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AD45 and AE40 SERIES II UNDERGROUND

1. g00950427 Illustration 232 View of rear differential 3 Remove differential filler plugs 3 and 4 The oil level should be at the bottom of the filler plug openings Add oil if necessary Reference For information on lubricants refer to the Operation and Maintenance Manual Lubricant Viscosities for the machine that is being serviced Note If the oil level is higher than the filler plug opening do not allow the oil to drain to the proper level Install the filler plugs 124 Maintenance Section Drive Shaft Universal Joints Splines and Bearings Inspect Lubricate Drive Shaft Universal Joints Splines and Bearings Inspect Lubricate SMCS Code 3251 040 3251 086 3253 040 SN 3253 086 SN 3267 040 BD 3267 086 BD Inspect the drive shaft universal joints for wear loose bolts or missing bolts Tighten loose bolts and replace missing bolts Inspect the drive shaft splines and bearings for wear Replace worn components 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 Wipe off the fittings before any lubricant is applied Illustration 233 g00950506 1 Lubricate all drive shaft universal joints through nine fittings
2. Fe T Illustration 351 900953029 1 Remove the transmission breather from the transmission cover 2 Wash the breather in clean nonflammable solvent 3 Allow the breather to dry 4 Install the clean transmission breather i01871361 Transmission Magnetic Screen Clean SMCS Code 3030 070 MGS The machine must be level the parking brake engaged and the engine stopped Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin 167 Maintenance Section Transmission Breather Clean NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 352 g00953038 1 Remove the magnetic screen cover and the wave washer assembly 2 Remove the screen magnet and tube assembly from the housing g00953041 Illustration 353 3 Wash the magnet screen and tube assembly in clean nonflammable solvent Clean the magnets with a cloth a stiff bristle b
3. Illustration 234 900950507 2 Lubricate the center drive shaft slip joint spline through the fitting g00950509 Illustration 236 g00950510 3 Lubricate the front oscillation drive shaft bearing through remote mounted fitting 1 Illustration 237 g00950511 125 Maintenance Section Ejector Cylinder Bearing Lubricate Illustration 238 Rear view of AD45 machine g00950527 Illustration 239 Left side view of AE40 Series II machine 4 Lubricate the rear oscillation drive shaft bearing through one remote mounted fitting 2 5 Lubricate the rear intermediate drive shaft center bearing through one remote mounted fitting 3 101864514 Ejector Cylinder Bearing Lubricate SMCS Code 5305 086 BD 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 Wipe off the fittings before any lubricant is applied Illustration 240 g00950579 1 Lubricate the left ejector cylinder bearing in the rod end of the ejector cylinder through remote mounted fitting 1 2 Lubricate the right ejector cylinder bearing in the rod end of the ejector cylinder through remote mounted fitting 2 g00950580 Illustration 241 3 M
4. Illustration 331 g00952594 Check the clearance between the front frame and the rear frame steering stops Reference For additional information about the correct procedure refer to Steering System Systems Operation Testing and Adjusting Steering Neutralizer Valve Check and Adjust for the machine that is being serviced 101871013 Steering System Oil Change SMCS Code 4332 044 Operate the machine to warm the steering system oil The machine must be on level the parking brake engaged and the engine stopped Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin 160 Maintenance Section Steering System Oil Change NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 1 Remove the steering tank filler cap slowly to relieve any steering tank pressure Remove the filler cap to prevent a vacuum in the steering tank Install the filler cap after the tank is drained
5. 121 Engine Mounts Inspect eeeeeeeeeeneeeeeeeeees 129 Engine Valve Rotators Inspect eee 134 Turbocharger Inspect secese 170 Every 3000 Service Hours or 2 Years Cooling System Coolant DEAC Change 113 Cooling System Coolant Extender ELC Add 117 Cooling System Pressure Cap Clean Replace 119 Engine Valve Lash Check Adjust ee 133 Every 3 Years Seat Belt Replace ccceceeeeeeeesseeeseseeeeeees 151 Every 6000 Service Hours or 4 Years Cooling System Coolant ELC Change 114 Cooling System Water Temperature Regulator REpIaCE ee ere 119 Engine Water Pump Inspect nsec 134 99 Maintenance Section Automatic Brake Application System Low Transmission Oil Pressure Test 101869573 Automatic Brake Application System Low Transmission Oil Pressure Test SMCS Code 4284 081 Certain Caterpillar machines may be equipped with an optional Automatic Brake Application ABA system The ABA system warns the operator of an impending brake application low transmission oil pressure and applies the parking brake if the pressure further decreases e g engine stalled If your machine is equipped with the optional ABA system perform the following test to check that the system is functioning correctly Note Before testing the operation of the Automatic Brake Application ABA system test the holding ability of the machine parking brake Referenc
6. Refill Capacities for the machine that is being serviced 15 Start the engine and run the engine at low idle Check for leaks pa AS SERN Illustration 298 g00952032 16 With the oil cold check the oil level in sight gauge 8 For the AD45 truck check the oil level with the body fully lowered For the AE40 Series ll truck check the oil level with the ejector plate fully retracted and the tailgate fully raised 17 Maintain the oil level to the FULL mark in the sight gauge 18 Remove filler cap 9 and add oil if necessary 101869547 Indicators and Gauges Test SMCS Code 7000 081 7450 081 Before you operate the machine perform the following checks and make any necessary repairs e Look for broken lenses on the gauges Also look for broken indicator lights broken switches and other broken components in the operator s station e Move the engine start switch key to the ON position and check the Caterpillar Monitoring System self test Reference For information on the Caterpillar Monitoring System self test refer to the Operation and Maintenance Manual Caterpillar Monitoring System Self Test for the machine that is being serviced e Make sure the parking brake is engaged Start the engine e Check for oil leaks Repair any oil leaks around the covers or around the hoses e Look for inoperative gauges e Turn on all machine lights Check for proper operation e Sound the horn
7. cceeeeeeeeseteeeeeteeeeeees 159 Suspension Cylinder Check seee 163 Wheel Bolt Torque Check n se 171 Every 500 Service Hours or 3 Months Brake Oil Filter Replace n 106 Engine Crankcase Breather Clean 0 129 Fuel Tank Cap and Strainer Clean 00 140 Parking Brake Release Oil Filter Replace 148 Steering System Oil Filter Replace 2 161 Torque Converter Oil Filter Replace 165 Transmission Oil Filter Replace 00 169 Every 1000 Service Hours or 6 Months Brake Accumulator Check ccccsssseeeeeeeees 105 Ejector Line Screen Inspect Clean 0 125 Frame and Body Support Pads Clean Inspect 137 Hoist Torque Converter and Brake Oil Change eseis eoe eriein eaa ieee 142 Hoist Torque Converter and Brake Tank Screen CHAN EENE E PE T E A E A 145 Oscillating Hitch Adjust s e 147 98 Maintenance Section Maintenance Interval Schedule Rollover Protective Structure ROPS and Falling Object Protective Structure FOPS Inspect 149 Steering System Oil Change cccccceeees 159 Transmission Breather Clean cccessseeees 167 Transmission Magnetic Screen Clean 167 Transmission Oil Change 168 Every 2000 Service Hours or 1 Year Differential Thrust Pin Clearance Check 120 Differential and Final Drive Oil Change
8. e Stop the engine 101773398 Oil Filter Inspect SMCS Code 1308 507 3067 507 5068 507 Inspect a Used Filter for Debris Illustration 299 g00907074 The Element is Shown with Debris Use a 4C 5084 Filter Cutter to cut the filter element open Spread apart the pleats and inspect the element for metal and for other debris An excessive amount of debris in the filter element can indicate a possible failure If metals are found in the filter element a magnet can be used to differentiate between ferrous and nonferrous metals Ferrous metals can indicate wear on steel parts and on cast iron parts Nonferrous metals can indicate wear on the aluminium parts of the engine such as main bearings rod bearings or turbocharger bearings Small amounts of debris may be found in the filter element This could be caused by friction and by normal wear Consult your Caterpillar dealer to arrange for further analysis if an excessive amount of debris is found Using an oil filter element that is not recommended by Caterpillar can result in severe engine damage to engine bearings to the crankshaft and to other parts This can result in larger particles in unfiltered oil The particles could enter the lubricating system and the particles could cause damage Oscillating Hitch Adjust SMCS Code 7113 025 g00952100 Illustration 300 Adjust the oscillating hitch bearing preload at the initial 250 Service Hours or 1
9. Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 221 g00950132 Front view of engine 1 Remove the water temperature regulator housing 2 Remove the gasket the water temperature regulator and the seal from the water temperature regulator housing NOTICE Former water temperature regulators may be used if they meet the test specifications and are not damaged or have excessive buildup or deposits NOTICE Since Caterpillar engines incorporate a shunt design cooling system it is mandatory to always operate the engine with a water temperature regulator Depending on load failure to operate with a water tem perature regulator could result in either an overheating or an overcooling condition NOTICE If the water temperature regulator is installed incor rectly it will cause the engine to overheat 3 Install a new seal in the water temperature regulator housing Install a new water temperature regulator and a new gasket Install the water temperature regulator housing and the hose 4 Refill the cooling system Reference For all cooling system requirements refer to the Operation and Maintenance Manual SEBU6250 Caterpillar Machine Fluids Recommendations Reference For information on the cooling system capacity refer t
10. Illustration 183 g00954948 1 Loosen two mounting bolts 1 and locknut 2 2 Turn adjusting nut 3 to obtain the correct adjustment 3 Tighten the locknut and mounting bolts 4 Check the belt deflection If the amount of deflection is incorrect repeat Steps 1 to 3 Adjust the Air Conditioning Compressor Belt Illustration 184 g00954950 1 Loosen two mounting bolts 1 and locknut 2 2 Turn adjusting nut 3 to obtain the correct adjustment 3 Tighten the locknut and the mounting bolts 4 Check the belt deflection If the amount of deflection is incorrect repeat Steps 1 to 3 101857128 Body Pivot Bearings Lubricate SMCS Code 7258 086 BD NOTICE Check that the lines attached to all remote grease fit tings are undamaged If the lines are split grease will not reach the bearings or pins Machine damage will result Wipe all fittings clean before lubricating yi Illustration 185 g00946696 Rear view of AD45 machine 1 Lubricate the left body pivot bearing through remote mounted fitting 1 2 Lubricate the right body pivot bearing through remote mounted fitting 2 i01857165 Brake Accumulator Check SMCS Code 4263 535 g00946733 Illustration 186 Correct brake accumulator charge pressure is necessary for efficient hydraulic brake operation Special tools and equipment are required to test the accumulator Reference For the correct testing and char
11. Precleaner Clean for the machine that is being serviced G Inspect fuel tank 6 Make sure that the filler cap is installed correctly Check the welds and mounting brackets for the fuel tank Look for any leaks or damage to the fuel tank H Inspect the hydraulic systems Check for leaks worn hoses and for damaged lines Repair any leaks worn hoses and damaged lines Check the oil level in hydraulic tank 7 Check the level in steering tank 8 Make sure that the filler caps are installed Inspect the tank covers for damaged bolts loose bolts or missing bolts Tighten loose bolts and replace missing bolts Check the welds and mounting brackets for the hydraulic tank and the steering tank Inspect the tank for leaks or for damage If necessary make repairs I Inspect the front suspension cylinders for leaks or damage Repair any leaks in the suspension cylinders Check for the following conditions If any of these conditions are present refer to Operation and Maintenance Manual Suspension Cylinder Check for the machine that is being serviced e The chrome has been wiped off and the whole length of the chrome is used during normal operation e The ride is harsh and the suspension cylinders extend fully when the machine is empty J Inspect tires for cuts gouges and proper inflation Remove large rocks from the treads Look for abnormal wear or uneven wear that may indicate mechanical problems elsewhe
12. Remove drain plug 2 from the filter housing Wash the drain plug and filter housing in clean nonflammable solvent Install the filter housing drain plug 4 Inspect seal 3 in the filter base If the seal is damaged replace it with a new seal 5 Install the new element in the filter housing Install the filter housing and element 6 Start the engine and run the engine at low idle Check for leaks g00952935 Illustration 348 166 Maintenance Section Torque Converter Sump Screen Clean 7 With the oil cold check the oil level in sight gauge 5 For the AD45 truck check the oil level with the body fully lowered For the AE40 Series ll truck check the oil level with the ejector plate fully retracted and the tailgate fully raised 8 Maintain the oil level to the FULL mark in the sight gauge 9 Remove filler cap 6 and add oil if necessary 101871346 Torque Converter Sump Screen Clean SMCS Code 3101 070 Z3 Clean the screen whenever there is a failure of the torque converter The machine must be level the parking brake engaged and the engine stopped A WARNING Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers befor
13. Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Wipe covers and surfaces around openings before checking or adding oil Park on a level surface Note Perform Steps 1 and 2 to the final drive on each wheel g00950397 Illustration 230 1 Position the wheels so that the drain level plug 1 for the final drive is even with the center line of the wheel 2 Remove the drain level plug The oil level should be at the bottom of the drain level plug opening If necessary remove filler plug 2 and add oil through the filler opening Reference For information on lubricants refer to the Operation and Maintenance Manual Lubricant Viscosities for the machine that is being serviced 123 Maintenance Section Differential and Final Drive Oil Level Check Note If the oil level is higher than the filler plug opening do not allow the oil to drain to the level of the filler plug opening Install the filler plug Note All of the drain level plugs are magnetic plugs The magnetic will attract metal from the oil A bearing failure is indicated by an increased amount of metal on the magnetic plug Note If any abnormal particles are found consult your Caterpillar dealer Illustration 231 g00950420 View of front differential
