SESV1661
SESV1661
SESV1661
TECHNICAL PRESENTATION
769C/771C/773B/775B
MAINTENANCE
ice
769C Serv
Procedu re
769C/771C/773B/775B
OFF-HIGHWAY TRUCKS
MAINTENANCE
769C/771C/773B/775B OFF-HIGHWAY TRUCKS
MAINTENANCE
AUDIENCE
Level I - Operators and service personnel responsible for performing daily maintenance and scheduled
preventive maintenance on Off-highway Trucks.
CONTENT
This presentation illustrates graphics and machine views similar to those used in the Operation and
Maintenance Manuals. The Operation and Maintenance Manual must be used in conjunction with this
presentation.
OBJECTIVES
After learning the information in this presentation, the student will be able to:
1. identify and explain the coolant, fuel and lubrication requirements;
2. locate and identify all filters and service points in a walk-around inspection; and
3. perform the proper maintenance procedures.
REFERENCES
768C/769C Operation and Maintenance Manual SEBU6747
772B/773B Operation and Maintenance Manual SEBU6748
771C Operation and Maintenance Manual SEBU6749
775B Operation and Maintenance Manual SEBU6750
Cold Weather Recommendations Operation and Maintenance Manual SEBU5898
SUPPLEMENTAL MATERIAL
Specification Sheets
Salesgrams
Video Tapes
Booklets
SUPPLEMENTAL MATERIAL
Special Instructions
Brochures
Miscellaneous
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TABLE OF CONTENTS
INTRODUCTION ........................................................................................................................7
Material Overview ..................................................................................................................8
SAFETY .......................................................................................................................................9
MACHINE OPERATION...........................................................................................................34
Monitoring Systems and Cab Features .................................................................................34
Machine Controls..................................................................................................................41
Machine Walk-around Inspection .........................................................................................49
After Starting the Engine ......................................................................................................50
Towing Information ..............................................................................................................52
MAINTENANCE .......................................................................................................................60
Tire Inflation ........................................................................................................................60
Cooling System.....................................................................................................................62
Fuel Specifications................................................................................................................66
Lubrication System ...............................................................................................................68
Scheduled Oil Sampling (S•O•S)..........................................................................................69
Lubrication Specifications ....................................................................................................71
Lubrication Viscosities and Refill Capacities .......................................................................74
MAINTENANCE INTERVALS.................................................................................................79
When Required .....................................................................................................................80
10 Service Hours or Daily.....................................................................................................85
50 Service Hours or Weekly .................................................................................................92
250 Service Hours or Monthly..............................................................................................95
500 Service Hours or Three Months.....................................................................................99
1000 Service Hours or Six Months.....................................................................................104
2000 Service Hours or One Year.........................................................................................110
3000 Service Hours or Two Years.......................................................................................113
SLIDE LIST..............................................................................................................................116
INSTRUCTOR NOTES
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INTRODUCTION
• Refer to Operation and The maintenance procedures for the 769C/771C/773B/775B Off-highway
Maintenance Manual Trucks will be discussed in detail throughout this presentation. This
training material is to be used in conjunction with the Operation and
Maintenance Manual for the particular truck being discussed.
769C/771C/773B/775B
MAINTENANCE
ice
769C Serv
Procedure
Material Overview
• Subjects parallel This presentation is to be used in conjunction with the Operation and
manual Maintenance Manual. The subject matter and the order of topics
discussed parallel the Operation and Maintenance Manual. Some topics
covered in the Operation and Maintenance Manual will not be discussed
in this presentation, but other material available in the Caterpillar
• Supplementary
literature distribution system will be referenced for supplementary
material is referenced
information.
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WARNING
SAFETY
3
SAFETY
WARNING
• Read Operation and Located in the cab, this warning label (arrow) informs the operator that he
Maintenance Manual must read and understand the Operation and Maintenance Manual before
Warning (arrow)
operating the machine. Improper machine operation is dangerous and
could result in injury or death.
• ROPS warning (arrow) The Rollover Protective Structure (ROPS) warning label (arrow), located
above the right cab door, informs service personnel that altering (such as
welding on or drilling holes in the structural members) the ROPS may
weaken the ROPS.
1. Front suspension The front suspension cylinder upper warning label (1) informs service
cylinder warning personnel that removal of the front suspension cylinder cover or valves
will cause the truck to drop suddenly if not properly blocked. Serious
injury or death could result if a person is trapped between the tire and the
platform or fender.
2. Front suspension
cylinder warning The front suspension cylinder lower warning label (2) informs service
personnel that the front suspension cylinder contains high pressure. Do
not remove any valve, hydraulic fitting or valve cover, nor disassemble
any parts until all pressure has been relieved.
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• Rear suspension The rear suspension cylinder warning labels (arrows) inform service
cylinder warning personnel that the rear suspension cylinders contain high pressure. Do not
(arrows)
remove any valve, hydraulic fitting or valve cover, nor disassemble any
parts until all pressure has been relieved.
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• Brake cylinder The brake cylinder warning label (arrow) informs service personnel that
warning (arrow) the brake cylinders contain compressed spring force. Improper
disassembly can cause the chamber parts to separate with enough force to
cause personal injury.
The brake cylinders are located behind the hydraulic tank on the left side
of the truck.
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1. Battery warning The battery warning label (1) informs service personnel that improper
jumper cable connections can cause explosions resulting in personal
injury.
The brown information label located just below the battery warning label
informs service personnel how to connect battery jumper cables.
NOTICE
Never turn the disconnect key off with the engine running. Engine
damage could result.
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WARNING
Always connect the battery positive (+) to battery positive (+) and the
battery negative (-) to stalled machine frame (-).
WARNING WARNING
signed by
see other side
date
SEHS7332
Side 1 Side 2
10
• Do Not Operate Tag This slide illustrates the DO NOT OPERATE tag.
WARNING
TIRE
EXPLOSION
ZONE
11
• Tire explosion zone This slide illustrates the tire explosion zone. It is important that service
personnel stay out of the zone as much as possible when adjusting the
• Stand behind tread
pressure in the tires. Service personnel should stand behind the tread and
use a self-connecting chuck when inflating a tire.
• Use self-connecting
chuck
Dry nitrogen (N2) gas is recommended by Caterpillar for inflation of tires.
• Inflate with dry
nitrogen
WARNING
2
1
12
1. Body up retaining Body up retaining pins (1) must always be installed through the pin holes
pins in the frame and the body before working under the body.
WARNING
BATTERIES
AIR FILTERS
DIFFERENTIAL
ENGINE
RADIATOR
BODY LOCK
ENGINE PINS
FRONT FINAL
WHEEL BEARINGS HOIST, CONVERTER TRANSMISSION DRIVES
AND BRAKE OIL TANK
HYDRAULIC TANK
13
GENERAL INFORMATION
• 769C/771C
This slide illustrates a top and side view of the 769C/771C Off-highway
Components
Trucks. Some of the truck components are identified.
