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Operation and Maintenance Manual: R1300G Load Haul Dump
Operation and Maintenance Manual: R1300G Load Haul Dump
Operation and Maintenance Manual: R1300G Load Haul Dump
SEBU7329-01
December 2003
Operation and
Maintenance
Manual
R1300G Load Haul Dump
LJB1-Up (Machine)
i01658146
Operation .............................................................. 72
Foreword ................................................................. 4
Operating Techniques ........................................... 74
Safety Section Parking .................................................................. 78
Safety Signs and Labels ......................................... 6
Remote Control System ........................................ 81
General Hazard Information ................................. 12
Transportation Information .................................... 88
Crushing Prevention and Cutting Prevention ........ 14
Towing Information ................................................ 91
Burn Prevention .................................................... 15
Adjustments .......................................................... 98
Fire Prevention and Explosion Prevention ............ 15
Maintenance Section
Fire Extinguisher Location .................................... 17
Torque Specifications .......................................... 100
Tire Information ..................................................... 18
Tire Inflation Information ..................................... 103
Electrical Storm Injury Prevention ......................... 18
Lubricant Viscosities and Refill Capacities ......... 104
Mounting and Dismounting ................................... 19
Maintenance Locations ....................................... 107
Before Starting Engine .......................................... 19
Maintenance Interval Schedule .......................... 110
Engine Starting ..................................................... 20
Reference Information Section
Before Operation ................................................... 20
Reference Materials ............................................ 170
Operation .............................................................. 20
Index Section
Engine Stopping ................................................... 21
Index ................................................................... 172
Parking .................................................................. 21
Operation Section
Monitoring Systems and Operator Station
Features .............................................................. 28
Foreword Maintenance
The maintenance section is a guide to equipment
Literature Information care. The Maintenance Interval Schedule (MIS) lists
the items to be maintained at a specific service
This manual should be stored in the operator’s interval. Items without specific intervals are listed
compartment in the literature holder or seat back under the "When Required" service interval. The
literature storage area. Maintenance Interval Schedule lists the page
number for the step-by-step instructions required to
This manual contains safety information, operation accomplish the scheduled maintenance. Use the
instructions, transportation information, lubrication Maintenance Interval Schedule as an index or "one
information and maintenance information. safe source" for all maintenance procedures.
Some photographs or illustrations in this publication
show details or attachments that can be different Maintenance Intervals
from your machine. Guards and covers might have
been removed for illustrative purposes. Use the service hour meter to determine servicing
intervals. Calendar intervals shown (daily, weekly,
Continuing improvement and advancement of monthly, etc.) can be used instead of service hour
product design might have caused changes to your meter intervals if they provide more convenient
machine which are not included in this publication. servicing schedules and approximate the indicated
Read, study and keep this manual with the machine. service hour meter reading. Recommended service
should always be performed at the interval that
Whenever a question arises regarding your occurs first.
machine, or this publication, please consult your
Caterpillar dealer for the latest available information. Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is
specified in the maintenance intervals chart might
Safety be necessary.
The safety section lists basic safety precautions. In Perform service on items at multiples of the original
addition, this section identifies the text and locations requirement. For example, at every 500 service
of warning signs and labels used on the machine. hours or 3 months, also service those items listed
under every 250 service hours or monthly and every
Read and understand the basic precautions listed 10 service hours or daily.
in the safety section before operating or performing
lubrication, maintenance and repair on this machine.
California Proposition 65 Warning
Operation Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
The operation section is a reference for the new birth defects, and other reproductive harm.
operator and a refresher for the experienced
operator. This section includes a discussion of Battery posts, terminals and related accessories
gauges, switches, machine controls, attachment contain lead and lead compounds. Wash hands
controls, transportation and towing information. after handling.
Photographs and illustrations guide the operator
through correct procedures of checking, starting, Certified Engine Maintenance
operating and stopping the machine.
Proper maintenance and repair is essential to
Operating techniques outlined in this publication are keep the engine and machine systems operating
basic. Skill and techniques develop as the operator correctly. As the heavy duty off-road diesel engine
gains knowledge of the machine and its capabilities. owner, you are responsible for the performance
of the required maintenance listed in the Owner
Manual, Operation and Maintenance Manual, and
Service Manual.
5
Foreword
g00751314
Illustration 1
Where:
Safety Section
i01909390
Do Not Operate
g00994954
Illustration 4
g00994953
Illustration 2
g00892002 g00892055
Illustration 5 Illustration 7
Structural damage, an overturn, modification, al- No clearance for person in this area when ma-
teration, or improper repair can impair this struc- chine turns. Severe injury or death from crushing
ture’s protection capability thereby voiding this could occur. Connect steering frame lock between
certification. Do not weld on or drill holes in the front and rear frames before lifting, transporting,
structure. Consult an Elphinstone dealer to deter- or servicing machine in articulation area. Discon-
mine this structure’s limitations without voiding nect lock and secure before resuming operation.
its certification.
No Clearance
g00994956
Illustration 8
g00994955
Illustration 6
g00892146 g00892207
Illustration 9 Illustration 11
Use grab handle not STIC control when entering No clearance for person in operator’s station ac-
or leaving operator’s station. cess area when machine turns. Severe injury or
death from crushing could occur.
Severe injury or death may be caused by crushing
when machine turns Engage transmission/primary steering lock before
leaving the operator’s station.
g00994957
Illustration 10
g00994958
Illustration 12
This safety label is located on the inside of the
operator station door. This safety label is located on both sides of the
lift arm.
9
Safety Section
Safety Signs and Labels
g00892335 g00892476
Illustration 13 Illustration 15
No clearance for person in this area when bucket High Pressure Cylinder!
control group lowers. Severe injury or death from
crushing could occur. Do not remove any valve, hydraulic fitting, or valve
core, nor disassemble any parts until pressure
Install bucket control group safety pins before ser- has been relieved, or personal injury may occur.
vicing machine in this area.
To relieve pressure:
Remove safety pins and secure before resuming
operation. 1. Refer to the Service Manual for the correct
method of dissipating hydraulic system
pressure.
High Pressure Cylinder (Ride
Control) 2. Relieve gas pressure in the accumulator
cylinder by opening the charging valve one
turn only.
g00994959
Illustration 14
g00994960
Illustration 16
10
Safety Section
Safety Signs and Labels
This safety label is located near the brake This safety label is located on the right side of the
accumulator. battery compartment.
g00892403
Illustration 17
To relieve pressure:
g00994961
Illustration 18
11
Safety Section
Safety Signs and Labels
g00994962 g00994963
Illustration 20 Illustration 22
This safety label is located near the cooling system This safety label is located on the brake release
pressure cap. cylinder (if equipped).
g00100414
Illustration 23
g00994964
Illustration 24
g00946835
Illustration 25
Refer to Special Publication, NENG2500, “Tools and • A vacuum cleaner that is equipped with a high
Shop Products Guide” for the following items: efficiency particulate air filter (HEPA) can also be
used.
• Tools that are suitable for collecting fluids and
equipment that is suitable for collecting fluids • Use exhaust ventilation on permanent machining
jobs.
• Tools that are suitable for containing fluids and
equipment that is suitable for containing fluids • Wear an approved respirator if there is no other
way to control the dust.
Obey all local regulations for the disposal of liquids.
• Comply with applicable rules and regulations
for the work place. In the United States, use
Asbestos Information Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”.
g00702022
Illustration 29
Do not work beneath the cab of the machine unless Any contact with hot coolant or with steam
the cab is properly supported. can cause severe burns. Allow cooling system
components to cool before the cooling system is
Unless you are instructed otherwise, never attempt drained.
adjustments while the machine is moving or while
the engine is running. Check the coolant level only after the engine has
been stopped.
Never jump across the starter solenoid terminals
in order to start the engine. Unexpected machine Ensure that the filler cap is cool before removing
movement could result. the filler cap. The filler cap must be cool enough
to touch with a bare hand. Remove the filler cap
Whenever there are equipment control linkages the slowly in order to relieve pressure.
clearance in the linkage area will change with the
movement of the equipment or the machine. Stay Cooling system conditioner contains alkali. Alkali
clear of areas that may have a sudden change in can cause personal injury. Do not allow alkali to
clearance with machine movement or equipment contact the skin, the eyes, or the mouth.
movement.
i01329099
Fire Prevention and Explosion
Burn Prevention Prevention
SMCS Code: 7000
SMCS Code: 7000
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 g00704000
to the engine contain hot coolant. Illustration 31
16
Safety Section
Fire Prevention and Explosion Prevention
g00704135
Illustration 33
i01557411
Servicing tires and rims can be dangerous. Only
trained personnel that use proper tools and proper
Tire Information procedures should perform this maintenance. If
correct procedures are not used for servicing tires
SMCS Code: 7000 and rims, the assemblies could burst with explosive
force. This explosive force can cause serious
Explosions of air inflated tires have resulted from personal injury or death. Carefully obey the specific
heat-induced gas combustion inside the tires. instructions from your tire dealer.
Explosions can be caused by heat that is generated
by welding, by heating rim components, by external
i01122596
fire, or by excessive use of brakes.
g00337832
Illustration 36
(A) At least 15 m (50 ft)
(B) At least 500 m (1500 ft)
i02006130 i01909924
g00037860 g00995248
Illustration 37 Illustration 38
Mount the machine and dismount the machine Make sure the steering frame lock is stored in the
only at locations that have steps and/or handholds. unlocked position as shown. The steering frame
Before you mount the machine, clean the steps and lock must be removed to steer the machine.
the handholds. Inspect the steps and handholds.
Make any necessary repairs. Note: Start the engine only from the operator station.
Never short across the starter terminals or across
Face the machine whenever you mount the machine the batteries. Shorting could bypass the engine
and whenever you dismount the machine. neutral start system. Shorting could also damage
the electrical system.
Maintain a three-point contact with the steps and
with the handholds. Before you mount the machine, perform a
walk around inspection. Look for any damaged
Note: Three-point contact can be two feet and one components and leaks. Report discrepancies and
hand. Three-point contact can also be one foot and make any necessary repairs before operating the
two hands. machine.
Do not mount a moving machine. Do not dismount Reference: For more information, refer to the
a moving machine. Never jump off the machine. Operation and Maintenance Manual, “Walk Around
Do not carry tools or supplies when you try to Inspection” for the machine that is being serviced.
mount the machine or when you try to dismount the
machine. Use a hand line to pull equipment onto When you enter the operator station, inspect the
the platform. Ensure the steering and transmission condition of the seat belt and the condition of the
lock lever is in the LOCKED position when you mounting hardware. Replace any damaged parts
enter the operator compartment or when you exit and any worn parts. Regardless of appearance,
the operator compartment. Do not use any controls replace the seat belt after three years of use. Do not
as handholds. use a seat belt extension on a retractable seat belt.
Alternate Exit Adjust the seat so that full pedal travel can be
achieved when the operator’s back is against the
Machines that are equipped with cabs may have back of the seat.
alternate exits. For additional information on
machines that are equipped with alternate exits, Make sure that the machine is equipped with
see Operation and Maintenance Manual, “Alternate a lighting system that is adequate for the job
Exit”. conditions. Make sure that all lights are working
properly.
Before you maneuver the machine, make sure Turn the battery disconnect switch to the OFF
that no personnel are between the machine and position and remove the engine start switch key.
the trailing equipment. Block up the hitch of the Remove the disconnect switch key if you do not
trailing equipment in order to align the hitch with operate the machine for an extended period of
the drawbar. Maneuver the machine. Connect the time. This will prevent drainage of the battery. A
machine to the trailing equipment. battery short circuit, any current draw from certain
components, and vandalism can cause drainage
Know the maximum dimensions of your machine. of the battery.
Any modifications to the inside of the operator Do not mount items (fire extinguishers, first aid
station should not project into the defined space. kits, work lights, etc) by welding brackets to the
The addition of a radio, fire extinguisher, and other ROPS/FOPS Structure or by drilling holes in the
equipment must be installed so that the defined ROPS/FOPS Structure. Welding brackets or drilling
space is maintained. Any item that is brought into holes in the ROPS/FOPS Structures can weaken
the operator station should not project into the the structures. Consult your Caterpillar dealer for
defined space. A lunch box or other loose items mounting guidelines.
must be secured. Objects must not pose an impact
hazard in rough terrain or in the event of a machine The Tip Over Protection Structure (TOPS) is another
rollover. type of guard that is used on mini hydraulic
excavators. This structure protects the operator in
the event of a tipover. The same guidelines for the
i01992325
inspection, the maintenance and the modification of
Guards the ROPS/FOPS Structure are required for the Tip
Over Protection Structure.
(Operator Protection)
SMCS Code: 7000; 7150; 7325 Other Guards (If Equipped)
Protection from flying objects and/or falling objects
There are different types of guards that are used to
protect the operator. The machine and the machine is required for special applications. Logging
application determines the type of guard that should applications and demolition applications are two
examples that require special protection.
be used.
A daily inspection of the guards is required in order A front guard needs to be installed when a work
tool that creates flying objects is used. Mesh
to check for structures that are bent, cracked or
loose. Never operate a machine with a damaged front guards that are approved by Caterpillar or
structure. polycarbonate front guards that are approved by
Caterpillar are available for machines with a cab or
an open canopy. On machines that are equipped
The operator becomes exposed to a hazardous
situation if the machine is used improperly or if poor with cabs, the windshield should also be closed.