14. a wire brush or a scraper If you find cracks or damage contact your Caterpillar dealer for the specific repair procedures 4 Remove the body retaining pin If the pin cannot be removed raise the dump body to release the tension Place the pin in the stored position in the rear frame AE40 Series Il The tailgate may move suddenly and without warning resulting in personal injury or death When it is necessary to work under the tailgate with the tailgate raised install the tailgate retain ing pins through the pin bores in the tailgate and body g00943713 Illustration 273 1 Fully retract the ejector plate and raise the tailgate until the pin bores on the body align with the pin bores on the tailgate Install the tailgate retaining pin a eae a AE4O ELP Illustration 274 g00951548 2 Clean the ejector body with a wire brush or a scraper Inspect the ejector body If the body is damaged or worn repair the body If you find cracks contact your Caterpillar dealer for the specific repair procedure 3 Remove the tailgate retaining pin If the pin cannot be removed raise the tailgate to release the tension After lowering the tailgate place the pin in the stored position in the body i01866693 Frame and Body Support Pads Clean Inspect SMCS Code 7051 040 7051 070 7258 040 7258 070 AD45 To prevent personal injury or death do not work under the truck with the body bed rai
15. and brake hydraulic tank filler cap 6 Remove the strainer 7 Wash the cap and the strainer in clean nonflammable solvent Allow them to dry 8 Inspect the cap seal Use a new seal if the used one is damaged Install the strainer 9 Fill the hoist torque converter and brake hydraulic tank Reference For information on lubricants and refill capacities refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities for the machine that is being serviced 10 Start the engine and run the engine at low idle Check for leaks g00951948 Illustration 291 11 With the oil cold check the oil level in sight gauge 1 For the AD45 truck check the oil level with the body fully lowered For the AE40 Series ll truck check the oil level with the ejector plate fully retracted and the tailgate fully raised 12 Maintain the oil level to the FULL mark in the sight gauge 13 Remove filler cap 2 add oil if necessary 144 Maintenance Section Hoist Torque Converter and Brake Oil Level Check 101868920 Hoist Torque Converter and Brake Oil Level Check SMCS Code 5050 535 FLV A WARNING Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to coll
16. backup alarm should continue to sound until the transmission direction and speed control is moved to the NEUTRAL position or to the FORWARD position Illustration 176 g00946518 Rear view of AD45 g00946519 Illustration 177 Rear view of AE40 Series II The backup alarm is located at the rear of the machine 102 Maintenance Section Battery Recycle 6 Illustration 178 g00896957 To adjust the sound level turn the adjustment knob that is on the back of the alarm The backup alarm is set at the highest sound level when the machine is shipped from the factory The adjustment knob should remain at the HIGH position unless the job site requires a lower sound level i01765195 Battery Recycle SMCS Code 1401 561 Always recycle a battery Never discard a battery Always return used batteries to one of the following locations e A battery supplier e An authorized battery collection facility e Recycling facility 101856935 Battery Electrolyte Level Check SMCS Code 1401 535 ESG Table 13 Battery Electrolyte Level Battery Interval Conventional 100 Hours Low Maintenance 250 Hours Maintenance Free No Interval Tighten the battery retainers on all of the batteries Tighten the battery retainers at every 1000 hours Check the following areas at a minimum interval of 1000 hours Check the following areas more frequently during adverse conditions Il
17. camera low coolant level control dash indicator lamps Illustration 208 g00249860 View of battery compartment under the operator s station 17 80 Amp Main 101863424 Cooling System Coolant DEAC Change SMCS Code 1352 044 1395 044 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 the pressure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 113 Maintenance Section Cooling System Coolant DEAC Change NOTICE Do not change the coolant until you read and under stand the cooling system information in Special Pub lication SEBU6250 Caterpillar Machine Fluids Rec ommendations Failure to do so could result in damage to the cooling system components Note This procedure pertains only to Caterpillar Diesel Engine Antifreeze Coolant DEAC This does not pertain to machines that are shipped from the fact
18. element 2 Remove and discard the used breather element 3 Install the new breather element Tighten the retaining clamp 4 Install cover 1 101868954 Hoist Torque Converter and Brake Tank Screen Clean SMCS Code 5056 070 Z3 There is one return screen and two suction screens inside the hoist torque converter and brake tank Clean the return screen and suction screens whenever there is a failure of the brakes torque converter hoist eject cylinders or hoist pumps Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates g00993169 Illustration 295 Note Hand tighten the NPT pipe nipple Do not use tools 1 Remove the tank drain plug Open the drain valve by installing a 1 inch NPT pipe nipple 88 mm 3 50 inch long in the bottom of the tank to open the internal drain valve and drain the oil Drai
19. element Store the primary element in a clean dry location 128 Maintenance Section Engine Air Filter Secondary Element Replace A primary element may be cleaned for a maximum of six times Also replace the primary element if the primary element has been in service for one year 10 Install a clean primary element and the wing nut Tighten the wing nut finger tight Do not use a tool to tighten the nut Note Make sure that the primary filter element is properly seated and sealed Note If the air filter restriction indicator remains on after starting the engine or the exhaust smoke is still black after installing a clean primary element install a new primary filter element If the indicator remains on after installing a new primary filter element replace the secondary filter element Reference For the correct procedure to replace the secondary filter element refer to the Operation and Maintenance Manual Engine Air Filter Secondary Element Replace for the machine that is being serviced 101864772 Engine Air Filter Secondary Element Replace SMCS Code 1054 510 SE NOTICE Service the air cleaner only with the engine stopped Engine damage could result NOTICE Always replace the secondary element Do not at tempt to reuse it by cleaning Engine damage could result Replace the engine air filter secondary element under the following conditions e Aclean primary element has been installed and a
20. further priming is necessary Note The engine ECM is cooled by fuel It may be necessary to block the fuel from flowing through the ECM during priming in order to force the fuel to flow to the injectors 5 Push the priming pump plunger inward and turn the priming pump plunger clockwise This will lock the priming pump plunger 101867384 Fuel System Primary Filter Clean Replace SMCS Code 1260 070 1260 510 Clean the primary element when the engine has a loss of power or when the exhaust smoke is black A WARNING Personal injury or death can result if spilled fuel ignites Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire To help prevent possible injury turn the battery disconnect switch to the OFF position when changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Do not fill fuel filters with f
21. in damage to the engine Allow the engine to cool before adding coolant If the machine is to be stored in or shipped to an area with freezing temperatures the cooling system must be protected to the lowest outside ambient tempera ture The engine cooling system is normally protected to a minimum of 29 C 20 F with Caterpillar Antifreeze when shipped from the factory unless special require ments are defined NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Excessive additive greater than the recommended 6 initial fill together with concentrations of antifreeze greater than 60 cause deposits to form and can re sult in radiator tube blockage and overheating NOTICE Mixing ELC with other products reduces the effective ness of the coolant and shortens coolant life Use on ly Caterpillar products or commercial products that have passed the Caterpillar EC 1 specifications for premixed or concentrate coolants U
22. month service interval and then at every 1000 service hours or 6 monthly service interval Reference For the correct oscillating hitch bearing adjustment procedures refer to Steering Systems Specifications Oscillating Hitch for the machine that is being serviced or contact your Caterpillar dealer 147 Maintenance Section Oscillating Hitch Adjust i01869706 Oscillating Hitch Lubricate SMCS Code 7113 086 NOTICE Check that the lines attached to all remote grease fit tings are undamaged If the lines are split grease will not reach the bearings or pins Machine damage will result Wipe all fittings clean before lubricating Illustration 301 900952133 1 Lubricate the upper hitch bearing through remote mounted fitting 1 2 Lubricate the lower hitch bearing through remote mounted fitting 2 g00952140 Illustration 302 Rear view of AD45 machine 3 Lubricate the front oscillation bearing through remote mounted fitting 3 4 Lubricate the rear oscillation bearing through remote mounted fitting 4 148 Maintenance Section Parking Brake Release Oil Filter Replace Illustration 303 g00952146 Left side view of AE40 Series II machine 5 Lubricate the rear oscillation bearing through remote mounted fitting 5 6 Lubricate the front oscillation bearing through remote mounted fitting 6 101869854 Parking Brake Release Oil Filter Replace SMCS Code 4267 510
23. necessary repairs Make sure that all loose connections and all parts are tightened to the specified torques Replace any missing parts before starting the engine or before operating the machine 151 Maintenance Section Seat Belt Replace Inspect the machine for leaks If leaks are observed find the source of the leak and correct the leak If leaks are suspected check the fluid levels more frequently than the recommended intervals 152 Maintenance Section Service Inspection AD45 F G H EN o Illustration 312 Inspection points for the service inspection A Ground level controls B Front lights C Cooling system D Engine E Power train hydraulic system F Air cleaner G Fuel tank H Hydraulic system 1 Front suspension cylinders J Tires K Steering hydraulic system L Rear axle M Frame and body N Articulating hitch and
24. new element in the housing Install the element and housing in the housing base 6 Start the engine and operate the engine at low idle Inspect for leaks g00946895 Illustration 191 7 With the oil cold check the oil level in the sight gauge 3 For the AD45 truck check the oil level with the body fully lowered For the AE40 Series Il truck check the oil level with the ejector plate fully retracted and the tailgate fully raised 8 Maintain the oil level to the FULL mark in the sight gauge 9 Remove oil filler cap 4 and add oil if necessary 107 Maintenance Section Braking System Test 101857847 Braking System Test SMCS Code 4250 081 4251 081 4267 081 Note Perform the following brake test at the start of each shift and before entering a ramp Be sure the area around the machine is clear of personnel and obstructions Be sure the steering frame lock is in the stored position Test the brakes on a dry level surface Fasten the seat belt before testing the brakes The following tests are to determine if the parking brake and the service brakes are functional These tests are not intended to measure the maximum brake holding effort Brake holding effort required to hold a machine at a specific engine rom will vary from machine to machine due to differences in engine setting power train efficiency etc as well as differences in brake holding ability Engine rom at beginning of machine movement wi
25. of the engine A WARNING Electrical Shock Hazard Unit Injector System 90 120 Volts Perform the first valve lash check for new engines and rebuilt engines at the first oil change The initial wear and seating of the valve train components causes this valve lash adjustment to be required Subsequent checks of the valve lash and adjustments of the valve lash are scheduled for every 3000 service hours Engine valve rotators should also be inspected when the valve lash is checked Reference For information on inspecting the engine valve rotators refer to Operation and Maintenance Manual Engine Valve Rotators Inspect for the machine that is being serviced NOTICE Only qualified service personnel should perform this maintenance Refer to the Service Manual or your Caterpillar dealer for the complete valve lash adjust ment procedure Operation of Caterpillar engines with improper valve adjustments can reduce engine efficiency This re duced efficiency could result in excessive fuel usage and or shortened engine component life 133 Maintenance Section Engine Valve Lash Check Adjust Illustration 264 g00951266 If the valve clearance is within 0 08 mm 0 003 inch of nominal clearance given adjustment is not required If the clearance is not within these limits set the clearance as specified in table 14 Table 14 Valve Clearance Setting Intake 0 38 mm 0 015 inch Exhaust 0 76 mm 0
26. of the filler openings If distilled water is not available use clean drinking water e A battery should not require more than 30 cc 1 8306 in 1 ounce of water per cell per week This requirement should exist with the proper charging rate and with a moderate climate e In extreme temperatures check the water in the cells weekly Cell water usage could be higher in extreme temperatures 101856382 Battery Battery Cable or Battery Disconnect Switch Replace SMCS Code 1401 510 1402 510 1411 510 Reference For information on tilting the cab refer to Operation and Maintenance Manual Cab Tilt for the machine that is being serviced 1 The batteries are located under the cab Tilt the cab to access the batteries Turn the engine start switch to the OFF position Turn all switches to the OFF position Illustration 181 3 Disconnect the negative end g00946530 Turn the battery disconnect switch to the OFF position and remove the key Disconnect the negative end of the battery cable from the electric starting motor of the battery cable from the battery Disconnect the positive end of the battery cable from the battery Replace the battery or make all necessary repairs to the battery Connect the positive end of the battery cable to the battery Connect the negative end of the battery cable to the battery 10 Conne
27. or hot components to contact the skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 190 Note The brake oil filter should be replaced every 500 service hours or 3 months This frequency can increase if the filter is dirty Observe brake filter indicator 1 while repeatedly applying the brakes Replace the filter if the indicator is in the red area with the machine running and the brake accumulator charging 1 Release the pressure in the braking system Reference For information on releasing the pressure in the braking system refer to Braking System Systems Operation Testing and Adjusting Braking System Pressure Release for the machine that is being serviced 2 Remove brake filter housing 2 Remove the element and discard 3 Wash the filter housing in clean nonflammable solvent 4 Inspect the seal in the filter housing If the seal is damaged replace the seal with a new seal 5 Install the
28. oscillating hitch g00952317 O Automatic lubrication system if equipped P Rollover Protective Structure ROPS and Falling Object Protective Structure FOPS Illustration 313 g00943874 A Inspect the ground level controls for proper operation Replace a damaged or worn engine shutdown switch 1 Replace a damaged or worn battery disconnect switch 2 B Inspect the lights for broken lamps lenses and proper operation Replace broken lamps and lenses C Inspect the cooling system for leaks worn hoses and debris Repair any leaks and damaged hoses Remove any debris that could block the air flow through the radiator il i ii pt i l seag Illustration 314 g00943815 D Inspect the engine Use dipstick 3 to check the engine oil level Check for oil leaks coolant leaks and exhaust leaks Check the belts of the engine for proper tension and for good condition Check the level in the washer fluid bottle 153 Maintenance Section Service Inspection Illustration 315 g00952402 E Inspect the hydraulic system for the torque converter and transmission 4 Check for leaks from the torque converter and from the transmission Check for worn hoses and for damaged lines Repair any leaks worn hoses and damaged lines g00952419 Illustration 316 F Check engine air precleaner 5 for accumulated debris If necessary clean engine air precleaner 5 Fo
