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SEBU8480 November 2009

Operation and Maintenance Manual


988H Wheel Loader
BXY4000-Up (988H)

SAFETY.CAT.COM

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Important Safety Information


Most accidents that involve product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, skills and tools to perform these functions properly. Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. The hazards are identied by the Safety Alert Symbol and followed by a Signal Word such as DANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.

The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. The message that appears under the warning explains the hazard and can be either written or pictorially presented. A non-exhaustive list of operations that may cause product damage are identied by NOTICE labels on the product and in this publication. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard. The warnings in this publication and on the product are, therefore, not all inclusive. You must not use this product in any manner different from that considered by this manual without rst satisfying yourself that you have considered all safety rules and precautions applicable to the operation of the product in the location of use, including site-specic rules and precautions applicable to the worksite. If a tool, procedure, work method or operating technique that is not specically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that the product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair procedures that you intend to use. The information, specications, and illustrations in this publication are on the basis of information that was available at the time that the publication was written. The specications, torques, pressures, measurements, adjustments, illustrations, and other items can change at any time. These changes can affect the service that is given to the product. Obtain the complete and most current information before you start any job. Caterpillar dealers have the most current information available.

When replacement parts are required for this product Caterpillar recommends using Caterpillar replacement parts or parts with equivalent specications including, but not limited to, physical dimensions, type, strength and material. Failure to heed this warning can lead to premature failures, product damage, personal injury or death. In the United States, the maintenance, replacement, or repair of the emission control devices and systems may be performed by any repair establishment or individual of the owner's choosing.

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3 Table of Contents

Table of Contents
Foreword ................................................................. 4

Engine Starting ..................................................... 74 Parking .................................................................. 75 Transportation Information .................................... 78 Towing Information ................................................ 80 Engine Starting (Alternate Methods) ..................... 83

Safety Section
Safety Messages .................................................... 6 Additional Messages ............................................. 12 General Hazard Information ................................. 14 Crushing Prevention and Cutting Prevention ........ 16 Burn Prevention .................................................... 17 Fire Prevention and Explosion Prevention ............ 17 Fire Extinguisher Location .................................... 20 Tire Information ..................................................... 21 Electrical Storm Injury Prevention ......................... 21 Before Starting Engine .......................................... 21 Visibility Information .............................................. 22 Restricted Visibility ................................................ 22 Engine Starting ..................................................... 23 Before Operation .................................................. 23 Operation .............................................................. 23 Engine Stopping ................................................... 24 Parking .................................................................. 24 Slope Operation .................................................... 24 Equipment Lowering with Engine Stopped ........... 25 Sound Information and Vibration Information ....... 25 Operator Station ................................................... 28

Maintenance Section
Tire Ination Information ....................................... 86 Lubricant Viscosities and Rell Capacities ........... 87 Maintenance Support ............................................ 93 Maintenance Interval Schedule ............................ 95

Reference Information Section


Reference Materials ............................................ 162

Index Section
Index ................................................................... 165

Product Information Section


General Information .............................................. 29 Identication Information ....................................... 33

Operation Section
Before Operation .................................................. 37 Machine Operation ............................................... 39

4 Foreword

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Foreword
Literature Information
This manual should be stored in the operator's compartment in the literature holder or seat back literature storage area. This manual contains safety information, operation instructions, transportation information, lubrication information and maintenance information. Some photographs or illustrations in this publication show details or attachments that can be different from your machine. Guards and covers might have been removed for illustrative purposes. Continuing improvement and advancement of product design might have caused changes to your machine which are not included in this publication. Read, study and keep this manual with the machine. Whenever a question arises regarding your machine, or this publication, please consult your Caterpillar dealer for the latest available information.

Maintenance
The maintenance section is a guide to equipment care. The Maintenance Interval Schedule (MIS) lists the items to be maintained at a specic service interval. Items without specic intervals are listed under the "When Required" service interval. The Maintenance Interval Schedule lists the page number for the step-by-step instructions required to accomplish the scheduled maintenance. Use the Maintenance Interval Schedule as an index or "one safe source" for all maintenance procedures.

Maintenance Intervals
Use the service hour meter to determine servicing intervals. Calendar intervals shown (daily, weekly, monthly, etc.) can be used instead of service hour meter intervals if they provide more convenient servicing schedules and approximate the indicated service hour meter reading. Recommended service should always be performed at the interval that occurs rst. Under extremely severe, dusty or wet operating conditions, more frequent lubrication than is specied in the maintenance intervals chart might be necessary. Perform service on items at multiples of the original requirement. For example, at every 500 service hours or 3 months, also service those items listed under every 250 service hours or monthly and every 10 service hours or daily.

Safety
The safety section lists basic safety precautions. In addition, this section identies the text and locations of warning signs and labels used on the machine. Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance and repair on this machine.

California Proposition 65 Warning


Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Battery posts, terminals and related accessories contain lead and lead compounds. Wash hands after handling.

Operation
The operation section is a reference for the new operator and a refresher for the experienced operator. This section includes a discussion of gauges, switches, machine controls, attachment controls, transportation and towing information. Photographs and illustrations guide the operator through correct procedures of checking, starting, operating and stopping the machine. Operating techniques outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the machine and its capabilities.

Certied Engine Maintenance


Proper maintenance and repair is essential to keep the engine and machine systems operating correctly. As the heavy duty off-road diesel engine owner, you are responsible for the performance of the required maintenance listed in the Owner Manual, Operation and Maintenance Manual, and Service Manual.

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5 Foreword

It is prohibited for any person engaged in the business of repairing, servicing, selling, leasing, or trading engines or machines to remove, alter, or render inoperative any emission related device or element of design installed on or in an engine or machine that is in compliance with the regulations (40 CFR Part 89). Certain elements of the machine and engine such as the exhaust system, fuel system, electrical system, intake air system and cooling system may be emission related and should not be altered unless approved by Caterpillar.

3. Check Character (character 9) 4. Machine Indicator Section (MIS) or Product Sequence Number (characters 10-17). These were previously referred to as the Serial Number. Machines and generator sets produced before First Quarter 2001 will maintain their 8 character PIN format. Components such as engines, transmissions, axles, etc. and work tools will continue to use an 8 character Serial Number (S/N).

Machine Capacity
Additional attachments or modications may exceed machine design capacity which can adversely affect performance characteristics. Included would be stability and system certications such as brakes, steering, and rollover protective structures (ROPS). Contact your Caterpillar dealer for further information.

Caterpillar Product Identication Number


Effective First Quarter 2001 the Caterpillar Product Identication Number (PIN) has changed from 8 to 17 characters. In an effort to provide uniform equipment identication, Caterpillar and other construction equipment manufacturers are moving to comply with the latest version of the product identication numbering standard. Non-road machine PINs are dened by ISO 10261. The new PIN format will apply to all Caterpillar machines and generator sets. The PIN plates and frame marking will display the 17 character PIN. The new format will look like the following:

Illustration 1

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Where: 1. Caterpillar's World Manufacturing Code (characters 1-3) 2. Machine Descriptor (characters 4-8)

6 Safety Section Safety Messages

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Safety Section
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Safety Messages
SMCS Code: 7000 There are several specic safety messages on this machine. The exact location of the hazards and the description of the hazards are reviewed in this section. Please become familiarized with all safety messages. Make sure that all of the safety messages are legible. Clean the safety messages or replace the safety messages if you cannot read the words. Replace the illustrations if the illustrations are not legible. When you clean the safety messages, use a cloth, water and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the safety messages. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the safety message. Loose adhesive will allow the safety message to fall. Replace any safety message that is damaged or missing. If a safety message is attached to a part that is replaced, install a safety message on the replacement part. Any Caterpillar dealer can provide new safety messages.

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7 Safety Section Safety Messages

Illustration 2 (1) Do Not Operate. (2) Pressurized System (3) Falling Hazard (4) Crushing Hazard (5) No Clearance (6) Parking Brake

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(7) Do Not Weld or Drill on the ROPS.

8 Safety Section Safety Messages

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Illustration 3 (3) Falling Hazard (5) No Clearance (8) Improper Connections of The Jump Start Cable (9) Seat belt (10) Product Link

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9 Safety Section Safety Messages

Do Not Operate (1)

Pressurized System (2)

Illustration 5

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This warning label is located on the back side of the access door for the radiator ller cap.

Illustration 4

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This warning label is located in the cab on the inside of the front door post.

Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve the pressure.

DO NOT OPERATE OR WORK ON THIS MACHINE UNLESS YOU HAVE READ AND UNDERSTAND THE INSTRUCTIONS AND WARNINGS IN THE OPERATION AND MAINTENANCE MANUALS. FAILURE TO FOLLOW THE INSTRUCTIONS OR HEED THE WARNINGS COULD RESULT IN INJURY OR DEATH. CONTACT ANY CATERPILLAR DEALER FOR REPLACEMENT MANUALS. PROPER CARE IS YOUR RESPONSIBILITY.

Falling Hazard (3)

Illustration 6

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This warning is located on each side of the machine.

Fall Hazard. Severe injury or death could occur from falling while servicing components on the machine at elevated positions. Use proper precautions and / or external access devices.

10 Safety Section Safety Messages

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Crushing Hazard (4)

Parking Brake (6)

Illustration 7

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Illustration 9

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This warning label is located on both sides of the machine at the articulation joint.

This warning is located near the articulation joint on the cover for the parking brake.

Connect the steering frame lock between the front and the rear frames before lifting, transporting, or servicing the machine in the articulation area. Disconnect the steering frame lock and secure the steering frame lock before resuming operation. Severe injury or death could occur.

Before you manually release the parking brake, be sure to stop the engine and block the wheels in order to prevent machine movement, which could result in personal injury. Before disassembling the brake, relieve the brake oil pressure by repeatedly applying the brakes until the brake oil pressure gauge indicates zero. Refer to Operation and Maintenance Manual, Parking Brake Manual Release for the proper procedure.

No Clearance (5)

Illustration 8

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This warning label is located on both sides of the machine at the articulation joint.

Stay back a safe distance. No clearance for a person in this area when the machine turns. Severe injury or death from crushing could occur.

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11 Safety Section Safety Messages

Do Not Weld or Drill on the ROPS (7)

Improper Connections of The Jump Start Cable (8)

Illustration 10

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Illustration 11

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This warning label is located on the outside of the cab on the left side below the window.

This warning label is located in the battery compartment.

Structural damage, an overturn, modication, alteration, or improper repair can impair this structure's protection capability thereby voiding this certication. Do not weld on or drill holes in the structure. Consult a Caterpillar dealer to determine this structure's limitations without voiding its certication. Rollover Protective Structure (ROPS) and Falling Object Protective Structure (FOPS) Certication The structure, when properly installed on a machine which is not altered to exceed the certication test mass meets, at the time of installation, criteria established by:SAE J396, SAE J1040 APRIL 88, ISO 3471 1986, ISO 3471 1994, SAE J231 JANUARY 81, and ISO 3449 1992 LEVEL II.

There is limited battery access. Jump starting at the battery, or improper jumper cable connections at the starter, can cause explosion resulting in personal injury. Do not jump start the machine at the battery. Use the remote starting receptacle or jump start to the positive battery post on the starter. If remote starting receptacle can not be used, jumper cables may be used at the starter. Always connect the positive (+) cable to positive (+) terminal of the starter and connect negative () cable from external source to engine block. Follow procedure from the Operation and Maintenance Manual.

12 Safety Section Additional Messages

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Seat belt (9)

Product Link (10)


This warning label is located in the cab.

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Illustration 12

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This warning label is located in the cab near the cup holder.

This machine is equipped with a Caterpillar Product Link communication device which must be deactivated within 12 m (40 ft) of a blast zone. Failure to do so could result in serious injury or death.

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A seat belt should be worn at all times during machine operation to prevent serious injury or death in the event of an accident or machine overturn. Failure to wear a seat belt during machine operation may result in serious injury or death.

Additional Messages
SMCS Code: 7000 There are several specic messages on this machine. The exact location of the messages and the description of the information are reviewed in this section. Please become familiar with all messages. Make sure that all of the messages are legible. Clean the messages or replace the messages if you cannot read the words. Replace the illustrations if the illustrations are not legible. When you clean the messages, use a cloth, water, and soap. Do not use solvent, gasoline, or other harsh chemicals to clean the messages. Solvents, gasoline, or harsh chemicals could loosen the adhesive that secures the messages. Loose adhesive will allow the messages to fall. Replace any message that is damaged, or missing. If a message is attached to a part that is replaced, install a message on the replacement part. Any Caterpillar dealer can provide new messages.

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13 Safety Section Additional Messages

Illustration 13

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Air Conditioner (1)

Data Privacy (2)

Illustration 14

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Illustration 15

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This lm is located in the cab on the back right post.

This message is located on the window inside the cab.

14 Safety Section General Hazard Information

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The Product Link System is a satellite communication device that transmits information regarding the machine back to Caterpillar and Caterpillar dealers and customers. All logged events and diagnostic codes that are available to the Caterpillar Electronic Technician (ET) on the CAT data link can be sent to the satellite. Information can also be sent to the Product Link System. The information is used to improve Caterpillar products and Caterpillar services. Refer to Operation and Maintenance Manual, Product Link for more information.
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General Hazard Information


SMCS Code: 7000

Illustration 17

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Wear a hard hat, protective glasses, and other protective equipment, as required. Do not wear loose clothing or jewelry that can snag on controls or on other parts of the equipment. Make sure that all protective guards and all covers are secured in place on the equipment. Keep the equipment free from foreign material. Remove debris, oil, tools, and other items from the deck, from walkways, and from steps. Secure all loose items such as lunch boxes, tools, and other items that are not a part of the equipment.

Illustration 16

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Attach a Do Not Operate warning tag or a similar warning tag to the start switch or to the controls before you service the equipment or before you repair the equipment. These warning tags (Special Instruction, SEHS7332) are available from your Caterpillar dealer. Know the width of your equipment in order to maintain proper clearance when you operate the equipment near fences or near boundary obstacles. Be aware of high voltage power lines and power cables that are buried. If the machine comes in contact with these hazards, serious injury or death may occur from electrocution.

Know the appropriate work site hand signals and the personnel that are authorized to give the hand signals. Accept hand signals from one person only. Do not smoke when you service an air conditioner. Also, do not smoke if refrigerant gas may be present. Inhaling the fumes that are released from a ame that contacts air conditioner refrigerant can cause bodily harm or death. Inhaling gas from air conditioner refrigerant through a lighted cigarette can cause bodily harm or death. Never put maintenance uids into glass containers. Drain all liquids into a suitable container. Obey all local regulations for the disposal of liquids. Use all cleaning solutions with care. Report all necessary repairs. Do not allow unauthorized personnel on the equipment. Unless you are instructed otherwise, perform maintenance with the equipment in the servicing position. Refer to Operation and Maintenance Manual for the procedure for placing the equipment in the servicing position.

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15 Safety Section General Hazard Information

When you perform maintenance above ground level use appropriate devices such as ladders or man lift machines. If equipped, use the machine anchorage points and use approved fall arrest harnesses and lanyards.

Pressurized Air and Water


Pressurized air and/or water can cause debris and/or hot water to be blown out. This could result in personal injury. When pressurized air and/or pressurized water is used for cleaning, wear protective clothing, protective shoes, and eye protection. Eye protection includes goggles or a protective face shield. The maximum air pressure for cleaning purposes must be reduced to 205 kPa (30 psi) when the nozzle is deadheaded and the nozzle is used with an effective chip deector and personal protective equipment. The maximum water pressure for cleaning purposes must be below 275 kPa (40 psi).

Illustration 18

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Always use a board or cardboard when you check for a leak. Leaking uid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If uid is injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury.

Trapped Pressure
Pressure can be trapped in a hydraulic system. Releasing trapped pressure can cause sudden machine movement or attachment movement. Use caution if you disconnect hydraulic lines or ttings. High pressure oil that is released can cause a hose to whip. High pressure oil that is released can cause oil to spray. Fluid penetration can cause serious injury and possible death.

Containing Fluid Spillage


Care must be taken in order to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the equipment. Prepare to collect the uid with suitable containers before opening any compartment or disassembling any component that contains uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for the following items:

Fluid Penetration
Pressure can be trapped in the hydraulic circuit long after the engine has been stopped. The pressure can cause hydraulic uid or items such as pipe plugs to escape rapidly if the pressure is not relieved correctly. Do not remove any hydraulic components or parts until pressure has been relieved or personal injury may occur. Do not disassemble any hydraulic components or parts until pressure has been relieved or personal injury may occur. Refer to the Service Manual for any procedures that are required to relieve the hydraulic pressure.

Tools that are suitable for collecting uids and


equipment that is suitable for collecting uids

Tools that are suitable for containing uids and


equipment that is suitable for containing uids Obey all local regulations for the disposal of liquids.

16 Safety Section Crushing Prevention and Cutting Prevention

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Asbestos Information

Comply with applicable rules and regulations

for the work place. In the United States, use Occupational Safety and Health Administration (OSHA) requirements. These OSHA requirements can be found in 29 CFR 1910.1001. of asbestos.

Obey environmental regulations for the disposal Stay away from areas that might have asbestos
particles in the air.

Dispose of Waste Properly


Illustration 19
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Caterpillar equipment and replacement parts that are shipped from Caterpillar are asbestos free. Caterpillar recommends the use of only genuine Caterpillar replacement parts. Use the following guidelines when you handle any replacement parts that contain asbestos or when you handle asbestos debris. Use caution. Avoid inhaling dust that might be generated when you handle components that contain asbestos bers. Inhaling this dust can be hazardous to your health. The components that may contain asbestos bers are brake pads, brake bands, lining material, clutch plates, and some gaskets. The asbestos that is used in these components is usually bound in a resin or sealed in some way. Normal handling is not hazardous unless airborne dust that contains asbestos is generated. If dust that may contain asbestos is present, there are several guidelines that should be followed:

Illustration 20

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Improperly disposing of waste can threaten the environment. Potentially harmful uids should be disposed of according to local regulations. Always use leakproof containers when you drain uids. Do not pour waste onto the ground, down a drain, or into any source of water.
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Never use compressed air for cleaning. Avoid brushing materials that contain asbestos. Avoid grinding materials that contain asbestos. Use a wet method in order to clean up asbestos
materials.

Crushing Prevention and Cutting Prevention


SMCS Code: 7000 Support the equipment properly before you perform any work or maintenance beneath that equipment. Do not depend on the hydraulic cylinders to hold up the equipment. Equipment can fall if a control is moved, or if a hydraulic line breaks. Do not work beneath the cab of the machine unless the cab is properly supported. Unless you are instructed otherwise, never attempt adjustments while the machine is moving or while the engine is running.

A vacuum cleaner that is equipped with a high

efciency particulate air lter (HEPA) can also be used. jobs.

Use exhaust ventilation on permanent machining Wear an approved respirator if there is no other
way to control the dust.

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17 Safety Section Burn Prevention

Never jump across the starter solenoid terminals in order to start the engine. Unexpected machine movement could result. Whenever there are equipment control linkages the clearance in the linkage area will change with the movement of the equipment or the machine. Stay clear of areas that may have a sudden change in clearance with machine movement or equipment movement. Stay clear of all rotating and moving parts. If it is necessary to remove guards in order to perform maintenance, always install the guards after the maintenance is performed. Keep objects away from moving fan blades. The fan blade will throw objects or cut objects. Do not use a kinked wire cable or a frayed wire cable. Wear gloves when you handle wire cable. When you strike a retainer pin with force, the retainer pin can y out. The loose retainer pin can injure personnel. Make sure that the area is clear of people when you strike a retainer pin. To avoid injury to your eyes, wear protective glasses when you strike a retainer pin. Chips or other debris can y off an object when you strike the object. Make sure that no one can be injured by ying debris before striking any object.
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Ensure that the ller cap is cool before removing the ller cap. The ller cap must be cool enough to touch with a bare hand. Remove the ller cap slowly in order to relieve pressure. Cooling system conditioner contains alkali. Alkali can cause personal injury. Do not allow alkali to contact the skin, the eyes, or the mouth.

Oils
Hot oil and hot components can cause personal injury. Do not allow hot oil to contact the skin. Also, do not allow hot components to contact the skin. Remove the hydraulic tank ller cap only after the engine has been stopped. The ller cap must be cool enough to touch with a bare hand. Follow the standard procedure in this manual in order to remove the hydraulic tank ller cap.

Batteries
Electrolyte is an acid. Electrolyte can cause personal injury. Do not allow electrolyte to contact the skin or the eyes. Always wear protective glasses for servicing batteries. Wash hands after touching the batteries and connectors. Use of gloves is recommended.
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Fire Prevention and Explosion Prevention


SMCS Code: 7000

Burn Prevention
SMCS Code: 7000 Do not touch any part of an operating engine. Allow the engine to cool before any maintenance is performed on the engine. Relieve all pressure in the air system, in the oil system, in the lubrication system, in the fuel system, or in the cooling system before any lines, ttings or related items are disconnected.

Coolant
When the engine is at operating temperature, the engine coolant is hot. The coolant is also under pressure. The radiator and all lines to the heaters or to the engine contain hot coolant. Any contact with hot coolant or with steam can cause severe burns. Allow cooling system components to cool before the cooling system is drained. Check the coolant level only after the engine has been stopped.
Illustration 21
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General
All fuels, most lubricants, and some coolant mixtures are ammable. To minimize the risk of re or explosion, Caterpillar recommends the following actions.

18 Safety Section Fire Prevention and Explosion Prevention

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Always perform a Walk-Around Inspection, which may help you identify a re hazard. Do not operate a machine when a re hazard exists. Contact your Caterpillar dealer for service. Understand the use of the primary exit and alternative exit on the machine. Refer to Operation and Maintenance Manual, Alternative Exit. Do not operate a machine with a uid leak. Repair leaks and clean up uids before resuming machine operation. Fluids that are leaking or spilled onto hot surfaces or onto electrical components can cause a re. A re may cause personal injury or death. Remove ammable material such as leaves, twigs, papers, trash, etc. These items may accumulate in the engine compartment or around other hot areas and hot parts on the machine. Keep the access doors to major machine compartments closed and access doors in working condition in order to permit the use of re suppression equipment, in case a re should occur. Clean all accumulations of ammable materials such as fuel, oil and debris from the machine. Do not operate the machine near any ame. Keep shields in place. Exhaust shields (if equipped) protect hot exhaust components from oil spray or fuel spray in case of a break in a line, in a hose, or in a seal. Exhaust shields must be installed correctly. Do not weld or ame cut on tanks or lines that contain ammable uids or ammable material. Empty and purge the lines and tanks. Then clean the lines and tanks with a nonammable solvent prior to welding or ame cutting. Ensure that the components are properly grounded in order to avoid unwanted arcs. Dust that is generated from repairing nonmetallic hoods or fenders may be ammable and/or explosive. Repair such components in a well ventilated area away from open ames or sparks. Use suitable Personal Protection Equipment (PPE). Inspect all lines and hoses for wear or deterioration. Replace damaged lines and hoses. The lines and the hoses should have adequate support and secure clamps. Tighten all connections to the recommended torque. Damage to the protective cover or insulation may provide fuel for res. Store fuels and lubricants in properly marked containers away from unauthorized personnel. Store oily rags and ammable materials in protective containers. Do not smoke in areas that are used for storing ammable materials.
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Illustration 22

Use caution when you are fueling a machine. Do not smoke while you are fueling a machine. Do not fuel a machine near open ames or sparks. Always stop the engine before fueling. Fill the fuel tank outdoors. Properly clean areas of spillage. Follow practices for safe fueling that are described in the Operation section of the Operation and Maintenance Manual section and follow local regulations. Never store ammable uids in the operator compartment of the machine.

Battery and Battery Cables

Illustration 23

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19 Safety Section Fire Prevention and Explosion Prevention

Caterpillar recommends the following in order to minimize the risk of re or an explosion related to the battery. Do not operate a machine if battery cables or related parts show signs of wear or damage. Contact your Caterpillar dealer for service. Follow safe procedures for engine starting with jump start cables. Improper jumper cable connections can cause an explosion that may result in injury. Refer to Operation and Maintenance Manual, Engine Starting with Jump Start Cables for specic instructions. Do not charge a frozen battery. This may cause an explosion. Gases from a battery can explode. Keep any open ames or sparks away from the top of a battery. Do not smoke in battery charging areas. Never check the battery charge by placing a metal object across the terminal posts. Use a voltmeter in order to check the battery charge. Daily inspect battery cables that are in areas that are visible. Inspect cables, clips, straps, and other restraints for damage. Replace any damaged parts. Check for signs of the following, which can occur over time due to use and environmental factors:

An exposed wire on the ground cable between the battery and the disconnect switch may cause the disconnect switch to be bypassed if the exposed area comes into contact with a grounded surface. This may result in an unsafe condition for servicing the machine. Repair components or replace components before servicing the machine.

Fire on a machine can result in personal injury or death. Exposed battery cables that come into contact with a grounded connection can result in res. Replace cables and related parts that show signs of wear or damage. Contact your Caterpillar dealer.

Wiring
Check electrical wires daily. If any of the following conditions exist, replace parts before you operate the machine.

Fraying Signs of abrasion or wear Cracking Discoloration Cuts on insulation Other damage
Make sure that all clamps, guards, clips, and straps are reinstalled correctly. This will help to prevent vibration, rubbing against other parts, and excessive heat during machine operation. Attaching electrical wiring to hoses and tubes that contain ammable uids or combustible uids should be avoided. Consult your Caterpillar dealer for repair or for replacement parts. Keep wiring and electrical connections free of debris.

Fraying Abrasion Cracking Discoloration Cuts on the insulation of the cable Fouling Corroded terminals, damaged terminals, and loose
terminals Replace damaged battery cable(s) and replace any related parts. Eliminate any fouling, which may have caused insulation failure or related component damage or wear. Ensure that all components are reinstalled correctly. An exposed wire on the battery cable may cause a short to ground if the exposed area comes into contact with a grounded surface. A battery cable short produces heat from the battery current, which may be a re hazard.

Lines, Tubes and Hoses


Do not bend high pressure lines. Do not strike high pressure lines. Do not install any lines that are bent or damaged. Use the appropriate backup wrenches in order to tighten all connections to the recommended torque.

20 Safety Section Fire Extinguisher Location

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Ether
Ether (if equipped) is commonly used in cold weather applications. Ether is ammable and poisonous. Follow the correct cold engine starting procedures. Refer to the section in the Operation and Maintenance Manual with the label Engine Starting. Do not spray ether manually into an engine if the machine is equipped with a thermal starting aid for cold weather starting. Use ether in well ventilated areas. Do not smoke while you are replacing an ether cylinder or while you are using an ether spray. Do not store ether cylinders in living areas or in the operator compartment of a machine. Do not store ether cylinders in direct sunlight or in temperatures above 49 C (120.2 F). Keep ether cylinders away from open ames or sparks. Dispose of used ether cylinders properly. Do not puncture an ether cylinder. Keep ether cylinders away from unauthorized personnel.

Illustration 24

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Check lines, tubes and hoses carefully. Wear Personal Protection Equipment (PPE) in order to check for leaks. Always use a board or cardboard when you check for a leak. Leaking uid that is under pressure can penetrate body tissue. Fluid penetration can cause serious injury and possible death. A pin hole leak can cause severe injury. If uid is injected into your skin, you must get treatment immediately. Seek treatment from a doctor that is familiar with this type of injury. Replace the affected parts if any of the following conditions are present:

Fire Extinguisher
As an additional safety measure, keep a re extinguisher on the machine. Be familiar with the operation of the re extinguisher. Inspect the re extinguisher and service the re extinguisher regularly. Follow the recommendations on the instruction plate. Consider installation of an aftermarket Fire Suppression System, if the application and working conditions warrant the installation.
i00977136

End ttings are damaged or leaking. Outer coverings are chafed or cut. Wires are exposed. Outer coverings are swelling or ballooning. Flexible parts of the hoses are kinked. Outer covers have exposed embedded armoring. End ttings are displaced.
Make sure that all clamps, guards, and heat shields are installed correctly. During machine operation, this will help to prevent vibration, rubbing against other parts, excessive heat, and failure of lines, tubes and hoses. Do not operate a machine when a re hazard exists. Repair any lines that are corroded, loose or damaged. Leaks may provide fuel for res. Consult your Caterpillar dealer for repair or for replacement parts. Use genuine Caterpillar parts or the equivalent, for capabilities of both the pressure limit and temperature limit.

Fire Extinguisher Location


SMCS Code: 7000 Make sure that a re extinguisher is on the machine. Make sure that you are familiar with the operation of the re extinguisher. Inspect the re extinguisher and service the re extinguisher on a regular basis. Obey the recommendations on the instruction plate. The recommended location for mounting the re extinguisher is on the platform behind the cab.

SEBU8480

21 Safety Section Tire Information

If the re extinguisher is mounted on the ROPS, strap the mounting plate to a leg of the ROPS. If the weight of the re extinguisher is more than 4.5 kg (10 lb), mount the re extinguisher as low as possible on one leg. Do not mount the re extinguisher on the upper one-third area of the leg. Note: Do not weld the ROPS in order to install the re extinguisher. Also, do not drill holes in the ROPS in order to mount the re extinguisher on the ROPS.
i01557411

Nitrogen inated tires reduce the potential of a tire explosion because nitrogen does not aid combustion. Nitrogen helps to prevent oxidation of the rubber, deterioration of rubber, and corrosion of rim components. To avoid overination, proper nitrogen ination equipment and training in the usage of the equipment are necessary. A tire blowout or a rim failure can result from improper equipment or from misused equipment. When you inate a tire, stand behind the tread and use a self-attaching chuck. Servicing tires and rims can be dangerous. Only trained personnel that use proper tools and proper procedures should perform this maintenance. If correct procedures are not used for servicing tires and rims, the assemblies could burst with explosive force. This explosive force can cause serious personal injury or death. Carefully obey the specic instructions from your tire dealer.
i01122596

Tire Information
SMCS Code: 7000 Explosions of air inated tires have resulted from heat-induced gas combustion inside the tires. Explosions can be caused by heat that is generated by welding, by heating rim components, by external re, or by excessive use of brakes. A tire explosion is much more violent than a blowout. The explosion can propel the tire, the rim components, and the axle components as far as 500 m (1500 ft) or more from the machine. Both the force of the explosion and the ying debris can cause property damage, personal injury, or death.

Electrical Storm Injury Prevention


SMCS Code: 7000 When lightning is striking in the vicinity of the machine, the operator should never attempt the following procedures:

Mount the machine. Dismount the machine.


If you are in the operator's station during an electrical storm, stay in the operator's station. If you are on the ground during an electrical storm, stay away from the vicinity of the machine.
Illustration 25 (A) At least 15 m (50 ft) (B) At least 500 m (1500 ft)
g00337832 i00934890

Do not approach a warm tire. Maintain a minimum distance, as shown. Stay outside the shaded area in Illustration 25. Do not use water or calcium as a ballast for the tires. Dry nitrogen gas is recommended for ination of tires. If the tires were originally inated with air, nitrogen is still preferred for adjusting the pressure. Nitrogen mixes properly with air.

Before Starting Engine


SMCS Code: 1000; 7000 The steering frame lock must be in the unlocked position in order to steer the machine. Start the engine only from the operator compartment. Never short across the starter terminals or across the batteries. Shorting could bypass the engine neutral start system. Shorting could also damage the electrical system.

22 Safety Section Visibility Information

SEBU8480

Inspect the condition of the seat belt and the condition of mounting hardware. Replace any parts that are worn or damaged. Regardless of the appearance, replace the seat belt after three years of use. Do not use a seat belt extension on a retractable seat belt. Adjust the seat so that there is full pedal travel while the operator's back is against the back of the seat. Make sure that the machine is equipped with a lighting system that is adequate for the job conditions. Make sure that all lights are working properly. Before you start the engine or before you move the machine, make sure that no one is on the machine, underneath the machine, or around the machine. Make sure that there are no personnel in the area.
i03162317

Operator training Warning symbols or warning signs on machines


or on vehicles

A system of communication Communication between workers and operators


prior to approaching the machine Modications of the machine conguration by the user that result in a restriction of visibility shall be evaluated.
i03297985

Restricted Visibility
SMCS Code: 7000 The size and the conguration of this machine may result in areas that can not be seen when the operator is seated. Illustration 26 provides an approximate visual indication of areas of signicant restricted visibility. Illustration 26 indicates restricted visibility areas at ground level inside a radius of 12 m (40 ft) from the operator on a machine without the use of optional visual aids. This illustration does not provide areas of restricted visibility for distances outside a radius of 12 m (40 ft). This machine may be equipped with optional visual aids that may provide visibility to some of the restricted visibility areas. Refer to this Operation and Maintenance Manual, Mirror for more information on additional visibility. If your machine is equipped with cameras, refer to this Operation and Maintenance Manual, Camera for more information on additional visibility. For areas that are not covered by the optional visual aids, the job site organization must be utilized to minimize hazards of this restricted visibility. For more information regarding job site organization refer to Operation and Maintenance Manual, Visibility Information.

Visibility Information
SMCS Code: 7000 Before you start the machine, perform a walk-around inspection in order to ensure that there are no hazards around the machine. While the machine is in operation, constantly survey the area around the machine in order to identify potential hazards as hazards become visible around the machine. Your machine may be equipped with visual aids. Some examples of visual aids are Closed Circuit Television (CCTV) and mirrors. Before operating the machine, ensure that the visual aids are in proper working condition and that the visual aids are clean. Adjust the visual aids using the procedures that are located in this Operation and Maintenance Manual. If equipped, the Work Area Vision System shall be adjusted according to Operation and Maintenance Manual, SEBU8157, Work Area Vision System. It may not be possible to provide direct visibility on large machines to all areas around the machine. Appropriate job site organization is required in order to minimize hazards that are caused by restricted visibility. Job site organization is a collection of rules and procedures that coordinates machines and people that work together in the same area. Examples of job site organization include the following:

Safety instructions Controlled patterns of machine movement and


vehicle movement

Workers that direct trafc to move when it is safe Restricted areas

SEBU8480

23 Safety Section Engine Starting

Check for the presence of personnel. Ensure that all personnel are clear of the machine.
i01943255

Before Operation
SMCS Code: 7000 Make sure that there are no personnel on the machine or in the area around the machine. Clear all obstacles from the path of the machine. Beware of hazards such as wires, ditches, etc. Make sure that all windows are clean. Secure the doors and the windows in the open position or in the shut position. Adjust the rear view mirrors (if equipped) for the best vision of the area near the machine. Ensure that the horn, the backup alarm (if equipped), and all other warning devices are working properly. Fasten the seat belt securely.
Illustration 26 Top view of the machine
g01660074 i03690422

Operation
SMCS Code: 7000 Only operate the machine while you are sitting in a seat. The seat belt must be fastened while you operate the machine. Only operate the controls while the engine is running. While you operate the machine slowly in an open area, check for proper operation of all controls and all protective devices. Before you move the machine, make sure that no one will be endangered. Do not allow riders on the machine unless the machine has an additional seat with a seat belt. Never use the work tool for a work platform. Note any needed repairs during machine operation. Report any needed repairs. Carry work tools at approximately 40 cm (15 inches) above ground level. Do not go close to the edge of a cliff, an excavation, or an overhang.

Note: The shaded areas indicate the approximate location of areas with signicant restricted visibility.
i03690423

Engine Starting
SMCS Code: 1000; 7000 If a warning tag is attached to the engine start switch or to the controls, do not start the engine and do not move any controls. Move all hydraulic controls to the HOLD position before you start the engine. Move the transmission control to the NEUTRAL position. Engage the parking brake. Diesel engine exhaust contains products of combustion which can be harmful to your health. Always operate the engine in a well ventilated area. If you are in an enclosed area, vent the exhaust to the outside. Briey sound the horn before you start the engine.

