SEBU7792-03

August 2007

Operation and
Maintenance
Manual
793D Off-Highway Truck
FDB1-Up (Machine)
 i01658146

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should also
have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and
could result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
SEBU7792-03 3
Table of Contents

Table of Contents Transportation Information .................................... 88

Jacking Location Information ................................ 90

Foreword ................................................................. 4
Towing Information ................................................ 91
Safety Section Engine Starting (Alternate Methods) ..................... 99
Safety Messages .................................................... 6
Maintenance Section
Additional Messages ............................................. 14
Tire Inflation Information ..................................... 103
General Hazard Information ................................. 19
Lubricant Viscosities and Refill Capacities ......... 104
Crushing Prevention and Cutting Prevention ........ 22
Maintenance Access ........................................... 108
Burn Prevention .................................................... 22
Maintenance Support .......................................... 109
Fire Prevention and Explosion Prevention ............ 23
Maintenance Interval Schedule ........................... 110
Fire Extinguisher Location .................................... 24
Reference Information Section
Tire Information ..................................................... 25
Reference Materials ............................................ 194
Electrical Storm Injury Prevention ......................... 25
Index Section
Before Starting Engine .......................................... 26
Index ................................................................... 196
Engine Starting ..................................................... 26

Before Operation .................................................. 26

Visibility Information .............................................. 26

Operation .............................................................. 27

Parking .................................................................. 28

Slope Operation .................................................... 28

Sound Information and Vibration Information ....... 29

Operator Station ................................................... 31

Guards (Operator Protection) ............................... 31

Product Information Section

General Information .............................................. 33

Identification Information ....................................... 34

Operation Section
Before Operation .................................................. 37

Machine Operation ............................................... 40

Engine Starting ..................................................... 78

Parking .................................................................. 84
4 SEBU7792-03
Foreword
Foreword
Literature Information
This manual should be stored in the operator’s
compartment in the literature holder or seat back
literature storage area.
This manual contains safety information, operation
instructions, transportation information, lubrication
information and maintenance information.
Some photographs or illustrations in this publication
show details or attachments that can be different
from your machine. Guards and covers might have
been removed for illustrative purposes.
Continuing improvement and advancement of
product design might have caused changes to your
machine which are not included in this publication.
Read, study and keep this manual with the machine.
Whenever a question arises regarding your machine,
or this publication, please consult your Caterpillar
dealer for the latest available information.
Safety
The safety section lists basic safety precautions. In
addition, this section identifies the text and locations
of warning signs and labels used on the machine.
Read and understand the basic precautions listed
in the safety section before operating or performing
lubrication, maintenance and repair on this machine.
Operation
The operation section is a reference for the new
operator and a refresher for the experienced
operator. This section includes a discussion of
gauges, switches, machine controls, attachment
controls, transportation and towing information.
Photographs and illustrations guide the operator
through correct procedures of checking, starting,
operating and stopping the machine.
Operating techniques outlined in this publication are
basic. Skill and techniques develop as the operator
gains knowledge of the machine and its capabilities.
Maintenance
The maintenance section is a guide to equipment
care. The Maintenance Interval Schedule (MIS) lists
the items to be maintained at a specific service
interval. Items without specific intervals are listed
under the "When Required" service interval. The
Maintenance Interval Schedule lists the page
number for the step-by-step instructions required to
accomplish the scheduled maintenance. Use the
Maintenance Interval Schedule as an index or "one
safe source" for all maintenance procedures.
Maintenance Intervals
Use the service hour meter to determine servicing
intervals. Calendar intervals shown (daily, weekly,
monthly, etc.) can be used instead of service hour
meter intervals if they provide more convenient
servicing schedules and approximate the indicated
service hour meter reading. Recommended service
should always be performed at the interval that
occurs first.
Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is
specified in the maintenance intervals chart might
be necessary.
Perform service on items at multiples of the original
requirement. For example, at every 500 service
hours or 3 months, also service those items listed
under every 250 service hours or monthly and every
10 service hours or daily.
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm.
Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands
after handling.
Certified Engine Maintenance
Proper maintenance and repair is essential to keep
the engine and machine systems operating correctly.
As the heavy duty off-road diesel engine owner, you
are responsible for the performance of the required
maintenance listed in the Owner Manual, Operation
and Maintenance Manual, and Service Manual.
SEBU7792-03 5
Foreword

It is prohibited for any person engaged in the 3. Check Character (character 9)

business of repairing, servicing, selling, leasing, or
trading engines or machines to remove, alter, or 4. Machine Indicator Section (MIS) or Product
render inoperative any emission related device or Sequence Number (characters 10-17). These were
element of design installed on or in an engine or previously referred to as the Serial Number.
machine that is in compliance with the regulations
(40 CFR Part 89). Certain elements of the machine Machines and generator sets produced before First
and engine such as the exhaust system, fuel system, Quarter 2001 will maintain their 8 character PIN
electrical system, intake air system and cooling format.
system may be emission related and should not be
altered unless approved by Caterpillar. Components such as engines, transmissions, axles,
etc. and work tools will continue to use an 8 character
Serial Number (S/N).
Machine Capacity
Additional attachments or modifications may exceed
machine design capacity which can adversely affect
performance characteristics. Included would be
stability and system certifications such as brakes,
steering, and rollover protective structures (ROPS).
Contact your Caterpillar dealer for further information.

Caterpillar Product Identification

Number
Effective First Quarter 2001 the Caterpillar Product
Identification Number (PIN) has changed from 8 to 17
characters. In an effort to provide uniform equipment
identification, Caterpillar and other construction
equipment manufacturers are moving to comply
with the latest version of the product identification
numbering standard. Non-road machine PINs are
defined by ISO 10261. The new PIN format will apply
to all Caterpillar machines and generator sets. The
PIN plates and frame marking will display the 17
character PIN. The new format will look like the
following:

g00751314
Illustration 1

Where:

1. Caterpillar’s World Manufacturing Code

(characters 1-3)

2. Machine Descriptor (characters 4-8)

6 SEBU7792-03
Safety Section
Safety Messages

Safety Section
i02835206

Safety Messages
SMCS Code: 7000; 7405

There are several specific safety messages on this

machine. The exact location of the hazards and
the description of the hazards are reviewed in this
section. Please become familiarized with all safety
messages.

Make sure that all of the safety messages are legible.

Clean the safety messages or replace the safety
messages if you cannot read the words. Replace
the illustrations if the illustrations are not legible.
When you clean the safety messages, use a cloth,
water and soap. Do not use solvent, gasoline, or
other harsh chemicals to clean the safety messages.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety message. Loose
adhesive will allow the safety message to fall.

Replace any safety message that is damaged, or

missing. If a safety message is attached to a part
that is replaced, install a safety message on the
replacement part. Any Caterpillar dealer can provide
new safety messages.
SEBU7792-03 7
Safety Section
Safety Messages

g01413668
Illustration 2
8 SEBU7792-03
Safety Section
Safety Messages

g01413938
Illustration 3
SEBU7792-03 9
Safety Section
Safety Messages

g01413976
Illustration 4
10 SEBU7792-03
Safety Section
Safety Messages

g01414140
Illustration 5
SEBU7792-03
Do Not Operate (1)
This safety message is located inside the cab.
g01379128
Do not operate or work on this equipment unless
you have read and understand the instructions
and warnings in the Operation and Maintenance
Manuals. Failure to follow the instructions or
heed the warnings could result in serious injury
or death.
11
Safety Section
Safety Messages
Seat Belt (2)
This safety message is located inside the cab.
g01370908
A seat belt should be worn at all times during ma-
chine operation to prevent serious injury or death
in the event of an accident or machine overturn.
Failure to wear a seat belt during machine opera-
tion may result in serious injury or death.
High Compressed Spring (3)
This safety message is positioned on the brake
chambers. The brake chambers are located on the
inside of the left frame rail.
g01065910
Personal injury can result from being struck by
parts propelled by a released spring force.
Make sure to wear all necessary protective equip-
ment.
Follow the recommended procedure and use all
recommended tooling to release the spring force.
12
Safety Section
Safety Messages
Gas Under Pressure (4)
This safety message is located on the accumulator
for the Automatic Retarder Control (ARC) system.
The accumulator for the ARC system is located on
the left inside frame rail near the transmission.
g01123184
Gas under pressure. Rapid discharge from dis-
connecting or disassembly could cause personal
injury or death. See service manual before reliev-
ing pressure or charging.
Explosion Hazard (5)
This safety message is located on the battery access
cover.
g01370909
Explosion Hazard! Improper jumper cable connec-
tions can cause an explosion resulting in serious
injury or death. Batteries may be located in sep-
arate compartments. Refer to the Operation and
Maintenance Manual for the correct jump starting
procedure.
SEBU7792-03
Do Not Weld or Drill the ROPS (6)
This safety message is located outside on the top
right side of the cab.
g01185288
Structural damage, an overturn, modification, al-
teration, or improper repair can impair this struc-
ture’s protection capability thereby voiding this
certification. Do not weld on or drill holes in the
structure. Consult a Caterpillar dealer to deter-
mine this structure’s limitations without voiding
its certification.
Hot Coolant Under Pressure (7)
This label is located on the expansion tank beside
each radiator filler cap.
g01371640
The coolant is hot and the coolant is under pres-
sure. Do not touch the hot surfaces. Refer to the
Operation and Maintenance Manual for the proce-
dure to follow when you check the radiator.
SEBU7792-03
Gas Under Pressure (8)
This safety message is located on the steering
accumulators. The steering accumulators are located
on the front of the right outside frame rail.
g01123184
Gas under pressure. Rapid discharge from dis-
connecting or disassembly could cause personal
injury or death. See service manual before reliev-
ing pressure or charging.
13
Safety Section
Safety Messages
Shock Hazard (9)
This safety message is located on the valve cover
and on the Electronic Control Module (ECM).
g01372247
WARNING: Shock/Electrocution Hazard-Read the
Operation and Maintenance Manual. Could cause
serious injury or death.
The ECM sends a high voltage signal to the unit
injectors. To help prevent personal injury or death,
disconnect the unit injector connector. Do not come
in contact with the harness connector for the unit
injector while the engine is operating.
14
Safety Section
Additional Messages
High Pressure Cylinder (10)
This safety message is located on each of the four
suspension cylinders.
g01370912
Hydraulic accumulator contains gas and oil under
high pressure. Improper removal or repair proce-
dures could cause severe injury. To remove or re-
pair, instructions in the service manual must be
followed. Special equipment is required for test-
ing and charging.
For information on servicing the suspension
cylinders, refer to Special Instruction, SEHS9411,
“Suspension Cylinder Servicing”.
SEBU7792-03
Crushing Hazard (11)
This safety message is located on each of the four
suspension cylinders.
g01370911
HIGH PRESSURE CYLINDER
Do not remove any valve, hydraulic fitting, or valve
core, nor disassemble any parts until pressure
has been relieved.
To relieve pressure, truck frame must be proper-
ly supported. Failure to comply with this warning
will cause unexpected machine movement result-
ing in serious injury or death.
Refer to your Service Manual for correct proce-
dures for relieving pressure and/or correct charg-
ing procedures.
See your Caterpillar dealer who has tools and
detailed information for servicing and charging
cylinders.
For information on servicing the suspension
cylinders, refer to Special Instruction, SEHS9411,
“Suspension Cylinder Servicing”.
i02233134
Additional Messages
SMCS Code: 1000; 7000; 7405
There are several specific messages on these
machines. The exact location of the messages and
the description of the messages are reviewed in
this section. Please become familiarized with all
messages.
SEBU7792-03 15
Safety Section
Additional Messages

Make sure that all of the messages are legible.

Clean the messages or replace the messages if the
words or images are unreadable. When you clean
the messages, use a cloth, water and soap. Do not
use solvent, gasoline, or other harsh chemicals to
clean the messages. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures the
messages. Loose adhesive will allow the messages
to fall.

Replace any message that is damaged, or missing.

If a message is attached to a part that is replaced,
install a message on the replacement part. Any
Caterpillar dealer can provide new messages.
16 SEBU7792-03
Safety Section
Additional Messages

g01126349
Illustration 6
SEBU7792-03 17
Safety Section
Additional Messages

g01174002
Illustration 7
18 SEBU7792-03
Safety Section
Additional Messages

Retarding Guidelines (1)

This message is located on the inside of the right cab

door.

g00955999
Illustration 10

Do Not Lift (4)

g01171647 This message is located on the shipping eyes that
Illustration 8
Typical Example are located inside the frame rails.

This machine is equipped with one of two possible The shipping eyes are not lifting points.
configurations for retarding.

For more information on retarding, refer to Operation

and Maintenance Manual, “Retarding”.

Information for Air Conditioner System Service

(2)

This message is located inside the cab below the

A/C switch.

Do not work on the air conditioning system until you

have read the service manual and you understand
the service manual.
g01126496
Illustration 11

24 Volt Electrical System (5)

This message is located on the door for the battery

compartment.

This machine is equipped with a 24 volt electrical

system.

g00934175
Illustration 9

ELC (Extended Life Coolant) Cooling System (3)

This message is located on the reservoir for the

radiator.

This machine is shipped from the factory with ELC.

SEBU7792-03 19
Safety Section
General Hazard Information

g01126478 g01147122
Illustration 12 Illustration 14

Do Not Load Material on the Canopy (6)

i02443908

This message is located inside the cab on the left

front ROPS post.
General Hazard Information
SMCS Code: 7000
Do not load any material on the canopy of the truck.

g00104545
Illustration 15
g01147071
Illustration 13
Attach a “Do Not Operate” warning tag or a similar
Information for the Hydraulic Accumulator (7) warning tag to the start switch or to the controls
before you service the equipment or before you
This message is located on each of the four repair the equipment. These warning tags (Special
suspension cylinders. Instruction, SEHS7332) are available from your
Caterpillar dealer.
This message shows the specifications for the
suspension cylinders. Know the width of your equipment in order to maintain
proper clearance when you operate the equipment
near fences or near boundary obstacles.

Be aware of high voltage power lines and power

cables that are buried. If the machine comes in
contact with these hazards, serious injury or death
may occur from electrocution.
20
Safety Section
General Hazard Information
g00702020
Illustration 16
Wear a hard hat, protective glasses, and other
protective equipment, as required.
Do not wear loose clothing or jewelry that can snag
on controls or on other parts of the equipment.
Make sure that all protective guards and all covers
are secured in place on the equipment.
Keep the equipment free from foreign material.
Remove debris, oil, tools, and other items from the
deck, from walkways, and from steps.
Secure all loose items such as lunch boxes, tools,
and other items that are not a part of the equipment.
Know the appropriate work site hand signals and
the personnel that are authorized to give the hand
signals. Accept hand signals from one person only.
Do not smoke when you service an air conditioner.
Also, do not smoke if refrigerant gas may be present.
Inhaling the fumes that are released from a flame that
contacts air conditioner refrigerant can cause bodily
harm or death. Inhaling gas from air conditioner
refrigerant through a lighted cigarette can cause
bodily harm or death.
Never put maintenance fluids into glass containers.
Drain all liquids into a suitable container.
Obey all local regulations for the disposal of liquids.
Use all cleaning solutions with care. Report all
necessary repairs.
Do not allow unauthorized personnel on the
equipment.
Unless you are instructed otherwise, perform
maintenance with the equipment in the servicing
position. Refer to Operation and Maintenance Manual
for the procedure for placing the equipment in the
servicing position.
SEBU7792-03
Pressurized Air and Water
Pressurized air and/or water can cause debris
and/or hot water to be blown out. This could result in
personal injury.
When pressurized air and/or pressurized water is
used for cleaning, wear protective clothing, protective
shoes, and eye protection. Eye protection includes
goggles or a protective face shield.
The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the
nozzle is deadheaded and the nozzle is used with
an effective chip deflector and personal protective
equipment. The maximum water pressure for
cleaning purposes must be below 275 kPa (40 psi).
Trapped Pressure
Pressure can be trapped in a hydraulic system.
Releasing trapped pressure can cause sudden
machine movement or attachment movement. Use
caution if you disconnect hydraulic lines or fittings.
High pressure oil that is released can cause a hose to
whip. High pressure oil that is released can cause oil
to spray. Fluid penetration can cause serious injury
and possible death.
Fluid Penetration
Pressure can be trapped in the hydraulic circuit long
after the engine has been stopped. The pressure can
cause hydraulic fluid or items such as pipe plugs to
escape rapidly if the pressure is not relieved correctly.
Do not remove any hydraulic components or parts
until pressure has been relieved or personal injury
may occur. Do not disassemble any hydraulic
components or parts until pressure has been relieved
or personal injury may occur. Refer to the Service
Manual for any procedures that are required to
relieve the hydraulic pressure.
Illustration 17
g00687600
SEBU7792-03
Always use a board or cardboard when you check
for a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak can
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury.
Containing Fluid Spillage
Care must be taken in order to ensure that fluids
are contained during performance of inspection,
maintenance, testing, adjusting and repair of the
equipment. Prepare to collect the fluid with suitable
containers before opening any compartment or
disassembling any component that contains fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for the following items:
• Tools that are suitable for collecting fluids and
equipment that is suitable for collecting fluids
• Tools that are suitable for containing fluids and
equipment that is suitable for containing fluids
Obey all local regulations for the disposal of liquids.
Asbestos Information
g00702022
Illustration 18
Caterpillar equipment and replacement parts that are
shipped from Caterpillar are asbestos free. Caterpillar
recommends the use of only genuine Caterpillar
replacement parts. Use the following guidelines
when you handle any replacement parts that contain
asbestos or when you handle asbestos debris.
21
Safety Section
General Hazard Information
Use caution. Avoid inhaling dust that might be
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is usually
bound in a resin or sealed in some way. Normal
handling is not hazardous unless airborne dust that
contains asbestos is generated.
If dust that may contain asbestos is present, there
are several guidelines that should be followed:
• Never use compressed air for cleaning.
• Avoid brushing materials that contain asbestos.
• Avoid grinding materials that contain asbestos.
• Use a wet method in order to clean up asbestos
materials.
• A vacuum cleaner that is equipped with a high
efficiency particulate air filter (HEPA) can also be
used.
• Use exhaust ventilation on permanent machining
jobs.
• Wear an approved respirator if there is no other
way to control the dust.
• Comply with applicable rules and regulations
for the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”.
• Obey environmental regulations for the disposal
of asbestos.
• Stay away from areas that might have asbestos
particles in the air.
22
Safety Section
Crushing Prevention and Cutting Prevention
Dispose of Waste Properly
g00706404
Illustration 19
Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
disposed of according to local regulations.
Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
i01359664
Crushing Prevention and
Cutting Prevention
SMCS Code: 7000
Support the equipment properly before you perform
any work or maintenance beneath that equipment.
Do not depend on the hydraulic cylinders to hold
up the equipment. Equipment can fall if a control is
moved, or if a hydraulic line breaks.
Do not work beneath the cab of the machine unless
the cab is properly supported.
Unless you are instructed otherwise, never attempt
adjustments while the machine is moving or while
the engine is running.
Never jump across the starter solenoid terminals
in order to start the engine. Unexpected machine
movement could result.
Whenever there are equipment control linkages the
clearance in the linkage area will change with the
movement of the equipment or the machine. Stay
clear of areas that may have a sudden change in
clearance with machine movement or equipment
movement.
Stay clear of all rotating and moving parts.
SEBU7792-03
If it is necessary to remove guards in order to perform
maintenance, always install the guards after the
maintenance is performed.
Keep objects away from moving fan blades. The fan
blade will throw objects or cut objects.
Do not use a kinked wire cable or a frayed wire cable.
Wear gloves when you handle wire cable.
When you strike a retainer pin with force, the retainer
pin can fly out. The loose retainer pin can injure
personnel. Make sure that the area is clear of people
when you strike a retainer pin. To avoid injury to
your eyes, wear protective glasses when you strike
a retainer pin.
Chips or other debris can fly off an object when you
strike the object. Make sure that no one can be
injured by flying debris before striking any object.
i01329099
Burn Prevention
SMCS Code: 7000
Do not touch any part of an operating engine.
Allow the engine to cool before any maintenance is
performed on the engine. Relieve all pressure in the
air system, in the oil system, in the lubrication system,
in the fuel system, or in the cooling system before
any lines, fittings or related items are disconnected.
Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.
Any contact with hot coolant or with steam can cause
severe burns. Allow cooling system components to
cool before the cooling system is drained.
Check the coolant level only after the engine has
been stopped.
Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to touch
with a bare hand. Remove the filler cap slowly in
order to relieve pressure.
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.
SEBU7792-03
Oils
Hot oil and hot components can cause personal
injury. Do not allow hot oil to contact the skin. Also,
do not allow hot components to contact the skin.
Remove the hydraulic tank filler cap only after the
engine has been stopped. The filler cap must be
cool enough to touch with a bare hand. Follow the
standard procedure in this manual in order to remove
the hydraulic tank filler cap.
Batteries
Electrolyte is an acid. Electrolyte can cause personal
injury. Do not allow electrolyte to contact the skin or
the eyes. Always wear protective glasses for servicing
batteries. Wash hands after touching the batteries
and connectors. Use of gloves is recommended.
i01359795
Fire Prevention and Explosion
Prevention
SMCS Code: 7000
g00704000
Illustration 20
All fuels, most lubricants, and some coolant mixtures
are flammable.
Flammable fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause
a fire. Fire may cause personal injury and property
damage.
Remove all flammable materials such as fuel, oil, and
debris from the machine. Do not allow any flammable
materials to accumulate on the machine.
Store fuels and lubricants in properly marked
containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials.
23
Safety Section
Fire Prevention and Explosion Prevention
Do not operate the machine near any flame.
Exhaust shields (if equipped) protect hot exhaust
components from oil spray or fuel spray in case of
a break in a line, in a hose, or in a seal. Exhaust
shields must be installed correctly.
Do not weld on lines or on tanks that contain
flammable fluids. Do not flame cut lines or tanks
that contain flammable fluid. Clean any such lines or
tanks thoroughly with a nonflammable solvent prior
to welding or flame cutting.
Check all electrical wires daily. Repair any wires
that are loose or frayed before you operate the
machine. Clean all electrical connections and tighten
all electrical connections.
Dust that is generated from repairing nonmetallic
hoods or nonmetallic fenders can be flammable
and/or explosive. Repair such components in a well
ventilated area away from open flames or sparks.
Inspect all lines and hoses for wear or for
deterioration. The hoses must be properly routed.
The lines and the hoses must have adequate support
and secure clamps. Tighten all connections to the
recommended torque. Leaks can cause fires.
Illustration 21
g00704059
Use caution when you are refueling a machine. Do
not smoke while you are refueling a machine. Do
not refuel a machine near open flames or sparks.
Always stop the engine before refueling. Fill the fuel
tank outdoors.
24
Safety Section
Fire Extinguisher Location
g00704135
Illustration 22
Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or
a hydrometer.
Improper jumper cable connections can cause
an explosion that can result in injury. Refer to
the Operation Section of this manual for specific
instructions.
Do not charge a frozen battery. This may cause an
explosion.
Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.
Ether
Ether is flammable and poisonous.
Use ether in well ventilated areas. Do not smoke
while you are replacing an ether cylinder or while you
are using an ether spray.
Do not store ether cylinders in living areas or in the
operator compartment of a machine. Do not store
ether cylinders in direct sunlight or in temperatures
above 49 °C (120 °F). Keep ether cylinders away
from open flames or sparks.
SEBU7792-03
Dispose of used ether cylinders properly. Do not
puncture an ether cylinder. Keep ether cylinders
away from unauthorized personnel.
Do not spray ether into an engine if the machine is
equipped with a thermal starting aid for cold weather
starting.
Lines, Tubes and Hoses
Do not bend high pressure lines. Do not strike high
pressure lines. Do not install any lines that are bent
or damaged.
Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Caterpillar dealer for
repair or for replacement parts.
Check lines, tubes and hoses carefully. Do not use
your bare hand to check for leaks. Use a board or
cardboard to check for leaks. Tighten all connections
to the recommended torque.
Replace the parts if any of the following conditions
are present:
• End fittings are damaged or leaking.
• Outer coverings are chafed or cut.
• Wires are exposed.
• Outer coverings are ballooning.
• Flexible part of the hoses are kinked.
• Outer covers have embedded armoring.
• End fittings are displaced.
Make sure that all clamps, guards, and heat shields
are installed correctly. During machine operation, this
will help to prevent vibration, rubbing against other
parts, and excessive heat.
i02345316
Fire Extinguisher Location
SMCS Code: 7000; 7419
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.
SEBU7792-03
The fire extinguisher needs to be at least a 4.5 kg
(10 lb) fire extinguisher unless the machine has
a permanent, built in extinguishing system. The
mounting location must not damage any safety
features. The mounting location must not obstruct
the operator compartment, or the operator from
accessing or exiting the cab.
A shelf is located directly behind the operator
and above the circuit breaker panel. This shelf is
the recommended location for mounting the fire
extinguisher. The fire extinguisher can also be
mounted to a leg of the ROPS. Strap the mounting
plate to a leg of the ROPS. Mount the fire extinguisher
as low as possible on the ROPS leg. Do not mount
any fire extinguisher on the upper one-third portion
of a ROPS leg.
Do not weld a bracket on the Rollover Protective
Structure (ROPS) in order to install the fire
extinguisher. Also, do not drill holes in the ROPS in
order to mount the fire extinguisher on the ROPS.
i01557411
Tire Information
SMCS Code: 7000
Explosions of air inflated tires have resulted from
heat-induced gas combustion inside the tires.
Explosions can be caused by heat that is generated
by welding, by heating rim components, by external
fire, or by excessive use of brakes.
A tire explosion is much more violent than a
blowout. The explosion can propel the tire, the rim
components, and the axle components as far as
500 m (1500 ft) or more from the machine. Both the
force of the explosion and the flying debris can cause
property damage, personal injury, or death.
g00337832
Illustration 23
(A) At least 15 m (50 ft)
(B) At least 500 m (1500 ft)
25
Safety Section
Tire Information
Do not approach a warm tire. Maintain a minimum
distance, as shown. Stay outside the shaded area in
Illustration 23.
Do not use water or calcium as a ballast for the tires.
Dry nitrogen gas is recommended for inflation of tires.
If the tires were originally inflated with air, nitrogen
is still preferred for adjusting the pressure. Nitrogen
mixes properly with air.
Nitrogen inflated tires reduce the potential of
a tire explosion because nitrogen does not aid
combustion. Nitrogen helps to prevent oxidation of
the rubber, deterioration of rubber, and corrosion of
rim components.
To avoid overinflation, proper nitrogen inflation
equipment and training in the usage of the equipment
are necessary. A tire blowout or a rim failure can
result from improper equipment or from misused
equipment.
When you inflate a tire, stand behind the tread and
use a self-attaching chuck.
Servicing tires and rims can be dangerous. Only
trained personnel that use proper tools and proper
procedures should perform this maintenance. If
correct procedures are not used for servicing tires
and rims, the assemblies could burst with explosive
force. This explosive force can cause serious
personal injury or death. Carefully obey the specific
instructions from your tire dealer.
i01122596
Electrical Storm Injury
Prevention
SMCS Code: 7000
When lightning is striking in the vicinity of the
machine, the operator should never attempt the
following procedures:
• Mount the machine.
• Dismount the machine.
If you are in the operator’s station during an electrical
storm, stay in the operator’s station. If you are on the
ground during an electrical storm, stay away from
the vicinity of the machine.
26
Safety Section
Before Starting Engine
i02016010
Before Starting Engine
SMCS Code: 1000; 7000
Note: Start the engine only from the operator’s
compartment. Never short across the starter
terminals or across the batteries. Shorting could
bypass the engine neutral start system. Shorting
could also damage the electrical system.
Before you mount the machine, perform a
walk around inspection. Look for any damaged
components or leaks. Report discrepancies and
make any necessary repairs before operating the
machine. See the operation section in this Operation
and Maintenance Manual, “Daily Inspection” for more
information.
Once you mount the machine, inspect the platform
for any loose items or debris. Remove obstructions
from the screen on the air filter housing. Check levels
in the coolant tanks. Look for any other signs of
damage or wear.
When you enter the cab, inspect the condition of the
seat belt and the condition of mounting hardware.
Replace any damaged parts and any worn parts.
Regardless of appearance, replace the seat belt after
three years of use. Do not use a seat belt extension
on a retractable seat belt.
Adjust the seat in order to achieve full pedal travel
when the operator’s back is against the back of the
seat.
Make sure that the machine is equipped with a
lighting system that is adequate for the job conditions.
Make sure that all lights are working properly.
Before you start the engine or before you move the
machine, make sure that no one is on the machine,
underneath the machine, or around the machine.
Make sure that there are no personnel in the area.
i02684097
Engine Starting
SMCS Code: 1000; 7000
If a warning tag is attached to the engine start switch
or to the machine controls, do not start the engine.
Also, do not move any machine controls.
Make sure that the dump body is down. Put the hoist
control in the FLOAT position.
Move the transmission direction and speed control to
the NEUTRAL position.
SEBU7792-03
Engage the parking brake control.
Diesel engine exhaust contains products of
combustion which can be harmful to your health.
Always start the engine in a well ventilated area.
Always operate the engine in a well ventilated area.
If you are in an enclosed area, vent the exhaust to
the outside.
Check for the presence of bystanders or maintenance
personnel. Ensure that all personnel are clear of the
machine.
Briefly sound the horn before you start the engine.
i01378270
Before Operation
SMCS Code: 7000
Clear all personnel from the machine and from the
area.
Clear all obstacles from the path of the machine.
Beware of hazards such as electrical wires, ditches,
etc.
Make sure that all windows are clean. Secure the
doors in the shut position.
For the best visibility of the area that is close to the
machine, adjust the rearview mirrors (if equipped).
Make sure that the machine horn, the backup alarm
(if equipped), the action alarm, the dash indicator
lights and all other warning devices are working
properly.
Fasten the seat belt securely.
i02773460
Visibility Information
SMCS Code: 7000
Before you start the machine, the operator shall
perform a walk-around inspection in order to ensure
that there are no hazards around the machine.
While the machine is in operation, the operator should
constantly survey the area around the machine. The
operator needs to identify potential hazards as a
hazard becomes visible around the machine.
SEBU7792-03
Your machine may be equipped with mirrors or other
visual aids. An example of a visual aid is Closed
Circuit Television (CCTV). The operator should
ensure that the visual aids are in proper working
condition and that the visual aids are clean. Adjust
the visual aids for the best visibility of all areas
around the machine.
It may not be possible to provide direct visibility on
large machines to all areas around the machine.
Appropriate job site organization is required in order
to minimize hazards that are caused by restricted
visibility. Job site organization is a collection of rules
and procedures that coordinates machines and
people that work together in the same area. Examples
of job site organization include the following:
• Safety instructions
• Controlled patterns of machine movement
• Controlled patterns of vehicle movement
• Restricted areas
• Operator training
• Warning symbols or warning signs on machines
or on vehicles
• A system of communication
• Communication between workers and operators
prior to approaching the machine
Modifications of the machine configuration that result
in a restriction of visibility shall be verified according
to “ISO 5006”.
i02018050
Operation
SMCS Code: 7000
Machine Operating Temperature
Range
The standard machine configuration is intended for
use within an ambient temperature of −40 °C (−40 °F)
to 50 °C (122 °F). Special configurations for different
ambient temperatures may be available. Consult
your Caterpillar dealer for additional information on
special configurations of your machine.
27
Safety Section
Operation
Machine Operation
Only operate the machine while you are in a seat.
The seat belt must be fastened while you operate the
machine. Only operate the controls while the engine
is running.
Before you move the machine, you must make sure
that no one will be endangered.
While you operate the machine slowly in an open
area, check for proper operation of all controls and all
protective devices.
Do not allow riders on the machine unless the
machine has the following equipment:
• Additional seat
• Additional seat belt
• Rollover Protective Structure (ROPS)
Note any needed repairs during machine operation.
Report any needed repairs.
When the truck is on a upward slope, avoid dumping
the truck. The truck could tip backward.
Avoid any conditions that can lead to tipping the
machine. The machine can tip when you work on
hills, on banks and on slopes. Also, the machine
can tip when you cross ditches, ridges or other
unexpected obstacles.
Avoid operating the machine across the slope. When
possible, operate the machine up the slopes and
down the slopes.
Maintain control of the machine. Do not load the
machine beyond the machine capacity.
Never straddle a wire cable. Never allow other
personnel to straddle a wire cable.
Know the maximum dimensions of your machine.
Always keep the Rollover Protective Structure
(ROPS) installed during machine operation.
Always anticipate the grade and select the proper
gear range for the grade.
Lower the truck bed completely before travel. Keep
the hoist control in the FLOAT position during travel.
When the machine is being loaded, stay in the cab
of the machine.
Obey all road signs.
28
Safety Section
Parking
A signalman should be present, when you move the
machine in a building or out of a building.
NOTICE
Caterpillar recommends stopping the truck immedi-
ately if a flat tire is discovered. Driving on a flat tire
may cause damage to the tire and rim.
i01735812
Parking
SMCS Code: 7000
Park the machine on a level surface. If you must park
on a grade, chock the machine’s wheels.
Apply the service brakes in order to stop the
machine. Move the transmission control (lever) to the
NEUTRAL position. Move the throttle control to the
LOW IDLE position. Engage the parking brake.
Turn the engine start switch to the OFF position in
order to stop the engine. Remove the engine start
switch key.
Turn the battery disconnect switch to the OFF
position. Remove the disconnect switch key if you
do not operate the machine for an extended period
of time. This will prevent current discharge of the
battery. Any of the following conditions can cause
a current discharge of the battery: a battery short
circuit, any current draw from certain components,
and vandalism.
i02780235
Slope Operation
SMCS Code: 7000
Machines that are operating safely in various
applications depend on these criteria: the machine
model, configuration, machine maintenance,
operating speed of the machine, conditions of the
terrain, fluid levels, and tire inflation pressures. The
most important criteria are the skill and judgment of
the operator.
A well trained operator that follows the instructions
in the Operation and Maintenance Manual has
the greatest impact on stability. Operator training
provides a person with the following abilities:
observation of working and environmental conditions,
feel for the machine, identification of potential
hazards, and operating the machine safely by making
appropriate decisions.
When you work on side hills and when you work on
slopes, consider the following important points:
SEBU7792-03
Speed of travel – At higher speeds, forces of inertia
tend to make the machine less stable.
Roughness of terrain or surface – The machine
may be less stable with uneven terrain.
Direction of travel – Avoid operating the machine
across the slope. When possible, operate the
machine up the slopes and operate the machine
down the slopes. Place the heaviest end of the
machine uphill when you are working on an incline.
Mounted equipment – Balance of the machine
may be impeded by the following components:
equipment that is mounted on the machine, machine
configuration, weights, and counterweights.
Nature of surface – Ground that has been newly
filled with earth may collapse from the weight of the
machine.
Surface material – Rocks and moisture of the
surface material may drastically affect the machine’s
traction and machine’s stability. Rocky surfaces may
promote side slipping of the machine.
Slippage due to excessive loads – This may cause
downhill tracks or downhill tires to dig into the ground,
which will increase the angle of the machine.
Width of tracks or tires – Narrower tracks or
narrower tires further increase the digging into the
ground which causes the machine to be less stable.
Implements attached to the drawbar – This may
decrease the weight on the uphill tracks. This may
also decrease the weight on the uphill tires. The
decreased weight will cause the machine to be less
stable.
Height of the working load of the machine –
When the working loads are in higher positions, the
stability of the machine is reduced.
Operated equipment – Be aware of performance
features of the equipment in operation and the effects
on machine stability.
Operating techniques – Keep all attachments or
pulled loads low to the ground for optimum stability.
Machine systems have limitations on slopes –
Slopes can affect the proper function and operation
of the various machine systems. These machine
systems are needed for machine control on slopes.
SEBU7792-03
Note: Safe operation on steep slopes may require
special machine maintenance. Excellent skill of
the operator and proper equipment for specific
applications are also required. Consult the Operation
and Maintenance Manual sections for the proper fluid
level requirements and intended machine use.
i02598972
Sound Information and
Vibration Information
SMCS Code: 7000
Sound Level Information
The operator Equivalent Sound Pressure Level
(Leq) is 78 dB(A) when “ANSI/SAE J1166 OCT 98”
is used to measure the value for an enclosed cab.
This is a work cycle sound exposure level. The cab
was properly installed and maintained. The test was
conducted with the cab doors and the cab windows
closed.
Hearing protection may be needed when the
machine is operated with an open operator station for
extended periods or in a noisy environment. Hearing
protection may be needed when the machine is
operated with a cab that is not properly maintained or
when the doors and windows are open for extended
periods or in a noisy environment.
The average exterior sound pressure level is 87
dB(A) when the “SAE J88Apr95 - Constant Speed
Moving Test” procedure is used to measure the value
for the standard machine. The measurement was
conducted under the following conditions: distance of
15 m (49.2 ft) and “the machine moving forward in an
intermediate gear ratio”.
Sound Level Information for
Machines in European Union
Countries and in Countries that
Adopt the “EU Directives”
The dynamic operator sound pressure level is 78
dB(A) when “ISO 6394:1998” is used to measure the
value for an enclosed cab. The cab was properly
installed and maintained. The test was conducted
with the cab doors and the cab windows closed.
29
Safety Section
Sound Information and Vibration Information
“The European Union Physical
Agents (Vibration) Directive
2002/44/EC”
Vibration Data for Off-Highway Trucks
Information Concerning Hand/Arm Vibration
Level
When the machine is operated according to the
intended use, the hand/arm vibration of this machine
is below 2.5 meter per second squared.
Information Concerning Whole Body Vibration
Level
This section provides vibration data and a method for
estimating the vibration level for off-highway trucks.
Note: Vibration levels are influenced by many
different parameters. Many items are listed below.
• Operator training, behavior, mode, and stress
• Job site organization, preparation, environment,
weather, and material
• Machine type, quality of the seat, quality of the
suspension system, attachments, and condition of
the equipment
It is not possible to get precise vibration levels for
this machine. The expected vibration levels can be
estimated with the information in Table 1 in order
to calculate the daily vibration exposure. A simple
evaluation of the machine application can be used.
Estimate the vibration levels for the three vibration
directions. For typical operating conditions, use the
average vibration levels as the estimated level. With
an experienced operator and smooth terrain, subtract
the Scenario Factors from the average vibration level
in order to obtain the estimated vibration level. For
aggressive operations and severe terrain, add the
Scenario Factors to the average vibration level in
order to obtain the estimated vibration level.
Note: All vibration levels are in meter per second
squared.
30 SEBU7792-03
Safety Section
Sound Information and Vibration Information

Table 1
“ISO Reference Table A - Equivalent vibration levels of whole body vibration emission for earthmoving equipment.”

