SEBU8480

November 2009

Operation and
Maintenance
Manual
988H Wheel Loader
BXY4000-Up (988H)

SAFETY.CAT.COM
 i03684547

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 identified 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 identified 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 first
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-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically 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, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, 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 Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture 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.
SEBU8480 3
Table of Contents

Table of Contents Engine Starting ..................................................... 74

Parking .................................................................. 75
Foreword ................................................................. 4
Transportation Information .................................... 78
Safety Section Towing Information ................................................ 80
Safety Messages .................................................... 6
Engine Starting (Alternate Methods) ..................... 83
Additional Messages ............................................. 12
Maintenance Section
General Hazard Information ................................. 14
Tire Inflation Information ....................................... 86
Crushing Prevention and Cutting Prevention ........ 16
Lubricant Viscosities and Refill Capacities ........... 87
Burn Prevention .................................................... 17
Maintenance Support ............................................ 93
Fire Prevention and Explosion Prevention ............ 17
Maintenance Interval Schedule ............................ 95
Fire Extinguisher Location .................................... 20
Reference Information Section
Tire Information ..................................................... 21
Reference Materials ............................................ 162
Electrical Storm Injury Prevention ......................... 21
Index Section
Before Starting Engine .......................................... 21
Index ................................................................... 165
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

Product Information Section

General Information .............................................. 29

Identification Information ....................................... 33

Operation Section
Before Operation .................................................. 37

Machine Operation ............................................... 39

4 SEBU8480
Foreword
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.
Safety
The safety section lists basic safety precautions. In
addition, this section identifies 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.
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.
Maintenance
The maintenance section is a guide to equipment
care. The Maintenance Interval Schedule (MIS) lists
the items to be maintained at a specific service
interval. Items without specific 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 first.
Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is
specified 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.
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.
Certified 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.
SEBU8480 5
Foreword

It is prohibited for any person engaged in the 3. Check Character (character 9)

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.
Machine Capacity
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).

Additional attachments or modifications may exceed

machine design capacity which can adversely affect
performance characteristics. Included would be
stability and system certifications such as brakes,
steering, and rollover protective structures (ROPS).
Contact your Caterpillar dealer for further information.

Caterpillar Product Identification

Number
Effective First Quarter 2001 the Caterpillar Product
Identification Number (PIN) has changed from 8 to 17
characters. In an effort to provide uniform equipment
identification, Caterpillar and other construction
equipment manufacturers are moving to comply
with the latest version of the product identification
numbering standard. Non-road machine PINs are
defined 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:

g00751314
Illustration 1

Where:

1. Caterpillar's World Manufacturing Code (characters

1-3)

2. Machine Descriptor (characters 4-8)

6 SEBU8480
Safety Section
Safety Messages

Safety Section
i03308503

Safety Messages
SMCS Code: 7000

There are several specific 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.
SEBU8480 7
Safety Section
Safety Messages

g01689635
Illustration 2
(1) Do Not Operate. (4) Crushing Hazard (7) Do Not Weld or Drill on the ROPS.
(2) Pressurized System (5) No Clearance
(3) Falling Hazard (6) Parking Brake
8 SEBU8480
Safety Section
Safety Messages

g01689636
Illustration 3
(3) Falling Hazard (8) Improper Connections of The Jump Start (9) Seat belt
(5) No Clearance Cable (10) Product Link
SEBU8480 9
Safety Section
Safety Messages

Do Not Operate (1) Pressurized System (2)

g01371640
Illustration 5

This warning label is located on the back side of the

access door for the radiator filler cap.

g01379128
Illustration 4
Pressurized system: Hot coolant can cause seri-
This warning label is located in the cab on the inside ous burn. To open cap, stop engine, wait until ra-
of the front door post. diator is cool. Then loosen cap slowly to relieve
the pressure.

DO NOT OPERATE OR WORK ON THIS MACHINE

Falling Hazard (3)
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 IN-
JURY OR DEATH. CONTACT ANY CATERPILLAR
DEALER FOR REPLACEMENT MANUALS. PROP-
ER CARE IS YOUR RESPONSIBILITY.

g01397286
Illustration 6

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 precau-
tions and / or external access devices.
10 SEBU8480
Safety Section
Safety Messages

Crushing Hazard (4) Parking Brake (6)

g01371647 g01435623
Illustration 7 Illustration 9

This warning label is located on both sides of the This warning is located near the articulation joint on
machine at the articulation joint. 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. Dis-
connect the steering frame lock and secure the
steering frame lock before resuming operation.
Severe injury or death could occur.
No Clearance (5)
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 un-
til the brake oil pressure gauge indicates zero.
Refer to Operation and Maintenance Manual,
Parking Brake Manual Release for the proper
procedure.

g01371644
Illustration 8

This warning label is located on both sides of the

machine at the articulation joint.

Stay back a safe distance. No clearance for a per-

son in this area when the machine turns. Severe
injury or death from crushing could occur.
SEBU8480
Do Not Weld or Drill on the ROPS
(7)
g00944234
Illustration 10
This warning label is located on the outside of the
cab on the left side below the window.
Structural damage, an overturn, modification, al-
teration, or improper repair can impair this struc-
ture's protection capability thereby voiding this
certification. Do not weld on or drill holes in the
structure. Consult a Caterpillar dealer to deter-
mine this structure's limitations without voiding
its certification.
Rollover Protective Structure (ROPS) and Falling
Object Protective Structure (FOPS) Certification
The structure, when properly installed on a machine
which is not altered to exceed the certification 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.
11
Safety Section
Safety Messages
Improper Connections of The Jump
Start Cable (8)
g01370909
Illustration 11
This warning label is located in the battery
compartment.
There is limited battery access. Jump starting at
the battery, or improper jumper cable connections
at the starter, can cause explosion resulting in per-
sonal 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 (+) ter-
minal of the starter and connect negative () cable
from external source to engine block. Follow
procedure from the Operation and Maintenance
Manual.
12 SEBU8480
Safety Section
Additional Messages

Seat belt (9) Product Link (10)

This warning label is located in the cab.

g01370917

g01371636
This machine is equipped with a Caterpillar Prod-
Illustration 12 uct Link communication device which must be de-
activated within 12 m (40 ft) of a blast zone. Failure
This warning label is located in the cab near the cup to do so could result in serious injury or death.
holder.

i02880316

A seat belt should be worn at all times during ma-
chine operation to prevent serious injury or death
in the event of an accident or machine overturn.
Failure to wear a seat belt during machine opera-
tion may result in serious injury or death.
Additional Messages
SMCS Code: 7000
There are several specific 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.
SEBU8480 13
Safety Section
Additional Messages

g01433752
Illustration 13

Air Conditioner (1) Data Privacy (2)

g01118600 g01418953
Illustration 14 Illustration 15

This film 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
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.
i03559343
General Hazard Information
SMCS Code: 7000
Illustration 16
g00104545
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.
SEBU8480
g00702020
Illustration 17
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.
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 flame 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 fluids 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.
SEBU8480 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 deflector and personal protective
equipment. The maximum water pressure for
cleaning purposes must be below 275 kPa (40 psi).
Illustration 18
g00687600
Always use a board or cardboard when you check
for a leak. Leaking fluid 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 fluid 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 Containing Fluid Spillage

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 fittings.
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.
Fluid Penetration
Pressure can be trapped in the hydraulic circuit long
after the engine has been stopped. The pressure can
cause hydraulic fluid or items such as pipe plugs to
escape rapidly if the pressure is not relieved correctly.
Care must be taken in order to ensure that fluids
are contained during performance of inspection,
maintenance, testing, adjusting and repair of the
equipment. Prepare to collect the fluid with suitable
containers before opening any compartment or
disassembling any component that contains fluids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for the following items:
Tools that are suitable for collecting fluids and
equipment that is suitable for collecting fluids
Tools that are suitable for containing fluids and
equipment that is suitable for containing fluids

Do not remove any hydraulic components or parts Obey all local regulations for the disposal of liquids.
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.
16
Safety Section
Crushing Prevention and Cutting Prevention
Asbestos Information
g00702022
Illustration 19
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 fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
asbestos fibers 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:
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.
A vacuum cleaner that is equipped with a high
efficiency particulate air filter (HEPA) can also be
used.
Use exhaust ventilation on permanent machining
jobs.
Wear an approved respirator if there is no other
way to control the dust.
SEBU8480
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.
Obey environmental regulations for the disposal
of asbestos.
Stay away from areas that might have asbestos
particles in the air.
Dispose of Waste Properly
g00706404
Illustration 20
Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
disposed of according to local regulations.
Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
i01359664
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.
SEBU8480
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 fly 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 fly off an object when you
strike the object. Make sure that no one can be
injured by flying debris before striking any object.
i01329099
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, fittings 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.
17
Safety Section
Burn Prevention
Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to touch
with a bare hand. Remove the filler 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 filler cap only after the
engine has been stopped. The filler 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 filler 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.
i03659986
Fire Prevention and Explosion
Prevention
SMCS Code: 7000
g00704000
Illustration 21
General
All fuels, most lubricants, and some coolant mixtures
are flammable.
To minimize the risk of fire or explosion, Caterpillar
recommends the following actions.
18 SEBU8480
Safety Section
Fire Prevention and Explosion Prevention

Always perform a Walk-Around Inspection, which

may help you identify a fire hazard. Do not operate
a machine when a fire 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 fluid leak. Repair

leaks and clean up fluids before resuming machine
operation. Fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause a
fire. A fire may cause personal injury or death.

Remove flammable 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 fire suppression
equipment, in case a fire should occur.
Clean all accumulations of flammable materials such
as fuel, oil and debris from the machine.
Do not operate the machine near any flame.
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 flame cut on tanks or lines that contain
flammable fluids or flammable material. Empty and
purge the lines and tanks. Then clean the lines and
tanks with a nonflammable solvent prior to welding
or flame cutting. Ensure that the components are
properly grounded in order to avoid unwanted arcs.
Illustration 22
g00704059
Use caution when you are fueling a machine. Do not
smoke while you are fueling a machine. Do not fuel
a machine near open flames 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 flammable fluids in the
operator compartment of the machine.
Battery and Battery Cables

Dust that is generated from repairing nonmetallic

hoods or fenders may be flammable and/or explosive.
Repair such components in a well ventilated area
away from open flames 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 fires.

Store fuels and lubricants in properly marked

containers away from unauthorized personnel. Store
oily rags and flammable materials in protective
containers. Do not smoke in areas that are used for Illustration 23
g00704135
storing flammable materials.
SEBU8480
Caterpillar recommends the following in order to
minimize the risk of fire 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 specific instructions.
Do not charge a frozen battery. This may cause an
explosion.
Gases from a battery can explode. Keep any open
flames 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:
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 fire hazard.
19
Safety Section
Fire Prevention and Explosion Prevention
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
fires. 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 flammable fluids or combustible fluids should
be avoided.
Consult your Caterpillar dealer for repair or for
replacement parts.
Keep wiring and electrical connections free of debris.
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
g00687600
Illustration 24
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 fluid 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 fluid 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:
End fittings 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 fittings 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 fire hazard
exists. Repair any lines that are corroded, loose
or damaged. Leaks may provide fuel for fires.
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.
SEBU8480
Ether
Ether (if equipped) is commonly used in cold weather
applications. Ether is flammable 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 flames or sparks.
Dispose of used ether cylinders properly. Do not
puncture an ether cylinder. Keep ether cylinders
away from unauthorized personnel.
Fire Extinguisher
As an additional safety measure, keep a fire
extinguisher on the machine.
Be familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
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
Fire Extinguisher Location
SMCS Code: 7000
Make sure that a fire extinguisher is on the machine.
Make sure that you are familiar with the operation of
the fire extinguisher. Inspect the fire extinguisher and
service the fire extinguisher on a regular basis. Obey
the recommendations on the instruction plate.
The recommended location for mounting the fire
extinguisher is on the platform behind the cab.
SEBU8480
If the fire extinguisher is mounted on the ROPS, strap
the mounting plate to a leg of the ROPS. If the weight
of the fire extinguisher is more than 4.5 kg (10 lb),
mount the fire extinguisher as low as possible on one
leg. Do not mount the fire extinguisher on the upper
one-third area of the leg.
Note: Do not weld the ROPS in order to install the
fire extinguisher. Also, do not drill holes in the ROPS
in order to mount the fire extinguisher on the ROPS.
i01557411
Tire Information
SMCS Code: 7000
Explosions of air inflated 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
fire, 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 flying debris can cause
property damage, personal injury, or death.
g00337832
Illustration 25
(A) At least 15 m (50 ft)
(B) At least 500 m (1500 ft)
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 inflation of tires.
If the tires were originally inflated with air, nitrogen
is still preferred for adjusting the pressure. Nitrogen
mixes properly with air.
21
Safety Section
Tire Information
Nitrogen inflated 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 overinflation, proper nitrogen inflation
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 inflate 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 specific
instructions from your tire dealer.
i01122596
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.
i00934890
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
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
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 traffic to move when it is safe
Restricted areas
SEBU8480
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
Modifications of the machine configuration by the
user that result in a restriction of visibility shall be
evaluated.
i03297985
Restricted Visibility
SMCS Code: 7000
The size and the configuration 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 significant 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.
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.

g01660074
Illustration 26 i03690422
Top view of the machine
Operation
Note: The shaded areas indicate the approximate
location of areas with significant restricted visibility. SMCS Code: 7000

Only operate the machine while you are sitting in

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.
Briefly sound the horn before you start the engine.
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.
24
Safety Section
Engine Stopping
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
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.
SEBU8480
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, configuration, machine maintenance,
operating speed of the machine, conditions of the
terrain, fluid levels, and tire inflation 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, identification 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
configuration, weights, and counterweights.
Nature of surface Ground that has been newly
filled 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.
SEBU8480
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 specific
applications are also required. Consult the Operation
and Maintenance Manual sections for the proper fluid
level requirements and intended machine use.
i01329161
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 fluid 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.
25
Safety Section
Equipment Lowering with Engine Stopped
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.
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 SEBU8480
Safety Section
Sound Information and Vibration Information

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 influenced 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 Typical Operating Vibration Levels Scenario Factors

Type Activity X axis Y axis Z axis X axis Y axis Z axis
load and carry motion 0,84 0,81 0,52 0,23 0,20 0,14

Wheel mining application(1) 1,27 0,97 0,81 0,47 0,31 0,47

Loader transfer(2) 0,76 0,91 0,49 0,33 0,35 0,17
V-shape motion(3) 0,99 0,84 0,54 0,29 0,32 0,14
(1) Loading at the face
(2) Travel at high speed on the job site or on public roads
(3) Loading a truck in short cycles
SEBU8480
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.
27
Safety Section
Sound Information and Vibration Information
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 SEBU8480
Safety Section
Operator Station

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 find your local

dealer:

Caterpillar, Inc.
www.cat.com

i03634321

Operator Station
SMCS Code: 7000

Any modifications 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, fire extinguisher, and other
equipment must be installed so that the defined
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 defined
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.
SEBU8480 29
Product Information Section
General Information

Product Information i02217425

Section Bucket Rated Load

SMCS Code: 6700

General Information
i03648672
Failure to comply to the rated load can cause pos-
sible personal injury or attachment damage. Re-
Specifications view the rated load of a particular attachment be-
fore performing any operation. Make adjustments
SMCS Code: 7000 to the rated load as necessary.