24 Safety Section Engine Stopping

SEBU8480

Avoid operating the machine across the slope. When possible, operate the machine up the slopes and down the slopes. If the machine begins to sideslip on a downgrade, immediately remove the load and turn the machine downhill. Avoid any conditions that can lead to tipping the machine. The machine can tip when you work on hills, on banks and on slopes. Also, the machine can tip when you cross ditches, ridges or other unexpected obstructions. Maintain control of the machine. Do not overload the machine beyond the machine capacity. Never straddle a wire cable. Never allow other personnel to straddle a wire cable. Know the maximum dimensions of your machine. Always keep the Rollover Protective Structure (ROPS) installed during machine operation.
i02624835

Turn the battery disconnect switch to the OFF position. If the machine will not be operated for an extended period of time, remove the key in order to avoid battery discharge that may be caused by a battery short circuit, by the current draw via certain components, or by vandalism.
i03745198

Slope Operation
SMCS Code: 7000 Machines that are operating safely in various applications depend on these criteria: the machine model, conguration, machine maintenance, operating speed of the machine, conditions of the terrain, uid levels, and tire ination pressures. The most important criteria are the skill and judgment of the operator. A well trained operator that follows the instructions in the Operation and Maintenance Manual has the greatest impact on stability. Operator training provides a person with the following abilities: observation of working and environmental conditions, feel for the machine, identication of potential hazards, and operating the machine safely by making appropriate decisions. When you work on side hills and when you work on slopes, consider the following important points: Speed of travel At higher speeds, forces of inertia tend to make the machine less stable. Roughness of terrain or surface The machine may be less stable with uneven terrain. Direction of travel Avoid operating the machine across the slope. When possible, operate the machine up the slopes and operate the machine down the slopes. Place the heaviest end of the machine uphill when you are working on an incline. Mounted equipment Balance of the machine may be impeded by the following components: equipment that is mounted on the machine, machine conguration, weights, and counterweights. Nature of surface Ground that has been newly lled with earth may collapse from the weight of the machine. Surface material Rocks and moisture of the surface material may drastically affect the machine's traction and machine's stability. Rocky surfaces may promote side slipping of the machine.

Engine Stopping
SMCS Code: 1000; 7000 Do not stop the engine immediately after the machine has been operated under load. This can cause overheating and accelerated wear of engine components. After the machine is parked and the parking brake is engaged, allow the engine to run for two minutes before shutdown. This allows hot areas of the engine to cool gradually.
i01353455

Parking
SMCS Code: 7000 Park the machine on a level surface. If you must park the machine on a downgrade, block the tires. Apply the service brake in order to stop the machine. Move the transmission control to the NEUTRAL position. Engage the parking brake. Lower all work tools to the ground. Activate any control locks. Stop the engine. Turn the engine start switch to the OFF position and remove the key.

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25 Safety Section Equipment Lowering with Engine Stopped

Slippage due to excessive loads This may cause downhill tracks or downhill tires to dig into the ground, which will increase the angle of the machine. Width of tracks or tires Narrower tracks or narrower tires further increase the digging into the ground which causes the machine to be less stable. Implements attached to the drawbar This may decrease the weight on the uphill tracks. This may also decrease the weight on the uphill tires. The decreased weight will cause the machine to be less stable. Height of the working load of the machine When the working loads are in higher positions, the stability of the machine is reduced. Operated equipment Be aware of performance features of the equipment in operation and the effects on machine stability. Operating techniques Keep all attachments or pulled loads low to the ground for optimum stability. Machine systems have limitations on slopes Slopes can affect the proper function and operation of the various machine systems. These machine systems are needed for machine control. Note: Safe operation on steep slopes may require special machine maintenance. Excellent skill of the operator and proper equipment for specic applications are also required. Consult the Operation and Maintenance Manual sections for the proper uid level requirements and intended machine use.
i01329161

i03699940

Sound Information and Vibration Information


SMCS Code: 7000

Sound Level Information


The operator Equivalent Sound Pressure Level (Leq) is 75 dB(A) when ANSI/SAE J1166 FEB 2008 is used to measure the value for an enclosed cab. This is a work cycle sound exposure level. The cab was properly installed and maintained. The test was conducted with the cab doors and the cab windows closed. Hearing protection may be needed when the machine is operated with an open operator station for extended periods or in a noisy environment. Hearing protection may be needed when the machine is operated with a cab that is not properly maintained or when the doors and windows are open for extended periods or in a noisy environment. The average exterior sound pressure level is 81 dB(A) when the SAE J88FEB 2006 - Constant Speed Moving Test procedure is used to measure the value for the standard machine. The measurement was conducted under the following conditions: distance of 15 m (49.2 ft) and the machine moving forward in an intermediate gear ratio.

Equipment Lowering with Engine Stopped


SMCS Code: 7000 Before lowering any equipment with the engine stopped, clear the area around the equipment of all personnel. The procedure to use will vary with the type of equipment to be lowered. Keep in mind most systems use a high pressure uid or air to raise or lower equipment. The procedure will cause high pressure air, hydraulic, or some other media to be released in order to lower the equipment. Wear appropriate personal protective equipment and follow the established procedure in the Operation and Maintenance Manual, Equipment Lowering with Engine Stopped in the Operation Section of the manual.

Sound Level Information for Machines in European Union Countries and in Countries that Adopt the EU Directives
The dynamic operator sound pressure level is 72 dB(A) when ISO 6396:2008 is used to measure the value for an enclosed cab. The cab was properly installed and maintained. The test was conducted with the cab doors and the cab windows closed.

The European Union Physical Agents (Vibration) Directive 2002/44/EC


Vibration Data for Wheel Loaders
Information Concerning Hand/Arm Vibration Level When the machine is operated according to the intended use, the hand/arm vibration of this machine is below 2.5 meter per second squared.

26 Safety Section Sound Information and Vibration Information

SEBU8480

Information Concerning Whole Body Vibration Level This section provides vibration data and a method for estimating the vibration level for wheel loaders. Note: Vibration levels are inuenced by many different parameters. Many items are listed below.

Operator training, behavior, mode, and stress Job site organization, preparation, environment,
weather, and material

Machine type, quality of the seat, quality of the

suspension system, attachments, and condition of the equipment

It is not possible to get precise vibration levels for this machine. The expected vibration levels can be estimated with the information in Table 1 in order to calculate the daily vibration exposure. A simple evaluation of the machine application can be used. Estimate the vibration levels for the three vibration directions. For typical operating conditions, use the average vibration levels as the estimated level. With an experienced operator and smooth terrain, subtract the Scenario Factors from the average vibration level in order to obtain the estimated vibration level. For aggressive operations and severe terrain, add the Scenario Factors to the average vibration level in order to obtain the estimated vibration level. Note: All vibration levels are in meter per second squared.
Table 1

ISO Reference Table A - Equivalent vibration levels of whole body vibration emission for earthmoving equipment. Machine Type Typical Operating Activity load and carry motion Wheel Loader mining application(1) transfer(2) V-shape
(1) (2) (3)

Vibration Levels X axis 0,84 1,27 0,76 0,99 Y axis 0,81 0,97 0,91 0,84 Z axis 0,52 0,81 0,49 0,54 X axis 0,23 0,47 0,33 0,29

Scenario Factors Y axis 0,20 0,31 0,35 0,32 Z axis 0,14 0,47 0,17 0,14

motion(3)

Loading at the face Travel at high speed on the job site or on public roads Loading a truck in short cycles

SEBU8480

27 Safety Section Sound Information and Vibration Information

Note: Refer to ISO/TR 25398 Mechanical Vibration Guideline for the assessment of exposure to whole body vibration of ride on operated earthmoving machines for more information about vibration. This publication uses data that is measured by international institutes, organizations and manufacturers. This document provides information about the whole body exposure of operators of earthmoving equipment. Refer to Operation and Maintenance Manual, SEBU8257, The European Union Physical Agents (Vibration) Directive 2002/44/EC for more information about machine vibration levels. The Caterpillar suspension seat meets the criteria of ISO 7096. This represents vertical vibration level under severe operating conditions. This seat is tested with the input spectral class EM3. The seat has a transmissibility factor of SEAT<1.0. The whole body vibration level of the machine varies. There is a range of values. The low value is 0.5 meter per second squared. The machine meets the short term level for the design of the seat in ISO 7096. The value is 1.13 meter per second squared for this machine. Guidelines for Reducing Vibration Levels on Earthmoving Equipment Properly adjust machines. Properly maintain machines. Operate machines smoothly. Maintain the conditions of the terrain. The following guidelines can help reduce the whole body vibration level: 1. Use the right type and size of machine, equipment, and attachments. 2. Maintain machines according to the manufacturer's recommendations. a. Tire pressures b. Brake and steering systems c. Controls, hydraulic system and linkages 3. Keep the terrain in good condition. a. Remove any large rocks or obstacles. b. Fill any ditches and holes. c. Provide machines and schedule time in order to maintain the conditions of the terrain. 4. Use a seat that meets ISO 7096. Keep the seat maintained and adjusted. a. Adjust the seat and suspension for the weight and the size of the operator.

b. Inspect and maintain the seat suspension and adjustment mechanisms. 5. Perform the following operations smoothly. a. Steer b. Brake c. Accelerate. d. Shift the gears. 6. Move the attachments smoothly. 7. Adjust the machine speed and the route in order to minimize the vibration level. a. Drive around obstacles and rough terrain. b. Slow down when it is necessary to go over rough terrain. 8. Minimize vibrations for a long work cycle or a long travel distance. a. Use machines that are equipped with suspension systems. b. Use the ride control system on wheel loaders. c. If no ride control system is available, reduce speed in order to prevent bounce. d. Haul the machines between workplaces. 9. Less operator comfort may be caused by other risk factors. The following guidelines can be effective in order to provide better operator comfort: a. Adjust the seat and adjust the controls in order to achieve good posture. b. Adjust the mirrors in order to minimize twisted posture. c. Provide breaks in order to reduce long periods of sitting. d. Avoid jumping from the cab. e. Minimize repeated handling of loads and lifting of loads. f. Minimize any shocks and impacts during sports and leisure activities.

28 Safety Section Operator Station

SEBU8480

Sources
The vibration information and calculation procedure is based on ISO/TR 25398 Mechanical Vibration - Guideline for the assessment of exposure to whole body vibration of ride on operated earthmoving machines. Harmonized data is measured by international institutes, organizations and manufacturers. This literature provides information about assessing the whole body vibration exposure of operators of earthmoving equipment. The method is based on measured vibration emission under real working conditions for all machines. You should check the original directive. This document summarizes part of the content of the applicable law. This document is not meant to substitute the original sources. Other parts of these documents are based on information from the United Kingdom Health and Safety Executive. Refer to Operation and Maintenance Manual, SEBU8257, The European Union Physical Agents (Vibration) Directive 2002/44/EC for more information about vibration. Consult your local Caterpillar dealer for more information about machine features that minimize vibration levels. Consult your local Caterpillar dealer about safe machine operation. Use the following web site in order to nd your local dealer: Caterpillar, Inc. www.cat.com
i03634321

Operator Station
SMCS Code: 7000 Any modications to the inside of the operator station should not project into the operator space or into the space for the companion seat (if equipped). The addition of a radio, re extinguisher, and other equipment must be installed so that the dened operator space and the space for the companion seat (if equipped) is maintained. Any item that is brought into the cab should not project into the dened operator space or the space for the companion seat (if equipped). A lunch box or other loose items must be secured. Objects must not pose an impact hazard in rough terrain or in the event of a rollover.

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29 Product Information Section General Information

Product Information Section General Information


i03648672

i02217425

Bucket Rated Load


SMCS Code: 6700

Specications
SMCS Code: 7000

Failure to comply to the rated load can cause possible personal injury or attachment damage. Review the rated load of a particular attachment before performing any operation. Make adjustments to the rated load as necessary. Note: Rated loads should be used as a guide. Different work tools and poor ground conditions have effects on rated loads. The operator is responsible for being aware of these effects. Rated loads are based upon a standard machine with the following conditions:

Intended Use
This machine is classied as a Wheel Loader as described in ISO 6165:2001. This machine normally has a front mounted bucket or another work tool for the principal intended functions of digging, loading, lifting, carrying, and moving material such as earth, crushed rock or gravel. Additional work tools allow this machine to perform other specic tasks.

Proper lubricants Full fuel tank Enclosed ROPS 80 kg (176 lb) operator 35/65-33 or equivalent tires
Consult your Caterpillar dealer about the rated load for a specic work tool. The rated operating load is dened by the SAE standard J818 (May 1987) and by the ISO 5998 (1986) as 50 percent of the full turn static tipping load. The dump clearance and the reach are given for each bucket at maximum lift height and at a 45 degree dump angle. Clearance is measured from the ground to the bucket edge when the bucket is in the full DUMP position. The reach is measured from the front tire to the bucket edge.

Application/Conguration Restrictions
Refer to Machine Data below for information about maximum machine weight. Lift arm height restrictions will be found in the Operation and Maintenance Manual for the appropriate work tool. The maximum fore and aft slope for proper lubrication is 25 degrees continuous and 35 degrees intermittent. This machine is approved for use in environments with no explosive gases.

Machine Data
This machine is equipped with a C-18 Engine. Basic machine specications are listed below.
Table 2

988H Wheel Loader Approximate Weight Length with Bucket Width across Tires Height over ROPS 53944 kg (118926 lb) 12185 mm (480 inch) 3574 mm (141 inch) 4128 mm (163 inch)

30 Product Information Section General Information

SEBU8480

Illustration 27

g00835725

Dimension (A) represents the dump clearance. Dimension (B) represents the reach.

The following table provides the rated operating loads for the standard machine conguration.

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31 Product Information Section General Information

Table 3

Rated Load 3.88 m

Ground Engaging Tools

Rated Volume

Rated Operating Load

Dump Clearance A

Reach B

Spade Rock with Teeth and Segments (Standard Bucket)

6.4 m3 (8.33 yd3)

11340 kg (25000 lb)

3742 mm (147 inch)

1494 mm (59 inch)

Wide Spade Rock with Teeth and Segments

6.9 m3 (9 yd3)

11340 kg (25000 lb)

3682 mm (145 inch)

1554 mm (61 inch)

General Purpose with Bolt-On Cutting Edges

7 m3 (9.2 yd3)

11340 kg (25000 lb)

3790 mm (149 inch)

1720 mm (68 inch)

Straight Rock with Teeth and Segments

6.3 m3 (8.2 yd3)

11340 kg (25000 lb)

4011 mm (158 inch)

1526 mm (60 inch)

Rock Quarry (Heavy Duty) with Teeth and Segments

6.4 m3 (8.33 yd3)

11340 kg (25000 lb)

3728 mm (147 inch)

1543 mm (61 inch)

Mining (Heavy Duty) with Teeth and Segments

6.4 m3 (8.33 yd3)

11340 kg (25000 lb)

3811 mm (150 inch)

1577 mm (62 inch)

Spade Rock with Bolt-On Cutting Edges

6.9 m3 (9 yd3)

11340 kg (25000 lb)

3638 mm (143 inch)

1881 mm (74 inch)

Spade Rock with Teeth and Segments

6.6 m3 (8.75 yd3)

11340 kg (25000 lb)

3742 mm (147 inch)

1494 mm (59 inch)

32 Product Information Section General Information

SEBU8480

Table 4

Rated Load 4.25 m

Ground Engaging Tools

Rated Volume

Rated Operating Load

Dump Clearance A

Reach B

Spade Rock with Teeth and Segments (Standard Bucket)

6.4 m3 (8.33 yd3)

11340 kg (25000 lb)

4155 mm (164 inch)

1591 mm (63 inch)

Wide Spade Rock with Teeth and Segments

6.9 m3 (9 yd3)

11340 kg (25000 lb)

4095 mm (161 inch)

1652 mm (65 inch)

General Purpose with Bolt-On Cutting Edges

7 m3 (9.2 yd3)

11340 kg (25000 lb)

4203 mm (165 inch)

1818 mm (72 inch)

Straight Rock with Teeth and Segments

6.3 m3 (8.2 yd3)

11340 kg (25000 lb)

4424 mm (174 inch)

1623 mm (64 inch)

Rock Quarry (Heavy Duty) with Teeth and Segments

6.4 m3 (8.33 yd3)

11340 kg (25000 lb)

4141 mm (163 inch)

1641 mm (65 inch)

Mining (Heavy Duty) with Teeth and Segments

6.4 m3 (8.33 yd3)

11340 kg (25000 lb)

4225 mm (166 inch)

1674 mm (66 inch)

Spade Rock with Bolt-On Cutting Edges

6.9 m3 (9 yd3)

11340 kg (25000 lb)

4051 mm (159 inch)

1699 mm (67 inch)

Spade Rock with Teeth and Segments

6.6 m3 (8.75 yd3)

11340 kg (25000 lb)

3742 mm (147 inch)

1494 mm (59 inch)

SEBU8480

33 Product Information Section Identication Information

Identication Information
i03770369

Plate Locations and Film Locations


SMCS Code: 1000; 7000 The Product Identication Number (PIN) is used to identify a powered machine that is designed for an operator to ride. For quick reference, record the identication numbers in the spaces that are provided below the illustration.
Illustration 29
g01883459

Product Identication Number (PIN)

Engine Power primary engine (kW)__________________ Engine Power for additional engine if equipped
(kW)_________ _______________________________________________ market (kg)_________ _______________________________________

Typical machine operating weight for European

Year of construction_____________________________________ Machine Type____________________________________________


For the name, the address and the country of origin for the manufacturer, see the PIN plate. For machines compliant to 1998/37/EC, the following information is stamped onto the CE plate. For quick reference, record this information in the spaces provided below.

Illustration 28 Left side of front frame

g00996995

Machine PIN _________ _______________________________________

European Union
Note: The CE plate is on machines that are certied to the valid European Union requirements at that time. If the machine is equipped with the plate for the European Union, this plate will be attached to the PIN plate. The CE plate is positioned on the bottom left side of the plate for the PIN. For machines compliant to 2006/42/EC, the following information is stamped onto the CE plate. For quick reference, record this information in the spaces provided below.

Illustration 30

g01062968

Engine Power primary engine (kW)__________________ Typical machine operating weight for European
market (kg)_________ _______________________________________

Year ________________________________________________________

34 Product Information Section Identication Information

SEBU8480

Serial Number
Caterpillar products such as engines, transmissions, and major attachments that are not designed for an operator to ride are identied by Serial Numbers. For quick reference, record the identication numbers in the spaces that are provided below the illustration.

Illustration 33 Right side of planetary case

g00838375

Transmission Serial Number_________ ____________________

Certication
Illustration 31 Rear view of the torque converter housing
g00997052

Sound

Torque Converter Serial Number _________ ______________

Illustration 34 Typical example Illustration 32 Engine valve cover


g01000186

g00933634

Engine Serial Number _________ ___________________________

If equipped, the lm is used to verify the environmental sound certication of the machine. The value that is listed on the lm indicates the guaranteed sound level. The guaranteed sound level is measured at the time of manufacture. Refer to Operation and Maintenance Manual, Sound Information and Vibration Information for the guaranteed sound level for your machine.

SEBU8480

35 Product Information Section Identication Information

ROPS/FOPS Film

Illustration 35

g00944234

This warning lm is located on the outside of the cab on the left side below the window. This machine has been certied to the standards that are listed on the certication label. The maximum mass of the machine, which includes the operator and the attachments without a payload, should not exceed the mass on the certication label.
i03637212

Emissions Certication Film


SMCS Code: 1000; 7000; 7405

Certication Label for Emissions


Note: This information is pertinent in the United States, in Canada, and in Europe. Consult your Caterpillar dealer for an Emission Control Warranty Statement. This label is located on the engine.

36 Product Information Section Identication Information

SEBU8480

i03765310

Declaration of Conformity
SMCS Code: 1000; 7000
Table 5

An EC Declaration of Conformity document was provided with the machine if it was manufactured to comply with specic requirements for the European Union. In order to determine the details of the applicable Directives, review the complete EC Declaration of Conformity provided with the machine. The extract shown below from an EC Declaration of Conformity for machines that are declared compliant to 2006/42/EC applies only to those machines originally CE marked by the manufacturer listed and which have not since been modied.

EC DECLARATION OF CONFORMITY OF MACHINERY Manufacturer: Caterpillar Inc., 100 N.E. Adams Street, Peoria, Illinois 61629, USA Person authorized to compile the Technical File and to communicate relevant part (s) of the Technical File to the Authorities of European Union Member States on request: Standards & Regulations Manager,Caterpillar France S.A.S 40, Avenue Leon-Blum, B.P. 55, 38041 Grenoble Cedex 9, France I, the undersigned, _________, hereby certify that the construction equipment specied hereunder Description: Generic Denomination: Function: Model/Type: Serial Number: Commercial Name: Caterpillar Earth moving Equipment Wheeled loader 988H Wheel Loader

Fulls all the relevant provisions of the following Directives Directives 2006/42/EC 2000/14/EC amended by 2005/88/EC, Note (1) 2004/108/EC Note (1) N/A N/A Notied Body Document No.

Annex -_____ Guaranteed Sound Power Level -_____dB (A) Representative Equipment Type Sound Power Level - _____dB (A) Engine Power per ____-____ kW Rated engine speed - _____ rpm Technical Documentation accessible through person listed above authorized to compile the Technical File

Done at: Date:

Signature Name/Position

Note: The above information was correct as of September 2009, but may be subject to change, please refer to the individual declaration of conformity issued with the machine for exact details.

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37 Operation Section Before Operation

Operation Section Before Operation


i02189821

i01922360

Daily Inspection
SMCS Code: 1000; 7000

Mounting and Dismounting


SMCS Code: 7000

Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact skin. At operating temperature, the engine coolant is hot and under pressure. Steam can cause personal injury. Check the coolant level only after the engine has been stopped and the cooling system pressure cap is cool enough to touch with your bare hand. Remove the cooling system pressure cap slowly to relieve pressure. Cooling system conditioner contains alkali. Avoid contact with the skin and eyes to prevent personal injury. NOTICE Accumulated grease and oil on a machine is a re hazard. Remove this debris with steam cleaning or high pressure water, at least every 1000 hours or each time any signicant quantity of oil is spilled on a machine. Note: For maximum service life of the machine, make a thorough daily inspection before you operate the machine. Inspect the machine for leaks. Remove any debris from the engine compartment and the undercarriage. Ensure that all guards, covers, and caps are secured. Inspect all hoses and belts for damage. Inspect all lights and mirrors for damage. Make the needed repairs before you operate the machine. Perform the following procedures on a daily basis.

Illustration 36 Typical example

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Mount the machine and dismount the machine only at locations that have steps and/or handholds. Before you mount the machine, clean the steps and the handholds. Inspect the steps and handholds. Make all necessary repairs. Face the machine whenever you get on the machine and whenever you get off the machine. Maintain a three-point contact with the steps and with the handholds. Note: Three-point contact can be two feet and one hand. Three-point contact can also be one foot and two hands. Do not mount a moving machine. Do not dismount a moving machine. Never jump off the machine. Do not carry tools or supplies when you try to mount the machine or when you try to dismount the machine. Use a hand line to pull equipment onto the platform. Do not use any controls as handholds when you enter the operator compartment or when you exit the operator compartment.

Operation and Maintenance Manual, Bucket


Cutting Edges - Inspect/Replace - Inspect/Replace - Inspect/Replace

Operation and Maintenance Manual, Bucket Stops Operation and Maintenance Manual, Bucket Tips Operation and Maintenance Manual, Bucket Wear
Plates - Inspect/Replace Alarm - Test

Alternate Exit
Machines that are equipped with cabs have alternate exits. For additional information, see Operation and Maintenance Manual, Alternate Exit.

Operation and Maintenance Manual, Backup

38 Operation Section Before Operation

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Operation and Maintenance Manual, Cooling


System Coolant Level - Check Level - Check

The steering frame lock is located at the articulation joint on the left side of the machine.

Operation and Maintenance Manual, Engine Oil Operation and Maintenance Manual, Engine Air
Filter Service Indicator - Inspect System Oil Level - Check

Operation and Maintenance Manual, Hydraulic Operation and Maintenance Manual, Loader
Boom Pin and Lift Cylinder Pin - Inspect and Bearings - Lubricate Inspect

Operation and Maintenance Manual, Loader Pins


Illustration 38
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Operation and Maintenance Manual, Seat Belt Operation and Maintenance Manual, Transmission
Oil Level - Check Clean

Operation and Maintenance Manual, Windows Refer to the Maintenance Section for the detailed procedures. Refer to the Maintenance Interval Schedule for a complete list of scheduled maintenance.
i01922365

Connect steering frame lock (1) when the machine is being lifted and when the machine is being transported. Also connect the steering frame lock if you are performing service work near the articulation joint. Install pin (2) and secure the pin with locking pin (3).

Steering Frame Lock


SMCS Code: 7506

No clearance for person in this area when machine turns. Severe injury or death from crushing could occur.

Illustration 39

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Separate steering frame lock (1) before the machine is operated. Move the steering frame lock to the front frame and install pin (2). Secure the pin with locking pin (3).

Illustration 37

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39 Operation Section Machine Operation

Machine Operation
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Alternate Exit
SMCS Code: 7310

Illustration 41

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Mechanical Suspension
Backrest (1) Pull up on the backrest in order to remove extension.
Illustration 40
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The right side cab window can be used as an alternate exit. The window can only be opened from the inside of the cab. Pull latch (2) backward and push the latch outward in order to open the window to the partial open position. Remove pin (1) from the window and push the window to the fully open position.
i02203596

Lumbar Support (2) Push the lever backward in order to increase support to the lower back. Pull the lever forward in order to decrease support to the lower back. Release the lever in order to lock the seat into position. Rotate knob (3) in order to adjust the angle of the armrest in the operating position. Cushion Angle Adjustment (4) Pull the lever upward. Hold the lever upward and move the seat cushion to the desired angle. Release the lever in order to lock the seat cushion into position. The seat cushion can be adjusted to one of three positions. Fore and Aft Position (5) Pull the lever upward. Hold the lever upward and slide the seat forward or backward to the desired position. Release the lever in order to lock the seat into position.

Seat
SMCS Code: 7312 Note: The operator's seat that is provided with this machine is in compliance with the appropriate class of ISO 7096. Adjust the seat in order to allow full travel of the pedals. Make the seat adjustments when the operator is sitting against the back of the seat.

40 Operation Section Machine Operation

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Seat Backrest Angle Adjustment (6) Pull the lever upward. Hold the lever upward and adjust the backrest to the desired angle. Release the lever in order to lock the backrest into position. Seat Height (7) Pull the lever upward. Hold the lever upward and move the seat to the desired height. Release the lever in order to lock the seat into position.

Lengthening the Seat Belt

Air Suspension (If Equipped)


Seat Height (Air suspension) (7) Push in on the air valve knob (7) in order to raise the height of the seat. Pull out on the air valve knob (7) in order to lower the height of the seat.
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Illustration 42

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1. Unfasten the seat belt.

Seat Belt
SMCS Code: 7327 Note: This machine was equipped with a seat belt when the machine was shipped from Caterpillar. At the time of installation, the seat belt and the instructions for installation of the seat belt meet the SAE J386 and ISO 6683 standards. See your Caterpillar dealer for all replacement parts. Always check the condition of the seat belt and the condition of the mounting hardware before you operate the machine.
Illustration 43
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Seat Belt Adjustment for Non-Retractable Seat Belts


Adjust both ends of the seat belt. The seat belt should be snug but comfortable.

2. To remove the slack in outer loop (1), rotate buckle (2). This will free the lock bar. This permits the seat belt to move through the buckle. 3. Remove the slack from the outer belt loop by pulling on the buckle. 4. Loosen the other half of the seat belt in the same manner. If the seat belt does not t snugly with the buckle in the center, readjust the seat belt.

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41 Operation Section Machine Operation

Shortening the Seat Belt

Releasing The Seat Belt

Illustration 44

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Illustration 46

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1. Fasten the seat belt. Pull out on the outer belt loop in order to tighten the seat belt. 2. Adjust the other half of the seat belt in the same manner. 3. If the seat belt does not t snugly with the buckle in the center, readjust the seat belt.

Pull up on the release lever. This will release the seat belt.

Seat Belt Adjustment for Retractable Seat Belts


Fastening The Seat Belt

Fastening The Seat Belt

Illustration 47 Illustration 45
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Pull seat belt (4) out of the retractor in a continuous motion. Fasten seat belt catch (3) into buckle (2). Make sure that the seat belt is placed low across the lap of the operator. The retractor will adjust the belt length and the retractor will lock in place. The comfort ride sleeve will allow the operator to have limited movement.

Fasten the seat belt catch (3) into the buckle (2). Make sure that the seat belt is placed low across the lap of the operator.

42 Operation Section Machine Operation

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Releasing The Seat Belt


Slips and falls can result in personal injury. Use the machines access systems when adjusting the mirrors. If the mirrors cannot be reached using the machine access systems follow the instructions found within the Operation and Maintenance Manual, Mirror in order to access the mirrors. Note: Your machine may not be equipped with all of the mirrors that are described in this topic.

Illustration 48

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Push the release button on the buckle in order to release the seat belt. The seat belt will automatically retract into the retractor.

Extension of the Seat Belt

When using retractable seat belts, do not use seat belt extensions, or personal injury or death can result. The retractor system may or may not lock up depending on the length of the extension and the size of the person. If the retractor does not lock up, the seat belt will not retain the person. Longer, non-retractable seat belts and extensions for the non-retractable seat belts are available. Caterpillar requires only non-retractable seat belts to be used with a seat belt extension. Consult your Caterpillar dealer for longer seat belts and for information on extending the seat belts.

Illustration 49 (1) Left Outside Mirror (2) Right Outside Mirror

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Illustration 50
i03290932

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Mirror (If Equipped)


SMCS Code: 7319

(3) Left Inside Mirror (4) Right Inside Mirror

Mirrors provide additional visibility around your machine. Make sure that the mirrors are in proper working condition and that the mirrors are clean. Adjust all mirrors at the beginning of each work period and adjust the mirrors when you change operators. The appropriate organization of the job site is also recommended in order to minimize hazards due to visibility. For more information refer to this Operation and Maintenance Manual, Visibility Information.

Adjust all mirrors as specied in the Operation and Maintenance Manual. Failure to heed this warning can lead to personal injury or death.

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43 Operation Section Machine Operation

Modied Machines or machines that have additional equipment or attachments may inuence your visibility.

Right Outside Mirror (2)

Mirror Adjustment
Park the machine on a level surface. Lower the work tool to the ground. Move the hydraulic lockout control to the LOCKED
position. For further details on this procedure, refer to Operation and Maintenance Manual, Operator Controls
Illustration 52
g01631673

Stop the engine. Adjust rear view mirrors in order to provide visibility
behind the machine at a maximum distance of 30 m (98 ft) from the rear corners of the machine.

Note: You may need to use hand tools in order to adjust certain types of mirrors.

If equipped, adjust the right outside mirror (2) so that an area of at least 1 m (3.3 ft) from the side of the machine can be seen from the operator seat. Additionally, provide as much visibility to the rear as possible.

Left Outside Mirror (1)

Left Inside Mirror (3)

Illustration 51

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Illustration 53

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If equipped, adjust the left outside mirror (1) so that an area of at least 1 m (3.3 ft) from the rear of the machine can be seen from the operator seat.

If equipped, adjust the left inside mirror (3) so that an area of at least 1 m (3.3 ft) from the side of the machine can be seen from the operator seat. Additionally, provide as much visibility to the rear as possible.

44 Operation Section Machine Operation

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Right Inside Mirror (4)

Illustration 54

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If equipped, adjust the right inside mirror (4) so that an area of at least 1 m (3.3 ft) from the side of the machine can be seen from the operator seat. Additionally, provide as much visibility to the rear as possible.
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Operator Controls
SMCS Code: 7300; 7301; 7451 Note: Your machine may not be equipped with all of the controls that are discussed in this topic. The operation section is a reference for the new operator and a refresher for the experienced operator. This section includes descriptions of gauges, switches, machine controls, attachment controls, transportation, and towing information. Illustrations guide the operator through correct procedures of checking, starting, operating, and stopping the machine. Operating techniques that are outlined in this publication are basic. Skill and techniques develop as the operator gains knowledge of the machine and the capabilities of the machine.

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45 Operation Section Machine Operation

Overhead Switch Panels

Illustration 55

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Illustration 56 (1) Front Window Wiper and Washer (2) Ride Control (3) Torque Converter Lockup Control (4) Beacon Switch (5) Autoshift Control (6) Rear Window Wiper/Washer Switch (7) Fan Speed Switch (8) Heating and Air Conditioning Switch (9) Temperature Control (10) HID Light Switch (11) Stairway Access Light (12) Main Lighting Switch

g02023046

(13) Reduced Rimpull Switch (14) Kickout and Positioner Control (15) Override Switch for the Automatic Lubrication System (If equipped) (16) Reversing Fan Switch (17) Hazard Light Switch

Front Window Wiper and Washer (1)


Front Window Wiper and Washer Turn the knob clockwise in order to turn on the window wiper. Push the knob in order to activate the window washer. Spring force will return the knob after use. Note: For machines that have intermittent front wipers, there are several positions that will affect the wipers.

Turn the knob in a clockwise direction. The following settings may be selected: OFF position, LONG DELAY position, INTERMITTENT DELAY position, SHORT DELAY position, LOW position, and HIGH position.

Ride Control (2)


Ride Control Switch (If Equipped) Travel at high speeds over rough terrain causes bucket movement and a swinging motion. The ride control system acts as a shock absorber by dampening forces from the bucket. This helps to stabilize the entire machine.

46 Operation Section Machine Operation

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ON Push the bottom of the ride control switch in order to turn on the ride control system. When the ride control switch is in the ON position, the ride control system will be operational at all times. This function is used primarily during servicing the accumulator. For normal operation, the ride control switch should be placed in either the automatic position or in the OFF position during the loading cycle. Failure to move the ride control switch to the recommended position could result in damage to the machine. OFF Push the ride control switch to the middle position in order to turn off the ride control system. AUTOMATIC Push the top of the ride control switch in order to turn on the automatic ride control. When the switch for the ride control system is in the AUTOMATIC position, an indicator light on the front dash panel comes on. A light on the switch comes on also. The automatic ride control turns on when the ground speed exceeds 9.6 km/h (6 mph). The automatic ride control turns off when the ground speed is less than 9.6 km/h (6 mph).

Pressing the upshift gear speed switch on the STIC control will cause the machine to shift into the next highest gear. Pressing the downshift gear speed switch on the STIC control will cause the machine to shift into the next lowest gear. The indicator light that is located on the instrument panel will illuminate when the autoshift control is activated. The downshift gear speed switch on the STIC control is active in all gears. The downshift gear speed switch on the STIC control can cause transmission downshifts at machine speeds that are higher than normal. Pressing the downshift gear speed switch on the STIC control will cause a downshift of one gear. The downshift will only occur if the machine speed and the engine speed will not result in an engine overspeed condition. Holding down the downshift gear speed switch on the STIC control will cause the transmission to continue to downshift as the machine speed decreases. The transmission will remain in the downshifted gear for three seconds after the downshift switch is released. Then, automatic shifting is resumed. Turn switch (5) to a selected gear speed in order to activate the autoshift function. The transmission will shift from rst gear through fourth gear automatically. The highest gear that will be used is determined by the selection on the switch. As the machine slows, the transmission will automatically downshift. The transmission will not shift lower than second gear. Note: The 988H does not have a separate Quick-Shift function as the former 988F model. In the automatic mode of autoshift, the transmission will automatically shift from the rst gear to the second gear. This happens when the operator shifts the direction from forward to reverse. When one then shifts from reverse to forward, the transmission will remain in second gear. This feature only functions when the machine is in rst gear. A transmission quick-shift can only occur when the operator shifts the direction from forward to reverse. This feature does not affect any directional shift in any of the other gears.