Machine Typical Operating Vibration Levels Scenario Factors

Type Activity X axis Y axis Z axis X axis Y axis Z axis
loading process 0,20 0,22 0,21 0,19 0,17 0,19

Off-Highway travel loaded 0,61 0,63 0,82 0,21 0,24 0,34

Trucks travel unloaded 0,73 0,73 0,87 0,20 0,25 0,33
unloading 0,37 0,37 0,33 0,14 0,13 0,08

Note: Refer to “ISO/TR 25398 Mechanical Vibration -
Guideline for the assessment of exposure to whole
body vibration of ride on operated earthmoving
machines” for more information about vibration.
This publication uses data that is measured
by international institutes, organizations and
manufacturers. This document provides information
about the whole body exposure of operators of
earthmoving equipment. Refer to Operation and
Maintenance Manual, SEBU8257, “The European
Union Physical Agents (Vibration) Directive
2002/44/EC” for more information about machine
vibration levels.
The Caterpillar suspension seat meets the criteria of
“ISO 7096”. This represents vertical vibration level
under severe operating conditions. This seat is tested
with the input “spectral class EM1”. The seat has a
transmissibility factor of “SEAT<1.1”.
a. Remove any large rocks or obstacles.
b. Fill any ditches and holes.
c. Provide machines and schedule time in order
to maintain the conditions of the terrain.
4. Use a seat that meets “ISO 7096”. Keep the seat
maintained and adjusted.
a. Adjust the seat and suspension for the weight
and the size of the operator.
b. Inspect and maintain the seat suspension and
adjustment mechanisms.
5. Perform the following operations smoothly.
a. Steer

The whole body vibration level of the machine varies. b. Brake

There is a range of values. The low value is 0.5
meter per second squared. The machine meets the c. Accelerate.
short term level for the design of the seat in “ISO
7096”. The value is 1.02 meter per second squared d. Shift the gears.
for this machine.
6. Move the attachments smoothly.
Guidelines for Reducing Vibration Levels on
Earthmoving Equipment 7. Adjust the machine speed and the route in order
to minimize the vibration level.
Properly adjust machines. Properly maintain
machines. Operate machines smoothly. Maintain the a. Drive around obstacles and rough terrain.
conditions of the terrain. The following guidelines can
help reduce the whole body vibration level: b. Slow down when it is necessary to go over
rough terrain.
1. Use the right type and size of machine, equipment,
and attachments. 8. Minimize vibrations for a long work cycle or a long
travel distance.
2. Maintain machines according to the
manufacturer’s recommendations. a. Use machines that are equipped with
suspension systems.
a. Tire pressures
b. Use the ride control system on off-highway
b. Brake and steering systems trucks.

c. Controls, hydraulic system and linkages c. If no ride control system is available, reduce
speed in order to prevent bounce.
3. Keep the terrain in good condition.
d. Haul the machines between workplaces.
SEBU7792-03
9. Less operator comfort may be caused by other risk
factors. The following guidelines can be effective
in order to provide better operator comfort:
a. Adjust the seat and adjust the controls in order
to achieve good posture.
b. Adjust the mirrors in order to minimize twisted
posture.
c. Provide breaks in order to reduce long periods
of sitting.
d. Avoid jumping from the cab.
e. Minimize repeated handling of loads and lifting
of loads.
f. Minimize any shocks and impacts during sports
and leisure activities.
Sources
The vibration information and calculation procedure
is based on “ISO/TR 25398 Mechanical Vibration
- Guideline for the assessment of exposure
to whole body vibration of ride on operated
earthmoving machines”. Harmonized data is
measured by international institutes, organizations
and manufacturers.
This literature provides information about assessing
the whole body vibration exposure of operators of
earthmoving equipment. The method is based on
measured vibration emission under real working
conditions for all machines.
You should check the original directive. This
document summarizes part of the content of the
applicable law. This document is not meant to
substitute the original sources. Other parts of these
documents are based on information from the United
Kingdom Health and Safety Executive.
Refer to Operation and Maintenance Manual,
SEBU8257, “The European Union Physical
Agents (Vibration) Directive 2002/44/EC” for more
information about vibration.
Consult your local Caterpillar dealer for more
information about machine features that minimize
vibration levels. Consult your local Caterpillar dealer
about safe machine operation.
Use the following web site in order to find your local
dealer:
Caterpillar, Inc.
www.cat.com
31
Safety Section
Operator Station
i01649970
Operator Station
SMCS Code: 7000; 7301; 7325
Any modifications to the inside of the operator
station should not project into the operator space.
The addition of a radio, fire extinguisher, and other
equipment must be installed so that the defined
operator space is maintained. Any item that is brought
into the cab should not project into the defined
operator space. A lunch box or other loose items
must be secured. Objects must not pose an impact
hazard in rough terrain or in the event of a rollover.
i01992325
Guards
(Operator Protection)
SMCS Code: 7000; 7150; 7325
There are different types of guards that are used to
protect the operator. The machine and the machine
application determines the type of guard that should
be used.
A daily inspection of the guards is required in order to
check for structures that are bent, cracked or loose.
Never operate a machine with a damaged structure.
The operator becomes exposed to a hazardous
situation if the machine is used improperly or if poor
operating techniques are used. This situation can
occur even though a machine is equipped with an
appropriate protective guard. Follow the established
operating procedures that are recommended for your
machine.
32 SEBU7792-03
Safety Section
Guards

Rollover Protective Structure • Demolition applications

(ROPS), Falling Object Protective
• Rock quarries
Structure (FOPS) or Tip Over
Protection Structure (TOPS) • Forestry products

The ROPS/FOPS Structure (if equipped) on your Additional guards may be required for specific
machine is specifically designed, tested and certified applications or work tools. The Operation and
for that machine. Excavators are not equipped Maintenance Manual for your machine or your
with ROPS structures. Any alteration or any work tool will provide specific requirements for the
modification to the ROPS/FOPS Structure could guards. Consult your Caterpillar dealer for additional
weaken the structure. This places the operator information.
into an unprotected environment. Modifications or
attachments that cause the machine to exceed the
weight that is stamped on the certification plate also
place the operator into an unprotected environment.
Excessive weight may inhibit the brake performance,
the steering performance and the ROPS. The
protection that is offered by the ROPS/FOPS
Structure will be impaired if the ROPS/FOPS
Structure has structural damage. Damage to the
structure can be caused by an overturn, a falling
object, a collision, etc.

Do not mount items (fire extinguishers, first aid

kits, work lights, etc) by welding brackets to the
ROPS/FOPS Structure or by drilling holes in the
ROPS/FOPS Structure. Welding brackets or drilling
holes in the ROPS/FOPS Structures can weaken
the structures. Consult your Caterpillar dealer for
mounting guidelines.

The Tip Over Protection Structure (TOPS) is

another type of guard that is used on mini hydraulic
excavators. This structure protects the operator in
the event of a tipover. The same guidelines for the
inspection, the maintenance and the modification of
the ROPS/FOPS Structure are required for the Tip
Over Protection Structure.

Other Guards (If Equipped)

Protection from flying objects and/or falling objects is
required for special applications. Logging applications
and demolition applications are two examples that
require special protection.

A front guard needs to be installed when a work

tool that creates flying objects is used. Mesh
front guards that are approved by Caterpillar or
polycarbonate front guards that are approved by
Caterpillar are available for machines with a cab or
an open canopy. On machines that are equipped with
cabs, the windshield should also be closed. Safety
glasses are recommended when flying hazards exist
for machines with cabs and machines with open
canopies.

If the work material extends above the cab, top

guards and front guards should be used. Typical
examples of this type of application are listed below:
SEBU7792-03 33
Product Information Section
General Information

Product Information Cab structure is ROPS certified to ISO 3471:1994 up

to 124000 kg (273373 lb) as a rigid frame dumper
Section ROPS only option. This number excludes dumper
body weight. This number also excludes carryback
debris weight.

General Information
i02445979

Specifications
SMCS Code: 7000

g01026111
Illustration 24
Approximate dimensions are shown. Dimensions will vary
depending on the configuration and the options.
(A) 7.6 m (25 ft)
(B) 6.7 m (22 ft)
(C) 13.1 m (43 ft)

The empty weight of a fully assembled 793D

Off-Highway Truck with a dual slope body and
with standard liners is approximately 149240 kg
(329000 lb). The empty weight of the 793D will
depend on the configuration and the options.

Intended Use
The 793D Off-Highway Truck is an earthmoving
machine. The 793D is classified as a dumper as
described in ISO 6165:2001. This is a self-propelled
wheeled machine with a rigid frame and wheel
steering. This dumper has an open body that is
intended for the following applications: transporting
loose material and dumping loose material

Application/Configuration Restrictions
The Target Gross Machine Operating Weight
(including payload) for the 793D Off-Highway Truck
is 383739 kg (846000 lb). The braking systems and
the steering systems in the 793D Off-Highway Truck
are in compliance with ISO standards when tested
to Caterpillar Global Mining Division’s 10/10/20
Overload policy.
34 SEBU7792-03
Product Information Section
Identification Information

Identification Information This plate is positioned on the bottom left side of the
plate for the Product Identification Number (PIN).

i02234486 Note: The CE plate is on machines that are certified

Plate Locations and Film
Locations
SMCS Code: 1000; 7000
The Product Identification Number (PIN) will be used
to identify a powered machine that is designed for
an operator to ride.
Serial Numbers will be used to identify engines,
transmissions and major attachments.
For quick reference, record the identification numbers
in the spaces that are provided below the illustration.
Product Identification Number (PIN)
to the European Union requirements that were
effective at that time.
If the machine is equipped with the plate for the
European Union, this plate will be attached to the PIN
plates. Several pieces of information are stamped
onto the CE plate. For quick reference, record this
information in the spaces that are provided below.
• Engine Power (kW)______________________________________
• Machine Weight (kg)____________________________________
• Compliance Year_________________________________________
Serial Number Plate (SN)

g01126777
Illustration 27
g01126677
Illustration 25
The tire and the wheel have been removed for ease of viewing.
(2) Dump Body Serial Number __________________________

(1) Machine PIN____________________________________________

European Union

g01127065
Illustration 28

(3) Transmission Serial Number_________________________

g01120192
Illustration 26
SEBU7792-03 35
Product Information Section
Identification Information

Structural damage, an overturn, modification, al-

teration, or improper repair can impair this struc-
ture’s protection capability thereby voiding this
certification. Do not weld on or drill holes in the
structure. Consult a Caterpillar dealer to deter-
mine this structure’s limitations without voiding
its certification.

g01127136
Illustration 29

(4) Engine Serial Number_________________________________

g01125202
Illustration 31
The following information is stamped on the
component.
This machine has been certified to the standards that
are listed on the certification plate. The maximum
mass of the machine, which includes the operator
and the attachments without a body or a payload,
should not exceed the mass on the certification plate.

i01859454

Emissions Certification Film

SMCS Code: 1000; 7000; 7405

Note: This information is pertinent in the United

States, in Canada, and in Europe.
g01190662
Illustration 30 A typical example is shown.

(5) Torque Converter Serial Number___________________

Differential Sequence Number___________________________

Wheel Station Sequence Number______________________

Certification
ROPS/FOPS Plate
This certification plate is located outside the cab on
the right side of the ROPS.
36 SEBU7792-03
Product Information Section
Identification Information

g00777800
Illustration 32
SEBU7792-03
Operation Section
Before Operation
i02189821
Mounting and Dismounting
SMCS Code: 7000
g00037860
Illustration 33
Typical example
Mount the machine and dismount the machine only
at locations that have steps and/or handholds. Before
you mount the machine, clean the steps and the
handholds. Inspect the steps and handholds. Make
all necessary repairs.
Face the machine whenever you get on the machine
and whenever you get off the machine.
Maintain a three-point contact with the steps and with
the handholds.
Note: Three-point contact can be two feet and one
hand. Three-point contact can also be one foot and
two hands.
Do not mount a moving machine. Do not dismount a
moving machine. Never jump off the machine. Do
not carry tools or supplies when you try to mount the
machine or when you try to dismount the machine.
Use a hand line to pull equipment onto the platform.
Do not use any controls as handholds when you
enter the operator compartment or when you exit the
operator compartment.
Alternate Exit
Machines that are equipped with cabs have alternate
exits. For additional information, see Operation and
Maintenance Manual, “Alternate Exit”.
37
Operation Section
Before Operation
i02684714
Daily Inspection
SMCS Code: 1000; 7000
For a maximum service life of the machine, complete
a thorough walk-around inspection before you mount
the machine and before you start the engine.
Note: If the machine has not been operated for more
than 48 hours, qualified personnel should complete a
service inspection before you operate the machine.
Inspect the area around the machine and under the
machine. Visually inspect the condition of all major
components. Look for loose bolts, trash buildup,
oil leakage, coolant leakage, broken parts, or worn
parts.
Note: If you observe a leak, find the source of the
leak and correct the leak. If you suspect a leak or you
observe a leak, check the fluid levels more frequently.
Remove any trash and any debris. Report any
abnormalities to the shop. Make any necessary
repairs before you operate the machine.
Check the grease fittings on the machine for leaks
and for damage.
Grease all of the fittings that need to be serviced on
a daily basis.
g01349067
Illustration 34
Inspect cover (1) on the connection for the VIMS.
Inspect warning light (2). Make sure that the covers
for engine shutdown switch (3), battery disconnect
switch (4), and switch (5) for the transmission lockout
are down.
Inspect the ladders for damage.
Inspect the radiator for leaks. Remove any debris
that could block the air flow.
Inspect the engine for oil leaks and for coolant leaks.
38 SEBU7792-03
Operation Section
Before Operation

Inspect both front tires. Check the tire inflation. Make
sure that you check the inside of the tire for damage
and for wear. Inspect the tire treads for damage.
Remove large rocks from the treads. Check the
wheel and the rim for bolts that are loose or missing.
Make sure that the ladders and hand rails are secure.
Make sure that all of the windows are clean. Make
sure that the operator’s vision is not impaired by dust,
mud, or other foreign materials. Adjust the mirrors
for proper vision.

Inspect all four rear tires. Check the tire inflation.

Make sure that you check the inside of the tire for
damage and for wear. Inspect the tire treads for
damage. Remove large rocks from the treads. Check
the final drives for bolts that are loose or missing.
Check for rocks that are stuck between the tires.
Make sure that the rock ejectors swing freely.
Note: Rust behind a bolt may indicate that the bolt is
loose. Shiny metal areas around a bolt may indicate
that the bolt is loose.
When it is necessary to work under the machine
with the body (bed) raised, attach the body (bed)
retaining cable to the rear tow point. Install the
rear tow point pin through the end of the retaining
cable.
Failure to properly secure the body (bed) may re-
sult in personal injury or death.

Inspect the steering cylinders for leaks and for
damage. Inspect the steering tie rods for wear and
for damage. Inspect the front suspension cylinders
for leaks and for damage.
Inspect the torque converter and the transmission
for leaks.
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)”.

Check the level in the fuel tank . Look for any leaks in
the fuel tank. Look for damage to the fuel tank.

Inspect the rear axle for leaks. Check the rear

suspension cylinders for leaks and for damage.
Check the lights for proper operation. Inspect the
lights for damage.

Inspect the hydraulic tank for leaks and for damage.

Make sure that the filler cap is installed.

Inspect the steering tank for leaks and for damage.

Make sure that the filler cap is installed. g01129419
Illustration 36

Inspect body (8) and the frame (9) for cracks. Inspect
the body and the frame for damage.

g01129543
Illustration 35

Check level gauge (6) on the automatic lubricant

reservoir. Inspect tank (7) for leaks. g01190105
Illustration 37

Remove any debris that may obstruct the air filters. Inspect hoist cylinders (10) for leaks or for damage.
Remove any debris from the platform. Inspect the hoist cylinders for cracking on the chrome
and for marks on the chrome.
SEBU7792-03 39
Operation Section
Before Operation

Perform the following daily procedures for your

machine:

• Operation and Maintenance Manual, “Air Tank

Moisture and Sediment - Drain”

• Operation and Maintenance Manual, “Backup

Alarm - Test”

• Operation and Maintenance Manual, “Brakes,

Indicators and Gauges - Test”

• Operation and Maintenance Manual, “Cooling

System Coolant Level - Check”

• Operation and Maintenance Manual, “Differential

and Final Drive - Check”

• Operation and Maintenance Manual, “Engine Oil

Level - Check”

• Operation and Maintenance Manual, “Engine Oil

Level - Log Additions”

• Operation and Maintenance Manual, “Hoist and

Brake Tank Oil Level - Check”

• Operation and Maintenance Manual, “Seat Belt -

Inspect”

• Operation and Maintenance Manual, “Steering

System Oil Level - Check”

• Operation and Maintenance Manual, “Torque

Converter Sump Oil Level - Check”
40 SEBU7792-03
Operation Section
Machine Operation

Machine Operation i02554993

Seat
i02241904
SMCS Code: 7312
Alternate Exit
There are two sets of mounting holes on the floor of
SMCS Code: 7254; 7308; 7310 the cab that allow the operator seat to be mounted in
different positions. The seat may be mounted farther
toward the rear of the cab in order to accommodate
larger operators. The companion seat has only one
set of mounting holes.

In order to reduce fatigue, periodically adjust the seat

cushion and the backrest for additional comfort.

Air Suspension Seat with

Three-Point Operator Restraint

g01129968
Illustration 38

The operator may choose to exit the cab through

right hand door (1). This exit is only an alternate exit.

g01129976
Illustration 39

Note: Use the handholds when you climb on the

machine or when you climb off the machine.
In order to use the access ladder on the left hand side
of the machine, unhook chain (2) and climb through
the opening in the handrail. Step on the air filter
housing. Use ladder (3) to exit the machine. Face the
ladder and descend down the ladder to the ground.
g01131959
Illustration 40
Armrest Adjustment Knob (1) – Rotate knob (1)
clockwise in order to raise the front of the armrest.
Rotate the knob counterclockwise in order to lower
the front of the armrest. The armrest can be adjusted
to the vertical position.
SEBU7792-03 41
Operation Section
Machine Operation

Shoulder Belt Adjustment (2) – Pull the spring pin Seat Belt Adjustment for
behind the vertical post for the shoulder belt and
adjust the height of the shoulder belt. Release pin into
Three-Point Operator Restraint
a locking position. For more information on the seat
At the time of installation, the three-point operator
belt adjustment and shoulder belt adjustment, refer
restraint and the instructions for installation of the
to Operation and Maintenance Manual, “Seat Belt”.
three-point operator restraint meet the SAE J386
standards and the SAE J2292 standards.
Ride Indicator (3) – Ride indicator (3) will indicate
optimum quality of the ride. With your weight on the
seat, the white indicator bar should be in the green Shoulder Belt Adjustment
zone.

Back Cushion Angle Lever (4) – Lift

handle (4) in order to adjust the angle of the
back cushion. Release the handle in order
to lock the back cushion in the desired position.

Fore/Aft Adjustment (5) – Lift handle (5)

in order to move the seat forward or move
the seat rearward. Release the handle in
order to lock the seat in place.

Height Adjustment (6) – In order to move

the seat downward, pull out knob (6). In
order to move the seat upward, push in the
knob.

Ride Adjustment Lever (7) – Push down

on lever (7) in order to increase the stiffness
of the ride . Pull up on the lever in order to
decrease the stiffness of the ride . Illustration 41 g01146638

Seat Cushion Tilt (8) – The front of the Pull spring pin (1) in order to release the vertical post.
seat cushion is pinned in a groove. Grasp
the seat cushion and position the groove Move the shoulder belt to the desired height.
for the desired angle over the pin.
Release the pin for the vertical post into the locked
position.
Lumbar Support Knob (9) – Turn knob (9)
counterclockwise in order to increase the
lumbar support. Turn the knob clockwise in
order to decrease the lumbar support.

i02252479

Seat Belt
SMCS Code: 7327

Note: This machine was equipped with a seat belt

when the machine was shipped from Caterpillar. See
your Caterpillar dealer for all replacement parts.

Always check the condition of the seat belt and

the condition of the mounting hardware before you
operate the machine.
42 SEBU7792-03
Operation Section
Machine Operation

Fastening The Seat Belt Releasing The Seat Belt

g01134273 g01134154
Illustration 42 Illustration 43

Pull seat belt (4) out of the retractors in a continuous
motion.
Fasten seat belt catch (3) into buckle (2). Make sure
that the seat belt is placed low across the lap and
over the center of the shoulder of the operator.
Grasp the seat belt near the latch.
Push the release button on the buckle in order to
release the seat belt.
Guide the seat belt into the automatic retractors.

The retractors will adjust the length of the seat

belt. The lap belt retractor will lock in position. The
shoulder belt retractor will remain free until certain
conditions cause the shoulder belt retractor to lock.
The buckle and retractor assemblies will allow the
operator to have some unrestricted movement for
comfort.
Seat Belt Adjustment for
Retractable Seat Belts
At the time of installation, the retractable seat belt
and the instructions for installation of the retractable
seat belt meet the SAE J386 standards.
SEBU7792-03 43
Operation Section
Machine Operation

Fastening The Seat Belt Seat Belt Adjustment for

non-retractable seat belts
At the time of installation, the non-retractable
seat belt and the instructions for installation of
the non-retractable seat belt meet the SAE J386
standards.

Note: Adjust both ends of the seat belt. The seat belt
should be snug but comfortable.

Lengthening the Seat Belt

g01134940
Illustration 44

Pull seat belt (7) out of the retractor in a continuous

motion.

Fasten seat belt catch (6) into buckle (5). Make sure
that the seat belt is placed low across the lap of the
operator.

The retractor will adjust the length of the seat belt

and the retractor will lock in position. The buckle and
retractor assemblies will allow the operator to have g00100709
some unrestricted movement for comfort. Illustration 46

1. Unfasten the seat belt.

Releasing The Seat Belt

g01146764
Illustration 47
g01134775
Illustration 45
2. To remove the slack in outer loop (8), rotate buckle
Grasp the seat belt near the latch. (9). This will free the lock bar. This permits the
seat belt to move through the buckle.
Push the release button on the buckle in order to
release the seat belt. 3. Remove the slack from the outer belt loop by
pulling on the buckle.
Guide the seat belt into the automatic retractor.
4. Loosen the other half of the seat belt in the same
manner. If the seat belt does not fit snugly with the
buckle in the center, readjust the seat belt.
44 SEBU7792-03
Operation Section
Machine Operation

Shortening the Seat Belt Releasing The Seat Belt

g00100713 g00100717
Illustration 48 Illustration 50

1. Fasten the seat belt. Pull out on the outer belt loop Pull up on the release lever. This will release the seat
in order to tighten the seat belt. belt.

2. Adjust the other half of the seat belt in the same

manner.
Extension of the Seat Belt

3. If the seat belt does not fit snugly with the buckle
in the center, readjust the seat belt.
Fastening The Seat Belt
When using retractable seat belts, do not use seat
belt extensions, or personal injury or death can
result.

The retractor system may or may not lock up de-

pending on the length of the extension and the
size of the person. If the retractor does not lock
up, the seat belt will not retain the person.

Longer, non-retractable seat belts and extensions for

the non-retractable seat belts are available.

Caterpillar requires only non-retractable seat belts to

be used with a seat belt extension.

Consult your Caterpillar dealer for longer seat belts

g01146774
and for information on extending the seat belts.
Illustration 49

Fasten seat belt catch (10) into buckle (9). Make sure i02725203
that the seat belt is placed low across the lap of the
operator. Operator Controls
SMCS Code: 7300; 7451
SEBU7792-03 45
Operation Section
Machine Operation

g01367205
Illustration 51
(1) Steering column tilt and telescope control (11) Ether starting aid switch (22) Service brake pedal
(2) Cigar lighter (12 V) (12) Automatic retarder control (23) Accelerator pedal
(3) Multifunction switch (13) Brake release switch (24) Transmission selection lever
(4) Horn button (14) Test switch for traction control system (25) Parking brake switch
(5) Hazard flasher switch (15) Heated mirror switch (26) Parking brake reset valve
(6) Switch for headlights, parking lights and (16) Air conditioner switch (27) Interior light
taillights (17) Fan speed switch (28) Hoist control lever
(7) Switch for the Fog lights (18) Temperature variable control (29) Secondary brake pedal
(8) Switch for rear work lights (19) Panel light switch (30) Power window switch
(9) Switch for access lights (20) Engine start switch
(10) Throttle backup switch (21) Retarder control lever
46 SEBU7792-03
Operation Section
Machine Operation

g01185916
Illustration 54
(40) Cab Visor

Note: Your machine may not be equipped with all of

the controls that are described in this topic.

Illustration 52
g01171960
Steering Wheel Control
Ground level controls
(31) Transmission Lockout Switch (If Equipped)
(32) VIMS Service Port
(33) Switch for Engine Service Lights
(34) Engine Shutdown Switch
(35) Battery Disconnect Switch
(36) Switch for Access Lights

Note: The ground level controls are mounted below

the front bumper if the machine is equipped with the
sound suppression arrangement.

g01191787
Illustration 55

Steering System
Steering System – This machine is
equipped with a closed centered, hydraulic
steering system. There is no mechanical
connection between the steering wheel and steering
cylinders that move the front wheels. Under normal
conditions, when the engine is running, movement of
g01169846
Illustration 53 the steering wheel will turn the front wheels. When
These features are located on the circuit breaker panel behind the steering wheel is turned clockwise, the front
the operator seat. wheels will turn to the right. When the steering wheel
(37) 12 V Power receptacle is turned counterclockwise, the front wheels will turn
(38) VIMS Service Port to the left. When the steering wheel is released, the
(39) ET and ECAP Service Port front wheels will remain in the selected position.
SEBU7792-03
Secondary Steering System
Personal injury or death can occur if steering is
lost completely during operation.
Do not continue to operate the machine using the
secondary steering.
If the secondary steering activates during opera-
tion, immediately park the machine in a safe loca-
tion. Inspect the machine and correct the condi-
tion which made the use of the secondary steer-
ing necessary.
Secondary Steering System – This
machine is equipped with an secondary
steering system. If a failure of the steering
system occurs, the operator will be warned and the
secondary steering system will provide a limited
amount of steering. The VIMS warning system will
alert the operator with a category 3 warning. This
warning states that the machine must be safely shut
down immediately in order to avoid damage to the
machine or personal injury. Refer to Operation and
Maintenance Manual , “Vital Information Management
System (VIMS)” for additional information. The
secondary steering system uses the steering wheel
in order to steer the machine. The secondary steering
system will provide sufficient stored energy in order
to complete the following: turn the front wheels from
the straight ahead position to either left against the
steering stop, or right against the steering stop., turn
the front wheels against the opposite steering stop.,
and turn the front wheels back to the straight ahead
position.. The secondary steering operates in forward
and reverse.
Steering Column Tilt and Telescope
Control (1)
Tilt Control (1) – Pull the lever upward in order to
tilt the steering column. Adjust the position of the
steering wheel while you hold the lever . Release the
lever. The steering wheel will remain in the desired
position.
Telescope Control (1) – Push the lever downward
in order to telescope the steering column. Adjust
the position of the steering wheel while you hold
the lever. Release the lever. The steering wheel will
remain in the desired position.
47
Operation Section
Machine Operation
Cigar Lighter (12 V) (2)
Cigar Lighter (2) – Push the lighter inward
and release the lighter. When the lighter is
ready to use, the lighter will move outward.
The lighter can also be used as a 12 volt
power receptacle.
Multifunction Switch (3)
Multifunction switch (3) controls the windshield
wipers, the windshield washer, the brightness of the
headlights, and the turn signals.
Windshield Wipers
Windshield Wipers – The rotary switch
on the lever controls the windshield wipers.
There are six different modes for the
windshield wipers.
OFF Position
Intermittent Position 3 – The wipers will
operate intermittently. This is the smallest
interval of time between cycles.
Intermittent Position 2 – The wipers will
operate intermittently.
Intermittent Position 1 – The wipers will
operate intermittently. This is the largest
interval of time between cycles.
Continuous Position 1 – The wipers will
operate continuously at a slow speed.
Continuous Position 2 – The wipers will
operate continuously at a high speed.
Window Washer
Window Washer – The button on the end
of the lever activates the windshield washer.
48
Operation Section
Machine Operation
Dimmer Switch
Dimmer Switch – The lever toggles up
and down in order to adjust the headlights
between high beam and low beam.
Directional Turn Signals
Turn Signal Left – Pull rearward on the
lever in order to activate the left turn signal.
When the left turn signal is activated, an
indicator will illuminate on the dash panel. The turn
signal will remain on until the lever is manually
returned to the Middle position.
Turn Signal Right – Push forward on
the lever in order to activate the right
turn signal. When the right turn signal is
activated, an indicator will illuminate on the dash
panel. The turn signal will remain on until the lever is
manually returned to the Middle position.
Horn (4)
Horn (4) – Depress the large button in
the center of the steering wheel in order to
sound the horn.
Hazard Flasher Switch (5)
Hazard Flashers (5) – Push the top half
of the switch in order to turn on the hazard
flashers. Push the bottom half of the switch
in order to turn off the hazard flashers.
Switch for Headlights, Parking
Lights, and Taillights (6)
Switch for Headlights, Parking Lights,
and Taillights (6) – The switch for the
headlights, parking lights, and taillights is a
three-position switch. Push the top half of the switch
to the first detent in order to activate the parking lights
and the taillights. Push the top half of the switch to
the second detent in order to activate the headlights,
the parking lights and the taillights. Push the bottom
half of the switch in order to turn off all the headlights,
the parking lights and the taillights.
SEBU7792-03
Switch for Fog Lights (7)
Switch for Fog Lights (7) – Push the top
half of the switch in order to turn on the
fog light. Push the bottom half of the switch
in order to turn off the fog lights. This switch only
operates the lower headlights.
Switch for Rear Work Lights (8)
Switch for Rear Work Lights (8) – Push
the top half of the switch in order to turn on
the rear work lights. Push the bottom half of
the switch in order to turn off the rear work lights.
Switch for Access Lights (9)
Switch for Access Lights (9) – Use
this switch in order to turn on or turn off
the lighting in the area around the stair
assembly.
Note: There are two switches that activate these
lights. One switch is located in the cab and the other
switch is located on the ground level controls near
the bottom of the stair assembly. The position of one
switch will determine whether the other switch is in
the ON position or in the OFF position.
Throttle Backup Switch (10)
Throttle Backup Switch (10) – If the
throttle position sensor on the accelerator
does not function, use the switch to
raise the engine RPM above low idle in order to
allow transportation to a service area. Place the
transmission control lever in the desired gear. Hold
the switch in the depressed position. While the switch
is held in the depressed position, the engine RPM will
raise from 650 RPM to 1300 RPM. When the switch
is released, the engine RPM will return to 650 RPM.
Ether Starting Aid Switch (11)
Ether Starting Aid Switch (11) – The
ether starting aid switch controls the use
of the ether starting aid. The switch is
normally in the AUTO position. When the switch is
in the AUTO position, the ether injection system
automatically injects a selected amount of ether into
the engine during starting. Push the top half of the
switch in order to inject the ether manually.
SEBU7792-03
Note: The ether starting aid switch should only
be used in the MANUAL position for cold weather
starting. See Special Publication, SEBU5898, “Cold
Weather Recommendations”.
Automatic Retarder Control (12)
Automatic Retarder Control (ARC)( 12) –
Push the top half of the switch in order to
select the ON position for the ARC system.
This sustains the machine at a constant speed on
a downgrade. If necessary, use retarder control
lever (21) to apply more retarding force during the
operation of the ARC system. Push the bottom half
of the switch in order to select the OFF position for
the ARC system.
The ARC should remain in the ON position during
normal operation. For more information, refer to
Operation and Maintenance Manual, “Retarding”.
Brake Release Switch (13)
Brake Release Switch (13) – Lift the latch
on the bottom half of the brake release
switch in order to unlock the switch. Push
the top half of the switch in order to operate the
electric motor for the parking brake release pump.
Push the bottom half of the switch in order to
deactivate the electric motor for the parking brake
release pump.
Note: Only use the brake release switch in order
to release the brakes for towing. Do NOT keep the
brake release control in the ON position longer than
20 seconds. For more information, refer to Operation
and Maintenance Manual, “Towing With Inoperable
Engine”.
Test Switch for the Traction Control
System (14)
Test Switch for the Traction Control
System (14) – Push the top half of the
switch in order to test the Traction Control
System (TCS). Hold the switch in place during the
test. Release the switch in order to end the test of the
Traction Control System (TCS).
See Operation and Maintenance Manual, “Traction
Control System (TCS) - Test” for more information.
49
Operation Section
Machine Operation
Heated Mirror Switch (15) (If
Equipped)
Heated Mirror Switch (15) – Push in the
top of the switch in order to apply heat to
the exterior mirrors. The heated mirrors will
be operational when the engine start switch is in the
ON position. Push in the bottom of the switch in order
to turn off the heated mirrors.
Heating and Air Conditioning
Controls
Air Conditioner Switch (16)
Air Conditioner Switch (16) – Push the
top of the switch in order to turn on the air
conditioning system. Push the bottom of the
switch to turn off the air conditioning system.
Fan Speed Switch (17)
Fan Speed Switch (17) – The fan speed
switch controls the four-speed blower fan.
Off – Move the switch to this position in
order to turn off the blower fan.
Low – Move the switch to this position for
a low fan speed.
Medium – Move the switch to this position
for a medium fan speed.
High – Move the switch to this position for
a high fan speed.
Max – Move the switch to this position for
the maximum fan speed.
Temperature Variable Control (18)
Temperature Variable Control (18) – Adjust the
control anywhere between MINIMUM position (left)
and MAXIMUM position (right). This will control the
amount of heating and the amount of cooling.
50
Operation Section
Machine Operation
Heating and Air Conditioning System
Operation
The heating and air conditioning system can perform
four functions:
Heating
Position fan switch (17) to desired speed. Adjust
temperature variable control (18) for the desired
temperature.
Air Conditioning
Place switch (16) in the ON position. Position fan
switch (17) to desired speed. Adjust temperature
variable control (18) for the desired temperature.
Pressurizing
When heating or cooling is not desired, pressurize
the cab in order to prevent dust from entering.
Adjust temperature variable control (18) to a
comfortable temperature. Position fan switch (17) to
a speed that is needed to keep out the dust.
Note: Opening any cab window will eliminate the
controlled air pressure in the cab.
Defogging
Place switch (16) in the ON position. Position fan
switch (17) to a speed that is needed to remove
moisture from the air in the cab. This prevents
moisture from forming on the windshield and the
windows. Adjust temperature variable control (18)
until the moisture level is lowered.
Panel Light Switch (19)
Panel Light Switch (19) – Depress the
top half of the switch and hold the switch in
order to increase the intensity of the panel
lights. Depress the bottom half of the switch and hold
the switch in order to decrease the intensity of the
panel lights.
Engine Start Switch (20)
Engine Start Switch (20) – The engine start switch
starts the engine.
SEBU7792-03
OFF position – When you insert the
engine start switch key and when you
remove the engine start switch key, the
engine start switch must be in the OFF position. To
disconnect the power to the electrical circuits in the
cab, turn the engine start switch to the OFF position.
Also, turn the engine start switch to the OFF position
in order to stop the engine.
ON position – To activate the electrical
circuits in the cab, turn the engine start
switch key clockwise to the ON position.
START position – To start the engine,
turn the engine start switch key clockwise
to the START position. When the engine
start switch key is released, the engine start switch
key will return to the ON position.
Note: If the engine fails to start, return the engine
start switch key to the OFF position. This must be
done before you attempt to start the engine again.
Retarder Control Lever (21)
Aggressive application of retarder capacity in slip-
pery conditions may cause loss of operator con-
trol and/or power train damage. Apply the retarder
gradually in slippery conditions. Serious injury or
death may occur if the retarder is applied too ag-
gressively in slippery conditions.
NOTICE
Do not use the retarder control as a parking brake.
Do not use the retarder control to stop the ma-
chine.
Retarder Control Lever (21) – The retarder control
lever is used to regulate engine speed and machine
speed when you travel down a grade. Move the
retarder control lever rearward in order to apply
more retarding force and slow the machine. Move
the retarder control lever forward in order to reduce
retarding force and allow the machine speed to
increase.
Refer to Operation and Maintenance Manual,
“Retarding” for additional information.
SEBU7792-03 51
Operation Section
Machine Operation

Service Brake Control Pedal (22) Shift Pattern

Service Brake Control Pedal (22) – During normal
operation, depress the service brake control pedal in
order to stop the machine. Also, depress the service
brake control pedal in order to slow the machine.

Refer to Operation and Maintenance Manual,

“Braking” for additional information.

Note: Do not use the service brake for the purpose of

maintaining the machine speed on a long downgrade.
Use the automatic retarder control and/or the manual
retarder control in order to maintain the machine
speed on a long downgrade. On a long downgrade,
the retarder controls provide the operator with the
ability to better regulate the amount of retarding
force. Refer to Operation and Maintenance Manual,
“Retarding” for more information on the retarder
controls.

Accelerator Pedal (23)

Accelerator Pedal (23) – The accelerator pedal
controls the fuel flow to the engine. As the accelerator
pedal is depressed, the engine rpm will increase.

Transmission Control Lever (24)

Transmission Control Lever (24) – Use the
transmission control lever to select FORWARD
speed, NEUTRAL position, and REVERSE
direction. Refer to Operation and Maintenance
Manual, “Changing Direction and Speed” for more
information. g01012497
Illustration 56
Typical Shift Pattern
(A) Reverse Position
(B) Neutral Position
(C) First Gear Forward
(D) Second Gear Forward
(E) Third Gear Forward
(F) Fourth Gear Forward
(G) Fifth Gear Forward
(H) Sixth Gear Forward
(I) Seventh Gear Forward

Parking Brake Switch (25)

NOTICE
Do not use the parking brake to stop the machine.

Parking Brake Switch (25) – Move the

parking brake switch forward to the OFF
position in order to release the parking
brake. Move the parking brake switch rearward to the
ON position in order to engage the parking brake.