14
• 769C/771C Power train Power flows from the engine to the rear wheels through the power train.
components In this illustration, the power train components and their locations on the
769C/771C are identified by their color. The components of the
769C/771C power train are:
Gray - Engine
Red - Torque Converter
Blue - Transfer Gears
Orange - Front and Rear Drive Shafts
Green - Transmission
Brown - Differential
Yellow - Final Drive
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3
2
1
5
6 4
15
• 769C Model view - Shown is the right side of the 769C truck. Some of the components that
right side are visible from the right side of the truck are:
1. Battery compartment
1. Battery compartment
2. Air filters 2. Air filters
3. Steering tank 3. Steering tank
4. Front wheel bearings
4. Front wheel bearings (behind access cover)
5. Fuel tank
5. Fuel tank
6. Final drive
6. Final drive
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3 2
16
• 769C Model view - left Shown is the left side of the 769C truck. Some of the components that are
side visible from the left side of the truck are:
4. Air reservoirs NOTE: Two service/retarder brake air reservoirs are located below
the cover on top of the hoist, converter and brake hydraulic tank.
One parking/secondary brake air reservoir is located in the
compartment behind the operator's cab.
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BATTERIES
AIR FILTERS
DIFFERENTIAL
ENGINE
RADIATOR
BODY LOCK
ENGINE PINS
FRONT FINAL
WHEEL BEARINGS HOIST, CONVERTER TRANSMISSION DRIVES
AND BRAKE OIL TANK
HYDRAULIC TANK
17
• 773B/775B This slide illustrates a top and side view of the 773B/775B Off-highway
Components Trucks. Some of the truck components are identified.
On the 773B/775B, the hoist cylinders are located outside of the main
frame rails and the transmission is mounted to the differential on the
rear axle housing.
18
• 773B/775B Power train Power flows from the engine to the rear wheels through the power train.
components In this illustration, the power train components and their locations on the
773B/775B are identified by their color. The components of the
773B/775B power train are:
Gray - Engine
Red - Torque Converter
Blue - Transfer Gears
Orange - Drive Shaft
Green - Transmission
Brown - Differential
Yellow - Final Drive
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2
3
5 4
6
19
• 773B Model view - Shown is the right side of the 773B truck. Some of the components that
right side are visible from the right side of the truck are:
1. Battery compartment
1. Battery compartment
2. Air filters 2. Air filters
3. Steering tank 3. Steering tank
4. Front wheel bearings (behind access cover)
4. Front wheel bearings
5. Fuel tank
5. Fuel tank 6. Final drive
6. Final drive
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3 2
20
• 773B Model view - left Shown is the left side of the 773B truck. Some of the components that are
side visible from the left side of the truck are:
4. Air reservoirs NOTE: Two service/retarder brake air reservoirs are located below
the cover on top of the hoist, converter and brake hydraulic tank.
One parking/secondary brake air reservoir is located in the
compartment behind the operator's cab.
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COMBINATION SERVICE
INFORMATION PLATE
ENGINE
INFORMATION
PLATE
ENGINE
SERIAL
NUMBER
21
• Serial number plate This slide illustrates the location of the Product Identification Number
locations (PIN), Engine Serial Number, Transmission Serial Number, Combination
Service Information plate and the Engine Information plate on the Off-
highway Trucks.
• Serial numbers
required for ordering
When performing maintenance on the trucks, it may be necessary to order
parts and service replacement parts. To be assured of receiving the correct parts, the Dealer
information needs the identification numbers from your specific machine. The serial
number of the machine and the major components (transmission, engine,
etc.) should be recorded for ordering parts, service specifications and
maintenance procedures.
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22
• Product Identification The Product Identification Number (PIN) plate (arrow) is located on the
Number (PIN) plate left side of the machine frame in front of the left tire.
(arrow)
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23
• Engine Serial Number The Engine Serial Number plate (arrow) is located on the left side of the
plate (arrow) engine block near the front of the engine.
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24
• Transmission Serial The Transmission Serial Number plate (arrow) is located on the left side
Number plate (arrow) of the transmission near the top of the housing.
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25
• Combination Service The Combination Service Information plate (arrow) is located on the left
Information plate side of the steering column in the cab. The Combination Service
(arrow)
Information plate contains the model number, serial number, and the
arrangement number of the machine, the engine and the transmission.
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26
• Engine Information The Engine Information plate (arrow) is located on the right side of the
plate (arrow) engine on a valve cover. The Engine Information plate contains the
model number, serial number, arrangement number, performance
specifications (commonly referred to as the "0T" specifications),
maximum altitude, static fuel setting (rack setting), rated horsepower,
high idle rpm and full load rpm of the engine.
• Engine performance
specs are on the The information on the Engine Information plate is critical if the
Engine Information performance of the engine must be tested or adjusted.
plate
NOTE TO THE INSTRUCTOR: The engine information plate
location is not shown in the Operation and Maintenance Manual.
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27
MACHINE OPERATION
• Front panel
Shown is the right side of the front panel. The engine start switch is
components:
shown at the lower left. To the right of the engine start switch are several
rocker switches. The rocker switches control (from left to right):
• Rocker switches (left
to right) - Park, tail and head lights
- Park, tail and head
lights - Supplemental steering and brake retraction (for towing)
- Supplemental
steering and brake - Starting aid (ether solenoid)
retraction (towing)
- Starting aid (ether - Push down on BOTTOM half--Electronic Monitoring System (EMS)
solenoid) functional test
Push down on TOP half--Automatic Electronic Traction Aid (AETA)
- Bottom half--EMS
functional test functional test
Top half--AETA
functional test - Automatic Retarder Control (ARC)
- ARC
- Not used
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• Electronic Monitoring Directly above the rocker switches is the Electronic Monitoring System
System panel (arrow) (EMS) panel (arrow). This panel, combined with an action light and an
action sound indicator, provides three categories of information to the
operator.
Category 1: Only the Light Emitting Diode (LED) on the panel turns on,
requiring operator awareness. Examples of Category 1 information are:
parking brake ENGAGED, alternator not charging, and plugged or
restricted fuel filter.
Category 2: The LED on the panel and the action light turn on, requiring
operator response. Examples of Category 2 information are: high coolant
temperature, high torque converter/brake oil temperature, and plugged or
restricted transmission filter.
Category 3: The LED on the panel, the action light and the action sound
indicator turn on, requiring immediate shutdown of the truck. Examples
of Category 3 information are: low coolant flow, low engine oil pressure,
low brake air pressure, brake system failure (overstroke of the brake
cylinder), and low steering oil flow.