Intended Use Note: Rated loads should be used as a guide.

This machine is classified 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 specific tasks.
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:
Proper lubricants

Application/Configuration Full fuel tank

Restrictions Enclosed ROPS
Refer to Machine Data below for information about 80 kg (176 lb) operator
maximum machine weight.
35/65-33 or equivalent tires
Lift arm height restrictions will be found in the
Operation and Maintenance Manual for the Consult your Caterpillar dealer about the rated load
appropriate work tool. for a specific work tool.

The maximum fore and aft slope for proper lubrication The rated operating load is defined by the SAE
is 25 degrees continuous and 35 degrees intermittent. standard J818 (May 1987) and by the ISO 5998
(1986) as 50 percent of the full turn static tipping load.
This machine is approved for use in environments
with no explosive gases. The dump clearance and the reach are given for
each bucket at maximum lift height and at a 45
Machine Data degree dump angle. Clearance is measured from the
ground to the bucket edge when the bucket is in the
This machine is equipped with a C-18 Engine. full DUMP position. The reach is measured from the
front tire to the bucket edge.
Basic machine specifications are listed below.
Table 2
988H Wheel Loader
Approximate Weight 53944 kg (118926 lb)
Length with Bucket 12185 mm (480 inch)
Width across Tires 3574 mm (141 inch)
Height over ROPS 4128 mm (163 inch)
30 SEBU8480
Product Information Section
General Information

g00835725
Illustration 27
Dimension (A) represents the dump clearance. Dimension (B)
represents the reach.

The following table provides the rated operating loads

for the standard machine configuration.
SEBU8480 31
Product Information Section
General Information

Table 3

Rated Load
3.88 m

Dump Clearance Reach

Ground Engaging Tools Rated Volume Rated Operating Load
A B

Spade Rock with Teeth and 3742 mm

6.4 m3 (8.33 yd3) 11340 kg (25000 lb) 1494 mm (59 inch)
Segments (Standard Bucket) (147 inch)

Wide Spade Rock with Teeth 3682 mm

6.9 m3 (9 yd3) 11340 kg (25000 lb) 1554 mm (61 inch)
and Segments (145 inch)

General Purpose with Bolt-On 3790 mm

7 m3 (9.2 yd3) 11340 kg (25000 lb) 1720 mm (68 inch)
Cutting Edges (149 inch)

Straight Rock with Teeth and 4011 mm

6.3 m3 (8.2 yd3) 11340 kg (25000 lb) 1526 mm (60 inch)
Segments (158 inch)

Rock Quarry (Heavy Duty) with 3728 mm

6.4 m3 (8.33 yd3) 11340 kg (25000 lb) 1543 mm (61 inch)
Teeth and Segments (147 inch)

Mining (Heavy Duty) with Teeth 3811 mm

6.4 m3 (8.33 yd3) 11340 kg (25000 lb) 1577 mm (62 inch)
and Segments (150 inch)

Spade Rock with Bolt-On 3638 mm

6.9 m3 (9 yd3) 11340 kg (25000 lb) 1881 mm (74 inch)
Cutting Edges (143 inch)

Spade Rock with Teeth and 3742 mm

6.6 m3 (8.75 yd3) 11340 kg (25000 lb) 1494 mm (59 inch)
Segments (147 inch)
32 SEBU8480
Product Information Section
General Information

Table 4

Rated Load
4.25 m

Dump Clearance Reach

Ground Engaging Tools Rated Volume Rated Operating Load
A B

Spade Rock with Teeth and 4155 mm

6.4 m3 (8.33 yd3) 11340 kg (25000 lb) 1591 mm (63 inch)
Segments (Standard Bucket) (164 inch)

Wide Spade Rock with Teeth 4095 mm

6.9 m3 (9 yd3) 11340 kg (25000 lb) 1652 mm (65 inch)
and Segments (161 inch)

General Purpose with Bolt-On 4203 mm

7 m3 (9.2 yd3) 11340 kg (25000 lb) 1818 mm (72 inch)
Cutting Edges (165 inch)

Straight Rock with Teeth and 4424 mm

6.3 m3 (8.2 yd3) 11340 kg (25000 lb) 1623 mm (64 inch)
Segments (174 inch)

Rock Quarry (Heavy Duty) with 4141 mm

6.4 m3 (8.33 yd3) 11340 kg (25000 lb) 1641 mm (65 inch)
Teeth and Segments (163 inch)

Mining (Heavy Duty) with Teeth 4225 mm

6.4 m3 (8.33 yd3) 11340 kg (25000 lb) 1674 mm (66 inch)
and Segments (166 inch)

Spade Rock with Bolt-On 4051 mm

6.9 m3 (9 yd3) 11340 kg (25000 lb) 1699 mm (67 inch)
Cutting Edges (159 inch)

Spade Rock with Teeth and 3742 mm

6.6 m3 (8.75 yd3) 11340 kg (25000 lb) 1494 mm (59 inch)
Segments (147 inch)
SEBU8480 33
Product Information Section
Identification Information

Identification Information
i03770369

Plate Locations and Film

Locations
SMCS Code: 1000; 7000

The Product Identification Number (PIN) is used to

identify a powered machine that is designed for an
operator to ride.

For quick reference, record the identification numbers g01883459

Illustration 29
in the spaces that are provided below the illustration.
Engine Power primary engine (kW)__________________
Product Identification Number (PIN)
Engine Power for additional engine if equipped
(kW)________________________________________________________

Typical machine operating weight for European

market (kg)________________________________________________

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.

g00996995
Illustration 28
Left side of front frame

Machine PIN ________________________________________________

European Union
Note: The CE plate is on machines that are certified
to the valid European Union requirements at that
time. g01062968
Illustration 30
If the machine is equipped with the plate for the
European Union, this plate will be attached to the PIN Engine Power primary engine (kW)__________________
plate. The CE plate is positioned on the bottom left
side of the plate for the PIN. Typical machine operating weight for European
market (kg)________________________________________________
For machines compliant to 2006/42/EC, the
following information is stamped onto the CE plate. Year ________________________________________________________
For quick reference, record this information in the
spaces provided below.
34 SEBU8480
Product Information Section
Identification Information

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

g00838375
Illustration 33
Right side of planetary case

Transmission Serial Number_____________________________

Certification
g00997052
Illustration 31
Rear view of the torque converter housing
Sound

Torque Converter Serial Number _______________________

g00933634
Illustration 34
Typical example
g01000186
Illustration 32
If equipped, the film is used to verify the environmental
Engine valve cover sound certification of the machine. The value that
is listed on the film indicates the guaranteed sound
Engine Serial Number ____________________________________ 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
Identification Information

ROPS/FOPS Film

g00944234
Illustration 35

This warning film is located on the outside of the

cab on the left side below the window. This machine
has been certified to the standards that are listed
on the certification label. The maximum mass of
the machine, which includes the operator and the
attachments without a payload, should not exceed
the mass on the certification label.

i03637212

Emissions Certification Film

SMCS Code: 1000; 7000; 7405

Certification 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 SEBU8480
Product Information Section
Identification Information

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 specific
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 modified.

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 specified hereunder
Description: Generic Denomination: Earth moving Equipment
Function: Wheeled loader
Model/Type: 988H Wheel Loader
Serial Number:
Commercial Name: Caterpillar
Fulfils all the relevant provisions of the following Directives

Directives Notified Body Document No.

2006/42/EC N/A
2000/14/EC amended by 2005/88/EC,
Note (1)
2004/108/EC N/A

Note (1) 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: Signature

Date: 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.
SEBU8480
Operation Section
Before Operation
i02189821
Mounting and Dismounting
SMCS Code: 7000
g00037860
Illustration 36
Typical example
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.
Alternate Exit
Machines that are equipped with cabs have alternate
exits. For additional information, see Operation and
Maintenance Manual, Alternate Exit.
37
Operation Section
Before Operation
i01922360
Daily Inspection
SMCS Code: 1000; 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 fire haz-
ard. Remove this debris with steam cleaning or high
pressure water, at least every 1000 hours or each time
any significant 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.
Operation and Maintenance Manual, Bucket
Cutting Edges - Inspect/Replace
Operation and Maintenance Manual, Bucket Stops
- Inspect/Replace
Operation and Maintenance Manual, Bucket Tips
- Inspect/Replace
Operation and Maintenance Manual, Bucket Wear
Plates - Inspect/Replace
Operation and Maintenance Manual, Backup
Alarm - Test
38 SEBU8480
Operation Section
Before Operation

Operation and Maintenance Manual, Cooling The steering frame lock is located at the articulation
System Coolant Level - Check joint on the left side of the machine.

Operation and Maintenance Manual, Engine Oil

Level - Check

Operation and Maintenance Manual, Engine Air

Filter Service Indicator - Inspect

Operation and Maintenance Manual, Hydraulic

System Oil Level - Check

Operation and Maintenance Manual, Loader

Boom Pin and Lift Cylinder Pin - Inspect

Operation and Maintenance Manual, Loader Pins

and Bearings - Lubricate
g01000479
Illustration 38
Operation and Maintenance Manual, Seat Belt -
Inspect Connect steering frame lock (1) when the machine
is being lifted and when the machine is being
Operation and Maintenance Manual, Transmission transported. Also connect the steering frame lock if
Oil Level - Check you are performing service work near the articulation
joint. Install pin (2) and secure the pin with locking
Operation and Maintenance Manual, Windows - pin (3).
Clean

Refer to the Maintenance Section for the detailed

procedures. Refer to the Maintenance Interval
Schedule for a complete list of scheduled
maintenance.

i01922365

Steering Frame Lock

SMCS Code: 7506

g01000480
Illustration 39
No clearance for person in this area when machine
turns. Severe injury or death from crushing could Separate steering frame lock (1) before the machine
occur. is operated.

Move the steering frame lock to the front frame and

install pin (2). Secure the pin with locking pin (3).

g01000477
Illustration 37
SEBU8480 39
Operation Section
Machine Operation

Machine Operation
i03654709

Alternate Exit
SMCS Code: 7310

g00922622
Illustration 41

Mechanical Suspension
Backrest (1) Pull up on the backrest in
order to remove extension.

g01961157
Illustration 40
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
Seat
SMCS Code: 7312
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.

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.
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.
40 SEBU8480
Operation Section
Machine Operation

Lengthening the Seat Belt

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.

Air Suspension (If Equipped)

Seat Height (Air suspension) (7) Push g00100709
in on the air valve knob (7) in order to raise Illustration 42
the height of the seat. Pull out on the air
valve knob (7) in order to lower the height of the seat. 1. Unfasten the seat belt.

i03415082

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.
g00932817
Always check the condition of the seat belt and Illustration 43
the condition of the mounting hardware before you
operate the machine. 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.
Seat Belt Adjustment for
Non-Retractable Seat Belts 3. Remove the slack from the outer belt loop by
pulling on the buckle.
Adjust both ends of the seat belt. The seat belt should
be snug but comfortable. 4. Loosen the other half of the seat belt in the same
manner. If the seat belt does not fit snugly with the
buckle in the center, readjust the seat belt.
SEBU8480 41
Operation Section
Machine Operation

Shortening the Seat Belt Releasing The Seat Belt

g00100713 g00100717
Illustration 44 Illustration 46

1. Fasten the seat belt. Pull out on the outer belt loop Pull up on the release lever. This will release the seat
in order to tighten the seat belt. belt.

2. Adjust the other half of the seat belt in the same

manner.
Seat Belt Adjustment for
Retractable Seat Belts
3. If the seat belt does not fit snugly with the buckle
in the center, readjust the seat belt. Fastening The Seat Belt
Fastening The Seat Belt

g00867598
Illustration 47

g00932818 Pull seat belt (4) out of the retractor in a continuous

Illustration 45
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.
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.
42 SEBU8480
Operation Section
Machine Operation

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 Man-
ual, 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.

g00039113
Illustration 48

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 Illustration 49

g01625347

belt extensions, or personal injury or death can (1) Left Outside Mirror
result. (2) Right Outside Mirror

The retractor system may or may not lock up de-

pending 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.
g01625349
Illustration 50
i03290932 (3) Left Inside Mirror
(4) Right Inside Mirror
Mirror
(If Equipped) Mirrors provide additional visibility around your
machine. Make sure that the mirrors are in proper
working condition and that the mirrors are clean.
SMCS Code: 7319
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

Adjust all mirrors as specified in the Operation recommended in order to minimize hazards due to
and Maintenance Manual. Failure to heed this visibility. For more information refer to this Operation
warning can lead to personal injury or death. and Maintenance Manual, Visibility Information.
SEBU8480 43
Operation Section
Machine Operation

Modified Machines or machines that have additional Right Outside Mirror (2)
equipment or attachments may influence your
visibility.

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

Stop the engine. Illustration 52

g01631673

Adjust rear view mirrors in order to provide visibility If equipped, adjust the right outside mirror (2) so
behind the machine at a maximum distance of
that an area of at least 1 m (3.3 ft) from the side of
30 m (98 ft) from the rear corners of the machine.
the machine can be seen from the operator seat.
Additionally, provide as much visibility to the rear as
Note: You may need to use hand tools in order to
possible.
adjust certain types of mirrors.

Left Outside Mirror (1) Left Inside Mirror (3)

g01631674
g01631656 Illustration 53
Illustration 51

If equipped, adjust the left inside mirror (3) so that

If equipped, adjust the left outside mirror (1) so that
an area of at least 1 m (3.3 ft) from the side of
an area of at least 1 m (3.3 ft) from the rear of the
the machine can be seen from the operator seat.
machine can be seen from the operator seat.
Additionally, provide as much visibility to the rear as
possible.
44 SEBU8480
Operation Section
Machine Operation

Right Inside Mirror (4)

g01631675
Illustration 54

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.

i03747127

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.
SEBU8480 45
Operation Section
Machine Operation

Overhead Switch Panels

g00999856
Illustration 55

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
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).
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 first
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 efficient 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.
SEBU8480
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 first 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 first 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 first 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.
SEBU8480
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.
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.
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.
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.
47
Operation Section
Machine Operation
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.
g00841327
Illustration 57
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.
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 first
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 floodlights.
Front Floodlights Rotate the knob
clockwise to the fourth position in order to
turn on front floodlights.
48
Operation Section
Machine Operation
Reduced Rimpull Switch (13)
The reduced rimpull switch reduces the potential
for wheel slippage without reducing the hydraulic
efficiency. 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
g01382071
Illustration 58
Machines that are equipped with the rimpull switch, located on the
right side of the control console
Type 2 BXY1900-Up
g01382090
Illustration 59
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.
SEBU8480
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 first 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 first speed, the impeller clutch
pressure will remain at the maximum level until the
transmission is placed into first speed.
The reduced rimpull switch will continue to limit
rimpull until the transmission is shifted out of first
speed.
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 float detent is activated and the boom is at least
a foot above the kickout position.
Note: If the boom is a foot or less above the lower
kickout position, placing the lift control lever in the
float detent will cause the bucket to float 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.
SEBU8480 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 SEBU8480
Operation Section
Machine Operation

Steering Control Console

g00998180
Illustration 60
(1) STIC Control (2) Armrest

STIC Control (1) Direction Control

The STIC Control controls the following machine REVERSE Move the top of the trigger switch (1C)
functions: Steering, Direction Control, and Speed to R. This will enable the machine to move in the
Control. reverse direction.