Refer to Operation and Maintenance Manual,

“Braking” for additional information.
52
Operation Section
Machine Operation
Note: This machine is equipped with spring-applied
parking brakes. The spring force engages the
brakes on all four wheels. Hydraulic pressure is
used to disengage the brakes. If hydraulic pressure
is unavailable, the brakes will remain engaged. If
hydraulic pressure is unavailable and the machine
must be towed, refer to Operation and Maintenance
Manual , “Towing With Inoperable Engine”.
Parking Brake Reset Valve (26)
Parking Brake Reset Valve (26) – The parking
brake reset valve is a mechanical valve that will
automatically close if the supply pressure from
the secondary air reservoir drops below 414 kPa
(60 psi). The valve is placed in the air supply line
for the parking brake. When this valve actuates, the
air supply to the parking brake valve is cut off. This
applies the parking brake. Once the parking brake
reset valve is applied, the parking brake reset valve
will not release until following two events occur:
• The air pressure in the secondary air reservoir
must be above 414 kPa (60 psi).
• The operator must manually reset the valve by
pushing in on the popup indicator.
The valve will not close during truck operation unless
the operator is operating the truck after activation of
the low air pressure warning buzzer. The operator
will be warned to stop operating the truck because of
low air pressure if the pressure drops below 517 kPa
(75 psi). If the operator continues to operate the
truck, the parking brake reset valve will close when
the air pressure drops below 414 kPa (60 psi). This
will apply the parking brake.
If the system air pressure drops below 414 kPa
(60 psi), the amber popup indicator in the cab will
rise. The operator can not push down the popup
indicator in order to deactivate the parking brake
until the air system pressure rises above 414 kPa
(60 psi). Typically, air pressures that are low enough
to automatically activate the parking brake reset
valve are experienced only after the machine is shut
down and after the system air pressure is purged.
As an automatic mechanism, the parking brake
reset valve ensures that the parking brake does
not release without a specific operator action. The
parking brake reset valve will not automatically
apply the parking brake when the truck is shut
down. The operator must still follow the proper
parking and shutdown procedures.
SEBU7792-03
Interior Light (27)
Interior Light (27) – Use the switch on the
interior light in order to turn on or turn off
the interior light. When the door is open, an
automatic switch turns on the interior light.
Hoist Control Lever (28)
NOTICE
The body must be lowered and in the FLOAT position
when operating the machine. This will help prevent
damage to the body, caused by vibrations from the
haul road.
LOWER Position – Hold the hoist control
lever completely forward in order to lower
the dump body. When the lever is released,
the lever will return to the FLOAT position .
FLOAT Position – When the hoist control
lever is in the FLOAT position, the dump
body will seek a level. The hoist control will
stay in this position until the lever is manually moved.
HOLD Position – When the hoist control
is in the HOLD position, the dump body will
not move. The hoist control will stay in this
position until the lever is manually moved.
RAISE Position – Hold the hoist control
lever completely backward in order to raise
the dump body and empty the load. When
the lever is released, the lever will return to the HOLD
position .
Control Pedal for the Secondary
Brake System (29)
To avoid the possibility of a unexpected machine
movement when parking on a slope, always block
the wheels securely before leaving the machine
unattended.
If the secondary brake system is required in order
to stop the machine, do not operate the machine
until a complete check has been made of the en-
tire braking system and until all necessary repairs
have been made.
Control Pedal for the Secondary Brake System
(29) – Use secondary brake control (29) in order to
stop the machine if service brake control (22) does
not stop the machine properly.
SEBU7792-03
Refer to Operation and Maintenance Manual,
“Braking” for additional information.
Power Window Switch (30)
Power Window Switch (30) – Push the
top half of the switch in order to close the
window on the left side of the cab. Push the
bottom half of the switch in order to open the window.
Transmission Lockout Switch (31)
(If Equipped)
Transmission Lockout Switch (31) –
The transmission lockout disables the
transmission while the engine is running.
The LED indicator will illuminate when the lockout
is activated.
Before the transmission lockout is activated the
machine must meet all of the following conditions:
• The machine must be stopped.
• The parking brake must be ON.
• The shift lever must be in NEUTRAL.
Before the transmission lockout is deactivated the
machine must meet all of the following conditions:
• The machine must be stopped.
• The parking brake must be ON.
• The shift lever must be in NEUTRAL.
• The engine start switch must be cycled from the
ON position to the OFF position and back to the
ON position.
Note: When the transmission lockout switch is
moved to the OFF position, the LED indicator will
turn off. The LED indicator will turn off even if the
transmission lockout is still activated. This will occur
when the machine does not meet all the conditions
for the deactivation of the transmission lockout.
VIMS Service Port (32) and (38)
VIMS Service Port (32) and (38) – This
service port allows service personnel to
connect a laptop computer with the software
for the Vital Information Management System (VIMS).
53
Operation Section
Machine Operation
Engine Service Lights (33)
Engine Service Lights (33) – Move this
switch to the ON position in order to light
the engine area.
Engine Shutdown Switch (34)
Engine Shutdown Switch (34) – See
Operation and Maintenance Manual,
“Engine Shutdown Switch”.
Battery Disconnect Switch (35)
Battery Disconnect Switch (35) – See
Operation and Maintenance Manual,
“Battery Disconnect Switch”.
Switch for Access Lights (36)
Switch for Access Lights (36) – Use
this switch in order to turn on or turn off
the lighting in the area around the stair
assembly.
Note: There are two switches that activate these
lights. One switch is located in the cab and the other
switch is located on the ground level controls near
the bottom of the stair assembly. The position of one
switch will determine whether the other switch is in
the ON position or in the OFF position.
12 V Power Receptacle (37)
“+12 V” Power Receptacle (37) – This
port provides 12 V power. The maximum
power output is 5 Amp.
ET and ECAP Service Port (39)
ET and ECAP Service Port (39) – This
service port (3) allows service personnel to
connect a laptop computer that is equipped
with the Electronic Technician (ET) or with the
Electronic Control Analyzer Programmer (ECAP).
This will allow service personnel to diagnose machine
systems and the engine.
54 SEBU7792-03
Operation Section
Machine Operation

Cab Visor (40)

Cab Visor (40) – Grasp handle (40) and pull
downward in order to lower the cab visor for the front
window. Grasp the handle and press upward in order
to raise the cab visor for the front window.
i02834874
Battery Disconnect Switch
SMCS Code: 1411
S/N: FDB1-566
NOTICE
Never move the battery disconnect switch to the OFF
position while the engine is operating. Serious dam-
age to the electrical system could result.
OFF – To deactivate the electrical
system, turn the battery disconnect switch
counterclockwise to the OFF position.
Turn the battery disconnect switch to the OFF
position and remove the disconnect switch key
when you service the electrical system or other
components on the machine.
Turn the battery disconnect switch to the OFF
position and remove the disconnect switch key if you
do not operate the machine for an extended period of
a month or more. This will prevent the battery from
being discharged. The following problems can cause
battery discharge.
• Short circuits
• Current draw via some components
• Vandalism
Note: The battery disconnect switch does not release
hydraulic pressure from the secondary steering
system or hydraulic pressure from the automatic
retarder control system. In order to release the
hydraulic pressure, move the engine start switch to
the OFF position. This will activate a solenoid valve
in order to release the hydraulic pressure from the
accumulators.

i02834863

Illustration 57
g01349114
Battery Disconnect Switch
The battery disconnect switch (1) is located on the lower right front
side of the machine on the bumper. SMCS Code: 1411

Note: When an electrical power source is S/N: FDB567-Up

connected to the auxiliary start receptacle,
the battery disconnect switch is bypassed NOTICE
and the electrical system will energize when Never move the battery disconnect switch to the OFF
the battery disconnect switch is in the OFF position while the engine is operating. Serious dam-
(disabled) position. This allows jump starting age to the electrical system could result.
capabilities regardless of the position of the
battery disconnect switch.

Battery Disconnect Switch (1) – When

the battery disconnect switch is in the OFF
position, the electrical system is disabled.
When the battery disconnect switch is turned to the
ON position, the battery remains connected to the
entire electrical system.

ON – In order to activate the electrical

system, insert the disconnect switch key
and turn the battery disconnect switch
clockwise. The battery disconnect switch must be
turned to the ON position before you start the engine.
SEBU7792-03
g01349114
Illustration 58
The battery disconnect switch (1) is located on the lower right front
side of the machine on the bumper.
Note: When an electrical power source is
connected to the auxiliary start receptacle and
the battery disconnect switch is in the OFF
(disabled) position, the electrical system will
remain de-energized. This prevents jump starting
capabilities when the battery disconnect switch
is in the OFF position.
Battery Disconnect Switch (1) – When
the battery disconnect switch is in the OFF
position, the electrical system is disabled.
When the battery disconnect switch is turned to the
ON position, the battery remains connected to the
entire electrical system.
ON – In order to activate the electrical
system, insert the disconnect switch key
and turn the battery disconnect switch
clockwise. The battery disconnect switch must be
turned to the ON position before you start the engine.
OFF – To deactivate the electrical
system, turn the battery disconnect switch
counterclockwise to the OFF position.
Turn the battery disconnect switch to the OFF
position and remove the disconnect switch key
when you service the electrical system or other
components on the machine.
Turn the battery disconnect switch to the OFF
position and remove the disconnect switch key if you
do not operate the machine for an extended period of
a month or more. This will prevent the battery from
being discharged. The following problems can cause
battery discharge.
• Short circuits
• Current draw via some components
• Vandalism
55
Operation Section
Machine Operation
Note: The battery disconnect switch does not release
hydraulic pressure from the secondary steering
system or hydraulic pressure from the automatic
retarder control system. In order to release the
hydraulic pressure, move the engine start switch to
the OFF position. This will activate a solenoid valve
in order to release the hydraulic pressure from the
accumulators.
i02684767
Engine Shutdown Switch
SMCS Code: 7418-ZS
Illustration 59
g01349087
The engine shutdown switch (1) is located on the
lower right front side of the machine on the bumper.
Engine Shutdown Switch (1) – Use the
engine shutdown switch to stop the engine
from the ground level. In order to use the
engine shutdown switch, raise the guard. Move the
toggle switch to the OFF position. This will stop the
engine. After the engine stops, lower the guard.
Lowering the guard will turn the toggle switch to the
ON position.
During normal operation, use the engine start switch
to stop the engine.
The engine shutdown switch does not deactivate the
machine’s electrical system.
Note: The engine shutdown switch does not release
hydraulic pressure from the secondary steering
system or hydraulic pressure from the automatic
retarder control system. In order to release the
hydraulic pressure, move the engine start switch to
the OFF position. This will activate a solenoid valve
in order to release the hydraulic pressure from the
accumulators.
56
Operation Section
Machine Operation
i02790532
Product Link
(If Equipped)
SMCS Code: 7490; 7606
Product Link is a satellite communication device
that transmits information regarding the machine to
Caterpillar and to Caterpillar dealers and customers.
The device contains a Global Positioning System and
a satellite transmitter/receiver. All logged events and
diagnostic codes that are available to the Caterpillar
Electronic Technician (ET) on the CAT data link
can be sent to the satellite. Information can also
be sent to the Product Link from the satellite. The
information that is sent by the Product Link goes to
the satellite, and then to the receiving station. The
receiving station transmits the data to Caterpillar. The
information can then be sent to Caterpillar dealers
and customers.
Data concerning the machine, the condition, and the
operation is being transmitted by Product Link to
Caterpillar and to Caterpillar dealers. The information
that is transmitted may include the following: machine
serial number, location of the machine, operational
data, fault codes, emission data, fuel usage, service
meter hours, software version number, hardware
version number, and installed attachments.
Caterpillar and Caterpillar dealers may use this
information for the following: providing services to
the customer or providing services to the machine,
checking or maintaining Product Link equipment,
monitoring the machine’s health and the machine’s
performance, helping to maintain the machine and/or
helping to improve the machine efficiency, evaluating
or improving Caterpillar products and services,
complying with legal requirements and complying
with valid court orders, performing market research,
and offering the customer new products and offering
the customer new services.
Caterpillar may share the collected information with
Caterpillar companies, dealers, and authorized
representatives. Caterpillar will not sell collected
information to any third party and Caterpillar will
not rent collected information to any third party.
Caterpillar will exercise reasonable efforts to keep
the information secure. Caterpillar Inc. recognizes
customer privacy.
Note: Product Link is automatically activated when
the battery disconnect switch is in the ON position.
The system consists of three main components:
• Hardware, which includes the following, data
module, antenna, wiring, and additional mounting
hardware.
SEBU7792-03
• Satellite System and Caterpillar Network
• PC Software
This machine is equipped with a Caterpillar Prod-
uct Link communication device which must be de-
activated within 12 m (40 ft) of a blast zone. Failure
to do so could result in serious injury or death.
If the machine is required to work within 12 m
(40 ft) of a blast area, then the operator must take
one of the following precautions:
• Disconnect the Product Link module from the
power source by disconnecting the wiring harness
at the Product Link module.
• Temporarily remove the Product Link module from
the machine.
• Install an ON/OFF switch in order to allow the
Product Link module to be turned off from the
inside of the cab.
This warning does not supersede the published
requirements or the regulations that are found in “Title
30 of the Code of Federal Regulations (CFR)”. Every
operation of a mine should conduct an assessment of
hazards that meets all of the requirements of “Title 30
of the Code of Federal Regulations (CFR)”. This will
ensure safe operation in the storage, transportation,
loading, and blasting of explosive material. The
following specifications are provided in order to
aid in conducting assessments of hazards. These
specifications are also provided in order to aid in
ensuring compliance with all local regulations:
• The power of the transmitter for the Product Link is
5 to 10 Watts.
• The operating frequency range for the Product Link
is 148 - 150 MHz.
Refer to System Operation, Troubleshooting,
Testing and Adjusting, RENR7911, “Product Link
121SR/321SR” for more information about this
service tool.
SEBU7792-03 57
Operation Section
Machine Operation

Regulatory Compliance

g01349141
Illustration 61
g01131982 The service light is located on the lower right front side of the
Illustration 60
machine on the bumper.
Consult your Caterpillar dealer with any questions
that concern the operation of the Product Link in a A service light with a blue lens is visible from ground
specific country. level. This service light will alert the service person or
maintenance personnel that an event is present now
and that diagnostic information is available. There are
i02685185 two types of events that are recognized and stored.
These events are Data Events and Maintenance
Vital Information Management Events. These events will be discussed further in the
System (VIMS) manual.

SMCS Code: 7601

Note: Due to ongoing improvements in the Vital

Information Management System (VIMS), the
information that is provided here should only be used
as general guidelines. This information will change
in the future. If you find a display that does not agree
with the information that is listed here, please refer
to Special Instruction, REHS0126, “Diagnostic Code
Information for Caterpillar Electronic Control” and/or
System Operation, RENR2630, “Vital Information
Management System (VIMS)” for more detailed
information. This might refer to other service manuals
that are specific to the module that is causing the g01140240
Illustration 62
malfunction.

VIMS is designed to alert the operator of an VIMS consists of indicators (1), gauge cluster (2),
immediate problem or of an impending problem in speedometer/tachometer display (3), and display (4).
one or more of the machine systems. The abnormal
conditions are called events. Data from the sensors
on the machine is stored and analyzed by VIMS.
58 SEBU7792-03
Operation Section
Machine Operation

Indicators
Retarder ON (11) – This indicator will be
ON when the Automatic Retarder Control
(ARC) is ON. The indicator will also be on
when you use the manual retarder or the service
brake. This indicator will also be ON for 3 seconds
during powerup in order to permit the operator to
know that the indicator is functioning properly. It is
important for the operator to visually inspect this
indicator. If the indicator does not come on during
powerup, or if the indicator glows dimly during
powerup, or if the indicator remains ON and the
service brakes are not being used, find the cause
immediately.

g01140294 Traction Control System ON (12) – This

Illustration 63
indicator will be ON when the Traction
Control System (TCS) is engaging. This
Left Turn (5) – This indicator will be ON
indicator will also be ON for 3 seconds during
when the external lights are signalling a left
powerup in order to permit the operator to know that
turn.
the indicator is functioning properly. It is important
for the operator to visually inspect this indicator. If
Dump Body UP (6) – This indicator will the indicator does not come on during powerup, or
be ON when the sensor on the rear of the if the indicator glows dimly during powerup, or if the
truck determines that the dump body is not indicator remains ON and the TCS is not ON, find the
completely DOWN. This indicator will also be ON cause immediately.
for 3 seconds during powerup in order to permit the
operator to know that the indicator is functioning
properly. It is important for the operator to visually Gauge Cluster
inspect this indicator. If the indicator does not come
on during powerup, or if the indicator glows dimly
during powerup, or if the indicator remains ON and
the dump body is completely DOWN, find the cause
immediately.

Reverse (7) – This indicator will be ON

when the transmission direction and speed
control lever is in the REVERSE position.

High Beams ON (8) – This indicator will

be ON when the headlights are set on high
beam. See Operation and Maintenance
Manual, “Multifunction Switch” for additional
information. Illustration 64
g01140360

Right Turn (9) – This indicator will be ON Engine Coolant Temperature (13) – This
when the external lights are signalling a indicates the engine coolant temperature.
right turn. The red range indicates overheating.

Action Light (10) – This indicator will Brake Oil Temperature (14) – This
be ON when a condition that requires the indicates the brake oil temperature. The red
operator to take action is present. Warning range indicates overheating.
Category 2 and Warning Category 3 trigger the action
light. See “Warning Categories” for additional details System Air Pressure (15) – This indicates
on the warning categories. the system air pressure. The red range
indicates low air pressure.
SEBU7792-03
Fuel Level (16) – This indicates the
amount of fuel in the fuel tank. Add fuel
when the gauge indicates in the red range.
Speedometer and Tachometer
g01140374
Illustration 65
Tachometer (17) shows the engine speed.
Speedometer (18) consists of three digits. The
ground speed indicator shows the ground speed of
the machine in kilometers per hour or miles per hour.
Actual Gear Indicator (19) of the transmission
consists of two digits. The two digits indicate the
actual transmission gear that is engaged. The left
digit is the actual gear. The right digit shows the
direction that was selected.
Display
g01140378
Illustration 66
The display provides the operator with information
about events from the machine systems.
Categories of Events
There are two types of events.
59
Operation Section
Machine Operation
• Data Events
• Maintenance Events
A Data Event occurs when the machine is operating
outside of the normal limits. Message area (22) will
provide instructions.
The second row of text in message area (22) will
display the necessary action of the operator.
A Maintenance Event occurs when internal
diagnostics determine that there is an electrical fault.
The maintenance event is shown in message area
(22). The display will show “ERROR” and “CALL
SHOP”.
The service codes MID Module ID #, CID (Component
ID #), and FMI (Fault Mode ID #) will be shown to
the service technician if the “F1” key on keypad (23)
is pressed.
For troubleshooting system events, the service
technician should use the latest version of
Troubleshooting, Testing and Adjusting, RENR2631,
“Vital Information Management System (VIMS)” for
more detailed current information.
Warning Categories
VIMS provides three warning categories. The first
category requires only operator awareness. The
second warning category states that the operation
of the machine or the maintenance procedure for
the machine must be changed. The third warning
category states that the machine must be safely shut
down immediately.
The warning category of an event may be raised to a
highercategory automatically. Event duration is used
in order to determine if a change in the category
is necessary. An example of an event that would
require a category change: The category 2 warning
for the transmission lubrication temperature changes
to a category 3 warning after 150 seconds.
The following information is recorded in the event
list for each event:
• Time of occurrence
• The number times the event was acknowledged.
• The machine’s location
• Warning Category 1
60 SEBU7792-03
Operation Section
Machine Operation

In this category, alert indicator (20) will flash.

Information will be shown in message area (22). If
applicable data exists, the data will also be shown
on universal gauge (21). The operator must be
aware that a machine system requires attention. The
message area will display the recommended action.
The “OK” key on keypad (23) can be used in order
to acknowledge the warning. When this warning
category is acknowledged, the warning will pause for
a predetermined time period. After this time period,
if the abnormal condition is still present, the warning
will reappear. These warnings may be acknowledged
again.

• Warning Category 2
In this category, alert indicator (20) and action light
(10) will flash. Information will be shown in message
area (22). If applicable data exists, the data will
also be shown on universal gauge (21). This warns
the operator that a change in machine operation is
required in order to avoid possible damage to the
indicated system. The message area will display the
recommended action. The “OK” key on keypad (23)
can be used in order to acknowledge the warning.
When this warning category is acknowledged, the
warning will pause for a predetermined time period.
After this time period, if the abnormal condition is still
present, the warning will reappear. These warnings
may be acknowledged again.

• Warning Category 2-S (severe category 2)

In this category, alert indicator (20) and action
light (10) will flash and the action alarm will sound
continuously. A category 2-S indicates that the
operator should immediately change the operation
of the machine. When this change is made to the
acceptable condition, the action alarm will cease. A
category 2-S warning will not pause.

• Warning Category 3
In this category, alert indicator (20) and action
light (10) will flash and the action alarm will sound
intermittently. Information will be shown in message
area (22). If applicable data exists, the data will also
be shown on universal gauge (21). This message
states that the machine must be safely shut down
immediately in order to avoid damage to the machine
or personal injury. A category 3 warning will not
pause.

Do not operate the machine until the cause has been

corrected.
SEBU7792-03 61
Operation Section
Machine Operation

Warning Operation
Table 2
Warning Operation
Warning Warning Indications(1) Required Action from the Possible Result(2)
Category Operator
Alert Indicator Action Light The Action
Flashes. Flashes. Alarm
Sounds.
No immediate action is No harmful effects or
1 X required. The system damaging effects will
needs attention soon. occur.
Change machine operation Damage to machine
2 X X or perform maintenance to components will occur.
the system.
Immediately change Severe damage to
2-S X X X(3) machine operation. machine components
will occur.
Immediately perform a safe Injury to the operator
3 X X X(4) engine shutdown. or severe damage to
components will occur.
(1) The active warning indications are marked with an X.
(2) If the required action is not carried out, the following results will occur.
(3) The sound from the action alarm will be steady.
(4) The sound from the action alarm will pulsate.

Engine Shutdown Events • A warning category 2 will occur when the engine
oil level is low and the engine is running. The
VIMS has the ability to stop the engine when any message center for VIMS will inform the operator
one or more of the following engine shutdown events of low engine oil level. The message center will
exist: also instruct the operator to add oil immediately.

• Low engine oil level • A warning category 3 will occur when the engine
oil pressure is low and the engine is running. The
• Low engine oil pressure message center for VIMS will inform the operator
of low engine oil pressure. The message center
• Low engine coolant level will also instruct the operator to stop the engine
immediately.
• High engine coolant temperature
• A warning category 2 will occur when the engine
All of the following conditions must also be met coolant level is low and the engine is running. The
before an engine shutdown event will cause VIMS message center for VIMS will inform the operator
to shut down the engine: of a low engine coolant level. The message center
will also instruct the operator to add coolant.
• The engine has been running longer than 20
seconds. • A warning category 2 will occur when the engine
coolant temperature is high and the engine is
• The engine must be at low idle or elevated low idle. running. The message center will inform the
operator of high engine coolant temperature. The
• The ground speed must be zero. message center will also instruct the operator to
reduce the load on the engine.
• The parking brake must be in the ON position.
Operation
The following events will warn the operator before
VIMS will shut down the engine: If the engine is stopped, and one or more engine
shutdown events is active, VIMS will allow the engine
to be started. After the engine is started, the following
conditions must exist before VIMS can shut down
the engine.
62
Operation Section
Machine Operation
• The engine must be at low idle or elevated low idle.
• The ground speed must be zero.
• The parking brake must be in the ON position.
If these conditions exist for 20 seconds after the
engine is started, VIMS will ask the Engine Electronic
Control Module (Engine ECM) to stop the engine.
If the operator uses the accelerator control to
increase the engine speed or if the operator places
the parking brake control in the OFF position, VIMS
will not stop the engine. VIMS assumes that an
operator is in control of the machine.
If one or more engine shutdown events occurs during
machine operation, VIMS will not stop the engine.
VIMS will alert the operator of the abnormal machine
condition.
VIMS will then ask the Engine ECM to shut down the
engine when the following conditions are met:
• The engine has been running longer than 20
seconds.
• The engine must be at low idle or elevated low idle.
• The ground speed must be zero.
• The parking brake must be in the ON position.
If the engine is shutdown because of an engine
shutdown event, the event list in VIMS will show
the event that caused the shutdown. An unknown
event will follow this event. The unknown event is
the request by VIMS to the Engine ECM in order to
stop the engine.
VIMS Self Test
Illustration 67
g01140642
In order to check the operation of VIMS, observe the
self test when the engine start switch is turned from
the OFF position to the ON position.
SEBU7792-03
VIMS will perform an automatic self test at start-up
whenever the engine start switch is turned to the ON
position. First, VIMS calibrates the gauge cluster and
the tachometer. Before the beginning of the system
test, the gauge cluster and the tachometer go from
the initial value to zero. Then, VIMS performs a test.
The self test is a test of the display components. The
self test will last for 4 - 6 seconds. The action alarm
will sound during this self test. The action light will be
powered during the self test. The backlighting of the
ground speed readout and of the actual gear readout
will be powered during the self test. The backlighting
of the message center will be powered during the self
test. It is important for the operator to visually inspect
the LED lights during the self test. If the LED lights do
not come on during powerup, or if the LED lights glow
dimly during the self test, find the cause immediately.
The following series of events will occur during the
self test of VIMS:
• Alert indicator (20) flashes.
• Data logging indicator (24) scrolls.
• Universal gauge (21) starts at zero and sweeps
to full scale.
• Gauge warning area (25) that is on each end of the
universal gauge is turned to the ON position.
• Message area (22) shows the following information:
Configuration software – Several numbers and/or
letters followed by a “C”.
Source code software – Several numbers and/or
letters followed by a “S”.
Hardware – Several numbers and/or letters followed
by an “H”.
• The level of the tachometer rises from zero to the
top of the scale. Then, the level of the tachometer
returns to zero or to the current engine rpm.
• The ground speed indicator turns on every
segment of the readout. Then, the readout appears
to read “188”.
• The actual gear indicator for the transmission turns
on every segment of the readout. Then, the readout
appears to be a “0” with an “X” and a “+” sign on top
of the “0”. There should be two of these symbols.
• The external lights for the payload blink.
• The action light is continually on.
• The action alarm SOUNDS.
SEBU7792-03 63
Operation Section
Machine Operation

• The gauge cluster goes from zero to the top of the i02344922
scale. Then, the level of the gauge cluster shows
the current values of the machine. Vital Information Management
System (VIMS) Keypad
• The service light flashes one time if no events are
present. The service light flashes three times if any SMCS Code: 7601
events are logged.

If all of the checks and all of the fluid levels are

correct, the time and the service meter hours will be
displayed on message area (22).

If the above test is completed, turn the engine start

switch to the START position.

If the test is not completed or problems are noted,

consult your Caterpillar dealer.

Message area (22) will display the time and the

service meter hours when the engine is running and
when no events are present.

If an event is present, message area (22) will show

information about the event. If applicable data exists,
the data will also be shown on universal gauge (21).
Check the fluid and/or the electrical system that was
indicated. Make all necessary repairs before starting
the engine.

g01177548
Illustration 68
(1) Alert indicator
(2) Message center module
(3) Data logging indicator
(4) Gauge warning area
(5) Universal gauge
(6) Message area
(7) “F1” key
(8) “F3” key
(9) “ID” key
(10) “F2” key
(11) Forward key
(12) Backward key
(13) “GAUGE” key
(14) “OK” key
(15) Indicator light
(16) Keypad

The Vital Information Management System (VIMS)

uses keypad (16) to allow the operator to request
information. The keypad controls the display of text
in message area (6).

Indicator light (1) will flash whenever a key is

pressed. The indicator light informs the operator that
the command has been accepted.
64 SEBU7792-03
Operation Section
Machine Operation

Some information can be requested by using the TEST – Entering 8378 will run the self test of the
numbers on the keypad . The series of numbers is VIMS. Refer to Operation And Maintenance Manual,
called a Service Program Code. The letters that are “Vital Information Management System (VIMS)” for
associated with the numbers describe the requested additional information about the self test of the VIMS.
operation of the Service Program Codes.
BLT – Entering 258 will cause the intensity of
Note: After entering the Service Program Code on the message area to begin scrolling by 5 percent
the keypad, the code must be completed by pressing increments. The corresponding percentage of the
“OK” key (21). intensity is displayed in the message area. Use
Backward key (14) and Forward key (15) in order to
The following table contains the Service Program select the desired intensity. Press “OK” key (8) in
Codes that are needed by the operator. Refer order to accept the new selection.
to Service Manual, RENR2630 and RENR2631,
“785 - 797 Off-Highway Trucks Vital Information CON – Entering 266 will cause the contrast of
Management System” for additional Service Program the message area to begin scrolling by 5 percent
Codes. increments. The corresponding percentage of the
contrast is displayed in the message area. Use
Table 3 Backward key (14) and Forward key (15) in order to
Service Program Codes select the desired intensity. Press “OK” key (8) in
order to accept the new selection.
Numbers Letters Description
52 LA Change the Language. Keys
86 UN Metric Units or English Units
868 TOT View the Cumulative Data.
“OK” Key
73738 RESET Reset the Cumulative Data. “OK” key (21) is used in order to indicate that entries
are complete. This key is also used in order to
3564 DLOG Log the Data or Stop Logging
the Data.
acknowledge all events.

8378 TEST Test of the VIMS “F1” Key

258 BLT Backlighting Intensity of the
Message Area
266 CON Contrast of the Message Center
LA – Entering 52 causes the text in the message
area to toggle between two languages.
UN – Entering 86 toggles between Metric units and
English units.
TOT – Entering 868 shows the total number of loads,
the total payload, the total travel distance, and the
total travel time. This data is called the cumulative
data. The cumulative data can be reset. The totals
since the last reset will be listed. Scroll through the list
with Forward key (24) and with Backward key (23).
RESET – Entering 73738 clears the cumulative data.
DLOG – Entering 3564 will cause the VIMS to start
logging data. If the VIMS is already logging data,
entering 3564 will cause the VIMS to stop logging
data. Data logging indicator (9) will be ON when
the VIMS is logging data. The data from all of the
parameters will be recorded. The data is stored
in a file and the file can be downloaded by using
the VIMS-PC software for analysis of the machine
systems.
“F1” key (20) is used by the operator in order to
request additional information about a data event.
There are two types of events. Data events warn the
operator that the value of a monitored parameter is
not in the specified range. Maintenance events warn
the operator about electrical problems.
When a data event is displayed in message area
(6), pressing the “F1” key will show the actual data
about the condition. For example, if the condition is
high temperature, pressing the “F1” key will show the
value of the temperature.
When a maintenance event is displayed in the
message area, pressing the “F1” key will display the
diagnostic code information. See Service Manual,
RENR2630 and RENR2631, “785 - 797 Off-Highway
Trucks Vital Information Management System”
and Special Instruction, REHS0126, “Caterpillar
Electronic Control Codes”for a complete list of MID
values, of CID values and of FMI values.
Note: The switches do not have any CID or FMI
diagnostic information. The message area will
show the state of the switch. Some examples of
information that will be shown on the message area
are “CLOSED”, “OPEN”, “NEUTRAL” and “UP”.
SEBU7792-03 65
Operation Section
Machine Operation

Forward Key and Backward Key (Table 4, contd)

Lt Exh Temp 106
Backward key (23) and Forward key (24) allow
scrolling forward or backward in order to display rows Rt-Lt Exh Temp 107
of text in message area (13). Rt Exh Temp 108
F Aftclr Temp 111
“GAUGE” Key
R Aftclr Temp 112
“GAUGE” key (22) is used to determine the measured
Wastegate Pos 114
value of a particular parameter. The value will be
shown in message area (13). The value will also be Cool Fan Spd 115
shown on universal gauge (11) in message center
Cold Mode 116
module (6).
Eng Derate 117
When the “GAUGE” key is pressed, the following
Air Fltr 118
information is shown in the message center module:
Eng Load 121
• The name of the parameter and the ID of the Fuel Fltr 122
parameter are displayed in the first row of text.
Fuel Lvl 123
• The value of the parameter and the corresponding Throttl Pos 125
units are displayed in the second row of text.
Eng Fuel Rate 129
• The universal gauge displays the value on an Eng Oil Lvl 130
analog gauge.
Eng Oil Pres 131
This information is shown for one parameter at a
Cnkcase Pres 133
time. Use the Forward key and the Backward key to
scroll through the available parameters. Eng Cool Flow 134
Eng Cool Temp 135
Each parameter has an identification number so
that specific information can be requested. To view Aftclr Lvl 137
specific parameter information, enter the identification
Eng Cool Lvl 138
number. Then press the “GAUGE” key.
Sys Voltage 140
Parameter information remains on the message
center until “OK” key (26) is pressed. Default data Hi Boost Pres 145
(time of day and service meter hours) is then shown. Lo Boost Pres 146

The following items are the available parameters Cnkcase Pres 147
and the corresponding identification numbers of the Total Fuel 187
parameters:
Eng Fan Spd #1 197
Note: The parameters that are available on
individual machines may differ slightly. Eng Fan Spd #2 198
Table 4
Parameter Information of the VIMS Rt-Lt Fan Spd 199
Name of the Parameter Identification
Number of the Eng Fan Temp 200
Parameter
Eng Spd 100 RAX Dvrt Sol St 229
Lt Trbo In Pres 102 TC Filter 310
Rt Trbo In Pres 103 TC Out Spd 311
Air Fltr 104 312
TC Screen
Boost Pres 105
TC Out Temp 313
(continued)
(continued)
66 SEBU7792-03
Operation Section
Machine Operation

(Table 4, contd) (Table 4, contd)

Diff Temp 325 Eng Fan Spd 520
Diff Fltr Sw 327 RtF-LtF Susp Cyl 710
Diff Lube Pres 328 RtR-LtR Susp Cyl 711
Trn Lockout St 340 Lt F Susp Cyl 720
Trn Gear 349 Lt R Susp Cyl 721
Trn Lube Temp 350 Rt F Susp Cyl 722
Gear Select 351 Rt R Susp Cyl 723
Actual Gear 352 Body Angle 724
Trn Out Spd 355 Ground Spd 725
Trn Chrg Fltr 356 Body Pos 726
Trn Lube Fltr 357 Body Lvr 727
Trn Slip 358 Payload 728
Lckup Slip 359 Payload Status 729
Brk Pump Spd 377 Haul Distance 730
Retarder 380 User Shutdown 742
Brk Lockdn 382 Auto Lube 751
Lt R Wheel Spd 418 Atmos Pres 790
Rt R Wheel Spd 419 Amb Air Temp 791
Mach Lock Sw 432 Machine Pitch 792
RtR-RtF BrkTemp 436 Machine Rack 793
LtR-LtF BrkTemp 437 Hoist Lvr Pos 798
Strg Pmp Pres 440 Hoist Status 799
Lo Strg Pres 441 VIMS Event List 800
Hi Strg Pres 442 Payload Data 801
Strg Oil Temp 444 VIMS Snapshot 802
Brk/Air Pres 452 Diff Pres Lo 812
ParkBrk 453 Max Bias/Sec 849
Brk Fltr 454 Max Pitch/Sec 850
Brk Stroke 456 Max Rack/Sec 851
Lt F Brk Temp 460 Cycle P Fela 852
Lt R Brk Temp 461 Manual Erec 860
Rt F Brk Temp 462 Cycle R Fela 862
Rt R Brk Temp 463 Fela Trigger 869
RtF-Ltf Brk Temp 464 Lo Oil Pres 907
RtR-LtR Brk Temp 465 Tkph F Tires 983
ParkBk FltrSw 466 Tkph R Tires 984
Eng Oil Fltr 485 Tkph F Warn 986
ParkBk Fltr Sw 493 Tkph R Warn 987
Hoist Screen 505 Trn Oil Lvl 1022
Diff Oil Lvl 513 Retatder Mode 1023
(continued)
SEBU7792-03 67
Operation Section
Machine Operation

If an event occurs, the message area will display i02242653

information about the event. After the problem is
corrected, the display in the message area will revert Backup Alarm
to the former display. Events will always override
parameter values. SMCS Code: 7406

“ID” Key
“ID” key (26) is used to enter the operator’s
identification number.

If this is required, this identification number should be

entered at the beginning of an operator’s shift.

When the “ID” key is pressed, a prompt for “ENTER

ID” will be shown on the first row of text in the
message area. The operator may enter an ID number
up to seven digits long on the second row.

If “OK” key (21) is not pressed within five seconds Illustration 69

after the last number is entered, the identification
number will not be recorded. Then, the display will
return to the previous condition.
If the “ID” key is pressed during the entry, the current
entry will be cancelled and the process will start
again. This is helpful if a mistake is made during the
entry. Backward key (23) will delete the last number
of the entry.
g01130536
Location of the backup alarm
The backup alarm sounds when the transmission is in
the REVERSE position. The alarm alerts the people
behind the machine that the machine is backing up.
The backup alarm is on the rear of the machine at
the center of the machine.

“F2” Key and “F3” Key i02304953

“F2” key (25) and “F3” key (27) are not currently used
Fast Fill Service Center
in this application. (If Equipped)
SMCS Code: 7513

g01154427
Illustration 70

(1) Port for Steering/Fan Drive Oil

68 SEBU7792-03
Operation Section
Machine Operation

(2) Port for Jacket Water Coolant
(3) Port for Hoist and Brake Oil
(4) Port for Autolube Reservoir
Power switch (18) controls the amount of oil flow.
Move the switch to the top position in order to begin
the fill. Move the switch to the middle position in order
to stop the fill. Move the switch to the bottom position
in order to test the system.

(5) Level Indicator for Transmission and Torque
Converter Oil (Full Volume Below Operating
Temperature)
(6) Level Indicator for Hoist and Brake Oil (Full
Volume Below Operating Temperature)
(7) Level Indicator for Hoist and Brake Oil (Full
Volume at Operating Temperature)
(8) Level Indicator for Transmission and Torque
Converter Oil (Full Volume at Operating
Temperature)
Note: There is no indicator lamp in order to show a
full fuel level. Air is released through the vent while
the tank is filled. When the tank reaches the full level
the check valve inside the fuel tank closes. This
creates pressure within the fuel tank. A piston that is
operated by a diaphragm starts to shut off the fuel
flow at approximately 37.9 kPa (5.50 psi). The line
pressure brings the nozzle to the OFF position.
Refer to Specifications, System Operation,
Troubleshooting, Testing and Adjusting, RENR8387,
“793 Off-Highway Truck Fast Fill Service Center” for
more information on the Fast Fill Service Center.

(9) Level Indicator for Jacket Water Coolant (Full

i02571807
Volume)

(10) Port for Transmission and Torque Converter Oil

Braking
SMCS Code: 4250; 4251; 4278; 4284
(11) Port for Aftercooler Coolant

(12) Port for Engine Oil Parking Brake

(13) Port for Diesel Fuel
(14) Level Indicator for Engine Oil (Full Volume with
Engine On)
(15) Level Indicator for Steering and Common
Cooling System Oil (Full Volume with Engine
Stopped)
NOTICE
Do not use the parking brake to stop the machine.
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.

