793F y 793F XQ Mantenimiento

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MAINTENANCE INTERVALSOperation and Maintenance Manual Excerpt

SEBU8406-04May 2011

Operation andMaintenanceManual793F and 793F XQ Off-Highway TruckSND1-Up (Machine)SSP1-Up (Machine)

SAFETY.CAT.COM

SEBU8406-04 137Maintenance Section

Maintenance Interval Schedule

i04322549

Maintenance Interval ScheduleSMCS Code: 1000; 7000

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

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

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

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

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

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

When Required

Air Conditioner Filter - Clean .............................. 140Air Tank - Inspect ................................................ 142Automatic Lubrication Reservoir - Fill ................. 143Battery - Recycle ................................................ 144Battery or Battery Cable - Inspect/Replace ........ 144Brake Oil Cooler Screen - Clean ........................ 147Cab Air Filter - Clean/Replace ............................ 153Display and Camera - Clean ............................... 165Engine Air Filter Primary Element - Clean/Replace ............................................................. 168Engine Air Filter Secondary Element - Replace .. 169Engine Air Precleaner - Clean ............................ 170Ether Starting Aid Cylinder - Replace ................. 178Film (Product Identification) - Clean ................... 179Fuel System - Fill ................................................ 183Fuel System - Prime ........................................... 184

Fuel System Primary Filter (Water Separator) -Drain ................................................................. 185Fuses, Circuit Breakers and Relays -Replace/Reset .................................................. 188High Intensity Discharge Lamp (HID) - Replace .. 194Hoist Screens - Clean ......................................... 195Oil Filter - Inspect ................................................ 209Radiator, Aftercooler and Air Conditioner Condenser- Clean .............................................................. 210Rim - Inspect ....................................................... 215Torque Converter Sump Screen - Clean ............. 226Traction Control System (TCS) - Test ................. 229Window Washer Bottle - Fill ................................ 231Window Wiper - Inspect/Replace ........................ 232Windows - Clean ................................................. 232

Every 10 Service Hours or Daily

Air Tank Moisture and Sediment - Drain ............. 142Backup Alarm - Test ............................................ 144Braking System - Test ......................................... 148Cooling System Coolant Level - Check .............. 158Differential and Final Drive Oil Level - Check ..... 164Engine Oil Level - Check .................................... 173Front Wheel Oil Level - Check ............................ 182Hydraulic Tank Oil Level - Check ........................ 206Hydraulic Tank Oil Level - Check ........................ 207Indicators and Gauges - Test .............................. 207Seat Belt - Inspect .............................................. 216Torque Converter Sump Oil Level - Check ......... 226

Initial 50 Service Hours

Hydraulic Oil Filter - Replace .............................. 197Hydraulic Oil Filter - Replace .............................. 198Hydraulic Oil Filter - Replace .............................. 199Hydraulic Oil Filter - Replace .............................. 201Rear Axle Oil Filter - Replace ............................. 212Torque Converter Oil Filter - Replace ................. 224Transmission Oil Filter - Replace ........................ 231

Initial 250 Service Hours

Engine Valve Lash - Check/Adjust ...................... 177

Every 250 Service Hours or Monthly

Magnetic Plug (Wheels) - Check ........................ 208Tire Inflation - Check ........................................... 223

Every 500 Service Hours

Cooling System Coolant Sample (Level 1) -Obtain ............................................................... 159Differential and Final Drive Oil Sample - Obtain .. 164Engine Oil Sample - Obtain ................................ 174Front Wheel Oil Sample - Obtain ........................ 182Hydraulic System Oil Sample - Obtain ............... 202Hydraulic System Oil Sample - Obtain ............... 202Torque Converter and Transmission Oil Sample -Obtain ............................................................... 228

138 SEBU8406-04Maintenance SectionMaintenance Interval Schedule

Every 500 Service Hours or 3 Months

Air Conditioner Filter - Clean .............................. 140Air Dryer - Check ................................................ 140Belts - Inspect/Replace ....................................... 145Breather (Fuel Tank) - Replace ........................... 151Breather (Hoist and Brake Tank) - Replace ........ 151Breather (Steering Tank) - Replace .................... 152Breather (Torque Converter and Transmission) -Replace ............................................................. 152Cab Air Filter - Clean/Replace ............................ 153Cable (Truck Body Retaining) - Inspect .............. 154Differential and Final Drive Oil - Inspect ............. 164Electric Drive Pump (Powered Stairway) Oil Level -Check ................................................................ 167Engine Crankcase Breather - Clean ................... 172Engine Oil and Filter - Change ........................... 174Frame - Clean/Inspect ........................................ 179Front Wheel Oil - Change ................................... 181Front Wheel Oil - Inspect .................................... 182Fuel System Primary Filter (Water Separator) -Replace ............................................................. 185Fuel System Secondary Filter - Replace ............ 186Fuel Tank Water and Sediment - Drain ............... 187Hoses and Clamps - Inspect/Replace ................ 196Platform (Powered Stairway) - Lubricate ............ 210Rear Axle Oil Filter - Replace ............................. 212Secondary Steering - Check ............................... 217Suspension Cylinder - Check ............................. 223Torque Converter Outlet Screen - Replace ......... 225Transmission Magnetic Screen - Clean .............. 230