Torque Converter Lockup Control (3)


Torque Converter Lockup Switch Pressing the top of the switch enables the lockup clutch for all gears except for the rst gear forward. When the engine speed is in the correct speed range, the torque converter will lock up. The indicator light on the instrument panel will illuminate when the torque converter lockup switch is activated. This feature provides more efcient operation for high speeds and for carrying loads.

Beacon Switch (4)


Rotating Beacon Press the top of switch in order to turn on the rotating beacon. Press the bottom of the switch in order to turn off the rotating beacon.

Autoshift Control (5)


Manual Mode The gear speed is selected by rotating the switch to the manual position. Automatic Mode The operator selects the highest desired operating speed from the options on the switch. The control selects the proper transmission gear according to the ground speed of the machine.

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47 Operation Section Machine Operation

Rear Window Wiper/Washer Switch (6)


Rear Window Wiper and Washer Turn the knob clockwise in order to turn on the window wiper. Push the knob in order to activate the window washer. Spring force will return the knob after use. Note: For machines that have intermittent front wipers, there are several positions that will affect the wipers. Turn the knob in a clockwise direction. The following settings may be selected: OFF position, LONG DELAY position, INTERMITTENT DELAY position, SHORT DELAY position, LOW position, and HIGH position.

Stairway Access Light (11)


Stairway Access Light Press the top of switch in order to turn on the stairway access light. Press the bottom of the switch in order to turn off the stairway access light.

Fan Speed Switch (7)


The heating or the air conditioning must be activated in order for the fan to operate. Fan Speed Switch The switch controls the speed of the blower fan motor for the heating and air conditioning system. Low Press the top of the switch. Medium Move the switch to the middle position. High Press the bottom of the switch.
Illustration 57
g00841327

Note: The stairway access light can also be controlled by the switch next to the engine shutdown control. The engine shutdown control is located on the left rear bumper.

Heating and Air Conditioning Switch (8)


Air Conditioner Press the top of the switch. Off Move the switch to the center position in order to deactivate the heating and air conditioning system. This will also deactivate the blower fan motor. Heater Press the bottom of the switch.

Main Lighting Switch (12)


Off Rotate the knob counterclockwise in order to shut off all of the lights. Parking Lights and Cab Interior Lights Rotate the knob clockwise to the rst position in order to turn on both the parking lights and the interior cab lights. Roading Lights Rotate the knob clockwise to the second position in order to turn on the roading lights. Rear Floodlights Rotate the knob clockwise to the third position in order to turn on the rear oodlights. Front Floodlights Rotate the knob clockwise to the fourth position in order to turn on front oodlights.

Temperature Control (9)


Temperature Variable Control Turn the knob clockwise for warmer air. Turn the knob counterclockwise for cooler air.

HID Light Switch (10)


Press the top of the switch in order to turn on the lights. Press the bottom of the switch in order to turn off the lights.

48 Operation Section Machine Operation

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Reduced Rimpull Switch (13)


The reduced rimpull switch reduces the potential for wheel slippage without reducing the hydraulic efciency. The reduced rimpull switch is a four-position switch. Each setting corresponds to a maximum allowable percentage of maximum rimpull. There are two types of settings for the maximum allowable percentage of maximum rimpull. Type 1 BXY1-1899

Operating with Reduced Rimpull To select a reduced rimpull setting, move the reduced rimpull switch to the desired setting and move the reduced or maximum rimpull switch that is located on the right side control console to the REDUCED position. If the machine is in rst speed, the reduced rimpull switch will provide an impeller clutch pressure which limits the rimpull to the desired level when the left brake pedal is fully released. Depressing the left brake pedal will further reduce rimpull from the selected percentage. The rimpull that is commanded by the fully released pedal will equal the reduced rimpull that is selected on the reduced rimpull switch. When a lower rimpull is selected, pedal travel will result in a more gradual decrease in rimpull. If the machine is not in rst speed, the impeller clutch pressure will remain at the maximum level until the transmission is placed into rst speed.

Illustration 58

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Machines that are equipped with the rimpull switch, located on the right side of the control console

The reduced rimpull switch will continue to limit rimpull until the transmission is shifted out of rst speed.

Type 2 BXY1900-Up

Kickout and Positioner Control (14)


Lift Kickout Position and Lower Kickout Position To set the lift kickout, raise the bucket to the desired position above the midway point. Then depress the bottom of the kickout set switch. The boom will return to the programmed position when the raise detent is activated and the boom is below the kickout position. To set the lower kickout, lower the bucket to the desired position below the midway point. Then depress the bottom of the kickout set switch. The boom will return to the programmed position when the oat detent is activated and the boom is at least a foot above the kickout position.

Illustration 59

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Machines that are equipped with the fuel management switch, located on the right side of the control console

Note: The rimpull settings may be adjusted in order to meet operating conditions. Reference: To change the maximum allowable percentages for each setting of the rimpull switch, refer to Testing and Adjusting, RENR3095, Power Train.

Note: If the boom is a foot or less above the lower kickout position, placing the lift control lever in the oat detent will cause the bucket to oat and the bucket will hit the ground. Bucket Kickout Position To set the bucket kickout position, tilt the bucket to the desired digging angle and depress the top of the kickout set switch. The bucket will return to the programmed position when the tilt control lever is placed in the tilt back detent and the bucket is dumped beyond the kickout.

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49 Operation Section Machine Operation

Override Switch for the Automatic Lubrication System (15)


Press the top of the switch and release the switch. This will override the automatic lubrication system. This will dispense grease to the lubrication points. After lubrication is complete, the automatic lubrication system will return to normal operation.

Reversing Fan Switch (16)


The reversing fan will reverse the direction of the cooling fan in order to purge debris that is trapped in the radiator grill. The auto reversing fan automatically reverses the cooling fan for 20 seconds after every 20 minute interval. Then, the cooling fan returns to the normal direction. Switch (16) provides a manual override control that will immediately initiate the purge cycle when the engine is on. Press the top of the switch and release the switch in order to manually activate the reversing fan. Then, the cycle will reset the timer for the automatic purge cycle. Note: Your machine may be equipped with a feature that will not allow the cooling fan to automatically reverse when the parking brake is applied. Pressing the reversing fan switch (16) will override this feature.

Hazard Light Switch (17)


Hazard Lights Press the top of the switch in order to turn on the hazard lights. Press the bottom of the switch in order to turn off the hazard lights.

50 Operation Section Machine Operation

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Steering Control Console

Illustration 60 (1) STIC Control (2) Armrest

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STIC Control (1)


The STIC Control controls the following machine functions: Steering, Direction Control, and Speed Control. Speed Control Push upshift switch (1A) in order to shift the machine into the next highest speed. Push downshift switch (1B) in order to shift the machine into the next lowest speed.

Direction Control REVERSE Move the top of the trigger switch (1C) to R. This will enable the machine to move in the reverse direction. NEUTRAL Move the trigger switch (1C) to N. This will disengage the transmission. FORWARD Move the bottom of the trigger switch (1C) to F. This will enable the machine to move in the forward direction. The active transmission direction will be shown on the speedometer. Steering Control Note: The steering frame lock must be in the unlocked position in order to steer the machine. Move the STIC control to the right of the center position in order to steer the machine to the right.

1 indicates First Speed. 2 indicates Second Speed. 3 indicates Third Speed.


Note: When the parking brake is engaged, the machine can only be shifted into second speed or into third speed.

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51 Operation Section Machine Operation

Move the STIC control to the left of the center position in order to steer the machine to the left. Note: When you release the STIC control, the STIC control will return to the center position. However, the machine will maintain the current travel direction. STIC Control Lock Move the lock lever (1D) all the way to the left in order to mechanically lock the STIC control. The transmission controls will be electronically locked. Move the lock lever (1D) all the way to the front in order to unlock the STIC control. The transmission controls will unlock.

Armrest (2)
Push down the knob (2A) in order to move the control console forward or backward. Release the knob in order to lock the console into position. Turn the knobs (2B) counterclockwise in order to adjust the height and the angle of the armrest. Turn the knobs clockwise in order to secure the armrest in the position that is desired.

Electrohydraulic Control Console


Note: Your machine may not be equipped with all of the controls that are discussed in this topic.

52 Operation Section Machine Operation

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Illustration 61 Standard control console (1) Tilt Control (2) Lift Control (3) Third Valve Control (4) Implement Console Adjustment Lever (5) Ashtray (6) Turn Signal (7) Armrest Adjustment Knob (8) Economy Mode (9) Third Valve Lockout (10) Lighter (11) Armrest (12) Console Adjustment Knob (13) (14) (15) (16) (17) Horn Implement Lockout Store Button Resume Switch Set Switch

g02023579

Tilt Control (1)


Note: Do not use any lubricants on any part of the implement controls. DUMP Push the bucket tilt lever forward in order to dump a load from the bucket. HOLD The bucket tilt lever will return to the HOLD position when the lever is released from the DUMP position or from the TILT BACK position. The bucket will remain in the selected position. TILT BACK Pull the bucket tilt lever backward in order to tilt back the bucket.

The control lever is detented in the full TILT BACK position. When the lever is moved into the soft detent, the operator will feel an increased resistance from the lever. Once in the detent, the lever should be released in order to automatically return to the HOLD position. The attachment will continue to tilt back until the attachment reaches the digging angle that is preset by the tilt kickout. In order to manually override the detent, the lever must be moved at least 6 from the HOLD position. The detent will not be activated if the lever is held in the detent position for more than 1 second.

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53 Operation Section Machine Operation

The control lever is detented in the full DUMP position. When the control lever is moved into the soft detent, the operator will feel an increased resistance from the lever. Once in the detent, the lever should be released in order to automatically return to the HOLD position. The attachment will continue to dump until the attachment reaches the digging angle that is preset by the tilt kickout. In order to manually override the detent, the control lever must be moved at least 6 from the HOLD position. The detent will not be activated if the lever is held in the detent position for more than 1 second. Note: A machine with ride control may experience partial lowering of the lift arms when the lever is held in the DUMP position with the bucket against the bucket stops and the lift arms are fully raised. To avoid partial lowering of the lift arms, return the lever to the HOLD position. An optional feature can be enabled to help prevent this situation. Enable Dump Stop Snubbing by using Caterpillar Electronic Technician.

The control lever is detented in the fully raised position. When the lever is moved into the soft detent, the operator will feel an increased resistance from the lever. Once in the detent, the lever should be released in order to automatically return to the HOLD position. The attachment will continue to raise until the attachment reaches the lift kickout height. In order to manually override the detent, the lever must be moved at least 6 from the HOLD position. The detent will not be activated if the lever is held in the detent position for more than 1 second. The control lever is detented in the FLOAT position. When the lever is moved into the soft detent, the operator will feel an increased resistance from the lever. Once in the detent position, the lever should be released in order to automatically return to the HOLD position. The attachment will continue to lower until the attachment reaches the kickout height. In order to manually override the detent, the lever must be moved at least 6 from the HOLD position. The detent will not be activated if the lever is held in the detent position for more than 1 second.

Lift Control (2)


Note: Do not use any lubricants on any part of the implement controls. FLOAT Push the bucket lift lever forward through the detent. The bucket will lower to the ground. The bucket will oat with the contour of the ground. The bucket lift lever will remain in the FLOAT position until the lever is moved out of the detent. The bucket lift lever will return to the HOLD position when the lever is released. NOTICE NEVER use FLOAT position to lower a loaded bucket. Machine damage can result from bucket falling too fast. LOWER Push the bucket lift lever forward in order to lower the bucket. The bucket lift lever will return to the HOLD position when the lever is released. RAISE Pull the bucket lift lever backward in order to raise the bucket. Release the bucket lift lever in order to stop lifting the bucket. The bucket lift lever will return to the HOLD position when the lever is released.

Third Valve Control (3) (If Equipped)


Pull back the lever in order to pressurize the left auxiliary hydraulic line. Push the lever forward in order to pressurize the right auxiliary hydraulic line. Reference: Refer to Third Valve Lockout for more information with locking and unlocking the third valve control.

Implement Console Adjustment Lever (4)


Turn the knob (4) counterclockwise in order to adjust the height of the implement control. Turn the knob clockwise in order to secure the implement control in the position that is desired.

Ashtray (5)
Pull out on the ashtray in order to open the ashtray.

Turn Signals (6)


Turn Signals (if equipped) Move the switch to the left in order to turn on the left turn signal. Move the switch to the right in order to turn on the right turn signal.

Armrest Adjustment Knob (7)


Turn the knobs (7) counterclockwise in order to adjust the height and the angle of the armrest. Turn the knobs clockwise in order to secure the armrest in the position that is desired.

54 Operation Section Machine Operation

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Fuel Management Switch (8) (If Equipped)


Fuel Management Switch This switch is a three-position rocker switch that is designed to improve fuel consumption with minimal impact on productivity. The fuel management switch limits the engine speed when the machine is not digging. When the machine is digging, the machine will return to normal operation for maximum production. Maximum Production The middle position of the switch will allow your machine to operate at the highest potential for productivity. Balanced Fuel Management The bottom position of the switch will allow your machine to operate in a more economical mode that will reduce fuel consumption with a minimal reduction in performance. When the balanced fuel management mode is active, an indicator will illuminate on the fuel management switch. Maximum Fuel Management The top position of the switch will allow your machine to operate in the most economical mode that will reduce fuel consumption with a minimal reduction in performance. When the maximum fuel management mode is active, an indicator will illuminate on the fuel management switch. Note: Set the throttle lock for the engine before you engage the transmission in order to avoid a surge in engine speed or a surge in machine acceleration. Set the throttle lock for the engine before you operate the hydraulics in order to avoid a surge in engine speed or a surge in machine acceleration. Refer to Service Manual, RENR6217, Electronic Control System Components for additional information.

Illustration 62

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The hydraulic lockout switch has a locking tab that must be pressed before the switch can be moved.

Lighter (10)
Lighter Push the lighter inward and release the lighter. The lighter will move outward slightly when the lighter is ready

for use.

Console Adjustment Knob (12)


Push down on the knob (12) in order to move the control console forward or backward. Release the knob in order to lock the console into position.

Horn (13)
Horn Press the button in order to sound the horn. Use the horn in order to alert personnel.

Implement Lockout (14)


LOCKED Press the top of the switch in order to electronically lock the implement controls. UNLOCKED Press the bottom of the switch in order to electronically unlock the implement controls.

Third Valve Lockout Switch (9)


Hydraulic Lockout The hydraulic lockout switch is designed to deactivate the hydraulic controls. Press the top of the switch in order to deactivate the control levers. Deactivate the hydraulic controls before you exit the seat or before you service the machine. The control levers should always be deactivated when the machine is left unattended. Hydraulics Unlock Press the bottom of the switch in order to activate the hydraulic controls.

Store Button (15)


STORE The STORE key is used with the payload control system. Use the STORE key to store payload data. Use the STORE key to make a selection from a menu. Use the STORE key to enter a number.

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55 Operation Section Machine Operation

Resume Switch (16)


Resume/Accel Switch Press the throttle lock control to the ON position. Refer to Operation and Maintenance Manual, Operator Controls - Instrument Panel. Press the set/decel switch and release the switch in order to set the throttle. In order to accelerate, press the resume/accel switch and hold the switch. The machine will accelerate. When the switch is released the previous setting will resume. The throttle setting may be cancelled by pressing the right brake pedal or turning the throttle lock control to the OFF position.

When the switch is ON, the transmission will engage rst gear in the selected direction. The forward switch (1) engages the transmission in forward gear. The reverse switch (2) engages the transmission in reverse gear. The transmission will remain in gear until the switch is released.

Instrument Panel
Note: Your machine may not be equipped with all of the controls that are discussed in this topic.

Set Switch (17)


Set/Decel Switch Press the throttle lock control to the ON position. Refer to Operation and Maintenance Manual, Operator Controls - Instrument Panel. Press the set/decel switch and release the switch in order to set the throttle. Once the speed is set, press the switch and hold the switch in order to decelerate. The machine will decelerate. When the switch is released the previous setting will resume. The throttle setting may be cancelled by pressing the right brake pedal or turning the throttle lock control to the OFF position.

Transmission Override (If Equipped)

Illustration 63

g02029285

The transmission override control is mounted on the right hand side of hand rest.

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Illustration 64 (1) Gauge Display (2) Speedometer/Tachometer Display (3) Indicators (4) Operator Mode Switch (5) Throttle Lock Control (6) Left Service Brake Control and Impeller Clutch (7) Engine Brake Control (8) Right Service Brake Control (9) Engine Start Switch (10) Throttle Control (11) Parking Brake Control

g02030175

Gauge Display (1)


Refer to Operation and Maintenance Manual, Monitoring System for details on the gauge display.

Operator Mode Switch (4)


Press the switch in order to change the information that is displayed within the Monitoring System. Refer to Operation and Maintenance Manual, Monitoring System for additional information.

Speedometer/Tachometer Display (2)


Refer to Operation and Maintenance Manual, Monitoring System for details on the speedometer/tachometer display.

Throttle Lock Control (5)


Throttle Lock Control The throttle lock switch is located on the left side of the instrument panel. Engage the switch in order to keep the engine at the current rpm. When the throttle lock is active, an indicator light will illuminate on the front dash. Use the throttle lock control on long hauls in order to avoid driver fatigue. Fatigue may result from depressing the throttle control for an extended period of time. ON Push the top of the switch in order to turn on throttle lock control.

Indicators (3)
Refer to Operation and Maintenance Manual, Monitoring System for details on the indicators.

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57 Operation Section Machine Operation

OFF To release the throttle lock control, push the switch to the center position or depress the right brake pedal. Automatic Idle Kickdown Push the bottom of the switch in order to turn on Automatic Idle Kickdown. This function automatically drops the engine speed, if the operator is not operating the machine for a period of time and the throttle lock is set. The system automatically resumes the engine speed to the previous setting when the operator starts to operate the machine again. Setting the Throttle Lock The throttle lock can be set for a desired rpm. 1. Push the throttle lock control to the ON or AUTO position. 2. The indicator light for the throttle lock will illuminate when the on/off switch is in the ON or AUTOposition. 3. Depress the throttle control in order to achieve the desired engine rpm.

In order to decelerate to a lower rpm, continue pressing the Set/Decel switch. Once the switch is released the new throttle speed will be set.

Left Service Brake Control and Impeller Clutch (6)


The left brake pedal controls both the brake pressure and the impeller clutch pressure. Partially depress the left brake pedal in order to reduce the impeller clutch pressure. The brake pressure is increased as the operator pushes down the pedal farther. This feature allows the operator to control the maximum drive train torque. Lowering the maximum drive train torque supplies more engine power to the implements and to the steering. When the operator is digging, the left brake pedal can be used to stop any excessive tire slip.

Engine Brake Control (7)


The engine brake control is operated by using a pedal that is located in the cab of the operator's compartment. The engine brake control aids in preventing excessive wear on the service brakes by decreasing the speed of the engine. The engine brake control should be used before applying the right service brake pedal. The engine brake control should not be used with the left brake pedal. Apply the engine brake control when the machine is travelling downhill. The transmission can be downshifted while you are using the engine brake control. The right service brake pedal can also be applied, if necessary.

Illustration 65

g02024158

4. Depress Set/Decel switch (1) in order to set the throttle. Cancelling the Throttle Setting The throttle setting may be cancelled by depressing the right brake pedal or by moving the on/off switch to the OFF position. When the right brake pedal is used to cancel a throttle setting, press Resume/Accel switch (2) in order to resume the throttle setting. Accelerate or Decelerate In order to accelerate to a higher rpm, continue pressing the Resume/Accel switch. Once the switch is released the new throttle speed will be set.

Note: The torque converter lockup switch should be in the ON position in order to use the engine brake control. Engine Overspeed Protection If your machine is equipped with engine brake control, the engine has overspeed protection. The engine brake will automatically be activated if engine speed exceeds 2275 rpm. When engine speed drops below 1900 rpm the engine brake will automatically be deactivated. Reference: Refer to the topic Torque Converter Lockup Control in Operation and Maintenance Manual, Operator Controls (Overhead Switch Panels) for more information.

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Right Service Brake Control (8)


Right Brake Pedal The right brake pedal decelerates the machine. Engage Depress the right brake pedal for normal braking of the machine. Disengage Release the right pedal in order to release the brakes.

Engine Idle Shutdown


This function shuts down the engine after the operator is not operating the machine for a period of time. This function does not shut down other systems, such as AC, which can run down the battery after idle shutdown. This function can be enabled or disabled by a Caterpillar dealer technician. Engine Idle Shutdown may be required for local regulations. The Engine Idle Shutdown (EIS) shuts down the engine if the following conditions are met:

Engine Start Switch (9)


OFF When you insert the engine start switch key and when you remove the engine start switch key, the engine start switch must be in the OFF position. To disconnect the power to the electrical circuits in the cab, turn the engine start switch to the OFF position. Also, turn the engine start switch to the OFF position in order to stop the engine. ON To activate the electrical circuits in the cab, turn the engine start switch clockwise to the ON position. START To start the engine, turn the engine start switch clockwise to the START position. When the engine start switch key is released, the engine start switch will return to the ON position. Note: If the engine fails to start, return the engine start switch to the OFF position. This must be done before you attempt to start the engine again.

The parking brake is applied. Release the service brake. Release the throttle pedal. Gear in neutral The implement is not active.
Engine Idle Shutdown The control limits the engine speed to 1000 rpm at 20 seconds before shutdown and turns on the action lamp. An alarm sounds for 5 seconds before the engine shuts down. An operator can move one of the controls in order to cancel a shutdown. Using the brake pedal to cancel a shutdown is the recommended option for the operator.
i03646475

Battery Disconnect Switch


SMCS Code: 1411

Throttle Control (10)


Depressing the Throttle Control Depress the throttle control in order to increase the engine speed. Releasing the Throttle Control Release the throttle control in order to decrease the engine speed.

Parking Brake (11)


Parking Brake The parking brake knob is located next to the engine start switch on the right side of the dashboard. Use the parking brake after the machine has been stopped.
Illustration 66
g01000504

Pull the knob outward in order to engage the parking brake. Push the knob inward in order to release the parking brake.

The battery disconnect switch is located behind the battery compartment on the right rear bumper.

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59 Operation Section Machine Operation

1. With the battery disconnect switch in the ON position, verify that electrical components in the operator compartment are functioning. Verify that the hour meter is displaying information. Verify that the engine will crank. 2. Turn the battery disconnect switch to the OFF position. 3. Verify that the following items are not functioning: electrical components in the operator compartment, hour meter, and engine cranking. If any of the items continue to function with the battery disconnect switch in the OFF position, consult your Caterpillar dealer.

Illustration 67

g01098630

Disconnect Switch ON To activate the electrical system, insert the key for the battery disconnect switch and turn the key clockwise. The battery disconnect switch must be turned to the ON position before you start the engine. Disconnect Switch OFF To deactivate the electrical system, turn the battery disconnect switch counterclockwise to the OFF position. The battery disconnect switch and the engine start switch perform different functions. Turn off the battery disconnect switch in order to disable the entire electrical system. The battery remains connected to the electrical system when you turn off the engine start switch. Turn the battery disconnect switch to the OFF position and remove the key when you service the electrical system or any other machine components. Also turn the battery disconnect switch to the OFF position and remove the key when the machine will not be used for an extended period of a month or more. This will prevent drainage of the battery. NOTICE Never move the battery disconnect switch to the OFF position while the engine is operating. Serious damage to the electrical system could result. To ensure that no damage to the engine occurs, verify that the engine is fully operational before cranking the engine. Do not crank an engine that is not fully operational. Perform the following procedure in order to check the battery disconnect switch for proper operation:

60 Operation Section Machine Operation

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i02319896

i03753018

Backup Alarm
SMCS Code: 7406

Monitoring System
SMCS Code: 7451; 7490

Functional Test
The Caterpillar Monitoring System performs an automatic internal test when the engine start switch is moved from the OFF position to the ON position. The test veries proper operation of the outputs (displays, alert indicators, and the action alarm) and the internal circuits. The operator must observe the displays in order to determine whether the monitoring system is operating properly. The length of time for the test is approximately three seconds.
g01000537

Illustration 68

1. During this test, the action light is on continuously and the action alarm sounds once. 2. All of the alert indicators ash. Also, the X10 indicator, the indicator for the hour meter, and all units of measurement come on in the display window. The digital readout shows 8.8.8.X.8.8.. 3. On the speedometer/tachometer display, the gear/direction readout shows an asterisk and the digital speedometer shows 188 mph and km/h. 4. All of the gauge needles ramp straight up. Then, the gauge needles go to the right and to the left. The gauge needles then show the actual current readings. 5. The display then goes into the Normal Mode of operation or the display scrolls through the modes if the service input and the clear input are grounded or the operator switch input is grounded.

The backup alarm is located on the lower right side behind the radiator grill. Backup Alarm The alarm will sound when the transmission control is in the REVERSE position. The backup alarm is used to alert people behind the machine when the machine is backing up.

Illustration 69

g01117861

The volume for the backup alarm is nonadjustable.

Illustration 70

g01078295

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61 Operation Section Machine Operation

The Caterpillar Monitoring System is an electronic monitoring system that continuously monitors machine systems. The system consists of Speedometer/Tachometer Display (1), Indicators (2), Gauge Display (3), and Monitoring System Display (4).

Reduced Rimpull (2C) This light indicates that the rimpull switch has been moved to reduced rimpull. Throttle Lock (2D) This light indicates that the throttle lock is activated.

Speedometer/Tachometer Module (1)

Autolube (2E) This light indicates that the automatic lubrication system is not functioning properly. Consult your Caterpillar dealer for more information. Autoshift Control (2F) This light indicates that the autoshift control is activated. Ride Control (2G) This light indicates that the ride control system is activated.

Illustration 71

g01078299

Lockup Clutch (2H) This light indicates that the torque converter lockup control is activated. Primary Steering Pressure (2I) This light indicates that a low primary steering pressure has been detected. Action Indicator (2J) This light indicates that the monitoring system has detected a fault.

Tachometer (1A) The tachometer displays the engine rpm during operation. Speedometer (1B) The speedometer displays the machine ground speed in mph or in km/h. Gear/Direction Readout (1C) The gear readout displays the selected transmission gear and the selected direction.

Indicators (2)

Gauge Module (3)

Illustration 72

g02024357

Illustration 73

g01078298

Indicators (2A) This display will indicate normal machine functions. Turn Signal/Hazards (2B) This light indicates that the turn signals or the hazard ashers have been activated.

Coolant Temperature (3A) This gauge indicates the temperature of the engine coolant. If the gauge needle is in the red zone, the coolant temperature is excessive.

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Torque Converter Oil Temperature (3B) This gauge reads the temperature of the torque converter oil. If the gauge is in the red zone, the torque converter oil temperature is excessive. Hydraulic Oil Temperature (3C) This gauge indicates the temperature of the hydraulic oil. If the gauge needle is in the red zone, the hydraulic oil temperature is excessive. Fuel Level (3D) This gauge shows the amount of fuel in the fuel tank. If the gauge needle is in the red zone, the fuel tank is low on fuel.

Monitoring System Display (4)


Warning Categories
The Caterpillar Monitoring System noties the operator of an immediate problem with a machine system or an impending problem with a machine system. The Caterpillar Monitoring System provides four warning categories. The categories are based on the severity of the problem. The categories dictate the required response of the operator.
Table 6

WARNING OPERATION Warning Category 1 Warning Indications Flashing Indicator X Flashing Action Lamp
(1)

Sounding of the Action Alarm

Required Action No immediate action is required. The system needs attention soon.

Possible Result

(2)

No harm or damage

Change machine operation or perform maintenance to the system. X X


(3)

Severe damage to components Severe damage to components Injury to the operator or severe damage to components

2-S 3

X X

X X

Immediately change the machine operation. Immediately perform a safe engine shutdown.

(4)

(1) (2) (3) (4)

The warning indicators that are active are marked with an X. This is the possible result if no action is taken. The alarm is on continuously. The alarm is on intermittently.

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63 Operation Section Machine Operation

Alert Indicators

Engine Overspeed (4H) This light indicates that the engine speed is too high. Fuel Pressure (4I) This light indicates that the fuel pressure is low.

Hydraulic Oil Filter (4J) The light indicates that the hydraulic oil lter is plugged and the bypass valve is open. NOTICE If the hydraulic oil lter is plugged, the bypass valve will open. Unltered hydraulic oil will ow through the system and damage to other system components may occur. Display Window (4K) The display window provides a digital readout that can show total operating hours of the engine (hour meter), current engine speed (tachometer), total travel distance (odometer), or active diagnostic codes. Also, the gauges in the gauge display may be monitored digitally in the display window.

Illustration 74

g01078301

Parking Brake (4A) This light indicates that the parking brake is engaged. If the machine is in neutral, only the indicator lights. However, if the machine is in FORWARD or REVERSE, the action lamp and the action alarm also activate. Charging System (4B) This light indicates that the battery voltage is outside the battery charge range. While the engine is running, the light also turns on when the alternator frequency is low. Brake Oil Pressure (4C) This light indicates that the axle oil pressure is low. Brake Oil Temperature (Axle) (4D) This light indicates that the brake oil temperature (axle) is high. Transmission Oil Filter (4E) This light indicates that the transmission oil lter is plugged. NOTICE If the transmission oil lter is plugged, the bypass valve will open. Unltered transmission oil will ow through the system and damage to other system components may occur. Engine Oil Pressure (4F) This light indicates that the engine oil pressure is low. Inlet Air Temperature (4G) This light indicates that the air inlet temperature is high.

Illustration 75 Location of the Operator Mode Switch

g01001702

Press the operator mode switch on the lower left side of the dashboard until the desired information is selected. The proper unit of measurement (C, kPa, miles, km, rpm, liters, or service code) will be indicated at the top of the display window. Hour meter (4L) The total operating hours of the engine can be found here. Use the hour meter to determine maintenance

intervals.

Reference: For more information, refer to Service Manual, SENR1394, Caterpillar Monitoring System.

64 Operation Section Machine Operation

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i03756185

Payload Control System (PCS) (If Equipped)


SMCS Code: 7494

The Messenger display consists of an LCD screen and four push buttons. See Illustration 77.

Illustration 77 Components in the display of the Messenger (1) (2) (3) (4) (5) LCD screen Back button Up/left button Down/right button OK button

g01304775

Display Buttons
The display has four navigation buttons. The buttons are located below the LCD screen. The four buttons are the following:

Back button Up/left button


Illustration 76
g02026033

Down/right button OK button Function of the Display Buttons


The function of each button is described below. Back Button

The following information is a brief overview of the basic functions of the system. The Payload Control System (PCS) is an electronic system that will provide an accurate weight of the material that is loaded by a wheel loader.

Messenger Display
The Messenger display is the main interface between the operator and the PCS. The Messenger display is used for the following purposes:

Display the bucket payload weight and display the


truck payload weight. operator.

Display the messages of the system to the Navigate through the menus. Adjust settings. Enter data.

Illustration 78 Back button

g01322949

The back button (2) is used for the following purposes:

Exit the currently selected menu.

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65 Operation Section Machine Operation

Remove the last selected character from a data


entry screen.

OK Button

Alternate between the main weigh screen and the


menu selection screen Up/Left Button
g01322951

Illustration 81 OK button

The OK button (5) is used for the following purposes:


Illustration 79 Up/left button
g01322948

Enter the highlighted menu. Select the highlighted list selection item. Select the highlighted character on a data entry
screen. screen.

The Up/left button (3) is used for the following purposes:

Highlight the previous menu item. Highlight the previous list selection item. Highlight the next character or the next action item
that is on the left side of a data entry screen. Down/Right Button

Select the highlighted action on a data entry Acknowledge a popup event or a diagnostic. Additional Functions
Three additional functions can be performed by pressing a combination of the buttons simultaneously. The functions and the combination of buttons are described below. Enter the Simple Calibration Update Screen Enter the simple calibration update screen by pressing the back and up/left buttons simultaneously.

Illustration 80 Down/right button

g01322950

Enter the Weigh Screen Enter the weigh screen from any menu screen by pressing the up/left and down/right buttons simultaneously. Enter the Standby Screen Enter the standby Screen from the weigh screen by pressing the down/right and OK buttons simultaneously. Press any button in order to move from the Standby screen to the weigh screen.

The down/right button (4) is used for the following purposes:

Highlight the next menu item. Highlight the next list selection item. Highlight the next character or the action item that
is on the right side of a data entry screen.

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Basic Operation of the Messenger


Selecting An Item From the Menu Press the OK button in order to select one of the menu items. The title of the menu is shown in a banner along the top of the display. The options that are available for each menu item will then be displayed. The options may be displayed individually or the options may be displayed in groups. If a down arrow appears, pressing the down/right button will highlight the next option. The down arrow is displayed in the left most column of the display. If an up arrow appears pressing the up/left button will highlight the previous option. The up arrow is displayed in the left most column of the display. Press the OK button in order to select a menu option. Press the back button in order to move up to the previous menu.

Store Switch

Illustration 83 Store switch (8) Store switch

g02026034

Reweigh / Clear/Zero Switch

Illustration 82 Reweigh / clear/zero switch (6) Reweigh switch (17) Clear/zero switch

g02026037

The reweigh / clear/zero switch is a rocker switch. The reweigh / clear/zero switch is located to the right of the display of the Messenger. See Illustration 82. The upper half of the switch functions as the reweigh switch(6). The lower half functions as the clear switch and the zero switch(7). This switch is used for the following three functions:

Illustration 84

g01962780

The store switch (8) is a push button switch that is located on the implement control pod. The store switch is shown in Illustration 83. The following can be performed with the store switch:

Storing the current truck information in the


Electronic Control Module (ECM) memory zero

Reweighing a bucket Clearing the display Zeroing the system

Resetting the truck weight and bucket weight to

Weighing Materials
The steps that are used in order to obtain an accurate weight are listed below. Perform the following before weighing the material: 1. Exercise the pins by raising the bucket at least three times. 2. Set the raise kickout at least 5% above the end of weigh point. Note: The default end of weigh point is 65%.

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67 Operation Section Machine Operation

3. Zero the system at the typical operating engine speed. Avoid the following actions while the bucket is being lifted:

Extreme changes in engine speed Directional shifts Harsh turning or jerky turning
Perform the following in order to weigh a bucket of material: 1. Load the bucket with material. 2. Fully rack back the bucket. 3. Set the engine rpm to the normal operating speed. 4. Make sure that the bucket is below the start of weigh point. Note: The default start of weigh point is 50% of the lift arm height. 5. Move the lift lever smoothly into the FULL DETENT position and raise the bucket. The material will be weighed as the bucket travels through the weigh range. When weighing is complete, the top line of the display will show the weight of the material in the bucket. The bottom line of the display will show the accumulated weight of material in the truck.

The Product Link PL121SR is capable of two-way communication between the machine and a remote user. The remote user can be a dealer or a customer. At any time, a user can request updated information from a machine such as hours of use or the location of the machine. Also, the system parameters for Product Link PL121SR can be changed. Data is transmitted from the machine to a satellite. Next, the data is transmitted to a ground station. The receiving station transmits the data to Caterpillar Inc. The data can then be sent to a Caterpillar dealer and to the customer.

Data Broadcasts
Machine data about the machine's condition and operation is being transmitted by Product Link to Caterpillar and/or Caterpillar dealers in order to better serve the customer and to improve Caterpillar products and services. The information that is transmitted may include the following data: machine serial number, location of the machine, fault codes, emissions data, fuel usage, service meter hours, version numbers for software and hardware, and installed attachments. Caterpillar and/or Caterpillar dealers may use this information for various purposes: providing services to the customer and/or the machine, checking or maintaining Product Link equipment, monitoring the machine's health or performance, helping to maintain the machine, improving the machine's efciency, evaluating or improving Caterpillar products and services, complying with legal requirements and valid court orders, performing market research, and offering the customer new products and services. Caterpillar may share some or all of the collected information with Caterpillar afliated companies, dealers, and authorized representatives. Caterpillar will not sell or rent collected information to any other third party and will exercise reasonable efforts to keep the information secure. Caterpillar recognizes and respects customer privacy. For more information, please contact your local Caterpillar dealer.

