CAT + Caterpillar 769C Truck Operation & Maintenance Manual by Heavy Equipment Manual

Product:TRUCK

Model:769CTRUCK01X

Configuration:769CTRUCK01X02877-05473(MACHINE)POWEREDBY3408ENGINE

OperationandMaintenanceManual 768CTRACTOR,769CTRUCK

MediaNumber-SEBU5608-01PublicationDate-01/09/1981DateUpdated-26/04/2005

Foreword

Thisbookisaguidetoequipmentcare.Theillustratedstep-by-stepinstructionsaregroupedby servicingintervals;itemsnothavingspecificintervalsarelistedunderWHENREQUIRED.

CirclednumbersintheLUBRICATIONANDMAINTENANCECHARTaretokeythecharted itemstotheinstructionsinthebook.

Usetheservicemetertodetermineservicingintervals.Calendarintervals(daily,weekly,2weeks, etc.)shownmaybeusedinsteadofservicemeterintervalsifitprovidesmoreconvenientservicing schedules;andapproximatestheindicatedservicemeterreading.

NOTE:Underextremelysevere,dustyorwetoperatingconditions,morefrequentlubricationthan isspecifiedintheLUBRICATIONANDMAINTENANCECHARTmaybenecessary.

Performpreviousintervalitemsatmultiplesoftheoriginalrequirements.Forexample,atEVERY 100SERVICEHOURSOR2WEEKS,alsoperformthoseitemslistedunderEVERY50 SERVICEHOURSORWEEKLYandEVERY10SERVICEHOURSORDAILY.

Somephotographsinthispublicationmayshowdetailsorattachmentsthatmaybedifferentfrom yourunit.Also,theROPS(RolloverProtectiveStructure),forsomephotographs,mayhavebeen removedforillustrativepurposes.

Continuingimprovementandadvancementofproductdesignmaycausechangestoyourmachine whichmaynotbeincludedinthispublication.Eachpublicationisreviewedandrevised,as required,toupdateandincludethesechangesinlatereditions.

ServiceMeter

WheneveraquestionarisesregardingyourCaterpillarproduct,orthispublication,pleaseconsult yourCaterpillardealerforthelatestavailableinformation.

MonJan2201:07:30UTC+05302024

Product:TRUCK

Model:769CTRUCK01X

Configuration:769CTRUCK01X02877-05473(MACHINE)POWEREDBY3408ENGINE

OperationandMaintenanceManual 768CTRACTOR,769CTRUCK

MediaNumber-SEBU5608-01PublicationDate-01/09/1981DateUpdated-26/04/2005

Safety

BodyRetainingPins

Lubrication,maintenanceorrepairofthismachinecanbedangerous unlessperformedproperly.Eachpersonmustsatisfyhimselfthathehas thenecessaryskillandinformation,propertoolsandequipment,and thathisworkmethodissafeandcorrect.Caterpillardealersare availabletoprovideserviceandinformation.

Whenitisnecessarytoworkunderthetruckwiththebody(bed) raised,installthebodyRETAININGPINthroughthepinholesinthe frameandbody.

2.Raisethebodyuntilthepinhole(3)intheframe,alignswiththepinhole(4)inthebody.Install thepin.

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Removalofthiscoverorvalveswillcausetrucktodropsuddenlyifnot properlyblocked.Seriousinjuryordeathcouldresultifpersonis trappedbetweentireandplatformorfender.Seeservicemanualfor correctprocedure.

Readandunderstandwarningandcautioninformationprovidedonthemachine.Followthe servicinginstructionscarefully.

PININSTOREDPOSITION

1.Pullbackthepinretainingrod(1)andremovethepin(2)fromthestoragehole.

AttachaDONOTOPERATEtagorsimilarWARNINGtag,tothecontrolswhilethemachineis beingserviced.

TurnthedisconnectswitchOFFandremovethekeybeforeservicingtheelectricalsystem.

Allinspections,adjustments,lubricationormaintenanceshouldbemadewithenginestopped, brakesappliedandwithallsafetylocksorcontrolsintheappliedposition,unlessotherwise specified.

