Manual Maintenance Intervals Caterpillar Ad40 Ae40 II Underground Articulated Trucks

SAFETY.CAT.
COM
AD40 SERIES II and

AE40 SERIES II
UNDERGROUND
ARTICULATED TRUCKS
Maintenance Intervals
Excerpted from Operation & Maintenance Manual ((SEBU7315-03)
2007 Caterpillar
All Rights Reserved
102
Maintenance Section
Maintenance Interval Schedule
Seat - Inspect ..................................................... 168

Maintenance Interval Schedule Service Inspection ............................................... 169
Steering Cylinder Bearings - Lubricate ............... 178
SMCS Code: 1000; 7000 Steering System Oil Level - Check ..................... 183
Suspension and Suspension Cylinder Bearings
Note: All safety information, warnings and - Lubricate .......................................................... 184
instructions must be read and understood before Tailgate and Tailgate Cylinder Bearings
you perform any operation or any maintenance - Lubricate .......................................................... 185
procedure. Transmission Oil Level - Check .......................... 193
V-Belts - Inspect/Adjust ...................................... 194
Before each consecutive interval is performed, all of Windows - Clean ................................................. 197
the maintenance requirements from the previous
intervals must be performed. Every 50 Service Hours or Weekly
Automatic Lubrication System (Hydraulic Type)

When Required Filler Filter - Clean .............................................. 106
Cab Air Filter - Clean/Replace ............................ 117
Battery - Recycle ................................................ 108 Fire Suppression System - Check ...................... 149
Battery, Battery Cable or Battery Disconnect Fuel System Water Separator - Drain ................. 155
Switch - Replace ................................................ 109 Tire Inflation - Check ........................................... 185
Brake Oil Cooler Screen - Clean ......................... 112
Circuit Breakers - Reset ...................................... 120 Initial 250 Service Hours (or at first oil
Ejector Line Screen - Inspect/Clean ................... 136 change)
Engine Air Filter Secondary Element
- Replace ............................................................ 138
Exhaust Purifier - Inspect/Clean ......................... 147 Engine Valve Lash - Inspect/Adjust .................... 145
Fuel System - Prime ............................................ 152 Oscillating Hitch - Adjust .................................... 164
Fuses - Replace .................................................. 157
Hoist, Torque Converter and Brake System Every 250 Service Hours or Monthly
Screens - Clean ................................................. 161
Oil Filter - Inspect ................................................ 164 Air Conditioner - Test .......................................... 104
Radiator Core - Clean ......................................... 167 Automatic Lubrication System (Hydraulic Type)
Steering Suction Screen - Clean ........................ 179 Inline Filter - Clean ............................................. 106
Torque Converter Sump Screen - Clean ............ 188 Battery Electolyte Level - Check ......................... 109
Window Washer Reservoir - Fill .......................... 196 Cab Pivot and Lockdown Pins
Window Wiper - Inspect/Replace ....................... 197 - Check/Lubricate .............................................. 119
Cooling System Coolant Additive (DEAC)
Every 10 Service Hours or Daily - Add .................................................................. 124
Differential and Final Drive Oil Level - Check ...... 132
Automatic Lubrication System (Hydraulic Type) Drive Shaft Universal Joints, Splines and
- Fill .................................................................... 105 Bearings - Inspect/Lubricate ............................. 134
Automatic Lubrication System (Electric Type) Engine Oil and Filter - Change ............................ 141
- Fill .................................................................... 105 Engine Oil Sample - Obtain ................................. 143
Backup Alarm - Test ........................................... 107 Engine Shutdown to Idle Protection System
Body Pivot Bearings - Lubricate ......................... 110 - Test .................................................................. 144
Braking System - Test ........................................ 114 Fan Drive Bearing and Belt Tightener
Cooling System Coolant Level - Check .............. 127 - Lubricate .......................................................... 148
Ejector Cylinder Bearings - Lubricate ................. 135 Fire Suppression System - Check ...................... 149
Engine Air Filter Primary Element Frame and Body - Inspect .................................. 149
- Clean/Replace ................................................. 137 Fuel System Primary Filter - Clean/Replace ....... 152
Engine Air Precleaner - Clean ............................. 139 Fuel System Secondary Filter - Replace ............. 154
Engine Oil Level - Check ..................................... 142 Low Transmission Oil Pressure Automatic Brake
Fire Suppression System - Check ...................... 149 Application (ABA) System - Test ........................ 163
Fuel Tank Water and Sediment - Drain .............. 156 Steering Frame Stop Clearance - Check ............ 179
Hoist Cylinder Bearings - Lubricate .................... 158 Suspension Cylinder - Check ............................. 184
Hoist, Torque Converter and Brake System Wheel Nut Torque - Check ................................. 196
Oil Level - Check ................................................ 160
Indicators and Gauges - Test ............................. 162
Oscillating Hitch - Lubricate ................................ 165
103
Maintenance Section
Maintenance Interval Schedule
Every 500 Service Hours or 3 Months Every 3 Years
Brake Control Oil Filter - Replace ....................... 111 Seat Belt - Replace ............................................. 168
Differential and Final Drive Oil Sample
- Obtain .............................................................. 133 Every 6000 Service Hours or 4 Years
Engine Crankcase Breather - Clean ................... 140
Fire Suppression System - Check ...................... 149
Cooling System Coolant (ELC) - Change ........... 122
Fuel Tank Cap and Strainer - Clean ................... 155
Cooling System Water Temperature Regulator
Hoist, Torque Converter and Brake System Oil
- Replace ............................................................ 129
Sample - Obtain ................................................. 160
Engine Water Pump - Inspect ............................. 146
Parking Brake Release Oil Filter - Replace ......... 166
Steering System Oil Filter - Replace ................... 182
Steering System Oil Sample - Obtain ................. 183
Torque Converter Oil Filter - Replace ................. 186
Transmission Oil Filter - Replace ........................ 191
Transmission Oil Sample - Obtain ...................... 193
Every 1000 Service Hours or 6 Months
Axle Breather - Clean .......................................... 107

Brake Accumulator Pressure - Check ................ 111
Differential and Final Drive Oil - Change ............. 130
Ejector Line Screen - Inspect/Clean ................... 136
Falling Object Protective Structure (FOPS)
- Inspect ............................................................. 147
Frame and Body Support Pads
- Clean/Inspect .................................................. 151
Hoist, Torque Converter and Brake System Oil
- Change ............................................................ 158
Oscillating Hitch - Adjust .................................... 164
Steering System Oil - Change ............................ 180
Torque Converter and Hydraulic Breather
- Replace ............................................................ 186
Transmission Breather - Clean ........................... 189
Transmission Magnetic Screen - Clean .............. 189
Transmission Oil - Change .................................. 190
Every 2000 Service Hours or 1 Year
Differential Thrust Pin - Check ............................ 133

Engine Mounts - Inspect ..................................... 140
Turbocharger - Inspect ....................................... 194
Wheel Bearings - Check/Adjust .......................... 195
Every 3000 Service Hours or 2 Years
Cooling System Coolant (DEAC) - Change ........ 121

Cooling System Coolant Extender (ELC)
- Add .................................................................. 126
Cooling System Pressure Cap
- Clean/Replace ................................................. 128
Engine Valve Lash - Inspect/Adjust .................... 145
Engine Valve Rotators - Inspect ......................... 146
104
Maintenance Section
Maintenance Interval Items
Air Conditioner - Test

SMCS Code: 7320-081
4
Inhaling air conditioner refrigerant gas through a

lit cigarette or other smoking method or inhaling
fumes released from a flame contacting air
conditioner refrigerant gas can cause bodily harm
or death. Do not smoke when servicing air
conditioners or whenever refrigerant gas may be
present.
4. Check for refrigerant in the system. Feel
suction line (4) and discharge line (5). If the
1. Start and run the engine at high idle. system contains refrigerant, the discharge line
(the smaller hose of the two) will be warmer
than the suction line. If the system does not
contain, or is very low on refrigerant, poor
cooling will result.
2
5. If poor cooling is experienced, turn the air
conditioner off and stop the engine.
6. Inspect and adjust the deflection of the air

conditioner compressor belt.
Reference: Refer to Operation and Maintenance

1
3 Manual, "V-Belts - Inspect/Adjust" for the machine
that is being serviced.
7. Perform Steps 1 and 2. If poor cooling is still

2. Turn the temperature control switch (1) to the experienced, have your Caterpillar dealer
maximum cold position. Move air conditioner service the air conditioner system.
switch (2) to the ON position and set fan control
switch (3) on high.
3. Allow two minutes for the air conditioning

system to stabilize.
105
Maintenance Section
Automatic Lubrication System Automatic Lubrication System

(Electric Type) - Fill (Hydraulic Type) - Fill
SMCS Code: 7540-544-EA SMCS Code: 7540-544-HR
2
3
1
1. Check the grease level in the reservoir. Use a Note: The lubricant tank (if equipped) should be
manual grease gun or grease pump to fill the refilled at regular intervals. Refills should be
reservoir through filler fitting (3) in the pump performed daily to prevent emptying the system.
body.
1. Use a manual lubricant gun or pump to fill the
2. Fill the reservoir to the MAXIMUM indicator (1) reservoir through filler fitting (2) in the pump
on the reservoir. body. Fill the reservoir until lubricant appears at
overflow relief valve (1).
NOTICE
2. Check all lubricant lines for leakage.
When filling the reservoir, caution should be used as
extreme pressure and overfilling can cause damage 3. Check hydraulic lines for leakage. Check for
to the reservoir assembly. worn or damaged hoses.
3. With the battery disconnect switch and the 4. Check all lubricant injectors are operative.
engine start switch in the ON position, trigger a Check all bearings that are lubricated by the
lubrication cycle by pressing switch (2) on the automatic lubrication system for signs of
side of the cover assembly. lubrication.
4. Observe the stirring paddle in the lubricant 5. Inspect the electrical system for worn or frayed
reservoir. When the pump is operating, the wiring, damaged connectors or a tripped circuit
stirring paddle should be rotating. breaker.
5. Check all discharge lines for leakage. Reference: For more information on the automatic
lubrication system, refer to Systems Operation,
6. Check all injectors are operative. Check all Testing and Adjusting, "Automatic Lubrication
bearings that are lubricated by the automatic System, Hydraulic Type" for the machine that is
lubrication system for signs of greasing. being serviced.
7. Inspect the electrical system for worn or 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.
106
Maintenance Section
Automatic Lubrication System Automatic Lubrication System

(Hydraulic Type) Filler Filter - (Hydraulic Type) Inline Filter -
Clean Clean
SMCS Code: 7540-070-HR SMCS Code: 7540-070-HR
Clean the filler filter (if equipped) every 50 Service Clean the inline filter (if equipped) every 250 Service
Hours or Weekly. Hours or Monthly.
Reference: For information on cleaning the Reference: For information on cleaning the
automatic lubrication system filler filter, refer to automatic lubrication system inline filter, refer to
Systems Operation, Testing and Adjusting, Systems Operation, Testing and Adjusting,
"Automatic Lubrication System, Hydraulic Type" for "Automatic Lubrication System, Hydraulic Type" for
the machine that is being serviced. the machine that is being serviced.
107
Maintenance Section
Axle Breather - Clean Backup Alarm - Test

SMCS Code: 3278-070-BRE SMCS Code: 7406-081
Location of the Front Axle Breather. Rear View of AD40 Series II
Location of the Rear Axle Breather. Rear View of AE40 Series II
1. Remove the breathers from the front and rear Make sure that the parking brake is engaged.
axle housings.
Turn the engine start switch to the ON position to
2. Wash the breathers in clean, nonflammable perform the test.
solvent.
Make sure that the area behind the machine is clear
3. Allow the breathers to dry. of personnel and clear of obstacles.
4. Install the clean breathers. Apply the service brake. Move the transmission
control to the REVERSE position.
The backup alarm should start to sound

immediately. The backup alarm should continue to
sound until the transmission control is moved to the
NEUTRAL position or the FORWARD position.
108
Maintenance Section
Battery - Recycle
SMCS Code: 1401-561
Always recycle a battery. Never discard a battery.
Always return used batteries to one of the following

locations:
A battery supplier.
An authorized battery collection facility.
Recycling facility.
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.
109
Maintenance Section
Battery, Battery Cable or Battery Electrolyte Level -

Battery Disconnect Switch - Check
Replace
SMCS Code: 1401-535
SMCS Code: 1401-510; 1402-510; 1411-510
Battery Electrolyte Level
1. The batteries are located under the cab. Tilt Battery Interval
the cab to access the batteries. Conventional 100 Hours
Low Maintenance 250 Hours
Reference: For information on tilting the cab, refer
Maintenance Free No Interval
to Operation and Maintenance Manual, "Cab - Tilt"
for the machine that is being serviced.
Tighten the battery retainers on all of the batteries.
2. Turn the engine start switch to the OFF Tighten the battery retainers at every 1000 hours.
position. Turn all switches to the OFF position.
Check the following areas at a minimum interval of
1000 hours. Check the following areas more
frequently during adverse conditions.
3. Turn the battery disconnect switch to the OFF

position and remove the key.
4. Disconnect the negative end (-) of the battery 1. The batteries are located under the cab. Tilt
cable from the electric starting motor. the cab to access the batteries.
5. Disconnect the negative end (-) of the battery Reference: For information on tilting the cab, refer
cable from the battery. to Operation and Maintenance Manual, "Cab - Tilt"
6. Disconnect the positive end (+) of the battery
cable from the battery.
7. Replace the battery or make all necessary

repairs to the battery.
8. Connect the positive end (+) of the battery

cable to the battery.
9. Connect the negative end (-) of the battery

cable to the battery.
10. Connect the negative end (-) of the battery

cable to the electric starting motor.
11. Install the key. Turn the battery disconnect

switch to the ON position. 2. Clean the battery surface with a clean cloth.
110
Maintenance Section
3. Disconnect all battery cables from the batteries.