29. streak the window replace the wiper blades
30. the filler cap after the tank is drained to prevent dirt from entering the system Note Hand tighten the NPT pipe nipple Do not use tools 2 Remove tank drain plug 2 from the steering tank Open the drain valve by installing a 1 inch NPT pipe nipple 88 mm 3 50 inch long to open the internal drain valve and drain the oil 3 Remove bolts 1 from the steering tank cover and remove the cover 4 Clean the debris from the bottom of the steering tank Illustration 341 g009527 14 5 Remove four bolts 3 retainer plate 4 and suction screen 5 6 Wash the screen in clean nonflammable solvent 7 Install suction screen 5 retaining plate 4 and mounting bolts 3 8 Clean the steering tank cover in clean nonflammable solvent Inspect the cover gasket If the gasket is damaged use a new gasket 9 Install the steering tank cover and bolts 10 Fill the steering tank Reference For information on lubricants and the refill capacity refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities for the machine that is being serviced 11 Start and run the engine at low idle Inspect the steering tank for leaks 12 Maintain the low level to the FULL mark in the sight gauge 13 Add oil if necessary Stop the engine 101871167 Suspension Cylinder Check SMCS Code 7201 535 Make sure the body is empty For the AD45 truck lower the dump body For the AE40 series II
31. to prevent dirt from entering the system g00952739 Illustration 332 Note Hand tighten the NPT pipe nipple Do not use tools 2 Remove the tank drain plug from the steering tank Open the drain valve by installing a 1 inch NPT pipe nipple 88 mm 3 50 inch long to open the internal drain valve and drain the oil Drain the oil into a suitable container 3 Remove the pipe nipple and install the drain plug BEN Illustration 333 g00952743 4 Remove filler cap 1 5 Remove the strainer retaining ring 6 Remove the strainer Wash the cap and strainer in clean nonflammable solvent 7 Inspect the cap seal Use a new seal if the seal is damaged 8 Install the strainer and the retaining ring 9 Fill the steering tank Reference For information on lubricants and the refill capacity refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities for the machine that is being serviced 10 Install the filler cap 11 Start the engine and run at low idle Check for leaks g00952752 Illustration 334 12 Maintain the oil level to the FULL mark in sight gauge 2 13 Remove the filler cap and add oil if necessary 101871097 Steering System Oil Filter Replace SMCS Code 431F 510 5068 510 A WARNING Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin NOTICE Care must be taken
32. truck fully retract the ejector plate Stop the machine gradually on a level surface without using the brakes 163 Maintenance Section Suspension Cylinder Check Engage the parking brake Stop the engine Ct Illustration 342 g00952831 Check the front suspension cylinders against the dimensions from the last time you performed the charging procedure If you do not have those dimensions the following dimension can be a guideline e Distance A of the cylinder from pin to pin should be 882 6 mm 34 7 0 25 inch Note If the height of the front cylinder is not within the acceptable range perform the charging procedure Reference For the charging procedure refer to Systems Operation Testing and Adjusting Suspension Cylinders for the machine that is being serviced 101871150 Suspension and Suspension Cylinder Bearings Lubricate SMCS Code 7200 086 7201 086 BD 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 Wipe all fittings clean before lubricating 164 Maintenance Section Tailgate and Tailgate Cylinder Bearings Lubricate s Illustration 343 go09528 11 1 Lubricate the right upper suspension cylinder bearing through remote mounted fitting 1 2 Lubricate the left lowe
33. under the cab Accidental cab lowering can cause severe person al injury or death from crushing could occur A WARNING Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates The machine must be level and the parking brake engaged The oil must be warm and the engine stopped Illustration 257 g00951023 The engine oil filters are located on the left side of the engine Tilt the cab to access the filters Reference For information on tilting the cab refer to Operation and Maintenance Manual Cab Tilt for the machine that is being serviced 131 Maintenance Section Engine Oil and Filter Change Illustration 258 g00951058 1 Open the drain valve and allow the oil to drain into a suitable container Close the drain valve Illustration 259 g00951064 2 Remove the used oil filter elements and dis
34. 030 inch OINTAKE VALVES EXHAUST VALVES 7 5 3 1 OA OAOA fe 63 G3 GD 8 0 o E 65 G5 C 8 6 4 2 Illustration 265 g00951267 Reference For further information on checking the engine valve lash refer to Systems Operation Testing and Adjusting 3408E amp 3412E Engines for the machine that is being serviced Contact your Caterpillar dealer for additional information 134 Maintenance Section Engine Valve Rotators Inspect 101770623 Engine Valve Rotators Inspect SMCS Code 1109 040 A WARNING When inspecting the valve rotators protective glasses or face shield and protective clothing must be worn to help prevent being burned by hot oil or spray NOTICE A valve rotator which does not operate properly will accelerate valve face wear and valve seat wear and shorten valve life If a damaged rotator is not replaced valve face guttering could result and cause pieces of the valve to fall into the cylinder This can cause piston and cylinder head damage Valve rotators cause the valve to rotate when the engine runs This helps to prevent deposits from building up on the valve and the valve seats Illustration 266 go0905744 Perform the following steps after the valve lash is set but before the valve covers are installed 1 Start the engine Operate the engine at low idle 2 Observe the top surface of each valve rotator The valve rotators shou
35. 101863237 Circuit Breakers Reset SMCS Code 1420 529 NOTICE Replace circuit breakers with the same type and size only Otherwise electrical damage can result If itis necessary to reset circuit breakers frequently an electrical problem may exist Contact your Caterpillar dealer reset the circuit breaker If the electrical system is working properly the button will remain depressed If the button does not remain depressed check the appropriate electrical circuit Repair the electrical circuit if necessary a Circuit Breakers Push in the button to Illustration 206 g00949839 1 Spare 2 Spare 3 15 Amp Caterpillar Monitoring System engine ECM shutdown to idle system 4 15 Amp Window wipers washers residual brake pressure stop lights exhaust back pressure control 5 15 Amp Engine start switch fire suppression control 6 Spare 7 15 Amp Parking brake control brake release system 8 15 Amp Transmission control Ch e EERE EEE EI s erse re Ger Illustration 207 g00949848 9 15 Amp Engine ECM recorder 10 Spare 11 15 Amp Block light rear cab flood light Automatic Retarder Control ARC 12 15 Amp Cab tilt control hoist ejector control 13 30 Amp Automatic Head lights tail lights dash lamps 14 30 Amp Automatic Rear lights 15 30 Amp Air conditioner 16 15 Amp Horn automatic lubrication system reversing
36. 71783 Turbocharger Inspect SMCS Code 1052 040 If the turbocharger fails during engine operation severe damage to the turbocharger compressor wheel can result If the turbocharger fails during engine operation severe damage to the engine can also result For example damage to the turbocharger compressor wheel could cause parts from the turbocharger compressor wheel to enter the engine cylinder These parts from the compressor wheel can cause additional damage to the following engine components pistons intake valves exhaust valves and cylinder head Note Turbocharger failure can cause large quantities of oil to enter the intake and exhaust systems Loss of engine lubricant can result in serious engine damage If no turbocharger bearing failure has occurred minor leakage of a turbocharger housing during an extended period of operation at low idle will not cause problems Do not continue to operate the engine when a turbocharger bearing failure is accompanied by a significant loss of engine performance One of the following characteristics will be present with a loss of engine performance e Engine smoke e Speeding up of the engine with no load Note For specifications used to check the turbocharger refer to Specifications 3408E HEUI Engine for the machine that is being serviced 101871868 Wheel Bolt Torque Check SMCS Code 4210 535 g00953329 Illustration 361 Check the wheel bolt torque at
37. AD45 and AE40 SERIES II UNDERGROUND ARTICULATED TRUCKS Maintenance Intervals Excerpted from Operation amp Maintenance Manual SEBU7326 01 CATERPILLAR 97 Maintenance Section Maintenance Interval Schedule 101907748 Maintenance Interval Schedule SMCS Code 1000 7000 Note All safety information warnings and instructions must be read and understood before you perform any operation of any maintenance procedure Note Before each consecutive interval is performed all of the maintenance requirements from the previous intervals must be performed When Required Battery Recycle 0 eeeeeeeeeeeeneeeeeeeneeeeeeeenees 102 Battery Battery Cable or Battery Disconnect Switch a 6 nrin ee 103 Brake Oil Cooler Screen Clean sisses 105 Circuit Breakers Reset eeens 112 Engine Air Filter Secondary Element Replace 128 Exhaust Purifier Inspect Clean ssec 135 Fuel System Prime c ceceeeeeeeeeeeeeeseteeeteteeees 137 Fuses Replace 0 ccccceeeeeeeeeeeeeneeeeeeeneeeeeeeaaes 141 Hoist Torque Converter and Brake Tank Breather PRE PlaCO az sic Ean A ESEA a S 144 Oil Filter Inspect oo eee eeceeeeeeeeeeteeteteeteteees 146 Radiator Core Clean sseni 149 Steering Tank Screen Clean s s 162 Torque Converter Sump Screen Clean 166 Window Washer Bottle Fill eeeeeeeee 171 Window Wiper Inspect Replace 0 172 Every 10 Service Hours or Da
38. FI Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates g00952181 Illustration 304 1 Remove drain plug 2 from the bottom of filter housing 1 Drain the oil into a suitable container Install drain plug 2 in the filler housing and tighten finger tight Note Removing drain plug from the bottom of filter housing may not drain all of the oil from the filter Avoid spillage when removing the filter housing and filter element Ket ia Py STN Illustration 305 g00952184 2 Remove filter housing 1 and filter element 4 Discard the used filter element 3 Remove drain plug 2 from the filter housing Wash the drain plug and filter housing in clean nonflammable solvent Install the filter housing drain plug 4 Inspect seal 8 in the filter base If the seal is damaged replace the seal with a
39. air of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates g00953154 Illustration 356 2 Remove drain plug 2 from the bottom of filter housing 1 and drain the into a suitable container Install drain plug 2 in the filter housing and tighten finger tight 169 Maintenance Section Transmission Oil Filter Replace Note Removing the drain plug from the bottom of the filter housing may not drain all the oil from the filter housing Avoid spillage when removing the filter housing and filter element Illustration 357 g00953160 3 Remove filter housing 1 and element 4 Dispose of the used filter element 4 Remove drain plug 2 from the filter housing Wash the drain plug and filter housing in clean nonflammable solvent Install the filter housing drain plug 5 Inspect seal 3 in the filter base If the seal is damaged replace the seal with a new seal 6 Install a new filter element in filter housing Install the filter housing and element 7 Start and run the engine at low idle Inspect for leaks 8 Operate the transmission control to circulate oi
40. and legible 101773416 Seat Belt Inspect SMCS Code 7327 040 Illustration 309 g00207536 Always check the condition of the seat belt and the condition of the belt mounting hardware before you operate the machine Inspect the seat belt for worn or frayed webbing Illustration 310 g00907537 Inspect the belt mounting hardware Replace any belt mounting hardware that is worn or damaged Keep the mounting bolts tight Regardless of the appearance replace the seat belt once during every three year interval 101773427 Seat Belt Replace SMCS Code 7327 510 Illustration 311 g00907536 Regardless of the appearance of the seat belt the seat belt should be replaced at every three year interval A date label is attached to each seat belt Use this label in order to determine the age of the seat belt Consult your Caterpillar dealer for replacement of the seat belt i01870130 Service Inspection SMCS Code 7000 For maximum service life of the machine make a thorough service inspection when you perform lubrication and maintenance work Look around the machine and under the machine Inspect the condition of all major components Check all grease fittings Look for the following discrepancies e loose bolts e trash buildup e oil coolant or fuel leaks e broken parts or worn parts e cracks in the frames Remove any trash and any debris As needed adjust the tire inflation Make any
41. at all of the old seal is removed 3 Lubricate the sealing surface of the new filter element with clean diesel fuel 4 Install the new filter by hand Tighten the filter element until the sealing surface contacts the base Tighten the filter element an additional 3 4 of a turn Note There are rotation index marks on each filter spaced 90 degrees 1 4 turn apart Use these marks as a guide when tightening the filter 5 Prime the fuel system Reference For information on priming the fuel system refer to the Operation and Maintenance Manual Fuel System Prime for the machine that is being serviced 6 Start the engine and inspect the filter for leaks Make any necessary repairs 140 Maintenance Section Fuel System Water Separator Drain i01867663 Fuel System Water Separator Drain SMCS Code 1263 543 Note The water separator is not a filter The water separator separates the water from the fuel Personal injury or death can result if spilled fuel ignites Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire To help prevent possible injury turn the battery disconnect switch to the OFF position when changing fuel filters or water separator elements Clean up fuel spills immediately 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
42. ater pressure is 280 kPa 40 psi 4 If washed rinse the element in clean water and air dry thoroughly 5 Install the clean filter element and cover Note When rips or tears are noticed in the filter element or a reduction of air circulation is noticed in the cab after cleaning filter install a new element Cab Pressurizer Filter g00949690 Illustration 204 Note When the debris reaches the full level on the precleaner empty the precleaner 1 Loosen the retaining nut and remove cover 2 Remove precleaner cup 1 Empty the precleaner cup 111 Maintenance Section Cab Tilt Pin and Lockdown Pin Check Lubricate 2 Wash the cover and the precleaner cup in clean water and allow to air dry 3 Install the precleaner cup and the cover Tighten the retaining nut finger tight Do not use a tool to tighten the retaining nut 4 Loosen clamp bolt 3 and remove end cap 4 Remove the rubber baffle from the end cap Empty the dust from the end cap 5 Install the rubber baffle in the end cap 6 Remove the wing nut on the filter element Remove the filter element 7 Clean the filter element with pressure air or wash the element in warm water and a nonsudsing household detergent When you use air pressure the maximum air pressure is 205 kPa 30 psi When you use water pressure the maximum water pressure is 280 kPa 40 psi 8 If washed rinse the element in clean water and air dry thoroughly 9 I
