LUBRICATION & MAINTENANCE CHART 222360 Fig. 1 · 2011. 10. 28. · 4/23/09 3 fs222360_er15...

4/23/09 1 FS222360_Er15

LUBRICATION & MAINTENANCE CHART 222360Fig. 1

SECTION A-A

SECTION C-CSECTION B-B

20-F

20-L20-F

22FUEL TANK VENT HOSE

A

A

B

B

C

C

20-D

20-D20-F

20-D

LEFT SIDE FUEL TANKRIGHT SIDE FUEL TANK

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LEFT VIEW

RIGHT VIEW

4-L4-F

TRANSFER CASE COOLER

DIFFERENTIAL OIL COOLER

22

BRAKE OIL COOLER

2-A

4-D

21

2

1-D

1-F 1-L

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DO

IN OUT

INOUT

ROTATED FORCLARITY

OUT INOUT IN

O UTININ

45

9

PUMP, BRAKECOOLING

PUMPDRIVE

PUMP,TRANSMISSION

PROPSHAFT

PUMP,ACCUMULATOR

SYSTEM

HYDRAULIC TANKMOUNTING GROUP

30

41TORQUE

CONVERTERSUCTIONSCREEN

TORQUECONVERTER

PUMP, ADDITIONALBRAKE COOLING &

HYDRAULIC SYSTEM

TRUCKBODY

FILTER,STEERING

ENGINE

FRONT

TRUCKBODY

AS VIEWEDFROM REAR

FRONT

10TORQUE

CONVERTERINLET CHARGE

FILTER 9 30

HYDRAULICCHARGEFILTER

AS VIEWEDFROM REAR

AS VIEWEDFROM LEFT

AS VIEWEDFROM TOP

FILTER,STEERING

27

27

15

12-D

12-L

12-F

77

7

7

9

9

LOCK UPCHARGE

LUBE

TRANSMISSION FILTERS

9

9

CHECKVALVE1" NPT

DIFFPUMP

TFCPUMP

TFCSUCTION

11

TFCPRESSURE

13

DIFFPRESSURE

39

FROM TFCPUMP

TO TRANSFERCASE COOLER

FROM DIFFPUMP

5 PSIPRESSURE

SWITCH(TFC LOW

PSI SWITCH)

65 PSICHECKVALVE

65 PSICHECKVALVE

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HYDRAULIC TANK

VIEW A-A

BREATHER BOXAS VIEWED FROM REAR OF MACHINE

TRANSMISSION TANK

29

29

35

HYDRAULIC TANKFILLER CAP

19

17

17-L

28

6-F6-LSIGHT GLASS

6-LDIPSTICK

6-D

BATTERY BOX

TRANSMISSION GUARD GROUP AXLE ASSEMBLY

24-D

A

A24-L

TO BREATHER BOX

TRANSMISSION TANK

25(DIFFERENTIAL BREATHER)

TRACTION CONTROL GROUP

24-F

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NOTE: SOME ITEMS, WHICH ARE NORMALLY HIDDEN, ARE SHOWNHERE FOR CLARITY ONLY.

LEFT SIDE VIEW

LEFT SIDE

LEFT SIDE REARAS VIEW FROM FRONT

AS VIEWED FROM REAR

AS VIEWED FROM REAR

SPINDLE

HUB

BRAKES, CAT 793

FINAL DRIVE

26-D

AIR CLEANER

MUFFLERHEAT SHIELD

PIPE

23aPRIMARYELEMENT

23bSECONDARYELEMENT

FRONT OF TRUCK

REAR SUSPENSION CYLINDER

LOWER PRESSURE GAUGE,LEFT CYLINDER

38

LOWER PRESSURE GAUGE,RIGHT CYLINDER

NITROGEN CHARGINGVALVE5

REAR AXLE ASSEMBLY

NITROGEN CHARGING VALVE

UPPER PRESSURE GAUGE,LEFT CYLINDER

UPPER PRESSURE GAUGE,RIGHT CYLINDER

37

37

LEFT REAR SUSPENSIONCYLINDER

RIGHT REARSUSPENSION CYLINDER

45ADJUST PIN TO0.002 ± 0.001 FT-LBS.

