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735 y 740 CAT Operating y Maintenance PDF
735 y 740 CAT Operating y Maintenance PDF
735 y 740 CAT Operating y Maintenance PDF
October 2009
Operation and
Maintenance
Manual
735 and 740 Articulated Trucks
B1N1-Up (Machine)
B1P1-Up (Machine)
SAFETY.CAT.COM
i03684547
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SEBU7815-10 3
Table of Contents
Parking .................................................................. 25
Foreword Maintenance
The maintenance section is a guide to equipment
Literature Information care. The Maintenance Interval Schedule (MIS) lists
the items to be maintained at a specific service
This manual should be stored in the operator's interval. Items without specific intervals are listed
compartment in the literature holder or seat back under the "When Required" service interval. The
literature storage area. Maintenance Interval Schedule lists the page
number for the step-by-step instructions required to
This manual contains safety information, operation accomplish the scheduled maintenance. Use the
instructions, transportation information, lubrication Maintenance Interval Schedule as an index or "one
information and maintenance information. safe source" for all maintenance procedures.
Some photographs or illustrations in this publication
show details or attachments that can be different Maintenance Intervals
from your machine. Guards and covers might have
been removed for illustrative purposes. Use the service hour meter to determine servicing
intervals. Calendar intervals shown (daily, weekly,
Continuing improvement and advancement of monthly, etc.) can be used instead of service hour
product design might have caused changes to your meter intervals if they provide more convenient
machine which are not included in this publication. servicing schedules and approximate the indicated
Read, study and keep this manual with the machine. service hour meter reading. Recommended service
should always be performed at the interval that
Whenever a question arises regarding your machine, occurs first.
or this publication, please consult your Caterpillar
dealer for the latest available information. Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is
specified in the maintenance intervals chart might
Safety be necessary.
The safety section lists basic safety precautions. In Perform service on items at multiples of the original
addition, this section identifies the text and locations requirement. For example, at every 500 service
of warning signs and labels used on the machine. hours or 3 months, also service those items listed
under every 250 service hours or monthly and every
Read and understand the basic precautions listed 10 service hours or daily.
in the safety section before operating or performing
lubrication, maintenance and repair on this machine.
California Proposition 65 Warning
Operation Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
The operation section is a reference for the new birth defects, and other reproductive harm.
operator and a refresher for the experienced
operator. This section includes a discussion of Battery posts, terminals and related accessories
gauges, switches, machine controls, attachment contain lead and lead compounds. Wash hands
controls, transportation and towing information. after handling.
Photographs and illustrations guide the operator
through correct procedures of checking, starting, Certified Engine Maintenance
operating and stopping the machine.
Proper maintenance and repair is essential to keep
Operating techniques outlined in this publication are the engine and machine systems operating correctly.
basic. Skill and techniques develop as the operator As the heavy duty off-road diesel engine owner, you
gains knowledge of the machine and its capabilities. are responsible for the performance of the required
maintenance listed in the Owner Manual, Operation
and Maintenance Manual, and Service Manual.
SEBU7815-10 5
Foreword
g00751314
Illustration 1
Where:
Safety Section
i02871880
Safety Messages
SMCS Code: 7000
g01430152
Illustration 2
8 SEBU7815-10
Safety Section
Safety Messages
g01430151
Illustration 3
g01370904 g01370908
Do not operate or work on this machine unless A seat belt should be worn at all times during ma-
you have read and understand the instructions chine operation to prevent serious injury or death
and warnings in the Operation and Maintenance in the event of an accident or machine overturn.
Manuals. Failure to follow the instructions or heed Failure to wear a seat belt during machine opera-
the warnings could result in injury or death. Con- tion may result in serious injury or death.
tact any Caterpillar dealer for replacement manu-
als. Proper care is your responsibility.
SEBU7815-10 9
Safety Section
Safety Messages
g01430344
g01065910
g01371647
g01142855
g01371640 g01430347
The coolant is hot and the coolant is under pres- Install dump body prop before working under a
sure. Do not touch the hot surfaces. Refer to the raised dump body to prevent it from falling which
Operation and Maintenance Manual for the proce- could result in personal injury or death.
dure to follow when you check the radiator.
g01053243
g01370909
g01430342
i02885514
Additional Messages
SMCS Code: 1000; 7000; 7405
This machine is equipped with a Caterpillar Prod- Make sure that all of the messages are legible.
uct Link communication device which must be de- Clean the messages or replace the messages if the
activated within 12 m (40 ft) of a blast zone. Failure words or images are unreadable. When you clean
to do so could result in serious injury or death. 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.
14 SEBU7815-10
Safety Section
Additional Messages
Replace any message that is damaged, or missing. The Product Link System is a satellite communication
If a message is attached to a part that is replaced, device that transmits information regarding the
install a message on the replacement part. Any machine back to Caterpillar and Caterpillar dealers
Caterpillar dealer can provide new messages. and customers. All logged events and diagnostic
codes that are available to the Caterpillar Electronic
Retarding Guidelines Technician (ET) on the CAT data link can be sent
to the satellite. Information can also be sent to the
This message is located inside the cab. Product Link System. The information is used to
improve Caterpillar products and Caterpillar services.
g01319966
Illustration 4
g01418953
Typical example Illustration 6
Information for Air Conditioner System Service ELC (Extended Life Coolant) Cooling System
This message is located inside the cab. This message is located behind the cab near the cap
for the cooling system.
Do not work on the air conditioning system until you
have read the service manual and you understand This machine is shipped from the factory with ELC.
the service manual.
g00955999
Illustration 7
g01294295
Illustration 5
24 Volt Electrical System
Product Link Data Privacy
This message is located near the batteries and
This message is located in the cab. the auxiliary start receptacle on the left front of the
machine.
i03559343
g01126478
Illustration 8
Alternate Exit
This film identifies an alternate exit. for more Attach a “Do Not Operate” warning tag or a similar
information on the alternate exit, refer to Operation warning tag to the start switch or to the controls
and Maintenance Manual, “Alternate Exit”. before you service the equipment or before you
repair the equipment. These warning tags (Special
Instruction, SEHS7332) are available from your
Caterpillar dealer.
g01002993
Illustration 9
g00702020
Illustration 11
Pressurized Air and Water Always use a board or cardboard when you check
for a leak. Leaking fluid that is under pressure can
Pressurized air and/or water can cause debris penetrate body tissue. Fluid penetration can cause
and/or hot water to be blown out. This could result in serious injury and possible death. A pin hole leak can
personal injury. cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
When pressurized air and/or pressurized water is from a doctor that is familiar with this type of injury.
used for cleaning, wear protective clothing, protective
shoes, and eye protection. Eye protection includes Containing Fluid Spillage
goggles or a protective face shield.
Care must be taken in order to ensure that fluids
The maximum air pressure for cleaning purposes are contained during performance of inspection,
must be reduced to 205 kPa (30 psi) when the maintenance, testing, adjusting and repair of the
nozzle is deadheaded and the nozzle is used with equipment. Prepare to collect the fluid with suitable
an effective chip deflector and personal protective containers before opening any compartment or
equipment. The maximum water pressure for disassembling any component that contains fluids.
cleaning purposes must be below 275 kPa (40 psi).
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for the following items:
SEBU7815-10 17
Safety Section
Crushing Prevention and Cutting Prevention
• Tools that are suitable for collecting fluids and • Use exhaust ventilation on permanent machining
equipment that is suitable for collecting fluids jobs.
• Tools that are suitable for containing fluids and • Wear an approved respirator if there is no other
equipment that is suitable for containing fluids way to control the dust.
Obey all local regulations for the disposal of liquids. • Comply with applicable rules and regulations
for the work place. In the United States, use
Occupational Safety and Health Administration
Asbestos Information (OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”.
g00702022
Illustration 13
Unless you are instructed otherwise, never attempt Check the coolant level only after the engine has
adjustments while the machine is moving or while been stopped.
the engine is running.
Ensure that the filler cap is cool before removing the
Never jump across the starter solenoid terminals filler cap. The filler cap must be cool enough to touch
in order to start the engine. Unexpected machine with a bare hand. Remove the filler cap slowly in
movement could result. order to relieve pressure.
Whenever there are equipment control linkages the Cooling system conditioner contains alkali. Alkali can
clearance in the linkage area will change with the cause personal injury. Do not allow alkali to contact
movement of the equipment or the machine. Stay the skin, the eyes, or the mouth.
clear of areas that may have a sudden change in
clearance with machine movement or equipment Oils
movement.
Hot oil and hot components can cause personal
Stay clear of all rotating and moving parts. injury. Do not allow hot oil to contact the skin. Also,
do not allow hot components to contact the skin.
If it is necessary to remove guards in order to perform
maintenance, always install the guards after the Remove the hydraulic tank filler cap only after the
maintenance is performed.
engine has been stopped. The filler cap must be
cool enough to touch with a bare hand. Follow the
Keep objects away from moving fan blades. The fan standard procedure in this manual in order to remove
blade will throw objects or cut objects.
the hydraulic tank filler cap.
Do not use a kinked wire cable or a frayed wire cable.
Wear gloves when you handle wire cable. Batteries
When you strike a retainer pin with force, the retainer Electrolyte is an acid. Electrolyte can cause personal
pin can fly out. The loose retainer pin can injure injury. Do not allow electrolyte to contact the skin or
personnel. Make sure that the area is clear of people the eyes. Always wear protective glasses for servicing
when you strike a retainer pin. To avoid injury to batteries. Wash hands after touching the batteries
your eyes, wear protective glasses when you strike and connectors. Use of gloves is recommended.
a retainer pin.
i03659986
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.
Fire Prevention and Explosion
Prevention
i01329099 SMCS Code: 7000
Burn Prevention
SMCS Code: 7000
Coolant
When the engine is at operating temperature, the g00704000
engine coolant is hot. The coolant is also under Illustration 15
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant. General
Any contact with hot coolant or with steam can cause All fuels, most lubricants, and some coolant mixtures
severe burns. Allow cooling system components to are flammable.
cool before the cooling system is drained.
SEBU7815-10 19
Safety Section
Fire Prevention and Explosion Prevention
To minimize the risk of fire or explosion, Caterpillar Store fuels and lubricants in properly marked
recommends the following actions. containers away from unauthorized personnel. Store
oily rags and flammable materials in protective
Always perform a Walk-Around Inspection, which containers. Do not smoke in areas that are used for
may help you identify a fire hazard. Do not operate storing flammable materials.
a machine when a fire hazard exists. Contact your
Caterpillar dealer for service.
Attaching electrical wiring to hoses and tubes that Make sure that all clamps, guards, and heat shields
contain flammable fluids or combustible fluids should are installed correctly. During machine operation, this
be avoided. will help to prevent vibration, rubbing against other
parts, excessive heat, and failure of lines, tubes and
Consult your Caterpillar dealer for repair or for hoses.
replacement parts.
Do not operate a machine when a fire hazard
Keep wiring and electrical connections free of debris. exists. Repair any lines that are corroded, loose
or damaged. Leaks may provide fuel for fires.
Lines, Tubes and Hoses Consult your Caterpillar dealer for repair or for
replacement parts. Use genuine Caterpillar parts or
the equivalent, for capabilities of both the pressure
Do not bend high pressure lines. Do not strike high
pressure lines. Do not install any lines that are bent or limit and temperature limit.
damaged. Use the appropriate backup wrenches in
order to tighten all connections to the recommended Ether
torque.
Ether (if equipped) is commonly used in cold weather
applications. Ether is flammable and poisonous.
i01392300
g00337832
Illustration 20
(A) At least 15 m (50 ft)
(B) At least 500 m (1500 ft)
g00735725
Do not approach a warm tire. Maintain a minimum
Illustration 19 distance, as shown. Stay outside the shaded area in
Illustration 20.
The fire extinguisher must be mounted in the cab.
Mount the fire extinguisher on the front wall of the Do not use water or calcium as a ballast for the tires.
cab under the dash on the left side next to the door. Dry nitrogen gas is recommended for inflation of tires.
If the tires were originally inflated with air, nitrogen
Do not mount the fire extinguisher on the ROPS. is still preferred for adjusting the pressure. Nitrogen
mixes properly with air.
The fire extinguisher mounting must be capable of
withstanding a force that is equivalent to twenty times Nitrogen inflated tires reduce the potential of
the effect of gravity. a tire explosion because nitrogen does not aid
combustion. Nitrogen helps to prevent oxidation of
i01557411
the rubber, deterioration of rubber, and corrosion of
rim components.
Tire Information
To avoid overinflation, proper nitrogen inflation
SMCS Code: 7000 equipment and training in the usage of the equipment
are necessary. A tire blowout or a rim failure can
Explosions of air inflated tires have resulted from result from improper equipment or from misused
heat-induced gas combustion inside the tires. equipment.
Explosions can be caused by heat that is generated
by welding, by heating rim components, by external When you inflate a tire, stand behind the tread and
fire, or by excessive use of brakes. use a self-attaching chuck.
A tire explosion is much more violent than a Servicing tires and rims can be dangerous. Only
blowout. The explosion can propel the tire, the rim trained personnel that use proper tools and proper
components, and the axle components as far as procedures should perform this maintenance. If
500 m (1500 ft) or more from the machine. Both the correct procedures are not used for servicing tires
force of the explosion and the flying debris can cause and rims, the assemblies could burst with explosive
property damage, personal injury, or death. force. This explosive force can cause serious
personal injury or death. Carefully obey the specific
instructions from your tire dealer.
SEBU7815-10 23
Safety Section
Electrical Storm Injury Prevention
i01122596 i01995114
• A system of communication
• Communication between workers and operators
prior to approaching the machine
g01687496
Illustration 21
Top view of the machine
i01439977 i02624835
Only operate the machine while you are seated in the Do not stop the engine immediately after the
operator seat. The seat belt must be fastened while machine has been operated under load. This can
you operate the machine. A passenger must sit on cause overheating and accelerated wear of engine
the seat that is provided. If a passenger is carried the components.
seat belt must be fastened.
After the machine is parked and the parking brake
Before you move the machine, you must make sure is engaged, allow the engine to run for two minutes
that no one will be endangered. before shutdown. This allows hot areas of the engine
to cool gradually.
Check the proper operation of the steering controls
and of the braking controls for the machine while the
i01522321
machine is moving slowly in an open area.
Table 1
“ISO Reference Table A - Equivalent vibration levels of whole body vibration emission for earthmoving equipment.”
Note: Refer to “ISO/TR 25398 Mechanical Vibration - a. Remove any large rocks or obstacles.
Guideline for the assessment of exposure to whole
body vibration of ride on operated earthmoving b. Fill any ditches and holes.
machines” for more information about vibration.
This publication uses data that is measured c. Provide machines and schedule time in order
by international institutes, organizations and to maintain the conditions of the terrain.
manufacturers. This document provides information
about the whole body exposure of operators of 4. Use a seat that meets “ISO 7096”. Keep the seat
earthmoving equipment. Refer to Operation and maintained and adjusted.
Maintenance Manual, SEBU8257, “The European
Union Physical Agents (Vibration) Directive a. Adjust the seat and suspension for the weight
2002/44/EC” for more information about machine and the size of the operator.
vibration levels.
b. Inspect and maintain the seat suspension and
The Caterpillar suspension seat meets the criteria of adjustment mechanisms.
“ISO 7096”. This represents vertical vibration level
under severe operating conditions. This seat is tested 5. Perform the following operations smoothly.
with the input “spectral class EM1”. The seat has a
transmissibility factor of “SEAT<1.1”. a. Steer
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.
SEBU7815-10 29
Safety Section
Operator Station
Sources Guards
(Operator Protection)
The vibration information and calculation procedure
is based on “ISO/TR 25398 Mechanical Vibration SMCS Code: 7000; 7150; 7325
- Guideline for the assessment of exposure
to whole body vibration of ride on operated There are different types of guards that are used to
earthmoving machines”. Harmonized data is protect the operator. The machine and the machine
measured by international institutes, organizations application determines the type of guard that should
and manufacturers. be used.
This literature provides information about assessing A daily inspection of the guards is required in order to
the whole body vibration exposure of operators of check for structures that are bent, cracked or loose.
earthmoving equipment. The method is based on Never operate a machine with a damaged structure.
measured vibration emission under real working
conditions for all machines. The operator becomes exposed to a hazardous
situation if the machine is used improperly or if poor
You should check the original directive. This operating techniques are used. This situation can
document summarizes part of the content of the occur even though a machine is equipped with an
applicable law. This document is not meant to appropriate protective guard. Follow the established
substitute the original sources. Other parts of these operating procedures that are recommended for your
documents are based on information from the United machine.
Kingdom Health and Safety Executive.
Caterpillar, Inc.
www.cat.com
30 SEBU7815-10
Safety Section
Body Support
Do not mount items (fire extinguishers, first aid Install the steering frame locks before entering the
kits, work lights, etc) by welding brackets to the area around the oscillating hitch.
ROPS/FOPS Structure or by drilling holes in the
ROPS/FOPS Structure. Welding brackets or drilling If the body must be raised, perform the following
holes in the ROPS/FOPS Structures can weaken procedure in order to install the body support.
the structures. Consult your Caterpillar dealer for
mounting guidelines. Note: The body must be empty before the body
support is installed.
The Tip Over Protection Structure (TOPS) is
another type of guard that is used on mini hydraulic 1. Raise the body enough to lift the body support and
excavators. This structure protects the operator in then move the hoist control to the HOLD position.
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.
Table 3
735 B1N880-Up
Metric Unit English Unit
Weight 31400 kg 69230 lb
Overall Height 4006 mm 13 ft 2 inch
(including
exhaust)
Overall Width 3823 mm 12 ft 6 inch
(including
mirrors)
Overall Length 10889 mm 35 ft 9 inch
Table 4
740
Metric Unit English Unit
Weight 32840 kg 72400 lb
Overall Height 4049 mm 13 ft 3 inch
(including
exhaust)
Overall Width 3823 mm 12 ft 6 inch
(including
mirrors)
Overall Length 10889 mm 35 ft 9 inch
SEBU7815-10 33
Product Information Section
Identification Information
g02000052 g01120192
Illustration 23 Illustration 25
The PIN plate for this machine is located on the left This plate is positioned on the bottom left side of
side of the front frame. plate (1) for the PIN.
(1) Machine PIN____________________________________________ Note: The CE plate is on machines that are certified
to the European Union requirements that were
European Union effective at that time.
• Year of Construction____________________________________
For the name and the address of the manufacturer,
and the country of origin of the machine, refer to the
g01880193
Illustration 24 PIN plate.
34 SEBU7815-10
Product Information Section
Identification Information
Certification
ROPS/FOPS Plate
These films are located inside the cab.
g02000056
Illustration 26
The engine serial number plate is located on the left Structural damage, an overturn, modification, al-
side of the engine. teration, or improper repair can impair this struc-
ture's protection capability thereby voiding this
Transmission Serial Number 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.
g02000058
Illustration 27
Suspension Cylinder Strut This machine has been certified to the standards that
are listed on the certification plate. The maximum
The following information is stamped onto the mass of the machine, which includes the operator
suspension cylinder: and the attachments without a payload, should not
exceed the mass on the certification plate.
• ACC. 200-4300 EC08
• CAT INC. ITALY
• SN: XXXXXXXXX
• YEAR: 2003
• V: 4L
• PS: 222 BAR
SEBU7815-10 35
Product Information Section
Identification Information
Sound
g01928317
Illustration 29
A typical example of this film is shown. Your machine may have a
different value.
i03638040
i03657369
Declaration of Conformity
SMCS Code: 1000; 7000
Table 5
An EC Declaration of Conformity document was provided with the machine if it was manufactured to comply with specific
requirements for the European Union. In order to determine the details of the applicable Directives, review the complete
EC Declaration of Conformity provided with the machine. The extract shown below from an EC Declaration of Conformity
for machines that are declared compliant to “2006/42/EC” applies only to those machines originally “CE” marked by the
manufacturer listed and which have not since been modified.
Note (1) Annex -_____ Guaranteed Sound Power Level -_____dB (A)
Representative Equipment Type Sound Power Level - _____dB (A)
Engine Power per ____-____ kW Rated engine speed - _____ rpm
Technical Documentation accessible through person listed above authorized to compile the Technical File
Note: The above information was correct as of October 2009, but may be subject to change, please refer to the individual
declaration of conformity issued with the machine for exact details.