(16) Level Indicator for Aftercooler Coolant (Full

Volume)

(17) Level Indicator for Autolube Reservoir (Full

Volume)

(18) Power Switch for the Fast Fill Service Center

The control box for the Fast Fill Service Center is

mounted on the left side of the front bumper of the
machine. The Fast Fill Service Center is designed
in order to keep dirt and mud from contaminating
your fluid systems. The system minimizes fluid loss
during disconnection. The control box contains eight
g01171333
fluid fill ports. The operator or the service personnel Illustration 71
will connect the couplings to these ports. Each port
corresponds to the eight fluids that are serviced by When the air system is drained, parking brake reset
the system. The hoses for the fluids are connected to valve (1) will not allow the parking brake to be
the back of the control box. The hoses then run to the released until the parking brake reset valve has been
designated reservoirs. The full fluid level is monitored reset.
by a fluid level sensor that is located at each of the
fluid reservoirs. The level indicators will illuminate
when the reservoir is full.
SEBU7792-03
Move parking brake control (switch) (2) to the OFF
position in order to release the parking brake. Move
the parking brake switch to the ON position in order
to engage the parking brake.
The parking brake switch is located on the console
next to the transmission control. Use the parking
brake switch to engage or disengage the parking
brake when you park the machine.
This machine is equipped with spring-applied parking
brakes. The spring force engages the brakes on all
four wheels. Hydraulic pressure is used to disengage
the brakes. If hydraulic pressure is unavailable, the
brakes will remain engaged.
g01171334
Illustration 72
If hydraulic pressure is unavailable and the machine
must be towed, use brake release control (3) in
order to disengage the parking brake. For further
information, refer to Operation and Maintenance
Manual, “Towing with Inoperable Engine” or consult
your Caterpillar dealer.
Service Brake
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
spring pressure.
g01171335
Illustration 73
69
Operation Section
Machine Operation
During normal operation, depress service brake
control (pedal) (4) in order to stop the machine. Also,
depress the pedal in order to slow the machine.
Note: Do not use the service brake for the purpose of
maintaining the machine speed on a long downgrade.
Use the automatic retarder control and/or the manual
retarder control in order to maintain the machine
speed on a long downgrade. On long downgrade
conditions, the retarder controls provide the operator
with the ability to better regulate the amount of
retarding force. Refer to Operation and Maintenance
Manual, “Retarding” for more information on the
retarder controls.
The service brake pedal applies all four wheel
brakes. The pedal is fully variable. The amount of
braking force depends on the position of the pedal.
Secondary Brake
To avoid the possibility of a unexpected machine
movement when parking on a slope, always block
the wheels securely before leaving the machine
unattended.
If the secondary brake system is required in order
to stop the machine, do not operate the machine
until a complete check has been made of the en-
tire braking system and until all necessary repairs
have been made.
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.
g01171339
Illustration 74
The secondary brake will stop the machine in the
event of any single failure of the service brake. The
secondary brake pedal (5) applies all four wheel
brakes. The pedal is fully variable. The amount of
braking will depend on the position of the pedal.
70
Operation Section
Machine Operation
If a failure of the service brake occurs, the operator
will be warned and the secondary brake will provide a
limited amount of braking. The VIMS warning system
will alert the operator with a category 3 warning. This
warning states that the machine must be safely shut
down immediately in order to avoid damage to the
machine or personal injury. Refer to Operation and
Maintenance Manual , “Vital Information Management
System (VIMS)” for additional information.
The secondary brake will provide sufficient braking
capacity in order to stop the machine one time, in
accordance with ISO 3450 testing. The secondary
brake operates in forward and reverse.
i02344464
Changing Direction and Speed
SMCS Code: 1000; 7000
NOTICE
To avoid striking overpasses, electrical power lines
and obstructions, always lower the body before mov-
ing the machine.
NOTICE
The machine must be stopped and engine at low idle
before changing directions.
After moving the shift lever, do not accelerate until af-
ter hearing or feeling the transmission clutches en-
gage.
Illustration 75
g01171083
Use transmission control lever (1) to select
FORWARD, NEUTRAL and REVERSE transmission
speeds.
Make sure that the machine is stopped and that
the engine is at low idle when you change direction
between FORWARD and REVERSE, or between
REVERSE and FORWARD.
SEBU7792-03
When you move the transmission control lever
from NEUTRAL to any forward speed, first gear is
engaged. At low ground speeds, the machine will be
in torque converter drive.
When the engine accelerates and the ground speed
increases, the transmission automatically upshifts.
During higher ground speeds of first gear and of other
forward gears, the lockup clutch will be engaged.
Then, the machine is in direct drive. During shifts, the
machine will be in torque converter drive.
While the machine is in motion, moving the
transmission control lever to a higher gear will not
force an upshift. Shifting of the transmission is
governed by ground speed.
When the ground speed and the engine speed are
reduced by an increased load or by deceleration,
the transmission automatically downshifts. The
transmission downshifts one gear at a time in order
to select the correct gear.
A downshift inhibitor prevents the machine from
forcing a downshift. When the machine is in motion
and transmission control lever (1) is moved to a
lower gear, the transmission will not force a sudden
downshift. The transmission will not downshift until
the proper ground speed is achieved.
Shift Inhibiting
Use the Electronic Control Analyzer Programmer
(ECAP) or the Electronic Technician (ET) to program
the gear limit. See Service Manual, SENR1502,
“Power Train Electronic Control System” for additional
information.
Shifting is limited in the following situations: limiting
machine speed, engine overspeed protection,
coasting in neutral, management of directional shifts,
limiting top gear, reverse neutralizer, limiting body up
gear, and differential oil temperature.
Engine Overspeed Protection
If the engine speed reaches 2100 rpm, the alert
indicator and the action alarm of the Vital Information
Management System (VIMS) will activate. When
the engine speed reaches 2150 rpm, the Automatic
Retarder Control (ARC) will automatically begin to
apply the brake. If the engine speed reaches 2300
rpm, the transmission will upshift to the next higher
gear. If the transmission is in the highest gear and the
engine speed reaches 2300 rpm, the torque converter
will shift into TORQUE CONVERTER DRIVE in order
to protect the power train from engine overspeed.
NOTICE
Do not exceed 2300 rpm or engine damage can result.
SEBU7792-03 71
Operation Section
Machine Operation

Coasting in Neutral
The transmission will not shift into NEUTRAL if the
machine speed is above 8 km/h (5 mph).
Management of Directional Shifts
If the transmission is in a forward gear and the
transmission control is moved into the REVERSE
position, the transmission will remain in forward gear
until the machine speed is below 8 km/h (5 mph).
Then, the transmission will shift into NEUTRAL.
The transmission will not shift from NEUTRAL into
REVERSE until the machine speed is below 3 km/h
(2 mph).
Limiting Top Gear
The machine will not operate above THIRD gear until
the temperature of the oil in the differential is above
−4 °C (25 °F). The machine will not operate above
FOURTH gear until the temperature of the oil in the
differential is above 38 °C (100 °F).
i02343864
Retarding
SMCS Code: 3121; 7000
NOTICE
Do not use the retarder control as a parking brake.
Do not use the retarder control to stop the ma-
chine.

The transmission will not shift to a gear above the

selected top gear limit. The machine comes from the
factory with the highest gear as the top gear limit.
The top gear limit can be programmed to SIXTH gear Aggressive application of retarder capacity in slip-
through FOURTH gear. Use the Electronic Technician pery conditions may cause loss of operator con-
(ET) to change the top gear limit. trol and/or power train damage. Apply the retarder
gradually in slippery conditions. Serious injury or
Reverse Neutralizer death may occur if the retarder is applied too ag-
gressively in slippery conditions.
If the body is raised and the transmission is in
REVERSE, the transmission will shift into NEUTRAL.
The transmission will not shift into REVERSE until the Retarder Control
body is lowered completely and until the transmission
control is moved into NEUTRAL. The hoist control
must also be in the HOLD or FLOAT position.

The reverse neutralizer has no effect on forward

gears. If necessary, the forward gears can be
engaged from either neutral or reverse gear.

Limiting Body Up Gear

This function limits the gear of the machine while the
body is up. The gear is limited until the body position
sensor tells the ECM that the body is DOWN. The
chassis ECM prevents upshifting to any gear higher
than the stored value. The value of the gear limit is
programmable by the service personnel. Use the ET
service tool. The allowed range for this gear limit is
FIRST gear to THIRD gear. The value of the factory
setting for the gear limit is FIRST gear.
Note: the transmission will not operate above the
programmed gear until the body is completely down.
Differential Oil Temperature
At start-up, the shifting of the transmission will be
limited until the differential oil reaches the operating
temperature range.
Illustration 76
g01169966
The retarder system allows the machine to maintain
a constant speed on long downgrades.
The retarder will not apply all of the normal braking
capacity.
Retarder Control (Lever) (1) – Move
retarder lever (1) downward in order to
apply the retarder. Move the lever upward
in order to release the retarder. The position of the
lever determines the amount of retarding force. As
you move the lever downward, retarding force will
increase.
72
Operation Section
Machine Operation
Automatic Retarder Control (ARC)
g01169968
Illustration 77
When the proper gear is selected during Automatic
Retarder Control (ARC) operation, machine speed
and engine speed will be automatically regulated.
When the transmission shifts to the selected gear
and the engine rpm increases to 1900 rpm, the ARC
will apply the retarder in order to maintain the engine
speed at 1900 ± 50 rpm. Use retarder lever (1) in
order to apply additional retarding during operation
of the ARC.
Automatic Retarder Control (ARC) (2) –
Push the top half of switch (2) in order to
select the ON position for the ARC. Push
the bottom half of the switch in order to select the
OFF position for the ARC.
The switch for the ARC should remain in the ON
position during all normal operation. When you place
the switch in the OFF position, the ARC will not
control the engine speed during normal operation.
However, the ARC will override the switch if the
engine speed is too high. See the Operation and
Maintenance Manual, “Changing Direction and
Speed” in order to learn more about the engine
overspeed protection.
Manual Retarding
Travel at a constant machine speed. Do not speed
up immediately before you retard the machine. Do
not try to do all the retarding at the bottom of a hill.
Keep retarding steady and keep the machine speed
under control.
Never coast down a grade in NEUTRAL. Always keep
the transmission in gear. When the machine speed
is greater than 8 km/h (5 mph), the Power Train
Electronic Control System will not allow you to shift
from forward gear into NEUTRAL or into REVERSE.
1. Make sure that switch (2) for the ARC is in the ON
position during all normal operation.
SEBU7792-03
g01170003
Illustration 78
2. Select the proper gear on transmission control (3)
before you start down the grade. The actual gear
should also match the selected gear before you
start down the grade.
Note: Determine the proper gear for the conditions,
the load, and the downgrade. If you do not know the
proper gear, use the common practice of selecting
the gear that is required to go up the grade when the
machine is loaded.
3. Maintain a constant machine speed.
4. If the machine builds up excessive speed during
retarding, the engine can overspeed. Use the
manual retarder lever in order to reduce the
machine speed.
Note: The machine is equipped with automatic
overspeed protection. See Operation and
Maintenance Manual, “Changing Direction and
Speed” for further information on the operation of the
overspeed protection.
a. Adjust lever (1) in order to maintain a proper
rpm and a constant speed. If skidding is
experienced, ease off the lever.
b. Avoid repeated engaging and disengaging of
the lever.
c. If braking is needed, depress the service brake
control (pedal).
SEBU7792-03
g01169975
Illustration 79
5. Frequently observe the brake oil temperature
gauge (4). Keep the brake oil temperature in the
normal range.
6. If the brake oil temperature is high after travelling
down the grade, select a lower gear when you
travel down that grade again.
7. If the needle enters the red range on the gauge,
the oil cooler capacity has been exceeded.
Reduce the load on the machine or slow the
machine speed.
Retarding Guidelines
The maximum operating weight of a loaded 793D
Off-Highway Truck is 383740 kg (846000 lb).
Illustration 80
g01171647
Retarding capabilities for the standard machine configuration
73
Operation Section
Machine Operation
g01170743
Illustration 81
Retarding capabilities for the additional retarding configuration
The film that shows the retarding capabilities for your
machine’s configuration is located on the inside of the
cab. Refer to Operation and Maintenance Manual,
“Additional Messages” for more information. The
retarding capabilities that are listed on this film are
based on an ambient temperature of 32 °C (90 °F).
The actual retarding capabilities for each gear will
vary depending on the following conditions: outside
temperatures, rolling resistance, load, the condition
of the cooling system, tire size, and altitude.
Engine speed that is relative to ground speed will
vary due to differences in tire size between brands
and types.
Do not exceed an engine speed of 1950 rpm.
i02343496
Operation Information
SMCS Code: 7000
Loading
Take care when you drive into the loading area.
Maintain a safe distance from the machine in front of
your machine.
Avoid hitting sharp rocks and overflow.
Position the machine on level ground. Stop the
machine and park the machine. See Operation and
Maintenance Manual, “Stopping the Machine”for the
recommended procedure.
74
Operation Section
Machine Operation
g01169364
Illustration 82
Keep hoist control (4) in the FLOAT position during
the loading of the machine. Also, keep the hoist
control in the FLOAT position when the machine
travels.
Use service brake pedal (1) in order to stop the
machine.
Move transmission control (lever) (2) to the
NEUTRAL position. Move parking brake switch (3)
to the ON position.
The operator of the machine should stay in the cab
while the truck is being loaded.
Note: Do not load any material on the canopy of the
body.
The Truck Payload System calculates the weight of
the material as the material is being loaded into the
truck.
A new payload cycle starts when the truck finishes
dumping the previous payload and the truck dump
body is fully down.
Do not put the machine in gear before the last portion
of the load has been recorded on the display. This
may affect the accuracy of the payload weight.
SEBU7792-03
The truck can be repositioned during loading. If the
truck moves more than 160 m (525 feet), the Truck
Payload System will believe that the loading cycle
is completed. Also, the additional loader passes will
not be recorded.
The Truck Payload System measures the load by
using the pressures of the suspension cylinder.
The truck may bounce during loading which will delay
the display of the payload.
The display will show no weight until the suspension
cylinder pressure stabilizes and the truck is full
enough to get an accurate weight.
Payload Status Lamps (If Equipped)
g01177009
Illustration 83
• As the truck is being loaded, green payload status
lamps (5) will illuminate. The “Loading” message
and the payload weight will be displayed on the
VIMS message center inside the cab.
• When the payload measurement system
determines that 95 percent of the target weight will
be achieved with another pass with the loading
equipment, red lamps (6) will begin to flash. The
VIMS message center will display “Last Pass”.
• When the payload weight reaches 95 percent or
more of the target weight, the red lights will stay on
continuously and the VIMS message center will
display “Fully Loaded”.
• The payload measurement system measures the
weight of the load again once the truck has exited
the load site. The measurement is made when the
truck has shifted into second gear. The payload
status lamps will turn off and the VIMS message
center will display the “Payload” message and the
final payload weight.
• The payload information automatically disappears
from the VIMS message center after the load has
been measured. The message center then returns
to the default mode.
SEBU7792-03
External Payload Display (If Equipped)
g01177012
Illustration 84
• As the truck is being loaded, external payload
displays (7) will display the weight of the material
that is in the truck dump body. The “Loading”
message and the payload weight will be displayed
on the VIMS message center inside the cab.
• When the payload measurement system
determines that 95 percent of the target weight will
be achieved with another pass with the loading
equipment, the VIMS message center will display
“Last Pass”.
• When the payload weight reaches 95 percent or
more of the target weight, the VIMS message
center will display “Fully Loaded”.
• The payload measurement system measures
the weight of the load again once the truck has
exited the load site. The measurement is made
when the truck has shifted into second gear. The
VIMS message center will display the “Payload”
message and final payload weight.
• The payload information automatically disappears
from the VIMS message center after the load
has been measured. The message center then
returns to the default mode. The external payload
displays will continue to display the payload until
the payload is dumped.
Note: The external payload display receives data
through the VIMS telemetry port.
Accurate Payload Information
• Do not load the machine on a surface that has a
slope of more than 5 percent.
• The information may not be accurate if the
suspension cylinders are not properly charged.
75
Operation Section
Machine Operation
• Do not allow the operator of the loading machine
to press with the loading tool on the top of the last
load.
• Do not move the truck more than 160 m (525 ft)
while the truck is being loaded.
• Do not move the hoist control while the truck is
being loaded.
• Calibrate the VIMS after components are replaced.
Calibrate the VIMS after substantial changes are
made to the empty weight of the truck. There is
a substantial change in weight when wear plates
are added to the body.
• The information will not be accurate if the truck
is loaded with a conveyor. If the truck is loaded
with a continuous flow, the information will not
be accurate. These systems do not provide an
abrupt increase in the pressure of the suspension
cylinders. The abrupt increase of the pressure of
the suspension cylinders causes the VIMS to begin
the loading cycle.
• Do not move away from the loading site before
the pressures of the suspension cylinders have
stabilized. Do not move away from the loading
site before the message center displays the final
weight.
• Do not ignore fault codes.
Refer to the Systems Operation, RENR2635, “784C,
785C, 789C, 793C, 793D, 797 and 797B Off-Highway
Truck/Tractors VIMS Truck Payload System” for
additional information.
Hauling
NOTICE
Do not use the retarder control as a parking brake or
to stop the machine.
Pay attention to your surroundings. Keep a safe
distance from any machines in front of your machine.
Do not drive over unprotected power cables. Do not
drive under low power cables.
Know the maximum height of the machine. Know
the maximum width of the machine. Maintain proper
clearances.
Always travel with the hoist control in the FLOAT
position. Shift to the top speed that is anticipated. All
further shifts will be automatic.
During normal operation, use the service brake for
all normal braking.
76
Operation Section
Machine Operation
Roads can be slick from ice or from snow. Also, roads
can be slick from being wet. Reduce the speed of
the machine in order to compensate for poor ground
conditions.
Travelling Down a Grade
Never coast down a grade in NEUTRAL. Always keep
the transmission in gear. When the machine speed
is greater than 8 km/h (5 mph), the Power Train
Electronic Control System will not allow you to shift
from forward gear into NEUTRAL or into REVERSE.
Illustration 85
g01169623
When you approach a downgrade that is long or
steep, Automatic Retarder Control (ARC) Switch (8)
should be in the ON position. Select the desired gear
before you start the downgrade. The actual gear of
the transmission should also match the selected gear
before you start the downgrade.
Determine the proper gear for the conditions, the
load, and the downgrade. If you do not know the
proper gear, use the common practice of selecting
the gear that is required to go up the grade when the
machine is loaded.
See Operation and Maintenance Manual, “Retarding”
in this Section for further information.
SEBU7792-03
Preventing Overspeed
g01169624
Illustration 86
If the machine builds up excessive speed, use the
retarder control (lever) (9) in order to reduce the
vehicle speed. If braking force is needed, use the
service brake.
Note: If the engine reaches 2300 rpm and the
transmission is in the same gear as the transmission
direction and speed control, the transmission will
upshift one gear. If the transmission is in the top gear,
the torque converter lockup clutch will disengage.
NOTICE
Do not shift into the NEUTRAL position and do not
freewheel down a grade.
If the brake oil temperature gauge enters the red
range, reduce the travel speed or stop the machine
until the oil cools. This will prevent damage to the
brake components.
Dumping
Positioning
Personal injury or death can occur when backing
the machine over soft edges. Use care when back-
ing into the dump area. Stay clear of soft edges
that could collapse under the machine.
If the load is frozen in the machine bed and dump-
ing is attempted on a slope, the machine can tip
over causing personal injury or death.
Inspect the dump area before you bring in a loaded
truck.
Take care when you drive into the dump area.
Maintain a safe distance from other machines.
SEBU7792-03 77
Operation Section
Machine Operation

Avoid hitting sharp rocks.
Be certain that no personnel are near the dump area.
Position the machine on level ground. Stop the
machine and park the machine. See Operation and
Maintenance Manual, “Stopping the Machine”for the
recommended procedure.
When the transmission is in the REVERSE position
and the hoist control is moved to the RAISE position
or to the LOWER position, the transmission will
promptly shift to the NEUTRAL position. If the
machine is on a slope, apply the brakes in order
to stop the machine from moving. If the reverse
neutralizer must be bypassed, see “Shifting into
REVERSE with the Body Raised” for the procedure.

The reverse neutralizer has no effect on the forward

gears. If the situation is required, the forward gears
can be engaged from the NEUTRAL position or the
REVERSE position.

Shifting into REVERSE with the Body Raised

When the body (bed) is raised, perform the following

steps in order to return the transmission control to
the REVERSE position:

1. Move the hoist control to the HOLD position.

2. Move the transmission control to the NEUTRAL

g01169627
Illustration 87 position.

Before you move hoist control (4) to the RAISE 3. Pause for three seconds.
position, make sure that the machine is at the location
to dump. Also, move parking brake release switch (3) 4. Move the transmission control to the REVERSE
to the ON position and move transmission control (2) position.
to the NEUTRAL position.

Note: If the parking brake is not engaged or if the

service brake is not applied, the machine may roll
backward.

Dumping
Move the hoist control to the FLOAT position in order
to lower the body. Leave the hoist control in the
FLOAT position until the body is completely lowered.

Note: This machine is equipped with an automatic

SNUB feature that activates just before the body is
completely lowered. This reduces the FLOAT speed
in order to prevent the body from contacting the
frame too hard. Leave the hoist control in the FLOAT
position until the body is completely lowered in order
to allow the SNUB feature to soften the impact of the
body.

Completely lower the body before you pull out for

the return trip. This will prevent the body from hitting
power lines or overhead obstructions.

Reverse Neutralizer
The machine will not shift into the REVERSE position
while the body (bed) is being raised or the hoist
control is in the RAISE position or in the LOWER
position.
78 SEBU7792-03
Operation Section
Engine Starting

Engine Starting
i02399077

Engine Starting
SMCS Code: 1000; 7000

Diesel engine exhaust contains products of com-

bustion which may cause personal injury.

Always start and operate the engine in a well ven-

tilated area, and, if in an enclosed area, vent the
exhaust to the outside.

Do not allow a companion to ride on the ma-

chine unless the companion is seated within the
Rollover Protective Structure (ROPS) or Falling
Object Protection Structure (FOPS) with the seat
belt fastened. The companion must have the seat
belt fastened while the machine is in operation.
The operator of the machine is responsible for the g01169186
Illustration 88
safety of the companion. Personal injury or death
may occur if the companion is not restrained and
1. Make sure that parking brake switch (4) is
protected.
engaged.

NOTICE 2. Adjust the operator’s seat. Adjust the mirrors.

Do not crank the engine for more than 30 seconds. Al-
low the starter to cool for two minutes before cranking 3. Fasten the seat belt.
again. Turbocharger damage can result if the engine
rpm is not kept low until the oil gauge display verifies 4. Move transmission control (3) to the NEUTRAL
that the oil pressure is sufficient. position.

5. The dump body should be down and hoist control

The machine will not start unless the following (5) should be in the FLOAT position.
conditions exist:
6. Make sure that no one is on the machine,
• The transmission control lever is in the NEUTRAL underneath the machine or around the machine.
position. Make sure that there are no personnel in the area.

• The engine speed is 0 rpm. 7. Sound horn (6).

• The prelubrication of the engine (if equipped) is NOTICE

complete or the prelubrication system is turned
OFF. Excessive ether (starting fluid) can cause piston and
ring damage.

8. Leave ether starting aid switch (1) in the AUTO

position.
SEBU7792-03 79
Operation Section
Engine Starting

Note: The ether starting aid switch should be used in
the MANUAL position only for cold weather starting.
For starting below −18°C (0°F), use of additional cold
weather starting aids is recommended. A coolant
heater, a fuel heater or some extra battery capacity
may be required. At temperatures below −23°C
(−10°F), consult your Caterpillar dealer or refer to
the Special Publication, SEBU5898, “Cold Weather
Recommendations”.
9. Before you start the engine, wait for the self
test of the VIMS. The self test will activate
when engine start switch (2) is turned to the ON
position. See Operation and Maintenance Manual,
“Vital Information Management System (VIMS)
Self-Test” for further information.
10. Turn the engine start switch (2) to the START
position.
Note: Do not depress the accelerator control.
11. Release the engine start switch when the engine
starts.
• Engine coolant temperature
• Engine rpm
• Position of engine start switch
• Position of the ether starting aid switch
NOTICE
Excessive ether (starting fluid) can cause piston and
ring damage.
Note: The ether starting aid switch should be used in
the MANUAL position only for cold weather starting.
See Special Publication, SEBU5898, “Cold Weather
Recommendations”.
Manual ether injection is recommended only for cold
weather starting. Push the top half of ether starting
aid switch (1). This causes the ether to be injected for
an additional five seconds after the standard cycle
has been completed.

Note: If the engine does not start, return the engine

Engine Block Heater (If Equipped)
start switch to the OFF position before you attempt
to start the engine again.

Ether Starting Aid To avoid shocks or other injuries, never use an

ungrounded or inadequate extension cord. Use a
three-wire extension cord with a three-wire plug
which is rated for at least a 15 amp load and is
protected by a suitable fuse or circuit breaker.

Always inspect the heater electrical cord for worn

or frayed insulation before plugging into current.

A 240 volt engine block heater warms the engine

coolant and the engine oil in order to aid starting. The
power cable for the engine block heater is available
from your Caterpillar dealer.

g01169291
Illustration 89

Ether starting aid switch (1) should be in the AUTO

position during normal operation. When the starting
motor is engaged and the temperatures of the engine
coolant and of the oil are below 10°C (50°F), the
ether will be automatically injected into the engine.
The Electronic Technician (ET) must be used to turn
off the automatic injections.

The Electronic Control Module (ECM) for the engine

determines the need for the ether injection system.
Five parameters determine the amount of ether that
is injected and the duration of the injection.

• Size of the engine

80
Operation Section
Engine Starting
g01198199
Illustration 90
The power cable connects to the engine block heater
at power receptacle (7). The power receptacle is
located on the right side of the engine. First connect
the one end of the power cable to the engine block
heater. Next, connect the other end of the power
cable to a 240 volt power outlet. Before starting the
machine or moving the machine, disconnect the
end of the power cable from the power outlet. Then,
disconnect the other end of the power cable from the
engine block heater.
Engine Cold Mode
Engine cold mode is used to control fuel injection
timing when the engine is cold. Engine cold mode
changes the fuel injection timing in order to prevent
engine damage. Engine cold mode also reduces
white smoke. Engine cold mode is activated when the
engine coolant temperature is below 70 °C (158 °F).
Engine cold mode remains active until the engine
coolant temperature is warmer than 73 °C (163 °F).
Elevated Low Idle
Elevated low idle prevents overcooling of the engine.
Elevated low idle also accelerates engine warm-up.
SEBU7792-03
g01012376
Illustration 91
Map for coolant temperature versus engine speed
The Engine ECM will activate the elevated low idle
after 10 minutes following start-up.
When the engine coolant temperature is less than
70 °C (158 °F), engine idle speed is raised to 1600
RPM. Between 70 °C (158 °F) and 75 °C (167 °F),
the engine idle speed is gradually reduced to the
normal low idle speed. When the engine coolant
temperature is greater than 75 °C (167 °F), the
elevated low idle is disabled. When the elevated low
idle is disabled, the engine speed returns to the low
idle speed. The machine comes from the factory with
the low idle set to 700 rpm.
Activated
The following items must be present before elevated
low idle will activate:
• The transmission control is in the NEUTRAL
position.
• The parking brake is in the ON position.
• The ground speed of the machine is zero.
Deactivated
The following actions will deactivate elevated low idle:
• The accelerator control (pedal) is depressed by
more than 25 percent of the pedal’s travel.
• The manual ether switch is depressed.
• The transmission is moved into gear.
SEBU7792-03 81
Operation Section
Engine Starting

• The parking brake is disengaged.
Note: Elevated low idle will activate again after 30
seconds if the transmission is in the NEUTRAL
position and if the parking brake is in the ON position
and if the accelerator has not been depressed. If the
accelerator has been depressed, elevated low idle
will activate again after 10 minutes.
Cold Cylinder Cutout
The Engine ECM will activate the cold cylinder cutout
after 10 seconds following start-up.
Note: During the cold cylinder cutout, the engine may
seem to misfire. This does not indicate the need for
any type of engine repair.
During a cold start-up and periods of extended time
at low idle, the Engine ECM will automatically turn
off one electronic unit injector at a time. The Engine
ECM checks the rack in order to determine if the
cylinder is firing. If the cylinder is firing, the Engine
ECM turns on the electronic unit injector. If the
cylinder is not firing, the electronic unit injector will
remain disengaged. This reduces the white smoke
that is caused by unburned fuel.
• The ground speed of the machine is zero.
Deactivated
The following actions will deactivate the cold cylinder
cutout:
• The accelerator control (pedal) is depressed by
more than 25 percent of the pedal’s travel.
• The manual ether switch is depressed.
• The transmission is moved into gear.
• The parking brake is disengaged.
Note: If the transmission is in the NEUTRAL position
and the parking brake is in the ON position, the cold
cylinder cutout will activate again after 10 minutes.
i02398955
Engine and Machine Warm-Up
SMCS Code: 1000; 7000

The cold cylinder cutout becomes active when the

engine coolant temperature decreases to 63 °C
(145 °F). The cold cylinder cutout will also activate
when the aftercooler coolant temperature decreases
to 3 °C (37 °F). The cold cylinder cutout is deactivated
when the engine coolant temperature rises above
70 °C (158 °F). The cold cylinder cutout will also
deactivate when the aftercooler coolant temperature
increases to 10 °C (50 °F).

The cold cylinder cutout can be deactivated with

the Electronic Control Analyzer Programmer or the
Electronic Technician.

The cold cylinder cutout provides a way for the

Engine ECM to perform the following functions:

• The reduction of the output of white smoke during

a cold start-up

• The reduction of the use of ether injection

• The reduction of warm-up time
Activated
g01168988
Illustration 92
The following conditions are required for the cold
cylinder cutout to activate.

• The parking brake is engaged.

• The transmission is in NEUTRAL.
82
Operation Section
Engine Starting
Do not allow a companion to ride on the ma-
chine unless the companion is seated within the
Rollover Protective Structure (ROPS) or Falling
Object Protection Structure (FOPS) with the seat
belt fastened. The companion must have the seat
belt fastened while the machine is in operation.
The operator of the machine is responsible for the
safety of the companion. Personal injury or death
may occur if the companion is not restrained and
protected.
1. Start the engine. Refer to Operation and
Maintenance Manual, “Engine Starting” for the
proper procedure.
Note: Only operate the controls if the engine is
running.
2. Check the operation of the steering and the
brakes. Check the secondary brake. Do not
operate the machine if any discrepancies are
found.
3. Frequently observe message area (4), warnings,
service lights, and all gauges (1). All gauges
should be at normal operating range. The alert
indicator, the action light and the action alarm
should be off.
4. Make sure that the truck body is in the DOWN
position and hoist control (10) in the FLOAT
position.
5. Retarder control (lever) (2) should be in the UP
position and switch (3) for the ARC should be in
the ON position.
6. Depress service brake control (pedal) (5). Make
sure that the parking brake reset valve (9) is
depressed.
7. Disengage parking brake release lever (8). Move
transmission control (7) to the desired direction
and the desired gear.
8. Release service brake control (pedal) (5) and
depress accelerator control (pedal) (6).
Note: In order to provide maximum sound
suppression, keep all doors closed and keep all
windows closed.
SEBU7792-03
Machine warm-up
When the oil is allowed to warm-up gradually, the
bearing components maintain optimum operating
positions. High speeds during a cold start-up will
cause the temperatures of the rotating components
to be very different from the temperatures of the
stationary components. High temperature differences
within the bearing may result in less durability of the
bearing component.
Preparing to operate the machine
1. Do not attempt to move the machine without
normal brake air pressure.
2. In order to prevent injury, make sure that no one
is working on the machine or near the machine.
Keep the machine under control at all times in
order to prevent injury.
3. Know the maximum height of the machine. Know
the maximum width of the machine. Maintain
proper clearance.
4. Only operate the machine if the engine is running.
5. Before the machine operates at a high speed,
check the operation of the brake system and of
the steering system. These systems should be
checked while the machine maintains a low speed.
6. Make sure that the Automatic Retarder Control
(ARC) operates properly before you travel down a
grade with a machine that is loaded. Test the ARC
on a short grade before the machine is loaded.
7. In order to prevent injury, make sure that no one
is working on the machine or near the machine.
Keep the machine under control at all times in
order to prevent injury.
8. Reduce engine speed when you are maneuvering
in tight quarters or when you are driving over a
rise.
Reference: For further operating information, See
Operation and Maintenance Manual, “Operation
Information”.
SEBU7792-03 83
Operation Section
Engine Starting

i02344423

Differential Warm-up and

Break-in
SMCS Code: 3258; 7000

Note: Correct oil levels are critical in the rear axle

housing. Check the oil level prior to operation. Allow
sufficient time for the oil to fill all of the compartments
in the final drive housing. Allow sufficient time for the
oil to fill all of the compartments in the differential
housing.

Warm-Up
When the oil is allowed to warm-up gradually, the
bearing components maintain optimum operating
positions. High speeds during a cold start-up will
cause the temperatures of the rotating components
to be very different from the temperatures of the
stationary components. High temperature differences
within the bearing may result in less durability of the
bearing component.

At start-up, the shifting of the transmission will be

limited until the differential oil reaches the operating
temperature range. See Operation and Maintenance
Manual, “Changing Direction and Speed” for further
information.

Break-In
The running surfaces of gears and of bearings are
conditioned during break-in. Break-in brings bearing
components to optimum operating positions.

Break-in

1. For 15 to 20 minutes, load the machine with 60%

to 75% of the capacity.

2. Limit the top speed to fourth gear for approximately

15 to 20 minutes.

Placing significant load on bearing components at a

lower speed creates a favorable condition of contact
between the mating surfaces.
84 SEBU7792-03
Operation Section
Parking

Parking
i02442032

Stopping the Machine

SMCS Code: 7000

Personal injury or death can result from not en-

gaging the parking brake.

If the parking brake is not engaged, the machine g01220157

Illustration 94
may roll while personnel are on or near the ma-
chine.
2. Move transmission control lever (3) to the
NEUTRAL position.
Always engage the parking brake before leaving
the machine.
3. Move parking brake switch (4) to the ON position
in order to engage the parking brake.
NOTICE
Do not use the parking brake to stop the machine.

NOTICE
Do not use the retarder control as a parking brake or
to stop the machine.

Stop the machine on level ground.

g01168947
Illustration 93

1. Release accelerator control (pedal) (2). Depress

service brake control (pedal) (1).
SEBU7792-03 85
Operation Section
Parking

i02571878 i02685316

Stopping the Engine Stopping the Engine if an

SMCS Code: 1000; 7000
Electrical Malfunction Occurs
SMCS Code: 1000; 7000
Park the machine on level ground. See Operation
and Maintenance Manual, “Stopping the Machine” for
Turn the engine start switch to the OFF position.
the recommended procedure.
If the engine does not stop, perform the following
procedure.
NOTICE
Stopping the engine immediately after it has been 1. Engage the parking brake.
working under load can result in overheating and ac-
celerated wear of the engine components.

If the engine has been operating at high rpm and/or

high loads, run at low idle for at least three minutes
to reduce and stabilize internal engine temperature
before stopping the engine.

Avoiding hot engine shutdowns will maximize tur-

bocharger shaft and bearing life.

1. In order to allow the engine to gradually cool,

operate the engine at low idle for three minutes.

2. Turn the engine start switch key to the OFF g01349087

position in order to stop the engine.
NOTICE
Never turn the battery disconnect switch key to OFF
with the engine running. Electrical system damage
could result.
3. Turn the battery disconnect switch to the OFF
position. Remove the key.
4. If the machine is parked, chock the wheels.
5. Drain the water from the brake air reservoir
and the air start tank. Refer to Operation and
Maintenance Manual, “Air Tank Moisture and
Sediment - Drain”.
Illustration 95
Note: The engine shutdown control (1) is located
on the lower right front side of the machine on the
bumper.
2. Dismount the machine. Raise the guard and
locate engine shutdown control (1).
3. Move the toggle switch up to the OFF position in
order to stop the engine.
Note: Do not operate the machine again until the
malfunction has been corrected.
i02338426
Cable (Truck Body Retaining)
SMCS Code: 5154; 7258

When it is necessary to work under the machine

with the body (bed) raised, attach the body (bed)
retaining cable to the rear tow point. Install the
rear tow point pin through the end of the retaining
cable.

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

sult in personal injury or death.
86 SEBU7792-03
Operation Section
Parking

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.

Installation Procedure
1. Remove all material and any residue from the
body before the body is secured in the raised
position.

2. Park the machine on a level surface.

3. Raise the body to the fully raised position.

g01167292
Illustration 97

5. Position cable end (1) in rear tow point (3).

6. Install pin (2) through the tow point and the cable
end.

7. Lower the body until the cable is tight.

Removal Procedure
1. Raise the body to the fully raised position in order
to loosen the cable.

2. Release the cable end from the tow point.

3. Return the cable end to the stored location.

4. Lower the body.

g01167291
Illustration 96

4. Remove cable end (1) from the stored location.

SEBU7792-03 87
Operation Section
Parking

i02380923

Leaving the Machine

SMCS Code: 7000

1. Use the steps and the handholds when you get off
the machine. Make sure that the steps are clear of
debris before you dismount.

g00037860
Illustration 98

2. Face the machine and maintain a three-point

contact with the steps and with the handholds.

Note: Three-point contact can be two feet and one

hand. Three-point contact can also be one foot and
two hands.

3. Inspect the engine compartment for debris. Clean

out any debris in order to avoid a fire.

4. Turn the battery disconnect switch to the OFF

position. Remove the disconnect key, and secure
the lock on the cover plate. This will help to
prevent a battery short circuit. Removing the
key will also help to protect the battery from
vandalism and from any possible current draw by
components over extended time periods.