24-L

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TOP VIEW

VIEW A-A

FRONT OF TRUCK

AS VIEWED FROM THEREAR OF THE MACHINE

VIEWED FROM LEFTSECTION B-BLH SUSPENSION MODULE

VIEWED FROM REAR

HYDRAULIC MODULE

16

16

14

1616

14148

A A

18MAIN HYDRAULIC FILTER

CONNECTS TO RHCYLINDER STR PIVOT

CONNECTS TO FRONTBULKHEAD FITTING RH

WHIFFLETREE

CONNECTS TO REAR BULKHEAD FITTING RH WHIFFLETREE

CONNECTS TO FRONT BULKHEADFITTING LH WHIFFLETREE

CONNECTS TO BOTTOM PORTWHIFFLETREE TUBE PORT

CONNECTS TO LH CYLINDER STR PIVOT

CONNECTS TO REAR BULKHEAD FITTINGLH WHIFFLETREE

CONNECTS TO TOP PORT WHIFFLETREETUBE PIVOT

CONNECTS TO RH CYLINDER ROD STR PIVOT

CONNECTS TO LH CYLINDER ROD STR PIVOT

B

B

LIMIT SWITCH

ADJUSTMENTLINK

STRUT

34

STEERING HOUSING

SCISSOR LINKS

UPPER TAPER POPPER

STEERING HOUSING

34

LOWER TAPER POPPER

LOWER BEARING

3

UPPER BEARING

SEAL

32-F

32-L

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A

A

19

25

6

33

10a

15

TO HYDRAULIC TANK

TO DIFFERENTIAL

TO TRANSMISSION TANK

TO TORQUE CONVERTER

TO TRANSFER CASE

TOP OF TRANSFER CASE

24-F

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VIEW B-B

VIEW A-A

B B

HYDRAULIC TANKTO 19

TRANSFER CASE

TO 15

ELBOW TO TORQUE CONVERTER FILTER

PUMP DRIVE

TORQUE CONVERTER

FLYWHEEL HOUSING

TO DIFFERENTIAL BREATHERTO TRANSMISSION TANKBREATHER

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CH240C & 200C SERIES II LUBRICATION INFORMATIONThe service points shown in the preceding illustrations are called out in the Lubrication Chart below. This informa-tion includes lubrication points, filters, breathers and fill points for various liquids. The service points are identified with a number, some of which are followed by a letter (F, D, or L). The letter “F” signifies a fill point, the letter “D” signifies a drain point, and the letter “L” signifies a level checkpoint. This can be a sight glass, a plug, a dipstick, or a standpipe. The information in the lubrication chart is intended to supplement the original manufacturer's recommen-dations. Refer to the equipment manufacturer's manual for additional recommendations. If a conflict exists between this lubrication chart and the manufacturer's manual, the equipment manufacturer's manual takes precedence.

Use the “Maintenance Interval Schedule” found in the Caterpillar 789C Off-Highway Truck docu-ment SEBU7174. Insert the additional Kress components listed in the charts on the following pages into the appropri-ate interval section for your site’s maintenance schedule. If you have any questions about sampling or maintenance intervals, contact your local Caterpillar dealer.

TIME INTERVAL

SERVICEPOINT FIG.# SERVICE POINT DESCRIPTION REQUIRED SERVICE LUBE

# OFFITTINGS

8 HOURS 1-L 2 Engine Crankcase Oil Check level EO 1 dipstick4-L 2 Engine Coolant Check level GLY 1 cap6-L 4 Transmission Fluid Check level TDTO 1 dipstick

6-L 4 Transmission Fluid Check levelQuick Check ONLY TDTO 1 sight glass

The Transmission Tank has a Dipstick and a Sight Gauge. The Sight Gauge is to be used as a Quick visual check only. The Dipstick is for accurate measuring of the fluid level. The vehicle needs to be set at the ride height with the engine off. Check the dipstick for fluid level and fill, if needed, to the “Full” mark,

12-L 3 Transfer Case Oil Check level TFCO sight glass17-L 4 Hydraulic Tank Check level HO sight glass20-L 1 Fuel Tank Check level DF sight tube23a 5 Primary Engine Air Filters Check indicators 4 filters

23b 5 Secondary Engine Air Filter Change every 4th primary change 4 filters

24-L 4 Axle/differential Check level GO sight glass29 4, 7 Accumulator Precharge Check Pressure DRY N2 5 gauges35 4 Front Strut(Top) Nitrogen Charge Check Pressure DRY N2 2 gauges36 2 Front Strut(Bottom) Nitrogen Fitting Check Pressure DRY N2 2 fittings37 4 Rear Suspension Upper Nitrogen Gauge Check Pressure DRY N2 2 gauges38 4 Rear Suspension Lower Nitrogen Gauge Check Pressure DRY N2 2 gauges