Speed Control NEUTRAL Move the trigger switch (1C) to N.

This will disengage the transmission.
Push upshift switch (1A) in order to shift the machine
into the next highest speed. FORWARD Move the bottom of the trigger switch
(1C) to F. This will enable the machine to move in
Push downshift switch (1B) in order to shift the the forward direction.
machine into the next lowest speed.
The active transmission direction will be shown on
1 indicates First Speed. the speedometer.

2 indicates Second Speed. Steering Control

3 indicates Third Speed.
Note: When the parking brake is engaged, the
machine can only be shifted into second speed or
into third speed.
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.
SEBU8480 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 SEBU8480
Operation Section
Machine Operation

g02023579
Illustration 61
Standard control console
(1) Tilt Control (7) Armrest Adjustment Knob (13) Horn
(2) Lift Control (8) Economy Mode (14) Implement Lockout
(3) Third Valve Control (9) Third Valve Lockout (15) Store Button
(4) Implement Console Adjustment Lever (10) Lighter (16) Resume Switch
(5) Ashtray (11) Armrest (17) Set Switch
(6) Turn Signal (12) Console Adjustment Knob

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.
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.

TILT BACK Pull the bucket tilt lever

backward in order to tilt back the bucket.
SEBU8480
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.
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 float 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.
53
Operation Section
Machine Operation
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.
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 SEBU8480
Operation Section
Machine Operation

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 Illustration 62
g01429368

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.
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)

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.
Third Valve Lockout Switch (9)
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.

Hydraulic Lockout The hydraulic Store Button (15)

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.
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.

Hydraulics Unlock Press the bottom of

the switch in order to activate the hydraulic
controls.
SEBU8480 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
first 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)

g02029285
Illustration 63

The transmission override control is mounted on the

right hand side of hand rest.
56 SEBU8480
Operation Section
Machine Operation

g02030175
Illustration 64
(1) Gauge Display (5) Throttle Lock Control (8) Right Service Brake Control
(2) Speedometer/Tachometer Display (6) Left Service Brake Control and Impeller (9) Engine Start Switch
(3) Indicators Clutch (10) Throttle Control
(4) Operator Mode Switch (7) Engine Brake Control (11) Parking Brake Control

Gauge Display (1) Operator Mode Switch (4)

Refer to Operation and Maintenance Manual, Press the switch in order to change the information
Monitoring System for details on the gauge display. that is displayed within the Monitoring System. Refer
to Operation and Maintenance Manual, Monitoring
Speedometer/Tachometer Display (2) System for additional information.

Refer to Operation and Maintenance Manual, Throttle Lock Control (5)

Monitoring System for details on the
speedometer/tachometer display.
Indicators (3)
Refer to Operation and Maintenance Manual,
Monitoring System for details on the indicators.
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.
SEBU8480
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.
g02024158
Illustration 65
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.
57
Operation Section
Machine Operation
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.
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.
58 SEBU8480
Operation Section
Machine Operation

Right Service Brake Control (8) Engine Idle Shutdown

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.
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) The parking brake is applied.

OFF When you insert the engine start

Release the service brake.
switch key and when you remove the
engine start switch key, the engine start
Release the throttle pedal.
switch must be in the OFF position. To disconnect
the power to the electrical circuits in the cab, turn the
Gear in neutral
engine start switch to the OFF position. Also, turn
the engine start switch to the OFF position in order
The implement is not active.
to stop the engine. Engine Idle Shutdown The control
limits the engine speed to 1000 rpm at 20
ON To activate the electrical circuits seconds before shutdown and turns on the
in the cab, turn the engine start switch action lamp. An alarm sounds for 5 seconds before
clockwise to the ON position. the engine shuts down.

START To start the engine, turn the An operator can move one of the controls in order
engine start switch clockwise to the START to cancel a shutdown. Using the brake pedal to
position. When the engine start switch key cancel a shutdown is the recommended option for
is released, the engine start switch will return to the the operator.
ON position.
i03646475
Note: If the engine fails to start, return the engine
start switch to the OFF position. This must be done Battery Disconnect Switch
before you attempt to start the engine again.
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.
g01000504
Illustration 66
Pull the knob outward in order to engage the parking
brake. Push the knob inward in order to release the The battery disconnect switch is located behind the
parking brake. battery compartment on the right rear bumper.
SEBU8480 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,
g01098630
consult your Caterpillar dealer.
Illustration 67

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 dam-
age 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 SEBU8480
Operation Section
Machine Operation

i02319896 i03753018

Backup Alarm Monitoring System

SMCS Code: 7406 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 verifies 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.

1. During this test, the action light is on continuously

Illustration 68
g01000537 and the action alarm sounds once.

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.
2. All of the alert indicators flash. 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.

g01117861
Illustration 69

The volume for the backup alarm is nonadjustable.

g01078295
Illustration 70
SEBU8480
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).
Speedometer/Tachometer Module
(1)
Illustration 71
g01078299
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)
g02024357
Illustration 72
Indicators (2A) This display will indicate normal
machine functions.
Turn Signal/Hazards (2B) This light
indicates that the turn signals or the hazard
flashers have been activated.
61
Operation Section
Machine Operation
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.
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.
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.
Gauge Module (3)
g01078298
Illustration 73
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.
62 SEBU8480
Operation Section
Machine Operation

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 notifies 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 Indications (1)
Warning
Flashing Flashing Action Sounding of the Required Action Possible Result (2)
Category
Indicator Lamp Action Alarm
1 X No immediate action is
required. The system No harm or damage
needs attention soon.
2 X X Change machine
operation or perform Severe damage to
maintenance to the components
system.
2-S X X X (3) Immediately change the Severe damage to
machine operation. components
3 X X X (4) Injury to the operator
Immediately perform a
or severe damage to
safe engine shutdown.
components
(1) The warning indicators that are active are marked with an X.
(2) This is the possible result if no action is taken.
(3) The alarm is on continuously.
(4) The alarm is on intermittently.
SEBU8480
Alert Indicators
g01078301
Illustration 74
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 filter is
plugged.
NOTICE
If the transmission oil filter is plugged, the bypass
valve will open. Unfiltered transmission oil will flow
through the system and damage to other system com-
ponents 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.
63
Operation Section
Machine Operation
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 filter is
plugged and the bypass valve is open.
NOTICE
If the hydraulic oil filter is plugged, the bypass valve
will open. Unfiltered hydraulic oil will flow 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 75
g01001702
Location of the Operator Mode Switch
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 SEBU8480
Operation Section
Machine Operation

i03756185 The Messenger display consists of an LCD screen

and four push buttons. See Illustration 77.
Payload Control System (PCS)
(If Equipped)
SMCS Code: 7494

g01304775
Illustration 77
Components in the display of the Messenger
(1) LCD screen
(2) Back button
(3) Up/left button
(4) Down/right button
(5) OK button

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
g02026033
Illustration 76
Down/right button
The following information is a brief overview of the
basic functions of the system. OK button

The Payload Control System (PCS) is an electronic Function of the Display Buttons
system that will provide an accurate weight of the
material that is loaded by a wheel loader. The function of each button is described below.

Back Button
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.
g01322949
Illustration 78
Display the messages of the system to the
operator. Back button

Navigate through the menus. The back button (2) is used for the following
purposes:
Adjust settings.
Exit the currently selected menu.
Enter data.
SEBU8480 65
Operation Section
Machine Operation

Remove the last selected character from a data OK Button

entry screen.

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:

g01322948
Enter the highlighted menu.
Illustration 79
Up/left button Select the highlighted list selection item.
The Up/left button (3) is used for the following Select the highlighted character on a data entry
purposes: screen.

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
screen.
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.
g01322950
Illustration 80
Down/right button
Enter 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.
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.
66 SEBU8480
Operation Section
Machine Operation

Basic Operation of the Messenger Store Switch

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 g02026034
order to select a menu option. Press the back button Illustration 83
in order to move up to the previous menu. Store switch
(8) Store switch
Reweigh / Clear/Zero Switch

g02026037
Illustration 82
Reweigh / clear/zero switch
(6) Reweigh switch
(17) Clear/zero switch

The reweigh / clear/zero switch is a rocker switch. Illustration 84

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:
Reweighing a bucket
Clearing the display
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
Resetting the truck weight and bucket weight to
zero

Zeroing the system 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%.

SEBU8480
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.
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
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.
67
Operation Section
Machine Operation
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 efficiency,
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 affiliated 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.
Operation in a Blast Site
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.
68 SEBU8480
Operation Section
Machine Operation

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 specifications
are provided in order to aid in conducting any related
hazard assessment and to ensure compliance with
all local regulations:
The transmit power rating for the Product Link
PL121SR transmitter is five 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.
NOTICE
Transmission of information using Product Link is sub-
ject to legal requirements that may vary from location
to location, including, but not limited to, radio frequen-
cy 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 satisfied.
In the event that a machine outfitted with Product Link
is located in or relocated to a location where (i) le-
gal requirements are not satisfied or (ii) transmitting
or processing of such information across multiple lo-
cations would not be legal, Caterpillar disclaims any
and all liability related to such failure to comply and
Caterpillar may discontinue the transmission of infor-
mation from that machine.
Consult your Caterpillar dealer with any questions
that concern the operation of the Product Link in a
specific country.

Information for the initial installation of the Product

Link PL121SR is available in Special Instruction,
REHS2365, Installation Guide for the Product Link
PL121SR.

Operation, configuration, and troubleshooting

information for the Product Link PL121SR can be
found in System Operation Troubleshooting Testing
and Adjusting, RENR7911.

Regulatory Compliance

g01131982
Illustration 85
SEBU8480 69
Operation Section
Machine Operation

g01435306
Illustration 86

Note: A translated extract of the above document

is provided below.
70 SEBU8480
Operation Section
Machine Operation

Table 7

DECLARATION OF CONFORMITY

We, Quake Global, Inc (Previously Quake Wireless, Inc up to January 2001)

of 9765 Clairemont Mesa Blvd, Suite A (Previously 5575 Ruffin 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 Notified Body:
BABT, Claremont House, 34 Molesey Foad, Walton-on-Thames, KT12 4RQ, UK

Identification mark: 0168 The equipment will also carry the

Class 2 Equipment identifier.

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 identifier

SEBU8480
i03180601
Camera
SMCS Code: 7347; 7348
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 specified
guidelines. Consult your Caterpillar dealer before any
adjustments are made to the system.
For more information refer to Operation and
Maintenance Manual, Monitoring System.
71
Operation Section
Machine Operation
i02881245
Operation Information
SMCS Code: 7000
Follow these basic instructions whenever you are
operating the machine:
To prevent injury, make sure that no one is working
on the machine or near the machine. Always
maintain control of the machine.
Raise the bucket or the work tool enough to
negotiate any obstacles.
Before you release the parking brake, depress the
service brake pedal in order to keep the machine
from moving.
Drive the machine forward for best visibility and
for best control.
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
significant wear and/or damage to the right service
brake pedal and final 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.
72
Operation Section
Machine Operation
i03774670
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:
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 flash.
to stop the gear display from flashing, 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:
SEBU8480
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
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 flash 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 flash when the lights on
the monitoring system flash. The action alarm will
continuously sound.
Note: The action alarm intermittently sounds if the
service brake loses oil pressure on early machines.
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 nec-
essary repairs before returning the machine to opera-
tion.
SEBU8480 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 first 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 fighting 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
Engine Starting
i02699406
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. Briefly 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. Al-
low 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 verifies
that the oil pressure is sufficient.
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:
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.
SEBU8480
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 inves-
tigate 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 five 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:
Allow the engine to warm up for approximately 15
minutes when the temperature is higher than 0C
(32F).
Allow the engine to warm up for approximately 30
minutes or more when the temperature is below
0C (32F).
More time may be required if the temperature is
less than 18C (0F). More time may also be
required if the hydraulic functions are sluggish.
SEBU8480 75
Operation Section
Parking

Parking i03765354

Parking Brake Override

i01358133 (If Equipped)
Stopping the Machine SMCS Code: 3065; 4250; 4267; 4284
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.

g02029434
Illustration 87
5. Lower the work tool to the ground and apply slight
downward pressure. The parking brake override (1) is located on the right
side of the rear bumper.
i00982184
Block wheels before activating the auxiliary parking
Stopping the Engine brake release in order to prevent the machine from
moving.
SMCS Code: 1000; 7000
Pull the auxiliary release in order to disengage the
parking brake.
NOTICE
Stopping the engine immediately after it has been
For normal parking brake operation, the auxiliary
working under load, can result in overheating and ac- parking brake must be pushed in.
celerated wear of the engine components.
Note: Do not operate the machine again until the
See the following stopping procedure, to allow the en- problem has been corrected.
gine 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

five 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.
76 SEBU8480
Operation Section
Parking

i01925768 2. Move the hydraulic lockout control to the

UNLOCKED position.
Stopping the Engine if an
Electrical Malfunction Occurs 3. Push the lift control to the LOWER position in
order to lower the bucket or the work tool to the
SMCS Code: 1000; 7000 ground. The lift control will return to the HOLD
position when the control lever is released.
If the engine start switch is in the OFF position but
the engine does not stop, use the engine shutdown 4. Move the hydraulic lockout control to the LOCKED
switch to stop the engine. 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.

g00804787
Illustration 88

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

g00933004
problem has been corrected. Illustration 89

6. A ball valve is located near the left rear of the main

i01921267 control valve. This ball valve is used for manually
Equipment Lowering with lowering the work tool. Slowly turn the square
stem in the clockwise direction. The square
Engine Stopped stem should be rotated 90 degrees. After the work
tool is resting on the ground, rotate the square
SMCS Code: 7000 stem counterclockwise.

1. Turn the engine start switch to the ON position.

SEBU8480 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 fire.