Every 750 Service Hours or Monthly

Lubrication Pump Oil Level - Check ................... 208

Every 1000 Service Hours or 6 Months

Air Dryer Desiccant - Replace ............................ 141Frame and Body - Inspect .................................. 180Frame and Body Support Pads - Clean/Inspect .. 180Hydraulic Oil Filter - Replace .............................. 197Hydraulic Oil Filter - Replace .............................. 198Hydraulic Oil Filter - Replace .............................. 199Hydraulic Oil Filter - Replace .............................. 201Rear Axle Lubrication Magnetic Screen - Clean .. 211Rollover Protective Structure (ROPS) - Inspect .. 216Seat Suspension - Inspect/Lubricate .................. 217Service Brakes - Inspect ..................................... 219Steering Ball Stud - Inspect ................................ 221Steering Linkage - Inspect .................................. 222Torque Converter Oil Filter - Replace ................. 224Torque Converter and Transmission Oil -Change ............................................................. 227Transmission Oil Filter - Replace ........................ 231

Every 1000 Service Hours or 1 Year

Breather (Differential and Final Drive) - Replace .. 150

Every 2000 Service Hours or 1 Year

Breather (Front Axle) - Replace .......................... 150Damper (Crankshaft) - Inspect ........................... 161Differential Thrust Pin Clearance - Check .......... 162Hydraulic Tank Oil - Change ............................... 203Hydraulic Tank Oil - Change ............................... 205Lubrication Pump Oil - Change ........................... 207

Every Year

Cooling System Coolant Sample (Level 2) -Obtain ............................................................... 159Electric Drive Pump (Powered Stairway) Oil -Change ............................................................. 166Sound Suppression (Covers, Panels) -Inspect/Replace ................................................ 220

Every 2 Years

Receiver Dryer (Refrigerant) - Replace .............. 214

Every 3000 Service Hours or 2 Years

Cooling System Coolant Extender (ELC) - Add .. 156Cooling System Pressure Cap - Clean/Replace .. 160Cooling System Relief Valve - Clean .................. 161Differential and Final Drive Oil - Change ............ 162Engine Water Pump - Inspect ............................. 177Radiator, Aftercooler and Air Conditioner Condenser- Clean .............................................................. 210

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

Seat Belt - Replace ............................................. 217

Every 4000 Service Hours

Engine Valve Lash - Check/Adjust ...................... 177

Every 6000 Service Hours or 4 Years

Cooling System Coolant (ELC) - Change ........... 154

Every 12 000 Service Hours or 6 Years

Drive Shaft Spider and Bearing - Replace .......... 166Steering Ball Stud - Replace ............................... 222

Every 15 000 Service Hours

Rim - Inspect ....................................................... 214

Every 24 000 Service Hours

Drive Shaft Slip Joint - Replace .......................... 166

Every 1 704 700 L (450 000 US gal) of Fuelor 9000 Service Hours

Engine Components - Rebuild/Install Reman ..... 172


Maintenance Interval Schedule

Every 3 407 000 L (900 000 US gal) of Fuel or18 000 Service Hours

Engine Components - Clean/Inspect, Rebuild/InstallReman, Install New ........................................... 171

140 SEBU8406-04Maintenance SectionAir Conditioner Filter - Clean

i03702882

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

If a reduction in air circulation is noticed, clean theradial seal air filter for the air conditioner.

The air filter element for the air conditioner is locatedbehind the access door on the left rear of the cab.

1. Prepare the machine for maintenance. Refer toOperation and Maintenance Manual, Prepare theMachine for Maintenance.

g01993019Illustration 141

2. Open the access door and remove air filterelement (1).

3. Visually inspect the air filter element beforecleaning. Inspect the air filter element for damageto the seal, the pleats, and the outer cover.Replace a damaged air filter element with a newair filter element.

4. Use low pressure compressed air in order toremove the dust from the dirty air filter element. Airpressure must not exceed 207 kPa (30 psi). Directthe air flow up the pleats and down the pleats fromthe inside of the filter element. Take extreme carein order to avoid damage to the pleats.

5. Install the clean air filter element and close theaccess door.

i03446760

Air Dryer - Check(If Equipped with Air Start)SMCS Code: 4285-535

S/N: SSP1-Up

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

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

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

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


2. Drain the air tank. Refer to Operation andMaintenance Manual, Air Tank Moisture andSediment - Drain for the proper procedure.


Air Dryer Desiccant - Replace


Air dryer (1) is located on the outside frame rail in front of the rightfront suspension cylinder.

3. If there is moisture in the air tank, replace thedesiccant cartridge. Consult your Caterpillar dealerfor information about replacing the desiccantcartridge.

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

Note: For more information on the operation of theair dryer, refer to Systems Operation/Testing andAdjusting, KENR8572, 793F Off-Highway Truck AirSystem and Brakes, Air Dryer.

i03447800

Air Dryer Desiccant - Replace(If Equipped with Air Start)SMCS Code: 4285-510-DSS

S/N: SSP1-Up




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


142 SEBU8406-04Maintenance SectionAir Tank - Inspect


Air dryer (1) is located on the outside frame rail in front of the rightfront suspension cylinder.

