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769C TRUCK

Product: TRUCK

Model: 769C TRUCK 01X

Configuration: 769C TRUCK 01X02877-05473 (MACHINE) POWERED BY 3408 ENGINE

Operation and Maintenance Manual

768C TRACTOR, 769C TRUCK

Media Number -SEBU5608-01

Foreword

-01/09/1981

Updated -26/04/2005

This book is a guide to equipment care. The illustrated step-by-step instructions are grouped by servicing intervals; items not having specific intervals are listed under WHEN REQUIRED.

Circled numbers in the LUBRICATION AND MAINTENANCE CHART are to key the charted items to the instructions in the book.

Use the service meter to determine servicing intervals. Calendar intervals (daily, weekly, 2 weeks, etc.) shown may be used instead of service meter intervals if it provides more convenient servicing schedules; and approximates the indicated service meter reading.

NOTE: Under extremely severe, dusty or wet operating conditions, more frequent lubrication than is specified in the LUBRICATION AND MAINTENANCE CHART may be necessary.

Perform previous interval items at multiples of the original requirements. For example, at EVERY 100 SERVICE HOURS OR 2 WEEKS, also perform those items listed under EVERY 50 SERVICE HOURS OR WEEKLY and EVERY 10 SERVICE HOURS OR DAILY.

Some photographs in this publication may show details or attachments that may be different from your unit. Also, the ROPS (Rollover Protective Structure), for some photographs, may have been removed for illustrative purposes.

Continuing improvement and advancement of product design may cause changes to your machine which may not be included in this publication. Each publication is reviewed and revised, as required, to update and include these changes in later editions.

Service Meter

Whenever a question arises regarding your Caterpillar product, or this publication, please consult your Caterpillar dealer for the latest available information.

Mon Jan 22 01:07:30 UTC+0530 2024

Product: TRUCK

Model: 769C TRUCK 01X

Configuration: 769C TRUCK 01X02877-05473 (MACHINE) POWERED BY 3408 ENGINE

Operation and Maintenance Manual

768C TRACTOR, 769C TRUCK

Media Number -SEBU5608-01

Safety

Body Retaining Pins

-01/09/1981

-26/04/2005

Lubrication, maintenance or repair of this machine can be dangerous unless performed properly. Each person must satisfy himself that he has the necessary skill and information, proper tools and equipment, and that his work method is safe and correct. Caterpillar dealers are available to provide service and information.

When it is necessary to work under the truck with the body (bed) raised, install the body RETAINING PIN through the pin holes in the frame and body.

PIN INSTALLED IN FRAME AND BODY

2. Raise the body until the pin hole (3) in the frame, aligns with the pin hole (4) in the body. Install the pin.

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Removal of this cover or valves will cause truck to drop suddenly if not properly blocked. Serious injury or death could result if person is trapped between tire and platform or fender. See service manual for correct procedure.

Read and understand warning and caution information provided on the machine. Follow the servicing instructions carefully.

1. Pull back the pin retaining rod (1) and remove the pin (2) from the storage hole.

Attach a DO NOT OPERATE tag or similar WARNING tag, to the controls while the machine is being serviced.

Turn the disconnect switch OFF and remove the key before servicing the electrical system.

PIN IN STORED POSITION

If engine is not running, do not release emergency or parking brake systems unless machine is blocked or restrained.

Use caution when removing radiator cap, drain plugs, grease fittings or pressure taps.

Product: TRUCK

Model: 769C TRUCK 01X

Configuration: 769C TRUCK 01X02877-05473 (MACHINE) POWERED BY 3408 ENGINE

Operation and Maintenance Manual

768C TRACTOR, 769C TRUCK

Media Number -SEBU5608-01

Maintenance Recommendations

Cooling

NOTICE

Never add coolant to an overheated engine; allow engine to cool first.

Check specific gravity of antifreeze solution frequently in cold weather to assure adequate protection.

When permanent antifreeze and water solutions are used in the cooling system, the solution should be drained and replaced EVERY 2000 SERVICE HOURS OR 1 YEAR.