43. card the used oil filter elements 3 Clean the filter housing base Make sure that all of the old seal is removed from the filter base 4 Apply a thin film of clean engine oil to the new filter element seal 5 Install both filters hand tight Tighten the filters until the sealing surface contacts the filter base Tighten the filter element by an additional 3 4 of a turn Note There are rotation index marks on each filter spaced 90 degrees 1 4 turn apart Use these rotation marks as a guide when tightening the filters 132 Maintenance Section Engine Shutdown to Idle Protection System Test wy d Illustration 260 g00951067 6 Remove filler cap 1 Fill the crankcase with new oil Clean the filler cap and install the filler cap Reference For information on lubricants and refill capacities refer to the Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities for the machine that is being serviced 7 Start the engine and run the engine at low idle for five minutes Inspect the engine oil filter for leaks Stop the engine 8 Maintain the oil level in the hatched area on the SAFE OPERATING RANGE side of dipstick 2 Add oil if necessary 101866116 Engine Shutdown to Idle Protection System Test SMCS Code 1408 081 1 Start the engine 2 Depress the accelerator pedal to achieve engine rpm above low idle g00951 190 Illustration 261 3 Disconnect conne
44. ct the negative end of the battery cable to the electric starting motor 11 Install the key Turn the battery disconnect switch to the ON position i01876860 Belts Inspect Adjust Replace SMCS Code 1357 025 1357 040 1357 510 For maximum engine performance and utilization of your engine inspect the belts for wear and for cracking Check and adjust the belt tension to minimize belt slippage which will decrease belt life and cause poor performance of the alternator and any driven equipment 1 2 Inspect the condition of the belts If a belt is worn or is damaged replace the belt 104 Maintenance Section Body Pivot Bearings Lubricate 3 Inspect the tension of the alternator belt and air conditioning compressor belts 4 Check the belt tightener for wear alignment and that it is maintaining correct belt tension Q Illustration 182 g00954945 To check the belt tension apply 110 N 25 Ib of force midway between the pulleys Correctly adjusted belts will deflect 17 3 mm 0 67 0 12 inch If new belt s are installed check belt adjustment again after 30 minutes of operation For multiple belt drive applications always replace belts in matched sets If only one belt of a matched set is replaced it will carry more of a load than the belts not replaced since the older belts are stretched The additional load on the new belt could cause it to break Adjust the Alternator Belt
45. ctor 1 from coolant temperature switch 2 Engine speed should reduce to low idle Reconnect the wiring at the connector Illustration 262 g00951195 4 Disconnect connector 3 from oil pressure switch 4 Engine speed should reduce to low idle Reconnect the connector 5 Stop the engine Illustration 263 g00951197 6 Disconnect wire 5 from coolant level sensor 6 Secure the wire to prevent it from touching any metal objects or protruding through the fan guard 7 Start the engine and depress the accelerator control Engine speed should not increase above low idle 8 Stop the engine Reconnect the wire to the coolant level sensor 9 Seal wiring connector with electrical corrosion protectant 10 Replace any cable ties that were removed when disconnecting wiring connectors Note If the engine shutdown to idle protection system does not function correctly check the electrical system or contact your Caterpillar dealer 101866230 Engine Valve Lash Check Adjust SMCS Code 1102 025 1102 535 A WARNING Ensure that the engine can not be started while this maintenance is being performed To help pre vent possible injury do not use the starting motor to turn the flywheel Hot engine components can cause burns Allow additional time for the engine to cool before mea suring adjusting valve lash clearance Note The following warning is located on the valve covers or valve base covers
46. cuum in the tank Install the cap after the tank is drained to prevent dirt from entering the system Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 289 g00951917 Note Hand tighten the NPT pipe nipple Do not use tools 2 Remove the tank drain plug Open the drain valve by installing a 1 inch NPT pipe nipple 88 mm 3 50 inch long in the bottom of the tank to open the internal drain valve and drain the oil Drain the oil into a suitable container g00951920 Illustration 290 3 Remove the drain plug from the brake oil cooler and drain the oil Drain the oil into a suitable container Clean and install the plug 143 Maintenance Section Hoist Torque Converter and Brake Oil Change 4 Remove the pipe nipple Clean and install the tank drain plug 5 Remove the hoist torque converter
47. d 01867519 Fuel System Secondary Filter Replace SMCS Code 1261 510 SE A WARNING Personal injury or death can result if spilled fuel ignites Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire To help prevent possible injury turn the battery disconnect switch to the OFF position when changing fuel filters or water separator elements Clean up fuel spills immediately NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 139 Maintenance Section Fuel System Secondary Filter Replace NOTICE Do not fill fuel filters with fuel before installing them The fuel will not be filtered and could be contaminated Contaminated fuel will cause accelerated wear to fuel system parts The fuel system should be primed prior to starting the engine Illustration 279 g0095 1660 1 Remove the fuel filter element with a strap type wrench Discard the used filter 2 Clean the filter housing base Make sure th
48. d be rotating 5 Check all discharge lines for leakage 6 Check all injectors are operative Check all bearings that are lubricated by the automatic lubrication system for signs of greasing 7 Inspect the electrical system or worn frayed wiring damaged connectors or a tripped circuit breaker Note For more information on the automatic lubrication system refer to Systems Operation Testing and Adjusting Automatic Lubrication System Electric Type for the machine that is being serviced 101872267 Automatic Lubrication Inline Filter Clean Hydraulic Type SMCS Code 7540 070 HR SA A Illustration 175 g00953599 Clean the inline filter if equipped every 250 service hours or monthly Reference For information on cleaning the automatic lubrication system inline filter refer to Systems Operation Testing and Adjusting Automatic Lubrication System Hydraulic Type for the machine that is being serviced 101 Maintenance Section Automatic Lubrication Inline Filter Clean 101855693 Backup Alarm Test SMCS Code 7406 081 Make sure that the parking brake is engaged Turn the engine start switch to the ON position to perform the test Make sure that the area behind the machine is clear of personnel and clear of obstacles Apply the service brake Move the transmission direction and speed control to the REVERSE position The backup alarm should start to sound immediately The
49. e For more information on testing the parking brake holding ability refer to the Operation and Maintenance Manual Braking System Test for the machine that is being serviced 1 Be sure the area around the machine is clear of personnel and obstructions g00952087 Illustration 170 1 Transmission oil pressure switch for brake application 2 Connector 2 Disconnect transmission oil pressure switch 1 from the transmission wiring harness at connector 2 Note The correct transmission oil pressure switch can be identified by the EL331 blue wire and the EL330 grey wire in the transmission wiring harness that is connected to the switch 3 Remove switch 1 from the manifold on the transmission Install a 9S 4191 Plug 9 16 18 straight thread O ring type in the manifold where the switch was removed Reconnect the switch to the transmission wiring harness at connector 2 Illustration 171 g00940746 4 Move the transmission control to the NEUTRAL position Start the engine 5 Disengage the parking brake by moving the parking brake control to the OFF position 6 Move the transmission direction and speed control to the FIRST SPEED FORWARD position 7 Gradually increase the engine speed to 1300 rom The parking brake should remain engaged and the machine should not move Note The parking brake indicator and the action lamp should flash and the action alarm should sound 8 Reduce the engi
50. e Section Steering System Oil Level Check i01871099 Steering System Oil Level Check SMCS Code 4332 535 FLV Illustration 338 g00952788 The steering tank is located on the right side of the machine 1 With the engine running maintain the oil level to the FULL mark in sight gauge 1 g00952789 Illustration 339 2 Stop the engine 3 Remove filler cap 2 slowly to relieve any steering tank pressure Add oil if necessary 4 Clean the filler cap and install the filler cap 101870723 Steering Tank Screen Clean SMCS Code 4332 070 Z3 A WARNING Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 340 g00952620 1 Remove the steering tank filler cap slowly to relieve any steering tank pressure Remove the filler cap to prevent a vacuum in the steering tank Install
51. e open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 349 g00952990 Note Approximately 15 L 4 US gal of oil will drain when cover assembly 1 is removed 1 Remove bolts 2 from cover assembly 1 Remove the cover assembly Drain the oil into a suitable container 2 Remove the screen and baffle retaining nut 5 3 Remove baffle 3 and screen 4 from the cover 4 Wash the screen baffle and cover in clean nonflammable solvent Do not crush the screen 5 Inspect the cover gasket for damage If damaged use a new gasket 6 Assemble the screen and baffle on the cover Install the cover assembly 7 Start the engine and run the engine at low idle Inspect for leaks Illustration 350 900952994 8 With the oil cold check the oil level in sight gauge 6 For the AD45 truck check the oil level with the body fully lowered For the AE40 Series ll truck check the oil level with the ejector plate fully retracted and the tailgate fully raised 9 Maintain the oil level to the FULL mark in the sight gauge 10 Remove filler cap 7 and add oil if necessary 101871355 Transmission Breather Clean SMCS Code 3030 070 BRE
52. e screen mesh Replace the screen adapter if the mesh is worn or damaged 4 Inspect the hose assembly seals and the screen adapter seals Replace the seals if they are worn or damaged 5 Install the screen adapter hose assembly flanges and bolts 6 Start the engine Eject and retract the ejector plate several times Check for leaks i01864768 Engine Air Filter Primary Element Clean Replace SMCS Code 1054 070 PY 1054 510 PY Illustration 244 g00950627 Service the air cleaner daily or if the air filter restriction indicator located on the dash panel comes on Stop the engine NOTICE Service the air cleaner only with the engine stopped Engine damage could result if the air cleaner is ser viced while the engine is running Illustration 245 g00250630 1 Loosen wing nut 1 2 Use handle 2 to remove the engine air filter primary element from the air cleaner housing 3 Inspect the air filter service indicator on the secondary element This indicator is normally green If the indicator is red replace the secondary element Reference For the correct procedure to replace the secondary filter element refer to the Operation and Maintenance Manual Engine Air Filter Secondary Element Replace for the machine that is being serviced g00950634 Illustration 246 4 Clean the inside of the air cleaner housing 5 Inspect the primary element If the pleats the gaskets or the seal
53. each wheel Continue to check the torque on new wheels and rebuilt wheels Check the torque until the torque remains at the specified amount Reference For the correct wheel bolt torque refer to Power Train Specifications Final Drive Brake and Wheel for the machine that is being serviced 171 Maintenance Section Wheel Bolt Torque Check i01871904 Window Clean SMCS Code 7310 070 7340 070 Illustration 362 g00953351 Use commercially available window cleaning solutions to clean the windows Only clean the outside windows from the ground unless handholds are available Use a mop or use a similar device with a long handle to clean the windows from the ground 101871882 Window Washer Bottle Fill SMCS Code 7306 544 KE NOTICE When operating in freezing temperatures use Caterpillar nonfreezing window washer solvent or equivalent System damage can result from freezing nato Illustration 363 g00953340 The window washer reservoir is located at the rear of the operator station Remove the cap and fill the window washer reservoirs Refit the cap 172 Maintenance Section Window Wiper Inspect Replace 101871895 Window Wiper Inspect Replace SMCS Code 7305 040 7305 070 g00953347 Illustration 364 Inspect the condition of the wiper blades on the front and rear windows Replace the wiper blades if the wiper blades are worn or damaged If the wiper blades
54. ean nonflammable solvent 8 Install strainer 6 in the filler opening 9 Install the fuel tank cap 101867877 Fuel Tank Water and Sediment Drain SMCS Code 1273 543 M amp S NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates g00951692 Illustration 284 The drain valve is located on the right side of the machine under the fuel tank ve g00951696 Illustration 285 1 Open turn counterclockwise drain valve 1 and allow the water and sediment to drain out of opening 2 into a suitable container 2 Close drain valve 1 i01868070 Fuses Replace SMCS Code 1417 510 Fuses Fuses protect the electrical system from damage caused by overloaded circuits Replace the fuse if the element separates If the element of a new fuse separates check the circuit Repair the circuit if necessary NOTICE Replace the fuses with the same type and size only Otherwise electrical damage can result If
55. ect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates g00951948 Illustration 292 NOTICE Ensure the dump body is fully lowered AD45 or the ejector plate is fully retracted and the tailgate fully raised AE40 Series II when checking the tank oil lev el The hoist torque converter and brake hydraulic tank is located on the right side of the machine 1 With the oil cold check the oil level in sight gauge 1 For the AD45 truck check the oil level with the body fully lowered For the AE40 Series ll truck check the oil level with the ejector plate fully retracted and the tailgate fully raised 2 Maintain the oil level to the FULL mark in the sight gauge 3 Remove filler cap 2 add oil if necessary 4 Clean the filler cap and install the filler cap Note If the system has been drained it will be necessary to stop the engine and add oil several times 101874943 Hoist Torque Converter and Brake Tank Breather Replace SMCS Code 5057 Illustration 293 g00954327 1 Remove cover 1 g00954328 Illustration 294 2 Loosen the retaining clamp on the bottom of breather
56. el system while priming the engine Periodic removal of the fitting will result in in creased wear of the threads in the fuel filter base and will lead to fuel leakage Do not allow dirt to enter the fuel system Thorough ly clean the area around any fuel system component that will be disconnected Fit a suitable cover over any disconnected fuel system component in order to pro tect it from dirt and debris NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates 138 Maintenance Section Fuel System Primary Filter Clean Replace g00951618 Illustration 277 1 Turn the priming pump counterclockwise and pull out the priming pump plunger This will unlock the hand priming pump 2 Use the hand priming pump to fill the engine fuel lines with fuel Continue to prime the fuel system until the pump resists operation 3 Start the engine and inspect the fuel system for leaks 4 If the engine will not start or continues to misfire or smoke
