LUBRICATION & MAINTENANCE CHART Fig F 20-L 20-F 22 FUEL TANK VENT HOSE SECTION C-C SECTION B-B SECTION A-A 20-D 20-D 20-D 20-F

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1 20-F 20-L 20-F 22 FUEL TNK VENT HOSE SECTION - SECTION C-C SECTION B-B C RIGHT SIDE FUEL TNK B LEFT SIDE FUEL TNK B C 20-D 20-D 20-D 20-F Fig. 1 4/23/09 1 FS222360_Er15

2 1-F 1-L 21 2 DIFFERENTIL OIL COOLER TRNSFER CSE COOLER 1-D 4-L 4-F RIGHT VIEW BRKE OIL COOLER D LEFT VIEW Fig. 2 4/23/09 2 FS222360_Er15

3 OUT IN OUT IN TORQUE CONVERTER ENGINE DIFF PRESSURE 39 ROTTED FOR CLRITY PUMP, DDITIONL BRKE COOLING & HYDRULIC SYSTEM PUMP, BRKE COOLING PUMP DRIVE PROP SHFT PSI CHECK VLVE FROM DIFF PUMP TFC PRESSURE 13 FROM TFC PUMP TRUCK BODY TO TRNSFER CSE COOLER FRONT PUMP, TRNSMISSION S VIEWED FROM TOP 27 PUMP, CCUMULTOR SYSTEM S VIEWED FROM RER PSI PRESSURE SWITCH (TFC LOW PSI SWITCH) DIFF PUMP IN OUT 15 7 OUT IN 7 TRNSMISSION FILTERS 12-L LOCK UP CHRGE LUBE PSI CHECK VLVE 12-F CHECK VLVE 1" NPT 12-D TFC PUMP TFC SUCTION 11 FRONT O D 10 TORQUE CONVERTER INLET CHRGE FILTER 30 HYDRULIC CHRGE FILTER TRUCK BODY 41 TORQUE CONVERTER SUCTION SCREEN FILTER, STEERING FILTER, STEERING S VIEWED FROM LEFT HYDRULIC TNK MOUNTING GROUP S VIEWED FROM RER Fig. 3 4/23/09 3 FS222360_Er15

4 BTTERY BOX 6-F 6-L DIPSTICK 6-L SIGHT GLSS HYDRULIC TNK FILLER CP TRNSMISSION TNK 6-D TRNSMISSION TNK HYDRULIC TNK L 25 (DIFFERENTIL BRETHER) TRCTION CONTROL GROUP 24-F TO BRETHER BOX BRETHER BOX S VIEWED FROM RER OF MCHINE TRNSMISSION GURD GROUP XLE SSEMBLY 24-D VIEW - 24-L Fig. 4 4/23/09 4 FS222360_Er15

5 NOTE: SOME ITEMS, WHICH RE NORMLLY HIDDEN, RE SHOWN HERE FOR CLRITY ONLY. MUFFLER HET SHIELD SPINDLE PIPE HUB IR CLENER FINL DRIVE 26-D 23a PRIMRY ELEMENT BRKES, CT 793 FRONT OF TRUCK 23b SECONDRY ELEMENT RER SUSPENSION CYLINDER LEFT SIDE VIEW 38 LOWER PRESSURE GUGE, LEFT CYLINDER 45 DJUST PIN TO ± FT-LBS. LOWER PRESSURE GUGE, RIGHT CYLINDER 5 NITROGEN CHRGING VLVE 24-L LEFT SIDE NITROGEN CHRGING VLVE RER XLE SSEMBLY S VIEWED FROM RER RIGHT RER SUSPENSION CYLINDER 37 LEFT RER SUSPENSION CYLINDER UPPER PRESSURE GUGE, LEFT CYLINDER UPPER PRESSURE GUGE, RIGHT CYLINDER 37 LEFT SIDE RER S VIEW FROM FRONT S VIEWED FROM RER Fig. 5 4/23/09 5 FS222360_Er15

6 HYDRULIC MODULE 16 TOP VIEW 18 MIN HYDRULIC FILTER 14 CONNECTS TO RH CYLINDER STR PIVOT FRONT OF TRUCK CONNECTS TO LH CYLINDER STR PIVOT CONNECTS TO RER BULKHED FITTING LH WHIFFLETREE CONNECTS TO FRONT BULKHED FITTING RH WHIFFLETREE CONNECTS TO TOP PORT WHIFFLETREE TUBE PIVOT CONNECTS TO RH CYLINDER ROD STR PIVOT UPPER TPER POPPER S VIEWED FROM THE RER OF THE MCHINE SEL CONNECTS TO RER BULKHED FITTING RH WHIFFLETREE CONNECTS TO FRONT BULKHED FITTING LH WHIFFLETREE CONNECTS TO BOTTOM PORT WHIFFLETREE TUBE PORT CONNECTS TO LH CYLINDER ROD STR PIVOT UPPER BERING VIEW - LIMIT SWITCH STRUT B STEERING HOUSING LOWER BERING DJUSTMENT LINK STEERING HOUSING 32-F 32-L SCISSOR LINKS SECTION B-B LH SUSPENSION MODULE VIEWED FROM RER LOWER TPER POPPER VIEWED FROM LEFT Fig. 6 B 4/23/09 6 FS222360_Er15