Donotpermitsmokingoropenfiresaroundfuelsorotherflammablematerial.

Donotallowunauthorizedpersonnelonmachinewhenitisbeingserviced.

Donotsmokewhenobservingbatteryelectrolytelevel.Batteriesgiveoffflammablefumes.

Donotallowelectrolytesolutiontocontactskinoreyes.Electrolytesolutionisanacid.

Whenusingboosterstartingcables,attachgroundcablelastandremovefirsttopreventsparks nearthebattery,whichcouldcausebatteryvaporstoexplode.Attachboostercabletostarter groundterminalsonmachinetobestarted.

Coolantconditionercontainsalkali,avoidcontactwithskinandeyes.

Alwaysinspectcoolingsystemwithenginestoppedandcool.Theradiatorcapshouldbecool enoughtobetouchedwithbarehands.Removeradiatorfillercapslowlytorelievepressure. Steammaycausepersonalinjury.

Whenmountingordismounting,facemachineandusestepsandgrabironsprovidedatfrontof machine.

Wearprotectiveclothing,safetyglasses,respiratororothersafetyitemswhennecessary.

Cleansteps,grabironsandareasofmachineyouwillbeworkingonoraround.

Becarefulwhenworkingonmachine.Hotpartssuchasexhaustmanifolds,filters,brakes,engine oil,etc.,cancausepersonalinjury.

Operateengineinawellventilatedareaonly.

Ifitisnecessarytooperatetheengineinaclosedarea,venttheexhausttotheoutside.

Whenstartingfromauxiliarypowersource,turnoffdisconnectswitchandremovethekeybefore connectingbatterycables.

Hydraulicoilisflammable.Donotweldontubesthatarefilledwithoil.Cleanthemthoroughly beforeheatingorwelding.

Hothydraulicoilcancausepersonalinjury.Removehydraulictankfillercapslowlytorelieve tankpressure.Allowoiltocoolbeforedraining.

Ifengineisnotrunning,donotreleaseemergencyorparkingbrakesystemsunlessmachineis blockedorrestrained.

Usecautionwhenremovingradiatorcap,drainplugs,greasefittingsorpressuretaps.

MonJan2201:09:25UTC+05302024

Product:TRUCK

Model:769CTRUCK01X

Configuration:769CTRUCK01X02877-05473(MACHINE)POWEREDBY3408ENGINE

OperationandMaintenanceManual 768CTRACTOR,769CTRUCK

MediaNumber-SEBU5608-01PublicationDate-01/09/1981DateUpdated-26/04/2005

MaintenanceRecommendations

Cooling

NOTICE

Neveraddcoolanttoanoverheatedengine;allowenginetocoolfirst.

Checkspecificgravityofantifreezesolutionfrequentlyincoldweather toassureadequateprotection.

Whenpermanentantifreezeandwatersolutionsareusedinthecooling system,thesolutionshouldbedrainedandreplacedEVERY2000 SERVICEHOURSOR1YEAR.

However,whenadditionsofinhibitoraremadetothecoolingsystem EVERY500SERVICEHOURSOR3MONTHS,itisnotnecessaryto drainandrefillyearly.Theantifreezechangeperiodcanbeextended to4000servicehoursor2years.

DonotuseCaterpillarCoolingSystemConditionerwithDowtherm 209Full-FillCoolant.

Ifmachineistobestoredin,orshippedto,anareawithbelowfreezing temperatures;thecoolingsystemmusteitherbeprotectedtothelowest expectedambienttemperature,ordrainedcompletely.

NOTE:Theenginecoolingsystemisprotectedto-20°F(-29°C),withpermanent-typeantifreeze, whenshippedfromthefactory.

Usecleanwaterthatislowinscaleformingminerals,notsoftenedwater.AddCaterpillarCooling SystemConditioner,orequivalent,tomaintaina3%concentration.

Wheneverdrainingandrefillingcoolingsystem,alwaysrecheckthecoolantlevelwhentheengine reachesnormaloperatingtemperature.