3. Remove all flammable debris in order to reduce a

fire 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
Transportation Information
i01671778
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).
g00863991
Illustration 90
Properly chocked trailer wheels
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 floor 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.
SEBU8480
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
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.
Inflate the tires to the correct pressure.
Use a self-attaching inflation chuck in order to inflate
the tire. Stand behind the tire tread while you inflate
the tires.
Reference: For more information, refer to the
Operation and Maintenance Manual, Tire Inflation
Information.
Check with the proper officials 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).
SEBU8480
i02792781
Lifting and Tying Down the
Machine
SMCS Code: 7000; 7500
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 Main-
tenance Manual, Lifting and Tying Down the
Machine for the proper technique for securing
the machine. Refer to Operation and Maintenance
Manual, Specifications for specific weight in-
formation.
g01394473
Illustration 91
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 configuration 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.
79
Operation Section
Transportation Information
Reference: Refer to Operation and Maintenance
Manual, Specifications for the dimensions and
weight of the machine.
Lifting Point In order to lift the machine,
attach the lifting devices to the lifting points.
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 sufficient 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 identified 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 identified 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.
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 identified 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
Towing Information
i02973621
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.
SEBU8480
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 sufficient control for moving a
disabled machine downhill and sufficient braking for
moving a disabled machine downhill.
The requirements for different situations cannot
be specified. 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:
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.
SEBU8480
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.
g00286064
Illustration 92
Typical example
(A) Rod End
(B) Head End
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
NOTICE
Be sure the cylinder hoses are connected correctly be-
fore 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.
81
Operation Section
Towing Information
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 ma-
chine 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.
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.
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 SEBU8480
Operation Section
Towing Information

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. Illustration 95
g01000620

1. Connect the steering frame lock and block the 3. Install the bolts in the forcing holes. Tighten these
wheels. 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.

g01000600
Illustration 93

g01000616
Illustration 94

2. Remove the three bolts from the storage holes in

the cover.
SEBU8480
Engine Starting (Alternate
Methods)
i02407539
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 in-
jury if it contacts the skin or eyes.
Always wear eye protection when starting a ma-
chine with jump start cables.
Improper jump start procedures can cause an ex-
plosion resulting in personal injury.
When using jumper cables, always connect the
positive (+) jumper cable to the positive (+) bat-
tery terminal first. Next, connect the negative (-)
jumper cable to the frame away from the batteries.
Follow the procedure in the Operation and Main-
tenance 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.
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.
83
Operation Section
Engine Starting (Alternate Methods)
NOTICE
When starting from another machine, make sure that
the machines do not touch. This could prevent dam-
age 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 start-
ing. 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.
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.
84
Operation Section
Engine Starting (Alternate Methods)
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 final 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
Engine Starting with Auxiliary
Start Receptacle
SMCS Code: 1463
g00841348
Illustration 96
SEBU8480
g01092630
Illustration 97
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.
SEBU8480 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 Inflation Information
Maintenance Section
Tire Inflation Information
i02096880
Tire Inflation with Nitrogen
SMCS Code: 4203
Caterpillar recommends the use of dry nitrogen gas
for tire inflation 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.
Proper nitrogen inflation equipment, and training
in using the equipment, are necessary to avoid
over inflation. A tire blowout or rim failure can re-
sult from improper or misused equipment and per-
sonal injury or death can occur.
A tire blowout and/or rim failure can occur if the in-
flation equipment is not used correctly, due to the
fact that a fully charged nitrogen cylinder's pres-
sure is approximately 15000 kPa (2200 psi).
There are other benefits to using nitrogen in addition
to reducing the risk of an explosion. The use of
nitrogen for tire inflation 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.
A tire blowout or a rim failure can cause personal
injury.
Use a self-attaching inflation chuck and stand be-
hind the tread when inflating a tire, to prevent per-
sonal injury.
Note: Do not set the tire inflation equipment regulator
higher than 140 kPa (20 psi) over the recommended
tire pressure.
Use 6V-4040 Inflation Group or an equivalent
inflation group to inflate tires with a nitrogen gas
cylinder.
SEBU8480
Reference: For tire inflation instructions, refer to
Special Instruction, SMHS7867, Nitrogen Tire
Inflation Group.
For nitrogen inflation, use the same tire pressures
that are used for air inflation. Consult your tire dealer
for operating pressures.
i02284174
Tire Inflation Pressure
SMCS Code: 4203; 7500
The tire inflation pressure for machines that are
shipped from the factory is suitable for shipping only.
Always obtain the proper tire inflation pressures for
your machine from the tire supplier before placing
the machine into operation. The recommended tire
inflation pressures for the front tires and for the rear
tires will vary for each application.
Proper tire inflation pressure and maintenance of
the tire inflation pressure is critical for optimum tire
life. The tire inflation 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 inflation pressure.
i02610518
Tire Inflation Pressure
Adjustment
SMCS Code: 4203
Always obtain the proper tire inflation 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
significantly change when you move the machine
into freezing temperatures. If you inflate the tire to
the correct pressure in a warm shop, the tire will be
underinflated 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 inflation
pressures.
SEBU8480 87
Maintenance Section
Lubricant Viscosities and Refill Capacities

Lubricant Viscosities and Lubricant Viscosities for Ambient

Refill Capacities Temperatures
NOTICE
i03653123 Do NOT use only the Oil Viscosities column when
determining the recommended oil for a machine com-
Lubricant Viscosities partment. The Oil Type and Classification column
MUST also be used.
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 reflects 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.
NOTICE
The footnotes are a key part of the Lubricant
Viscosities for Ambient Temperatures tables. Read
ALL footnotes that pertain to the machine compart-
ment in question.
Note: Use the oil type and the classification
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).

Machines that are operated continuously should

use oils that have the higher oil viscosity in the final
drives and in the differentials. The oils that have the
higher oil viscosity will maintain the highest possible
oil film 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
film 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 SEBU8480
Maintenance Section
Lubricant Viscosities and Refill Capacities

Table 8
Lubricant Viscosities for Ambient Temperatures(1)
C F
Compartment or System Oil Type and Classification Oil Viscosities
Min Max Min Max
SAE 0W20 40 10 40 50
SAE 0W30 40 30 40 86
Cat DEO-ULS SAE 0W40 40 40 40 104
Cat DEO Multigrade
Cat DEO SYN(4) SAE 5W30 30 30 22 86
Engine Crankcase(2)(3)
Cat Arctic DEO SYN(5) SAE 5W40 30 50 22 122
Cat ECF-1-a, Cat ECF-2,
Cat ECF-3(6) SAE 10W30(7) 18 40 0 104
SAE 10W40 18 50 0 122
SAE 15W40 9.5 50 15 122
SAE 0W20(8) 40 10 40 50
SAE 0W30(9) 40 20 40 68

Cat TDTO SAE 5W30(9) 30 20 22 68

Cat TDTO-TMS
Power Shift Transmission SAE 10W 20 10 4 50
Cat Arctic TDTO
commercial TO-4 SAE 30(10) 0 35 32 95
SAE 50(10)(11) 10 50 50 122
TDTO-TMS(10)(12) 20 43 4 110
SAE 0W20 40 40 40 104

Cat HYDO Advanced 10(13)(14) SAE 0W30 40 40 40 104

Cat MTO(13)(14) SAE 5W30 30 40 22 104
Cat DEO(13)(14)
Cat DEO-ULS(13)(14) SAE 5W40 30 40 22 104
Cat TDTO(13)(14)
Cat Arctic TDTO(13)(14) SAE 10W(15) 20 40 4 104
Hydraulic Systems
Cat TDTO-TMS(13)(14) SAE 30 10 50 50 122
Cat DEO SYN(13)(14)
Cat Arctic DEO SYN(13)(14) SAE 10W30 20 40 4 104
Cat ECF-1-a, Cat ECF-2,
Cat ECF-3, Cat TO-4, Cat SAE 15W40 15 50 5 122
TO-4M, Cat BF-1(13)(14) Cat MTO 20 40 4 104
Cat TDTO-TMS(16) 15 50 5 122
SAE 0W20(8) 40 0 40 32
SAE 0W30(9) 40 10 40 50
SAE 5W30(9) 35 10 31 50
Cat TDTO
Drive Axles Cat TDTO-TMS SAE 10W 25 15 13 59
commercial TO-4
SAE 30 20 43 4 110
SAE 50 10 50 50 122
TDTO-TMS(12) 30 43 22 110
External Lubrication Points Advanced 3Moly NLGI Grade 2 20 40 4 104
(continued)
SEBU8480 89
Maintenance Section
Lubricant Viscosities and Refill Capacities

(Table 8, contd)
Lubricant Viscosities for Ambient Temperatures(1)
C F
Compartment or System Oil Type and Classification Oil Viscosities
Min Max Min Max
Steering Column(17)
Drive Shaft Universal
Multipurpose Grease NLGI Grade 2 30 40 22 104
Joints(18)
Drive Shaft Support Bearing
(1) 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 specification 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 specifications. Commercial alternative diesel engine oils must meet one or more of these Cat ECF
specifications.
(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 specification 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 specification 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 specification 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 filter 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 benefit 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 specifications,
and that have a minimum zinc additive level of 0.09 percent (900 ppm). Commercial biodegradable hydraulic oil must meet the Cat BF-1
specification. 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 specification requirements)
(17) HMU Steering
(18) 980 Drive Shaft is maintenance free.
90 SEBU8480
Maintenance Section
Lubricant Viscosities and Refill Capacities

i02164900

Capacities (Refill)
SMCS Code: 7560

Table 9
Approximate Refill Capacities
Component or System Liters US gal
Engine Crankcase(1) 60 15.5
Transmission 83 21.9
Hydraulic Tank 267 70.5
Hydraulic System (Two Valve)(2) 390 99.6
Cooling System 95 25.1
Fuel Tank 711 187.8
Front Differential and Final
186 49.1
Drives(3)(4)
Rear Differential and Final
186 49.1
Drives(3)(4)
Lift Cylinder Pin Joint(5) 38 10
Boom Pin Joint(5) .25 .07
(1) This includes changing the oil filter.
(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 final drive.
(5) This is the capacity for one pin joint. There is a total of two.
SEBU8480 91
Maintenance Section
Lubricant Viscosities and Refill Capacities

Settings of the Injectors for the

Autolube System (If Equipped)

g01032039
Illustration 98
988H Wheel Loader
(A) A-Pin (F) F-Pin (K) K-Pin
(B) B-Pin (G) G-Pin (L) Steering Cylinder Pins
(C) C-Pin (H) Pin for Upper Articulation Joint (X) Trunnions
(E) E-Pin (J) Pin for Lower Articulation Joint (Y) Y-Pin

The controller of the autolube system is preset from Table 10

the factory and shipped from the factory so that Pins Qty (Injectors) Settings (Turns)
lubrication is dispensed at 15 minute intervals, and all
of the injectors are preset at the full flow setting. This A 0
can cause an excessive buildup of grease around B 2 8
some of the joints. As a result, the grease reservoir
may need to be filled more frequently. The injectors C 2
for selected joints can be adjusted in order to reduce E 3 5
the flow of grease without adversely affecting the life
of the pin. The injectors are set by the factory at the F 2 2
full flow setting. This setting is equivalent to 8 turns G 1 8
open. When the injectors are adjusted, the injectors
should first be closed. Then, the injectors should H 1
be opened by the number of specified turns. The 2
J 1
recommended settings for the injectors at each pin
location are listed in Table 10. K 0 8
L 4 2
X 2 8
Y 0 8

Note: By using the above settings, the buildup of

grease will be reduced and the interval between refills
of the reservoir will be extended to approximately
250 hours. Grease levels in the reservoir must be
checked in order to ensure an uninterrupted flow.
92 SEBU8480
Maintenance Section
Lubricant Viscosities and Refill Capacities

i01822901

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 specific
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.
SEBU8480
Maintenance Support
i03291524
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
General Precautions
Personal injury or death can result from sudden
machine movement.
Sudden movement of the machine can cause in-
jury 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 ob-
structions 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
Removing any sensors or switches from the
implement system
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 seri-
ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve
the pressure.
Wait until the radiator is cool.
93
Maintenance Section
Maintenance Support
Slowly loosen cooling system pressure cap in order
to relieve any system pressure.
Hydraulic Pressure
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 pre-
vent possible injury, release the hydraulic system
pressure before working on any fitting, hose, or
hydraulic component.
Lower all attachments to the ground before ser-
vice is started. If the hydraulic system must be ser-
viced, tested, or adjusted with the attachment in
the raised position, the attachments and lift cylin-
ders 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 en-
gine 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.
94
Maintenance Section
Maintenance Support
NOTICE
Never remove the fill/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 filler cap. Make
sure that the filler 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.
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.
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.
SEBU8480
i03636245
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 sen-
sors) 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:
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.
SEBU8480
i03748060
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, fluids, filters, 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.
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
95
Maintenance Section
Maintenance Interval Schedule
Window Wiper - Inspect/Replace ........................ 160
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 ............................ 108
Fuel System Primary Filter (Water Separator) -
Check/Drain ...................................................... 133
Fuel Tank Water and Sediment - Drain ............... 137
Tire Inflation - Check ........................................... 156
Every 100 Service Hours or 2 Weeks
Axle Oscillation Bearings - Lubricate .................. 100
Steering Cylinder Bearings - Lubricate ............... 155
Initial 250 Service Hours
Electronic Unit Injector - Inspect/Adjust .............. 120
Engine Valve Lash - Check ................................. 131
Engine Valve Rotators - Inspect ......................... 131
Transmission Oil Filter - Replace ........................ 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
96 SEBU8480
Maintenance Section
Maintenance Interval Schedule

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
SEBU8480 97
Maintenance Section
Alternator - Inspect

i02154861

Alternator - Inspect
SMCS Code: 1405-040

g01092660
Illustration 100

Apply grease through one fitting on the upper pivot

bearing.
g01092657
Illustration 99

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. Illustration 101
g01092661

When the engine is operated for short periods of Apply grease through one fitting on the lower pivot
time, the batteries may not fully recharge. Make bearing.
sure that the alternator is properly functioning. The
alternator will charge the batteries.
i02216552
Reference: For additional information, refer to the
appropriate Service Manual for this machine.
Automatic Lubrication Grease
Tank - Fill
i02147795 (If Equipped)
Articulation Bearings - SMCS Code: 7540-544-TNK
Lubricate
SMCS Code: 7057-086-BD; 7065-086-BD;
7066-086-BD A pressure hazard is present. Severe personal in-
jury or death can result from removing hoses or
Wipe off the fittings before any lubricant is applied. fittings that are under pressure. Relieve the pres-
sure in the system before you remove hoses or
fittings.
98 SEBU8480
Maintenance Section
Automatic Lubrication System Components - Check

The Centro-Matic Lubrication i03578320

System Automatic Lubrication System

Reference: Before any service work is performed on Components - Check
the lubrication system, refer to Special Instructions,
REHS1394 or consult your Caterpillar dealer.
(If Equipped)
SMCS Code: 7540-535
Bulk Fill
1. In order to fill the reservoir, remove the lower and
upper plugs from the side of the reservoir.
A pressure hazard is present. Severe personal in-
jury or death can result from removing hoses or
2. Attach the appropriate pump to the lower inlet.
fittings that are under pressure. Relieve the pres-
sure in the system before you remove hoses or
3. Fill the reservoir until visual indicator on the lid
fittings.
of the tank indicates FULL or until the grease
appears at the top vent port.
Reference: Before any service work is performed on
Reference: For the correct type of grease, refer the lubrication system, refer to Special Instructions,
to Operation and Maintenance Manual, Lubricant REHS1394 or consult your Caterpillar dealer.
Viscosities.

4. Remove the pump and replace both plugs.

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 fitting. The
grease fitting is located at the base of the reservoir.

Reference: For the correct type of grease, refer

to Operation and Maintenance Manual, Lubricant
Viscosities.