SEBU7815-10 37
Operation Section
Before Operation
Daily Inspection
Before Operation SMCS Code: 1000; 7000
• Bent
• Twisted
• Permanent Deformation
4. Stow one steering frame lock on either side of the
rear frame.
g01009597
Illustration 31
Steering frame lock in the stowed position
g01009624
Illustration 32
Steering frame lock in the installed position
i02885399
Alternate Exit
SMCS Code: 7308; 7310
g01436415 g01041280
Illustration 33 Illustration 34
The right side rear cab window can be used as an Lumbar Knob (1) – Turn knob (1)
alternate exit. The window can only be opened from clockwise in order to increase the amount
the inside of the cab. To open the window, refer to of support to the lower back. There are four
Operation and Maintenance Manual, “Windows”. settings. Reset the lumbar knob by turning the knob
clockwise to the first position.
Only use the alternate exit when it is not possible to
exit the cab via the cab door. Seat Angle Lever (2) – Push lever (2) in
order to release the locking mechanism for
i02247196
the backrest. The backrest will tilt forward.
Push the backrest to the desired position. Release
Seat the lever in order to lock the backrest in position.
g00100713
Illustration 37
1. Fasten the seat belt. Pull out on the outer belt loop
in order to tighten the seat belt.
3. If the seat belt does not fit snugly with the buckle
in the center, readjust the seat belt.
g00932818
Illustration 38
Fasten the seat belt catch (3) into the buckle (2).
Illustration 36
g00932817 Make sure that the seat belt is placed low across the
lap of the operator.
SEBU7815-10 41
Operation Section
Machine Operation
g00100717 g00039113
Illustration 39 Illustration 41
Pull up on the release lever. This will release the seat Push the release button on the buckle in order to
belt. release the seat belt. The seat belt will automatically
retract into the retractor.
Seat Belt Adjustment for
Retractable Seat Belts Extension of the Seat Belt
Fasten seat belt catch (3) into buckle (2). Make sure i03309601
that the seat belt is placed low across the lap of the
operator. Mirror
The retractor will adjust the belt length and the SMCS Code: 7319
retractor will lock in place. The comfort ride sleeve
will allow the operator to have limited movement.
g01690619
Illustration 43
Mirrors provide additional visibility around your Left Side Rear View Mirrors (2)
machine. Make sure that the mirrors are in proper
working condition and that the mirrors are clean.
Adjust all mirrors at the beginning of each work period
and adjust the mirrors when you change operators.
Mirror Adjustment
• Park the machine on a level surface.
• Fully lower the body.
g01690620
• Stop the engine. Illustration 44
Note: You may need to use hand tools in order to Adjust the left side rear view mirrors (2) so that an
adjust certain types of mirrors. area of at least 1 m (3.3 ft) from the side of the
machine can be seen. Refer to illustration 44. Also
adjust the left side rear view mirrors in order to see
the following:
i02832537
Operator Controls
SMCS Code: 7300; 7451
S/N: B1N1-320
S/N: B1P1-621
g01188035
Illustration 45
44 SEBU7815-10
Operation Section
Machine Operation
(1) Rear Wiper/Washer Switch (10) Secondary Steering Test Switch (18) Service Brake Control
(2) Parking Light Switch (11) Air Conditioning Switch (19) Accelerator Control
(3) Headlight Switch (12) Temperature Control Switch (20) Transmission Control
(4) Hazard Flasher Switch (13) Fan Speed Control (21) Parking Brake Control
(5) Floodlight Switch (14) Multifunction Switch (22) Hoist Control
(6) Engine Start Switch (15) Cigar Lighter
(7) Engine Compression Brake Control (16) Steering Column Tilt and Telescope
(8) Differential Lock Switch Control
(9) Heated Mirror Switch (17) Differential Lock Control
Type 1
Engine Start Switch (6)
Press the bottom of the switch in order to activate
The engine start switch is operated by a key. The
the parking lights. Return the switch to the central
position in order to deactivate the parking lights. engine start switch has three positions.
Type 2
Engine Compression Brake Control
(7)
Press the top of the switch in order to activate the
headlights. The headlights can be high beam or the Refer to Operation and Maintenance Manual, “Engine
headlights can be low beam. Press the bottom of the Compression Brake Control” for more information.
switch in order to deactivate the headlights.
SEBU7815-10 45
Operation Section
Machine Operation
OFF – The switch is spring loaded. The Dimmer Switch – Push the dimmer switch
switch will automatically return to the OFF away from the steering wheel in order to
position when the switch is released. This change the headlight beams from low beam
deactivates the secondary steering motor. to high beam. Also, pull the dimmer switch toward
the steering wheel in order to change the headlight
beams from high beam to low beam.
Air Conditioning Switch (11)
The air conditioning switch is a rocker switch with
Directional Turn Signal Control
two positions:
Right Directional Signal Lights – Push the lever
away from the operator in order to activate the right
ON position – Press the top of the switch
turn signals. When the lever is pushed forward away
in order to activate the air conditioning
from the operator, an indicator light will illuminate on
system.
the front dash. The right turn signal will flash until the
lever is manually returned to the OFF position.
OFF position – Press the bottom of
the switch in order to deactivate the air OFF Position – In the OFF position, the directional
conditioning system. signal lights will not flash.
Low speed
46 SEBU7815-10
Operation Section
Machine Operation
Intermittent Operation with Short Delay Decreasing Speed – Release the pedal in order to
– The front window wiper will operate decrease the travel speed.
intermittently and the delay will be short.
Transmission Control (20)
Continuous Operation at Low Speed –
The front window wiper will operate Refer to Operation and Maintenance Manual,
continuously at slow speed. “Transmission Control” for more information.
g01187866
Illustration 46
(1) Rear Wiper/Washer Switch (9) Differential Lock Switch (17) Steering Column Tilt and Telescope
(2) Parking Light Switch (10) Heated Seat Switch Control
(3) Headlight Switch (11) Secondary Steering Test Switch (18) Differential Lock Control
(4) Hazard Flasher Switch (12) Air Conditioning Switch (19) Service Brake Control
(5) Floodlight Switch (13) Temperature Control Switch (20) Accelerator Control
(6) Engine Start Switch (14) Fan Speed Control (21) Transmission Control
(7) Engine Compression Brake Control (15) Multifunction Switch (22) Parking Brake Control
(8) Heated Mirror Switch (16) Cigar Lighter (23) Hoist Control
48 SEBU7815-10
Operation Section
Machine Operation
Engine Start Switch (6) ON – Push the top half of the switch in
order to activate the secondary steering
The engine start switch is operated by a key. The motor.
engine start switch has three positions.
OFF – The switch is spring loaded. The
OFF – The engine is shut off. The key can
switch will automatically return to the OFF
only be inserted into the engine start switch
position when the switch is released. This
when the engine start switch is in the OFF
deactivates the secondary steering motor.
position. The key can only be removed from the
engine start switch when the engine start switch is
in the OFF position.
SEBU7815-10 49
Operation Section
Machine Operation
OFF position – Press the bottom of OFF Position – In the OFF position, the directional
the switch in order to deactivate the air signal lights will not flash.
conditioning system.
Left Directional Signal Lights – Pull the lever
toward the operator in order to activate the left turn
Temperature Control Switch (13) signals. When the lever is pulled back toward the
operator, an indicator light will illuminate on the front
Turnthe temperature control switch clockwise dash. The left turn signals will flash until the lever is
or counterclockwise in order to adjust the air manually returned to the OFF position.
temperature within the cab.
Window Wiper/Washer Switch
Fan Speed Control (14) Front Window Wiper Switch – The wiper
Fan speed switch – This is a rotary control control knob has six positions. Select each
switch with four speed settings. position by twisting the knob clockwise and
by twisting the knob counterclockwise.
OFF position – The fan is deactivated. Front Window Wiper – The front window
wiper is deactivated.
Refer to Operation and Maintenance Manual, Note: If the single camera system can be placed in
“Differential Lock Control” for more information. manual mode, notify service personnel.
Display
Keypad
g01291176
Illustration 48
(A) Camera Selection Button (multiple camera only)
(B) Automatic Brightness
(C) Standby Function
(D) Contrast Button
(E) Brightness Button
(F) Decrease Adjustment Button
(G) Increase Adjustment Button
(H) Power Button (disabled)
(I) Camera Select LEDs (multiple camera only)
(J) Button Status LEDs
(K) Light Sensor
Adjustment
Table 6
Display Button Operation for single camera system
Operation Procedure Notes
Brightness Adjustment Press button (E) in order to enable the Press any other display button in order
“Brightness Adjustment”, then press to exit brightness adjustment mode.
either button (F) or (G) in order to adjust
the brightness.
Contrast Adjustment Press button (D) in order to enable the Press any other display button in order
Contrast Adjustment, then press either to exit the contrast adjustment mode.
button (6) or (7) in order to adjust the
contrast level.
Automatic Brightness ON/OFF Press button (B) in order to turn the When WAVS is placed in the “Automatic
automatic brightness ON/OFF. Brightness” mode, the display will
illuminate or dim automatically as the
ambient light increases or decreases.
The brightness starting set point can
be changed by the operator. In order
to change the starting set point, turn
the auto brightness on and adjust the
brightness to the desired level.
Standby ON/OFF Press button (C) in order to turn the Standby may be useful at night, when
standby ON/OFF. the display is not desired.
If the standby mode is ON, the display
will remain dark until a WAVS input
is detected, however, the power and
standby LED should remain on.
LED Indicators
If LED for button (H) and the LED (I) for the camera flash together, the image will turn off because the ambient temperature is
below −25 °C (−13°F) or above 70 °C (158 °F).
Marker Line 1. Hold the display securely and loosen the mounting
clamp handle.
i03747693
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.
g00785229
Illustration 52
g01038927
Illustration 53
Brake Oil Temperature (5) – The brake Engine Oil Pressure (16) – The engine
oil temperature for one of the axle is high. oil pressure is low. The engine oil pressure
Stop the machine at a convenient location gauge will indicate in the red zone. Also, the
and investigate the cause. action light will flash and the action alarm will sound.
Stop the machine immediately. Do not operate the
Brake Oil Pressure (6) – The brake machine until the engine oil pressure is normal.
oil pressure is low. Stop the machine
immediately. Stop the engine and Fuel Level (17) – The fuel level gauge will
investigate the cause. Do not operate the machine indicate in the red zone when the fuel level
until the brake oil pressure is normal. is 10% of the tank capacity.
Action Light (7) – Malfunction in a LCD display (18) – Display (18) is used to display
machine system. the following information: machine ground speed,
actual gear, and direction. The LCD display is also
used in order to view diagnostic fault codes.
Tachometer (8) – The tachometer will indicate the
engine rpm. Engine Compression Brake(19) – The
engine compression brake is activated.
Transmission Fault (9) – There is a
general fault in the transmission. Stop the
machine immediately. Stop the engine and High Beam (20) – High beam headlights
investigate the cause. are on.
Differential Lock (12) – Differential lock is Engine Overspeed (22) for (S/N:
activated. B1P4219-Up) – The machine is increasing
speed. The transmission is within 250 rpm
of making an upshift. The retardation effect of the
Hoist Control (13) – The hoist control is retarder will be temporarily lost because the retarder
not in the FLOAT position. disengages during a gearshift. When the upshift is
complete, the retarder will engage again but the
retarder will be less effective due to the higher gear
that is being engaged. Prevent the upshift by using
Right Turn Signal (14) – Right turn signal the service brakes to slow the machine.
light is operating.
56 SEBU7815-10
Operation Section
Machine Operation
The self-diagnostic test verifies that the outputs • Engine Compression Brake (19)
(gauges, alert indicators and alarms) are operating
correctly. • Transmission Hold (21)
When you turn the engine start switch key to the • Filter Warning (23)
ON position, the following systems are tested for
approximately one second: Alert indicators, Gauges, Warning Category 2
and LCD displays
In this category, one of the following conditions will
The gauges must go to the far right positions. All alert occur:
indicators must come on momentarily. All segments
of the LCD displays must come on momentarily. The • An alert indicator will illuminate or a gauge will
action alarm must sound. indicate in the red zone.
In this category, one of the following conditions will The Monitoring System is designed to alert the
occur: operator to an immediate problem with any of the
machine systems that are monitored. The Monitoring
• An alert indicator will illuminate. System is also designed to alert the operator to an
impending problem with any of the machine systems
• The action light will flash. that are monitored.
Warning Category 3
In this category, one of the following conditions will
occur:
g01194265
Illustration 56
• An alert indicator will illuminate.
Left Turn Signal (1) – Left turn signal light
• The action light will flash. is operating.
Refer to Table 7 for a breakdown of the categories Tachometer (9) – The tachometer will indicate the
of warnings and the reasons for generating the engine rpm.
warnings that are indicated by the filter warning (1).
Parking Brake (10) – For Warning
Table 7 Category 1, the parking brake is engaged.
Category Possible Causes For Warning Category 2S, the parking brake
is engaged while you are operating the machine.
The air filter is restricted. An immediate change of the machine operation is
1 The fuel filter has been restricted for at required.
least one hour.
The air filter is plugged. Charging System (11) – For Warning
2 The fuel filter has been restricted for Category 1, the charging system is
more than four hours.
operating higher than normal or lower than
The transmission filter is plugged. normal. For Warning Category 3, there is a problem
3
The OTG filter is plugged. with the charging circuit that may cause damage to
the machine. Stop the machine immediately and
Note: Because a variety of different filters can investigate the cause of the problem. Do not operate
cause a category 1 warning, a category 2 warning the machine until the problem has been corrected.
and a category 3 warning, it is important to use
ET, or the messenger display (If equipped), in Differential Lock (12) – Differential lock is
order to check the cause of the warning. activated.
Brake Oil Temperature (6) – The brake Engine Overspeed (15) for (S/N:
oil temperature for one of the axle is high. B1P4219-Up) – The machine is increasing
Stop the machine at a convenient location speed. The transmission is within 250 rpm
and investigate the cause. of making an upshift. The retardation effect of the
retarder will be temporarily lost because the retarder
disengages during a gearshift. When the upshift is
Power Train (7) – A category 2S warning complete, the retarder will engage again but the
alerts the operator of an overheating retarder will be less effective due to the higher gear
condition in the output transfer gear. An that is being engaged. Prevent the upshift by using
immediate change of the machine operation is the service brakes to slow the machine.
required. A category 3 warning alerts the operator of
a general fault in the transmission. Stop the machine
immediately. Stop the engine and investigate the Note: Engine overspeed (15) is only available for
cause. (S/N: B1P4219-Up) and on 740 machines with the
transmission software update.
Action Light (8) – Malfunction in a
machine system.
SEBU7815-10 59
Operation Section
Machine Operation
Machine Security (22) – If equipped, the • An alert indicator will illuminate or a gauge will
indicator will illuminate when the machine indicate in the red zone.
security system is activated and an attempt
to start the machine is made. The alert indicator that illuminates or the gauge that
indicates in the red zone identifies the machine
Transmission Oil Temperature (23) – system that needs attention. Warning category 1
The transmission oil temperature gauge requires operator awareness. The indicators that
will indicate in the red zone and the action illuminate with a green or amber color indicate
light will flash when the transmission oil temperature Warning Category 1.
exceeds 124 °C (255 °F) . Stop the machine at a
convenient location and investigate the cause. The following systems have indications in Warning
Category 1:
Fuel Level (24) – The fuel level gauge will • Filter Warning (Restricted Air Filter) (2)
indicate in the red zone when the fuel level
is 10% of the tank capacity. • Parking Brake (10)
In this category, one of the following conditions will Immediate shutdown of the machine is required in
occur: order to prevent damage.
• An alert indicator will illuminate or a gauge will The following systems have indications in Warning
indicate in the red zone. Category 3:
• The action light will flash. • Filter Warning (Plugged Transmission Filter) (2)
Warning Category 3
In this category, one of the following conditions will
occur:
SEBU7815-10 61
Operation Section
Machine Operation
The Messenger display automatically turns on when Navigating the Messenger Display
the ignition switch is turned to the ON position. The
Messenger system will prompt the operator with the Selection of Menu Screens
following request. Press the back button in order to
continue as an existing operator with existing totals.
Press “OK” in order to select a different operator
with new totals. When an operator selects “OK”, the
system goes to the “operator” menu in order to allow
the operator to select the operator's name from the
list of registered operators. If the current operator
is not registered with the Messenger then edit an
empty position or edit an existing operator's name.
Refer to “Operator”. Activating any operator will reset
the “cycle data” and “operator totals”. If the “back
button” is selected, the Messenger system goes to
the “Performance” menu. The system will continue
recording “cycle data” and “operator totals” from the
last operation of the machine. g01126242
Illustration 59
g01125445
Illustration 58
Messenger display
Menu Tree
Table 8 shows the five menu options that can be
selected from the “Main Menu” and the subsequent
submenus that are available with each menu option.
Table 8
Performance
“Press choose an
Operator
operator”
“Cycle Data”
“Operator Totals”
Totals
“Jobsite totals”
Main Menu
“Lifetime totals”
“Monitoring system”
Settings
“Transmission”
“diagnostics/events”
Service “System Parameters”
“System Info”
“Engine speed” – When you scroll to this option, “Please choose an operator” – When you scroll to
the display will show the engine RPM. this screen, the display will show the list of operators
that have been registered on the system and empty
“Ground speed” – When you scroll to this option, positions for the names of new operators. To select
the display will show the ground speed in Miles per a registered operator or an empty position, use the
Hour or in Kilometers per Hour. scroll up/left button (3) and the scroll down/right
button (4) in order to highlight your choice and select
“Engine coolant temp” – When you scroll to this your choice with the “OK” button.
option, the display will show the engine coolant
temperature in degrees Fahrenheit or in degrees Note: The system memory will be full with fifty names.
Celsius. Be sure that operators do not enter a duplicate name.
“Shift Lever” – When you scroll to this option, the The following options are available through the
display will show the position of the shift lever. “Please choose an operator” selection.
“Torque conv temp” – When you scroll to this “Activate” – Press the “OK” button in order to
option, the display will show the torque converter activate the selected operator.
oil temperature in degrees Fahrenheit or in degrees
Celsius. “Edit Name” – Press the “OK” button in order to
change the name of the selected operator or enter a
“Fuel Level” – When you scroll to this option, the new name. Use the scroll up/left button (3) and the
display will show the amount of fuel that is measured scroll down/right button (4) to highlight your choice
in the fuel tank as a percentage of a full tank. of either one of the following:“Accept”, “Cancel”,
lower case letters, upper case letters, numbers, and
“Actual Gear” – When you scroll to this option, the symbols. When your choice is highlighted, press
display will show the gear that is currently engaged the “OK” button in order to enter the choice in the
in the transmission. selected part of the name of the operator. Press
the “Back” button anytime in order to move the
“Trans Hold Status” – When you scroll to this cursor on the screen. Select the “Accept” option in
option, the display will show the status of the order to return to the “Please Choose an Operator”
transmission hold. screen with the new name or the changed name in
the system. Select the “Cancel” option in order to
“Battery Voltage” – When you scroll to this option, return to the “Please Choose an Operator” screen
the display will show the battery voltage in Volts. but without making any changes to the names in the
system.
“Operator”
“Totals”
g01125457
Illustration 63
g01121726
Illustration 64
Press the “OK” button in order to select the “Operator” option from
the “Main Menu”. Press the “OK” button in order to select the “Totals” option from
the “Main Menu”.
The following option is available through the
“Operator” menu: When you select the “Total” option from the “Main
Menu”, you are given the additional menu options
that are shown in Table 9.
64 SEBU7815-10
Operation Section
Machine Operation
Use the scroll up/left button (3) and the scroll “Wait time/cycle” – When you scroll to this option,
down/right button (4) in order to move between the you see an indication of the average machine idle
various screens and use the “Back” button in order to time per cycle.
return to the “Main Menu”.
“Total time/cycle” – When you scroll to this option,
After an operator is activated, the Messenger system the average time for a cycle is displayed.
will start to calculate all of the Operator Totals.
Whenever an operator's name is activated with the “Distance/cycle” – When you scroll to this option,
Messenger, all the totals are zeroed. For proper you see the average distance that was travelled per
operation of the system, an operator needs to be cycle.
activated with the Messenger at the start of work.
“Fuel/cycle” – When you scroll to this option, you
The system resets the Cycle Data and Operator see the calculation of the average amount of fuel that
Totals when an operator is activated on the system. was used per cycle, shown in liters or US gallons.