Safety glasses are recommended when flying
operating techniques are used. This situation can
hazards exist for machines with cabs and machines
occur even though a machine is equipped with an
appropriate protective guard. Follow the established with open canopies.
operating procedures that are recommended for
If the work material extends above the cab, top
your machine.
guards and front guards should be used. Typical
examples of this type of application are listed below:
Rollover Protective Structure
(ROPS), Falling Object Protective • Demolition applications
Structure (FOPS) or Tip Over • Rock quarries
Protection Structure (TOPS)
• Forestry products
The ROPS/FOPS Structure (if equipped) on your
machine is specifically designed, tested and Additional guards may be required for specific
certified for that machine. Excavators are not applications or work tools. The Operation and
equipped with ROPS structures. Any alteration or Maintenance Manual for your machine or your
any modification to the ROPS/FOPS Structure could work tool will provide specific requirements for the
weaken the structure. This places the operator guards. Consult your Caterpillar dealer for additional
into an unprotected environment. Modifications or information.
attachments that cause the machine to exceed
the weight that is stamped on the certification
plate also place the operator into an unprotected
environment. Excessive weight may inhibit the
brake performance, the steering performance
and the ROPS. The protection that is offered by
the ROPS/FOPS Structure will be impaired if the
ROPS/FOPS Structure has structural damage.
Damage to the structure can be caused by an
overturn, a falling object, a collision, etc.
23
Product Information Section
General Information
Product Information
Section
General Information
i01774750
NOTICE
Do NOT use electrical components (ECM or ECM sen-
sors) or electronic component grounding points for
grounding the welder.
g00995253
Illustration 42
(12) Operator station
(13) Final drives
g00995250
Illustration 40
(1) Engine compartment
(2) Transmission compartment
(3) Battery compartment
(4) Bucket control group safety pin
(5) Lift arm
(6) Fuel tank
g00995254
Illustration 43
(14) Radiator
i01911196
• proper lubricants
• full fuel tank
• enclosed ROPS
• 75 kg (165 lb) operator
• 17.5x25 20PR L-5 tires or equivalent for the
R1300G Load Haul Dump
g00995560
Illustration 44
Dimension (A) represents the dump clearance. Dimension (B) represents the reach.
i01911206
g00995572
Illustration 47
g00995570
Illustration 45
Machine PIN_________________________________________________
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.
g00995577
Illustration 48
g00995579
Illustration 49
i01911209 i01912408
g00995582 g00995855
Illustration 50 Illustration 52
Illustration 51
g00995583 Note: The front lights, the rear lights, and the dome
lamp can be turned on when the engine start switch
Engine shutdown switch (1) is located on the right is in the OFF position.
rear side of the machine.
ON Position (3) – To activate the electrical
Engine Shutdown Switch (1) – Use engine circuits in the operator station, turn the
shutdown switch (1) in order to stop the engine start switch key clockwise to the
engine from the ground level. In order to ON position.
use engine shutdown switch (1), push the engine
shutdown switch knob in to the OFF position. This START Position (4) – To start the engine,
will stop the engine. After the engine stops, turn the turn the engine start switch clockwise to
knob clockwise. This will reset the engine shutdown the START position. When the engine start
switch to the ON position. switch key is released, the engine start switch will
return to the ON position.
During normal operation, use the engine start switch
to stop the engine. Note: If the engine fails to start, return the engine
start switch to the OFF position. This must be done
Note: The engine shutdown switch (1) does not before you attempt to start the engine again.
deactivate the machine’s electrical system.
30
Operation Section
Monitoring Systems and Operator Station Features
i01912411
g00995858
Illustration 53
NOTICE
Never turn the battery disconnect switch to the OFF
position with the idle timer activated (engine running).
Electrical system damage could result.
31
Operation Section
Monitoring Systems and Operator Station Features
Warning Operation
Table 3
Warning Operation
Warning Indications(1)
Alert Indicator
Warning Flashes(3) or Required Action from
Action Lamp The Action Possible Result(2)
Category a Gauge will the Operator
Flashes(4) Alarm Sounds
Show in the Red
Range
Warning Categories
The monitoring system provides three warning
categories. The first category requires only operator
awareness. The second warning category requires
the operation of the machine or the maintenance
procedure for the machine to be changed. The
third warning category requires immediate safe
shutdown of the machine.
Warning Category 1
In this category, only the appropriate alert indicators
will flash. The alert indicator informs the operator
that a machine system needs attention. The Illustration 55
g00995863
condition of the machine system should not
endanger the operator. Also, the condition of the Parking Brake (1) – Indicates the parking
machine system should not damage the machine. brake is engaged and the transmission
is in NEUTRAL. The alert indicator should
flash during start-up. It should go out when the
parking brake is disengaged.
Low idle must be corrected. Adjust the low idle Warning Category 2
setting to the high side of low idle when the most
common electrical loads are turned on. Reducing In this category, one of the following conditions will
loads will also help. Use the medium fan speed occur:
instead of the high fan speed.
• An alert indicator and the action lamp will flash.
If this procedure does not cause the alert indicator
to turn off, stop the machine and investigate the • A gauge will show in the red range and the action
cause of the fault. The fault may be caused by an lamp will flash.
alternator belt that is loose or broken. Also, the
batteries may be faulty. This warns the operator that a change in machine
operation is required in order to reduce excessive
If the light remains on near normal operating speeds temperature in one or more of the systems. Move
and with light electrical loads, stop the machine and the machine to a convenient place in order to park
investigate the cause of the fault. The fault may be the machine and stop the engine. Investigate the
caused by an alternator belt that is loose or broken. cause of the alert indicator or the gauge and report
Also, the batteries or the alternator may be faulty. the problem immediately.
Maintenance Required (3) (Not Used)
g00995865
Illustration 57
g00995864
Illustration 56
33
Operation Section
Monitoring Systems and Operator Station Features
Gauges
SMCS Code: 7450
g01003592
Illustration 61
g00996204
Illustration 60
Fuel Level (4) – Indicates the amount of Rear Brake Oil Pressure Gauge (9) (If Equipped) –
fuel remaining in the fuel tank. Shows the hydraulic pressure in the rear braking
circuit when the service brakes are fully applied. The
rear brake oil pressure should be 6890 ± 345 kPa
(1000 ± 50 psi).
Tachometer (5) – The tachometer displays the
engine speed during machine operation.
35
Operation Section
Monitoring Systems and Operator Station Features
g00996208
Illustration 64
g00996210
Illustration 66
i01912942
Residual Brake Oil Pressure Indicator (5)
(If Equipped) – Indicates that there is oil Light Switches
pressure in the service brake section of
the wheel brakes. The lamp will illuminate when the SMCS Code: 1429-ZS; 7451
service brakes are applied. The lamp should go
out when the brakes are released. If this indicator
stays on, the brakes are holding residual brake oil
pressure. Stop the machine and investigate the
cause.
g00996212
Illustration 67
g00949389
Illustration 68
i01912945 i01913517
g00996553 g00996559
Illustration 69 Illustration 70
Front Window Wiper and Washer Switch Remote Control Switch (If Equipped) –
(1) – Turn the knob clockwise to turn on Move the switch to the upper position to
the front window wiper. Push the knob to activate the remote control system.
activate the window washer. Spring force will return
the knob when released. Reference: For more information about the remote
control operating instructions, refer to the Operation
Side Window Wiper and Washer Switch and Maintenance Manual, “Remote Control System”
(2) – Turn the knob clockwise to turn on for the machine that is being serviced.
the side window wiper. Push the knob to
activate the window washer. Spring force will return
the knob when released.
Personal injury or machine damage can result if
Rear Window Wiper and Washer Switch the remote control switch is turned on while man-
(3) – Turn the knob clockwise to turn on ually operating the machine. If the remote control
the rear window wiper. Push the knob to switch is turned on during manual operation, the
activate the window washer. Spring force will return engine will shut down and the brakes will apply.
the knob when released.
i01913520
g00996564
Illustration 73
g00996563
Illustration 72
39
Operation Section
Monitoring Systems and Operator Station Features
g00996571
Illustration 74
g00996574
Illustration 77
g00996572
Illustration 75
Operator Modes
g00996575
Illustration 78
g00996573
Illustration 76
40
Operation Section
Monitoring Systems and Operator Station Features
i01913532
Service Ports
SMCS Code: 0350
g00996576
Illustration 79
i01913533 i01913534
g01003597 g00995561
Illustration 81 Illustration 82
Horn – Push the horn button in order Backup Alarm – The backup alarm will
to sound the horn. Use the horn button sound when the transmission direction and
for alerting personnel or for signalling speed control is in the REVERSE position.
personnel. The backup alarm warns personnel behind the
machine that the machine is backing up.
g00896957
Illustration 83
g00100709
Illustration 86
g01003601
Illustration 85
1. Unfasten the seat belt.
Fore and Aft Lever (1) – Pull up fore and
aft lever (1). 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.
g00100713 g00100717
Illustration 88 Illustration 90
1. Fasten the seat belt. Pull out on the outer belt Pull up on the release lever. This will release the
loop in order to tighten the seat belt. seat belt.
g00867598
Illustration 91
Alternate Exit
SMCS Code: 7310
Push the release button on the buckle in order to In order to exit the operator station through the rear
release the seat belt. The seat belt will automatically window, exert outwards pressure on the window
retract into the retractor. until the window separates from the operator station
frame.
Extension of the Seat Belt
g01003607
Longer, non-retractable seat belts and extensions Illustration 93
for the non-retractable seat belts are available.
In order to remove the rear window from outside
Caterpillar requires only non-retractable seat belts the operator station, pull on the locking strip tab to
to be used with a seat belt extension. remove the locking strip. Exert inwards pressure
on the window until it separates from the operator
Consult your Caterpillar dealer for longer seat belts station frame.
and for information on extending the seat belts.
In order to install the window and seal, contact your
Caterpillar dealer for the correct sealing method.
46
Operation Section
Machine Controls and Operation
Braking
SMCS Code: 4250; 4251; 4267; 4278; 4284
Parking Brake
This machine is equipped with spring applied
parking brakes. The spring force engages the g01003609
Illustration 94
brakes on all four wheels. Hydraulic pressure is
used to disengage the brakes. If the hydraulic
pressure is unavailable, the brakes will remain Loss of brake oil pressure will cause the action
engaged. alarm to sound, action lamp (3) and brake
accumulator oil pressure indicator (2) to flash.
If hydraulic pressure is unavailable and the machine Further loss of oil pressure will cause parking brake
must be towed, use the 1DE3048 Portable Hydraulic indicator (1) to come on and the parking brake will
Pump in order to release the parking brake. automatically engage to stop the machine.
Reference: For further information on towing an Note: If the machine was started with the parking
inoperable machine, consult your Caterpillar dealer brake control in the OFF position, reset the control
or refer to Operation and Maintenance Manual, by moving it to the ON position and then to the OFF
“Towing Information” for the machine that is being position before the parking brake will disengage.
serviced.
NOTICE
The standard parking brake control is a pull-to-engage
type. When the knob is pulled OUT, the parking brake
Personal injury could result from the sudden stop will be engaged.
of the machine. The parking brake is automatically
engaged when brake oil pressure drops below an Certain mining regulations require machines to be
adequate operating pressure. equipped with a push-to-engage parking brake con-
trol. When the knob is pushed IN, the parking brake
If the brake system oil pressure drops below is engaged.
normal operating pressure, the action alarm will
sound. The brake oil pressure indicator and the Before operating the machine, ensure you are familiar
action lamp will start flashing. with the operation of the parking brake control.
g00996201
Illustration 95
47
Operation Section
Machine Controls and Operation
i01929767
Direction Selection
g01003921
Illustration 103
2 – Second Speed
3 – Third Speed
4 – Fourth Speed
g01004251
Illustration 105
Throttle Pedal – The throttle pedal is located on the The STIC steering control lever must be moved
floor of the operator station. past center in the opposite direction to which the
machine was turning to return to straight ahead
Depressing the Throttle Control – Depress travel.
the throttle pedal in order to increase the
engine speed.
NOTICE
This machine is equipped with an Engine Shutdown to
Idle Protection System that will shut the engine down
to idle if a major engine fault occurs.
i01930333
LOWER (2) – Push the lever forward to
Joystick Control lower the bucket. The lever will return to
the HOLD position when released.
SMCS Code: 5063; 6107
Note: The joystick control functions will be RAISE (3) – Pull the lever back to raise
disabled when the operator station door is opened the bucket. The lever will return to the
approximately 150 mm (6 inch). Ensure the operator HOLD position when released.
station door is firmly closed before operating the
machine. DUMP (4) – Push the lever across to the
right to dump the bucket. The lever will
NOTICE return to the HOLD position when released.
The standard joystick control lever is a pull-back-to-
raise, push-forward-to-lower type. TILT BACK (5) – Pull the lever across to
the left to tilt the bucket back. The lever
Certain mining regulations require machines to be will return to the HOLD position when
equipped with a push-right-to-raise, pull-left-to-lower released.
type.
HOLD (6) – The lever will return to
Before operating the machine, ensure you are familiar
the HOLD position automatically when
with the operation of the type of joystick control lever
released. The bucket will remain in the
on your machine.
selected position when in the HOLD position.