2. Refill 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 filled with the
recommended lubricant, loosen the fitting to the
supply line. Operate the pump until lubricant flows
from the outlet. Then, tighten fitting.
SEBU8480 99
Maintenance Section
Axle Oil Cooler Filter - Replace

g01032039
Illustration 102
(A) A-Pin (F) F-Pin (K) K-Pin
(B) B-Pin (G) G-Pin (L) Steering Cylinder Pins
(C) C-Pin (H) Pin for Upper Articulation Joint (X) Trunnions
(E) E-Pin (J) Pin for Lower Articulation Joint (Y) Y-Pin

1. Remove any buildup of grease. Check that each i02610378

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
(Refill), Settings of the the Injectors for the
Autolube System.
3. Check the grease level at the top vent port of the
reservoir.
Reference: For filling procedures, refer to
Operation and Maintenance Manual, Automatic
Lubrication Grease Tank - Fill.
Axle Oil Cooler Filter - Replace
SMCS Code: 3004-510-AOC
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
100 SEBU8480
Maintenance Section
Axle Oscillation Bearings - Lubricate

4. Apply a thin coat of clean differential oil to the seal

of each new oil filter. Install each new oil filter hand
tight until the seal of the oil filter contacts the base.
Note the position of each index mark on each filter
in relation to a fixed point on each filter base.

Note: There are rotation index marks on each oil

filter that are spaced 90 degrees or 1/4 of a turn away
from each other. When you tighten each oil filter, use
the rotation index marks as a guide.

5. Tighten each filter according to the instructions

that are printed on each filter. Use the index marks
as a guide. For non-Caterpillar filters, use the
g01092743
instructions that are provided with the filter.
Illustration 103
Front Filter Note: You may need to use a Caterpillar strap
wrench, or another suitable tool, in order to turn
the filter to the amount that is required for final
installation. Make sure that the installation tool does
not damage the filter.

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.

g01092745 i03506621
Illustration 104
Rear Filter
Axle Oscillation Bearings -
The filters are located under the access door on the Lubricate
left cab platform.
SMCS Code: 3268-086-BD; 3278-086-BD
1. Stop the engine.
Wipe off the fittings before any lubricant is applied.
2. Use a strap type wrench to remove the filters.
Dispose of the used filters properly.

3. Clean the filter mounting bases. Make sure that

all of the used seal is removed from each filter
mounting base.

g01841714
Illustration 106

g00101318
Illustration 105
SEBU8480 101
Maintenance Section
Backup Alarm - Test

g01841715
Illustration 107

Apply lubricant through the two remote fittings 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.
g01091949
Illustration 108
i02319912 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 Illustration 109
g01117861
position or to the FORWARD position.
The volume for the backup alarm is nonadjustable.
102 SEBU8480
Maintenance Section
Battery - Clean

i02155427 i02155501

Battery - Clean Battery Hold-Down - Tighten

SMCS Code: 1401-070 SMCS Code: 7257-527

g01093084 g01093110
Illustration 110 Illustration 111

Open the battery compartment on the right rear side Open the battery compartment on the right rear side
of the machine. 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
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).

Battery - Recycle i03657099

SMCS Code: 1401-561 Battery or Battery Cable -

Always recycle a battery. Never discard a battery. Inspect/Replace
Always return used batteries to one of the following SMCS Code: 1401-040; 1401-510; 1402-040;
locations: 1402-510

A battery supplier
An authorized battery collection facility Personal injury may occur from failure to properly
service the batteries.
Recycling facility
Batteries give off flammable fumes that can ex-
plode. Electrolyte is an acid and can cause per-
sonal injury if it contacts the skin or eyes.

Prevent sparks near the batteries. Sparks could

cause vapors to explode. Do not allow jumper ca-
ble ends to contact each other or the engine. Im-
proper jumper cable connections can cause an ex-
plosion.

Always wear protective glasses when working

with batteries.

1. Turn the engine start switch key OFF. Turn all of

the switches OFF.
SEBU8480 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.
g00935723
6. Inspect the battery terminals for corrosion. Inspect Illustration 112
the battery cables for wear or damage.
1. Stop the engine. Access the belt from the right
7. Make any necessary repairs. If necessary, replace side of the machine.
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.

Recycle the Battery

g00935724
Always recycle a battery. Never discard a battery. Illustration 113

Always return used batteries to one of the following
locations:
A battery supplier
An authorized battery collection facility
Note: The belt can be serviced via the engine access
door or the vent and the firewall can be removed for
easier access.
2. Inspect the condition of belt (2). If the belt is
cracked or frayed, replace the belt.

Recycling facility 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
i01832060
shown.
Belts - Inspect/Adjust/Replace
i02215711
SMCS Code: 1397-025; 1397-040; 1397-510
Brake Accumulator - Check
Note: The alternator and the refrigerant compressor
are driven by a single serpentine belt. 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
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 five 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
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.
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 specific engine rpm varies from one
machine to another machine. The variations include
differences in the engine setting, the power train
efficiency, the brake holding ability, etc.
SEBU8480
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.
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.
SEBU8480
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
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.
g00804790
Illustration 114
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.
105
Maintenance Section
Bucket Cutting Edges - Inspect/Replace
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 specified
torque.
5. Raise the bucket and remove the blocking. Lower
the bucket to the ground.
6. After a few hours of operation, check the bolts for
proper torque.
i03753062
Bucket Lift and Bucket Tilt
Control - Inspect/Clean
SMCS Code: 5258-571; 5702-571
g02024419
Illustration 115
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 SEBU8480
Maintenance Section
Bucket Stops - Inspect/Replace

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
g00101352
Illustration 117
(1) Usable
(2) Replace
(3) Overworn

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

Removal

g00554961
Illustration 116

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.
g01389463
Illustration 118
i03574841
Note: Retainers are often damaged during the
Bucket Tips - Inspect/Replace removal process. Caterpillar recommends the
installation of a new retainer when bucket tips are
SMCS Code: 6805-040; 6805-510 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.

g01175361
Illustration 119
SEBU8480 107
Maintenance Section
Bucket Tips - Inspect/Replace

1. Use a pry bar in order to disengage retainer (5). 1. Remove the mounting bolts and the side cutters.

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.
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.

4. Clean adapter (6).

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.

g01389456
Illustration 122
(7) Side cutter

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.

g01124736
Illustration 120

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)

g01389457
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)

5. Make sure that there is not a gap between the

side plate on the bucket and the shear ledge on
the side cutter.
g01389740
Illustration 121 6. Torque the mounting bolts to the correct
Bucket with side cutters specification.
Side cutters
108 SEBU8480
Maintenance Section
Bucket Wear Plates - Inspect/Replace

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.
g01389458
Illustration 124

i01098709

Bucket Wear Plates -

Inspect/Replace
SMCS Code: 6120-040; 6120-510

g01903698
Illustration 125

g00577650
Illustration 127

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.

g01389459
Illustration 126 i01908538
(12)
(13)
Side protector
Pin Cab Air Filter - Clean/Replace
(14) Retainer
(15) Side plate SMCS Code: 7342-070; 7342-510
(16) Shim
Note: Clean the cab air filters more often if the
1. Hit pin (13) from the side of the bucket without machine is being operated in dusty conditions.
the retainer in order to remove side protector (12)
from side plate (15).
SEBU8480 109
Maintenance Section
Camera - Clean

Display

g00994599
Illustration 128
g01223034
Illustration 129
1. Remove the filter cover behind the seat. Remove
WAVS display
the filter element.
Use a soft, damp cloth in order to clean the display.
2. Open the access door on the left side of the cab.
The display has a soft plastic surface that can be
Remove the filter element.
easily damaged by an abrasive material. The display
is not sealed. Do not immerse the display with
3. Clean the filter elements with pressure air or
liquid.
wash the filter elements in warm water with a
nonsudsing household detergent.
Camera
4. If water and detergent are used to clean the filter
elements, rinse the filter elements in clean water
and allow the filter elements to air dry thoroughly.

Note: If either filter element is damaged, install a

new filter element.

5. Install the filter elements. Install the filter cover

and close the access door.

i02816405

Camera - Clean
(If Equipped) g01223051
Illustration 130
SMCS Code: 7348-070 The WAVS camera is located on the rear of the machine in the
center of the fan guard.
In order to maintain sufficient vision, keep the Work
Area Vision System (WAVS) camera lens and the Use a damp cloth or water spray in order to clean
display 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 SEBU8480
Maintenance Section
Case Drain Oil Filters - Replace

i01543124 i02155537

Case Drain Oil Filters - Replace Circuit Breakers - Reset

(If Equipped) SMCS Code: 1420-529
SMCS Code: 5091-510
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.

g01093167
Illustration 132
g00801622
Illustration 131 The circuit breakers are located under a small access
(1) Case drain filter for the steering pump. (2) Case drain filter for door on the right cab platform.
the implement pump. (3) Case drain filter for the fan motor.
Main Circuit (1) 105 amp
The case drain filters are located under the access
door in the platform behind the cab.

1. Stop the engine. Alternator (2) 105 amp

2. Use a strap type wrench to remove the filter
element. Dispose of the used filter element
properly.
Engine Start Switch (3) 10 amp
3. Clean the filter mounting base. Make sure that
all of the used gasket is removed from the filter
mounting base.
Electronic Control Module (ECM) (4)
4. Lubricate the gasket of a new filter element with 15 amp
clean hydraulic oil.

5. Install the new filter element by hand. When the

gasket contacts the filter mounting base, tighten
the filter element by an additional 3/4 turn.

6. Repeat the above steps for the other two case

drain filters.

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 filters for leaks. Make

any necessary repairs.
SEBU8480 111
Maintenance Section
Cooling System Coolant (ELC) - Change

i02156049 If an Extended Life Coolant was previously used,

flush the cooling system with clean water. No other
Cooling System Coolant (ELC) cleaning agents are required. Use the following
- Change procedure to change the cooling system coolant
(ELC).
SMCS Code: 1350-044-NL

Pressurized system: Hot coolant can cause seri-

ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve
the pressure.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- g01093449
Illustration 133
ing any compartment or disassembling any compo-
nent containing fluids.
The cooling system pressure cap is located on the
left side of the machine on the top of the radiator.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
1. Slowly loosen the cooling system pressure cap
suitable to collect and contain fluids on Caterpillar
in order to relieve system pressure. Remove the
products.
cooling system pressure cap.
Dispose of all fluids according to local regulations and
mandates.

NOTICE
Topping off or mixing Cat ELC with other products that
do not meet Caterpillar EC-1 specifications 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 specification for
pre-mixed or concentrate coolants. Use only Extender
with Cat ELC.
g01093450
Failure to follow these recommendations can result in Illustration 134
shortened cooling system component life. The drain valve is located at the rear of the machine under the
engine compartment.

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.
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.

If you change the coolant of a machine to Extended
Life Coolant from another type of coolant, use a
Caterpillar cleaning agent to flush the cooling system.
After you drain the cooling system, thoroughly flush
the cooling system with clean water. All of the
cleaning agent must be removed from the cooling
system.
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 SEBU8480
Maintenance Section
Cooling System Coolant Extender (ELC) - Add

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 (Refill) 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.
NOTICE
Topping off or mixing Cat ELC with other products that
do not meet Caterpillar EC-1 specifications 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 specification 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.

9. Check the coolant level.

When a Caterpillar Extended Life Coolant (ELC) is
Reference: Refer to Operation and Maintenance used, an Extender must be added to the cooling
Manual, Cooling System Level - Check for the system.
correct procedure.

10. Install the cooling system pressure cap. Stop the

engine.

i02156106

Cooling System Coolant

Extender (ELC) - Add
SMCS Code: 1352-544-NL

Pressurized system: Hot coolant can cause seri-
ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve
the pressure.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g01093449
Illustration 135
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.

Refer to Special Publication, NENG2500, Caterpillar

Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

g01093450
Illustration 136
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 fl 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.
g01093449
6. Install the cooling system pressure cap. Illustration 139

NOTICE
i02156161 Topping off or mixing Cat ELC with other products that
Cooling System Coolant Level do not meet Caterpillar EC-1 specifications reduces
the effectiveness of the coolant and shortens coolant
- Check service life.

SMCS Code: 1350-535-FLV Use only Caterpillar products or commercial products

that have passed the Caterpillar EC-1 specification 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.

Note: If it is necessary to add coolant daily, check

Illustration 137
g01093538 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.

g01093541
Illustration 138

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 SEBU8480
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain

i02279462 Complete the information on the label for the

sampling bottle before you begin to take the
Cooling System Coolant samples.
Sample (Level 1) - Obtain
Keep the unused sampling bottles stored in plastic
SMCS Code: 1350-008; 1395-008; 7542 bags.

Note: It is not necessary to obtain a Coolant
Sample (Level 1) if the cooling system is filled
with Cat ELC (Extended Life Coolant). Cooling
systems that are filled 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 filled with any other coolant
instead of Cat ELC. This includes the following
types of coolants.
Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples
from any other location.
Keep the lids on empty sampling bottles until you
are ready to collect the sample.
Place the sample in the mailing tube immediately
after obtaining the sample in order to avoid
contamination.
Never collect samples from expansion bottles.

Commercial long life coolants that meet the Never collect samples from the drain for a system.
Caterpillar Engine Coolant Specification -1
(Caterpillar EC-1)

Cat Diesel Engine Antifreeze/Coolant (DEAC)

Commercial heavy-duty coolant/antifreeze

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g01093449
Illustration 140
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies Slowly remove the cooling system pressure cap.
suitable to collect and contain fluids on Caterpillar
products. Open the left side engine access door.
Dispose of all fluids 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. g01120387
Illustration 141
Use the following guidelines for proper sampling of
the coolant: Remove the cap over the coolant sample port.
SEBU8480 115
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain

Attach a hose to a couple. Install the threaded end Obtain coolant samples directly from the coolant
of the coupling into the drain valve in order to unseat sample port. You should not obtain the samples
the internal drain valve. from any other location.

Close the engine access door and return the pressure Keep the lids on empty sampling bottles until you
cap. are ready to collect the sample.

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
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 fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids. g01093449
Illustration 142
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies Slowly remove the cooling system pressure cap.
suitable to collect and contain fluids on Caterpillar
products. Open the left side engine access door.

Dispose of all fluids 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. Illustration 143
g01120387

Use the following guidelines for proper sampling of
the coolant:
Complete the information on the label for the
sampling bottle before you begin to take the
samples.
Keep the unused sampling bottles stored in plastic
bags.
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.
116 SEBU8480
Maintenance Section
Cooling System Water Temperature Regulator - Replace

For additional information about coolant analysis, see
Special Publication, SEBU6250, Caterpillar Machine
Fluids Recommendations or consult your Caterpillar
dealer.
i01925931
Cooling System Water
The water temperature regulator is located on the left
side of the engine near the primary fuel filter.
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.

Temperature Regulator - NOTICE

Replace Caterpillar engines incorporate a shunt design cooling
system and require operating the engine with a ther-
SMCS Code: 1355-510; 1393-010 mostat installed.