7 a 33 TO HYDRULIC TNK TO TORQUE CONVERTER TO DIFFERENTIL TO TRNSMISSION TNK TO TRNSFER CSE TOP OF TRNSFER CSE 24-F Fig. 7 4/23/09 7 FS222360_Er15

8 TO DIFFERENTIL BRETHER TO TRNSMISSION TNK BRETHER ELBOW TO TORQUE CONVERTER FILTER TORQUE CONVERTER FLYWHEEL HOUSING PUMP DRIVE VIEW - VIEW B-B TRNSFER CSE TO 15 HYDRULIC TNK TO 19 B B Fig. 8 4/23/09 8 FS222360_Er15

9 CH240C & 200C SERIES II LUBRICTION INFORMTION The service points shown in the preceding illustrations are called out in the Lubrication Chart below. This information 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 recommendations. 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 document SEBU7174. Insert the additional Kress components listed in the charts on the following pages into the appropriate interval section for your site s maintenance schedule. If you have any questions about sampling or maintenance intervals, contact your local Caterpillar dealer. TIME INTERVL SERVICE POINT FIG.# SERVICE POINT DESCRIPTION REQUIRED SERVICE LUBE # OF FITTINGS 8 HOURS 1-L 2 Engine Crankcase Oil Check level EO 1 dipstick 4-L 2 Engine Coolant Check level GLY 1 cap 6-L 4 Transmission Fluid Check level TDTO 1 dipstick 6-L 4 Transmission Fluid Check level Quick Check ONLY TDTO 1 sight glass 50 HOURS Or uto Lube 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 glass 17-L 4 Hydraulic Tank Check level HO sight glass 20-L 1 Fuel Tank Check level DF sight tube 23a 5 Primary Engine ir Filters Check indicators 4 filters 23b 5 Secondary Engine ir Filter Change every 4th primary change 4 filters 24-L 4 xle/differential Check level GO sight glass 29 4, 7 ccumulator Precharge Check Pressure DRY N 2 5 gauges 35 4 Front Strut(Top) Nitrogen Charge Check Pressure DRY N 2 2 gauges 36 2 Front Strut(Bottom) Nitrogen Fitting Check Pressure DRY N 2 2 fittings 37 4 Rear Suspension Upper Nitrogen Gauge Check Pressure DRY N 2 2 gauges 38 4 Rear Suspension Lower Nitrogen Gauge Check Pressure DRY N 2 2 gauges Tire Valve Check ir Pressure 8 valves Service & Park Brakes Check for Proper Function Seat Belts Inspect 5 4 Rear xle Pivot Pin & Rear Suspension Cylinder Pivots Grease MPG 4 fitting 8 6 Whiffletree Pivot Grease MPG 1 fitting 14 6 Steering Cylinder Rod & Head Grease MPG 4 fittings 16 6 Steering Draglink Connections Grease MPG 4 fitting 44 1 Cab ir Filter Clean or Replace 1 filter 4/23/09 9 FS222360_Er15

10 TIME INTERVL 250 HOURS 500 HOURS 1000 HOURS 2000 HOURS 5000 HOURS SERVICE # OF POINT FIG.# SERVICE POINT DESCRIPTION REQUIRED SERVICE LUBE FITTINGS 4-L 2 Coolant Check Condition GLY cap 33 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 fittings 32-L 6 Front Wheel Bearings Check Level GO 4 plugs 32-F 6 Front Wheel Bearings dd to Check Level GO 4 plugs 9 3 Transmission Filter Change 3 filters 40 2 Secondary Fuel Filter Clean 2 filters 10 3 Torque Converter Filter Change 1 filter 21 2 Primary Fuel Filter (Water Separator) Change 1 filter 28 4 Tranmission Tank Strainer Clean 1 strainer 18 6 Main Psi Hydraulic Filter Change 1 filter 12-D 3 Transfer Gear Case Drain 1 plug 12-F 3 Transfer Gear Case Refill TFCO 1 plug 13 3 Transfer Case Filter Psi Change 1 filter 11 3 Transfer Case Filter (Suction) Change 1 filter 2a 2 Oil Renewal Filter Change 1 filter 1-D 2 Engine Oil Drain 1 plug 1-F 2 Engine Oil Refill EO cap 2 2 Engine Oil Filter Change 3 filters 30 3 Hydraulic Charge Filter (Brake Cooling Change 1 filter 42 1 Suspension Filter, Front Change 2 filters 43 3 Steering Filter, Inlet Change 1 filter 33 7 Breather Box Filter Clean or Replace as needed 2 filters 6-D 5 Transmission & Cooler Drain Fluids plugs 6-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 filter 15 3 Transfer Case Breather Clean or Replace as needed 1 breather 19 4 Hydraulic Tank Breather Clean or Replace as needed 1 breather 22 1 Fuel Tank Vent Hose Inspect - Clean Drain Hose End 2 hoses 25 4 Differential Breather Clean or Replace as needed 1 breather 6 7 Transmission Tank Breather Clean or Replace as needed 1 breather 10a 7 Torque Converter Breather Clean or Replace as needed 1 breather 26-D 5 Final Drive Drain 2 plugs 24-D 4 xle/differential Drain 1 plug 24-F 7 xle/differential/final Drive Refill GO 1 plug 17 4 Hydraulic Tank Change fluid or as fluid sampling dictates. lso check tank cleanliness & all interior tank HO 1 tank parts for proper serviceability 41 3 Torque Converter Screen Change 1 screen 22 2 Upper Drive Shaft Slip Joint Grease ULTR 1 fitting 4/23/09 10 FS222360_Er15