If you need to maintain the existing Cycle Data
and Operator Totals, do not use “Activate” in the Operator Totals
“Operator” menu. Alternatively, you can view previous
Cycle Data and Operator Totals for all the operators The following information is available through the
by using Electronic Technician version 2005A or later. “Operator Totals” display. Use the scroll up/left button
(3) and the scroll down/right button (4) in order to
Note: The system memory will only save the last fifty move between the various screens and use the
sets of totals. “Back” button in order to return to the “Totals” Menu:
For the purpose of incrementing the load counter, “Total load cnt” – If you select this option, the
a single load is counted when a forward travel at a display will show the number of times that the
minimum specific speed is followed by a body raise machine discharged a load.
for more than 5 seconds. (The default speed for the
minimum specific speed is 5 km/h (3.1 mph).) “Tot Fwd Dist Trav” – When you scroll to this
option, the Messenger shows the distance that
The Messenger system will interpret second and the machine has driven in forward gear since the
subsequent loads as the truck on a regular cycle. activation of the current operator.
Cycle data that is displayed by the Messenger
system will be the average of these cycles. “Tot Rev Dist Trav” – When you scroll to this option,
the Messenger shows the distance that the machine
The calculation of machine idle time is based on the has driven in reverse gear since the activation of the
combination of the following factors: The machine is current operator.
stationary with the hoist in the FLOAT position and
the engine is running. “Mac Idle Time” – When you scroll to this option,
the Messenger shows the time that the machine has
The Messenger system resets the Cycle Data when been stationary with the hoist in the FLOAT position
an operator is activated on the system. If you need and the engine is running.
to maintain the existing Cycle Data, do not use
“Activate” in the “Operator” menu.
SEBU7815-10 65
Operation Section
Machine Operation
“Machine hrs” – When you scroll to this option, “Total load cnt” – If you select this option, the
the Messenger shows the number of hours that the Messenger shows the number of times that the
machine has been operating since the activation of machine has discharged a load in the machine's
the current operator. lifetime.
“Total Fuel” – When you scroll to this option, “Tot Fwd Dist Trav” – When you scroll to this
the Messenger shows information about the fuel option, the Messenger shows the total distance
consumption of the machine since the activation of that the machine has driven in forward gear in the
the current operator. machine's lifetime.
Jobsite totals “Tot Rev Dist Trav” – When you scroll to this option,
the Messenger shows the total distance that the
The following information is available through the machine has driven in reverse gear in the machine's
“Jobsite totals” display. Use the scroll up/left button lifetime.
(3) and the scroll down/right button (4) in order to
move between the various screens and use the “Mac Idle Time” – When you scroll to this option,
“Back” button in order to return to the “Totals” Menu: the Messenger shows the time that the machine has
been stationary with the hoist in the FLOAT position
Electronic Technician version 2005A or later is and with a running engine in the machine's lifetime.
required in order to zero the counters.
“Machine hrs” – When you scroll to this option, the
“Total load cnt” – If you select this option, the Messenger shows the total number of hours that the
Messenger shows the number of times that the machine has been operating in the machine's lifetime.
machine has discharged a load on the current job
site. “Total Fuel” – When you scroll to this option,
the Messenger shows information about the fuel
“Tot Fwd Dist Trav” – When you scroll to this consumption of the machine in the machine's lifetime.
option, the Messenger shows the total distance that
the machine has driven in forward gear on the current “Settings”
job site.
These totals cannot be zeroed without a factory Use the scroll up/left button (3) and the scroll
password. down/right button (4) in order to move between the
various screens and use the “Back” button in order to
return to the “Main Menu”.
66 SEBU7815-10
Operation Section
Machine Operation
“Info unit status” – This option shows the units that g01121734
are used by the transmission ECM. Illustration 67
Press the “OK” button in order to select the “diagnostics/events”
“Machine Hours” – This option shows the total option from the “Service” menu.
number of machine hours that is recorded on the
transmission ECM. The following option is available if you are in this
menu.
SEBU7815-10 67
Operation Section
Machine Operation
“diagnostics/events” – Select this option in order “Fuel temp” – When you scroll to this option, the
to view events that are logged by the monitoring fuel temperature is displayed.
system.
“Engine coolant temp” – When you scroll to this
System Parameters option, the coolant temperature is displayed.
When you select the “System Parameters” option “Fuel Position” – When you scroll to this option, the
from the “Service” you are given the additional menu fuel position is displayed.
options that are shown in Table 12.
“Rated fuel limit” – When you scroll to this option,
Table 12 the rated fuel limit is displayed.
Engine
“FRC fuel limit” – When you scroll to this option,
Transmission the FRC fuel limit is displayed.
System Hoist
Parameters
“Diagnosic clock” – When you scroll to this option,
Brake the diagnostic clock is displayed.
Shift
Transmission
Filter
“TOS” – When you scroll to this option, the
Use the scroll up/left button (3) and the scroll transmission output speed is displayed.
down/right button (4) in order to move between the
various screens and use the “Back” button in order to “Action Alarm St” – When you scroll to this option,
return to the Service Menu. the status of the action alarm is displayed.
“Throttle position” – When you scroll to this option, “Trans Output Spd2” – When you scroll to this
the throttle position is displayed. option, the speed that is recorded by transmission
output speed 2 is displayed.
“Engine load factor” – When you scroll to this
option, the engine load factor is displayed. “Torque Conv Speed” – When you scroll to this
option, the torque converter speed is displayed.
“boost prs” – When you scroll to this option, the
boost pressure is displayed. “Eng Speed (T/C ECM)” – When you scroll to this
option, the engine speed that is measured by the
“Turbo outlet prs” – When you scroll to this option, transmission ECM is displayed.
the turbocharger outlet pressure is displayed.
“Ground Speed” – When you scroll to this option,
“Fuel pressure (ga)” – When you scroll to this the ground speed is displayed.
option, the fuel pressure is displayed.
“Lockup clutch status” – When you scroll to this
“Atmos prs” – When you scroll to this option, the option, the status of the lockup clutch is displayed.
atmospheric pressure is displayed.
“Retarder Lvr Pos” – When you scroll to this option,
“Oil Prs (abs)” – When you scroll to this option, the the position of the retarder lever is displayed.
absolute engine oil pressure is displayed.
“Hold Lamp status” – When you scroll to this
“Oil prs” – When you scroll to this option, the engine option, the status of the hold lamp is displayed.
oil pressure is displayed.
“Primary Steer Prs” – When you scroll to this
“Inlet air temp” – When you scroll to this option, the option, the primary steering pressure is displayed.
inlet air temperature is displayed.
68 SEBU7815-10
Operation Section
Machine Operation
“Primary Steer WI” – When you scroll to this option, “HC Input line 0” – When you scroll to this option,
the status of the warning indicator for the primary the status of the harness code input is displayed.
steering is displayed.
“HC Input line 1” – When you scroll to this option,
“Sec Steer Relay” – When you scroll to this the status of the harness code input is displayed.
option, the status of the secondary steering relay is
displayed. “HC Input line 2” – When you scroll to this option,
the status of the harness code input is displayed.
“Sec Steer WI” – When you scroll to this option, the
status of the secondary steering warning indicator “HC Input line 3” – When you scroll to this option,
is displayed. the status of the harness code input is displayed.
“Ignition SW Status” – When you scroll to this “HC Input line 4” – When you scroll to this option,
option, the status of the ignition switch is displayed. the status of the harness code input is displayed.
“Starter Relay St” – When you scroll to this option, “Action Lamp St” – When you scroll to this option,
the status of the starter relay is displayed. the status of the action lamp is displayed.
“Backup Alarm St” – When you scroll to this option, “Battery Voltage” – When you scroll to this option,
the status of the backup alarm is displayed. the battery voltage is displayed.
“Charging sys WI” – When you scroll to this option, “Hoist Low Val Adj” – When you scroll to this
the status of the warning indicator for the charging option, the system indicates the adjustment for the
system is displayed. float position.
“Diff Lock Sw” – When you scroll to this option, the “Hoist Sys Enable status” – When you scroll to
status of the differential lock switch is displayed. this option, the system shows the installation status
of the hoist system.
“Crs Axle Lck Sel Sw” – When you scroll to this
option, the status of the switch for the cross axle lock Hoist
selector is displayed.
“Hoist Lever Mode” – When you scroll to this
“Crs Axle Lck Sol St” – When you scroll to this option, the hoist lever position is displayed.
option, the status of the solenoid for the cross axle
lock is displayed. “Hoist Lever %” – When you scroll to this option,
the control signal for the hoist lever is displayed as a
“Int Axle Dif Sol St” – When you scroll to this percentage of a full PWM signal.
option, the status of the solenoid for the inter axle
differential is displayed. “Hoist Output” – When you scroll to this option,
the status of the solenoid valves for the hoist control
“Diff Lock Lamp St” – When you scroll to this valve is displayed.
option, the status of the differential lock lamp is
displayed. “Hoist Low Sol Curr” – When you scroll to this
option, the hoist lower solenoid current is displayed
“O/P Tran Gr Temp” – When you scroll to this as a percentage of maximum current.
option, the status of the temperature switch for the oil
in the output transfer gear is displayed. “Hoist not in Flt WI” – When you scroll to this
option, the status of the warning indicator for the
“O/P Tran Gr Flt” – When you scroll to this option, “hoist not in float” is displayed.
the status of the filter for the output transfer gear is
displayed. “Hoist Raise Sol Curr” – When you scroll to this
option, the hoist raise solenoid current is displayed
“O/P Tran Gr Prs” – When you scroll to this option, as a percentage of maximum current.
the oil pressure for the output transfer gear is
displayed. Brake
“Trans Oil Temp” – When you scroll to this option, “Park Brake” – When you scroll to this option,
the transmission oil temperature is displayed. the status of the system for the parking brake is
displayed.
“Harness Code” – When you scroll to this option,
the harness code is displayed.
SEBU7815-10 69
Operation Section
Machine Operation
“Shift Lever” – When you scroll to this option, the Use the scroll up/left button (3) and the scroll
position of the shift lever is displayed. down/right button (4) in order to move between the
various screens and use the “Back” button in order to
“Shift Lever %” – When you scroll to this option, return to the Service Menu.
the control signal for the shift lever is displayed as a
percentage of a full PWM signal. Monitoring system
“Actual Gear” – When you scroll to this option, the In this screen, the Messenger system will display
display will show the gear that is currently engaged information about the part number of the hardware
in the transmission. for the Messenger ECM and the part number of the
software for the Messenger ECM.
“Top Dr Gr Sw” – When you scroll to this option, the
status of the switch for the top drive gear is displayed. Engine
The Product Link PL121SR is capable of two-way This blast site warning does not supersede the
communication between the machine and a remote published requirements or regulations found in “Title
user. The remote user can be a dealer or a customer. 30 of the Code of Federal Regulations (CFR)”. This
At any time, a user can request updated information warning does not allow deviation from the published
from a machine such as hours of use or the location requirements or regulations found in “Title 30 of
of the machine. Also, the system parameters for the Code of Federal Regulations (CFR)”. A hazard
Product Link PL121SR can be changed. Data is assessment should be conducted by each customer.
transmitted from the machine to a satellite. Next, the Every customer should meet all of the requirements
data is transmitted to a ground station. The receiving of “Title 30 of the Code of Federal Regulations (CFR)”
station transmits the data to Caterpillar Inc. The data in order to ensure the safe storage, transportation,
can then be sent to a Caterpillar dealer and to the loading, and blasting of any explosive.
customer.
The following Product Link PL121SR specifications
are provided in order to aid in conducting any related
Data Broadcasts hazard assessment and to ensure compliance with
Machine data about the machine's condition and all local regulations:
operation is being transmitted by Product Link to
Caterpillar and/or Caterpillar dealers in order to • The transmit power rating for the Product Link
better serve the customer and to improve Caterpillar PL121SR transmitter is five to ten watts
products and services. The information that is
transmitted may include the following data: machine • The operating frequency range for the Product Link
serial number, location of the machine, fault codes, PL121SR module is 148 MHz to 150 MHz.
emissions data, fuel usage, service meter hours,
Consult your Caterpillar dealer if there are any
version numbers for software and hardware, and
installed attachments. questions.
NOTICE
Transmission of information using Product Link is sub-
ject to legal requirements that may vary from location
to location, including, but not limited to, radio frequen-
cy use authorization. The use of Product Link must be
limited to those locations where all legal requirements
for the use of the Product Link communication network
have been satisfied.
g01435306
Illustration 69
Table 14
DECLARATION OF CONFORMITY
We, Quake Global, Inc (Previously Quake Wireless, Inc up to January 2001)
of 9765 Clairemont Mesa Blvd, Suite A (Previously 5575 Ruffin Road, Suite 100 up to March 2002)
San Diego
CA 92124, Usa (Previously 92123)
declare under our sole responsibility that the product
QHE2500, Q2000,Q1500, Q1400, Q1200S, Q1200SG, Q1200SH, Q1200SM and Q1200SV
to which this declaration relates, is in conformity with the following standards and / or other normative documents.
EN 301 721 V1.2.1 (June 2001)
EN 300 489-20V1.2.1 (November 2002)
EN 60950-1/A11:2004, 1st Edition
We hereby declare that all essential radio test suites have been carried out and that the above named product is in conformity
to all the essential requirements of Directive “1999/5/EC”.
The conformity assessment procedure referred to in Article 10 and detailed in Annex [IV] of Directive “1999/5/EC” has been
followed with the involvement of the following Notified Body:
BABT, Claremont House, 34 Molesey Foad, Walton-on-Thames, KT12 4RQ, UK
The technical documentation relevant to the above equipment will be held at:
Polina Braunstein
President
i02304792 i03309730
NOTICE
Do not engage the parking brake while the machine is
moving unless the service brakes fail. The use of the
parking brake as a service brake in regular operation
will cause severe damage to the parking brake.
g01117861
Illustration 70
g01015187
Illustration 72
Engage – Press the pedal in order to engage the The engine compression brake control is located to
service brakes. Use the service brakes for reducing the right side of the steering column. The control has
ground speed or for stopping the machine. four positions:
Disengage – Release the pedal in order to DISENGAGED position – Move the engine
disengage the service brakes. compression brake control to position (1). This will
disengage the engine compression brake.
Use correct gear selection and the engine
compression brake in order to control the speed of FIRST STAGE position – Move the engine
the machine on downgrades. Supplement the engine compression brake control to position (2). This
compression brake with the service brakes if the will provide a minimum engagement of the engine
machine requires additional retardation to avoid an compression brake. The engine compression brake
engine overspeed. will be engaged on two cylinders.
Note: Repeated engagement of the service brakes SECOND STAGE position – Move the engine
on downgrades may cause excessive wear and compression brake control to position (3). This
overheating of the service brakes. Refer to Operation will provide medium engagement of the engine
and Maintenance Manual, “Engine Compression compression brake. The engine compression brake
Brake Control”. will be engaged on four cylinders.
i02300815 i03297846
g01430241
Illustration 76
(A) Interaxle Differential Lock
(B) Cross Axle Differential Locks
g00949308
Illustration 75
There are two types of differential locks that may
be engaged. The first type of differential lock is the
The transmission has seven forward gears, neutral interaxle differential lock. The interaxle differential
and two reverse gear. lock (A) allows the front axle to rotate at a different
speed than the rear axle. When you engage the
The transmission control incorporates the following interaxle differential lock it prevents the front axle or
three switches: the rear axles from losing traction, this can help when
you are climbing a grade or when poor traction could
• High gear switch (1) cause the front axle to spin.
• Neutral lock button (2) If additional traction is required, the cross axle
differential locks (B) may also be engaged.
• Transmission hold switch (3)
Transmission hold allows the operator to hold the NOTICE
transmission in the gear that is currently engaged. Use the differential lock only in conditions where wheel
spin has, or will be encountered. If wheel spin has al-
The neutral lock button prevents the transmission ready developed, release pressure from the accelera-
control from being accidentally moved. You must tor pedal and allow the engine speed to fall sufficient-
depress the neutral lock button in order to move the ly to stop wheel spin before engaging the differential
transmission control from the NEUTRAL position. The lock. Failure to follow this procedure can result in ma-
neutral lock button also prevents the transmission chine damage.
control from being moved into the NEUTRAL position
from the Drive position or from the REVERSE Keep steering maneuvers to a minimum when the dif-
position. ferential lock is engaged. Steering maneuvers with the
differential lock engaged can result in machine dam-
The transmission hold switch also controls the shift age.
sequence for R1 and R2.
The high gear switch allows the operator to select the NOTICE
upper gear limit for the transmission. Incorrect use of the interaxle differential lock and of
the cross axle differential locks will cause severe ma-
Refer to Operation and Maintenance Manual, chine damage. Use the locks only in very soft ground.
“Operation Information” for additional information. Disengage the locks as soon as ground conditions al-
low.
78 SEBU7815-10
Operation Section
Machine Operation
When the axles are locked and the wheels are locked
the axles and the wheels rotate at the same speed.
SMCS Code: 7310 Rotate knob (1) and knob (4) clockwise in order to
secure the windows in the CLOSED position.
The right side windows and the left side rear window
of the cab can be opened in order to provide Note: The right side rear window serves as an
ventilation. The windows in the cab can only be alternate exit.
opened from the inside.
80 SEBU7815-10
Operation Section
Machine Operation
Left Side Window All six wheels must be in contact with firm ground.
Dumping without firm ground support under the rear
wheels changes the balance of the machine. It is
possible for the tractor or it is possible for the trailer
to overturn if dumping is performed incorrectly.
Pull the latch in order to close the window. Engage Operating The Machine
the latch in order to lock the window in the CLOSED
position. 1. Check for adequate clearance around the
machine.
2. Position the machine in the loading area. 8. Stop the machine with the service brake control.
Move the parking brake control to the ENGAGED
3. The operator of the machine should stay in the position.
cab while the machine is being loaded.
9. Move the transmission control to the N position.
4. Stop the machine with the service brake control
and move the parking and secondary brake 10. Move the hoist control to the LOWER position
control to the ENGAGED position. and increase the engine speed.
5. Move the transmission control to the N position. 11. Hold the hoist control until the body is about
600 mm (24 inch) from the frame. Release the
6. Ensure that the hoist control is in the FLOAT hoist control and reduce the engine speed. The
position. hoist control will move to the FLOAT position. The
body will continue to lower under the effect of
7. Load the machine. gravity until the body rests on the rear frame.
8. When the machine is loaded, move the 12. Move the transmission control to the D
transmission control to the 1 position. Move position. Move the parking brake control to the
the parking and secondary brake control to the DISENGAGED position and drive the machine to
DISENGAGED position. Drive the machine slowly the new location.
away from the loading area.
Note: When a machine is equipped with a
9. Leave the loading area with care. tailgate, the capacity of the body is increased and
material spillage is reduced. The tailgate is either
Dumping a mechanically activated scissors tailgate or a
hydraulically activated underslung tailgate. However,
material must be free flowing in order to eliminate
1. Clear the area of personnel and obstructions
before dumping. If a spotter is present, follow the hang-up at the gate.
spotter's directions.
Changing Speed and Direction
2. Position the machine straight ahead before
dumping. Ensure that all the wheels are in contact Machines with the following serial numbers have
with firm ground. eight gears and one reverse gear: B1N1-879
3. Stop the machine with the service brake control. Machines with the following serial numbers have
Move the parking brake control to the ENGAGED seven gears and two reverse gears: B1N880-UP and
position. B1P1-UP
(3) 3 position
82 SEBU7815-10
Operation Section
Machine Operation
Disengage the neutral lock by pressing neutral lock 3. Press and hold high gear switch (9). After
switch (8) and move the transmission control forward approximately 5 seconds, the actual gear indicator
in order to select the following gear positions: display will scroll between “8F”, “7F”, “6F”, “5F”
and “4F”. Each gear will flash for approximately
• DRIVE (D) 3 seconds.
• THIRD GEAR (3) Note: “8F” will only flash on machines with the
following serial numbers: B1N1-879
• SECOND GEAR (2)
4. When the indicator displays the required gear,
• FIRST GEAR (1) release high gear switch (9). This will set the
high gear limit to the gear that is displayed. The
Stop the machine and ensure that the engine is at transmission will not upshift higher than this
low idle before you move the transmission control selected gear.
from the N position.
Press and hold the high gear switch (9) in order to
If the transmission control is moved to the D position, return the transmission to normal drive.
first gear and torque converter drive will be engaged.