If the thermostat is installed wrong, it will cause the

Pressurized system: Hot coolant can cause seri-
ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve
the pressure.
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.

Replace the water temperature regulator on a regular
basis in order to reduce the chance of unscheduled
5. Tighten the hose clamps.
downtime and the chance of problems with the
cooling system.
6. Refill the cooling system.
The water temperature regulator should be replaced
after the cooling system has been cleaned. Replace i01923122
the water temperature regulator and replace the
seals while the cooling system is completely drained Crankshaft Vibration Damper
or while the cooling system coolant is drained to a
level that is below the water temperature regulator
- Inspect
housing. SMCS Code: 1205-040
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 regu-
larly scheduled basis could cause severe engine dam-
age.

g01000821
Illustration 145

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
g01002350 gear train noise at variable points in the speed range.
Illustration 144
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. g00801038
Illustration 146
Inspect the vibration damper for dents in the outer Final Drive
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

Differential and Final Drive Oil

- Change
SMCS Code: 3278-044; 4050-044 g00840713
Illustration 147
Front Differential
NOTICE
Care must be taken to ensure that fluids are contained
1. Position the wheels so that the front final drive
during performance of inspection, maintenance, test-
drain plugs (2) are facing downward. Remove
ing, adjusting and repair of the product. Be prepared to
the front final drive drain plugs (2) and the front
collect the fluid with suitable containers before open-
differential drain plug (4). Allow the oil to drain into
ing any compartment or disassembling any compo-
a suitable container.
nent containing fluids.
2. Remove the front final drive filler plugs (1) and the
Refer to Special Publication, NENG2500, Caterpillar
front differential filler plug (3).
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
3. After the oil has drained, clean the drain plugs and
products.
install the drain plugs.
Dispose of all fluids according to local regulations and
4. Fill the final drives to the bottom of the filler plug
mandates.
openings.

Reference: Refer to Operation and Maintenance

Manual, Lubricant Viscosities and Refill
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 filler plugs and install the filler plugs.

118 SEBU8480
Maintenance Section
Differential and Final Drive Oil Level - Check

g00840708
Illustration 148
Rear Differential Filler Plug (3)
7. Repeat steps 2 through 6 for the rear final drives
and the rear differential.
Note: The rear differential does not require the
1U-9891 Hydraulic Oil Additive.
8. If the specified amount of oil will not fit in the final
drives, install the final drive filler plugs. Operate
the machine on level ground for a few minutes in
order to equalize the oil level in the axles.
9. Remove the final drive filler plugs and add the
remaining oil. The oil level should reach the
bottom of the filler plug opening.
g00801038
Illustration 149
1. Position the wheels so that final drive drain plug
(2) is facing downward. Remove oil filler plug (1).
The oil level should be at the bottom of the filler
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 filler plug opening,
do not allow the oil to drain to the proper level.
Install the filler plug.

Note: If the oil level is higher than the filler plug

opening, do not allow the oil to drain to the proper
level. Install the filler plug.

i01624405

Differential and Final Drive Oil

Level - Check
SMCS Code: 3278-535-FLV; 4050-535-FLV
g00801039
Illustration 150
Front Differential
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, Caterpillar

Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.
SEBU8480 119
Maintenance Section
Differential and Final Drive Oil Sample - Obtain

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, Caterpillar

Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

g00840708 Dispose of all fluids according to local regulations and

Illustration 151
mandates.
Rear Differential

2. Remove differential filler plug (3). The oil level 1. Operate the machine for a few minutes before
should be at the bottom of the filler plug opening. obtaining the oil sample. This will thoroughly mix
Add oil, if necessary. the oil for a more accurate sample.

Reference: Refer to Operation and Maintenance

Manual, Lubricant Viscosities for the correct type
of oil.

If the oil level is higher than filler plug opening, do

not allow the oil to drain to the proper level. Install
filler plug (3).

i02339342

Differential and Final Drive Oil

Sample - Obtain
g01167372
SMCS Code: 3278-008; 4050-008; 4070-008; 7542 Illustration 152
Differential Filler Plug

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 incor-
rect interpretation that could lead to concerns by both
dealers and customers.

g00760182
Illustration 153
Final Drive Filler Plug

2. The differential and final 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 filler openings on the
differential and final drives.
120 SEBU8480
Maintenance Section
Drive Shaft Spline (Center) - Lubricate

Note: This procedure requires a sample for each

final 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 Illustration 155
g01093575

Center Drive Shaft

SMCS Code: 3253-086; 3253-086-SN; 3253
The fitting for the drive shaft support bearing is
NOTICE located toward the front of the articulation joint.
To prevent damage to the seal, fully articulate the ma-
chine to the right or to the left, before lubricating the Apply lubricant through one or two fittings.
spline.
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 crank-
shaft 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
Illustration 154
g00879773 to the cylinder block will be the result.

Wipe all fittings before applying lubricant. The operation of Caterpillar engines with improper
adjustments of the electronic unit injector can reduce
Apply lubricant through one fitting on the drive shaft engine efficiency. This reduced efficiency could result
spline. in excessive fuel usage and/or shortened engine
component life.
i03715441
Adjust the electronic unit injector at the same interval
Drive Shaft Support Bearing - as the valve lash adjustment.
Lubricate Refer to your machine's Service Manual or your
Caterpillar dealer for the complete adjustment
SMCS Code: 3267-086-BD
procedure.
Wipe off the fitting before any lubricant is applied.
SEBU8480
i01902270
Engine Air Filter Primary
Element - Clean/Replace
SMCS Code: 1054-070-PY; 1054-510-PY
To avoid personal injury, always wear eye and face
protection when using pressurized air.
NOTICE
Caterpillar recommends certified air filter cleaning ser-
vices that are available at Caterpillar dealers. The
Caterpillar cleaning process uses proven procedures
to assure consistent quality and sufficient filter life.
Observe the following guidelines if you attempt to
clean the filter element:
Do not tap or strike the filter element in order to re-
move dust.
Do not wash the filter element.
Use low pressure compressed air in order to remove
the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage
to the pleats.
Do not use air filters with damaged pleats, gaskets, or
seals. Dirt entering the engine will cause damage to
engine components.
NOTICE
Service the air filter only with the engine stopped. En-
gine damage could result.
1. Open the engine compartment. The air filter is
located on the right side of the machine.
g00845360
Illustration 156
121
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
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.
Illustration 157
g00101415
3. Remove the primary filter element from the air
cleaner housing. In order to remove the engine air
filter 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.
g00328468
Illustration 158
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 filtered, dry air at a maximum pressure
of 207 kPa (30 psi).
Note: Pressurized air will not remove deposits of
carbon and oil.
122 SEBU8480
Maintenance Section
Engine Air Filter Secondary Element - Replace

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 filter.
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.
11. Install a clean primary filter element over the
engine air filter secondary element. Apply firm
pressure to the end of the primary element as
you gently rock the filter 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.

Use Steps 7 through 10 in order to inspect the

i01625408
primary element:
Engine Air Filter Secondary
Element - Replace
SMCS Code: 1054-510-SE

NOTICE
Service the air filter only with the engine stopped. En-
gine damage could result.

NOTICE
Always replace the secondary element. Do not at-
tempt to reuse it by cleaning. Engine damage could
result.
g00328470
Illustration 159

Note: Replace the secondary element when you

7. Place a light bulb inside the filter element. Use
service the primary element for the third time. If
a 60 watt blue light in a dark room or in a similar
a clean primary element has been installed but a
facility. Inspect the primary element for light that
warning for the air filter still occurs, replace the
may show through the filter material.
secondary element. Also replace the secondary
element if the exhaust smoke remains black after
8. Inspect the primary element while you rotate the
installation of a clean primary element.
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 filter 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 confirm the results of the
inspection.

10. Discard a damaged primary element.

Use Steps 11 through 13 to install a clean

primary element: Illustration 160
g00841360

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

Do not use a filter if the pleats, the gaskets or the seals the machine.
are damaged.
SEBU8480 123
Maintenance Section
Engine Air Filter Service Indicator - Inspect

g00804954 g00841372
Illustration 161 Illustration 164

4. Cover the air inlet opening. Clean the inside of

the air filter 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 filter element.

7. Install a clean primary element and install the

g00804960
Illustration 162
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.
cover on the air filter housing. Fasten the clips in
order to secure the cover.
8. Close the engine access door.
i01549255
Engine Air Filter Service
Indicator - Inspect
SMCS Code: 7452-040

NOTICE
Service the air cleaner only with the engine stopped.
Engine damage could result.

g00805000
Illustration 163

3. Remove the secondary filter element.

124 SEBU8480
Maintenance Section
Engine Air Filter Service Indicator - Inspect/Replace

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

SMCS Code: 1055-070
g00804672
Illustration 165
NOTICE
Open the engine access door on the left side of the Service the air cleaner only with the engine stopped.
machine. Engine damage could result.
The air filter service indicator is located on the air
inlet line.

If the yellow piston in the filter 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

g00841375
Illustration 167

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.

g00804672
Illustration 166
SEBU8480
i01923427
Engine Mounts - Inspect
SMCS Code: 1152-040
g01000916
Illustration 168
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
Specifications manual for your machine's engine.
i03649497
Engine Oil (High Speed) and
Oil Filter - Change
(If Equipped)
SMCS Code: 1318-510
Selection of the Oil Change Interval
NOTICE
A 500 hour engine oil change interval is available, pro-
vided that the operating conditions and recommend-
ed multigrade oil types are met. When these require-
ments 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 filter 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.
125
Maintenance Section
Engine Mounts - Inspect
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 filters or of fuel
filters 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 filters are recommended.
Program A
Verification 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:
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.
126 SEBU8480
Maintenance Section
Engine Oil (High Speed) and Oil Filter - Change

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
g00841360
Reference: Special Publication, PEDP7076, Illustration 169
Understanding the SOS Oil Analysis Tests

Procedure for Changing the Engine

Oil and Filter

Hot oil and components can cause personal in-

jury.

Do not allow hot oil or components to contact

skin.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
g01000950
Illustration 170
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.

Dispose of all fluids 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.

g00841382
Illustration 171

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 (Refill) 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.

g01001013
Check for leaks.
Illustration 172
11. Check the engine oil level.
4. Use a strap type wrench to remove the engine oil
filter. Dispose of the used filter properly. Reference: Refer to Operation and Maintenance
Manual, Engine Oil Level - Check for the correct
5. Clean the filter mounting base. Make sure that the procedure.
used seal is completely removed.
12. Close the engine access doors.

i01923584

Engine Oil Level - Check

SMCS Code: 1000-535-FLV

NOTICE
Do not under fill or overfill engine crankcase with oil.
Either condition can cause engine damage.

g00101318
Illustration 173

6. Apply a thin film of clean engine oil to the seal

on the new filter element. Install a new engine oil
filter hand tight until the seal of the engine oil filter
contacts the base. Note the position of the index
marks on the filter in relation to a fixed point on
the filter base.

Note: There are rotation index marks on the engine

oil filter that are spaced 90 degrees or 1/4 of a turn
away from each other. When you tighten the engine
oil filter, use the rotation index marks as a guide. Illustration 174
g00841382

7. Tighten the filter according to the instructions 1. Open the engine access door on the left side of
that are printed on the filter. Use the index marks the machine.
as a guide. For non-Caterpillar filters, use the
instructions that are provided with the filter.

Note: You may need to use a Caterpillar strap

wrench, or another suitable tool, in order to turn
the filter to the amount that is required for final
installation. Make sure that the installation tool does
not damage the filter.
128 SEBU8480
Maintenance Section
Engine Oil Sample - Obtain

i01908025

Engine Oil Sample - Obtain

SMCS Code: 1348-008; 7542

g01001056
Illustration 175

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
g01001331
a more accurate measurement of the engine oil Illustration 177
level.
The sampling valve for the engine oil is located on
the engine oil filter base on the right side of the
engine compartment.

i03711621

Engine Oil and Filter - Change

g00999790
Illustration 176 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 filler cap (2) and add oil.
Clean the oil filler cap and install the oil filler cap.
5. Close the engine access door.
Selection of the Oil Change Interval
NOTICE
A 500 hour engine oil change interval is available, pro-
vided that the operating conditions and recommend-
ed multigrade oil types are met. When these require-
ments 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 filter 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
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 filters or of fuel
filters 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 filters are recommended.
Program A
Verification 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:
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.
129
Maintenance Section
Engine Oil and Filter - Change
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
Procedure for Changing the Engine
Oil and Filter
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
g01001064
Illustration 178
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 SEBU8480
Maintenance Section
Engine Oil and Filter - Change

2. Close the drain valve (1). Raise the bottom guard.
6. Apply a thin film of clean engine oil to the seal
on the new filter element. Install a new engine oil
filter hand tight until the seal of the engine oil filter
contacts the base. Note the position of the index
marks on the filter in relation to a fixed point on
the filter base.

Note: There are rotation index marks on the engine

oil filter that are spaced 90 degrees or 1/4 of a turn
away from each other. When you tighten the engine
oil filter, use the rotation index marks as a guide.

7. Tighten the filter according to the instructions

that are printed on the filter. Use the index marks
as a guide. For non-Caterpillar filters, use the
instructions that are provided with the filter.
g00841382
Illustration 179
Note: You may need to use a Cat strap wrench, or
3. Open the engine access door on the left side of another suitable tool, in order to turn the filter to the
the machine. amount that is required for final installation. Make
sure that the installation tool does not damage the
filter.

g01001013
Illustration 180

4. Use a strap type wrench to remove the engine oil g01001078

Illustration 182
filter. Dispose of the used filter properly.
8. Remove the engine oil filler cap and fill the engine
5. Clean the filter mounting base. Make sure that the crankcase with oil.
used gasket is completely removed.
Reference: Refer to Operation and Maintenance
Manual, Capacities (Refill) for the proper
amount of oil.

9. Clean the oil filler cap and install the oil filler 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.
g00101318
Illustration 181
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 qualified 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.
g00882731
Illustration 183
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 Water Pump - Inspect
Engine Valve Rotators - Inspect
SMCS Code: 1361-040
SMCS Code: 1109-040
Failure of the engine water pump may cause severe
engine overheating problems such as cracks in the
cylinder head or piston seizure.
When inspecting the valve rotators, protective
Visually inspect the water pump for leaks. If you find
glasses or face shield and protective clothing
leaks, all of the seals on the water pump must be
must be worn, to prevent being burned by hot oil
replaced.
or spray.
Note: For more information, refer to the appropriate
Caterpillar recommends replacing valve rotators that Disassembly and Assembly manual for your
are operating improperly. An improperly operating machine's engine.
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
i01548876
Ether Starting Aid Cylinder -
Replace
(If Equipped)
SMCS Code: 1456-510-CD
Ether is poisonous and flammable.
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 fires.
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 unautho-
rized personnel.
To avoid possible injury, be sure the brakes are ap-
plied and all controls are in Hold or Neutral when
starting the engine.
Illustration 184
g00805191
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
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.
i02236759
Fuel System - Prime
SMCS Code: 1250-548
1. Open the engine access door on the left side of
the machine.
g01002079
Illustration 185
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 flow into the suitable
container until the fuel flows in a steady stream.
6. Turn the toggle switch (1) to the OFF position.
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 misfires, further priming is
necessary.
SEBU8480 133
Maintenance Section
Fuel System Primary Filter (Water Separator) - Check/Drain

Note: Failure to tighten fittings 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
g01002112
Illustration 187
SMCS Code: 1263-535; 1263-543 Type 1

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, Caterpillar

Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

g01482573
mandates. Illustration 188
Type 2

2. The water separator is located on the bottom of

the primary fuel filter. 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.