2. Replace the air dryer desiccant cartridge if watercannot be absorbed. In order to replace thedesiccant cartridge, refer to Disassembly andAssembly, KENR8579, 793F Off-Highway TruckMachine Systems, Air Dryer - Disassemble and,Air Dryer - Assemble or consult your Caterpillardealer.

i02444297

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

S/N: SSP1-Up

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

i03447866

Air Tank Moisture andSediment - Drain(If Equipped with Air Start)SMCS Code: 4272-543-MAS

S/N: SSP1-Up






Automatic Lubrication Reservoir - Fill


Air tank drain valve (1) is located on the outside frame rail in frontof the right front suspension cylinder.

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

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

4. Close the drain valve for the air tank.

i03770671

Automatic LubricationReservoir - FillSMCS Code: 7540-544-TNK


g02042673Illustration 145Machines that are equipped with the electric start use an electricmotor on the automatic lubrication pump.

g02042676Illustration 146Machines that are equipped with the air start use an air motor onthe automatic lubrication pump.

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

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

3. Fill the autolube reservoir through fast fill port (2).

144 SEBU8406-04Maintenance SectionBackup Alarm - Test

4. Fill the reservoir until grease appears at the outletfor the vent port.

Note: Level indicator (3) can also be used in order todetermine when the reservoir is full.

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

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

The automatic lubrication reservoir provideslubrication for many components. There are fivebanks of injectors on the machine.

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

i03652288

Backup Alarm - TestSMCS Code: 7406-081

The backup alarm alerts the personnel behind themachine that the machine is backing up. The backupalarm is located at the rear of the machine.

1. Park the machine on a level surface and stop theengine.

2. Make sure that the area behind the machine isclear of personnel and clear of obstacles.

3. Turn the engine start switch to the ON position.

Note: Do not start the engine.

4. Turn the fan speed switch to the OFF positionand turn off the entertainment radio (if equipped).Open a door or a window.

5. Apply the service brakes.

6. Move the transmission control to the R positionand listen for the backup alarm. The backup alarmshould sound immediately. The backup alarmshould continue to sound until the transmissioncontrol is moved out of the R position.

7. Move the transmission control to the P positionand release the service brake.

8. If the backup alarm did not function, or if thebackup alarm did not function properly, contactyour Caterpillar dealer.

i00993589

Battery - RecycleSMCS Code: 1401-561

Always recycle a battery. Never discard a battery.

Always return used batteries to one of the followinglocations:

A battery supplier

An authorized battery collection facility

Recycling facility

i04334142

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

Failure to properly service the batteriesmay causeperonal injury.

Prevent sparks near the batteries. They couldcause vapors to explode. Do not allow the jumpstart cable ends to contact each other or themachine.

Do not smoke when checking battery electrolytelevels.

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 batterypositive (+) and the battery negative () to batterynegative ().

Jump start only with an energy source with thesame voltage as the stalled machine.

Turn off all lights and accessories on the stalledmachine. Otherwise, they will operate when theenergy source is connected.


Belts - Inspect/Replace

g01794777Illustration 147Batteries for serial number prefix SSP are located on the frontbumper.


Batteries for serial number prefix SND are located on the rightplatform.

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


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

3. Turn the battery disconnect switch to the OFFposition. Lock out the battery disconnect switch.

4. Remove the battery access covers.

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

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

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

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

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

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

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

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

12. Install the battery access covers.

13.Remove the lockout for the battery disconnectswitch. Turn the battery disconnect switch to theON position.

i04030841

Belts - Inspect/ReplaceSMCS Code: 1397-040; 1397-510

Note: In order to view the belts, it may be necessaryto use a portable access system (ladder, stairassembly, man lift, or other portable access system)that is suitable and compliant to local regulations.

Prepare the machine for maintenance. Refer toOperation and Maintenance Manual, Prepare theMachine for Maintenance.

Inspection

Refrigerant Compressor Belt

This machine is equipped with a serpentine belt thatdrives the refrigerant compressor.

146 SEBU8406-04Maintenance SectionBelts - Inspect/Replace

g02162032Illustration 149Inspect the refrigerant compressor belt through the areas that arenot obstructed by the belt guard. Do not remove the belt guardfor inspection.


Rear view of refrigerant compressor belt arrangement forreference.

Inspect the refrigerant compressor belt for thefollowing conditions: cracks, wear, stretch, frayedareas, and missing pieces. If necessary, replace thebelt.

Alternator Belt

This machine is equipped with a serpentine belt thatdrives the alternator.

g02162033Illustration 151Inspect the alternator belt through the areas that are not obstructedby the belt guard. Do not remove the belt guard for inspection.

g02220973Illustration 152Front view of alternator belt arrangement for reference.

Inspect the alternator belt for the following conditions:cracks, wear, stretch, frayed areas, and missingpieces. If necessary, replace the belt.

ReplacementRefer to Disassembly and Assembly, KENR8578,793F Off-Highway Truck Engine Supplement forinformation on replacing the refrigerant compressorbelt and the alternator belt.


Brake Oil Cooler Screen - Clean

i03591340

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

When it is necessary to work under the machinewith the body (bed) raised, attach the body (bed)retaining cables to the rear tow points. Install therear tow point pins through the ends of the retain-ing cables.

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

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

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

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

Dispose of all fluids according to local regulations andmandates.