However, when additions of inhibitor are made to the cooling system EVERY 500 SERVICE HOURS OR 3 MONTHS, it is not necessary to drain and refill yearly. The antifreeze change period can be extended to 4000 service hours or 2 years.

Do not use Caterpillar Cooling System Conditioner with Dowtherm 209 Full-Fill Coolant.

If machine is to be stored in, or shipped to, an area with below freezing temperatures; the cooling system must either be protected to the lowest expected ambient temperature, or drained completely.

-26/04/2005

NOTE: The engine cooling system is protected to -20°F (-29°C), with permanent-type antifreeze, when shipped from the factory.

Use clean water that is low in scale forming minerals, not softened water. Add Caterpillar Cooling System Conditioner, or equivalent, to maintain a 3% concentration.

Whenever draining and refilling cooling system, always recheck the coolant level when the engine reaches normal operating temperature.

Filling at over 5 U.S. gallons (19 liters) per minute can cause air pockets in the cooling system.

Premix antifreeze solution to provide protection to the lowest expected ambient temperature. Pure undiluted antifreeze will freeze at -10°F (-23°C).

Operate with a thermostat in the cooling system all year-round. Cooling system problems can arise without a thermostat.

Electrical

NOTICE

When using jumper cables to start machine, be sure to connect in parallel: POSITIVE (+) to POSITIVE (+) and NEGATIVE (-) to NEGATIVE (-).

When using external electrical source to start machine, turn disconnect switch off and remove key before attaching jumper cables. Insert key and turn disconnect switch on, before starting.

Hydraulic

NOTICE

Make-up oil added to the hydraulic system must mix with the oil already in the tank. Use only petroleum products unless system is equipped for use with special products.

Water or air can cause pump failure. If hydraulic oil becomes cloudy, then water or air is entering the system. Drain fluid, retighten hydraulic suction line clamps, purge and refill system. See your Caterpillar dealer for purging instructions. Fuel

NOTICE

Fill fuel tank at the end of each day of operation to drive out moisture laden air and to prevent condensation. Do not fill the tank to the brim. The fuel expands when it gets warm and may overflow.

Check fuel level with dipstick in filler opening.

Water and sediment should be drained from the fuel tank at the start of each shift or after the fuel tank has been filled and allowed to stand for 5 to 10 minutes.

Drain fuel tank of moisture and sediment as required by prevailing conditions.

Drain water and sediment from the main fuel storage tank weekly, and before the tank is refilled. This will help prevent water or sediment from being pumped from the storage tank into the machine fuel tank.

After changing fuel filters, always bleed fuel system to remove air bubbles from system.

Air Intake

Check precleaner screen daily for accumulation of dust and debris.

Service air cleaners when RED band in indicator locks in visible position.

Scheduled Oil Sampling

Use Scheduled Oil Sampling to monitor machine condition and maintenance requirements.

Each oil sample should be taken when the oil is hot, and well mixed, to insure a sample which is representative of the oil in the compartment.

Consult your Caterpillar dealer for complete information, and assistance in establishing a Scheduled Oil Sampling program for your equipment.

General

NOTICE

Accumulated grease and oil on a machine is a fire hazard. Remove this debris, with steam cleaning or high pressure water, at least every 1000 hours or any time any significant quantity of oil is spilled on a machine.

Drain moisture and sediment from air reservoirs at the beginning of each day of operation.

Wipe all fittings, caps and plugs before servicing.

Private Network For SIS Licensees.

Mon Jan 22 01:09:33 UTC+0530 2024

Product: TRUCK

Model: 769C TRUCK 01X

Configuration: 769C TRUCK 01X02877-05473 (MACHINE) POWERED BY 3408 ENGINE

Operation and Maintenance Manual

768C TRACTOR, 769C TRUCK

Media Number -SEBU5608-01 Publication Date -01/09/1981 Date Updated -26/04/2005

Refill Capacities (Approximate)

NOTE: These capacities are approximate and should be used as a guide for refill only. DO NOT use these values for billing or any such purpose.