4. Close the engine access door.

g00841382
Illustration 186

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

the machine.
134 SEBU8480
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace

i03355824

Fuel System Primary Filter

(Water Separator) Element -
Replace
SMCS Code: 1260-510; 1263-510-FQ

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- g01002123
Illustration 190
nent containing fluids.
Type 1
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies 2. The water separator is located on the bottom of
suitable to collect and contain fluids on Caterpillar the primary fuel filter. Open the drain valve on the
products. water separator bowl. Allow the water and the fuel
to drain into a suitable container.
Dispose of all fluids according to local regulations and
mandates. 3. Use a strap type wrench to remove the filter from
the filter mounting base.

NOTICE 4. Remove the water separator bowl from the filter

Do not fill fuel filters with fuel before installing them.
The fuel will not be filtered 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.
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.

g01482573
g00841382 Illustration 191
Illustration 189
Type 2
1. Open the engine access door on the left side of
the machine. a. The steel fuel filter (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 filter

element by hand. Do not use tools to tighten the
water separator bowl.
SEBU8480
g00101318
Illustration 192
8. Apply a thin coat of oil to the seal on the new filter.
Install the new filter hand tight until the seal of
the engine oil filter contacts the base. Note the
position of the index marks on the filter in relation
to a fixed point on the filter base.
Note: There are rotation index marks on the fuel filter
that are spaced 90 degrees or 1/4 of a turn away
from each other. When you tighten the fuel filter, use
the rotation index marks as a guide.
9. Tighten the filter according to the instructions
that are printed on the filter. Use the index marks
as a guide. For non-Caterpillar filters, use the
instructions that are provided with the filter.
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 fill the filter
element with fuel.
Reference: Refer to Operation and Maintenance
Manual, Fuel System Prime for the correct
procedure.
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 fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
NOTICE
Do not fill fuel filters with fuel before installing them.
The fuel will not be filtered 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.
g00841360
Illustration 193
1. Open the engine access door on the right side of
the machine.
136 SEBU8480
Maintenance Section
Fuel Tank Cap and Strainer - Clean

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

g01002138
The fuel tank cap is located on the left side of the
Illustration 194 machine.
2. Remove the used filter element. Dispose of the 1. Remove the fuel tank cap.
used filter element properly.
2. Inspect the seal for damage. Replace the seal, if
3. Clean the filter mounting base. Make sure that all necessary.
of the used seal is removed.
3. Remove the filter assembly from the cap.

g00101318
Illustration 195
g00930457
Illustration 196
4. Apply a thin coat of clean diesel fuel to the seal on
the new fuel filter. Install the new fuel filter hand Note: Refer to Operation and Maintenance Manual,
tight until the seal of the fuel filter contacts the General Hazard Information for information on
base. Note the position of the index marks on the Containing Fluid Spillage.
filter in relation to a fixed point on the filter base.
4. Remove the strainer from the filler tube.
Note: There are rotation index marks on the fuel filter
that are spaced 90 degrees or 1/4 of a turn away 5. Wash the fuel tank cap and the strainer in a clean,
from each other. When you tighten the fuel filter, use nonflammable solvent.
the rotation index marks as a guide.
6. Install a new cap filter kit. Install the other
5. Tighten the filter according to the instructions components in reverse order.
that are printed on the filter. Use the index marks
as a guide. For non-Caterpillar filters, use the 7. Install the strainer and the fuel tank cap.
instructions that are provided with the filter.

Note: You may need to use a Caterpillar strap

wrench, or another suitable tool, in order to turn
the filter to the amount that is required for final
installation. Make sure that the installation tool does
not damage the filter.

6. Prime the fuel system.

SEBU8480 137
Maintenance Section
Fuel Tank Water and Sediment - Drain

i02156799 i02741651

Fuel Tank Water and Sediment Fuses - Replace

- Drain
SMCS Code: 1273-543-M&S
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
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.

Dispose of all fluids according to local regulations and

mandates.

g01093757
Illustration 199

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.
g01093885
Illustration 197
NOTICE
The fuel tank drain valve is located on the left side of Replace the fuses with the same type and size only.
the machine at the bottom of the fuel tank. Otherwise, electrical damage can result.

If it is necessary to replace fuses frequently, an electri-

cal problem may exist. Contact your Caterpillar dealer

g01093886
Illustration 198

Open the fuel tank drain valve. Allow the water and
sediment to drain into a suitable container. Close the
fuel tank drain valve.
138 SEBU8480
Maintenance Section
Fuses - Replace

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
g01119139
Illustration 200

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

SEBU8480 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

g01353212
Illustration 201 Front Work Lights 15 amp
Typical example

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 SEBU8480
Maintenance Section
High Intensity Discharge Lamp (HID) - Replace

1. Remove the electrical power from the high

Rear Monitor (Vision) 10 amp intensity discharge lamp (HID). The electrical
power must be removed from the HID lamp for
at least five minutes, in order to ensure that the
bulb is cool.
Voltage Converter 10 amp
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

Autolube System 10 amp part of the lens assembly. The bulb is not removed
separately from the lens assembly. Replace the
entire lens assembly on these HID lamps.

Window Wipers 10 amp 3. Remove the bulb from the HID lamp.

4. Install the replacement bulb in the HID lamp.

Seat 15 amp If the bulb is an integral part of the lens assembly,

install the replacement lens assembly in the HID
lamp.

Blower Fan 20 amp Note: In order to avoid failure to the bulb that is
premature, avoid touching the bulb's surface with
your bare hands. Clean any fingerprints from the bulb
with alcohol prior to operation.

i02245859
5. Reassemble the housing for the HID lamp. Ensure
that any printing on the lens is oriented correctly
High Intensity Discharge Lamp with respect to the HID lamp's mounting position
on the machine.
(HID) - Replace
(If Equipped) 6. Reattach the electrical power to the HID lamp.

SMCS Code: 1434-510 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 i03307817
power before servicing HID lamps.
Hydraulic System Oil - Change
SMCS Code: 5056-044

HID bulbs become very hot during operation. Selection of the Oil Change Interval
Before servicing, remove power from lamp for at
least five minutes to ensure lamp is cool. 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,
NOTICE
the clutches, the final drives, or the differentials.
Although HID bulb materials may change over time,
The standard change interval is 2000 hours. The oil
HID bulbs produced at the time of the printing of this
should be monitored in additional increments of 500
manual contain mercury. When disposing of this com-
hours. The extended 4000 hour interval can be used
ponent, or any waste that contains mercury, please
if the following criteria are met.
use caution and comply with any applicable laws.
SEBU8480
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 filter 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 benefits from
the improved performance designed into Cat HYDO
Advanced 10.
Oil Filters
Caterpillar oil filters are recommended. The interval
for changing the oil filter should be 500 hours.
Oil
The 4000 hour interval for changing the oil is for the
following oil types.
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 identified by the following
classifications: 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.
141
Maintenance Section
Hydraulic System Oil - Change
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:
Significant changes in wear metals should be
monitored. These metals include iron, copper,
chromium, lead, aluminum, and tin.
The following additives should be observed for
significant changes: Zinc, calcium, magnesium,
and phosphorus.
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.
The recommended level of cleanliness for
Caterpillar machines that are operated in the field
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.
There should not be significant changes in sodium,
silicon, copper, and potassium.
The allowable level of oxidation is 40 percent (0.12
Abs units).
The kinematic viscosity at 100 C (212 F) should
not exceed a 2 cSt change.
142
Maintenance Section
Hydraulic System Oil - Change
Procedure for Changing the
Hydraulic Oil
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids 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.
g01152499
Illustration 202
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 filler cap (2). Remove
the filler strainer from the hydraulic tank filler neck.
Wash the filler cap and the strainer in a clean,
nonflammable solvent. Install the strainer.
5. Inspect the gasket on the hydraulic tank filler cap
for damage. Replace the gasket, if necessary.
SEBU8480
6. Remove the drain plug from the bottom of the
hydraulic tank. Wash the drain plug in a clean,
nonflammable 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 compo-
nents 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 filter.
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 Refill
Capacities for the correct type of oil and for the
correct amount of oil.
11. Install filler 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 filled with oil before the engine is
started. This is necessary in order to ensure proper
operation of the pumps.
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 fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, Caterpillar

Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
g00935858
Illustration 203
Dispose of all fluids according to local regulations and
2. Remove the cap from port (6). Attach a drain hose mandates.
that is equipped with a quick connect fitting 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 filled.

4. Remove the cap from port (9). Attach a drain hose

that is equipped with a quick connect fitting 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
g01001201
pour hydraulic oil until the hydraulic oil comes out Illustration 204
of the drain hose that is attached to tee (7).
The hydraulic oil filter is located behind the mud flap
5. Remove the drain hose and install the cap onto on the front of the hydraulic tank.
port (9). The case for the implement pump is now
filled. Note: The mud flap may be removed for easier
access to the filter.
6. Replace any hydraulic oil that was lost during the
installation of the hoses. 1. Stop the engine.

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.
144 SEBU8480
Maintenance Section
Hydraulic System Oil Level - Check

7. Tighten the filter according to the instructions

that are printed on the filter. Use the index marks
as a guide. For non-Caterpillar filters, use the
instructions that are provided with the filter.

Note: You may need to use a Caterpillar strap

wrench, or another suitable tool, in order to turn
the filter to the amount that is required for final
installation. Make sure that the installation tool does
not damage the filter.

8. Start the engine and run the engine at low idle.

Inspect the hydraulic system for leaks.

g01001186
9. Check the level of the hydraulic oil.
Illustration 205
Reference: Refer to Operation and Maintenance
2. Use a strap type wrench to remove the hydraulic Manual, Hydraulic System Oil Level - Check for
oil filter element. Dispose of the used filter the correct procedure.
properly.

3. Remove the filler cap and the strainer from the i01923843
hydraulic oil filler tube. Wash the filler cap and the
strainer in a clean nonflammable solvent. Allow Hydraulic System Oil Level -
the strainer to air dry. Check
4. Inspect the strainer for damage. Replace the SMCS Code: 5056-535-FLV
strainer, if necessary. Install the strainer and the
filler cap. Note: The work tool must be positioned on the
ground in order to have an accurate reading.
5. Clean the filter mounting base. Make sure that
all of the used gasket is removed from the filter
mounting base.

g01001204
Illustration 207

g00101318
The hydraulic tank is located on the right side of the
Illustration 206 machine.
6. Apply a thin coat of hydraulic oil to the seal on
the new filter. Install the new hydraulic oil filter
hand tight until the seal of the hydraulic oil filter
contacts the filter base. Note the position of the
index marks on the filter in relation to a fixed point
on the filter base.

Note: There are rotation index marks on the hydraulic

oil filter that are spaced 90 degrees or 1/4 of a turn
away from each other. When you tighten the hydraulic
oil filter, use the rotation index marks as a guide.
SEBU8480
g00935879
Illustration 208
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 filler cap (2) and add
hydraulic oil.
3. If hydraulic oil was added, clean the hydraulic tank
filler cap and install the hydraulic tank filler cap.
i02156928
Hydraulic System Oil Sample
- Obtain
SMCS Code: 5050-008; 5056-008; 7542
g01093962
Illustration 209
Obtain a sample of the hydraulic oil from the
hydraulic oil sampling valve. The sampling valve is
located on the hydraulic oil filter 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.
145
Maintenance Section
Hydraulic System Oil Sample - Obtain
i01923846
Hydraulic Tank Breaker Relief
Valve - Clean
SMCS Code: 5118-070
Illustration 210
g01001206
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, nonflammable solvent. Shake the relief
valve dry or use pressure air.
3. Install the hydraulic tank breaker relief valve.
i02157156
Lift Cylinder Pin Oil - Change
SMCS Code: 7070-044-OC
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
146 SEBU8480
Maintenance Section
Lift Cylinder Pin Oil - Change

g00560502 g01094058
Illustration 211 Illustration 213
Pin Joint (K)
1. Park the machine on level ground and engage
the parking brake. Lower the bucket so that the 5. Fill the pin joint with SAE 80W90 oil until oil
bottom of the bucket is flat on the ground. Stop escapes from the filler opening.
the engine.
6. Clean the filler plug and install the filler plug.

g01094056
Illustration 212
Pin Joint (K) g01094059
Illustration 214

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 filler plug for pin joint (K). The filler
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.

g01094061
Illustration 215
Pin Joint (Y)

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

g01094064
Illustration 216

g00560502
Illustration 218

1. Park the machine on level ground and engage

the parking brake. Lower the bucket so that the
bottom of the bucket is flat on the ground.

g01094065
Illustration 217
Pin Joint (Y)

8. Remove the filler plug for pin joint (Y). The filler
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 Illustration 219
g01094058
escapes from the filler opening. Pin Joint (K)

Note: It will be necessary to use a funnel and a hose
to fill the pin joint through the filler opening.
11. Clean the filler plug and install the filler plug.
2. Clean the area around the filler plug for pin joint
(K). Slowly loosen the filler plug.
3. If the oil escapes from the filler opening, the oil
level in the pin joint is correct. If the oil level is
low, add SAE 80W90 until oil escapes from the
filler opening.

4. Clean the filler plug and install the filler plug.

148 SEBU8480
Maintenance Section
Loader Boom Pin Oil - Change

1. Park the machine on level ground and engage

the parking brake. Lower the bucket so that the
bottom of the bucket is flat on the ground. Stop
the engine.

g01094064
Illustration 220

g00811718
Illustration 222
The A-pin joints (1) do not have drain plugs.

g01094065
Illustration 221
Pin Joint (Y)

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

i02280356

Loader Boom Pin Oil - Change

SMCS Code: 6118-044-OC

NOTICE Illustration 223

Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
g01094359
A-Pin Joint
2. Remove the filler 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 filler plug opening. Insert the correct amount
of tubing through the filler 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.
SEBU8480
5. Fill the sampling bottle and withdraw the tube from
the filler 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 filler 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
Loader Boom Pin Oil Level -
Check
SMCS Code: 6118-535-FLV
g00560643
Illustration 224
1. Park the machine on level ground and engage
the parking brake. Lower the bucket so that the
bottom of the bucket is flat on the ground.
149
Maintenance Section
Loader Boom Pin Oil Level - Check
g01094359
Illustration 225
A-Pin Joint
2. Clean the area around the filler plugs for both
A-pin joints. Slowly loosen each filler plug.
3. If the oil escapes from the filler opening, the oil
level is correct. If the oil level is low, add SAE
80W90 until oil escapes from the filler opening.
4. Clean the filler plugs and install the filler plugs.
i01613549
Loader Boom Pin and Lift
Cylinder Pin - Inspect
SMCS Code: 5102-040-PN; 6501-040-PN
g00818239
Illustration 226
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 SEBU8480
Maintenance Section
Loader Pins and Bearings - Lubricate

i02158811

Loader Pins and Bearings -

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

g01094969
Illustration 229
C-Pin Joints

For the C-pin joints, apply lubricant through the

fittings at the bottom of each bucket link.
g00560806
Illustration 227

Wipe off the fittings before any lubricant is applied.