Fillingatover5U.S.gallons(19liters)perminutecancauseairpocketsinthecoolingsystem.

Premixantifreezesolutiontoprovideprotectiontothelowestexpectedambienttemperature.Pure undilutedantifreezewillfreezeat-10°F(-23°C).

Operatewithathermostatinthecoolingsystemallyear-round.Coolingsystemproblemscanarise withoutathermostat.

Electrical

NOTICE

Whenusingjumpercablestostartmachine,besuretoconnectin parallel:POSITIVE(+)toPOSITIVE(+)andNEGATIVE(-)to NEGATIVE(-).

Whenusingexternalelectricalsourcetostartmachine,turndisconnect switchoffandremovekeybeforeattachingjumpercables.Insertkey andturndisconnectswitchon,beforestarting.

Hydraulic

NOTICE

Make-upoiladdedtothehydraulicsystemmustmixwiththeoil alreadyinthetank.Useonlypetroleumproductsunlesssystemis equippedforusewithspecialproducts.

Wateroraircancausepumpfailure.Ifhydraulicoilbecomescloudy, thenwaterorairisenteringthesystem.Drainfluid,retighten hydraulicsuctionlineclamps,purgeandrefillsystem.Seeyour Caterpillardealerforpurginginstructions.

Fuel

NOTICE

Fillfueltankattheendofeachdayofoperationtodriveoutmoisture ladenairandtopreventcondensation.Donotfillthetanktothebrim. Thefuelexpandswhenitgetswarmandmayoverflow.

Checkfuellevelwithdipstickinfilleropening.

Waterandsedimentshouldbedrainedfromthefueltankatthestartofeachshiftorafterthefuel tankhasbeenfilledandallowedtostandfor5to10minutes.

Drainfueltankofmoistureandsedimentasrequiredbyprevailingconditions.

Drainwaterandsedimentfromthemainfuelstoragetankweekly,andbeforethetankisrefilled. Thiswillhelppreventwaterorsedimentfrombeingpumpedfromthestoragetankintothe machinefueltank.

Afterchangingfuelfilters,alwaysbleedfuelsystemtoremoveairbubblesfromsystem.

AirIntake

Checkprecleanerscreendailyforaccumulationofdustanddebris.

ServiceaircleanerswhenREDbandinindicatorlocksinvisibleposition.

ScheduledOilSampling

UseScheduledOilSamplingtomonitormachineconditionandmaintenancerequirements. Eachoilsampleshouldbetakenwhentheoilishot,andwellmixed,toinsureasamplewhichis representativeoftheoilinthecompartment.

ConsultyourCaterpillardealerforcompleteinformation,andassistanceinestablishinga ScheduledOilSamplingprogramforyourequipment.

General NOTICE

Accumulatedgreaseandoilonamachineisafirehazard.Removethis debris,withsteamcleaningorhighpressurewater,atleastevery1000 hoursoranytimeanysignificantquantityofoilisspilledona machine.

Drainmoistureandsedimentfromairreservoirsatthebeginningofeachdayofoperation. Wipeallfittings,capsandplugsbeforeservicing.

MonJan2201:09:33UTC+05302024

Product:TRUCK

Model:769CTRUCK01X

Configuration:769CTRUCK01X02877-05473(MACHINE)POWEREDBY3408ENGINE

OperationandMaintenanceManual 768CTRACTOR,769CTRUCK

MediaNumber-SEBU5608-01PublicationDate-01/09/1981DateUpdated-26/04/2005

NOTE:Thesecapacitiesareapproximateandshouldbeusedasaguideforrefillonly.DONOTuse thesevaluesforbillingoranysuchpurpose.

MonJan2201:09:44UTC+05302024

Product:TRUCK

Model:769CTRUCK01X

Configuration:769CTRUCK01X02877-05473(MACHINE)POWEREDBY3408ENGINE

MonJan2201:09:53UTC+05302024

Product:TRUCK

Model:769CTRUCK01X

Configuration:769CTRUCK01X02877-05473(MACHINE)POWEREDBY3408ENGINE

Walk-AroundInspection

Formaintenanceandoperatorpersonnelsafety,andmaximumservicelifeofthemachine,makea thoroughwalk-aroundinspectionwhenperforminglubricationandmaintenancework.Inspect underandaroundthemachineforsuchitemsaslooseormissingbolts,trashbuildup,cutor gougedtires,oilorcoolantleaks.