57. em 4 Clean the pressure cap and inspect the pressure cap Install the pressure cap 5 Start the engine and check for leaks Allow the coolant level to stabilize 6 If necessary add premixed coolant in order to bring the coolant to the proper level in the sight gauge i01863687 Cooling System Level Check SMCS Code 1350 535 FLV 1395 535 FLV A WARNING 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 the pressure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates vw T g00950097 Illustration 218 1 Maintain the coolant level in the sight gauge located on the right side of the machine If it is necessary to add coolant daily check for leaks 2 Inspect the radiator core for debris Clean the radiator core if necessary Reference For information on cleaning the radiator core refer to the Operation and Ma
58. erviced Check all of the grease fittings 155 Maintenance Section Service Inspection Illustration 320 g00993186 P Inspect Rollover Protective Structure ROPS or Falling Object Protective Structure FOPS 13 for cracks in welds castings or any metal section on the ROPS FOPS Check the mounting bolts and the mounting pads for damage Consult your Caterpillar dealer for necessary repairs Inspect the operator s station Check the Caterpillar Monitoring System for diagnostic codes Correct any discrepancies 156 Maintenance Section Service Inspection AE40 Series Il A P 0 N Illustration 321 900952469 Inspection points for the service inspection A Ground level controls H Hydraulic system O Automatic lubrication system if B Front lights 1 Front suspension cylinders equipped C Cooling system J Tires P Rollover Protective Structure ROPS D Engine K Steering hydraulic system and Falling Object Protective Structure E Power train h
59. ging procedures for the brake accumulator refer to Systems Operation Testing and Adjusting Brake Accumulator Test and Charge for the machine that is being serviced or consult your Caterpillar dealer 105 Maintenance Section Brake Accumulator Check 101857629 Brake Oil Cooler Screen Clean SMCS Code 4257 070 4295 070 Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Clean the brake oil cooler screen whenever there is a failure of the hoist torque converter or brake hydraulic system goo0946944 Illustration 187 Note Hand tighten the NPT pipe nipple Do not use tools 1 Remove tank drain valve plug 1 from the hoist torque converter and brake hydraulic tank Open the drain valve by installing a 1 1 4 inch NPT pipe nipple 88 mm 3 50 inch long to open the internal drain valve and drain
60. he air intake precleaner rotor operation 5 Periodically remove the precleaner and wash in water 01865682 Engine Crankcase Breather Clean SMCS Code 1317 070 Illustration 250 g00950943 1 Stop the engine 2 Loosen hose clamps 1 and 2 and remove the hose from the breather 3 Loosen breather retaining clamp 3 and remove the clamp and the breather 4 Wash the breather in a clean nonflammable solvent Shake the element dry or use pressure air in order to dry the breather element 5 Inspect the hose for damage Replace the hose if necessary 6 Install the breather Tighten the breather clamp 7 Install the hose on the breather Tighten the hose clamps 129 Maintenance Section Engine Crankcase Breather Clean Illustration 251 g00950944 8 Repeat Steps 1 through 7 for the breather on the other side of the engine i01865691 Engine Mounts Inspect SMCS Code 1152 040 Illustration 253 g00950963 Caterpillar recommends inspecting the engine mounts for deterioration and for proper bolt torque This will help to prevent excessive engine vibration that is caused by improper mounting 130 Maintenance Section Engine Oil Level Check Reference For the proper bolt torques for the engine mounts refer to Specifications 3408E HEUI Engine for the machine that is being serviced i01866047 Engine Oil Level Check SMCS Code 1000 535 FLV NOTICE Do not underfill o
61. he cooling system capacity refer to the Operation and Maintenance Manual Refill Capacities for the machine that is being serviced 5 Start the engine Run the engine with the cooling system pressure cap removed Run the engine until the water temperature regulator opens and the coolant level stabilizes 115 Maintenance Section Cooling System Coolant Additive DEAC Add Note If Caterpillar antifreeze is being used do not add supplemental coolant additive or change the element at this time vT Illustration 214 g00949925 6 Maintain the coolant level to within 13 mm 0 50 inch of the bottom of the filler pipe or to the proper level in the sight gauge 7 Install the cooling system pressure cap 8 Stop the engine 101863543 Cooling System Coolant Additive DEAC Add SMCS Code 1352 538 1395 538 Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Coolant Additive contains alkali Avoid contact with skin and e
62. ily Automatic Lubrication Grease Tank Fill 100 Automatic Lubrication Grease Tank Fill 100 Backup Alarm Test cccseeeeeeseeeeeenseeeeeeeaes 101 Belts Inspect Adjust Replace cceeeeeee 103 Body Pivot Bearings Lubricate 0 104 Braking System Test cccceeeeeeeeeeeteeteteeees 107 Cooling System Level Check sses 118 Ejector Cylinder Bearing Lubricate 125 Engine Air Filter Primary Element Clean Replace ccccceccceceseeceseeteneeeeeeeeseeees 126 Engine Air Precleaner Clean nesese 128 Engine Oil Level Check 0 0 eeeeeeeeeeeees 130 Fire Suppression System Check s es 135 Fuel Tank Water and Sediment Drain 141 Hoist Cylinder Bearings Lubricate 142 Hoist Torque Converter and Brake Oil Level CHECK ccc tan iced nee a ae i o Eada 144 Indicators and Gauges Test ccseeeeeeeeeeees 146 Oscillating Hitch Lubricate cceeeeeeees 147 Seat Belt Inspect o eeeeceeceeeeeeeeeseeeeteeeteneees 150 Service Inspection ececeeeeeeeeseeeeeeeeteteeeeeneees 151 Steering Cylinder Bearings Lubricate 159 Steering System Oil Level Check 0006 162 Suspension and Suspension Cylinder Bearings EUDIICAteS a safes aetetedecaes areia tes 163 Tailgate and Tailgate Cylinder Bearings Lubricate eens in ananasa ankaa ti 164 Transmission Oil Leve
63. intenance Manual Radiator Core Clean for the machine that is being serviced a g00949921 Illustration 219 3 If coolant level is low loosen the pressure cap slowly to relieve pressure Remove the pressure cap Add coolant as required to within 13 mm 0 50 inch of the bottom of the filler pipe or to the proper level in the sight gauge 4 Inspect the pressure cap and cap seal for damage deposits or foreign material Clean the pressure cap with a clean cloth or replace the cap if it is damaged 5 Install the cooling system pressure cap 101863732 Cooling System Pressure Cap Clean Replace SMCS Code 1382 070 1382 510 A WARNING 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 the pressure g00949921 Illustration 220 119 Maintenance Section Cooling System Pressure Cap Clean Replace 1 Loosen the pressure cap slowly in order to relieve cooling system pressure Remove the pressure cap 2 Inspect the pressure cap for damage foreign material and for deposits 3 Inspect the condition of the pressure cap seal Replace the pressure cap if damaged If the seal is not damaged use a 9S 8140 Pressurizing Pump to pressure test the pressure cap The correct cap relief pressure is stamped on the radiator cap If the pressure cap does not hold the correct pressure install a new cap 4 I
64. ion 354 g00953064 Note Hand tighten the NPT pipe nipple Do not use tools 3 Remove the transmission drain plug Open the drain valve by installing a 1 inch NPT pipe nipple 88 mm 3 5 inch long in the bottom of the transmission to open the internal drain valve Drain the oil into a suitable container 4 Remove the pipe nipple Clean the drain plug and install the transmission drain plug g00953092 Illustration 355 5 Remove filler cap 2 Fill the transmission with oil through the filler tube Clean the filler cap and install the filler cap Reference For information on lubricants and refill capacities refer to the Operation and Maintenance Manual Lubricants Viscosities and Refill Capacities for the machine that is being serviced 6 Start and run the engine at low idle Inspect the machine for leaks 7 Operate the transmission control to circulate oil in the transmission 8 Maintain the oil level to the FULL mark on sight gauge 1 Add oil if necessary 9 Stop the engine i01871600 Transmission Oil Filter Replace SMCS Code 3067 510 1 Park the machine on a level surface Engage the parking brake Stop the engine A WARNING Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and rep
65. it is necessary to replace fuses frequently an electri cal problem may exist Contact your Caterpillar dealer 142 Maintenance Section Hoist Cylinder Bearings Lubricate Illustration 286 View of battery compartment under the operator s station 1 675 Amp Fusible link g00951772 Illustration 287 View under right side of console cover in the operator s station 2 8 Amp if equipped voltage reducer 3 5 Amp Torque converter lock up i01868381 Hoist Cylinder Bearings Lubricate SMCS Code 7551 086 CD NOTICE Check that the lines attached to all remote grease fit tings are undamaged If the lines are split grease will not reach the bearings or pins Machine damage will result Wipe all fittings clean before lubricating g00951840 Illustration 288 Rear view of the AD45 machine 1 Lubricate the left upper hoist cylinder bearing through remote mounted fitting 1 2 Lubricate the left lower hoist cylinder bearing through remote mounted fitting 2 3 Lubricate the right lower hoist cylinder bearing through remote mounted fitting 3 4 Lubricate the right upper hoist cylinder bearing through remote mounted fitting 4 101868836 Hoist Torque Converter and Brake Oil Change SMCS Code 5050 044 Operate the machine long enough to warm the oil The machine must be level the parking brake engaged and the engine stopped 1 Remove the filler cap to prevent a va
66. itting 2 in the pump body Fill the reservoir until lubricant appears at overflow relief valve 1 2 Check all lubricant lines for leakage 3 Check hydraulic lines for leakage Check for worn or damaged houses 4 Check all lubricant injectors are operative Check all bearings that are lubricated by the automatic lubrication system for signs of lubrication 5 Inspect the electrical system for worn or frayed wiring damaged connectors or a tripped circuit breaker Reference For more information on the automatic lubrication system refer to Systems Operation Testing and Adjusting Automatic Lubrication System Hydraulic Type for the machine that is being serviced 101872083 Automatic Lubrication Grease Tank Fill Electric Type SMCS Code 7540 544 HR go0953494 Illustration 174 1 Check the grease level in the reservoir Use a manual grease gun or grease pump to fill the reservoir through filler fitting 3 in the pump body 2 Fill the reservoir to MAXIMUM indicator 1 NOTICE When filling the reservoir caution should be used as extreme pressure and overfilling can cause damage to the reservoir assembly 3 With the battery disconnect switch and the engine start switch in the ON position trigger a lubrication cycle by pressing switch 2 on the side of the cover assembly 4 Observe the stirring paddle in the lubricant reservoir When the pump is operating the stirring paddle shoul
67. l Check sses 170 Window Clean sccessseciisrsieesssrrsrrreesrrrrrrnnens 171 Every 50 Service Hours or Weekly Automatic Lubrication Filler Filter Clean 100 Cab Air Filter Clean Replace ccccceee 110 Fuel System Water Separator Drain 140 Tire Inflation Check ccccccecececeeeeeeeeeeeeeeeeeees 164 Initial 250 Service Hours or at first oil change Engine Valve Lash Check Adjust c ee 133 Oscillating Hitch Adjust ceeeeeeeeeeeeeees 147 Every 250 Service Hours or Monthly Automatic Brake Application System Low Transmission Oil Pressure Test ceee 99 Automatic Lubrication Inline Filter Clean 101 Battery Electrolyte Level Check n se 102 Cab Tilt Pin and Lockdown Pin Check EUIBRICALG 222 22 E E ERT 111 Cooling System Coolant Additive DEAC Add 115 Differential and Final Drive Oil Level Check 123 Drive Shaft Universal Joints Splines and Bearings Inspect Lubricate ccccceeeeeeeeseeeeeteeeeseeteaes 124 Engine Oil and Filter Change 130 Engine Shutdown to Idle Protection System MOS seater ea tents deta sy cere cebe cee A 132 Fan Drive Bearing and Belt Tightener LUBE ies vi ove d ods ceeds a O 135 Frame and Body Inspect n e 135 Fuel System Primary Filter Clean Replace 138 Fuel System Secondary Filter Replace 139 Steering Stop Check 0
68. l in the transmission 170 Maintenance Section Transmission Oil Level Check Illustration 358 g00953168 9 Maintain the oil level to the FULL mark on sight gauge 5 Remove filler cap 6 and add oil if necessary Reference For information on lubricants and refill capacities refer to the Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities for the machine that is being serviced 10 Stop the engine 101871603 Transmission Oil Level Check SMCS Code 3030 535 FLV The transmission oil filler tube and sight gauge are located on the right side of the machine near the articulating hitch g00953216 Illustration 359 a j amp al Gh es 6 Illustration 360 g00953217 3 FULL mark when engine is stopped 4 FULL mark when engine is running Check the transmission oil level with the machine on a level surface and the parking brake engaged 1 While the engine is running maintain the oil level to FULL mark 4 in sight gauge 1 When the engine is stopped maintain the oil to FULL mark 3 in sight gauge 1 2 If necessary remove oil filler cap 2 and add oil Clean the filler cap and install the filler cap Reference For information on lubricants and refill capacities refer to the Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities for the machine that is being serviced 1018
69. ld turn slightly when the valves close If the valve fails to rotate contact your Caterpillar dealer 101866298 Engine Water Pump Inspect SMCS Code 1361 040 Illustration 267 g00951327 Front view of engine A water pump that has failed may cause severe engine overheating problems The engine overheating problems could result in the following problems e Cracks in the cylinder head e Piston seizure e Other potential engine damage Visually inspect the water pump for leaks If leaks are found all of the seals on the water pump must be replaced Note For further information refer to Disassembly and Assembly 3408E amp 3412E Engine for the machine that is being serviced 101866342 Exhaust Purifier Inspect Clean SMCS Code 1089 040 1089 070 Illustration 268 g00951352 Inspect the catalytic purifier for damage and for leaks If necessary make repairs If the catalytic purifier is damaged consult your Caterpillar dealer If the engine has low power the catalytic purifier may be blocked Clean the catalytic purifier Reference For information on cleaning the catalytic purifier refer to the Operation and Maintenance Manual Emission Control Systems for the machine that is being serviced i01866399 Fan Drive Bearing and Belt Tightener Lubricate SMCS Code 1358 086 1359 086 BD a oak g00951357 Illustration 269 1 Lubricate
70. lustration 179 g00946649 1 The batteries are located under the cab Tilt the cab to access the batteries Reference For information on tilting the cab refer to the Operation and Maintenance Manual Cab Tilt for the machine that is being serviced g00946657 Illustration 180 2 Clean the battery surface with a clean cloth 3 Disconnect all battery cables from the batteries Reference To disconnect the battery cables refer to the Operation and Maintenance Manual Battery Battery Cable or Battery Disconnect Switch Replace for the machine that is being serviced 4 Clean the battery cables and the battery posts Coat the battery posts with 1P 0808 Multipurpose Grease or petroleum jelly 5 Connect the battery cables to the batteries 103 Maintenance Section Battery Battery Cable or Battery Disconnect Switch Replace Reference To connect the battery cables refer to the Operation and Maintenance Manual Battery Battery Cable or Battery Disconnect Switch Replace for the machine that is being serviced Coat the terminals with 1P 0808 Multipurpose Grease or petroleum jelly Then install the post cover For conventional batteries and batteries of low maintenance follow these additional instructions e Inspect the battery electrolyte level in each battery cell A maintenance free battery does not require inspection e Maintain the level of the distilled water to the bottom