Body Pivot Bearings -
Reference: To disconnect the battery cables, refer Lubricate
to Operation and Maintenance Manual, "Battery,
Battery Cable or Battery Disconnect Switch -
Replace" for the machine that is being serviced. SMCS Code: 7258-086-BD; 7424-086
4. Clean the battery cables and the battery posts. NOTICE

Coat the battery posts with 1P-0808 Check that the lines attached to all remote grease
Multipurpose Grease or petroleum jelly. fittings are undamaged. If the lines are split, grease
will not reach the bearings or pins. Machine damage
5. Connect the battery cables to the batteries. will result.
Reference: To connect the battery cables, refer to
Operation and Maintenance Manual, "Battery, Wipe all fittings clean before lubricating.
Battery Cable or Battery Disconnect Switch -
Replace" for the machine that is being serviced.
6. Coat the terminals with 1P-0808 Multipurpose

Grease or petroleum jelly. Then, install the post
cover.
7. For conventional batteries and batteries of low 1 2

maintenance, follow these additional
instructions:
Inspect the battery electrolyte level in each

battery cell. A maintenance free battery does
not require inspection.
Maintain the level of the distilled water to the Location of Body Pivot Bearings Remote Lubrication Point
bottom of the filler openings. If distilled water is (AD40 Series II)
not available, use clean drinking water.
1. Lubricate the left body pivot bearing through
A battery should not require more than 30 cc (1 remote mounted fitting (1).
ounce) of water per cell per week. This
requirement should exist with the proper 2. Lubricate the right body pivot bearing through
charging rate and with a moderate climate. remote mounted fitting (2).
In extreme temperatures, check the water in the

cells weekly. Cell water usage could be higher
in extreme temperatures.
111
Maintenance Section
Brake Accumulator Pressure - Brake Control Oil Filter -

Check Replace
SMCS Code: 4263-535 SMCS Code: 4295-510
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,
testing, adjusting and repair of the machine. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
any component containing fluids.
Correct brake accumulator charge pressure is
necessary for efficient hydraulic brake operation. Refer to Special Publication, NENG2500, "Caterpillar
Tools and Shop Products Guide", for tools and
Special tools and equipment are required to test the supplies suitable to collect and contain fluids in
accumulator. Caterpillar machines.
Reference: For the correct testing and charging Dispose of fluids according to local regulations and
procedures for the brake accumulator, refer to mandates.
Braking System, Systems Operation, Testing and
Adjusting, "Brake Accumulator - Test and Charge"
for the machine that is being serviced or consult
your Caterpillar dealer.
Note: The brake control oil filter should be

replaced every 500 Service Hours or 3 Months.
This frequency can be increased 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.
112
Maintenance Section
Release the pressure in the braking system.

1.
Brake Oil Cooler Screen -
Reference: For information on releasing the Clean
pressure in the braking system, refer to Braking
System, Systems Operation, Testing and Adjusting,
"Braking System Pressure - Release" for the SMCS Code: 4257-070; 4295-070
machine that is being serviced.
2. Remove brake filter housing (2). Remove the

element and discard. Hot oil and hot components can cause personal
3. Wash the filter housing in clean nonflammable
contact the skin.
solvent.
4. Inspect the seal in the filter housing. If the seal NOTICE

is damaged, replace the seal with a new seal. Care must be taken to ensure that fluids are contained
5. Install the new element in the housing. Install testing, adjusting and repair of the machine. Be
the element and housing in the housing base.
6. Start the engine and operate the engine at low
idle. Inspect for leaks.
Refer to Special Publication, NENG2500, "Caterpillar
supplies suitable to collect and contain fluids in
Caterpillar machines.
4 Dispose of fluids according to local regulations and
3 mandates.
Clean the brake oil cooler screen whenever there is

a failure of the hoist, torque converter or brake
hydraulic system.
7. With the oil cold, check the oil level in sight

gauge (3). For AD40 Series II trucks check the
oil level with the body fully lowered. For AE40
Series II trucks check the oil level with the
ejector plate fully retracted and the tailgate fully
raised.
8. Maintain the oil level to the FULL COLD mark in

the sight gauge. 1
9. Remove oil filler cap (4) and add oil if

necessary.
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 inches) long, to
open the internal drain valve and drain the oil.
113
Maintenance Section
3 ejector plate fully retracted and the tailgate fully
raised.

2 the sight gauge.
12. Remove oil filler cap (5) and add oil if

necessary.
2. Remove drain plug (2) from the oil cooler and

drain the oil. Clean and install the plug.
3. Remove plug (3) from the end of the cooler.
4. Remove the screen. Clean the screen in clean

nonflammable solvent.
5. Install the screen in the cooler.
6. Clean plug (3) in clean, nonflammable solvent.

Inspect the seal. Replace if it is damaged.
7. Install the plug.
8. 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.
4
114
Maintenance Section
Braking System - Test Service Brake Holding Ability Test
SMCS Code: 4251-081; 4267-081 1. Move the transmission control to the NEUTRAL
position. Start the engine.
Personal injury can result if the machine moves

while testing.
If the machine begins to move during test, reduce

the engine speed immediately, apply the service
brakes and engage the parking brake.
Repair the brake immediately.
NOTICE
Perform the following brake tests at the start of each
shift and before entering a ramp.
2. Apply the service brake pedal.
Be sure the area around the machine is clear of
personnel and obstructions. Be sure the steering
frame lock link 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 maximum
holding effort. Brake holding effort required to hold
a machine at a specific engine rpm 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 rpm at beginning of machine movement, 3. Disengage the parking brake by moving the
with the brake applied, should be compared against parking brake control to the OFF position.
the engine rpm 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.
4. Move the transmission control to the FIRST

SPEED FORWARD position.
115
Maintenance Section
5. Gradually increase engine speed to 1300 rpm. Parking Brake Holding Ability Test
The machine should not move.
6. Reduce the engine speed to low idle. Move the NOTICE

transmission control to the NEUTRAL position. The standard parking brake control switch is a pull-to-
Engage the parking brake. Stop the engine. engage type. When the knob is pulled OUT, the
brakes will be applied.
NOTICE
If the machine moved while testing the brakes, contact Certain mining regulations require machines to be
your Caterpillar dealer. equipped with a push-to-engage parking brake control
switch. When the knob is pushed IN, the brakes are
Have the dealer inspect and, if necessary, repair the applied.
service brakes before returning the machine to
operation. Before operating the machine ensure you are familiar
with the operation of the parking brake control switch.
Standard Pull-to-Engage Type

while testing.
If the machine begins to move, reduce the engine

speed immediately, apply the service brakes and
engage the parking brake. Repair the brake
immediately.
1. Move the transmission control to the NEUTRAL

position. Start the engine.
2. Engage the parking brake by pulling the parking

brake control knob out to the ON position.
116
Maintenance Section
Optional Push-to-Engage Type

while testing.
If the machine begins to move, reduce the engine

speed immediately, apply the service brakes and
engage the parking brake. Repair the brake
immediately.

3. Move the transmission control to the FIRST position. Start the engine.
2. Engage the parking brake by pushing the

Note: The parking brake indicator light should parking brake control knob in to the ON
illuminate and the fault alarm should sound. position.
4. Gradually increase engine speed to 1300 rpm.

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
Have the dealer inspect and, if necessary, repair the

parking brake before returning the machine to
operation.
3. Move the transmission control to the FIRST
117
Maintenance Section
Cab Air Filter - Clean/Replace

SMCS Code: 7342-070; 7342-510
Clean the cab air filter elements 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
Note: The parking brake indicator light should
illuminate and the fault alarm should sound. 1
4. Gradually increase engine speed to 1300 rpm.

5. Reduce the engine speed to low idle. Move the

transmission control to the NEUTRAL position. 2
Stop the engine.
NOTICE
If the machine moved while testing the brakes, contact
Have the dealer inspect and, if necessary, repair the

1. Remove bolt (1) that fastens recirculation filter
parking brake before returning the machine to
assembly (2).
operation.
2. Remove the cover and the air conditioning
recirculation filter from the cannister.
3. Clean the recirculation filter using air pressure.

When you use air pressure, the maximum air
pressure is 205 kPa (30 psi).
4. Install the filter in the cannister. 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.
118
Maintenance Section
Air Conditioning Filter Cab Pressurizer Filter
1 2
1 1
2 3
4
1. Release two latches (1). Remove air Note: When the debris reaches the full level on the
conditioning filter cover (2). precleaner, empty the precleaner.
1. Loosen the retaining nut and remove cover (2).

Remove precleaner cup (1). Empty the
precleaner cup.
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
3 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.
2. Remove air conditioning filter (3) from the air 5. Install the rubber baffle in the end cap.
conditioning duct.
6. Remove the wing nut on the filter element.
3. Clean the filter element with pressure air or Remove the filter element.
wash the element in warm water and a
nonsudsing household detergent. When you 7. Clean the filter element with pressure air or
use air pressure, the maximum air pressure is wash the element in warm water and a
205 kPa (30 psi). When you use water nonsudsing household detergent. When you
pressure, the maximum water pressure is 275 use air pressure, the maximum air pressure is
kPa (40 psi). 205 kPa (30 psi). When you use water
pressure, the maximum water pressure is 275
4. If washed, rinse the element in clean water and kPa (40 psi).
air dry thoroughly.
8. If washed, rinse the element in clean water and
5. Install the clean filter element and cover. air dry thoroughly.
Note: When rips or tears are noticed in the filter 9. Install the filter element and wing nut. Tighten
element, or a reduction of air circulation is noticed the wing nut finger tight. Do not use a tool to
in the cab after cleaning filter, install a new element. tighten the wing nut.
10. Install the end cap. Tighten clamp bolt (3)

finger tight. Do not use a tool to tighten the
clamp bolt.
119
Maintenance Section
Lubricate one fitting (4) on each cab lockdown

Cab Pivot and Lockdown Pins - 7.
pin assembly.
Check/Lubricate
SMCS Code: 7325-086-BD; 7325-535-BD;
7325-086-LX; 7325-535-LX
Do not work on or near the cab or left side of the

engine until the cab is in the fully tilted (over-
center) position.
Isolate the batteries by turning the battery

disconnect switch OFF and removing the key prior
to performing any service work under the cab.
Accidental cab lowering can cause severe

personal injury or death.
1. Tilt the cab.

to Operation and Maintenance Manual, "Cab -Tilt"
2. Check the cab pivot 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.
4
3
Wipe all fittings before lubricating.
4. Lubricate one fitting (1) on each cab pivot pin.
5. Lubricate the tilt cylinder pivot pin (rod end)

through fitting (2).
6. Lubricate the tilt cylinder pivot pins (cylinder

anchor end) through two fittings (3).
120
Maintenance Section
Circuit Breakers - Reset

SMCS Code: 1420-529
10 11
NOTICE 9 12
Replace circuit breakers with the same type and size
only. Otherwise, electrical damage can result.
16
13 14 15
If it is necessary to reset circuit breakers frequently,
an electrical problem may exist. Contact your
Caterpillar dealer.
Circuit Breakers - Push in the button to

(9) 15 Amp - Engine ECM recorder.
reset the circuit breaker. If the electrical
system is working properly, the button will
(10) Spare.
remain depressed. If the button does not remain
depressed, check the appropriate electrical circuit.
(11) 15 Amp - Block light, rear cab flood light,
Repair the electrical circuit, if necessary.
Automatic Retarder Control (ARC).
(12) 15 Amp - Cab tilt control, hoist/ejector control.