• EMS LED's (top row): The LED's on the EMS panel represent the following systems:
- Transmission oil
filter Top row (from left to right)
- Brake air pressure
- Transmission oil filter
- Engine oil pressure
- Brake air pressure
- Coolant flow - Engine oil pressure
- Coolant flow
• EMS LED's (bottom - Coolant temperature
row):
28
• Front panel Located on the left side of the front panel are (from top to bottom):
components:
- Windshield
wiper/washer switch
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29
• Front panel gauges: Located in the center of the front panel are four gauges. The gauges
- Converter/retarder monitor the following:
oil temperature
(upper left) - Converter/retarder oil temperature (upper left)
- Brake air pressure - Brake air pressure (lower left)
(lower left) - Tachometer
- Tachometer
- Speedometer
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RPM
MPH
MAN.
CAT P
AUT.
AUT
30
• Front panel back lit Located above the gauges are several indicators that cannot normally be
indicators: seen but will illuminate when their function is selected. The indicators are
- Left directional and as follows:
warning hazard
- High beam
- Left directional and warning hazard indicator
- EMS action light - Retarder ON indicator
- Right directional and - High beam indicator
warning hazard - EMS action light (Categories 2 and 3)
- Right directional and warning hazard indicator
31
• Transmission actual On top of the console is the transmission actual gear indicator (arrow).
gear indicator (arrow) The actual gear indicator displays to the operator the gear in which the
transmission is operating.
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1 2
32
1. Starting and Behind the operator's seat are the starting and charging diagnostic
charging diagnostic connector (1), the service hour meter (2) and the CAT Data Link
connector
connector (3).
2. Service hour meter
3. CAT Data Link A service tool can be connected to the starting and charging diagnostic
connector connector which allows a serviceman to check for existing or potential
problems in the starting and charging electrical system.
Another service tool can be connected to the CAT Data Link connector
which allows a serviceman to program, diagnose faults or retrieve logged
information from the Electronically Programmable Transmission Control
(EPTC II).
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33
Machine Controls
1. Transmission shift To the right of the operator's seat is the shift console. Located on the shift
lever
console are the transmission shift lever (1) and the parking brake air
2. Parking brake air switch (2).
switch
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2
1
34
1. Service brake pedal On the floor are the service brake pedal (1) and the accelerator pedal (2).
2. Accelerator pedal
Above the brake and accelerator pedals are the fuses and circuit breakers.
• Fuses and circuit
breakers
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35
• Secondary brake lever Operator controls on the steering column are the secondary brake lever
(red) (red) and the retarder lever (black).
• Retarder lever (black)
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36
1. Tilt steering lock On the left side of the steering column are the tilt steering lock (1) and the
2. Turn signal and turn signal and hazard switch (2).
hazard switch
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37
1. Dimmer switch On the floor to the left of the steering column are the dimmer switch (1)
2. Horn button and the horn button (2).
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38
• Heating and air Shown are the heating and air conditioning controls located on the front
conditioning controls of the passenger (buddy) seat.
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39
• Hoist control lever The hoist control lever (arrow) activates the four positions of the hoist
(arrow) control valve. The four positions are: RAISE, HOLD, FLOAT and
LOWER.
• Reverse inhibitor
operation
A reverse inhibitor switch is located in the cab behind the operator’s seat
on the hoist lever linkage. If the transmission is in REVERSE when the
body is being raised, the reverse inhibitor switch is used to shift the
transmission to NEUTRAL. The transmission will remain in NEUTRAL
until:
1. The hoist lever is moved into the HOLD or FLOAT position; and
2. the shift lever has been cycled into and out of NEUTRAL.
• Operator's seat
Also shown is the operator's seat, which includes the seat belt and
numerous seat adjustment levers.
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40
The video tape listed above shows earlier trucks with a different dash
design. Although the dash is a different design, all switches and
controls operate the same.
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AIR FILTER
RESTRICTION INDICATOR
SUSPENSION
COOLANT LEVEL CYLINDER HEIGHT
WINDOWS
SEAT BELT
SUSPENSION
CYLINDER
HEIGHT TIRE INFLATION
PRESSURE
41
42
4. Warm up engine 4. Warm up the engine and hydraulic systems by steering left to right
and hydraulic against the stops and raising and lowering the body.
1 2
3 4
43
AIR SUPPLY
PARK BRAKE RELEASE FROM PARKING BRAKE
AIR SWITCH
NORMAL OPERATION
PARKING
RELIEF VALVE
BRAKE
RELEASE
PARKING BRAKE VALVE
RELEASE PUMP
CHECK VALVE
DIVERTER
VALVE TOWING
PUMP
44
• Parking brake system Shown is a schematic of the parking brake system during NORMAL
- Normal operation OPERATION with the parking brakes released.
Normally, oil flows from the parking brake release pump through the
parking brake release filter and a check valve to the parking brake release
valve. Oil also flows to a diverter valve and is blocked at the diverter
valve. When the parking brakes are released, an air supply from the
parking brake air switch in the cab moves a spool in the parking brake
release valve down. Supply oil can then flow to the parking brake piston
and release the parking brakes.
• Towing pump oil flows
to hydraulic tank When the key start switch is turned ON, the supplemental steering system
during supplemental
is energized for three seconds to check the system. Since the towing
steering test
pump is driven by the same electric motor as the supplemental steering
pump, the diverter valve allows the towing pump oil to flow directly to
the hydraulic tank during the supplemental steering test.
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AIR SUPPLY
PARK BRAKE RELEASE FROM PARKING BRAKE
AIR SWITCH
DURING TOWING
RELIEF VALVE PARKING
BRAKE
RELEASE
PARKING BRAKE VALVE
RELEASE PUMP
CHECK VALVE
DIVERTER
VALVE TOWING
PUMP
45
• Parking brake system Shown is a schematic of the parking brake system during TOWING with
- During towing the parking brakes released.
• Towing pump is
If the parking brakes need to be released for service work or towing, an
energized with
supplemental
electric motor can be energized with the supplemental steering/brake
steering/brake retraction switch on the dash in the cab. The electric motor then drives
two pumps. One pump provides supply oil for releasing the parking
brakes and the second pump supplies oil for supplemental steering.
• Diverter valve must be
shifted before towing A diverter valve must be shifted before the towing pump can supply oil to
the parking brake system. To shift the diverter valve, loosen the two
diverter valve clamp bolts and slide the plate and the spool to the left.
After the spool is shifted, tighten the diverter valve clamp bolts. Now,
when the electric motor is energized, supply oil will flow from the towing
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• Check valve prevents A check valve prevents supply oil from the towing pump from flowing to
oil flow to normal the normal parking brake release pump.
parking brake release
Towing supply oil flows through the parking brake release valve to
• Air supply required for
towing release the parking brakes as long as supply air is available from the
parking brake air switch in the cab.