Note: The high gear limit will also be cancelled when
As you increase engine speed and the ground speed the engine start switch is moved to the OFF position.
increases, the transmission will upshift. As the ground
speed continues to increase, the transmission will Press neutral lock switch (8) and pull the transmission
upshift automatically. control backward to the R position in order to select
reverse gear. Transmission hold is automatically
activated when reverse gear is selected. The machine
must be stationary before you select reverse gear.
SEBU7815-10 83
Operation Section
Machine Operation
Transmission hold switch (7) allows the operator to • As you approach the up grade, press the
hold the transmission in the gear that is currently transmission hold switch in order to hold the
engaged. transmission in the selected gear and prevent
unwanted upshifts. When the machine is in first
Transmission hold is activated by pressing switch (7). gear and the machine ground speed decreases the
Power Train ECM will unlock the torque converter.
Transmission hold is cancelled by pressing switch (7) When any other forward gear has been selected
for a second time. the Power Train ECM will override the transmission
hold and the transmission will downshift one gear
Note: The transmission will automatically downshift below the selected gear. This will only occur when
when the machine speed falls below the minimum the engine rpm and the ground speed fall below the
speed for the selected gear. If the transmission downshift point. In order to allow the transmission
is in first gear and the machine speed falls below to shift normally through the gears, press the
the minimum speed, the torque converter will transmission hold switch again when you reach
automatically unlock. the top of the up grade.
Use the following procedure in order to select the • If you are driving in soft ground conditions, the
second reverse gear. transmission might shift frequently between gears.
If this occurs select the lower gear of the two gears
Note: Only machines with the following serial number in order to retain the selected gear. In order to
are equipped with two reverse speeds: B1N880-Up allow the transmission to shift normally through the
and B1P1-UP gears, press the transmission hold switch again
when the ground conditions improve.
With the machine in REVERSE, press and release
transmission hold switch (7). Once the machine • Under certain conditions, disabling the lockup
reaches the appropriate ground speed, the function for FIRST GEAR on the machine may
transmission will automatically shift into the second be beneficial. The FIRST GEAR lockup function
reverse gear. When the ground speed is reduced, the is enabled on the machine. The lockup function
transmission will automatically downshift into the first for first gear (1F LUC) has been made into a
reverse gear. In order to shift back into the second configurable option within Caterpillar Electronic
reverse gear, the operator must press transmission Technician ( CAT ET). This enhancement will allow
hold switch (7). the customer to select the appropriate configuration
in order to suit the application. Revising the setting
The transmission should be held in gear under the for the lockup function for first gear can help to
following conditions. maintain momentum. Revising the setting will
eliminate unnecessary gearshifts on certain grades
• If you are driving the machine down a grade or underfoot conditions. The default setting from
and the engine compression brake is selected. the factory for the lockup function for first gear
Consider the ground conditions and consider the is Enabled. Caterpillar recommends the version
degree of the down grade. Use your experience to ET2008A or a later version. When FIRST LOCKUP
select the gear that will give the best performance is enabled, the shift pattern is 1C-1LU-2C-2LU.
from the retarder. As you approach the down grade When FIRST LOCKUP is disabled, the shift pattern
manually select the appropriate gear. Drive the is 1C-2C-2LU.
machine at a safe speed down the grade. When
you reach the bottom of the down grade, select the At all times, drive the machine at a safe speed
gear that is suitable for the ground conditions. according to the following conditions.
g01293363
Illustration 85
g01293361
Illustration 83
g01293362
Illustration 84
SEBU7815-10 85
Operation Section
Machine Operation
g01293365
Illustration 87
g01290491
Illustration 89
3. Install pin (8) and keeper pin (7) in the rear cab
mount. Pin (8) should be installed from the rear
of the cab mount.
g01293366
Illustration 88
Note: If necessary, use the cab tilt pump to raise the
7. Use the cab tilt pump to tilt the cab until the holes cab slightly in order to install pins (5) and (8).
in cylinder (10) are aligned with the holes in
support bar (9) on the cylinder. Install locking pin
(11) into the support bar on the cylinder. Slowly
turn control lever (3) on the pump in an upward
direction. This will allow the cab to rest on the
locking pin in the support bar on the cylinder. Fully
turn the control lever on the pump to the down
position.
1. Use the cab tilt pump to take the load off locking
pin (11) in cylinder (10). Remove the locking pin
from the cylinder.
Note: When you install the keeper pin (6), ensure i02253478
that the shaft of the keeper pin goes all the way
through the pin (5) and the loop (13) on the side of Tailgate
the bracket for the cab mount. Also, ensure that the
keeper pin is installed correctly in order to allow the SMCS Code: 7000; 7271
spring tension in the ring to keep the ring against the
shaft of the keeper pin. If the machine is equipped with a tailgate, the tailgate
will operate automatically.
4. Install pin (5) and keeper pin (6) in the front cab
mount. Pin (5) should be installed from the front When the hoist control is moved into the RAISE
of the cab mount. position, the tailgate will open as the body is raised.
5. Turn control lever (3) on the cab tilt pump in a When the hoist control is moved into the LOWER
upward direction in order to fully lower the cab position, the tailgate will close as the body is lowered.
onto pins (5) and (8).
The machine must be moved slowly forward until the
6. Use bolts (1)and the washers in order to install machine is clear of the load. The LOWER position is
cover (2). then selected. This prevents the tailgate from moving
material back into the body. Damage to the tailgate
7. Lower the hood. Refer to the Operation and is also avoided.
Maintenance Manual, “Hood Control”.
When a machine is equipped with a tailgate, the
capacity of the body is increased and material spillage
i01995422 is reduced. The tailgate is either a mechanically
activated scissors tailgate or a hydraulically activated
Secondary Steering underslung tailgate. However, material must be free
flowing in order to eliminate hang-up at the gate.
SMCS Code: 4300-SE; 7000
i00961742 i02252107
Articulated trucks have different operating Park the machine on a level surface. Ensure that the
characteristics from the operating characteristics of parking brake is fully engaged.
rigid frame trucks. Twisting stress between the front
frame and the rear frame of an articulated truck is
eliminated by an oscillating hitch. The oscillating
hitch is installed between the tractor and the trailer.
The oscillating hitch allows unlimited oscillation
between the tractor and the trailer.
i02601212
2. Pull control (switch) (1) outward. Hold the switch The lubrication system will automatically lubricate all
in this position. Move the switch in a upward of the points that are connected to the system. The
direction in order to raise the hood. system is on a timed cycle.
3. Release the switch (1) when the hood is in the Operator Controls
fully raised position.
Low Level
Note: You will hear a repetitive clicking noise when
the hood has reached the fully raised position.
g01074472
Illustration 95
Location of the LED that indicates low level
The signal lamp is in the rear of the cab on the right side.
Illustration 94
g00785414 A yellow LED illuminates on the signal lamp when
the reservoir needs to be refilled. Refer to Operation
1. Pull control (switch) (1) outward. Hold the switch and Maintenance Manual, “Automatic Lubrication
in this position. Move the switch in a downward Grease Tank - Fill”.
direction in order to lower the hood.
Error Indicator
2. Release switch (1) when the hood is in the fully
lowered position.
Release the support for the cover and close the cover
when the operation is complete. Turn the two latches
in the cover clockwise in order to lock the cover.
SEBU7815-10 89
Operation Section
Machine Operation
g01074473 g01074461
Illustration 96 Illustration 98
Location of the LED that indicates an error Location of the mode switch on the signal lamp
The signal lamp is in the rear of the cab on the right side. The signal lamp is in the rear of the cab on the right side.
A red LED illuminates when the system is not The system is equipped with a mode switch that
operating correctly. The system may be operating can be used to select the appropriate duty cycle,
incorrectly due to an empty reservoir or due to a as follows.
system failure. Reset the system with the test button
on the lubrication pump after a refill or repair. For the • Switch on the ignition.
location of the test button, refer to Special Instruction,
REHS2054 for more information. • Depress the mode switch until the required duty
cycle is selected.
Duty Cycle Indicators
• The signal lamp will indicate the new selected duty
cycle.
g01073661
Illustration 97
Location of the LED that indicates duty cycle
The signal lamp is in the rear of the cab on the right side.
g01129176
Illustration 100
Heavy duty cycle
Engine Starting
NOTICE
Do not crank the engine for more than 30 seconds.
i02887531 Allow the starting motor to cool for two minutes before
cranking again.
Engine Starting
Turbocharger (if equipped) damage can result, if the
SMCS Code: 1000; 7000 engine rpm is not kept low until the engine oil light/
gauge verifies the oil pressure is sufficient.
Engine Starting Above 0°C (32°F)
Engine Starting Below 0°C (32°F)
with Ether Starting Aid
Diesel engine exhaust contains products of com-
bustion which may be harmful to your health The ether starting aid functions automatically under a
combination of all of the following conditions:
Always start and operate the engine in a well-ven-
tilated area and, if in an enclosed area, vent the • The engine coolant temperature is below 0 degrees
exhaust to the outside. celsius.
5. Move the hoist control to the HOLD position. Engine and Machine Warm-Up
6. Turn the engine start switch to the ON position in SMCS Code: 1000; 7000
order to check the Caterpillar Monitoring System
for correct operation. As soon as the engine starts, observe all gauges and
indicators. All gauges should indicate in the proper
7. Turn the engine start switch to the START position range. Indicators should be on or off according to the
in order to start the engine. Release the engine function of the indicator.
start switch key when the engine starts.
The Monitoring System must not be giving any
8. Operate the engine at low idle until the Caterpillar warnings. The Monitoring System must have
Monitoring System verifies that the engine oil completed the self-diagnostic routine successfully
pressure is normal. before the engine is started.
Note: If the engine fails to start, return the engine When the engine is cold, operate the engine at low
start switch to the OFF position before you attempt idle for at least five minutes. Observe the following
to start the engine again. recommendations.
Warm-Up
At start-up, operate the machine in fourth gear or in
a lower gear until the oil is warm. Allowing the oil to
warm-up gradually permits bearing components to
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.
Break-In
The running surfaces of the gears and the bearings
are conditioned during break-in. Break-in brings
bearing components to optimum operating positions.
Parking i01514483
NOTICE
Stopping the engine immediately after it has been
working under load can result in overheating and ac-
celerated wear of the engine components.
1. Stop the machine and run the engine at low idle for
g00785713
five minutes. Do not stop the engine immediately Illustration 102
after the engine has been working under load.
This can result in overheating and in accelerated 2. The access cover should be held in the OPEN
wear of the engine components. position by support (1).
2. Turn the engine start switch to the OFF position 3. Move engine shutdown switch (2) to the STOP
and remove the engine start switch key. position.
If the engine continues to run, open the hood. Cover 2. Tilt the cab in order to access the hoist control
the air intake with a strong, clean board. This will valve. Refer to Operation and Maintenance
starve the engine of air. Use this procedure as a last Manual, “Cab - Tilt”.
resort. Refer to Operation and Maintenance Manual,
“Hood Control”. Note: The hoist control valve is located under the
cab on the left side of the front frame.
i02636979
g01136493
Illustration 105
Test panel at the rear of the cab on the left side
735 (S/N: B1N1-535) and 740 (S/N: B1P1-334)
g01035886
Illustration 108
18. Lower the cab and secure the cab in place with
Illustration 107
g01336431 the pins for the cab. Refer to Operation and
Typical example for 735 (S/N: B1N1-535) and 740 (S/N: B1P1-334) Maintenance Manual, “Cab - Tilt”.
96 SEBU7815-10
Operation Section
Parking
i00962142
Transportation Information
i03655140
g01874433 g01874876
Illustration 111 Illustration 113
1. Remove the exhaust tube (1) from the exhaust 3. Loosen the retaining bolts on the antenna for
stack. Store the exhaust tube in the cab. product link (3) and allow the bracket to slide
down the guard. Tighten the bolts after lowering
the antenna.
g01874875
Illustration 112
g01874879
2. Fold the mirrors (2) to the proper orientation Illustration 114
toward the cab. Perform this step on both sides of
the machine. 4. Make sure that the mud flaps (4) are locked into
the proper position. Perform this step on both
sides of the machine.
SMCS Code: 7000; 7500 Park the machine on a level surface. Engage the
parking brake. Lower the dump body and shut off
the engine.
g00948691
Illustration 117
g00757156
Illustration 119
Two lifting holes (1) are positioned at the rear of the
machine in the dump body. Two lifting points (2) are 6. Lift the machine from the positions (1) and (2).
positioned at the front of the machine. The two lifting These positions are shown in illustrations 117 and
points at the front of the machine are located under 119.
covers. The covers must be removed in order to
access the front lifting points. 7. Remove the slings, cables and beams when the
machine has been lowered.
Note: Do not use lifting holes (3) to lift the
machine. These holes are provided in order to Tying Down the Machine
enable the body to be lifted off the machine.
Each machine is equipped with brackets for tying
Perform the following steps in order to remove the down the machine.
covers and lift the machine:
g00757158
Illustration 120
g00757155
Two points for tying down are positioned at the front
Illustration 118 of the machine. One point is located on the left side
of the machine. One point is located on the right side
2. Remove two bolts (4) and retain the bolts and of the machine.
washers. Remove cover (5) in order to access the
left side front lifting point.
g00757159
Illustration 121
g01047559
Illustration 122
g01133880
Illustration 123
Improper hookup and towing is dangerous and Before you tow the machine, make sure that the
could result in injury or death to yourself or oth- tow line or the tow bar is in good condition. Make
ers. sure that the tow line or the tow bar has enough
strength for the towing procedure that is involved.
The towing connection must be rigid, or towing The strength of the tow line or of the tow bar should
must be done by two machines of the same size be at least 150% of the gross weight of the towing
as the towed machine. If two machines are used, machine. This is true for a disabled machine that is
connect a machine on each end of the towed ma- stuck in the mud and for towing on a grade.
chine.
Keep the tow line angle to a minimum. Do not exceed
If only one machine is used for towing, that ma- a 30° angle from the straight ahead position.
chine must be larger than the towed machine.
Quick machine movement could overload the tow
Be sure that all necessary repairs and adjust- line or the tow bar. This could cause the tow line
ments have been made before a machine that or the tow bar to break. Gradual, steady machine
has been towed to a service area is put back into movement will be more effective.
operation.
Normally, the towing machine should be as large
as the disabled machine. Make sure that the towing
Follow the recommendations that are listed below in machine has enough brake capacity, enough weight,
order to perform the towing procedure correctly. and enough power. The towing machine must be
able to control both machines for the grade that is
Note: To prevent the machine from moving, place involved and for the distance that is involved.
blocks under the machine wheels. This must be done
before you release the parking brake. You must provide sufficient control and sufficient
braking when you are moving a disabled machine
The machine is equipped with a spring applied, oil downhill. This may require a larger towing machine
pressure released parking brake. The parking brake or additional machines that are connected to the rear.
is mounted on the center axle. This will prevent the machine from rolling away.
If the engine cannot be run, the transmission pump If the machine is being towed downhill and the
will be inoperable. This may prevent the release of machine requires articulation, the steering frame
the parking brake. locks can be removed. This maneuver will require
two towing machines. One towing machine must be
The parking brake can be released manually when attached to the front of the disabled machine in order
there is not enough oil pressure in the system. to control the tractor. An additional towing machine
must be attached to the rear of the disabled machine
Refer to Operation and Maintenance Manual, in order to control the trailer.
“Parking Brake Manual Release”.
Do not release the parking brake or remove the
The following towing instructions are for moving a blocks from the wheels, until the weight of the
disabled machine for a short distance at low speed. disabled machine is held or controlled by the
towing machine.
Move the machine at a speed of 2 km/h (1.2 mph)
or less to a convenient location for repair. Always The requirements of all situations cannot be
haul the machine if long distance moving is listed. Minimum towing machine capacity is required
required. on smooth, level surfaces. Maximum towing machine
capacity is required on inclines or on uneven
surfaces.
104 SEBU7815-10
Operation Section
Towing Information
Note: Consult your Caterpillar dealer for more 4. Hook up the towing machine or towing machines
information about towing a disabled machine. to the disabled machine. Ensure that the
combination of towing machines is enough for the
Towing a Machine that has an towing of the disabled machine.
If the machine is in the straight ahead position and 7. When the machine is at the required destination,
the machine needs towing for only a short distance, it block the wheels again.
is unnecessary for the steering system to be disabled.
8. Manually engage the parking brake.
If the machine is not in the straight ahead position,
adjustment will be necessary. Adjust the position of 9. Return hydraulic hose (1) and hydraulic hose (2)
the machine by using the secondary steering. to the original positions.
• final drive
g00758066 • differential
Illustration 124
• transmission
1. Locate the hydraulic hoses behind the left front
wheel. • transfer gear
2. Place a suitable container under the hydraulic Remove the corresponding drive shafts and axle
hoses. Remove the hose clips that secure the shafts in order for the machine to be towed .
hydraulic hoses to the machine frame. Loosen the
nut on hydraulic hose (1) and disconnect hose
(1). Loosen the nut on hydraulic hose (2) and
disconnect hose (2). The container will catch oil
when the hydraulic hoses are disconnected. Install
hose (1) on the connector for hose (2). Install
hose (2) on the connector for hose (1). Tighten
the nuts. This will allow the machine to articulate
without spilling oil.
i02252130
g01130535
Illustration 127
106 SEBU7815-10
Operation Section
Towing Information
10. Install plug (4) and the gasket. Tighten the plug to
a torque of 14 ± 3 N·m (10 ± 2 lb ft).
6. Stop the engine on the machine that is being 17. When the engine is running and the charging
used as an electrical source. If you are using system is in operation, conclude the failure
an auxiliary power source, turn off the charging analysis on the starting system and on the
system. charging system of the stalled machine, as
required.
7. Ensure that the battery caps are tight. Ensure
that the battery caps are correctly placed on both
machines. Ensure that the batteries in the stalled
machine are not frozen. Ensure that there is
enough electrolyte in the batteries.
g00785712
Illustration 129
Maintenance Section
Personal injury or death could result with improp-
Tire Inflation Information er tire inflation techniques.
Tire Inflation with Nitrogen Note: Do not set the tire inflation equipment regulator
SMCS Code: 4203 higher than 140 kPa (20 psi) over the recommended
tire pressure.
Caterpillar recommends the use of dry nitrogen gas
for tire inflation and for tire pressure adjustments. Use 6V-4040 Nitrogen Tire Inflation Group or an
This includes all machines with rubber tires. Nitrogen equivalent part to inflate tires from a nitrogen gas
is an inert gas that will not aid combustion inside the cylinder. Refer to Special Instruction, SMHS7867 for
tire. tire inflation instructions.
Front 414 60
Michelin
XADT
26.5R25 193B E3 Center
and 379 55
Rear
Front 310 45
Michelin
XAD-65
850/65R255 196B
Center
g00103698 E3
Illustration 130 and 290 42
Rear
(continued)
SEBU7815-10 111
Maintenance Section
Tire Inflation Information
735
Tire Shipping Pressure
Inflation Inflation
Tire Type
Axle Pressure Pressure SMCS Code: 4203; 7500
Size
(kPa) (psi)
S/N: B1N880-Up
Front 428 62 As shown, the tire inflation pressure is cold inflation
Goodyear shipping pressure.
RL-2+
26.5R25 E3 6S Center
and 393 57
Rear
Front 428 62
Goodyear
GP-2B Center
26.5R25 E2 4S and 393 57
Rear
Front 428 62
Goodyear
GP-4B Center
26.5R25 E4/L4 4S and 393 57
Rear
740
Tire Inflation Pressure
Bridgestone
Front 359 52
Adjustment
VLT Center
29.5R25 E3 and 345 50 SMCS Code: 4203
Rear
Front 448 65 The tire pressure in a warm shop area 18° to 21°C
Bridgestone (65° to 70°F) will significantly change when you move
VKT Center the machine into freezing temperatures. If you inflate
29.5R25 E2 and 428 62 the tire to the correct pressure in a warm shop, the
Rear tire will be underinflated in freezing temperatures.
Front 359 52 Low pressure shortens the life of a tire.
Bridgestone
VLTS Center When you operate the machine in freezing
29.5R25 E4 and 345 50 temperatures, see Special Publication, SEBU5898,
Rear
“Cold Weather Recommendations”.
Front 448 65
Bridgestone
VMT Center
29.5R25 E3 and 428 62
Rear
Lubricant Viscosities and Note: The availability of the various Caterpillar oils
will vary by region.
