Before working on or operating the truck, read the Operation and Maintenance Manual thoroughly for information on safety, maintenance and operating techniques.
Safety precautions and Warnings are provided in the manual and on the truck. Be sure to identify and understand all symbols before starting the truck.
The first step to perform when approaching the truck is to make a thorough walk around inspection. Look around and under the truck for loose or missing bolts, trash build-up and for coolant, fuel or oil leaks. Look for indications of cracks. Pay close attention to high stress areas as shown in the Operation and Maintenance Manual.
The front wheel bearing oil level is checked and filled by removing the plug (1) in the center of the wheel bearing cover. The oil should be level with the bottom of the plug hole. The fill plug is a magnetic plug. Inspect the fill plug weekly for metal particles. If any metal particles are found, remove the wheel cover and inspect the bearings for wear. When draining the oil, rotate the wheel so the drain plug (2) is at its lowest position.
The service interval for changing the front wheel bearing oil is 500 hours.
Use Final Drive and Axle Oil (FDAO) or commercial FD-1. As a substitute, Transmission Drive Train Oil (TDTO) with a commercial TO-4 may be used.
Check the tire inflation pressure. Operating the truck with the wrong tire inflation pressure can cause heat build-up in the tire and accelerate tire wear. Caterpillar recommends inflating tires with dry nitrogen instead of air to reduce heat build-up and potential combustion. Nitrogen also slows rubber deterioration and rim corrosion.
Check the front suspension cylinders for leaks or structural damage. Check the charge condition of the front suspension cylinders when the truck is empty and on level ground.
Measure the charge height of the suspension cylinders and compare the dimension with the dimension that was recorded the last time the cylinders were charged. Recharge the cylinders with oil and nitrogen if necessary.
A grease outlet fitting (arrow) is located on one side of each front suspension cylinder. The grease supply fitting is located on the opposite side of the suspension cylinder. No grease outlet fittings should be located on the same side of the suspension cylinder as the grease fill location.
Having an outlet fitting on the same side of the suspension cylinder as the grease fill location will prevent proper lubrication of the cylinder.
Make sure that grease is flowing from the outlet fittings to verify that the suspension cylinders are being lubricated and that the pressure in the cylinders is not excessive.
If the machine is equipped with the optional caliper type front brakes, inspect the brake linings (1) for wear. The thickness of the brake linings (not including carrier) must not be less than 3.15 mm (.125 in). Measure the lining at both ends because one end can wear more than the other.
The clearance between the brake carrier guide pins (2) and the brake disc (3) must not be less than 1.5 ± 0.5 mm (.06 ± .02 in.).
The primary fuel filter (1) is mounted between the right front wheel and the engine cooling fan.
A reusable fuel/water separator mounts directly to the filter element. Periodically open the valve (2) under the separator bowl and drain any water into an approved container.
After changing fuel filters, hold switch (3) upward to activate the electric fuel priming pump to refill the fuel lines and filters with fuel.
Jacket water coolant samples can be taken at the Scheduled Oil Sampling (S•O•S) coolant analysis tap (arrow). The tap is located behind the two engine oil filter elements on the right front of the engine.
The transmission filters (1) are located behind the fuel tank and under the center tube.
Transmission oil samples can be taken at the S•O•S tap (2).
The oil filter bypass switch (3) provides input signals to the monitoring system, which sounds an alarm in the cab to warn the operator when the filter is restricted.
A pressure test port (4) is available for monitoring charge pressure for the transmission control valves.
The fuel tank is located on the right side of the truck. The fuel level sight gauge (1) is used to check the fuel level during the walk around inspection. A fuel level sender is located on the fuel level sight gauge. The fuel level sender provides input signals to the monitoring system, which informs the operator of the fuel level.
Open the drain valve below the tank to remove condensation and sediment from the fuel tank.
Inspect the condition of the fuel tank breather (above tank) and the fuel fill cap (2) at regular intervals.
Fuel can be added at the attachment quick service fuel fill connector (3).
The rear axles are equipped with planetary-type final drives. Rotate the final drive until the drain plug (1) is at the lowest position, as shown. The final drive oil level is checked and filled by removing the magnetic plug (2). The oil should be level with the bottom of the plug hole.
Fill the rear axle housing with oil before filling the final drives with oil. Allow enough time for the oil to settle in all of the compartments. This can be as much as 20 minutes during cold temperatures. The oil is drained by removing the drain plug.
The magnetic inspection plugs should be removed weekly from the final drives and checked for metal particles. For some conditions, checking the magnetic plugs is the only way to identify a problem which may exist.
Use FDAO (Final Drive and Axle Oil) or Transmission Drive Train Oil (TDTO) with a specification of TO-4 or newer. These oils provide:
- Maximum frictional capability required for gears
- Increased lubrication capability for bearings
Check the differential oil level by removing the magnetic inspection plug (1). The oil should be level with the bottom of the fill plug opening.
Inspect the rear suspension cylinders for leaks or structural damage. Check the charge condition of the rear suspension cylinders when the truck is empty and on level ground.
Measure the charge height of the suspension cylinders, and compare the dimension with the dimension that was recorded the last time the cylinders were charged. Recharge the cylinders if necessary.
Inspect the condition of the rear axle breather (2) at regular intervals. The breather prevents pressure from building up in the axle housing. Excessive pressure in the axle housing can cause brake cooling oil to leak through the Duo-Cone seals in the wheel brake assemblies.
