..................... 177
Torque Converter Sump Oil Level - Check ......... 184
Initial 50 Service Hours

Brake Cooling Oil Filter - Replace ....................... 115
Oil Filter (Steering, Hydraulic Fan) - Replace ..... 161
Parking Brake Release Oil Filter - Replace ........ 162
Rear Axle Oil Filter - Replace ............................. 164
Steering System Oil Filter - Replace ................... 176
Torque Converter Oil Filter - Replace ................. 181
Transmission Oil Filter - Replace ........................ 188
Initial 250 Service Hours

Engine Valve Lash and Bridge - Adjust .............. 143
Every 250 Service Hours or Monthly

Braking System - Test .......................................... 118
Front Wheel Oil - Inspect .................................... 149
Magnetic Plug (Wheels) - Check ........................ 161
Tire Inflation - Check ........................................... 181
Initial 500 Hours (for New Systems, Refilled

Systems, and Converted Systems)
Cooling System Coolant Sample (Level 2) Obtain ............................................................... 127
Every 500 Service Hours

Differential and Final Drive Oil Sample - Obtain .. 134
Engine Oil Sample - Obtain ................................ 142
Front Wheel Oil Sample - Obtain ........................ 150
Hoist and Brake Tank Oil Sample - Obtain ......... 159
Steering System Oil Sample - Obtain ................. 178
Torque Converter and Transmission Oil Sample Obtain ............................................................... 186
Every 500 Service Hours or 3 Months

Air Conditioner Filter - Clean .............................. 109
Air Dryer - Check ................................................ 109
Air/Hydraulic Cylinder Breather - Clean ............... 111
Automatic Lubrication Reservoir - Fill .................. 112
Belts - Inspect/Adjust/Replace ............................. 113
Brake Cooling Oil Filter - Replace ....................... 115
Cab Air Filter - Clean/Replace ............................ 120
Cable (Truck Body Retaining) - Inspect .............. 121
108
Maintenance Section
Differential and Final Drive Oil - Inspect .............

Drive Shaft Slip Joint - Lubricate ........................
Engine Crankcase Breather - Clean ...................
Engine Oil Filter (Oil Renewal System) Change .............................................................
Engine Oil and Filter - Change ...........................
Frame - Clean/Inspect ........................................
Front Wheel Oil - Change ...................................
Fuel System Primary Filter (Water Separator)
Element - Replace ............................................
Fuel System Primary Filter - Clean .....................
Fuel System Secondary Filter - Replace ............
Fuel Tank Water and Sediment - Drain ...............
Hoist and Brake Tank Breather - Replace ..........
Oil Filter (Steering, Hydraulic Fan) - Replace .....
Parking Brake Release Oil Filter - Replace ........
Rear Axle Oil Filter - Replace .............................
Secondary Steering - Check ...............................
Steering System Oil Filter - Replace ...................
Suspension Cylinder - Check .............................
Torque Converter Oil Filter - Replace .................
Torque Converter Outlet Screen - Replace .........
Torque Converter Sump Breather - Clean ..........
Transmission Magnetic Screen - Clean ..............
Transmission Oil Filter - Replace ........................
SEBU7792-02
133
135
139
140
142
145
149
151
153
154
155
157
161
162
164
168
176
180
181
183
183
187
188
Every 1000 Service Hours or 6 Months

Air Dryer Desiccant - Replace ............................
Frame and Body Support Pads - Clean/Inspect ..
Rollover Protective Structure (ROPS) - Inspect ..
Seat Suspension - Inspect/Lubricate ..................
Service Brakes - Inspect .....................................
Steering Ball Stud - Inspect ................................
Steering Linkage - Inspect ..................................
Torque Converter and Transmission Oil Change .............................................................
Every 3 Years After Date of Installation or

Every 5 Years After Date of Manufacture
Seat Belt - Replace ............................................. 167
Every 4000 Service Hours

Engine Valve Lash and Bridge - Adjust .............. 143
Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add .. 124

Cooling System Water Temperature Regulator Replace ............................................................. 130
Engine Water Pump - Inspect ............................. 144
VIMS Module Battery - Replace ......................... 189
Every 12 000 Service Hours or 6 Years

Cooling System Coolant (ELC) - Change ........... 123
Steering Ball Stud - Replace ............................... 174
Every 15 000 Service Hours

109
148
167
168
169
170
174
184
Every 2000 Service Hours or 1 Year

Breather (Fuel Tank) - Replace ...........................
Differential Thrust Pin Clearance - Check ..........
Differential and Final Drive Breather - Replace ..
Differential and Final Drive Oil - Change ............
Front Axle Breather - Replace ............................
Hoist and Brake Tank Oil - Change ....................
Rear Axle Housing End Play - Adjust .................
Steering System Oil - Change ............................
Suction Screen (Rear Axle Lubrication) - Clean ..
Radiator Core - Clean ......................................... 163
120
131
131
132
148
157
163
175
178
Every Year
Receiver Dryer (Refrigerant) - Replace .............. 165
Sound Suppression (Covers, Panels) Inspect/Replace ................................................ 170

Cooling System Pressure Cap - Clean/Replace .. 128
Cooling System Relief Valve - Clean .................. 129
Rim - Inspect ....................................................... 166
Every 1 393 000 L (368 000 US gal) of Fuel

or 8000 Service Hours
Engine Components - Rebuild/Install Reman ..... 138
Every 2 786 000 L (736 000 US gal) of Fuel or

16 000 Service Hours
Engine Components - Clean/Inspect, Rebuild/Install
Reman, Install New ........................................... 138
SEBU7792-02
109
Maintenance Section
Air Conditioner Filter - Clean
i02390098
Air Conditioner Filter - Clean

SMCS Code: 7320
2. Drain the primary air tank and drain the secondary

air tank. Refer to Operation and Maintenance
Manual, Air Tank Moisture and Sediment - Drain
for the proper procedure.
If a reduction in air circulation is noticed, clean the

filter element for the air conditioner.
The filter element for the air conditioner is located in
the compartment in the front of the cab.
1. Park the machine on a level surface and engage
the parking brake.
2. Loosen the door retaining screws and open the
door.
Illustration 119
g01167619
Air dryer (1) is located on the frame in front of the left front
suspension cylinder.
The tire and the wheel have been removed for ease of viewing.
Illustration 118
g01165826
3. Remove filter element (1).

4. Clean the element by gently tapping the element
on a smooth surface.
5. Install the clean element. Close the door and
tighten the retaining screws.
i02685548
Air Dryer - Check

SMCS Code: 4285
The air lines to and from the air dryer must be at

atmospheric pressure. If the air lines are not at atmospheric pressure, personal injury could result.
Release the air pressure from the air system completely before performing maintenance.
the parking brake.
3. If there is moisture in the air tanks, replace

the desiccant cartridge or rebuild the desiccant
cartridge. Consult your Caterpillar dealer for
information about replacing the desiccant cartridge
and for instructions for rebuilding the desiccant
cartridge.
Note: Small amounts of moisture may be in the
system due to condensation in the system.
i02340897
Air Dryer Desiccant - Replace

SMCS Code: 4285
Air lines to and from the air dryer must be at

atmospheric pressure. Release the air pressure
from the air system completely before performing
maintenance.
110
Maintenance Section
Air Tank Moisture and Sediment - Drain
SEBU7792-02
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 tank
into a suitable container.
3. Close the drain valve for the air tank.
Secondary Air Tank
Illustration 120
g01167619
Air dryer (1) is located on the frame in front of the left front
suspension cylinder.
Replace the air dryer desiccant cartridge or rebuild

the air dryer desiccant cartridge if water cannot be
absorbed. Consult your Caterpillar dealer for service
or for replacement parts.
Illustration 122
i02602974
Air Tank Moisture and

Sediment - Drain
The drain valve for the secondary air tank is located on the right
hand side of the cab exterior.
SMCS Code: 4272

Park the machine on a level surface and engage the
parking brake.
Primary Air Tank
Illustration 121
g01132579
g01132606
Drain valve (1) for the primary air tank is located on the right hand
side of the platform.
2. Check for moisture and sediment in the air tank.

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111
Maintenance Section
Air/Hydraulic Cylinder Breather - Clean
Primary Air Tank (If Equipped

with the Sound Suppression
Arrangement)
Illustration 123
g01302805
Illustration 124
2. Check for moisture and sediment in the air tank.

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

cylinders (3) and (4).
i02251322
Air/Hydraulic Cylinder
Breather - Clean
SMCS Code: 4258
When it is necessary to work under the machine

with the body (bed) raised, attach the body (bed)
retaining cable to the rear tow point. Install the
rear tow point pin through the end of the retaining
cable.
Failure to properly secure the body (bed) may result in personal injury or death.
the parking brake.
2. Raise the dump body to the fully raised position
and install the truck body retaining cable to the
rear tow point pin. For the proper procedure, refer
to Operations and Maintenance Manual, Cable
(Truck Body Retaining).
3. Stop the engine.
g01133243
Breather for the rear air/hydraulic cylinders

Breather for the front air/hydraulic cylinders
Rear air/hydraulic cylinders
Front air/hydraulic cylinders
5. Wash both breathers in clean nonflammable

solvent. Allow the breathers to dry.
6. Install the clean breathers.
7. Remove the truck body retaining cable and lower
the body.
112
Maintenance Section
Automatic Lubrication Reservoir - Fill
SEBU7792-02
i02365140
Automatic Lubrication
Reservoir - Fill
If any of the remote lines become damaged, install a

fitting in place of the remote line. Lubricate the item
at the fittings until the remote line can be replaced.
See Systems Operation, Testing and Adjusting,
SENR4724, Automatic Lubrication System for
additional details.
SMCS Code: 7540
i02253468
Backup Alarm - Test

SMCS Code: 7406
Illustration 125
g01133458
1. Remove plug (1) for the upper port in order to vent

the autolube reservoir.
Note: If the plug for the upper port is not removed,
pressure will cause the wiper seal on the follower
assembly inside the reservoir to fail when the
reservoir is filled. Grease on the top side of the
follower assembly may prevent the autolube system
from functioning properly. Also, grease on the top
side of the follower assembly may cause damage
to the autolube system.
2. Fill the autolube reservoir through fill port (2).
Place a suitable container under the upper port in
order to collect any grease that is spilled. Fill the
reservoir until grease appears at the upper port. If
the machine is equipped with a Fast Fill Service
Center, the level indicator will illuminate when
the reservoir is full. For more information on the
Fast Fill Service Center, refer to Operation and
Maintenance Manual, Fast Fill Service Center.
Note: The bulk capacity of the grease reservoir is
27 kg (60 lb).
3. Install the plug in the upper port.
The automatic lubrication reservoir provides
lubrication for many components. There are fittings
on the left side of the machine, fittings on the
right side of the machine, and fittings on the rear
differential housing.
Illustration 126
g01130536
Location of the backup alarm

parking brake.
Turn the engine start switch to the ON position in
order to perform the test.
Make sure that the area behind the machine is clear
of personnel and clear of obstacles.
Move the transmission direction and speed control
lever to the REVERSE position.
The backup alarm should sound immediately. The
backup alarm should continue to sound until the
transmission direction and speed control lever is
moved to the NEUTRAL position or to the FORWARD
position.
i00993589
Battery - Recycle
SMCS Code: 1401
Always recycle a battery. Never discard a battery.
Always return used batteries to one of the following
locations:
A battery supplier
SEBU7792-02
113
Maintenance Section
Battery or Battery Cable - Inspect/Replace
An authorized battery collection facility
8. Connect the positive end + of the battery cable

to the battery.
Recycling facility
i02341243
Battery or Battery Cable Inspect/Replace
9. Connect the negative end of the battery cable

to the battery.
10. Connect the negative end of the battery cable
to the frame near the battery disconnect switch.
SMCS Code: 1401-040; 1401-510; 1402-040;

1402-510
11. Install the key. Turn the battery disconnect switch

to the ON position.
i02253729
Note: When you replace the batteries, always use

the same type of battery. This machine requires
Maintenance Free batteries or Low Maintenance
High Output batteries.
Belts - Inspect/Adjust/Replace

the parking brake.
Inspection
2. Turn the engine start switch to the OFF position.

Turn all of the switches to the OFF position.

parking brake.
3. Turn the battery disconnect switch to the OFF

position. Remove the key. Refer to Operation and
Maintenance Manual, Battery Disconnect Switch
for more information.
To maximize the engine performance, inspect

the belt for wear and for cracking. Check the
belt tension. Belt slippage will decrease the life
of the belt. A correctly adjusted belt will deflect
13 to 19 mm (0.50 to 0.75 inch). Refer to the Engine
Specifications, Belt Tension Chart.
4. Disconnect the negative end of the battery

cable from the frame near the battery disconnect
switch.
SMCS Code: 1356; 1357; 1405-036
Note: Do not allow the disconnected battery cable to

contact the battery disconnect switch.
Illustration 128
g01135583
The refrigerant compressor has a belt tensioner. If

shoulder (2) of the belt tensioner is aligned with red
zone (1) of the indicator, replace the belt.
Illustration 127
g01131766
5. Disconnect the negative end of the battery

cable from the battery.
6. Disconnect the positive end + of the battery
cable from the battery.
7. Replace the battery or make all necessary repairs
to the battery.
Adjustment and Replacement

Alternator
1. Park the machine on a level surface. Engage the
parking brake and stop the engine.
114
Maintenance Section
Belts - Inspect/Adjust/Replace
SEBU7792-02
Refrigerant Compressor
Illustration 129
Illustration 130
g01135171
Illustration 131
g01135219
Illustration 132
g01135507
g01135196
2. Loosen mounting bolt (5) and adjusting nuts (3).

3. If necessary, remove belt guard (4).
4. If necessary, remove the belt and replace the belt.
5. Turn adjusting nuts (3) in order to increase or
decrease the belt tension.
6. If the belt guard was removed, reinstall the belt
guard.
Belt tensioner for the refrigerant compressor belt

2. In order to release the tension on the belt, Insert a
12.7 mm (0.50 inch) ratchet into square hole (6) in
the belt tensioner, and pry the belt tensioner in a
counterclockwise direction.
3. If necessary, remove the belt and replace the belt.
7. Tighten the adjusting nuts. Tighten the mounting

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

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

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

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

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

to be 30 minutes.
SEBU7792-02
115
Maintenance Section
Brake Cooling Oil Filter - Replace
Refer to Engine Supplement, Disassembly and

Assembly, Belt Tightener - Remove and Install for
more information on replacement of the belts.
i02398611
Brake Cooling Oil Filter Replace

SMCS Code: 1366-FI
Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact skin.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Illustration 134
g01198005
The brake cooling oil filters are located behind the fuel tank. The
fuel tank has been removed for ease of viewing.
2. Remove filter housings (1).

3. Remove the used filter elements and discard the
used filter elements properly.
4. Wash the filter housings in clean nonflammable
solvent.
Refer to Special Publication, NENG2500, Caterpillar

Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
5. Inspect the seal in each housing base. If a seal is

damaged, replace the seal with a new seal.
Dispose of all fluids according to local regulations and

mandates.
7. Install the filter housings.
6. Install the new filter elements in the filter housings.
8. Start the engine and operate the engine at low

idle. Make sure that the parking brake is engaged.
Check for leaks and make any necessary repairs.
9. Check the oil level in the hoist/brake tank. If
necessary, add oil. For the proper procedure, refer
to Operation and Maintenance Manual, Hoist and
Brake Tank Oil Level - Check.
i02320005
Brake Oil Cooler Screen Clean

Illustration 133
g01137716
SMCS Code: 4257; 4295
Location of the brake cooling oil filters


contact skin.
116
Maintenance Section
Brake Oil Cooler Screen - Clean
SEBU7792-02
NOTICE
Tools and Shop Products Guide for tools and supplies
products.
mandates.
After a failure in the brake circuit, clean the screens
for the brake oil coolers. There are three screens that
need to be cleaned. There is one screen for the front
brake oil cooler and there are two screens for the
rear brake oil cooler.
Illustration 136
g01176679
Screen locations
Back side view of the housing for the rear brake oil cooler screens.
3. Remove covers (1) for the rear brake oil cooler

screens. One cover is located at the front of the
screen housing and one cover is located at the
rear of the screen housing.
4. Remove the rear oil cooler screens. Wash the oil
cooler screens in a clean, nonflammable solvent.
5. Install the rear oil cooler screens.
6. Install the covers for the rear brake oil cooler
screens.
Illustration 135
g01159886
The rear brake oil cooler screens are located on the right side
behind the rear brake oil cooler and in front of the hydraulic tank.
(2) Rear brake oil coolers
(3) Oil cooler for the steering/fan drive
2. Drain the oil from rear brake oil coolers (2) with
drain (4).
Illustration 137
g01159904
The front brake oil cooler screen is located inside the left frame rail
between the fuel tank and the torque converter.
The tire and the rim for the front left side have been removed for
ease of viewing.
7. Drain the oil from the front brake oil cooler screen
with drain (6).
SEBU7792-02
117
Maintenance Section
Brake Tank (Makeup) - Clean
8. Remove cover (5) for the front oil cooler screen.