Additional Features
Reference: More complete information is available from your Caterpillar dealer. Refer to Operation and Maintenance Manual, SEBU8092, Payload Control System for additional features. For information about earlier versions of the Payload Control System, refer to Operation and Maintenance Manual, SEBU7012, Payload Control System.
i03555467

Operation in a Blast Site

Product Link (If Equipped)


SMCS Code: 7606 The Product Link PL121SR is a satellite communication device that transmits information regarding the machine to Caterpillar, Caterpillar dealers, and Caterpillar customers. The unit contains a Global Positioning System receiver (GPS receiver) and a satellite transceiver.

If the machine is required to work within 12 m (40 ft) of a blast site, then Product Link PL121SR must be disabled. In order to disable theProduct Link PL121SR install a Product Link Disconnect Switch in the machine cab that will allow the Product Link PL121SR module to be shut off. Refer to Special Instruction, REHS2365, An Installation Guide for the Product Link PL121SR and for the PL300 for more details and installation instructions. You may also disconnect the Product Link PL121SR module from the main power source by disconnecting the wiring harness at the Product Link module.

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This blast site warning does not supersede the published requirements or regulations found in Title 30 of the Code of Federal Regulations (CFR). This warning does not allow deviation from the published requirements or regulations found in Title 30 of the Code of Federal Regulations (CFR). A hazard assessment should be conducted by each customer. Every customer should meet all of the requirements of Title 30 of the Code of Federal Regulations (CFR) in order to ensure the safe storage, transportation, loading, and blasting of any explosive. The following Product Link PL121SR specications are provided in order to aid in conducting any related hazard assessment and to ensure compliance with all local regulations:

NOTICE Transmission of information using Product Link is subject to legal requirements that may vary from location to location, including, but not limited to, radio frequency use authorization. The use of Product Link must be limited to those locations where all legal requirements for the use of the Product Link communication network have been satised. In the event that a machine outtted with Product Link is located in or relocated to a location where (i) legal requirements are not satised or (ii) transmitting or processing of such information across multiple locations would not be legal, Caterpillar disclaims any and all liability related to such failure to comply and Caterpillar may discontinue the transmission of information from that machine. Consult your Caterpillar dealer with any questions that concern the operation of the Product Link in a specic country.

The transmit power rating for the Product Link


PL121SR transmitter is ve to ten watts

The operating frequency range for the Product Link


PL121SR module is 148 MHz to 150 MHz. Consult your Caterpillar dealer if there are any questions. Information for the initial installation of the Product Link PL121SR is available in Special Instruction, REHS2365, Installation Guide for the Product Link PL121SR. Operation, conguration, and troubleshooting information for the Product Link PL121SR can be found in System Operation Troubleshooting Testing and Adjusting, RENR7911.

Regulatory Compliance

Illustration 85

g01131982

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69 Operation Section Machine Operation

Illustration 86

g01435306

Note: A translated extract of the above document is provided below.

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Table 7

DECLARATION OF CONFORMITY We, of Quake Global, Inc (Previously Quake Wireless, Inc up to January 2001) 9765 Clairemont Mesa Blvd, Suite A (Previously 5575 Rufn Road, Suite 100 up to March 2002) San Diego CA 92124, Usa (Previously 92123) declare under our sole responsibility that the product QHE2500, Q2000,Q1500, Q1400, Q1200S, Q1200SG, Q1200SH, Q1200SM and Q1200SV to which this declaration relates, is in conformity with the following standards and / or other normative documents. EN 301 721 V1.2.1 (June 2001) EN 300 489-20V1.2.1 (November 2002) EN 60950-1/A11:2004, 1st Edition We hereby declare that all essential radio test suites have been carried out and that the above named product is in conformity to all the essential requirements of Directive 1999/5/EC. The conformity assessment procedure referred to in Article 10 and detailed in Annex [IV] of Directive 1999/5/EC has been followed with the involvement of the following Notied Body: BABT, Claremont House, 34 Molesey Foad, Walton-on-Thames, KT12 4RQ, UK Identication mark: 0168 The equipment will also carry the Class 2 Equipment identier.

The technical documentation relevant to the above equipment will be held at: Quake Global Inc (Previously Quake Wireless, Inc. up to January 2001) 9765 Clairemont Mesa Blvd, Suite A San Diego, CA 92124, USA

Polina Braunstein President

(signature of authorized person)

(date)

Class 2 equipment identier

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71 Operation Section Machine Operation

i03180601

i02881245

Camera
SMCS Code: 7347; 7348

Operation Information
SMCS Code: 7000 Follow these basic instructions whenever you are operating the machine:

Rear View Camera (If Equipped)


The rear view camera system consists of a camera that is located in the middle of the rear top hood panel and a VIDEO MODE SETTING menu on the monitor. Note: The rear view camera system has been set up by the factory or by a Caterpillar dealer in order to provide views which comply with specied guidelines. Consult your Caterpillar dealer before any adjustments are made to the system. For more information refer to Operation and Maintenance Manual, Monitoring System.

To prevent injury, make sure that no one is working


on the machine or near the machine. Always maintain control of the machine. negotiate any obstacles.

Raise the bucket or the work tool enough to Before you release the parking brake, depress the
service brake pedal in order to keep the machine from moving. for best control.

Drive the machine forward for best visibility and Reduce the engine speed when you maneuver in
tight quarters and when you are going over a hill.

Downhill Operation
Maintain a ground speed that is slow enough for the conditions. Before you operate down a hill, select the proper gear before you start down the grade. The proper gear should allow the machine to maintain the appropriate speed on the down grade. The throttle control should not be at high idle and the engine should not overspeed. In most situations, the proper gear will be the same gear that is required to drive up the grade. If the machine builds up excessive speed, the engine can overspeed. This can result in damage to the engine, the hydraulic pump and/or the power train. Use the right service brake pedal or the engine brake (if equipped) in order to slow the machine until a lower gear can be selected. Select the lower gear and proceed. Using the right service brake pedal continuously to control travel speed of the machine can cause the brake (axle) oil to overheat. Using the right service brake pedal to stop at high speeds can cause the brake (axle) oil to overheat. This can result in signicant wear and/or damage to the right service brake pedal and nal drive. Note: The left impeller clutch/brake pedal should not be used for downhill braking. Using the left impeller clutch/brake pedal will disengage the engine from the power train. This can result in an increased load on the brakes.

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i03774670

Engine Deceleration Impeller Clutch Lockout Lock Up Clutch


When this feature is enabled, the transmission control will lock out the impeller clutch and the lockup clutch when the machine speed is above 13.5 km/h (8.5 mph) and the left brake pedal is applied. This prevents the machine from overspeeding. The engine speed will also be proportional to control of the left brake pedal . Depress the left brake pedal in order to lower the engine speed. The transmission will resume normal operation when the machine speed is below 12 km/h (7.5 mph).
i03772675

Changing Direction and Speed


SMCS Code: 7000 Speed changes at full engine speed and directional changes at full engine speed are possible. However, when you change directions, deceleration will maximize the comfort of the operator. Use the left brake pedal to decelerate. Deceleration will also maximize the service life of power train components.

Coasting in Neutral
Coasting in neutral is not recommended at high speeds. A warning buzzer will activate inside the cab if your machine is coasting in neutral at a speed above 16 km/h (10 mph).

Transmission Control (If equipped)


For frequent downhill operations, the transmission control has a feature for neutral coasting in order to prevent the machine from overspeeding. Refer to Service Manual, Power Train Troubleshooting/ Testing & Adjusting for additional information. The feature for neutral coasting is turned on as a factory setting. If this function is not desired, turn off this function in Electronic Technician (ET). When this feature is activated, the following four functions apply:

Parking Brake
SMCS Code: 7000

Personal injury could result from the sudden stop of the machine. The parking brake is automatically engaged when brake oil pressure drops below an adequate operating pressure. If the brake loses oil pressure, the alert indicator for the brakes will ash and the action alarm will sound. The alert indicator for the brakes is on the dash panel. Loss of oil pressure will cause the parking brake to automatically engage. This will stop the machine. Anticipate a sudden stop. Correct the cause of the loss of oil pressure. Do not operate the machine without normal brake oil pressure. The action light will also ash when the lights on the monitoring system ash. The action alarm will continuously sound. Note: The action alarm intermittently sounds if the service brake loses oil pressure on early machines.

Neutral lockout Engine Decel Impeller Clutch Lockout Lockup Clutch Lockout
The transmission control will not allow the transmission to shift into NEUTRAL when the machine speed is above 12 km/h (7.5 mph). If this occurs, the gear display will ash. to stop the gear display from ashing, engage the transmission back into gear or decrease the machine speed to a speed that is below 12 km/h (7.5 mph).

Engine Deceleration and Lock Out of the Impeller Clutch and Lockup Clutch (If equipped)
The Lock Up Clutch (LUC) must be equipped to enable the function for neutral coasting. When the function for neutral coasting is enabled, the following functions are also enabled:

Driving Through the Parking Brake


NOTICE Driving the machine through the parking brakes for an extended period can cause severe damage to the braking system. Inspect the parking brake system and make any necessary repairs before returning the machine to operation.

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73 Operation Section Machine Operation

You have the ability to drive through the parking brake in order to move the machine to a safe location. In order to drive the machine through the parking brake, follow these steps: 1. After the parking brake is set, move the transmission control in the NEUTRAL position. Select the rst gear or second gear. 2. Shift the transmission control into one of the following positions: FORWARD, NEUTRAL, and FORWARD or REVERSE, NEUTRAL, and REVERSE. Note: 1F and 2F are the only gears that are available to drive in forward through the parking brake. 1R and 2Rare the only gears that are available to drive in reverse through the parking brake. Although Other gears are selectable, the other gears will not provide the drive through capabilities. 3. Increase the engine speed and move the machine to a safe location. Note: Machine movement will be jerky since the power train is ghting the parking brake. Note: A Warning Category 2S will activate during machine movement. The event will be logged, but the level two alarm should deactivate once the transmission is returned to the NEUTRAL position. 4. Shift the transmission control into the NEUTRAL position in order to stop the machine. 5. Before you return the machine to operation, inspect the brake system and make any necessary repairs.
i03774734

Secondary Steering (If Equipped)


SMCS Code: 7000 The activation of the secondary steering system indicates a failure of the primary steering. If the primary steering warning indicator comes on during operation, steer the machine to a safe location and immediately stop the machine. Stop the engine and investigate the cause of the problem. Note: The secondary steering only works while the machine is in motion. Complete any necessary repairs before you return the machine to operation.

74 Operation Section Engine Starting

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Engine Starting
i02699406

i01925846

Engine and Machine Warm-Up


SMCS Code: 1000; 7000 After the engine has been started, allow the monitoring system to complete the self test. NOTICE Keep engine speed low until the engine oil pressure alert indicator goes out. If the alert indicator does not go out within ten seconds, stop the engine and investigate the cause before starting again. Failure to do so can cause engine damage. 1. Allow a cold engine to warm up at LOW IDLE for at least ve minutes. To help the hydraulic components to warm up faster, engage the attachment controls and disengage the attachment controls. 2. Look at the indicators and the gauges frequently during operation. Refer to Operation and Maintenance Manual, Monitoring System. The hydraulic oil will warm up faster, if the bucket control is held in the CLOSE position for short periods of ten seconds or less. This will allow the hydraulic oil to reach relief pressure, which causes the hydraulic oil to warm up more rapidly. Cycle all controls in order to allow warm hydraulic oil to circulate through all hydraulic cylinders and through all hydraulic lines. When you idle the engine in order to warm up the engine, observe the following recommendations:

Engine Starting
SMCS Code: 1000; 7000 1. Make sure that the parking brake is engaged. 2. Make sure that the transmission control is in the NEUTRAL position. 3. Make sure that the control levers are in the HOLD position. 4. Adjust the mirrors for best visibility. 5. Move the steering control to the desired position. 6. Fasten the seat belt. 7. Before the engine is started, check for the presence of bystanders or maintenance personnel. Ensure that all personnel are clear of the machine. Briey sound the forward horn before you start the engine. 8. Turn the engine start switch to the START position in order to start the engine. Ether will be automatically injected if the ambient conditions call for a starting aid. NOTICE Do not crank the engine for more than 30 seconds. Allow the starter to cool for two minutes before cranking again. Turbocharger damage can result if the engine rpm is not kept low until the oil gauge display veries that the oil pressure is sufcient. 9. Release the engine start switch key after the engine starts. For starting below 18C (0F), the use of one of the following cold weather starting aids is recommended:

Allow the engine to warm up for approximately 15


minutes when the temperature is higher than 0C (32F). minutes or more when the temperature is below 0C (32F). less than 18C (0F). More time may also be required if the hydraulic functions are sluggish.

Allow the engine to warm up for approximately 30

Coolant heater Fuel heater Jacket water heater Extra battery capacity
Reference: At temperatures below 23C (10F), consult your Caterpillar dealer for additional information or refer to Special Publication, SEBU5898, Cold Weather Recommendations for All Caterpillar Machines.

More time may be required if the temperature is

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75 Operation Section Parking

Parking
i01358133

i03765354

Stopping the Machine


SMCS Code: 7000 NOTICE Do not engage the secondary brake while the machine is moving unless the primary service brake fails. The use of the secondary brake as a service brake in regular operation will cause severe damage to the brake system. 1. Park the machine on a level surface. If it is necessary to park on a grade, block the wheels. 2. Apply the service brakes in order to stop the machine. 3. Move the transmission control to the NEUTRAL position. 4. Engage the parking brake. 5. Lower the work tool to the ground and apply slight downward pressure.
i00982184

Parking Brake Override (If Equipped)


SMCS Code: 3065; 4250; 4267; 4284

Illustration 87

g02029434

The parking brake override (1) is located on the right side of the rear bumper.

Stopping the Engine


SMCS Code: 1000; 7000 NOTICE Stopping the engine immediately after it has been working under load, can result in overheating and accelerated wear of the engine components. See the following stopping procedure, to allow the engine to cool, and to prevent excessive temperatures in the turbocharger center housing, which could cause oil coking problems. 1. While the machine is stopped, run the engine for ve minutes at low idle. This allows hot areas of the engine to cool gradually. 2. Turn the engine start switch to the OFF position and remove the key.

Block wheels before activating the auxiliary parking


brake release in order to prevent the machine from moving. parking brake.

Pull the auxiliary release in order to disengage the For normal parking brake operation, the auxiliary
parking brake must be pushed in. Note: Do not operate the machine again until the problem has been corrected.

76 Operation Section Parking

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i01925768

Stopping the Engine if an Electrical Malfunction Occurs


SMCS Code: 1000; 7000 If the engine start switch is in the OFF position but the engine does not stop, use the engine shutdown switch to stop the engine.

2. Move the hydraulic lockout control to the UNLOCKED position. 3. Push the lift control to the LOWER position in order to lower the bucket or the work tool to the ground. The lift control will return to the HOLD position when the control lever is released. 4. Move the hydraulic lockout control to the LOCKED position. 5. Turn the engine start switch to the OFF position. Note: If the work tools will not lower, the pilot supply on/off solenoid may be inoperable. In this case, proceed to Step 6.

Personal injury or death may occur from failure to adhere to the following warnings. Keep all personnel away from the boom drop area when lowering the boom with the engine stopped. Keep all personnel away from the front linkage when lowering the boom.

Illustration 88

g00804787

The engine shutdown switch is located on the side of the left rear bumper. Stop (1) Lift up the cover and move the switch to position (1) in order to stop the engine. Note: The engine shutdown control does not shut off the electrical system of the machine. Run (2) Push down the cover and the switch to position (2) in order to allow the engine to be operated. Note: Do not operate the machine again until the problem has been corrected.
i01921267 g00933004

Illustration 89

Equipment Lowering with Engine Stopped


SMCS Code: 7000 1. Turn the engine start switch to the ON position.

6. A ball valve is located near the left rear of the main control valve. This ball valve is used for manually lowering the work tool. Slowly turn the square stem in the clockwise direction. The square stem should be rotated 90 degrees. After the work tool is resting on the ground, rotate the square stem counterclockwise.

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77 Operation Section Parking

i02063754

Leaving the Machine


SMCS Code: 7000 1. Use the steps and the handholds when you get off the machine. Face the machine and use both hands. Make sure that the steps are clear of debris before you dismount. 2. Inspect the engine compartment for debris. Clean out any debris and paper in order to avoid a re. 3. Remove all ammable debris in order to reduce a re hazard. Dispose of all debris properly. 4. Turn the battery disconnect switch to the OFF position. If the machine will not be operated for an extended period of a month or more, remove the battery disconnect switch key. 5. Install all covers and all vandalism protection locks.

78 Operation Section Transportation Information

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Transportation Information
i01671778

8. Lock the door and the access covers. Attach any vandalism protection. 9. Secure the machine, any equipment, and any tools with adequate tie-downs in order to prevent movement during shipping. 10. Cover the exhaust opening. The turbocharger (if equipped) should not rotate when the engine is not operating. Damage to the turbocharger can result.
i01925785

Shipping the Machine


SMCS Code: 7000; 7500 Investigate the travel route for overpass clearances. Make sure that there will be adequate clearance if the machine that is transported has a ROPS, a cab, or a canopy. Remove ice, snow, or other slippery material from the loading dock and from the transport machine before you load the machine. This will help to prevent slippage of the machine. This will also help to prevent a shift while the machine is moving in transit. Obey the appropriate laws that govern the parameters of the load (weight, width, and length).

Roading the Machine


SMCS Code: 7000 Before you road a machine, consult your tire dealer for recommended tire pressures and for speed limitations. Limitations for TON-kilometer per hour (TON-mile per hour) must be obeyed. Consult your tire dealer for the speed limit of the tires that are used. When you travel for long distances, schedule stops in order to allow the tires and the components to cool. Stop for 30 minutes after every 40 km (25 miles) or after every hour. Perform a thorough daily inspection. Refer to Operation and Maintenance Manual, Daily Inspection. Bring the engine coolant, the crankcase oil, and the transmission oil up to the correct levels.

Illustration 90 Properly chocked trailer wheels

g00863991

Inate the tires to the correct pressure. Use a self-attaching ination chuck in order to inate the tire. Stand behind the tire tread while you inate the tires. Reference: For more information, refer to the Operation and Maintenance Manual, Tire Ination Information. Check with the proper ofcials in order to obtain the required licenses and other similar items. Travel at a moderate speed. Observe all speed limitations when you road the machine. Carry the work tool as low to the ground as possible. Disable the controls for the work tool when the machine is roaded. For more information, refer to Operation and Maintenance Manual, Operator Controls (Electrohydraulic Control Console).

1. Chock the trailer wheels or the rail car wheels before you load the machine. 2. After the machine is positioned, connect the steering frame lock in order to hold the front frame and the rear frame in place. 3. Lower the bucket or the work tool to the oor of the transport vehicle. Move the transmission control to the NEUTRAL position. 4. Engage the parking brake. 5. Turn the engine start switch to the OFF position. Remove the engine start switch key. 6. Move all of the control levers in order to relieve any trapped pressure. 7. Turn the battery disconnect switch to the OFF position. Remove the battery disconnect switch key.

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79 Operation Section Transportation Information

i02792781

Lifting and Tying Down the Machine


SMCS Code: 7000; 7500

Reference: Refer to Operation and Maintenance Manual, Specications for the dimensions and weight of the machine. Lifting Point In order to lift the machine, attach the lifting devices to the lifting points.

Improper lifting and improper tie-downs can allow the load to shift or fail and cause injury or damage. Use only properly rated cables and slings with lift and tie down points provided. Follow the instructions in Operation and Maintenance Manual, Lifting and Tying Down the Machine for the proper technique for securing the machine. Refer to Operation and Maintenance Manual, Specications for specic weight information.

Tie Down Point In order to tie down the machine, attach the tie-downs to the tie down points. Use properly rated cables and properly rated slings to lift the machine. Position the crane or the lifting device in order to lift the machine in a level position. The width of the spreader bar must be sufcient to prevent the lifting cables or the lifting straps from contacting the machine. 1. Engage the parking brake before you sling the machine and before you secure the machine with tie-downs. 2. Install the frame lock pin prior to lifting the machine. 3. Attach two lifting cables to the rear of the machine. There is one lifting eye on each side of the rear of the machine. The lifting eyes are identied by a label that shows a hook. 4. Attach two lifting cables to the front of the machine. There is one eye on each side of the front of the machine. The lifting eyes are identied by a label that shows a hook. 5. Connect the four lifting cables to the spreader bars. The spreader bars must be centered over the machine. 6. If equipped, secure any attachments.

Illustration 91

g01394473

NOTICE Improper lifting or tie-downs can allow the load to shift and cause injury or damage. Install the steering frame lock link before lifting. Note: Do not use handles or steps in order to lift or tie down the machine. Note: The machine shipping weight that is listed is the weight of the most common conguration of the machine. If attachments have been installed on your machine, the weight of your machine and the center of gravity of your machine may vary.

7. Lift the machine. Move the machine to the desired position. 8. When the machine is positioned, place the blocks behind the tires. 9. Secure the machine at the tie-down positions. The positions are identied on the machine by a label. Check all of the laws that govern the load characteristics (height, weight, width, and length). Reference: For shipping instructions, refer to Operation and Maintenance Manual, Shipping the Machine.

80 Operation Section Towing Information

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Towing Information
i02973621

Keep the tow line angle to a minimum. Do not exceed a 30 angle from the straight ahead position. Quick machine movement could overload the tow line or the tow bar. This could cause the tow line or the tow bar to break. Gradual, smooth machine movement is recommended. Normally, the towing machine should be as large as the disabled machine. The towing machine must have enough brake capacity, enough weight, and enough power for the grade that is involved and for the distance that is involved. It may be necessary to connect a larger machine or additional machines to the machine that is disabled. This will provide sufcient control for moving a disabled machine downhill and sufcient braking for moving a disabled machine downhill. The requirements for different situations cannot be specied. Minimal towing machine capacity is required on smooth, level surfaces. Maximum towing machine capacity is required on inclines or on poor surface conditions. Any towed machine with a load must be equipped with a brake system that can be operated from the operator's compartment. When you tow the machine from the front, attach the tow line to the tow eyes on the frame. In order to tow the machine from the rear, attach the tow line to the recovery hitch. Note: The recovery hitch is only for machine retrieval. Do not use the recovery hitch for any of the following:

Machine Retrieval
SMCS Code: 7000

Personal injury or death could result when towing a disabled machine incorrectly. Block the machine to prevent movement before releasing the brakes. The machine can roll free if it is not blocked. In order to properly perform the towing procedure, use the following recommendations. This machine is equipped with spring applied parking brakes. The parking brakes are released by oil pressure. If the engine is inoperable or if the brake oil system is inoperable, the parking brakes are applied. The machine cannot be moved. Use these towing instructions for moving a disabled machine over a short distance. Do not move the machine faster than 2 km/h (1.2 mph). Move the machine to a convenient location for repair. Use these instructions for emergency situations only. Always haul the machine if long distance moving is required. Shielding must be provided on the towing machine in order to protect the operator in case the tow line breaks or the tow bar breaks. Do not allow riders on the machine which is being towed. Before you tow the machine, inspect the condition of the tow line or of the tow bar. Make sure that the tow line or the tow bar is sturdy enough to tow the disabled machine. The tow line or the tow bar must have a strength that is equal to 1.5 times the gross weight of the machine that is being towed. Use a tow bar with this strength or a tow line with this strength to tow a disabled machine that is stuck in the mud. Also, use a tow bar with this strength or a tow line with this strength to tow a disabled machine up a grade. Do not use a chain for pulling. A chain link may break. This can cause personal injury. Use a wire cable with cable loops or end rings. Position an observer at a safe location. The observer should stop the pulling procedure if the cable starts to break or the cable starts to unravel. If the towing machine moves without the pulled machine, stop the pulling procedure.

a lifting point a tie down point towing a trailer towing another vehicle
Consult your Caterpillar dealer for more information about towing a disabled machine.

Towing with the Engine Idle


If the engine is running, the machine can be towed for a short distance under certain conditions. The power train and the steering system must be operable. Tow the machine for a short distance only. For example, pull the machine out of mud or pull the machine to the side of the road. The operator on the towed machine must steer the machine in the direction of the tow line.

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81 Operation Section Towing Information

Carefully obey all of the instructions that are outlined in this topic.

Towing with the Engine Stopped


Perform the following steps before you tow the machine.

When the axle shafts are removed, the machine has no service or parking brakes. The machine can roll and cause personal injury or death. Block the wheels securely so that the machine cannot move. The towing connection must be rigid, or towing must be done by two machines of the same size or larger than the towed machine. Connect a machine on each end of towed machine. 2. If failure of the internal transmission or of the drive train is suspected, remove the axle shafts. Reference: For more information on the axle shaft, refer to the Service Manual for your machine or consult your Caterpillar dealer.

Illustration 92 Typical example (A) Rod End (B) Head End

g00286064

NOTICE Release the parking brake to prevent excessive wear and damage to the parking brake system when towing the machine. 3. Release the parking brake. Reference: For information about the manual release of the parking brake, refer to Operation and Maintenance Manual, Parking Brake Manual Release. 4. Inspect the machine for power train damage. If damage is suspected, remove the axle shafts. 5. Fasten the tow bar.

NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. NOTICE Be sure the cylinder hoses are connected correctly before operating the machine. With the hoses reversed, the steering system will not function. 1. Reverse the hydraulic steering hose connections on one cylinder only. This will allow the steering cylinders to move freely.

Personal injury or death can result from brake malfunction. Make sure all necessary repairs and adjustments have been made before a machine that has been towed to a service area, is put back into operation. 6. Remove the wheel blocks. Tow the machine slowly. Do not exceed 2 km/h (1.2 mph).

82 Operation Section Towing Information

SEBU8480

i01922637

Parking Brake Manual Release


SMCS Code: 4267; 7000

Personal injury or death can result from a brake malfunction. Do not operate the machine if the brake was applied due to a malfunction of the oil system or the brake. Correct any problem before attempting to operate the machine. 1. Connect the steering frame lock and block the wheels.

Illustration 95

g01000620

3. Install the bolts in the forcing holes. Tighten these bolts until an opposing force is felt. Note: Before you operate the machine, remove the bolts from the forcing holes and install bolts in the storage holes.

Illustration 93

g01000600

Illustration 94

g01000616

2. Remove the three bolts from the storage holes in the cover.

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83 Operation Section Engine Starting (Alternate Methods)

Engine Starting (Alternate Methods)


i02407539

NOTICE When starting from another machine, make sure that the machines do not touch. This could prevent damage to engine bearings and electrical circuits. Turn on (close) the battery disconnect switch prior to the boost connection to prevent damage to electrical components on the stalled machine. Severely discharged maintenance free batteries do not fully recharge from the alternator after jump starting. The batteries must be charged to proper voltage with a battery charger. Many batteries thought to be unusable are still rechargeable. This machine has a 24 volt starting system. Use only the same voltage for jump starting. Use of a higher voltage damages the electrical system.

Engine Starting with Jump Start Cables


SMCS Code: 1000; 7000

Failure to properly service the batteries may cause personal injury. Prevent sparks near the batteries. They could cause vapors to explode. Do not allow the jump start cable ends to contact each other or the machine. Do not smoke when checking battery electrolyte levels. Electrolyte is an acid and can cause personal injury if it contacts the skin or eyes. Always wear eye protection when starting a machine with jump start cables. Improper jump start procedures can cause an explosion resulting in personal injury. When using jumper cables, always connect the positive (+) jumper cable to the positive (+) battery terminal rst. Next, connect the negative (-) jumper cable to the frame away from the batteries. Follow the procedure in the Operation and Maintenance Manual. Jump start only with an energy source of the same voltage as the stalled machine. Turn off all lights and accessories on the stalled machine. Otherwise, they will operate when the energy source is connected.

Use of Jump Start Cables


1. Place the transmission control on the stalled machine in the NEUTRAL position. Engage the parking brake. Lower all attachments to the ground. Move all controls to the HOLD position. 2. On the stalled machine, turn the engine start switch to the OFF position. Turn off the accessories. 3. On the stalled machine, turn the battery disconnect switch to the ON position. 4. Move the machine or the auxiliary power source close to the stalled machine so that the cables can reach. DO NOT ALLOW THE MACHINE OR THE AUXILIARY POWER SOURCE TO CONTACT THE STALLED MACHINE. 5. Stop the engine on the machine that is the electrical source. (If you are using an auxiliary power source, turn off the charging system.) 6. Check the battery caps for correct placement and for correct tightness. Make these checks on both machines. Make sure that the batteries in the stalled machine are not frozen. Check the batteries for low electrolyte. 7. Connect the positive jump start cable to the positive cable terminal of the discharged battery. Do not allow positive cable clamps to contact any metal except for battery terminals. Note: Batteries in series may be in separate compartments. Use the terminal that is connected to the starter solenoid. This battery is normally on the same side of the machine as the starter.

Do not attempt to charge a battery that has ice in any of the cells. Charging a battery in this condition can cause an explosion that may result in personal injury or death. Always let the ice melt before attempting to charge.

84 Operation Section Engine Starting (Alternate Methods)

SEBU8480

8. Connect the positive jump start cable to the positive terminal of the electrical source. Use the procedure from Step 7 in order to determine the correct terminal. 9. Connect one end of the negative jump start cable to the negative terminal of the electrical source. 10. Make the nal connection. Connect the negative cable to the frame of the stalled machine. Make this connection away from the battery, away from the fuel, away from the hydraulic lines, and away from all moving parts. 11. Start the engine of the machine that is the electrical source. (If you are using an auxiliary power source, energize the charging system on the auxiliary power source.) 12. Allow the electrical source to charge the batteries for two minutes. 13. Attempt to start the stalled engine. Reference: For more information, refer to Operation and Maintenance Manual, Engine Starting. 14. Immediately after the stalled engine starts, disconnect the jump start cables in reverse order.
i02154845

Illustration 97

g01092630

The auxiliary start receptacle is located behind the battery compartment on the right rear bumper. Some Caterpillar products may be equipped with an auxiliary start receptacle. All other machines can be equipped with an auxiliary start receptacle from parts service. Then, a permanent receptacle is always available for jump starting. There are two cable assemblies that can be used to jump start the stalled machine. You can jump start the machine from another machine that is equipped with an auxiliary start receptacle or you can use an auxiliary power pack. Your Caterpillar dealer can provide the correct cable lengths for your application. 1. Determine the cause of the failure. Use this procedure if the machine does not have a diagnostic connector. 2. Place the transmission control on the stalled machine in the NEUTRAL position. Engage the parking brake. Lower the implement to the ground. Move all controls to the HOLD position. 3. On a stalled machine, turn the engine start switch to the OFF position. Turn off the accessories. 4. On a stalled machine, turn the battery disconnect switch to the ON position. 5. Move the machine or the auxiliary power source close to the stalled machine so that the cables can reach. DO NOT ALLOW THE MACHINE OR THE AUXILIARY POWER SOURCE TO CONTACT THE STALLED MACHINE. 6. Stop the engine on the machine that is the electrical source. (If you are using an auxiliary power source, turn off the charging system.) 7. On the stalled machine, connect the appropriate cable to the auxiliary start receptacle.

Engine Starting with Auxiliary Start Receptacle


SMCS Code: 1463

Illustration 96

g00841348

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85 Operation Section Engine Starting (Alternate Methods)

8. Connect the other end of this cable to the auxiliary start receptacle of the electrical source. 9. Start the engine of the machine that is the electrical source. (If you are using an auxiliary power source, energize the charging system on the auxiliary power source.) 10. Allow the electrical source to charge the batteries for two minutes. 11. Attempt to start the stalled engine. Refer to Operation and Maintenance Manual, Engine Starting. 12. Immediately after the stalled engine starts, disconnect the cable from the electrical source. 13. Disconnect the other end of this cable from the stalled machine. 14. Conclude with a failure analysis on the starting charging system of the stalled machine, as required. Check the machine when the engine is running and the charging system is in operation.

86 Maintenance Section Tire Ination Information

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Maintenance Section Tire Ination Information


i02096880

Reference: For tire ination instructions, refer to Special Instruction, SMHS7867, Nitrogen Tire Ination Group. For nitrogen ination, use the same tire pressures that are used for air ination. Consult your tire dealer for operating pressures.
i02284174

Tire Ination with Nitrogen


SMCS Code: 4203 Caterpillar recommends the use of dry nitrogen gas for tire ination and for tire pressure adjustments. This includes all machines with rubber tires. Nitrogen is an inert gas that will not aid combustion inside the tire.

Tire Ination Pressure


SMCS Code: 4203; 7500 The tire ination pressure for machines that are shipped from the factory is suitable for shipping only. Always obtain the proper tire ination pressures for your machine from the tire supplier before placing the machine into operation. The recommended tire ination pressures for the front tires and for the rear tires will vary for each application. Proper tire ination pressure and maintenance of the tire ination pressure is critical for optimum tire life. The tire ination pressure should always be obtained from the tire supplier due to changes in the technology of tires, equipment, and job applications. Reference: Refer to the latest edition of Special Publication, Caterpillar Performance Handbook for general information on tire ination pressure.
i02610518

Proper nitrogen ination equipment, and training in using the equipment, are necessary to avoid over ination. A tire blowout or rim failure can result from improper or misused equipment and personal injury or death can occur. A tire blowout and/or rim failure can occur if the ination equipment is not used correctly, due to the fact that a fully charged nitrogen cylinder's pressure is approximately 15000 kPa (2200 psi). There are other benets to using nitrogen in addition to reducing the risk of an explosion. The use of nitrogen for tire ination lessens the slow oxidation of the rubber. Use of nitrogen also slows gradual tire deterioration. This is especially important for tires that are expected to have a long service life of at least four years. Nitrogen reduces the corrosion of rim components. Nitrogen also reduces problems that result from disassembly.

Tire Ination Pressure Adjustment


SMCS Code: 4203 Always obtain the proper tire ination pressures and maintenance recommendations for the tires on your machine from your tire supplier. The tire pressure in a warm shop area 18 to 21C (65 to 70F) will signicantly change when you move the machine into freezing temperatures. If you inate the tire to the correct pressure in a warm shop, the tire will be underinated in freezing temperatures. Low pressure shortens the life of a tire. Reference: When you operate the machine in freezing temperatures, refer to Special Publication, SEBU5898, Cold Weather Recommendations for All Caterpillar Machines in order to adjust tire ination pressures.

A tire blowout or a rim failure can cause personal injury. Use a self-attaching ination chuck and stand behind the tread when inating a tire, to prevent personal injury. Note: Do not set the tire ination equipment regulator higher than 140 kPa (20 psi) over the recommended tire pressure. Use 6V-4040 Ination Group or an equivalent ination group to inate tires with a nitrogen gas cylinder.

SEBU8480

87 Maintenance Section Lubricant Viscosities and Rell Capacities

Lubricant Viscosities and Rell Capacities


i03653123

Lubricant Viscosities for Ambient Temperatures


NOTICE Do NOT use only the Oil Viscosities column when determining the recommended oil for a machine compartment. The Oil Type and Classication column MUST also be used. NOTICE The footnotes are a key part of the Lubricant Viscosities for Ambient Temperatures tables. Read ALL footnotes that pertain to the machine compartment in question. Note: Use the oil type and the classication that is recommended for the various machine compartments. Note: Some machine compartments allow the use of more than one oil type. For the best results, do not mix oil types. Note: Different brands of oils may use different additive packages. For the best results, do not mix oil brands. Note: Caterpillar oil is the preferred oil. All other listed oils are acceptable oils. Caterpillar has determined that H Series Medium Wheel Loaders equipped with the High Ambient Cooling Attachment can operate with Cat HYDO Advanced 10 Hydraulic System Oil in ambient temperatures from 20 C (4 F) to 50 C (122 F).