5. Install all the covers and install all the vandalism

protection locks.
88
Operation Section
Transportation Information
Transportation Information
i00704122
Shipping the Machine
SMCS Code: 7000; 7500
Consult your Caterpillar dealer for shipping
instructions for your machine.
Investigate the travel route for overpass clearances.
Make sure that there is adequate clearance for the
machine that is being transported.
In order to prevent the machine from slipping during
loading or shifting in transit, remove ice, snow or
other slippery material. Remove these materials from
the loading dock and the area of the transport.
NOTICE
Obey all state and local laws governing the weight,
width and length of a load.
Remove the starting aid (ether) cylinder, if equipped.
Make sure the cooling system has proper antifreeze if
moving machine to a colder climate.
Observe all regulations governing wide loads.
1. Block the trailer wheels or rail car wheels before
loading.
2. Secure the machine with tie-downs when you
transport the machine on a rail car or on a
tractor-trailer.
3. Cover the exhaust opening. If the machine is
equipped with a turbocharger, damage can result
to the turbocharger. Damage can occur if the
turbocharger rotates and the engine is not running.
SEBU7792-03
i02342953
Roading the Machine
SMCS Code: 7000; 7500
Before you road a machine, consult the following:
• Your Caterpillar dealer
• Your tire dealer
• The proper officials for your area
Obtain the required licenses and other similar items.
Obey all the laws that govern the weight and the size
of a vehicle.
Limitations for TON-kilometer per hour (TON-mile per
hour) must be obeyed. Consult your tire dealer for
the speed limit of the tires that are used.
When you travel for long distances, schedule stops in
order to allow the tires and the components to cool.
Stop for 30 minutes after every 40 km (25 miles) or
after every hour.
Perform a Walk-Around Inspection and measure the
fluid levels in each of the compartments.
Bring the engine coolant, the crankcase oil, and the
transmission oil up to the correct levels.
Inflate the tires to the correct pressure.
Use a self-attaching inflation chuck in order to inflate
the tire. Stand behind the tire tread while you inflate
the tires. Refer to the Operation And Maintenance
Manual, “Tire Inflation Information” for information
on tire inflation.
Travel at a moderate speed. Observe all speed
limitations when you road the machine.
The service brakes can be used for stopping the
machine whenever it is necessary. Using the service
brakes for controlling travel speed or stopping
from high travel speeds can cause the brake oil to
overheat. This will cause damage to the power train
and excessive wear of the service brakes.
SEBU7792-03 89
Operation Section
Transportation Information

i02345894

Lifting and Tying Down the

Machine
SMCS Code: 7000; 7500

g01172140
Illustration 99

3. Spreader bar widths should be sufficient for

NOTICE
Improper lifting or tie-downs can allow the machine to
shift. This can cause damage to the machine.
This machine is not intended to be lifted after
assembly. This machine is not intended to be
tied down after assembly. For instructions on the
assembly of this machine, refer to Special Instruction,
REHS2210, “793D Off-Highway Truck Assembly
Procedure”.
1. Weight and instructions are listed herein.
This information is applicable to units that are
manufactured by Caterpillar.
preventing contact with the machine.
4. Use the two rear holes and two front holes that
are provided for tie-downs.
Install the tie-downs at several locations. Place blocks
under the front wheels and under the rear wheels.
Check the appropriate laws that govern the weight of
the load. Check the appropriate laws that govern the
width of the load and the length of the load.
Consult your Caterpillar dealer for shipping
instructions for your machine.

Note: The empty weight of a fully assembled 793D

Off-Highway Truck with body is 154200 ± 6800 kg
(340000 ± 15000 lb). The empty weight of the 793D
will depend on the configuration and the options.

2. For lifting objects, use properly rated cables and

properly rated slings. Position the crane for a level
machine lift.
90 SEBU7792-03
Operation Section
Jacking Location Information

Jacking Location In order to secure the front suspension cylinder on

each side of the machine, use suitable tooling that
Information can be mechanically secured in the raised position
(20 ton minimum capacity). Place this tooling under
front suspension cylinder (2) in order to prevent the
i02603108 extension of the cylinder.
Jacking Locations
Rear of the Machine
SMCS Code: 7000
Note: If the machine is equipped with the sound
Position the machine on a level surface that is free suppression arrangement, the sound suppression
of overhead obstructions. Engage the parking brake. cover must be removed from the differential before
Shut off the engine. the tooling that is used for lifting the machine is
placed in position.
The body should be empty and lowered before lifting
the machine.

Any tooling that is used for lifting the machine or for

securing the machine in the raised position should
be used on a concrete surface that is capable of
supporting the weight of the machine.

Front of the Machine

g01160631
Illustration 101

In order to raise the rear of the machine, use suitable

tooling that can be mechanically secured in the
raised position (55 ton minimum capacity). Place this
tooling under the flat surface on the bottom of the
differential housing. The tooling should be placed in
front of bracket (3) which is used to mount the rear
suspension cylinder.
g01146790
Illustration 100
Note: Do not attempt to raise the rear of the machine
In order to lift the front of each side of the machine, with the lift stands between the two rear suspension
use suitable tooling that can be secured in the raised cylinders.
position (55 ton minimum capacity). Place this tooling
under the flat surface on the bottom on casting
(1) which is used to mount the front suspension
cylinder. The tooling should be placed near the
welded joint between the casting and the front frame
crossmember that is under the engine.
SEBU7792-03
Towing Information
i02654733
Towing the Machine
SMCS Code: 7000
Personal injury or death could result when towing
a disabled machine incorrectly.
Block the machine to prevent movement before
releasing the brakes. The machine can roll free if
it is not blocked.
Note: The engine must be operable or an auxiliary
power unit must be available in order to provide
steering capability. Refer to Operation and
Maintenance Manual, “Towing With Inoperable
Engine” for additional information.
Note: Empty the body and lower the body before
towing a disabled machine. Do not tow a machine
with material in the body and do not tow a machine
with the body in the raised position. Failure to dump
the load will result in damage to the frame and other
components.
The towing machine must be as large as the disabled
machine. Make sure that the towing machine has
enough brake capacity, enough weight, and enough
power. The towing machine must be able to control
both machines for the grade and for the distance that
is involved.
The towing force on the rear or on the front of an
Off-Highway Truck must not exceed either of the
following structural limits:
• 40 percent of the gross machine weight
• 1110000 N (249540 lb)
Maintain sufficient control and sufficient braking of
the disabled machine when the disabled machine
is being moved downhill. This may require a larger
towing machine or additional machines that are
connected to the rear of the machine that is being
towed. This will prevent the machine from rolling
away out of control.
These towing instructions are for moving a disabled
machine for a short distance at low speed. Move the
machine at a speed of 2 km/h (1.2 mph) or less to a
convenient location for repair. These instructions are
only for moving machines.
91
Operation Section
Towing Information
This machine is equipped with spring-applied parking
brakes. These brakes are released with hydraulic
pressure. If the engine is inoperable, move the brake
release control to the ON position. This will operate
the motor for the electric powered parking and
secondary brake release pump. Refer to Operation
and Maintenance Manual, “Towing With Inoperable
Engine” for additional information.
Shields must be provided on both machines. This will
protect the operator if either the tow line or the tow
bar breaks.
DO NOT allow anyone except the operator to be on
the machine that is being towed by a cable.
DO NOT use a chain for pulling a disabled machine.
A chain link can break. This may cause possible
personal injury. Use a wire cable with ends that have
loops or rings. Put an observer in a safe position in
order to watch the pulling procedure. The observer
must be able to stop the procedure, if necessary.
Stop the procedure if the cable starts to break or if
the cable starts to unravel. Stop pulling whenever
the towing machine moves without moving the towed
machine.
Before towing, make sure that the tow line or the tow
bar is in good condition. Make sure that the tow line
or the tow bar has enough strength for the towing
procedure that is involved. The capacity of the tow
line or of the tow bar must be at least 150 percent
of the gross weight of the disabled machine. Under
certain conditions, failure of the tow line or the tow
bar will occur if the tow line or the tow bar is less than
150 percent capacity. A machine that is retrieved
from the mud or a machine that is being towed up a
grade are examples of these conditions.
92
Operation Section
Towing Information
g01178774
Illustration 102
When the machine is towed from the front, use both
tow points (1). When the machine is towed from the
front, configure the tow bar or the tow line in a Y
configuration. Failure to configure the front towing
device in a Y configuration will cause damage to the
disabled machine.
When the machine is towed from the front, pull in
line with the disabled machine. Pulling the disabled
machine at an angle will cause one of the legs of the
Y configuration to break . Keep the tow line angle
to a minimum. DO NOT exceed a 15 degree angle
from the straight ahead position. Pulling the disabled
machine at an angle will cause the frame or the rear
axle housing to bend. Steer the tires of the towed
truck in the direction of the pull.
Quick machine movement could overload the tow
line or the tow bar. This could cause the tow line
or the tow bar to break. Gradual, steady machine
movement will be more effective.
Note: Do not apply more lifting force to the front of the
machine than the lifting force that would be required
to raise an empty machine with a hydraulic jack.
SEBU7792-03
g01178772
Illustration 103
Whenever it is possible, tow the machine from the
front. Certain conditions may require the machine to
be towed from the rear. Tow the machine from the
rear in order to reposition the machine and enable
the machine to be safely towed from the front. When
the machine is towed from the rear, only attach
the tow line to rear tow point pin (2) that is used to
connect the truck body retaining cable. Only tow a
machine from the rear, if all of the following additional
conditions are true.
• The machine will be towed across a smooth, level
surface.
• The engine of the towed machine is operable.
• The steering system of the towed machine is
operable.
• The braking system of the towed machine is
operable.
• The machine will be towed slowly for a short
distance.
• The body of the towed machine is empty and
lowered.
• The towed machine has an operator in control of
the steering and braking.
SEBU7792-03 93
Operation Section
Towing Information

Consult your Caterpillar dealer for additional details i02343150

about towing a disabled machine.
Lowering the Body with Engine
i02343100
Stopped
Dumping with Engine Stopped SMCS Code: 7000

SMCS Code: 1000; 7000 1. If the engine is inoperable, turn the engine start
switch to the ON position.
If the engine is inoperable, use an auxiliary power
unit as a separate hydraulic source. Consult your
Caterpillar dealer for further information.

Also, a second truck may be used as an outside

hydraulic source. Consult your Caterpillar dealer for
further information.

Note: Make sure that someone is observing the

machine. Make sure that the observer can signal the
operator. If you are dumping on a slope, the wheels
on the disabled truck may start to raise. The observer
is needed to warn the operator to stop raising the bed
if this happens. The observer can also make sure
that the area is free of personnel. g01168867
Illustration 104

2. Move hoist control to LOWER position (1).

g01168865
Illustration 105

3. Press and hold brake release switch (3) for 20

seconds.

4. If the body does not lower, hold the hoist control in

RAISE position (2) for 15 seconds. Move the hoist
control to the LOWER position.

If the body does not lower still, use an auxiliary power

unit as a separate hydraulic source. Consult your
Caterpillar dealer for further information.

Also, a second truck may be used as an outside

hydraulic source. Consult your Caterpillar dealer for
further information.
94 SEBU7792-03
Operation Section
Towing Information

i02394138
NOTICE
Towing With Power Train When towing the machine, attach tow line to the front
Failure tow hooks or rear tow pin only.

SMCS Code: 1000; 4000; 7000

Note: If the engine is inoperable refer to
Operation and Maintenance Manual, “Towing
With Inoperable Engine”.
Personal injury or death could result when towing
a disabled machine incorrectly.
Block the machine to prevent movement before
releasing the brakes. The machine can roll free if
it is not blocked.
3. Hook up the towing machine. Refer to Operation
and Maintenance Manual, “Towing the Machine”
for the guidelines.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

g01131076
Illustration 107

4. Remove drain plug (3) from the final drives.

Drain the differential/final drive oil into a suitable
container.

5. Remove the covers from each rear wheel.

g01134383
Illustration 106 6. Remove the axle shafts. Refer to the Power
(1) Parking brake reset valve Train Disassembly and Assembly, “Axle Shaft -
(2) Parking brake switch Remove” for the procedure.

Perform the following procedure on the disabled 7. Remove any damaged power train components
machine. that may rotate when the machine is towed.

1. Engage parking brake switch (2). Note: When there is failure of the final drive, clean
the system before you tow the machine. Debris in the
2. Block the wheels. wheel can cause extensive damage to the machine
when you tow the machine.

8. Replace the cover for each rear wheel.

SEBU7792-03 95
Operation Section
Towing Information

9. Install drain plug (3) for the final drives.

10. Remove the blocks from the wheels.

In order to prevent possible personal injury, re-
lease the air pressure from the air tank before dis-
11. Start the engine. Make sure that none of the
connecting any components of the air system.
power train components are causing additional
damage.

12. Make sure that the parking brake reset valve (1)
is depressed and disengage parking brake switch
(2).

13. Check the steering by turning the steering wheel

to the right and to the left.

14. Check the braking by applying the service brake

pedal.

Note: The wheel bearings are not in oil when the final
drives are drained. The maximum distance for towing
is 30.5 m (100 ft) when the final drives are drained.

15. Tow the disabled machine while the engine of

the disabled machine is running. Pull the disabled
machine with the towing machine.

16. Make sure that none of the power train

components are causing additional damage.

17. After the repairs are completed, install the axle

shafts. Refer to the Power Train Disassembly and
Assembly, “Axle Shaft - Install ” for the procedure.

18. Fill the differential and final drives. See Operation

and Maintenance Manual, “Capacities (Refill)”.
Before you operate the machine, check the
oil level in the final drives. See Operation and
Maintenance Manual, “Differential and Final Drive
Oil - Check”.
i02246546
Towing With Inoperable Engine
SMCS Code: 1000; 4000; 7000
Personal injury or death could result when towing
a disabled machine incorrectly.
Block the machine to prevent movement before
releasing the brakes. The machine can roll free if
it is not blocked.
g01134709
Illustration 108
1. Place transmission control (1) in the NEUTRAL
position. Engage parking brake switch (3).
2. Block the wheels.
NOTICE
When towing the machine, attach tow line to the front
tow hooks or rear tow pin only.
3. Hook up the towing machine. Refer to Operation
and Maintenance Manual, “Towing the Machine”
for the guidelines.
4. Check the steering on the disabled machine. If the
steering needs assistance, use an auxiliary power
unit as a separate hydraulic source. Consult your
Caterpillar dealer for further information.
96 SEBU7792-03
Operation Section
Towing Information

g01131085
Illustration 110

g01131130
Illustration 109

5. If there is not sufficient air pressure in the air

system, the air system can be charged with air
from another source.

NOTICE
Do not exceed the air pressure of 830 ± 35 kPa
(120 ± 5 psi) or damage can occur to the air system
components.

Note: The air pressure in the air system must be at

550 kPa (80 psi) in order to allow the supply oil to
disengage the parking brakes.

a. Before you attempt to charge the system,

remove the air pressure from the brake system.
Refer to Operation and Maintenance Manual,
“Ait Tank Moisture and Sediment - Drain”.

b. Connect a hose from an outside air supply to

fitting (4).
Note: This machine is equipped with a female quick
disconnect fitting. Use Caterpillar 1U-8328 Fitting
(QUICK DISCONNECT, MALE) in order to connect
hose.
c. Remove the supply hose.
g01131106
Illustration 111
Note: This machine is equipped with spring-applied
parking brakes. These brakes are released with
hydraulic pressure. When the engine is inoperable
or when the hydraulics are inoperable, the parking
brake will be applied.

6. Install a pressure gauge in the pressure tap of

either junction block (5). The junction blocks are
located in the parking brake release lines. The
gauge will measure the hydraulic pressure that is
needed in order to release the parking brake.
SEBU7792-03 97
Operation Section
Towing Information

NOTICE
The parking brake must be fully released. Partial
brake engagement and brake damage could occur if
proper hydraulic pressure is not maintained.

Do not allow the parking brake release pressure

to drop below 3445 kPa (500 psi) when the towed
machine is moving.

g01136849
Illustration 112

Note: An electric drive pump provides hydraulic

pressure in order to disengage the parking brakes.
This pump also provides hydraulic pressure to the
hoist in order to lower the body when the engine is
stopped.
7. Move brake release switch (6) to the ON position.
Hold brake release switch (6) until the VIMS
message center indicates that the parking brake
is released.
8. Apply the service brake pedal on the disabled
machine in order to check the braking. If the
brakes are functioning, release the brakes.
9. Rotate the steering wheel to each side in order to
check the steering.
Illustration 113 g01134709
11. Depress parking brake reset valve (2).
12. Move parking brake switch (3) to the OFF
position. Turn the engine start switch to the ON
position.
13. Keep transmission control (1) in neutral.
14. Pull the disabled machine with the towing
machine. Monitor the hydraulic pressure gauge
that was installed in Step 6. Do not continue to
tow the machine if the hydraulic pressure is below
3445 kPa (500 psi).

10. Remove the blocks from the wheels.

g01136852
Illustration 114
98 SEBU7792-03
Operation Section
Towing Information

15. Monitor air pressure gauge (7). The air pressure

in the air system must be at 550 kPa (80 psi) in
order to tow the machine. If air pressure drops
below 550 kPa (80 psi) stop the towing procedure
and recharge the air system. Refer to Step 5.
SEBU7792-03
Engine Starting (Alternate
Methods)
i02247404
Engine Starting with an
External Air Supply
SMCS Code: 1000; 7000
In order to prevent possible personal injury, re-
lease the air pressure from the air tank before dis-
connecting any components of the air system.
NOTICE
Do not exceed the air pressure of 830 ± 35 kPa
(120 ± 5 psi) or damage can occur to the air system
components.
Note: Before charging the air tank from an external
air supply, drain the water from the external air supply.
g01131645
Illustration 115
Note: This machine is equipped with a female quick
disconnect fitting. Use Caterpillar 1U-8328 Fitting
(QUICK DISCONNECT, MALE) in order to connect
hose.
1. Remove the cover from fitting (1). Connect the
hose from the auxiliary air supply to fitting (1).
2. Allow the air tank to refill.
99
Operation Section
Engine Starting (Alternate Methods)
3. After the engine start, remove the hose from
the auxiliary air supply. Install the cover to quick
disconnect fitting (1).
i02247572
Engine Starting with Jump
Start Cables
SMCS Code: 1000; 1401; 7000
Failure to properly service the batteries may cause
peronal injury.
Prevent sparks near the batteries. They could
cause vapors to explode. Do not allow the jump
start cable ends to contact each other or the
machine.
Do not smoke when checking battery electrolyte
levels.
Electrolyte is an acid and can cause personal in-
jury if it contacts skin or eyes.
Always wear eye protection when starting a ma-
chine with jump start cables.
Improper jump start procedures can cause an ex-
plosion resulting in personal injury.
Always connect the battery positive (+) to battery
positive (+) and the battery negative (−) to battery
negative (−).
Jump start only with an energy source with the
same voltage as the stalled machine.
Turn off all lights and accessories on the stalled
machine. Otherwise, they will operate when the
energy source is connected.
100 SEBU7792-03
Operation Section
Engine Starting (Alternate Methods)

NOTICE
When starting from another machine, make sure that
the machines do not touch. This could prevent dam-
age to engine bearings and electrical circuits.

Turn on (close) the battery disconnect switch prior to

the boost connection to prevent damage to electrical
components on the stalled machine.

Severely discharged maintenance free batteries do

not fully recharge from the alternator after jump start-
ing. The batteries must be charged to proper voltage
with a battery charger. Many batteries thought to be
unusable are still rechargeable. g01131766
Illustration 116

This machine has a 24 volt starting system. Use only

7. Check the battery caps for correct placement
the same voltage for jump starting. Use of a welder or
and for correct tightness. Make these checks on
higher voltage damages the electrical system.
both machines. Make sure that the batteries in
the stalled machine are not frozen. Check the
Refer to Special Instruction, Battery Test Procedure,
batteries for low electrolyte.
SEHS7633, available from your Caterpillar dealer, for
complete testing and charging information.
8. Connect the positive jump start cable to the
positive cable terminal of the discharged battery.
Use of Jump Start Cables Do not allow positive cable clamps to contact any
metal except for battery terminals.
When auxiliary start receptacles are not available,
use the following procedure.
9. Batteries in series may be in separate
compartments. Use the terminal that is connected
1. Determine the reason that the engine will not
to the starter solenoid. This battery is normally on
start. Refer to Special Instruction, REHS0354,
the same side of the machine as the starter.
“Charging System Troubleshooting”.
10. Connect the positive jump start cable to the
2. Move the transmission direction and speed control
positive terminal of the electrical source. Use the
lever to the NEUTRAL position on the stalled
procedure from Step 9 in order to determine the
machine. Move all controls to the HOLD position.
correct terminal.
3. On a stalled machine, turn the start switch key to
11. Connect one end of the negative jump start cable
the OFF position. Turn off the accessories.
to the negative terminal of the electrical source.
4. On a stalled machine, turn the battery disconnect
12. Make the final connection. Connect the negative
switch to the ON position.
cable to the frame of the stalled machine. Make
this connection away from the battery, the fuel, the
5. Move the machines together in order for the cables
hydraulic lines, or moving parts.
to reach. DO NOT ALLOW THE MACHINES TO
CONTACT EACH OTHER.
13. Start the engine on the machine that is the
electrical source. Also, you can energize the
6. Stop the engine of the machine that is being used
charging system on the auxiliary power source.
as an electrical source. When you use an auxiliary
power source, turn off the charging system.
14. Allow the electrical source to charge the batteries
for two minutes.

15. Attempt to start the stalled engine. Refer to

Operation and Maintenance Manual, “Engine
Starting”. See the beginning of this topic.

16. Immediately after the stalled engine starts,

disconnect the jump start cables in reverse order.
SEBU7792-03
17. Conclude with a failure analysis on the starting
charging system. Check the stalled machine, as
required. Check the machine when the engine is
running and the charging system is in operation.
i02797778
Engine Starting with Auxiliary
Start Receptacle
SMCS Code: 1450; 1463
S/N: FDB1-566
An auxiliary start receptacle provides a dedicated
connection that is available for jump starting.
Note: When an electrical power source is connected
to the auxiliary start receptacle, the battery disconnect
switch is bypassed and the electrical system will
energize when the battery disconnect switch is in the
OFF (disabled) position. This allows jump starting
capabilities regardless of the position of the battery
disconnect switch.
Some Caterpillar products may be equipped with
auxiliary start receptacles. All other machines can be
equipped with a receptacle from parts service.
There are two cable assemblies that can be used
to jump the stalled machine. You can jump the
machine from another machine that is equipped
with this receptacle or an auxiliary power pack. Your
Caterpillar dealer can provide the correct cable
lengths for your application.
There are two cable assemblies that can be used to
jump the stalled machine. A stalled machine can be
jump started from another machine that is equipped
with an auxiliary start receptacle or a stalled machine
can be jump started from an auxiliary power pack.
You can jump the machine from another machine that
is equipped with this receptacle or an auxiliary power
pack. Your Caterpillar dealer can provide the correct
cable lengths for your application.
g01175768
Illustration 117
101
Operation Section
Engine Starting (Alternate Methods)
1. Determine the failure of the machine to start. Refer
to Special Instructions, REHS0354, “Charging
System Troubleshooting”.
2. Place the transmission direction and speed control
lever in the NEUTRAL position on the stalled
machine. Engage the parking brake. Move all
controls to the HOLD position.
3. On the stalled machine, turn the start switch key
to the OFF position. Turn off all of the accessories.
4. Turn on the battery disconnect switch.
5. Move the machine that is used for the electrical
source close to the stalled machine. The cables
must reach. DO NOT ALLOW THE MACHINES
TO CONTACT EACH OTHER.
6. Stop the engine on the machine that is used for
the electrical source. When you use an auxiliary
power source, turn the charging system to the
OFF position.
7. On the stalled machine, connect the appropriate
jump start cable to the auxiliary start receptacle.
8. Connect the other end of this cable to the
electrical source. You must connect the cable to
the auxiliary start receptacle.
9. Start the engine on the machine that is used
for the electrical source. Energize the charging
system if an auxiliary power source is used.
10. Allow the electrical source to charge the batteries
for two minutes.
11. Attempt to start the stalled engine. Refer to
Operation and Maintenance Manual, “Engine
Starting”. See the beginning of this topic.
12. Immediately after the stalled engine starts,
disconnect the jump start cable from the electrical
source.
13. Disconnect the other end of this cable from the
stalled machine.
14. Conclude with a failure analysis on the starting
charging system. Check the stalled machine, as
required. Check the machine when the engine is
running and the charging system is in operation.
102
Operation Section
Engine Starting (Alternate Methods)
i02797960
Engine Starting with Auxiliary
Start Receptacle
SMCS Code: 1450; 1463
S/N: FDB567-Up
An auxiliary start receptacle provides a dedicated
connection that is available for jump starting.
Note: When an electrical power source is connected
to the auxiliary start receptacle and the battery
disconnect switch is in the OFF (disabled) position,
the electrical system will remain de-energized. This
prevents jump starting capabilities when the battery
disconnect switch is in the OFF position.
There are two cable assemblies that can be used
to jump the stalled machine. You can jump the
machine from another machine that is equipped
with this receptacle or an auxiliary power pack. Your
Caterpillar dealer can provide the correct cable
lengths for your application.
There are two cable assemblies that can be used to
jump the stalled machine. A stalled machine can be
jump started from another machine that is equipped
with an auxiliary start receptacle or a stalled machine
can be jump started from an auxiliary power pack.
You can jump the machine from another machine that
is equipped with this receptacle or an auxiliary power
pack. Your Caterpillar dealer can provide the correct
cable lengths for your application.
g01175768
Illustration 118
1. Determine the failure of the machine to start. Refer
to Special Instructions, REHS0354, “Charging
System Troubleshooting”.
2. Place the transmission direction and speed control
lever in the NEUTRAL position on the stalled
machine. Engage the parking brake. Move all
controls to the HOLD position.
SEBU7792-03
3. On the stalled machine, turn the start switch key
to the OFF position. Turn off all of the accessories.
4. Turn on the battery disconnect switch.
5. Move the machine that is used for the electrical
source close to the stalled machine. The cables
must reach. DO NOT ALLOW THE MACHINES
TO CONTACT EACH OTHER.
6. Stop the engine on the machine that is used for
the electrical source. When you use an auxiliary
power source, turn the charging system to the
OFF position.
7. On the stalled machine, connect the appropriate
jump start cable to the auxiliary start receptacle.
8. Connect the other end of this cable to the
electrical source. You must connect the cable to
the auxiliary start receptacle.
9. Start the engine on the machine that is used
for the electrical source. Energize the charging
system if an auxiliary power source is used.
10. Allow the electrical source to charge the batteries
for two minutes.
11. Attempt to start the stalled engine. Refer to
Operation and Maintenance Manual, “Engine
Starting”. See the beginning of this topic.
12. Immediately after the stalled engine starts,
disconnect the jump start cable from the electrical
source.
13. Disconnect the other end of this cable from the
stalled machine.
14. Conclude with a failure analysis on the starting
charging system. Check the stalled machine, as
required. Check the machine when the engine is
running and the charging system is in operation.
SEBU7792-03 103
Maintenance Section
Tire Inflation Information

Maintenance Section Reference: For tire inflation instructions, refer to

Special Instruction, SMHS7867, “Nitrogen Tire
Inflation Group”.

Tire Inflation Information For nitrogen inflation, use the same tire pressures
that are used for air inflation. Consult your tire dealer
for operating pressures.
i02096880

Tire Inflation with Nitrogen i02610518

SMCS Code: 4203 Tire Inflation Pressure

Caterpillar recommends the use of dry nitrogen gas
for tire inflation and for tire pressure adjustments.
This includes all machines with rubber tires. Nitrogen
is an inert gas that will not aid combustion inside the
tire.
Proper nitrogen inflation equipment, and training
in using the equipment, are necessary to avoid
over inflation. A tire blowout or rim failure can re-
sult from improper or misused equipment and per-
sonal injury or death can occur.
A tire blowout and/or rim failure can occur if the in-
flation equipment is not used correctly, due to the
fact that a fully charged nitrogen cylinder’s pres-
sure is approximately 15000 kPa (2200 psi).
Adjustment
SMCS Code: 4203
Always obtain the proper tire inflation pressures and
maintenance recommendations for the tires on your
machine from your tire supplier. The tire pressure
in a warm shop area 18° to 21°C (65° to 70°F) will
significantly change when you move the machine
into freezing temperatures. If you inflate the tire to
the correct pressure in a warm shop, the tire will be
underinflated in freezing temperatures. Low pressure
shortens the life of a tire.
Reference: When you operate the machine in
freezing temperatures, refer to Special Publication,
SEBU5898, “Cold Weather Recommendations for All
Caterpillar Machines” in order to adjust tire inflation
pressures.

There are other benefits to using nitrogen in addition

to reducing the risk of an explosion. The use of
nitrogen for tire inflation lessens the slow oxidation
of the rubber. Use of nitrogen also slows gradual tire
deterioration. This is especially important for tires
that are expected to have a long service life of at
least four years. Nitrogen reduces the corrosion of
rim components. Nitrogen also reduces problems
that result from disassembly.

A tire blowout or a rim failure can cause personal

injury.

Use a self-attaching inflation chuck and stand be-

hind the tread when inflating a tire, to prevent per-
sonal injury.

Note: Do not set the tire inflation equipment regulator

higher than 140 kPa (20 psi) over the recommended
tire pressure.

Use 6V-4040 Inflation Group or an equivalent

inflation group to inflate tires with a nitrogen gas
cylinder.
104
Maintenance Section
Lubricant Viscosities and Refill Capacities
Lubricant Viscosities and
Refill Capacities
i02445927
Lubricant Viscosities
SMCS Code: 1000; 7000; 7581
The proper oil viscosity grade is determined by the
minimum ambient temperature at engine start-up and
during operation. In order to determine the proper
oil viscosity grade, refer to the “Min” column and the
“Max” column in the table. The “Min” column indicates
the coldest ambient temperature condition for starting
a cold machine and for operating a cold machine.
The “Max” column indicates the oil viscosity grade
for operating the machine at the highest ambient
temperature that is anticipated. Use the highest
oil viscosity grade that is allowed for the ambient
temperature at engine start-up and during operation.
Oil viscosity grade in the differential and in the
final drives should not be based solely on ambient
temperatures. The duration of operation and the
oil temperatures during operation should also be
considered. Machines that are operated continuously
should use oils that have the higher oil viscosity grade
in the final drives and in the differentials. The oils
that have the higher oil viscosity grade will maintain
the highest possible oil film thickness. Consult your
dealer if additional information is needed.
Operation of the transmission with an oil viscosity
grade that is too high can cause damage to the
friction disc. Operation of the transmission with an
oil temperature that is too low can cause damage
to the friction disc. Also, damage to the friction disc
can be caused by extended shift time and a slow rise
in clutch pressure. Thicker oil does not provide the
correct amount of oil flow in some areas and thicker
oil can reduce the lube flow in some areas.
For vehicle operation in the ambient temperature
range of 0 to 50 °C (32 to 122 °F), SAE 30 TDTO is
the recommended viscosity.
NOTICE
If the ambient temperature at engine start-up or dur-
ing operation is below -10°C (14°F), perform the pro-
cedures in Operation and Maintenance Manual, “En-
gine and Machine Warm-Up”. Check the differential
compartment and the final drive compartment for the
proper fluid level. Failure to warm-up the oil or improp-
er lubrication levels prior to operation will cause dam-
age to the machine.
SEBU7792-03
NOTICE
The brake systems on the off-highway trucks MUST
use SAE 10W TDTO/TO-4 oil. Do not use FDAO or
TDTO/TO-4 in the engine.
Caterpillar Transmission/Drive Train Oil (TDTO)
is balanced in order to provide maximum friction
material life in the following components: power
shift transmissions, steering systems, body hoist
systems, torque converters, and brake systems.
Transmission/Drive Train Oil (TDTO) may decrease
brake chatter in Caterpillar machines that are
equipped with oil cooled disc brakes. TDTO
has passed the requirements for the TO-4 oil
specification. The TO-4 oil specification includes
frictional requirements and gear wear requirements.
Caterpillar also offers Transmission Multi-Season Oil
(TMS). TMS oil exceeds the shear stability and the
performance requirements of Caterpillar TO-4M oil.
TMS oil provides the maximum performance and the
maximum protection for Caterpillar transmissions.
Note: Multigrade oils must meet the requirements
of Caterpillar TO-4M for use in transmissions.
Multigrade oils that use high molecular weight
polymers as viscosity index improvers may lose the
viscosity effectiveness because of temporary shear
and permanent shear of the polymer viscosity index
improver. These types of multigrade oils are not
recommended for Caterpillar transmissions. The
Caterpillar TO-4M oil requirement includes a test
for the shear stability of multigrade oil. If Caterpillar
Transmission/Drive Train Oil (TDTO) is not available,
use commercial oils that comply with Caterpillar TO-4
or TO-4M oil specifications.
Caterpillar Final Drive and Axle Oil (FDAO) is
balanced in order to provide maximum friction
material life in the following components: differentials,
final drives, and front wheels. Final Drive and Axle Oil
provides the maximum performance for the following
Caterpillar components: differentials, final drives, and
front wheels.
Note: Do NOT use Caterpillar gear oil that is
Extreme Pressure (EP) or commercial gear oil in
the components for Off-Highway Trucks. Gear oil is
not compatible with duo-cone seals and the friction
materials. Gear oil may decrease the efficiency of the
transmission and the performance of the brakes.
Note: Refer to Special Publication, SEBU5898, “Cold
Weather Recommendations” for the selection of oil
when the machine is operated below −20 °C (−4 °F).
SEBU7792-03 105
Maintenance Section
Lubricant Viscosities and Refill Capacities

Table 5
Recommendation for Lubricant Viscosities for Ambient (Outside) Temperatures for Off-Highway Trucks
°C °F
Compartment or System Oil Type and Classification Oil Viscosities
Min Max Min Max
SAE 0W-20 −40 10 −40 50
SAE 0W-30 −40 30 −40 86
SAE 0W-40 -40 40 -40 104
Cat DEO Multigrade
Cat DEO SYN(3) SAE 5W-30 −30 30 −22 86
Engine Crankcase(1)(2) Cat Arctic DEO SYN
Cat ECF-1(4) SAE 5W-40 −30 50 −22 122
API CG-4 Multigrade (5)
SAE 10W-30 −18 40 0 104
SAE 10W-40 -18 50 0 122
SAE 15W-40 −10 50 15 122
SAE 0W-20(6) −40 10 −40 50
SAE 0W-30(7) −40 20 −40 68
Cat TDTO
Transmission and Torque Cat TDTO-TMS SAE 5W-30(7) −30 20 −22 68
Converter Cat Arctic TDTO SAE 10W −20 10 −4 50
commercial TO-4
SAE 30 0 50 32 122
TDTO-TMS (8) -10 50 14 122
SAE 0W-20 −40 40 −40 104

Cat HYDO SAE 0W-30 -40 40 -40 104

Cat DEO SAE 0W-40 -40 40 -40 104
Cat MTO
Cat TDTO SAE 5W-30 -30 40 -22 104
Cat TDTO-TMS
Cat DEO SYN SAE 5W-40 -30 40 -22 104
Steering System(9)(10)
Cat Arctic DEO SYN SAE 30(10) 10 50 50 122
Cat Arctic TDTO
Cat ECF-1 SAE 10W-30 −20 40 −4 104
API CG-4
API CF SAE 15W-40 −15 50 5 122
commercial TO-4 Cat MTO −25 40 −13 104
Cat TDTO-TMS(8) −20 50 -4 122
Cat TDTO SAE 0W-20(6)(11) -40 40 -40 104
Hoist and Brake System Cat Arctic TDTO
commercialTO-4 SAE 10W(11) −20 50 −4 122
(continued)
106 SEBU7792-03
Maintenance Section
Lubricant Viscosities and Refill Capacities

(Table 5, contd)
Recommendation for Lubricant Viscosities for Ambient (Outside) Temperatures for Off-Highway Trucks
°C °F
Compartment or System Oil Type and Classification Oil Viscosities
Min Max Min Max
SAE 50(14) (14) 32 (14) 90
Differential, Front Wheels Cat FDAO(12)
and Final Drives Commercial FD-1(13) SAE 60(14) (14) 50 (14) 122
(1) Supplemental heat is recommended for cold soaked starts below the minimum ambient temperature. Supplemental heat may be required
for cold soaked starts that are above the minimum temperature that is stated, depending on the parasitic load and other factors. Cold
soaked starts occur when the engine has not been operated for a period of time and the oil has become more viscous due to cooler
ambient temperatures.
(2) API CF oils are not recommended for Caterpillar 3500 Series and smaller Direct Injection (DI) diesel engines. API CF-4 oils are not
recommended for machines with Caterpillar diesel engines.
(3) Cat Arctic DEO SYN is an SAE 0W-30 viscosity grade oil.
(4) API CI-4, API CI-4 PLUS, and API CH-4 oils are acceptable if the requirements of Caterpillar’s ECF-1 (Engine Crankcase Fluid specification
- 1) are met. API CI-4, API CI-4 PLUS, and API CH-4 oils that have not met the requirements of Caterpillar’s ECF-1 specification may
cause reduced engine life.
(5) API CG-4 oils are acceptable for use in all Caterpillar machine diesel engines. When API CG-4 oils are used, the oil change interval
should not exceed 250 hours. API CG-4 oils that meet API CI-4, API CI-4 PLUS, or API CH-4 must also meet the requirements of the
Caterpillar ECF-1 specification.
(6) First Choice: Cat Arctic TDTO SYN SAE 0W-20. Second choice: Oils of full synthetic base stock without viscosity index improvers that
meet the performance requirements of the TO-4 specification for the SAE 30 viscosity grade. Typical viscosity grades are SAE 0W-20,
SAE 0W-30, and SAE 5W-30. Third Choice: Oils with a TO-4 type additive package and a lubricant viscosity grade of SAE 0W-20,
SAE 0W-30, or SAE 5W-30.
(7) First choice: Oils of full synthetic base stock without viscosity index improvers that meet the performance requirements of the TO-4
specification for the SAE 30 viscosity grade. Typical viscosity grades are SAE 0W-20, SAE 0W-30, and SAE 5W-30. Second Choice: Oils
with a TO-4 type additive package and a lubricant viscosity grade of SAE 0W-20, SAE 0W-30, or SAE 5W-30.
(8) TDTO-TMS (Transmission Multi-Season) (synthetic blend that exceeds the TO-4/TO-4M multigrade specification requirements).
(9) This compartment is common to the radiator cooling fan motor and the common rail hydraulic system. The common rail hydraulic system
provides oil to the steering system.
(10) Cat TDTO SAE 30 is the preferred oil for the steering system.
(11) The maximum allowable oil viscosity at 100 °C (212 °F) is 6.6 cSt ("ASTM D445").
(12) Cat FDAO (Final Drive and Axle Oil) (exceeds the FD-1 specification requirements).
(13) Cat TDTO or a commercial TO-4 oil may be used as a second choice in place of the recommended Cat FDAO or commercial FD-1 oil.
(14) Cat FDAO oil or commercial FD-1 SAE 60 is preferred in most applications, particularly continuous operation. If the ambient temperature
is below −10°C (14°F), warm up the oil prior to operation. The oil must be maintained to a temperature above −10°C (14°F) during
operation. If the ambient temperature is below −25°C (−13°F), consult your Caterpillar dealer for instructions. Failure to warm up the oil prior
to operation will cause damage to the machine.