9. Remove the front oil cooler screen. Wash the oil
cooler screen in a clean, nonflammable solvent.
10. Install the front oil cooler screen.
11. Install the cover for the front brake oil cooler
screen.
i02270875
Brake Tank (Makeup) - Clean
2. Raise the truck body to the fully raised position

3. Stop the engine.
4. Remove the top cover of brake makeup oil tank
(1).
5. Clean the cover and the brake makeup oil tank in
clean nonflammable solvent.
6. Inspect the cover seal and replace the cover seal
if the cover seal is damaged.
7. Install the cover.
the body.
i02381189
SMCS Code: 4291
Brakes, Indicators and Gauges

- Test

cable.
SMCS Code: 4251; 7000; 7450

Before you operate the machine, perform the
following checks.
1. Inspect the brake indicator lights in the cab.
Look for broken lenses on the gauges. Check for
broken indicator lights, broken switches, and other
broken components in the cab.
2. Make sure that the parking brake is engaged. Turn
the engine start switch to the ON position and
monitor the self test of the VIMS. See Operation
and Maintenance Manual, Vital information
System (VIMS) Self Test for further information.
The indicator lights on the dash will illuminate for 3
seconds. Replace any inoperative indicator lights.
Look for any inoperative gauges.
3. Start the engine. Check the brake system for the
following: oil leaks, air leaks, and damaged brake
lines.
Illustration 138
g01137610
The brake makeup oil tank is located on the inside rail on the left
side of the machine near the center tube.

the parking brake.
4. Turn on all machine lights. Check for proper

operation.
5. Sound the horn. Listen for proper operation.
6. Test the parking brake. For the proper test
procedure, refer to Operation and Maintenance
Manual, Braking System - Test.
118
Maintenance Section
Braking System - Test
SEBU7792-02
7. Test the service brakes. For the proper test

procedure, refer to Operation and Maintenance
Manual, Braking System - Test.
2. Check the area around the machine. Make sure

that the machine is clear of personnel and clear of
obstacles.
8. Engage the parking brake. Stop the engine.
3. Test the brakes on a dry, level surface.
Make any necessary repairs before machine

operation. Consult your Caterpillar dealer for more
information.
4. Start the engine and allow the air system to build

up to the operating pressure.
i02454317

SMCS Code: 4250
Personal injury can result if the machine moves

while testing.
If the machine begins to move during test, reduce
the engine speed immediately and engage the
parking brake.
If the machine moves when testing the brakes,

contact your Caterpillar dealer.
Have the dealer inspect and repair the brakes before returning the machine to operation. Failure to
have the brakes inspected and repaired can cause
injury or death.
The following tests are used to determine if the
parking brake, the secondary brake, and the service
brake are functional. These tests are not intended
to measure the maximum brake holding effort. The
brake holding effort that is required to sustain a
machine at a specific engine rpm varies depending
on the machine. The variations are the differences in
the engine setting, in the power train efficiency, and
in the brake holding ability, etc.
Note: Service personnel should perform this test
monthly. Document the results of each monthly test.
Compare the engine rpm from the previous month
to the current engine rpm. This will determine the
system deterioration.
Parking Brake Holding Ability Test

The air control valve for the parking brake activates
all the wheel brakes. The parking brakes are applied
by spring pressure and the parking brakes are
released by oil pressure.
1. Fasten the seat belt before you test the brakes.
Illustration 139
g01167667
(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 FIRST
SPEED FORWARD position.
8. Gradually increase the engine speed to 1300 rpm.
The machine should not move.
9. Reduce the engine speed to low idle. Move
the transmission control lever to the NEUTRAL
position. Leave the parking brake engaged. Stop
the engine.
NOTICE
If the machine moved while testing the brakes, contact
your Caterpillar dealer.
Have the dealer inspect and, if necessary, repair the
parking brakes before returning the machine to operation.
Test for the Parking Brake Reset

Valve
obstacles.
SEBU7792-02
119
Maintenance Section

4. Purge the air from the air system at the air tanks.
5. Make sure that the parking brake reset valve is
engaged. The valve will pop up to the engaged
position.
7. Disengage the parking brake.
8. Move the transmission control lever to the FIRST
position. Engage the parking brake switch. Stop
the engine.
11. In order to disengage the parking brake reset
valve , push down the knob.
NOTICE
parking brakes before returning the machine to operation.
Secondary Brake Holding Ability

Test
The secondary brake air control valve activates all
the wheel brakes. The secondary brakes are applied
by spring pressure and the secondary brakes are
released by oil pressure.
obstacles.
Illustration 140
g01167673
5. Apply secondary brake control (4).

6. Depress the parking brake reset valve.
7. Release the parking brake.
position. Engage the parking brake. Stop the
engine.
NOTICE
Have the Caterpillar dealer inspect and, if necessary,
repair the parking/secondary brakes before returning
the machine to operation.
Service Brake Holding Ability Test

The service brake air control valve activates all the
wheel brakes. The service brakes are applied by oil
pressure and the service brakes are released by oil
pressure.
obstacles.
120
Maintenance Section
Breather (Fuel Tank) - Replace
SEBU7792-02

the parking brake.
rear tow point pin. For the proper procedure for the
installation and removal of the truck body retaining
cable, refer to Operations and Maintenance
Manual, Cable (Truck Body Retaining).
3. Stop the engine.
Illustration 141
g01190530
5. Apply service brake control (5).

6. Depress the parking brake reset valve.
7. Release the parking brake.
position. Engage the parking brake. Stop the
engine.
NOTICE
service brake before returning the machine to operation.
Illustration 142
g01172150
4. Remove fuel tank breather (1).

5. Properly discard the used breather.
6. Install a new breather.
the body.
i01766189
Cab Air Filter - Clean/Replace

SMCS Code: 7311; 7342
i02345985
Breather (Fuel Tank) - Replace

SMCS Code: 1273-510-BRE

cable.
Illustration 143
Location of the filter element for the cab
(1) Cover
(2) Retaining screws
g00903640
SEBU7792-02
121
Maintenance Section
Cable (Truck Body Retaining) - Inspect
The filter element for the cab is located inside the

operators compartment.
1. Loosen retaining screws (2). Remove cover (1)
and the filter element.
2. Inspect the cable ends and the cable connection

for the truck body for any of the following
conditions:
Distortion such as bends or twists
2. Wash the filter element in a nonsudsing detergent.
Wear
3. Rinse the filter element in clean water. Allow the

filter element to air dry.
Corrosion
4. Install the clean filter element and cover (1).

Tighten retaining screws (2).
Note: When rips or tears are noticed in the filter
element, install a new filter element. When a
reduction of air circulation is noticed in the cab after
cleaning the filter element, install a new filter element.
i02385071
Cable (Truck Body Retaining)

- Inspect
Cracks or gouges
If any of the above conditions exist, replace
the truck body retaining cable and the cable
connection for the truck body. Consult your
Caterpillar dealer for proper replacement parts.
i02342172
Circuit Breakers - Reset

SMCS Code: 1420
SMCS Code: 5154-040; 7258
A raised body (bed) may fall unexpectedly if a

damaged cable is used. Use of a damaged cable
could result in personal injury or death.
Inspect the cable for damage and do not use a
cable that is damaged.
Wear gloves when handling the cable.
1. Inspect the cable for any of the following
conditions:
Reduction in the diameter

Broken wires
Worn wires
Corroded wires
Loose strands or loose wires
Loose cable ends or separation between the
cable and the cable end
Kinks
Cuts
Flat spots
Illustration 144
g01167724
122
Maintenance Section
Circuit Breakers - Reset
SEBU7792-02
Stop Lights and Dome light (7) 10 Amp
Brake Retraction Motor (8) 20 Amp
Air Conditioner (9) 15 Amp
Alternator (10) 105 Amp
Illustration 145
g01167816
Circuit Breaker/Reset Push in the

button in order to reset the circuit breaker. If
the electrical system is working properly, the
button will remain depressed. If the button does not
remain depressed, check the appropriate electrical
circuit. Repair the electrical circuit, if necessary.
Note: The circuit breakers for the low beam
headlights, the high beam headlights, and the fog
lights are automatic reset circuit breakers.
VIMS Message Center (11) 10 Amp
Window Washer and Wiper (12) 10

Amp
Power Train Electronic Control Module
(13) 10 Amp
Air Dryer (14) 10 Amp
VIMS Main Module (1) 15 Amp

Heated Mirrors (15) 25 Amp
Gauges (2) 10 Amp
Power Window (16) 10 Amp
Backup Alarm (3) 10 Amp
Access Lights (17) 15 Amp
Engine Starting Aid (4) 20 Amp
Steering Accumulator Pressure (5) 10

Amp
Brake Electronic Control Module (18)

10 Amp
Electronic Fuel Injection (19) 15 Amp
Keyswitch (6) 10 Amp

24 to 12 Volt Converter (20) 10 Amp
SEBU7792-02
123
Maintenance Section
Cooling System Coolant (ELC) - Change
i02317853
Cooling System Coolant (ELC)

- Change
SMCS Code: 1353; 1395
Personal injury can result from hot coolant, steam

and alkali.
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove cooling system pressure cap slowly to
relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
touch with your bare hand.
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns.
NOTICE
Mixing Cat Extended Life Coolant (ELC) with other
products reduces the effectiveness of the coolant
and shortens coolant life. Use only Caterpillar products or commercial products that have passed the
Caterpillar EC-1 specifications for premixed or concentrate coolants. Use only Cat Extender with Cat
ELC. Failure to follow these recommendations could
result in damage to the cooling systems components.
If ELC cooling system contamination occurs, refer to
Operation and Maintenance, Extended Life Coolant
(ELC) under the topic ELC Cooling System Contamination.
This machine was factory filled with Cat Extended Life
Coolant.
Drain the coolant whenever the coolant is dirty or
whenever foaming is observed.
Cooling System Coolant Additive contains alkali.

Avoid contact with skin and eyes.
NOTICE
products.
mandates.
Illustration 146
NOTICE
Do not change the coolant until you read and understand the material in the Cooling System Specifications section.
g01159005
(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 will

relieve system pressure. Remove the filler caps.
124
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
SEBU7792-02
Note: If you are using Caterpillar antifreeze, do not

add the supplemental coolant additive at this time
and/or change the element at this time.
10. Install filler caps (1) and (2).
i02317854
Cooling System Coolant

Extender (ELC) - Add
SMCS Code: 1353; 1395

and alkali.
Illustration 147
g01159976
3. Open drain valves (3) for the jacket water cooling

system and the aftercooler cooling system. Drain
the coolant into a suitable container.
Note: When the drain valves are opened, the coolant
will drain from both systems. Opening one drain
valve will drain that system and the other system will
remain partially full.
4. Close the drain valves. Fill the system with clean
water and a 6 to 10% concentration of cooling
system cleaner.
5. Start the engine and operate the engine for 90
minutes. Stop the engine and drain the cleaning
solution into a suitable container.
6. When the engine is stopped, flush the system with
water until the draining water is clear. Drain the
water into a suitable container.
7. Close the drain valves.
8. Add the coolant solution.
Special Publication, SEBU6250, Cooling

System Specifications
Operation and Maintenance Manual, Capacities

(Refill)
9. Start the engine. Run the engine without the filler

caps. Run the engine until the thermostat opens
and the coolant level stabilizes. This should purge
the air from the system. Check the coolant level.
Operation and Maintenance Manual, Cooling

System Coolant Level - Check

burns.
NOTICE
Adding coolant to an overheated engine could result in
damage to the engine. Allow the engine to cool before
adding coolant.
If the machine is to be stored in, or shipped to, an area
with freezing temperatures, the cooling system must
be protected to the lowest outside (ambient) temperature.
The engine cooling system is normally protected to a minimum of29C (20F) with Caterpillar
Antifreeze, when shipped from the factory unless
special requirements are defined.
SEBU7792-02
125
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
NOTICE
products.
mandates.
NOTICE
Excessive additive (greater than the recommended
6% initial fill) together with concentrations of antifreeze
greater than 60% cause deposits to form and can result in radiator tube blockage and overheating.
NOTICE
Mixing Cat Extended Life Coolant (ELC) with other
products reduces the effectiveness of the coolant
and shortens coolant life. Use only Caterpillar products or commercial products that have passed the
Caterpillar EC-1 specifications for premixed or concentrate coolants. Use only Cat Extender with Cat
ELC. Failure to follow these recommendations could
result in damage to the cooling systems components.
If ELC cooling system contamination occurs, refer to
Operation and Maintenance, Extended Life Coolant
(ELC) under the topic ELC Cooling System Contamination.
This machine was factory filled with Cat Extended Life
Coolant.
Refer to Special Publication, SEBU6250, Cooling
System Specification for the cooling system
requirements.
Use 8T-5296 Test Kit in order to check the
concentration.
Illustration 148
g01159006

(3) Level gauges
2. Loosen filler caps (1) and (2) slowly in order to

relieve pressure. Remove the filler caps.
3. Check level gauges (3). If necessary, drain
enough coolant in order to allow the addition of
the liquid coolant additive.
Note: Make sure that the coolant is drained into a
suitable container.
4. Refer to the table in Special Publication,
SEBU6250, Extended Life Coolant (ELC).
This table lists the correct amount of Caterpillar
Extended Life Coolant (ELC) extender that should
be added to the cooling system.
5. Clean the filler caps and inspect the filler caps.
Install the filler caps.
6. Start the engine and check for leaks. Allow the
coolant level to stabilize.
7. If necessary, add premixed coolant in order to
bring the coolant in the green range on the coolant
level gauge.
126
Maintenance Section
Cooling System Coolant Level - Check
SEBU7792-02
i02317855
Cooling System Coolant Level

- Check
If the needle is in the red range, allow the system

to cool and add coolant.
i01985667

Sample (Level 1) - Obtain
SMCS Code: 1353; 1395

and alkali.
SMCS Code: 1395-554

NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both
dealers and customers.
Note: Level 1 results may indicate a need for
Level 2 Analysis.

burns.
Illustration 150
g01028921
Right side view of engine

(1) Sampling valve
Sampling valve (1) for the jacket water cooling system

is located on the right side of the engine water pump.
Illustration 149
g01159008
(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.

parking brake.
Use level gauges (1) and (2) to check the coolant
levels. The needle should be in the green range.
SEBU7792-02
127
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
For additional information about coolant analysis, see

Special Publication, SEBU6250, Caterpillar Machine
Fluids Recommendations or consult your Caterpillar
dealer.
i01987259

Sample (Level 2) - Obtain
SMCS Code: 1395-554
Illustration 151
g01028922
Left side view of engine

(2) Sampling valve
Sampling valve (2) for the water cooled aftercooler

system is located on the left side of the engine water
pump.
NOTICE
Obtain the sample of the coolant as close as possible

to the recommended sampling interval. In order
to receive the full effect of SOS analysis, you
must establish a consistent trend of data. In order
to establish a pertinent history of data, perform
consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from
Use the following guidelines for proper sampling of
the coolant:
Complete the information on the label for the

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

bags.
Obtain coolant samples directly from the coolant
Illustration 152
g01028921
Right side view of the engine

(1) Sampling valve
Sampling valve (1) for the jacket water cooling system

is located on the right side of the engine water pump.
sample port. You should not obtain the samples

from any other location.
Keep the lids on empty sampling bottles until you

are ready to collect the sample.
Place the sample in the mailing tube immediately

after you obtain the sample in order to avoid
contamination of the sample.
Never collect samples from expansion bottles.

Never collect samples from the drain for a system.
Submit the sample for Level 1 analysis.
Illustration 153
Left side view of the engine
(2) Sampling valve
g01028922
128
Maintenance Section
Cooling System Pressure Cap - Clean/Replace
SEBU7792-02
Sampling valve (2) for the water cooled aftercooler

system is located on the left side of the engine water
pump.
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. Supplies
for collecting samples can be obtained from your
Caterpillar dealer.
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.
For additional information about coolant analysis, see
Special Publication, SEBU6250, Caterpillar Machine
Fluids Recommendations or consult your Caterpillar
dealer.
i02347060
Cooling System Pressure Cap

- Clean/Replace
SMCS Code: 1382
Illustration 154
g01159005

2. Remove filler caps (1) and (2) slowly in order to

relieve the pressure.
3. Inspect the filler caps for damage, for foreign
material, and for deposits.

and alkali.
burns.
4. Clean the filler caps with a clean cloth or replace

the filler caps, if necessary.
5. Install the filler caps.
SEBU7792-02
129
Maintenance Section
Cooling System Relief Valve - Clean
i02347062
Cooling System Relief Valve Clean
2. Slowly remove filler caps (1) and (2). This will

3. Remove the bolts from the relief valve and remove
the valve assembly.
SMCS Code: 1370

and alkali.
burns.
Illustration 156
(4)
(5)
(6)
(7)
(8)
g00302286
Valve
Valve seals
Gasket
Valve cover
Mounting bolts

4. Inspect valve (4),valve seals (5) and gasket (6).

If necessary, replace the valves, the seals or the
gaskets.
If the system overheats or if coolant is leaking, clean

the relief valves or replace the relief valves.
5. Inspect valve cover (7) and mounting bolts (8).

parking brake and stop the motor.
Illustration 155
(3) Cooling system relief valves
g01172742
6. Assemble the relief valve. Install the relief valve.