Refill Capacities
Note: After considering the information that is found
in the associated footnotes, Caterpillar oils are the
i03655143 preferred oils. ALL other oil type and categories that
are listed in the applicable section are acceptable
Lubricant Viscosities oils.
SMCS Code: 1000; 7000; 7581 Note: Do not use BIO oils as a replacement for Cat
TDTO and TO-4 oils.
The proper lubricant viscosity grade is determined by
the minimum outside temperature when the machine
is started. The proper lubricant viscosity grade is also
determined by the maximum outside temperature
while the machine is operated. Use the column that
is designated “Min” on the table to determine the
lubricant viscosity grade that is required when you
start a cold machine and you operate a cold machine.
Use the column that is designated “Max” on the table
to select the lubricant viscosity grade for operating
the machine at the highest temperature that is
anticipated. Use the highest SAE viscosity grade of
oil that is allowed for the temperature when you start
the machine. In order to maintain the highest possible
thickness of oil, machines that are continuously
operated should use an oil that has a higher viscosity
in the final drives and in the differentials. Consult your
Caterpillar Dealer if additional information is needed.
NOTICE
Not following the recommendations found in these ta-
bles and associated footnotes can lead to reduced
performance and compartment failure.
NOTICE
Do NOT use only the “Oil Viscosities” column when
determining the recommended oil for a machine com-
partment. The “Oil Type and Category” column MUST
also be used.
Note: Only use the oil type and the oil category
that is recommended for the various machine
compartments.
Table 19
Lubricant Viscosities for Ambient Temperatures
Compartment or System °C °F
Oil Viscosities Min Max Min Max
SAE 0W-20 −40 10 −40 50
SAE 0W-30 -40 30 -40 86
Engine Crankcase(1)(2)(6) SAE 0W-40 -40 40 -40 104
Cat DEO-ULS
Cat DEO Multigrade SAE 5W-30 −30 30 −22 86
Cat DEO SYN (3) SAE 5W-40 −30 50 −22 122
Cat Arctic DEO SYN (4)
Cat ECF-1-a, Cat ECF-2, Cat ECF-3(5) SAE 10W-30(6) −18 40 0 104
SAE 10W-40 -18 50 0 122
SAE 15W-40 −9.5 50 15 122
Hoist (Ejector), Steering and Brake System, SAE 0W-20(7)(8) −40 40 −40 104
Brake Control Valve Damper, and Suspension
Hydraulic System
Cat TDTO SAE 10W(8)(9) −20 50 −4 122
Cat Arctic TDTO
commercial TO-4
SAE 0W-20(7) -40 22 -40 72
SAE 0W-30(10) -40 30 -40 86
Torque Converter and Transmission
Cat TDTO SAE 5W-30(10) -30 30 -22 86
Cat TDTO-TMS
Cat Arctic TDTO SAE 10W(9) -20 22 -4 72
commercial TO-4
SAE 30 10 50 50 122
Cat TDTO-TMS(11) 10 50 50 122
Output Transfer Gear SAE 0W-20(7)(12) -40 -10 -40 14
Cat TDTO
Cat Arctic TDTO SAE 30 -20 50 -4 122
commercial TO-4
(continued)
116 SEBU7815-10
Maintenance Section
Lubricant Viscosities and Refill Capacities
Compartment or System °C °F
Oil Viscosities Min Max Min Max
SAE 0W-20(7)(12) -40 -10 -40 14
Differential and Final Drive
Cat TDTO SAE 50(13) -15 40 5 104
Cat TDTO-TMS
Cat Arctic TDTO SAE 60(13) -10 50 14 122
commercial TO-4
Cat TDTO-TMS -25 22 -13 72
(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, allowing the oil to become more viscous due to
cooler ambient temperatures.
(2) Cat DEO-ULS or commercial oils meeting Cat ECF-3 specification are strongly recommended for use in diesel engines that are equipped
with Diesel Particulate Filters (DPF) and other aftertreatment devices.
(3) Cat DEO SYN is an SAE 5W-40 viscosity grade oil.
(4) Cat Arctic DEO SYN is an SAE 0W-30 viscosity grade oil.
(5) Cat Engine Crankcase Fluid specifications Commercial alternative diesel engine oils must meet one or more of these Cat ECF specifications.
(6) SAE 10W-30 is the preferred viscosity grade for the 3116, 3126, C7, C-9 and the C9 diesel engines when the ambient temperature is
between -18° C (0° F) and 40° C (104° F).
(7) First Choice: Cat Arctic TDTO SAE 0W-20. Second Choice: Oils of full synthetic base stock that do not have viscosity index improvers and
do meet the performance requirements of the TO-4 specification for the SAE 30 viscosity grade. Typical lubricant viscosity grades are SAE
0W-20, SAE 0W-30, and SAE 5W-30. Third Choice: Oils that contain a TO-4 additive package and a lubricant viscosity grade of SAE
0W-20, SAE 0W-30, or SAE 5W-30.
(8) The maximum allowable oil viscosity at 100°C is 6.6 cSt (“ASTM D445”).
(9) SAE 10W viscosity grade oil used in Caterpillar machine compartments must have a minimum viscosity of 5.6 cSt at 100 °C (212 °F)
(“ASTM D445”).
(10) First Choice: Oils of full synthetic base stock that do not have viscosity index improvers and do 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.
(11) Cat TDTO-TMS (Transmission Multi-Season) (synthetic blend that exceeds the TO-4M multigrade specification requirements).
(12) Do NOT use when the typical daily maximum ambient temperature is above −10 °C (14 °F).
(13) Cat TDTO SAE 50 or TO-4 SAE 50 is preferred in most applications, particularly continuous operation. If the ambient temperature is below
−15 °C (5 °F), warm up the oil prior to operation. The oil must be maintained to a temperature above −15 °C (5 °F) during operation. If the
ambient temperature is below −15 °C (5 °F), perform the procedures in the Operation and Maintenance Manual, “Differential Warm-up and
Break-in” prior to 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.
Cat Ultra 5Moly Greases are formulated with special Cat Ultra 5Moly Grease is formulated not to contain
blends of naphthenic petroleum base oils that have lead, antimony, barium, zinc, phosphorous, or
low pour points. This allows the Cat Ultra 5Moly chlorine additives. Thus, when Cat Ultra 5Moly
Greases to pump at lower temperatures. The ability to Greases are compared to many other types of
pump Cat Ultra 5Moly Greases at lower temperatures grease, the Cat Ultra 5Moly Greases are more
means added insurance that all of the grease joints environmentally friendly.
in the machine will be adequately lubricated even if
the ambient temperature drops unexpectedly. This
is particularly important when the machine's critical
Cat Desert Gold Grease
lubrication points rely on an automatic lubrication Cat Desert Gold Grease is formulated in order to
system.
protect the most severely loaded joints in Caterpillar
machines against galling, wear, and corrosion. This
A significant challenge exists in order to get grease protection is sustained while work is being done at
to pump into the joints at low temperatures. Once
moderate temperatures to very hot temperatures with
the grease gets to the joint, the grease must have
wet conditions or dry conditions.
extremely high resistance to galling, wear, fretting,
water washout, and corrosion in order to adequately
Cat Desert Gold Grease is an NLGI grade 2 grease.
protect highly loaded joints.
This grease is made with a synthetic base oil that
has a very high viscosity and a Calcium Sulfonate
Even under severely loaded conditions, the grease
Complex thickener. This grease also has 5%
should preferably have a very long working life.
Molybdenum diSulfide (MoS2 or “Moly”) and tackifier.
In order to make greases that meet these greater
demands, a Calcium Sulfonate Complex thickener
As the temperature changes, Cat Desert Gold
with a properly blended naphthenic oil and/or a
Grease will experience a minimal change in viscosity
synthetic base oil is required. This is the reason that because the base is a synthetic oil. Because Cat
Caterpillar uses these ingredients in Cat Ultra 5Moly
Desert Gold Grease has a synthetic base oil with a
Greases.
high viscosity, Cat Desert Gold Grease maintains a
thick lubricant film even at very hot temperatures.
Cat Ultra 5Moly Greases also have 5% Moly, instead
of the 0% to 3% that is found in most other greases.
Cat Desert Gold Grease is made with a Calcium
This additional Moly greatly improves the ability of the Sulfonate Complex thickener. This provides the
grease to protect parts from damage in applications
necessary protection against galling, wear, fretting,
with severe impact (slamming). In addition, the Moly
water washout, and corrosion. Cat Desert Gold
in Cat Ultra 5Moly Grease is a special grade that has Grease also has a very long life. This grease will
a median particle size of 3 microns in order to meet
resist breakdown even when the application is under
the special requirements of some rolling element
extremely heavy loads and with frequent oscillations.
bearings. This protection is sustained while work is being done
at moderate temperatures to very hot temperatures
Cat Ultra 5Moly Greases are also made to be extra
with wet conditions or dry conditions.
tacky. In some applications, the film of grease must
adhere to the vertical surfaces. An example of this
Cat Desert Gold Grease has 5% molybdenum instead
application is swing gears for excavators. Many
of the 0% to 3% that is found in most other greases.
conventional greases do not have enough of the This additional molybdenum greatly improves the
tacky characteristic in order to allow the grease to
ability of the grease to protect parts from damage
stay in place. In addition, many of these greases do
in applications with severe impact (slamming).
not have the performance in order to adequately In addition, the molybdenum in Cat Desert Gold
protect the gear teeth in these applications.
Grease is a special grade. This grade has a median
particle size of 3 microns in order to meet the special
Cat Ultra 5Moly Grease exceeds the NLGI requirements of some rolling element bearings.
certification of “GC-LB”. (This certification relates to
extended service intervals in automotive chassis
Cat Desert Gold Grease is made to be extra tacky. In
points and in wheel bearings with disc brakes in some applications, the film of grease must adhere to
automobiles, vans, and light trucks.)
the vertical surfaces. An example of this application
is swing gears for excavators. Many conventional
Note: If the application calls for Cat Ultra 5Moly greases do not have enough of the tackifier to allow
Grease and Cat Ultra 5Moly Grease is not available,
the grease to stay in place. In addition, many of these
consult the data sheets for the grease. From
greases do not have the performance, particularly at
these data sheets, use a substitute that meets the high ambient temperatures, to adequately protect the
performance characteristics of Cat Ultra 5Moly
gear teeth in these applications.
Grease.
SEBU7815-10 119
Maintenance Section
Lubricant Viscosities and Refill Capacities
Cat Desert Gold Grease has the ability to prevent Because the base oil is synthetic, Cat Arctic
galling and wear at very hot temperatures under Platinum Grease has a minimal change in viscosity
extremely severe loads and conditions. In moderate as the temperatures drop. Because the synthetic
temperatures, Cat Desert Gold Grease can be base oil has a very low viscosity, the Cat Arctic
used in those extremely severe applications if an Platinum Grease that is made with this base oil
improvement over Cat Ultra 5Moly Grease is desired. has a minimal change in viscosity and flows easily
as the temperature drops. Cat Arctic Platinum
Cat Desert Gold Grease can be used in applications Grease pumps easily at extremely low temperatures.
that require the lubricant to last for very long periods In fact, Cat Arctic Platinum Grease NLGI grade
of time because this grease has an extremely high 0 can be pumped through standard automatic
performance and long life. lubrication systems that are machine mounted and at
temperatures down to −50 °C (−58 °F). This means
Cat Desert Gold Grease exceeds the NLGI that the grease can be pumped through those long
certification of “GC-LB”. (This certification relates to unheated lines and into the required joints.
extended service intervals in automotive chassis
points and in wheel bearings with disc brakes in Cat Arctic Platinum Grease is made with Calcium
automobiles, vans, and light trucks.) Sulfonate Complex thickener in order to provide the
necessary protection against galling, wear, fretting,
Note: If the application calls for Cat Desert Gold water washout, and corrosion.
Grease and Cat Desert Gold Grease is not available,
consult the data sheets for the grease. From Cat Arctic Platinum Grease performs well for long
these data sheets, use a substitute that meets the periods of time. This grease resists breakdown even
performance characteristics of Cat Desert Gold with extremely heavy loads in applications with
Grease. With consideration given to the application, frequent oscillations. This grease provides protection
Cat Ultra 5Moly Grease, or Cat Arctic Platinum that will be sustained in conditions that are wet or dry.
Grease may perform adequately. However, the use Also, this grease will provide protection in moderate
of these greases may require a different schedule temperatures as well as extremely cold temperatures.
for lubrication.
Cat Arctic Platinum Grease has 5% of molybdenum
Cat Desert Gold Grease is formulated not to contain instead of 0% or 3% that is found in most of the
lead, antimony, barium, zinc, phosphorous, or other greases. This additional molybdenum greatly
chlorine additives. Thus, when Cat Desert Gold improves the ability of the grease in order to protect
Grease is compared to many other types of grease, parts from damage in applications with severe
the Cat Desert Gold Grease is more environmentally impact (slamming). In addition, the molybdenum in
friendly. Cat Arctic Platinum Grease is a special grade. This
molybdenum has a median particle size of 3 microns
Cat Arctic Platinum in order to meet the special requirements of some
rolling element bearings.
Cat Arctic Platinum Grease is formulated to
protect the most heavily loaded joints in Caterpillar Cat Arctic Platinum Grease is made to be extra
tacky. In some applications, the film of grease must
machines against galling, wear, and corrosion. With
adhere to the vertical surfaces. An example of this
dependence on the consistency of the grease, this
protection is sustained, while work is being done in application is swing gears for excavators. Many
conventional greases do not have enough tackifier
moderate temperatures and in temperatures that may
to adhere well to the vertical surfaces. This ability is
reach a temperature of −50 °C (−58 °F). In addition,
the conditions may be wet or dry. Cat Arctic Platinum necessary in order to adequately protect the gear
teeth in these applications.
Grease is available in NLGI grade 0.
Cat Arctic Platinum Grease is made with a synthetic Cat Arctic Platinum Grease has the ability to prevent
galling and wear at very cold temperatures under
base oil that has a very low viscosity and a Calcium
extremely severe loads and conditions. In moderate
Sulfonate Complex thickener. The performance is
enhanced with 5% Molybdenum diSulfide (MoS2 or temperatures, Cat Arctic Platinum Grease can be
used in the application if the compartment is sealed
“Moly”) and tackifier.
tightly in order to contain the grease.
Table 20
Grease Application Chart
(By Machine)
Hydraulic System
Pressurized system: Hot coolant can cause seri-
ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve Personal injury can result from hydraulic oil pres-
the pressure. sure and hot oil.
To relieve the pressure from the coolant system, Hydraulic oil pressure can remain in the hydraulic
move the engine start switch to the OFF position. system after the engine has been stopped. Seri-
Allow the cooling system pressure cap to cool. The ous injury can be caused if this pressure is not re-
cap must be cool enough to touch with a bare hand. leased before any service is done on the hydraulic
Remove the cooling system pressure cap slowly in system.
order to relieve pressure.
Make sure all of the attachments have been low-
ered, oil is cool before removing any components
Fuel System or lines. Remove the oil filler cap only when the en-
gine is stopped, and the filler cap is cool enough
To relieve the pressure from the fuel system, move to touch with your bare hand.
the engine start switch to the OFF position.
Relieving the pressure in the brake circuit will not 6. Depress the brake pedal repeatedly. This will
release the nitrogen precharge pressure in the brake relieve any pressure that may be present in the
accumulators. brake hydraulic system.
Make sure all of the attachments have been low- 2. If equipped, turn the battery disconnect switch to
ered, oil is cool before removing any components the OFF position. If there is no battery disconnect
or lines. Remove the oil filler cap only when the en- switch, remove the negative battery cable at the
gine is stopped, and the filler cap is cool enough battery.
to touch with your bare hand.
NOTICE
Do NOT use electrical components (ECM or ECM sen-
sors) or electronic component grounding points for
grounding the welder.
Every Year
Brake Accumulator (Service) - Check ................. 133
Cooling System Coolant Sample (Level 2) -
Obtain ............................................................... 141
i01524136 Install grill (2) and four bolts (1). Lower the hood.
Aftercooler Core -
Inspect/Clean i02695981
Personal injury can result without following prop- If the yellow LED on the signal lamp is illuminated,
er procedure. When using pressure air, wear a pro- the minimum grease level in the reservoir has been
tective face shield and protective clothing. reached.
Maximum air pressure at the nozzle must be less • Ensure that the filler hose is primed with grease in
than 205 kPa (30 psi) for cleaning purposes. order to prevent air from being introduced in the
grease reservoir.
g00792092
Illustration 131 g01074471
Illustration 133
Location of the coupling on the lubrication pump
Raise the hood. Refer to Operation and Maintenance
Manual, “Hood Control”. Remove two bolts (1) from
each side of grill (2). Remove grill (2) in order to • Remove the dust cap from the coupling for the filler.
access the aftercooler core.
• Carefully clean the coupling for the filler and the
coupling on the filler hose. The coupler for the filler
hose is supplied with each Autolube system.
g00792093
Illustration 132
• Fill the reservoir up to the maximum level that is Note: When you use high pressure water or high
indicated on the reservoir. pressure air to clean the machine, do not spray
directly onto the lubrication pump. Water or dirt may
• Remove the filler hose and fit the dust cap. enter the lubrication pump through the de-arating
openings.
• Place the filler hose back in the hose's proper
place in order to ensure that the coupling of the Note: The automatic lubrication system reduces
filler hose remains clean. the time and effort that is taken in order to grease
the machine significantly. However, do not neglect
Note: Every 500 service hours replace the filter or grease points that are not served by the automatic
every 500 service hours clean the filter for the filler lubrication system.
on the lubrication pump. The filter is behind the
connector on the reservoir. Grease Recommendations
Note: If the pumping action seems to go heavy,
Grease should not contain graphite or PTFE. Use the
check the filter behind the coupling for the filler on the correct grease in the automatic lubrication system.
lubrication pump. Gently clean the filter or replace
the filter. If the filter is damaged, the filter must be
The use of a partially fluid grease that is above the
replaced. maximum temperature that is indicated in Table 25
is not permitted. Use of a partially fluid grease that is
Note: If too much grease is pumped into the reservoir,
above the maximum indicated temperature can lead
the surplus grease will exit the vent at the side of the to the following.
lubrication pump. Any air that is introduced during the
filling procedure will also escape via this route.
• Excessive component wear
Note: Due to the slow capability of a hand held
grease gun, the use of a grease gun is not • A reduction in the efficiency of the system
recommended in order to fill the reservoir. Table 25
Minimum Maximum
Periodic Checks operating operating Prescribed
temperature of temperature of NLGI Grade
• Check the grease level in the reservoir. Refill the the system the system
reservoir on time. 2
−25 °C (−13 °F) 80 °C (176 °F)
• Check that the signal lamp is functioning. −25 °C (−13 °F) 0 °C (32 °F) 0/1
−25 °C (−13 °F) 80 °C (176 °F) SYNTHETIC 2
• Check that the duty cycle that is indicated on the
signal lamp is correct for the operating conditions. −25 °C (−13 °F) 0 °C (32 °F) SYNTHETIC 0/1
• Check the grease lines for damage and check the Axle Breathers - Clean/Replace
grease lines for leakage.
SMCS Code: 3278-070-BRE; 3278-510-BRE
• Check the conditions of the grease points that
are served by the system. Sufficient fresh grease Park the machine on a level surface. Move the
should be present. parking brake control to the ENGAGED position.
Lower the body and shut off the engine. Block the
• Check the operation of the system. Perform a wheels.
cycle test. Refer to System Operation, Testing and
Adjusting, RENR6739 for more information. Install the Steering Frame Lock. Refer to Operation
and Maintenance Manual, “Steering Frame Lock”.
• Clean the lubrication pump and clean the
surroundings of the lubrication pump.
Battery - Recycle
SMCS Code: 1401-561
• A battery supplier
• An authorized battery collection facility
• Recycling facility
g00781678
Illustration 137
Rear axle breather (3) is located on the right side of the rear frame i01951790
above the rear axle.
Battery or Battery Cable -
Use the following procedure to clean the breathers.
Inspect/Replace
Note: Before you remove the breathers, block the
front frame of the machine. SMCS Code: 1401-510; 1402-510
1. Remove each breather. Inspect the condition of the cables to the batteries
and inspect the condition of the batteries.
132 SEBU7815-10
Maintenance Section
Belts - Inspect/Adjust/Replace
5. Perform the necessary repairs. Replace the 5. Remove the belt from the engine.
cables or the batteries, as needed.