Recommended Grease Cat MPGM grease will pump through centralized

Cat MPGM (Multipurpose Grease w/Moly)
Cat MPGM is an NLGI grade 2 grease. This grease is
made with petroleum base oil and a lithium complex
thickener. This grease also has 3% Molybdenum
diSulfide (MoS2 or “Moly”). Cat MPGM is formulated
for use in applications with low severity to high
severity at moderate temperatures. In addition, the
Moly in Cat MPGM is a special grade that has a
median particle size of 3 microns in order to meet
the special requirements of some rolling element
bearings. Cat MPGM is recommended for heavily
loaded pin joints, and high impact applications in
machines such as track-type tractors, backhoe
loaders and skid steer loaders.
Cat MPGM meets the NLGI certification of “GC-LB”.
(This certification relates to extended service
intervals in automotive chassis points and in wheel
bearings with disc brakes in automobiles, vans, and
light trucks.)
autolube systems at ambient temperatures down
to −18 °C (0 °F) and will perform well in medium to
high severity applications up to 41 °C (106 °F). In
less severe applications, this grease can be used
at higher temperatures.
Note: If the application calls for a multipurpose
grease with molybdenum and Cat MPGM is not
available, consult the data sheets for the greases.
Use a substitute that meets or use a substitute that
exceeds the performance characteristics of Cat
MPGM.
Severe Applications
Caterpillar has greases which are made with a
Calcium Sulfonate Complex thickener. This type of
grease is necessary for more severe applications.
These greases provide more load carrying (galling
resistance), lower wear, longer working life,
exceptional water washout, and resistance to
corrosion.
SEBU7792-03 107
Maintenance Section
Lubricant Viscosities and Refill Capacities

Note: For further information, refer to Special

Publication, SEBU6250, “Caterpillar Machine Fluids NOTICE
Recommendations”, “Lubricating Grease”. If the ambient temperature at engine start-up or
during operation is below −10°C (14°F), perform
the procedures in Operation and Maintenance
i02763634
Manual, “Differential Warm-up and Break-in”. Check
Capacities (Refill) the differential compartment and the final drive
compartment for the proper fluid level. Failure to
SMCS Code: 7560 warm up the oil or improper lubrication levels prior to
operation will cause damage to the machine.
The refill capacities will vary depending on the
service procedures and conditions. Refer to the Operation and Maintenance Manual,
“Lubricant Viscosities” for information regarding the
Note: Observe all sight gauges and level indicators correct lubricant.
in order to ensure that the systems and/or
compartments are refilled to the proper levels.
i01822901
Table 6
Compartment or US Imperial
S·O·S Information
System Liters Gallons Gallon
SMCS Code: 1000; 7000; 7542
Engine Oil with Filter 291 77 64
System for 227 60 50 S·O·S Services is a highly recommended process
Transmission and for Caterpillar customers to use in order to minimize
Torque Converter owning and operating cost. Customers provide
oil samples, coolant samples, and other machine
System for Hoist and 1137 300 250 information. The dealer uses the data in order to
Brakes provide the customer with recommendations for
Steering Hydraulic 265 70 58 management of the equipment. In addition, S·O·S
System Services can help determine the cause of an existing
product problem.
Each Front Wheel 21 5.5 4.6
(Standard Power
Train Arrangement) Refer to Special Publication, SEBU6250, “Caterpillar
Machine Fluid Recommendations” for detailed
Each Front Wheel 26.5 7 5.8 information concerning S·O·S Services.
(Extended Life Power
Train Arrangement) Refer to the Operation and Maintenance Manual,
System for 1022 270 225 “Maintenance Interval Schedule” for a specific
Differential and Final sampling location and a service hour maintenance
Drive (Standard interval.
Power Train
Arrangement) Consult your Caterpillar dealer for complete
System for 1022 270 225 information and assistance in establishing an S·O·S
Differential and Final program for your equipment.
Drive (Extended
Life Power Train
Arrangement)
Fuel Tank (Type 1) 4353 1150 958
Fuel Tank (Type 2) 4921 1300 1082
Cooling System 852 225 187
Windshield Washer 4 1.0 0.9
108 SEBU7792-03
Maintenance Section
Maintenance Access

Maintenance Access • The coolant drain valve for the aftercooler

• The coolant sampling valve for the aftercooler
i02600597

Access Doors and Covers • The engine oil filter

(If Equipped with the Sound • The engine oil dipstick
Suppression Arrangement) • The engine oil sampling valve
SMCS Code: 7251; 7263; 7273 • The filler tube for the engine oil
• The fuel priming pump
• The quick disconnect fitting for the air system
reservoir

• The secondary fuel filters

• The water pump for the aftercooler cooling system

g01301659
Illustration 119

Open access door (1) in order to access the following

items:

• The alternator
• The belts
• The coolant drain valve for the jacket water cooling
system

• The coolant sampling valve for the jacket water

cooling system

• The drain valve for the engine oil

• The fuel/water separator
• The primary fuel filter
• The refrigerant compressor
• The water pump for the jacket water cooling system
Open access door (2) in order to access the following
items:

• The air conditioner lines

SEBU7792-03 109
Maintenance Section
Maintenance Support

Maintenance Support 3. Clamp the ground cable from the welder to the
component that will be welded. Place the clamp
as close as possible to the weld. Make sure that
i02377450 the electrical path from the ground cable to the
component does not go through any bearing. Use
Match Tire Size this procedure in order to reduce the possibility of
(Dual Tire Configuration) damage to the following components:

SMCS Code: 4203 • Bearings of the drive train

The tires in a dual tire configuration should be • Hydraulic components

the same brand, the same type and the same
construction. The tires should also be the same size. • Electrical components
This includes tires of the same size with even wear.
Match the tire size in dual tire configurations for • Other components of the machine
increased service life of the lower power train.
4. Protect any wiring harnesses from the debris
The following conditions may result from tire sizes which is created from welding. Protect any wiring
that are not closely matched: unequal loading of harnesses from the splatter which is created from
the tire, unequal tire wear, elevated stresses on welding.
the wheel bearings, and elevated stresses on the
structures for the lower power train. 5. Use standard welding procedures in order to weld
the materials together.
For the correct methods of checking the variation
in tire size, refer to Service Magazine, SEPD0766,
10 January 2005, “Match Tire Size in Dual Tire
Configurations for Increased Service Life”.

i02000840

Welding on Machines and

Engines with Electronic
Controls
SMCS Code: 1000; 7000

Proper welding procedures are necessary in order to

avoid damage to the electronic controls and to the
bearings. When possible, remove the component
that must be welded from the machine or the engine
and then weld the component. If you must weld near
an electronic control on the machine or the engine,
temporarily remove the electronic control in order to
prevent heat related damage. The following steps
should be followed in order to weld on a machine or
an engine with electronic controls.

1. Turn off the engine. Place the engine start switch

in the OFF position.

2. If equipped, turn the battery disconnect switch to

the OFF position. If there is no battery disconnect
switch, remove the negative battery cable at the
battery.

NOTICE
Do NOT use electrical components (ECM or ECM sen-
sors) or electronic component grounding points for
grounding the welder.
110
Maintenance Section
Maintenance Interval Schedule
i02835005
Maintenance Interval Schedule
SMCS Code: 1000; 7000
Ensure that all safety information, warnings and
instructions are read and understood before any
operation or any maintenance procedures are
performed.
The user is responsible for the performance of
maintenance, 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 ............................... 112
Automatic Lubrication Reservoir - Fill .................. 115
Battery - Recycle ................................................. 115
Battery or Battery Cable - Inspect/Replace ......... 116
Brake Oil Cooler Screen - Clean ......................... 118
Brake Tank (Makeup) - Clean ............................. 120
Cab Air Filter - Clean/Replace ............................ 123
Circuit Breakers - Reset ...................................... 124
Engine Air Filter Primary Element - Clean/
Replace ............................................................. 138
Engine Air Filter Secondary Element - Replace .. 140
Engine Air Precleaner - Clean ............................ 140
Ether Starting Aid Cylinder - Replace ................. 148
Frame and Body - Inspect .................................. 150
Fuel System - Prime ........................................... 153
Fuel System Primary Filter (Water Separator) -
Drain ................................................................. 154
Fuel System Priming Filter - Replace ................. 156
High Intensity Discharge Lamp (HID) - Replace .. 158
Hoist Screens - Clean ......................................... 159
Hoist and Brake Tank Suction Screen -
Inspect/Clean/Replace ...................................... 162
Magnetic Plug (Wheels) - Check ........................ 164
Oil Filter - Inspect ................................................ 165
Rear Axle Housing End Play - Adjust ................. 167
Rim - Inspect ....................................................... 169
Suction Screen (Torque Converter) - Clean ........ 182
Traction Control System (TCS) - Test ................. 189
Windows - Clean ................................................. 192
Window Washer Reservoir - Fill .......................... 192
Window Wiper - Inspect/Replace ........................ 193
SEBU7792-03
Every 10 Service Hours or Daily
Air Tank Moisture and Sediment - Drain .............. 113
Backup Alarm - Test ............................................. 115
Brakes, Indicators and Gauges - Test ................. 120
Cooling System Coolant Level - Check .............. 129
Differential and Final Drive Oil Level - Check ..... 136
Engine Oil Level - Check .................................... 143
Engine Oil Level - Log Additions ......................... 144
Hoist and Brake Tank Oil Level - Check ............. 161
Seat Belt - Inspect .............................................. 170
Steering System Oil Level - Check ..................... 181
Torque Converter Sump Oil Level - Check ......... 186
Initial 50 Service Hours
Brake Cooling Oil Filter - Replace ....................... 118
Oil Filter (Steering, Hydraulic Fan) - Replace ..... 164
Parking Brake Release Oil Filter - Replace ........ 166
Rear Axle Oil Filter - Replace ............................. 167
Steering System Oil Filter - Replace ................... 180
Transmission Oil Filter - Replace ........................ 190
Initial 250 Service Hours
Engine Valve Lash and Bridge - Adjust .............. 146
Every 250 Service Hours or Monthly
Braking System - Test ......................................... 121
Front Wheel Oil - Inspect .................................... 152
Magnetic Plug (Wheels) - Check ........................ 164
Tire Inflation - Check ........................................... 185
Initial 500 Hours (for New Systems, Refilled
Systems, and Converted Systems)
Cooling System Coolant Sample (Level 2) -
Obtain ............................................................... 130
Every 500 Service Hours
Cooling System Coolant Sample (Level 1) -
Obtain ............................................................... 129
Differential and Final Drive Oil Sample - Obtain .. 137
Engine Oil Sample - Obtain ................................ 145
Front Wheel Oil Sample - Obtain ........................ 153
Hoist and Brake Tank Oil Sample - Obtain ......... 162
Steering System Oil Sample - Obtain ................. 181
Torque Converter and Transmission Oil Sample -
Obtain ............................................................... 189
Every 500 Service Hours or 3 Months
Air Conditioner Filter - Clean ............................... 112
Air Dryer - Check ................................................. 112
Air/Hydraulic Cylinder Breather - Clean ............... 114
Automatic Lubrication Reservoir - Fill .................. 115
Belts - Inspect/Adjust/Replace ............................. 116
Brake Cooling Oil Filter - Replace ....................... 118
Cab Air Filter - Clean/Replace ............................ 123
Cable (Truck Body Retaining) - Inspect .............. 124
Differential and Final Drive Oil - Inspect ............. 136
SEBU7792-03 111
Maintenance Section
Maintenance Interval Schedule

Drive Shaft Slip Joint - Lubricate ........................ 138
Engine Crankcase Breather - Clean ................... 142
Engine Oil Filter (Oil Renewal System) -
Change ............................................................. 143
Engine Oil and Filter - Change ........................... 145
Frame - Clean/Inspect ........................................ 148
Front Wheel Oil - Change ................................... 152
Fuel System Primary Filter (Water Separator)
Element - Replace ............................................ 154
Fuel System Primary Filter - Clean ..................... 156
Fuel System Secondary Filter - Replace ............ 157
Fuel Tank Water and Sediment - Drain ............... 158
Hoist and Brake Tank Breather - Replace .......... 160
Oil Filter (Steering, Hydraulic Fan) - Replace ..... 164
Parking Brake Release Oil Filter - Replace ........ 166
Rear Axle Oil Filter - Replace ............................. 167
Secondary Steering - Check ............................... 172
Steering System Oil Filter - Replace ................... 180
Suspension Cylinder - Check ............................. 184
Torque Converter Outlet Screen - Replace ......... 185
Torque Converter Sump Breather - Clean .......... 186
Transmission Magnetic Screen - Clean .............. 190
Transmission Oil Filter - Replace ........................ 190
Every 3 Years After Date of Installation or
Every 5 Years After Date of Manufacture
Seat Belt - Replace ............................................. 171
Every 4000 Service Hours
Engine Valve Lash and Bridge - Adjust .............. 146
Every 6000 Service Hours or 3 Years
Cooling System Coolant Extender (ELC) - Add .. 127
Every 6000 Service Hours or 4 Years
Cooling System Water Temperature Regulator -
Replace ............................................................. 133
Engine Water Pump - Inspect ............................. 147
VIMS Module Battery - Replace ......................... 191
Every 12 000 Service Hours or 6 Years
Cooling System Coolant (ELC) - Change ........... 126
Steering Ball Stud - Replace ............................... 178

Every 1000 Service Hours or 6 Months Every 15 000 Service Hours

Air Dryer Desiccant - Replace ............................. 112 Rim - Inspect ....................................................... 170
Frame and Body Support Pads - Clean/Inspect .. 151
Rollover Protective Structure (ROPS) - Inspect .. 170 Every 1 393 000 L (368 000 US gal) of Fuel
Seat Suspension - Inspect/Lubricate .................. 171 or 8000 Service Hours
Service Brakes - Inspect ..................................... 173
Steering Ball Stud - Inspect ................................ 174 Engine Components - Rebuild/Install Reman ..... 141
Steering Linkage - Inspect .................................. 178
Torque Converter and Transmission Oil - Every 2 786 000 L (736 000 US gal) of Fuel or
Change ............................................................. 187 16 000 Service Hours
Every 2000 Service Hours or 1 Year Engine Components - Clean/Inspect, Rebuild/Install
Reman, Install New ........................................... 141
Breather (Fuel Tank) - Replace ........................... 123
Differential Thrust Pin Clearance - Check .......... 134
Differential and Final Drive Breather - Replace .. 134
Differential and Final Drive Oil - Change ............ 135
Front Axle Breather - Replace ............................ 151
Hoist and Brake Tank Oil - Change .................... 160
Rear Axle Housing End Play - Adjust ................. 167
Steering System Oil - Change ............................ 179
Suction Screen (Rear Axle Lubrication) - Clean .. 182

Every Year
Cooling System Coolant Sample (Level 2) -
Obtain ............................................................... 130
Receiver Dryer (Refrigerant) - Replace .............. 168
Sound Suppression (Covers, Panels) -
Inspect/Replace ................................................ 173

Every 3000 Service Hours or 2 Years

Cooling System Pressure Cap - Clean/Replace .. 131
Cooling System Relief Valve - Clean .................. 132
Radiator Core - Clean ......................................... 166
112 SEBU7792-03
Maintenance Section
Air Conditioner Filter - Clean

i02390098 2. Drain the primary air tank and drain the secondary
air tank. Refer to Operation and Maintenance
Air Conditioner Filter - Clean Manual, “Air Tank Moisture and Sediment - Drain”
for the proper procedure.
SMCS Code: 7320

If a reduction in air circulation is noticed, clean the

filter element for the air conditioner.

The filter element for the air conditioner is located in

the compartment in the front of the cab.

1. Park the machine on a level surface and engage

the parking brake.

2. Loosen the door retaining screws and open the

door.

g01167619
Illustration 121
Air dryer (1) is located on the frame in front of the left front
suspension cylinder.
The tire and the wheel have been removed for ease of viewing.

g01165826
3. If there is moisture in the air tanks, replace
Illustration 120 the desiccant cartridge or rebuild the desiccant
cartridge. Consult your Caterpillar dealer for
3. Remove filter element (1). information about replacing the desiccant cartridge
and for instructions for rebuilding the desiccant
4. Clean the element by gently tapping the element cartridge.
on a smooth surface.
Note: Small amounts of moisture may be in the
5. Install the clean element. Close the door and system due to condensation in the system.
tighten the retaining screws.

i02340897
i02685548

Air Dryer - Check Air Dryer Desiccant - Replace

SMCS Code: 4285
SMCS Code: 4285

Air lines to and from the air dryer must be at

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

1. Park the machine on a level surface and engage

the parking brake.
SEBU7792-03 113
Maintenance Section
Air Tank Moisture and Sediment - Drain

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

g01167619
Illustration 122
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.

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.
g01132579
Illustration 124
i02602974 The drain valve for the secondary air tank is located on the right
hand side of the cab exterior.
Air Tank Moisture and
Sediment - Drain 1. Open drain valve (2) for the air tank.

SMCS Code: 4272 2. Check for moisture and sediment in the air tank.
Drain the moisture and sediment from the air tank
Park the machine on a level surface and engage the into a suitable container.
parking brake.
3. Close the drain valve for the air tank.

Primary Air Tank

g01132606
Illustration 123
Drain valve (1) for the primary air tank is located on the right hand
side of the platform.
114 SEBU7792-03
Maintenance Section
Air/Hydraulic Cylinder Breather - Clean

Primary Air Tank (If Equipped

with the Sound Suppression
Arrangement)

g01302805
Illustration 125

1. Open drain valve (3) for the air tank. Illustration 126
g01133243

(1) Breather for the rear air/hydraulic cylinders

2. Check for moisture and sediment in the air tank. (2) Breather for the front air/hydraulic cylinders
Drain the moisture and sediment from the air tank (3) Rear air/hydraulic cylinders
into a suitable container. (4) Front air/hydraulic cylinders

3. Close the drain valve for the air tank. 4. Remove breathers (1) and (2) for air/hydraulic
cylinders (3) and (4).
i02251322
5. Wash both breathers in clean nonflammable
Air/Hydraulic Cylinder solvent. Allow the breathers to dry.

Breather - Clean 6. Install the clean breathers.

SMCS Code: 4258 7. Remove the truck body retaining cable and lower
the body.

When it is necessary to work under the machine

with the body (bed) raised, attach the body (bed)
retaining cable to the rear tow point. Install the
rear tow point pin through the end of the retaining
cable.

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

sult in personal injury or death.

1. Park the machine on a level surface and engage

the parking brake.

2. Raise the dump body to the fully raised position

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

3. Stop the engine.

SEBU7792-03
i02365140
Automatic Lubrication
Reservoir - Fill
SMCS Code: 7540
g01133458
Illustration 127
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.
115
Maintenance Section
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.
i02253468
Backup Alarm - Test
SMCS Code: 7406
g01130536
Illustration 128
Location of the backup alarm
Park the machine on a level surface and engage the
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
116
Maintenance Section
Battery or Battery Cable - Inspect/Replace
• An authorized battery collection facility
• Recycling facility
i02341243
Battery or Battery Cable -
Inspect/Replace
SMCS Code: 1401-040; 1401-510; 1402-040;
1402-510
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.
1. Park the machine on a level surface and engage
the parking brake.
2. Turn the engine start switch to the OFF position.
Turn all of the switches to the OFF position.
3. Turn the battery disconnect switch to the OFF
position. Remove the key. Refer to Operation and
Maintenance Manual, “Battery Disconnect Switch”
for more information.
4. Disconnect the negative end “−” of the battery
cable from the frame near the battery disconnect
switch.
Note: Do not allow the disconnected battery cable to
contact the battery disconnect switch.
g01131766
Illustration 129
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.
SEBU7792-03
8. Connect the positive end “+” of the battery cable
to the battery.
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.
11. Install the key. Turn the battery disconnect switch
to the ON position.
i02253729
Belts - Inspect/Adjust/Replace
SMCS Code: 1356; 1357; 1405-036
Inspection
Park the machine on a level surface and engage the
parking brake.
To maximize the engine performance, inspect
the belt for wear and for cracking. Check the
belt tension. Belt slippage will decrease the life
of the belt. A correctly adjusted belt will deflect
13 to 19 mm (0.50 to 0.75 inch). Refer to the Engine
Specifications, “Belt Tension Chart”.
g01135583
Illustration 130
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.
Adjustment and Replacement
Alternator
1. Park the machine on a level surface. Engage the
parking brake and stop the engine.
SEBU7792-03 117
Maintenance Section
Belts - Inspect/Adjust/Replace

Refrigerant Compressor

g01135171
Illustration 131
g01135219
Illustration 133

g01135196
Illustration 132
g01135507
Illustration 134
2. Loosen mounting bolt (5) and adjusting nuts (3).
Belt tensioner for the refrigerant compressor belt

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

1. Park the machine on a level surface. Engage the
parking brake and stop the engine.
4. If necessary, remove the belt and replace the belt.
2. In order to release the tension on the belt, Insert a
5. Turn adjusting nuts (3) in order to increase or
12.7 mm (0.50 inch) ratchet into square hole (6) in
decrease the belt tension.
the belt tensioner, and pry the belt tensioner in a
counterclockwise direction.
6. If the belt guard was removed, reinstall the belt
guard.
3. If necessary, remove the belt and replace the belt.
7. Tighten the adjusting nuts. Tighten the mounting
4. Shoulder (2) of the belt tensioner should be
bolt.
aligned with green zone (7) of the indicator.
8. Check the belt tension on a new belt after 30
5. Check the belt tension on a new belt after 30
minutes of operation.
minutes of operation.
Note: The break-in period for the belt is considered
Note: The break-in period for the belt is considered
to be 30 minutes.
to be 30 minutes.
118
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, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
g01137716
Illustration 135
Location of the brake cooling oil filters
1. Park the machine on a level surface. Engage the
parking brake and stop the engine.
SEBU7792-03
Illustration 136
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.
5. Inspect the seal in each housing base. If a seal is
damaged, replace the seal with a new seal.
6. Install the new filter elements in the filter housings.
7. Install 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
SMCS Code: 4257; 4295
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact skin.
SEBU7792-03 119
Maintenance Section
Brake Oil Cooler Screen - Clean

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

Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and g01176679

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.
1. Park the machine on a level surface. Engage the
parking brake and stop the engine.
Illustration 138
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.

g01159886
Illustration 137
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
g01159904
Illustration 139
2. Drain the oil from rear brake oil coolers (2) with The front brake oil cooler screen is located inside the left frame rail
drain (4). 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).
120
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.
12. 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.
13. 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”.
i02270875
Brake Tank (Makeup) - Clean
SMCS Code: 4291
When it is necessary to work under the machine
with the body (bed) raised, attach the body (bed)
retaining cable to the rear tow point. Install the
rear tow point pin through the end of the retaining
cable.
Failure to properly secure the body (bed) may re-
sult in personal injury or death.
Illustration 140
g01137610
The brake makeup oil tank is located on the inside rail on the left
side of the machine near the center tube.
1. Park the machine on a level surface and engage
the parking brake.
SEBU7792-03
2. Raise the truck 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.
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.
8. Remove the truck body retaining cable and lower
the body.
i02381189
Brakes, Indicators and Gauges
- Test
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.
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”.
SEBU7792-03
7. Test the service brakes. For the proper test
procedure, refer to Operation and Maintenance
Manual, “Braking System - Test”.
8. Engage the parking brake. Stop the engine.
Make any necessary repairs before machine
operation. Consult your Caterpillar dealer for more
information.
i02454317
Braking System - Test
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 be-
fore 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.
121
Maintenance Section
Braking System - Test
2. Check the area around the machine. Make sure
that the machine is clear of personnel and clear of
obstacles.
3. Test the brakes on a dry, level surface.
4. Start the engine and allow the air system to build
up to the operating pressure.
Illustration 141
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 oper-
ation.
Test for the Parking Brake Reset
Valve
1. Fasten the seat belt before you test the brakes.
2. Check the area around the machine. Make sure
that the machine is clear of personnel and clear of
obstacles.
122 SEBU7792-03
Maintenance Section
Braking System - Test

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

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.

6. Start the engine and allow the air system to build

up to the operating pressure.

7. Disengage the parking brake.

8. Move the transmission control lever to the FIRST

SPEED FORWARD position. g01167673
Illustration 142
9. Gradually increase the engine speed to 1300 rpm.
The machine should not move. 5. Apply secondary brake control (4).

10. Reduce the engine speed to low idle. Move
the transmission control lever to the NEUTRAL
position. Engage the parking brake switch. Stop
the engine.
11. In order to disengage the parking brake reset
valve , push down the knob.
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 oper-
ation.
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.
1. Fasten the seat belt before you test the brakes.
2. Check the area around the machine. Make sure
that the machine is clear of personnel and clear of
obstacles.
3. Test the brakes on a dry, level surface.
4. Start the engine and allow the air system to build
up to the operating pressure.
6. Depress the parking brake reset valve.
7. Release the parking brake.
8. Move the transmission control lever to the FIRST
SPEED FORWARD position.
9. Gradually increase the engine speed to 1300 rpm.
The machine should not move.
10. Reduce the engine speed to low idle. Move
the transmission control lever to the NEUTRAL
position. Engage the parking brake. Stop the
engine.
NOTICE
If the machine moved while testing the brakes, contact
your Caterpillar dealer.
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.
1. Fasten the seat belt before you test the brakes.
2. Check the area around the machine. Make sure
that the machine is clear of personnel and clear of
obstacles.

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

4. Start the engine and allow the air system to build

up to the operating pressure.
SEBU7792-03 123
Maintenance Section
Breather (Fuel Tank) - Replace

1. Park the machine on a level surface and engage

the parking brake.

2. Raise the truck body to the fully raised position

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

3. Stop the engine.

g01190530
Illustration 143

5. Apply service brake control (5).

6. Depress the parking brake reset valve.

7. Release the parking brake.

8. Move the transmission control lever to the FIRST

SPEED FORWARD position.

9. Gradually increase the engine speed to 1300 rpm. Illustration 144

g01172150
The machine should not move.
4. Remove fuel tank breather (1).
10. Reduce the engine speed to low idle. Move
the transmission control lever to the NEUTRAL 5. Properly discard the used breather.
position. Engage the parking brake. Stop the
engine. 6. Install a new breather.

NOTICE 7. Remove the truck body retaining cable and lower

If the machine moved while testing the brakes, contact the body.
your Caterpillar dealer.
i01766189
Have the dealer inspect and, if necessary, repair the
service brake before returning the machine to opera- Cab Air Filter - Clean/Replace
tion.
SMCS Code: 7311; 7342

i02345985

Breather (Fuel Tank) - Replace

SMCS Code: 1273-510-BRE

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.
g00903640
Failure to properly secure the body (bed) may re- Illustration 145
sult in personal injury or death. Location of the filter element for the cab
(1) Cover
(2) Retaining screws
124 SEBU7792-03
Maintenance Section
Cable (Truck Body Retaining) - Inspect

The filter element for the cab is located inside the
operator’s compartment.
1. Loosen retaining screws (2). Remove cover (1)
and the filter element.
2. Wash the filter element in a nonsudsing detergent.
3. Rinse the filter element in clean water. Allow the
filter element to air dry.
4. Install the clean filter element and cover (1).
Tighten retaining screws (2).
Note: When rips or tears are noticed in the 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.
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
• Wear
• Corrosion
• Cracks or gouges
If any of the above conditions exist, replace
the truck body retaining cable and the cable
connection for the truck body. Consult your
Caterpillar dealer for proper replacement parts.
i02342172

i02385071 Circuit Breakers - Reset

Cable (Truck Body Retaining) SMCS Code: 1420
- Inspect
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

g01167724
Illustration 146
• 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
SEBU7792-03 125
Maintenance Section
Circuit Breakers - Reset

Stop Lights and Dome light (7) – 10 Amp

Brake Retraction Motor (8) – 20 Amp

Air Conditioner (9) – 15 Amp

Alternator (10) – 105 Amp

g01167816 VIMS Message Center (11) – 10 Amp

Illustration 147

Circuit Breaker/Reset – Push in the

button in order to reset the circuit breaker. If
Window Washer and Wiper (12) – 10
the electrical system is working properly, the
Amp
button will remain depressed. If the button does not
remain depressed, check the appropriate electrical
circuit. Repair the electrical circuit, if necessary.
Power Train Electronic Control Module
(13) – 10 Amp
Note: The circuit breakers for the low beam
headlights, the high beam headlights, and the fog
lights are automatic reset circuit breakers.
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

Brake Electronic Control Module (18) –

Steering Accumulator Pressure (5) – 10 10 Amp
Amp

Electronic Fuel Injection (19) – 15 Amp

Keyswitch (6) – 10 Amp

24 to 12 Volt Converter (20) – 10 Amp

126 SEBU7792-03
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.
NOTICE
Mixing Cat Extended Life Coolant (ELC) with other
products reduces the effectiveness of the coolant
and shortens coolant life. Use only Caterpillar prod-
ucts or commercial products that have passed the
Caterpillar EC-1 specifications for premixed or con-
centrate 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 Contam-
ination.
This machine was factory filled with Cat Extended Life
Coolant.
Drain the coolant whenever the coolant is dirty or
whenever foaming is observed.

Do not attempt to tighten hose connections when 1. Park the machine on a level surface. Engage the
the coolant is hot, the hose can come off causing parking brake and stop the engine.
burns.

Cooling System Coolant Additive contains alkali.

Avoid contact with skin and eyes.

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

Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.
g01159005
Illustration 148
NOTICE (1) Filler cap for the aftercooler cooling system
Do not change the coolant until you read and under- (2) Filler cap for the jacket water cooling system
stand the material in the Cooling System Specifica-
tions section. 2. Slowly loosen filler caps (1) and (2). This will
relieve system pressure. Remove the filler caps.
SEBU7792-03
g01159976
Illustration 149
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”
127
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
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
Personal injury can result from hot coolant, steam
and alkali.
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove cooling system pressure cap slowly to
relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
touch with your bare hand.
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
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) temper-
ature.
The engine cooling system is normally protect-
ed to a minimum of−29°C (−20°F) with Caterpillar
Antifreeze, when shipped from the factory unless
special requirements are defined.
128 SEBU7792-03
Maintenance Section
Cooling System Coolant Extender (ELC) - Add

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

Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

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 re-
sult 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 prod-
ucts or commercial products that have passed the
Caterpillar EC-1 specifications for premixed or con-
centrate 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 Contam-
ination.
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.
1. Park the machine on a level surface. Engage the
parking brake and stop the engine.
Illustration 150
g01159006
(1) Filler cap for the aftercooler cooling system
(2) Filler cap for the jacket water cooling system
(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.
SEBU7792-03 129
Maintenance Section
Cooling System Coolant Level - Check

i02317855 If the needle is in the red range, allow the system

to cool and add coolant.
Cooling System Coolant Level
- Check i01985667

SMCS Code: 1353; 1395 Cooling System Coolant

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.
Sample (Level 1) - Obtain
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 incor-
rect interpretation that could lead to concerns by both
dealers and customers.
Note: Level 1 results may indicate a need for
Level 2 Analysis.

Cooling System Coolant Additive contains alkali.

Avoid contact with skin and eyes.

g01028921
Illustration 152
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.

g01159008
Illustration 151
(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.

Park the machine on a level surface and engage the

parking brake.

Use level gauges (1) and (2) to check the coolant

levels. The needle should be in the green range.
130 SEBU7792-03
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

Cooling System Coolant

Sample (Level 2) - Obtain
SMCS Code: 1395-554

NOTICE
g01028922 Always use a designated pump for oil sampling, and
Illustration 153
use a separate designated pump for coolant sampling.
Left side view of engine Using the same pump for both types of samples may
(2) Sampling valve contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
Sampling valve (2) for the water cooled aftercooler rect interpretation that could lead to concerns by both
system is located on the left side of the engine water dealers and customers.
pump.

Obtain the sample of the coolant as close as possible

to the recommended sampling interval. In order
to receive the full effect of S·O·S analysis, 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
your Caterpillar dealer.

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 Illustration 154
g01028921
samples. Right side view of the engine
(1) Sampling valve
• Keep the unused sampling bottles stored in plastic
bags.
Sampling valve (1) for the jacket water cooling system
is located on the right side of the engine water pump.
• Obtain coolant samples directly from the coolant
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. g01028922
Illustration 155
Left side view of the engine
(2) Sampling valve
SEBU7792-03 131
Maintenance Section
Cooling System Pressure Cap - Clean/Replace

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 g01159005
Illustration 156
Cooling System Pressure Cap (1) Filler cap for the aftercooler cooling system

- Clean/Replace (2) Filler cap for the jacket water cooling system

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

SMCS Code: 1382 relieve the pressure.

3. Inspect the filler caps for damage, for foreign

material, and for deposits.
Personal injury can result from hot coolant, steam
and alkali. 4. Clean the filler caps with a clean cloth or replace
the filler caps, if necessary.
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines 5. Install the filler caps.
to heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.

Remove cooling system pressure cap slowly to

relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
touch with your bare hand.

Do not attempt to tighten hose connections when

the coolant is hot, the hose can come off causing
burns.

Cooling System Coolant Additive contains alkali.

Avoid contact with skin and eyes.

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

parking brake and stop the engine.
132 SEBU7792-03
Maintenance Section
Cooling System Relief Valve - Clean

i02347062 2. Slowly remove filler caps (1) and (2). This will
relieve the pressure.
Cooling System Relief Valve -
Clean 3. Remove the bolts from the relief valve and remove
the valve assembly.
SMCS Code: 1370

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 Illustration 158
g00302286
touch with your bare hand. (4) Valve
(5) Valve seals
Do not attempt to tighten hose connections when (6) Gasket
the coolant is hot, the hose can come off causing (7) Valve cover
burns. (8) Mounting bolts

Cooling System Coolant Additive contains alkali. 4. Inspect valve (4),valve seals (5) and gasket (6).
Avoid contact with skin and eyes. 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.
1. Park the machine on a level surface. Engage the
parking brake and stop the motor.
5. Inspect valve cover (7) and mounting bolts (8).
6. Assemble the relief valve. Install the relief valve.
7. Install the filler caps.

g01172742
Illustration 157
(1) Filler cap for the aftercooler cooling system
(2) Filler cap for the jacket water cooling system
(3) Cooling system relief valves
SEBU7792-03 133
Maintenance Section
Cooling System Water Temperature Regulator - Replace

i02347151

Cooling System Water

Temperature Regulator -
Replace
SMCS Code: 1355; 1393

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.
g01159005
Illustration 159
(1) Filler cap for the aftercooler cooling system
(2) Filler cap for the jacket water cooling system
2. Remove filler caps (1) and (2) slowly in order to
relieve the pressure.

Cooling System Coolant Additive contains alkali.

Avoid contact with skin and eyes.

Note: The thermostats should be replaced after

the cooling system has been cleaned. Replace the
thermostats while the cooling system is completely
drained or while the cooling system coolant is drained
to a level that is below the thermostat housing.

NOTICE
Failure to replace the engine’s thermostat on a regu-
larly scheduled basis could cause severe engine dam-
age.

Replace the four thermostats on a regular basis in

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

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

parking brake and stop the engine.

g01172817
Illustration 160

Note: Make sure that the coolant level is below the

thermostat housings.
134 SEBU7792-03
Maintenance Section
Differential Thrust Pin Clearance - Check

3. Disconnect the hose assemblies from thermostat i02320510

housing assemblies (3).
Differential Thrust Pin
4. Remove the thermostat housing assemblies. Clearance - Check
5. Remove the gasket, the thermostat, and the seal SMCS Code: 3258; 3260; 3284
from the thermostat housing assembly.

NOTICE
Former thermostats may be used, if they meet test
specifications and are not damaged or have excessive
buildup or deposits.

NOTICE
Since Caterpillar engines incorporate a shunt design
cooling system, it is mandatory to always operate the
engine with a thermostat.

Depending on load, failure to operate with a thermo-

stat could result in either an overheating or an over-
g01160191
cooling condition. Illustration 161

See the Adjustment Procedure For the Pin. This

NOTICE adjustment procedure is located in the Power Train
If the thermostat is installed incorrectly, it will cause Testing and Adjusting, “Differential and Bevel Gear -
the engine to overheat. Adjust” for your machine.

6. Install a new seal in the thermostat housing. Install i02320548

a new thermostat and a new gasket.
Differential and Final Drive
Repeat Steps 5 and 6 for the three remaining
thermostats.
Breather - Replace
SMCS Code: 3258; 4050
7. Install the thermostat housing assemblies on
the engine cylinder head. Connect the hose
assemblies to the thermostat housing assemblies.

8. Tighten the hose clamps.

g01160212
Illustration 162

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

parking brake and stop the engine.
SEBU7792-03
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 S·O·S (Scheduled
Oil Sampling) program. For more information on
S·O·S services, refer to Operation and Maintenance
Manual, “S·O·S Information”. When a S·O·S
program is used, the oil change interval is based
on the following:
• The condition of the oil
• The S·O·S recommendation
When a S·O·S program is not used, the oil change
interval is based on the following:
• 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.
g01160272
Illustration 163
1. Rotate the wheels so that final drive drain plug (1)
is in the lowest position on the rear wheel.
2. Park the machine on a level surface. Engage the
parking brake and stop the engine.
135
Maintenance Section
Differential and Final Drive Oil - Change
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
3. Remove the final drive drain plug. Drain the oil
into a suitable container.
4. Clean the drain plug. Install the drain plug.
5. Repeat Step 1 through Step 4 for the other final
drive.
g01160274
Illustration 164
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.
136
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 −10°C (14°F), 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.
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.
Note: The final drives may need to be repositioned in
order to place the final drive drain plug in the lowest
position.
Note: Allow oil to fill all of the compartments. Correct
oil levels are critical in the differential and final drives.
g01160268
Illustration 165
13. Maintain the proper oil level (5) for the differential
to the bottom of sight gauge (4).
14. Operate the machine on level ground for a few
minutes.
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.
SEBU7792-03
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
Differential and Final Drive Oil
- Inspect
SMCS Code: 4208
Inspect the differential and final drive oil for any of the
following symptoms that may indicate a mechanical
failure:
• A high amount of metal on the magnetic plug
• An increased level of nickel concentration in the
S·O·S sample
• An increase in the size of the particle count in the
S·O·S sample
• Oil leaks in the area around the drive wheel
bearings
The rear wheel bearings do not need to be adjusted
or inspected until the scheduled overhaul. Unless a
symptom of an obvious failure appears, do not adjust
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.
i02394551
Differential and Final Drive Oil
Level - Check
SMCS Code: 3258; 4050
Correct oil levels are critical in the differential and
final drives. Check the oil level after repairs and after
maintenance. Check the oil level prior to operation.
SEBU7792-03 137
Maintenance Section
Differential and Final Drive Oil Sample - Obtain

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.

g01192672
Illustration 168

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
Illustration 166
g01195747 at the correct oil level. Make sure that the filler
Location of the sight gauge for the differential and final drives
plug is positioned above the oil level in the final
drive in order to prevent any oil from draining out.
1. Park the machine on a level surface and engage Allow the oil to fill all of the compartments before
the parking brake. 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

Differential and Final Drive Oil

Sample - Obtain
SMCS Code: 3258-008; 4050-008; 4070-008; 7542

g01160336
Illustration 167

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.

g01160351
Illustration 169
138
Maintenance Section
Drive Shaft Slip Joint - Lubricate
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 incor-
rect interpretation that could lead to concerns by both
dealers and customers.
Sampling valve (1) for the differential and final drive
oil is located on the base of the rear axle oil filter.
Refer to the following publications for information
about obtaining an oil sample.
• Operation and Maintenance Manual, “S·O·S
Information”
• Special Publication, SEBU6250, “S·O·S Oil
Analysis”
• Special Publication, PEHP6001, “How To Take A
Good Oil Sample”
• Special Publication, PEDP8025, “Fluid Analysis
Interpretaion Guide”
i02321492
Drive Shaft Slip Joint -
Lubricate
SMCS Code: 3253
g01160565
Illustration 170
Park the machine on a level surface. Engage the
parking brake and stop the engine.
SEBU7792-03
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.
1. Park the machine on a level surface. Engage the
parking brake and stop the engine.
g00102316
Illustration 171
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.
6. Install clean primary air filter elements. Install the
covers for the air filter housings.
Note: Refer to “Cleaning Primary Air Filter Elements”.
SEBU7792-03 139
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
• 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 ser-
vices available at participating Caterpillar dealers. The
Caterpillar cleaning process uses proven procedures
to assure consistent quality and sufficient filter life.