7. Install the filler caps.
130
Maintenance Section
Cooling System Water Temperature Regulator - Replace
SEBU7792-02
i02347151
Cooling System Water

Temperature Regulator Replace
SMCS Code: 1355; 1393

and alkali.
burns.
Illustration 157
g01159005

2. Remove filler caps (1) and (2) slowly in order to


Note: The thermostats should be replaced after
the cooling system has been cleaned. Replace the
thermostats while the cooling system is completely
drained or while the cooling system coolant is drained
to a level that is below the thermostat housing.
NOTICE
Failure to replace the engines thermostat on a regularly scheduled basis could cause severe engine damage.
Replace the four thermostats on a regular basis in
order to reduce the chance of unscheduled downtime
and of problems with the cooling system.
Illustration 158
g01172817
Note: Make sure that the coolant level is below the

thermostat housings.
SEBU7792-02
3. Disconnect the hose assemblies from thermostat

housing assemblies (3).
4. Remove the thermostat housing assemblies.
5. Remove the gasket, the thermostat, and the seal
from the thermostat housing assembly.
131
Maintenance Section
Differential Thrust Pin Clearance - Check
i02320510
Differential Thrust Pin

Clearance - Check
SMCS Code: 3258; 3260; 3284
NOTICE
Former thermostats may be used, if they meet test
specifications and are not damaged or have excessive
buildup or deposits.
NOTICE
Since Caterpillar engines incorporate a shunt design
cooling system, it is mandatory to always operate the
engine with a thermostat.
Depending on load, failure to operate with a thermostat could result in either an overheating or an overcooling condition.
Illustration 159
NOTICE
If the thermostat is installed incorrectly, it will cause
the engine to overheat.
See the Adjustment Procedure For the Pin. This

adjustment procedure is located in the Power Train
Testing and Adjusting, Differential and Bevel Gear Adjust for your machine.
6. Install a new seal in the thermostat housing. Install

a new thermostat and a new gasket.
Repeat Steps 5 and 6 for the three remaining
thermostats.
7. Install the thermostat housing assemblies on
the engine cylinder head. Connect the hose
assemblies to the thermostat housing assemblies.
g01160191
i02320548
Differential and Final Drive

Breather - Replace
SMCS Code: 3258; 4050
8. Tighten the hose clamps.
Illustration 160
g01160212

132
Maintenance Section
Differential and Final Drive Oil - Change
SEBU7792-02
2. Remove differential and final drive breather (1).

3. Install a new differential and final drive breather.
i02454361
Differential and Final Drive Oil

- Change
SMCS Code: 3258; 4050
The oil change interval for the differential and final
drives can be monitored with a SOS (Scheduled
Oil Sampling) program. For more information on
SOS services, refer to Operation and Maintenance
Manual, SOS Information. When a SOS
program is used, the oil change interval is based
on the following:
The condition of the oil
NOTICE
products.
mandates.
3. Remove the final drive drain plug. Drain the oil
4. Clean the drain plug. Install the drain plug.
The SOS recommendation

When a SOS program is not used, the oil change
interval is based on the following:
5. Repeat Step 1 through Step 4 for the other final

drive.
4000 service hours or 1 year if Caterpillar

FDAO/FD-1 oil is used.
2000 service hours or 1 year if Caterpillar

TDTO/TO-4 oil is used.
Illustration 161
g01160272
1. Rotate the wheels so that final drive drain plug (1)

is in the lowest position on the rear wheel.
Illustration 162
g01160274
6. Remove differential drain plug (3) and allow the oil

to drain into a suitable container.
Note: Inspect the magnetic drain plug and the
oil. Refer to Operation and Maintenance Manual,
Differential and Final Drive Oil - Inspect for further
information.
7. Clean the drain plug. Install the drain plug.
8. Remove sight gauge (4). Wipe the surface around
the opening for the sight glass.
SEBU7792-02
133
Maintenance Section
Differential and Final Drive Oil - Inspect
9. Before the differential and final drives are filled,

refer to Operation and Maintenance Manual,
Lubricant Viscosities and Operation and
Maintenance Manual, Capacities (Refill).
NOTICE
If the ambient temperature at engine start-up or
during operation is below 10C (14F), perform
the procedures in Operation and Maintenance
Manual, Differential Warm-up and Break-in. Check
the differential compartment and the final drive
compartment for the proper fluid level. Failure to
warm up the oil or improper lubrication levels prior to
operation will cause damage to the machine.
10. Fill the differential compartment to the bottom of
the opening for the sight gauge.
11. Clean the sight gauge and install the sight gauge.
15. Stop the machine. Check the oil level. If

necessary, adjust the oil level to the bottom of the
sight gauge.
Note: If it is necessary to add oil, use final drive filler
plug (2). make sure that the filler plug is positioned
above the oil level in the final drive in order to prevent
any oil from draining out.
Note: Overfilling the differential and final drives will
cause overheating and foaming of the oil in long
hauling applications and high speed applications. A
reduction of the life of components may be the result
of overheating and foaming of the oil.
i02450436

- Inspect
12. Remove final drive filler plugs (2). Fill each final
drive to the bottom of the filler plug opening. When
the final drive drain plug is in the lowest position,
the final drive filler plug will be at the correct oil
level.
SMCS Code: 4208
Note: The final drives may need to be repositioned in

order to place the final drive drain plug in the lowest
position.
A high amount of metal on the magnetic plug
Note: Allow oil to fill all of the compartments. Correct

oil levels are critical in the differential and final drives.
Inspect the differential and final drive oil for any of the
following symptoms that may indicate a mechanical
failure:
An increased level of nickel concentration in the

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

SOS sample
Oil leaks in the area around the drive wheel

bearings
The rear wheel bearings do not need to be adjusted

or inspected until the scheduled overhaul. Unless a
symptom of an obvious failure appears, do not adjust
or inspect the rear wheel bearings. If the differential
and 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.
Illustration 163
g01160268
i02394551
13. Maintain the proper oil level (5) for the differential
to the bottom of sight gauge (4).

Level - Check
14. Operate the machine on level ground for a few

minutes.
SMCS Code: 3258; 4050
Note: The differential and final drive oil level needs to

be checked and maintained at operating temperature.
After the oil has been changed in the differential
and final drives, adjustment of the oil level may
be necessary when the truck reaches operating
temperature.
Correct oil levels are critical in the differential and

final drives. Check the oil level after repairs and after
maintenance. Check the oil level prior to operation.
134
Maintenance Section
Differential and Final Drive Oil Sample - Obtain
SEBU7792-02
The differential and final drive oil level needs to be

checked and maintained at operating temperature.
If the oil level is checked cold, adjustment of the
oil level may be necessary when the truck reaches
operating temperature.
Illustration 166
Illustration 164
g01195747
Location of the sight gauge for the differential and final drives

the parking brake.
g01192672
4. If necessary, add oil. Use filler plug (3) for the

final drive in order to add oil. When the drain
plug is in the lowest position, the filler plug will be
at the correct oil level. Make sure that the filler
plug is positioned above the oil level in the final
drive in order to prevent any oil from draining out.
Allow the oil to fill all of the compartments before
rechecking the oil level.
Note: Overfilling the differential and final drives will
cause overheating and foaming of the oil in long
hauling applications and high speed applications. A
reduction of the life of components may be the result
of overheating and foaming of the oil.
i02320757

Sample - Obtain
SMCS Code: 3258-008; 4050-008; 4070-008; 7542
Illustration 165
g01160336
2. Use sight gauge (1) to check the oil level for the
differential and final drives.
3. Maintain the proper oil level (2) at the bottom of
the sight gauge.
Illustration 167
g01160351
SEBU7792-02
135
Maintenance Section
Drive Shaft Slip Joint - Lubricate
NOTICE
Sampling valve (1) for the differential and final drive
oil is located on the base of the rear axle oil filter.
Refer to the following publications for information
about obtaining an oil sample.
Operation and Maintenance Manual, SOS

Information
Special Publication, SEBU6250, SOS Oil

Analysis
Special Publication, PEHP6001, How To Take A

Good Oil Sample
Special Publication, PEDP8025, Fluid Analysis

Interpretaion Guide
Apply lubricant to the grease fitting on the drive shaft

spline.
i02346978
Engine Air Filter Primary

Element - Clean/Replace
SMCS Code: 1051; 1054
NOTICE
Service the air cleaner only with the engine stopped.
Engine damage could result.
Service the air cleaner filter elements when
the action light is activated. The action light
is located on the dash panel. The action
light will activate when there is an inlet air
restriction, and the VIMS display will provide a
message regarding the specific problem. Refer
to Operation and Maintenance Manual, Vital
Information Management System (VIMS) for
further information.
i02321492
Drive Shaft Slip Joint Lubricate

SMCS Code: 3253
Illustration 169
g00102316
2. Remove covers (1) for the air filter housings.

3. Remove primary filter elements (2) from the air
filter housings.
4. Clean the inside of the air filter housings.
5. Clean the dust valves on the bottom for the air
filter housings.
Illustration 168
g01160565
6. Install clean primary air filter elements. Install the

covers for the air filter housings.
Note: Refer to Cleaning Primary Air Filter Elements.
Park the machine on a level surface. Engage the

136
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
If the alert indicator activates after starting the engine

or the exhaust smoke is still black after installation
of clean primary filter elements, install new primary
filter elements. If the alert indicator remains activated,
replace the secondary elements.
Cleaning Primary Air Filter

Elements
SEBU7792-02
Vacuum cleaning
Pressurized Air
Pressurized air can be used to clean primary air filter
elements that have not been cleaned more than two
times. Pressurized air will not remove deposits of
carbon and oil. Use filtered, dry air with a maximum
pressure of 207 kPa (30 psi).
NOTICE
Caterpillar recommends certified air filter cleaning services available at participating Caterpillar dealers. The
Caterpillar cleaning process uses proven procedures
to assure consistent quality and sufficient filter life.
Observe the following guidelines if you attempt to
clean the filter element:
Do not tap or strike the filter element in order to remove dust.
Do not wash the filter element.
Use low pressure compressed air in order to remove
the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage
to the pleats.
Do not use air filters with damaged pleats, gaskets, or
seals. Dirt entering the engine will cause damage to
engine components.
The primary air filter element can be used up to
six times if the element is properly cleaned and the
element is properly inspected. When the primary
air filter element is cleaned, check for rips or tears
in the filter material. The primary air filter element
should be replaced at least one time per year. This
replacement should be performed regardless of the
number of cleanings.
NOTICE
Do not clean the air filter elements by bumping or tapping. This could damage the seals. Do not use elements with damaged pleats, gaskets, or seals. Damaged elements will allow dirt to pass through. Engine
damage could result.
Visually inspect the primary air filter elements before
cleaning. Inspect the air filter elements for damage
to the seal, the gaskets, and the outer cover. Discard
any damaged air filter elements.
There are two common methods that are used to
clean primary air filter elements:
Pressurized air
Illustration 170
g00281692
Note: When the primary air filter elements are

cleaned, always begin with the clean side (inside)
in order to force dirt particles toward the dirty side
(outside).
Aim the hose so that the air flows inside the element
along the length of the filter in order to help prevent
damage to the paper pleats. Do not aim the stream of
air directly at the primary air filter element. Dirt could
be forced further into the pleats.
Vacuum Cleaning
Vacuum cleaning is another method for cleaning
primary air filter elements which require daily cleaning
because of a dry, dusty environment. Cleaning with
pressurized air is recommended prior to vacuum
cleaning. Vacuum cleaning will not remove deposits
of carbon and oil.
SEBU7792-02
137
Maintenance Section
Engine Air Filter Secondary Element - Replace
Inspecting the Primary Air Filter

Elements
Illustration 172
g00644798
(1) Secondary element

Illustration 171
g00281693
Inspect the clean, dry primary air filter element. Use

a 60 watt blue light in a dark room or in a similar
facility. Place the blue light in the primary air filter
element. Rotate the primary air filter element. Inspect
the primary air filter element for tears and/or holes.
Inspect the primary air filter element for light that may
show through the filter material. If it is necessary in
order to confirm the result, compare the primary air
filter element to a new primary air filter element that
has the same part number.
Do not use a primary air filter element that has any
tears and/or holes in the filter material. Do not use
a primary air filter element with damaged pleats,
gaskets or seals. Discard damaged primary air filter
elements.
2. Remove secondary elements (1) and properly

discard the secondary elements.
3. Cover the air inlet openings. Clean the inside of
the air cleaner housings.
4. Uncover the air inlet openings. Install the new
secondary elements.
5. Install the primary elements.
i02363128
Engine Air Precleaner - Clean

SMCS Code: 1055
i02347040
Engine Air Filter Secondary

Element - Replace
SMCS Code: 1051; 1054
NOTICE
Always replace the secondary element. Do not attempt to reuse it by cleaning. Engine damage could
result.
Note: Replace the engine air filter secondary
elements when you service the engine air filter
primary elements for the third time. Replace the
secondary elements if the exhaust smoke remains
black and the clean primary elements have been
installed.
Illustration 173
g01180274
Note: Do not paint dust valves (3). Paint will cause

the rubber to harden and the rubber may not seal
properly.
Perform the following procedure for each engine air
precleaner.
138
Maintenance Section
Engine Components - Clean/Inspect, Rebuild/Install Reman, Install New
2. Loosen clamp (1) on the precleaner and remove

lower precleaner bowl (2) and dust valve (3).
3. Clean the lower precleaner bowl and the dust
valve with air pressure.
4. Make sure that all of the tubes within the
precleaner are free of dirt. Clean the tubes, if
necessary.
5. Install the clean lower precleaner bowl, and the
clean dust valve and tighten the clamp on the
precleaner.
NOTICE
Do not operate the machine with the dust valves removed. Engine damage can occur.
SEBU7792-02
Piston Rings
Wiring Harness
Rebuild Components and/or Install

Remanufactured Components
Cylinder Heads
Turbochargers
Oil Coolers
Oil Pump
Scavenge Oil Pump
Water Pump
i02381002
Engine Components Clean/Inspect, Rebuild/Install

Reman, Install New
SMCS Code: 1000-012-IC, NW; 1000-022-MC;
1000-571-IC; 1000
Clean Components and Inspect

Components for Reusability
Aftercooler Core
Camshaft
Camshaft Lifters
Caterpillar recommends this additional maintenance

for the following engine components. Consult your
Caterpillar dealer for further information.
Connecting Rods
The quantity of burned fuel that is shown with the

service hours assumes a load factor of 40 percent. If
the load factor is higher than 40 percent, the number
of service hours for the overhaul interval will be
lower. If the load factor is lower than 40 percent, the
number of service hours for the overhaul interval will
be higher. The quantity of consumed fuel is a better
indicator for the overhaul interval than service hours.
Cylinder Block
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 Crankshaft
Thrust Plates
Crankshaft
Cylinder Liners
Damper
Gear Train
Piston Crowns and Piston Skirts
Piston Pins
Spacer Plates
i02381004
Engine Components Rebuild/Install Reman

SMCS Code: 1000-022-MC; 1000
Caterpillar recommends this additional maintenance
for the following engine components. Consult your
Caterpillar dealer for further information.
SEBU7792-02
139
Maintenance Section
Engine Crankcase Breather - Clean
The quantity of burned fuel that is shown with the

service hours assumes a load factor of 40 percent. If
the load factor is higher than 40 percent, the number
of service hours for the mid-life service interval will
be lower. If the load factor is lower than 40 percent,
the number of service hours for the mid-life service
interval will be higher. The quantity of consumed fuel
is a better indicator for the mid-life service interval
than service hours.
Air Compressor
Air Starter
Alternator
Fuel Transfer Pump
High Pressure Turbochargers (3516B High Altitude
Engine)
Turbochargers (3516B High Displacement Engine)

Injectors
Refrigerant Compressor
Wastegate (3516B High Altitude Engine)
i02322735
Engine Crankcase Breather Clean