• Brake release
pressure controlled During towing and normal operation, the brake release pressure is
by relief valve in controlled by the relief valve located in the parking brake release valve.
2
1
46
1. Supplemental The supplemental steering pump (1) and the towing pump (2) are located
steering pump above the torque converter (below the frame).
2. Towing pump
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47
• Diverter valve (arrow) The diverter valve (arrow) must be shifted before towing. On the
769C/771C, the diverter valve is located on the left hoist cylinder bracket
(769C shown). On the 773B/775B, the diverter valve is located on the
left frame behind the hydraulic tank.
To shift the diverter valve, loosen the two diverter valve clamp bolts and
slide the plate and the spool to the left. After the spool is shifted, tighten
the diverter valve clamp bolts. Now, when the electric motor is energized,
supply oil can flow from the towing pump through the diverter valve to
the parking brake release valve.
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1 2
3 4
48
1. Diverter valve clamp To review, the basic steps required to tow a truck are:
bolts
2. 6V3965 Pressure Tap - Connect a towing machine to the front and/or rear of the truck with
3. Parking brake air
cables of acceptable strength.
switch
- Loosen the diverter valve clamp bolts (1) and shift the diverter valve
4. Supplemental
steering/brake
bracket and spool to the left (as you face the valve).
retraction switch
- Install a 6V3965 Pressure Tap and an 8T0856 Gauge [0 - 6000 kPa
• Steps to tow a truck:
(0 - 870 psi)] on the parking brake release filter (2) with a gauge hose
- Connect towing long enough to permit monitoring of the parking brake release
machine pressure in the cab.
- Shift diverter valve
- Monitor parking
- Put the parking brake air switch (3) in the RELEASE position.
brake release
pressure in cab - Turn the key start switch to the ON position and energize the
- Put parking brake air supplemental steering/brake retraction switch (4) on the dash. The
switch in RELEASE parking brake release pressure should increase to 3790 kPa (550 psi).
position
• Minimum pressures NOTE: The parking brake release hydraulic pressure must increase
required to release the to a minimum of 3170 kPa (460 psi) on 769C/771C trucks and
parking brakes
3790 kPa (550 psi) on 773B/775B trucks. During towing, the
supplemental steering/brake retraction switch on the dash must be
energized whenever the parking brake release pressure decreases
below these pressures or the brakes will drag.
At least 550 kPa (80 psi) air pressure must be available at the parking
brake release valve to ensure full release of the brakes for towing.
The operator can stop the truck during towing with the parking
brake air switch in the cab.
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TIRE INFLATION
49
MAINTENANCE
• Tire inflation
Tire Inflation
The topic of this section is tire inflation, tire shipping pressure, and proper
inflation procedures. Be sure to use the Operation and Maintenance
Manual to obtain the proper inflation techniques and pressure
recommendations.
• Radial tires use "Star"
rating system The term "Two Star" is used by tire manufacturers to represent the
strength index (load carrying capacity) for large industrial radial tires.
The "Star" rating system is similar to the "Ply Rating" system used for
bias ply tires.
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• Dry nitrogen gas is Dry nitrogen (N2) gas is recommended by Caterpillar for tire inflation on
recommended for tire all rubber tire machines. Nitrogen is an inert gas and will not support
inflation
combustion inside the tire.
• Dry nitrogen reduces
risk of explosion, tire
In addition to reducing the risk of explosion, using nitrogen to inflate tires
oxidation and rim lessens the slow oxidation of the rubber and gradual tire deterioration.
Corrosion of rim components is reduced and, therefore, disassembly is
easier.
A tire inflated in a warm shop area, 18°C to 21°C (65°F to 70°F), will be
underinflated if the machine works in freezing temperatures. Low tire
pressure shortens the life of a tire.
• Adjust tire inflation
pressures for cold
When operating in freezing temperatures, refer to the "Cold Weather
weather
Recommendations Operation and Maintenance Manual" (Form
SEBU5898) for adjusted tire inflation pressures.
• Always obtain The operating tire inflation pressure is based on the weight of a
inflation pressure ready-to-work machine without attachments, at rated payload, and in
from tire manufacturer average operating conditions. Operating tire pressures may vary for each
application or job site. Always obtain the correct operating tire inflation
pressure from the tire manufacturer.
COOLING SYSTEM
50
- Overheating
- Overcooling
- Pitting
- Cavitation Erosion
- Cracked Heads
- Piston Seizures
• 40% of engine failures - Plugged Radiators
result from cooling
Over 40% of engine failures result from cooling system problems.
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WATER REQUIREMENTS
51
• Water is critical to The water used in the cooling system is critical for good cooling system
cooling system performance.
performance
- Use water analysis. If distilled water is not available, select the best
- Never use salt water
quality fresh water available and use water analysis to define the
water quality.
- Never use water
- Never use salt water.
• 3 to 6% Coolant Conditioner
• 30 to 60% Caterpillar Antifreeze
• Correct Operating Temperature
• Correct Operating Pressure
• Fill System Slowly
• Adjust Fan Belts
• Keep Radiator Fins Straight and Clean
52
• Critical Cooling Some critical points to remember when servicing the cooling system are:
System Points
• Maintain 3 - 6%
• Maintain a 3 - 6% concentration of coolant conditioner.
coolant conditioner
- Too much conditioner will form insoluble salts that cause water
pump seal wear, plugging and will coat parts with excessive
deposits that prevent heat transfer.
- Not enough conditioner will result in severe cavitation erosion
which will pit and corrode cylinder liner and block surfaces.
- To prevent overinhibitting, never use both the liquid supplemental
coolant additive and the supplemental coolant additive element at
the same time.
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D
FUEL SPECIFICATIONS
53
Fuel Specifications
Sulfur (ASTM D2788, D3605 or D1552) 0.5% Maximum (See Sulfur Topic)
Viscosity, Kinematic @ 38°C (100°F) 20.0 centistokes Maximum
(ASTM D445) 1.4 centistokes Minimum
Water & Sediment (ASTM D1796) 0.1% Maximum
54
• Fuel Specifications Caterpillar diesel engines have the ability to burn a wide variety of fuels.
These fuels are divided into two general groups: preferred and
permissible. The preferred fuels provide maximum engine service life
and performance. The chart above lists the specifications for preferred
distillate fuel for diesel engines.
The permissible fuels are crude oils or blended fuels. Use of permissible
fuels can result in higher maintenance costs and reduced engine service
life. Using permissible fuels can significantly reduce service interval
hours.
The percentage of sulfur in the fuel will affect the engine oil
recommendations. The following is a summary of fuel sulfur and oil
recommendations:
1. Use API CF-4 performance oils.
2. With fuel sulfur below 0.5%, any API CF-4 oils will have a
sufficient Total Base Number (TBN) for acid neutralization.