71. n the element mounting base Make sure all of the old seal is removed 4 Replace with a new maintenance element 5 Coat the seal of a new element with a thin film of clean engine oil 6 Install and turn the element until the seal contacts the base then tighten 3 4 of a turn more 7 Open the inlet and outlet valves 8 Clean the pressure cap and inspect the pressure cap Install the pressure cap 9 Start the engine and check for leaks Allow the coolant level to stabilize 10 If necessary add premixed coolant in order to bring the coolant to the proper level in the sight gauge 101863569 Cooling System Coolant Extender ELC Add SMCS Code 1352 538 NL 1395 538 NL A WARNING Personal injury can result from hot coolant steam and alkali At operating temperature engine coolant is hot and under pressure The radiator and all lines to heaters or the engine contain hot coolant or steam Any contact can cause severe burns Remove cooling system pressure cap slowly to relieve pressure only when engine is stopped and cooling system pressure cap is cool enough to touch with your bare hand Do not attempt to tighten hose connections when the coolant is hot the hose can come off causing burns Cooling System Coolant Additive contains alkali Avoid contact with skin and eyes 117 Maintenance Section Cooling System Coolant Extender ELC Add NOTICE Adding coolant to an overheated engine could result
72. n the oil into a suitable container 145 Maintenance Section Hoist Torque Converter and Brake Tank Screen Clean 2 Remove bolts 2 from the hydraulic tank cover and remove the cover 3 Clean the debris from the bottom of the tank g00952019 Illustration 296 4 Remove the retaining nuts from bolts 3 Remove the cover located at the bottom of hoist return screen 4 Remove and clean or discard the screen 5 Install new or clean screen 4 the screen cover and cover retaining nuts 6 Clean the hydraulic tank cover in clean nonflammable solvent Inspect the cover gasket If the gasket is damaged use a new gasket eit een RN Illustration 297 g00952025 7 Remove four bolts 5 that hold suction pipes 6 and 7 to the hydraulic tank Remove the suction pipe seal and screen assemblies 8 Remove the suction screens from the pipes 9 Wash the screens in clean nonflammable solvent 10 Inspect the suction pipe seals Replace if damaged 146 Maintenance Section Indicators and Gauges Test 11 Inspect the suction screens in the pipe assemblies 12 Install the suction pipe screen and seal assemblies in the hydraulic tank Secure the pipes to the hydraulic tank with bolts 5 13 Install the tank cover and bolts 14 Fill the hydraulic tank Reference For information on lubricants and refill capacities refer to Operation and Maintenance Manual Lubricant Viscosities and
73. n to machines that are shipped from the factory with Extended Life Coolant ELC and machines that are maintained with Extended Life Coolant ELC Reference For all cooling system requirements refer to Caterpillar Machine Fluids Recommendations SEBU6250 Cooling System Specifications Use the 8T 5296 Test Kit in order to check the concentration Add Coolant Additive If Required Illustration 215 g00949921 1 Loosen the pressure cap slowly to relieve cooling system pressure Remove the pressure cap 2 It may be necessary to drain enough coolant from the radiator to allow for the addition of the liquid supplemental coolant additive Note Make sure the coolant is drained into a suitable container 3 Add liquid supplemental coolant additive conditioner according to the requirements of your cooling system as determined by the coolant additive concentration test 4 Clean the pressure cap and inspect the pressure cap Install the pressure cap 5 Start the engine and check for leaks Allow the coolant level to stabilize 6 If necessary add premixed coolant in order to bring the coolant to the proper level in the sight gauge Change Coolant Conditioner Element If Required Illustration 216 g00949952 1 Loosen the pressure cap slowly to relieve cooling system pressure Remove the pressure cap 2 Close element inlet valve 1 and outlet valve 2 Remove and discard element 3 3 Clea
74. ne speed to low idle move the transmission direction and speed control to the NEUTRAL position Engage the parking brake NOTICE If the parking brake disengaged and the machine moved while testing the Automatic Brake Application ABA system have the system inspected and re paired immediately before returning the machine to operation Contact your Caterpillar dealer or refer to the Braking Section of the machine Service Manual 9 Remove the plug and install transmission oil pressure switch for brake application 1 in the transmission manifold Connect the switch to the harness at connector 2 100 Maintenance Section Automatic Lubrication Filler Filter Clean Automatic Lubrication Filler Filter Clean Hydraulic Type SMCS Code 7540 070 HR Illustration 172 g00953579 Clean the filler filter if equipped every 50 service hours or weekly Reference For information on cleaning the automatic lubrication system filler filter refer to Systems Operation Testing and Adjusting Automatic Lubrication System Hydraulic Type for the machine that is being serviced Automatic Lubrication Grease Tank Fill Hydraulic Type SMCS Code 7540 544 HR g00953529 Illustration 173 Note The lubricant tank if equipped should be refilled at regular intervals Refills should be performed daily to prevent emptying the system 1 Use a manual lubricant gun or pump to fill the reservoir through filler f
75. new seal 5 Install the new element in the filter housing Install the filter housing and element g00952191 Illustration 306 6 Start the engine and operate the engine at low idle Check for leaks 7 With the oil cold check the oil level in sight gauge 5 For the AD45 truck check the oil level with the body fully lowered For the AE40 Series ll truck check the oil level with the ejector plate fully retracted and the tailgate fully raised 8 Maintain the oil level to the FULL mark in sight gauge 5 9 Remove filler cap 6 and add oil if necessary 149 Maintenance Section Radiator Core Clean i01869990 Radiator Core Clean SMCS Code 1353 070 KO Illustration 307 g00907092 You can use compressed air high pressure water or steam to remove dust and other debris from the radiator core However the use of compressed air is preferred Care must be taken when you are using high pressure water High pressure water can cause damage to the radiator Using a water spray nozzle on the pressure washer which will disperse the water pressure is preferred Reference For the complete procedure for cleaning the radiator core refer to Special Publication SEBD0518 Know Your Cooling System for the machine that is being serviced i01870049 Rollover Protective Structure ROPS and Falling Object Protective Structure FOPS Inspect SMCS Code 7325 040 NOTICE Do not attempt to st
76. nflation Remove large rocks from the treads Look for abnormal wear or uneven wear that may indicate mechanical problems elsewhere Make sure that you check the inside of the tire for damage or for wear Inspect the tire treads for damage If necessary repair the tires Look for damaged rims Replace any missing valve caps Check the wheels for bolts that are loose or missing Note Rust behind a bolt may indicate that the bolt is loose Shiny metal areas around a bolt may indicate that the bolt is loose Illustration 317 g00952458 K Inspect the steering hydraulic system for leaks worn hoses and damaged lines If necessary repair leaks worn hoses and damaged lines Inspect steering cylinders 9 L Inspect the rear axle for leaks Inspect the rear lights for damage Illustration 318 g00952460 M Inspect the frame and the dump body Check frame 10 for cracks or damage Inspect dump body 11 for damage wear or distortion Check for uneven wear of the body support pads N Inspect the articulating hitch and the oscillating hitch for wear damage and loose or missing bolts Have necessary repairs made BaO O OOl o g00952465 Illustration 319 O Inspect the automatic lubrication system Inspect tank 12 for leaks Fill tank 12 with lubricant For the correct procedure refer to the Operation and Maintenance Manual Automatic Lubrication System Fill for the machine that is being s
77. nstall the filter element and wing nut Tighten the wing nut finger tight Do not use a tool to tighten the wing nut 10 Install end cap 4 Tighten clamp bolt 3 finger tight Do not use a tool to tighten the clamp bolt 101863183 Cab Tilt Pin and Lockdown Pin Check Lubricate SMCS Code 7301 086 7301 535 A WARNING Do not work on or near the cab or left side of the engine until the cab is in the fully tilted position Disconnect the batteries by turning the battery disconnect switch to the OFF and remove the key before performing and service work under the cab Accidental cab lowering can cause severe person al injury or death from crushing could occur 1 Tilt the cab Reference For information on tilting the cab refer to Operation and Maintenance Manual Cab Tilt for the machine that is being serviced 112 Maintenance Section Circuit Breakers Reset 2 Check the cab tilt pins and bearings tilt cylinder pins and bearings and the cab lockdown pins and bearings for wear or damage 3 Check all mounting bolts and tighten if necessary g00949797 Illustration 205 Note Wipe all fittings before lubricating 4 Lubricate one fitting 1 on each cab tilt pin 5 Lubricate the tilt cylinder tilt pin rod end through fitting 2 6 Lubricate the tilt cylinder tilt pins cylinder anchor end through two fittings 3 7 Lubricate one fitting 4 on each cab lockdown pin assembly
78. nstall the pressure cap i01863760 Cooling System Water Temperature Regulator Replace SMCS Code 1355 510 A WARNING 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 the pressure Replace the water temperature regulator on a regular basis in order to reduce the chance of unscheduled downtime and of problems with the cooling system The water temperature regulator should be replaced after the cooling system has been cleaned Replace the water temperature regulator while the cooling system is completely drained or while the cooling system coolant is drained to a level that is below the water temperature regulator housing NOTICE Failure to replace the engine s water temperature reg ulator on a regularly scheduled basis could cause se vere engine damage Note If you are only replacing a water temperature regulator drain the cooling system coolant to a level that is below the water temperature regulator housing 120 Maintenance Section Differential Thrust Pin Clearance Check NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500
79. o the Operation and Maintenance Manual Refill Capacities for the machine that is being serviced 101864361 Differential Thrust Pin Clearance Check SMCS Code 3258 535 T9 g00950497 Illustration 222 For the correct thrust pin adjustment procedures for the front and rear differentials refer to Power Train Specifications Differential and Bevel Gear for the machine that is being serviced or contact your Caterpillar dealer Differential and Final Drive Oil Change SMCS Code 3258 044 4050 044 Note The oil change interval for the differential and for the final drives can be monitored with the S O S Scheduled Oil Sampling program The change intervals is based on the condition of the oil If scheduled oil sampling program is not used the oil change interval for the differential and the final drives is at 2000 service hours Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Cate
80. ons Failure to do so could result in damage to the cooling system components NOTICE Mixing ELC with other products reduces the effective ness of the coolant and shortens coolant life Use on ly Caterpillar products or commercial products that have passed the Caterpillar EC 1 specifications for premixed or concentrate coolants Use only Caterpillar Extender with Caterpillar ELC Failure to follow these recommendations could result in the damage to cool ing systems components If ELC cooling system contamination occurs see the topic Extended Life Coolant ELC in the Operation and Maintenance Manual SEBU6250 Caterpillar Machine Fluids Recommendations Note This procedure pertains to machines using Extended Life Coolant ELC only If the coolant is dirty or if you observe any foaming in the cooling system drain the coolant before the recommended interval Illustration 212 g00949921 1 Loosen the pressure cap slowly to relieve cooling system pressure Remove the pressure cap 1 mi Illustration 213 g00949922 2 Open the drain valve for the engine cooling system Drain the coolant into a suitable container The drain valve is located on the bottom radiator tube 3 Flush the cooling system with water until the draining water is clear Close the drain valve 4 Add the coolant solution Add coolant slowly to help avoid air locks 20 L 5 US gal per minute Reference For information on t
81. ory with Extended Life Coolant ELC Also this does not pertain to the machines that are maintained with Extended Life Coolant ELC If the coolant is dirty or if you observe any foaming in the cooling system drain the coolant before the recommended interval Illustration 209 g00949921 1 Loosen the pressure cap slowly to relieve cooling system pressure Remove the pressure cap g00949922 Illustration 210 2 Open the drain valve for the engine cooling system Drain the coolant into a suitable container The drain valve is located on the bottom radiator tube 114 Maintenance Section Cooling System Coolant ELC Change 3 Close the drain valve Fill the system with clean water and a 6 to 10 percent concentration of cooling system cleaner 4 Start and run the engine for 90 minutes Stop the engine and drain the cleaning solution into a suitable container 5 When the engine is stopped flush the cooling system with water until the draining water is clear Drain the water into a suitable container 6 Close the drain valve 7 Add the coolant solution Add coolant slowly to help avoid air locks 20 L 5 US gal per minute Reference For additional information on the cooling system capacity refer to the Operation and Maintenance Manual Refill Capacities for the machine that is being serviced 8 Start the engine Run the engine with the cooling system pressure cap removed Run the engine un
82. ove the ejector plate to the fully ejected position Lubricate the ejector body cylinder bearings in the head end of the ejector cylinder through two fittings 3 one on each side of the machine 101864765 Ejector Line Screen Inspect Clean SMCS Code 5057 040 Z3 5057 070 Z3 Clean the ejector line screen every 1000 service hours or 6 monthly or whenever there is failure of the regenerative sequence valve 126 Maintenance Section Engine Air Filter Primary Element Clean Replace Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustration 242 g00950622 1 Remove four bolts 1 flanges 2 and the body end of hose assembly 3 2 Remove the ejector line screen adapter from behind the hose flanges g00950623 Illustration 243 3 Wash screen adapter 4 in clean nonflammable solvent Inspect th