Tire Valve Check Air Pressure 8 valvesService & Park Brakes Check for Proper FunctionSeat Belts Inspect

50 HOURSOr Auto

Lube

5 4 Rear Axle Pivot Pin & Rear Suspension Cylinder Pivots Grease MPG 4 fitting

8 6 Whiffletree Pivot Grease MPG 1 fitting14 6 Steering Cylinder Rod & Head Grease MPG 4 fittings16 6 Steering Draglink Connections Grease MPG 4 fitting44 1 Cab Air Filter Clean or Replace 1 filter

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250HOURS

4-L 2 Coolant Check Condition GLY cap33 7 Breather Box Filter Check and/or Clean 2 filters

34 Front Suspension Bearings Lube, Pump till grease is expelled from Dust seal at top. MPG 2 fittings

27 3 Prop Shaft, Pump Drive Lube MPG 2 fittings32-L 6 Front Wheel Bearings Check Level GO 4 plugs32-F 6 Front Wheel Bearings Add to Check Level GO 4 plugs

500HOURS

9 3 Transmission Filter Change 3 filters40 2 Secondary Fuel Filter Clean 2 filters10 3 Torque Converter Filter Change 1 filter21 2 Primary Fuel Filter (Water Separator) Change 1 filter28 4 Tranmission Tank Strainer Clean 1 strainer18 6 Main Psi Hydraulic Filter Change 1 filter

12-D 3 Transfer Gear Case Drain 1 plug12-F 3 Transfer Gear Case Refill TFCO 1 plug13 3 Transfer Case Filter Psi Change 1 filter11 3 Transfer Case Filter (Suction) Change 1 filter2a 2 Oil Renewal Filter Change 1 filter

1-D 2 Engine Oil Drain 1 plug1-F 2 Engine Oil Refill EO cap2 2 Engine Oil Filter Change 3 filters30 3 Hydraulic Charge Filter (Brake Cooling Change 1 filter42 1 Suspension Filter, Front Change 2 filters43 3 Steering Filter, Inlet Change 1 filter33 7 Breather Box Filter Clean or Replace as needed 2 filters

1000HOURS

6-D 5 Transmission & Cooler Drain Fluids plugs6-F 4 Transmission & Cooler Refill Fluids TDTO cap

7 3 Grease Zerks On Transfer Case Bushing Housing

Pump Lube till grease expells from around bushing. MPG 4 fittings

39 3 Differential Case Filter Psi Change 1 filter15 3 Transfer Case Breather Clean or Replace as needed 1 breather19 4 Hydraulic Tank Breather Clean or Replace as needed 1 breather22 1 Fuel Tank Vent Hose Inspect - Clean Drain Hose End 2 hoses25 4 Differential Breather Clean or Replace as needed 1 breather6 7 Transmission Tank Breather Clean or Replace as needed 1 breather

10a 7 Torque Converter Breather Clean or Replace as needed 1 breather2000

HOURS26-D 5 Final Drive Drain 2 plugs

24-D 4 Axle/differential Drain 1 plug24-F 7 Axle/differential/Final Drive Refill GO 1 plug

17 4 Hydraulic Tank

Change fluid or as fluid sam-pling dictates. Also check tank cleanliness & all interior tank parts for proper serviceability

HO 1 tank

41 3 Torque Converter Screen Change 1 screen5000

HOURS22 2 Upper Drive Shaft Slip Joint Grease ULTRA 1 fitting

TIME INTERVAL


# OFFITTINGS

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6000HOURS

4-D 1 Engine Coolant Drain plug4-F 1 Engine Coolant Refill GLY cap3 6 Front Suspension Scissors Lube MPG 4 fittings

LIQUIDS LISTPART # LUBRICANT TYPE ABBR.105031 Electrical Sealer -203394 Freon: Air conditioner refrigerant R-134a -033162 Diesel Fuel, meeting ASTM D-975 (Grade 2-D)/cetane No.40 DF

147862 Engine Oil 10w30 A.P.I. Classification: CG4/CF4 per Caterpillar document SEBU6385; Meeting Military Spec. Mil-l-2104-d; 0 Deg. F. And Below Use Fluid Heaters E040

147803Antifreeze/Coolant, extended Life. Ethylene glycol base containing approximately 90-97% ethylene glycol; 1.5-3% corrosion inhibitors; up to 5% water and anti-foam agents. Mixture should be approxi-mately 50/50 water and antifreeze.