3. For fuel sulfur values above 0.5%, the new oil TBN should be a
minimum of 10 times the fuel sulfur.
STMG 661 - 68 -
8/94
LUBRICATION SYSTEM
55
Lubrication System
56
1 2
3 4
57
Three oil compartments are equipped with S•O•S oil sample valves.
1. S•O•S sampling Shown are the locations of the engine, the torque converter, hoist and
valve locations: brake cooling, and the transmission oil S•O•S oil sample valves (1).
2. Engine oil
3. Torque converter, - The engine oil sample valve is in a tube near the engine oil cooler on
hoist and brake the right side of the engine (2).
cooling oil
4. Transmission oil - The torque converter, hoist and brake cooling oil sample valve is
located on the torque converter in the torque converter outlet
manifold (3).
- The transmission oil sample valve is located on the left side of the
transmission in a manifold with the transmission lube oil pressure
tap (4).
STMG 661 - 71 -
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58
LUBRICATION SPECIFICATIONS
Compartment Specification
Hoist, Converter
TDTO T0-4
and Brake Cooling
Differential, Final Drives
TDTO T0-4
and Front Wheels
59
• Off-highway Truck Higher performance ratings and new emission standards require better
lubrication oils. Older oil technology (API CD and CE) cannot withstand the higher
temperatures required to obtain the new emission standards.
- Handles higher - CF-4 engine oil can withstand higher temperatures before coking
and has better dispersing capability for controlling soot.
• Transmission system
oil (TDTO TO-4) • Transmission System Oil (TDTO TO-4)
- Maximum frictional - TDTO TO-4 provides maximum frictional capability required for
capability clutch discs used in transmissions.
- Increases rimpull
- Increases rimpull because of reduced slippage.
- Use straight weight
oil only
- Use only mono-viscosity (straight weight) oils. Multi-viscosity oils
- Never use engine oil use viscosity improvers which, when subjected to shearing
situations, are reduced to the lower weight rating. For example,
when a 10W-30 oil is used in a sheer condition, after time the oil
will only perform to 10W specifications.
- Maximum frictional • Differentials, Final Drives and Front Wheels (TDTO TO-4)
capability
- TDTO TO-4 provides maximum frictional capability required for
- Increased bearing gears.
NOTE: Sometimes more than one type of oil can be used in a system.
In this presentation, the preferred oil is discussed.
STMG 661 - 74 -
8/94
LUBRICANT VISCOSITIES
FOR AMBIENT (OUTSIDE) TEMPERATURES
Compartment Oil °C °F
or System Viscosities Min. Max. Min. Max.
*(SPC) Special oils with synthetic base stocks that do not contain
polymer viscosity index improvers. The higher viscosity index of
the "synthetic" oils provide natural multiviscosity properties.
60
• Engine lubrication The table above illustrates the lubrication viscosities for the engine
crankcase on Off-highway Trucks.
NOTE: "SPC" denotes special oils with synthetic base stocks that do
not contain polymer viscosity index improvers. The high viscosity
index of the "synthetic" oils provides natural multi-viscosity
properties.
STMG 661 - 75 -
8/94
LUBRICANT VISCOSITIES
FOR AMBIENT (OUTSIDE) TEMPERATURES
Compartment Oil °C °F
or System Viscosities Min. Max. Min. Max.
Transmission SAE 0W30*(SPC) -40 +20 -40 +68
CAT TDTO SAE 0W20*(SPC) -40 +10 -40 +50
CAT TO-4 -22
SAE 5W20*(SPC) -30 +10 +50
All Trucks SAE 10W -25 +10 -13 +50
except SAE 30 -15 +35 +5 +95
768C, 769C,
771C SAE 50 -5 +50 +23 +122
Transmission SAE 10W -20 +22 -4 +75
768C,769C,
771C SAE 30 +10 +35 +50 +95
SAE 0W30*(SPC) -40 +40 -40 +104
Steering
Hydraulic SAE 0W20*(SPC) -40 +40 -40 +104
System SAE 5W20*(SPC) -30 +40 -22 +104
CAT HYDO SAE 5W20 -25 +10 -13 +50
CAT TDTO
SAE 10W -25 +40 -13 +104
CAT TO-4
CAT DEO SAE 10W30 -20 +40 -4 +104
API CF-4 SAE 15W40 -15 +50 +5 +122
61
• Transmission and The above table lists the lubrication viscosities for the transmission and
steering system steering system.
NOTE: "SPC" denotes special oils with synthetic base stocks that do
not contain polymer viscosity index improvers. The high viscosity
index of the "synthetic" oils provides natural multi-viscosity
properties.
STMG 661 - 76 -
8/94
LUBRICANT VISCOSITIES
FOR AMBIENT (OUTSIDE) TEMPERATURES
Compartment Oil °C °F
or System Viscosities Min. Max. Min. Max.
SAE 0W30*(SPC) -40 0 -40 +32
Differential, SAE 0W20*(SPC) -40 -10 -40 +14
Final Drives,
and Front SAE 5W20*(SPC) -30 -10 -22 +14
Wheels SAE 10W -35 -10 -31 +14
CAT TDTO
CAT TO-4 SAE 30 -25 +15 -13 +59
SAE 50 -15 +50 +5 +122
Hoist, SAE 0W30*(SPC) -40 +20 -40 +68
Converter, SAE 0W20*(SPC) -40 +10 -40 +50
and Brake SAE 5W20*(SPC) -30 -22 +50
+10
CAT TDTO
CAT TO-4 SAE 10W -25 +50 -13 +122
*(SPC) Special oils with synthetic base stocks that do not contain
polymer viscosity index improvers. The higher viscosity index of
the "synthetic" oils provide natural multiviscosity properties.
62
• Differential, final The above table list the lubrication viscosities for the differential, final
drives, front wheels, drives, front wheels, and the hoist, converter and brake systems.
hoist, converter and
brake systems
NOTE: "SPC" denotes special oils with synthetic base stocks that do
not contain polymer viscosity index improvers. The high viscosity
index of the "synthetic" oils provides natural multi-viscosity
properties.
STMG 661 - 77 -
8/94
COOLING SYSTEM
Refill Capacity - 30 gal.
Conditioner: 3% to 6%
Antifreeze: 30% to 60%
DIFFERENTIAL AND
FINAL DRIVE OIL
ENGINE OIL Refill Capacity - 22 gal.
Refill Capacity - 12 gal. Type: TDTO (TO-4)
Type: DEO CF-4 30W: -13°F to +59°F
10W30: -4°F to +104°F 50W: +5°F to +122°F
15W40: +5 to +122°F
FRONT WHEEL OIL HOIST, CONVERTER AND BRAKE OIL TRANSMISSION OIL
Refill Capacity - .62 gal. (each) Tank Capacity - 58 gal. Tank Capacity - 22 gal.