Clean the brake oil cooler screen(s) whenever thereis a failure in the brake circuit.



(1) Housing for the brake oil cooler screen on machines withstandard retarding

g01917944Illustration 154(2) Housings for the brake oil cooler screens on machines with

additional retarding

148 SEBU8406-04Maintenance SectionBraking System - Test

2. Remove the drain plug and drain the oil into asuitable container. Remove the cover from thescreen housing .

3. Remove the spring and remove the screenfrom the housing. Clean the screen in cleannonflammable solvent.

4. Inspect the seal in the housing. If the seal isdamaged, replace the seal with a new seal.

5. Install the clean screen and the spring. Install thecover.

6. If this machine is equipped with additionalretarding, repeat step 2 through 5 for the otherbrake oil cooler screen.

7. Start the engine and operate the engine at an idle.Check for leaks and make any necessary repairs.

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

i03450700

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

Personal injury can result if the machine movesduring testing. If the machine begins to move dur-ing testing, reduce the engine speed immediatelyand place the transmission control in the P posi-tion in order to engage the parking brake.

The following tests are used to determine if theservice brake system, the secondary brake system,and the parking brake system are functional. Thesetests are not intended to measure the maximumbrake holding effort. The brake holding effort that isrequired to sustain a machine at a specific enginerpm varies depending on the machine. The variationsare the differences in the engine setting, in the powertrain efficiency, and in the brake holding ability, etc.

During the test of the brakes, compare the previousengine rpm and the recent engine rpm. This willdetermine the system deterioration.


Service Brake Holding Ability Test1. Fasten the seat belt before you test the brakes.

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

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

4. Start the engine.

5. Depress service brake control (1) in order to applythe service brakes.

6. Move the transmission control to the D position.

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

8. Reduce the engine speed to an idle. Move thetransmission control to the P position. Stop theengine.

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

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

Secondary Brake Holding AbilityTest1. Fasten the seat belt before you test the brakes.

SEBU8406-04 149Maintenance SectionBraking System - Test




5. Depress secondary brake control (2) in order toapply the secondary brakes.

6. Move the transmission control to the D position.




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

Parking Brake Holding Ability Test1. Fasten the seat belt before you test the brakes.





5. When the transmission control is in the P position,depress button (3) for the high gear limit RAISEand depress button (4) for the high gear limitLOWER at the same time.

6. While both buttons are depressed, Move thetransmission control to the D position.

Note: The buttons can now be released and theparking brake will remain on.




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

150 SEBU8406-04Maintenance SectionBreather (Differential and Final Drive) - Replace

i03452901

Breather (Differential and FinalDrive) - ReplaceSMCS Code: 3258-510-BRE; 4050-510-BRE

Note: In order to access the breather, it may benecessary to use a portable access system (ladder,stair assembly, man lift, or other portable accesssystem) that is suitable and compliant to localregulations.



2. Remove final drive breather (1).

3. Install a new final drive breather.

i03454800

Breather (Front Axle) - ReplaceSMCS Code: 3282-510-BRE; 4251-510-BRE




Note: In order to access the breather, it may benecessary to use a portable access system (ladder,stair assembly, man lift, or other portable accesssystem) that is suitable and compliant to localregulations.



2. Remove breather (1) from each front wheel.

3. Install a new breather on each front wheel.


Breather (Fuel Tank) - Replace

i04339961

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



Note: The breather may also be accessed with thedump body in the DOWN position. In order to accessthe breather with the dump body in the DOWNposition, use a portable access system (ladder, stairassembly, man lift, or other portable access system)that is suitable and compliant to local regulations.

1. Secure the dump body in the fully raised positionand prepare the machine for maintenance. Referto Operation and Maintenance Manual, Preparethe Machine for Maintenance.


2. Remove fuel tank breather (1).

3. Install a new fuel tank breather.

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

i04340083

Breather (Hoist and BrakeTank) - ReplaceSMCS Code: 5056-510-BRE; 5057-510-BRE





152 SEBU8406-04Maintenance SectionBreather (Steering Tank) - Replace


2. Remove breather (1) for the hoist/brake tank.

3. Install a new breather for the hoist/brake tank.


i03454883

Breather (Steering Tank) -ReplaceSMCS Code: 4332-510-BRE



2. Remove steering tank breather (1).

3. Install a new steering tank breather.

i04339982

Breather (Torque Converterand Transmission) - ReplaceSMCS Code: 3030-510-BRE; 3101-510-BRE






Cab Air Filter - Clean/Replace


Shown with the dump body in the raised position

2. Remove torque converter and transmissionbreather (1).

3. Install a new torque converter and transmissionbreather.


i03855636

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


The filter element for the cab is located inside the operator station.

The operator's seat has been removed for ease of viewing.


2. Loosen retaining screws (3). Remove cover (2)and filter element (1).

3. Wash the filter element in a nonsudsing detergent.

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

5. Install the clean filter element and the cover.Tighten the retaining screws.

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

154 SEBU8406-04Maintenance SectionCable (Truck Body Retaining) - Inspect

i03655302

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

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

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

Wear gloves when handling the cable.