Observe the following guidelines if you attempt to

clean the filter element:

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

move dust.

Do not wash the filter element.

Use low pressure compressed air in order to remove g00281692

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.
Illustration 172
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).

Do not use air filters with damaged pleats, gaskets, or Aim the hose so that the air flows inside the element
seals. Dirt entering the engine will cause damage to along the length of the filter in order to help prevent
engine components. 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.
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 Vacuum Cleaning
air filter element is cleaned, check for rips or tears
in the filter material. The primary air filter element Vacuum cleaning is another method for cleaning
should be replaced at least one time per year. This primary air filter elements which require daily cleaning
replacement should be performed regardless of the because of a dry, dusty environment. Cleaning with
number of cleanings. pressurized air is recommended prior to vacuum
cleaning. Vacuum cleaning will not remove deposits
of carbon and oil.
NOTICE
Do not clean the air filter elements by bumping or tap-
ping. This could damage the seals. Do not use ele-
ments with damaged pleats, gaskets, or seals. Dam-
aged elements will allow dirt to pass through. Engine
damage could result.

Visually inspect the primary air filter elements before

cleaning. Inspect the air filter elements for damage
to the seal, the gaskets, and the outer cover. Discard
any damaged air filter elements.

There are two common methods that are used to

clean primary air filter elements:

• Pressurized air
140 SEBU7792-03
Maintenance Section
Engine Air Filter Secondary Element - Replace

Inspecting the Primary Air Filter

Elements

g00644798
Illustration 174
(1) Secondary element
g00281693
Illustration 173
2. Remove secondary elements (1) and properly
Inspect the clean, dry primary air filter element. Use discard the secondary elements.
a 60 watt blue light in a dark room or in a similar
facility. Place the blue light in the primary air filter 3. Cover the air inlet openings. Clean the inside of
element. Rotate the primary air filter element. Inspect the air cleaner housings.
the primary air filter element for tears and/or holes.
Inspect the primary air filter element for light that may 4. Uncover the air inlet openings. Install the new
show through the filter material. If it is necessary in secondary elements.
order to confirm the result, compare the primary air
filter element to a new primary air filter element that 5. Install the primary elements.
has the same part number.
i02363128
Do not use a primary air filter element that has any
tears and/or holes in the filter material. Do not use Engine Air Precleaner - Clean
a primary air filter element with damaged pleats,
gaskets or seals. Discard damaged primary air filter SMCS Code: 1055
elements.

i02347040

Engine Air Filter Secondary

Element - Replace
SMCS Code: 1051; 1054

NOTICE
Always replace the secondary element. Do not at-
tempt to reuse it by cleaning. Engine damage could
result.
g01180274
Illustration 175
Note: Replace the engine air filter secondary
elements when you service the engine air filter Note: Do not paint dust valves (3). Paint will cause
primary elements for the third time. Replace the the rubber to harden and the rubber may not seal
secondary elements if the exhaust smoke remains properly.
black and the clean primary elements have been
installed. Perform the following procedure for each engine air
precleaner.
1. Park the machine on a level surface. Engage the
parking brake and stop the engine. 1. Park the machine on a level surface. Engage the
parking brake and stop the engine.
SEBU7792-03 141
Maintenance Section
Engine Components - Clean/Inspect, Rebuild/Install Reman, Install New

2. Loosen clamp (1) on the precleaner and remove • Piston Rings

lower precleaner bowl (2) and dust valve (3).
• Wiring Harness
3. Clean the lower precleaner bowl and the dust
valve with air pressure.
Rebuild Components and/or Install
4. Make sure that all of the tubes within the Remanufactured Components
precleaner are free of dirt. Clean the tubes, if
necessary. • Cylinder Heads
5. Install the clean lower precleaner bowl, and the • Turbochargers
clean dust valve and tighten the clamp on the
precleaner. • Oil Coolers

NOTICE • Oil Pump

Do not operate the machine with the dust valves re-
moved. Engine damage can occur. • Scavenge Oil Pump
• Water Pump
i02381002
Clean Components and Inspect
Engine Components - Components for Reusability
Clean/Inspect, Rebuild/Install
Reman, Install New • Aftercooler Core

SMCS Code: 1000-012-IC, NW; 1000-022-MC;

• Camshaft
1000-571-IC; 1000
• Camshaft Lifters
Caterpillar recommends this additional maintenance
for the following engine components. Consult your
• Connecting Rods
Caterpillar dealer for further information.
• Crankshaft
The quantity of burned fuel that is shown with the
service hours assumes a load factor of 40 percent. If
• Cylinder Block
the load factor is higher than 40 percent, the number
of service hours for the overhaul interval will be
• Cylinder Liners
lower. If the load factor is lower than 40 percent, the
number of service hours for the overhaul interval will
• Damper
be higher. The quantity of consumed fuel is a better
indicator for the overhaul interval than service hours.
• Gear Train
• Piston Crowns and Piston Skirts
Install New Components
• Piston Pins
• All Seals, Gaskets and O-rings
• Spacer Plates
• Camshaft Bearings
i02381004
• Engine Mounts
Engine Components -
• Engine Software
Rebuild/Install Reman
• Fuel Pressure Regulating Valve
SMCS Code: 1000-022-MC; 1000
• Fuel Priming Pump
Caterpillar recommends this additional maintenance
• Gear Train Bushings, Bearings and Thrust Plates for the following engine components. Consult your
Caterpillar dealer for further information.
• Main Bearings, Rod Bearings and Crankshaft
Thrust Plates
142 SEBU7792-03
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
g01160965
Illustration 176
SMCS Code: 1317-070
1. Park the machine on a level surface and engage
The engine in this machine is equipped with six
the parking brake.
engine crankcase breathers. Two of the breathers
are on the valve covers on the right side and four of
2. Stop the engine. Loosen clamps (4). Remove
the breathers are on the valve covers on the left side.
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.
SEBU7792-03 143
Maintenance Section
Engine Oil Filter (Oil Renewal System) - Change

i02398716 1. Remove used engine oil filters (1) and discard the
used engine oil filters .
Engine Oil Filter (Oil Renewal
System) - Change 2. Clean the oil filter base assemblies. Make sure
that all of the former gaskets are removed.
(If Equipped)
3. Apply a thin film of clean engine oil to each seal of
SMCS Code: 1318; 1348; 1349 each new engine oil filter .

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

each filter until the seal of each engine oil filter
Hot oil and hot components can cause personal contacts the base. Note the position of the index
injury. Do not allow hot oil or hot components to marks on each filter in relation to a fixed point on
contact the skin. the filter base.

Note: Caterpillar filters have rotation index marks

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

Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
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: 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 move-
ment.

Use caution when working between the wheels

and the frame. If the wheels must be turned, en-
sure that all personnel are clear of the machine
Illustration 177
g01162192 before any movement.
(1) Engine oil filters
(2) Oil filler cap
(3) Dipstick
144
Maintenance Section
Engine Oil Level - Log Additions
NOTICE
Do not under fill or overfill engine crankcase with oil.
Either condition can cause engine damage.
g01162246
Illustration 178
Location of the dipstick for the engine oil
The tire and the wheel have been removed for ease of viewing.
g01162249
Illustration 179
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.
SEBU7792-03
i02326857
Engine Oil Level - Log
Additions
(If Equipped with the Oil
Renewal System)
SMCS Code: 1348
g00408438
Illustration 180
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 S·O·S analysis will determine if the oil needs to
be changed.
The graph in Illustration 180 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 S·O·S analysis.
SEBU7792-03 145
Maintenance Section
Engine Oil Sample - Obtain

i02326499

Engine Oil Sample - Obtain

Hot oil and hot components can cause personal
SMCS Code: 1000-008 injury. Do not allow hot oil or hot components to
contact the skin.

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

Refer to Special Publication, NENG2500, “Caterpillar

g01162265
Illustration 181
Sampling Valve For The Engine Oil
The sampling valve for the engine oil is located above
the engine oil filters.
Refer to the following publications for information
about obtaining an oil sample.
• Operation and Maintenance Manual, “S·O·S
Information”
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
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.

• Special Publication, SEBU6250, “S·O·S Oil Consult your Caterpillar dealer for the latest oil
Analysis” recommendations.

• Special Publication, PEHP6001, “How To Take A
Good Oil Sample”
• Special Publication, PEDP8025, “Fluid Analysis
Interpretation Guide”
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.

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 S·O·S Oil Analysis will determine if the oil needs
to be changed. In order to change the engine oil
filters only, refer to Operation and Maintenance
Manual, “Engine Oil Filter (Oil Renewal System) -
Change”. For more information on the Oil Renewal
System, refer to Systems Operation, RENR2223, “Oil Illustration 182
g01162319
Renewal System”.
146
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 .
g01162326
Illustration 183
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.
4. Apply a thin film of clean engine oil to the seal of
each new engine oil filter.
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
rotation index marks as a guide.
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.
SEBU7792-03
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.
Hot engine components can cause burns. Allow
additional time for the engine to cool before mea-
suring valve clearance.
Electrical shock hazard. The electronic unit injec-
tor system uses 90-120 volts.
Valve Bridge
The engine in this machine is equipped with a
nonadjustable valve bridge. Proceed with the
valve lash adjustment.
Valve Lash Adjustment
NOTICE
Operation of Caterpillar Engines with improper engine
valve lash adjustments will reduce the engine efficien-
cy. This reduced efficiency could result in excessive
fuel usage and/or shortened engine component life.
Measure the engine valve lash with the engine
stopped. To obtain an accurate measurement, allow
at least 20 minutes for the valves to cool to engine
cylinder head and block temperature.
If the valve clearance is within 0.08 mm (0.0031 inch)
of the given nominal clearance, no adjustment is
required. If the clearance is not within the given limits,
set the clearance to the amount that is specified in
the chart.
SEBU7792-03 147
Maintenance Section
Engine Water Pump - Inspect

Table 7 Water Pump for the Jacket Water

VALVE CLEARANCE SETTING Cooling System
Inlet 0.5 mm (0.02 inch)
A water pump (1) that has failed might cause
Exhaust 1.00 mm (0.04 inch) 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”.
g00653920
Illustration 184 Auxiliary Water Pump for the
To check the engine valve lash, refer to System Aftercooler Cooling System
Operation, Testing And Adjusting, SENR1123,
“3500B Engines For Caterpillar Built Machines”, An auxiliary water pump (2) that has failed might
“Valve Lash and Valve Bridge Adjustment”. Consult cause severe engine overheating problems. The
your Caterpillar dealer for any additional information. engine overheating problems could result in the
following problems.

i02326985 • Valve failures

Engine Water Pump - Inspect • Warped intake manifolds
SMCS Code: 1361
• 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”.

g01162405
Illustration 185
(1) Water pump for the jacket water cooling system
(2) Auxiliary water pump for the aftercooler cooling system
148
Maintenance Section
Ether Starting Aid Cylinder - Replace
i02330233
Ether Starting Aid Cylinder -
Replace
SMCS Code: 1456
Breathing ether vapors or repeated contact of
ether with skin can cause personal injury. Person-
al injury may occur from failure to adhere to the
following procedures.
Use ether only in well ventilated areas.
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 operator’s 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.
Keep ether cylinders out of the reach of unautho-
rized personnel.
To avoid possible injury, be sure the brakes are ap-
plied and all controls are in Hold or Neutral when
starting the engine.
Illustration 186
g01163382
The two ether starting aid cylinders are mounted
behind the radiator.
1. Park the machine on a level surface. Engage the
parking brake and stop the engine.
2. Loosen the clamps and unscrew the ether starting
aid cylinders.
SEBU7792-03
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
Frame - Clean/Inspect
SMCS Code: 7051
Note: The graphics that are shown are for illustrative
purposes. This is an in-chassis inspection.
When it is necessary to work under the machine
with the body (bed) raised, attach the body (bed)
retaining cable to the rear tow point. Install the
rear tow point pin through the end of the retaining
cable.
Failure to properly secure the body (bed) may re-
sult in personal injury or death.
g01167516
Illustration 187
1. Park the machine on a level surface and engage
the parking brake.
2. Raise the dump body to the fully raised position
and install the truck body retaining cable to the
rear tow point pin. For the proper procedure, refer
to Operations and Maintenance Manual, “Cable
(Truck Body Retaining)”.
3. Stop the engine.
SEBU7792-03 149
Maintenance Section
Frame - Clean/Inspect

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

When it is necessary to work under the machine

with the body (bed) raised, attach the body (bed)
retaining cable to the rear tow point. Install the
rear tow point pin through the end of the retaining
cable.
Failure to properly secure the body (bed) may re-
sult in personal injury or death.
g00980907
Illustration 189
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.

1. 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)”.

g00980933
Illustration 190

b. Inspect the area around the bolt holes of the

rear axle a-frame.

g00980903
Illustration 188

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.
150 SEBU7792-03
Maintenance Section
Frame and Body - Inspect

g00980956 g00981044
Illustration 191 Illustration 193

c. Inspect the bottom of the differential housing in e. Inspect the differential housing in the area
the area that is indicated by shading. around the lower half of the differential
mounting surface that is indicated by shading.

i02340811

Frame and Body - Inspect

SMCS Code: 7258

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
Illustration 192
g01167529 cable.

d. Inspect the top rear sides of the differential Failure to properly secure the body (bed) may re-
housing in the area that is indicated by shading. sult in personal injury or death.

1. Park the machine on a level surface and engage

the parking brake.

2. Raise the dump body to the fully raised position

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

3. Stop the engine.

SEBU7792-03
g01167539
Illustration 194
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.
i02340837
Frame and Body Support Pads
- Clean/Inspect
SMCS Code: 7258
When it is necessary to work under the machine
with the body (bed) raised, attach the body (bed)
retaining cable to the rear tow point. Install the
rear tow point pin through the end of the retaining
cable.
Failure to properly secure the body (bed) may re-
sult in personal injury or death.
1. Park the machine on a level surface and engage
the parking brake.
151
Maintenance Section
Frame and Body Support Pads - Clean/Inspect
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.
g01167566
Illustration 195
4. Clean the body support pads with high pressure
water or steam.
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
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 move-
ment.
Use caution when working between the wheels
and the frame. If the wheels must be turned, en-
sure that all personnel are clear of the machine
before any movement.
152 SEBU7792-03
Maintenance Section
Front Wheel Oil - Change

1. Position the front wheel so that drain plug (1) is

facing downward.

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

parking brake and stop the engine.

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

Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.
g01163437
Illustration 196

3. Remove the drain plug.

1. Park the machine on a level surface. Engage the
parking brake and stop the engine.
4. Allow the oil to drain into a suitable container.
2. Remove breather (1) from each front wheel.
5. Clean the drain plug and install the drain plug.
3. Install a new breather on each front wheel.
6. Remove the filler plug (2).

i02330775 7. Fill the oil compartment to the bottom of the

opening for the filler plug. Refer to Operation
Front Wheel Oil - Change and Maintenance Manual, “Lubricant Viscosities”.
Refer to Operation and Maintenance Manual,
SMCS Code: 4006 “Capacities (Refill)”.

Note: The oil change interval for the front wheel 8. Clean the filler plug and install the filler plug. Use
bearing can be monitored with the S·O·S scheduled the same procedure for the other front wheel
oil sampling program. The interval is based on bearing.
the condition of the oil. If the S·O·S scheduled oil
sampling program is not used, the oil change for
the front wheel bearing should be performed at 500 i02388737
service hours or 3 months.
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
S·O·S sample

• An increase in the size of the particle count in the

S·O·S sample
g01163440
Illustration 197
• Oil leaks in the area around the front wheel spindle
SEBU7792-03
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
SMCS Code: 4201-008; 7542
g01180364
Illustration 198
Filler plug for the front wheel
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 incor-
rect interpretation that could lead to concerns by both
dealers and customers.
The oil sample for the front wheel is obtained with a
sampling gun through the filler plug.
Refer to the following publications for information
about obtaining an oil sample.
• Operation and Maintenance Manual, “S·O·S
Information”
• Special Publication, SEBU6250, “S·O·S Oil
Analysis”
• Special Publication, PEHP6001, “How To Take A
Good Oil Sample”
• Special Publication, PEDP8025, “Fluid Analysis
Interpretaion Guide”
153
Maintenance Section
Front Wheel Oil Sample - Obtain
i02435121
Fuel System - Prime
SMCS Code: 1258
Fuel leaked or spilled onto hot surfaces or elec-
trical 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.
1. Park the machine on a level surface. Engage the
parking brake and stop the engine.
g01167459
Illustration 199
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.
154 SEBU7792-03
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
Park the machine on a level surface. Engage the
parking brake and stop the engine.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
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.
g01167092
Illustration 200 To help prevent possible injury, turn the battery
The fuel/water separators are located on the right inside frame rail disconnect switch to the OFF position when
in front of the front axle. changing fuel filters or water separator elements.
Clean up fuel spills immediately.
SEBU7792-03 155
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace

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

Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

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 Illustration 202
g01167178
system parts. The fuel system should be primed prior
The fuel/water separator is located on the right inside frame rail
to starting the engine. in front of the front axle.

1. Park the machine on a level surface and engage 3. Remove drain tube assembly (3) from the bottom
the parking brake. 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.

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
g01167276 fixed point on the mounting base.
Illustration 201
View of the back side of the fuel tank
Note: There are rotation index marks on each filter
2. Stop the engine and close fuel shutoff valve (1). that is spaced 90 degrees (1/4 turn) away from
each other. When you tighten the elements, use the
rotation index marks as a guide.

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.

156 SEBU7792-03
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
7. Install the filter element and the filter housing.
Tighten bolt (2) to a torque of 25 ± 7 N·m
(18 ± 5 lb ft).
8. Open the fuel shutoff valve. Prime the fuel system.
Refer to Operation and Maintenance Manual,
“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.

Fuel System Primary Filter - i02345997

Clean Fuel System Priming Filter -

(If Equipped) Replace
SMCS Code: 1260; 1261
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.
1. Park the machine on a level surface and engage
the parking brake.
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.
1. Park the machine on a level surface and engage
the parking brake.

g01167276
g01167019 Illustration 204
Illustration 203
View of the back side of the fuel tank 2. Stop the engine and close fuel shutoff valve (1).
2. Stop the engine and close fuel shutoff valve (1).

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.
SEBU7792-03
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the machine. Be prepared
to collect the fluid with suitable containers before
opening any compartment or disassembling any com-
ponent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide”, for tools and sup-
plies suitable to collect and contain fluids.
Dispose of all fluids according to local regulations and
mandates.
g01172157
Illustration 205
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.
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 filter, use the rotation
index marks as a guide.
157
Maintenance Section
Fuel System Secondary Filter - Replace
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 filter to the amount
that is required for final installation. Make sure that
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
1. Park the machine on a level surface. Engage the
parking brake and stop the engine.
g01162420
Illustration 206
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 in-
stalling. The fuel would not be filtered and could be
contaminated. Contaminated fuel will cause acceler-
ated wear to fuel system parts.
4. Lubricate the seals of the new filters with clean
diesel fuel.
158
Maintenance Section
Fuel Tank Water and Sediment - Drain
5. Install the new filters by hand until the seal
contacts the mounting base. Note the position of
the index marks on the filters in relation to a fixed
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 filters, use the rotation
index marks as a guide.
6. 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.
7. Prime the fuel system. Refer to the Operation and
Maintenance Manual, “Fuel System - Prime”.
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.
i02338067
Fuel Tank Water and Sediment
- Drain
SMCS Code: 1273
g01167012
Illustration 207
View of the back side of the fuel tank
SEBU7792-03
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
Park the machine on a level surface. Engage the
parking brake and stop the engine.
Open fuel tank drain valve (1) and allow the moisture
and the sediment to drain into a suitable container.
Close the drain valve.
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.
NOTICE
Although HID bulb materials may change over time,
HID bulbs produced at the time of the printing of this
manual contain mercury. When disposing of this com-
ponent, or any waste that contains mercury, please
use caution and comply with any applicable laws.
1. Remove the electrical power from the high
intensity discharge lamp (HID). The electrical
power must be removed from the HID lamp for
at least five minutes, in order to ensure that the
bulb is cool.
SEBU7792-03
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 bulb’s 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 lamp’s 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.
i02335762
Hoist Screens - Clean
SMCS Code: 5068
When it is necessary to work under the machine
with the body (bed) raised, attach the body (bed)
retaining cable to the rear tow point. Install the
rear tow point pin through the end of the retaining
cable.
Failure to properly secure the body (bed) may re-
sult in personal injury or death.
159
Maintenance Section
Hoist Screens - Clean
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
Clean the screens whenever there is a failure of the
brakes, hoist cylinders, or hoist pumps.
1. Park the machine on a level surface and engage
the parking brake.
2. Raise the truck body to the fully raised position
and install the truck body retaining cable to the
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.
g01165827
Illustration 208
The hoist screens are located on the right rear of the center tube.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
4. Remove the bolts that attach hoses (2) to housings
(3) for the hoist screen. Drain the oil from the lines
into a suitable container.
160 SEBU7792-03
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.

7. 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.

8. Remove the truck body retaining cable and lower

the body.

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”.

i02340012

Hoist and Brake Tank Breather Illustration 209

g01172423

- Replace 4. Remove breather (1) and discard the breather

properly.
SMCS Code: 5057
5. Install a new breather.

6. Remove the truck body retaining cable and lower

When it is necessary to work under the machine the body.
with the body (bed) raised, attach the body (bed)
retaining cable to the rear tow point. Install the
i02685600
rear tow point pin through the end of the retaining
cable. Hoist and Brake Tank Oil -
Failure to properly secure the body (bed) may re- Change
sult in personal injury or death.
SMCS Code: 5056
1. Park the machine on a level surface and engage
NOTICE
the parking brake.
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
2. Raise the truck body to the fully raised position
ing, adjusting and repair of the product. Be prepared to
and install the truck body retaining cable to the
collect the fluid with suitable containers before open-
rear tow point pin. For the proper procedure for the
ing any compartment or disassembling any compo-
installation and removal of the truck body retaining
nent containing fluids.
cable, refer to Operations and Maintenance
Manual, “Cable (Truck Body Retaining)”.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
3. Stop the engine.
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

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.
SEBU7792-03
g01172912
Illustration 210
1. Remove filler cap (1) in order to prevent a vacuum
in the tank. Install the filler cap after the tank has
been drained. This will prevent dirt from entering
the system.
2. Remove tank drain valve plug (3). Install a
88.0 mm (3.50 inch) long NPT pipe nipple in
order to open the internal drain valve. The outer
diameter of the NPT pipe nipple should be 25 mm
(1 inch). Drain the oil into a suitable container.
Note: Hand tighten the NPT pipe nipple. Do not use
tools.
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”.
Refer to Operation and Maintenance Manual,
“Capacities (Refill)”.
161
Maintenance Section
Hoist and Brake Tank Oil Level - Check
g01349223
Illustration 211
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.
10. Add oil to the tank in order to raise the oil level to
the “FULL” mark in upper sight gauge (2).
11. Repeat Step 9 and Step 10 until the oil stabilizes
in the “FULL” mark in the upper sight gauge.
12. Lower the guard on the engine shutdown control.
Start the engine and operate the engine at low
idle. Check for leaks and make necessary repairs.
13. Raise the truck body until the hoist cylinders are
extended halfway. Lower the truck body and add
oil, if necessary.
14. Raise the truck body until the hoist cylinders are
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.
162 SEBU7792-03
Maintenance Section
Hoist and Brake Tank Oil Sample - Obtain

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

Analysis”

• Special Publication, PEHP6001, “How To Take A

Good Oil Sample”

• Special Publication, PEDP8025, “Fluid Analysis

Interpretaion Guide”

i02685621

Hoist and Brake Tank Suction

Screen - Inspect/Clean/Replace
g01172846
Illustration 212 SMCS Code: 5056
2. Maintain the oil level to the “FULL” mark on sight
NOTICE
gauge (2). If necessary, remove filler cap (1) and
Care must be taken to ensure that fluids are contained
add oil.
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
i02336350 collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
Hoist and Brake Tank Oil nent containing fluids.
Sample - Obtain Refer to Special Publication, NENG2500, “Caterpillar
SMCS Code: 5056-008; 7542 Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

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.

g01188933
Illustration 213
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.

Refer to the following publications for information Illustration 214

g01165906
about obtaining an oil sample.

• Operation and Maintenance Manual, “S·O·S

Information”
SEBU7792-03
Hoist and Brake Tank Suction Screen - Inspect/Clean/Replace
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.
Note: Hand tighten the NPT pipe nipple. Do not use
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.
g01165914
Illustration 215
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.
7. Install the clean suction screens and install the
hoses and flanges.
8. Clean the cover for the front of hoist and brake
tank in clean, nonflammable solvent. Inspect the
cover gasket. If the gasket is damaged, replace
the gasket.
9. Install the cover to the front of the tank.
10. Fill the hoist/brake tank. Refer to Operation and
Maintenance Manual, “Lubricant Viscosities”.
Refer to Operation and Maintenance Manual,
“Capacities (Refill)”.
163
Maintenance Section
g01349223
Illustration 216
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.
g01165956
Illustration 217
12. Add oil to the tank in order to raise the oil level to
the “FULL” mark in upper sight gauge (5).
13. Repeat Step 11 and Step 12 until the oil stabilizes
in the “FULL” mark in the upper sight gauge.
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.
15. Raise the truck body until the hoist cylinders are
extended halfway. Lower the truck body and add
oil, if necessary.
16. Raise the truck body until the hoist cylinders are
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.
164 SEBU7792-03
Maintenance Section
Magnetic Plug (Wheels) - Check

i02346919 i02398678

Magnetic Plug (Wheels) - Oil Filter (Steering, Hydraulic

Check Fan) - Replace
SMCS Code: 0663
(Hydraulic Pump Case Drain)
SMCS Code: 5068-510-ZH; 5068-510-HFN
Note: A weekly inspection of the magnetic plugs is
strongly recommended.

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, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g01172641 Refer to Special Publication, NENG2500, “Caterpillar
Illustration 218
(1) Magnetic plug on the front wheel Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

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

parking brake and stop the engine.

g01172642
Illustration 219
(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.

g01163566
Illustration 220

2. Push button (1) on the breaker relief valve.

SEBU7792-03
3. Slowly remove cap (2) on the steering hydraulic
tank in order to relieve the pressure.
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
contacts the mounting base. Note the position of
the index marks on the filters 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 filters, use the rotation
index marks as a guide.
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. 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.
10. Check the oil level. If necessary, add oil. Refer
to Operation and Maintenance Manual, “Steering
System Oil Level - Check”.
165
Maintenance Section
Oil Filter - Inspect
i02106227
Oil Filter - Inspect
SMCS Code: 1318; 3067; 5068; 7528
Inspect a Used Filter for Debris
g00100013
Illustration 221
The element is shown with debris.
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.
166
Maintenance Section
Parking Brake Release Oil Filter - Replace
i02320227
Parking Brake Release Oil
Filter - Replace
SMCS Code: 4257; 4295
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
1. Park the machine on a level surface. Engage the
parking brake and stop the engine.
g01160070
Illustration 222
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.
SEBU7792-03
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.
7. Install the filter housing.
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”.
i02340749
Radiator Core - Clean
SMCS Code: 1353
g01167490
Illustration 223
You can use compressed air, high pressure water,
or steam to remove dust and other debris from the
air side of the radiator core. However, the use of
compressed air is preferred.
SEBU7792-03 167
Maintenance Section
Rear Axle Housing End Play - Adjust

i02783212
NOTICE
High water pressure water and high water volume can
Rear Axle Oil Filter - Replace
damage the radiator.
SMCS Code: 4070; 5068
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.

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 g01162468
Illustration 224
applications.

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 Hot oil and hot components can cause personal
Play - Adjust”. Consult your Caterpillar dealer for any injury. Do not allow hot oil or hot components to
additional information. contact the skin.

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

Refer to Special Publication, NENG2500, “Caterpillar

Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

Note: The machine is shipped with a 6 micron filter

element for the rear axle. Caterpillar recommends
the use of a 6 micron element for the initial 50 service
hours. If the 6 micron element becomes plugged
before the initial 50 service hours, replace the 6
micron element with another 6 micron element.
When the machine reaches 50 service hours, replace
the 6 micron element with a 20 micron element. If
the element continues to become plugged after 50
service hours, consult your Caterpillar dealer.
168
Maintenance Section
Receiver Dryer (Refrigerant) - Replace
1. Park the machine on a level surface. Engage the
parking brake and stop the engine.
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.
Discard the used filter element.
4. Wash the filter housing in clean nonflammable
solvent.
5. Inspect the seals in the filter base. If the seals are
damaged, replace seals with new seals.
6. Install the new filter element in the filter housing.
Install the filter housing.
7. 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.
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”.
Note: Correct oil levels are critical in the differential
and final drives. Check the oil level after repairs and
after maintenance.
Note: The differential and final drive oil level needs to
be checked and maintained at operating temperature.
If the oil level is checked cold, adjustment of the
oil level may be necessary when the truck reaches
operating temperature.
SEBU7792-03
i02656745
Receiver Dryer (Refrigerant) -
Replace
SMCS Code: 7322-510
Personal injury can result from contact with refrig-
erant.
Contact with refrigerant can cause frost bite. Keep
face and hands away to help prevent injury.
Protective goggles must always be worn when re-
frigerant lines are opened, even if the gauges in-
dicate the system is empty of refrigerant.
Always use precaution when a fitting is removed.
Slowly loosen the fitting. If the system is still un-
der 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 con-
ditioner 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 prop-
erly remove the refrigerant from the air condition-
ing system.
NOTICE
If the refrigerant system has been open to the outside
air (without being plugged) for more than 30 minutes,
the receiver-dryer must be replaced. Moisture will en-
ter an open refrigerant system and cause corrosion
which will lead to component failure.
SEBU7792-03 169
Maintenance Section
Rim - Inspect

g01159180
Illustration 225
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 g01330970

Illustration 226
SMCS Code: 4209-040 Typical example
Cutaway view of the rim assembly
Inspect the rim whenever a tire is dismounted.
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.

Rim Base (3) – Inspect the rim base for the following:
wear, corrosion, cracks, and fretting.

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

wear, corrosion, cracks, and fretting.

Do not reuse rim components that are cracked,

worn, damaged, or pitted from corrosion. For more
information on the reusability of the rim components,
consult your Caterpillar dealer.
170 SEBU7792-03
Maintenance Section
Rim - Inspect

i02650677 For more information on magnetic particle inspection,

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

i02381197

Rollover Protective Structure

(ROPS) - Inspect
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 N·m (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.
g01331173
Illustration 227 Refer to Special Instruction, SEHS6929, “Inspection,
Typical example Maintenance, and Repair of ROPS and Attachment
Cutaway view of the rim assembly Installation Guidelines” or consult your Caterpillar
dealer for more information.
The following high stress areas of the rim should be
checked: i02429589

• (1) Areas of contact with flanges Seat Belt - Inspect

• (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
SMCS Code: 7327
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.

• (5) Butt welds

SEBU7792-03 171
Maintenance Section
Seat Belt - Replace

g01152685
Illustration 229

Illustration 228
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.
(1) Date of installation (retractor)
(2) Date of installation (buckle)
(3) Date of manufacture (tag) (fully extended web)
(4) Date 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.

Inspect the seat belt (3) for webbing that is worn or

i02302909
frayed. Replace the seat belt if the seat belt is worn
or frayed. Seat Suspension -
Consult your Caterpillar dealer for the replacement of Inspect/Lubricate
the seat belt and the mounting hardware.
SMCS Code: 7307; 7324
Note: Within three years of the date of installation or
within five years of the date of manufacture, replace Inspect
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 Seat Suspension
buckle, and the seat belt retractor.
Inspect the seat suspension for excessive looseness
If your machine is equipped with a seat belt and wear. If excessive looseness or wear is detected,
extension, also perform this inspection procedure for refer to Systems Operation, Testing and Adjusting,
the seat belt extension. Disassembly and Assembly, RENR8391, “Caterpillar
Comfort Series Seat with three point operator
restraint”, “Troubleshooting Chart”.
i02429594

Seat Belt - Replace Lubricate

SMCS Code: 7327-510
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.
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.
172 SEBU7792-03
Maintenance Section
Secondary Steering - Check

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.

i02798713

Secondary Steering - Check

SMCS Code: 4300-535-SST; 4324-535;
4331-535-SST

This machine is equipped with a secondary steering

system. The secondary steering will provide a limited Illustration 230
g01163448
amount of steering after steering system failure. The
(1) Steering Accumulators
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 dis-

connecting or disassembly could cause personal
injury or death. See service manual before reliev-
ing pressure or charging.

Personal injury or death can occur if steering is

g01163447
lost completely during operation. Illustration 231

Do not continue to operate the machine using the 1. Empty the truck body and park the machine on a
secondary steering. level surface. Engage the parking brake.

If the secondary steering activates during opera-
tion, immediately park the machine in a safe loca-
tion. Inspect the machine and correct the condi-
tion which made the use of the secondary steer-
ing necessary.
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

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 move-
ment.
Use caution when working between the wheels
and the frame. If the wheels must be turned, en-
sure that all personnel are clear of the machine
before any movement.
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.

5. Chock the wheels and release the parking brake.

SEBU7792-03
g01349223
Illustration 232
6. Stop the engine with ground level shutdown switch
(4). This permits the accumulators to stay charged
in order to provide stored energy for the secondary
steering system when the engine is stopped.
7. 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.
c. Turn the front wheels back to the straight ahead
position.
If the machine did not complete this series of turns,
consult your Caterpillar dealer.
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”.
173
Maintenance Section
Service Brakes - Inspect
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
• Compressed insulation material
• Insulation material with fluid saturation
• Loose insulation material
• Missing pieces of insulation material
• Tears in the insulation material
• Bent steel panels or broken steel panels
If any of these conditions exist, 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
174 SEBU7792-03
Maintenance Section
Steering Ball Stud - Inspect

• Missing pieces Inspection of Steering Ball Studs

If any of these conditions exist, perform the Table 8
necessary repairs and/or replace any damaged Recommended Tooling Krautkramer Branson USN
sound suppression covers. 52 or equivalent
Required Training Personnel that perform
Louvers the Ultrasonic testing will
be trained as UT level
Inspect the louver assembly. The louver assembly is II in accordance to the
on the front of the radiator. Inspect the louvers for the current SNT-TC-1A. This
following damage: training will include the
theory, the application, the
procedure, and the use of
• Bent steel mesh or broken steel mesh the equipment.
Personnel that perform the
• Burnt insulation material Magnetic particle testing
will be trained as MT level
• Compressed insulation material I in accordance to the
current SNT-TC-1A. This
• Insulation material with fluid saturation training will include the
theory, the application, the
• Loose insulation material procedure, and the use of
the equipment.
All training will be
• Missing pieces of insulation material documented in the
records of the person
• Tears in the insulation material that performed the test.
Personnel must
If any of these conditions exist, perform the necessary demonstrate sufficient
repairs and/or replace any damaged louvers. working skill of this
procedure and in the
methods of testing ball
i02381180 studs. Personnel must
be able to perform this
Steering Ball Stud - Inspect procedure without direct
guidance.
SMCS Code: 4303; 4305

This procedure provides instructions for the ultrasonic Note: Use a known damaged ball stud and a new
inspection of the steering cylinder and steering ball stud as baselines.
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.
SEBU7792-03 175
Maintenance Section
Steering Ball Stud - Inspect

g00842904
Illustration 233
Typical ball stud

Table 9
Critical Dimensions of Ball Studs
Sales Model Pt. No. of A B C D E F
Ball Stud
784/785 8X-9619 273 mm 188.283 mm 25.9 mm 53 mm 53.75 mm 82.55 mm
(10.7 inch) (7.4127 inch) (1.02 inch) (2.1 inch) (2.116 inch) (3.250 inch)
789 8X-9620 295 mm 210.283 mm 25.9 mm 53 mm 53.75 mm 82.55 mm
(11.6 inch) (8.2788 inch) (1.02 inch) (2.1 inch) (2.116 inch) (3.250 inch)
793 8X-9620 295 mm 210.283 mm 25.9 mm 53 mm 53.75 mm 82.55 mm
(11.6 inch) (8.2788 inch) (1.02 inch) (2.1 inch) (2.116 inch) (3.250 inch)
797 156-8136 295 mm 210.283 mm 25.9 mm 53 mm 53.75 mm 82.55 mm
(11.6 inch) (8.2788 inch) (1.02 inch) (2.1 inch) (2.116 inch) (3.250 inch)
797B 192-5702 341 mm 225.006 mm 25.9 mm 80.26 mm 79.53 mm 109.73 mm
(13.4 inch) (8.8585 inch) (1.02 inch) (3.160) (3.13 inch) (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.
176
Maintenance Section
Steering Ball Stud - Inspect
g00843601
Illustration 234
(1) Gel compound
(2) Display screen
(3) Krautkramer Branson USN 52
(4) 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.
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.
SEBU7792-03
g00843670
Illustration 235
(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.
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.
9. Document the following information.
• Date of inspection
• Serial number of the inspected truck
• Part number of the inspected ball studs
• Number of inspected ball studs
SEBU7792-03
• 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.
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.
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
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.
Safety
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.
177
Maintenance Section
Steering Ball Stud - Inspect
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) 14A is a prepared bath medium in the form of an aerosol spray.
(2) 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.
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 manufacturer’s
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.
178
Maintenance Section
Steering Ball Stud - Replace
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.
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
consult your Caterpillar dealer.
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.
SEBU7792-03
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.
Illustration 236
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.
SEBU7792-03 179
Maintenance Section
Steering System Oil - Change

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.