Type: TDTO (TO-4) System Capacity - 96 gal. System Capacity - 27 gal.
30W: -13°F to +59°F Type: TDTO (TO-4) Type: TDTO (TO-4)
50W: +5°F to +122°F 10W: -13°F to +122°F 10W: -4°F to +75°F
30W: +50°F to +95°F
63
• 769C/771C refill The approximate refill capacities for the 769C/771C Off-highway Trucks
capacities are shown on the above chart. The preferred oil specifications are also
shown.
STMG 661 - 78 -
8/94
COOLING SYSTEM
Refill Capacity - 40 gal.
Conditioner: 3% to 6%
Antifreeze: 30% to 60%
DIFFERENTIAL AND
FINAL DRIVE OIL
ENGINE OIL Refill Capacity - 41 gal.
Refill Capacity - 19 gal. Type: TDTO (TO-4)
Type: DEO CF-4 30W: -13°F to +59°F
10W30: -4°F to +104°F 50W: +5°F to +122°F
15W40: +5 to +122°F
FRONT WHEEL OIL HOIST, CONVERTER AND BRAKE OIL TRANSMISSION OIL
Refill Capacity - 1 gal. (each) Tank Capacity - 58 gal. Tank Capacity - 22 gal.
Type: TDTO (TO-4) System Capacity - 104 gal. System Capacity - 27 gal.
30W: -13°F to +59°F Type: TDTO (TO-4) Type: TDTO (TO-4)
50W: +5°F to +122°F 10W: -13°F to +122°F 10W: -13°F to +50°F
30W: +5°F to +95°F
50W: +23°F to +122°F
64
• 773B/775B refill The approximate refill capacities for the 773B/775B Off-highway Trucks
capacities are shown on the above chart. The preferred oil specifications are also
shown.
STMG 661 - 79 -
8/94
MAINTENANCE INTERVALS
65
MAINTENANCE INTERVALS
ETHER
STARTING AID
WINDSHIELD
WASHER
FUSES AND
CIRCUIT BREAKERS
MAINTENANCE
WHEN REQUIRED
ENGINE OIL
FILTER INSPECTION
66
The following list identifies the items that must be serviced When
Required.
1 2
3 4
67
• Engine air intake Shown are the air intake system components.
system components:
1. Precleaner bowls The precleaner bowls (1) must be emptied whenever dirt reaches the full
mark.
2. Air service indicator
Service the air filter elements when the yellow piston in the air service
indicator (2) moves into the red zone [approximately 760 mm (30 in.) of
water].
3. Primary element
4. Secondary element Two filter elements are installed in the filter housings. The large element
is the primary element (3) and the small element is the secondary
element (4).
1 2
3 4
68
1. Fuses and circuit The fuses and circuit breakers are located in the cab below the right side
of the dash (1).
2. Windshield wiper
Inspect the windshield wiper located in front of the windshield (2).
and body and frame
inspection
Inspect the body and frame for cracks. Always pay particular attention to
locations on the frame where castings and fabricated plates meet (2).
3. Windshield washer
reservoir The windshield washer reservoir is located in the engine compartment at
the right rear corner of the cab (3).
4. Ether cylinder
The ether starting aid system ether cylinder is located in the engine
compartment on the right side of the radiator shroud (4).
1 2
3 4
69
1. Oil cooler screen The oil cooler screen is located in the black manifold below the oil cooler
(1).
70
• Torque converter The torque converter scavenge screen (arrow) is located in the torque
scavenge screen converter sump.
(arrow)
STMG 661 - 85 -
8/94
STEERING FUEL
OIL TANK
RADIATOR
ENGINE SUSPENSION
OIL CYLINDERS
SUSPENSION
CYLINDERS
71
1 2
3 4
72
• Engine oil level The engine oil level is checked with the dipstick (1) which can be
1. Dipstick accessed by opening a small door in the rear engine cover. To add oil,
open the rear engine cover and fill through the tube (2).
3. Transmission and
The transmission tank and the hoist, converter and brake cooling tank (3)
hoist, converter and
brake cooling tanks are located on the left side of the truck. The oil levels are checked by
opening the small doors on the side of the tanks (4).
4. Oil level window
doors
STMG 661 - 87 -
8/94
1 2
3 4
73
1. Steering tank The steering tank (1) is located on the right platform. Check the steering
system oil level at the sight gauge on the side of the tank.
1 2
3 4
74
1 2
3 4
75
1. Fuel tank The fuel tank (1) is located on the right side of the truck. The fuel level
2. Fuel level gauge can be checked at the fuel level gauge (2).
1 2
3 4
76
• Suspension cylinders Check the front and rear suspension cylinders for leaks or structural
1. Front suspension damage. Measure the charge height of the suspension cylinders and
cylinder compare the dimension with the dimension that was recorded the last time
2. Check charge of
the cylinders were charged. Recharge the cylinders if necessary.
front cylinders
NOTE TO THE INSTRUCTOR: For additional information on the
3. Rear suspension
cylinders
suspension system, see the following publications:
77
• 10 hours/daily checks The remaining 10 Hours or Daily checks are performed in the operator's
performed in the compartment. They are as follows:
operator's cab
The brakes are checked by engaging one of the brake systems and placing
the shift lever in FIRST FORWARD. Accelerate the engine until the
truck moves. The truck must not move below 1200 rpm. This procedure
should be repeated for each brake lever or pedal.
See the Operation and Maintenance Manual for more information on the
remaining tests performed in the cab.
STMG 661 - 92 -
8/94
REAR SUSPENSION
CYLINDER BEARINGS
BODY PIVOT
BEARINGS
FRONT SUSPENSION
CYLINDER RODS
HOIST CYLINDER
BEARINGS
78
1 2
3 4
79
1. Cab air filter The cab air filter (1) is located in a compartment behind the operator's
seat.
2. Front suspension
Lubricate the front suspension cylinders at the grease fitting (2).
grease fitting
3. Suspension cylinder,
Located at the rear of the truck are the rear axle housing lateral control
body pivot, and
control rod bearings rod bearings, the rear suspension cylinder bearings and the body pivot
bearings, which all require grease (3 and 4).
4. Rear axle housing
lateral control rod
bearings
STMG 661 - 94 -
8/94
1 2
3 4
80
1. Rear axle and rear The rear axle connects to the frame and pivots at the "A" frame bearings
suspension cylinder (1 and 2). The rear suspension cylinders and the rear axle "A" frame
2. Rear axle "A" frame bearings require lubrication through the grease fittings.
3. Steering cylinder, tie The steering cylinder, tie rod and pin bearings (3) require lubrication
rod and pin bearings through the appropriate grease fittings.