2. Inspect the retaining cable for any of the followingconditions:

Reduction in the diameter

Broken wires

Worn wires

Corroded wires

Loose strands or loose wires

Loose cable ends or separation between thecable and the cable end

Kinks

Cuts

Flat spots

3. Inspect the retaining cable ends and the cableconnection for the truck body for any of thefollowing conditions:

Distortion such as bends or twists

Wear

Corrosion

Cracks or gouges

4. Inspect the retaining pins and locking hardwarefor any of the following conditions:

Distortion such as bends or twists

Wear

Corrosion

Cracks or gouges

If any of the above conditions exist, replacethe appropriate parts. , Consult your Caterpillardealer for proper replacement parts.

i04032116

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

Personal injury can result from hot coolant, steamand alkali.

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

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

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

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

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting, and repair of the product. Be preparedto collect the fluid with suitable containers beforeopening any compartment or disassembling any com-ponent containing fluids.

Refer to Special Publication, NENG2500, Dealer Ser-vice Tool Catalog for tools and supplies suitable tocollect and contain fluids on Cat products.


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


Cooling System Coolant (ELC) - Change

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

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

This machine was factory filled with Cat Extended LifeCoolant.

Change the coolant whenever the coolant is dirty orwhenever foaming is observed. Change the coolantduring scheduled maintenance intervals.



2. Slowly loosen filler cap (1). This will relieve systempressure. Remove the filler cap.


3. Open drain valve (2). Drain the coolant into asuitable container. Close the drain valve.

156 SEBU8406-04Maintenance SectionCooling System Coolant Extender (ELC) - Add


4. Remove drain valve plug (3) on the lower coolantline for the oil coolers. Install a 88.0 mm (3.50 inch)long NPT pipe nipple in order to open the internaldrain valve. The outer diameter of the NPT pipenipple should be 25 mm (1 inch).

5. Drain the coolant into a suitable container.Remove the pipe nipple. Clean the drain plug andinstall the drain plug.

6. Fill the system with clean water and a 6 to 10%concentration of cooling system cleaner.

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

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

9. Close the drain valve.

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

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

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

a. Start the engine without the filler cap.

b. Run the engine at low idle for 10 minutes.

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

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

12. Install the filler cap.

i03571658

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







Cooling System Coolant Extender (ELC) - Add

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

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

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




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




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

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



2. Loosen filler cap (1) slowly in order to relievepressure. Remove the filler cap.

3. Check coolant level gauge (2). If necessary, drainenough coolant in order to allow the addition ofthe liquid coolant additive.

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

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

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

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

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

158 SEBU8406-04Maintenance SectionCooling System Coolant Level - Check

i03571727

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






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

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

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





If coolant needs to be added daily, check for leaks.


2. Use coolant level gauge (1) in order to check thecoolant levels. The needle should be in the greenrange.

3. If the gauge indicator is in the red range, allowthe engine to cool and loosen filler cap (2) slowly.Then add premixed coolant in order to bring thecoolant in the green range on the coolant levelgauge.

Refer to Operation and Maintenance Manual,Cooling System Coolant Extender (ELC) - Add formore information.


Cooling System Coolant Sample (Level 1) - Obtain

i03572135

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

At operating temperature, engine coolant is hotand under pressure. Hot coolant and hot compo-nents can cause severe burns. Do not allow hotcoolant or hot components to contact the skin.

Note: In order to access the sampling valve, it maybe necessary to use a portable access system(ladder, stair assembly, man lift, or other portableaccess system) that is suitable and compliant to localregulations.

Obtain SOS samples as close as possible to therecommended sampling interval. In order to receivethe full effect of SOS analysis, you must establisha consistent trend of data. In order to establisha pertinent history of data, perform consistentsamplings that are evenly spaced. Supplies forcollecting samples can be obtained from yourCaterpillar dealer.

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



2. Obtain a coolant sample through sampling valve(1). Take the oil sample when the engine is cooland when the engine is operating at low idle.

3. Submit the sample for Level 1 SOS analysis.

Refer to the following publications for SOSinformation:

Operation and Maintenance Manual, SOSInformation

Special Publication, SEBU6250, CaterpillarMachine Fluids Recommendations, SOSServices Analysis

Special Publication, PEGJ0047, How to Take aGood SOS Sample

Special Publication, PEGJ0046, SOS Services:Understanding Your Results

Special Publication, PEHJ0191, SOS FluidAnalysis

i03572143

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

At operating temperature, engine coolant is hotand under pressure. Hot coolant and hot compo-nents can cause severe burns. Do not allow hotcoolant or hot components to contact the skin.




160 SEBU8406-04Maintenance SectionCooling System Pressure Cap - Clean/Replace


2. Obtain a coolant sample through sampling valve(1). Take the oil sample when the engine is cooland when the engine is operating at low idle.

3. Submit the sample for Level 2 SOS analysis.







i03572146

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








2. Remove filler cap (1) slowly in order to relievethe pressure.

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

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



Cooling System Relief Valve - Clean

i03572148

Cooling System Relief Valve -CleanSMCS Code: 1370-070






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



2. Remove filler cap (1) slowly in order to relievethe pressure.

3. Remove the mounting bolts from relief valveassembly (2) and remove the relief valveassembly.

g01428758Illustration 173(3) Gaskets(4) Mounting bolts(5) Seal(6) Relief valve(7) Cover plate

4. Clean all debris and deposits from the following:gaskets, mounting bolts, seal, relief valve, andcover plate.

5. Inspect the following: gaskets, mounting bolts,seal, relief valve, and cover plate. If necessary,replace any damaged parts.