SMCS Code: 1317-070
The engine in this machine is equipped with six
engine crankcase breathers. Two of the breathers
are on the valve covers on the right side and four of
the breathers are on the valve covers on the left side.
Illustration 174
g01160965

the parking brake.
2. Stop the engine. Loosen clamps (4). Remove
hose (2) from breather assemblies (1) and from
vent tube (3).
3. Remove the breather assemblies from the valve
covers.
4. Wash the breather in clean nonflammable solvent.
5. Install the breather assemblies on the valve
covers.
6. Install the hose on the breather assemblies and
on the vent tube. Tighten all clamps.
7. Repeat Step 2 through Step 6 in order to clean the
remaining breathers on the engine.
140
Maintenance Section
Engine Oil Filter (Oil Renewal System) - Change
i02398716
Engine Oil Filter (Oil Renewal

System) - Change
(If Equipped)
SEBU7792-02
1. Remove used engine oil filters (1) and discard the

used engine oil filters .
2. Clean the oil filter base assemblies. Make sure
that all of the former gaskets are removed.
SMCS Code: 1318; 1348; 1349
3. Apply a thin film of clean engine oil to each seal of

each new engine oil filter .

contact the skin.
4. Install the new engine oil filters by hand. Tighten

each filter until the seal of each engine oil filter
contacts the base. Note the position of the index
marks on each filter in relation to a fixed point on
the filter base.
NOTICE
products.
mandates.
The machine must be parked on a level surface and
the parking brake must be engaged. The oil must be
warm and the engine must be stopped.
Note: Caterpillar filters have rotation index marks

that are spaced 90 degrees or 1/4 of a turn away
from each other. When you tighten the filters, use the
rotation index marks as a guide.
5. Tighten each filter according to the instructions
that are printed on the filter. Use the index marks
as a guide.
Note: You may need to use a Caterpillar strap
wrench, or another suitable tool, in order to turn
the filters to the amount that is required for final
installation. Make sure that the installation tool does
not damage the filters.
6. Start the engine and operate the engine at low idle
for five minutes. Inspect engine oil filters (1) for oil
leaks. Make any necessary repairs.
7. Maintain the oil level between the ADD mark and
the FULL mark. These marks are on the LOW
IDLE side of dipstick (3). Stop the engine.
i02682174
Engine Oil Level - Check

SMCS Code: 1302; 1318; 1326
Personal injury or death can occur if personnel are

trapped between the wheel and the frame.
The steering system is hydraulically controlled
and wheels can crush personnel during movement.
Illustration 175
(1) Engine oil filters
(2) Oil filler cap
(3) Dipstick
g01162192
Use caution when working between the wheels

and the frame. If the wheels must be turned, ensure that all personnel are clear of the machine
before any movement.
SEBU7792-02
141
Maintenance Section
Engine Oil Level - Log Additions
i02326857
NOTICE
Do not under fill or overfill engine crankcase with oil.
Either condition can cause engine damage.
Engine Oil Level - Log

Additions
(If Equipped with the Oil
Renewal System)
SMCS Code: 1348
Illustration 176
g01162246
Location of the dipstick for the engine oil

Illustration 178
Illustration 177
g01162249
1. The machine must be on a level surface and the

parking brake must be engaged.
2. Check the oil level in the engine.
a. When the engine is running at low idle, maintain
the oil level between the ADD mark and the
FULL mark. These marks are on the LOW
IDLE side of dipstick (2).
b. When the engine is stopped, maintain the oil
level between the ADD mark and the FULL
mark. These marks are on the ENGINE
STOPPED side of the dipstick.
3. If necessary, remove oil filler cap (1) and add oil.
4. Clean the filler cap and install the filler cap.
g00408438
The Oil Renewal System (ORS) meters engine

oil that is blended into the fuel supply. This oil will
be consumed by the engine during the process of
combustion. Normal operation will continually lower
the oil level in the crankcase. Continually adding new
engine oil will allow the life of the oil to be extended.
An SOS analysis will determine if the oil needs to
be changed.
The graph in Illustration 178 plots the quantity of
added oil against the service hours during a 500 hour
period. This data can be used to determine if the
Oil Renewal System is working properly. Keeping a
daily maintenance log of all of the additions of oil is
necessary for the accuracy of this data. The daily
maintenance log is also necessary for adjustment of
the metering rate. The daily maintenance log will also
indicate the total amount of oil that has been added
since the last oil change. This information is needed
at the time of each SOS analysis.
142
Maintenance Section
Engine Oil Sample - Obtain
SEBU7792-02
i02326499
Engine Oil Sample - Obtain

SMCS Code: 1000-008

contact the skin.
NOTICE
products.
Illustration 179
g01162265

mandates.
Sampling Valve For The Engine Oil
The sampling valve for the engine oil is located above

the engine oil filters.

Information
Note: Some commercial oils that meet API

specifications may require shorter oil change
intervals. The oil change intervals are determined
by close monitoring of the oil condition and engine
wear metals. Caterpillar prefers the scheduled oil
sampling as the proper method of checking engine
wear metals.
Consult your Caterpillar dealer for the latest oil

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

the parking brake must be engaged. The oil must be
warm and the engine must be stopped.
Analysis
Good Oil Sample

Interpretation Guide
i02454647
Engine Oil and Filter - Change

SMCS Code: 1318
Note: If your machine is equipped with the Oil
Renewal System (ORS), engine oil is blended
into the fuel supply of the machine. This oil will
be consumed in the engine during the process of
combustion. Normal operation will continually lower
the oil level in the crankcase. Continually adding
new oil will allow the life of the oil to be extended.
An SOS Oil Analysis will determine if the oil needs
to be changed. In order to change the engine oil
filters only, refer to Operation and Maintenance
Manual, Engine Oil Filter (Oil Renewal System) Change. For more information on the Oil Renewal
System, refer to Systems Operation, RENR2223, Oil
Renewal System.
Illustration 180
g01162319
SEBU7792-02
143
Maintenance Section
Engine Valve Lash and Bridge - Adjust
1. Open drain valve (1) and drain the oil into a

suitable container. Close the drain valve .
8. Start the engine and operate the engine at low idle

for five minutes. Inspect the engine oil filter for oil
leaks. Make any necessary repairs.
9. Maintain the oil level between the ADD mark and
the FULL mark. These marks are on the LOW
IDLE side of dipstick (4). Stop the engine.
i02342142
Engine Valve Lash and Bridge

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

motor to turn the flywheel.
Illustration 181
g01162326
Hot engine components can cause burns. Allow

additional time for the engine to cool before measuring valve clearance.
2. Remove the used engine oil filters (2) and discard

the used engine oil filters.
3. Clean the oil filter base assemblies. Make sure
that all of the former gaskets are removed.
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
4. Apply a thin film of clean engine oil to the seal of

each new engine oil filter.
Valve Bridge
5. Install the new engine oil filters by hand. Tighten

each engine oil filter until the seal of each engine
oil filter contacts the base of the oil filter housing.
Note the position of the index marks on each filter
in relation to a fixed point on the filter base.
Note: Caterpillar filters have rotation index marks
that are spaced 90 degrees or 1/4 of a turn away
from each other. When you tighten the filters, use the
6. Tighten each filter according to the instructions
that are printed on the filter. Use the index marks
as a guide.
Note: You may need to use a Caterpillar strap
wrench, or another suitable tool, in order to turn
the filters to the amount that is required for final
installation. Make sure that the installation tool does
not damage the filters.
7. Remove oil filler cap (3). Fill the crankcase with
oil. Refer to Operation and Maintenance Manual,
Lubricant Viscosities for the type of oil. Refer to
Operation and Maintenance Manual, Capacities
(Refill) for the amount of oil.
The engine in this machine is equipped with a

nonadjustable valve bridge. Proceed with the
valve lash adjustment.
Valve Lash Adjustment

NOTICE
Operation of Caterpillar Engines with improper engine
valve lash adjustments will reduce the engine efficiency. This reduced efficiency could result in excessive
fuel usage and/or shortened engine component life.
Measure the engine valve lash with the engine
stopped. To obtain an accurate measurement, allow
at least 20 minutes for the valves to cool to engine
cylinder head and block temperature.
If the valve clearance is within 0.08 mm (0.0031 inch)
of the given nominal clearance, no adjustment is
required. If the clearance is not within the given limits,
set the clearance to the amount that is specified in
the chart.
144
Maintenance Section
Engine Water Pump - Inspect
SEBU7792-02
Water Pump for the Jacket Water

Cooling System
Table 7
VALVE CLEARANCE SETTING

Inlet
Exhaust
0.5 mm (0.02 inch)

1.00 mm (0.04 inch)
A water pump (1) that has failed might cause

severe engine overheating problems. The engine
overheating problems could result in the following
problems.
Cracks in the cylinder head

Piston seizure
Other potential engine damage
Visually inspect water pump (1) for leaks. If leaks are
found, all the seals need to be replaced.
Note: See Service Manual, Engine Disassembly
and Assembly.
Illustration 182
g00653920
To check the engine valve lash, refer to System

Operation, Testing And Adjusting, SENR1123,
3500B Engines For Caterpillar Built Machines,
Valve Lash and Valve Bridge Adjustment. Consult
your Caterpillar dealer for any additional information.
i02326985
Engine Water Pump - Inspect

SMCS Code: 1361
Auxiliary Water Pump for the

Aftercooler Cooling System
An auxiliary water pump (2) that has failed might
cause severe engine overheating problems. The
engine overheating problems could result in the
following problems.
Valve failures
Warped intake manifolds
Other potential engine damage
Visually inspect auxiliary water pump (2) for leaks. If
leaks are found, all the seals need to be replaced.
Note: See Service Manual, Engine Disassembly
and Assembly.
Illustration 183
g01162405
(1) Water pump for the jacket water cooling system

(2) Auxiliary water pump for the aftercooler cooling system
SEBU7792-02
145
Maintenance Section
Ether Starting Aid Cylinder - Replace
i02330233
Ether Starting Aid Cylinder Replace

SMCS Code: 1456
3. Remove the used gasket for each ether starting

aid cylinder and install the new gasket that is
provided for each ether starting aid cylinder.
4. Install the new ether starting aid cylinders. Tighten
the clamps.
i02340776
Breathing ether vapors or repeated contact of

ether with skin can cause personal injury. Personal injury may occur from failure to adhere to the
following procedures.
Use ether only in well ventilated areas.
Frame - Clean/Inspect
SMCS Code: 7051
Note: The graphics that are shown are for illustrative
purposes. This is an in-chassis inspection.
Do not smoke while changing ether cylinders.

Use ether with care to avoid fires.
Do not store replacement ether cylinders in living
areas or in the operators compartment.
Do not store ether cylinders in direct sunlight or
at temperatures above 49 C (120 F).
Discard cylinders in a safe place. Do not puncture
or burn cylinders.

cable.
Keep ether cylinders out of the reach of unauthorized personnel.

To avoid possible injury, be sure the brakes are applied and all controls are in Hold or Neutral when
starting the engine.
Illustration 185
Illustration 184
g01163382
The two ether starting aid cylinders are mounted

behind the radiator.
2. Loosen the clamps and unscrew the ether starting
aid cylinders.
g01167516

the parking brake.
3. Stop the engine.
146
Maintenance Section
Frame - Clean/Inspect
SEBU7792-02
4. Clean the frame with a high pressure washer.

5. Inspect the frame for damage and for cracks.
If you find cracks or damage, consult your
Caterpillar dealer for specific repair procedures.
Do not operate the machine until the necessary
repairs have been made.
Note: Refer to Special instruction, REHS0541,
Procedure for the Inspection, Repair, and
Component Replacement on the Frames of
Off-Highway Truck/Tractor.
Rear Axle A-Frame and Differential

Housing

cable.
Illustration 187
g00980907
a. Inspect the inside face of the rear axle a-frame

in the area that is indicated by the shading.
Inspect the welds of the rear axle a-frame.

Illustration 188
g00980933
b. Inspect the area around the bolt holes of the

rear axle a-frame.
Illustration 186
g00980903
2. Clean the rear axle a-frame and the differential

housing with a wire brush or with a scraper.
Inspect the designated areas for cracks. If you find
cracks or damage, consult your Caterpillar dealer
for specific repair procedures.
SEBU7792-02
Illustration 189
147
Maintenance Section
Frame and Body - Inspect
g00980956
c. Inspect the bottom of the differential housing in

the area that is indicated by shading.
Illustration 191
g00981044
e. Inspect the differential housing in the area

around the lower half of the differential
mounting surface that is indicated by shading.
i02340811
Frame and Body - Inspect

SMCS Code: 7258
g01167529

cable.
d. Inspect the top rear sides of the differential

housing in the area that is indicated by shading.
Illustration 190

the parking brake.
3. Stop the engine.
148
Maintenance Section
Frame and Body Support Pads - Clean/Inspect
SEBU7792-02

3. Stop the engine.
Illustration 193
g01167566
4. Clean the body support pads with high pressure

water or steam.
Illustration 192
g01167539
4. Clean the frame with a wire brush or a scraper.

Inspect the dump body. If the frame is damaged
or worn, consult your Caterpillar dealer for repair
procedures.
5. Clean the dump body with a wire brush or a
scraper. Inspect the dump body. If the dump body
is damaged or worn, consult your Caterpillar
dealer for repair procedures.
5. Visually inspect each of the body support pads.

Look for damage or uneven wear of the body
support pads. Look for gaps between the body
support pads and the mating surfaces. If problems
are found, consult your Caterpillar dealer for more
information or for specific repair procedures.
i02457383
Front Axle Breather - Replace

SMCS Code: 4251
i02340837
Frame and Body Support Pads

- Clean/Inspect

SMCS Code: 7258


cable.

the parking brake.
SEBU7792-02
149
Maintenance Section
Front Wheel Oil - Change
1. Position the front wheel so that drain plug (1) is

facing downward.
NOTICE
products.
Illustration 194
g01163437

2. Remove breather (1) from each front wheel.
3. Install a new breather on each front wheel.
i02330775
Front Wheel Oil - Change

SMCS Code: 4006
Note: The oil change interval for the front wheel
bearing can be monitored with the SOS scheduled
oil sampling program. The interval is based on
the condition of the oil. If the SOS scheduled oil
sampling program is not used, the oil change for
the front wheel bearing should be performed at 500
service hours or 3 months.

mandates.
3. Remove the drain plug.
4. Allow the oil to drain into a suitable container.
5. Clean the drain plug and install the drain plug.
6. Remove the filler plug (2).
7. Fill the oil compartment to the bottom of the
opening for the filler plug. Refer to Operation
and Maintenance Manual, Lubricant Viscosities.
Capacities (Refill).
8. Clean the filler plug and install the filler plug. Use
the same procedure for the other front wheel
bearing.
i02388737
Front Wheel Oil - Inspect

SMCS Code: 4006
Inspect the front wheel oil for any of the following
symptoms that may indicate a failure of the wheel
bearings:
A high amount of metal on the magnetic plug

An increased level of nickel concentration in the
SOS sample
An increase in the size of the particle count in the

SOS sample
Illustration 195
g01163440
Oil leaks in the area around the front wheel spindle
150
Maintenance Section
Front Wheel Oil Sample - Obtain
SEBU7792-02
The front wheel bearings do not need to be adjusted

or inspected until the scheduled overhaul. Unless a
symptom of an obvious failure appears, do not adjust
or inspect the front wheel bearings. If the front wheel
oil has any of the above symptoms, the front wheel
bearings may need to be inspected. Consult your
Caterpillar dealer for more information.
i02330789
Front Wheel Oil Sample Obtain
i02435121
Fuel System - Prime

SMCS Code: 1258
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Clean up fuel
spills immediately.
Note: The engine start switch must be in the OFF
position in order to prime the fuel system.
SMCS Code: 4201-008; 7542

Illustration 196
g01180364
Filler plug for the front wheel
NOTICE
The oil sample for the front wheel is obtained with a
sampling gun through the filler plug.

Information

Analysis

Good Oil Sample

Interpretaion Guide
Illustration 197
g01167459
2. Pull out on switch (1) in order to release the switch.

3. Hold the switch upward in order to activate the
electric fuel priming pump. The priming pump will
fill the engine fuel lines and the fuel filters with fuel.
Note: Button (2) is the circuit breaker reset for the
electric fuel priming pump. Push in the button in order
to reset the circuit breaker. If the electrical system is
working properly, the button will remain depressed.
If the button does not remain depressed, check the
electrical circuit for the priming pump. Repair the
electrical circuit, if necessary.
4. As the air is purged from the fuel system, fuel
pressure will increase. Listen for the electric fuel
priming pump to come under load. Do not continue
priming the fuel system after the priming pump is
under load. Do not operate the priming pump for
more than two minutes.
SEBU7792-02
151
Maintenance Section
Fuel System Primary Filter (Water Separator) - Drain
5. Start the engine.