2 3
1 4 (13) 30 Amp (Automatic) - Head lights, tail lights,
dash lamps.
(14) 30 Amp (Automatic) - Rear lights.

8
5 6 7 (15) 30 Amp - Air conditioner.
(16) 15 Amp - Horn, automatic lubrication system,

reversing camera, low coolant level control,
dash indicator lamps.
(1) Spare.
(2) Spare. 17
(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. View of Battery Compartment under Cab.
(7) 15 Amp - Parking brake control, brake release (17) 80 Amp - Main.
system.
(8) 15 Amp - Transmission control.

121
Maintenance Section
Cooling System Coolant

(DEAC) - Change
SMCS Code: 1352-044; 1395-044
Pressurized system: Hot coolant can cause

serious burn. To open cap, stop engine, wait until
radiator is cool. Then loosen cap slowly to relieve
the pressure.
1. Remove the pressure cap slowly to relieve

NOTICE
cooling system pressure. Remove the pressure
Care must be taken to ensure that fluids are contained cap.

Dispose of fluids according to local regulations and

mandates.
NOTICE
Do not change the coolant until you read and 2. Open the drain valve for the engine cooling
understand the material in Maintenance Manual, system. Drain the coolant into a suitable
Caterpillar Machine Fluids Recommendations, container. The drain valve is located on the
SEBU6250, "Cooling System Specifications". bottom radiator tube.
3. Close the drain valve. Fill the system with clean

Note: This procedure pertains only to Caterpillar
water and a 6 to 10 percent concentration of
Diesel Engine Antifreeze/Coolant (DEAC). This
cooling system cleaner.
does not pertain to machines that are shipped from
the factory with Extended Life Coolant (ELC). Also
4. Start and run the engine for 90 minutes. Stop
this does not pertain to the machines that are
the engine and drain the cleaning solution into a
maintained with Extended Life Coolant (ELC).
suitable container.
If the coolant is dirty or if you observe any foaming
5. When the engine is stopped, flush the cooling
in the cooling system, drain the coolant before the
system with water until the draining water is
recommended interval.
clear. Drain the water into a suitable container.
6. Close the drain valve.

122
Maintenance Section
Add the coolant solution. Add coolant slowly to

7.
help avoid air locks, 20 liters (5 US gal) per
Cooling System Coolant (ELC)
minute. - Change
Reference: For information on the cooling system
capacity, refer to Operation and Maintenance SMCS Code: 1395-044-NL
Manual, "Refill Capacities" for the machine that is
being serviced.
8. Start the engine. Run the engine with the Pressurized system: Hot coolant can cause
cooling system pressure cap removed. Run the serious burn. To open cap, stop engine, wait until
engine until the water temperature regulator opens
and the coolant level stabilizes.
the pressure.
Note: If Caterpillar antifreeze is being used, do not
add supplemental coolant additive or change the NOTICE
element at this time. Care must be taken to ensure that fluids are contained


mandates.
9. Maintain the coolant level to within 13 mm NOTICE

(0.5 inch) of the bottom of the filler pipe or to Do not change the coolant until you read and
the proper level in the sight gauge. understand the material in Maintenance Manual,
Caterpillar Machine Fluids Recommendations,
10. Install the cooling system pressure cap. SEBU6250, "Cooling System Specifications".
11. Stop the engine.

NOTICE
Mixing Extended Life coolant (ELC) with other
products reduces the effectiveness of the coolant and
shortens coolant life. Use only 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
cooling system components.
If ELC cooling system contamination occurs, refer to

Extended Life Coolant (ELC) under the topic
Contamination of the ELC Cooling System.
This machine was factory filled with Extended Life

Coolant.
123
Maintenance Section
Note: This procedure pertains to machines using 7. Add the coolant solution. Add coolant slowly to
Extended Life Coolant (ELC) only. help avoid air locks, 20 liters (5 US gal) per
minute.
If the coolant is dirty or if you observe any foaming
in the cooling system, drain the coolant before the Reference: For information on the cooling system
recommended interval. capacity, refer to 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 until the water temperature regulator opens
and the level stabilizes.
Note: If Caterpillar antifreeze is being used, do not

add supplemental coolant additive or change the
element at this time.

cap.
9. Maintain the coolant level to within 13 mm

(0.5 inch) of the bottom of the filler pipe or to
the proper level in the sight gauge.
10. Install the cooling system pressure cap.
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. 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.

124
Maintenance Section
Cooling System Coolant NOTICE

Additive (DEAC) - Add during performance of inspection, maintenance,
SMCS Code: 1352-544 prepared to collect the fluid with suitable containers

Personal injury can result from hot coolant, steam Tools and Shop Products Guide", for tools and
and alkali. supplies suitable to collect and contain fluids in
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines to Dispose of fluids according to local regulations and
heaters or the engine contain hot coolant or mandates.
steam. Any contact can cause severe burns.
Remove cooling system pressure cap slowly to NOTICE

relieve pressure only when the engine is stopped Excessive coolant additive (greater than the
and cooling system pressure cap is cool enough recommended 6 percent initial fill) together with
to touch with your bare hand. concentrations of antifreeze greater than 60 percent
cause deposits to form and may result in radiator tube
Do not attempt to tighten hose connections when blockage and overheating.
the coolant is hot, the hose can come off causing
burns. Note: This procedure pertains only to Caterpillar
Diesel Engine Antifreeze/Coolant (DEAC) only. This
Cooling System Coolant Additive contains alkali. procedure does not pertain to machines that are
Avoid contact with skin and eyes. shipped from the factory with Extended Life
Coolant (ELC) and machines that are maintained
with Extended Life Coolant (ELC).
NOTICE
Adding coolant to an overheated engine could result Reference: For all cooling system requirements,
in damage to the engine. Allow the engine to cool refer to Maintenance Manual, "Caterpillar Machine
before adding coolant. Fluids Recommendations".
If the machine is to be stored in, or shipped to, an area Use the 8T-5296 Test Kit to check the
with freezing temperatures, the cooling system must concentration.
be protected to the lowest outside (ambient)
temperature.
Add Coolant Additive (If Required)
The engine cooling system is normally protected
to -36C (-33F) with Caterpillar Antifreeze, when
shipped from the factory unless special requirements
are defined.
125
Maintenance Section
1. Loosen the pressure cap slowly to relieve 5. Coat the seal of a new element with a thin film
cooling system pressure. Remove the pressure of clean engine oil.
cap.
6. Install and turn the element until the seal
2. It may be necessary to drain enough coolant contacts the base, then tighten 3/4 of a turn
from the radiator to allow for the addition of the more.
liquid cooling system additive.
7. Open the inlet and outlet valves.
Note: Make sure the coolant is drained into a
suitable container. 8. Clean the pressure cap and inspect the
pressure cap. Install the pressure cap.
3. Add liquid supplemental coolant additive
(conditioner) according to the requirements of 9. Start the engine and check for leaks. Allow the
your cooling system as determined by the coolant level to stabilize.
coolant additive concentration test.
10. If necessary, add premixed coolant in order to
4. Clean the pressure cap and inspect the bring the coolant to the proper level in the sight
pressure cap. Install the pressure cap. glass.
5. Start the engine and check for leaks. Allow the

coolant level to stabilize.

bring the coolant to the proper level in the sight
gauge.
Change Coolant Conditioner

Element (If Required)
1. Loosen the pressure cap slowly to relieve

cap.
2. Close element inlet valve (1) and outlet valve (2).

Remove and discard element (3).
3. Clean the element mounting base. Make sure

all of the old seal is removed.
4. Replace with a new maintenance element.

126
Maintenance Section
Cooling System Coolant NOTICE

Extender (ELC) - Add during performance of inspection, maintenance,
SMCS Code: 1352-544-NL prepared to collect the fluid with suitable containers

Personal injury can result from hot coolant, steam Tools and Shop Products Guide", for tools and
and alkali. supplies suitable to collect and contain fluids in
At operating temperature, engine coolant is hot Caterpillar machines.
and under pressure. The radiator and all lines to
heaters or the engine contain hot coolant or Dispose of fluids according to local regulations and
steam. Any contact can cause severe burns. mandates.
Remove cooling system pressure cap slowly to
relieve pressure only when the engine is stopped NOTICE
and cooling system pressure cap is cool enough Excessive coolant additive (greater than the
to touch with your bare hand. recommended 6 percent initial fill) together with
concentrations of antifreeze greater than 60 percent
Do not attempt to tighten hose connections when cause deposits to form and may result in radiator tube
the coolant is hot, the hose can come off causing blockage and overheating.
burns.
Cooling System Coolant Additive contains alkali. NOTICE

Avoid contact with skin and eyes. Mixing Extended Life coolant (ELC) with other
products reduces the effectiveness of the coolant and
shortens coolant life. Use only Caterpillar products or
NOTICE commercial products that have passed the Caterpillar
Adding coolant to an overheated engine could result EC-1 specifications for premixed or concentrate
in damage to the engine. Allow the engine to cool coolants. Use only Caterpillar Extender with
before adding coolant. Caterpillar ELC. Failure to follow these
recommendations could result in the damage to
If the machine is to be stored in, or shipped to, an area cooling system components.
with freezing temperatures, the cooling system must
be protected to the lowest outside (ambient) If ELC cooling system contamination occurs, refer to
temperature. Extended Life Coolant (ELC) under the topic
Contamination of the ELC Cooling System.
The engine cooling system is normally protected
to -36C (-33F) with Caterpillar Antifreeze, when This machine was factory filled with Extended Life
shipped from the factory unless special requirements Coolant.
are defined.
When a Caterpillar Extended Life Coolant (ELC) is
used, an Extender must be added to the cooling
system.
Reference: For the proper service interval, refer to

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 all cooling system requirements,

refer to Maintenance Manual, "Caterpillar Machine
Fluids Recommendations".
127
Maintenance Section
Cooling System Coolant Level

- Check
SMCS Code: 1350-535-FLV

the pressure.
1. Loosen the pressure cap slowly to relieve

NOTICE
cap. Care must be taken to ensure that fluids are contained
2. It may be necessary to drain enough coolant testing, adjusting and repair of the machine. Be
from the radiator to allow for the addition of the prepared to collect the fluid with suitable containers
liquid coolant Extender. before opening any compartment or disassembling
Note: Make sure the coolant is drained into a
suitable container. Refer to Special Publication, NENG2500, "Caterpillar
3. Add the recommended amount of ELC supplies suitable to collect and contain fluids in
Extender to the coolant system. Caterpillar machines.
4. Clean the pressure cap and inspect the Dispose of fluids according to local regulations and
pressure cap. Install the pressure cap. mandates.
5. Start the engine and check for leaks. Allow the

coolant level to stabilize.

bring the coolant to the proper level in the sight
gauge.
1. Maintain the coolant level in the sight gauge

located on the right hand 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 Operation and Maintenance Manual,
"Radiator Core - Clean" for the machine that is
being serviced.
128
Maintenance Section
Cooling System Pressure Cap

- Clean/Replace
SMCS Code: 1382-070; 1382-510

the pressure.
3. If coolant level is low, remove the pressure cap

slowly to relieve pressure. Add coolant as
required to within 13 mm (.5 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.

pressure.
2. Inspect the pressure cap for damage, foreign

material and for deposits.
3. Inspect the condition of the pressure cap

gasket. Replace the pressure cap if damaged.
If the gasket is not damaged, use 9S-8140
Service Tool 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. Install the pressure cap.