Product: TRUCK

Model: 769C TRUCK 01X

Configuration: 769C TRUCK 01X02877-05473 (MACHINE) POWERED BY 3408 ENGINE

Operation and Maintenance Manual

768C TRACTOR, 769C TRUCK

Media Number -SEBU5608-01

Serial Number Locations ENGINE

COMBINATION PLATE - CHASSIS AND ENGINE Bolt Torques

Date -01/09/1981

Updated -26/04/2005

Rights Reserved.

Network For SIS Licensees. Mon Jan 22 01:09:53 UTC+0530 2024

Product: TRUCK

Model: 769C TRUCK 01X

Configuration: 769C TRUCK 01X02877-05473 (MACHINE) POWERED BY 3408 ENGINE

Operation and Maintenance Manual

768C TRACTOR, 769C TRUCK

Media Number -SEBU5608-01

Walk-Around Inspection

Date -01/09/1981

Updated -26/04/2005

For maintenance and operator personnel safety, and maximum service life of the machine, make a thorough walk-around inspection when performing lubrication and maintenance work. Inspect under and around the machine for such items as loose or missing bolts, trash buildup, cut or gouged tires, oil or coolant leaks.

Product: TRUCK

Model: 769C TRUCK 01X

Configuration: 769C TRUCK 01X02877-05473 (MACHINE) POWERED BY 3408 ENGINE

Operation

and Maintenance Manual

768C TRACTOR, 769C TRUCK

Media Number -SEBU5608-01

Publication Date -01/09/1981

Fuel And Lubricant Specifications

Date Updated -26/04/2005

NOTE: The abbreviations listed below follow S.A.E. J754 nomenclature. The classifications follow S.A.E. J183 classifications. The MIL specifications are U.S.A. Military Specifications. These definitions will be of assistance in purchasing. The specific classifications for this machine are found on the RECOMMENDED LUBRICANTS chart.

Diesel Fuel

Distillate fuels that conform to ASTM No. 1 or No. 2 Fuel Oil or No. 1D or No. 2D Diesel Fuel Oil. Specifications with a minimum cetane of 35 are preferred fuels and provide proven maximum engine service life.

Some crude oils and blended fuels are regarded as permissible and can be used with extra fuel filters and adjusted oil change periods. However, this will result in less than maximum engine service life.

Contact your Caterpillar dealer regarding the Caterpillar SPECIAL INSTRUCTION titled "FUELS FOR CATERPILLAR DIESEL ENGINES", FORM SEHS7067, which specifies requirements for other preferred and permissible fuels.

Transmission Oil (CD/TO-2)

Use Service Classification CD oils that have satisfactory friction retention performance in the Caterpillar Oil Test No. TO-2: Referred to as Service Class CD/TO-2 oil.

Engine Oils (CD)

Use oils that meet Engine Service Classification CD (MIL-L-2104C) or CD/TO-2.

Hydraulic Oil (HYDO)

Use Engine Service Classification CC (MIL-L-2104B), (MIL-L-46152), CD, CD/TO-2, or industrial-type hydraulic oils which are certified by the supplier as having antiwear, antifoam, antirust and antioxidation additive properties for heavy duty use.

Multipurpose-type Gear Lubricant (MPL)

Use Gear Lubricant Classification GL-5 (MIL-L-2105B).

Lubricating Grease (MPG)

Use Multipurpose-type Grease ( MPG). Multipurpose-type grease which contains 3% to 5% molybdenum disulfide is preferred. NLGI No. 2 Grade is suitable for most temperatures. Use NLGI No. 1 or No. 0 Grade for extremely low temperatures.

Product: TRUCK

Model: 769C TRUCK 01X

Configuration: 769C TRUCK 01X02877-05473 (MACHINE) POWERED BY 3408 ENGINE

Operation and Maintenance Manual

768C TRACTOR, 769C TRUCK

Media Number -SEBU5608-01

Date -01/09/1981

Lubrication And Maintenance Chart

Updated -26/04/2005

Product: TRUCK

Model: 769C TRUCK 01X

Configuration: 769C TRUCK 01X02877-05473 (MACHINE) POWERED BY 3408 ENGINE

Operation and Maintenance Manual

768C TRACTOR, 769C TRUCK

Media Number -SEBU5608-01

Date -01/09/1981

Every 10 Service Hours Or Daily

(1)Cooling System

Updated -26/04/2005

Always inspect cooling system with the engine stopped. Remove filler cap slowly to relieve pressure. Steam can cause personal injury.