Lubricant Viscosities
SMCS Code: 7581

Selecting the Viscosity


Ambient temperature is the temperature of the air in the immediate vicinity of the machine. This may differ due to the machine application and from the generic ambient temperature for a geographic region. In order to select the proper oil viscosity, review the regional ambient temperature and the potential ambient temperature for a given machine application. Use the higher temperature of the two ambient temperatures in order to select the oil viscosity. Use the highest oil viscosity that is allowed for the ambient temperature when you start the machine. For arctic applications, the preferred method is the use of heaters for machine compartments and a high viscosity oil. The proper oil viscosity grade is determined by the minimum outside ambient temperature. This is the temperature when the machine is started and while the machine is operated. In order to determine the proper oil viscosity grade, refer to the Min column in the table. This information reects the coldest ambient temperature condition for starting a cold machine and for operating a cold machine. Refer to the Max column in the table in order to select the oil viscosity grade for operating the machine at the highest temperature that is anticipated. Machines that are operated continuously should use oils that have the higher oil viscosity in the nal drives and in the differentials. The oils that have the higher oil viscosity will maintain the highest possible oil lm thickness. Consult your dealer if additional information is needed. Note: SAE 0W oil and SAE 5W oil are not recommended for heavily loaded machines or machines that are operated continuously. These viscosity grades are not recommended for use in hydraulic hammers. The oils that have the higher oil viscosity will maintain the highest possible oil lm thickness. Consult your dealer if additional information is needed. Note: Some machine models and/or machine compartments do not allow the use of all available viscosity grades.

88 Maintenance Section Lubricant Viscosities and Rell Capacities

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Table 8

Lubricant Viscosities for Ambient Temperatures(1) Compartment or System Oil Type and Classication Oil Viscosities SAE 0W20 SAE 0W30 Cat DEO-ULS Cat DEO Multigrade Cat DEO SYN(4) Cat Arctic DEO SYN(5) Cat ECF-1-a, Cat ECF-2, Cat ECF-3(6) SAE 0W40 SAE 5W30 SAE 5W40 SAE 10W30(7) C Min 40 40 40 30 30 18 18 9.5 40 40 30 20 0 10 20 40 40 30 30 20 10 20 15 20 15 40 40 35 25 20 10 30 20 Max 10 30 40 30 50 40 50 50 10 20 20 10 35 50 43 40 40 40 40 40 50 40 50 40 50 0 10 10 15 43 50 43 40 Min 40 40 40 22 22 0 0 15 40 40 22 4 32 50 4 40 40 22 22 4 50 4 5 4 5 40 40 31 13 4 50 22 4 F Max 50 86 104 86 122 104 122 122 50 68 68 50 95 122 110 104 104 104 104 104 122 104 122 104 122 32 50 50 59 110 122 110 104
(continued)

Engine Crankcase(2)(3)

SAE 10W40 SAE 15W40 SAE 0W20(8) SAE 0W30(9) Cat TDTO Cat TDTO-TMS Cat Arctic TDTO commercial TO-4 SAE 5W30(9) SAE 10W SAE 30(10)

Power Shift Transmission

SAE 50(10)(11) TDTO-TMS(10)(12) SAE 0W20 Cat HYDO Advanced 10(13)(14) Cat MTO(13)(14) Cat DEO(13)(14) Cat DEO-ULS(13)(14) Cat TDTO(13)(14) Cat Arctic TDTO(13)(14) Cat TDTO-TMS(13)(14) Cat DEO SYN(13)(14) Cat Arctic DEO SYN(13)(14) Cat ECF-1-a, Cat ECF-2, Cat ECF-3, Cat TO-4, Cat TO-4M, Cat BF-1(13)(14) SAE 0W30 SAE 5W30 SAE 5W40 SAE 10W(15)

Hydraulic Systems

SAE 30 SAE 10W30 SAE 15W40 Cat MTO Cat TDTO-TMS(16) SAE SAE 0W20(8) 0W30(9)

Drive Axles

Cat TDTO Cat TDTO-TMS commercial TO-4

SAE 5W30(9) SAE 10W SAE 30 SAE 50 TDTO-TMS(12)

External Lubrication Points

Advanced 3Moly

NLGI Grade 2

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89 Maintenance Section Lubricant Viscosities and Rell Capacities

(Table 8, contd)

Lubricant Viscosities for Ambient Temperatures(1) Compartment or System Steering Drive Shaft Universal Joints(18) Drive Shaft Support Bearing
(1)

Oil Type and Classication

Oil Viscosities

C Min 30 Max 40 Min 22

F Max 104

Column(17)

Multipurpose Grease

NLGI Grade 2

When you are operating the machine in temperatures below 20C (4F), refer to Special Publication, SEBU5898, Cold Weather Recommendations. This is available from your Caterpillar dealer. (2) Supplemental heat is recommended for cold-soaked starts below the minimum ambient temperature. Supplemental heat may be required for cold-soaked starts that are above the minimum temperature that is stated, depending on the parasitic load and other factors. Cold-soaked starts occur when the engine has not been operated for a period of time, allowing the oil to become more viscous due to cooler ambient temperatures. (3) Cat DEO-ULS or commercial oils meeting Cat ECF-3 specication are strongly recommended for use in diesel engines that are equipped with Diesel Particulate Filters (DPF) and other aftertreatment devices. (4) Cat DEO SYN is an SAE 5W-40 viscosity grade oil. (5) Cat Arctic DEO SYN is an SAE 0W-30 viscosity grade oil. (6) Cat Engine Crankcase Fluid specications. Commercial alternative diesel engine oils must meet one or more of these Cat ECF specications. (7) SAE 10W-30 is the preferred viscosity grade for the 3116, 3126, C7, C-9 and the C9 diesel engines when the ambient temperature is between -18 C (0 F) and 40 C (104 F). (8) First Choice: Cat Arctic TDTO - SAE 0W-20. Second Choice: Oils of full synthetic basestock that do not have viscosity index improvers and do meet the performance requirements of the Cat TO-4 specication for the SAE 30 viscosity grade. Typical lubricant viscosity grades are SAE 0W-20, SAE 0W-30, and SAE 5W-30. Third Choice: Oils that contain a TO-4 additive package and a lubricant viscosity grade of SAE 0W-20, SAE 0W-30, or SAE 5W-30. (9) First Choice: Oils of full synthetic basestock that do not have viscosity index improvers and do meet the performance requirements of the Cat TO-4 specication for the SAE 30 viscosity grade. Typical viscosity grades are SAE 0W-20, SAE 0W-30, and SAE 5W-30. Second Choice: Oils with a TO-4 type additive package and a lubricant viscosity grade of SAE 0W-20, SAE 0W-30, or SAE 5W-30. (10) Except for machines that are equipped with a hydraulic drive winch gear case. Use SAE 30 viscosity grade for 0C (32F) to 43C (110F) or Cat TDTO-TMS for 20C (-4F) to 50C (122F). (11) Except for machines that are equipped with ICM controlled transmissions. Do not use SAE 50 viscosity grade oil in ICM controlled transmissions. (12) Cat TDTO-TMS (Transmission Multi-Season) (synthetic blend that exceeds the Cat TO-4M multigrade specication requirements). (13) Cat HYDO Advanced 10 is the preferred oil for use in most Caterpillar machine hydraulic and hydrostatic transmission systems when ambient temperature is between 20 C (4 F) and 40 C (104 F). Cat HYDO Advanced 10 has an SAE viscosity grade of 10W. Cat HYDO Advanced 10 has a 50% increase in the standard oil drain interval for machine hydraulic systems (3000 hours versus 2000 hours) over second and third choice oils - when following the maintenance interval schedule for oil lter changes and for oil sampling that is stated in the Operation and Maintenance Manual for your particular machine. 6000 hour oil drain intervals are possible when using SOS Services oil analysis. Contact your Cat dealer for details. In order to gain the most benet from the improved performance designed into Cat HYDO Advanced 10, when switching to Cat HYDO Advanced 10, cross contamination with the previous oil should be kept to less than 10%. (14) Second choice oils are Cat MTO, Cat DEO, Cat DEO-ULS, Cat TDTO, Cat Arctic TDTO, Cat TDTO-TMS, Cat DEO SYN, Cat Arctic DEO SYN. Third choice oils are commercial oils that meet Cat ECF-1-a, Cat ECF-2, Cat ECF-3, Cat TO-4, or the Cat TO-4M specications, and that have a minimum zinc additive level of 0.09 percent (900 ppm). Commercial biodegradable hydraulic oil must meet the Cat BF-1 specication. Refer to the machine Operation and Maintenance Manual and/or contact your local Caterpillar dealer before using commercial oils that meet Cat BF-1 in Cat Hydraulic Excavators. The minimum viscosity for commercial alternative oils used in most Cat machine hydraulic and hydrostatic transmission systems is 6.6 cSt at 100 C (212 F) (ASTM D445). (15) For machines equipped with a High Ambient Cooling Attachment the maximum ambient temperature is 50 C (122 F) (16) Cat TDTO-TMS (Transmission Multi-Season) (synthetic blend that exceeds the Cat TO-4M multigrade speci cation requirements) (17) HMU Steering (18) 980 Drive Shaft is maintenance free.

90 Maintenance Section Lubricant Viscosities and Rell Capacities

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Capacities (Rell)
SMCS Code: 7560
Table 9

Approximate Rell Capacities Component or System Engine Crankcase(1) Transmission Hydraulic Tank Hydraulic System (Two Cooling System Fuel Tank Front Differential and Final Drives(3)(4) Rear Differential and Final Drives(3)(4) Lift Cylinder Pin Joint(5) Boom Pin Joint(5)
(1)

Liters 60 83 267

US gal 15.5 21.9 70.5 99.6 25.1 187.8 49.1 49.1 10 .07

Valve)(2)

390 95 711 186 186 38 .25

This includes changing the oil lter. (2) This includes the hydraulic tank, the hydraulic lines, and all hydraulic components. (3) Allow 3 L (3.2 qt) for the addition of 1U-9891 Hydraulic Oil Additive. (4) If the machine is equipped with an axle oil cooler, increase the oil by 10 L (2.6 US gal) for each differential and nal drive. (5) This is the capacity for one pin joint. There is a total of two.

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91 Maintenance Section Lubricant Viscosities and Rell Capacities

Settings of the Injectors for the Autolube System (If Equipped)

Illustration 98 988H Wheel Loader (A) A-Pin (B) B-Pin (C) C-Pin (E) E-Pin (F) F-Pin (G) G-Pin (H) Pin for Upper Articulation Joint (J) Pin for Lower Articulation Joint Table 10 (K) K-Pin (L) Steering Cylinder Pins (X) Trunnions (Y) Y-Pin

g01032039

The controller of the autolube system is preset from the factory and shipped from the factory so that lubrication is dispensed at 15 minute intervals, and all of the injectors are preset at the full ow setting. This can cause an excessive buildup of grease around some of the joints. As a result, the grease reservoir may need to be lled more frequently. The injectors for selected joints can be adjusted in order to reduce the ow of grease without adversely affecting the life of the pin. The injectors are set by the factory at the full ow setting. This setting is equivalent to 8 turns open. When the injectors are adjusted, the injectors should rst be closed. Then, the injectors should be opened by the number of specied turns. The recommended settings for the injectors at each pin location are listed in Table 10.

Pins A B C E F G H J K L X Y

Qty (Injectors) 0 2 2 3 2 1 1 1 0 4 2 0

Settings (Turns)

5 2 8 2 8 2 8 8

Note: By using the above settings, the buildup of grease will be reduced and the interval between rells of the reservoir will be extended to approximately 250 hours. Grease levels in the reservoir must be checked in order to ensure an uninterrupted ow.

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SOS Information
SMCS Code: 1348; 1395; 3080; 4070; 4250; 4300; 5050; 7542 SOS Services is a highly recommended process for Caterpillar customers to use in order to minimize owning and operating cost. Customers provide oil samples, coolant samples, and other machine information. The dealer uses the data in order to provide the customer with recommendations for management of the equipment. In addition, SOS Services can help determine the cause of an existing product problem. Refer to Special Publication, SEBU6250, Caterpillar Machine Fluid Recommendations for detailed information concerning SOS Services. Refer to the Operation and Maintenance Manual, Maintenance Interval Schedule for a specic sampling location and a service hour maintenance interval. Consult your Caterpillar dealer for complete information and assistance in establishing an SOS program for your equipment.

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93 Maintenance Section Maintenance Support

Maintenance Support
i03291524

Slowly loosen cooling system pressure cap in order to relieve any system pressure.

System Pressure Release


SMCS Code: 1250-553-PX; 1300-553-PX; 1350-553-PX; 3000-553-PX; 4250-553-PX; 4300-553-PX; 5050-553-PX; 6700-553-PX; 7540-553-PX

Hydraulic Pressure

General Precautions

Hydraulic oil pressure can remain in the hydraulic system on this machine after the engine and pump have been stopped. Serious injury can result if this pressure is not released before any service is done on the hydraulic systems. In order to prevent possible injury, release the hydraulic system pressure before working on any tting, hose, or hydraulic component. Lower all attachments to the ground before service is started. If the hydraulic system must be serviced, tested, or adjusted with the attachment in the raised position, the attachments and lift cylinders must be supported properly. Always move the machine to a location away from the travel of other machines. Be sure that other personnel are not near the machine when the engine is running and tests or adjustments are being made. Note: The pressure in the hydraulic system must be released before hose assemblies or components can be removed or disconnected. Note: Hydraulic lockout control must be in the UNLOCKED position. 1. Ensure that the machine is on a smooth, horizontal surface. Ensure that the machine is away from working machines and personnel. Lower all implements to the ground. Install the articulation lock pin. Note: Permit only one operator on the machine. Keep all other personnel away from the machine or in the view of the operator. 2. Activate the parking brake. Place all implements on the ground. 3. If equipped, move all joysticks into all positions repeatedly. 4. Place the lift cylinders in the FLOAT position. The oil will return to the hydraulic tank. This will relieve pressure in the circuit. 5. Stop the engine.

Personal injury or death can result from sudden machine movement. Sudden movement of the machine can cause injury to persons on or near the machine. To prevent injury or death, make sure that the area around the machine is clear of personnel and obstructions before operating the machine. Perform this procedure in order to release compressed air pressure or hydraulic oil pressure. Put blocks in front of the wheels and behind the wheels. Perform this procedure before performing any of the following service procedures:

Disconnecting any hydraulic connections for the


implement system implement system

Removing any sensors or switches from the Working on the bucket or linkage

Brake Pressure
To release any brake oil pressure, depress the brake pedal repeatedly.

Cooling System Pressure

Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve the pressure. Wait until the radiator is cool.

94 Maintenance Section Maintenance Support

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i03636245

NOTICE Never remove the ll/vent plug from the hydraulic tank if the oil is hot. Air can enter the system and cause pump damage. 6. In order to release all remaining pressure in the hydraulic oil tank, hold down the plunger on the breaker relief valve. The breaker relief valve is located on the hydraulic oil tank. Note: The pressure in the hydraulic oil tank may also be released by slowly loosening the ller cap. Make sure that the ller cap is cool enough to touch with your bare hand. 7. Ensure that all pressure is relieved in the secondary hydraulic system. Ensure that all pressure is relieved in the auxiliary hydraulic system. 8. Make sure that all of the hydraulic pressure is relieved before any work is performed on the hydraulic system or any hydraulic component. 9. Tighten the cap on the hydraulic tank.

Welding on Machines and Engines with Electronic Controls


SMCS Code: 1000; 7000 Do not weld on any protective structure. If it is necessary to repair a protective structure, contact your Caterpillar dealer. Proper welding procedures are necessary in order to avoid damage to the electronic controls and to the bearings. When possible, remove the component that must be welded from the machine or the engine and then weld the component. If you must weld near an electronic control on the machine or the engine, temporarily remove the electronic control in order to prevent heat related damage. The following steps should be followed in order to weld on a machine or an engine with electronic controls. 1. Turn off the engine. Place the engine start switch in the OFF position. 2. If equipped, turn the battery disconnect switch to the OFF position. If there is no battery disconnect switch, remove the negative battery cable at the battery. NOTICE Do NOT use electrical components (ECM or ECM sensors) or electronic component grounding points for grounding the welder. 3. Clamp the ground cable from the welder to the component that will be welded. Place the clamp as close as possible to the weld. Make sure that the electrical path from the ground cable to the component does not go through any bearing. Use this procedure in order to reduce the possibility of damage to the following components:

Lock Valve Pressure


The procedures in this section may be used in the following operations:

Maintenance on lock valves Maintenance on hydraulic cylinders


1. Fully slacken the locknut. 2. Use an appropriate allen wrench in order to adjust the screw as far as possible in a counterclockwise direction. Record the number of turns in order to reset the lock valve later. The pressure in the lock valve will now be relieved. 3. Reset the lock valve after all the pressure has been relieved.

Bearings of the drive train Hydraulic components Electrical components Other components of the machine
4. Protect any wiring harnesses and components from the debris and the spatter which is created from welding. 5. Use standard welding procedures in order to weld the materials together.

Steering Pressure
To release any steering oil pressure, move the steering control through all travel positions several times in both directions. Move the steering wheel several times in both directions in order to relieve the pilot pressure in the steering system. If you are servicing the steering cylinders, the steering valve, or the steering hoses, slowly crack the lines in order to purge any trapped oil that may be in the steering system.

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95 Maintenance Section Maintenance Interval Schedule

i03748060

Window Wiper - Inspect/Replace ........................ 160

Maintenance Interval Schedule


SMCS Code: 7000 Ensure that all safety information, warnings and instructions are read and understood before any operation or any maintenance procedures are performed. The user is responsible for the performance of maintenance, including all adjustments, the use of proper lubricants, uids, lters, and the replacement of components due to normal wear and aging. Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and/or accelerated wear of components. Use mileage, fuel consumption, service hours, or calendar time, WHICH EVER OCCURS FIRST, in order to determine the maintenance intervals. Products that operate in severe operating conditions may require more frequent maintenance. Note: Before each consecutive interval is performed, all maintenance from the previous interval must be performed. Note: If Cat HYDO Advanced 10 hydraulic oil is used, the hydraulic oil change interval is extended to 3000 hours. SOS services may extend the oil change even longer. Consult your Caterpillar dealer for details.

Every 10 Service Hours or Daily


Alternator - Inspect ............................................... 97 Backup Alarm - Test ............................................ 101 Bucket Cutting Edges - Inspect/Replace ............ 105 Bucket Stops - Inspect/Replace .......................... 106 Bucket Wear Plates - Inspect/Replace ............... 108 Cooling System Coolant Level - Check ............... 113 Engine Air Filter Service Indicator - Inspect ........ 123 Engine Oil Level - Check .................................... 127 Engine Water Pump - Inspect ............................. 131 Hydraulic System Oil Level - Check ................... 144 Loader Boom Pin and Lift Cylinder Pin - Inspect .. 149 Loader Pins and Bearings - Lubricate ................ 150 Seat Belt - Inspect .............................................. 153 Starting Motor - Inspect ...................................... 155 Transmission Oil Level - Check .......................... 159 Turbocharger - Inspect ........................................ 160 Windows - Clean ................................................. 161

Every 50 Service Hours or Weekly


Cab Air Filter - Clean/Replace ............................ Fuel System Primary Filter (Water Separator) Check/Drain ...................................................... Fuel Tank Water and Sediment - Drain ............... Tire Ination - Check ........................................... 108 133 137 156

Every 100 Service Hours or 2 Weeks


Axle Oscillation Bearings - Lubricate .................. 100 Steering Cylinder Bearings - Lubricate ............... 155

When Required
Automatic Lubrication Grease Tank - Fill .............. 97 Automatic Lubrication System Components Check .................................................................. 98 Axle Oil Cooler Filter - Replace ............................ 99 Battery - Recycle ................................................ 102 Battery or Battery Cable - Inspect/Replace ........ 102 Bucket Lift and Bucket Tilt Control Inspect/Clean .................................................... 105 Bucket Tips - Inspect/Replace ............................ 106 Camera - Clean .................................................. 109 Circuit Breakers - Reset ....................................... 110 Engine Air Filter Primary Element - Clean/ Replace ............................................................. 121 Engine Air Filter Secondary Element - Replace .. 122 Engine Air Precleaner - Clean ............................ 124 Ether Starting Aid Cylinder - Replace ................. 132 Fuel System - Prime ........................................... 132 Fuses - Replace .................................................. 137 High Intensity Discharge Lamp (HID) - Replace .. 140 Loader Boom Pin Oil Level - Check .................... 149 Oil Filter - Inspect ................................................ 151 Radiator Core - Clean ......................................... 152 Seat Side Rails - Adjust ...................................... 154 Secondary Steering - Test .................................. 155 Window Washer Reservoir - Fill .......................... 160

Initial 250 Service Hours


Electronic Unit Injector - Inspect/Adjust .............. Engine Valve Lash - Check ................................. Engine Valve Rotators - Inspect ......................... Transmission Oil Filter - Replace ........................ 120 131 131 158

Every 250 Service Hours or Monthly


Battery - Clean .................................................... 102 Belts - Inspect/Adjust/Replace ............................ 103 Brake Accumulator - Check ................................ 103 Braking System - Test ......................................... 104 Differential and Final Drive Oil Level - Check ...... 118 Drive Shaft Spline (Center) - Lubricate ............... 120 Engine Air Filter Service Indicator Inspect/Replace ................................................ 124 Engine Oil (High Speed) and Oil Filter - Change .. 125 Engine Oil Sample - Obtain ................................ 128 Engine Oil and Filter - Change ........................... 128

Initial 500 Service Hours


Cooling System Coolant Sample (Level 2) Obtain ................................................................ 115 Loader Boom Pin Oil Level - Check .................... 149 Seat Side Rails - Adjust ...................................... 154

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Every 500 Service Hours or 3 Months


Cooling System Coolant Sample (Level 1) Obtain ................................................................ 114 Differential and Final Drive Oil Sample - Obtain .. 119 Engine Oil (High Speed) and Oil Filter - Change .. 125 Engine Oil and Filter - Change ........................... 128 Fuel System Primary Filter (Water Separator) Element - Replace ............................................ 134 Fuel System Secondary Filter - Replace ............ 135 Fuel Tank Cap and Strainer - Clean ................... 136 Hydraulic System Oil Filter (Steering and Implement Pilot) - Replace ................................................. 143 Hydraulic System Oil Sample - Obtain ............... 145 Transmission Oil Filter - Replace ........................ 158 Transmission Oil Sample - Obtain ...................... 159

Every 1000 Service Hours or 6 Months


Articulation Bearings - Lubricate ........................... 97 Battery Hold-Down - Tighten ............................... 102 Case Drain Oil Filters - Replace .......................... 110 Drive Shaft Support Bearing - Lubricate ............. 120 Rollover Protective Structure (ROPS) - Inspect .. 153 Transmission Oil - Change ................................. 156

Every 2000 Service Hours or 1 Year


Axle Oil Cooler Filter - Replace ............................ 99 Cooling System Coolant Sample (Level 2) Obtain ................................................................ 115 Crankshaft Vibration Damper - Inspect ................ 116 Differential and Final Drive Oil - Change ............. 117 Electronic Unit Injector - Inspect/Adjust .............. 120 Engine Mounts - Inspect ..................................... 125 Engine Valve Lash - Check ................................. 131 Engine Valve Rotators - Inspect ......................... 131 Hydraulic System Oil - Change ........................... 140 Hydraulic Tank Breaker Relief Valve - Clean ...... 145 Lift Cylinder Pin Oil Level - Check ...................... 147 Loader Boom Pin Oil - Change ........................... 148 Refrigerant Receiver-Dryer - Replace ................ 152

Every 3 Years After Date of Installation or Every 5 Years After Date of Manufacture
Seat Belt - Replace ............................................. 154

Every 4000 Service Hours or 2 Years


Hydraulic System Oil - Change ........................... 140

Every 6000 Service Hours or 3 Years


Cooling System Coolant Extender (ELC) - Add ... 112 Lift Cylinder Pin Oil - Change ............................. 145

Every 12 000 Service Hours or 6 Years


Cooling System Coolant (ELC) - Change ............ 111 Cooling System Water Temperature Regulator Replace .............................................................. 116

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97 Maintenance Section Alternator - Inspect

i02154861

Alternator - Inspect
SMCS Code: 1405-040

Illustration 100

g01092660

Apply grease through one tting on the upper pivot bearing.


Illustration 99
g01092657

The alternator is located on the right side of the machine. Caterpillar recommends a scheduled inspection of the alternator. Inspect the alternator for loose connections and for proper battery charging. Keep the batteries fully charged. Air temperature affects the cranking power of the batteries. Keep the batteries warm. The engine will not crank if the batteries are too cold. A warm engine will not crank if the batteries are too cold. When the engine is operated for short periods of time, the batteries may not fully recharge. Make sure that the alternator is properly functioning. The alternator will charge the batteries. Reference: For additional information, refer to the appropriate Service Manual for this machine.
i02147795

Illustration 101

g01092661

Apply grease through one tting on the lower pivot bearing.


i02216552

Automatic Lubrication Grease Tank - Fill (If Equipped)


SMCS Code: 7540-544-TNK

Articulation Bearings Lubricate


SMCS Code: 7057-086-BD; 7065-086-BD; 7066-086-BD Wipe off the ttings before any lubricant is applied.

A pressure hazard is present. Severe personal injury or death can result from removing hoses or ttings that are under pressure. Relieve the pressure in the system before you remove hoses or ttings.

98 Maintenance Section Automatic Lubrication System Components - Check

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The Centro-Matic Lubrication System


Reference: Before any service work is performed on the lubrication system, refer to Special Instructions, REHS1394 or consult your Caterpillar dealer.

i03578320

Automatic Lubrication System Components - Check (If Equipped)


SMCS Code: 7540-535

Bulk Fill
1. In order to ll the reservoir, remove the lower and upper plugs from the side of the reservoir. 2. Attach the appropriate pump to the lower inlet. 3. Fill the reservoir until visual indicator on the lid of the tank indicates FULL or until the grease appears at the top vent port. Reference: For the correct type of grease, refer to Operation and Maintenance Manual, Lubricant Viscosities. 4. Remove the pump and replace both plugs.

A pressure hazard is present. Severe personal injury or death can result from removing hoses or ttings that are under pressure. Relieve the pressure in the system before you remove hoses or ttings. Reference: Before any service work is performed on the lubrication system, refer to Special Instructions, REHS1394 or consult your Caterpillar dealer.

The Quicklub Lubrication System


Reference: Before any service work is performed on the lubrication system, refer to Special Instructions, REHS1396 or consult your Caterpillar dealer.

Filling the Reservoir


1. Fill the reservoir through the grease tting. The grease tting is located at the base of the reservoir. Reference: For the correct type of grease, refer to Operation and Maintenance Manual, Lubricant Viscosities. 2. Rell the reservoir when the grease reaches the MIN mark on the reservoir. 3. Fill the reservoir to the MAX mark on the reservoir.

Priming the System


After the reservoir has been lled with the recommended lubricant, loosen the tting to the supply line. Operate the pump until lubricant ows from the outlet. Then, tighten tting.

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99 Maintenance Section Axle Oil Cooler Filter - Replace

Illustration 102 (A) A-Pin (B) B-Pin (C) C-Pin (E) E-Pin (F) F-Pin (G) G-Pin (H) Pin for Upper Articulation Joint (J) Pin for Lower Articulation Joint (K) K-Pin (L) Steering Cylinder Pins (X) Trunnions (Y) Y-Pin

g01032039

1. Remove any buildup of grease. Check that each pin joint is receiving a fresh supply of grease. Reference: If a fresh supply of grease is not present, refer to Special Instructions, REHS1394 for system troubleshooting procedures. 2. Check for an excessive buildup of grease at each pin joint. Reference: For adjustment information, refer to Operation and Maintenance Manual, Capacities (Rell), Settings of the the Injectors for the Autolube System. 3. Check the grease level at the top vent port of the reservoir. Reference: For lling procedures, refer to Operation and Maintenance Manual, Automatic Lubrication Grease Tank - Fill.

i02610378

Axle Oil Cooler Filter - Replace


SMCS Code: 3004-510-AOC NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates.

100 Maintenance Section Axle Oscillation Bearings - Lubricate

SEBU8480

4. Apply a thin coat of clean differential oil to the seal of each new oil lter. Install each new oil lter hand tight until the seal of the oil lter contacts the base. Note the position of each index mark on each lter in relation to a xed point on each lter base. Note: There are rotation index marks on each oil lter that are spaced 90 degrees or 1/4 of a turn away from each other. When you tighten each oil lter, use the rotation index marks as a guide. 5. Tighten each lter according to the instructions that are printed on each lter. Use the index marks as a guide. For non-Caterpillar lters, use the instructions that are provided with the lter. Note: You may need to use a Caterpillar strap wrench, or another suitable tool, in order to turn the lter to the amount that is required for nal installation. Make sure that the installation tool does not damage the lter. 6. Start the engine and run the engine at low idle. Check for leaks. 7. Check the level of the differential oil. Reference: Refer to Operation and Maintenance Manual, Differential and Final Drive Oil Level Check for the correct procedure.
Illustration 104 Rear Filter
g01092745 i03506621

Illustration 103 Front Filter

g01092743

The lters are located under the access door on the left cab platform. 1. Stop the engine. 2. Use a strap type wrench to remove the lters. Dispose of the used lters properly. 3. Clean the lter mounting bases. Make sure that all of the used seal is removed from each lter mounting base.

Axle Oscillation Bearings Lubricate


SMCS Code: 3268-086-BD; 3278-086-BD Wipe off the ttings before any lubricant is applied.

Illustration 106

g01841714

Illustration 105

g00101318

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101 Maintenance Section Backup Alarm - Test

Illustration 107

g01841715

Apply lubricant through the two remote ttings on the right side of the machine. Fitting (1) applies grease to the rear axle oscillation bearing. Fitting (2) applies grease to the front axle oscillation bearing.
Illustration 108
i02319912 g01091949

The backup alarm is located behind the rear grill.

Backup Alarm - Test


SMCS Code: 7406-081 Turn the engine start switch key to the ON position in order to perform the test. Apply the service brake. Move the transmission direction control lever to the REVERSE position. The alarm should start to sound immediately. The alarm will continue to sound until the transmission direction control lever is moved to the NEUTRAL position or to the FORWARD position.

Illustration 109

g01117861

The volume for the backup alarm is nonadjustable.

102 Maintenance Section Battery - Clean

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Battery - Clean
SMCS Code: 1401-070

Battery Hold-Down - Tighten


SMCS Code: 7257-527

Illustration 110

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Illustration 111

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Open the battery compartment on the right rear side of the machine. Clean the battery terminals and the surfaces of the batteries with a clean cloth. Coat the battery terminals with petroleum jelly. Make sure that the battery cables are installed securely.
i00993589

Open the battery compartment on the right rear side of the machine. Over time, the vibration of an operating machine can cause the battery hold-downs to loosen. To help to prevent loose batteries and the possibility of loose cable connections, tighten the eight nuts on the two hold-downs to a torque of 2.50 0.25 Nm (22 2 lb in).
i03657099

Battery - Recycle
SMCS Code: 1401-561 Always recycle a battery. Never discard a battery. Always return used batteries to one of the following locations:

Battery or Battery Cable Inspect/Replace


SMCS Code: 1401-040; 1401-510; 1402-040; 1402-510

A battery supplier An authorized battery collection facility Recycling facility


Personal injury may occur from failure to properly service the batteries. Batteries give off ammable fumes that can explode. Electrolyte is an acid and can cause personal injury if it contacts the skin or eyes. Prevent sparks near the batteries. Sparks could cause vapors to explode. Do not allow jumper cable ends to contact each other or the engine. Improper jumper cable connections can cause an explosion. Always wear protective glasses when working with batteries. 1. Turn the engine start switch key OFF. Turn all of the switches OFF.

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103 Maintenance Section Belts - Inspect/Adjust/Replace

2. Turn the battery disconnect switch OFF. Remove the key. 3. Disconnect the negative battery cable from the disconnect switch. Note: Do not allow the disconnected battery cable to contact the disconnect switch. 4. Disconnect the negative battery cable at the battery. 5. Disconnect the positive battery cable at the battery. 6. Inspect the battery terminals for corrosion. Inspect the battery cables for wear or damage. 7. Make any necessary repairs. If necessary, replace the battery cables or the battery. 8. Connect the positive battery cable at the battery. 9. Connect the negative battery cable at the battery. 10. Connect the battery cable at the battery disconnect switch. 11. Install the key and turn the battery disconnect switch ON.
Illustration 112
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1. Stop the engine. Access the belt from the right side of the machine.

Recycle the Battery


Always recycle a battery. Never discard a battery. Always return used batteries to one of the following locations:
Illustration 113
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A battery supplier An authorized battery collection facility Recycling facility


i01832060

Note: The belt can be serviced via the engine access door or the vent and the rewall can be removed for easier access. 2. Inspect the condition of belt (2). If the belt is cracked or frayed, replace the belt. 3. Use a ratchet with a square head to loosen belt tensioner (1) during replacement. Make sure that the belt is installed in the correct pattern, as shown.
i02215711

Belts - Inspect/Adjust/Replace
SMCS Code: 1397-025; 1397-040; 1397-510 Note: The alternator and the refrigerant compressor are driven by a single serpentine belt.

Brake Accumulator - Check


SMCS Code: 4263-535 1. Turn the engine start switch to the ON position. The alert indicator for brake oil pressure should come on if the braking system is not at normal operating pressure. Refer to Operation and Maintenance Manual, Monitoring System for the location of the alert indicators.

104 Maintenance Section Braking System - Test

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2. Start the engine. Run the engine at half speed for two minutes in order to increase the accumulator pressure. The alert indicator for brake oil pressure should go off. 3. Stop the engine. Apply the service brake pedal and release the service brake pedal. The rate for this process is 1 second on and 1 second off. Do this process until the alert indicator for brake oil pressure comes on. This will decrease the accumulator pressure. A minimum of ve applications of the service brake pedal are required with new discs. The number of applications could be as low as three when the lining material on the brake discs is at replacement thickness. 4. If the alert indicator comes on after less than 3 applications of the brake, measure the accumulator precharge pressure. An authorized Caterpillar dealer can measure the nitrogen gas pressure in the accumulator. Use only dry nitrogen gas for recharging. Reference: Refer to Testing and Adjusting, RENR6365, 834H/836H Tier 3 Braking System, Accumulator Charging Valve (Brake)-Test and Adjustfor the correct procedure.
i01739721

Service Brake Holding Ability Test

Personal injury can result if the machine moves while testing. If the machine begins to move during test, reduce the engine speed immediately and engage the parking brake. 1. Start the engine. Raise the implement slightly. Apply the service brake. Release the parking brake. 2. Move the transmission control to THIRD SPEED FORWARD while the service brakes are applied. Make sure that the autoshift control is in the OFF position. 3. Gradually increase the engine speed to high idle. The machine should not move. 4. Reduce the engine speed to low idle. Move the transmission direction control to the NEUTRAL position. Engage the parking brake. Lower the implement to the ground. Stop the engine. If the machine moved during the test, consult your Caterpillar dealer for a brake inspection. Make any necessary repairs before the machine is returned to operation.

Braking System - Test


SMCS Code: 4251-081; 4267-081

Fasten the seat belt before you test the brakes. Park the machine on a dry, level surface. Check the area around the machine. Make sure
that the machine is clear of personnel and clear of obstacles.