Illustration 108
g01004271 Joystick Control Lever - Optional
Type
The joystick control lever performs the following
functions:
NOTICE
Never use the FLOAT position to lower a loaded buck-
et.
Machine damage can result from a bucket that falls Illustration 109 g01004272
too fast.
53
Operation Section
Machine Controls and Operation
HOLD (6) – The lever will return to “CLEAR” key (1) – Use the “CLEAR” key in order to
the HOLD position automatically when exit from a function, or use the "CLEAR" key in order
released. The bucket will remain in the to erase an entry.
selected position when in the HOLD position.
“STORE” key (3) – Use the “STORE” key in order to
store payload data. Use the “STORE” key in order
EJECT EJECTOR BUCKET (A4) –
to make a selection from a menu. Use the “STORE”
Depress and hold the left side of switch key in order to enter a number.
(A) while pushing the lever across to the
DUMP position. This will cause the ejector bucket
“SCROLL” key (5) – Use the “SCROLL” key in order
to eject the load. The lever will return to the HOLD to move through options of a menu.
position when released.
“NEXT FUNCTION” key (6) – Use the “NEXT
RETRACT EJECTOR BUCKET (A5) – FUNCTION” key in the setup, service and calibration
Depress and hold the left side of switch modes.
(A) while pulling the lever across to the
TILT BACK position. This will cause the ejector
plate to retract into the ejector bucket. The lever Measuring the Load of a Bucket on
will return to the HOLD position automatically when the Go
released. The lever will return to the HOLD position
when released. 1. Push “CLEAR” key (1) in order to set display (7)
at zero.
• Keep the bucket in a fully tilted back position. • Adjust the bucket into the fully tilted back
position.
• Raise the load at steady rate.
• Raise the lift arms slightly.
• Keep the engine speed high when the load is
lifted for the greatest accuracy. • Press “REW” key (2).
• Operate the lift arms smoothly and avoid • The machine and lift arms must be kept
sudden stops or jerky motion. stationary while the measurement is performed.
Note: Display (7) will show “WEIGH” as the system • If the total load of the truck is too large, then
measures the load. When the measurement is repeat the above steps.
complete, the top row of the display shows the
weight of the bucket. The bottom row of the display 3. Dump the load into the truck and press the
shows the total weight for the current truck. If “STORE” key (3).
the “REW” indicator comes on then the load was
incorrectly measured. Either the lift arms were not
raised smoothly, or the engine speed was not above
Using the “EXC” Key
1/2 maximum speed. Press “REW” key (2) and 1. Approach the truck as the measurement of the
measure the load again.
last load is performed.
3. Dump the load into the truck. Repeat the above 2. If display (7) shows that the total load of the
steps until the truck is loaded.
truck is too large, then perform the following
procedures:
4. Push “STORE” key (3) in order to save the
payload data in the memory. Display (7) will reset
automatically. The payload display is ready for • Dump some material into the truck.
a new truck.
• Adjust the bucket into the fully tilted back
position.
Measuring the Load of a Bucket in
the Stationary Position • Raise the lift arms slightly.
Measure the load of the bucket in a stationary • The machine and lift arms must be kept
stationary while the measurement is performed.
position. Adjust the final load of the bucket in order
to attain the correct load of the truck.
• Press “EXC” key (4) in order to measure the
addition of material to the total of the truck.
After measuring the final load of the bucket, the
total load of the truck may be too large. One of two
steps can be performed. • Display (7) will update the total load of the
truck automatically.
• Dump partial loads back into the pile and use
“REW” key. • If the total load of the truck is not large enough,
then repeat the above steps.
• Dump partial loads into the truck and use “EXC” 3. Press “STORE” key (3) and dump the excess
key.
material back into the pile.
The system will calculate the new load of the truck
automatically. Additional Features
Using the “REW” Key Reference: More complete information is available
from your Caterpillar dealer. Refer to the Operation
and Maintenance Manual, SEBU7012, “Payload
1. Remain at the pile as the measurement of the
last load is performed. Control System” for additional features.
i01911184
g01004894
Illustration 113
Note: During normal operation use the engine start 6. If possible, turn the battery disconnect switch to
switch to shutdown the engine. the OFF position.
System Reset Button (3) – This button 7. Notify the appropriate mine personnel.
is used to override the fire suppression
control so that the machine can be moved 8. Stand by (at a safe distance) with a portable fire
after discharge of the fire suppression system and extinguisher.
loss of system pressure.
Note: Stand by with a portable fire extinguisher to
The “SYSTEM RESET” button must be held in for guard against any fire that may reignite after the fire
the engine to operate. Upon release, the engine will suppression system has discharged. Remain alert
shutdown after six seconds. until the possibility of reignition is past.
Fire Suppression Control Detection Fault (Yellow) (5) – This indicator and the
audio sounder will pulse once every ten seconds
(Automatic) when the fire suppression control detects a fault in
the detection circuit. The fire suppression control will
return to normal when the fault condition is cleared.
g00899282
6. If possible, turn the battery disconnect switch to
Illustration 115 the OFF position.
Typical example
7. Notify the appropriate mine personnel.
NOTICE
If the fire suppression system has been activated, the
system must be flushed and recharged. Have the ma-
chine cleaned, inspected and repaired before return-
Illustration 116
g00899283 ing the machine to operation.
Typical example
NOTICE
Before operating the machine, be sure the bucket
control group safety pins are removed and put in the
stored position. Damage to the front frame and to the
lift arm can result if the machine is operated with the
bucket control group safety pins installed in the lift
arm.
g01004614
Illustration 119
3. Raise lift arm (1) until the safety pin bore can be
aligned with the front frame tower.
g01004598
Illustration 118
4. Remove the safety pins from the stored position.
Remove the steering frame lock before the machine Fully insert each safety pin (2) into the bores
is operated. Remove pin (1) from the bores of the of the lift arm on each side of the machine, as
front and rear frames and install the pin in the shown.
stored position, as shown.
5. Lower the lift arm until the safety pins contact
the front frame tower.
i01930913
Bucket Control Group Safety 6. Move the bucket to the fully dumped position.
Pins Note: The following steps are for the removal of the
bucket control group safety pins.
SMCS Code: 7507
7. Raise lift arm (1) until the safety pins are above
both sides of the front frame tower.
g01004615
Illustration 120
Walk-Around Inspection
SMCS Code: 1000; 7000
• loose bolts
• trash buildup
• oil, coolant, or fuel leaks
• broken parts or worn parts
• cracks in the frames
Remove any trash and any debris. Report any
abnormalities to the shop. Make any necessary
repairs before you operate the machine.
g01004250
Illustration 121
Inspection points for the walk-around inspection
(A) Frame (I) Steering frame lock (P) Radiator
(B) Left front tire (J) Right rear tire (Q) Rear lights
(C) Front lights (K) Air cleaner (R) Powertrain
(D) Bucket and linkage (L) Engine (S) Left rear tire
(E) Right front tire (M) Fuel tank (T) Windows
(F) Steering cylinder (N) Automatic lubrication reservoir (if
(G) Window washer bottle equipped)
(H) Hydraulic tank (O) Ground level controls
(B) Inspect the left front tire. Check the tire inflation.
Make sure that you check the inside of the tire
for damage or for wear. Inspect the tire treads
for damage. Remove large rocks from the
treads. Check the wheel for nuts and washers
that are loose or missing.
(D) Inspect the bucket and linkage for damage or (M) Inspect the fuel tank. Make sure that the filler
for excessive wear. cap is installed correctly. Look for any leaks or
damage to the fuel tank.
(E) Repeat procedure (B) for the right front tire.
(N) Inspect the automatic lubrication reservoir (if
(F) Inspect the steering cylinder. Look for leaks, equipped) for leaks.
cracking, or marks on the chrome. Inspect the
articulating hitch. (O) Inspect the ground level controls. Make sure
that the engine shutdown switch and the battery
disconnect switch are in the ON position.
g01004275
Illustration 123
(I) Check that the steering frame lock is not (R) Inspect the power train. Use dipstick (7) to
installed. The machine will not steer if the check the transmission oil level when the engine
steering frame lock is installed. is running at low idle. Check for leaks from the
torque converter and from the transmission.
(J) Repeat procedure (B) for the right rear tire.
(S) Repeat procedure (B) for the left rear tire.
(K) Inspect the air cleaner. Remove debris that may
obstruct the air cleaner. (T) Make sure that all of the windows are clean.
Make sure that the operator’s vision is not
impaired by dust, mud, or other foreign
materials.
g01004276
Illustration 124
i01618562 i01930928
g00037860
Illustration 126
Face the machine whenever you mount the machine Illustration 127
g01004634
and whenever you dismount the machine. Maintain
a three-point contact with the step and with Note: Adjust the seat at the beginning of each
handholds. shift or adjust the seat when there is a change of
operators.
Note: Three-point contact can be two feet and one
hand. Three-point contact can also be one foot and When the operator is seated against the back of
two hands. the seat, adjust the seat in order to allow full pedal
travel. The operator may adjust the seat forward or
Do not mount a moving machine. Do not dismount backward.
a moving machine. Never jump off the machine. Do
not try to mount the machine when you carry tools Inspect the belt mounting hardware. If the hardware
or supplies. Do not try to dismount the machine is damaged or worn, replace the hardware. Keep
when you are carrying tools or supplies. Use a the mounting bolts tight.
hand line to pull equipment onto the platform. Do
not use any controls as handholds when you enter Fasten the seat belt before you start the engine.
the cab or when you exit the cab.
Reference: For further information on the seat
and the seat belt, refer to the Operation and
Maintenance Manual, “Seat, Seat Belt” for the
machine that is being serviced.
65
Operation Section
Before Starting Engine
Engine Starting
i01931633
Always start and operate the engine in a well ven- Illustration 131 g01004897
tilated area, and, if in an enclosed area, vent the
exhaust to the outside. 6. Move joystick control lever (3) to the HOLD
position.
1. 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.
Note: Before you start the engine, wait for the self
test of the Caterpillar Monitoring System. The self
test will activate when the engine start switch is
turned to the ON position. g01004898
Illustration 132
Reference: Refer to the Operation and
Maintenance Manual, “Caterpillar Monitoring 7. Move parking brake control (4) to the ON position
System - Self Test” in this section for further to engage the parking brake.
information.
8. Sound the horn.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
i01931949
NOTICE
Engine Starting with Jump When starting from another machine, make sure that
Start Cables the machines do not touch. This could prevent dam-
age to engine bearings and electrical circuits.
SMCS Code: 1000; 1401; 7000
Turn on (close) the battery disconnect switch prior to
the boost connection to prevent damage to electrical
components on the stalled machine.
Failure to properly service the batteries may cause Severely discharged maintenance free batteries do
personal injury. not fully recharge from the alternator after jump start-
ing. The batteries must be charged to proper voltage
Prevent sparks near the batteries. They could with a battery charger. Many batteries thought to be
cause vapors to explode. Do not allow the jump unusable are still rechargeable.
start cable ends to contact each other or the
machine. This machine has a 24 volt starting system. Use only
the same voltage for jump starting. Use of a higher
Do not smoke when checking battery electrolyte voltage damages the electrical system.
levels.
Refer to Special Instruction, Battery Test Procedure,
Electrolyte is an acid and can cause personal in- SEHS7633, available from your Caterpillar dealer, for
jury if it contacts the skin or eyes. complete testing and charging information.
Always wear eye protection when starting a ma-
chine with jump start cables. Reference: Refer to Special Instruction, SEHS7633,
“Battery Test Procedure” available from your
Improper jump start procedures can cause an ex- Caterpillar dealer, for complete testing and charging
plosion resulting in personal injury. information.
When using jumper cables, always connect the Use of Jump Start Cables
positive (+) jumper cable to the positive (+) bat-
tery terminal first. Next, connect the negative (-) If the machine is equipped with an auxiliary start
jumper cable to the frame away from the batteries. receptacle, use the auxiliary start receptacle. When
Follow the procedure in the Operation and Main- the auxiliary start receptacle is not available, use
tenance Manual. the following procedure.
Jump start only with an energy source of the same Reference: Refer to the Operation and Maintenance
voltage as the stalled machine. Manual, “Engine Starting with Auxiliary Start
Receptacle” for further information.
Turn off all lights and accessories on the stalled
machine. Otherwise, they will operate when the 1. Use 6V-2150 Starting and Charging Analyzer in
energy source is connected. order to determine the cause of the failure of
the engine to start. Refer to Special Instruction,
SEHS776, 8, “Use of a 6V-2150 Starting/Charger
Analyzer Group” for further information. Use
this procedure if the machine does not have a
diagnostic connector.
5. Move the machines together in order for 15. Attempt to start the stalled engine.
the cables to reach. DO NOT ALLOW THE
MACHINES TO CONTACT EACH OTHER. Reference: Refer to the Operation and
Maintenance Manual, “Engine Starting” for the
6. Stop the engine on the machine that is being machine that is being serviced.
used as the electrical source. If you are using
an auxiliary power source, turn off the charging 16. Immediately after the stalled engine starts,
system. disconnect the jump start cables in reverse order.
i01931950
10. Connect the positive jump start cable to the Some Caterpillar products may be equipped with
positive terminal of the electrical source. Use the auxiliary start receptacles as standard. All other
procedure from Step 9 to determine the correct machines can be equipped with a receptacle from
terminal. parts service. Then, a permanent receptacle is
always available for jump starting.