The body up retaining pins are stored inside a cross-tube (1) in a body support beam directly above the retaining bracket (2). When work is to be performed while the body is raised, the body up retaining pins must be installed through the holes in the body retaining bracket and the rear frame support (3) to hold the body in the raised position. The body is shown in the lowered position
Shown are the transmission hydraulic tank (1) and the hoist, converter, and brake hydraulic tank (2). Both tanks are equipped with oil level sight gauges.
The oil level of both hydraulic tanks should first be checked with cold oil and the engine stopped. The level should again be checked with warm oil and the engine running.
The lower sight gauge (3) on the hoist, converter and brake hydraulic tank can be used to check the tank level when the hoist cylinders are in the RAISED position. When the hoist cylinders are lowered, the hydraulic oil level will increase. After the hoist cylinders are lowered, check the hydraulic tank oil level with the upper sight gauge (4).
Check lower transmission oil sight gauge (5) with the engine off and oil cold. Use the upper gauge (6) with engine at idle and oil warm.
Inspect the hoist, converter, and brake hydraulic tank breather for plugging. The breather is located on the frame rail above the hydraulic tank.
Inspect the condition of both hydraulic tank fill cap vents (located on top of the tank) at regular intervals.
Located in front of the fuel tank on the right side of the truck is the torque converter charging filter (1).
Hoist, converter and brake oil samples can be taken at the S•O•S tap (2) at the base of the filter.
The dual engine oil filters (1) are located on the right front of the engine.
Engine oil samples can be taken at the S•O•S tap (2) located on the front of the oil filter base.
The secondary fuel filter (3) is located at the right front of the engine, in front of the engine oil filters.
A fuel filter bypass switch (4) is located on the filter base. The bypass switch provides an input signal to the Engine ECM indicating if the filters are restricted.
The engine lockout control switch (1) allows the engine to be safely locked out while service is performed. The engine must be stopped to activate the engine lockout mode. When the engine lockout mode is activated, the following conditions exist:
- The engine starter is disabled.
- The secondary steering is disabled.
- The prelube function is disabled.
The following conditions must be met before the engine lockout mode will activate:
- The transmission control must be in the PARK position.
- The engine must be OFF.
When the switch is activated, one of the following results will occur:
- The indicator lamp (2) will illuminate continuously to indicate that the machine is in the engine lockout mode.
- The indicator lamp will flash to indicate that the engine lockout mode will not activate until the transmission control is in the PARK position and the engine is OFF.
The batteries are located inside the front bumper, at the base of the radiator cowling (1).
Inspect the battery connections for corrosion or damage. Keep the battery terminals clean and coated with petroleum jelly.
Inspect the electrolyte level in each battery cell, except maintenance free. Maintain the level to the bottom of the fill openings with distilled water.
The coolant level on the 777F is checked with the jacket water coolant sight gauge (2) located below the cab on the side of the front cowling. Coolant is added by removing the radiator cap (3) located inside an access door on the upper deck.
The water used in the cooling system is critical for good cooling system performance. Use distilled or deionized water whenever possible to prevent acids or scale deposits in the cooling system. Acids and scale deposits result from contaminants that are found in most common water sources.
Never use water alone. All water is corrosive at engine operating temperatures without coolant additives. Also, water alone has none of the lubrication properties that are required for water pump seals.
The steering system hydraulic tank is located on the right platform.
Check the steering system oil level at the sight gauge (1), on the side of the tank.
The steering system oil filter (2) cleans the oil before it enters the hydraulic tank.
The steering system uses a pressure compensated piston type pump mounted to the rear of the engine. Case drain oil from the steering pump returns to the steering tank through a case drain filter (3).
Before removing the fill cap (4) to add oil to the steering system, depress the pressure release button (5) on top of the breather to release any pressure from the tank.
The steering system filter base and the case drain filter base have bypass valves that allow the steering oil to bypass the filters if they are plugged.
Shown are the air intake system components. Check the air filter restriction indicator (1). If the yellow piston is in the red zone, the air filters are restricted and must be serviced.
The air filter housing covers serve as the precleaner assemblies. When servicing the filter elements, clean the precleaners (2) and dust valves (3) using air or water pressure, or detergent wash.
The dust valve is OPEN when the engine is OFF and closes when the engine is running. The dust valve must be flexible and closed when the engine is running or the precleaner will not function properly and the air filters will have a shortened life.
Two filter elements are installed in the filter housings. The large element is the primary element and the small element is the secondary element.
Air intake system tips:
- The primary element can be cleaned a maximum of six times.
- Never clean the secondary element for reuse. Always replace the secondary element.
- Air filter restriction causes black exhaust smoke and low power.
To check the fluid level of the windshield washer reservoir, open the access door located at the left rear of the cab, behind the cab door. Open the filler cap (1) to check the fluid level and fill as necessary.
To the left of the filler spout is the air conditioner filter (2). Clean or replace the filter element when a reduction of circulation in the cab is noticed.
The remaining 10 Hours or Daily checks are performed in the operator's compartment:
- Brakes: Check operation
- Indicators and gauges: Test operation
- Seat belt: Inspect
- Back-up alarm: Test operation
- Secondary steering: Test operation
The service brakes are checked by depressing the pedal (1) and placing the shift lever in FIRST FORWARD. Accelerate the engine until the truck moves. The truck must not move below 1200 rpm. This procedure should be repeated to test the secondary brakes by depressing the secondary brake pedal (2).
The cab air filter (3) is located inside the cab door, in the left-rear corner behind the trainer seat.
Clean or replace the cab fresh air filter when necessary.
See You Soon!!!
MARYGAR
creativity of writer is purely impressive. It has touched to the level of expertise with his writing. Everything is up to the mark. Written perfectly and I can use such information for my coming assignment. check on car
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