129
Maintenance Section
Cooling System Water

Temperature Regulator -
Replace
SMCS Code: 1355-510; 1393-010
Pressurised system: Hot coolant can cause

radiator is cool. Then open cap slowly to relieve
pressure.
Replace the water temperature regulator on a

regular basis 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 Front View of Engine
below the water temperature regulator housing.
1. Remove the water temperature regulator
housing.
NOTICE
Failure to replace the engine's water temperature 2. Remove the gasket, the water temperature
regulator on a regularly scheduled basis could cause regulator and the seal from the water
severe engine damage. temperature regulator housing.
Note: If you are only replacing a water temperature NOTICE

regulator, drain the cooling system coolant to a Former water temperature regulators may be used, if
level that is below the water temperature regulator they meet test specifications and are not damaged or
housing. have excessive buildup or deposits.
NOTICE NOTICE
Care must be taken to ensure that fluids are contained Since Caterpillar engines incorporate a shunt design
during performance of inspection, maintenance, cooling system, it is mandatory to always operate the
testing, adjusting and repair of the machine. Be engine with a water temperature regulator.
before opening any compartment or disassembling Depending on load, failure to operate with a water
any component containing fluids. temperature regulator could result in either an
overheating or an overcooling condition.
supplies suitable to collect and contain fluids in NOTICE
Caterpillar machines. If the water temperature regulator is installed
incorrectly, it will cause the engine to overheat.
mandates.
130
Maintenance Section
Install a new seal in the water temperature

3.
regulator housing. Install a new water
Differential and Final Drive Oil -
temperature regulator and a new gasket. Install Change
the water temperature regulator housing.
4. Refill the cooling system. SMCS Code: 3278-044; 4050-044
Reference: For all cooling system requirements, Note: The oil change interval for the differential and
refer to Maintenance Manual, "Caterpillar Machine for the final drives can be monitored with the
Fluids Recommendations". SOS (Scheduled Oil Sampling) program. The oil
change interval is based on the condition of the oil.
Reference: For information on the cooling system If scheduled oil sampling program is not used, the
capacity, refer to Operation and Maintenance oil change interval for the differential and final drives
Manual, "Refill Capacities" for the machine that is is at 2000 service hours.
being serviced.

contact the skin.
NOTICE


mandates.
1. Position the wheels so that final drive drain/level

plugs are facing downward. Remove the final
drive drain/level plugs and allow the oil to drain
into a suitable container.
131
Maintenance Section
2. Clean the area around the drain plug. Clean

the drain plug. Install the drain plug.
4
7. Position each wheel so that drain/level plugs (3)

for the final drives are flush with the center line
of each wheel. Remove filler plugs (4).
View of Front Differential.
8. Fill the final drives to the bottom of the drain/
level plug openings.

Capacities" for the machine that is being serviced.
1 9. Clean the drain/level plugs and install the drain/

2 level plugs. Clean the filler plugs and install the
filler plugs.
10. Operate the machine for a few minutes and

recheck the oil level. The oil level should reach
the bottom of the drain/level plug openings.
View of Rear Differential
11. Add oil if necessary. Install the plugs.
3. Remove differential drain plugs (2) and allow the
oil to drain into a suitable container.
4. Clean the drain plugs. Install the drain plugs.
5. Remove differential filler plugs (1). Fill the

differential to the bottom of the filler plug
opening.

6. Clean the area around the filler plug. Clean the

filler plug. Install the filler plug.
132
Maintenance Section
Differential and Final Drive Oil

Level - Check
3
SMCS Code: 3278-535-FLV; 4050-535-FLV
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.
View of Front Differential.

2
1. Position the wheel so that the drain/level plug

(1) for the final drive is flush with the center line
of the wheel.
View of Rear Differential
2. Remove the drain/level plug. The oil level
should be at the bottom of the drain/level plug 3. Remove the differential filler plugs (3) and (4).
opening. If necessary, remove filler plug (2) and The oil level should be at the bottom of the filler
add oil through the filler opening. plug opening. Add oil, if necessary.
Reference: For information on lubricants, refer to Reference: For information on lubricants, refer to
Operation and Maintenance Manual, "Lubricant Operation and Maintenance Manual, "Lubricant
Viscosities" for the machine that is being serviced. Viscosities" for the machine that is being serviced.
Note: If the oil level is higher than the filler plug Note: If the oil level is higher than the filler plug
opening, do not allow the oil to drain to the proper opening, do not allow the oil to drain to the proper
level. Install the filler plugs. level. Install the filler plugs.
Note: All of the drain/level plugs are magnetic

plugs. The magnetic plugs will attract metal from
the oil. A bearing failure is indicated by an
increased amount of metal on the magnetic plug.
If any abnormal particles are found, consult your

Caterpillar dealer.
133
Maintenance Section
Differential and Final Drive Oil Differential Thrust Pin - Check

Sample - Obtain
SMCS Code: 3258-535-T9
SMCS Code: 3258-008; 4050-008; 7542-008
For information that pertains to obtaining a sample

of the differential and final drive oil, refer to
Operation and Maintenance Manual, "Sampling
Interval and Location of Sampling Valve" for the
machine that is being serviced. Also refer to
Maintenance Manual, "Caterpillar Machine Fluids
Recommendations".
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
134
Maintenance Section
Drive Shaft Universal Joints,

Splines and Bearings - Inspect/
Lubricate
SMCS Code: 3251-040; 3253-040-SN;
3267-040-BD; 3251-086; 3253-086-SN;
3267-086-BD
Inspect the drive shaft universal joints for wear,

loose or missing bolts. Tighten loose bolts and
replace missing bolts. Inspect the drive shaft
splines and bearings for wear. Replace worn
components.
2. Lubricate the center drive shaft slip joint spline

NOTICE
through the fitting.
Check that the lines attached to all remote grease
fittings are undamaged. If the lines are spilt, grease
will result.
Wipe all fittings clean before lubricating. 1
1. Lubricate all drive shaft universal joints through 1

nine fittings.
3. Lubricate the front oscillation drive shaft

bearing through remote mounted fitting (1).
135
Maintenance Section
Ejector Cylinder Bearings -

Lubricate
SMCS Code: 5305-086-BD
NOTICE
fittings are undamaged. If the lines are split, grease
2 3
will result.
Wipe all fittings clean before lubricating.
1
2 3
2
Location of Drive Shaft Bearing Remote Lubrication Point (AD40 1. Lubricate the left ejector cylinder bearing in the
Series II) 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).
2
3
3
Location of Drive Shaft Bearing Remote Lubrication Point (AE40

Series II)
4. Lubricate the rear oscillation drive shaft bearing

through one remote mounted fitting (2).
5. Lubricate the intermediate drive shaft center 3. Move the ejector plate to the fully ejected
bearing through one remote mounted fitting (3). 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).
136
Maintenance Section
Ejector Line Screen - Inspect/

Clean
4
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.

injury. Do not allow hot oil or hot components to 3. Wash screen adapter (4) in clean,
contact the skin. nonflammable solvent. Inspect the screen
mesh. Replace the screen adapter if the mesh
is worn or damaged.
NOTICE
Care must be taken to ensure that fluids are contained 4. Inspect the hose assembly seals and the
during performance of inspection, maintenance, screen adapter seals. Replace the seals if they
testing, adjusting and repair of the machine. Be are worn or damaged.
before opening any compartment or disassembling 5. Install the screen adapter, hose assembly,
any component containing fluids. flanges and bolts.
Refer to Special Publication, NENG2500, "Caterpillar 6. Start the engine. Eject and retract the ejector
Tools and Shop Products Guide", for tools and plate several times. Check for leaks.

mandates.
2
1
3
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.
137
Maintenance Section
For the correct procedure to replace

Engine Air Filter Primary Reference:
the secondary element, refer to Operation and
Element - Clean/Replace Maintenance Manual, "Engine Air Filter Secondary
Element - Replace" for the machine that is being
serviced.
SMCS Code: 1054-070-PY; 1054-510-PY
4. Clean the inside of the air cleaner housing.

Service the air cleaner daily or if the air filter
restriction indicator located on the dash panel 5. Inspect the primary element. If the pleats, the
comes on. Stop the engine. gaskets, or the seals are damaged, discard the
primary element. Replace a damaged primary
NOTICE element with a clean primary element.
Service the air cleaner only with the engine stopped to
prevent engine damage. NOTICE
Do not clean the primary element by bumping or
tapping them. Do not use primary element with
damaged pleats, gaskets or seals. Engine damage
can result.
1 Make sure the cleaned primary element is completely

dry before installing into the air cleaner housing.
Water remaining in the elements can cause false
indications of contamination in Scheduled Oil
Sampling test results.
2
6. If the primary element is not damaged, clean

the primary element.
The primary element can be cleaned by using

1. Loosen wing nut (1). the following methods:
2. Use handle (2) to remove the engine air filter Air pressure.
primary element from the air cleaner housing.
Water pressure.
3. Inspect the air filter service indicator on the
secondary element. This indicator is normally Detergent washing.
green. If the indicator is red replace the
secondary element. When you use air pressure, the maximum air
pressure is 205 kPa (30 psi). When you use
water pressure, the maximum water pressure is
275 kPa (40 psi).
138
Maintenance Section
Engine Air Filter Secondary

Element - Replace
SMCS Code: 1054-510-SE
NOTICE
Always replace the secondary element. Do not
attempt to reuse it by cleaning. Engine damage could
result.
Replace the engine air filter secondary element

under the following conditions:
7. When you clean the inside pleats and the
outside pleats, direct the air along the pleats or The air filter service indicator is red.
direct the water along the pleats.
The engine air filter primary element is serviced
The primary element can be washed in a for the third time.
solution that consists of warm water and of
nonsudsing household detergent. Fully rinse The exhaust smoke remains black and a clean
the pleats. Allow the primary element to air dry primary element has been installed.
completely.
1. Remove the wing nut and the primary element.
8. Inspect the primary element after you clean the
primary element. Do not use a primary element Reference: For additional information, refer to
if the pleats, the gaskets or the seals are Operation and Maintenance Manual, Engine Air
damaged. Filter Primary Element - Clean/ Replace for the
9. Cover the clean primary element. Store the
primary element in a clean, dry location.
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.
If the air restriction indicator remains on after
starting the engine, or the exhaust smoke is still 2. Remove the split pin, air filter service indicator
black after installation of a clean primary filter and the secondary element.
element, install a new primary filter element. If the
indicator remains on after installing a new primary 3. Cover the air inlet opening. Clean the inside of
filter element, replace the secondary element. the air cleaner housing.
Reference: For the correct procedure to replace 4. Direct low air pressure into the air filter service
the secondary element, refer to Operation and indicator in order to reset the indicator. This
Maintenance Manual, "Engine Air Filter Secondary will change the color of the indicator from a red
Element - Replace" for the machine that is being color to a green color.
serviced.
5. Uncover the air inlet opening. Install a new
secondary element. Install the air filter service
indicator and split pin.
139
Maintenance Section
Install the primary element and the wing nut.

6.
Tighten the wing nut finger tight. Do not use a
Engine Air Precleaner - Clean
tool to tighten the nut.
SMCS Code: 1055-070
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 the air intake precleaner rotor operation.
5. Periodically remove the precleaner and wash in

water.
140
Maintenance Section
Engine Crankcase Breather - Engine Mounts - Inspect

Clean
SMCS Code: 1152-040
SMCS Code: 1317-070
1
2
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 clean, nonflammable

solvent. Shake, or use pressure air, to dry the
breather.
5. Inspect the hose for damage. Replace if

necessary. Caterpillar recommends checking the engine
mounts for deterioration and for proper bolt torque.
6. Install the breather. Tighten the breather This will help to prevent excessive engine vibration
clamp. that is caused by improper mounting.
7. Install the hose to the breather and tighten the Reference: For the proper bolt torques for the
hose clamps. engine mounts, refer to Specifications, "3408E
HEUI Engine", for the machine that is being
serviced.
8. Repeat Steps 1 through 7 for the breather on

the other side of the engine.
141
Maintenance Section
The machine must be level and the parking brake

Engine Oil and Filter - Change must be engaged. The oil must be warm and the
engine stopped.
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 latest oil

recommendations.
Do not work on or near the cab or left side of the The engine oil filters are located on the left side of
engine until the cab is in the fully tilted (over- the engine. Tilt the cab to access the filters.
center) position.
Isolate the batteries by turning the battery to Operation and Maintenance Manual, "Cab - Tilt"
disconnect switch to the OFF position and remove for the machine that is being serviced.
the key prior to performing any service work under
the cab.
Accidental cab lowering can cause severe

personal injury or death.

contact the skin.
NOTICE
1. Open the drain valve and drain the oil into a
suitable container. Close the drain valve.


mandates.
142
Maintenance Section
Remove the used oil filter elements and discard

2.
the used oil filter elements.
Engine Oil Level - Check
3. Clean the filter housing base. Make sure all of SMCS Code: 1000-535-FLV
the old filter seal is removed from the filter
base.
NOTICE
4. Apply a thin film of clean engine oil to the new Do not underfill or overfill the engine crankcase with
filter element seals. oil. Either condition can cause engine damage.
5. Install both filters hand tight, until the seals of

the filters contact the filter base. Tighten the
filters 3/4 turn more.
Note: There are rotation index marks on each filter,

spaced 90 (1/4 turn) apart. Use these rotation
marks as a guide when tightening the filters.
Check the engine oil level with the machine level

2 and the parking brake engaged.
The dipstick is located on the cab side of the

engine.
6. Remove filler cap (1). Fill the crankcase with

new oil. Clean and install the filler cap.

7. Start and run the engine at low idle for five

minutes. Inspect for leaks.
8. Maintain the oil level in the hatched area on the

SAFE OPERATING RANGE side of dipstick (2). Engine Dipstick
Add oil if necessary. Stop the engine.
143
Maintenance Section
Engine Oil Sample - Obtain

SMCS Code: 1000-008; 7542-008
1 For information that pertains to obtaining a sample

2
of the engine oil, refer to Operation and
Maintenance Manual, "Sampling Interval and
Location of Sampling Valve" for the machine that is
being serviced. Also refer to Maintenance Manual,
"Caterpillar Machine Fluids Recommendations".
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.