11. Connect one end of the negative jump start
cable to the negative terminal of the electrical There are two cable assemblies that can be used
source. to jump start the stalled machine. You can jump the
machine from another machine that is equipped
12. Make the final connection. Connect the negative with this receptacle or an auxiliary power pack. Your
cable to the frame of the stalled machine. Make Caterpillar dealer can provide the correct cable
this connection away from the battery, the fuel, lengths for your application.
the hydraulic lines, or moving parts.
1. Determine the reason that the engine will not
13. Start the engine on the machine that is the start. Refer to Special Instruction, SEHS7768,
electrical source. Also, you can energize the “Use of a 6V-2150 Starting/Charger Analyzer
charging system on the auxiliary power source. Group” for further information. Use this procedure
if the machine does not have a diagnostic
14. Allow the electrical source to charge the connector.
batteries for two minutes.
70
Operation Section
Engine Starting
Operation
i01931952
• Before you disengage the parking brake, depress 6. Move parking brake control (2) to the OFF
the service brake pedal in order to keep the position to disengage the parking brake.
machine from moving.
g01005086
Illustration 138
i01759577
Operating Techniques
i01932034
Operating Technique
Information
SMCS Code: 7000
g00942665
Illustration 142
Typical example
g00942662
Illustration 140
Typical example
g00942667
Illustration 143
Typical example
g00942663
Illustration 141
Typical example
i01932035
g00942707
Illustration 146
Typical example
g01005152
Illustration 147
g00942662
Illustration 148
Typical example
76
Operation Section
Operating Techniques
g00942712
Illustration 151
Typical example
NOTICE
Striking the stops unnecessarily and repetitively can
result in accelerated wear and high maintenance cost
of the loader linkage.
g01005151
Illustration 149
i01932036
7. When you reach the dump area, move the
joystick control lever to the RAISE position. Bucket Loading Hauling Units
SMCS Code: 7000
g01005153
Illustration 150
8. When at the correct height, move the joystick Illustration 152 g00942731
control lever to the DUMP position. Typical example
9. To control dumping, move the joystick control 1. To reduce the loader turning and the travel
lever to the DUMP position. Then, return the lever distance, position the hauling unit at an angle to
to the HOLD position. Repeat this procedure the material that is being loaded (if possible).
until the bucket is empty.
2. The optimum travel distance should be long
enough so that the bucket can reach the
lift height without slowing the movement of
the loader. This may vary due to specific
underground loading areas.
77
Operation Section
Operating Techniques
g01005152
Illustration 155
g00942733
Illustration 154
Typical example
NOTICE
Striking the stops unnecessarily and repetitively can
result in accelerated wear and high maintenance cost
of the loader linkage.
78
Operation Section
Parking
Parking
i01931964
If the parking brake is not engaged, the machine Illustration 157 g01005128
may roll while personnel are on or near the ma-
chine. 3. Move transmission direction control switch (3)
to the NEUTRAL position. Move steering and
Always engage the parking brake before leaving transmission lock lever (4) to the LOCKED
the machine. position.
NOTICE
Do not engage the parking brake while the machine is
moving unless the service brakes fail. The use of the
parking brake as a service brake in regular operation g01005129
Illustration 158
will cause severe damage to the parking brake.
4. Move parking brake control (5) to the ON position
1. Park the machine on a level surface. If it is in order to engage the parking brake.
necessary to park on a grade, block the wheels.
5. Lower the bucket to the ground and apply a
slight downward pressure.
g01005126
Illustration 156
i01931968 i01931969
NOTICE
Stopping the engine immediately after it has been
working under load can result in overheating and ac-
celerated wear of the engine components.
i01761956
i01761975
g00901356
Illustration 161
NOTICE
Never turn the battery disconnect switch key to OFF
with the engine running. Electrical system damage
could result.
81
Operation Section
Remote Control System
Remote Control System Motion Control Lever – This lever is used to control
the machine forward/reverse direction, directional
steering, engine throttle selection and to apply the
i01762006 brakes.
This section contains basic operating procedures Forward (1) – Push the motion control lever forward
for the Caterpillar Elphinstone remote control to move the machine in a forward direction.
system. There are two types of systems available on
Caterpillar Elphinstone Load Haul Dump machines, Reverse (2) – Pull the motion control lever back to
the DIRECT system and the PROPORTIONAL move the machine in a reverse direction.
system.
Left Turn (3) – Move the motion control lever to the
These basic operations are for the Control Master left to steer the machine in a left direction.
transmitter and receiver. Other brands of transmitter
and receiver may be used with the Caterpillar Right Turn (4) – Move the motion control lever to the
Elphinstone remote control interface. right to steer the machine in a right direction.
For more information on the type of transmitter Brake Control (Proportional System) – The brakes
and receiver for your machine, refer to the will release when the motion control lever is moved
manufacturer’s instructions or contact the supplier to the FORWARD position or to the REVERSE
of the transmitter and receiver. position. The brakes will apply when the motion
control lever is returned to the center position. The
i01931955
lever will return to the center position when released.
g00901537
Illustration 162
82
Operation Section
Remote Control System
g00901395 g00901401
Illustration 164 Illustration 166
Bucket Control Lever – This lever is used to control Lower RPM Switch (10) (Direct System) – Press and
the bucket functions of the machine. hold this switch to activate the part throttle function.
The engine speed should increase to a preset
speed which is approximately 1/2 the maximum
engine rpm.
Note: The remote shutdown switch can be used to Before using the machine on remote control do
stop the machine in an emergency. If the remote a walk around inspection. Check levels of oil and
shutdown switch is pressed while the machine is water and check for leaks and damage.
operating on remote control, the machine brakes
will apply, the transmission will select neutral, and Operate the machine manually to ensure that all
the engine will shutdown. controls operate normally and the brakes operate
effectively.
Engine Stop Switch (17) – Press the spring return
switch up to shut the engine off. Always ensure no personnel are near the machine
or in the area where the machine will be operating
Engine Pre-heat/Override Switch (18) – Not used. while it is on remote control.
Park Brake Switch (19) – Push the switch up to Under no circumstances should any service work or
engage the parking brake. No moving functions will testing and adjusting be carried out on the machine
operate when the park brake switch is in the ON while the machine is operating on remote control.
position.
1. Park the machine in a convenient and safe
Note: The park brake switch is also the reset switch location to start remote control operation.
for the remote control receiver. When the receiver
is locked out either by an emergency stop, loss 2. Move the transmission direction and speed
of signal, tilt switch activated or initial power up, control to the NEUTRAL position. Move the
the park brake switch must be moved to the ON steering and transmission lock control to the
position. locked position.
84
Operation Section
Remote Control System
NOTICE
The transmission direction and speed control must be
in the NEUTRAL position.
g01005100
Illustration 168
g00901748
Illustration 171
g00901819
Illustration 172
2. Disengage the parking brake by moving park 6. The machine can now be operated on remote
brake switch (3) down to the OFF position. control from the transmitter.
3. Switch the lights ON if required and raise the
bucket to the carry position, approximately i01931962
400 mm (15 inch) above the ground.
Parking (Remote Control)
4. Direct System - Move motion control lever (1) to
the desired direction and select either full throttle SMCS Code: 7600-ZM
or part throttle to move the machine. The motion
control lever has to be in either the FORWARD
position or the REVERSE position and either part
throttle or full throttle positions selected before
the brakes will release. The brakes will apply
when the motion control lever is returned to the
center position. The lever will return to the center
position when released.
g00901851
Illustration 174
86
Operation Section
Remote Control System
NOTICE
Stopping the engine immediately after it has been
working under load can result in overheating and ac-
celerated wear of the engine components.
g01005123
Illustration 175
i01778443 i02009352
There are three ways to stop the machine in an The remote control system has an inbuilt protection
emergency: system to safeguard the machine against accidental
damage. If the receiver loses communication with
the transmitter, the transmitter tilt switch is activated,
or a power loss or fault occurs to the transmitter,
receiver, or remote control interface, the following
forced shutdown will occur:
NOTICE
Obey all state and local laws governing the weight,
width and length of a load.
g00901921
Illustration 177
i01762989
i01931965
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.
90
Operation Section
Transportation Information
g01005130
Illustration 178
Towing Information Before you tow the machine, inspect the condition
the tow line or of the tow bar. Make sure that the
tow line or the tow bar is sturdy enough to tow the
i01931622 disabled machine. The tow line or the tow bar must
have a strength that is equal to 1.5 times the gross
Towing the Machine weight of the machine that is being towed. Use
a tow bar with this strength or a tow line with this
SMCS Code: 7000 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.
Personal injury or death could result when towing
a disabled machine incorrectly. Do not use a chain for pulling. A chain link may
break. This can cause personal injury. Use a wire
Block the machine to prevent movement before rope cable with cable loops or end rings. Position
releasing the brakes. The machine can roll free if an observer at a safe location. The observer should
it is not blocked. 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
In order to properly perform the towing procedure, the pulling procedure.
use the following recommendations.
Keep the tow line angle to a minimum. Do not
This machine is equipped with spring applied exceed a 30 degree angle from the straight ahead
parking brakes that are released by oil pressure. If position.
the engine is inoperable or if the brake oil system is
inoperable, the parking brakes are engaged. The Quick machine movement could overload the tow
machine can not be moved. line or the tow bar. This could cause the tow line
or the tow bar to break. Gradual, smooth machine
The parking brake can be disengaged manually in movement will be more effective.
the event of insufficient oil pressure in the system.
Normally, the towing machine should be as large as
Reference: For additional information, refer to the the disabled machine. The towing machine must
Operation and Maintenance Manual, “Parking Brake have enough brake capacity, enough weight, and
Manual Release” for the machine that is being enough power for the grade that is involved and for
serviced. the distance that is involved.
Use these towing instructions for moving a disabled It may be necessary to connect a larger machine
machine over a short distance. Do not move the or additional machines to the disabled machine
machine faster than 2 km/h (1.2 mph). Move the in order to provide sufficient control and sufficient
machine to a convenient location for repair. Use braking. This will prevent the disabled machine from
these instructions for emergency situations only. rolling away out of control on a downgrade.
Always haul the machine if long distance moving
is required. The requirements for all different situations cannot
be specified. Minimal towing machine capacity
Shielding must be provided on both machines in is required on smooth, level surfaces. Maximum
order to protect the operator in case the tow line towing machine capacity is required on inclines or
breaks or the tow bar breaks. on poor surface conditions.
Do not allow riders on a machine that is being If possible, dump the load before attempting to tow
towed unless the operator can control the steering the machine. Any towed machine with a load must
and/or the braking. be equipped with a braking system that can be
operated from the operator’s station.
Towing with an Operable Engine Reference: For information about the manual
release of the parking brake, refer to the
If the engine is running, the machine can be towed Operation and Maintenance Manual, “Parking
for a short distance under certain conditions. The Brake Manual Release” for the machine that is
power train and steering system must be operable. being serviced.
Tow the machine for a short distance only. For
example, pull the machine out of mud or pull the NOTICE
machine to the side of the road. Release the parking brake to prevent excessive wear
and damage to the parking brake system when towing
The operator on the towed machine must steer the the machine.
machine in the direction of the tow line.
Carefully obey all of the instructions that are outlined 6. Remove the wheel blocks. Tow the machine
in this topic. slowly. Do not exceed 2 km/h (1.2 mph).
2. If failure of the internal transmission or of the Personal injury or death can result from a brake
drive line is suspected, remove the axle shafts. malfunction. Do not operate the machine if the
brake was applied due to a malfunction of the oil
Reference: For information on removing the axle system or the brake.
shafts, refer to the Power Train, Disassembly
and Assembly, “Axle Shafts - Remove” for the Correct any problem before attempting to operate
machine that is being serviced. the machine.
g00943691
Illustration 182 i02007659
12. Position switch (8) (from the portable hydraulic Brake Release
pump) inside the operator station. (If Equipped)
13. Press and hold switch (8) in the ON position SMCS Code: 4267
to activate the portable hydraulic pump. Brake
accumulator oil pressure indicator (5) will go out Certain Caterpillar machines fitted with remote
when the braking system has full oil pressure. controls may be equipped with an optional brake
release system. The brake release system is used to
Note: Operation of the switch should only take place recover a machine from a stope or dangerous area.
from inside the operator station. Observe brake
indicators and gauges (if equipped) while operating If the parking brake is engaged due to a machine
the portable hydraulic pump. fault, or if the machine becomes partially buried in
a rock fall, the brake release system can be used to
14. When the braking system has full oil pressure, disengage the parking brake to enable the machine
move parking brake control (6) to the OFF to be towed.
position to disengage the parking brake. Hold
switch (8) in the ON position until parking brake If the recovery machine is equipped with a recovery
indicator (4) on the Caterpillar Monitoring System bar, the recovery bar can be used to activate the
panel goes out. The parking brake is now brake release system. If the disabled machine is
disengaged. equipped with a recovery hook, the recovery hook
can be used to activate the brake release system.