Do not allow conditioner, which contains alkali, to contact skin or eyes.

NOTE: If it is necessary to add coolant daily, inspect cooling system for leaks.

1. Remove filler cap slowly to relieve pressure. Maintain coolant level to within 1/2 inch (1 cm) of bottom of fill pipe.

2. Clean and inspect cap. If seal is damaged, disassemble cap and replace seal.

3. Assemble and install cap.

(2)Engine Crankcase

NOTICE

Machine must be level with bed lowered and parking brake applied.

1. Measure oil level with machine level and parking brake set. Before starting, oil level must be in SAFE STARTING RANGE on ENGINE STOPPED side of dipstick.

2. With engine running and oil warm, maintain oil level between the ADD and FULL marks on the ENGINE RUNNING side of dipstick.

(3)Air Reservoirs

1. Drain moisture and sediment from the engine governor control reservoir (C), the parking/emergency reservoir (A) and the service/retarder reservoirs (B).

2. To drain reservoirs, open drain valves by lifting levers (A), (B) and (C). Allow moisture and sediment to drain. Close valves by returning levers to the down position.

(4)Brakes - Test for Proper Function

Make certain area is clear of personnel and obstructions before testing brakes.

Service Brakes

1. Start engine and allow air system to build up full operating pressure.

2. Depress service brake pedal.

3. Place transmission in first range.

4. Accelerate engine to 1200 RPM.

5. Truck should not move. If truck moved, have repairs made.

Emergency Brakes

1. Start engine and allow air system to build up full operating pressure.

2. Apply emergency brake lever.

3. Place transmission in first range.

4. Accelerate engine to 1200 RPM.

5. Truck should not move. If truck moved, have repairs made.

(5)Indicator Lights

Test all indicator lights at the beginning of each shift.

Replace any lights that do not function properly.

(6)Emergency Steering - Test

If the emergency steering was used during operation, immediately park vehicle in a safe location. Inspect the machine and correct condition which made use of the emergency steering necessary.

NOTICE

To minimize battery drain, leave switch ON only long enough to test emergency steering.

1. With engine stopped, push emergency steering switch ON.

2. Turn steering wheel right and left. Push steering switch to OFF.

If the emergency steering did not function properly, contact your Caterpillar dealer for service or information.

(7)Back Up Alarm

1. Move transmission lever to the reverse position. Back up alarm should sound intermittenly.

2. If back up alarm fails to operate properly, contact your Caterpillar dealer for information or service. Copyright 1993 - 2024 Caterpillar Inc. All Rights Reserved. Private Network For SIS Licensees. Mon Jan 22 01:11:13 UTC+0530 2024

Product: TRUCK

Model: 769C TRUCK 01X

Configuration: 769C TRUCK 01X02877-05473 (MACHINE) POWERED BY 3408 ENGINE

Operation and Maintenance Manual

768C TRACTOR, 769C TRUCK

Every 50 Service Hours Or Weekly

(8)Transmission, Hoist And Brake Hydraulic System

Maintain oil level to FULL mark in sight gauge.

(9)Steering Hydraulic Tank

Maintain oil level above ADD mark in the sight gauge.

(10)Batteries

Batteries give off flammable fumes that can explode. Do not smoke when observing electrolyte level.

Electrolyte is an acid and can cause personal injury if it contacts skin or eyes.

1. Open battery access cover.

2. Clean top of batteries. Maintain electrolyte to bottom of filler openings with distilled water. Close access door.

(11)Rear Suspension Cylinder Bearings

Lubricate two fittings on each cylinder. Total four fittings.

(12)Rear Axle Housing Lateral Control Rod

Lubricate two fittings.

(13)Body Pivot Bearings

Lubricate two fittings.

(14)Horizontal Pivot - 768C

Lubricate 2 fittings.

(15)Hitch Yoke - 768C

Lubricate 1 fitting.

(16)Yoke Lower Bearings (768C)

Lubricate 2 fittings.

This is the sample of the manual click on the download link for complete manual

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