83. r overfill the engine crankcase with oil Either condition can cause engine damage Illustration 254 g00951 104 Check the engine oil level with the machine level and the parking brake engaged The dipstick is located on the cab side of the engine Illustration 255 g00951105 Engine dipstick i a rhe UU Illustration 256 g00951 107 1 Before starting the engine the oil level must be in the hatched area on the SAFE STARTING RANGE side of dipstick 2 2 With the engine running and the oil warm maintain the oil level in the hatched area on the SAFE OPERATING RANGE side of the dipstick 3 Remove filler cap 1 and add oil if necessary 4 Clean the filler cap and install the filler cap i01865763 Engine Oil and Filter Change SMCS Code 1318 044 Note Some commercial oils that meet API specifications may require shorter oil change intervals The oil change intervals are determined by close monitoring of the oil condition and engine wear metals Caterpillar prefers scheduled oil sampling as the proper method of checking engine wear metals Consult your Caterpillar dealer for the latest oil recommendations A WARNING Do not work on or near the cab or left side of the engine until the cab is in the fully tilted position Disconnect the batteries by turning the battery disconnect switch to the OFF position and remove the key before performing any service work
84. r suspension cylinder bearing through remote mounted fitting 2 3 Lubricate the front suspension frame left pivot bearing through remote mounted fitting 3 4 Lubricate the left upper suspension cylinder bearing through remote mounted fitting 4 5 Lubricate the front suspension frame right pivot bearing through remote mounted fitting 5 6 Lubricate the right lower suspension cylinder bearing through remote mounted fitting 6 101871223 Tailgate and Tailgate Cylinder Bearings Lubricate SMCS Code 5107 086 BD 7271 086 BD 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 Wipe all fittings clean before lubricating LN Illustration 344 g00952850 1 Lubricate the tailgate pivot and cylinder bearings through three remote mounted fittings 1 on each side of the machine 101871248 Tire Inflation Check SMCS Code 4203 535 Al 4203 535 PX g00952922 Illustration 345 Measure the tire pressure on each tire Consult your Caterpillar dealer for correct load rating and for the correct operating pressures Inflate the tires if necessary Reference For additional information about tire inflation tire pressures and tire inflation pressure adjustment refer to the Operation and Maintenance Manual Tire Inflation Informa
85. r the correct procedure refer to Operation and Maintenance Manual Engine Air Precleaner Clean for the machine that is being serviced G Inspect fuel tank 6 Make sure that the filler cap is installed correctly Check the welds and mounting brackets for the fuel tank Look for any leaks or damage to the fuel tank H Inspect the hydraulic systems Check for leaks worn hoses and for damaged lines Repair any leaks worn hoses and damaged lines 154 Maintenance Section Service Inspection Check the oil level in hydraulic tank 7 Check the level in steering tank 8 Make sure that the filler caps are installed Inspect the tank covers for damaged bolts loose bolts or missing bolts Tighten loose bolts and replace missing bolts Check the welds and mounting brackets for the hydraulic tank and the steering tank Inspect the tank for leaks or for damage If necessary make repairs 1 Inspect the front suspension cylinders for leaks or damage Repair any leaks in the suspension cylinders Check for the following conditions If any of these conditions are present refer to Operation and Maintenance Manual Suspension Cylinder Check for the machine that is being serviced e The chrome has been wiped off and the whole length of the chrome is used during normal operation e The ride is harsh and the suspension cylinders extend fully when the machine is empty J Inspect tires for cuts gouges and proper i
86. raighten the ROPS structure Do not repair the ROPS by welding reinforcement plates to the structure If there are any cracks in the welds in the castings or in any metal section of the ROPS consult your Cater pillar dealer for repairs 150 Maintenance Section Seat Belt Inspect Illustration 308 g00952272 Inspect the ROPS FOPS for bolts that are loose or damaged Use original equipment parts only to replace bolts that are damaged or missing Tighten the mounting bolts to the correct torque Reference For the correct bolt torques refer to the Power Train Specifications Cab Mounting FOPS or Cab Mounting ROPS for the machine that is being serviced Note Apply thread lubricant to all ROPS FOPS bolt threads before installation Failure to apply lubricant can result in improper bolt torque Replace ROPS FOPS mounting supports if the ROPS FOPS rattles or makes a noise when the machine is operated on a rough surface Check cab lockdown pins for wear and serviceability Lubricate the cab pivot pins Check for full extension and retraction of the cab lockdown pins Check for correct cab tilt sequence Check for leaks from lockdown pin hydraulic cylinders Do not repair the ROPS FOPS by welding reinforcement plates to the ROPS FOPS Consult your Caterpillar dealer for repair of cracks in any welds in any castings or any metal section of the ROPS FOPS Ensure any certification labels are firmly fixed
87. re Make sure that you check the inside of the tire for damage or for wear Inspect the tire treads for damage If necessary repair the tires Look for damaged rims Replace any missing valve caps Check the wheels for bolts that are loose or missing Note Rust behind a bolt may indicate that the bolt is loose Shiny metal areas around a bolt may indicate that the bolt is loose 158 Maintenance Section Service Inspection Illustration 325 g00952458 K Inspect the steering hydraulic system for leaks worn hoses and damaged lines If necessary repair leaks worn hoses and damaged lines Inspect steering cylinders 9 L Inspect the rear axle for leaks Inspect the rear lights for damage g00952543 Illustration 326 M Inspect the frame and the ejector body Check frame 10 for cracks or damage Inspect ejector body 11 for damage wear or distortion Check for uneven wear of the body support pads N Inspect the articulating hitch and the oscillating hitch for wear damage and loose or missing bolts Have necessary repairs made Illustration 327 g00952465 O Inspect the automatic lubrication system Inspect tank 12 for leaks Fill tank 12 with lubricant For the correct procedure refer to the Operation and Maintenance Manual Automatic Lubrication System Fill for the machine that is being serviced Check all of the grease fittings 00952467 Illustration 328 P In
88. rning the machine to oper ation 101862774 Cab Air Filter Clean Replace SMCS Code 7342 070 7342 510 Note Clean the cab air filter weekly or when a reduction of air circulation in the cab is noticed If working in less dusty conditions the service interval for the cab air filters can be extended Air Conditioning Recirculation Filter g00949643 Illustration 201 1 Remove bolt 1 that fastens recirculation filter assembly 2 2 Remove the cover and the air conditioning recirculation filter from the canister 3 Clean the recirculation filter using air pressure When you use air pressure the maximum air pressure should be 205 kPa 30 psi 4 Install the filter in the canister Install the cover and refit the filter assembly Note When rips or tears are noticed in the filter element or a reduction of air circulation is noticed in the cab after cleaning filter install a new element Air Conditioning Filter Illustration 202 go094965 1 1 Release two latches 1 Remove air conditioning filter cover 2 sec MUKKAAKARAAAABNAIN a Lull oR Illustration 203 g00949654 2 Remove air conditioning filter 3 from the air conditioning duct 3 Clean the filter element with pressure air or wash the element in warm water and a nonsudsing household detergent When you use air pressure the maximum air pressure is 205 kPa 30 psi When you use water pressure the maximum w
89. rpillar products Dispose of all fluids according to local regulations and mandates Wipe covers and surfaces around openings before checking or adding oil Park on a level surface Illustration 223 g002950196 1 Position the wheels so that final drive drain level plugs 1 are facing downward Remove the final drive drain level plugs and allow the oil to drain into a suitable container 121 Maintenance Section Differential and Final Drive Oil Change 2 Clean the area around the drain level plug Clean the drain level plug Illustration 224 909950294 View of front differential Illustration 225 g002950210 View of rear differential 3 Remove front differential drain plugs 3 and allow the oil to drain into a suitable container 4 Clean the drain plugs and install the drain plugs 5 Remove differential filler plugs 2 Fill the differential to the bottom of the filler plug opening Reference For information on lubricants and refill capacities refer to the Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities for the machine that is being serviced 6 Clean the area around the filler plug Clean the filler plug Install the filler plug 122 Maintenance Section Differential and Final Drive Oil Change g00950216 Illustration 226 7 Position each wheel so that drain level plugs 1 for the final drives are even with the center line of the
90. rush or pressure air 168 Maintenance Section Transmission Oil Change NOTICE Do not drop or rap the magnets against any hard ob jects Replace any damaged magnets 4 Clean the cover and inspect the seal Replace the seal if it is damaged 5 Install the clean screen magnet and tube assembly with the magnet opening down 6 Install the cover Tighten the cover bolts 7 Fill the transmission with oil Reference Refer to Operation and Maintenance Manual Transmission Oil Level Check for the machine that is being serviced 101871482 Transmission Oil Change SMCS Code 3030 044 1 Operate the machine to warm the transmission oil 2 Park the machine on a level surface Engage the parking brake Stop the engine A WARNING Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates Illustrat
91. s are damaged discard the primary element Replace a damaged primary element with a clean primary element 127 Maintenance Section Engine Air Filter Primary Element Clean Replace NOTICE Do not clean the primary elements by bumping or tap ping them Do not use primary elements with dam aged pleats gaskets or seals Engine damage can re sult Make sure the cleaned primary elements are com pletely dry before installing them into the filter hous ing Water remaining in the elements can cause false indications of contamination in S O S Analysis test re sults 6 If the primary element is not damaged clean the primary element The primary element can be cleaned by using the following methods e Pressure air e Pressure water e Detergent washing When you use pressure air the maximum air pressure is 205 kPa 30 psi When you use pressure water the maximum water pressure is 280 kPa 40 psi Illustration 247 g00905242 7 When you clean the inside pleats and the outside pleats direct the air along the pleats or direct the water along the pleats The primary element can be washed in a solution that consists of warm water and of nonsudsing household detergent Fully rinse the pleats Allow the primary element to air dry completely 8 Inspect the primary element after you clean the primary element Do not use a primary element if the pleats the gasket or the seals are damaged 9 Cover the clean primary
92. se only Caterpillar Extender with Caterpillar ELC Failure to follow these recommendations could result in the damage to cool ing systems components If ELC cooling system contamination occurs see the topic Extended Life Coolant ELC in the Operation and Maintenance Manual SEBU6250 Caterpillar Machine Fluids Recommendations When a Caterpillar Extended Life Coolant ELC is used an Extender must be added to the cooling system 118 Maintenance Section Cooling System Level Check Reference For the proper service interval refer to the Operation and Maintenance Manual Maintenance Interval Schedule for the machine that is being serviced The amount of extender is determined by the cooling system capacity Reference For information on the cooling system capacity refer to the Operation and Maintenance Manual Refill Capacities for the machine that is being serviced Reference For all cooling system requirements refer to Caterpillar Machine Fluids Recommendations SEBU6250 or consult your Caterpillar dealer g00949921 Illustration 217 1 Loosen the pressure cap slowly to relieve cooling system pressure Remove the pressure cap 2 It may be necessary to drain enough coolant from the radiator to allow for the addition of the liquid coolant extender Note Make sure that the coolant is drained into a suitable container 3 Add the recommended amount of ELC Extender to the cooling syst
93. sed When it is necessary to work under the truck with the body bed raised install the body bed retain ing pins through the pin holes in the frame and body Illustration 275 g00951543 1 Raise the dump body until the retaining bores on the dump body align with the retaining bores on the frame Install the two body retaining pins g00951578 Illustration 276 2 Clean the body support pads with high pressure water or steam If damage is found contact your Caterpillar dealer for the specific repair procedure 137 Maintenance Section Frame and Body Support Pads Clean Inspect 3 Visually inspect each of the body support pads Look for uneven wear of the body support pads Look for gaps between the body support pads and the mating surfaces If problems are found contact your Caterpillar dealer for additional information 4 Remove the body retaining pins If the pins cannot be removed raise the dump body to release the tension After lowering the dump body place the pins in the stored position in the dump body 101866816 Fuel System Prime SMCS Code 1250 548 After changing the fuel filters or if the engine fuel system is run dry prime purge the fuel system to fill filters and remove air bubbles from the system NOTICE Do not loosen the fuel lines at the fuel manifold The engine components may be damaged Do not remove the fitting in the fuel filter base in order to release air from the fu
94. sion control to the NEUTRAL position Lower the bucket to the ground Stop the engine NOTICE If the machine moved while testing the brakes contact your Caterpillar dealer Have the dealer inspect and if necessary repair the parking brakes before returning the machine to oper ation 109 Maintenance Section Braking System Test Optional Push to Engage Type Personal injury can result if the machine moves while testing the parking brake If the machine begins to move during the test re duce the engine speed immediately and apply the service brakes 1 Move the transmission control to the NEUTRAL position Start the engine Illustration 198 g00940749 2 Engage the parking brake by pushing the parking brake control in to the ON position Illustration 199 g00992888 3 Move the transmission control to the FIRST SPEED FORWARD position 110 Maintenance Section Cab Air Filter Clean Replace Illustration 200 go0947041 Note The parking brake indicator and the action lamp should illuminate The action alarm should sound 4 Gradually increase the engine speed to 1300 rpm The machine should not move 5 Reduce the engine speed to low idle Move the transmission control to the NEUTRAL position Stop the engine NOTICE If the machine moved while testing the brakes contact your Caterpillar dealer Have the dealer inspect and if necessary repair the parking brakes before retu
95. spect Rollover Protective Structure ROPS or Falling Object Protective Structure FOPS 13 for cracks in welds castings or any metal section on the ROPS FOPS Check the mounting bolts and the mounting pads for damage Consult your Caterpillar dealer for necessary repairs Inspect the operator s station Check the Caterpillar Monitoring System for diagnostic codes Correct any discrepancies i01870669 Steering Cylinder Bearings Lubricate SMCS Code 4303 086 BD 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 Wipe off the fittings before any lubricant is applied Illustration 329 g00952584 1 Lubricate the right steering cylinder bearing in the head end of the steering cylinder through remote mounted fitting 1 2 Lubricate the left steering cylinder bearing in the head end of the steering cylinder through remote mounted fitting 2 g00952585 Illustration 330 3 Lubricate the left steering cylinder bearing in the rod end of the steering cylinder through remote mounted fitting 3 159 Maintenance Section Steering Cylinder Bearings Lubricate 4 Lubricate the right steering cylinder bearing in the rod end of the steering cylinder through remote mounted fitting 4 i01870697 Steering Stop Check SMCS Code 7188 535