Note: The service brakes can be used to stop the
machine when the machine has brake oil pressure. The machine may be equipped with the optional
Use the service brakes to control the machine when steering release system. The steering release
the machine is being towed. system is activated when the brake release system
is activated. When the steering release system is
Note: Using the service brakes will cause the activated the oil in the rod end and the head end of
braking system oil pressure to decrease. If brake the steering cylinder is open to the hydraulic tank.
accumulator oil pressure indicator (5) comes on, The machine will articulate freely.
operate the portable hydraulic pump to increase the
braking system pressure. Ensure that the braking
system pressure is maintained for the duration of
the towing.
95
Operation Section
Towing Information
Ensure that the disabled machine cannot move be- Note: Some types of bucket hardware allow direct
fore disconnecting the recovery bar. bolt-on fastening of the recovery bar to the bucket.
For more information on attaching the recovery bar
to the bucket, contact your Caterpillar dealer.
g00901945
Illustration 183
Personal injury or death could result when towing If the disabled machine is in a stope or dangerous
a disabled machine incorrectly. area, the recovery machine must be operated by
remote control.
Ensure that the recovery machine is securely
attached to the hitch with the brakes applied to The brake release system must only be activated
prevent the machines from rolling unexpectedly. by a tow line securely attached to the recovery ma-
Keep all personnel clear of the disabled machine chine. The tow line must be securely attached to
until it has been towed to a safe place and the the recovery hook of the disabled machine prior
wheels securely blocked. to activating the brake release system. Failure to
securely attach the tow line may result in the dis-
abled machine moving. Uncontrolled movement of
the disabled machine can cause serious personal
injury or death.
g01004861
Illustration 187
Adjustments 3. Raise the lift arm to the full height. Move the
joystick control lever to the FLOAT position to
lower the lift arm. The lift arm positioner should
i01932553 bring the lift arm to a controlled stop at the
correct height for digging.
Lift Arm Positioner
SMCS Code: 5112
g01000381
Illustration 188
g00947050
Illustration 191
g00947053
Illustration 192
g00280501
Illustration 193
Mismatched or incorrect fasteners can result in
damage or malfunction, or personal injury. Table 6
Take care to avoid mixing metric dimensioned fas- Initial Installation Torque
Width of Clamp
On New Hose
teners and inch dimensioned fasteners.
7.9 mm (0.31 inch) 0.9 ± 0.2 N·m (8 ± 2 lb in)
Exceptions to these torques are given in the Service 13.5 mm (0.53 inch) 4.5 ± 0.5 N·m (40 ± 4 lb in)
Manual, if necessary.
15.9 mm (0.63 inch) 7.5 ± 0.5 N·m (65 ± 4 lb in)
Prior to installation of any hardware, ensure that Reassembly or Retightening
Width of Clamp
components are in near new condition. Bolts and Torque
threads must not be worn or damaged. Threads 7.9 mm (0.31 inch) 0.7 ± 0.2 N·m (6 ± 2 lb in)
must not have burrs or nicks. Hardware must be
free of rust and corrosion. Clean the hardware with a 13.5 mm (0.53 inch) 3.0 ± 0.5 N·m (27 ± 4 lb in)
non-corrosive cleaner. Do not lubricate the fastener
15.9 mm (0.63 inch) 4.5 ± 0.5 N·m (40 ± 4 lb in)
threads except for the rust preventive. The rust
preventive should be applied by the supplier of that
component for purposes of shipping and storage.
i01763383
Other applications for lubricating components may
also be specified in the Service Manual. Standard Torque for Constant
Torque Hose Clamps
i01763380
SMCS Code: 1000; 7000
Torques for Ground Engaging
Tool Bolts Use a constant torque hose clamp in place of any
standard hose clamp. Ensure that the constant
SMCS Code: 6800; 7000 torque hose clamp is the same size as the standard
hose clamp. Due to extreme temperature changes,
Table 5 the hose will heat set. Heat setting can cause hose
BOLT SIZE RECOMMENDED TORQUE (1) clamps to loosen. Loose hose clamps can result
INCH in leaks. There have been reports of component
N·m lb ft failures that have been caused by hose clamps that
5/8 270 ± 40 200 ± 30 have loosened. The constant torque hose clamp will
help prevent these failures.
3/4 475 ± 60 350 ± 45
7/8 750 ± 90 550 ± 65
1 1150 ± 150 850 ± 110
1 1/4 2300 ± 300 1700 ± 220
(1) These values are only for Caterpillar bolts for cutting edges.
101
Maintenance Section
Torque Specifications
i01763384
g00735086
5/16 25 ± 6 N·m (18 ± 4 lb ft)
Illustration 194
3/8 47 ± 9 N·m (35 ± 7 lb ft)
Use a torque wrench for proper installation of the 7/16 70 ± 15 N·m (50 ± 11 lb ft)
constant torque hose clamps. The constant torque
hose clamp is installed correctly under the following 1/2 105 ± 20 N·m (75 ± 15 lb ft)
conditions: 9/16 160 ± 30 N·m (120 ± 22 lb ft)
• Screw tip (1) extends 6.35 mm (0.25 inch) (X) 5/8 215 ± 40 N·m (160 ± 30 lb ft)
beyond the housing. 3/4 370 ± 50 N·m (275 ± 37 lb ft)
• The belleville washers are collapsed nearly 7/8 620 ± 80 N·m (460 ± 60 lb ft)
flat after screw (2) is tightened to a torque of 1 900 ± 100 N·m (660 ± 75 lb ft)
11 ± 1 N·m (98 ± 9 lb in).
1 1/8 1300 ± 150 N·m (960 ± 110 lb ft)
1 1/4 1800 ± 200 N·m (1320 ± 150 lb ft)
1 3/8 2400 ± 300 N·m (1780 ± 220 lb ft)
1 1/2 3100 ± 350 N·m (2280 ± 260 lb ft)
Table 8
Inch Taperlock Studs
Thread Size
Standard Torque
Inch
1/4 8 ± 3 N·m (6 ± 2 lb ft)
5/16 17 ± 5 N·m (13 ± 4 lb ft)
3/8 35 ± 5 N·m (26 ± 4 lb ft)
7/16 45 ± 10 N·m (33 ± 7 lb ft)
1/2 65 ± 10 N·m (48 ± 7 lb ft)
5/8 110 ± 20 N·m (80 ± 15 lb ft)
3/4 170 ± 30 N·m (125 ± 22 lb ft)
7/8 260 ± 40 N·m (190 ± 30 lb ft)
1 400 ± 60 N·m (300 ± 44 lb ft)
1 1/8 525 ± 60 N·m (390 ± 44 lb ft)
1 1/4 750 ± 80 N·m (550 ± 60 lb ft)
1 3/8 950 ± 125 N·m (700 ± 90 lb ft)
1 1/2 1200 ± 150 N·m (880 ± 110 lb ft)
102
Maintenance Section
Torque Specifications
i01763388
Table 10
Metric Taperlock Studs
Thread Size
Standard Torque
Metric
M6 8 ± 3 N·m (6 ± 2 lb ft)
M8 17 ± 5 N·m (13 ± 4 lb ft)
M10 35 ± 5 N·m (26 ± 4 lb ft)
M12 65 ± 10 N·m (48 ± 7 lb ft)
M16 110 ± 20 N·m (80 ± 15 lb ft)
M20 170 ± 30 N·m (125 ± 22 lb ft)
M24 400 ± 60 N·m (300 ± 44 lb ft)
M30 750 ± 80 N·m (550 ± 60 lb ft)
M36 1200 ± 150 N·m (880 ± 110 lb ft)
103
Maintenance Section
Tire Inflation Information
Lubricant Viscosities
SMCS Code: 1000; 7000; 7581
Table 12
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
SAE 0W40 −40 +40 −40 +104
Caterpillar Multigrade DEO
API Multigrade CH-4 SAE 5W30 −30 +30 −22 +86
Engine Crankcase API Multigrade CG-4
API Multigrade CF-4 SAE 5W40 −30 +40 −22 +104
Global DHD-1 Multigrade
SAE 10W30 −20 +40 −4 +104
SAE 10W40 −20 +50 −4 +122
SAE 15W40 −15 +50 +5 +122
SAE 0W20 (2) −40 +10 −40 +50
SAE 0W30 (2) −40 +20 −40 +68
SAE 5W30 (2) −30 +20 −22 +68
Caterpillar TDTO
Power Shift Transmission Commercial TO-4 SAE 10W −20 +10 −4 +50
Caterpillar TDTO-TMS
SAE 30 0 +35 +32 +95
SAE 50 +10 +50 +50 +122
TDTO-TMS (3) −10 +43 +14 +110
SAE 0W20 (2) −40 +40 −40 +104
SAE 0W30 (2) −40 +40 −40 +104
Caterpillar Biodegradable
Hydraulic Oil (HEES) SAE 5W30 (2) −30 +40 −22 +104
Caterpillar HYDO
Caterpillar DEO SAE 5W40 −30 +40 −22 +104
Caterpillar TDTO SAE 10W −20 +40 −4 +104
Caterpillar MTO
API CG-4 SAE 30 +10 +50 +50 +122
Hydraulic Systems API CF-4
API CF SAE 10W30 −20 +40 −4 +104
Commercial TO-4 SAE 15W40 −15 +50 +5 +122
Caterpillar TO-4M
Caterpillar TDTO-TMS Caterpillar MTO −25 +40 −13 +104
API CH-4
Commercial BF-1(4) Cat Biodegradable
Global DHD-1 Hydraulic Oil (HEES) −40 +43 −40 +110
(4)
i01931636
Capacities (Refill)
SMCS Code: 7560
Table 13
Approximate Refill Capacities
Compartment or US Imperial
System Liters Gallons Gallons
Engine Crankcase 25 6.6 5.5
Transmission 45 11.9 9.9
Hydraulic Tank 88 23.2 19.3
Cooling System 67 17.7 14.7
Front Differential and
38 10 8.3
Final Drives
Rear Differential and
42 11.1 9.2
Final Drives
Fuel Tank 295 77.9 64.9
107
Maintenance Section
Maintenance Locations
Maintenance Locations
i01931637
g01005078
Illustration 195
(1) Front axle breather (7) Fuel tank filler screen (12) Transmission magnetic screen
(2) Hydraulic system oil filler screen (8) Engine oil filter (13) Transmission oil filter
(3) Hydraulic system oil filters (9) Automatic lubrication system filters (if (14) Primary fuel filter
(4) Cab return air filter equipped) (15) Secondary fuel filter
(5) Cab pressurizer filter (10) Engine crankcase breather
(6) Engine air filters (11) Rear axle breather
Table 14
Change Sampling Sampling
Type of Fluid
Interval Interval Valve
Engine Oil 250 Hours 250 Hours Yes(1)
Transmission
1000 Hours 500 Hours Yes(1)
Oil
Hydraulic Oil 2000 Hours 500 Hours Yes(1)
Differential
and Final 1000 Hours 500 Hours No
Drive Oil
Coolant 6000 Hours 500 Hours No
(1) Machines may be equipped with optional sampling valves g01005841
Illustration 198
Consult your Caterpillar dealer for complete Sampling valve for the hydraulic system oil
information and for assistance in establishing a
S·O·S program for your equipment. The sampling valve for the hydraulic system oil is
located on a manifold near the articulation hitch.
Location of Sampling Valves
g00996592
Illustration 199
g01005469
Sampling port for the final drive oil
Illustration 196
Sampling valve for the engine oil
g00996598
Illustration 200
Sampling port for the front differential oil
g01005840
Illustration 197
Sampling valve for the transmission and torque converter oil
Application
Studies have revealed that obtaining oil samples at
every 500 hours is too long a time interval in some
applications in order to predict potential failure
modes. A sampling interval at every 250 hours
provides more data between oil change intervals.
More data increases the chance for detecting a
potential failure.
Articulated Hitch Bearings - Lubricate ................ 112 Every 500 Service Hours or 3 Months
Automatic Lubrication Grease Tank - Fill ............ 113
Backup Alarm - Test ............................................ 114 Engine Crankcase Breather - Clean ................... 139
Belts - Inspect/Adjust/Replace ............................ 116 Fuel Tank Cap and Strainer - Clean ................... 148
Braking System - Test ......................................... 118 Hydraulic System Oil Filter - Replace ................. 151
Bucket Pivot Bearings - Lubricate ....................... 120 Transmission Oil Filter - Replace ........................ 167
Central Lubrication System - Lubricate ............... 121
Cooling System Level - Check ............................ 129 Every 1000 Service Hours or 6 Months
Engine Air Filter Primary Element -
Clean/Replace .................................................. 136 Brake Accumulator - Check ................................ 117
Engine Oil Level - Check .................................... 140 Differential and Final Drive Oil - Change ............ 132
Fire Suppression System - Check ...................... 145 Ride Control Accumulator - Check ...................... 158
Fuel Tank Water and Sediment - Drain ............... 149 Rollover Protective Structure (ROPS) - Inspect .. 159
Hydraulic System Oil Level - Check .................... 152 Steering and Transmission Lock Control (STIC
Implement and Steering Lockout (STIC Steering) - Steering) - Lubricate ......................................... 164
Test ................................................................... 153 Transmission Oil - Change .................................. 166
Indicators and Gauges - Test .............................. 154
Lift Arm and Cylinder Bearings - Lubricate ......... 155 Every 2000 Service Hours or 1 Year
Rear Axle Trunnion Bearings - Lubricate ............ 158
Brake Discs - Check ........................................... 117
Seat Belt - Inspect .............................................. 159
Brake Release System - Test .............................. 118
Service Inspection .............................................. 160
Steering Cylinder Bearings - Lubricate ............... 163 Crankshaft Vibration Damper - Inspect ............... 132
Engine Mounts - Inspect ..................................... 139
Tilt Cylinder and Tilt Lever Bearings - Lubricate .. 164
Engine Valve Lash - Check/Adjust ...................... 143
Tilt Linkage Bearings - Lubricate ........................ 165
Transmission Oil Level - Check ........................... 168 Engine Valve Rotators - Inspect .......................... 143
Hydraulic System Oil - Change ........................... 150
Window - Clean .................................................. 169
Hydraulic Tank Breaker Relief Valve - Clean ...... 153
Turbocharger - Inspect ........................................ 168
111
Maintenance Section
Maintenance Interval Schedule
Every 3 Years
Seat Belt - Replace ............................................. 160
Reference: For the correct bolt torque, refer to Wipe off the fittings before any lubricant is applied.