4. Hoist cylinder
bearings The hoist cylinder bearings (4) require lubrication through the grease
fittings at the frame and body connections.
STMG 661 - 95 -
8/94
COOLING SYSTEM
CONDITIONER ELEMENT
FAN DRIVE
BEARING
MAINTENANCE
250 HOURS/MONTHLY
AIR CONDITIONER
BELT
ENGINE OIL
AND FILTERS
FINAL DRIVES
AIR DRYER
81
1 2
3 4
82
1. Engine oil filters and The engine oil filters and the engine oil drain valve are located on the left
drain valve side of the engine (1).
2. Cooling system
The cooling system conditioner element is located on the right side of the
conditioner element
engine below the fuel filters (2).
3. Batteries
The batteries are located in the compartment on the right front platform
(3).
4. Air conditioner,
alternator and fan The air conditioner and alternator belts are adjusted by tightening a nut on
a threaded rod. The fan belts are kept tight with springs connected to a
belt tightener pulley. The fan bearings and the belt tightener bearings are
lubricated through grease fittings located on the right side of the fan
pulley (4).
STMG 661 - 97 -
8/94
1 2
3 4
83
1. Air dryer and hoist The air dryer (1) is located on the frame behind the left front tire. Check
control bellcrank the desiccant for saturation. The humidity of the local climate will
determine how often the desiccant must be changed.
2. Hoist control
bellcrank
The hoist control bellcrank (1and 2) requires lubrication through the
grease fitting.
3. Drive shaft universal
joints and splines The drive shaft universal joints and splines (3) require lubrication through
the appropriate grease fittings.
4. Differential oil level
Check the differential oil level (4) by removing the fill plug in the center
of the rear axle housing. The oil should be level with the bottom of the
fill plug opening.
STMG 661 - 98 -
8/94
1 2
3 4
84
1. Front wheel bearing Check the oil level of the front wheel bearings (1 and 2) by removing the
fill plug in the center of the wheel cover. The oil should be level with the
2. Front wheel bearing
bottom of the fill plug opening.
oil level
PRIMARY AND
SECONDARY
FUEL FILTERS
85
NOTE: The parking brake release filter is located behind the right
front tire on the 769C and 771C Trucks (see slide No. 88).
STMG 661 - 100 -
8/94
1 2
3 4
86
1. Steering filter The steering filter (1) is located on top of the steering tank on the right
platform.
2. Primary fuel filter The primary fuel filter (2) is located inside the right frame near the front
suspension cylinder.
3. Secondary fuel
filters The secondary fuel filters (3) are located on the right side of the engine.
NOTE: The 769C and 771C have only one secondary fuel filter.
STMG 661 - 101 -
8/94
1 2
3 4
87
1. Fuel tank cap and fill The fuel tank cap is equipped with a breather that must be kept clean. If
screen the breather becomes plugged, fuel flow will be restricted and the engine
will have low power. The fill screen is located in the fill tube (1).
2. Engine crankcase
breathers
The engine crankcase breathers (2) are located on the valve covers. If the
breathers become plugged, pressure in the crankcase will be forced out at
other locations causing oil leakage.
• 773B/775B:
On the 773B/775B, the torque converter charge filter and the parking
3. Torque converter
charge filter and
brake release filter (3) are located on the inside of the right frame in front
parking brake of the crosstube. The transmission charge filter (4) is located on the
release filter inside of the right frame behind the crosstube.
4. Transmission
charge filter
STMG 661 - 102 -
8/94
88
• 769C/771C: On the 769C/771C, the transmission charge filter (1) and the torque
1. Transmission converter charge filter (2) are located on the inside of the right frame near
charge filter the torque converter.
2. Torque converter
charge filter
STMG 661 - 103 -
8/94
89
• Parking brake release On the 769C/771C, the parking brake release filter (arrow) is located
filter (arrow) outside of the right frame behind the right front tire.
STMG 661 - 104 -
8/94
STEERING OIL
DIFFERENTIAL
MAINTENANCE
1000 HOURS/6 MONTHS
ROLLOVER PROTECTION
STRUCTURE (ROPS) MAIN FRAME AND
BODDY SUPPORT PADS
AIR
DRYER
FINAL DRIVES
FRONT WHEEL
BEARINGS
HOIST, CONVERTER TRANSMISSION
AND BRAKE COOLING OIL OIL
90
1 2
3 4
91
1. Transmission and The transmission tank and the hoist, torque converter, and brake cooling
hoist, torque oil tank are located on the left side of the truck (1). Drain the oil from the
converter, and brake
tanks by removing the plugs in the bottom of the tanks (2) and installing a
2. Drain plugs 25 mm (1.0 in.) NPT pipe nipple.
Wash the fill caps and the fill screens located inside the fill tubes.
3. Transmission case
The transmission case must also be drained by removing the plug (3).
4. Transmission
magnetic screen Remove and clean the transmission magnetic screen The magnetic
screen is located in the transmission case behind the cover (4).
STMG 661 - 106 -
8/94
1 2
3 4
92
1. Transmission tank Clean the transmission tank breather located on top of the transmission
breather tank (1).
• Hoist, torque Clean the hoist, torque converter, and brake cooling oil tank breather. On
converter, and brake
the 769C/771C, the breather (2) is located below the rear engine hood.
cooling oil tank
breather: On the 773B/775B, the breather (3) is located below the frame to the right
of the supplemental steering/brake retraction motor.
2. 769C/771C
Repack or replace the desiccant cartridge in the air dryer (4) when it can
4. Replace desiccant in no longer absorb water. The humidity of the local climate will determine
air dryer how often the desiccant needs to be replaced.
STMG 661 - 107 -
8/94
1 2
3 4
93
1. Change final drive Change the oil in both final drives (1). Position the wheels with the final
drive drain plug at the bottom and remove the drain plug. Fill the final
drives with oil to the bottom of the fill hole.
2. Change differential
Change the oil in the differential (2). Fill the differential with oil to the
bottom of the fill hole.
3. Clean rear axle
housing breather Clean the rear axle housing breather (3). The breather prevents pressure
from building up in the axle housing. Pressure in the axle housing may
cause brake cooling oil to leak through the Duo-Cone seals in the wheel
brake assemblies.
4. Change front wheel
bearing oil Change the oil in the front wheel bearings (4). Position the wheels with
the front wheel bearing drain plug at the bottom and remove the drain
plug. Fill the final drives with oil to the bottom of the fill hole.
STMG 661 - 108 -
8/94
1 2
3 4
94
1. Inspect ROPS and Inspect the ROPS and the mounting supports and bolts (1 and 2). Tighten
mounting supports the ROPS bolts to a torque of 720 ± 25 N•m (530 ± 20 lb. ft.).