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

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact the skin.

1. Operate the engine until the steering hydraulic oil

is warm. Park the machine on a level surface and g01163770
Illustration 237
engage the parking brake. Stop the engine.
4. Open drain valve (1).
2. Push button (3) on the breaker relief valve.
5. Allow the oil to drain into a suitable container.
3. Slowly, remove filler cap (4) on the steering Close the drain valve.
hydraulic tank in order to relieve the pressure.
6. Remove retaining ring (6) for the filler strainer.
NOTICE
Care must be taken to ensure that fluids are contained 7. Remove filler strainer (7). Wash the cap and the
during performance of inspection, maintenance, test- strainer in clean, nonflammable solvent. Allow the
ing, adjusting and repair of the product. Be prepared to cap and the strainer to dry.
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- 8. Inspect cap seal (5). Use a new seal if the used
nent containing fluids. seal is damaged.

Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
9. Install the strainer and the retaining ring for the
strainer.
NOTICE
Do not fill the steering hydraulic tank when the engine
is running. Discharge from the secondary steering ac-
cumulators could overfill the tank when the engine is
stopped.
180 SEBU7792-03
Maintenance Section
Steering System Oil Filter - Replace

10. Fill the steering hydraulic tank. Refer to Operation

And Maintenance Manual, “Lubricant Viscosities”.
Refer to Operation And Maintenance Manual,
“Capacities (Refill)”.

11. Use the reading from the upper sight gauge to

maintain the steering oil level. When the engine is
not running, the oil level should be at the “FULL”
mark in upper sight gauge (2).

12. Install the filler cap.

13. Operate the engine until the steering hydraulic oil

is warm. Inspect the machine for leaks and make
any necessary repairs.

14. Stop the engine. Allow the steering accumulators

to completely discharge and check the oil level.
Use the reading from the upper sight gauge to
maintain the steering oil level.

15. When the engine is stopped, the oil level should

be at the “FULL” mark in the upper sight gauge. If
necessary, add oil.

i02331551

Steering System Oil Filter - Illustration 238 g01163863

Replace
2. Push button (3) on the breaker relief valve.
SMCS Code: 4304; 5068
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.
Hot oil and hot components can cause personal 4. Remove four nuts (1) from the filter cover.
injury. Do not allow hot oil or hot components to
contact the skin. 5. Pull filter assembly (2) out of the tank.

1. Park the machine on level ground and engage the

parking brake. Stop the engine.

g01163878
Illustration 239

6. Remove filter cover (5) from stud (10).

7. Remove spring pin (7) and spacer (8).

8. Remove used filter elements (9) and discard the

used filter elements.
SEBU7792-03
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.
14. 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.
15. Check the steering system oil level. If necessary,
add oil. For the proper procedure, refer to
Operation and Maintenance Manual, “Steering
System Oil Level - Check”.
i02331710
Steering System Oil Level -
Check
SMCS Code: 4332
g01192510
Illustration 240
1. Park the machine on a level surface and engage
the parking brake.
2. Stop the engine and allow the secondary steering
accumulators to completely discharge before the
oil level is observed.
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.
181
Maintenance Section
Steering System Oil Level - Check
NOTICE
Do not fill the steering hydraulic tank when the engine
is running. Discharge from the secondary steering ac-
cumulators could overfill the tank when the engine is
stopped.
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
SMCS Code: 4300-008; 4332-008; 7542
g01163967
Illustration 241
Sampling port (1) for the steering oil is located on the
steering solenoid and relief valve.
Refer to the following publications for information
about obtaining an oil sample.
• Operation and Maintenance Manual, “S·O·S
Information”
• Special Publication, SEBU6250, “S·O·S Oil
Analysis”
• Special Publication, PEHP6001, “How To Take A
Good Oil Sample”
182 SEBU7792-03
Maintenance Section
Suction Screen (Rear Axle Lubrication) - Clean

• Special Publication, PEDP8025, “Fluid Analysis 4. Wash the screen and the magnetic tube assembly
Interpretaion Guide” in clean, nonflammable solvent. Clean the
magnets with a cloth, a stiff bristle brush or air
pressure.
i02337440

Suction Screen (Rear Axle 5. Install the magnetic tube assembly and the screen.

Lubrication) - Clean 6. Inspect seal (4). If the seal is damaged, replace

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

8. Start the engine and operate the engine at low

Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
1. Park the machine on a level surface. Engage the
parking brake and stop the engine.
idle. Make sure that the parking brake is engaged.
Check for leaks and make any necessary repairs.
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,
add oil. For the proper procedure, refer to
Operation and Maintenance Manual, “Differential
and Final Drive Oil - Check”.

Note: Correct oil levels are critical in the differential

and final drives. Check the oil level after repairs and
after maintenance.

Note: The differential and final drive oil level needs to

be checked and maintained at operating temperature.
If the oil level is checked cold, adjustment of the
oil level may be necessary when the truck reaches
operating temperature.

g01166714 i02682176
Illustration 242

2. Remove screen cover plate (1 ).

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

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact the skin.

g01166878
Illustration 243

3. Remove screen (2) and magnetic tube assembly

(3).

NOTICE
Do not drop or rap the magnets against any hard ob-
jects. Replace any damaged magnets.
SEBU7792-03 183
Maintenance Section
Suction Screen (Torque Converter) - Clean

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

Refer to Special Publication, NENG2500, “Caterpillar

Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and g01164303

Illustration 245
mandates.
5. Remove the bolts from screen cover (3). The
1. Park the machine on a level surface. Engage the screen cover is located at the lower left rear corner
parking brake and stop the engine. of the sump. Remove the cover and the screen
assembly.

6. Wash the screen assembly and the cover in a

clean, nonflammable solvent. Do not crush the
screen assembly.

7. Inspect the cover gasket for damage. If the cover

gasket is damaged, use a new gasket.

8. Install the screen. Install the cover assembly.

g01164290
Illustration 244

2. Remove filler cap (1) in order to prevent a vacuum

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

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

converter sump. Install a 100 mm (4 inch) long
NPT pipe nipple in order to open the internal drain
valve. The outer diameter of the NPT pipe nipple
should be 25 mm (1 inch). Drain the oil into a
suitable container.
Note: Hand tighten the NPT pipe nipple. Do not use
tools.
4. Remove the pipe nipple. Clean the drain plug and
install the drain plug.
g01164452
Illustration 246
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,
“Capacities (Refill)”.
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.
184
Maintenance Section
Suspension Cylinder - Check
12. 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.
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.
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.
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.
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.
SEBU7792-03
Front Suspension Cylinder
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 move-
ment.
Use caution when working between the wheels
and the frame. If the wheels must be turned, en-
sure that all personnel are clear of the machine
before any movement.
g01163979
Illustration 247
(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.
SEBU7792-03 185
Maintenance Section
Tire Inflation - Check

Rear Suspension Cylinder

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

Refer to Special Publication, NENG2500, “Caterpillar

Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.
g01163990
Illustration 248
(Y) Distance between the pins
1. Park the machine on a level surface. Engage the
parking brake and stop the engine.
Measure distance (Y) for the rear suspension
cylinders. Compare the present distance to the
distance from the previous time. If you do not have
those dimensions, perform the charging procedure.
See Testing And Adjusting, “Suspension Cylinder
(Rear) - Purge and Charge” for the charging
procedure.

Note: When the rear suspension cylinders are

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

i02416817

Tire Inflation - Check

SMCS Code: 4203

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.
i02332019
Torque Converter Outlet
Screen - Replace
g01164086
Illustration 249
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.
Note: Removing the drain plug from the bottom of
the screen housing may not drain all of the oil from
the screen.

SMCS Code: 3103 3. Remove the screen housing. Remove the screen.
Discard the used screen.

4. Wash the screen housing in clean, nonflammable

solvent.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to 5. Inspect the seal in the base of the screen housing.
contact skin. If the seal is damaged, replace the seal with a
new seal.
186 SEBU7792-03
Maintenance Section
Torque Converter Sump Breather - Clean

6. Install the new screen in the screen housing.

Install the screen housing.

7. 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.

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

necessary, add oil. For the proper procedure, refer
to Operation and Maintenance Manual, “Torque
Converter Sump Oil Level - Check”.

i02335501

Torque Converter Sump

Breather - Clean
SMCS Code: 3101

g01167449
Illustration 250
When it is necessary to work under the machine
with the body (bed) raised, attach the body (bed) 4. Remove breather (1).
retaining cable to the rear tow point. Install the
rear tow point pin through the end of the retaining 5. Wash the breather in a clean, nonflammable
cable. solvent. Allow the breather to air dry.

Failure to properly secure the body (bed) may re- 6. Install the breather.
sult in personal injury or death.
7. Remove the truck body retaining cable and lower
the body.
Note: The breather for the torque converter sump
also vents the transmission case.
i02682170
1. Park the machine on a level surface and engage
the parking brake. Torque Converter Sump Oil
2. Raise the truck body to the fully raised position
Level - Check
and install the truck body retaining cable to the SMCS Code: 3101; 3103
rear tow point pin. For the proper procedure for the
installation and removal of the truck body retaining Note: The oil level in the transmission is supplied by
cable, refer to Operations and Maintenance the torque converter sump.
Manual, “Cable (Truck Body Retaining)”.
1. Park the machine on a level surface.
3. Stop the engine.
2. Operate the engine at low idle with the
transmission in neutral and with the parking brake
engaged.

Note: The engine should be on in order to check the

cold oil (oil at ambient temperature) level of the torque
converter, and the engine should be on in order to
check the hot oil (oil at operating temperature) level
of the torque converter.
SEBU7792-03
g01347318
Illustration 251
3. Check the oil level in the torque converter sump.
a. If the torque converter oil is cold, use lower
sight gauge (3) in order to check the oil level.
b. If the torque converter oil is in the operating
temperature range, use upper sight gauge (2)
in order to check the oil level.
4. If necessary, add oil. The torque converter oil and
transmission oil is added at filler cap (1).
Note: If the system has been drained, refer to
Operation and Maintenance Manual, “Torque
Converter and Transmission Oil - Change” for the
proper procedure.
i02682180
Torque Converter and
Transmission Oil - Change
SMCS Code: 3101
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
1. Park the machine on a level surface. Engage the
parking brake and stop the engine.
187
Maintenance Section
Torque Converter and Transmission Oil - Change
g01164290
Illustration 252
2. Remove filler cap (1) in order to prevent a vacuum
in the torque converter sump. Install the filler cap
after the torque converter sump is drained. This
will prevent dirt from entering the system.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
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.
Note: Hand tighten the NPT pipe nipple. Do not use
tools.
4. Remove the pipe nipple. Clean the drain valve
plug and install the drain valve plug.
188 SEBU7792-03
Maintenance Section
Torque Converter and Transmission Oil - Change

12. Check the oil level in the torque converter sump.

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

13. 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.

14. Operate the engine until the torque converter oil

reaches operating temperature. Torque converter
stalls may be performed in order to bring the
torque converter oil up to operating temperature.

15. Check the oil level with the engine at low idle and
g01164714
the transmission in neutral.
Illustration 253
16. Maintain the oil level until the oil level stabilizes
5. Remove drain plugs (3) from the transmission in the “FULL” mark of the upper sight gauge. If
extension housing. Drain the oil into a suitable necessary, add oil.
container. Clean the drain plugs and install drain
plugs. 17. Clean the filler cap and install the filler cap on the
filler tube.
6. Remove the filler cap.

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

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

g01164452
Illustration 254

10. Fill the torque converter to the top of upper sight

gauge (4). See Operation And Maintenance
Manual, “Lubricant Viscosities”. See Operation
And Maintenance Manual, “Capacities (Refill)”.

11. Operate the engine for ten seconds and then turn
off the engine. The oil level will decrease as oil
fills the system.
SEBU7792-03 189
Maintenance Section
Torque Converter and Transmission Oil Sample - Obtain

i02501245 i02334684

Torque Converter and Traction Control System (TCS)

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

1. Find a clear area and a level area. In this area,

turn the machine in a complete circle. Start the
machine and move the transmission direction and
speed control lever to the first gear Forward.

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

With the engine at low idle, drive the machine in
a complete circle.

g01251142
Illustration 255

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.
Refer to the following publications for information
about obtaining an oil sample.
• Operation and Maintenance Manual, “S·O·S
Information”
g01165483
Illustration 256
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.

• Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations”, “S·O·S Oil
Analysis”
• Special Publication, PEHP6001, “How To Take A
Good Oil Sample”
• Special Publication, PEDP8025, “Fluid Analysis
Interpretaion Guide”
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.

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.
190 SEBU7792-03
Maintenance Section
Transmission Magnetic Screen - Clean

i02335439 4. Wash the screen and the magnetic tube assembly

in clean, nonflammable solvent. Clean the
Transmission Magnetic Screen magnets with a cloth, a stiff bristle brush or air
- Clean pressure.

SMCS Code: 3030 5. Install the magnetic tube assembly, the screen,
and the wave washer.

6. Inspect seal (5). If the seal is damaged, replace

Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
the seal.
7. Install the screen cover plate.
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.

Note: The oil level in the transmission is supplied by

the torque converter sump.

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

necessary, add oil. For the proper procedure, refer
to Operation and Maintenance Manual, “Torque
Converter Sump Oil Level - Check”.

i02335442

Illustration 257
g01165690 Transmission Oil Filter -
Location of the transmission magnetic screen Replace
1. Park the machine on a level surface. Engage the SMCS Code: 3067
parking brake and stop the engine.

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact the skin.

g01166968
Illustration 258

2. Remove screen cover plate (1).

3. Remove wave washer (2), screen (3), and

magnetic tube assembly (4). g01165699
Illustration 259

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

Do not drop or rap the magnets against any hard ob- parking brake and stop the engine.
jects. Replace any damaged magnets.
SEBU7792-03
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
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.
Discard the used filter element.
4. Wash the filter housing in clean nonflammable
solvent.
5. Inspect the seals in the filter base. If the seals are
damaged, replace seals with new seals.
6. Install the new filter element in the housing. Install
the housing.
7. 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.
Note: The oil level in the transmission is supplied by
the torque converter sump.
8. Check the oil level in the torque converter sump. If
necessary, add oil. For the proper procedure, refer
to Operation and Maintenance Manual, “Torque
Converter Sump Oil Level - Check”.
191
Maintenance Section
VIMS Module Battery - Replace
i02018740
VIMS Module Battery - Replace
SMCS Code: 7490
g01043143
Illustration 260
(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 −40°C (32 to −40°F), 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.
192 SEBU7792-03
Maintenance Section
Windows - Clean

2. Turn the engine start switch to the ON position or i02680928

turn the keyswitch for the VIMS to the ON position.
Windows - Clean
3. Use the service tool for the VIMS to download all
of the stored information. The service tool for the SMCS Code: 7310; 7340
VIMS is not part of the machine. Failure to perform
this step may result in the loss of stored data.

4. Leave the engine start switch in the ON position

or leave the keyswitch for the VIMS in the ON
position. Leave the battery disconnect switch in
the ON position.

Note: If these switches remain in the ON position

during replacement, the date and the time of day are
less likely to require programming.

5. Remove the battery from the back of the VIMS

module. The battery is located behind plate (1).
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.
g01346892
Illustration 261
Use commercially available window cleaning
solutions to clean the windows. Only clean the
windows, when handholds are available.

7. Check the O-ring seal. The O-ring seal is located i02346847

under the cap. Make sure that the O-ring seal is in
the proper place. Make sure that the O-ring seal Window Washer Reservoir -
is not damaged. Install the cap. Tighten the cap
securely against the housing.
Fill
SMCS Code: 7306-544-KE
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 NOTICE
the time to be lost. After the battery has been When operating in freezing temperatures, use
replaced, the date will default to “01/01/00”. Also, Caterpillar nonfreezing window washer solvent or
the time will default to “00:00:00”. If necessary, use equivalent. System damage can result from freezing.
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.

g01139822
Illustration 262

Window washer reservoir (1) is located in the

compartment in the front of the cab.

Fill the reservoir with windshield washer fluid.

SEBU7792-03 193
Maintenance Section
Window Wiper - Inspect/Replace

i02335763

Window Wiper -
Inspect/Replace
SMCS Code: 7305

g01165832
Illustration 263

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.
194
Reference Information Section
Reference Materials
Reference Information
Section
Reference Materials
i02654341
Reference Material
SMCS Code: 1000; 7000
Special Publication, PECP9067, “One Safe Source”
Special Publication, NENG2500, “Caterpillar Tools
and Shop Products Guide”
Special Publication, SEBU6250, “Caterpillar Machine
Fluids Recommendations”
Special Publication, SEBU5898, “Cold Weather
Recommendations”
Special Publication, PEHP7076, “Understanding
S·O·S Services Test”
Special Publication, PEHP6001, “How to Take a
Good Oil Sample”
Special Publication, SEBD0518, “Know Your Cooling
System”
Specifications, SENR3130, “Torque Specifications”
Guideline For Reusable Parts And Salvage
Operations, SEBF8148, “General Salvage and
Reconditioning Techniques”
Systems Operation, Troubleshooting, Testing and
Adjusting, RENR7911, “Product Link”
Special Instruction, SEHS9586, “3500 Electronic Unit
Injection (EUI) Fuel Priming Procedure”
Systems Operation, Testing and Adjusting,
SENR4724, “Automatic Lubrication System”
Special Instruction, REHS2210, “793D Off-Highway
Truck Assembly Procedure”
Special Instruction, SEHS7332, “Do Not Operate
Warning Tag”
Parts Manual, SEBP3976, “793D Off-Highway Truck”
Service Manual, RENR8320, “793D Extended Life
Power Train Off-Highway Truck”
SEBU7792-03
Disassembly and Assembly, SENR1126, “3500B
Engines For Caterpillar Built Machines”
Systems Operation/Testing and Adjusting,
SENR1123, “3500B Engines For Caterpillar Built
Machines”
Special Publication, SMBU6981, “Emissions Control
Warranty Information”
Special Instructions, REHS0126, “Electronic Controls
Service Code Information Description List”
Service Manual, SENR1502, “Power Train Electronic
Control System”
Service Manual, SENR5664, “Air Conditioning and
Heating with R-134A (All Caterpillar Machines)”
Special Instructions, SEHS9411, “Suspension
Cylinder Servicing”
Safety Manual, SEBU5935
Video Tape, AEVN3780, “The Human Element - Mine
Safety & You”
Special Instructions, SEHS7633, “Battery Test
Procedure”
Guideline For Reusable Parts And Salvage
Operations, SEBF8443, “Procedure to Inspect and
Repair Wheels Used on Off-Highway Trucks”
Special Instruction, REHS2398, “Air Tank Inspection
for the Off-Highway Truck 769-797”
Service Magazine, SEBD1587, “What ROPS/FOPS
Certification Means”
Special Instruction, SEHS6929, “Inspection,
Maintenance and Repair of ROPS and Attachment
Installation Guidelines”
Special Instructions, SMHS7867, “Use Of 6V-4040
Nitrogen Tire Inflation Group”
Special Publication, SEBF8029, “Guideline for
Reusable Parts and Salvage Operations”
Video Tape, SEVN4142, “Mining Trucks - Cleanliness
and Component Life”
Systems Operation, Testing and Adjusting,
Disassembly and Assembly, RENR8391, “Caterpillar
Comfort Series Seat with three point operator
restraint”
Special Instruction, REHS0354, “Charging System
Troubleshooting”
SEBU7792-03 195
Reference Information Section
Reference Materials

Specifications, Systems Operation, Testing and
Adjusting, RENR2223, “Oil Renewal System”
Systems Operation, RENR2630, “785 - 797
Off-Highway Trucks Vital Information Management
System”
Troubleshooting, Testing and Adjusting, RENR2631,
“785 - 797 Off-Highway Trucks Vital Information
Management System”
SAE J313, “Diesel Fuels” This can be found in the
SAE handbook. Also, this publication can be obtained
from your local technological society, from your local
library, or from your local college.
SAE J754, “Nomenclature” This can normally be
found in the SAE handbook.
SAE J183, “Classification” This can normally be
found in the SAE handbook.

Testing and Adjusting, RENR8327, “793D Power “Engine Fluids Data Book”
Train Testing and Adjusting”
Engine Manufacturers Association
Systems Operation, RENR2635, “784C, 785C, Two North LaSalle Street, Suite 2200
789C, 793C, 793D, 797 and 797B Off-Highway Chicago, IL USA 60602
Truck/Tractors VIMS Truck Payload System” E-mail: ema@enginemanufacturers.org
Phone: (312) 827-8700
Specifications, System Operation, Troubleshooting, Facsimile: (312) 827-8737
Testing and Adjusting, RENR8387, “793 Off-Highway
Truck Fast Fill Service Center”
i01631981

Reuse and Salvage Guidelines, SEBF8271, “Salvage

of Steering Arm and Steering Arm (T-Bar) Tapers on
785, 789, 793, and 797 Off-Highway Trucks”
Disassembly and Assembly, RENR8332, “793D
Off-Highway Truck Machine Systems”
System Operation, Testing and Adjusting,
RENR8336, “793D Off-Highway Truck Steering
System”
Decommissioning and
Disposal
SMCS Code: 1000; 7000
When the machine is removed from service, local
regulations will vary. Disposal of the machine will vary
with local regulations. Consult the nearest Caterpillar
dealer for additional information.

Service Magazine, SEPD0766, 10 January 2005,

“Match Tire Size in Dual Tire Configurations for
Increased Service Life”

Operation and Maintenance Manual (Supplement),

SEBU8257, “The European Union Physical Agents
(Directive) 2002/44/EC”

Specifications, Systems Operation, Testing and

Adjusting, SENR2986, “Off-Highway Trucks/Tractors
Automatic Electronic Traction Aid (AETA)/Traction
Control System (TCS)”

System Operation, Testing and Adjusting,

RENR8330, “793D Air System and Brakes”

Guideline for Reusable Parts and Salvage

Operations, SEBF8095, “Service Brakes for
Off-Highway Trucks and Tractors”

Additional Reference Material

ASTM D2896, “TBN Measurements” This can
normally be obtained from your local technological
society, from your local library, or from your local
college.
196
Index Section
Index
A Changing Direction and Speed.............................. 70
Access Doors and Covers (If Equipped with the
Sound Suppression Arrangement) .................... 108
Additional Messages ............................................. 14
Air Conditioner Filter - Clean ................................ 112
Air Dryer - Check .................................................. 112
Air Dryer Desiccant - Replace .............................. 112
Air Tank Moisture and Sediment - Drain............... 113
Primary Air Tank................................................ 113
Primary Air Tank (If Equipped with the Sound
Suppression Arrangement) ............................. 114
Secondary Air Tank........................................... 113
Air/Hydraulic Cylinder Breather - Clean................ 114
Alternate Exit ......................................................... 40
Automatic Lubrication Reservoir - Fill................... 115
B
Backup Alarm ........................................................ 67
Backup Alarm - Test ............................................. 115
Battery - Recycle .................................................. 115
Battery Disconnect Switch..................................... 54
Battery or Battery Cable - Inspect/Replace .......... 116
Before Operation ............................................. 26, 37
Before Starting Engine .......................................... 26
Belts - Inspect/Adjust/Replace.............................. 116
Adjustment and Replacement........................... 116
Inspection.......................................................... 116
Brake Cooling Oil Filter - Replace ........................ 118
Brake Oil Cooler Screen - Clean .......................... 118
Brake Tank (Makeup) - Clean.............................. 120
Brakes, Indicators and Gauges - Test ................. 120
Braking .................................................................. 68
Parking Brake .................................................... 68
Secondary Brake ............................................... 69
Service Brake..................................................... 69
Braking System - Test.......................................... 121
Parking Brake Holding Ability Test ................... 121
Secondary Brake Holding Ability Test .............. 122
Service Brake Holding Ability Test ................... 122
Test for the Parking Brake Reset Valve ........... 121
Breather (Fuel Tank) - Replace ........................... 123
Burn Prevention..................................................... 22
Batteries............................................................. 23
Coolant............................................................... 22
Oils..................................................................... 23
C Reusability...................................................... 141
Cab Air Filter - Clean/Replace............................. 123
Cable (Truck Body Retaining) ............................... 85
Installation Procedure ........................................ 86
Removal Procedure ........................................... 86
Cable (Truck Body Retaining) - Inspect............... 124
Capacities (Refill) ................................................ 107
SEBU7792-03
Shift Inhibiting .................................................... 70
Circuit Breakers - Reset ...................................... 124
Cooling System Coolant (ELC) - Change............ 126
Cooling System Coolant Extender (ELC) - Add... 127
Cooling System Coolant Level - Check ............... 129
Cooling System Coolant Sample (Level 1) -
Obtain ................................................................ 129
Cooling System Coolant Sample (Level 2) -
Obtain ................................................................ 130
Cooling System Pressure Cap - Clean/Replace.. 131
Cooling System Relief Valve - Clean................... 132
Cooling System Water Temperature Regulator -
Replace.............................................................. 133
Crushing Prevention and Cutting Prevention ........ 22
D
Daily Inspection ..................................................... 37
Decommissioning and Disposal .......................... 195
Differential and Final Drive Breather - Replace ... 134
Differential and Final Drive Oil - Change ............. 135
Differential and Final Drive Oil - Inspect .............. 136
Differential and Final Drive Oil Level - Check...... 136
Differential and Final Drive Oil Sample - Obtain.. 137
Differential Thrust Pin Clearance - Check ........... 134
Differential Warm-up and Break-in ........................ 83
Break-In ............................................................. 83
Warm-Up............................................................ 83
Drive Shaft Slip Joint - Lubricate ......................... 138
Dumping with Engine Stopped .............................. 93
E
Electrical Storm Injury Prevention ......................... 25
Emissions Certification Film .................................. 35
Engine Air Filter Primary Element - Clean/
Replace.............................................................. 138
Cleaning Primary Air Filter Elements ............... 139
Inspecting the Primary Air Filter Elements....... 140
Engine Air Filter Secondary Element - Replace .. 140
Engine Air Precleaner - Clean ............................. 140
Engine and Machine Warm-Up ............................. 81
Machine warm-up .............................................. 82
Preparing to operate the machine...................... 82
Engine Components - Clean/Inspect, Rebuild/Install
Reman, Install New............................................ 141
Clean Components and Inspect Components for
Install New Components .................................. 141
Rebuild Components and/or Install
Remanufactured Components ....................... 141
Engine Components - Rebuild/Install Reman...... 141
Engine Crankcase Breather - Clean.................... 142
Engine Oil and Filter - Change ............................ 145
SEBU7792-03
Engine Oil Filter (Oil Renewal System) - Change (If
Equipped) .......................................................... 143
Engine Oil Level - Check ..................................... 143
Engine Oil Level - Log Additions (If Equipped with the
Oil Renewal System) ......................................... 144
Engine Oil Sample - Obtain ................................. 145
Engine Shutdown Switch....................................... 55
Engine Starting ................................................ 26, 78
Engine Block Heater (If Equipped)..................... 79
Engine Cold Mode ............................................. 80
Ether Starting Aid............................................... 79
Engine Starting (Alternate Methods) ..................... 99
Engine Starting with an External Air Supply .......... 99
Engine Starting with Auxiliary Start
Receptacle................................................. 101–102
Engine Starting with Jump Start Cables ................ 99
Use of Jump Start Cables ................................ 100
Engine Valve Lash and Bridge - Adjust ............... 146
Valve Bridge..................................................... 146
Valve Lash Adjustment .................................... 146
Engine Water Pump - Inspect.............................. 147
Auxiliary Water Pump for the Aftercooler Cooling
System ........................................................... 147
Water Pump for the Jacket Water Cooling
System ........................................................... 147
Ether Starting Aid Cylinder - Replace.................. 148
F Hoist and Brake Tank Suction Screen -
Fast Fill Service Center (If Equipped).................... 67
Fire Extinguisher Location ..................................... 24
Fire Prevention and Explosion Prevention ............ 23
Ether .................................................................. 24
Fire Extinguisher ................................................ 24
Lines, Tubes and Hoses .................................... 24
Foreword ................................................................. 5
California Proposition 65 Warning ....................... 4
Caterpillar Product Identification Number ............ 5
Certified Engine Maintenance.............................. 4
Literature Information........................................... 4
Machine Capacity ................................................ 5
Maintenance ........................................................ 4
Operation ............................................................. 4
Safety................................................................... 4
Frame - Clean/Inspect ......................................... 148
Rear Axle A-Frame and Differential Housing... 149
Frame and Body - Inspect ................................... 150
Frame and Body Support Pads - Clean/Inspect .. 151
Front Axle Breather - Replace ............................. 151
Front Wheel Oil - Change.................................... 152
Front Wheel Oil - Inspect..................................... 152
Front Wheel Oil Sample - Obtain......................... 153
Fuel System - Prime ............................................ 153
Fuel System Primary Filter - Clean (If Equipped).. 156
Fuel System Primary Filter (Water Separator) - Drain
(If Equipped) ...................................................... 154
Fuel System Primary Filter (Water Separator)
Element - Replace (If Equipped)........................ 154
Fuel System Priming Filter - Replace .................. 156
Fuel System Secondary Filter - Replace ............. 157
197
Index Section
Fuel Tank Water and Sediment - Drain ............... 158
G
General Hazard Information .................................. 19
Asbestos Information ......................................... 21
Containing Fluid Spillage ................................... 21
Dispose of Waste Properly ................................ 22
Fluid Penetration................................................ 20
Pressurized Air and Water ................................. 20
Trapped Pressure .............................................. 20
General Information............................................... 33
Guards (Operator Protection) ................................ 31
Other Guards (If Equipped)................................ 32
Rollover Protective Structure (ROPS), Falling
Object Protective Structure (FOPS) or Tip Over
Protection Structure (TOPS) ............................ 32
H
High Intensity Discharge Lamp (HID) - Replace (If
Equipped) .......................................................... 158
Hoist and Brake Tank Breather - Replace ........... 160
Hoist and Brake Tank Oil - Change ..................... 160
Hoist and Brake Tank Oil Level - Check .............. 161
Hoist and Brake Tank Oil Sample - Obtain .......... 162
Inspect/Clean/Replace....................................... 162
Hoist Screens - Clean.......................................... 159
I
Identification Information ....................................... 34
Important Safety Information ................................... 2
J
Jacking Location Information................................. 90
Jacking Locations .................................................. 90
Front of the Machine .......................................... 90
Rear of the Machine........................................... 90
L
Leaving the Machine ............................................. 87
Lifting and Tying Down the Machine...................... 89
Lowering the Body with Engine Stopped............... 93
Lubricant Viscosities............................................ 104
Recommended Grease.................................... 106
Lubricant Viscosities and Refill Capacities .......... 104
M
Machine Operation ................................................ 40
Magnetic Plug (Wheels) - Check ......................... 164
198
Index Section
Maintenance Access ........................................... 108
Maintenance Interval Schedule ............................ 110
Maintenance Section ........................................... 103
Maintenance Support .......................................... 109
Match Tire Size (Dual Tire Configuration) ........... 109
Mounting and Dismounting.................................... 37
Alternate Exit...................................................... 37
O (29)................................................................... 52
Oil Filter - Inspect ................................................ 165
Inspect a Used Filter for Debris ....................... 165
Oil Filter (Steering, Hydraulic Fan) - Replace
(Hydraulic Pump Case Drain) ............................ 164
Operation............................................................... 27
Machine Operating Temperature Range............ 27
Machine Operation............................................. 27
Operation Information............................................ 73
Dumping............................................................. 76
Hauling............................................................... 75
Loading .............................................................. 73
Operation Section.................................................. 37
SEBU7792-03
Operator Controls .................................................. 44
12 V Power Receptacle (37) .............................. 53
Accelerator Pedal (23) ....................................... 51
Automatic Retarder Control (12) ........................ 49
Battery Disconnect Switch (35).......................... 53
Brake Release Switch (13) ................................ 49
Cab Visor (40).................................................... 54
Cigar Lighter (12 V) (2) ...................................... 47
Control Pedal for the Secondary Brake System
Engine Service Lights (33)................................. 53
Engine Shutdown Switch (34)............................ 53
Engine Start Switch (20) .................................... 50
ET and ECAP Service Port (39)......................... 53
Ether Starting Aid Switch (11) ............................ 48
Hazard Flasher Switch (5) ................................. 48
Heated Mirror Switch (15) (If Equipped) ............ 49
Heating and Air Conditioning Controls............... 49
Hoist Control Lever (28)..................................... 52
Horn (4).............................................................. 48
Interior Light (27)................................................ 52
Multifunction Switch (3)...................................... 47
Panel Light Switch (19) ...................................... 50
Parking Brake Reset Valve (26)......................... 52
Parking Brake Switch (25) ................................. 51
Power Window Switch (30) ................................ 53
Retarder Control Lever (21) ............................... 50
Service Brake Control Pedal (22) ...................... 51
Steering Column Tilt and Telescope Control
(1)..................................................................... 47
Steering Wheel Control...................................... 46
Switch for Access Lights (36)............................. 53
Switch for Access Lights (9)............................... 48
Switch for Fog Lights (7) .................................... 48
Switch for Headlights, Parking Lights, and Taillights
(6)..................................................................... 48
Switch for Rear Work Lights (8) ......................... 48
Test Switch for the Traction Control System
(14)................................................................... 49
Throttle Backup Switch (10)............................... 48
Transmission Control Lever (24)........................ 51
Transmission Lockout Switch (31) (If
Equipped)......................................................... 53
VIMS Service Port (32) and (38)........................ 53
Operator Station .................................................... 31
Parking ............................................................ 28, 84
Parking Brake Release Oil Filter - Replace ......... 166
Plate Locations and Film Locations....................... 34
Certification ........................................................ 35
Product Identification Number (PIN) .................. 34
Serial Number Plate (SN) .................................. 34
Product Information Section .................................. 33
Product Link (If Equipped) ..................................... 56
Regulatory Compliance...................................... 57
SEBU7792-03
R Steering Ball Stud - Inspect ................................. 174
Radiator Core - Clean.......................................... 166
Rear Axle Housing End Play - Adjust .................. 167
Rear Axle Oil Filter - Replace .............................. 167
Receiver Dryer (Refrigerant) - Replace ............... 168
Reference Information Section ............................ 194
Reference Material .............................................. 194
Additional Reference Material.......................... 195
Reference Materials ............................................ 194
Retarding ............................................................... 71
Automatic Retarder Control (ARC) .................... 72
Manual Retarding............................................... 72
Retarder Control ................................................ 71
Retarding Guidelines ......................................... 73
Rim - Inspect ............................................... 169–170
Roading the Machine............................................. 88
Rollover Protective Structure (ROPS) - Inspect .. 170
S
S·O·S Information ................................................ 107
Safety Messages ..................................................... 6
Safety Section ......................................................... 6
Seat ....................................................................... 40
Air Suspension Seat with Three-Point Operator
Restraint........................................................... 40
Seat Belt ................................................................ 41
Extension of the Seat Belt ................................. 44
Seat Belt Adjustment for non-retractable seat
belts.................................................................. 43
Seat Belt Adjustment for Retractable Seat
Belts ................................................................. 42
Seat Belt Adjustment for Three-Point Operator
Restraint........................................................... 41
Seat Belt - Inspect ............................................... 170
Seat Belt - Replace.............................................. 171
Seat Suspension - Inspect/Lubricate................... 171
Inspect ............................................................. 171
Lubricate .......................................................... 171
Secondary Steering - Check................................ 172
Service Brakes - Inspect...................................... 173
Shipping the Machine ............................................ 88
Slope Operation..................................................... 28
Sound Information and Vibration Information ........ 29
Sound Level Information .................................... 29
Sound Level Information for Machines in European
Union Countries and in Countries that Adopt the
“EU Directives” ................................................. 29
Sources.............................................................. 31
“The European Union Physical Agents (Vibration)
Directive 2002/44/EC” ...................................... 29
Sound Suppression (Covers, Panels) -
Inspect/Replace (If Equipped with the Sound
Suppression Arrangement)................................ 173
Louvers ............................................................ 174
Sound Covers .................................................. 173
Sound Panels................................................... 173
Specifications ........................................................ 33
Intended Use...................................................... 33
199
Index Section
Inspection of Steering Ball Studs ..................... 174
Magnetic Particle Testing of Steering Ball Studs
with Portable Magnetic Yokes ........................ 177
Steering Ball Stud - Replace ............................... 178
Steering Linkage - Inspect................................... 178
Steering System Oil - Change ............................. 179
Steering System Oil Filter - Replace ................... 180
Steering System Oil Level - Check...................... 181
Steering System Oil Sample - Obtain.................. 181
Stopping the Engine .............................................. 85
Stopping the Engine if an Electrical Malfunction
Occurs ................................................................. 85
Stopping the Machine............................................ 84
Suction Screen (Rear Axle Lubrication) - Clean.. 182
Suction Screen (Torque Converter) - Clean ........ 182
Suspension Cylinder - Check .............................. 184
Front Suspension Cylinder............................... 184
Rear Suspension Cylinder ............................... 185
T
Table of Contents..................................................... 3
Tire Inflation - Check ........................................... 185
Tire Inflation Information ...................................... 103
Tire Inflation Pressure Adjustment ...................... 103
Tire Inflation with Nitrogen ................................... 103
Tire Information ..................................................... 25
Torque Converter and Transmission Oil -
Change .............................................................. 187
Torque Converter and Transmission Oil Sample -
Obtain ................................................................ 189
Torque Converter Outlet Screen - Replace ......... 185
Torque Converter Sump Breather - Clean ........... 186
Torque Converter Sump Oil Level - Check .......... 186
Towing Information ................................................ 91
Towing the Machine............................................... 91
Towing With Inoperable Engine ............................. 95
Towing With Power Train Failure ........................... 94
Traction Control System (TCS) - Test.................. 189
Transmission Magnetic Screen - Clean............... 190
Transmission Oil Filter - Replace ........................ 190
Transportation Information .................................... 88
V
VIMS Module Battery - Replace .......................... 191
Visibility Information............................................... 26
Vital Information Management System (VIMS) ..... 57
Display ............................................................... 59
Engine Shutdown Events................................... 61
Gauge Cluster.................................................... 58
Indicators ........................................................... 58
Speedometer and Tachometer........................... 59
VIMS Self Test ................................................... 62
Vital Information Management System (VIMS)
Keypad................................................................. 63
Keys ................................................................... 64
200 SEBU7792-03
Index Section

Welding on Machines and Engines with Electronic

Controls ............................................................. 109
Window Washer Reservoir - Fill .......................... 192
Window Wiper - Inspect/Replace ........................ 193
Windows - Clean ................................................. 192
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.

Delivery Date:

Product Information
Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

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Dealer Information
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Sales:

Parts:

Service:
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