Specifications, “Articulated Hitch” for the machine
that is being serviced.
i01911200
g00995555
Illustration 207
Apply the service brake. Move the transmission Always recycle a battery. Never discard a battery.
direction and speed control to the REVERSE
position. Always return used batteries to one of the following
locations:
The backup alarm should start to sound
immediately. The backup alarm should continue to • A battery supplier
sound until the transmission direction and speed
control is moved to the NEUTRAL position or to the • An authorized battery collection facility
FORWARD position.
• Recycling facility
i01911204
g00903040
Illustration 209
115
Maintenance Section
Battery, Battery Cable or Battery Disconnect Switch - Replace
i01911207
Reference: For more information on connecting 3. Turn the battery disconnect switch to the OFF
the battery cables, refer to the Operation and position and remove the key.
Maintenance Manual, “Battery, Battery Cable or
Battery Disconnect Switch - Replace” for the 4. Disconnect the negative end (-) of the battery
machine that is being serviced. cable from the frame near the battery disconnect
switch.
6. Coat the terminals with 1P-0808 Multipurpose
Grease or petroleum jelly. Then, install the post Note: Do not allow the disconnected battery cable
cover. to contact the battery disconnect switch.
116
Maintenance Section
Belts - Inspect/Adjust/Replace
5. Disconnect the negative end (-) of the battery If new belt(s) are installed, check belt adjustment
cable from the battery. again, after 30 minutes of operation. For multiple
belt drive applications, always replace belts in
6. Disconnect the positive end (+) of the battery matched sets.
cable from the battery.
If only one belt of a matched set is replaced, it will
7. Replace the battery or make all necessary carry more of a load than the belts not replaced
repairs to the battery. since the older belts are stretched. The additional
load on the new belt could cause it to break.
8. Connect the positive end (+) of the battery cable
to the battery.
Adjust the Alternator Belt
9. Connect the negative end (-) of the battery cable
to the battery.
i01912405
Belts - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510
g00908664
Illustration 213
g00995867
Illustration 216
g00996191
Illustration 217
Reference: For information on checking the brake The following tests are to determine if the parking
disc wear, refer to Systems Operation, Testing brake and the service brakes are functional. These
and Adjusting, “Brake Disc Wear - Check” for the tests are not intended to measure maximum holding
machine that is being serviced. effort. Brake holding effort required to hold a
machine at a specific engine rpm will vary from
machine to machine due to differences in engine
i01888912
setting, power train efficiency, etc., as well as
Brake Release System - Test differences in brake holding ability.
To carry out the brake test, first start the engine and
let the brake oil pressure build up to the operating
range. The parking brake will stay engaged until
operating oil pressure has been reached and the
parking brake control is moved to the OFF position
(parking brake disengaged). Once operating oil
pressure has been reached a test of the braking
system can be commenced.
i01912931
g00996198
Personal injury can result if the machine moves Illustration 219
while testing.
2. Depress the service brake pedal.
If the machine begins to move during test, reduce
the engine speed immediately and engage the
parking brake.
If the machine begins to move during the test, re- Wipe off the fittings before any lubricant is applied.
duce the engine speed immediately and apply the
service brakes.
g00996203
Illustration 223
g00996202
Illustration 222
5. Reduce the engine speed to low idle. Move Cab Air Filter - Clean/Replace
the transmission direction and speed control to
the NEUTRAL position. Lower the bucket to the (If Equipped)
ground. Stop the engine.
SMCS Code: 7342-070; 7342-510
NOTICE Note: Clean the cab air filters more often in dusty
If the machine moved while testing the brakes, contact conditions. When rips or tears are noticed in the
your Caterpillar dealer. filter, or a reduction of air circulation is noticed in
the cab after cleaning the filter, install a new filter.
Have the dealer inspect and, if necessary, repair the
parking brakes before returning the machine to oper-
ation.
121
Maintenance Section
Central Lubrication System - Lubricate
Return Air Filter 3. Install the precleaner cup and the cover. Tighten
the retaining nut finger tight. Do not use a tool to
tighten the retaining nut.
4. Remove wing nut (4) and end cap (3). Empty the
dust from the end cap.
2. Remove cover (2) and the return air filter from 8. Install the filter element and wing nut. Tighten
the air conditioning unit. the wing nut finger tight. Do not use a tool to
tighten the wing nut.
3. Clean the return air filter using pressure air. When
you use air pressure, the maximum air pressure 9. Install end cap (3). Tighten wing nut (4) finger
should be 205 kPa (30 psi). tight. Do not use a tool to tighten the wing nut.
NOTICE
Check that the lines attached to all the remote grease
fittings are undamaged. If the grease lines are split,
grease will not reach the components that require lu-
bricating. Machine damage will result.
g00996587
The fittings are located on the top of the front frame
Illustration 226 and on the right side of the lift arm.
Note: When the debris reaches the full level on the
precleaner, empty the precleaner.
g01001142
13. Apply lubricant through remote mounted fitting
Illustration 227 (13) for the bearing at the bucket end of the tilt
linkage.
1. Apply lubricant through remote mounted fitting
(1) for the left bucket pivot bearing. 14. Apply lubricant through remote mounted fitting
(14) for the right rear lift arm bearing.
2. Apply lubricant through remote mounted fitting
(2) for the bearing at the rod end of the left lift
cylinder. i01912944
g00996213
Illustration 229
g00996558 g00996566
Illustration 230 Illustration 231
(11) 15 Amp - Remote control system (if equipped). Reference: For the correct retaining bolt torque,
refer to Hydraulic Specifications, “Bucket Control”
(12) 15 Amp - Key start switch, fire suppression for the machine that is being serviced.
system.
124
Maintenance Section
Cooling System Coolant (DEAC) - Change
i01912933
NOTICE
Do not change the coolant until you read and under- Illustration 234 g00997221
stand the cooling system information in Special Pub-
lication, SEBU6250, “Caterpillar Machine Fluids Rec- 2. Remove the bottom guard.
ommendations”.
3. Open the drain valve for the engine cooling
Failure to do so could result in damage to the cooling system. Drain the coolant into a suitable
system components. container. The drain valve is located on the
bottom radiator tube.
Note: This procedure pertains only to Caterpillar
Diesel Engine Antifreeze/Coolant (DEAC). This 4. Close the drain valve. Fill the system with clean
does not pertain to machines that are shipped water and a 6 to 10 percent concentration of
from the factory with Extended Life Coolant (ELC). cooling system cleaner.
Also this does not pertain to the machines that are
maintained with Extended Life Coolant (ELC). 5. Start and run the engine for 90 minutes. Stop
the engine and drain the cleaning solution into a
If the coolant is dirty or if you observe any foaming suitable container.
in the cooling system, drain the coolant before the
recommended interval. 6. When the engine is stopped, flush the cooling
system with water until the draining water is
clear. Drain the water into a suitable container.
NOTICE
Do not change the coolant until you read and under-
stand the cooling system information in Special Pub-
lication, SEBU6250, “Caterpillar Machine Fluids Rec-
ommendations”.
NOTICE
g00996192 Mixing ELC with other products reduces the effective-
Illustration 235
ness of the coolant and shortens coolant life. Use on-
10. Maintain the coolant level to within 13 mm ly Caterpillar products or commercial products that
(0.50 inch) of the bottom of the filler pipe or to have passed the Caterpillar EC-1 specifications for
the proper level in the sight gauge. premixed or concentrate coolants. Use only Caterpillar
Extender with Caterpillar ELC. Failure to follow these
11. Install the cooling system pressure cap. recommendations could result in the damage to cool-
ing systems components.
12. Stop the engine.
If ELC cooling system contamination occurs see the
topic Extended Life Coolant (ELC) in the Operation
i01912934 and Maintenance Manual, SEBU6250, “Caterpillar
Machine Fluids Recommendations”.
Cooling System Coolant (ELC)
- Change Note: This procedure pertains to machines using
Extended life Coolant (ELC) only.
SMCS Code: 1352-044-NL; 1395-044-NL
If the coolant is dirty or if you observe any foaming
in the cooling system, drain the coolant before the
recommended interval.
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.
126
Maintenance Section
Cooling System Coolant (ELC) - Change
g00996195
Illustration 236
g00996192
Illustration 238
i01912937
NOTICE
Cooling System Coolant Excessive additive (greater than the recommended
Additive (DEAC) - Add 6% initial fill) together with concentrations of antifreeze
greater than 60% cause deposits to form and can re-
SMCS Code: 1352-538; 1395-538 sult in radiator tube blockage and overheating.
NOTICE
Adding coolant to an overheated engine could result in
damage to the engine. Allow the engine to cool before
adding coolant.
The engine cooling system is normally protected to a 1. Loosen the pressure cap slowly to relieve cooling
minimum of−29C (−20F) with Caterpillar Antifreeze, system pressure. Remove the pressure cap.
when shipped from the factory unless special require-
ments are defined. 2. It may be necessary to drain enough coolant
from the radiator to allow for the addition of the
liquid supplemental coolant additive.
NOTICE
Care must be taken to ensure that fluids are contained Note: Make sure the coolant is drained into a
during performance of inspection, maintenance, test- suitable container.
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- 3. Add liquid supplemental coolant additive
ing any compartment or disassembling any compo- (conditioner) according to the requirements
nent containing fluids. of your cooling system as determined by the
coolant additive concentration test.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies 4. Clean the pressure cap and inspect the pressure
suitable to collect and contain fluids on Caterpillar cap. Install the pressure cap.
products.
5. Start the engine and check for leaks. Allow the
Dispose of all fluids according to local regulations and coolant level to stabilize.
mandates.
128
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
2. Close element inlet valve (1) and outlet valve (2). Cooling System Coolant Additive contains alkali.
Remove and discard element (3). Avoid contact with skin and eyes.
7. Open the inlet and outlet valves. The engine cooling system is normally protected to a
minimum of−29C (−20F) with Caterpillar Antifreeze,
8. Clean the pressure cap and inspect the pressure when shipped from the factory unless special require-
cap. Install the pressure cap. ments are defined.
9. Start the engine and check for leaks. Allow the NOTICE
coolant level to stabilize. Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
10. If necessary, add premixed coolant in order to ing, adjusting and repair of the product. Be prepared to
bring the coolant to the proper level in the sight collect the fluid with suitable containers before open-
gauge. ing any compartment or disassembling any compo-
nent containing fluids.
g00996195
Illustration 241
130
Maintenance Section
Cooling System Pressure Cap - Clean/Replace
i01912928
g00996195
Illustration 244
i01912932
Replace the water temperature regulator on a 1. Remove water temperature regulator housing.
regular basis in order to reduce the chance of
unscheduled downtime and of problems with the 2. Remove the gasket, the water temperature
cooling system. regulator and the seal from the water temperature
regulator housing.
The water temperature regulator should be replaced
after the cooling system has been cleaned. Replace NOTICE
the water temperature regulator while the cooling Former water temperature regulators may be used, if
system is completely drained or while the cooling they meet the test specifications and are not damaged
system coolant is drained to a level that is below or have excessive buildup or deposits.
the water temperature regulator housing.
NOTICE NOTICE
Failure to replace the engine’s water temperature reg- Since Caterpillar engines incorporate a shunt design
ulator on a regularly scheduled basis could cause se- cooling system, it is mandatory to always operate the
vere engine damage. engine with a water temperature regulator.
g00996583
NOTICE
Illustration 246 Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
The crankshaft vibration damper is located at the ing, adjusting and repair of the product. Be prepared to
rear of the machine on the front of the engine. collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
Damage to the vibration damper or failure of nent containing fluids.
the vibration damper will increase torsional
vibrations. These vibrations will result in damage Refer to Special Publication, NENG2500, “Caterpillar
to the crankshaft and in damage to other engine Tools and Shop Products Guide” for tools and supplies
components. A deteriorating vibration damper will suitable to collect and contain fluids on Caterpillar
cause excessive gear train noise at variable points products.
in the speed range.