144
Maintenance Section
Engine Shutdown to Idle

Protection System - Test
SMCS Code: 1400-081
1. Start the engine.
2. Depress the accelerator control pedal to 4

achieve engine rpm above low idle. 3
Location of Oil Pressure Switch - Later Machines
4. Disconnect connector (3) from oil pressure

switch (4). Engine speed should reduce to low
idle. Reconnect the connector.
1
5. Stop the engine.
2
3. Disconnect connector (1) from coolant

5
temperature switch (2). Engine speed should
reduce to low idle. Reconnect the wiring at the 6
connector.
4
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
3
guard.
7. Start the engine and depress the accelerator

control. Engine speed should not increase
above low idle.
Location of Oil Pressure Switch - Earlier Machines 8. Stop the engine. Reconnect the wire to the
coolant level sensor.
9. Seal wiring connectors 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.
145
Maintenance Section
Engine Valve Lash - Inspect/

Adjust
SMCS Code: 1102-025
To prevent 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
measuring valve clearance. If the valve clearance is within 0.08 mm (.003 in) of
the nominal clearance given, adjustment is not
required. If the clearance is not within these limits,
Note: The following warning is located on the valve set the clearance as specified in the chart.
covers or valve base covers of the engine.
Valve Clearance Setting
Intake 0.38 mm (0.015 inch)
Exhaust 0.76 mm (0.030 inch)
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 checking the engine

valve rotators, refer to Operation and Maintenance
Manual, "Engine Valve Rotators - Inspect" for the Reference: For further information on checking the
machine that is being serviced. engine valve lash, refer to Systems Operation,
Testing and Adjusting, "3408E & 3412E Engines"
for the machine that is being serviced. Contact
NOTICE your Caterpillar dealer for any additional
Operation of Caterpillar engines with improper engine information.
valve lash adjustments will reduce the engine
efficiency. This reduced efficiency could result in
excessive fuel usage and/or shortened engine
component life.
Measure the valve lash with the engine stopped. To

obtain an accurate measurement, allow at least 20
minutes for valves to cool to engine cylinder head and
block temperature.
146
Maintenance Section
Engine Valve Rotators - Engine Water Pump - Inspect

Inspect
SMCS Code: 1361-040
SMCS Code: 1109-040
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.
Perform the following steps after the valve lash is

set, but before the valve covers are installed:
Front View of Engine
1. Start the engine and run the engine at low idle.
A water pump that has failed might cause severe
2. Observe the top surface of each valve rotator. engine overheating problems. The engine
The valve rotators should turn slightly when the overheating problems could result in the following
valves close. problems:
If the valve fails to rotate, contact your Caterpillar Cracks in the cylinder head.
dealer.
Piston seizure.
Other potential engine damage.
Visually inspect the water pump for leaks. If leaks

are found, all the seals need to be replaced.
Note: For further information, refer to Disassembly

and Assembly, "3408E & 3412E Engines" for the
147
Maintenance Section
Exhaust Purifier - Inspect/ Falling Object Protective

Clean Structure (FOPS) - Inspect
SMCS Code: 1091-040; 1091-070 SMCS Code: 7325-040
NOTICE
Do not attempt to straighten the FOPS structure. Do
not repair the FOPS 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 FOPS, consult your
Caterpillar dealer for repairs.
Inspect the catalytic purifier for damage and 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 Maintenance Manual,
"Emission Control Systems" for the machine that is
being serviced. Inspect for any loose or damaged bolts. Replace
damaged or missing bolts with original equipment
parts only.
Reference: For the correct bolt torques, refer to

Power Train, Specifications, "Cab Mounting" for the
Note: Apply thread lubricant to all FOPS bolt

threads before installing. Failure to apply lubricant
can result in improper bolt torque.
Replace FOPS mounting supports if the 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 straighten or repair by welding

reinforcement plates to the FOPS.
148
Maintenance Section
Contact your Caterpillar dealer for repair of cracks

in welds, castings or any metal section on the
Fan Drive Bearing and Belt
FOPS. Tightener - Lubricate
Ensure any certification labels are firmly fixed and
legible. SMCS Code: 1358-086; 1359-086-BD
1. Lubricate the fan drive bearing through fitting

(1).
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.
149
Maintenance Section
Fire Suppression System - Frame and Body - Inspect

Check
SMCS Code: 7051-040; 7258-040
SMCS Code: 7401-535
AD40 Series II
NOTICE
For detailed information on fire suppression system
service procedures, refer to the fire system
manufacturer's service information. To prevent personal injury or death, do not work
under the truck with the body (bed) raised.
When it is necessary to work under the truck with

the body (bed) raised, install the body (bed)
retaining pins through the pin bores in the frame
and body.
Perform fire suppression system checks and

service procedures in accordance with the fire
suppression system manufacturer's service
information.
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.
2. Inspect the dump body. If the dump body is

damaged or worn, repair the dump body.
150
Maintenance Section
3. Clean the frame with a wire brush or a scraper. 2. Clean the ejector body with a wire brush or a
If you find cracks or damage, contact your scraper. Inspect the ejector body. If the body
Caterpillar dealer for specific repair procedures. is damaged or worn, repair the body. If you
find cracks, contact your Caterpillar dealer for
4. Remove the body retaining pins. If the pins specific repair procedures.
cannot be removed, raise the dump body to
release the tension. After lowering the dump 3. Remove the tailgate retaining pin. If the pin
body, place the pins in the stored position in cannot be removed, raise the tailgate to release
the rear frame. the tension. After lowering the tailgate, place
the pin in the stored position in the body.
AE40 Series II
To prevent personal injury or death, do not work

under the tailgate with the tailgate raised.
When it is necessary to work under the tailgate

with the tailgate raised, install the tailgate safety
pin through the pin bores in the tailgate and body.
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.
151
Maintenance Section
Clean the body support pads with high

Frame and Body Support Pads 2.
pressure water or steam. If damage is found,
- Clean/Inspect contact your Caterpillar dealer for specific repair
procedures.
SMCS Code: 7051-040; 7258-040; 7051-070; 3. Visually inspect each of the body support pads.
7258-070 Look for uneven wear of the body support
pads. Look for gaps between the body support
AD40 Series II pads and the mating surfaces. If problems are
found, contact your Caterpillar dealer for more
information.
4. Remove the body retaining pins. If the pins

To prevent personal injury or death, do not work cannot be removed, raise the dump body to
under the truck with the body (bed) raised. release the tension. After lowering the dump
body, place the pins in the stored position in
When it is necessary to work under the truck with the dump body.
the body (bed) raised, install the body (bed)
retaining pins through the pin bores in the frame
and body.
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.
152
Maintenance Section
Fuel System - Prime Fuel System Primary Filter -

Clean/Replace
SMCS Code: 1250-548
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.
Fuel leaked or spilt onto hot surfaces or electrical

components can cause a fire.
Turn the battery disconnect switch to the OFF

position when servicing the fuel filters. Use a
suitable container to trap fuel that may leak or
Fuel Priming Pump (AD/AE40-129 to 148)
spill when removing the fuel filter elements.
NOTICE

Fuel Priming Pump (AD/AE40-149 & Up)

mandates.
1. Turn the priming pump counterclockwise and
pull out the priming pump plunger. This will NOTICE
unlock the hand priming pump. Do not fill fuel filters with fuel before installing them.
Contaminated fuel will cause accelerated wear to fuel
2. Use the hand priming pump to fill the engine
system components. The fuel system should be
fuel lines with fuel. Continue to prime the fuel
primed prior to starting the engine.
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 smokes, 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.
153
Maintenance Section
AD/AE40-129 to 148 AD/AE40-149 & Up
1. Loosen filter housing retaining bolt (1). 1. Remove the fuel filter assembly from the base
with a strap-type wrench.
2. Remove filter housing (2) and the element.
2. Remove the water separator bowl and seal
3. Remove the element from the housing case. from the filter element and discard the used
filter. Inspect the seal. If the seal is damaged,
4. Wash the element and housing in clean, use a new one.
nonflammable solvent.
3. Clean the filter mounting base. Be sure all of
5. Dry the element using pressure air. the old seal is removed.
6. Wash the filter housing base in clean, 4. Wash the water separator bowl in clean,
nonflammable solvent. nonflammable solvent.
7. Inspect the seal. Replace the seal if damaged. 5. Lubricate the seals of a new filter with clean
diesel fuel.
8. Install the clean element into the filter housing.
6. Install the seal and the water separator bowl on
9. Install the element and housing into the base. the new primary filter element.
10. Tighten the retaining bolt to a torque of 24 4 7. Install the filter assembly by hand. When the
Nm (18 3 lb ft). seal contacts the base, tighten 3/4 of a turn
more.
11. Prime the fuel system.
8. Prime the fuel system.
Reference: For information on priming the fuel
system, refer to Operation and Maintenance Reference: For information on priming the fuel
Manual, "Fuel System - Prime" for the machine that system, refer to Operation and Maintenance
is being serviced. Manual, "Fuel System - Prime" for the machine that
is being serviced.
12. Start the engine and inspect the filter for leaks.
Make any necessary repairs. If the engine has 9. Start the engine and inspect the filter for leaks.
a loss of power or the exhaust smoke is still Make any necessary repairs. If the engine has
black, replace the secondary filter. 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 Operation and Reference: For information on replacing the
Maintenance Manual, "Fuel System Secondary Filter secondary fuel filter, refer to Operation and
- Replace" for the machine that is being serviced. Maintenance Manual, "Fuel System Secondary Filter
- Replace" for the machine that is being serviced.
154
Maintenance Section
Fuel System Secondary Filter -

Replace
SMCS Code: 1261-510-SE


Secondary Fuel Filter (AD/AE40-149 & Up)
1. Remove the fuel filter element with a strap-type
wrench. Discard the used filter.
NOTICE
Care must be taken to ensure that fluids are contained 2. Clean the filter housing base. Be sure all of the
during performance of inspection, maintenance, old seal is removed.
prepared to collect the fluid with suitable containers 3. Lubricate the sealing surface of a new filter with
before opening any compartment or disassembling clean diesel fuel.
4. Install the new filter by hand. Tighten the filter
until the seal contacts the base. Tighten the
filter an additional 3/4 of a turn.
supplies suitable to collect and contain fluids in Note: There are rotation index marks on each filter,
Caterpillar machines. spaced 90 (1/4 turn) apart. Use these marks as a
guide when tightening the filter.
mandates. 5. Prime the fuel system.
Reference: For information on priming the fuel

NOTICE system, refer to Operation and Maintenance
Do not fill fuel filters with fuel before installing them. Manual, "Fuel System - Prime" for the machine that
Contaminated fuel will cause accelerated wear to fuel is being serviced.
system components. The fuel system should be
primed prior to starting the engine. 6. Start the engine and inspect the filter for leaks.
Make any necessary repairs.
Secondary Fuel Filter (AD/AE40-129 to 148)

155
Maintenance Section
Fuel System Water Separator - Fuel Tank Cap and Strainer -

Drain Clean
SMCS Code: 1263-543 SMCS Code: 1273-070-STR; 1273-070-Z2
Note: The water separator is not a filter. The water Note: Machines equipped with an optional fast-fill
separator separates the water from the fuel. fuel system do not contain a breather filter element
in the fuel tank cap. Perform Steps 3 and 5 only to
standard machines without the fast-fill fuel system.
AD/AE40-149 & Up


1 5
4
2
1. Open the drain valve and allow the water and 3

sediment to drain into a suitable container.
2. Close the drain valve. 1. Lift and turn lever (5) counterclockwise until it
stops. Remove the fuel tank 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

components in the reverse order.
156
Maintenance Section
Fuel Tank Water and Sediment

- Drain
SMCS Code: 1273-543-M&S
6
NOTICE
6. Remove strainer (6) from the filler opening.
7. Wash the strainer in a clean, nonflammable Tools and Shop Products Guide", for tools and
solvent. supplies suitable to collect and contain fluids in
8. Install strainer (6) in the filler opening.
9. Install the fuel tank cap. mandates.
The drain valve is located on the right side of the

machine under the fuel tank.
1 2
157
Maintenance Section
Open (turn counterclockwise) drain valve (1)

1.
and allow the water and sediment to drain out
Fuses - Replace
of opening (2). Close drain valve (1).
SMCS Code: 1417-510
Fuses - Fuses protect the electrical system

from damage caused by overloaded
circuits. Replace a fuse if the elements
separate. If the element of a new fuse separates,
have the circuit checked and repaired.
NOTICE
Replace fuses with the same type and size only.
Otherwise, electrical damage can result.
If it is necessary to replace fuses frequently, an

electrical problem may exist. Contact your Caterpillar
dealer.
View of Battery Compartment under Cab
(1) 675 Amp - Fusible link.
View under Right Side Console Panel in Cab
(2) 8 Amp (If Equipped) - Voltage reducer.
(3) 5 Amp - Torque converter lock-up.