6. If the engine starts but the engine runs rough,
continue to run the engine at low idle until the
engine runs smoothly.
7. If the engine does not start after several attempts,
refer to Special instruction, SEHS9586, 3500
Electronic Unit Injection (EUI) Fuel Priming
Procedure or consult your Caterpillar dealer.
i02338162
Fuel System Primary Filter

(Water Separator) - Drain
(If Equipped)
SMCS Code: 1263-543
NOTICE
products.
mandates.
Open drain valves (1) on the bottom of the fuel/water
separator elements in order to drain the water into an
approved container. Close the drain valves when all
of the water has been drained.
i02338293
Fuel System Primary Filter

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

ignites. Fuel leaked or spilled onto hot surfaces
or electrical components can cause a fire.
Illustration 198
g01167092
The fuel/water separators are located on the right inside frame rail
in front of the front axle.
To help prevent possible injury, turn the battery

disconnect switch to the OFF position when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
152
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
SEBU7792-02
NOTICE
products.
mandates.
NOTICE
Do not fill fuel filters with fuel before installing them.
The fuel will not be filtered and could be contaminated.
Contaminated fuel will cause accelerated wear to fuel
system parts. The fuel system should be primed prior
to starting the engine.
the parking brake.
Illustration 200
g01167178
The fuel/water separator is located on the right inside frame rail

in front of the front axle.
3. Remove drain tube assembly (3) from the bottom

of the drain valves for the fuel/water separator
elements.
4. Remove the fuel/water separator elements (2) with
a strap type wrench. Discard the used elements
properly.
5. Clean the mounting base. Make sure that both of
the old seals are removed.
6. Lubricate the seals of the new elements with clean
diesel fuel.
Illustration 199
g01167276
View of the back side of the fuel tank
2. Stop the engine and close fuel shutoff valve (1).
7. Install the new elements by hand until the seal

contacts the mounting base. Note the position of
the index marks on the elements in relation to a
fixed point on the mounting base.
Note: There are rotation index marks on each filter
that is spaced 90 degrees (1/4 turn) away from
each other. When you tighten the elements, use the
8. Tighten all filters according to the instructions that
are printed on the filter.
Note: You may need to use a strap type wrench or a
suitable tool in order to turn the filters to the amount
that is required for final installation. Make sure that
the installation tool does not damage the filters.
9. Install the drain tube assembly to the bottom of
the new elements.
10. Open the fuel shutoff valve.
SEBU7792-02
153
Maintenance Section
Fuel System Primary Filter - Clean
11. Prime the fuel system.

For information on priming the fuel system, refer
to the Operation and Maintenance Manual, Fuel
System - Prime.
12. Start the engine and inspect the filter for leaks.
Make any necessary repairs. If the engine has a
loss of power or the exhaust smoke is still black,
replace the secondary filters.
i02338079
Fuel System Primary Filter Clean

(If Equipped)
SMCS Code: 1260; 1261
8. Open the fuel shutoff valve. Prime the fuel system.

Fuel System - Prime.
9. Start the engine and inspect the filter for leaks.
Make any necessary repairs. If the engine has a
loss of power or the exhaust smoke is still black,
change the secondary filters.
i02345997
Fuel System Priming Filter Replace

SMCS Code: 1258-510-FI; 1261-510
NOTICE
Do not fill fuel filters with fuel before installing them.
Contaminated fuel will cause accelerated wear to fuel
system parts.
Clean the primary element when the engine has a
loss of power or when the exhaust smoke is black.
the parking brake.
Illustration 201
7. Install the filter element and the filter housing.

Tighten bolt (2) to a torque of 25 7 Nm
(18 5 lb ft).
g01167019

3. Loosen bolt (2).
4. Remove filter housing (3) and the filter element.
5. Wash the base and the element in clean,
nonflammable solvent.
6. If the filter base gasket is damaged, replace the
filter base gasket.
The fuel priming filter is located on the right side of the

engine directly below the electric fuel priming pump.
Fuel only flows through the filter when you activate
the priming pumps. Under normal circumstances,
the original fuel priming filter should last for the
entire service life of the machine. If the filter must be
replaced, use the procedure that follows.
the parking brake.
Illustration 202
g01167276
154
Maintenance Section
Fuel System Secondary Filter - Replace
SEBU7792-02
NOTICE
during performance of inspection, maintenance, testing, adjusting and repair of the machine. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any component containing fluids.
Tools and Shop Products Guide, for tools and supplies suitable to collect and contain fluids.
mandates.

suitable tool in order to turn the filter to the amount
the installation tool does not damage the filter.
9. Open the fuel shutoff valve.
10. Prime the fuel system. Refer to Operation and
Maintenance Manual, Fuel System - Prime.
i02327025
Fuel System Secondary Filter Replace

SMCS Code: 1261
Illustration 203
g01172157
3. Remove fuel priming filter (2) with a strap type

wrench. Discard the used filter properly.
4. Clean the filter mounting base. Make sure that the
former seal is removed.
5. Lubricate the seal of the new filter with clean
diesel fuel.
6. Install the new filter by hand. Tighten the filter until
the sealing surface contacts the base. Tighten the
filter for an additional 3/4 of a turn.
7. Install the new filter by hand until the seal contacts
the mounting base. Note the position of the index
marks on the filter in relation to a fixed point on
the mounting base.
that is spaced 90 degrees (1/4 turn) away from each
other. When you tighten the filter, use the rotation
index marks as a guide.
Illustration 204
g01162420
2. Remove secondary fuel filters (1) with a strap type

wrench. Discard the used filters properly.
3. Clean the filter mounting bases. Make sure that
the old filter seals are removed.
NOTICE
Do not fill the secondary fuel filter with fuel before installing. The fuel would not be filtered and could be
contaminated. Contaminated fuel will cause accelerated wear to fuel system parts.
4. Lubricate the seals of the new filters with clean
diesel fuel.
SEBU7792-02
155
Maintenance Section
Fuel Tank Water and Sediment - Drain
5. Install the new filters by hand until the seal

the index marks on the filters in relation to a fixed
point on the mounting base.
other. When you tighten the filters, use the rotation
NOTICE
products.
mandates.
7. Prime the fuel system. Refer to the Operation and

Maintenance Manual, Fuel System - Prime.


Open fuel tank drain valve (1) and allow the moisture
and the sediment to drain into a suitable container.
Close the drain valve.
i02338067
Fuel Tank Water and Sediment

- Drain
SMCS Code: 1273
i02245859
High Intensity Discharge Lamp

(HID) - Replace
(If Equipped)
SMCS Code: 1434-510
HID lamps operate at very high voltages. To avoid

electrical shock and personal injury, disconnect
power before servicing HID lamps.
HID bulbs become very hot during operation.

Before servicing, remove power from lamp for at
least five minutes to ensure lamp is cool.
Illustration 205
g01167012
NOTICE
Although HID bulb materials may change over time,
HID bulbs produced at the time of the printing of this
manual contain mercury. When disposing of this component, or any waste that contains mercury, please
use caution and comply with any applicable laws.
1. Remove the electrical power from the high
intensity discharge lamp (HID). The electrical
power must be removed from the HID lamp for
at least five minutes, in order to ensure that the
bulb is cool.
156
Maintenance Section
Hoist Screens - Clean
SEBU7792-02
2. Disassemble the housing for the HID lamp in order

to have access to the bulb.
Note: On some HID lamps, the bulb is an integral
part of the lens assembly. The bulb is not removed
separately from the lens assembly. Replace the
entire lens assembly on these HID lamps.
3. Remove the bulb from the HID lamp.
4. Install the replacement bulb in the HID lamp.
If the bulb is an integral part of the lens assembly,
install the replacement lens assembly in the HID
lamp.
Note: In order to avoid failure to the bulb that is
premature, avoid touching the bulbs surface with
your bare hands. Clean any fingerprints from the bulb
with alcohol prior to operation.
5. Reassemble the housing for the HID lamp. Ensure
that any printing on the lens is oriented correctly
with respect to the HID lamps mounting position
on the machine.
6. Reattach the electrical power to the HID lamp.
7. Check the HID lamp for proper operation.
Note: Consult your Caterpillar dealer for additional
information on HID lamps.
NOTICE
products.
mandates.
Clean the screens whenever there is a failure of the
brakes, hoist cylinders, or hoist pumps.
the parking brake.
3. Stop the engine.
i02335762
Hoist Screens - Clean

SMCS Code: 5068

cable.
Illustration 206
g01165827
The hoist screens are located on the right rear of the center tube.

contact the skin.
4. Remove the bolts that attach hoses (2) to housings
(3) for the hoist screen. Drain the oil from the lines
SEBU7792-02
157
Maintenance Section
Hoist and Brake Tank Breather - Replace
5. Remove the hoist screens from the housings.

Clean the hoist screens in clean nonflammable
solvent.
6. Install the clean hoist screens and the hoses. Use
new seals. Tighten the bolts.
the body.
i02340012
Hoist and Brake Tank Breather

- Replace
SMCS Code: 5057
Illustration 207
g01172423
4. Remove breather (1) and discard the breather

properly.
5. Install a new breather.

cable.
the parking brake.
3. Stop the engine.

the body.
i02685600
Hoist and Brake Tank Oil Change

SMCS Code: 5056
NOTICE
products.
mandates.
The machine must be level. The truck body must be
in the DOWN position. The parking brake must be
engaged and the engine must be stopped.
158
Maintenance Section
Hoist and Brake Tank Oil Level - Check
Illustration 208
SEBU7792-02
g01172912
Illustration 209
g01349223
1. Remove filler cap (1) in order to prevent a vacuum

in the tank. Install the filler cap after the tank has
been drained. This will prevent dirt from entering
the system.
9. Use engine shutdown control (4) to prevent

the engine from starting. Crank the engine for
approximately 15 seconds. The oil level will
decrease as oil fills the system.
2. Remove tank drain valve plug (3). Install a

88.0 mm (3.50 inch) long NPT pipe nipple in
order to open the internal drain valve. The outer
diameter of the NPT pipe nipple should be 25 mm
(1 inch). Drain the oil into a suitable container.
10. Add oil to the tank in order to raise the oil level to
the FULL mark in upper sight gauge (2).
Note: Hand tighten the NPT pipe nipple. Do not use

tools.
12. Lower the guard on the engine shutdown control.

Start the engine and operate the engine at low
idle. Check for leaks and make necessary repairs.
3. Remove the pipe nipple. Clean the drain plug and

install the drain plug.
4. Remove the filler cap.
5. Remove the retaining ring on the filler screen.
Remove the screen.
6. Wash the cap and the filler screen in clean,
nonflammable solvent. Allow the cap and the filler
screen to dry.
7. Inspect the cap seal. Use a new seal if the used
seal is damaged. Install the filler screen and the
retaining ring.
8. Fill the hoist/brake tank. Refer to Operation and
Maintenance Manual, Lubricant Viscosities.
11. Repeat Step 9 and Step 10 until the oil stabilizes

in the FULL mark in the upper sight gauge.
13. Raise the truck body until the hoist cylinders are
extended halfway. Lower the truck body and add
oil, if necessary.
fully extended. Lower the truck body and add oil, if
necessary.
15. Repeat Step 13 and Step 14 until the oil level
stabilizes in the FULL mark in the upper sight
gauge.
16. Install the filler cap.
i02399492
Hoist and Brake Tank Oil Level

- Check
SMCS Code: 5056
1. Park the machine on a level surface with the
truck body in the DOWN position and engage the
parking brake.
SEBU7792-02
159
Maintenance Section
Hoist and Brake Tank Oil Sample - Obtain

Analysis

Good Oil Sample

Interpretaion Guide
i02685621
Hoist and Brake Tank Suction

Screen - Inspect/Clean/Replace
Illustration 210
g01172846
2. Maintain the oil level to the FULL mark on sight

gauge (2). If necessary, remove filler cap (1) and
add oil.
i02336350
Hoist and Brake Tank Oil

Sample - Obtain
SMCS Code: 5056

NOTICE
products.
SMCS Code: 5056-008; 7542

mandates.
The machine must be level. The truck body must be
in the DOWN position. The parking brake must be
engaged and the engine must be stopped.
There are three suction screens on the hoist/brake
tank. Clean all of the screens whenever there is a
failure of brakes, hoist cylinders or hoist pumps.
Illustration 211
g01188933
The fuel tank is removed for ease of viewing.
Sampling valve (1) for the hoist and brake oil is

located at the base of the brake cooling oil filters.

Information
Illustration 212
g01165906
160
Maintenance Section
Hoist and Brake Tank Suction Screen - Inspect/Clean/Replace
SEBU7792-02
1. Remove tank drain plug (1). Install a 88.0 mm

(3.50 inch) long NPT pipe nipple in order to open
the internal drain valve. The outer diameter of the
NPT pipe nipple should be 25.4 mm (1.00 inch).
Drain the oil into a suitable container.
tools.
2. Remove the bolts from cover (2) on the front of
the hoist and brake tank. Remove the cover.
3. Clean the debris from the bottom of the tank.
Illustration 214
g01349223
11. Use ground level shutdown switch (4) to prevent

the engine from starting. Crank the engine for
approximately 15 seconds. The oil level will
decrease as oil fills the system.
Illustration 213
g01165914
View of the back side of the hoist and brake tank
4. Remove the flanges and three hoses (3).

5. Remove the suction screens from the tank.
6. Wash the suction screens in clean, nonflammable
solvent.
Illustration 215
7. Install the clean suction screens and install the

hoses and flanges.
12. Add oil to the tank in order to raise the oil level to
the FULL mark in upper sight gauge (5).
8. Clean the cover for the front of hoist and brake

tank in clean, nonflammable solvent. Inspect the
cover gasket. If the gasket is damaged, replace
the gasket.
13. Repeat Step 11 and Step 12 until the oil stabilizes

in the FULL mark in the upper sight gauge.
9. Install the cover to the front of the tank.

10. Fill the hoist/brake tank. Refer to Operation and
Maintenance Manual, Lubricant Viscosities.
g01165956
14. Lower the guard on the ground level shutdown

control. Start the engine. Run the engine at low
idle. Inspect the machine for oil leaks and make
necessary repairs.
extended halfway. Lower the truck body and add
oil, if necessary.
fully extended. Lower the truck body and add oil, if
necessary.
17. Repeat Step 15 and Step 16until the oil level
stabilizes in the FULL mark in the upper sight
gauge.
18. Clean the filler cap and install the filler cap.
SEBU7792-02
161
Maintenance Section
Magnetic Plug (Wheels) - Check
i02346919
Magnetic Plug (Wheels) Check
i02398678
Oil Filter (Steering, Hydraulic

Fan) - Replace
(Hydraulic Pump Case Drain)
SMCS Code: 0663

Note: A weekly inspection of the magnetic plugs is
strongly recommended.
SMCS Code: 5068-510

contact skin.
NOTICE
Illustration 216
g01172641
(1) Magnetic plug on the front wheel

products.
mandates.
Illustration 217
g01172642
(2) Magnetic plug on the rear wheel
All of the wheels have a magnetic plug. The magnetic

plug (1) and (2) will attract metal from the oil. A
bearing failure is indicated by an increased amount
of metal on the magnetic plug.
If excessive particles or abnormal particles are found,
consult your Caterpillar dealer.
Illustration 218
g01163566
2. Push button (1) on the breaker relief valve.

3. Slowly remove cap (2) on the steering hydraulic
tank in order to relieve the pressure.
162
Maintenance Section
Oil Filter - Inspect
SEBU7792-02
4. Remove case drain filter (3) for the hydraulic fan

and remove case drain filter (4) for the steering
system from the mounting bases with a strap type
wrench. Discard the used filters properly.
5. Clean the mounting bases. Make sure that all of
the old filter seals are removed.
6. Lubricate the seals of the new filters with clean oil.
7. Install the new filters by hand until the seal
the index marks on the filters in relation to a fixed
point on the mounting base.
other. When you tighten the filters, use the rotation
10. Check the oil level. If necessary, add oil. Refer
to Operation and Maintenance Manual, Steering
System Oil Level - Check.
i02106227
Use a filter cutter to cut the filter element open.