6. In order to Install a new belt, insert a square drive
6. Connect the negative battery cable to the into the hole in tensioner (2) and turn clockwise.
terminals of the battery.
7. Install belt (4) in the following order: drive pulley
7. Connect the negative battery cable at the battery (2), pulley (3), alternator pulley (5), and tensioner
disconnect switch. (1).
8. Install the key for the battery disconnect switch. 8. Lower the hood. Refer to Operation and
Turn the key to the ON position. Maintenance Manual, “Hood Control”.
i01486572
i02240445
g00772828
Illustration 139
SEBU7815-10 133
Maintenance Section
Brake Accumulator (Service) - Check
i02253515
Brake Accumulator (Service) - Personal injury can result from oil under high
pressure.
Check
DO NOT allow high pressure oil to contact skin.
SMCS Code: 4263-535
Wear appropriate protective equipment while
working with high pressure oil systems.
g01689905
Illustration 140
Brake Control Valve Damper Routine purging of the service brake lines ensures
that the system is free of air. Purge the brake groups
Oil - Change for the center axle and purge the brake groups for
the front axle.
SMCS Code: 4251-044; 4265-044
S/N: B1N1155-Up Refer to the appropriate Systems Operation, Testing
and Adjusting, “Service Brake Air - Purge” for more
S/N: B1P3884-Up information.
i01514959
Hot oil and hot components can cause personal Brakes, Indicators and Gauges
injury. Do not allow hot oil or hot components to
contact skin.
- Test
SMCS Code: 4251-081; 4267-081; 7000; 7450-081;
Park the machine on a level surface. Engage the 7490-081
parking brake. Lower the dump body and shut off
the engine. Before you operate the machine, perform the
following checks and make any necessary repairs.
Raise the hood. Refer to Operation and Maintenance
Manual, “Hood Control”. • Look for broken lenses on the gauges, broken
indicator lights, broken switches, and other broken
components in the cab.
Illustration 141
g01694913
• Test the parking brake. Refer to Operation and
Maintenance Manual, “Braking System - Test”.
1. Remove the brake control valve damper (1).
• Stop the engine.
2. Remove the drain plug (2). Allow the oil to drain
into a suitable container.
i03359342 Table 26
Personal injury can result if the machine moves Parking Brake Check
while testing.
The test for the parking brake must be carried out
If the machine begins to move during test, reduce with the rated load in the body.
the engine speed immediately and engage the
parking brake. Test the service brakes and the secondary steering
system on level ground before you carry out this
procedure.
The service brake holding ability test determines
whether the service brake is functional. This test is 1. Drive the machine onto an incline of 15%. The
not intended to measure the maximum brake holding machine must be pointing down the incline.
ability.
2. Engage the service brakes in order to stop
The holding ability of the service brakes at a specific the machine on the incline. The area around
engine rpm will be different for each machine. the machine must be clear of personnel and
obstacles.
The results of the test should be recorded. The
results should be compared to previous test results 3. Move the parking brake control to the ENGAGED
and subsequent test results. Use the comparison as position. Move the transmission control to the N
an indication of system deterioration for a particular position.
machine.
4. Shut off the engine.
1. Before you perform the test, ensure that you can
test the brakes on a surface which is level, dry, 5. Gradually disengage the service brakes.
and clear of obstacles. Fasten your seat belt.
Ensure that the transmission control is in the N 6. If the machine moves forward, engage the service
position and that the parking brake control is in brakes immediately. Start the engine. Disengage
the ENGAGED position. the parking brake and drive the machine onto
level ground. Shut off the engine.
Start the engine and wait until the brake system is
fully charged. 7. Check the thickness of the brake pad linings
and check the thickness of the brake disc. Refer
2. Engage the service brakes. Move the transmission to Specifications, RENR6724, “Parking Brake”.
control to the 1 position. Move the parking brake Replace parts if the specification is not met.
control to the DISENGAGED position.
If the machine moved during the test, the parking
3. Gradually increase the engine speed until the brake requires service.
machine moves forward. Record the engine speed
when the machine moves.
NOTICE
Reduce the engine speed immediately and move If the machine moved while testing the parking brake,
the parking brake control to the ENGAGED inspect the parking brake components for wear or
position. Move the transmission control to the N damage. Repair or replace the worn or damaged park-
position. Shut off the engine. ing brake components as required before returning the
machine to service.
4. The service brakes require service if the machine
moves below the following engine speeds:
136 SEBU7815-10
Maintenance Section
Cab Air Filter - Clean/Replace
NOTICE
An air recirculation filter element plugged with dust will
result in decreased performance and service life to the
air conditioner or cab heater.
i02242083
g01134376
Illustration 143
SEBU7815-10 137
Maintenance Section
Circuit Breakers - Reset
g01130087
Illustration 145
Reset the circuit breaker if a circuit breaker trips. The circuit breakers for the alternator and the battery
Press the button in order to reset the circuit breaker. are located on the front left of the machine under a
If the electrical system is working properly, the button panel on the front fender. Circuit breaker (4) for the
will remain pressed. If the button does not remain battery protects the battery from a dead short. Circuit
pressed or if the circuit breaker trips soon after being breaker (5) for the alternator protects the alternator
reset, check the appropriate electrical circuit. Repair from a power surge. Reset the circuit breaker if the
the electrical circuit, if necessary. circuit breaker trips. Press in the button in order
to reset the circuit. If the button does not remain
Headlamps – 15 amp pressed or if the circuit breaker trips soon after being
reset, check the appropriate electrical circuit. Repair
the electrical circuit, if necessary.
Battery (4)
i02395588 i02576412
S/N: B1P622-Up
Illustration 147
g01196383 Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
The circuit breakers for the alternator and the battery burns.
are located on the front left of the machine under a
panel on the front fender. Circuit breaker (1) for the Cooling System Coolant Additive contains alkali.
battery protects the battery from a dead short. Circuit Avoid contact with skin and eyes.
breaker (2) for the alternator protects the alternator
from a power surge. Reset the circuit breaker if the NOTICE
circuit breaker trips. Press in the button in order Do not change the coolant until you read and under-
to reset the circuit. If the button does not remain stand the cooling system information in Special Pub-
pressed or if the circuit breaker trips soon after being lication, SEBU6250, “Caterpillar Machine Fluids Rec-
reset, check the appropriate electrical circuit. Repair ommendations”.
the electrical circuit, if necessary.
Failure to do so could result in damage to the cooling
Battery (1) system components.
NOTICE
Alternator (2) Mixing Extended Life Coolant (ELC) with other prod-
ucts reduces the effectiveness of the coolant and
shortens coolant life. Use only Caterpillar products
or commercial products that have passed the Cater-
pillar EC-1 specification for premixed or concentrate
coolants. Use only Caterpillar Extender with Cater-
pillar ELC. Failure to follow these recommendations
could result in the damage to cooling systems com-
ponents.
SEBU7815-10 139
Maintenance Section
Cooling System Coolant (ELC) - Change
g01126897
Illustration 148
g01129288
1. Slowly remove the cap in order to gradually relieve Illustration 151
any system pressure.
5. Open vent (5) on the top of the engine.
13. Carefully raise the rear of plate (2). Install the Pressurized system: Hot coolant can cause seri-
two bolts (1) on either side of the plate in order to ous burn. To open cap, stop engine, wait until ra-
secure the plate into position. diator is cool. Then loosen cap slowly to relieve
the pressure.
Note: The weight of plate (2) is 60 kg (132 lb). Use a
suitable jack in order to raise the plate.
Park the machine on a level surface. Ensure that the
parking brake is fully engaged. Lower the dump body
i01865470 and shut off the engine.
Cooling System Coolant
Extender (ELC) - Add
SMCS Code: 1352-544-NL
g01125467
Illustration 153
Check the cooling system level in the coolant tank. Use the following guidelines for proper sampling of
The coolant level should be maintained halfway the coolant:
between the top and the bottom of the transparent
tube of the sight glass on the coolant tank. • Complete the information on the label for the
sampling bottle before you begin to take the
Add coolant, if necessary. Refer to Operation and samples.
Maintenance Manual, “Cooling System Coolant -
Change” for information on adding coolant. • Keep the unused sampling bottles stored in plastic
bags.
i02240137
• Obtain coolant samples directly from the coolant
Cooling System Coolant sample port. You should not obtain the samples
from any other location.
Sample (Level 1) - Obtain
• Keep the lids on empty sampling bottles until you
SMCS Code: 1395-554 are ready to collect the sample.
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.
g01129349 g01126897
Illustration 155 Illustration 156
Obtain the sample of the coolant as close as possible 2. Remove the cap slowly in order to gradually
to the recommended sampling interval. Supplies relieve any system pressure.
for collecting samples can be obtained from your
Caterpillar dealer. 3. Inspect the cap for damage, for foreign material,
and for deposits. If the cap is damaged, replace
Refer to Operation and Maintenance Manual, the cap. If the cap is not damaged, clean the cap
“Cooling System Coolant Sample (Level 1) - Obtain” with a clean cloth.
for the guidelines for proper sampling of the coolant.
4. Install the cap.
Submit the sample for Level 2 analysis.
i02240555
Reference: For additional information about coolant
analysis, refer to Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” or
Crankshaft Vibration Damper
consult your Caterpillar dealer. - Inspect
SMCS Code: 1205-040
i02234884
Cooling System Pressure Cap Park the machine on a level surface. Ensure that the
parking brake is fully engaged. Lower the dump body
- Clean/Replace and shut off the engine. Raise the hood. Refer to
Operation and Maintenance Manual, “Hood Control”.
SMCS Code: 1382-070; 1382-510
g01125939
Illustration 159
7. Remove drain plug (2) and level plug (3) from the
rear axle. Remove the drain plug slowly in order to
gradually release any system pressure. Allow the
oil to drain into a suitable container.
144 SEBU7815-10
Maintenance Section
Differential and Final Drive Oil Level - Check
8. Clean the drain plug and inspect the O-ring seal 18. Operate the machine for a few minutes in order
for damage. Lubricate the O-ring seal with gear oil to circulate the oil.
and install the drain plug.
19. Shut off the engine.
Note: The drain plug is magnetic. Check the plug
for ferrous particles that may indicate wear of the 20. Check the oil level of the differential and final
differential and final drive components. drives. Refer to Operation and Maintenance
Manual, “Differential and Final Drive Oil Level -
9. Start the engine and disengage the parking brake. Check”.
i02582439
g01125942
Illustration 160
11. Remove plug (1) from the front right final drive
and add oil to the final drive. Refer to Operation
and Maintenance Manual, “Capacities (Refill)” and
Operation and Maintenance Manual, “Lubricant
Viscosities”.
g01293542
Fill the final drive to the bottom of the plug hole. Illustration 161
Allow the oil to flow along the axle housing and Typical example
settle at a common level. Some models may have the filler plug toward the right side.
12. Install plug (1). 2. Remove differential filler plug (1) and clean the
area around the opening.
13. Repeat steps 9 through 12 for the rear left final
drive. 3. Check the oil level. Maintain the oil level to the
bottom of the filler plug opening.
14. Remove level plug (3) from the rear axle. Add oil
to the differential until the differential is full. Refer to 4. If necessary, add oil. Install the filler plug.
Operation and Maintenance Manual, “Capacities
(Refill)” and Operation and Maintenance Manual,
“Lubricant Viscosities”.
i02210940
SMCS Code: 3258-008; 4050-008; 7542-008 8. Wipe the area around plug (3) on the rear axle
housing. Remove the plug and the O-ring seal.
Note: Use a sampling gun for obtaining the oil Remove the plug slowly in order to gradually
samples. relieve any system pressure.
10. Clean the plug and check the plug for ferrous
particles that may indicate wear of the differential
and final drive components.
11. Lubricate the O-ring seal with gear oil. Install the
plug and the O-ring seal.
Inspect
1. Place a dial indicator on the drive shaft so that the
vertical end play in the spider can be measured.
If the drive shaft moves more than 0.15 mm
(0.006 inch) of movement relative to the yoke, the
spider needs to be replaced.
g01223034
Illustration 165
WAVS display 2. Place the dial indicator so that the horizontal
end play in the spider can be measured. If the
Use a soft, damp cloth in order to clean the display. spider has more than 0.15 mm (0.006 inch) of
The display has a soft plastic surface that can be movement relative to the yoke, the spider needs
easily damaged by an abrasive material. The display to be replaced.
is not sealed. Do not immerse the display with
liquid. Replace
Camera Do not reuse drive shaft bolts. Always use new drive
shaft bolts when you reassemble the drive shaft.
g01223051
Illustration 166
The WAVS camera is located on the rear of the machine near
the taillights.
g01402610
Illustration 167
Torque sequence Illustration 168
g01129457
1. Use four used bolts as alignment bolts. Install the 2. Remove the air cleaner cover.
used bolts. Tighten the bolts in the pattern that is
shown in Illustration 167. Make sure that the yoke
is fully seated against the spider. Torque the used
bolts to the designed specification.
i02240571
Element - Clean/Replace 3. Primary air filter element (1) fits tightly onto air
cleaner housing (2). Carefully release the seal by
SMCS Code: 1054-070-PY; 1054-510-PY rocking or twisting the primary air filter element
and remove the primary air filter element from the
NOTICE air cleaner housing. Avoid touching the primary
Service the air cleaner only with the engine stopped. air filter element against the sides of the air
Engine damage could result. cleaner housing as this may dislodge dust from
the primary air filter element.
Service the primary air filter element under the 4. Inspect the primary air filter element. If the pleats
following conditions: or the seals are damaged, replace the primary air
filter element.
• The indicator for the air filter is illuminated. Refer to
Operation and Maintenance Manual, “Monitoring
System”.
i01862775
A primary air filter element may be cleaned for a • The indicator for the air filter is illuminated after the
maximum of six times. Replace a primary air filter primary air filter element has been serviced. Refer
element after 1000 hours. to Operation and Maintenance Manual, “Monitoring
System”.
Note: Do not clean the primary air filter element
by bumping or by tapping as this may damage the Park the machine on a level surface. Ensure that the
primary air filter element. parking brake is fully engaged. Lower the dump body
and shut off the engine.
6. Inspect the primary air filter element before
installation. If the pleats, the gaskets, or the 1. Remove the primary air filter element.
seals are damaged, replace the primary air filter
element. Refer to the Operation and Maintenance
Manual, “Engine Air Filter Primary
7. Clean the inside of the air cleaner housing. Element-Clean/Replace”.
11. Start the engine. If the indicator for the air filter
is illuminated, replace the secondary air filter g00775377
Illustration 170
element.
Refer to the Operation and Maintenance Manual, 2. Carefully release the seal by rocking or twisting
“Engine Air Filter Secondary Element - Replace”. secondary air filter element (1). Remove the
secondary air filter element from air cleaner
housing (2).
7. Lower the hood. Refer to Operation and Park the machine on a level surface. Ensure that the
Maintenance Manual, “Hood Control”. parking brake is fully engaged. Lower the dump body
and shut off the engine.
i02240640
1. Raise the hood.
Engine Compression Brake
Refer to Operation and Maintenance Manual ,
Valve Lash - Check “Hood Control”.
SMCS Code: 1119-535
g01129538
NOTICE Illustration 171
Only qualified service personnel should perform this
maintenance. Refer to the Service Manual or your 2. Remove hose (1) from the breather. Remove
Caterpillar Dealer for the complete engine valve lash breather (2).
adjustment procedure.
3. Wash the breather in a clean, nonflammable
solvent. Wipe the breather with a clean, dry cloth.
Note: Stop the engine before you measure the Replace the breather if the breather is damaged.
engine valve lash. Allow the valves to cool for at least
20 minutes. 4. Inspect the breather seal. If necessary, install a
new seal.
Refer to Systems Operation, Testing and Adjusting,
SENR9832, “C15 and C18 Engines For Caterpillar 5. Ensure that the breather is dry.
Built Machines” for valve clearances and procedures
for checking the engine compression brake slave 6. Reposition the breather. Fasten the breather to
cylinder valve lash. the top of the engine. Tighten hose clamp (1) in
order to fasten the hose to the breather.
i02252566 1. Remove oil filler cap (2) and add oil until the oil
level is within the shaded area of the dipstick.
Engine Oil Level - Check
Refer to the Operation and Maintenance Manual,
SMCS Code: 1000-535-FLV “Lubricant Viscocities”. Refer to the Operation and
Maintenance Manual, “Capacities (Refill)”.
2. Clean oil filler cap (2) and install the oil filler cap.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to 3. Lower the hood.
contact skin.
i02248048
NOTICE
Do not under fill or overfill engine crankcase with oil.
Engine Oil Sample - Obtain
Either condition can cause engine damage. SMCS Code: 1000-008; 7542-008
g01131905
Illustration 174
The engine oil level should be checked while the Refer to Special Publication, SEBU6250, “S·O·S Oil
engine is cold and while the engine is not running. Analysis” for information that pertains to obtaining a
sample of the engine oil. Refer to Special Publication,
Check the dipstick (1) for the engine oil level. Maintain PEHP6001, “How to Take a Good Oil Sample” for
the oil level within the shaded area of the dipstick. more information about obtaining a sample of the
engine oil.
g01134248
Illustration 173
i02401395
NOTICE
Engine Oil and Filter - Change The oil drain intervals specified in table 28 are based
on the use of premium diesel engine oils.
SMCS Code: 1318-510
The preferred oil for attaining the specified intervals is
Selection of the Oil Change Interval Cat DEO Multigrade.
Table 28 Program A
735, 740 and 740E Articulated Trucks
Oil Change Interval (1) Verification for an Oil Change Interval of 500 Hours
Park the machine on a level surface. Ensure that the 3. Clean the oil drain valve and close the oil drain
parking brake is fully engaged. Lower the body and valve.
shut off the engine.
4. Clean the oil drain valve plug and install the oil
Note: Drain the crankcase while the oil is warm and drain valve plug.
while the oil is well circulated. This ensures that
waste particles will be suspended in the oil and that 5. Raise the hood. Refer to Operation and
these particles will be removed as the oil is drained. Maintenance Manual, “Hood Control”.
g01131820
g01019358 Illustration 177
Illustration 175
Instructions for the installation of the filter are 16. Carefully raise the rear of plate (2). Install one
printed on the side of each Caterpillar spin-on bolt (1) and the washer on either side of plate (2)
filter. For non-Caterpillar filters, refer to the in order to secure the plate into position.
installation instructions that are provided by the
supplier of the filter.
i02680477
NOTICE
Illustration 179
g00796357 Operation of Caterpillar Engines with improper engine
valve lash adjustments will reduce the engine efficien-
11. Remove dipstick (7) and then clean the dipstick. cy. This reduced efficiency could result in excessive
Reinstall the dipstick. fuel usage and/or shortened engine component life.
12. Remove the dipstick and check the oil level. Measure the engine valve lash with the engine
Maintain the oil level within the shaded area. If stopped. To obtain an accurate measurement, allow
necessary, add oil. at least 20 minutes for the valves to cool to engine
cylinder head and block temperature.
13. Install the oil filler cap.
14. Start the engine and allow the oil to warm. Check
the engine for leaks.
i00128925 i02252582
2. Watch the top surface of each valve rotator. When The interval between these inspections depends on
the intake valve or the exhaust valve closes, the the following factors:
engine valve rotator should turn slightly.
• The age of the machine
If an intake valve or an exhaust valve fails to rotate,
consult your Caterpillar Dealer. • The severity of the application
i01509524
• The loads that have been carried in the machine
2. Raise the hood. Refer to Operation and If the machine has been involved in a collision, or
Maintenance Manual, “Hood Control”. The ether if the machine has been involved in any kind of
starting aid cylinder is located on the left side of accident, the machine must be inspected thoroughly.
the engine near the air filter for the engine. Inspect the machine regardless of the date of the last
inspection.
3. Loosen the cylinder retaining clamp. Unscrew and
discard the empty ether starting aid cylinder. The machine must be clean before the machine is
inspected.
4. Remove the gasket. Install a new gasket. A new
gasket is provided with each new ether starting Proper repair of frames and structures requires
aid cylinder. specific knowledge of the following subjects:
5. Install a new ether starting aid cylinder. Tighten • Materials that have been used to manufacture the
the ether starting aid cylinder hand tight. Tighten frame members
the cylinder retaining clamp securely.
• Frame member construction
6. Lower the hood.
• Repair techniques that are recommended by the
manufacturer
All repairs should be carried out by a Caterpillar • Rear subassembly and hitch lugs (6)
dealer. If you carry out your own repairs, contact
your Caterpillar dealer for advice about proper repair • Radiator Mounts (7)
techniques.