158
Maintenance Section
Hoist Cylinder Bearings - Hoist, Torque Converter and

Lubricate Brake System Oil - Change
Operate the machine long enough to warm the oil.

NOTICE
Check that the lines attached to all remote grease The machine must be level, the parking brake
fittings are undamaged. If the lines are split, grease engaged and the engine stopped.
will result. 1. Remove the filler cap to prevent a vacuum in
the tank. Install the cap after the tank is
Wipe all fittings clean before lubricating. drained to prevent dirt from entering the
system.

2 3 contact the skin.
1 4
NOTICE
Location of Hoist Cylinder Bearings Remote Lubrication Point
(AD40 Series II)

1. Lubricate the left upper hoist cylinder bearing
through remote mounted fitting (1).
2. Lubricate the left lower hoist cylinder bearing Caterpillar machines.
3. Lubricate the right lower hoist cylinder bearing mandates.
4. Lubricate the right upper hoist cylinder bearing


use tools.
159
Maintenance Section
2. Remove the tank drain plug. Open the drain

valve by installing a 1 inch NPT pipe nipple, 88
mm (3.50 inches) long, in the bottom of the
tank, to open the internal drain valve and drain 2
the oil. Drain the oil into a suitable container.
1
raised.
3. Remove the drain plug from the brake oil cooler
and drain the oil. Drain the oil into a suitable 12. Maintain the oil level to the FULL COLD mark in
container. Clean and install the plug. the sight gauge.
4. Remove the pipe nipple. Clean and install the 13. Remove filler cap (2) and add oil if necessary.
tank drain plug.
5. Remove the hoist, torque converter 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.

Check for leaks.
160
Maintenance Section
Hoist, Torque Converter and Hoist, Torque Converter and

Brake System Oil Level - Brake System Oil Sample -
Check Obtain
SMCS Code: 5050-535-FLV SMCS Code: 5050-008

of the hoist, torque converter and brake oil, refer to
Operation and Maintenance Manual, "Sampling
2 Interval and Location of Sampling Valve" for the
machine that is being serviced. Also refer to
Maintenance Manual, "Caterpillar Machine Fluids
1
Recommendations".
NOTICE
Ensure the dump body is fully lowered (AD40 Series
II) or the ejector plate is fully retracted and the tailgate
fully raised (AE40 Series II) when checking the tank
oil level.
The hoist, torque converter and brake hydraulic

tank is located on the right side of the machine.

raised.

the sight gauge.
3. Remove filler cap (2) and add oil, if necessary.
Note: If the system has been drained, it will be

necessary to stop the engine and add oil several
times.
161
Maintenance Section

Hoist, Torque Converter and use tools.
Brake System Screens - Clean
1. Remove tank drain plug (1). Open the drain
SMCS Code: 5056-070-Z3 mm (3.50 inch) long, to open the internal drain
valve and drain the oil. Drain the oil into a
There is one return screen and two suction screens suitable container.
inside the hoist, torque converter and brake tank.
2. Remove bolts (2) from the hydraulic tank cover
Clean the return screen and the suction screens and remove the cover.
whenever there is a failure of the brakes, torque
converter, hoist/eject cylinders or hoist pumps. 3. Clean the debris from the bottom of the tank.

injury. Do not allow hot oil or hot components to 3
contact the skin.
NOTICE
4
4. Remove the retaining nuts from bolts (3).
Refer to Special Publication, NENG2500, "Caterpillar Remove the cover located at the bottom of
Tools and Shop Products Guide", for tools and hoist return screen (4). Remove and clean or
supplies suitable to collect and contain fluids in discard the screen.
5. Install new or clean screen (4), the screen cover
Dispose of fluids according to local regulations and and cover retaining nuts.
mandates.
6. Clean the hydraulic tank cover in clean, non-
flammable solvent. Inspect the cover gasket. If
the gasket is damaged, use a new gasket.
5
5
6
1
7
162
Maintenance Section
Remove four bolts (5) that hold suction pipes

7.
(6) and (7) to the hydraulic tank. Remove the
Indicators and Gauges - Test
suction pipe, seal and screen assemblies.
SMCS Code: 7000-081; 7450-081
8. Remove the suction screens from the pipes.
Before you operate the machine, perform the
9. Wash the screens in clean, nonflammable following checks and make any necessary repairs:
solvent.
Look for broken lenses on the gauges. Also,
10. Inspect the suction pipe seals. Replace if look for broken indicator lights, broken
damaged. switches and other broken components in the
cab.
11. Install the suction screens in the pipe
assemblies. Move the engine start switch to the ON position
and check the Caterpillar Monitoring System
12. Install the suction pipe, screen and seal self test.
assemblies in the hydraulic tank. Secure the
pipes to the hydraulic tank with bolts (5). Reference: For information on the Caterpillar
Monitoring System self test, refer to Operation and
13. Install the tank cover and bolts. Maintenance Manual, "Caterpillar Monitoring
System Self Test" for the machine that is being
14. Fill the hydraulic tank. serviced.
Reference: For information on lubricants and refill Make sure the parking brake is engaged. Start
capacities, refer to Operation and Maintenance the engine.
Capacities" for the machine that is being serviced. Check for oil leaks. Repair any oil leaks around
the covers or around the hoses.
15 . Start and run the engine at low idle. Inspect for
leaks. Look for inoperative gauges.
Turn on all machine lights. Check for proper

operation.
9 Sound the horn.
Stop the engine.

8
raised.

the sight gauge.

163
Maintenance Section
Remove pressure switch (1) from the manifold

Low Transmission Oil 3.
on the transmission. Install a 9S-4191 Plug (9/
Pressure Automatic Brake 16-18 straight thread O-ring) in the manifold
where the switch was removed. Reconnect the
Application (ABA) System - switch to the harness at connector (2).
Test
SMCS Code: 1435-081; 4284-081-AU
Certain 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 engages 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 position. Start the engine.
Automatic Brake Application (ABA) system, test the
holding ability of the machine parking brake. 5. Disengage the parking brake by moving the
parking brake control to the OFF position.
Reference: For information on testing the parking
brake holding ability, refer to Operation and 6. Move the transmission control to FIRST SPEED
Maintenance Manual, "Braking System - Test" for FORWARD.
the machine that is being serviced.
7. Gradually increase the engine speed to 1300
1. Be sure the area around the machine is clear of rpm. The parking brake should remain
personnel and obstructions. engaged and the machine should not move.
Note: The parking brake indicator and the action

lamp should flash and the action alarm should
sound.
2
8. Reduce the engine speed to low idle, move the
transmission control to the NEUTRAL position
and engage the parking brake.
1 NOTICE
If the parking brake disengaged and the machine
moved while testing the Automatic Brake Application
(ABA) system, have the system inspected/repaired
immediately before returning the machine to
(1) Transmission oil pressure switch - brake application. (2)
operation. Contact your Caterpillar dealer or refer to
Connector. the Braking Section in the Service Manual for the
2. Disconnect pressure switch (1) from the
transmission electrical harness at connector (2). 9. Remove the plug and install pressure switch (1)
in the transmission manifold. Connect the
Note: Pressure switch (1) can be identified by the switch to the harness at connector (2).
EL331 blue wire and EL330 grey wire in the
transmission electrical harness connected to the
switch.
164
Maintenance Section
Oil Filter - Inspect Oscillating Hitch - Adjust

SMCS Code: 1308-507; 3067-507; 5068-507 SMCS Code: 7113-025
Inspect a Used Filter for Debris
Adjust the oscillating hitch bearing preload at the

initial 250 Service Hours or 1 Month service interval
and then at every 1000 Service Hours or 6 Monthly
The Element is Shown with Debris service interval.
Use a 4C-5084 Filter Cutter to cut the filter element Reference: For the correct oscillating hitch bearing
open. Spread apart the pleats and inspect the adjustment procedures, refer to Steering System,
element for metal and other debris. An excessive Specifications, "Oscillating Hitch" for the machine
amount of debris in the filter element can indicate a that is being serviced or contact your Caterpillar
possible failure. dealer.
If metals are found in the filter element, a magnet

can be used to differentiate between ferrous and
non- ferrous metals.
Ferrous metals can indicate wear on the steel and

cast iron parts.
Non-ferrous 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.
Use of an oil filter element not recommended by

Caterpillar can result in severe engine damage to
engine bearings, crankshaft and other parts. This
can result in larger particles in unfiltered oil entering
the lubricating system and the particles could cause
damage.
165
Maintenance Section
Oscillating Hitch - Lubricate

SMCS Code: 7113-086
5
NOTICE
fittings are undamaged. If the lines are split, grease 6
will result.
Location of Oscillation Remote Lubrication Point (AE40 Series II)
5. Lubricate the rear oscillation bearing through

1
6. Lubricate the front oscillation bearing through
1. Lubricate the upper hitch bearing through

2. Lubricate the lower hitch bearing through

3 4
Location of Oscillation Remote Lubrication Point (AD40 Series

II)
3. Lubricate the front oscillation bearing through
4. Lubricate the rear oscillation bearing through

166
Maintenance Section
Parking Brake Release Oil

Filter - Replace
SMCS Code: 4267-510-FI
3

contact the skin. 1
NOTICE
during performance of inspection, maintenance, 4
any component containing fluids. 2

supplies suitable to collect and contain fluids in 2. Remove filter housing (1) and element (4).
Caterpillar machines. Discard the used element.
Dispose of fluids according to local regulations and 3. Remove drain plug (2) from the filter housing.
mandates. 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
2
5
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 6. Start the engine and run the engine at low idle.
filter housing and filter element.
Check for leaks.
167
Maintenance Section
With the oil cold, check the oil level in sight

7.
Radiator Core - Clean
Series II trucks check the oil level with the SMCS Code: 1353-070-KO
raised.

the sight gauge.
You can use compressed air, high pressure water

or steam to remove dust and other debris from the
air side of the radiator core. However, the use of
compressed air is preferred.
Note: Care must be taken when you are using high

pressure water. High pressure water can cause
damage to the radiator. Use of a water spray
nozzle on the pressure washer which will disperse
the water pressure is preferred.
Reference: For complete procedures for cleaning

the radiator core, refer to Special Publication,
SEBD0518, "Know Your Cooling System".
168
Maintenance Section
Seat - Inspect Seat Belt - Replace

Check the operation of the seat adjustment levers. Inspect for worn or frayed webbing.
Ensure that seat (1) can be adjusted properly for Check for worn or damaged buckle or anti-creep
maximum support for the operator. slide on each half of the belt. Replace the belt,
buckle or slides if they are worn or damaged.
Inspect the fabric of the seat cushion for wear.
Inspect the fabric of the backrest for wear. Replace the seat belt after three years of usage,
regardless of appearance. A date label, to
If necessary, repair the seat. determine the age of the belt, is sewn onto each
belt.
On machines equipped with retractable seat belts,

check for correct operation.
Inspect the belt mounting hardware. Replace any

damaged or worn hardware. Keep the mounting
bolts tight.
169
Maintenance Section
Service Inspection
SMCS Code: 1000; 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:
Loose bolts.
Trash buildup.
Oil, coolant, or fuel leaks.
Broken parts or worn parts.
Cracks in the frame.
Remove any trash and any debris. As needed,

adjust the tire inflation. Make any 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.
170
Maintenance Section
AD40 Series II
F G H I J K
D
C
A P O N
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. (I) Front suspension cylinders. (J) Tires. (K) Steering hydraulic system. (L) Rear axle. (M) Frame and body.
(N) Articulating hitch and oscillating hitch. (O) Automatic lubrication system (if equipped). (P) Falling object protective structure.
171
Maintenance Section
4
1
(A) Inspect the ground level controls for proper (E) Inspect the hydraulic systems for the torque
operation. Replace a damaged or worn engine converter and transmission (4). Check for leaks
shutdown switch (1). Replace a damaged or from the torque converter and from the
worn battery disconnect switch (2). transmission. Check for worn hoses and for
damaged lines. Repair any leaks, worn hoses
(B) Inspect the lights for broken lamps, lenses and and damaged lines.
proper operation. Replace broken lamps and
lenses.
(C) Inspect the cooling system for leaks, worn

hoses and debris. Repair any leaks and 5
damaged hoses. Remove any debris that could
block the air flow through the radiator. 8
6
7
(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 Precleaner - Clean for the machine that is
being serviced.
(D) Inspect the engine. Use dipstick (3) to check (G) Inspect fuel tank (6). Make sure that the filler
the engine oil level. Check for engine oil leaks, cap is installed correctly. Check the welds and
coolant leaks, and exhaust leaks. Check the mounting brackets for the fuel tank. Look for
belts of the engine for proper tension and for any leaks or damage to the fuel tank.
good condition. Check the level in the washer
fluid bottle. (H) Inspect the hydraulic system. Check for leaks,
worn hoses and damaged lines. Repair any
leaks, worn hoses and damaged lines.
172
Maintenance Section
Check the level in hydraulic tank (7). Check the (L) Inspect the rear axle for leaks. Inspect the rear
level in steering tank (8). Make sure that the filler lights for damage.
caps are installed. Inspect the tank covers for
damaged bolts, loose bolts or missing bolts.
Tighten loose bolts and replace missing bolts. 11
Check the welds and mounting brackets for the
hydraulic tank and the steering tank. Inspect the
tanks 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, for further
instructions refer to Operation and Maintenance
Manual, Suspension Cylinder - Check for the 10
The chrome has been wiped off and the whole (M) Inspect the frame and the dump body. Check
length of the chrome is used during normal frame (10) for cracks or damage. Inspect dump
operation. body (11) for damage, wear or distortion.
Check for uneven wear of the body support
The ride is harsh and the suspension cylinders pads.
extend fully when the machine is empty.
(N) Inspect the articulating hitch and the oscillating
(J) Inspect tires for cuts, gouges and proper hitch for wear, damage, and loose or missing
inflation. Remove large rocks from the treads. bolts. Have necessary repairs made.
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 12

caps. Check the wheel for nuts that are loose or
missing.
Note: Rust behind a nut may indicate that the nut

is loose. Shiny metal areas around a nut may
indicate that the nut is loose.
(0) Inspect the automatic lubrication system (if