GLY

223472 Gear Lube: SAE 60 gear lubricant meets CAT FD-1 Spec. GO221257 Hydraulic Oil 10 Wt.; CAT TO-4 Spec or equivalent HO

035620 741 EP multi-purpose lithium soap grease (for components other than high-temperature areas and drive shafts) MPG

150587 Transfer Case Oil SAE 30 TDTO oil or approved equivalent. Meeting military specs Mil-l-46152; +5 Deg. F. To -30 Deg. F. Use SAE 10 Wt.: -30 Deg. F. -54 Deg. F. Use SAE 5W20 TFCO

202887 Grease: B-51 Ultra-blue Lubricant (for upper & lower drive shafts) ULTRA

REPLACEMENT FILTERS LIST

PART NO. QTY DESCRIPTIONSERVICE

POINT CATERPILLAR NO.3 Engine Oil Filters 2 2P4005

212314 3 Transmission Filter Elements 9 1R07733 O-ring (For Installing 212314) 2S8439

040411 1 Strainer, Transmission Tank 28 3D6678212313 2 Torque Converter Filter Element 10 1R0741

2 O-ring (For Installing 212313 Filter) 8T6444212315 1 Torque Converter Screen 41 6E1473027602 3 Hydraulic Oil Filters 18, 42061322 3 O-ring (For Installing 027602 Filter)211606 1 Filter, Hydraulic Charge (Brake Cooling) 30

1 O-ring (Supplied With 211606 Filter)1 Fuel Filter, Primary (Water Seperator) 21 111-07161 O-Ring (For Installing 111-0716 Filter) 3J-1907

Gasket (2)(For Installing 111-0716 Filter) 4P-73832 Fuel Filter (Secondary) 40 1R07551 Oil Renewal Filter (Part of 222362) 2a 1R0750

050388 4 Primary Air Cleaner Element 23a017267 4 Secondary Air Cleaner Element 23b

1 Heater/AC Air Filter 44 1193355221642 1 Steering Filter Element 43 4T6915203608 1 TFC Suction Filter 11

TIME INTERVAL


# OFFITTINGS

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When replacing the Front Suspension filters ensure that “ALL” pressure has been discharged before proceeding. See Kress document FS222775 in the Service Manual for more details.

129530 1 TFC Pressure Filter 13 1R0719212314 1 Diff Pressure Filter Element 39 1R0773223552 2 Filter, Breather Box 33125427 1 Breather, Transfer Case 15 6G0078065934 1 Breather, Hydraulic Tank 19125427 1 Breather, Differential 25 6G0078065934 1 Breather, Transmission Tank 6014159 1 Breather, Torque Converter 10a

REPLACEMENT FILTERS LIST (Continued)

PART NO. QTY DESCRIPTIONSERVICE

POINT CATERPILLAR NO.

FILTER CANISTER SPRAYED SAFETY RED

MOUNTING PLATEWARNING PLATE ATTACHED

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The Transmission Tank has a Dipstick and a Sight Gauge. The Sight Gauge is to be used as aQuick visual check only. The Dipstick is for accurate measuring of the fluid level.

FLUID CAPACITY CHART

DESCRIPTION IMPERIAL UNITS METRIC UNITSA/C R-134a Refrigerant 5 lbs. 2.27 kgEngine Crankcase Oil 56 gal. 212 L

Engine Coolant 134 gal. 511.0 LTransmission Fluid 70 265

Transfer Case 6 22.7Hydraulic Oil 241 gal. 912.3 LDiesel Fuel 874 gal. (both tanks) 3308.5 L

Rear Axle & Differential 80 gal. 302.8 LFinal Drive 35 gal. per side 132.5 L

Front Wheel Bearings 12 gal. (6 per axle) 45.4 L (22.7 per axle)Front Suspension 35 lbs. (per module) 15.9 kg

LUBRICATION & MAINTENANCE CHART 222360 Fig. 1 · 2011. 10. 28. · 4/23/09 3 fs222360_er15...

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Transcript of LUBRICATION & MAINTENANCE CHART 222360 Fig. 1 · 2011. 10. 28. · 4/23/09 3 fs222360_er15...