• ATAAC Mounts (8)
Particular attention should be given to all welded
structures. The following items should be thoroughly Front Suspension A-Frame
inspected for cracks and for defects:
• Front frame
• Front suspension a-frame
• Rear frame
• Oscillating hitch
• Body
NOTICE
The areas highlighted are of particular importance but
other areas must not be neglected. The entire struc-
g01134326
ture must be carefully examined. Illustration 181
Oscillating Hitch
g01134271
Illustration 180
g01134329
Illustration 182
Inspect the following areas:
Inspect the entire oscillating hitch and pay particular
• Front engine mountings (1) attention to the following areas:
g00954460
Illustration 185
Inspect the following areas: Note: Inspect the mounts for the suspension after
the initial 2000 service hours and every 250 service
• Mountings for dump body (15) hours thereafter.
• Stops (16)
i02879830
Inspect the following areas: Prime the fuel system in order to fill the fuel filter with
fuel. It is necessary to prime the fuel system after the
fuel filters have been changed.
• The mountings (22) for the hoist cylinders
158 SEBU7815-10
Maintenance Section
Fuel System - Prime
Park the machine on a level surface and engage 7. Start the engine. If the engine starts but the engine
the parking brake. Lower the dump body and stop runs rough, continue to run the engine at low
the engine. idle until the engine runs smoothly. If the engine
will not start after several attempts, consult your
Raise the hood. Refer to Operation and Maintenance Caterpillar dealer.
Manual, “Hood Control”.
Type 2
Type 1
g01436644
Illustration 186
5. Continue to operate the priming pump in order Note: The engine start switch must be in the OFF
to build fuel pressure. This will create resistance position in order to prime the fuel system.
in the plunger. Operate the priming pump until
resistance is felt. 1. Open purge screw (4).
Note: Resistance will not be felt until the purge screw 2. Hold switch (3) upward in order to operate the
has been tightened. electric fuel priming pump. This will fill the engine
fuel lines and the fuel filters with fuel.
6. Push in the plunger. Turn the plunger clockwise in
order to lock the plunger.
SEBU7815-10 159
Maintenance Section
Fuel System Primary Filter - Clean/Inspect/Replace
Note: The priming pump will not come under load g01293871
until the purge screw has been tightened. Illustration 188
6. Start the engine. If the engine starts but the engine 4. Insert drain hose (2) into a suitable container.
runs rough, continue to run the engine at low Open valve (1) in order to drain the fuel from the
idle until the engine runs smoothly. If the engine filter. Close the valve.
will not start after several attempts, consult your
Caterpillar dealer.
i02583130
NOTICE
Do not fill fuel filter with fuel before installing the fuel
filter. Contaminated fuel causes accelerated wear to
fuel system parts. Illustration 189
g01293878
1. Park the machine on a level surface. Ensure that Note: The filter element has indicator marks at every
the parking brake is fully engaged. Lower the 90 degrees.
dump body and stop the engine.
11. Ensure that the end of the drain hose is attached
2. Raise the hood. Refer to Operation and to clip (6).
Maintenance Manual, “Hood Control”.
12. Prime the fuel system.
3. Clean the outside of the primary fuel filter element.
160 SEBU7815-10
Maintenance Section
Fuel System Secondary Filter - Replace
i02241230
NOTICE 5. Coat the seal for the new secondary fuel filter with
Care must be taken to ensure that fluids are contained clean diesel fuel prior to installation.
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to 6. Install the new secondary fuel filter by hand. Do
collect the fluid with suitable containers before open- not use a tool for installation of the secondary
ing any compartment or disassembling any compo- fuel filter. When the new filter base gasket
nent containing fluids. contacts the fuel filter base, tighten the secondary
fuel filter by an additional 270°.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies Note: The secondary fuel filter has indicator marks at
suitable to collect and contain fluids on Caterpillar every 90 degrees.
products.
7. Prime the fuel system.
Dispose of all fluids according to local regulations and
mandates. Refer to the Operation and Maintenance Manual,
“Fuel System - Prime”.
Note: Before you replace the secondary fuel filter, 8. Start the engine and check for leaks.
the primary fuel filter must be replaced. Refer to the
Operation and Maintenance Manual, “Fuel System 9. Lower the hood.
Primary Filter - Clean/Inspect/Replace”.
i02589433 i02252835
g01296435
Illustration 191
6. Allow the fuel strainer and the fuel tank cap to dry.
8. Reinstall the fuel tank cap. 1. Remove the fuel tank cap.
Fuel Tank Water and Sediment 2. Open purge screw (1) until fluid and sediment
starts to flow from the drain hole.
- Drain
3. Allow the fluid and sediment to flow into a suitable
SMCS Code: 1273-543-M&S container.
NOTICE 4. When the flow from the fuel tank is free of water
Care must be taken to ensure that fluids are contained and sediment, close the purge screw.
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
i02242140
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- Fuses - Replace
nent containing fluids.
SMCS Code: 1417-510
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies S/N: B1N1-320
suitable to collect and contain fluids on Caterpillar
products. S/N: B1P1-621
Do not fill the tank to the top. Fuel expands as it gets The fuses protect the electrical system from damage,
warm and may overflow. which can be caused by an electrical overload. If
the wire within a particular fuse separates due to an
electrical overload, the circuit will be broken. If the
Park the machine on a level surface. Ensure that the wire separates, replace the fuse.
parking brake is fully engaged. Lower the dump body
and shut off the engine.
Drain water and sediment from the fuel tank after the
fuel tank has been filled. Allow the machine to stand
for ten minutes before draining the fuel tank.
g01130118
Illustration 195
Fuses - Replace
SMCS Code: 1417-510
S/N: B1N321-Up
Heated Mirror and Differential Lock – 10
amp S/N: B1P622-Up
NOTICE
Replace fuses with the same type and size only. Oth-
erwise, electrical damage can result.
Horn – 10 amp
g01188010
Illustration 196
164 SEBU7815-10
Maintenance Section
Fuses - Replace
Horn – 10 amp
Headlights – 15 amp
A4 Actual Gear Switch with Key in ON
position – 7.5 amp
g00777923
Illustration 199
g00775136
Illustration 197
2. The breather is located on the top of the tank for
2. Lubricate the lower hoist cylinder bearings through the hoist and brake system oil. The tank for the
fitting (1) on each side of the machine. hoist and brake system oil is on the left side of the
machine. Release two latches (1) and lift cover
Note: In order to ensure proper lubrication of the plate (2) in order to access the top of the tank.
lower hoist cylinder bearings, raise the body and
install the body prop.
166 SEBU7815-10
Maintenance Section
Hoist System and Brake System Oil - Change
g00777924 g00778789
Illustration 200 Illustration 201
3. Remove filler cap (3) slowly in order to gradually 2. The tank is located on the left side of the machine
relieve any system pressure. under cover plate (2). Release two latches (1) and
lift cover plate (2) in order to access the top of the
4. Unscrew breather (4) and remove the breather tank.
from the machine.
i02253076
6. Fill the tank with new oil through the filler tube. NOTICE
Care must be taken to ensure that fluids are contained
Refer to Operation and Maintenance Manual, during performance of inspection, maintenance, test-
“Lubricant Viscocities” and Operation and ing, adjusting and repair of the product. Be prepared to
Maintenance Manual, “Capacities (Refill)”. collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
7. Start the engine and run the engine at low idle. nent containing fluids.
8. Check that there is adequate vertical clearance. Refer to Special Publication, NENG2500, “Caterpillar
Raise the dump body and lower the dump body. Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
9. Stop the engine. products.
10. Check the oil level. Add oil, if necessary. Dispose of all fluids according to local regulations and
mandates.
Refer to Operation and Maintenance Manual,
“Hoist System and Brake System Oil Level -
1. Park the machine on a level surface. Ensure that
Check”.
the parking brake is fully engaged. Lower the
dump body and shut off the engine. Allow the oil
11. Check the filler cap and the seal for damage.
to fully cool.
Replace any damaged components. Install the
filler cap.
12. Lower cover plate (2) and tighten two latches (1).
g00777923
Illustration 204
g00778263 g00686999
Illustration 205 Illustration 207
3. Remove filler cap (3) slowly in order to gradually 6. There are three filter elements (8) within screen
relieve any system pressure. (9). Remove the three filter elements and discard
the filter elements.
4. Unscrew bolt (4) and lift cover (5). The screen
assembly is fastened to the cover. 7. Wash the screen in clean nonflammable solvent.
Inspect the screen for damage. If necessary,
replace the screen. Allow the screen to dry.
11. Lower cover plate (2) and tighten two latches (1).
i02755857
g00949982
Illustration 210
g00778731
Illustration 208
The sampling valve for the hoist system and brake
system oil is located on the top of the tank. The tank
3. Sight glass (1) is located within panel (2) on the for the hoist system and brake system oil is located
left side of the machine. Check the oil level in on the left side of the machine.
sight glass (1).
Refer to Special Publication, SEBU6250, “S·O·S Oil
Analysis” for information that pertains to obtaining
a sample of the oil. Refer to Special Publication,
PEHP6001, “How To Take A Good Oil Sample” for
more information about obtaining a sample of the oil.
i01500832
Illustration 209
g00777514 NOTICE
Care must be taken to ensure that fluids are contained
The above photograph shows a typical installation.
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
4. When the oil is at operating temperature, oil must collect the fluid with suitable containers before open-
be above the lowest level mark (4) on the sight ing any compartment or disassembling any compo-
glass. Ensure that the oil remains above this level. nent containing fluids.
If necessary, add oil through the oil filler tube. Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies
Refer to Operation and Maintenance Manual, suitable to collect and contain fluids on Caterpillar
“Steering System Oil - Change” and Operation products.
and Maintenance Manual, “Lubricant Viscocities”.
Dispose of all fluids according to local regulations and
mandates.
i02264158
Illustration 211
g00777923 Adjusting Hitch Pin Clearance
1. To relieve the downward force, position a hydraulic
2. The strainer is located inside the filler tube on the
jack under the tractor portion of the hitch and
tank for the hoist system and the brake system oil.
slightly raise the hitch.
The tank is located on the left side of the machine.
Release two latches (1) and lift cover plate (2) in
order to access the top of the tank.
g00784811
Illustration 213
5. Wash the strainer in nonflammable solvent. Allow Adjusting the Thrust Plate
the strainer to dry before the strainer is reinstalled.
10. Lower cover plate (2) and tighten two latches (1).
g00784812
Illustration 214
SEBU7815-10 171
Maintenance Section
Oscillating Hitch - Lubricate
1. Remove three bolts (3) and remove locking plate Park the machine on a level surface. Ensure that the
(4). parking brake is fully engaged. Lower the dump body
and stop the engine.
i01523697
i02206939 i01836475
Personal injury can result from air pressure. Personal injury can result from contact with refrig-
erant.
Personal injury can result without following prop-
er procedure. When using pressure air, wear a pro- Contact with refrigerant can cause frost bite. Keep
tective face shield and protective clothing. face and hands away to help prevent injury.
Maximum air pressure at the nozzle must be less Protective goggles must always be worn when re-
than 205 kPa (30 psi) for cleaning purposes. frigerant lines are opened, even if the gauges in-
dicate the system is empty of refrigerant.
g00737759
Illustration 219
g00784814
i01512259 Illustration 221
Rollover Protective Structure ROPS mounting (4) on the front left of the cab.
(ROPS) - Inspect
SMCS Code: 7323-040; 7325-040
NOTICE
Do not attempt to straighten the ROPS structure. Do
not repair the ROPS by welding reinforcement plates
to the structure.
g00784815
Illustration 222
ROPS mounting (5) on the front right of the cab.
g00738669
Illustration 220
Carry out the following steps in order to inspect the Illustration 223
g00784816
ROPS: ROPS mounting (6) on the left side rear of the cab.
g00784817 g00932801
Illustration 224 Illustration 225
ROPS mounting (7) on the right side rear of the cab. Typical example
4. Inspect the following items: mounting bolts (1), Check the seat belt mounting hardware (1) for wear
pins (2), and rubber mounts (3). Replace any or for damage. Replace any mounting hardware that
damaged pins, bolts or rubber mounts with original is worn or damaged. Make sure that the mounting
equipment parts. bolts are tight.
5. Inspect the ROPS for bolts that are loose or Check buckle (2) for wear or for damage. If the buckle
damaged. Bolts that are loose, damaged or is worn or damaged, replace the seat belt.
missing should be replaced by original equipment
parts only. Inspect the seat belt (3) for webbing that is worn or
frayed. Replace the seat belt if the seat belt is worn
6. Ensure that bolts (1) are tightened to a torque of or frayed.
775 N·m (572 lb ft).
Consult your Caterpillar dealer for the replacement of
7. Close the hood. Refer to Operation and the seat belt and the mounting hardware.
Maintenance Manual, “Hood Control”.
Note: Within three years of the date of installation or
8. Remove the steering frame lock. Refer to within five years of the date of manufacture, replace
Operation and Maintenance Manual , “Steering the seat belt. Replace the seat belt at the date which
Frame Lock”. 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.
i02429589
Always check the condition of the seat belt and the i02429594
condition of the seat belt mounting hardware before
you operate the machine. Replace any parts that are Seat Belt - Replace
damaged or worn before you operate the machine.
SMCS Code: 7327-510
NOTICE
Check that the lines attached to all the remote grease
fittings are undamaged. If the grease lines are split,
grease will not reach the components that require lu-
bricating. Machine damage will result.
g01134606
Illustration 228
g00777478
Illustration 231
g01134607
Illustration 229
g00777491
Illustration 232
i01862859
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.
g00777480
Illustration 235
6. Fill the tank with new oil through the filler tube.
9. Check that there is adequate sideways clearance. 2. The oil filter elements and the screen are located
Steer the machine fully to the left and steer the inside the tank for the steering system. The tank is
machine fully to the right. located on the right side of the machine. Release
latch (1) and lift cover plate (2) in order to access
10. Stop the engine. the top of the tank.
i01499078
g00686996
Illustration 238
5. Remove cotter pin (6) and washer (7) from bolt (4).
This will allow the removal of the filter elements
from inside of the screen.
g00777478
Illustration 236
SEBU7815-10 179
Maintenance Section
Steering System Oil Level - Check
2. Shut off the engine and allow the level of the oil
to stabilize.
g00686999
Illustration 239
i01956203
i01865408
g00777478
Illustration 243
i01499079
Dispose of all fluids according to local regulations and 9. Install the filler cap.
mandates.
10. Lower cover plate (2) and tighten latch (1).
1. Park the machine on a level surface. Ensure that
the parking brake is fully engaged. Lower the
dump body and shut off the engine.
SEBU7815-10 181
Maintenance Section
Suspension System - Check
i02021470 i02253122
NOTICE
The suspension system may drop the machine
Check that the lines attached to all the remote grease
suddenly leaving no clearance between the axle
fittings are undamaged. If the grease lines are split,
housing, main frame, tires, and mud guards.
grease will not reach the components that require lu-
bricating. Machine damage will result.
Working in these areas can result in personal in-
jury or death by crushing.
Park the machine on a level surface. Engage the
Park the machine on level ground and block the parking brake. Lower the dump body and shut off
front frame before you go under the machine. the engine. Install the steering frame lock. Refer
to Operation and Maintenance Manual, “Steering
Frame Lock”.
1. Disengage the differential locks. Bring the
machine to a gentle stop on firm level ground.
If regular lubrication is performed at the recommended
intervals, only one or two shots of grease will be
2. Release the service brake. Wait for one second
required at each fitting.
before applying the parking brake.
Note: The fittings for lubrication of the front
3. Install suitable stands under the front frame.
suspension cylinders are located on the rear supports
for the fenders on the tractor.
g01043895
Illustration 245
Note: Measure distance (A) when the machine is 2. Lubricate the left front suspension cylinder
cool. bearings through fittings (1).
i03747942
g02023156
Illustration 249
i00062438
g00103147
Illustration 250
i02527691
Screen - Clean
2. Support plate (1) and remove the bolts from each
SMCS Code: 3101-070-Z3 side of the plate. Carefully lower the front of the
plate in order to access the transmission.
S/N: B1P1-Up
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- g01264589
Illustration 252
nent containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar 3. Remove cover (2). The screen is located behind
Dealer Service Tool Catalog” for tools and supplies the cover.
suitable to collect and contain fluids on Caterpillar
products. Note: A face seal and a wave washer are located
between the cover and the transmission housing.
Dispose of all fluids according to local regulations and
mandates. 4. Remove the screen and clean all the components
that were removed in clean, nonflammable
solvent. Replace any damaged components.
The screen is serviced at the same maintenance
interval as the oil change for the transmission and 5. Lubricate the seals with the oil that is being sealed
the torque converter. Clean the screen when the and then install the screen.
oil has been drained from the torque converter and
the transmission. Fill the torque converter and the 6. Install cover (2).
transmission with oil once the screen has been
installed. 7. Raise the front of plate (1) and secure the plate.
i02241714 3. Clean the area around filler cap (1) and filler tube
(2). Turn the handle on the dipstick in order to
Torque Converter and remove the dipstick. Remove the dipstick in order
Transmission Oil - Change to allow the oil to drain.
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.
2. The oil level dipstick is integral with the oil filler 5. Clean the area around drain plug (5).
cap for the torque converter and transmission oil.
The oil filler cap is located on the right side of the Note: Flange (6) is used for the ecology drain.
machine in front of the cab.
6. Remove the magnetic drain plug and the O-ring
seal. Allow the oil to drain into a suitable container.
Retain the magnetic drain plug and inspect the
magnetic drain plug for ferrous particles. Retain
the O-ring seal.
g01134736
Illustration 253
SEBU7815-10 185
Maintenance Section
Torque Converter and Transmission Oil - Change
8. Remove the oil filter for the torque converter and i02253241
transmission oil. Inspect the oil filter and discard
the oil filter. Refer to Operation and Maintenance Torque Converter and
Manual, “Oil Filter - Inspect”. Install a new oil filter.
Refer to Operation and Maintenance Manual,
Transmission Oil - Change
“Torque Converter and Transmission Oil Filter - SMCS Code: 3030-044-OC; 3101-044-OC
Replace”.
S/N: B1N880-Up
9. Fill the transmission with new oil through filler
tube (2). Fill the transmission to the “COLD S/N: B1P1-Up
SAFE START” range on the oil level dipstick.
Refer to the Operation and Maintenance Manual,
“Capacities (Refill)”, Operation and Maintenance
Manual, “Lubricant Viscosities” and Operation Hot oil and hot components can cause personal
and Maintenance Manual, “Torque Converter and injury. Do not allow hot oil or hot components to
Transmission Oil Level - Check”. contact skin.
10. Guide the dipstick down the filler tube and turn
the handle on the dipstick in order to make the NOTICE
seal between the filler tube and the filler cap. Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
11. Start the engine. Run the engine at low idle. ing, adjusting and repair of the product. Be prepared to
Inspect the transmission for leaks. collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
12. Shut off the engine. nent containing fluids.
13. Carefully raise plate (4) with a suitable hydraulic Refer to Special Publication, NENG2500, “Caterpillar
floor jack. Secure the plate in position with bolts Tools and Shop Products Guide” for tools and supplies
(3). suitable to collect and contain fluids on Caterpillar
products.
14. Remove the dipstick.
Dispose of all fluids according to local regulations and
15. Clean the dipstick by wiping. mandates.
9. Guide the dipstick down the filler tube and turn the
handle on the dipstick in order to make the seal
between the filler tube and the filler cap.
4. Clean the area around drain plug (5). 20. Raise the hood.
i02253217
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.
5. Fit a new oil filter. Fit the washer and the nut in
order to secure the oil filter to the transmission.
188 SEBU7815-10
Maintenance Section
Torque Converter and Transmission Oil Filter - 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.
Dispose of all fluids according to local regulations and 4. Remove element (4) from transmission oil filter
mandates. housing (2). Discard the used element.
i01863152 3. Wipe oil filler cap (1) and oil filler tube (2).
Torque Converter and Note: The oil level dipstick is integral with the oil filler
Transmission Oil Level - cap for the transmission oil. Oil filler tube (2) for the
torque converter and transmission oil is located on
Check the right side of the machine.
SMCS Code: 3030-535-FLV; 3101-535-FLV 4. Turn the handle on the oil level dipstick in order to
remove the dipstick. Remove the oil level dipstick.