9 equipped). Inspect tank (12) for leaks. Fill tank
(12) with lubricant. For the correct procedure,
refer to "Automatic Lubrication System - Fill" for
the machine that is being serviced. Check all
of the grease fittings.
(K) Inspect the steering hydraulic system for leaks,

worn hoses and damaged lines. If necessary
repair leaks, worn hoses and damaged lines.
Inspect the steering cylinders (9).
173
Maintenance Section
13
(P) Inspect Falling Object Protective Structure

(FOPS) (13) for cracks in welds, castings or any
metal section on the FOPS. Check mounting
bolts and mounting pads for damage. Consult
your Caterpillar dealer for necessary repairs.
Inspect the cab. Check the Caterpillar
Monitoring System for diagnostic codes.
Correct any discrepancies.
174
Maintenance Section
AE40 Series II
F G H I J K
D
C
A P O N
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. (I) Front suspension cylinders. (J) Tires. (K) Steering hydraulic system. (L) Rear axle. (M) Frame and body.
(N) Articulating hitch and oscillating hitch. (O) Automatic lubrication system (if equipped). (P) Falling object protective structure.
175
Maintenance Section
4
1
(A) Inspect the ground level controls for proper (E) Inspect the hydraulic systems for the torque
operation. Replace a damaged or worn engine converter and transmission (4). Check for leaks
shutdown switch (1). Replace a damaged or from the torque converter and from the
worn battery disconnect switch (2). transmission. Check for worn hoses and for
damaged lines. Repair any leaks, worn hoses
(B) Inspect the lights for broken lamps, lenses and and damaged lines.
proper operation. Replace broken lamps and
lenses.
(C) Inspect the cooling system for leaks, worn

hoses and debris. Repair any leaks and 5
damaged hoses. Remove any debris that could
block the air flow through the radiator. 8
6
7
(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 Precleaner - Clean for the machine that is
being serviced.
(D) Inspect the engine. Use dipstick (3) to check (G) Inspect fuel tank (6). Make sure that the filler
the engine oil level. Check for engine oil leaks, cap is installed correctly. Check the welds and
coolant leaks, and exhaust leaks. Check the mounting brackets for the fuel tank. Look for
belts of the engine for proper tension and for any leaks or damage to the fuel tank.
good condition. Check the level in the washer
fluid bottle. (H) Inspect the hydraulic system. Check for leaks,
worn hoses and damaged lines. Repair any
leaks, worn hoses and damaged lines.
176
Maintenance Section
Check the level in hydraulic tank (7). Check the (L) Inspect the rear axle for leaks. Inspect the rear
level in steering tank (8). Make sure that the filler lights for damage.
caps are installed. Inspect the tank covers for
damaged bolts, loose bolts or missing bolts.
Tighten loose bolts and replace missing bolts. 11
Check the welds and mounting brackets for the
hydraulic tank and the steering tank. Inspect the
tanks 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, for further
10
instructions refer to Operation and Maintenance
Manual, Suspension Cylinder - Check for the
The chrome has been wiped off and the whole (M) Inspect the frame and the ejector body. Check
length of the chrome is used during normal frame (10) for cracks or damage. Inspect
operation. ejector body (11) for damage, wear or
distortion.
The ride is harsh and the suspension cylinders
extend fully when the machine is empty. (N) Inspect the articulating hitch and the oscillating
hitch for wear, damage, and loose or missing
(J) Inspect tires for cuts, gouges and proper bolts. Have necessary repairs made.
inflation. 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.
12
Look for damaged rims. Replace any missing valve
caps. Check the wheel for nuts that are loose or
missing.
Note: Rust behind a nut may indicate that the nut

is loose. Shiny metal areas around a nut may
indicate that the nut is loose.
(O) Inspect the automatic lubrication system (if

equipped). Inspect tank (12) for leaks. Fill tank
9 (12) with lubricant. For the correct procedure,
refer to "Automatic Lubrication System - Fill" for
the machine that is being serviced. Check all
of the grease fittings.
(K) Inspect the steering hydraulic system for leaks,

worn hoses and damaged lines. If necessary
repair leaks, worn hoses and damaged lines.
Inspect the steering cylinders (9).
177
Maintenance Section
13
(P) Inspect Falling Object Protective Structure

(FOPS) (13) for cracks in welds, castings or any
metal section on the FOPS. Check mounting
bolts and mounting pads for damage. Consult
your Caterpillar dealer for necessary repairs.
Inspect the cab. Check the Caterpillar
Monitoring System for diagnostic codes.
Correct any discrepancies.
178
Maintenance Section
Lubricate the right steering cylinder bearing in

Steering Cylinder Bearings - 4.
the rod end of the steering cylinder through
Lubricate remote mounted fitting (4).
SMCS Code: 4303-086-BD
NOTICE
will result.
1 2
1. Lubricate the right steering cylinder bearing in

the head end of the steering cylinder through
2. Lubricate the left steering cylinder bearing in

the head end of the steering cylinder through
3. Lubricate the left steering cylinder bearing in

the rod end of the steering cylinder through
179
Maintenance Section
Steering Frame Stop Clearance Steering Suction Screen -

- Check Clean
SMCS Code: 7188-535 SMCS Code: 5056-070-Z3
Clean the suction screen whenever there is a failure

of a major steering system component.

contact the skin.
NOTICE
Check the clearance between the front and rear prepared to collect the fluid with suitable containers
frame steering stops. before opening any compartment or disassembling
Reference: For the correct procedure, refer to
Steering System, Systems Operation, Testing & Refer to Special Publication, NENG2500, "Caterpillar
Adjusting, "Steering Neutralizer Valve - Check and Tools and Shop Products Guide", for tools and
Adjust" for the machine that is being serviced. supplies suitable to collect and contain fluids in

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 to prevent dirt from entering the
system.

use tools.
180
Maintenance Section
Remove tank drain plug (2) from the steering

2.
tank. Open the drain valve by installing a 1 inch
Steering System Oil - Change
NPT pipe nipple, 88 mm (3.50 inches) long, to
open the internal drain valve and drain the oil. SMCS Code: 4332-044
3. Remove bolts (1) from the steering tank cover Operate the machine to warm the steering system
and remove the cover. oil.
4. Clean the debris from the bottom of the The machine must be level, the parking brake
steering tank. engaged and the engine stopped.
3 Hot oil and hot components can cause personal

contact the skin.
4
NOTICE
5 Care must be taken to ensure that fluids are contained
5. Remove four bolts (3), retainer plate (4) and
suction screen (5). Refer to Special Publication, NENG2500, "Caterpillar
6. Wash the screen in clean, nonflammable supplies suitable to collect and contain fluids in
solvent. Caterpillar machines.
7. Install suction screen (5), retaining plate (4) and Dispose of fluids according to local regulations and
mounting bolts (3). mandates.
8. Clean the steering tank cover in clean, non-

flammable solvent. Inspect the cover gasket. If 1. Remove the steering tank filler cap slowly to
the gasket is damaged, use a new gasket. relieve any steering tank pressure. Remove the
filler cap to prevent a vacuum in the steering
9. Install the steering tank cover and bolts. tank. Install the filler cap after the tank is
drained to prevent dirt from entering the
10. Fill the steering tank. system.
Reference: For information on lubricants and the

refill capacity, refer to Operation and Maintenance
11. Start and run the engine at low idle. Inspect

the steering tank for leaks.
12. Maintain the oil level to the FULL mark in the

sight gauge.
13. Add oil if necessary. Stop the engine.

use tools.
181
Maintenance Section
2. Remove the tank drain plug. Open the drain

mm (3.50 inches) long, in the bottom of the
tank, to open the internal drain valve. Drain the
oil into a suitable container. 2
3. Remove the pipe nipple and install the drain

plug.
1 12. Maintain the oil level to the FULL mark in sight

gauge (2).
13. Remove the filler cap and add oil, if necessary.
4. Remove filler cap (1).
5. Remove the strainer retaining ring.
6. Remove the strainer. Wash the cap and

strainer in clean, nonflammable solvent. Allow
them to dry.
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.

10. Install the filler cap.
11. Start the engine and run at low idle. Check for
leaks.
182
Maintenance Section
Steering System Oil Filter -

Replace 2
SMCS Code: 431F-510
4
5
contact the skin.
NOTICE
testing, adjusting and repair of the machine. Be 2. Remove bolt (1) and filter cover (2).
3. Remove and discard used filter element (4).
4. Remove screen (5).
Refer to Special Publication, NENG2500, "Caterpillar 5. Clean the cover and screen in clean,
Tools and Shop Products Guide", for tools and nonflammable solvent. Inspect cover seal. If
supplies suitable to collect and contain fluids in the seal is damaged, use a new seal.
6. Install the clean screen and new filter element.
mandates. 7. Install the cover. Tighten cover bolt (1) to 59
5 Nm (43 4 lb ft).
The machine must be level, the parking brake
engaged and the engine stopped. 8. Start the engine and run at low idle. Check for
leaks.
1. Remove the steering tank filler cap slowly to
relieve any steering tank pressure. Install the
filler cap.
1
3
9. Maintain the oil level to the FULL mark in sight

gauge (6).
10. Remove filler cap (3) and add oil, if necessary.

183
Maintenance Section
Steering System Oil Level - Steering System Oil Sample -

Check Obtain
SMCS Code: 4332-535-FLV SMCS Code: 4332-008

of the steering system oil, refer to Operation and
1
being serviced. Also refer to Maintenance Manual,
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).
2. Stop the engine.
3. Remove filler cap (2) slowly to relieve any

steering tank pressure. Add oil, if necessary.