MonJan2201:10:06UTC+05302024

Product:TRUCK

Model:769CTRUCK01X

Configuration:769CTRUCK01X02877-05473(MACHINE)POWEREDBY3408ENGINE

OperationandMaintenanceManual 768CTRACTOR,769CTRUCK

MediaNumber-SEBU5608-01PublicationDate-01/09/1981DateUpdated-26/04/2005

FuelAndLubricantSpecifications

NOTE:TheabbreviationslistedbelowfollowS.A.E.J754nomenclature.Theclassificationsfollow S.A.E.J183classifications.TheMILspecificationsareU.S.A.MilitarySpecifications.These definitionswillbeofassistanceinpurchasing.Thespecificclassificationsforthismachineare foundontheRECOMMENDEDLUBRICANTSchart.

DieselFuel

DistillatefuelsthatconformtoASTMNo.1orNo.2FuelOilorNo.1DorNo.2DDieselFuelOil. Specificationswithaminimumcetaneof35arepreferredfuelsandprovideprovenmaximum engineservicelife.

Somecrudeoilsandblendedfuelsareregardedaspermissibleandcanbeusedwithextrafuelfilters andadjustedoilchangeperiods.However,thiswillresultinlessthanmaximumengineservicelife.

ContactyourCaterpillardealerregardingtheCaterpillarSPECIALINSTRUCTIONtitled"FUELS FORCATERPILLARDIESELENGINES",FORMSEHS7067,whichspecifiesrequirementsfor otherpreferredandpermissiblefuels.

TransmissionOil(CD/TO-2)

UseServiceClassificationCDoilsthathavesatisfactoryfrictionretentionperformanceinthe CaterpillarOilTestNo.TO-2:ReferredtoasServiceClassCD/TO-2oil.

EngineOils(CD)

UseoilsthatmeetEngineServiceClassificationCD(MIL-L-2104C)orCD/TO-2.

HydraulicOil(HYDO)

UseEngineServiceClassificationCC(MIL-L-2104B),(MIL-L-46152),CD,CD/TO-2,or industrial-typehydraulicoilswhicharecertifiedbythesupplierashavingantiwear,antifoam, antirustandantioxidationadditivepropertiesforheavydutyuse.

Multipurpose-typeGearLubricant(MPL)

UseGearLubricantClassificationGL-5(MIL-L-2105B).

LubricatingGrease(MPG)

UseMultipurpose-typeGrease(MPG).Multipurpose-typegreasewhichcontains3%to5% molybdenumdisulfideispreferred.NLGINo.2Gradeissuitableformosttemperatures.UseNLGI No.1orNo.0Gradeforextremelylowtemperatures.

MonJan2201:10:48UTC+05302024

Product:TRUCK

Model:769CTRUCK01X

Configuration:769CTRUCK01X02877-05473(MACHINE)POWEREDBY3408ENGINE

MonJan2201:11:03UTC+05302024

Product:TRUCK

Model:769CTRUCK01X

Configuration:769CTRUCK01X02877-05473(MACHINE)POWEREDBY3408ENGINE

OperationandMaintenanceManual 768CTRACTOR,769CTRUCK

MediaNumber-SEBU5608-01PublicationDate-01/09/1981DateUpdated-26/04/2005 Every10ServiceHoursOrDaily

(1)CoolingSystem

Alwaysinspectcoolingsystemwiththeenginestopped.

Removefillercapslowlytorelievepressure.Steamcancausepersonal injury.

Donotallowconditioner,whichcontainsalkali,tocontactskinoreyes.

NOTE:Ifitisnecessarytoaddcoolantdaily,inspectcoolingsystemforleaks.