Dispose of all fluids according to local regulations and
Caterpillar recommends replacing the vibration mandates.
damper for any of the following reasons:
Wipe covers and surfaces around openings before
• The engine has had a failure because of a broken checking or adding oil. Park on a level surface.
crankshaft.
g00997225
Illustration 248
Location of the front differential drain plug
g00996597
Illustration 251
Location of the rear differential and transfer case dipstick/fill plug
g00996598
Illustration 250
Location of the front differential dipstick/fill plug
g00996592 g00996590
Illustration 252 Illustration 253
Location of the front differential breather
6. Position the wheels so that the fill/drain plugs are
even with the center line of the wheel. Remove
the fill/drain plugs.
SMCS Code: 3278-535-FLV; 4050-535-FLV 4. Clean the fill/drain plugs and install the fill/drain
plugs.
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.
g00996597
Illustration 257
Location of the rear differential and transfer case dipstick/fill plug
i01914495
g00997572
Illustration 261
g00997569
Illustration 258
4. Apply lubricant through one fitting for the front
1. Apply lubricant through six fittings in universal drive shaft support bearings.
joints.
i01914056
g00997573
Illustration 259
g00996873
Illustration 262
137
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
Service the air cleaner daily or if the yellow piston 4. Inspect the primary element. If the pleats, the
in filter element indicator (1) moves into the red gaskets, or the seals are damaged, discard the
zone with the engine running at high idle. Stop the primary element. Replace a damaged primary
engine. element with a clean primary element.
NOTICE NOTICE
Service the air cleaner only with the engine stopped. Do not clean the primary elements by bumping or tap-
Engine damage could result if the air cleaner is ser- ping them. Do not use primary elements with dam-
viced while the engine is running. aged pleats, gaskets or seals. Engine damage can re-
sult.
• Pressure air.
• Pressure water.
• Detergent washing.
When you use pressure air, the maximum air
pressure is 205 kPa (30 psi). When you use
pressure water, the maximum water pressure is
280 kPa (40 psi).
g00996874
Illustration 263
g00905242
Illustration 265
8. Cover the clean primary element. Store the Reference: For additional information, refer to the
primary element in a clean, dry location. Operation and Maintenance Manual, “Engine Air
Filter Primary Element - Clean/Replace” for the
A primary element may be cleaned for a machine that is being serviced.
maximum of six times. Also replace the primary
element if the primary element has been in
service for one year.
NOTICE
Engine Air Precleaner - Clean
Always replace the secondary element. Do not at- SMCS Code: 1055-070
tempt to reuse it by cleaning. Engine damage could
result.
NOTICE
Service the air cleaner only with the engine stopped.
Replace the engine air filter secondary element Engine damage could result.
under the following conditions:
i01928882
g00997575
Illustration 270
g01003364
Illustration 268 Caterpillar recommends inspecting the engine
mounts for deterioration and for proper bolt torque.
1. Loosen hose clamp (1) and remove the outlet This will help to prevent excessive engine vibration
hose from breather assembly (3). that is caused by improper mounting.
2. Remove bolt (2) and the breather assembly.
140
Maintenance Section
Engine Oil Level - Check
g00997576
Illustration 271
3. Clean the filler cap and install the filler cap. g00997874
Illustration 272
g00997878
Illustration 275
Illustration 274
g00997877 10. Start the engine and run the engine at low idle
for five minutes. Inspect the engine oil filter for
5. Remove used oil filter element (5) and discard leaks. Stop the engine.
the used oil filter element.
11. Maintain the oil level between the “ADD”
6. Clean the filter housing base. Make sure that all and “FULL” marks on dipstick (7). Add oil, if
of the old seal is removed from the filter base. necessary.
Note: There are rotation index marks on the filter, Engine Oil Pressure
that are spaced 90 degrees (1/4 turn) apart. Use
these rotation marks as a guide when tightening
the filter.
g01004612
Illustration 276
The oil pressure switches are located at the rear of the engine
142
Maintenance Section
Engine Shutdown to Idle Protection System - Test
1. Locate connector (1) or connector (2) for the Engine Coolant Level
engine oil pressure switch that has the EL722
pink wire and the EL723 pink wire attached to
the connector.
Note: If the engine did not remain at low idle during 1. Disconnect wire (1) from coolant level sensor
the test, check the electrical system or contact your (2). Secure the wire to prevent it from touching
Caterpillar dealer. any metal objects or protruding through the fan
guard.
Engine Coolant Temperature 2. Start the engine.
Note: If the engine did not remain at low idle during When inspecting the valve rotators, protective
the test, check the electrical system or contact your glasses or face shield and protective clothing
Caterpillar dealer. must be worn, to help prevent being burned by
hot oil or spray.
i01915790
NOTICE
Only qualified service personnel should perform this
maintenance. Refer to the Service Manual or your
Caterpillar dealer for the complete valve lash adjust-
ment procedure.
i01915081 i01915791
g00997578
Illustration 281
g00997853
A water pump that has failed may cause severe Illustration 282
engine overheating problems. The engine
overheating problems could result in the following Remove the catalytic purifier cover. Inspect the
problems: catalytic purifier for damage and for leaks. If
necessary, make repairs. If the catalytic purifier is
damaged, consult your Caterpillar dealer.
• Cracks in the cylinder head.
• Piston seizure. If the engine has low power, the catalytic purifier
may be blocked. Clean the catalytic purifier.
• Other potential engine damage.
Reference: For information on cleaning the catalytic
Visually inspect the water pump for leaks. If leaks purifier, refer to the Operation and Maintenance
are found, all of the seals on the water pump must Manual, “Emission Control Systems” for the machine
be replaced. that is being serviced.
NOTICE
Check that the lines attached to all the remote grease
fittings are undamaged. If the grease lines are split,
grease will not reach the components that require lu-
bricating. Machine damage will result.
i01915799
NOTICE
Do not loosen the fuel lines at the fuel manifold. The
engine components may be damaged.
g00997862 Do not remove the fitting in the fuel filter base in order
Illustration 283
to release air from the fuel system while priming the
engine. Periodic removal of the fitting will result in in-
1. Apply lubricant through the remote mounted creased wear of the threads in the fuel filter base and
fitting for the fan drive bearing. will lead to fuel leakage.
Note: To avoid seal damage do not over lubricate Do not allow dirt to enter the fuel system. Thorough-
the fan drive bearing. ly clean the area around any fuel system component
that will be disconnected. Fit a suitable cover over any
i01915798 disconnected fuel system component in order to pro-
tect it from dirt and debris.
Fire Suppression System -
Check NOTICE
(If Equipped) Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
SMCS Code: 7401-535 ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
Reference: For detailed information on the fire ing any compartment or disassembling any compo-
suppression system service procedures, refer to the nent containing fluids.
fire system manufacturer’s service information.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
g00997869
Illustration 284
Foam type fire suppression system
i01928515
Clean the primary element when the engine has a 1. Remove the fuel filter assembly from the base
loss of power or when the exhaust smoke is black. with a strap-type wrench.
Fuel System Secondary Filter - 2. Clean the filter housing base. Make sure that all
Replace of the old seal is removed.
SMCS Code: 1261-510-SE 3. Lubricate the sealing surface of the new filter
element with clean diesel fuel.
i01928525 i01928526
Note: The water separator is not a filter. The water Note: Machines equipped with an optional fast-fill
separator separates the water from the fuel. fuel system do not contain a breather filter element
in the fuel cap. Perform Steps 3 and 5 only to
standard machines without the fast-fill fuel system.
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 g01003349
Illustration 289
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids. The fuel tank cap is located on the right side of the
rear frame.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
g00906284
Illustration 290
g01003350 g01003355
Illustration 291 Illustration 292
6. Remove the strainer from the filler opening. The drain valve is located on the right side of the
machine under the fuel tank.
7. Wash the strainer in a clean, nonflammable
solvent.
i01928879
NOTICE
Replace the fuses with the same type and size only.
Otherwise, electrical damage can result.
g01003358 g01003361
Illustration 294 Illustration 295
View of the battery compartment
1. Relieve the hydraulic tank pressure by pushing
(1) 325 Amp - Fuse. on top of breaker relief valve (1) before removing
the oil filler cap.
i01928883
NOTICE
Care must be taken to ensure that fluids are contained g01003362
Illustration 296
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to 2. Remove oil filler cap (2) slowly to relieve any
collect the fluid with suitable containers before open- remaining pressure.
ing any compartment or disassembling any compo-
nent containing fluids. 3. Remove hydraulic tank drain plug (3). Drain the
oil into a suitable container.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and supplies 4. Clean the drain plug and install the drain plug.
suitable to collect and contain fluids on Caterpillar
products. 5. Change the hydraulic system oil filters.
Dispose of all fluids according to local regulations and Reference: For the correct procedure, refer to the
mandates. Operation and Maintenance Manual, “Hydraulic
System Oil Filter - Replace” for the machine that
Operate the machine for a few minutes in order to is being serviced.
warm the hydraulic system oil.
6. Remove the strainer from the hydraulic oil filler
Park the machine on level ground. Lower the bucket tube.
to the ground and apply slight downward pressure.
Engage the parking brake and stop the engine. 7. Wash the oil filler cap and the strainer in clean,
nonflammable solvent. Allow the oil filler cap and
the strainer to dry.
g01003365
Illustration 297
i01928889
g01003584
Illustration 299
Hot oil and hot components can cause personal 2. Remove oil filler cap (2).
injury. Do not allow hot oil or hot components to
contact the skin.
152
Maintenance Section
Hydraulic System Oil Level - Check
g01003603
Illustration 301
g01003618
Illustration 303
g01003582
Illustration 302
i02006133
g01003619
Be sure the area around the machine is clear of
Illustration 304 personnel and obstructions.
2. Open the hydraulic tank access cover located Be sure the steering frame lock is in the stored
on the upper right side of the machine. position.
3. Relieve the hydraulic tank pressure by pushing Fasten the seat belt before testing the steering and
on top of breaker relief valve (3) before removing implement lockout systems.
the filler cap.
4. Remove oil filler cap (2) slowly to relieve any Steering Mechanical Lockout
remaining pressure. Add oil, if necessary,
through the filler tube. 1. Park the machine on a level surface.
5. Clean the oil filler cap and install the oil filler cap. 2. Start the engine and raise the bucket slightly.
g01003370
Illustration 306
i01929299
NOTICE
If the machine moved while testing the steering me- Indicators and Gauges - Test
chanical lockout system, contact your Caterpillar deal-
SMCS Code: 7000-081; 7450-081
er. Have the dealer inspect and repair the steering me-
chanical lockout before returning the machine to oper-
ation.
5. Move the steering and transmission lock lever to Before you operate the machine, perform the
the UNLOCKED position. following checks and make any necessary repairs:
i01773398
g01005452
Illustration 308
g00907074
Illustration 311
The Element is Shown with Debris
Using an oil filter element that is not recommended 4. Move the parking brake control to the OFF
by Caterpillar can result in severe engine damage position in order to disengage the parking brake.
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.
i01929778
Pressure Sensor
(Transmission Oil) (Alert
Indicator and Brake
Application) - Test
(If Equipped) g01003907
Illustration 313
SMCS Code: 1408-081-PXS
5. Move the engine shutdown switch to the OFF
Certain Caterpillar machines may be equipped with position. The engine will stop.
an optional transmission oil pressure sensor (alert
indicator and brake application).
1. Be sure the area around the machine is clear of 6. Parking brake indicator (1) will come on and
personnel and obstructions. flash. Transmission oil pressure indicator (2) will
come on and flash.
2. Block the wheels.
i01929786
g01003924
Illustration 317
g01003917
Illustration 315
g00907092
Illustration 318
i01773405
Replace any parts that are worn or damaged. Illustration 320 g01005156
g00947096
Illustration 321
i01929793 i01773416
NOTICE
Do not attempt to straighten the ROPS structure. Do
not repair the ROPS by welding reinforcement plates
to the structure.
g00907536
Illustration 323
g01003925
Illustration 322
g00907536
Illustration 325
i01929795
Service Inspection
SMCS Code: 7000
• loose bolts
• trash buildup
• oil, coolant, or fuel leaks
• broken parts or worn parts
• cracks in the frames
Remove any trash and any debris. As needed,
adjust the tire inflation. Make any necessary repairs.
Make sure that all loose connections and all parts
are tightened to the specified torques. Replace any
missing parts before starting the engine or before
operating the machine.
161
Maintenance Section
Service Inspection
g01007484
Illustration 326
Inspection points for the service inspection
(A) Frame (H) Handholds and steps (N) Cooling system
(B) Tires (I) Engine (O) Rear lights
(C) Front lights (J) Engine air precleaner (P) Power train
(D) Bucket and linkage (K) Fuel tank (Q) Rollover Protective Structure (ROPS)
(E) Steering hydraulic system (L) Automatic lubrication system (if
(F) Window washer bottle equipped)
(G) Hydraulic system (M) Ground level controls
g01004855
Illustration 329
g01005154
Illustration 332
i01929796
g01004246
Illustration 336
Reference: For additional information about the Tilt Cylinder and Tilt Lever
correct procedure, refer to Steering System, Bearings - Lubricate
Systems Operation, Testing and Adjusting,
“Neutralizer Valve” for the machine that is being SMCS Code: 5104-086-BD; 6116-086-BD
serviced.