11 TIME INTERVL 6000 HOURS SERVICE # OF POINT FIG.# SERVICE POINT DESCRIPTION REQUIRED SERVICE LUBE FITTINGS 4-D 1 Engine Coolant Drain plug 4-F 1 Engine Coolant Refill GLY cap 3 6 Front Suspension Scissors Lube MPG 4 fittings LIQUIDS LIST PRT # LUBRICNT TYPE BBR Electrical Sealer Freon: ir conditioner refrigerant R-134a Diesel Fuel, meeting STM D-975 (Grade 2-D)/cetane No.40 DF Engine Oil 10w30.P.I. Classification: CG4/CF4 per Caterpillar document SEBU6385; Meeting Military Spec. Mil-l-2104-d; 0 Deg. F. nd Below Use Fluid Heaters ntifreeze/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 approximately GLY 50/50 water and antifreeze Gear Lube: SE 60 gear lubricant meets CT FD-1 Spec. GO Hydraulic Oil 10 Wt.; CT TO-4 Spec or equivalent HO EP multi-purpose lithium soap grease (for components other than high-temperature areas and drive shafts) Transfer Case Oil SE 30 TDTO oil or approved equivalent. Meeting military specs Mil-l-46152; +5 Deg. F. To -30 Deg. F. Use SE 10 Wt.: -30 Deg. F. -54 Deg. F. Use SE 5W20 TFCO Grease: B-51 Ultra-blue Lubricant (for upper & lower drive shafts) ULTR E040 MPG REPLCEMENT FILTERS LIST PRT NO. QTY DESCRIPTION SERVICE POINT CTERPILLR NO. 3 Engine Oil Filters 2 2P Transmission Filter Elements 9 1R O-ring (For Installing ) 2S Strainer, Transmission Tank 28 3D Torque Converter Filter Element 10 1R O-ring (For Installing Filter) 8T Torque Converter Screen 41 6E Hydraulic Oil Filters 18, O-ring (For Installing Filter) Filter, Hydraulic Charge (Brake Cooling) 30 1 O-ring (Supplied With Filter) 1 Fuel Filter, Primary (Water Seperator) O-Ring (For Installing Filter) 3J-1907 Gasket (2)(For Installing Filter) 4P Fuel Filter (Secondary) 40 1R Oil Renewal Filter (Part of ) 2a 1R Primary ir Cleaner Element 23a Secondary ir Cleaner Element 23b 1 Heater/C ir Filter Steering Filter Element 43 4T TFC Suction Filter 11 4/23/09 11 FS222360_Er15

12 REPLCEMENT FILTERS LIST (Continued) SERVICE PRT NO. QTY DESCRIPTION POINT CTERPILLR NO TFC Pressure Filter 13 1R Diff Pressure Filter Element 39 1R Filter, Breather Box Breather, Transfer Case 15 6G Breather, Hydraulic Tank Breather, Differential 25 6G Breather, Transmission Tank Breather, Torque Converter 10a When replacing the Front Suspension filters ensure that LL pressure has been discharged before proceeding. See Kress document FS in the Service Manual for more details. FILTER CNISTER SPRYED SFETY RED MOUNTING PLTE WRNING PLTE TTCHED 4/23/09 12 FS222360_Er15

13 FLUID CPCITY CHRT DESCRIPTION IMPERIL UNITS METRIC UNITS /C R-134a Refrigerant 5 lbs kg Engine Crankcase Oil 56 gal. 212 L Engine Coolant 134 gal L Transmission Fluid Transfer Case Hydraulic Oil 241 gal L Diesel Fuel 874 gal. (both tanks) L Rear xle & Differential 80 gal L Final Drive 35 gal. per side 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 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. 4/23/09 13 FS222360_Er15

DISTANCE TRAVELED 1 (miles/km) LUBRICANT &/OR PART 2. LUBRICATION AND SERVICING SCHEDULE Item. Months

DISTANCE TRAVELED 1 (miles/km) LUBRICANT &/OR PART 2. LUBRICATION AND SERVICING SCHEDULE Item. Months GENERAL Flexible hoses, thoroughly inspect all hoses - 12 ------- Front discharge tube, qty:2, check to see if clogged 3-3 ------- 01 ENGINE Air cleaner, inspect, clean, replace element if required 27