Spread apart the pleats and inspect the element for
metal and for other debris. An excessive amount of
debris in the filter element can indicate a possible
failure.
If metals are found in the filter element, a magnet can
be used to differentiate between ferrous metals and
nonferrous metals.
Ferrous metals can indicate wear on steel parts and
on cast iron parts.
Nonferrous metals can indicate wear on the
aluminum parts of the engine such as main bearings,
rod bearings, or turbocharger bearings.
Small amounts of debris may be found in the filter
element. This could be caused by friction and by
normal wear. Consult your Caterpillar dealer in order
to arrange for further analysis if an excessive amount
of debris is found.
Using an oil filter element that is not recommended
by Caterpillar can result in severe engine damage
to engine bearings, to the crankshaft, and to other
parts. This can result in larger particles in unfiltered
oil. The particles could enter the lubricating system
and the particles could cause damage.
i02320227
Parking Brake Release Oil

Filter - Replace
SMCS Code: 4257; 4295
Oil Filter - Inspect

SMCS Code: 1318; 3067; 5068; 7528
Inspect a Used Filter for Debris

contact the skin.
NOTICE
products.
Illustration 219
The element is shown with debris.
g00100013

mandates.
SEBU7792-02
163
Maintenance Section
Radiator Core - Clean

i02340749
Radiator Core - Clean

SMCS Code: 1353
Illustration 220
g01160070
2. Remove drain plug (2) from the bottom of filter

housing (1). Drain the oil into a suitable container.
Clean the drain plug and install the drain plug.
Note: Removing the drain plug from the bottom of the
filter housing may not drain all of the oil from the filter.
3. Remove filter housing (1) and the filter element.
Discard the used filter element.
4. Wash the filter housing in clean, nonflammable
solvent.
5. Inspect the seal in the housing base. If the seal is
damaged, replace the seal with a new seal.
6. Install the new element in the filter housing.
Illustration 221
g01167490
You can use compressed air, high pressure water,

or steam to remove dust and other debris from the
air side of the radiator core. However, the use of
compressed air is preferred.
NOTICE
High water pressure water and high water volume can
damage the radiator.
Use a water spray nozzle that will disperse the water.
See Special Publication, SEBD0518, Know Your
Cooling System for the complete procedure for
cleaning the radiator core.
7. Install the filter housing.

i02346912
Rear Axle Housing End Play Adjust

SMCS Code: 3282-025-EP
The end play adjustment of the rear axle housing
is recommended at the initial 2000 service hours.
Yearly inspection and maintenance of the end play of
the rear axle housing will maximize service life.
Note: The end play adjustment of the rear axle
housing is recommended at every 6 months in severe
applications.
164
Maintenance Section
Rear Axle Oil Filter - Replace
SEBU7792-02
To adjust the end play of the rear axle housing, refer

to Testing and Adjusting, RENR8327, 793D Power
Train Testing and Adjusting, Rear Axle Housing End
Play - Adjust. Consult your Caterpillar dealer for any
additional information.
i02327082
Rear Axle Oil Filter - Replace
2. Remove the drain plug from filter housing (1).

Drain the oil into a suitable container. Clean the
drain plug and install the drain plug.
Note: Removing the drain plug from the bottom of the
filter housing may not drain all of the oil from the filter.
3. Remove the filter housing and the filter element.
4. Wash the filter housing in clean nonflammable
solvent.
SMCS Code: 4070; 5068
5. Inspect the seals in the filter base. If the seals are

damaged, replace seals with new seals.
6. Install the new filter element in the filter housing.
Install the filter housing.
Note: The lubrication pump for the rear axle will not
operate with the oil temperature below 15 C (59 F).
8. Check the oil level in the rear axle. If necessary,
add oil. For the proper procedure, refer to
Operation and Maintenance Manual, Differential
and Final Drive Oil - Check.
Illustration 222
g01162468

contact the skin.
NOTICE
products.
mandates.
Note: Correct oil levels are critical in the differential

and final drives. Check the oil level after repairs and
after maintenance.
SEBU7792-02
165
Maintenance Section
Receiver Dryer (Refrigerant) - Replace
i02656745
Receiver Dryer (Refrigerant) Replace

SMCS Code: 7322-510
Personal injury can result from contact with refrigerant.

Contact with refrigerant can cause frost bite. Keep
face and hands away to help prevent injury.
Illustration 223
Protective goggles must always be worn when refrigerant lines are opened, even if the gauges indicate the system is empty of refrigerant.
Always use precaution when a fitting is removed.
Slowly loosen the fitting. If the system is still under pressure, release it slowly in a well ventilated
area.
Personal injury or death can result from inhaling
refrigerant through a lit cigarette.
Inhaling air conditioner refrigerant gas through a
lit cigarette or other smoking method or inhaling
fumes released from a flame contacting air conditioner refrigerant gas, can cause bodily harm or
death.
Do not smoke when servicing air conditioners or
wherever refrigerant gas may be present.
Use a certified recovery and recycling cart to properly remove the refrigerant from the air conditioning system.
NOTICE
If the refrigerant system has been open to the outside
air (without being plugged) for more than 30 minutes,
the receiver-dryer must be replaced. Moisture will enter an open refrigerant system and cause corrosion
which will lead to component failure.
g01159180
The refrigerant dryer is located in the refrigerant lines underneath

the cab.
Refer to Service Manual, SENR5664, Air

Conditioning and Heating R-134a for All Caterpillar
Machines for the proper procedure to change the
receiver-dryer assembly and for the procedure to
reclaim the refrigerant gas.
i02650497
Rim - Inspect
SMCS Code: 4209-040
Inspect the rim whenever a tire is dismounted.
166
Maintenance Section
Rim - Inspect
SEBU7792-02
i02650677
Rim - Inspect
SMCS Code: 4209-040
If regulatory agencies require a rim inspection, this
documentation can be used as a guideline.
The tires must be dismounted from the rim in order to
perform a magnetic particle inspection.
Illustration 224
g01330970
Typical example
Cutaway view of the rim assembly
Inspect the following components of the rim

assembly:
Bead Seat Band (1) Inspect the bead seat band
for the following: wear, corrosion, and cracks.
Lock Ring (2) Inspect the lock ring for the
following: wear, corrosion, cracks, flat spots, and
warping. When the lock ring is not assembled, the
two ends of the lock ring must overlap each other.
Illustration 225
g01331173
Typical example
Cutaway view of the rim assembly
Rim Base (3) Inspect the rim base for the following:
wear, corrosion, cracks, and fretting.
The following high stress areas of the rim should be

checked:
Flanges (4) Inspect the flanges for the following:

wear, corrosion, cracks, and fretting.
(1) Areas of contact with flanges
Do not reuse rim components that are cracked,

worn, damaged, or pitted from corrosion. For more
information on the reusability of the rim components,
(2) Contact areas with the lock ring and the groove
for the lock ring
(3) Welds on the rim disc

(4) Welds around the circumference of the rim base
(5) Butt welds
SEBU7792-02
167
Maintenance Section
Rollover Protective Structure (ROPS) - Inspect
For more information on magnetic particle inspection,

refer to Guideline For Reusable Parts And Salvage
Operations, SEBF8148, General Salvage and
Reconditioning Techniques or consult your
Caterpillar dealer.
.
Do not reuse rim components that are cracked,
worn, damaged, or pitted from corrosion. For more
information on the reusability of the rim components,
i02381197
Rollover Protective Structure

(ROPS) - Inspect
SMCS Code: 7325
Inspect the Rollover Protective Structure (ROPS)
for bolts that are loose or damaged. Replace any
damaged bolts and any missing bolts with original
replacement parts only. Tighten the bolts to a torque
of 1904 68 Nm (1400 50 lb ft).
Note: Apply oil to all bolt threads for the ROPS before
you install the bolts. Improper bolt torque can result if
you do not apply oil to the threads.
Do not weld reinforcement plates to the ROPS
in order to straighten the ROPS. Do not weld
reinforcement plates to the ROPS in order to repair
the ROPS.
Inspect the ROPS for any cracks in the welds, cracks
in the castings, or cracks in any metal section.
Refer to Special Instruction, SEHS6929, Inspection,
Maintenance, and Repair of ROPS and Attachment
Installation Guidelines or consult your Caterpillar
dealer for more information.
Illustration 226
g00932801
Typical example
Check the seat belt mounting hardware (1) for wear

or for damage. Replace any mounting hardware that
is worn or damaged. Make sure that the mounting
bolts are tight.
Check buckle (2) for wear or for damage. If the buckle
is worn or damaged, replace the seat belt.
Inspect the seat belt (3) for webbing that is worn or
frayed. Replace the seat belt if the seat belt is worn
or frayed.
Consult your Caterpillar dealer for the replacement of
the seat belt and the mounting hardware.
Note: Within three years of the date of installation or
within five years of the date of manufacture, replace
the seat belt. Replace the seat belt at the date which
occurs first. A date label for determining the age of
the seat belt is attached to the seat belt, the seat belt
buckle, and the seat belt retractor.
If your machine is equipped with a seat belt
extension, also perform this inspection procedure for
the seat belt extension.
i02429594
i02429589
Seat Belt - Inspect
Seat Belt - Replace
SMCS Code: 7327
SMCS Code: 7327-510
Always check the condition of the seat belt and the

condition of the seat belt mounting hardware before
you operate the machine. Replace any parts that are
damaged or worn before you operate the machine.
Within three years of the date of installation or within

five years of the date of manufacture, replace the
seat belt . Replace the seat belt at the date which
occurs first. A date label for determining the age of
the seat belt is attached to the seat belt, the seat belt
buckle, and the seat belt retractor.
168
Maintenance Section
Seat Suspension - Inspect/Lubricate
SEBU7792-02
Armrest (Seat)
Pivot the armrest to the vertical position. Apply dry
lubricant or silicone lubricant between the parts in the
mechanism for the armrest assembly.
i02685657
Secondary Steering - Check

SMCS Code: 4300-535-SST; 4324-535;
4331-535-SST
Illustration 227
(1) Date
(2) Date
(3) Date
(4) Date
g01152685
of installation (retractor)
of installation (buckle)
of manufacture (tag) (fully extended web)
of manufacture (underside) (buckle)
Consult your Caterpillar dealer for the replacement of

the seat belt and the mounting hardware.
If your machine is equipped with a seat belt
extension, also perform this replacement procedure
for the seat belt extension.
i02302909
This machine is equipped with a secondary steering

system. The secondary steering will provide a limited
amount of steering after steering system failure. The
steering accumulators provide stored energy for the
secondary steering until steering action exhausts the
hydraulic pressure in the accumulators.
Gas under pressure. Rapid discharge from disconnecting or disassembly could cause personal
injury or death. See service manual before relieving pressure or charging.
Seat Suspension Inspect/Lubricate

SMCS Code: 7307; 7324
Personal injury or death can occur if steering is

lost completely during operation.
Inspect
Do not continue to operate the machine using the

secondary steering.
Seat Suspension
Inspect the seat suspension for excessive looseness
and wear. If excessive looseness or wear is detected,
refer to Systems Operation, Testing and Adjusting,
Disassembly and Assembly, RENR8391, Caterpillar
Comfort Series Seat with three point operator
restraint, Troubleshooting Chart.
Lubricate
Seat Suspension
Adjust the seat fully rearward and apply a dry
lubricant to the front of the seat slide mechanism.
Adjust the seat fully forward and apply a dry lubricant
to the rear of the seat slide mechanism. Move the
seat rearward and forward several times in order to
distribute the lubricant.
If the secondary steering activates during operation, immediately park the machine in a safe location. Inspect the machine and correct the condition which made the use of the secondary steering necessary.

SEBU7792-02
Illustration 228
169
Maintenance Section
Service Brakes - Inspect
g01163448
(1) Steering Accumulators
Illustration 230
g01349223
5. Stop the engine with ground level shutdown switch

(4). This permits the accumulators to stay charged
in order to provide stored energy for the secondary
steering system when the engine is stopped.
6. Complete the following series of turns:
a. Turn the front wheels either left against the
steering stop or right against the steering stop.
b. Turn the front wheels against the opposite
steering stop.
Illustration 229
g01163447
1. Empty the truck body and park the machine on a

level surface. Engage the parking brake.
2. When the engine is stopped with the engine start
switch, check the steering hydraulic oil level.
Maintain the oil to the FULL mark in upper sight
gauge (2).
3. After engine start-up, check the oil level.
a. If the oil level registers FULL in lower sight
gauge (3), the accumulators are properly
charged.
b. If the oil level is below the FULL mark in the
lower sight gauge, check accumulator charge
before proceeding to the next step. Refer to
System Operation, Testing and Adjusting,
RENR8336, 793D Off-Highway Truck Steering
System or consult your Caterpillar dealer.
4. Turn the front wheels to the straight ahead
position.
c. Turn the front wheels back to the straight ahead

position.
If the machine did not complete this series of turns,
i02346399
Service Brakes - Inspect

SMCS Code: 4251
Record the initial measurement of the service
brake disc thickness when the machine is new or
when the brakes are rebuilt. Compare subsequent
measurements to the initial measurement in order to
determine the amount of wear.
Inspect the front brakes for wear and inspect the
brake system for leakage.
Inspect the rear brakes for wear and inspect the rear
brakes for system leakage.
For more information on the proper procedures,
refer to Systems Operation, Testing and Adjusting,
RENR8330, 793D Air System and Brakes, Service
Brake Discs - Check.
170
Maintenance Section
Sound Suppression (Covers, Panels) - Inspect/Replace
Note: Refer to Guideline for Reusable Parts and

Salvage Operations, SEBF8095, Service Brakes for
Off-Highway Trucks and Tractors when you rebuild
the brakes.
i02602002
Sound Suppression (Covers,

Panels) - Inspect/Replace
(If Equipped with the Sound
Suppression Arrangement)
SMCS Code: 1801-040; 1801-510; 7076-040;
7076-510; 7261-040; 7261-510
Sound Panels
Inspect the sound suppression panels. The sound
suppression panels are bolted on the front portion
of the machine in order to enclose the engine
compartment. Inspect the panels for the following
damage:
Broken fasteners or missing fasteners

Burnt insulation material
SEBU7792-02
Missing pieces
If any of these conditions exist, perform the
necessary repairs and/or replace any damaged
sound suppression covers.
Louvers
Inspect the louver assembly. The louver assembly is
on the front of the radiator. Inspect the louvers for the
following damage:
Bent steel mesh or broken steel mesh

Burnt insulation material
Compressed insulation material
Insulation material with fluid saturation
Loose insulation material
Missing pieces of insulation material
Tears in the insulation material
If any of these conditions exist, perform the necessary
repairs and/or replace any damaged louvers.
Compressed insulation material
i02381180
Insulation material with fluid saturation
Steering Ball Stud - Inspect
Loose insulation material
SMCS Code: 4303; 4305
Missing pieces of insulation material
This procedure provides instructions for the ultrasonic

inspection of the steering cylinder and steering
linkage ball studs. These instructions provide a
means of inspecting for cracks without removing
the ball studs from the machine. This procedure
is a non-destructive test. Perform this procedure
while the ball stud is still in the steering arm or in the
steering box.
Tears in the insulation material

Bent steel panels or broken steel panels
If any of these conditions exist, perform the
necessary repairs and/or replace any damaged
sound suppression liners.
Sound Covers
Inspect the sound suppression covers. The sound
suppression covers are fastened to the following
components: engine, torque converter, final drives,
and differential. Inspect the covers for the following
damage:
Broken fasteners or missing fasteners

Broken pieces
Cracks
Loose covers
SEBU7792-02
171
Maintenance Section
Inspection of Steering Ball Studs

Table 8
Recommended Tooling
Krautkramer Branson USN

52 or equivalent
Required Training
Personnel that perform

the Ultrasonic testing will
be trained as UT level
II in accordance to the
current SNT-TC-1A. This
training will include the
theory, the application, the
procedure, and the use of
the equipment.
Personnel that perform the
Magnetic particle testing
will be trained as MT level
I in accordance to the
current SNT-TC-1A. This
training will include the
theory, the application, the
procedure, and the use of
the equipment.
All training will be
documented in the
records of the person
that performed the test.
Personnel must
demonstrate sufficient
working skill of this
procedure and in the
methods of testing ball
studs. Personnel must
be able to perform this
procedure without direct
guidance.
Note: Use a known damaged ball stud and a new

ball stud as baselines.
Illustration 231
Typical ball stud
g00842904
172
Maintenance Section
SEBU7792-02
Table 9
Critical Dimensions of Ball Studs

Sales Model
Pt. No. of
Ball Stud
784/785
8X-9619
273 mm
(10.7 inch)
188.283 mm
(7.4127 inch)
25.9 mm
(1.02 inch)
53 mm
(2.1 inch)
53.75 mm
(2.116 inch)
82.55 mm
(3.250 inch)
789
8X-9620
295 mm
(11.6 inch)
210.283 mm
(8.2788 inch)
25.9 mm
(1.02 inch)
53 mm
(2.1 inch)
53.75 mm
(2.116 inch)
82.55 mm
(3.250 inch)
793
8X-9620
295 mm
(11.6 inch)
210.283 mm
(8.2788 inch)
25.9 mm
(1.02 inch)
53 mm
(2.1 inch)
53.75 mm
(2.116 inch)
82.55 mm
(3.250 inch)
797
156-8136
295 mm
(11.6 inch)
210.283 mm
(8.2788 inch)
25.9 mm
(1.02 inch)
53 mm
(2.1 inch)
53.75 mm
(2.116 inch)
82.55 mm
(3.250 inch)
797B
192-5702
341 mm
(13.4 inch)
225.006 mm
(8.8585 inch)
25.9 mm
(1.02 inch)
80.26 mm
(3.160)
79.53 mm
(3.13 inch)
109.73 mm
(4.320 inch)
1. Use a wire brush or use a scraper to thoroughly

clean the end of the ball stud. A clean surface
ensures a good seal with the transducer.
5. Use the range key to move the reflected signal to

9 on the display screen. Keep the signal at 9 on
the display screen. Adjust the reflected signal for
each ball stud to 100 percent of the screen height.
Adjust the reflected signal once per ball stud. This
will ensure that the surface is the opposite end of
the ball stud and that the surface is not the bottom
of the drilled holes.
Note: Drilled holes will reflect a signal.
6. Set the gate at 20 percent of the screen height.
Illustration 232
(1)
(2)
(3)
(4)
g00843601
Gel compound
Display screen
Krautkramer Branson USN 52
Transducer
2. Use a 2.25 MHz - 5Mhz straight beam transducer.