NOTICE
i01930320 Check that the lines attached to all the remote grease
fittings are undamaged. If the grease lines are split,
Steering and Transmission grease will not reach the components that require lu-
Lock Control (STIC Steering) - bricating. Machine damage will result.
g01005178
Illustration 337
g01005179 g01003613
Illustration 338 Illustration 340
g01003616
Illustration 341
g01004248
Illustration 342
Inflate the tires, if necessary. 3. Remove drain plug (1) and drain the oil into a
suitable container.
Reference: For additional information about tire
inflation, tire pressures, and tire inflation pressure 4. Change the transmission oil filter element.
adjustment, refer to the Operation and Maintenance
Manual, “Tire Inflation Information” for the machine Reference: For the correct procedure, refer
that is being serviced. to the Operation and Maintenance Manual,
“Transmission Oil Filter - Replace” for the
machine that is being serviced.
i01930325
Transmission Oil - Change 5. Remove the four bolts, cover (2) and the seal
that hold the magnetic screen assembly in place.
SMCS Code: 3030-044
6. Remove the magnetic screen assembly from the
torque converter housing.
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.
1. Operate the machine for a few minutes in order 9. Clean the magnets with a cloth, stiff bristle brush,
to warm the transmission oil. or pressure air.
13. Install the seal, the cover and the four bolts.
14. Clean the drain plug and install the drain plug.
g01004260
Illustration 343
167
Maintenance Section
Transmission Oil Filter - Replace
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.
g01004258
Illustration 345
Refer to Special Publication, NENG2500, “Caterpillar
15. Remove transmission breather (4). Wash the Tools and Shop Products Guide” for tools and supplies
transmission breather in clean, nonflammable suitable to collect and contain fluids on Caterpillar
solvent. Install the breather. products.
16. Remove oil filler cap (3) and fill the transmission Dispose of all fluids according to local regulations and
with oil. mandates.
17. Start and run the engine at low idle. Inspect the
machine for leaks.
20. Move the transmission directional control to the The transmission oil filter is located on the left side
NEUTRAL position. Engage the parking brake. of the machine in front of the engine.
21. Maintain the transmission oil level between the 1. Remove the drain plug from the bottom of the
“LOW” and “FULL” marks on dipstick (5). filter housing and allow the oil to drain into a
suitable container.
22. Remove oil filler cap (3) and add oil, if necessary.
2. Use a wrench in order to remove the filter
23. Clean and install oil filler cap (3). housing.
24. Stop the engine. 3. Remove the used filter element. Dispose of the
used filter element properly.
SMCS Code: 3067-510 6. Inspect the filter housing seal. Replace the seal
if the seal is damaged.
The machine must be level, the parking brake
engaged and the engine stopped.
168
Maintenance Section
Transmission Oil Level - Check
12. Inspect the transmission oil filter for leaks. 1. While the engine is running at low idle, maintain
the oil level between the “LOW” and “FULL”
marks on dipstick (2).
i01930334
Illustration 347
g01004268
Turbocharger - Inspect
13. Maintain the transmission oil level between the SMCS Code: 1052-040
“LOW” and “FULL” marks on dipstick (2) with the
engine running at low idle. If the turbocharger fails during engine operation,
severe damage to the turbocharger compressor
14. Remove oil filler cap (1) and add oil, if necessary. wheel can result. If the turbocharger fails during
engine operation, severe damage to the engine can
Reference: For information on lubricants and also result.
refill capacities, refer to the Operation and
Maintenance Manual, “Lubricant Viscosities and For example, damage to the turbocharger
Refill Capacities” for the machine that is being compressor wheel could cause parts from the
serviced. turbocharger compressor wheel to enter the engine
cylinder. These parts from the compressor wheel
15. Clean and install oil filler cap (1). can cause additional damage to the following
engine components: pistons, intake valves, exhaust
16. Stop the engine. valves and cylinder head.
• Engine smoke.
• Speeding up of the engine with no load.
Note: For specifications used to check the
turbocharger, refer to Specifications, “3306B
Engine” for the machine that is being serviced.
g01004274
i01930335 Illustration 350
i01930336
Window Wiper -
Inspect/Replace
(If Equipped)
SMCS Code: 7305-040; 7305-070
g01004270
Illustration 349
g01004273
Illustration 351
i01930337
Window Washer Bottle - Fill Inspect the condition of the wiper blades. Replace
the wiper blades if the wiper blades are worn or
(If Equipped) damaged. If the wiper blades streak the window,
replace the wiper blades.
SMCS Code: 7306-544-KE
NOTICE
When operating in freezing temperatures, use
Caterpillar nonfreezing window washer solvent or
equivalent. System damage can result from freezing.
170
Reference Information Section
Reference Materials
i01777502
Decommissioning and
Disposal
SMCS Code: 1000; 7000
Index
A Burn Prevention..................................................... 15
Batteries............................................................. 15
Adjustments........................................................... 98 Coolant............................................................... 15
Air Conditioning and Heating Control .................... 42 Oils..................................................................... 15
Air Conditioning and Heating System
Operation ......................................................... 42
Alternate Exit ......................................................... 45 C
Articulated Hitch Bearings - Inspect .................... 112
Articulated Hitch Bearings - Lubricate ................. 112 Cab Air Filter - Clean/Replace (If Equipped) ....... 120
Automatic Lubrication Filler Filter - Clean (Hydraulic Cab Pressurizer Filter ...................................... 121
Type - If Equipped)............................................. 113 Return Air Filter................................................ 121
Automatic Lubrication Grease Tank - Fill (Hydraulic Capacities (Refill) ................................................ 106
Type - If Equipped)............................................. 113 Caterpillar Monitoring System ............................... 30
Automatic Lubrication Inline Filter - Clean (Hydraulic Warning Categories ........................................... 31
Type - If Equipped)............................................. 113 Warning Operation............................................. 31
Autoshift Control (STIC Steering) .......................... 50 Caterpillar Monitoring System - Self Test .............. 65
Central Lubrication System - Lubricate (If
Equipped) .......................................................... 121
B Changing Direction and Speed.............................. 73
Circuit Breakers - Reset ...................................... 122
Backup Alarm ........................................................ 41 Collet Pin Bolt Torque - Check............................. 123
Backup Alarm - Test ............................................ 114 Cooling System Coolant (DEAC) - Change......... 124
Battery - Recycle ................................................. 114 Cooling System Coolant (ELC) - Change............ 125
Battery Disconnect Switch..................................... 28 Cooling System Coolant Additive (DEAC) - Add.. 127
Battery Electrolyte Level - Check ........................ 114 Add Coolant Additive (If Required) .................. 127
Battery, Battery Cable or Battery Disconnect Switch - Change Coolant Conditioner Element (If
Replace.............................................................. 115 Required) ....................................................... 128
Before Operation ................................................... 20 Cooling System Coolant Extender (ELC) - Add... 128
Before Operation (Remote Control)....................... 83 Cooling System Level - Check............................. 129
Before Starting Engine .................................... 19, 61 Cooling System Pressure Cap - Clean/Replace.. 130
Belts - Inspect/Adjust/Replace............................. 116 Cooling System Water Temperature Regulator -
Adjust the Air Conditioning Compressor Belt (If Replace.............................................................. 131
Equipped)....................................................... 117 Crankshaft Vibration Damper - Inspect ............... 132
Adjust the Alternator Belt ................................. 116 Crushing Prevention and Cutting Prevention......... 14
Brake Accumulator - Check ................................. 117
Brake Discs - Check ............................................ 117
Brake Release (If Equipped) ................................. 94 D
Brake Release with the Recovery Bar ............... 95
Brake Release with the Recovery Hook ............ 96 Decommissioning and Disposal .......................... 171
Brake Release System - Test (If Equipped)......... 118 Differential and Final Drive Oil - Change ............. 132
Braking .................................................................. 46 Differential and Final Drive Oil Level - Check ...... 135
Optional Push-to-Engage Type Parking Brake Drive Shaft Universal Joints, Splines and Bearings -
Control.............................................................. 47 Inspect/Lubricate ............................................... 136
Parking Brake..................................................... 46
Parking Brake Drive Through............................. 47
Service Brake..................................................... 47 E
Standard Pull-to-Engage Type Parking Brake
Control.............................................................. 46 Electrical Storm Injury Prevention ......................... 18
Braking System - Test.......................................... 118 Emergency Stopping (Remote Control)................. 87
Parking Brake Holding Ability Test ................... 119 Engine Air Filter Primary Element -
Service Brake Holding Ability Test ................... 118 Clean/Replace ................................................... 136
Bucket Control Group Safety Pins ......................... 59 Engine Air Filter Secondary Element - Replace .. 138
Bucket Loading Hauling Units ............................... 76 Engine Air Precleaner - Clean ............................. 138
Bucket Pivot Bearings - Lubricate ....................... 120 Engine and Machine Warm-Up ............................. 70
Bucket Rated Load ................................................ 25 Preparing to Operate the Machine..................... 71
Engine Crankcase Breather - Clean.................... 139
Engine Mounts - Inspect...................................... 139
Engine Oil and Filter - Change ............................ 140
173
Index Section
H
F
Horn....................................................................... 41
Fan Drive Bearing - Lubricate.............................. 144 Hydraulic System Oil - Change ........................... 150
Filter and Screen Locations................................. 107 Hydraulic System Oil Filter - Replace.................. 151
Fire Extinguisher Location ..................................... 17 Hydraulic System Oil Level - Check .................... 152
Fire Prevention and Explosion Prevention............. 15 Hydraulic Tank Breaker Relief Valve - Clean ....... 153
Ether .................................................................. 17
Fire Extinguisher ................................................ 17
Lines, Tubes and Hoses..................................... 17 I
Fire Suppression System - Check (If Equipped).. 145
Fire Suppression System (Dry Powder) (If Identification Information ....................................... 27
Equipped) ............................................................ 56 Idle Timer Control (Engine Shutdown) (If
Fire Suppression Control (Automatic)................ 57 Equipped) ............................................................ 30
Fire Suppression Control (Manual) .................... 57 Implement and Steering Lockout (STIC Steering) -
In Case of Fire ................................................... 58 Test .................................................................... 153
Fire Suppression System (Foam) (If Equipped) .... 55 Implement and Steering Hydraulic Lockout ..... 154
Fire Suppression Control (Engine Shutdown).... 55 Steering Mechanical Lockout........................... 153
Fire Suppression Control (Manual) .................... 55 Important Safety Information ................................... 2
In Case of Fire ................................................... 56 Indicators ............................................................... 35
Forced Shutdown of Machine (Remote Control) ... 87 Indicators and Gauges - Test............................... 154
Foreword.................................................................. 5
California Proposition 65 Warning ....................... 4
Caterpillar Product Identification Number ............ 5 J
Certified Engine Maintenance.............................. 4
Literature Information........................................... 4 Joystick Control ..................................................... 52
Machine Capacity ................................................ 5 Joystick Control Lever - Optional Type............... 52
Maintenance ........................................................ 4 Joystick Control Lever - Standard Type.............. 52
Operation ............................................................. 4
Safety................................................................... 4
Fuel System - Prime............................................ 145 L
Fuel System Primary Filter - Clean/Replace ....... 146
Fuel System Secondary Filter - Replace............. 147 Leaving the Machine ............................................. 80
Fuel System Water Separator - Drain.................. 148 Lift Arm and Cylinder Bearings - Lubricate.......... 155
Fuel Tank Cap and Strainer - Clean .................... 148 Lift Arm Positioner ................................................. 98
Fuel Tank Water and Sediment - Drain................ 149 Lift Arm Positioner Switch...................................... 38
Fuses - Replace .................................................. 149 Lifting and Tying Down the Machine...................... 89
Light Switches ....................................................... 36
Loading, Hauling and Dumping ............................. 75
Lubricant Viscosities............................................ 104
Lubricant Viscosities and Refill Capacities .......... 104
174
Index Section
Table of Contents..................................................... 3
Throttle Control...................................................... 51
Tilt Cylinder and Tilt Lever Bearings - Lubricate.. 164
Tilt Linkage Bearings - Lubricate......................... 165
Tire Inflation - Check ........................................... 165
Tire Inflation Information...................................... 103
Tire Inflation Pressure Adjustment ...................... 103
Tire Inflation with Nitrogen................................... 103
Tire Information ..................................................... 18
Tire Shipping Pressure ........................................ 103
Torque Specifications .......................................... 100
Torques for Ground Engaging Tool Bolts ............. 100
Towing Information ................................................ 91
Towing the Machine............................................... 91
Towing with an Inoperable Engine ..................... 92
Towing with an Operable Engine........................ 92
Transmission Control ............................................. 49
Direction Selection ............................................. 49
Speed Selection................................................. 49
Transmission Oil - Change .................................. 166
Transmission Oil Filter - Replace......................... 167
Transmission Oil Level - Check ........................... 168
Transmitter Controls .............................................. 81
Bucket Control Lever.......................................... 82
Motion Control Lever.......................................... 81
Transmitter Control Switches ............................. 82
Transportation Information..................................... 88
Turbocharger - Inspect......................................... 168
Delivery Date:
Product Information
Model:
Attachment Information:
Dealer Information
Name: Branch:
Address:
Sales:
Parts:
Service:
©2003 Caterpillar
All Rights Reserved Printed in U.S.A.