6. Install the relief valve assembly.


i04382949

Damper (Crankshaft) - InspectSMCS Code: 1205-040

The crankshaft vibration damper limits the torsionalvibration of the crankshaft. The visconic damper hasa weight that is located inside a fluid filled case.

Damage to the crankshaft vibration damper or failureof the damper can increase torsional vibrations. Thisvibration can result in damage to the crankshaft andto other engine components. A deteriorating dampercan cause excessive power train noise at variablepoints in the speed range.


2. Visually inspect the damper for the followingconditions:

dents

cracks

162 SEBU8406-04Maintenance SectionDifferential Thrust Pin Clearance - Check

bends

evidence of a fluid leak (The fluid in the damperis silicone. Silicone has transparent, viscous,and smooth characteristics.)

evidence of excessive heat (an infraredthermometer can be used to monitor thetemperature of the damper during operation.The temperature should not reach 93 C(200 F).

3. If any of these conditions exist, replace thecrankshaft vibration damper. For the replacementof the crankshaft vibration damper, refer toDisassembly and Assembly, KENR8578, 793FEngine Supplement, Damper - Remove andInstall.

i04030014

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

g02217373Illustration 174(1) Cover for the thrust pin


2. Refer to Testing and Adjusting, KENR8393, 793FPower Train, Differential and Bevel Gear -Adjust for the adjustment procedure for the thrustpin.

i03572413

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

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

The condition of the oil

The SOS recommendation


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



Differential and Final Drive Oil - Change




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

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

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


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

7. Remove drain valve plug (3). Install a 100 mm(4 inch) long NPT pipe nipple in order to openthe internal drain valve. The outer diameter of theNPT pipe nipple must be 38 mm (1.5 inch). Drainthe oil into a suitable container.

8. Clean the drain plug. Install the drain plug.

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

10. Fill the differential compartment through port (4).Fill the differential compartment to the bottom ofsight gauge (5).

11.Remove final drive filler plugs (2). Refer toillustration 175. Fill each final drive to the bottomof the filler plug opening. When the final drivedrain plug is in the lowest position, the final drivefiller plug will be at the correct oil level.

Note: Inspect any magnetic plugs and the usedoil. Refer to Operation and Maintenance Manual,Differential and Final Drive Oil - Inspect for furtherinformation.

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

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

12.Maintain the proper oil level for the differential tothe bottom of the sight gauge .

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

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

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

14.Park the machine according to the guidelines inOperation and Maintenance Manual, Prepare theMachine for Maintenance. Check for leaks andmake any necessary repairs.

15.Check the oil level. For the proper procedure,refer to Operation and Maintenance Manual,Differential and Final Drive Oil - Check. Ifnecessary, adjust the oil level to the bottom of thesight gauge.

164 SEBU8406-04Maintenance SectionDifferential and Final Drive Oil - Inspect

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

i03656917

Differential and Final Drive Oil- InspectSMCS Code: 4208


2. Inspect the differential and final drive oil for anyof the following symptoms that may indicate amechanical failure:

Discoloration and change in viscosity

A high amount of metal on the magnetic plug

Oil leaks in the area around the drive wheelbearings

Review the latest results and trends from theSOS samples

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

Consult your Caterpillar dealer for more information.

i03573292

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

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

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



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

3. Maintain the oil level at the bottom of the sightgauge. Correct oil levels are critical in thedifferential and final drives.

4. If necessary, add oil. Use port (2) to add oil.Allow the oil to fill all of the compartments beforerechecking the oil level.

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

i04030230

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



Display and Camera - Clean

Obtain SOS samples as close as possible to therecommended sampling interval. In order to receivethe full effect of SOS analysis, a consistent trendof data must be established. In order to establisha pertinent history of data, perform consistentsamplings that are evenly spaced. Supplies forcollecting samples can be obtained from yourCaterpillar dealer.



The left rear tires and wheels have been removed for ease ofviewing.

2. Obtain the differential and final drive oil samplethrough sampling valve (1) that is located on thebase of the rear axle oil filter. Take the oil samplewhen the engine is running at an idle. The enginemust be running in order to drive the lubricationpump for the rear axle.

3. Submit the sample for SOS analysis.







i04218936

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

The Work Area Vision System (WAVS) and the CatDetect Object Detection system both utilize multiplecameras and a display.

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



WAVS display

166 SEBU8406-04Maintenance SectionDrive Shaft Slip Joint - Replace

g02217954Illustration 180Cat Detect Object Detection display

2. Use a soft, damp cloth in order to clean thedisplay. The display has a soft plastic surface thatcan be easily damaged by an abrasive material.The display is not sealed. Do not immerse thedisplay with liquid.


The camera for WAVS and the Cat Detect Object Detection system.