Parking Brake Holding Ability Test

Personal injury can result if the machine moves while testing. If the machine begins to move, reduce the engine speed immediately and apply the service brake pedal. This test is performed when the parking brake is engaged. If the machine begins to move, compare the engine rpm to the engine rpm of a prior test. This will indicate the amount of system deterioration. 1. Start the engine. Raise the implement slightly. Engage the parking brake. 2. Move the transmission control to THIRD SPEED FORWARD. Make sure that the autoshift control is in the OFF position. The parking brake indicator light should come on.

Make sure that the steering frame lock is in the unlocked position.
The following tests are used to determine whether the braking system is functional. These tests are not intended to measure the maximum brake holding effort. The required brake holding effort for sustaining a machine at a specic engine rpm varies from one machine to another machine. The variations include differences in the engine setting, the power train efciency, the brake holding ability, etc.

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105 Maintenance Section Bucket Cutting Edges - Inspect/Replace

3. Gradually increase the engine speed to high idle. The machine should not move. 4. Reduce the engine speed to low idle. Move the transmission direction control to the NEUTRAL position. Lower the implement to the ground. Stop the engine. If the machine moved during the test, consult your Caterpillar dealer for a brake inspection. Make any necessary repairs before the machine is returned to operation.
i01548255

1. Raise the bucket and place blocking under the bucket. Lower the bucket onto the blocking. Note: Do not block up the bucket too high. Block up the bucket enough for removing the cutting edges and the end bits. 2. Remove bolts (1). Remove cutting edges (2) and the end bits. 3. Clean the contact surfaces. Inspect the cutting edges and install the cutting edges. If the opposite side of the cutting edge is not worn, use that side. If both sides of the cutting edge are worn, install a new cutting edge. 4. Install bolts (1). Tighten the bolts to the specied torque. 5. Raise the bucket and remove the blocking. Lower the bucket to the ground.

Bucket Cutting Edges Inspect/Replace


SMCS Code: 6801-040; 6801-510

Personal injury or death can result, if the bucket is not blocked up. Block the bucket before changing cutting edge.

6. After a few hours of operation, check the bolts for proper torque.
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Bucket Lift and Bucket Tilt Control - Inspect/Clean


SMCS Code: 5258-571; 5702-571

Illustration 114

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Illustration 115

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Check for bolts that are missing or loose. Replace any missing bolts and tighten any loose bolts. Reference: Refer to Operation and Maintenance Manual, Torques for Ground Engaging Tool Bolts for the correct torque. Inspect the cutting edges and the end bits. If wear or damage is evident, use the following procedure to replace the components.

Note: Do not use any lubricants on any part of this control. The moving parts of this control are selflubricated. Use the following procedure in order to clean the control levers. 1. Disconnect the wiring from the controls. 2. Disassemble the controls. 3. Wash the parts with warm soapy water.

106 Maintenance Section Bucket Stops - Inspect/Replace

SEBU8480

4. Rinse the parts thoroughly with water. 5. Dry the parts thoroughly. 6. Reassemble the controls. 7. Reconnect the wiring to the controls.
i02612625

Bucket Stops - Inspect/Replace


SMCS Code: 6001-040-SQ; 6001-510-SQ; 6102-040-SQ; 6102-510-SQ
Illustration 117 (1) Usable (2) Replace (3) Overworn
g00101352

Check the bucket tips for wear. If the bucket tip has a hole, replace the bucket tip.

Removal

Illustration 116

g00554961

Check for bucket stops that are damaged or missing. Replace the bucket stops, if necessary. Note: Recalibrate the tilt position sensor after you recalibrate the bucket stops. Consult your Caterpillar dealer for more information on calibrating the tilt position sensor.
Illustration 118
i03574841 g01389463

Bucket Tips - Inspect/Replace


SMCS Code: 6805-040; 6805-510

Note: Retainers are often damaged during the removal process. Caterpillar recommends the installation of a new retainer when bucket tips are rotated or replaced.

Personal injury or death can result from the bucket falling. Block the bucket before changing bucket tips. Note: In order to maximize the life of the bucket tip and the penetration of the bucket tip, the bucket tip can be rotated.

Illustration 119

g01175361

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107 Maintenance Section Bucket Tips - Inspect/Replace

1. Use a pry bar in order to disengage retainer (5). 2. Use the pry bar in order to remove retainer (5) from bucket tip (4). 3. Remove bucket tip (4) from adapter (6) with a slight counterclockwise rotation. 4. Clean adapter (6).

1. Remove the mounting bolts and the side cutters. 2. Clean the mounting surface of the side plate on the bucket and of the side cutter. Remove any burrs or protrusions on the mating surfaces.

Installation
1. Clean the adapter and the area around the latch, if necessary. 2. Install the new bucket tip onto the adapter with a slight clockwise rotation.

Illustration 122 (7) Side cutter

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Note: Some side cutters may be rotated for additional wear. 3. Install the side cutter. Note: Certain bolts may require thread compound. 4. Hand tighten the bolts.
Illustration 120
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3. Install the retainer. Make sure that the retainer's latch catches under the tip pocket. 4. Make sure that the latch is properly seated by trying to remove the bucket tip.

Side Cutters (If Equipped)

Illustration 123 Section A-A From Illustration 122 (8) Side cutter (9) Shear ledge on a side cutter (10) Side plate on a bucket (11) 0.0 mm (0.0 inch)

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5. Make sure that there is not a gap between the side plate on the bucket and the shear ledge on the side cutter.
Illustration 121 Bucket with side cutters Side cutters
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6. Torque the mounting bolts to the correct specication.

108 Maintenance Section Bucket Wear Plates - Inspect/Replace

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Side Protectors (If Equipped)


Inspect the wear of the side protector. When too much wear is present, replace the protector.

2. Clean side protector (12), pin (13), retainer (14) and side plate (15) before installation. Note: Lateral clearance between the side plate and the side protector should not exceed 1 mm (0.04 inch). Shims (16) may be required in order to decrease the lateral clearance which will decrease movement. Install the shims(16) between the side plate and the side protector on the opposite side of the retainer. 3. Put retainer (14) in side plate (15). 4. Align two pin holes of the new protector and the side plate. Hit the pin from the retainer side of the bucket. Note: If the pin and/or the retainer are worn, replace the pin and/or the retainer.
i01098709

Illustration 124

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Bucket Wear Plates Inspect/Replace


SMCS Code: 6120-040; 6120-510

Illustration 125

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Illustration 127

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Before damage to the bottom of the bucket occurs, repair damaged bucket wear plates or replace damaged bucket wear plates. Consult your Caterpillar dealer for the procedures.
Illustration 126 (12) (13) (14) (15) (16) Side protector Pin Retainer Side plate Shim
g01389459 i01908538

Cab Air Filter - Clean/Replace


SMCS Code: 7342-070; 7342-510 Note: Clean the cab air lters more often if the machine is being operated in dusty conditions.

1. Hit pin (13) from the side of the bucket without the retainer in order to remove side protector (12) from side plate (15).

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109 Maintenance Section Camera - Clean

Display

Illustration 128

g00994599

1. Remove the lter cover behind the seat. Remove the lter element. 2. Open the access door on the left side of the cab. Remove the lter element. 3. Clean the lter elements with pressure air or wash the lter elements in warm water with a nonsudsing household detergent. 4. If water and detergent are used to clean the lter elements, rinse the lter elements in clean water and allow the lter elements to air dry thoroughly. Note: If either lter element is damaged, install a new lter element. 5. Install the lter elements. Install the lter cover and close the access door.
i02816405

Illustration 129 WAVS display

g01223034

Use a soft, damp cloth in order to clean the display. The display has a soft plastic surface that can be easily damaged by an abrasive material. The display is not sealed. Do not immerse the display with liquid.

Camera

Camera - Clean (If Equipped)


SMCS Code: 7348-070 In order to maintain sufcient vision, keep the Work Area Vision System (WAVS) camera lens and the display clean.

Illustration 130

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The WAVS camera is located on the rear of the machine in the center of the fan guard.

Use a damp cloth or water spray in order to clean the camera lens. The camera is a sealed unit. The camera is not affected by high pressure spray. The camera is equipped with an internal heater to help counteract the effects of condensation, snow, or ice. Note: For more information on WAVS, refer to Operation and Maintenance Manual, SEBU8157, Work Area Vision System.

110 Maintenance Section Case Drain Oil Filters - Replace

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i01543124

i02155537

Case Drain Oil Filters - Replace (If Equipped)


SMCS Code: 5091-510

Circuit Breakers - Reset


SMCS Code: 1420-529 Circuit Breakers Depress the button in order to reset the circuit breaker. If the circuit is functioning properly, the button will remain depressed. If the button will not remain depressed, check the appropriate electrical circuit.

Illustration 132 Illustration 131


g00801622

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(1) Case drain lter for the steering pump. (2) Case drain lter for the implement pump. (3) Case drain lter for the fan motor.

The circuit breakers are located under a small access door on the right cab platform. Main Circuit (1) 105 amp

The case drain lters are located under the access door in the platform behind the cab. 1. Stop the engine. 2. Use a strap type wrench to remove the lter element. Dispose of the used lter element properly. 3. Clean the lter mounting base. Make sure that all of the used gasket is removed from the lter mounting base. 4. Lubricate the gasket of a new lter element with clean hydraulic oil. 5. Install the new lter element by hand. When the gasket contacts the lter mounting base, tighten the lter element by an additional 3/4 turn. 6. Repeat the above steps for the other two case drain lters. 7. Start the engine and run the engine at low idle. Operate the steering, the brakes, and the implement. 8. Stop the engine. Inspect the lters for leaks. Make any necessary repairs.

Alternator (2) 105 amp

Engine Start Switch (3) 10 amp

Electronic Control Module (ECM) (4) 15 amp

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111 Maintenance Section Cooling System Coolant (ELC) - Change

i02156049

Cooling System Coolant (ELC) - Change


SMCS Code: 1350-044-NL

If an Extended Life Coolant was previously used, ush the cooling system with clean water. No other cleaning agents are required. Use the following procedure to change the cooling system coolant (ELC).

Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve the pressure. NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. NOTICE Topping off or mixing Cat ELC with other products that do not meet Caterpillar EC-1 specications reduces the effectiveness of the coolant and shortens coolant service life. Use only Caterpillar products or commercial products that have passed the Caterpillar EC-1 specication for pre-mixed or concentrate coolants. Use only Extender with Cat ELC. Failure to follow these recommendations can result in shortened cooling system component life. Reference: For information about the addition of Extender to your cooling system, refer to Operation and Maintenance Manual, Cooling System Coolant Extender (ELC) - Add or consult your Caterpillar dealer. If you change the coolant of a machine to Extended Life Coolant from another type of coolant, use a Caterpillar cleaning agent to ush the cooling system. After you drain the cooling system, thoroughly ush the cooling system with clean water. All of the cleaning agent must be removed from the cooling system.
Illustration 134
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Illustration 133

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The cooling system pressure cap is located on the left side of the machine on the top of the radiator. 1. Slowly loosen the cooling system pressure cap in order to relieve system pressure. Remove the cooling system pressure cap.

The drain valve is located at the rear of the machine under the engine compartment.

2. If equipped, remove the bottom guard in order to access the coolant drain valve. 3. Open the drain valve. Allow the coolant to drain into a suitable container. 4. Flush the cooling system with clean water until the draining water is transparent. 5. Close the drain valve. Replace the bottom guard, if equipped. 6. Replace the water temperature regulator.

112 Maintenance Section Cooling System Coolant Extender (ELC) - Add

SEBU8480

Reference: Refer to Operation and Maintenance Manual, Cooling System Water Temperature Regulator - Replace for the correct procedure. 7. Add the coolant solution. Reference: Refer to Operation and Maintenance Manual, Capacities (Rell) for the capacity of the cooling system. 8. Start the engine. Run the engine without the cooling system pressure cap until the water temperature regulator opens and the coolant level stabilizes. 9. Check the coolant level. Reference: Refer to Operation and Maintenance Manual, Cooling System Level - Check for the correct procedure. 10. Install the cooling system pressure cap. Stop the engine.
i02156106

NOTICE Topping off or mixing Cat ELC with other products that do not meet Caterpillar EC-1 specications reduces the effectiveness of the coolant and shortens coolant service life. Use only Caterpillar products or commercial products that have passed the Caterpillar EC-1 specication for pre-mixed or concentrate coolants. Use only Extender with Cat ELC. Failure to follow these recommendations can result in shortened cooling system component life. When a Caterpillar Extended Life Coolant (ELC) is used, an Extender must be added to the cooling system.

Cooling System Coolant Extender (ELC) - Add


SMCS Code: 1352-544-NL

Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve the pressure. NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates.

Illustration 135

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The cooling system pressure cap is located on the left side of the machine on the top of the radiator. 1. Slowly loosen the cooling system pressure cap in order to relieve system pressure. Remove the cooling system pressure cap. 2. Use a 8T-5296 Coolant Test Kit to check the concentration of the coolant. If it is necessary, adjust the concentration of the coolant.

Illustration 136

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SEBU8480

113 Maintenance Section Cooling System Coolant Level - Check

3. If necessary, drain enough coolant from the radiator in order to allow the addition of the Extender. The coolant drain valve is located at the rear of the machine under the engine compartment. 4. Add 3 L (100 oz) of Extender to the cooling system. 5. Check the coolant level. Reference: Refer to Operation and Maintenance Manual, Cooling System Level - Check for the correct procedure. 6. Install the cooling system pressure cap.
i02156161

Illustration 139

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Cooling System Coolant Level - Check


SMCS Code: 1350-535-FLV

NOTICE Topping off or mixing Cat ELC with other products that do not meet Caterpillar EC-1 specications reduces the effectiveness of the coolant and shortens coolant service life. Use only Caterpillar products or commercial products that have passed the Caterpillar EC-1 specication for pre-mixed or concentrate coolants. Use only Extender with Cat ELC. Failure to follow these recommendations can result in shortened cooling system component life. 2. If the coolant level is low, slowly remove the cooling system pressure cap on the top left side of the machine and add the required coolant in order to maintain the coolant level within the sight gauge.

Illustration 137

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Note: If it is necessary to add coolant daily, check for leaks. 3. Inspect the cooling system pressure cap and the cap seal. Clean the cap and install the cap. If the cap is damaged, install a new cooling system pressure cap. 4. Inspect the radiator core for debris. Clean the radiator core, if necessary. Reference: Refer to Operation and Maintenance Manual, Radiator Core - Clean for more information.

Illustration 138

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The sight gauge is located on the left side of the machine. The sight gauge can be viewed through the vents on the left side of the machine. 1. Maintain the coolant level within the sight gauge.

114 Maintenance Section Cooling System Coolant Sample (Level 1) - Obtain

SEBU8480

i02279462

Complete the information on the label for the


sampling bottle before you begin to take the samples. bags.

Cooling System Coolant Sample (Level 1) - Obtain


SMCS Code: 1350-008; 1395-008; 7542 Note: It is not necessary to obtain a Coolant Sample (Level 1) if the cooling system is lled with Cat ELC (Extended Life Coolant). Cooling systems that are lled with Cat ELC should have a Coolant Sample (Level 2) that is obtained at the recommended interval that is stated in the Maintenance Interval Schedule. Note: Obtain a Coolant Sample (Level 1) if the cooling system is lled with any other coolant instead of Cat ELC. This includes the following types of coolants.

Keep the unused sampling bottles stored in plastic Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples from any other location. are ready to collect the sample.

Keep the lids on empty sampling bottles until you Place the sample in the mailing tube immediately
after obtaining the sample in order to avoid contamination.

Never collect samples from expansion bottles. Never collect samples from the drain for a system.

Commercial long life coolants that meet the


Caterpillar Engine Coolant Specication -1 (Caterpillar EC-1)

Cat Diesel Engine Antifreeze/Coolant (DEAC) Commercial heavy-duty coolant/antifreeze


NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. Note: Level 1 results may indicate a need for Level 2 Analysis. Obtain the sample of the coolant as close as possible to the recommended sampling interval. In order to receive the full effect of SOS analysis, you must establish a consistent trend of data. In order to establish a pertinent history of data, perform consistent samplings that are evenly spaced. Supplies for collecting samples can be obtained from your Caterpillar dealer. Use the following guidelines for proper sampling of the coolant:
Illustration 140
g01093449

Slowly remove the cooling system pressure cap. Open the left side engine access door.

Illustration 141

g01120387

Remove the cap over the coolant sample port.

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115 Maintenance Section Cooling System Coolant Sample (Level 2) - Obtain

Attach a hose to a couple. Install the threaded end of the coupling into the drain valve in order to unseat the internal drain valve. Close the engine access door and return the pressure cap. Submit the sample for level 1 analysis. For additional information about coolant analysis, see Special Publication, SEBU6250, Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer.
i02156175

Obtain coolant samples directly from the coolant


sample port. You should not obtain the samples from any other location. are ready to collect the sample.

Keep the lids on empty sampling bottles until you Place the sample in the mailing tube immediately
after obtaining the sample in order to avoid contamination.

Never collect samples from expansion bottles. Never collect samples from the drain for a system.

Cooling System Coolant Sample (Level 2) - Obtain


SMCS Code: 1350-008; 1395-008; 7542 NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. Note: Level 1 results may indicate a need for Level 2 Analysis. Obtain the sample of the coolant as close as possible to the recommended sampling interval. In order to receive the full effect of SOS analysis, you must establish a consistent trend of data. In order to establish a pertinent history of data, perform consistent samplings that are evenly spaced. Supplies for collecting samples can be obtained from your Caterpillar dealer. Use the following guidelines for proper sampling of the coolant:

Illustration 142

g01093449

Slowly remove the cooling system pressure cap. Open the left side engine access door.

Illustration 143

g01120387

Remove the cap over the coolant sample port. Attach a hose to a couple. Install the threaded end of the coupling into the drain valve in order to unseat the internal drain valve. Close the engine access door and return the pressure cap. Submit the sample for level 2 analysis.

Complete the information on the label for the


sampling bottle before you begin to take the samples. bags.

Keep the unused sampling bottles stored in plastic

116 Maintenance Section Cooling System Water Temperature Regulator - Replace

SEBU8480

For additional information about coolant analysis, see Special Publication, SEBU6250, Caterpillar Machine Fluids Recommendations or consult your Caterpillar dealer.
i01925931

The water temperature regulator is located on the left side of the engine near the primary fuel lter. 1. Remove the bolts that secure the regulator housing (1). Loosen the hose clamps (2). 2. Remove the regulator housing. Remove all of the used gasket from the housing. NOTICE Caterpillar engines incorporate a shunt design cooling system and require operating the engine with a thermostat installed. If the thermostat is installed wrong, it will cause the engine to overheat. Inspect gaskets before assembly and replace if worn or damaged. 3. Install a new gasket on the regulator housing. Install a new water temperature regulator. 4. Install the bolts and the cover. 5. Tighten the hose clamps. 6. Rell the cooling system.
i01923122

Cooling System Water Temperature Regulator Replace


SMCS Code: 1355-510; 1393-010

Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve the pressure. Replace the water temperature regulator on a regular basis in order to reduce the chance of unscheduled downtime and the chance of problems with the cooling system. The water temperature regulator should be replaced after the cooling system has been cleaned. Replace the water temperature regulator and replace the seals while the cooling system is completely drained or while the cooling system coolant is drained to a level that is below the water temperature regulator housing. Note: If you are only replacing the water temperature regulator, drain the cooling system coolant to a level that is below the water temperature regulator housing. NOTICE Failure to replace the engine's thermostat on a regularly scheduled basis could cause severe engine damage.

Crankshaft Vibration Damper - Inspect


SMCS Code: 1205-040

Illustration 145

g01000821

The crankshaft vibration damper is located at the rear end of the engine compartment. Damage to the vibration damper or failure of the vibration damper will increase torsional vibrations. These vibrations will result in damage to the crankshaft and to other engine components. A deteriorating vibration damper will cause excessive gear train noise at variable points in the speed range.

Illustration 144

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SEBU8480

117 Maintenance Section Differential and Final Drive Oil - Change

Caterpillar recommends replacing the vibration damper for any of the following reasons:

The engine has had a failure because of a broken


crankshaft.

The SOS oil analysis detected a worn crankshaft


front bearing.

The SOS oil analysis detected a large amount of


gear train wear that is not caused by a lack of oil. The vibration damper can be used again if none of the above conditions are found and the damper is not damaged. Inspect the vibration damper for dents in the outer case. Dents in the outer case may cause failure of the damper. Install a new vibration damper if the damper is damaged. Reference: Refer to the Disassembly and Assembly manual for your machine's engine for the necessary replacement procedure.
i02540144

Illustration 146 Final Drive

g00801038

Differential and Final Drive Oil - Change


SMCS Code: 3278-044; 4050-044 NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates.
Illustration 147 Front Differential
g00840713

1. Position the wheels so that the front nal drive drain plugs (2) are facing downward. Remove the front nal drive drain plugs (2) and the front differential drain plug (4). Allow the oil to drain into a suitable container. 2. Remove the front nal drive ller plugs (1) and the front differential ller plug (3). 3. After the oil has drained, clean the drain plugs and install the drain plugs. 4. Fill the nal drives to the bottom of the ller plug openings. Reference: Refer to Operation and Maintenance Manual, Lubricant Viscosities and Rell Capacities for the correct type of oil and for the correct amount of oil. 5. Add three 1 L (1.1 qt) bottles of 1U-9891 Hydraulic Oil Additive to the differential. 6. Clean the ller plugs and install the ller plugs.

118 Maintenance Section Differential and Final Drive Oil Level - Check

SEBU8480

Illustration 148 Rear Differential Filler Plug (3)

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Illustration 149

g00801038

7. Repeat steps 2 through 6 for the rear nal drives and the rear differential. Note: The rear differential does not require the 1U-9891 Hydraulic Oil Additive. 8. If the specied amount of oil will not t in the nal drives, install the nal drive ller plugs. Operate the machine on level ground for a few minutes in order to equalize the oil level in the axles. 9. Remove the nal drive ller plugs and add the remaining oil. The oil level should reach the bottom of the ller plug opening. Note: If the oil level is higher than the ller plug opening, do not allow the oil to drain to the proper level. Install the ller plug.
i01624405

1. Position the wheels so that nal drive drain plug (2) is facing downward. Remove oil ller plug (1). The oil level should be at the bottom of the ller plug opening. Add oil, if necessary. Reference: Refer to Operation and Maintenance Manual, Lubricant Viscosities for the correct type of oil. If the oil level is higher than the ller plug opening, do not allow the oil to drain to the proper level. Install the ller plug.

Differential and Final Drive Oil Level - Check


SMCS Code: 3278-535-FLV; 4050-535-FLV NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates.
Illustration 150 Front Differential
g00801039

SEBU8480

119 Maintenance Section Differential and Final Drive Oil Sample - Obtain

NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain uids on Caterpillar products.
Illustration 151 Rear Differential
g00840708

Dispose of all uids according to local regulations and mandates. 1. Operate the machine for a few minutes before obtaining the oil sample. This will thoroughly mix the oil for a more accurate sample.

2. Remove differential ller plug (3). The oil level should be at the bottom of the ller plug opening. Add oil, if necessary. Reference: Refer to Operation and Maintenance Manual, Lubricant Viscosities for the correct type of oil. If the oil level is higher than ller plug opening, do not allow the oil to drain to the proper level. Install ller plug (3).
i02339342

Differential and Final Drive Oil Sample - Obtain


SMCS Code: 3278-008; 4050-008; 4070-008; 7542 NOTICE Always use a designated pump for oil sampling, and use a separate designated pump for coolant sampling. Using the same pump for both types of samples may contaminate the samples that are being drawn. This contaminate may cause a false analysis and an incorrect interpretation that could lead to concerns by both dealers and customers.
Illustration 152 Differential Filler Plug
g01167372

Illustration 153 Final Drive Filler Plug

g00760182

2. The differential and nal drives are not equipped with sampling valves. Obtaining an oil sample will require the use of a vacuum pump or equivalent in order to extract the oil from the component. Extract the oil through the ller openings on the differential and nal drives.

120 Maintenance Section Drive Shaft Spline (Center) - Lubricate

SEBU8480

Note: This procedure requires a sample for each nal drive and each differential. There will be a total of three samples per axle and six samples for this procedure in total. Make sure that you properly record the location of each oil sample. Reference: For more information, refer to Special Publication, SEBU6250, Caterpillar Machine Fluids Recommendations and Special Publication, PEHP6001, How To Take A Good Oil Sample.
i01709255

Drive Shaft Spline (Center) Lubricate


SMCS Code: 3253-086; 3253-086-SN; 3253 NOTICE To prevent damage to the seal, fully articulate the machine to the right or to the left, before lubricating the spline.

Illustration 155 Center Drive Shaft

g01093575

The tting for the drive shaft support bearing is located toward the front of the articulation joint. Apply lubricant through one or two ttings.
i02061807

Electronic Unit Injector Inspect/Adjust


SMCS Code: 1251-025; 1251-040; 1290-025; 1290-040

The Electronic Control module produces high voltage. To prevent personal injury make sure the Electronic Control Module is not powered and the unit injector solenoids are disconnected. NOTICE The camshafts must be correctly timed with the crankshaft before an adjustment of the unit injector lash is made. The timing pins must be removed from the camshafts before the crankshaft is turned or damage to the cylinder block will be the result. The operation of Caterpillar engines with improper adjustments of the electronic unit injector can reduce engine efciency. This reduced efciency could result in excessive fuel usage and/or shortened engine component life. Adjust the electronic unit injector at the same interval as the valve lash adjustment. Refer to your machine's Service Manual or your Caterpillar dealer for the complete adjustment procedure.

Illustration 154

g00879773

Wipe all ttings before applying lubricant. Apply lubricant through one tting on the drive shaft spline.
i03715441

Drive Shaft Support Bearing Lubricate


SMCS Code: 3267-086-BD Wipe off the tting before any lubricant is applied.

SEBU8480

121 Maintenance Section Engine Air Filter Primary Element - Clean/Replace

i01902270

Engine Air Filter Primary Element - Clean/Replace


SMCS Code: 1054-070-PY; 1054-510-PY

2. Loosen the cover latches and remove the air cleaner cover. Note: The latches for the air cleaner housing may snap open when you release the latches.

To avoid personal injury, always wear eye and face protection when using pressurized air. NOTICE Caterpillar recommends certied air lter cleaning services that are available at Caterpillar dealers. The Caterpillar cleaning process uses proven procedures to assure consistent quality and sufcient lter life. Observe the following guidelines if you attempt to clean the lter element: Do not tap or strike the lter element in order to remove dust. Do not wash the lter element. Use low pressure compressed air in order to remove the dust from the lter element. Air pressure must not exceed 207 kPa (30 psi). Direct the air ow up the pleats and down the pleats from the inside of the lter element. Take extreme care in order to avoid damage to the pleats. Do not use air lters with damaged pleats, gaskets, or seals. Dirt entering the engine will cause damage to engine components. NOTICE Service the air lter only with the engine stopped. Engine damage could result. 1. Open the engine compartment. The air lter is located on the right side of the machine.
Illustration 157
g00101415

3. Remove the primary lter element from the air cleaner housing. In order to remove the engine air lter primary element, pull the element outward. While you pull the element outward, rock the element. Use Steps 4 through 6 in order to clean the primary element: 4. Inspect the primary element. If the pleats, the gaskets, or the seals are damaged, discard the element. Replace a damaged primary element with a clean primary element.

Illustration 158

g00328468

5. If the primary element is not damaged, clean the primary element. Pressurized air can be used to clean a primary element that has not been cleaned more than two times. Use ltered, dry air at a maximum pressure of 207 kPa (30 psi).
Illustration 156
g00845360

Note: Pressurized air will not remove deposits of carbon and oil.

122 Maintenance Section Engine Air Filter Secondary Element - Replace

SEBU8480

6. When you clean the primary element, always begin in the inside of the element (clean side). This will force dirt particles toward the outside of the element (dirty side). Direct the air along the length (inside) of the lter. This will help prevent damage to the paper pleats. Note: Do not aim the stream of air directly at the primary element. Dirt could be forced further into the pleats. Use Steps 7 through 10 in order to inspect the primary element:

11. Install a clean primary lter element over the engine air lter secondary element. Apply rm pressure to the end of the primary element as you gently rock the lter element. This seats the primary element. 12. Clean the cover for the air cleaner housing. Align the slot on the cover with the pin on the air cleaner housing. Install the cover. 13. Close the engine.
i01625408

Engine Air Filter Secondary Element - Replace


SMCS Code: 1054-510-SE NOTICE Service the air lter only with the engine stopped. Engine damage could result. NOTICE Always replace the secondary element. Do not attempt to reuse it by cleaning. Engine damage could result. Note: Replace the secondary element when you service the primary element for the third time. If a clean primary element has been installed but a warning for the air lter still occurs, replace the secondary element. Also replace the secondary element if the exhaust smoke remains black after installation of a clean primary element.

Illustration 159

g00328470

7. Place a light bulb inside the lter element. Use a 60 watt blue light in a dark room or in a similar facility. Inspect the primary element for light that may show through the lter material. 8. Inspect the primary element while you rotate the element. Inspect the primary element for tears and/or holes. Do not use a primary element that has any tears and/or holes in the lter material. Do not use a primary element with damaged pleats, gaskets, or seals. 9. If it is necessary, compare the primary element to a new primary element. Use a new primary element that has the same part number. This may be necessary in order to conrm the results of the inspection. 10. Discard a damaged primary element. Use Steps 11 through 13 to install a clean primary element: NOTICE Do not use a lter if the pleats, the gaskets or the seals are damaged.

Illustration 160

g00841360

1. Open the engine access door on the right side of the machine.

SEBU8480

123 Maintenance Section Engine Air Filter Service Indicator - Inspect

Illustration 161

g00804954

Illustration 164

g00841372

4. Cover the air inlet opening. Clean the inside of the air lter housing. 5. Inspect the gasket between the air inlet pipe and the air cleaner housing. Replace the gasket if the gasket is damaged. 6. Uncover the air inlet opening. Install a new secondary lter element. 7. Install a clean primary element and install the cover on the air lter housing. Fasten the clips in order to secure the cover.
Illustration 162
g00804960

8. Close the engine access door.


i01549255

2. Remove cover (1) and primary element (2). Reference: Refer to Operation and Maintenance Manual, Engine Air Filter Primary Element Clean/Replace for the correct procedure for servicing the primary element.

Engine Air Filter Service Indicator - Inspect


SMCS Code: 7452-040 NOTICE Service the air cleaner only with the engine stopped. Engine damage could result.

Illustration 163

g00805000

3. Remove the secondary lter element.

124 Maintenance Section Engine Air Filter Service Indicator - Inspect/Replace

SEBU8480

Open the access door on the left side of the machine. To check the condition of the service indicator, try resetting the service indicator. This should require less than three pushes of the reset button. Next, check the movement of the yellow piston in the service indicator. Start the engine and accelerate the engine to high idle for a few seconds. After the governor control pedal is released, the yellow piston should remain at the highest position that was achieved during acceleration. If either of these conditions are not met, replace the service indicator.
i01625411

Engine Air Precleaner - Clean


Illustration 165
g00804672

SMCS Code: 1055-070 NOTICE Service the air cleaner only with the engine stopped. Engine damage could result.

Open the engine access door on the left side of the machine. The air lter service indicator is located on the air inlet line. If the yellow piston in the lter service indicator is in the red zone, service the air cleaner.
i01548088

Engine Air Filter Service Indicator - Inspect/Replace


SMCS Code: 7452-040; 7452-510
Illustration 167
g00841375

1. Remove the precleaner. 2. Inspect the air inlet screen for dirt and for trash. Remove the screen. Clean the screen if the screen is dirty. 3. Inspect the precleaner tube openings. Remove dirt and debris. 4. Clean the precleaner with compressed air or wash the precleaner in warm water. Dry all the parts. 5. Install the precleaner screen.

Illustration 166

g00804672

SEBU8480

125 Maintenance Section Engine Mounts - Inspect

i01923427

Engine Mounts - Inspect


SMCS Code: 1152-040

Abnormally harsh operating cycles or harsh environments can shorten the service life of the engine oil. Arctic temperatures, corrosive environments, or extremely dusty conditions may require a reduction in engine oil change intervals. Also refer to Special Publication, SEBU5898, Cold Weather Recommendations for All Caterpillar Machines. Poor maintenance of air lters or of fuel lters requires reduced oil change intervals. Consult your Caterpillar dealer for more information if this product will experience abnormally harsh operating cycles or harsh environments.

Adjustment of the Oil Change Interval


Note: Your Caterpillar dealer has additional information on these programs. Cat oil lters are recommended.
Illustration 168
g01000916

Program A Verication for an Oil Change Interval of 500 Hours This program consists of three oil change intervals of 500 hours. Oil sampling and analysis is done at 250 hours and 500 hours for each of the three intervals for a total of six oil samples. The analysis includes oil viscosity and infrared (IR) analysis of the oil. If all of the results are satisfactory, the 500 hour oil change interval is acceptable for the machine in that application. Repeat Program A if you change the application of the machine. If a sample does not pass the oil analysis, take one of these actions:

Caterpillar recommends checking the engine mounts for deterioration. Checking the engine mounts will ensure that the bolts have the proper torque. This will prevent excessive engine vibration that is caused from improper mounting. Reference: For the proper bolt torques, refer to the Specications manual for your machine's engine.
i03649497

Engine Oil (High Speed) and Oil Filter - Change (If Equipped)
SMCS Code: 1318-510

Shorten the oil change interval to 250 hours. Proceed to Program B. Change to a preferred oil type in the Lubricant
Viscosities for Ambient Temperatures Table in this Operation and Maintenance Manual

Selection of the Oil Change Interval


NOTICE A 500 hour engine oil change interval is available, provided that the operating conditions and recommended multigrade oil types are met. When these requirements are not met, shorten the oil change interval to 250 hours, or use an SOS Services oil sampling and analysis program to determine an acceptable oil change interval. If you select an interval for oil and lter change that is too long, you may damage the engine. The normal engine oil change interval is listed in this Operation and Maintenance Manual, Maintenance Interval Schedule.

Program B Optimizing Oil Change Intervals Begin with a 250 hour oil change interval. The oil change intervals are adjusted by increments. Each increment is an additional 50 hours. Periodic oil sampling and analysis is done during each interval. The analysis includes oil viscosity and infrared (IR) analysis of the oil. Repeat Program B if you change the application of the machine. If an oil sample does not pass the analysis, shorten the oil change interval, or change to a preferred multigrade oil type in the listing above.

126 Maintenance Section Engine Oil (High Speed) and Oil Filter - Change

SEBU8480

References Reference: Special Publication, SEBU6250, Caterpillar Machine Fluids Recommendations Reference: Special Publication, SEBU5898, Cold Weather Recommendations for All Caterpillar Machines Reference: Special Publication, PEDP7035, Optimizing Oil Change Intervals Reference: Special Publication, PEDP7036, SOS Fluid Analysis Reference: Special Publication, PEDP7076, Understanding the SOS Oil Analysis Tests
Illustration 169
g00841360

Procedure for Changing the Engine Oil and Filter

Hot oil and components can cause personal injury. Do not allow hot oil or components to contact skin. NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. Your machine may be equipped with a high speed arrangement for changing the engine oil. The high speed arrangement allows the engine oil to be changed faster than the conventional method.
Illustration 170
g01000950

1. Open the engine access door on the right side of the machine. The high speed arrangement is located on the right side of the engine compartment. 2. Remove the cap that protects the male coupler. Connect an oil pump to the male coupler. Turn on the oil pump and withdraw the engine oil.