The diameter of the transducer should measure
12.7 mm (0.5 inch) to 25.4 mm (1.0 inch). The area
of concern is dimension (B) for this type of defect.
3. Apply standard gel compound to the transducer
and to the end of the ball stud. This will ensure
proper contact with the transducer.
4. Apply the transducer to the threaded end of the
ball stud.
Illustration 233
g00843670
(B) Interruptions that are in this area will appear between the 0 grid
mark and the 6.4 grid mark.
(C) Interruptions that are in this area will appear between the 8
grid mark and the 9 grid mark.
(G) Interruptions that are in this area will appear between the 6.5
grid mark and the 8 grid mark.
(H) Cracks that are in this area CAN NOT be detected.
7. Slowly move the transducer over all surfaces of

the end of the ball stud.
Note: An indication from approximately 0 to 6.4 grid
marks on the display screen indicates a damaged
ball stud. A complete loss of the reflected signal may
also indicate a damaged ball stud.
SEBU7792-02
Note: A complete loss of back wall CAN be a

indication of a possible damaged ball stud.
Note: A partial loss of the back wall with a small
indication between the 0 grid marks and the 6.4 grid
marks, which is less than 20% of the screen height,
can be an indication of a damaged ball stud.
Note: The area of concern (B) should occur
approximately between 0 grid marks and 6.4 grid
marks on the display screen. Reflected signals from
the drilled holes should occur approximately between
8 grid marks and 9 grid marks on the display screen.
Note: Although the ultrasonic beam spreads slightly,
cracks that are in Area (H) CAN NOT be detected.
8. Identify the ball stud as an acceptable ball stud or
as a damaged ball stud.
173
Maintenance Section
Application
Magnetic particle testing is based on the theory
that the magnetic field in a magnetized material
is interrupted by a discontinuity. The discontinuity
may be at the surface or near the surface of that
material. Magnetic particles that are applied to the
surface will gather at the discontinuity. The particles
can be observed with proper lighting. Magnetic
particle testing is used to detect cracks, laps,
seams, inclusions, and other discontinuities of any
ferromagnetic material. Testing can be used on any
weld, rough stock, rough parts, or finished parts that
can be magnetized.
Personnel
Serial number of the inspected truck
Personnel that perform the Magnetic particle testing

will be trained MT Level I in accordance with
SNT-TC-1A. This training will include the theory, the
application, the procedure, and use of the equipment.
The training will be documented in the training
records of the person. Personnel must demonstrate
sufficient skill in the ultrasonic testing of ball studs
without direct guidance.
Part number of the inspected ball studs
Safety
9. Document the following information.
Date of inspection
Number of inspected ball studs

Number of ball studs that were damaged per
truck
Initial of operator that performed the inspection

Any corrective action that was taken
If you find any questionable indications then the
ball studs need to be removed and verified with
Magnaflux. If the use of Magnaflux indicates that
the ball stud is free of indications, the ball stud may
be returned to service. The ball stud can only be
returned to service if there is more than 50% of the
service life remaining. If the ball stud is at more that
50% of life, the ball stud should be scrapped.
As this procedure is performed in the shop , safety

glasses and ear plugs should be worn and protective
shoes are advisable. Read the MSDS for hazard
information on the material that are used in this
procedure.
Required Equipment
Table 10
Magnetic Portable Yoke
25 lb DC or greater current
Wet Magnetic Particles
14A(1) Magnuflux Corp or

20B(2) Magnuflux Corp
Black Light
Microwatt per cm2

Intensity
(1)
(2)
Magnetic Particle Testing of

Steering Ball Studs with Portable
Magnetic Yokes
Scope
This procedure provides general guidelines for
magnetic particle testing with portable magnetic
yokes.
14A is a prepared bath medium in the form of an aerosol spray.

20B is a powder that is used as a bath medium in a stationary
machine. The powder can be mixed with water for use as a
spray.
Magnetic particle testing requires a method of

creating a magnetic field in the part, magnetic
particles which help locate the defect, and a means
to detect the particles.
Magnetic yokes induce the magnetism into the local
area to be tested. Yokes are portable C-shaped
electromagnets that induce a magnetic field mostly
between the poles. Yokes should be checked
annually. Check the yokes when there is a reason to
suspect that the power has decreased.
174
Maintenance Section
Steering Ball Stud - Replace
The suggested wet particles can be purchased

from Magnaflux Corporation and designated as 14A
Prepared Bath or as 20B Prepared Bath. The wet
particles are fluorescent and used with black light.
When the black light is regularly used, the intensity
of the black light must be verified weekly. Verify the
intensity of the black light when there is a reason
to suspect that the output has diminished. The
black light will be verified to the manufacturers
specifications.
Procedure
1. The surface of the part should be clean, dry,
and free of contaminants that could restrict the
movement of the particles. These contaminants
include dirt, grease, the weld splatter, sand, and
mill scale.
2. There are two methods of operation that differ in
the application of the magnetism and magnetic
particle.
a. When you use the wet particle, apply the bath
medium to the part before the magnetizing
current is applied. Remove the particle flow
immediately before magnetizing. The current
may be applied one to three times.
b. The continuous method calls for the application
of the magnetism while the magnetic particles
are being distributed on the part. The
continuous method should be used in most
applications.
3. Discontinuities are picked up best when the
discontinuities are normal or 90 degrees to the
direction of the magnetic field, but can be found
up to 45 degrees from the normal. With yokes, the
magnetic lines of force go between the poles or the
legs. When orientation of the defect is unknown,
or until a procedure has been established for
a particular job, a second test should be done
with the legs of the portable magnetic yoke at 90
degrees from the first position. Using a Pie Gauge
or a Quantitative Quality Indicator can ensure the
existence and direction of the magnetic field.
4. Immediately after testing, examine the surface
carefully with the proper lighting. Sharp, narrow
lines of particles indicate a defect at the surface. A
pattern that is not sharp may indicate a defect that
is beneath the surface. Interpretation of results
may be verified by visual examination under
magnification, etching, or making a cross section
of the part.
5. Use the following steps to demagnetize an area.
a. Place the legs of the yoke on the part.
SEBU7792-02
b. Move the legs on the part.

c. Slowly remove the yoke.
i02387439
Steering Ball Stud - Replace

SMCS Code: 4303; 4305
The recommended replacement interval for the
steering cylinder and steering linkage ball studs is
between 12000 operating hours and 15000 operating
hours or at the planned component rebuild of the
steering cylinder. For the replacement procedure,
refer to the Disassembly and Assembly, Off-Highway
Truck Machine Systems manual for your machine or
The replacement interval may vary and the
replacement interval is heavily dependent on the
haul cycle conditions. These conditions include the
following considerations: haul road condition, length
of hauls, number of turns per cycle, load, and grade
of the haul road.
Inspect the condition of the tapered steering bore
whenever a ball stud is replaced. Refer to Reuse and
Salvage Guidelines, SEBF8271, Salvage of Steering
Arm and Steering Arm (T-Bar) Tapers on 785, 789,
793, and 797 Off-Highway Trucks or consult your
Caterpillar dealer in order to determine whether
the tapered bore can be reused or machined to an
oversized dimension.
If the tapered bore is out of the specification and the
tapered bore is able to be salvaged, then an oversize
ball stud may be used. If the taper is too far out of
the specification, then an oversize ball stud cannot
be used. In this case, either the steering arm or the
steering box must be scrapped and replaced.
i01219914
Steering Linkage - Inspect

SMCS Code: 4305
Inspect the horizontal wear limits for the ball studs in
the steering linkage. At the same time, inspect the
outer bearing race. Also, inspect the grease fittings
and the seals.
SEBU7792-02
175
Maintenance Section
Steering System Oil - Change
Note: Properly lubricate the steering linkage in order

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

SMCS Code: 4332
Illustration 234
g00321663
(1) Link
(2) Steering arm
(3) Center arm
1. Attach the magnetic base of a 8T-5096 Dial

Indicator Group to link (1). This will allow the
horizontal movement of the ball stud to be
measured.
2. To measure the horizontal wear of the ball studs
and of the outer bearing races on the steering
cylinders, place the dial indicator against the side
of steering arm (2).
3. Set the dial indicator to zero.
4. Steer the front wheels in both directions. Record
the amount of horizontal play on the indicator dial.
This indicates the amount of wear in the ball studs
and the outer bearing races.
5. To measure the horizontal wear of the ball studs
and of the outer bearing races on the other ball
studs and outer bearing races, place the dial
indicator against the side of center arm (3).
6. Set the dial indicator to zero.
7. Steer the front wheels in both directions. Record
the amount of horizontal play on the indicator dial.
Note: Repeat this procedure in order to measure all
of the ball studs and outer bearing races.
8. The maximum amount of horizontal wear is
1.02 mm (0.040 inch). If any of the measurements
exceed this limit, replace the worn ball studs and
the outer bearing races.
9. Inspect all of the covers for the ball studs. Inspect
all grease fittings and seals. Replace any worn
components and any damaged components.

contact the skin.
1. Operate the engine until the steering hydraulic oil
is warm. Park the machine on a level surface and
engage the parking brake. Stop the engine.
3. Slowly, remove filler cap (4) on the steering
hydraulic tank in order to relieve the pressure.
NOTICE
products.
mandates.
176
Maintenance Section
Steering System Oil Filter - Replace
SEBU7792-02
10. Fill the steering hydraulic tank. Refer to Operation

And Maintenance Manual, Lubricant Viscosities.
Refer to Operation And Maintenance Manual,
11. Use the reading from the upper sight gauge to
maintain the steering oil level. When the engine is
not running, the oil level should be at the FULL
mark in upper sight gauge (2).
12. Install the filler cap.
13. Operate the engine until the steering hydraulic oil
is warm. Inspect the machine for leaks and make
any necessary repairs.
14. Stop the engine. Allow the steering accumulators
to completely discharge and check the oil level.
Use the reading from the upper sight gauge to
maintain the steering oil level.
15. When the engine is stopped, the oil level should
be at the FULL mark in the upper sight gauge. If
necessary, add oil.
i02331551
Steering System Oil Filter Replace

SMCS Code: 4304; 5068
Illustration 235
g01163770
4. Open drain valve (1).

5. Allow the oil to drain into a suitable container.
Close the drain valve.
6. Remove retaining ring (6) for the filler strainer.
7. Remove filler strainer (7). Wash the cap and the
strainer in clean, nonflammable solvent. Allow the
cap and the strainer to dry.
8. Inspect cap seal (5). Use a new seal if the used
seal is damaged.
9. Install the strainer and the retaining ring for the
strainer.
NOTICE
Do not fill the steering hydraulic tank when the engine
is running. Discharge from the secondary steering accumulators could overfill the tank when the engine is
stopped.

contact the skin.
1. Park the machine on level ground and engage the
parking brake. Stop the engine.
SEBU7792-02
177
Maintenance Section
Steering System Oil Level - Check
9. Install the new filter elements.

10. Install the spring pin and the spacer.
11. Inspect seal (6) for the filter cover. Inspect seal
(12) for retainer assembly (11). Replace any seals
that are damaged.
12. Install the filter cover on the stud. Tighten the filter
cover by hand.
13. Install the filter assembly into the tank. Install the
nuts for the filter cover.
15. Check the steering system oil level. If necessary,
Operation and Maintenance Manual, Steering
System Oil Level - Check.
i02331710
Illustration 236
g01163863
Steering System Oil Level Check

SMCS Code: 4332
3. Slowly remove filler cap (4) on the steering

hydraulic tank in order to relieve any pressure.
Install the filler cap after the pressure is relieved.
4. Remove four nuts (1) from the filter cover.
5. Pull filter assembly (2) out of the tank.
Illustration 238
g01192510

the parking brake.
2. Stop the engine and allow the secondary steering
accumulators to completely discharge before the
oil level is observed.
Illustration 237
g01163878
6. Remove filter cover (5) from stud (10).

7. Remove spring pin (7) and spacer (8).
8. Remove used filter elements (9) and discard the
used filter elements.
3. Use the reading from the upper sight gauge to

maintain the steering oil level. The oil level in
upper sight gauge (1) should be in the FULL
mark with the engine stopped .
4. If necessary, add oil.
178
Maintenance Section
Steering System Oil Sample - Obtain
SEBU7792-02

NOTICE
Do not fill the steering hydraulic tank when the engine
is running. Discharge from the secondary steering accumulators could overfill the tank when the engine is
stopped.
Note: When the engine is running, the oil level should
be at the FULL mark in lower sight gauge (2). If the
oil level in the lower sight gauge is low, check the
secondary steering. See Operation And Maintenance
Manual, Secondary Steering - Check for additional
information.
i02331813
Steering System Oil Sample Obtain
Interpretaion Guide
i02337440
Suction Screen (Rear Axle

Lubrication) - Clean
SMCS Code: 3016; 3278-070-Z3; 3291

contact the skin.
SMCS Code: 4300-008; 4332-008; 7542
Illustration 240
g01166714
2. Remove screen cover plate (1 ).
Illustration 239
g01163967
Sampling port (1) for the steering oil is located on the

steering solenoid and relief valve.

Information

Analysis

Good Oil Sample
Illustration 241
g01166878
3. Remove screen (2) and magnetic tube assembly

(3).
NOTICE
Do not drop or rap the magnets against any hard objects. Replace any damaged magnets.
SEBU7792-02
179
Maintenance Section
Suction Screen (Torque Converter) - Clean
4. Wash the screen and the magnetic tube assembly

in clean, nonflammable solvent. Clean the
magnets with a cloth, a stiff bristle brush or air
pressure.
5. Install the magnetic tube assembly and the screen.
6. Inspect seal (4). If the seal is damaged, replace
the seal.
7. Install the screen cover plate.
Note: The lubrication pump for the rear axle will not
operate with the oil temperature below 15 C (59 F).
9. Check the oil level in the rear axle. If necessary,
Operation and Maintenance Manual, Differential
and Final Drive Oil - Check.
NOTICE
products.
mandates.
Note: Correct oil levels are critical in the differential

and final drives. Check the oil level after repairs and
after maintenance.
i02682176
Suction Screen (Torque

Converter) - Clean
Illustration 242
g01164290
SMCS Code: 3101-070-Z3

in the torque converter sump. Install the filler cap
after the torque converter sump is drained. This
will prevent dirt from entering the system.

contact the skin.
3. Remove drain valve plug (2) in the torque

converter sump. Install a 100 mm (4 inch) long
NPT pipe nipple in order to open the internal drain
valve. The outer diameter of the NPT pipe nipple
should be 25 mm (1 inch). Drain the oil into a
suitable container.
tools.
4. Remove the pipe nipple. Clean the drain plug and
install the drain plug.
180
Maintenance Section
Suspension Cylinder - Check
SEBU7792-02

13. Operate the engine until the torque converter oil
reaches operating temperature. Torque converter
stalls may be performed in order to bring the
torque converter oil up to operating temperature.
14. Check the oil level with the engine at low idle and
the transmission in neutral.
Illustration 243
g01164303
5. Remove the bolts from screen cover (3). The

screen cover is located at the lower left rear corner
of the sump. Remove the cover and the screen
assembly.
6. Wash the screen assembly and the cover in a
clean, nonflammable solvent. Do not crush the
screen assembly.
7. Inspect the cover gasket for damage. If the cover
gasket is damaged, use a new gasket.
15. Maintain the oil level until the oil level stabilizes
in the FULL mark of the upper sight gauge. If
necessary, add oil.
16. Clean the filler cap and install the filler cap on the
filler tube.
NOTICE
Failure to properly fill the torque converter sump after
an oil change may cause damage to the power train
system. Follow the procedure that is described above.
The transmission direction and speed control MUST
be left in NEUTRAL until the system is full.
8. Install the screen. Install the cover assembly.
i02331858
Suspension Cylinder - Check