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

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

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

For more information on Cat Detect Object Detectionsystem, refer to Operation and Maintenance Manual,Cat Detect Object Detection.

i04337413

Drive Shaft Slip Joint - ReplaceSMCS Code: 3251-510


2. For information on removing the drive shaft(slip joint), refer to Disassembly and Assembly, KENR8397, 793F Off-Highway Truck PowerTrain or consult your Cat dealer.

i04337410

Drive Shaft Spider and Bearing- ReplaceSMCS Code: 3253-510


2. For information on removing the spider assemblyfor the drive shaft, refer to Disassembly andAssembly , KENR8397, 793F Off-Highway TruckPower Train or consult your Cat dealer.

i03829310

Electric Drive Pump (PoweredStairway) Oil - Change(If Equipped)SMCS Code: 5713-044-OC





Electric Drive Pump (Powered Stairway) Oil Level - Check



2. Remove tread plate (1) from the platform of thepowered stairway.


3. Remove filler cap (2) for the reservoir.

4. Use a suction device in order to extract the oilthrough the filler neck.

5. The oil level for the powered stairway is visiblethrough the clear plastic oil reservoir (3).

6. Fill the reservoir for the powered stairway to fulllevel (4). Refer to Operation And MaintenanceManual, Lubricant Viscosities. Refer to OperationAnd Maintenance Manual, Capacities (Refill).

i03828309

Electric Drive Pump (PoweredStairway) Oil Level - Check(If Equipped)SMCS Code: 5713-535-FLV



2. Remove tread plate (1) from the platform of thepowered stairway.


3. The oil level for the powered stairway is visiblethrough the clear plastic oil reservoir (2).

4. Maintain the oil volume at the full level (4).

Note: Do not operate the powered stairway when theoil volume is below minimum level (5).

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

168 SEBU8406-04Maintenance SectionEngine Air Filter Primary Element - Clean/Replace

i04030065

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

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

Service the air cleaner filter element when the enginefault indicator is activated. The engine fault indicatoris located inside the cab. The engine fault indicatorwill activate when there is an inlet air restriction,and the Advisor display will provide a messageregarding the specific problem. Refer to Operationand Maintenance Manual, Monitoring System forfurther information.

Note: In order to access the air filter elements, itmay be necessary to use a portable access system(ladder, stair assembly, man lift, or other portableaccess system) that is suitable and compliant to localregulations.

Wear the proper personal protection equipment whenpressurized air is used.


Location of the air filter housings.


Note: This machine is equipped with ultra highefficiency (primary) air filter elements.


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

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

4. Clean the inside of the air filter housings.

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

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

Cleaning Primary Air FilterElements

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

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

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

Do not wash the filter element.

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

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


Engine Air Filter Secondary Element - Replace

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

Visually inspect the primary air filter elements beforecleaning. Inspect the air filter elements for damage tothe seal, the gaskets, and the outer cover.

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

Pressurized air

Vacuum cleaning

Pressurized Air

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


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

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

Vacuum Cleaning

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

Inspecting the Primary Air FilterElements


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

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

i03574580

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

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

170 SEBU8406-04Maintenance SectionEngine Air Precleaner - Clean

Note: Replace the engine air filter secondaryelements when you service the engine air filterprimary elements for the third time. Replace thesecondary filter elements if the exhaust smokeremains black and the clean primary filter elementshave been installed.

Note: In order to access the air filter elements, itmay be necessary to use a portable access system(ladder, stair assembly, man lift, or other portableaccess system) that is suitable and compliant to localregulations.


2. Remove the air filter covers and remove theprimary filter elements from the air filter housings.

g01903515Illustration 190(1) Secondary filter element

3. Remove secondary filter elements (1) and properlydiscard the secondary elements.

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

5. Uncover the air inlet openings. Install the newsecondary filter elements.

6. Install the primary filter elements and install theair filter covers.

i03574742

Engine Air Precleaner - CleanSMCS Code: 1055-070


Note: In order to access the engine air precleaners,it may be necessary to use a portable access system(ladder, stair assembly, man lift, or other portableaccess system) that is suitable and compliant to localregulations.


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

Perform the following procedure for each engine airprecleaner.


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

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


Engine Components - Clean/Inspect, Rebuild/Install Reman, Install New

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

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

6. Repeat steps 2 through 5 for each precleaner.

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

i03994010

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


2. Refer to the Disassembly and Assembly manualand the Disassembly and Assembly supplementfor the removal and installation of enginecomponents.

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

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

Install New Components All Seals, Gaskets, and O-rings

Camshaft Bearings

Engine Mounts

Engine Software

Oil Pressure Regulating Valve

Fuel Pressure Regulating Valve

Fuel Priming Pump

Gear Train Bushings, Bearings, and Thrust Plates

Main Bearings, Rod Bearings, and CrankshaftThrust Plates

Piston Rings

Wiring Harness

Coolant Hoses

High Pressure Fuel Pump

Rebuild Components and/or InstallRemanufactured Components Cylinder Heads

Turbochargers

Oil Cooler Cores

Oil Pump

Scavenge Oil Pump

Water Pumps

Starter(s)

Refrigerant Compressor

Wastegate (High Altitude Arrangement) (C175-20797F Only)

Injectors

Air Compressor (If Equipped)

Clean Components and InspectComponents for Reusability Aftercooler

Camshaft

Camshaft Lifters

Connecting Rods

Crankshaft

Cylinder Block

Cylinder Liners

Damper

172 SEBU8406-04Maintenance SectionEngine Components - Rebuild/Install Reman

Gear Train

Piston Crowns and Piston Skirts

Piston Pins

Spacer Plates

i03994009

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


2. Refer to the Disassembly and Assembly manualand the Disassembly and Assembly supplementfor the removal and installation of enginecomponents.