Illustration 171

g00841382

3. Open the engine access door on the left side of the machine.

SEBU8480

127 Maintenance Section Engine Oil Level - Check

8. Clean the end of the male coupler for the high speed arrangement. Connect an oil pump to the male coupler for the high speed arrangement. Fill the crankcase with oil. Reference: Refer to Operation and Maintenance Manual, Capacities (Rell) for the proper amount of oil. 9. Clean the end of the male coupler for the high speed arrangement. Clean the cap that covers the male coupler and install the cap. 10. Start the engine and allow the oil to circulate. Check for leaks. 11. Check the engine oil level. Reference: Refer to Operation and Maintenance Manual, Engine Oil Level - Check for the correct procedure. 12. Close the engine access doors.
i01923584

Illustration 172

g01001013

4. Use a strap type wrench to remove the engine oil lter. Dispose of the used lter properly. 5. Clean the lter mounting base. Make sure that the used seal is completely removed.

Engine Oil Level - Check


SMCS Code: 1000-535-FLV NOTICE Do not under ll or overll engine crankcase with oil. Either condition can cause engine damage.

Illustration 173

g00101318

6. Apply a thin lm of clean engine oil to the seal on the new lter element. Install a new engine oil lter hand tight until the seal of the engine oil lter contacts the base. Note the position of the index marks on the lter in relation to a xed point on the lter base. Note: There are rotation index marks on the engine oil lter that are spaced 90 degrees or 1/4 of a turn away from each other. When you tighten the engine oil lter, use the rotation index marks as a guide. 7. Tighten the lter according to the instructions that are printed on the lter. Use the index marks as a guide. For non-Caterpillar lters, use the instructions that are provided with the lter. Note: You may need to use a Caterpillar strap wrench, or another suitable tool, in order to turn the lter to the amount that is required for nal installation. Make sure that the installation tool does not damage the lter.

Illustration 174

g00841382

1. Open the engine access door on the left side of the machine.

128 Maintenance Section Engine Oil Sample - Obtain

SEBU8480

i01908025

Engine Oil Sample - Obtain


SMCS Code: 1348-008; 7542

Illustration 175

g01001056

2. Remove engine oil dipstick (1) and wipe the dipstick with a clean cloth. Then, insert the dipstick and remove the dipstick again. This will ensure a more accurate measurement of the engine oil level.

Illustration 177

g01001331

The sampling valve for the engine oil is located on the engine oil lter base on the right side of the engine compartment.
i03711621

Engine Oil and Filter - Change


Illustration 176
g00999790

SMCS Code: 1318-510

3. When the engine is stopped, maintain the oil level within crosshatched region (A) of the dipstick. This region of the dipstick is marked Safe Starting Range. 4. If necessary, remove oil ller cap (2) and add oil. Clean the oil ller cap and install the oil ller cap. 5. Close the engine access door.

Selection of the Oil Change Interval


NOTICE A 500 hour engine oil change interval is available, provided that the operating conditions and recommended multigrade oil types are met. When these requirements are not met, shorten the oil change interval to 250 hours, or use an SOS Services oil sampling and analysis program to determine an acceptable oil change interval. If you select an interval for oil and lter change that is too long, you may damage the engine. The normal engine oil change interval is listed in this Operation and Maintenance Manual, Maintenance Interval Schedule.

SEBU8480

129 Maintenance Section Engine Oil and Filter - Change

Abnormally harsh operating cycles or harsh environments can shorten the service life of the engine oil. Arctic temperatures, corrosive environments, or extremely dusty conditions may require a reduction in engine oil change intervals. Also refer to Special Publication, SEBU5898, Cold Weather Recommendations for All Caterpillar Machines. Poor maintenance of air lters or of fuel lters requires reduced oil change intervals. Consult your Caterpillar dealer for more information if this product will experience abnormally harsh operating cycles or harsh environments.

References Reference: Special Publication, SEBU6250, Caterpillar Machine Fluids Recommendations Reference: Special Publication, SEBU5898, Cold Weather Recommendations for All Caterpillar Machines Reference: Special Publication, PEDP7035, Optimizing Oil Change Intervals Reference: Special Publication, PEDP7036, SOS Fluid Analysis Reference: Special Publication, PEDP7076, Understanding the SOS Oil Analysis Tests

Adjustment of the Oil Change Interval


Note: Your Caterpillar dealer has additional information on these programs. Cat oil lters are recommended. Program A Verication for an Oil Change Interval of 500 Hours This program consists of three oil change intervals of 500 hours. Oil sampling and analysis is done at 250 hours and 500 hours for each of the three intervals for a total of six oil samples. The analysis includes oil viscosity and infrared (IR) analysis of the oil. If all of the results are satisfactory, the 500 hour oil change interval is acceptable for the machine in that application. Repeat Program A if you change the application of the machine. If a sample does not pass the oil analysis, take one of these actions:

Procedure for Changing the Engine Oil and Filter


NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates.

Shorten the oil change interval to 250 hours. Proceed to Program B. Change to a preferred oil type in the Lubricant
Viscosities for Ambient Temperatures Table in this Operation and Maintenance Manual

Program B Optimizing Oil Change Intervals Begin with a 250 hour oil change interval. The oil change intervals are adjusted by increments. Each increment is an additional 50 hours. Periodic oil sampling and analysis is done during each interval. The analysis includes oil viscosity and infrared (IR) analysis of the oil. Repeat Program B if you change the application of the machine. If an oil sample does not pass the analysis, shorten the oil change interval, or change to a preferred multigrade oil type in the listing above.

Illustration 178

g01001064

1. Lower the bottom guard. Open the crankcase drain valve (1) and allow the oil to drain into a suitable container. Reference: Refer to Operation and Maintenance Manual, Power Guard Control for the proper removal of bottom guard.

130 Maintenance Section Engine Oil and Filter - Change

SEBU8480

2. Close the drain valve (1). Raise the bottom guard.

6. Apply a thin lm of clean engine oil to the seal on the new lter element. Install a new engine oil lter hand tight until the seal of the engine oil lter contacts the base. Note the position of the index marks on the lter in relation to a xed point on the lter base. Note: There are rotation index marks on the engine oil lter that are spaced 90 degrees or 1/4 of a turn away from each other. When you tighten the engine oil lter, use the rotation index marks as a guide. 7. Tighten the lter according to the instructions that are printed on the lter. Use the index marks as a guide. For non-Caterpillar lters, use the instructions that are provided with the lter. Note: You may need to use a Cat strap wrench, or another suitable tool, in order to turn the lter to the amount that is required for nal installation. Make sure that the installation tool does not damage the lter.

Illustration 179

g00841382

3. Open the engine access door on the left side of the machine.

Illustration 180

g01001013 g01001078

4. Use a strap type wrench to remove the engine oil lter. Dispose of the used lter properly. 5. Clean the lter mounting base. Make sure that the used gasket is completely removed.

Illustration 182

8. Remove the engine oil ller cap and ll the engine crankcase with oil. Reference: Refer to Operation and Maintenance Manual, Capacities (Rell) for the proper amount of oil. 9. Clean the oil ller cap and install the oil ller cap. 10. Start the engine and allow the oil to circulate. Check for leaks. 11. Check the engine oil level. Reference: Refer to Operation and Maintenance Manual, Engine Oil Level - Check for the correct procedure.

Illustration 181

g00101318

SEBU8480

131 Maintenance Section Engine Valve Lash - Check

i01923706

Engine Valve Lash - Check


SMCS Code: 1105-535 For the correct procedure, refer to the appropriate Service Manual module for your machine's engine or consult your Caterpillar dealer. Note: A qualied mechanic should adjust the engine valve lash because special tools and training are required. Note: The engine crankcase breather is located inside the valve cover. This breather does not require a maintenance interval. Caterpillar recommends replacing the crankcase breather during an engine overhaul. In order to replace the breather element, the valve cover will need to be replaced. NOTICE Attempts to clean the engine crankcase breather may cause damage to the element.
Illustration 183
g00882731

Start the engine and run the engine at low idle. Watch the top surface of each valve rotator. Whenever an inlet valve closes or an exhaust valve closes, each valve rotator should turn. If a valve rotator fails to turn, consult your Caterpillar dealer for service.
i01394313

i01935374

Engine Valve Rotators - Inspect


SMCS Code: 1109-040

Engine Water Pump - Inspect


SMCS Code: 1361-040 Failure of the engine water pump may cause severe engine overheating problems such as cracks in the cylinder head or piston seizure. Visually inspect the water pump for leaks. If you nd leaks, all of the seals on the water pump must be replaced. Note: For more information, refer to the appropriate Disassembly and Assembly manual for your machine's engine.

When inspecting the valve rotators, protective glasses or face shield and protective clothing must be worn, to prevent being burned by hot oil or spray. Caterpillar recommends replacing valve rotators that are operating improperly. An improperly operating valve rotator will shorten valve life because of accelerated wear on the valves. Also, metal particles from a damaged valve rotator could fall into the cylinder and damage to the piston head and to the cylinder head may result.

132 Maintenance Section Ether Starting Aid Cylinder - Replace

SEBU8480

i01548876

Ether Starting Aid Cylinder Replace (If Equipped)


SMCS Code: 1456-510-CD

3. Remove the used gasket. Install the new gasket that is provided with every new ether starting aid cylinder. 4. Install new ether starting aid cylinder. Tighten the ether starting aid cylinder hand tight. Tighten the cylinder retaining clamp securely. 5. Close the engine access door.

Ether is poisonous and ammable. Breathing ether vapors or repeated contact of ether with skin can cause personal injury. Use ether only in well ventilated areas. Do not smoke while changing ether cylinders. Use ether with care to avoid res. Do not store replacement ether cylinders in living areas or in the operator's compartment. Do not store ether cylinders in direct sunlight or at temperatures above 49 C (120 F). Discard cylinders in a safe place. Do not puncture or burn cylinders. Keep ether cylinders out of the reach of unauthorized personnel.

i02236759

Fuel System - Prime


SMCS Code: 1250-548 1. Open the engine access door on the left side of the machine.

Illustration 185

g01002079

To avoid possible injury, be sure the brakes are applied and all controls are in Hold or Neutral when starting the engine.

2. Attach a piece of bulk hose to a sampling probe. Install the sampling probe with the piece of bulk hose onto the valve assembly. Note: Consult your Caterpillar dealer for the proper tooling or refer to the parts manual for your machine. 3. Position a suitable container under the hose. 4. Turn the toggle switch (1) to the ON position. Toggle switch (1) is for the fuel priming pump. 5. Allow the air/fuel mixture to ow into the suitable container until the fuel ows in a steady stream. 6. Turn the toggle switch (1) to the OFF position.

Illustration 184

g00805191

7. Remove the sampling probe with the piece of bulk hose from the valve assembly. 8. Start the engine. The engine should start. The engine should run smoothly. If the engine does not start or the engine misres, further priming is necessary.

1. Open the engine access door on the right side of the machine. 2. Loosen cylinder retaining clamp (1). Remove empty ether starting aid cylinder (2) and discard the empty ether starting aid cylinder.

SEBU8480

133 Maintenance Section Fuel System Primary Filter (Water Separator) - Check/Drain

Note: Failure to tighten ttings could result in fuel leaks. 9. Clean residual fuel from the engine components. 10. Close the engine access door on the left side of the machine.
i02962202

Fuel System Primary Filter (Water Separator) Check/Drain


SMCS Code: 1263-535; 1263-543 NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates.
Illustration 188 Type 2 Illustration 187 Type 1

g01002112

g01482573

2. The water separator is located on the bottom of the primary fuel lter. Open the drain valve on the bottom of the water separator bowl. Allow the water and the fuel to drain into a suitable container. 3. Tighten the drain valve. Note: The water separator is under suction during normal engine operation. The drain valve must be tightened in order to prevent air leakage into the fuel system.
Illustration 186
g00841382

4. Close the engine access door.

1. Open the engine access door on the left side of the machine.

134 Maintenance Section Fuel System Primary Filter (Water Separator) Element - Replace

SEBU8480

i03355824

Fuel System Primary Filter (Water Separator) Element Replace


SMCS Code: 1260-510; 1263-510-FQ NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. NOTICE Do not ll fuel lters with fuel before installing them. The fuel will not be ltered and could be contaminated. Contaminated fuel will cause accelerated wear to fuel system parts. The fuel system should be primed prior to starting the engine.

Illustration 190 Type 1

g01002123

2. The water separator is located on the bottom of the primary fuel lter. Open the drain valve on the water separator bowl. Allow the water and the fuel to drain into a suitable container. 3. Use a strap type wrench to remove the lter from the lter mounting base. 4. Remove the water separator bowl from the lter element. Clean the water separator bowl and the O-ring groove. Note: The water separator bowl is reusable. Do not discard the water separator bowl.

Illustration 189

g00841382

Illustration 191 Type 2

g01482573

1. Open the engine access door on the left side of the machine.

a. The steel fuel lter (Type 2) is not reusable. 5. Inspect the O-ring seal in the water separator bowl for damage. Replace the O-ring seal, if necessary. 6. Lubricate the O-ring seal with clean diesel fuel or with engine oil. Place the O-ring seal in the water separator bowl. 7. Install the water separator bowl onto the new lter element by hand. Do not use tools to tighten the water separator bowl.

SEBU8480

135 Maintenance Section Fuel System Secondary Filter - Replace

i02301079

Fuel System Secondary Filter Replace


SMCS Code: 1261-510-SE NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids.
Illustration 192
g00101318

8. Apply a thin coat of oil to the seal on the new lter. Install the new lter hand tight until the seal of the engine oil lter contacts the base. Note the position of the index marks on the lter in relation to a xed point on the lter base. Note: There are rotation index marks on the fuel lter that are spaced 90 degrees or 1/4 of a turn away from each other. When you tighten the fuel lter, use the rotation index marks as a guide. 9. Tighten the lter according to the instructions that are printed on the lter. Use the index marks as a guide. For non-Caterpillar lters, use the instructions that are provided with the lter. 10. Tighten the drain valve on the water separator bowl. Note: The water separator element is under suction during normal engine operation. The drain valve must be tightened in order to prevent air leakage into the fuel system. 11. Prime the fuel system in order to ll the lter element with fuel. Reference: Refer to Operation and Maintenance Manual, Fuel System Prime for the correct procedure.

Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. NOTICE Do not ll fuel lters with fuel before installing them. The fuel will not be ltered and could be contaminated. Contaminated fuel will cause accelerated wear to fuel system parts. The fuel system should be primed prior to starting the engine.

Illustration 193

g00841360

1. Open the engine access door on the right side of the machine.

136 Maintenance Section Fuel Tank Cap and Strainer - Clean

SEBU8480

Reference: Refer to Operation and Maintenance Manual, Fuel System - Prime for the correct procedure. 7. Close the engine access door.
i02496986

Fuel Tank Cap and Strainer Clean


SMCS Code: 1273-070-Z2; 1273-070-STR
Illustration 194
g01002138

The fuel tank cap is located on the left side of the machine. 1. Remove the fuel tank cap. 2. Inspect the seal for damage. Replace the seal, if necessary. 3. Remove the lter assembly from the cap.

2. Remove the used lter element. Dispose of the used lter element properly. 3. Clean the lter mounting base. Make sure that all of the used seal is removed.

Illustration 195

g00101318

4. Apply a thin coat of clean diesel fuel to the seal on the new fuel lter. Install the new fuel lter hand tight until the seal of the fuel lter contacts the base. Note the position of the index marks on the lter in relation to a xed point on the lter base. Note: There are rotation index marks on the fuel lter that are spaced 90 degrees or 1/4 of a turn away from each other. When you tighten the fuel lter, use the rotation index marks as a guide. 5. Tighten the lter according to the instructions that are printed on the lter. Use the index marks as a guide. For non-Caterpillar lters, use the instructions that are provided with the lter. Note: You may need to use a Caterpillar strap wrench, or another suitable tool, in order to turn the lter to the amount that is required for nal installation. Make sure that the installation tool does not damage the lter. 6. Prime the fuel system.

Illustration 196

g00930457

Note: Refer to Operation and Maintenance Manual, General Hazard Information for information on Containing Fluid Spillage. 4. Remove the strainer from the ller tube. 5. Wash the fuel tank cap and the strainer in a clean, nonammable solvent. 6. Install a new cap lter kit. Install the other components in reverse order. 7. Install the strainer and the fuel tank cap.

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137 Maintenance Section Fuel Tank Water and Sediment - Drain

i02156799

i02741651

Fuel Tank Water and Sediment - Drain


SMCS Code: 1273-543-M&S NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates.

Fuses - Replace
SMCS Code: 1417-510 Note: Your machine may not be equipped with all of the fuses that are discussed in this topic. Fuses The fuses protect the electrical system from damage that is caused by overloaded circuits. Replace a fuse if the element separates. If the element of a new fuse separates, inspect the circuit. Repair the circuit, if necessary.

Illustration 199

g01093757

The fuses are located under a small access door on the right cab platform. Note: Your machine may be equipped with glass fuses or your machine may be equipped with blade fuses. NOTICE Replace the fuses with the same type and size only. Otherwise, electrical damage can result. If it is necessary to replace fuses frequently, an electrical problem may exist. Contact your Caterpillar dealer

Illustration 197

g01093885

The fuel tank drain valve is located on the left side of the machine at the bottom of the fuel tank.

Illustration 198

g01093886

Open the fuel tank drain valve. Allow the water and sediment to drain into a suitable container. Close the fuel tank drain valve.

138 Maintenance Section Fuses - Replace

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Glass Fuses (If equipped)

Rear Work Lights (11) 15 amp

Front Work Lights (12) 15 amp

Electronic Gauges (13) 10 amp

Lighter and Voltage Converter (14) 10 amp


Illustration 200
g01119139

Transmission Electronic Control (1) 10 amp Window Wipers (15) 10 amp Implement Electronic Control (2) 10 amp

Blower Fan (3) 20 amp Horn (16) 10 amp Automatic Lubrication (4) 10 amp Stairway Access Light (17) 10 amp Front Work Lights (5) 15 amp

Front Work Lights (6) 10 amp

Payload Control System (18) 10 amp

Rotating Beacon (7) 10 amp

Voltage Converter (8) 10 amp

Seat (9) 15 amp

Front Work Lights (10) 15 amp

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139 Maintenance Section Fuses - Replace

Blade Fuses (If equipped)

Voltage Converter 15 Amp

Product Link 10 amp

Rotating Beacon 10 amp

Headlights 15 amp

Rear Work Lights 15 amp

Illustration 201 Typical example

g01353212

Front Work Lights 15 amp

Open 10 amp Front Work Lights 2 15 amp Open 15 amp Headlights 2 15 amp Open 20 amp Payload Control System 10 amp Voltage Converter 2 10 Amp Electrical Monitoring System 10 amp Side Receiver Mast 10 Amp Power train Electronic Control Module (ECM) 10 amp Input/Output 10 Amp Implement Control 10 amp Horn 10 amp Electrical Power (Accessories) 10 amp Stairway Access Light 10 amp Side Receiver Mast 10 amp

140 Maintenance Section High Intensity Discharge Lamp (HID) - Replace

SEBU8480

Rear Monitor (Vision) 10 amp

1. Remove the electrical power from the high intensity discharge lamp (HID). The electrical power must be removed from the HID lamp for at least ve minutes, in order to ensure that the bulb is cool. 2. Disassemble the housing for the HID lamp in order to have access to the bulb. Note: On some HID lamps, the bulb is an integral part of the lens assembly. The bulb is not removed separately from the lens assembly. Replace the entire lens assembly on these HID lamps. 3. Remove the bulb from the HID lamp. 4. Install the replacement bulb in the HID lamp.

Voltage Converter 10 amp

Autolube System 10 amp

Window Wipers 10 amp

Seat 15 amp

If the bulb is an integral part of the lens assembly, install the replacement lens assembly in the HID lamp. Note: In order to avoid failure to the bulb that is premature, avoid touching the bulb's surface with your bare hands. Clean any ngerprints from the bulb with alcohol prior to operation.
i02245859

Blower Fan 20 amp

High Intensity Discharge Lamp (HID) - Replace (If Equipped)


SMCS Code: 1434-510

5. Reassemble the housing for the HID lamp. Ensure that any printing on the lens is oriented correctly with respect to the HID lamp's mounting position on the machine. 6. Reattach the electrical power to the HID lamp. 7. Check the HID lamp for proper operation. Note: Consult your Caterpillar dealer for additional information on HID lamps.

HID lamps operate at very high voltages. To avoid electrical shock and personal injury, disconnect power before servicing HID lamps.

i03307817

Hydraulic System Oil - Change


SMCS Code: 5056-044

HID bulbs become very hot during operation. Before servicing, remove power from lamp for at least ve minutes to ensure lamp is cool. NOTICE Although HID bulb materials may change over time, HID bulbs produced at the time of the printing of this manual contain mercury. When disposing of this component, or any waste that contains mercury, please use caution and comply with any applicable laws.

Selection of the Oil Change Interval


Your machine may be able to use a 4000 hour interval for the hydraulic oil. The hydraulic oil is in the system that is not integral to the service brakes, the clutches, the nal drives, or the differentials. The standard change interval is 2000 hours. The oil should be monitored in additional increments of 500 hours. The extended 4000 hour interval can be used if the following criteria are met.

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141 Maintenance Section Hydraulic System Oil - Change

HYDO Advanced 10
Cat HYDO Advanced 10 is the preferred oil for use in most Caterpillar machine hydraulic and hydrostatic transmission systems when ambient temperature is between 20 C (4 F) and 40 C (104 F). Cat HYDO Advanced 10 has an SAE viscosity grade of 10W. Cat HYDO Advanced 10 has a 50% increase in the standard oil drain interval (up to 3000 hours) for machine hydraulic systems over second and third choice oils when you follow the maintenance interval schedule for oil lter changes and for oil sampling that is stated in the Operation and Maintenance Manual. 6000 hour oil drain intervals are possible when using SOS Services oil analysis. When you switch to Cat HYDO Advanced 10, cross contamination with the previous oil should be kept to less than 10%. Consult your Cat dealer for details about the benets from the improved performance designed into Cat HYDO Advanced 10.

Monitoring the Condition of the Oil


The oil should be monitored during intervals of 500 hours. Caterpillar's standard SOS Fluids Analysis or an equivalent oil sampling program should be used. The current guidelines for cleanliness of the oil should be observed. Refer to Measured Data. If an oil sampling program is not available, the standard 2000 oil change interval should be used.

Measured Data
The following information should be monitored when you sample the oil:

Signicant changes in wear metals should be


monitored. These metals include iron, copper, chromium, lead, aluminum, and tin.

Oil Filters
Caterpillar oil lters are recommended. The interval for changing the oil lter should be 500 hours.

The following additives should be observed for


signicant changes: Zinc, calcium, magnesium, and phosphorus.

Oil
The 4000 hour interval for changing the oil is for the following oil types.

Contaminants should not be present. These

contaminants include fuel and antifreeze. Water content should be .5 percent or less.

The silicon level should not exceed 15 parts per


million for new oil. The particle counts should be monitored.

Caterpillar Hydraulic Oil (HYDO) CaterpillarTransmission/Drive Train Oil (TDTO) Caterpillar TDTO (TMS) Caterpillar Diesel Engine Oil Caterpillar Biodegradable Hydraulic Oil (HEES) Caterpillar Multipurpose Tractor Oil (MTO) Heavy-Duty Diesel Engine Oil with a minimum
zinc content of 900 parts per million (ppm) Heavy-duty oils are identied by the following classications: Cat ECF-1, API CF, API CG-4, and TO-4. Cat ECF-1, API CF, API CG-4, and TO-4 oils must have a minimum zinc additive of 900 parts per million (ppm) in order to be considered acceptable for use in a hydraulic system. Note: Industrial hydraulic oils are not recommended in Caterpillar hydraulic systems. These oils are more likely to cause corrosion and excessive wear.

The recommended level of cleanliness for

Caterpillar machines that are operated in the eld is ISO 18/15 or cleaner. The cleanliness should be monitored by particle count analysis. The levels of contamination should not exceed normal levels by more than two ISO codes. Action should be taken in order to determine the cause of the contamination. The system should be returned to the original levels of contamination. silicon, copper, and potassium. Abs units).

There should not be signicant changes in sodium, The allowable level of oxidation is 40 percent (0.12 The kinematic viscosity at 100 C (212 F) should
not exceed a 2 cSt change.

142 Maintenance Section Hydraulic System Oil - Change

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Procedure for Changing the Hydraulic Oil


NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. 1. Operate the machine in order to warm the hydraulic oil. 2. Park the machine on level ground. Lower the attachment to the ground and apply slight downward pressure. Engage the parking brake and stop the engine.

6. Remove the drain plug from the bottom of the hydraulic tank. Wash the drain plug in a clean, nonammable solvent. 7. Install a 6B-3156 Pipe Nipple into the drain valve in order to unseat the drain valve. Allow the hydraulic oil to drain into a suitable container. NOTICE Never start the engine while the hydraulic oil tank is being drained or while the hydraulic oil tank is empty. Excessive wear and damage to the hydraulic components can occur. 8. Remove the pipe nipple in order to close the drain valve. Install the hydraulic tank drain plug. 9. Change the hydraulic oil lter. Reference: Refer to Operation and Maintenance Manual, Hydraulic System Oil Filter - Replace for the correct procedure. 10. Fill the hydraulic tank with clean oil. Make sure that the oil level is at the FULL mark on sight gauge (4). Reference: Refer to Operation and Maintenance Manual, Lubricant Viscosities and Rell Capacities for the correct type of oil and for the correct amount of oil. 11. Install ller cap (2). Note: The steering pump and the implement pump must be primed before the engine is started. This is necessary in order to ensure proper operation of the pumps.

Filling the Cases of the Implement Pump and the Steering Pump
The cases of the steering pump and the implement pump must be lled with oil before the engine is started. This is necessary in order to ensure proper operation of the pumps.
Illustration 202
g01152499

3. The hydraulic tank is located on the right side of the machine. Press the button on the breaker relief valve (1) in order to relieve any tank pressure. 4. Remove the hydraulic tank ller cap (2). Remove the ller strainer from the hydraulic tank ller neck. Wash the ller cap and the strainer in a clean, nonammable solvent. Install the strainer. 5. Inspect the gasket on the hydraulic tank ller cap for damage. Replace the gasket, if necessary.

1. Open the access doors that are located behind the operator compartment.

SEBU8480

143 Maintenance Section Hydraulic System Oil Filter (Steering and Implement Pilot) - Replace

i02281910

Hydraulic System Oil Filter (Steering and Implement Pilot) - Replace


SMCS Code: 5068-510-PS NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain uids on Caterpillar products.
Illustration 203
g00935858

2. Remove the cap from port (6). Attach a drain hose that is equipped with a quick connect tting to tee (8). Place the end of the drain hose into a suitable container in order to collect excess hydraulic oil. Pour clean hydraulic oil into port (6). Continue to pour hydraulic oil until the hydraulic oil comes out of the drain hose that is attached to tee (8). 3. Remove the drain hose and install the cap onto port (6). The steering pump case is now lled. 4. Remove the cap from port (9). Attach a drain hose that is equipped with a quick connect tting to tee (7). Place the end of the drain hose into a suitable container in order to collect excess hydraulic oil. Pour clean hydraulic oil into port (9). Continue to pour hydraulic oil until the hydraulic oil comes out of the drain hose that is attached to tee (7). 5. Remove the drain hose and install the cap onto port (9). The case for the implement pump is now lled. 6. Replace any hydraulic oil that was lost during the installation of the hoses. Reference: Refer to Operation and Maintenance Manual, Hydraulic System Oil Level - Check for more information. Note: The oil must be free of bubbles. If bubbles are present in the oil, air is entering the hydraulic system. Inspect the suction hoses and the hose clamps.

Dispose of all uids according to local regulations and mandates.

Illustration 204

g01001201

The hydraulic oil lter is located behind the mud ap on the front of the hydraulic tank. Note: The mud ap may be removed for easier access to the lter. 1. Stop the engine.

144 Maintenance Section Hydraulic System Oil Level - Check

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7. Tighten the lter according to the instructions that are printed on the lter. Use the index marks as a guide. For non-Caterpillar lters, use the instructions that are provided with the lter. Note: You may need to use a Caterpillar strap wrench, or another suitable tool, in order to turn the lter to the amount that is required for nal installation. Make sure that the installation tool does not damage the lter. 8. Start the engine and run the engine at low idle. Inspect the hydraulic system for leaks.
Illustration 205
g01001186

9. Check the level of the hydraulic oil. Reference: Refer to Operation and Maintenance Manual, Hydraulic System Oil Level - Check for the correct procedure.
i01923843

2. Use a strap type wrench to remove the hydraulic oil lter element. Dispose of the used lter properly. 3. Remove the ller cap and the strainer from the hydraulic oil ller tube. Wash the ller cap and the strainer in a clean nonammable solvent. Allow the strainer to air dry. 4. Inspect the strainer for damage. Replace the strainer, if necessary. Install the strainer and the ller cap. 5. Clean the lter mounting base. Make sure that all of the used gasket is removed from the lter mounting base.

Hydraulic System Oil Level Check


SMCS Code: 5056-535-FLV Note: The work tool must be positioned on the ground in order to have an accurate reading.

Illustration 207
g00101318

g01001204

Illustration 206

The hydraulic tank is located on the right side of the machine.

6. Apply a thin coat of hydraulic oil to the seal on the new lter. Install the new hydraulic oil lter hand tight until the seal of the hydraulic oil lter contacts the lter base. Note the position of the index marks on the lter in relation to a xed point on the lter base. Note: There are rotation index marks on the hydraulic oil lter that are spaced 90 degrees or 1/4 of a turn away from each other. When you tighten the hydraulic oil lter, use the rotation index marks as a guide.

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145 Maintenance Section Hydraulic System Oil Sample - Obtain

i01923846

Hydraulic Tank Breaker Relief Valve - Clean


SMCS Code: 5118-070

Illustration 208

g00935879

1. Maintain the hydraulic oil level within the designated range (3). 2. If necessary, press hydraulic tank breaker relief valve (1) in order to relieve any tank pressure. Then, remove hydraulic tank ller cap (2) and add hydraulic oil. 3. If hydraulic oil was added, clean the hydraulic tank ller cap and install the hydraulic tank ller cap.
i02156928 g01001206

Illustration 210

The hydraulic tank breaker relief valve is located on the side of the hydraulic tank. 1. To relieve the pressure in the hydraulic tank, press the button on the top of the hydraulic breaker. Remove the hydraulic tank breaker relief valve. 2. Clean the hydraulic tank breaker relief valve in a clean, nonammable solvent. Shake the relief valve dry or use pressure air. 3. Install the hydraulic tank breaker relief valve.
i02157156

Hydraulic System Oil Sample - Obtain


SMCS Code: 5050-008; 5056-008; 7542

Lift Cylinder Pin Oil - Change


SMCS Code: 7070-044-OC NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates.

Illustration 209

g01093962

Obtain a sample of the hydraulic oil from the hydraulic oil sampling valve. The sampling valve is located on the hydraulic oil lter base on the front of the hydraulic tank. Refer to Special Publication, SEBU6250, SOS Oil Analysis for information that pertains to obtaining a sample of hydraulic oil. Refer to Special Publication, PEHP6001, How To Take A Good Oil Sample for more information about obtaining a sample of hydraulic oil.

146 Maintenance Section Lift Cylinder Pin Oil - Change

SEBU8480

Illustration 211

g00560502

Illustration 213 Pin Joint (K)

g01094058

1. Park the machine on level ground and engage the parking brake. Lower the bucket so that the bottom of the bucket is at on the ground. Stop the engine.

5. Fill the pin joint with SAE 80W90 oil until oil escapes from the ller opening. 6. Clean the ller plug and install the ller plug.

Illustration 212 Pin Joint (K)

g01094056

Illustration 214

g01094059

2. Remove the drain plug for pin joint (K). The drain plug is located on the right side of the machine. Allow the oil to drain into a suitable container. 3. Remove the ller plug for pin joint (K). The ller plug is located on the right side of the machine. 4. After the oil has drained, clean the drain plug and install the drain plug.

Illustration 215 Pin Joint (Y)

g01094061

7. Remove the drain plug for pin joint (Y). The drain plug is located on the inside of the left front loader frame. Allow the oil to drain into a suitable container.

SEBU8480

147 Maintenance Section Lift Cylinder Pin Oil Level - Check

i02157325

Lift Cylinder Pin Oil Level Check


SMCS Code: 7070-535-FLV

Illustration 216

g01094064

Illustration 218

g00560502

1. Park the machine on level ground and engage the parking brake. Lower the bucket so that the bottom of the bucket is at on the ground.

Illustration 217 Pin Joint (Y)

g01094065

8. Remove the ller plug for pin joint (Y). The ller plug is located on the inside of the left front loader frame. 9. After the oil has drained, clean the drain plug and install the drain plug. 10. Fill the pin joint with SAE 80W90 oil until oil escapes from the ller opening. Note: It will be necessary to use a funnel and a hose to ll the pin joint through the ller opening. 11. Clean the ller plug and install the ller plug.
Illustration 219 Pin Joint (K)
g01094058

2. Clean the area around the ller plug for pin joint (K). Slowly loosen the ller plug. 3. If the oil escapes from the ller opening, the oil level in the pin joint is correct. If the oil level is low, add SAE 80W90 until oil escapes from the ller opening. 4. Clean the ller plug and install the ller plug.

148 Maintenance Section Loader Boom Pin Oil - Change

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1. Park the machine on level ground and engage the parking brake. Lower the bucket so that the bottom of the bucket is at on the ground. Stop the engine.

Illustration 220

g01094064

Illustration 222 The A-pin joints (1) do not have drain plugs.

g00811718

Illustration 221 Pin Joint (Y)

g01094065

5. Repeat the procedure for pin joint (Y).


i02280356

Loader Boom Pin Oil - Change


SMCS Code: 6118-044-OC NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids. Refer to Special Publication, NENG2500, Caterpillar Tools and Shop Products Guide for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates.
Illustration 223 A-Pin Joint
g01094359

2. Remove the ller plugs for both A-pin joints. 3. Attach a piece of tubing that is at least 610 mm (2 ft) to a 1U-5718 vacuum pump. Mark the tubing 305 mm (12 inch) from the open end. Cut the open end of the tube at a 45 degree angle in order to allow the tube to be inserted into the joint properly. 4. Install a sampling bottle onto the vacuum pump and insert 305 mm (12 inch) of the tubing through the ller plug opening. Insert the correct amount of tubing through the ller plug opening in order to make sure that the end of the tubing is at the bottom of the oil cavity. Use the mark on the tubing from step 3 as a guide.

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149 Maintenance Section Loader Boom Pin Oil Level - Check

5. Fill the sampling bottle and withdraw the tube from the ller plug opening. 6. Drain the sampling bottle into a suitable container. 7. Until no oil remains in the A-pin joints, repeat the following steps: 4, 5, and 6. 8. Fill each pin joint with 0.25 L (8 oz) of SAE 80w90 oil. 9. Install the ller plugs for both A-pin joints. 10. Start the engine. Move the boom through a minimum of four complete cycles. This will force any trapped air to the top of the joint. Inspect the joint for leaks. Check the oil level of the joint. Reference: Refer to Operation and Maintenance Manual, Loader Boom Pin Oil Level - Check for more information. Reference: Refer to Special Publication, NEHP6013, SOS Fluid Analysis Products for more information.
i02157449

Illustration 225 A-Pin Joint

g01094359

2. Clean the area around the ller plugs for both A-pin joints. Slowly loosen each ller plug. 3. If the oil escapes from the ller opening, the oil level is correct. If the oil level is low, add SAE 80W90 until oil escapes from the ller opening. 4. Clean the ller plugs and install the ller plugs.
i01613549

Loader Boom Pin Oil Level Check


SMCS Code: 6118-535-FLV

Loader Boom Pin and Lift Cylinder Pin - Inspect


SMCS Code: 5102-040-PN; 6501-040-PN

Illustration 224

g00560643

1. Park the machine on level ground and engage the parking brake. Lower the bucket so that the bottom of the bucket is at on the ground.