SMCS Code: 7201
Make sure that the dump body is empty.
Stop the machine gradually on a level surface without
using the brakes.
Engage the parking brake and stop the engine.
Illustration 244
g01164452
9. Remove the filler cap and fill the torque converter

to the top of upper sight gauge (4). See Operation
And Maintenance Manual, Lubricant Viscosities.
See Operation And Maintenance Manual,
10. Operate the engine for ten seconds and then turn
off the engine. The oil level will decrease as oil
fills the system.
11. Check the oil level in the torque converter sump.
If necessary, add oil in order to raise the oil level
to the FULL mark of the upper sight gauge.
Note: All of the suspension cylinders that are shipped

from the factory receive a preliminary charge of
nitrogen and a preliminary charge of oil. During field
assembly, the suspension cylinders must be charged
with nitrogen.
SEBU7792-02
181
Maintenance Section
Tire Inflation - Check
Front Suspension Cylinder
Rear Suspension Cylinder

Illustration 246
g01163990
(Y) Distance between the pins
Measure distance (Y) for the rear suspension

cylinders. Compare the present distance to the
distance from the previous time. If you do not have
those dimensions, perform the charging procedure.
See Testing And Adjusting, Suspension Cylinder
(Rear) - Purge and Charge for the charging
procedure.
Illustration 245
g01163979
Note: When the rear suspension cylinders are

properly charged, the left rear suspension cylinder
will not show as much chrome as the right rear
suspension cylinder. This is due to the rigid frame
and to the weight of the cab.
(X) Distance of exposed chrome
Measure the distance of exposed chrome (X) for the

front suspension cylinders. Compare the present
distance to the distance from the previous time. If you
do not have those dimensions, perform the charging
procedure. See Testing And Adjusting, Suspension
Cylinder (Front) - Purge and Charge for the charging
procedure.
Note: There are two relief valves for the grease on
the forward side of the front suspension cylinder.
These relief valves are located 180 degrees from the
lubrication fitting. Do not plug the grease passage
of the relief valves.
i02416817
Tire Inflation - Check

SMCS Code: 4203
Measure the tire pressure on each tire. Adjust the tire
pressure, if necessary. Consult your tire supplier for
the correct tire operating pressures and load ratings.
See Operation and Maintenance Manual, Tire
Inflation Information for more tire information.
i02320374
Torque Converter Oil Filter Replace

SMCS Code: 3103

contact skin.
182
Maintenance Section
Torque Converter Oil Filter - Replace
SEBU7792-02
NOTICE
products.
mandates.
Illustration 248
(2)
(3)
(4)
(5)
g00644308
Cover
Filter element
Screen
Drain plug
2. Remove drain plug (5) from the bottom of the filter

housing and drain the oil into a suitable container.
Note: Removing the drain plug from the bottom of
the torque converter oil filter may not allow all of the
oil to drain from the filter housing. When you remove
the filter housing and the filter element, be careful to
avoid contact with hot oil.
3. Clean drain plug (5) and install the drain plug.
4. Remove cover (2).
5. Remove filter element (3). Discard the used
element into a suitable container.
6. Remove screen (4) from the filter housing and
clean the screen in clean nonflammable solvent.
Illustration 247
(1) Torque converter oil filter
g01160110
7. Clean the filter housing in clean nonflammable

solvent.
8. Inspect the cover seal. If the seal is damaged,
replace the cover seal with a new cover seal.
9. Install screen (4) and a new filter element (3).
10. Install the cover.
12. Check the oil level in the torque converter sump. If
to Operation and Maintenance Manual, Torque
Converter Sump Oil Level - Check.
SEBU7792-02
183
Maintenance Section
Torque Converter Outlet Screen - Replace
i02332019
Torque Converter Outlet

Screen - Replace
Note: Removing the drain plug from the bottom of

the screen housing may not drain all of the oil from
the screen.
3. Remove the screen housing. Remove the screen.
Discard the used screen.
SMCS Code: 3103
4. Wash the screen housing in clean, nonflammable

solvent.
contact skin.
NOTICE
products.
mandates.
5. Inspect the seal in the base of the screen housing.

If the seal is damaged, replace the seal with a
new seal.
6. Install the new screen in the screen housing.
Install the screen housing.
i02335501
Torque Converter Sump

Breather - Clean
SMCS Code: 3101

cable.
Note: The breather for the torque converter sump
also vents the transmission case.
the parking brake.
Illustration 249
g01164086
2. Remove drain plug (2) from the bottom of screen

housing (1) and drain the oil into a suitable
container. Clean the drain plug and install the
drain plug.

3. Stop the engine.
184
Maintenance Section
Torque Converter Sump Oil Level - Check
SEBU7792-02
Illustration 251
g01347318

a. If the torque converter oil is cold, use lower
sight gauge (3) in order to check the oil level.
Illustration 250
g01167449
4. Remove breather (1).
b. If the torque converter oil is in the operating

temperature range, use upper sight gauge (2)
in order to check the oil level.
5. Wash the breather in a clean, nonflammable

solvent. Allow the breather to air dry.
4. If necessary, add oil. The torque converter oil and

transmission oil is added at filler cap (1).
6. Install the breather.
Note: If the system has been drained, refer to

Operation and Maintenance Manual, Torque
Converter and Transmission Oil - Change for the
proper procedure.

the body.
i02682170
i02682180
Torque Converter Sump Oil

Level - Check
Torque Converter and

Transmission Oil - Change
SMCS Code: 3101; 3103
SMCS Code: 3101
Note: The oil level in the transmission is supplied by

the torque converter sump.
1. Park the machine on a level surface.
2. Operate the engine at low idle with the
transmission in neutral and with the parking brake
engaged.
Note: The engine should be on in order to check the
cold oil (oil at ambient temperature) level of the torque
converter, and the engine should be on in order to
check the hot oil (oil at operating temperature) level
of the torque converter.

contact the skin.
SEBU7792-02
Illustration 252
185
Maintenance Section
Torque Converter and Transmission Oil - Change
g01164290
Illustration 253
g01164714

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

extension housing. Drain the oil into a suitable
container. Clean the drain plugs and install drain
plugs.
NOTICE
6. Remove the filler cap.

products.
7. Remove the retaining ring on the filler screen.

Remove the screen.
8. Wash the cap and the filler screen in clean,
nonflammable solvent. Allow the cap and the filler
screen to dry.
9. Inspect the cap seal. Use a new seal if the used
seal is damaged. Install the filler screen and the
retaining ring.

mandates.
3. Remove drain valve plug (2) in the torque
converter sump. Install a 100 mm (4 inch) long
NPT pipe nipple in order to open the internal drain
valve. The outer diameter of the NPT pipe nipple
should be 25 mm (1 inch). Drain the oil into a
suitable container.
tools.
4. Remove the pipe nipple. Clean the drain valve
plug and install the drain valve plug.
Illustration 254
g01164452
10. Fill the torque converter to the top of upper sight

gauge (4). See Operation And Maintenance
Manual, Lubricant Viscosities. See Operation
And Maintenance Manual, Capacities (Refill).
11. Operate the engine for ten seconds and then turn
off the engine. The oil level will decrease as oil
fills the system.
186
Maintenance Section
Torque Converter and Transmission Oil Sample - Obtain

Add oil in order to raise the oil level to the FULL
mark of the upper sight gauge.
SEBU7792-02
i02501245
Torque Converter and

Transmission Oil Sample Obtain
SMCS Code: 3030-008; 3101-008; 7542
14. Operate the engine until the torque converter oil

reaches operating temperature. Torque converter
stalls may be performed in order to bring the
torque converter oil up to operating temperature.
15. Check the oil level with the engine at low idle and
the transmission in neutral.
16. Maintain the oil level until the oil level stabilizes
in the FULL mark of the upper sight gauge. If
necessary, add oil.
17. Clean the filler cap and install the filler cap on the
filler tube.
NOTICE
Failure to properly fill the torque converter sump after
an oil change may cause damage to the power train
system. Follow the procedure that is described above.
The transmission direction and speed control MUST
be left in NEUTRAL until the system is full.
Illustration 255
g01251142
The sampling valve for the transmission and torque

converter oil is located on the oil filter housing for the
torque converter in front of the hoist/brake tank.

Information
Special Publication, SEBU6250, Caterpillar
Machine Fluids Recommendations, SOS Oil

Analysis

Good Oil Sample

Interpretaion Guide
SEBU7792-02
187
Maintenance Section
Traction Control System (TCS) - Test
i02334684
i02335439
Traction Control System (TCS)

- Test
Transmission Magnetic Screen

- Clean
SMCS Code: 3288; 4801-081
SMCS Code: 3030
Note: This procedure determines if the Traction

Control System (TCS) is functioning. This procedure
also determines if the left rear brake and the right
rear brake activate at the correct time.
1. Find a clear area and a level area. In this area,
turn the machine in a complete circle. Start the
machine and move the transmission direction and
speed control lever to the first gear Forward.

contact the skin.
2. Turn the steering wheel all the way to the left.

With the engine at low idle, drive the machine in
a complete circle.
Illustration 257
g01165690
Location of the transmission magnetic screen

Illustration 256
g01165483
3. Continue to turn the machine and push the top

half of test switch (1) for the TCS. Hold the test
switch down. This will begin the test.
4. The machine will gradually slow down.
5. Release the test switch. The test will end and the
machine will increase speed.
6. Turn the steering wheel all the way to the right.
With the engine at low idle, drive the machine in
a complete circle.
7. Continue to turn the machine and push the top
half of the test switch for the TCS. Hold the test
switch down. This will begin the test.
Illustration 258
g01166968
2. Remove screen cover plate (1).

3. Remove wave washer (2), screen (3), and
magnetic tube assembly (4).
8. The machine will gradually slow down.

9. Release the test switch. The test will end and the
machine will increase speed.
10. If the TCS did not function properly, consult your
Caterpillar dealer for information and service.
NOTICE
Do not drop or rap the magnets against any hard objects. Replace any damaged magnets.
188
Maintenance Section
Transmission Oil Filter - Replace
SEBU7792-02
4. Wash the screen and the magnetic tube assembly

in clean, nonflammable solvent. Clean the
magnets with a cloth, a stiff bristle brush or air
pressure.
5. Install the magnetic tube assembly, the screen,
and the wave washer.
6. Inspect seal (5). If the seal is damaged, replace
the seal.
7. Install the screen cover plate.
i02335442
Transmission Oil Filter Replace
NOTICE
products.
mandates.
2. Remove drain plug (2) for filter housing (1). Drain
the oil into a suitable container. Clean the drain
plug and install the drain plug.
Note: All of the oil from the filter may not drain when
the drain plug from the bottom of the filter housing
is removed.
3. Remove the filter housing and the filter element.
4. Wash the filter housing in clean nonflammable
solvent.
SMCS Code: 3067
5. Inspect the seals in the filter base. If the seals are

damaged, replace seals with new seals.

contact the skin.
6. Install the new filter element in the housing. Install

the housing.
Illustration 259
g01165699

SEBU7792-02
189
Maintenance Section
VIMS Module Battery - Replace
i02018740
VIMS Module Battery - Replace
2. Turn the engine start switch to the ON position or

turn the keyswitch for the VIMS to the ON position.
3. Use the service tool for the VIMS to download all
of the stored information. The service tool for the
VIMS is not part of the machine. Failure to perform
this step may result in the loss of stored data.
SMCS Code: 7490
4. Leave the engine start switch in the ON position

or leave the keyswitch for the VIMS in the ON
position. Leave the battery disconnect switch in
the ON position.
Note: If these switches remain in the ON position
during replacement, the date and the time of day are
less likely to require programming.
5. Remove the battery from the back of the VIMS
module. The battery is located behind plate (1).
Illustration 260
g01043143
(1) Plate
A lithium battery is contained inside the main module

of the VIMS. The internal battery prevents the loss
of stored information. An example of the stored
information is the payload data. The internal battery
also retains the time and the date.
If power is removed from the main module of the
VIMS, the internal battery will begin to retain the
stored data. Power is removed from the main module
of the VIMS when the battery disconnect switch is
in the OFF position. The internal battery retains the
time and the date when the engine start switch is in
the OFF position. This will occur regardless of the
position of the battery disconnect switch.
Note: To prevent the loss of stored information,
replace the internal battery at the service interval. If
the ambient temperature is continuously in the range
of 0 to 40C (32 to 40F), cut the service interval
in half.
Note: If the Vital Information Management System
(VIMS) detects a failed battery, a fault code will
indicate that the battery needs a replacement. If
power is removed from the main module of the VIMS
during this fault code, loss of the stored data can
occur within several hours. The lithium battery fails
quickly. When the fault code is present, immediately
download the stored data. Then replace the internal
battery without turning off the engine start switch or
the battery disconnect switch.
Note: If ECM BKUP BATT ERR is displayed in the
message area of the VIMS, do NOT turn the engine
start switch to the OFF position. Go to Step 3.
1. Stop the machine and turn off the engine. Leave
the battery disconnect switch in the ON position.
Note: Do not allow dirt or water into the opening.

Keep the area clean.
6. Install a new internal battery. Be careful to align
the pins of the new battery with the sockets.
7. Check the O-ring seal. The O-ring seal is located
under the cap. Make sure that the O-ring seal is in
the proper place. Make sure that the O-ring seal
is not damaged. Install the cap. Tighten the cap
securely against the housing.
8. The real time clock format in the main module is
powered by this battery. A dead battery will cause
the date to be lost and a dead battery will cause
the time to be lost. After the battery has been
replaced, the date will default to 01/01/00. Also,
the time will default to 00:00:00. If necessary, use
the service tool for the VIMS to set the time and
the date. Refer to Service Manual, SENR6059,
Vital Information Management System (VIMS)
for additional information.
190
Maintenance Section
Windows - Clean
SEBU7792-02
i02680928
Windows - Clean
i02335763
Window Wiper Inspect/Replace
SMCS Code: 7310; 7340
SMCS Code: 7305
Illustration 261
g01346892
Use commercially available window cleaning

solutions to clean the windows. Only clean the
windows, when handholds are available.
i02346847
Window Washer Reservoir Fill

SMCS Code: 7306-544-KE
NOTICE
When operating in freezing temperatures, use
Caterpillar nonfreezing window washer solvent or
equivalent. System damage can result from freezing.
Illustration 262
g01139822
Window washer reservoir (1) is located in the

compartment in the front of the cab.
Fill the reservoir with windshield washer fluid.
Illustration 263
g01165832
Inspect windshield wiper blade (1). Replace the

windshield wiper blade if the wiper blade is worn or
damaged. Replace any windshield wiper blade that
streaks the windshield.

793D Off-Highway Truck - Maintenance Intervals

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793D Off-Highway Truck - Maintenance Intervals

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Excerpted from Operation & Maintenance Manual (SEBU7792-02-01)

Maintenance Interval Schedule

Every 10 Service Hours or Daily

Initial 50 Service Hours

Initial 250 Service Hours

Every 250 Service Hours or Monthly

Initial 500 Hours (for New Systems, Refilled

Every 500 Service Hours

Every 500 Service Hours or 3 Months

Differential and Final Drive Oil - Inspect .............

Every 1000 Service Hours or 6 Months

Every 3 Years After Date of Installation or

Every 4000 Service Hours

Every 6000 Service Hours or 3 Years

Every 6000 Service Hours or 4 Years

Every 12 000 Service Hours or 6 Years

Every 15 000 Service Hours

Every 2000 Service Hours or 1 Year

Radiator Core - Clean ......................................... 163

Every 3000 Service Hours or 2 Years

Rim - Inspect ....................................................... 166

Every 1 393 000 L (368 000 US gal) of Fuel

Every 2 786 000 L (736 000 US gal) of Fuel or

Air Conditioner Filter - Clean

2. Drain the primary air tank and drain the secondary

If a reduction in air circulation is noticed, clean the

3. Remove filter element (1).

Air Dryer - Check

The air lines to and from the air dryer must be at

3. If there is moisture in the air tanks, replace

Air Dryer Desiccant - Replace

Air lines to and from the air dryer must be at

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

Secondary Air Tank

Replace the air dryer desiccant cartridge or rebuild

Air Tank Moisture and

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

SMCS Code: 4272

Primary Air Tank

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

Primary Air Tank (If Equipped

1. Open drain valve (3) for the air tank.

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

3. Close the drain valve for the air tank.

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

When it is necessary to work under the machine

Breather for the rear air/hydraulic cylinders

5. Wash both breathers in clean nonflammable

If any of the remote lines become damaged, install a

SMCS Code: 7540

Backup Alarm - Test

1. Remove plug (1) for the upper port in order to vent

Location of the backup alarm

Park the machine on a level surface and engage the

An authorized battery collection facility

8. Connect the positive end + of the battery cable

Battery or Battery Cable Inspect/Replace

9. Connect the negative end of the battery cable

SMCS Code: 1401-040; 1401-510; 1402-040;

11. Install the key. Turn the battery disconnect switch

Note: When you replace the batteries, always use

1. Park the machine on a level surface and engage

2. Turn the engine start switch to the OFF position.