96. th the brake applied should be compared against the engine rom your specific machine was able to hold on a prior test as an indication of system deterioration To carry out the brake test first start the engine and let the brake oil pressure build up to the operating range The parking brake will stay engaged until operating oil pressure has been reached and the parking brake control is moved to the OFF position parking brake disengaged Once operating oil pressure has been reached a test of the braking system can be commenced Service Brake Holding Ability Test A WARNING Personal injury can result if the machine moves while testing If the machine begins to move during test reduce the engine speed immediately and engage the parking brake 1 Move the transmission control to the NEUTRAL position Start the engine 108 Maintenance Section Braking System Test 4 g00940766 Illustration 192 2 Apply the service brake pedal Illustration 193 g00940749 3 Disengage the parking brake by moving the parking brake control to the OFF position g00992888 Illustration 194 4 Move the transmission control to the FIRST SPEED FORWARD position 5 Gradually increase the engine speed to 1300 rom The machine should not move 6 Reduce the engine speed to low idle Move the transmission control to the NEUTRAL position Engage the parking brake Stop the engine NOTICE If the machine mo
97. the fan drive bearing through fitting 1 135 Maintenance Section Exhaust Purifier Inspect Clean 2 Lubricate the belt tightener pulley through fitting 2 Note If regular lubrication is performed at the recommended interval only two or three shots of lubricant will be required i01866430 Fire Suppression System Check SMCS Code 7401 535 Reference For detailed information on the fire suppression system service procedures refer to the fire system manufacturer s service information g00951410 Illustration 270 Foam type fire suppression system Perform fire suppression system checks and service procedures in accordance with the fire suppression system manufacturer s service information i01866667 Frame and Body Inspect SMCS Code 7051 040 7258 040 AD45 A WARNING The body bed may fall unexpectedly and without warning resulting in personal injury or death When it is necessary to work under the truck with the body bed raised install the body bed retain ing pins through the pin bores in the frame and body 136 Maintenance Section Frame and Body Inspect Illustration 271 g00951543 1 Raise the dump body until the pin bores on the dump body align with the pin bores on the frame Install the two body retaining pins g00951544 Illustration 272 2 Inspect the dump body If the dump body is damaged or worn repair the dump body 3 Clean the frame with
98. the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates g00951669 Illustration 280 1 Open the drain valve and allow the water and sediment to drain into a suitable container 2 Close the drain valve 101867731 Fuel Tank Cap and Strainer Clean SMCS Code 1273 070 STR 1273 070 Z2 Note Machines equipped with an optional fast fill fuel system do not contain a breather filter element in the fuel cap Perform Steps 3 and 5 only to standard machines without the fast fill fuel system g00951678 ampan O gy Illustration 282 g00906284 1 Lift lever 5 and turn the lever counterclockwise until the lever stops Lift the cap straight up to remove the cap 2 Inspect seal 4 for damage Replace the seal if necessary 3 Remove screws 1 filter assembly 2 valve 3 and gaskets 4 Wash the cap in a clean nonflammable solvent 5 Install a new filter kit in the cap Install the components in reverse order 141 Maintenance Section Fuel Tank Water and Sediment Drain Illustration 283 g00951679 6 Remove strainer 6 from the filler opening 7 Wash the strainer in a cl
99. the oil into a suitable container 106 Maintenance Section Brake Oil Filter Replace g00946983 Illustration 188 2 Remove drain plug 3 from the oil cooler and drain the oil into a suitable container Clean and install the plug 3 Remove plug 2 from the end of the cooler A Remove the screen Clean the screen in clean nonflammable solvent oa Install the screen in the cooler e gt Clean plug 2 in clean nonflammable solvent Inspect the seal Replace the seal if the seal is damaged NJ Install the plug Fill the hydraulic tank Reference For information on lubricants and refill capacities refer to Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities for the machine that is being serviced 9 Start the engine and operate the engine at low idle Check for leaks and make any necessary repairs Illustration 189 g00947009 10 With the oil cold check the oil level in sight gauge 4 For the AD45 truck check the oil level with the body fully lowered For the AE40 Series ll truck check the oil level with the ejector plate fully retracted and the tailgate fully raised 11 Maintain the oil level to the FULL mark in the sight gauge 12 Remove oil filler cap 5 and add oil if necessary 101857359 Brake Oil Filter Replace SMCS Code 4295 510 Hot oil and hot components can cause personal injury Do not allow hot oil
100. til the water temperature regulator opens and the coolant level stabilizes Note If you are using Caterpillar antifreeze do not add supplemental coolant additive or change the coolant conditioner element at this time g00949925 Illustration 211 9 Maintain the coolant level to within 13 mm 0 50 inch of the bottom of the filler pipe or to the proper level in the sight gauge 10 Install the cooling system pressure cap 11 Stop the engine 101863489 Cooling System Coolant ELC Change SMCS Code 1352 044 NL 1395 044 NL A WARNING 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 the pressure NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Do not change the coolant until you read and under stand the cooling system information in Special Pub lication SEBU6250 Caterpillar Machine Fluids Rec ommendati
101. tion for the machine that is being serviced 101871266 Torque Converter Oil Filter Replace SMCS Code 3004 510 The machine must be level the parking brake engaged and the engine stopped Hot oil and hot components can cause personal injury Do not allow hot oil or hot components to contact the skin NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates g00952933 Illustration 346 1 Remove drain plug 2 from the bottom of filter housing 1 and drain the oil into a suitable container Install drain plug 2 in the filter housing and tighten finger tight Note Removing the drain plug from the bottom of the filter housing may not drain all the oil from the filter housing Avoid spillage when removing the filter housing and filter element 165 Maintenance Section Torque Converter Oil Filter Replace 2 Illustration 347 g00952934 2 Remove filter housing 1 and element 4 Discard the used element 3
102. to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates The machine must be level the parking brake engaged and the engine stopped 1 Remove the steering tank filler cap slowly to relieve any steering tank pressure Install the filler cap g00952779 Illustration 335 161 Maintenance Section Steering System Oil Filter Replace Illustration 336 g00952780 2 Remove bolt 1 and filter cover 2 3 Remove and discard used filter element 4 4 Remove screen 5 5 Clean the cover and screen in clean nonflammable solvent Inspect the cover seal If the seal is damaged use a new seal 6 Install the clean screen and the new filter element 7 Install the cover Tighten cover bolt 1 to 59 5 Nem 43 4 Ib ft 8 Start the engine and run at low idle Check for leaks g00952784 Illustration 337 9 Maintain the oil level to the FULL mark in sight gauge 6 10 Remove filler cap 3 and add oil if necessary 162 Maintenanc
103. uel before installing them The fuel will not be filtered and could be contaminated Contaminated fuel will cause accelerated wear to fuel system parts The fuel system should be primed prior to starting the engine g00951651 Illustration 278 1 Remove the fuel filter assembly from the base with a strap type wrench 2 Remove the water separator bowl and seal from the filter element and discard the used filter Inspect the seal If the seal is damaged use a new one 3 Clean the filter mounting base Be sure all of the old seal is removed 4 Wash the water separator bowl in clean nonflammable solvent 5 Lubricate the seals of a new filter with clean diesel fuel 6 Install the seal and the water separator bowl on the new primary filter element 7 Install the filter assembly by hand When the seal contacts the base tighten 3 4 of a turn more 8 Prime the fuel system Reference For information on priming the fuel system refer to the Operation and Maintenance Manual Fuel System Prime for the machine that is being serviced 9 Start the engine and inspect the filter for leaks Make any necessary repairs If the engine has a loss of power or the exhaust smoke is still black replace the secondary filter Reference For information on replacing the secondary fuel filter refer to the Operation and Maintenance Manual Fuel System Secondary Filter Replace for the machine that is being service
104. ved while testing the brakes contact your Caterpillar dealer Have the dealer inspect and if necessary repair the service brake before returning the machine to opera tion Parking Brake Holding Ability Test NOTICE The standard parking brake control is a pull to engage type When the knob is pulled OUT the parking brake will be engaged Certain mining regulations require machines to be equipped with a push to engage parking brake con trol When the knob is pushed IN the parking brake is engaged Before operating the machine ensure you are familiar with the operation of the parking brake control Standard Pull to Engage Type Personal injury can result if the machine moves while testing the parking brake If the machine begins to move during the test re duce the engine speed immediately and apply the service brakes 1 Move the transmission control to the NEUTRAL position Start the engine g00940749 Illustration 195 2 Engage the parking brake by pulling the parking brake control knob out to the ON position Illustration 196 g00992888 3 Move the transmission control to FIRST SPEED FORWARD position Illustration 197 go0947041 Note The parking brake indicator and the action lamp should illuminate The action alarm should sound 4 Gradually increase the engine speed to 1300 rpm The machine should not move 5 Reduce the engine speed to low idle Move the transmis
105. warning for the air filter still occurs e The engine air filter primary element is serviced for the third time e The exhaust smoke remains black and a clean primary element has been installed 1 Remove the wing nut and the primary element Reference For additional information refer to the Operation and Maintenance Manual Engine Air Filter Primary Element Clean Replace for the machine that is being serviced g00950640 Illustration 248 2 Remove the split pin air filter service indicator and the secondary element 3 Cover the air inlet opening Clean the inside of the air cleaner housing 4 Direct low air pressure into the air filter service indicator in order to reset the indicator This will change the color of the indicator from a red color to a green color 5 Uncover the air inlet opening Install a new secondary element Install the air filter service indicator and the split pin 6 Install a clean primary element and wing nut Tighten the wing nut finger tight Do not use a tool to tighten the nut 101864776 Engine Air Precleaner Clean SMCS Code 1055 070 NOTICE Service the air cleaner only with the engine stopped Engine damage could result g00950641 Illustration 249 1 Stop the engine 2 Remove the engine air precleaner 3 Inspect the precleaner inlet screen for dirt and for trash If the screen is dirty clean the screen with compressed air 4 Check t
106. wheel Remove filler plugs 4 8 Fill the final drives slowly to the bottom of the drain level plug openings Reference For information on lubricants and refill capacities refer to the Operation and Maintenance Manual Lubricant Viscosities and Refill Capacities for the machine that is being serviced 9 Install the drain level plugs Clean the filler plugs and install the filler plugs 10 Operate the machine and recheck the oil level The oil level should reach the bottom of the drain level plug openings 11 Add oil if necessary Install the plugs aca A Illustration 227 g00954302 Location of the front axle breather g00954303 Illustration 228 Location of the rear axle breather for AD45 machines lED 2 Illustration 229 Location of the rear axle breather for AE40 Series II machines g00954304 12 Remove the breathers from the front and rear axle housing 13 Wash the breathers in nonflammable solvent 14 Allow the breathers to dry 15 Install the clean breathers 101864250 Differential and Final Drive Oil Level Check SMCS Code 3258 535 FLV 4050 535 FLV NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to
107. ydraulic system L Rear axle FOPS F Air cleaner M Frame and body G Fuel tank N Articulating hitch and oscillating hitch A Inspect the ground level controls for proper C Inspect the cooling system for leaks worn operation Replace a damaged or worn engine hoses and debris Repair any leaks and shutdown switch 1 Replace a damaged or damaged hoses Remove any debris that could worn battery disconnect switch 2 block the air flow through the radiator B Inspect the lights for broken lamps lenses and proper operation Replace broken lamps and lenses srani iti i d Illustration 322 g00943815 D Inspect the engine Use dipstick 3 to check the engine oil level Check for oil leaks coolant leaks and exhaust leaks Check the belts of the engine for proper tension and for good condition Check the level in the washer fluid bottle Illustration 323 g00952402 E Inspect the hydraulic system for the torque converter and transmission 4 Check for leaks from the torque converter and from the transmission Check for worn hoses and for damaged lines Repair any leaks worn hoses and damaged lines g00952419 Illustration 324 157 Maintenance Section Service Inspection F Check engine air precleaner 5 for accumulated debris If necessary clean engine air precleaner 5 For the correct procedure refer to Operation and Maintenance Manual Engine Air
108. yes 116 Maintenance Section Cooling System Coolant Additive DEAC Add NOTICE Adding coolant to an overheated engine could result in damage to the engine Allow the engine to cool before adding coolant If the machine is to be stored in or shipped to an area with freezing temperatures the cooling system must be protected to the lowest outside ambient tempera ture The engine cooling system is normally protected to a minimum of 29 C 20 F with Caterpillar Antifreeze when shipped from the factory unless special require ments are defined NOTICE Care must be taken to ensure that fluids are contained during performance of inspection maintenance test ing adjusting and repair of the product Be prepared to collect the fluid with suitable containers before open ing any compartment or disassembling any compo nent containing fluids Refer to Special Publication NENG2500 Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain fluids on Caterpillar products Dispose of all fluids according to local regulations and mandates NOTICE Excessive additive greater than the recommended 6 initial fill together with concentrations of antifreeze greater than 60 cause deposits to form and can re sult in radiator tube blockage and overheating Note This procedure pertains only to Caterpillar Diesel Engine Antifreeze Coolant DEAC This procedure does not pertai

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