1.Removefillercapslowlytorelievepressure.Maintaincoolantleveltowithin1/2inch(1cm)of bottomoffillpipe.

2.Cleanandinspectcap.Ifsealisdamaged,disassemblecapandreplaceseal.

3.Assembleandinstallcap.

(2)EngineCrankcase

Machinemustbelevelwithbedloweredandparkingbrakeapplied.

1.Measureoillevelwithmachinelevelandparkingbrakeset.Beforestarting,oillevelmustbein SAFESTARTINGRANGEonENGINESTOPPEDsideofdipstick.

2.Withenginerunningandoilwarm,maintainoillevelbetweentheADDandFULLmarkson theENGINERUNNINGsideofdipstick.

(3)AirReservoirs

1.Drainmoistureandsedimentfromtheenginegovernorcontrolreservoir(C),the parking/emergencyreservoir(A)andtheservice/retarderreservoirs(B).

2.Todrainreservoirs,opendrainvalvesbyliftinglevers(A),(B)and(C).Allowmoistureand sedimenttodrain.Closevalvesbyreturningleverstothedownposition.

(4)Brakes-TestforProperFunction

Makecertainareaisclearofpersonnelandobstructionsbeforetesting brakes.

ServiceBrakes

1.Startengineandallowairsystemtobuildupfulloperatingpressure.

2.Depressservicebrakepedal.

3.Placetransmissioninfirstrange.

4.Accelerateengineto1200RPM.

5.Truckshouldnotmove.Iftruckmoved,haverepairsmade.

EmergencyBrakes

1.Startengineandallowairsystemtobuildupfulloperatingpressure.

2.Applyemergencybrakelever.

3.Placetransmissioninfirstrange.

4.Accelerateengineto1200RPM.

5.Truckshouldnotmove.Iftruckmoved,haverepairsmade.

(5)IndicatorLights

Testallindicatorlightsatthebeginningofeachshift.

Replaceanylightsthatdonotfunctionproperly.

(6)EmergencySteering-Test

Iftheemergencysteeringwasusedduringoperation,immediatelypark vehicleinasafelocation.Inspectthemachineandcorrectcondition whichmadeuseoftheemergencysteeringnecessary.

NOTICE

Tominimizebatterydrain,leaveswitchONonlylongenoughtotest emergencysteering.

1.Withenginestopped,pushemergencysteeringswitchON.

2.Turnsteeringwheelrightandleft.PushsteeringswitchtoOFF.

Iftheemergencysteeringdidnotfunctionproperly,contactyourCaterpillardealerforserviceor information.

1.Movetransmissionlevertothereverseposition.Backupalarmshouldsoundintermittenly.

2.Ifbackupalarmfailstooperateproperly,contactyourCaterpillardealerforinformationor service.

MonJan2201:11:13UTC+05302024

Product:TRUCK

Model:769CTRUCK01X

Configuration:769CTRUCK01X02877-05473(MACHINE)POWEREDBY3408ENGINE

OperationandMaintenanceManual 768CTRACTOR,769CTRUCK

(8)Transmission,HoistAndBrakeHydraulicSystem

MaintainoilleveltoFULLmarkinsightgauge.

(9)SteeringHydraulicTank

MaintainoillevelaboveADDmarkinthesightgauge.

(10)Batteries

Batteriesgiveoffflammablefumesthatcanexplode.Donotsmoke whenobservingelectrolytelevel.

Electrolyteisanacidandcancausepersonalinjuryifitcontactsskinor eyes.

1.Openbatteryaccesscover.

2.Cleantopofbatteries.Maintainelectrolytetobottomoffilleropeningswithdistilledwater. Closeaccessdoor.

(11)RearSuspensionCylinderBearings

Lubricatetwofittingsoneachcylinder.Totalfourfittings.

(12)RearAxleHousingLateralControlRod

Lubricatetwofittings.

(13)BodyPivotBearings

Lubricatetwofittings.

(14)HorizontalPivot-768C

Lubricate2fittings.

(15)HitchYoke-768C

Lubricate1fitting.

(16)YokeLowerBearings(768C)

Lubricate2fittings.

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