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

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

Air Compressor (If Equipped)

Starter(s)

Alternator

High Pressure Fuel Pump

Fuel Priming Pump

Fuel Transfer Pump

Turbochargers (High Altitude Arrangement only)

Injectors

Refrigerant Compressor

Water Pumps

Coolant Hoses

i03575743

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


The engine in this machine is equipped with twoengine crankcase breathers (1) at the rear of theengine. One breather is on the right side of theflywheel housing and one breather is on the left sideof the flywheel housing.


2. Remove bolts from the clamps at the base of thebreathers. Loosen the hose clamps.

3. Remove the breathers from the hoses.

4. Wash the breathers in clean nonflammablesolvent.

5. Install the hoses and hose clamps on thebreathers. Install the clamps at the base of thebreathers.

6. Tighten all of the clamps.


Engine Oil Level - Check

i03575781

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

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



174 SEBU8406-04Maintenance SectionEngine Oil Sample - Obtain

2. Maintain the oil level within the green range onthe sight gauge.

a. If the engine is stopped and the oil is cold,maintain the oil level in green range (A).

b. If the engine is running at an idle and the oil isat operating temperature, maintain the oil levelin green range (B).

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

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

i03575920

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






2. Obtain the engine oil sample through samplingvalve (1) that is located on the oil lines on the leftside of the engine. Take the oil sample when theengine is operating at low idle.

3. Submit the sample for SOS analysis.







i04032117

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



Engine Oil and Filter - Change

NOTICECare must be taken to ensure that fluids are containedduring performance of inspection, maintenance, test-ing, adjusting, and repair of the product. Be preparedto collect the fluid with suitable containers beforeopening any compartment or disassembling any com-ponent containing fluids.

Refer to Special Publication, NENG2500, Dealer Ser-vice Tool Catalog for tools and supplies suitable tocollect and contain fluids on Cat products.


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

Consult your Caterpillar dealer for the latest oilrecommendations.

Note: In order to access the oil filler tube and theoil filters, it may be necessary to use a portableaccess system (ladder, stair assembly, man lift, orother portable access system) that is suitable andcompliant to local regulations.



2. Drain the engine crankcase with the oil warm.

a. If the oil drain valve is used, open drain valve(1) and drain the oil into a suitable container.Close the drain valve after the oil is drained.


b. If the high speed oil change is used, removethe dust cover and attach the oil drain hose tomale fitting (3) in order to drain the oil. Removethe oil drain hose after the oil is drained.


3. Remove drain plug (4) from the bottom of thecrossover tube . Drain the oil into a suitablecontainer. Inspect the seal for the drain plug.Replace a damaged seal with a new seal. Washthe drain plug in clean nonflammable solvent andinstall the drain plug.

4. Remove the drain plug from the bottom of filterhousings (5). Drain the oil into a suitable container.Inspect the seals for the drain plugs. Replace anydamaged seals with new seals. Wash the drainplugs in clean nonflammable solvent and installthe drain plugs.

176 SEBU8406-04Maintenance SectionEngine Oil and Filter - Change

5. Remove the covers from the bottom of the filterhousings.

6. Remove the filter elements from the filter housings.Properly discard the used filter element.

7. Inspect the seals for the housing cover. Replaceany damaged seals with new seals. Wash thehousing cover in clean nonflammable solvent.

NOTICECaterpillar oil filters are built to Caterpillar speci-fications. Use of an oil filter not recommended byCaterpillar could result in severe engine damage tothe engine bearings, crankshaft, etc., as a result ofthe larger waste particles from unfiltered oil enteringthe engine lubricating system. Only use oil filtersrecommended by Caterpillar.

8. In order to install the filter elements, align thecollapsible package to the opening of eachhousing. Press each filter element upward intothe housing until the element seats. Follow theinstructions on the package of the filter element.

Note: Do not touch the filter elements. Do not allowcontaminants to contact the filter elements.

9. Install the housing covers.

10. Fill the crankcase with oil. Refer to Operationand Maintenance Manual, Lubricant Viscositiesfor the type of oil. Refer to Operation andMaintenance Manual, Capacities (Refill) for theamount of oil.

a. If the filler tube is used, remove the filler cap (2)in order to fill with oil. install the filler cap afterthe oil is at the proper level. Refer to illustration197.

b. If the high speed oil change is used, remove thedust cover and attach the oil fill hose to malefitting (3) in order to fill with oil. Remove the oilfill hose and install the dust cover after the oil isat the proper level. Refer to illustration 197.

11.Start the engine and operate the engine at anidle for 5 minutes. Inspect the engine oil filters forleaks. Make any necessary repairs.



Engine Valve Lash - Check/Adjust

12.Maintain the oil level within the green range onthe sight gauge.

a. If the engine is stopped and the oil is cold,maintain the oil level in green range (A).

b. If the engine is running at low idle and the oil isat operating temperature, maintain the oil levelin green range (B).

793F y 793F XQ Mantenimiento

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Transcript of 793F y 793F XQ Mantenimiento