3. Steering tank drain Change the steering system oil. Drain the oil through the valve at the
valve
bottom rear of the tank (3).
4. Steering tank
Wash the steering tank fill cap and the fill screen located inside the fill
tube. Fill the steering tank (4) with oil to the FULL mark on the sight
gauge.
STMG 661 - 109 -
8/94
1 2
3 4
95
1. Front brakes Inspect the front brakes (1) and the rear brakes (2) for wear and system
2. Rear brakes leakage.
3. Main frame Clean and inspect the main frame (3) and the body support pads (4).
4. Body support pads
STMG 661 - 110 -
8/94
DIFFERENTIAL
ENGINE VALVE THRUST PIN
LASH
ENGINE VALVE
ROTATORS
MAINTENANCE
2000 HOURS/1 YEAR
FRONT WHEEL
BEARINGS
REAR WHEEL
BEARINGS
96
2
1
97
• Adjust bridges and Adjust the bridge (1) and the valve lash (clearance) (2).
valve lash
1. Bridge Run the engine at LOW IDLE and observe the valve rotators (3). The
2. Valve lash
valve rotators should turn slightly each time the valve closes.
3. Valve rotators
STMG 661 - 112 -
8/94
1 2
3 4
98
1. Adjust differential Adjust the clearance of the differential thrust pin (1).
2. Front and rear wheel Adjust the front wheel bearings (3).
COOLING
SYSTEM COOLANT
99
1 2
3 4
100
• Change cooling Remove the radiator cap slowly to relieve pressure. Inspect the radiator
cap gasket. Clean or replace the cooling system relief valve (1).
1. Radiator relief valve Drain the coolant with the radiator drain valve (2)
2. Radiator drain valve
Drain the coolant from all three coolers (engine, transmission and
3. Oil coolers
brake/torque converter) (3).
4. Air compressor
Drain the coolant from the air compressor (4).
NOTE: The 773B and 775B coolers are shown. The 769C and 771C
transmission coolers are mounted on the engine front support.
STMG 661 - 115 -
8/94
101
SLIDE LIST
SLIDE LIST
AIR FILTER
RESTRICTION INDICATOR
SUSPENSION
COOLANT LEVEL CYLINDER HEIGHT
DRAIN
INSPECTION AIR RESERVOIR WHEEL
MOISTURE NUTS
WINDOWS
SEAT BELT
SUSPENSION
CYLINDER
HEIGHT TIRE INFLATION
PRESSURE
• Engine oil indicator must go off in 15 seconds • Use distilled water whenever possible
• Check all gauges are in safe operating range LUBRICANT SPECIFICATION TERMINOLOGY
AIR SUPPLY
PARK BRAKE RELEASE FROM PARKING BRAKE
AIR SWITCH
DURING TOWING
RELIEF VALVE PARKING
BRAKE
RELEASE
PARKING BRAKE VALVE
RELEASE PUMP
CHECK VALVE
- 120 -
DIVERTER
VALVE TOWING
PUMP
COOLING SYSTEM
Refill Capacity - 30 gal.
Conditioner: 3% to 6%
- 121 -
DIFFERENTIAL AND
FINAL DRIVE OIL
ENGINE OIL Refill Capacity - 22 gal.
Refill Capacity - 12 gal. Type: TDTO (TO-4)
Type: DEO CF-4 30W: -13°F to +59°F
10W30: -4°F to +104°F 50W: +5°F to +122°F
15W40: +5 to +122°F
FRONT WHEEL OIL HOIST, CONVERTER AND BRAKE OIL TRANSMISSION OIL
Refill Capacity - .62 gal. (each) Tank Capacity - 58 gal. Tank Capacity - 22 gal.
Type: TDTO (TO-4) System Capacity - 96 gal. System Capacity - 27 gal.
30W: -13°F to +59°F Type: TDTO (TO-4) Type: TDTO (TO-4)
50W: +5°F to +122°F 10W: -13°F to +122°F 10W: -4°F to +75°F
30W: +50°F to +95°F
Serviceman's Handout No. 4
8/94
STMG 661
COOLING SYSTEM
Refill Capacity - 40 gal.
Conditioner: 3% to 6%
Antifreeze: 30% to 60%
- 122 -
DIFFERENTIAL AND
FINAL DRIVE OIL
ENGINE OIL Refill Capacity - 41 gal.
Refill Capacity - 19 gal. Type: TDTO (TO-4)
Type: DEO CF-4 30W: -13°F to +59°F
10W30: -4°F to +104°F 50W: +5°F to +122°F
15W40: +5 to +122°F
FRONT WHEEL OIL HOIST, CONVERTER AND BRAKE OIL TRANSMISSION OIL
Refill Capacity - 1 gal. (each) Tank Capacity - 58 gal. Tank Capacity - 22 gal.
Type: TDTO (TO-4) System Capacity - 104 gal. System Capacity - 27 gal.
30W: -13°F to +59°F Type: TDTO (TO-4) Type: TDTO (TO-4)
50W: +5°F to +122°F 10W: -13°F to +122°F 10W: -13°F to +50°F
30W: +5°F to +95°F
50W: +23°F to +122°F
Serviceman's Handout No. 5
STMG 661 - 123 - Serviceman's Handout No. 6
8/94
• Shrouded fans should have the fan blades fit 2/3 inside the shroud.
• 2260 square cm (350 square in.) of radiator area are required for
every 75 kW (100 hp).
• Torque converter heat and cool times between 91°C (195°F) and
129°C (265°F) should equal one another. Time is approximately 30
seconds.
MISCELLANEOUS SPECIFICATIONS
• If the supply flow of a hydraulic pump between 690 and 6900 kPa
(100 and 1000 psi) is reduced no more than:
- 10%: the pump is in like-new condition
- 15%: the pump is in good condition
- 20%: the pump is in poor condition
• Every 250 mm (10 in.) of water restriction above 500 mm (20 in.) of
water in an air filter increases intake air temperature 60°C (100°F).
• Temperature indications:
- below 60°C (140°F): about the threshold of pain (can hold hand on
piece)
- 60 to 100°C (140 to 212°F): too hot to touch/will not "fry"
(vaporize) small traces of moisture (water or saliva)
- 100 to 150°C (212 to 300°F): will fry moisture, no paint
discoloration
- over 150°C (300°F): Caterpillar Yellow starts discoloring
STMG 661 - 125 - Serviceman's Handout No. 8
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MAINTENANCE TOOLS
NOTE: S•O•S sample bottles and tooling are only sold in large quantities. For S•O•S sample
bottles and tooling, see your Caterpillar Dealer.
STMG 661 - 126 -
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INSTRUCTOR NOTES
STMG 661 - 127 -
8/94
INSTRUCTOR NOTES
SESV1661 Printed in U.S.A.