Illustration 226

g00818239

Inspect the Loader Boom Pin (A) for signs of leakage. If signs of leakage are found, check the oil level in the pin joint. Refer to Operation and Maintenance Manual, Loader Boom Pin Oil Level - Check for the correct procedure. Inspect Lift Cylinder Pins (Y) and (K) for signs of leakage. If signs of leakage are found, refer to Operation and Maintenance Manual, Lift Cylinder Pin Oil Level - Check for information on checking the oil level of the pins.

150 Maintenance Section Loader Pins and Bearings - Lubricate

SEBU8480

i02158811

Loader Pins and Bearings Lubricate


SMCS Code: 5104-086-BD; 6117-086-BD; 7070-086

Illustration 229 C-Pin Joints

g01094969

For the C-pin joints, apply lubricant through the ttings at the bottom of each bucket link.
Illustration 227
g00560806

Wipe off the ttings before any lubricant is applied. There is a total of nine ttings.

Illustration 230 E-Pin Joints

g01094970

For the E-pin joints, apply lubricant through three remote ttings on the bucket links.
Illustration 228 B-Pin Joint
g01094968

For the B-pin joint, apply lubricant through the tting on the top of the boom.

Illustration 231 F-Pin Joint (Right Side)

g01094972

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151 Maintenance Section Oil Filter - Inspect

i02106227

Oil Filter - Inspect


SMCS Code: 1308-507; 3004-507; 3067-507; 5068-507

Inspect a Used Filter for Debris

Illustration 232 F-Pin Joint (Left Side)

g01094974

For the F-pin joints, apply lubricant through the ttings at the bottom of each tilt lever.

Illustration 234 The element is shown with debris.

g00100013

Use a lter cutter to cut the lter element open. Spread apart the pleats and inspect the element for metal and for other debris. An excessive amount of debris in the lter element can indicate a possible failure. If metals are found in the lter element, a magnet can be used to differentiate between ferrous metals and nonferrous metals. Ferrous metals can indicate wear on steel parts and on cast iron parts. Nonferrous metals can indicate wear on the aluminum parts of the engine such as main bearings, rod bearings, or turbocharger bearings. Small amounts of debris may be found in the lter element. This could be caused by friction and by normal wear. Consult your Caterpillar dealer in order to arrange for further analysis if an excessive amount of debris is found. Using an oil lter element that is not recommended by Caterpillar can result in severe engine damage to engine bearings, to the crankshaft, and to other parts. This can result in larger particles in unltered oil. The particles could enter the lubricating system and the particles could cause damage.

Illustration 233 G-Pin Joint

g01094975

For the G-pin joint, apply lubricant through one remote tting on the inside of the right front loader frame.

152 Maintenance Section Radiator Core - Clean

SEBU8480

i02158840

i02728869

Radiator Core - Clean


SMCS Code: 1353-070-KO

Refrigerant Receiver-Dryer Replace


SMCS Code: 7322-510

Illustration 235

g01094991

On each side of the machine, the radiator core can be accessed through the vents and through the narrow access doors.

Illustration 237

g01095018

The refrigerant dryer is located behind the cab. Open the access panel on the operator platform in order to access the dryer. Before any service work is performed on the air conditioning system, refer to the Service Manual, SENR5664, Machine Preparation for Troubleshooting section in Testing and Adjusting. 1. Stop the engine for ve minutes in order to equalize the pressure in the air conditioning system.

Illustration 236

g00100062

You can use compressed air, high pressure water, or steam to remove dust and other debris from the radiator core. However, the use of compressed air is preferred. Refer to Special Publication, SEBD0518, Know Your Cooling System for the complete procedure for cleaning the radiator core.

SEBU8480

153 Maintenance Section Rollover Protective Structure (ROPS) - Inspect

i02159129

Rollover Protective Structure (ROPS) - Inspect


SMCS Code: 7325-040

Illustration 239

g01095101

Illustration 238 Typical In-Line Dryer (1) Inlet hose with air conditioner quick disconnects (2) Outlet hose with air conditioner quick disconnects

g00654556

Inspect the ROPS for bolts that are loose or damaged. Use original equipment parts only to replace bolts that are damaged or missing. Tighten the four cab mounting bolts to a torque of 1500 200 Nm (1106 147.5 lb ft). Note: Apply oil to all bolt threads before installation. Failure to apply oil can result in improper bolt torque. Do not repair the ROPS by welding reinforcement plates to the ROPS. Consult your Caterpillar dealer for repair of cracks in any welds, in any castings, or in any metal section of the ROPS.
i02429589

2. Disconnect the inlet hose (1) from the old in-line dryer. 3. Connect the inlet hose that was disconnected in Step 2 to the inlet on the new in-line dryer. 4. Start the engine and operate the air conditioning system. 5. With the air conditioning system in operation, disconnect the outlet hose (2) from the old in-line dryer. 6. Stop the engine for ve minutes in order to equalize the pressure in the air conditioning system. 7. Connect the outlet hose (2) that was disconnected in Step 5 to the outlet on the new in-line dryer. Note: Do not add oil to the in-line dryer. Note: If the in-line dryer assembly does not have quick disconnects, 30 mL (1 oz) of refrigerant oil will need to be added to the air conditioner system. Refer to the Service Manual, SENR5664, Refrigerant Recovery section in Testing and Adjusting for the proper procedure.

Seat Belt - Inspect


SMCS Code: 7327-040 Always check the condition of the seat belt and the condition of the seat belt mounting hardware before you operate the machine. Replace any parts that are damaged or worn before you operate the machine.

154 Maintenance Section Seat Belt - Replace

SEBU8480

Illustration 241 Illustration 240 Typical example


g00932801

g01152685

(1) (2) (3) (4)

Date of installation (retractor) Date of installation (buckle) Date of manufacture (tag) (fully extended web) Date of manufacture (underside) (buckle)

Check the seat belt mounting hardware (1) for wear or for damage. Replace any mounting hardware that is worn or damaged. Make sure that the mounting bolts are tight. Check buckle (2) for wear or for damage. If the buckle is worn or damaged, replace the seat belt. Inspect the seat belt (3) for webbing that is worn or frayed. Replace the seat belt if the seat belt is worn or frayed. Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware. Note: Within three years of the date of installation or within ve years of the date of manufacture, replace the seat belt. Replace the seat belt at the date which occurs rst. A date label for determining the age of the seat belt is attached to the seat belt, the seat belt buckle, and the seat belt retractor. If your machine is equipped with a seat belt extension, also perform this inspection procedure for the seat belt extension.
i02429594

Consult your Caterpillar dealer for the replacement of the seat belt and the mounting hardware. If your machine is equipped with a seat belt extension, also perform this replacement procedure for the seat belt extension.
i01547608

Seat Side Rails - Adjust


SMCS Code: 7312-025

Seat Belt - Replace


SMCS Code: 7327-510 Within three years of the date of installation or within ve years of the date of manufacture, replace the seat belt . Replace the seat belt at the date which occurs rst. A date label for determining the age of the seat belt is attached to the seat belt, the seat belt buckle, and the seat belt retractor.

Illustration 242

g00804394

Caterpillar recommends adjusting the side rails after the initial 500 hours of machine operation. After the initial 500 service hours, perform this procedure when it is necessary. Reference: Refer to Service Manual, SENR6615, Contour Series Seat for the adjustment procedure.

SEBU8480

155 Maintenance Section Secondary Steering - Test

i03694709

i01061080

Secondary Steering - Test


SMCS Code: 4300-081-SE; 4300-081-SST; 4324-081; 4324

Starting Motor - Inspect


SMCS Code: 1453-040 Caterpillar recommends a scheduled inspection of the starting system. Check the starting motor and the battery charger for proper operation. Check for loose electrical connections. Reference: For the complete procedure for inspecting the starting system, refer to the Systems Operation/Testing and Adjusting manual for your machine's engine.
i02168764

The service brake must be checked in order to ensure proper operation before you test the supplemental steering system. Personal injury, death, or property damage could occur if the supplemental steering system is tested and the service brake is not operational. Test the service brake before you test the supplemental steering system. Perform the following procedure if your machine is equipped with a ground driven supplemental steering and if the procedure is required by local regulations. Ensure that there are no hazards in the test area. The test area must be unobstructed and level. Operate the machine in second gear. Ensure that all air tanks and accumulators are properly charged. Ensure that there is no load in the work tool. Position the machine with the bucket or the work tool in the carry position with the machine in neutral. Release the parking brake. Apply the service brakes and put the engine at low idle. Ensure that The area around the machine is clear of personnel. Shift the transmission to second gear forward and slowly release the service brakes. Moderately increase the engine speed to high idle. Shift the transmission to neutral. Turn the ignition to the OFF position. Allow the machine to coast. While the machine is in motion, turn the machine to the left and to the right. If the machine responds to the steering input, the supplemental steering system is operating. Stop the machine with the service brakes. Apply the parking brake. The machine can then be returned to normal operation. If there is no response to the steering input, the supplemental steering system is not operating. Stop the machine immediately. Repair the supplemental steering system before returning the machine to service.

Steering Cylinder Bearings Lubricate


SMCS Code: 4303-086-BD Wipe off the ttings before any lubricant is applied. There is a total of four ttings.

Illustration 243

g01098863

Apply lubricant through the tting on the head end of each steering cylinder.

156 Maintenance Section Tire Ination - Check

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i03753360

Transmission Oil - Change


SMCS Code: 3030-044 NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids.
Illustration 244
g01098864

The bearing on the rod end of each steering cylinder is lubricated through two remote ttings on the inside of the right front loader frame. Apply lubricant through tting (1) for the right steering cylinder. Apply lubricant through tting (2) for the left steering cylinder.
i02305841

Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates. 1. Operate the machine in order to warm the transmission oil. 2. Park the machine on level ground. Lower the bucket to the ground and apply slight downward pressure. Engage the parking brake. Stop the engine.

Tire Ination - Check


SMCS Code: 4203-535-AI

Illustration 245

g01160201

Illustration 246

g01095645

Always obtain proper tire ination pressures and maintenance recommendations for the tires on your machine from your tire supplier. Measure the tire pressure on each tire. Inate the tires with nitrogen , if necessary. Reference: Refer to the Tire Ination Information section of the Operation and Maintenance Manual for more information.

3. There is an access hole in the transmission guard for the transmission drain plug. Note: The drain valve is an ecology drain valve. 4. Remove the transmission drain plug from the bottom of the transfer gear case. Attach a hose to a Oil Drain Coupling. Install the threaded end of the coupling into the drain valve in order to unseat the internal drain valve. Allow the oil to drain into a suitable container.

SEBU8480

157 Maintenance Section Transmission Oil - Change

Illustration 247

g01095647

Illustration 249

g00838905

5. The transmission oil ller tube is located near the articulation joint on the left side of the machine. Remove the transmission oil ller cap in order to ease drainage.

a. Remove bolts (1) and washers (2). Remove cover assembly (3) and seal (5). b. Remove screen tube assembly (6) and suction screen (7). c. Wash the screen tube assembly and the suction screen in a clean, nonammable solvent. d. Install screen tube assembly (6) and suction screen (7). e. Inspect seal (5) for damage. Replace the seal, if necessary. Install seal (5) and cover assembly (3). 7. Replace the transmission oil lter.

Illustration 248

g01095648

Reference: Refer to Operation and Maintenance Manual, Transmission Oil Filter - Replace for the correct procedure. 8. Clean the transmission drain plug. Install the transmission drain plug. 9. Fill the transmission with oil. Reference: Refer to Operation and Maintenance Manual, Capacities (Rell) for the proper amount of oil. 10. Clean the ller cap and install the ller cap.

6. The transmission magnetic screen is located on the left side of the transfer gear case. The screen may be accessed through the left side of the rear frame, as shown. Use the following procedure to clean the transmission magnetic screen: NOTICE Do not drop or rap the magnets against any hard objects. Replace any damaged magnets.

158 Maintenance Section Transmission Oil Filter - Replace

SEBU8480

i03753272

Transmission Oil Filter Replace


SMCS Code: 3067-510 NOTICE Care must be taken to ensure that uids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the uid with suitable containers before opening any compartment or disassembling any component containing uids.
Illustration 250 Transmission Breather
g00935383

11. Open the access door in the platform behind the cab. Remove the transmission breather. 12. Wash the breather in a clean, nonammable solvent. Allow the breather to air dry or use air pressure to dry the breather. Install the breather. 13. Start the engine and run the engine at low idle. 14. Slowly operate the transmission control in order to circulate the oil. Return the transmission to neutral. 15. Stop the engine. Inspect the entire transmission for leaks. 16. Check the transmission oil level. Reference: Refer to Operation and Maintenance Manual, Transmission Oil Level - Check for the correct procedure.

Refer to Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog for tools and supplies suitable to collect and contain uids on Caterpillar products. Dispose of all uids according to local regulations and mandates.

Illustration 251

g02024592

The transmission oil lter is located on the left side of the machine near the articulation joint. 1. Stop the engine and remove the key. 2. Turn the battery disconnect switch to the OFF position. 3. Remove plug (2) and allow the oil to drain into a suitable container. 4. Use a strap type wrench in order to remove the transmission lter housing (1). 5. Remove the used transmission oil lter element. Dispose of the used lter element properly. 6. Clean the transmission lter housing in a clean, nonammable solvent. Clean the lter housing base.

SEBU8480

159 Maintenance Section Transmission Oil Level - Check

7. Inspect the lter housing seal. Replace the seal if the seal is damaged. 8. Insert a new transmission oil lter element into the transmission lter housing. 9. Install the transmission lter housing into the lter housing base. Tighten the transmission lter housing by hand. Install plug (2). 10. Start the engine. Apply the service brakes. 11. Slowly operate the transmission controls in order to circulate the transmission oil. Return the transmission to NEUTRAL. 12. Engage the parking brake. Inspect the transmission oil lter for leaks. 13. Stop the engine. 14. Check the transmission oil level. Reference: Refer to Operation and Maintenance Manual, Transmission Oil Level - Check for the correct procedure.
i03753367

Illustration 253

g00936406

2. Check the oil level in the sight gauge. Maintain the oil level within the operating range while the engine is running. Note: The oil level varies signicantly when the engine is stopped. The oil level will be considerably higher than the operating range. The oil level should be above the middle of the gauge before the engine is started. 3. If necessary, remove the ller cap and add oil. Clean the ller cap and install the ller cap.
i02161205

Transmission Oil Level - Check


SMCS Code: 3030-535-FLV

Transmission Oil Sample Obtain


SMCS Code: 3080-008; 7542

Illustration 252

g02024665

The sight gauge is located on the left side of the machine near the articulation joint.

1. Operate the machine for a few minutes in order to warm the oil. Park the machine on level ground.

Illustration 254

g01095817

The sampling valve for the transmission oil is located on the transmission oil lter base on the left side of the machine.

160 Maintenance Section Turbocharger - Inspect

SEBU8480

Refer to Special Publication, SEBU6250, Caterpillar Machine Fluids Recommendations, SOS Oil Analysis for information that pertains to obtaining an oil sample from the transmission housing. Refer to Special Publication, PEHP6001, How To Take A Good Oil Sample for more information about obtaining an oil sample from the transmission housing.
i01394768

Turbocharger - Inspect
SMCS Code: 1052-040 If the turbocharger fails during engine operation, severe damage to the turbocharger compressor wheel and to the entire engine can result. Turbocharger bearing failures can cause large quantities of oil to enter the intake system and the exhaust system. Loss of engine oil can result in serious engine damage. Do not continue to operate the engine when a turbocharger bearing failure is accompanied by a signicant loss of engine performance. Engine smoke and speeding up of the engine with no load are characteristics of a loss of engine performance. Reference: For more information about inspecting the turbocharger, refer to the appropriate Service Manual for your machine's engine.
i02161333

Illustration 255

g01095908

The window washer reservoir is located beneath an access panel on the left cab platform . Fill the reservoir with window washer solvent.
i02168843

Window Wiper Inspect/Replace


SMCS Code: 7305-040; 7305-510

Window Washer Reservoir Fill


SMCS Code: 7306-544 NOTICE When operating in freezing temperatures, use Caterpillar nonfreezing window washer solvent or equivalent. System damage can result from freezing.
g01098903

Illustration 256

Inspect the front wiper blade and the rear wiper blade. Replace the wiper blades if the wiper blades are worn or damaged or if streaking occurs.

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161 Maintenance Section Windows - Clean

i00037755

Windows - Clean
SMCS Code: 7310-070

Illustration 257

g00038949

Use commercially available window cleaning solutions in order to clean the windows. Clean the outside windows from the ground unless handholds are available.

162 Reference Information Section Reference Materials

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Reference Information Section Reference Materials


i03291550

Special Publication, PEHJ0009, Product Data Sheet for Caterpillar Hydraulic Oil (HYDO) (SAE 10W) Special Publication, PEHP6047, Product Data Sheet for Caterpillar Biodegradable Hydraulic Oil (HEES)

Miscellaneous Publications
Power Train Disassembly and Assembly, RENR6422, Tire and Rim - Remove and Install Special Publication, PECP9067, One Safe Source Special Publication, PEDP9131, Fluid Contamination - The Silent Thief Special Publication, PEWJ0074, Cat Filter & Fluid Application Guide Special Publication, SEBD0400 , Dictionary of Pictographic Symbols Special Publication, SEBD0717, Diesel Fuels and Your Engine Special Publication, SEBF1015, Improving Component Durability - Final Drives and Differentials Special Publication, SEBU6250, Caterpillar Machine Fluid Recommendations Special Publication, SEBU5898, Cold Weather Recommendations Operation and Maintenance Manual, SEBU8257, The European Union Physical Agents (Vibration) Directive 2002/44/EC Special Publication, SENR5664, Air Conditioning and Heater R-134a for All Caterpillar Machines Special Publication, SENR9620, Improving Fuel System Durability Special Publication, SMBU6981, Emissions Control Warranty Information Special Instruction, SMHS7867, Nitrogen Tire Ination Group

Reference Material
SMCS Code: 1000; 7000

Cooling System
Special Publication, PMEP5027, Label - ELC Radiator Label Special Publication, PEHJ0067, Product Data Sheet for Caterpillar ELC Special Publication, PEHP9554, Product Data Sheet for Caterpillar DEAC (Diesel Engine Antifreeze/Coolant) Special Publication, SEBD0518, Know Your Cooling System Special Publication, SEBD0970, Coolant and Your Engine

Grease
Data Sheet, NEHP6010, Cat Ultra 5Moly Grease (NLGI grade 1 and grade 2) Data Sheet, NEHP6011, Cat Arctic Platinum Grease (NLGI grade 0) Data Sheet, NEHP6012, Cat Desert Gold Grease (NLGI grade 2) Data Sheet, NEHP6015, Cat High Speed Ball Bearing Grease (NLGI grade 2) Special Publication, PEGJ0035, Grease Selection Guide Data Sheet, PEHJ0088, Cat Multipurpose Grease (NLGI grade 2) Data Sheet, PEHP0002, Cat Advanced 3Moly Grease (NLGI grade 2)

Oil
Special Publication, PEHP3050, Product Data Sheet for Caterpillar Multipurpose Tractor Oil (MTO) Special Publication, PEHP6001, How to Take a Good Oil Sample Special Publication, PEHJ0007, Product Data Sheet for Caterpillar Arctic TDTO (SAE 0W-20) (synthetic blend)

Hydraulic Oil
Special Publication, PEGP6028, Caterpillar Hydraulic Systems Management Guide

SEBU8480

163 Reference Information Section Reference Materials

Special Publication, PEHJ0008, Product Data Sheet for Caterpillar Arctic DEO (SAE 0W-30) Special Publication, PEHJ0030, Product Data Sheet for Caterpillar Synthetic Gear Oil (SAE 75W-140) Special Publication, PEHJ0059, Product Data Sheet for Caterpillar DEO (SAE 10W-30) Special Publication, PEHP7506, Product Data Sheet for Caterpillar TDTO (SAE 10W, SAE 30, SAE 50) Special Publication, PEHP7508, Product Data Sheet for Caterpillar Gear Oil (GO) (SAE 80W-90 and SAE 85W-140) Special Publication, PEHP7062, Product Data Sheet for Caterpillar DEO Synthetic (SAE 5W-40) Special Publication, PEHP9530, Product Data Sheet for Caterpillar FDAO (SAE 60) Special Publication, PEHP9570, Product Data Sheet for Caterpillar FDAO Synthetic (Multigrade) Special Publication, PELJ0179, Caterpillar Engine Crankcase Fluid-1 Specications (Cat ECF-1) Special Publication, PEHP8035, Product Data Sheet for TDTO Transmission Multi-Season (TMS) Special Publication, SEBD0640, Oil and Your Engine

Safety Manuals
Safety Manual, SEBU5614, Safety Manual

SOS Information
Special Publication, PEDP7036, SOS Services Special Publication, PEHP7052, Making the Most of SOS Services Special Publication, PEHP7057, SOS Coolant Analysis Special Publication, PEHP7076, Understanding SOS Services Tests

Specications Manuals
Specications Manual, SENR3130, Torque Specications

Tools
Special Publication, NENG2500, Caterpillar Dealer Service Tool Catalog

Additional Reference Material


SAE J183, Classication This can normally be found in the SAE handbook. SAE J313, Diesel Fuels This can be found in the SAE handbook. Also, this publication can be obtained from your local technological society, from your local library, or from your local college. SAE J754, Nomenclature This can normally be found in the SAE handbook. Engine Manufacturers Association, Engine Fluids Data Book Engine Manufacturers Association Two North LaSalle Street, Suite 2200 Chicago, Illinois USA 60602 E-mail: ema@enginemanufacturers.org (312) 827-8700 Facsimile: (312) 827-8737

Parts Manuals
Parts Manual, SEBC1454

Product Link
Systems Operation, Troubleshooting, Testing and Adjusting, RENR7911, Product Link 121 SR/321SR Systems Operation, Troubleshooting, Testing and Adjusting, RENR5885, Product Link 151/201 Special Instruction, REHS2365, An Installation Guide for the Product Link PL121SR and for the PL300

ROPS/FOPS Structure
Special Publication, SEBD1587, What ROPS/FOPS Certication Means Special Publication, SEHS6929, Inspection, Maintenance and Repair of ROPS and Attachment Installation Guidelines

164 Reference Information Section Reference Materials

SEBU8480

i03645566

Decommissioning and Disposal


SMCS Code: 1000; 7000 When the product is removed from service, local regulations for the product decommissioning will vary. Disposal of the product will vary with local regulations. Consult the nearest Caterpillar dealer for additional information.

SEBU8480

165 Index Section

Index
A Additional Messages ............................................. 12 Air Conditioner (1).............................................. 13 Data Privacy (2) ................................................. 13 Alternate Exit ......................................................... 39 Alternator - Inspect ................................................ 97 Articulation Bearings - Lubricate............................ 97 Automatic Lubrication Grease Tank - Fill (If Equipped) ............................................................ 97 The Centro-Matic Lubrication System................ 98 The Quicklub Lubrication System ...................... 98 Automatic Lubrication System Components - Check (If Equipped) ........................................................ 98 Axle Oil Cooler Filter - Replace ............................. 99 Axle Oscillation Bearings - Lubricate................... 100 B Backup Alarm ........................................................ 60 Backup Alarm - Test ............................................ 101 Battery - Clean..................................................... 102 Battery - Recycle ................................................. 102 Battery Disconnect Switch..................................... 58 Battery Hold-Down - Tighten ............................... 102 Battery or Battery Cable - Inspect/Replace ......... 102 Recycle the Battery.......................................... 103 Before Operation ............................................. 23, 37 Before Starting Engine .......................................... 21 Belts - Inspect/Adjust/Replace............................. 103 Brake Accumulator - Check................................. 103 Braking System - Test.......................................... 104 Parking Brake Holding Ability Test ................... 104 Service Brake Holding Ability Test ................... 104 Bucket Cutting Edges - Inspect/Replace ............. 105 Bucket Lift and Bucket Tilt Control Inspect/Clean..................................................... 105 Bucket Rated Load ................................................ 29 Bucket Stops - Inspect/Replace .......................... 106 Bucket Tips - Inspect/Replace............................. 106 Installation........................................................ 107 Removal........................................................... 106 Side Cutters (If Equipped)................................ 107 Side Protectors (If Equipped)........................... 108 Bucket Wear Plates - Inspect/Replace ................ 108 Burn Prevention..................................................... 17 Batteries............................................................. 17 Coolant............................................................... 17 Oils..................................................................... 17 C Cab Air Filter - Clean/Replace............................. 108 Camera.................................................................. 71 Rear View Camera (If Equipped) ....................... 71 Camera - Clean (If Equipped).............................. 109 Camera ............................................................ 109 Display ............................................................. 109 Capacities (Rell) .................................................. 90 Settings of the Injectors for the Autolube System (If Equipped)......................................................... 91 Case Drain Oil Filters - Replace (If Equipped) ..... 110 Changing Direction and Speed.............................. 72 Coasting in Neutral ............................................ 72 Circuit Breakers - Reset ....................................... 110 Cooling System Coolant (ELC) - Change............. 111 Cooling System Coolant Extender (ELC) - Add.... 112 Cooling System Coolant Level - Check ................ 113 Cooling System Coolant Sample (Level 1) Obtain ................................................................. 114 Cooling System Coolant Sample (Level 2) Obtain ................................................................. 115 Cooling System Water Temperature Regulator Replace............................................................... 116 Crankshaft Vibration Damper - Inspect ................ 116 Crushing Prevention and Cutting Prevention ........ 16 D Daily Inspection ..................................................... 37 Declaration of Conformity ...................................... 36 Decommissioning and Disposal .......................... 164 Differential and Final Drive Oil - Change .............. 117 Differential and Final Drive Oil Level - Check....... 118 Differential and Final Drive Oil Sample - Obtain... 119 Drive Shaft Spline (Center) - Lubricate................ 120 Drive Shaft Support Bearing - Lubricate.............. 120 E Electrical Storm Injury Prevention ......................... 21 Electronic Unit Injector - Inspect/Adjust............... 120 Emissions Certication Film .................................. 35 Certication Label for Emissions........................ 35 Engine Air Filter Primary Element - Clean/ Replace.............................................................. 121 Engine Air Filter Secondary Element - Replace .. 122 Engine Air Filter Service Indicator - Inspect ........ 123 Engine Air Filter Service Indicator Inspect/Replace ................................................. 124 Engine Air Precleaner - Clean ............................. 124 Engine and Machine Warm-Up ............................. 74 Engine Mounts - Inspect...................................... 125 Engine Oil (High Speed) and Oil Filter - Change (If Equipped) .......................................................... 125 Procedure for Changing the Engine Oil and Filter ............................................................... 126 Selection of the Oil Change Interval ................ 125

166 Index Section

SEBU8480

Engine Oil and Filter - Change ............................ 128 Procedure for Changing the Engine Oil and Filter ............................................................... 129 Selection of the Oil Change Interval ................ 128 Engine Oil Level - Check ..................................... 127 Engine Oil Sample - Obtain ................................. 128 Engine Starting ................................................ 23, 74 Engine Starting (Alternate Methods) ..................... 83 Engine Starting with Auxiliary Start Receptacle .... 84 Engine Starting with Jump Start Cables ................ 83 Use of Jump Start Cables .................................. 83 Engine Stopping .................................................... 24 Engine Valve Lash - Check ................................. 131 Engine Valve Rotators - Inspect .......................... 131 Engine Water Pump - Inspect.............................. 131 Equipment Lowering with Engine Stopped...... 25, 76 Ether Starting Aid Cylinder - Replace (If Equipped) .......................................................... 132 F Fire Extinguisher Location ..................................... 20 Fire Prevention and Explosion Prevention ............ 17 Battery and Battery Cables ................................ 18 Ether .................................................................. 20 Fire Extinguisher ................................................ 20 General .............................................................. 17 Lines, Tubes and Hoses .................................... 19 Wiring................................................................. 19 Foreword ................................................................. 5 California Proposition 65 Warning ....................... 4 Caterpillar Product Identication Number ............ 5 Certied Engine Maintenance.............................. 4 Literature Information........................................... 4 Machine Capacity ................................................ 5 Maintenance ........................................................ 4 Operation ............................................................. 4 Safety................................................................... 4 Fuel System - Prime ............................................ 132 Fuel System Primary Filter (Water Separator) Check/Drain ....................................................... 133 Fuel System Primary Filter (Water Separator) Element - Replace ............................................. 134 Fuel System Secondary Filter - Replace ............. 135 Fuel Tank Cap and Strainer - Clean .................... 136 Fuel Tank Water and Sediment - Drain ............... 137 Fuses - Replace .................................................. 137 Blade Fuses (If equipped)................................ 139 Glass Fuses (If equipped)................................ 138 G General Hazard Information .................................. Asbestos Information ......................................... Containing Fluid Spillage ................................... Dispose of Waste Properly ................................ Fluid Penetration................................................ Pressurized Air and Water ................................. Trapped Pressure .............................................. 14 16 15 16 15 15 15

General Information............................................... 29 H High Intensity Discharge Lamp (HID) - Replace (If Equipped) .......................................................... 140 Hydraulic System Oil - Change ........................... 140 Procedure for Changing the Hydraulic Oil ....... 142 Selection of the Oil Change Interval ................ 140 Hydraulic System Oil Filter (Steering and Implement Pilot) - Replace .................................................. 143 Hydraulic System Oil Level - Check .................... 144 Hydraulic System Oil Sample - Obtain ................ 145 Hydraulic Tank Breaker Relief Valve - Clean....... 145 I Identication Information ....................................... 33 Important Safety Information ................................... 2 L Leaving the Machine ............................................. 77 Lift Cylinder Pin Oil - Change .............................. 145 Lift Cylinder Pin Oil Level - Check ....................... 147 Lifting and Tying Down the Machine...................... 79 Loader Boom Pin and Lift Cylinder Pin - Inspect.. 149 Loader Boom Pin Oil - Change............................ 148 Loader Boom Pin Oil Level - Check .................... 149 Loader Pins and Bearings - Lubricate ................. 150 Lubricant Viscosities.............................................. 87 Lubricant Viscosities for Ambient Temperatures ................................................... 87 Selecting the Viscosity ....................................... 87 Lubricant Viscosities and Rell Capacities ............ 87 M Machine Operation ................................................ Machine Retrieval.................................................. Towing with the Engine Idle ............................... Towing with the Engine Stopped........................ Maintenance Interval Schedule ............................. Maintenance Section ............................................. Maintenance Support ............................................ Mirror (If Equipped)................................................ Mirror Adjustment............................................... Monitoring System................................................. Functional Test................................................... Gauge Module (3) .............................................. Indicators (2) ...................................................... Monitoring System Display (4) ........................... Speedometer/Tachometer Module (1) ............... Mounting and Dismounting.................................... Alternate Exit...................................................... 39 80 80 81 95 86 93 42 43 60 60 61 61 62 61 37 37

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167 Index Section

O Oil Filter - Inspect ................................................ 151 Inspect a Used Filter for Debris ....................... 151 Operation............................................................... 23 Operation Information............................................ 71 Downhill Operation............................................. 71 Operation Section.................................................. 37 Operator Controls .................................................. 44 Electrohydraulic Control Console....................... 51 Engine Idle Shutdown ........................................ 58 Instrument Panel................................................ 55 Overhead Switch Panels.................................... 45 Steering Control Console................................... 50 Operator Station .................................................... 28 P Parking ............................................................ 24, 75 Parking Brake ........................................................ 72 Driving Through the Parking Brake.................... 72 Parking Brake Manual Release ............................. 82 Parking Brake Override (If Equipped).................... 75 Payload Control System (PCS) (If Equipped)........ 64 Additional Features ............................................ 67 Messenger Display ............................................ 64 Weighing Materials ............................................ 66 Plate Locations and Film Locations....................... 33 Certication ........................................................ 34 European Union ................................................. 33 Product Identication Number (PIN) .................. 33 Serial Number .................................................... 34 Product Information Section .................................. 29 Product Link (If Equipped) ..................................... 67 Data Broadcasts ................................................ 67 Operation in a Blast Site .................................... 67 Regulatory Compliance...................................... 68 R Radiator Core - Clean.......................................... 152 Reference Information Section ............................ 162 Reference Material .............................................. 162 Additional Reference Material.......................... 163 Cooling System................................................ 162 Grease ............................................................. 162 Hydraulic Oil..................................................... 162 Miscellaneous Publications.............................. 162 Oil..................................................................... 162 Parts Manuals .................................................. 163 Product Link ..................................................... 163 ROPS/FOPS Structure .................................... 163 SOS Information ............................................ 163 Safety Manuals ................................................ 163 Specications Manuals .................................... 163 Tools................................................................. 163 Reference Materials ............................................ 162 Refrigerant Receiver-Dryer - Replace ................. 152 Restricted Visibility ................................................ 22

Roading the Machine............................................. 78 Rollover Protective Structure (ROPS) - Inspect .. 153 S SOS Information .................................................. 92 Safety Messages ..................................................... 6 Safety Section ......................................................... 6 Seat ....................................................................... 39 Air Suspension (If Equipped) ............................. 40 Mechanical Suspension ..................................... 39 Seat Belt ................................................................ 40 Extension of the Seat Belt ................................. 42 Seat Belt Adjustment for Non-Retractable Seat Belts ................................................................. 40 Seat Belt Adjustment for Retractable Seat Belts ................................................................. 41 Seat Belt - Inspect ............................................... 153 Seat Belt - Replace.............................................. 154 Seat Side Rails - Adjust....................................... 154 Secondary Steering - Test ................................... 155 Secondary Steering (If Equipped) ......................... 73 Shipping the Machine ............................................ 78 Slope Operation..................................................... 24 Sound Information and Vibration Information ........ 25 Sound Level Information .................................... 25 Sound Level Information for Machines in European Union Countries and in Countries that Adopt the EU Directives ................................................. 25 Sources.............................................................. 28 The European Union Physical Agents (Vibration) Directive 2002/44/EC ...................................... 25 Specications ........................................................ 29 Application/Conguration Restrictions ............... 29 Intended Use...................................................... 29 Machine Data..................................................... 29 Starting Motor - Inspect ....................................... 155 Steering Cylinder Bearings - Lubricate................ 155 Steering Frame Lock ............................................. 38 Stopping the Engine .............................................. 75 Stopping the Engine if an Electrical Malfunction Occurs ................................................................. 76 Stopping the Machine............................................ 75 System Pressure Release ..................................... 93 Brake Pressure .................................................. 93 Cooling System Pressure .................................. 93 General Precautions .......................................... 93 Hydraulic Pressure............................................. 93 Lock Valve Pressure .......................................... 94 Steering Pressure .............................................. 94 T Table of Contents..................................................... 3 Tire Ination - Check ........................................... 156 Tire Ination Information........................................ 86 Tire Ination Pressure ........................................... 86 Tire Ination Pressure Adjustment ........................ 86 Tire Ination with Nitrogen ..................................... 86

168 Index Section

SEBU8480

Tire Information ..................................................... 21 Towing Information ................................................ 80 Transmission Oil - Change .................................. 156 Transmission Oil Filter - Replace ........................ 158 Transmission Oil Level - Check ........................... 159 Transmission Oil Sample - Obtain....................... 159 Transportation Information .................................... 78 Turbocharger - Inspect ........................................ 160 V Visibility Information............................................... 22 W Welding on Machines and Engines with Electronic Controls ............................................................... 94 Window Washer Reservoir - Fill .......................... 160 Window Wiper - Inspect/Replace ........................ 160 Windows - Clean ................................................. 161

Product and Dealer Information


Note: For product identication plate locations, see the section Product Identication Information in the Operation and Maintenance Manual. Delivery Date:

Product Information
Model: Product Identication Number: Engine Serial Number: Transmission Serial Number: Generator Serial Number: Attachment Serial Numbers: Attachment Information: Customer Equipment Number: Dealer Equipment Number:

Dealer Information
Name: Address: Branch:

Dealer Contact Sales: Parts: Service:

Phone Number

Hours

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