184
Maintenance Section
Suspension and Suspension Suspension Cylinder - Check

Cylinder Bearings - Lubricate
SMCS Code: 7201-535
SMCS Code: 7200-086; 7201-086-BD
NOTICE
will result.
Wipe all fittings clean before lubricating. A
1 2 3
4 5 6 Make sure the body is empty. Lower the dump

body (AD40 Series II) or fully retract the ejector
plate (AE40 Series II).
Stop the machine gradually on a level surface

without using the brakes.
1. Lubricate the right upper suspension cylinder Engage the parking brake. Stop the engine.
Check the front suspension cylinders against the
2. Lubricate the left lower suspension cylinder dimensions from the last time you performed the
bearing through remote mounted fitting (2). charging procedure. If you do not have those
dimensions, the following dimension can be a
3. Lubricate the front suspension frame, left pivot guideline.
Distance (A) of the cylinder from pin to pin
4. Lubricate the left upper suspension cylinder should be 882 6.0 mm (34.7 0.25 inch).
Note: If the height of the front cylinder is not within
5. Lubricate the front suspension frame, right the acceptable range, perform the charging
pivot bearing through remote mounted fitting procedure.
(5).
Reference: For the charging procedure, refer to
6. Lubricate the right lower suspension cylinder Service Module, "Suspension Cylinders" for the
bearing through remote mounted fitting (6). machine that is being serviced.
185
Maintenance Section
Tailgate and Tailgate Cylinder Tire Inflation - Check

Bearings - Lubricate
SMCS Code: 4203-535-AI
SMCS Code: 5107-086-BD; 7271-086-BD
NOTICE
will result.
Measure the tire pressure on each tire. Consult

your Caterpillar dealer for correct load rating and for
the correct operating pressures.
1 Inflate the tires, if necessary.
Reference: For information about tire inflation, tire

pressures, and tire inflation pressure adjustment,
refer to Operation and Maintenance Manual, "Tire
Inflation Information" for the machine that is being
serviced.
1. Lubricate the tailgate pivot and cylinder
bearings through three remote mounted fittings
(1) on each side of the machine.
186
Maintenance Section
Torque Converter and Torque Converter Oil Filter -

Hydraulic Breather - Replace Replace
SMCS Code: 3101-510-BRE; 5050-510-BRE SMCS Code: 3101-510-FI

engaged and the engine stopped.
1
contact the skin.
NOTICE
1. Remove cover (1). prepared to collect the fluid with suitable containers

2

mandates.
2. Loosen the retaining clamp on the bottom of

breather element (2). Remove and discard the
used breather element.
1
3. Install the new breather element. Tighten the
retaining clamp.
2
4. Install cover (1).


filter housing. Avoid spillage when removing the
187
Maintenance Section

raised.
3
the sight gauge.
2. Remove filter housing (1) and element (4).

Discard the used element.
3. Remove drain plug (2) from the filter housing.

Wash the drain plug and filter housing in clean,
drain plug.



Check for leaks.
5
4
188
Maintenance Section
Approximately 15 liters (4 US gallons) of oil

Torque Converter Sump Note:
will drain when cover assembly (1) is removed.
Screen - Clean
1. Remove bolts (2) from cover assembly (1).
Remove the cover assembly. Drain the oil into
SMCS Code: 3101-070-Z3 a suitable container.
Clean the screen whenever there is a failure of the 2. Remove the screen and baffle retaining nut (5).
torque converter.
3. Remove baffle (3) and screen (4) from the
The machine must be level, the parking brake cover.
4. Wash the screen, baffle and cover in clean,
nonflammable solvent. Do not crush the
screen.
Hot oil and hot components can cause personal 5. Inspect the cover gasket for damage. If
injury. Do not allow hot oil or hot components to damaged, use a new gasket.
contact the skin.
6. Assemble the screen and baffle on the cover.
Install cover assembly.
NOTICE
during performance of inspection, maintenance, Inspect for leaks.

7
supplies suitable to collect and contain fluids in 6

mandates.

raised.
2
the sight gauge.

1 4 3 5
189
Maintenance Section
Transmission Breather - Clean Transmission Magnetic Screen

- Clean
SMCS Code: 3030-070-BRE
SMCS Code: 3030-044


contact the skin.
NOTICE
1. Remove the transmission breather from the during performance of inspection, maintenance,
transmission cover. testing, adjusting and repair of the machine. Be
2. Wash the breather in clean, nonflammable before opening any compartment or disassembling
solvent. any component containing fluids.
3. Allow the breather to dry. Refer to Special Publication, NENG2500, "Caterpillar

4. Install the clean transmission breather. supplies suitable to collect and contain fluids in

mandates.
Location of Transmission Magnetic Screen - Earlier Machines

190
Maintenance Section
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.
Location of Transmission Magnetic Screen - Later Machines Hot oil and hot components can cause personal
1. Remove the magnetic screen cover and wave contact the skin.
washer assembly.
NOTICE
2. Remove the screen, magnet and tube assembly
from the housing. Care must be taken to ensure that fluids are contained


mandates.
3. Wash the magnet, screen and tube assembly in

clean, non-flammable solvent. Clean the
magnets with a cloth, a stiff bristle brush or
pressure air.
NOTICE
Do not drop or rap the magnets against any hard
objects. 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 Note: Hand tighten the NPT pipe nipple. Do not
assembly with the magnet opening down. use tools.
6. Install the cover. Tighten the cover bolts. 3. Remove the transmission drain plug. Open the
drain valve by installing a 1 inch NPT pipe
7. Fill the transmission with oil. nipple, 88 mm (3.50 inches) long, in the bottom
of the transmission, to open the internal drain
Reference: Refer to Operation and Maintenance valve. Drain the oil into a suitable container.
Manual, "Transmission Oil Level - Check" for the
191
Maintenance Section
Remove the pipe nipple. Clean the drain plug

4.
and install the transmission drain plug.
Transmission Oil Filter -
Replace
1 SMCS Code: 3067-510
1. Park the machine on a level surface. Engage

the parking brake. Stop the engine.

contact the skin.
NOTICE
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 prepared to collect the fluid with suitable containers
capacities, refer to Operation and Maintenance before opening any compartment or disassembling
Manual, "Lubricant Viscosities" and "Refill any component containing fluids.
6. Make sure the oil level is between the LOW and Tools and Shop Products Guide", for tools and
FULL marks (the shaded area) on dipstick (1). supplies suitable to collect and contain fluids in
7. Start and run the engine at low idle. Inspect for
leaks. Dispose of fluids according to local regulations and
mandates.
8. Operate the transmission control to circulate oil
in the transmission.
9. Maintain the oil level between the LOW and

FULL marks (the shaded area) on dipstick (1).
Add oil, if necessary.


filter housing. Avoid spillage when removing the
192
Maintenance Section
8. Operate the transmission control to circulate oil

in the transmission.
9. Maintain the transmission oil level between the

LOW and FULL marks (the shaded area) on
dipstick (5). Remove filler cap (6) and add oil, if
3 necessary.
3. Remove filter housing (1) and element (4).

Discard the used element.
4. Remove drain plug (2) from the filter housing.

Wash the drain plug and filter housing in clean,
drain plug.



Inspect for leaks.
193
Maintenance Section
Transmission Oil Level - Check Transmission Oil Sample -

Obtain
SMCS Code: 3030-535-FLV
SMCS Code: 3030-008

of the transmission oil, refer to Operation and
1 being serviced. Also refer to Maintenance Manual,
Check the transmission oil level with the machine

on a level surface, the transmission control in the
NEUTRAL position and the parking brake engaged.
When the engine is running and the oil is at

operating temperature, maintain the oil level
between the LOW and FULL marks (the shaded
area) on dipstick (1).
If necessary, remove filler cap (2) and add oil.

Clean the filler cap and install the filler cap.
Reference: For information on lubricants, refer to

Operation and Maintenance Manual, "Lubricant
Viscosities" for the machine that is being serviced.
194
Maintenance Section
Turbocharger - Inspect V-Belts - Inspect/Adjust

SMCS Code: 1052-040 SMCS Code: 1357-025; 1357-040
If the turbocharger fails during engine operation, For maximum engine performance and utilisation of
severe damage to the turbocharger compressor your engine, inspect the belts for wear and
wheel can result. If the turbocharger fails during cracking. Check and adjust the belt tension to
engine operation, severe damage to the engine can minimise belt slippage which will decrease belt life
also result. and cause poor performance of alternator and any
driven equipment.
For example, damage to the turbocharger wheel
could cause parts from the turbocharger wheel to 1. Inspect the condition of the belts.
enter the engine cylinder. These parts from the
compressor wheel can cause additional damage to 2. Inspect the tension of the alternator belt and air
the following engine components: pistons, intake conditioning compressor belts.
valves, exhaust valves and cylinder head.
3. Check the belt tensioner for wear/alignment
Note: Turbocharger failure can cause large and that it is maintaining correct belt tension.
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.
Engine smoke.
To check the belt tension, apply 110 N (25 lb) of
Speeding up of the engine with no load. force midway between the pulleys. Correctly
adjusted belts will deflect 14 to 20 mm (0.55 to
Note: For specifications used to check the 0.79 inch).
turbocharger, refer to Specifications, "3408E HEUI
Engine" for the machine that is being serviced. 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.
195
Maintenance Section
Adjust the Alternator Belt Wheel Bearings - Check/Adjust

SMCS Code: 7551-025-WHL; 7551-535-WHL
3 2
1. Loosen two mounting bolts (1) and locknut (2).

The wheel bearing adjustment should be performed
every 2000 Service Hours.
2. Turn adjusting nut (3) to obtain the correct
adjustment.
Reference: For wheel bearing adjustment
procedures, refer to Power Train, Specifications,
3. Tighten the locknut and the mounting bolts.
"Wheel Bearing Adjustment" for the machine that is
being serviced or contact your Caterpillar dealer.
4. Check the deflection. If the amount of
deflection is incorrect, repeat Steps 1 to 3.
Adjust the Air Conditioning

Compressor Belt
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 deflection. If the amount of

deflection is incorrect, repeat Steps 1 to 3.
196
Maintenance Section
Wheel Nut Torque - Check Window Washer Reservoir -

Fill
SMCS Code: 4210-535
SMCS Code: 7306-544
NOTICE
If operating in freezing temperatures, use Caterpillar
or any commercially available non-freezing window
washer solvent. System damage can result from
freezing.
Check the wheel nut torque at 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 nut torque, refer

to Power Train, Specifications, "Final Drive, Brake
and Wheel" for the machine that is being serviced.
The window washer reservoir is located at the rear
of the cab. Remove the cap and fill the window
washer reservoir. Refit the cap.
197
Maintenance Section
Window Wiper - Inspect/ Windows - Clean

Replace
SMCS Code: 7310-070
SMCS Code: 7305-040; 7305-070
Use commercially available window cleaning

solutions to clean the windows. Only clean the
Inspect the window wiper blades on the front and outside windows from the ground unless handholds
rear windows. Replace the window wiper blades if are available. Use a mop or use a similar device
the window wiper blades are worn or damaged. with a long handle to clean the windows from the
Replace any window wiper blade that streaks the ground.
window.

Manual Maintenance Intervals Caterpillar Ad40 Ae40 II Underground Articulated Trucks

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SAFETY.CAT.

AD40 SERIES II and

Excerpted from Operation & Maintenance Manual ((SEBU7315-03)

Seat - Inspect ..................................................... 168

Automatic Lubrication System (Hydraulic Type)

Every 500 Service Hours or 3 Months Every 3 Years

Every 1000 Service Hours or 6 Months

Axle Breather - Clean .......................................... 107

Every 2000 Service Hours or 1 Year

Differential Thrust Pin - Check ............................ 133

Every 3000 Service Hours or 2 Years

Cooling System Coolant (DEAC) - Change ........ 121

Air Conditioner - Test

Inhaling air conditioner refrigerant gas through a

6. Inspect and adjust the deflection of the air

Reference: Refer to Operation and Maintenance

7. Perform Steps 1 and 2. If poor cooling is still

3. Allow two minutes for the air conditioning

Automatic Lubrication System Automatic Lubrication System

7. Inspect the electrical system for worn or frayed

Note: For more information on the automatic

Automatic Lubrication System Automatic Lubrication System

Axle Breather - Clean Backup Alarm - Test

Location of the Front Axle Breather. Rear View of AD40 Series II

Location of the Rear Axle Breather. Rear View of AE40 Series II

The backup alarm should start to sound

Always recycle a battery. Never discard a battery.

Always return used batteries to one of the following

An authorized battery collection facility.

Battery, Battery Cable or Battery Electrolyte Level -

3. Turn the battery disconnect switch to the OFF

7. Replace the battery or make all necessary

8. Connect the positive end (+) of the battery

9. Connect the negative end (-) of the battery

10. Connect the negative end (-) of the battery

11. Install the key. Turn the battery disconnect

3. Disconnect all battery cables from the batteries.

4. Clean the battery cables and the battery posts. NOTICE

6. Coat the terminals with 1P-0808 Multipurpose

7. For conventional batteries and batteries of low 1 2

Inspect the battery electrolyte level in each

In extreme temperatures, check the water in the

Brake Accumulator Pressure - Brake Control Oil Filter -

Hot oil and hot components can cause personal

Note: The brake control oil filter should be

Release the pressure in the braking system.

2. Remove brake filter housing (2). Remove the

4. Inspect the seal in the filter housing. If the seal NOTICE

Clean the brake oil cooler screen whenever there is

7. With the oil cold, check the oil level in sight

8. Maintain the oil level to the FULL COLD mark in

9. Remove oil filler cap (4) and add oil if

1. Remove tank drain valve plug (1) from the hoist,

11. Maintain the oil level to the FULL COLD mark in

12. Remove oil filler cap (5) and add oil if

2. Remove drain plug (2) from the oil cooler and

3. Remove plug (3) from the end of the cooler.

4. Remove the screen. Clean the screen in clean

5. Install the screen in the cooler.

6. Clean plug (3) in clean, nonflammable solvent.