S/N: B1N1-879
5. Clean the dipstick by wiping with a clean cloth.
NOTICE
Care must be taken to ensure that fluids are contained 6. Install the dipstick fully.
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to 7. Remove the dipstick.
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
9. Guide the dipstick down the filler tube and turn the i02253575
handle on the dipstick in order to make the seal
between the filler tube and the filler cap. Torque Converter and
10. Lower the hood.
Transmission Oil Level -
Check
11. Start the engine. Operate the machine until the
temperature of the oil is at normal operating SMCS Code: 3030-535-FLV; 3101-535-FLV
temperature.
S/N: B1N880-Up
12. Park the machine on a level surface. Engage the S/N: B1P1-Up
parking brake. Allow the engine to operate at low
idle.
NOTICE
13. Raise the hood. Refer to Operation and Care must be taken to ensure that fluids are contained
Maintenance Manual, “Hood Control”. Turn the during performance of inspection, maintenance, test-
handle on the dipstick in order to remove the ing, adjusting and repair of the product. Be prepared to
dipstick. The portion of the oil level dipstick that is collect the fluid with suitable containers before open-
marked “HOT LOW IDLE” indicates the correct ing any compartment or disassembling any compo-
transmission oil level. Refer to illustration 264. nent containing fluids.
14. Clean the dipstick by wiping. Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies
15. Install the dipstick fully. suitable to collect and contain fluids on Caterpillar
products.
16. Remove the dipstick and check the oil level.
Dispose of all fluids according to local regulations and
17. Check the oil level on the “HOT LOW IDLE” mandates.
portion of the dipstick. Maintain the oil level within
the shaded area on the dipstick. If necessary, add The oil level should be checked before starting the
oil through filler tube (2). Refer to Operation and engine.
Maintenance Manual, “Lubricant Viscosities” and
Operation and Maintenance Manual, “Capacities 1. Park the machine on a level surface. Engage the
(Refill)”. parking brake and lower the dump body.
18. Guide the dipstick down the filler tube and turn 2. Raise the hood. Refer to Operation and
the handle of the dipstick in order to make the seal Maintenance Manual, “Hood Control”.
between the filler tube and the filler cap.
g01134715
Illustration 265
3. Wipe oil filler cap (1) and oil filler tube (2).
Note: The oil level dipstick is integral with the oil filler
cap for the transmission oil. Oil filler tube (2) for the
torque converter and transmission oil is located on
the left side of the machine near the air cleaner.
SEBU7815-10 191
Maintenance Section
Torque Converter and Transmission Oil Sample - Obtain
4. Turn the handle on the oil level dipstick in order to 16. Remove the dipstick and check the oil level.
remove the dipstick. Remove the oil level dipstick.
17. Check the oil level on the “HOT LOW IDLE”
5. Clean the dipstick by wiping with a clean cloth. portion of the dipstick. Maintain the oil level within
the shaded area on the dipstick. If necessary, add
6. Install the dipstick fully. oil through filler tube (2). Refer to Operation and
Maintenance Manual, “Lubricant Viscosities”.
7. Remove the dipstick.
18. Guide the dipstick down the filler tube and turn
the handle of the dipstick in order to make the seal
between the filler tube and the filler cap.
i02253577
9. Guide the dipstick down the filler tube and turn the
handle on the dipstick in order to make the seal
g01134963
between the filler tube and the filler cap. Illustration 267
10. Lower the hood. The sampling valve for the transmission oil is located
on the right side of the transmission.
11. Start the engine. Operate the machine until the
temperature of the oil is at normal operating Refer to Operation and Maintenance Manual,
temperature. SEBU6250, “S·O·S Oil Analysis” for information that
pertains to obtaining a sample of oil. Refer to Special
12. Park the machine on a level surface. Engage the Publication, PEHP6001, “How To Take A Good Oil
parking brake. Allow the engine to operate at low Sample” for more information about obtaining a
idle. sample of oil.
i01865427 i02655713
g00950127
Illustration 268 Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
The sampling valve for the torque converter and the contact skin.
transmission oil is located on the transmission oil
filter housing. The transmission oil filter housing is
located on the right side of the engine. Operate the machine until the oil is warm and the oil is
well circulated. Park the machine on a level surface.
Refer to Special Publication, SEBU6250, “S·O·S Oil Ensure that the parking brake is fully engaged. Lower
Analysis” for information that pertains to obtaining a the dump body and shut off the engine.
sample of the engine oil. Refer to Special Publication,
PEHP6001, “How To Take A Good Oil Sample” for Type 1
more information about obtaining a sample of the
engine oil.
g00773892
Illustration 269
Type 2
g01016190
Illustration 270
g00773892
Illustration 272
3. Clean oil filler tube (3) and oil level gauge (2).
Drain plug (1) for the transfer gear is located on the
4. Remove oil level gauge (2). Add the oil for the bottom of the transfer gear case.
transfer gear.
1. Remove the drain plug and allow the oil to drain
Refer to Operation and Maintenance Manual, into a suitable container.
“Capacities (Refill)” and refer to Operation and
Maintenance Manual, “Lubricant Viscosities”. 2. Clean the drain plug and install the drain plug.
5. Install the oil level gauge.
6. Remove oil level gauge (2) and clean the oil level
gauge. Install the oil level gauge.
g01016190
Illustration 273
3. Clean oil filler tube (3) and oil level gauge (2).
g00789452
4. Remove oil level gauge (2). Add the oil for the
Illustration 271 transfer gear.
7. Remove the oil level gauge and check the oil level Refer to Operation and Maintenance Manual,
on the oil level gauge. Add oil until the oil level “Capacities (Refill)” and refer to Operation and
is within the shaded area on the oil level gauge. Maintenance Manual, “Lubricant Viscosities”.
Add oil, if necessary. Refer to Operation and
Maintenance Manual, “Transfer Gear Oil Level - 5. Install the oil level gauge.
Check”.
6. Remove oil level gauge (2) and clean the oil level
8. Clean the oil level gauge and install the oil level gauge. Install the oil level gauge.
gauge.
Operate the machine until the oil is warm and the oil is
well circulated. Park the machine on a level surface.
Ensure that the parking brake is fully engaged. Lower
the dump body and shut off the engine.
Type 1
g01333997
Illustration 274
7. Remove the oil level gauge and check the oil level
on the oil level gauge. Add oil until the oil level
is within the shaded area on the oil level gauge.
Add oil, if necessary. Refer to Operation and
Maintenance Manual, “Transfer Gear Oil Level - g01266105
Check”. Illustration 275
8. Clean the oil level gauge and install the oil level Drain plug (1) for the transfer gear is located on the
gauge. bottom of the transfer gear case.
9. Clean up oil spills. 1. Remove the drain plug and allow the oil to drain
into a suitable container.
i02530832 2. Clean the drain plug and install the drain plug.
Transfer Gear Oil - Change
SMCS Code: 3159-044-OC
S/N: B1N880-Up
S/N: B1P1-Up
g00789454
Illustration 276
NOTICE
Care must be taken to ensure that fluids are contained
3. Clean oil filler tube (2) and oil level gauge tube (5).
during performance of inspection, maintenance, test-
Clean oil filler cap (3) and oil level gauge cap (4).
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
4. Oil filler cap (3) for the transfer gear is located in
ing any compartment or disassembling any compo-
front of the upper pin for the oscillating hitch. Oil
nent containing fluids.
level gauge (4) is located on the left of the filler
tube.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
5. Unscrew and remove oil filler cap (3). Add the oil
suitable to collect and contain fluids on Caterpillar
for the transfer gear.
products.
Refer to Operation and Maintenance Manual,
Dispose of all fluids according to local regulations and
“Capacities (Refill)” and refer to Operation and
mandates.
Maintenance Manual, “ Lubricant Viscosities”.
SEBU7815-10 195
Maintenance Section
Transfer Gear Oil - Change
7. Remove oil level gauge (4) and clean the oil level
gauge. Install the oil level gauge.
g01266115
Illustration 279
3. Clean oil filler tube (3) and oil level gauge tube (5).
Clean oil filler cap (2) and oil level gauge cap (4).
g00789452
Illustration 277
4. Oil filler cap (2) for the transfer gear is located in
8. Remove the oil level gauge and check the oil level front of the upper pin for the oscillating hitch. Oil
on the oil level gauge. Maintain the oil level within level gauge (4) is located on the left of the filler
the shaded area on the oil level gauge. Add oil, if tube.
necessary. Refer to Operation and Maintenance
Manual, “Transfer Gear Oil Level - Check”. 5. Unscrew and remove oil filler cap (2). Add the oil
for the transfer gear.
9. Clean the oil level gauge and install the oil level
gauge. Refer to Operation and Maintenance Manual,
“Capacities (Refill)” and refer to Operation and
10. Clean up oil spills. Maintenance Manual, “ Lubricant Viscosities”.
8. Remove oil level gauge (4) and clean the oil level
gauge. Install the oil level gauge.
g01266105
Illustration 278
10. Clean the oil level gauge and install the oil level 3. Remove hydraulic filter element (1) with a strap
gauge. type wrench. Discard the hydraulic filter element
properly.
11. Clean up oil spills.
4. Lubricate the seal on the new hydraulic filter
element with the oil that is being sealed.
i01516324
Transfer Gear Oil Filter - 5. Install the new hydraulic filter element and hand
tighten.
Replace
6. Start the engine and check for leaks from around
SMCS Code: 3159-510-FI the hydraulic filter element.
Type 1
Checking the Oil Level in the Transfer
Gear with Cold Oil
Check the oil level before the engine is started.
Illustration 282
g01016211 Install the steering frame locks. Refer to Operation
and Maintenance Manual, “Steering Frame Lock”.
2. The oil level gauge is located in front of the upper
pin for the oscillating hitch. Wipe oil level gauge 2. Start the engine and run the engine at low idle.
(1) and oil filler tube (2).
g01016211
Illustration 284
9. Install the oil level gauge into the oil level gauge
tube.
198 SEBU7815-10
Maintenance Section
Transfer Gear Oil Level - Check
g01016225 g01291313
Illustration 285 Illustration 286
Note: The oil level gauge is marked: “LOW 2L” (6) 2. The oil level gauge is located in front of the upper
and “MAX HOT LI” (5). pin for the oscillating hitch. Wipe oil level gauge
(1) and oil filler tube (2).
8. Check the oil on the oil level gauge.
3. Turn the handle on the oil level gauge in order to
9. If necessary, add oil through oil filler tube (2) remove the oil level gauge. Remove the oil level
until the level is on the shaded area of the oil gauge.
level gauge. Refer to Operation and Maintenance
Manual, “Lubricant Viscosities”. The refill 4. Clean the oil level gauge by wiping.
capacity that is maintained by this oil level
gauge is 24 L (6.34 US gal). 5. Install the oil level gauge fully.
Note: Do not overfill the output transfer gear 6. Remove the oil level gauge.
housing.
10. Install the oil level gauge into the oil level gauge
tube.
Type 2
Checking Oil Level in the Transfer Gear
Before Starting the Machine
Check the oil level before the engine is started.
9. Install the oil level gauge into the oil filler tube.
10. Install the oil level gauge into the oil level gauge
tube.
g01291313
Illustration 288
i02531081
3. The oil level gauge is located in front of the upper
pin for the oscillating hitch. Wipe oil level gauge
(1) and filler tube (2).
Transfer Gear Oil Level - Check
SMCS Code: 3159-535-FLV; 3159-535-OC
4. Turn the handle on the oil level gauge in order to
remove the oil level gauge. Remove the oil level S/N: B1N880-Up
gauge.
S/N: B1P1-Up
5. Clean the oil level gauge by wiping.
NOTICE
6. Install the oil level gauge fully. Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
7. Remove the oil level gauge. 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.
Type 1
Checking the Oil Level in the Transfer
Gear with Cold Oil
Check the oil level before the engine is started.
9. Install the oil level gauge into the oil level gauge
tube.
g00789543
1. Park the machine on a level surface. The parking
Illustration 290 brake must be engaged and the dump body must
be lowered. Stop the engine.
2. The oil level gauge is located in front of the upper
pin for the oscillating hitch. Wipe oil level gauge Install the steering frame locks. Refer to Operation
(1) and oil level gauge tube (2). and Maintenance Manual, “Steering Frame Lock”.
3. Turn the handle on the oil level gauge in order to 2. Start the engine and run the engine at low idle.
remove the oil level gauge. Remove the oil level
gauge.
g00789543
Illustration 292
SEBU7815-10 201
Maintenance Section
Transfer Gear Oil Level - Check
g01266304
Illustration 294
5. Remove oil level gauge (2) and clean the oil level
gauge.
Illustration 293
g00842888 7. Remove the oil level gauge.
10. Install the oil level gauge into the oil level gauge g01266148
tube. Illustration 295
i01865431
g00873494
Illustration 297
g00950258
Illustration 296
Transmission and Transfer 3. Loosen clamps (3) and remove breather (4) and
Gear Breather - Replace breather (5).
SMCS Code: 3030-510-BRE; 3159-510-BRE Note: The breathers for the transmission and the
transfer gear are sealed units and the breathers
The breathers for the transfer gear and the cannot be cleaned.
transmission are located to the rear of the cab on the
left side of the machine. 4. Install the new breathers and tighten clamps (3).
1. Install the steering frame lock. Refer to Operation 5. Replace the cover and remove the steering frame
and Maintenance Manual, “Steering Frame Lock”. lock.
i02889528
i01496481
Window Wiper -
Inspect/Replace
SMCS Code: 7305-040; 7305-510
g01125960
Park the machine on a level surface. Engage the
Illustration 299 parking brake. Lower the dump body and shut off
the engine.
Tighten the wheel nuts to a torque of 475 ± 60 N·m
(350 ± 44 lb ft).
i01492999
NOTICE
When operating in freezing temperatures, use
Caterpillar or any commercially available nonfreezing
window washer solvent.
g00776803
Illustration 301
i01495125
Windows - Clean
SMCS Code: 7310-070
g00776437
Illustration 302
Special Publication, PEHP7506, “Caterpillar When the machine is removed from service, local
Transmission/Drive Train Oil (TDTO) Data Sheet” regulations for the machine decommissioning will
vary. Disposal of the machine will vary with local
Special Publication, PEHP0003, “Caterpillar Fluids - regulations. Consult the nearest Caterpillar dealer
Lithium Grease Data Sheet” for additional information.
Index
A Cooling System Coolant Sample (Level 2) -
Obtain ................................................................ 141
Additional Messages ............................................. 13 Cooling System Pressure Cap - Clean/Replace.. 142
Aftercooler Core - Inspect/Clean ......................... 129 Crankshaft Vibration Damper - Inspect ............... 142
Alternate Exit ......................................................... 39 Crushing Prevention and Cutting Prevention ........ 17
Automatic Lubrication Grease Tank - Fill (If
Equipped) .......................................................... 129
Grease Recommendations .............................. 130 D
Periodic Checks ............................................... 130
Automatic Lubrication System (If Equipped) ......... 88 Daily Inspection ..................................................... 37
Operator Controls .............................................. 88 Declaration of Conformity ...................................... 36
Axle Breathers - Clean/Replace .......................... 130 Decommissioning and Disposal .......................... 205
Differential and Final Drive Oil - Change ............. 143
Differential and Final Drive Oil Level - Check...... 144
B Differential and Final Drive Oil Sample - Obtain.. 145
Differential Lock Control ........................................ 77
Backup Alarm ........................................................ 74 Cross Axle Differential Lock............................... 78
Backup Alarm - Test ............................................ 131 Interaxle Differential Lock .................................. 78
Battery - Recycle ................................................. 131 Normal Operation............................................... 78
Battery Disconnect Switch..................................... 53 Display and Camera - Clean (If Equipped with Work
Battery or Battery Cable - Inspect/Replace ......... 131 Area Vision System) .......................................... 146
Before Operation ............................................. 23, 37 Camera ............................................................ 146
Before Starting Engine .......................................... 23 Display ............................................................. 146
Belts - Inspect/Adjust/Replace............................. 132 Drive Shaft Universal Joints - Inspect/Replace ... 146
Body Pivot Bearings - Lubricate .......................... 132 Inspect ............................................................. 146
Body Support......................................................... 30 Replace............................................................ 146
Brake Accumulator (Service) - Check ................. 133
Brake Control Valve Damper Breather -
Replace.............................................................. 133 E
Brake Control Valve Damper Oil - Change.......... 134
Brake System Air - Purge .................................... 134 Electrical Storm Injury Prevention ......................... 23
Brakes, Indicators and Gauges - Test ................. 134 Emissions Certification Film .................................. 35
Braking System - Test.......................................... 135 Engine Air Filter Primary Element - Clean/
Parking Brake Check ....................................... 135 Replace.............................................................. 147
Burn Prevention..................................................... 18 Engine Air Filter Secondary Element - Replace .. 148
Batteries............................................................. 18 Engine and Machine Warm-Up ............................. 91
Coolant............................................................... 18 Warm-Up and Break-In of the Differential .......... 92
Oils..................................................................... 18 Engine Compression Brake Control ...................... 75
Engine Compression Brake Valve Lash - Check.. 149
Engine Crankcase Breather - Clean.................... 149
C Engine Oil and Filter - Change ............................ 151
Procedure for Changing Engine Oil and Filter.. 153
Cab - Tilt ................................................................ 84 Selection of the Oil Change Interval ................ 151
Lowering the Cab............................................... 85 Engine Oil Level - Check ..................................... 150
Tilting the Cab.................................................... 84 Engine Oil Sample - Obtain ................................. 150
Cab Air Filter - Clean/Replace............................. 136 Engine Shutdown Control...................................... 54
Capacities (Refill) ................................................ 122 Engine Starting ................................................ 23, 91
735 (S/N: B1N1-879) ....................................... 122 Engine Starting Above 0°C (32°F) ..................... 91
735 (S/N: B1N880-Up) and 740 (S/N: Engine Starting Below 0°C (32°F) with Ether
B1P1-Up) ....................................................... 122 Starting Aid....................................................... 91
Circuit Breakers - Reset .............................. 136, 138 Engine Starting (Alternate Methods) ................... 107
Circuit Breakers for the Alternator and for the Engine Starting with Auxiliary Start Receptacle .. 108
Battery............................................................ 137 Engine Starting with Jump Start Cables .............. 107
Cooling System Coolant (ELC) - Change............ 138 Engine Stopping .................................................... 25
Cooling System Coolant Extender (ELC) - Add... 140 Engine Valve Lash - Check ................................. 154
Cooling System Coolant Level - Check ............... 140 Engine Valve Rotators - Inspect .......................... 155
Cooling System Coolant Sample (Level 1) - Equipment Lowering with Engine Stopped............ 26
Obtain ................................................................ 141 Ether Starting Aid Cylinder - Replace.................. 155
SEBU7815-10 207
Index Section
O P
Table of Contents..................................................... 3
Tailgate .................................................................. 86
Tailgate Pivot Bearings - Lubricate (If Equipped).. 182
Tire Inflation - Check ........................................... 182
Tire Inflation Information....................................... 110
Tire Inflation Pressure Adjustment ....................... 113
Tire Inflation with Nitrogen.................................... 110
Tire Information ..................................................... 22
Tire Shipping Pressure ................................. 110–112
Torque Converter and Transmission Oil -
Change ...................................................... 184–185
Torque Converter and Transmission Oil Filter -
Replace...................................................... 187–188
Torque Converter and Transmission Oil Level -
Check......................................................... 189–190
Torque Converter and Transmission Oil Sample -
Obtain ........................................................ 191–192
Torque Converter Scavenge Screen - Clean....... 183
Towing Information .............................................. 103
Towing the Machine............................................. 103
Towing a Machine that has an Inoperable
Engine ............................................................ 104
Towing a Machine that has an Operable
Engine ............................................................ 104
Transfer Gear Oil - Change ......................... 192, 194
Type 1 ...................................................... 192, 194
Type 2 ...................................................... 193, 195
Transfer Gear Oil Filter - Replace ....................... 196
Transfer Gear Oil Level - Check .................. 196, 199
Type 1 ...................................................... 196, 200
Type 2 ...................................................... 198, 201
Transfer Gear Oil Sample - Obtain ...................... 202
Transmission and Transfer Gear Breather -
Replace.............................................................. 202
Transmission Control....................................... 76–77
Transportation Information .................................... 97
210 SEBU7815-10
Index Section
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:
Attachment Information:
Dealer Information
Name: Branch:
Address:
Sales:
Parts:
Service:
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