There is a total of nine fittings.

g01094970
Illustration 230
E-Pin Joints

For the E-pin joints, apply lubricant through three

remote fittings on the bucket links.
g01094968
Illustration 228
B-Pin Joint

For the B-pin joint, apply lubricant through the fitting

on the top of the boom.

g01094972
Illustration 231
F-Pin Joint (Right Side)
SEBU8480 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

g01094974
Illustration 232
F-Pin Joint (Left Side)

For the F-pin joints, apply lubricant through the

fittings at the bottom of each tilt lever.

g00100013
Illustration 234
The element is shown with debris.

Use a filter cutter to cut the filter element open.

Spread apart the pleats and inspect the element for
metal and for other debris. An excessive amount of
debris in the filter element can indicate a possible
failure.

If metals are found in the filter element, a magnet can

be used to differentiate between ferrous metals and
g01094975 nonferrous metals.
Illustration 233
G-Pin Joint Ferrous metals can indicate wear on steel parts and
on cast iron parts.
For the G-pin joint, apply lubricant through one
remote fitting on the inside of the right front loader Nonferrous metals can indicate wear on the
frame. aluminum parts of the engine such as main bearings,
rod bearings, or turbocharger bearings.

Small amounts of debris may be found in the filter

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 filter 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 unfiltered
oil. The particles could enter the lubricating system
and the particles could cause damage.
152 SEBU8480
Maintenance Section
Radiator Core - Clean

i02158840 i02728869

Radiator Core - Clean Refrigerant Receiver-Dryer -

SMCS Code: 1353-070-KO Replace
SMCS Code: 7322-510

g01094991
Illustration 235
g01095018
Illustration 237
On each side of the machine, the radiator core can
be accessed through the vents and through the The refrigerant dryer is located behind the cab. Open
narrow access doors. 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 five minutes in order to

equalize the pressure in the air conditioning
system.

g00100062
Illustration 236

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

g01095101
Illustration 239

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
g00654556
(1106 147.5 lb ft).
Illustration 238
Typical In-Line Dryer Note: Apply oil to all bolt threads before installation.
(1) Inlet hose with air conditioner quick disconnects Failure to apply oil can result in improper bolt torque.
(2) Outlet hose with air conditioner quick disconnects
Do not repair the ROPS by welding reinforcement
2. Disconnect the inlet hose (1) from the old in-line plates to the ROPS. Consult your Caterpillar dealer
dryer. for repair of cracks in any welds, in any castings, or
in any metal section of the ROPS.
3. Connect the inlet hose that was disconnected in
Step 2 to the inlet on the new in-line dryer.
i02429589
4. Start the engine and operate the air conditioning
system.
Seat Belt - Inspect
SMCS Code: 7327-040
5. With the air conditioning system in operation,
disconnect the outlet hose (2) from the old in-line
Always check the condition of the seat belt and the
dryer.
condition of the seat belt mounting hardware before
you operate the machine. Replace any parts that are
6. Stop the engine for five minutes in order to
damaged or worn before you operate the machine.
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.
154 SEBU8480
Maintenance Section
Seat Belt - Replace

g01152685
Illustration 241

Illustration 240
g00932801
Typical example
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.
(1) Date of installation (retractor)
(2) Date of installation (buckle)
(3) Date of manufacture (tag) (fully extended web)
(4) Date of manufacture (underside) (buckle)
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.

Inspect the seat belt (3) for webbing that is worn or

i01547608
frayed. Replace the seat belt if the seat belt is worn
or frayed. Seat Side Rails - Adjust
Consult your Caterpillar dealer for the replacement of SMCS Code: 7312-025
the seat belt and the mounting hardware.

Note: Within three years of the date of installation or

within five years of the date of manufacture, replace
the seat belt. Replace the seat belt at the date which
occurs first. 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

Seat Belt - Replace Illustration 242

g00804394

SMCS Code: 7327-510
Within three years of the date of installation or within
five years of the date of manufacture, replace the
seat belt . Replace the seat belt at the date which
occurs first. 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.
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 Starting Motor - Inspect

SMCS Code: 4300-081-SE; 4300-081-SST; SMCS Code: 1453-040
4324-081; 4324
Caterpillar recommends a scheduled inspection of
the starting system.

Check the starting motor and the battery charger

The service brake must be checked in order to en-
for proper operation. Check for loose electrical
sure proper operation before you test the supple-
connections.
mental steering system.
Reference: For the complete procedure for
Personal injury, death, or property damage could
inspecting the starting system, refer to the Systems
occur if the supplemental steering system is test-
Operation/Testing and Adjusting manual for your
ed and the service brake is not operational.
machine's engine.
Test the service brake before you test the supple-
mental steering system. i02168764

Perform the following procedure if your machine is

Steering Cylinder Bearings -
equipped with a ground driven supplemental steering Lubricate
and if the procedure is required by local regulations.
SMCS Code: 4303-086-BD
Ensure that there are no hazards in the test area. The
test area must be unobstructed and level. Operate Wipe off the fittings before any lubricant is applied.
the machine in second gear.
There is a total of four fittings.
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 g01098863
the steering input, the supplemental steering system Illustration 243
is operating. Stop the machine with the service
brakes. Apply the parking brake. The machine can Apply lubricant through the fitting on the head end
then be returned to normal operation. of each steering cylinder.

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.
156 SEBU8480
Maintenance Section
Tire Inflation - Check

i03753360

Transmission Oil - Change

SMCS Code: 3030-044

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, Caterpillar

g01098864
Illustration 244
The bearing on the rod end of each steering cylinder
is lubricated through two remote fittings on the inside
of the right front loader frame.
Apply lubricant through fitting (1) for the right steering
cylinder. Apply lubricant through fitting (2) for the left
steering cylinder.
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
1. Operate the machine in order to warm the
transmission oil.

i02305841 2. Park the machine on level ground. Lower the

bucket to the ground and apply slight downward
Tire Inflation - Check pressure. Engage the parking brake. Stop the
engine.
SMCS Code: 4203-535-AI

g01160201
Illustration 245
Always obtain proper tire inflation pressures and
maintenance recommendations for the tires on your
machine from your tire supplier. Measure the tire
pressure on each tire.
Inflate the tires with nitrogen , if necessary.
Reference: Refer to the Tire Inflation Information
section of the Operation and Maintenance Manual
for more information.
g01095645
Illustration 246
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
g01095647
Illustration 247
5. The transmission oil filler tube is located near the
articulation joint on the left side of the machine.
Remove the transmission oil filler cap in order to
ease drainage.
g01095648
Illustration 248
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 ob-
jects. Replace any damaged magnets.
157
Maintenance Section
Transmission Oil - Change
g00838905
Illustration 249
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, nonflammable 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 filter.
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 (Refill) for the proper amount
of oil.
10. Clean the filler cap and install the filler cap.
158 SEBU8480
Maintenance Section
Transmission Oil Filter - Replace

i03753272

Transmission Oil Filter -

Replace
SMCS Code: 3067-510

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g00935383
Illustration 250
Transmission Breather
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
11. Open the access door in the platform behind the suitable to collect and contain fluids on Caterpillar
cab. Remove the transmission breather. products.

12. Wash the breather in a clean, nonflammable Dispose of all fluids according to local regulations and
solvent. Allow the breather to air dry or use air mandates.
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 g02024592
correct procedure. Illustration 251

The transmission oil filter 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 filter housing (1).

5. Remove the used transmission oil filter element.

Dispose of the used filter element properly.

6. Clean the transmission filter housing in a clean,

nonflammable solvent. Clean the filter housing
base.
SEBU8480 159
Maintenance Section
Transmission Oil Level - Check

7. Inspect the filter housing seal. Replace the seal

if the seal is damaged.

8. Insert a new transmission oil filter element into the

transmission filter housing.

9. Install the transmission filter housing into the

filter housing base. Tighten the transmission filter
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. g00936406
Illustration 253
12. Engage the parking brake. Inspect the
transmission oil filter for leaks. 2. Check the oil level in the sight gauge. Maintain
the oil level within the operating range while the
13. Stop the engine. engine is running.

14. Check the transmission oil level.
Reference: Refer to Operation and Maintenance
Manual, Transmission Oil Level - Check for the
correct procedure.
Note: The oil level varies significantly 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 filler cap and add oil.

i03753367 Clean the filler cap and install the filler cap.
Transmission Oil Level - Check
i02161205
SMCS Code: 3030-535-FLV
Transmission Oil Sample -
Obtain
SMCS Code: 3080-008; 7542

g02024665
Illustration 252
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 Illustration 254

g01095817
warm the oil. Park the machine on level ground.
The sampling valve for the transmission oil is located
on the transmission oil filter base on the left side of
the machine.
160 SEBU8480
Maintenance Section
Turbocharger - Inspect

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
g01095908
Illustration 255
If the turbocharger fails during engine operation,
severe damage to the turbocharger compressor The window washer reservoir is located beneath an
wheel and to the entire engine can result. access panel on the left cab platform .
Turbocharger bearing failures can cause large Fill the reservoir with window washer solvent.
quantities of oil to enter the intake system and the
exhaust system. Loss of engine oil can result in
serious engine damage. i02168843

Do not continue to operate the engine when a Window Wiper -

turbocharger bearing failure is accompanied by
a significant loss of engine performance. Engine
Inspect/Replace
smoke and speeding up of the engine with no load SMCS Code: 7305-040; 7305-510
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

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.
SEBU8480 161
Maintenance Section
Windows - Clean

i00037755

Windows - Clean
SMCS Code: 7310-070

g00038949
Illustration 257

Use commercially available window cleaning

solutions in order to clean the windows. Clean the
outside windows from the ground unless handholds
are available.
162 SEBU8480
Reference Information Section
Reference Materials

Reference Information Special Publication, PEHJ0009, Product Data Sheet

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

Reference Materials Miscellaneous Publications

i03291550 Power Train Disassembly and Assembly, RENR6422,
Tire and Rim - Remove and Install
Reference Material
Special Publication, PECP9067, One Safe Source
SMCS Code: 1000; 7000
Special Publication, PEDP9131, Fluid Contamination
Cooling System - The Silent Thief

Special Publication, PMEP5027, Label - ELC Special Publication, PEWJ0074, Cat Filter & Fluid
Radiator Label Application Guide

Special Publication, PEHJ0067, Product Data Sheet Special Publication, SEBD0400 , Dictionary of
for Caterpillar ELC Pictographic Symbols

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)
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
Inflation Group
Oil
Special Publication, PEHP3050, Product Data Sheet
for Caterpillar Multipurpose Tractor Oil (MTO)

Special Publication, PEHP6001, How to Take a

Hydraulic Oil Good Oil Sample
Special Publication, PEGP6028, Caterpillar Special Publication, PEHJ0007, Product Data Sheet
Hydraulic Systems Management Guide for Caterpillar Arctic TDTO (SAE 0W-20) (synthetic
blend)
SEBU8480
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 Specifications (Cat ECF-1)
Special Publication, PEHP8035, Product Data Sheet
for TDTO Transmission Multi-Season (TMS)
Special Publication, SEBD0640, Oil and Your
Engine
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
Certification Means
Special Publication, SEHS6929, Inspection,
Maintenance and Repair of ROPS and Attachment
Installation Guidelines
163
Reference Information Section
Reference Materials
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
Specifications Manuals
Specifications Manual, SENR3130, Torque
Specifications
Tools
Special Publication, NENG2500, Caterpillar Dealer
Service Tool Catalog
Additional Reference Material
SAE J183, Classification 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
164 SEBU8480
Reference Information Section
Reference Materials

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
Index
A Camera - Clean (If Equipped).............................. 109
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 Replace............................................................... 116
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 Procedure for Changing the Engine Oil and
Cab Air Filter - Clean/Replace............................. 108
Camera.................................................................. 71
Rear View Camera (If Equipped) ....................... 71
165
Index Section
Camera ............................................................ 109
Display ............................................................. 109
Capacities (Refill) .................................................. 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 -
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 Certification Film .................................. 35
Certification 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
Filter ............................................................... 126
Selection of the Oil Change Interval ................ 125
166
Index Section
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 Important Safety Information ................................... 2
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 Identification Number ............ 5
Certified 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 Functional Test...................................................
General Hazard Information .................................. 14
Asbestos Information ......................................... 16
Containing Fluid Spillage ................................... 15
Dispose of Waste Properly ................................ 16
Fluid Penetration................................................ 15
Pressurized Air and Water ................................. 15
Trapped Pressure .............................................. 15
SEBU8480
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
Identification Information ....................................... 33
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 Refill Capacities ............ 87
M
Machine Operation ................................................ 39
Machine Retrieval.................................................. 80
Towing with the Engine Idle ............................... 80
Towing with the Engine Stopped........................ 81
Maintenance Interval Schedule ............................. 95
Maintenance Section ............................................. 86
Maintenance Support ............................................ 93
Mirror (If Equipped)................................................ 42
Mirror Adjustment............................................... 43
Monitoring System................................................. 60
60
Gauge Module (3) .............................................. 61
Indicators (2) ...................................................... 61
Monitoring System Display (4) ........................... 62
Speedometer/Tachometer Module (1) ............... 61
Mounting and Dismounting.................................... 37
Alternate Exit...................................................... 37
SEBU8480
O Roading the Machine............................................. 78
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 Belts ................................................................. 41
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
Certification ........................................................ 34
European Union ................................................. 33
Product Identification 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 Stopping the Engine .............................................. 75
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
Specifications Manuals .................................... 163
Tools................................................................. 163
Reference Materials ............................................ 162
Refrigerant Receiver-Dryer - Replace ................. 152
Restricted Visibility ................................................ 22
167
Index Section
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
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
Specifications ........................................................ 29
Application/Configuration Restrictions ............... 29
Intended Use...................................................... 29
Machine Data..................................................... 29
Starting Motor - Inspect ....................................... 155
Steering Cylinder Bearings - Lubricate................ 155
Steering Frame Lock ............................................. 38
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 Inflation - Check ........................................... 156
Tire Inflation Information........................................ 86
Tire Inflation Pressure ........................................... 86
Tire Inflation Pressure Adjustment ........................ 86
Tire Inflation with Nitrogen ..................................... 86
168 SEBU8480
Index Section

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

Visibility Information............................................... 22

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 identification plate locations, see the section Product Identification Information in the Operation
and Maintenance Manual.

Delivery Date:

Product Information
Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information
Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:
2009 Caterpillar Cat, Caterpillar, their respective logos, Caterpillar Yellow and the Power edge Printed in U.S.A.
All Rights Reserved trade dress, as well as corporate and product identity used herein, are trademarks
of Caterpillar and may not be used without permission.