CAT Operator Manual 569 30015167 - A

Part No.
30015167
March 2012
Rev. A
569 - 569PH Knuckleboom Loader

To the Operator
569 1111
To the Operator
569 ii 1111
To the Operator
TO THE OPERATOR
Introduction
do not use this machine unless you have read and understood this
manual and have the necessary training and authorization to operate
and maintain your machine properly.
remember that you are the key to safety. good safety practices protect
you and the people around you. make this manual a working part of your
safety program.
569 Loader
This operator's manual describes how to safely operate the Caterpillar Loaders. The Caterpillar loader is a truck
trailer–mounted loader used for handling random–length logs and tree–length stems.
Minimum trailer is a 40-foot (12.2 m) tandem-axle trailer (45-foot (13.7 m) for delimbers) with 40,000 pounds
(18,144 kg) GVW (gross vehicle weight) rating, and a mounting surface height of about 39 inches (99 cm).
Minimum truck is a 6 x 4 live tandem truck of not less than 50,000 pounds (22,680 kg) GVW rating. Truck must
have a double channel frame and minimum CA of 132 inches (334 cm). A CA of 144 to 168 inches (366 - 427 cm)
is recommended. A maximum CA for live heel of 144 inches (366 cm) is required.
Capacity at maximum reach: per sae j2417

569 Knuckle Boom: 32 foot (9.75 m) radius, 5 foot (1.5 m) elevation, 4,458 pounds (2,340 kg).
Follow the instructions in this operator's manual to safely operate the Caterpillar log loaders. Directions in this
manual are referenced from the operator's seat facing forward.
FORWARD
LEFT RIGHT
BACK
You can help improve this manual. If you find any mistakes or if you know of a way to improve the procedures,
please let us know. Mail your letter to: ATTN: TECHNICAL PUBLICATIONS, Caterpillar Forest Products Inc.,
3249 S. COUNTY ROAD 45, P.O. BOX 568, OWATONNA MN 55060–0568.
This operator's manual includes information available and current at the time of approval for printing. Cater-
pillar Forest Products, Inc. reserves the right to improve its product without giving prior notice or incurring
obligation.
This operator’s manual should be regarded as part of the machine. Suppliers of both new and second
hand machines are advised to retain documentary evidence that this manual was provided with the machine.
569 iii 1111

To the Operator
Safety Symbols
SAFETY ALERT SYMBOL
Means: ATTENTION. BE ALERT. YOUR SAFETY IS

INVOLVED.
This safety symbol is used for important safety messages.

When you see this symbol, follow the safety message to
avoid personal injury and/or property damage.
Understand signal words: DANGER, WARNING, and CAUTION are used with the SAFETY ALERT SYMBOL.
DANGER identifies the hazard or
DANGer unsafe practice that will result in severe

personal injury or death.
WARNING identifies the hazard or unsafe practice
WArNING that could result in severe personal injury or death.
CAUTION CAUTION identifies the hazard or unsafe practice

that could result in personal injury or property dam-
age.
NOTICe NOTICE identifies important installation, operation, or

maintenance information.
569 iv 1111
To the Operator
contents
product protection plan Engine Oil Pressure Warning Indicator..................4-5
Machine i Air Cleaner Warning Indicator...................................4-6
Attachment..........................................................................ii Hydraulic Oil Temp Wrng. Indicator........................4-6
To the Operator.................................................................iii Low Hydraulic Oil Wrng. Indicator...........................4-6
Safety Symbols..................................................................iv Switch Panel....................................................................4-7
Contents................................................................................v Ignition Switch................................................................4-8
Dome Light......................................................................4-8
01 - general safety.........................................................1-1 Error Code Indicator Lights........................................4-8
Safety Alert Symbol......................................................1-1 Circuit Breakers...............................................................4-9
Operator Preparation...................................................1-1 Heat Control Lever........................................................4-9
Avoid Contact with Stabilizers..................................1-1 Pilot Pressure Shut Off.............................................. 4-10
Battery Safety..................................................................1-2 Battery Disconnect Master Switch....................... 4-10
Control Shut Off Lever.................................................1-2 Throttle ......................................................................... 4-11
Electric Lines....................................................................1-3 Swing Pedal.................................................................. 4-11
Falling or Swinging Logs.............................................1-3 Left Joystick.................................................................. 4-12
Fire Prevention/First Aid..............................................1-4 Right Joystick............................................................... 4-13
Fluids Under Pressure..................................................1-4 Right Joystick Rocker Switch.................................. 4-14
Hand Holds & Steps......................................................1-5 Stabilizer Controls...................................................... 4-14
Hand Signals....................................................................1-5 Hourmeter..................................................................... 4-14
Hoses & Fittings..............................................................1-6 Operator’s Seat............................................................ 4-15
No Riders on Machine..................................................1-6 AM/FM Stereo Cassette............................................ 4-17
Operator Safety..............................................................1-7
Pinch Points.....................................................................1-7 05 - Pre-Start Inspection.............................................5-1
Practice Safe Maintenance.........................................1-7 Pre-Start Checks on the Ground..............................5-1
Pressure Settings...........................................................1-8 Pre-Start Checks on the Platform.............................5-2
Protective Clothing.......................................................1-8 Pre-Start Checks in the Cab.......................................5-3
Protective Devices/Equipment.................................1-8 Fire Prevention................................................................5-4
Radiator Cap....................................................................1-9
06 - Operation.....................................................................6-1
Refueling...........................................................................1-9
General Guidelines........................................................6-1
Servicing Control Valves........................................... 1-10
Electrocution Danger...................................................6-2
Servicing Machine with Engine Running........... 1-10
Overhead Loads Warning...........................................6-2
Starter Circuitry........................................................... 1-10
Getting on Machine......................................................6-3
Unauthorized Welding.............................................. 1-11
Machine Start Up...........................................................6-3
Unstable Platform....................................................... 1-11
Starting the Engine.......................................................6-4
02 - safety decals............................................................2-1 Starting Machine with Booster Battery.................6-5
Loader ............................................................................2-1 Indicator Lamp Checks................................................6-6
Carrier ............................................................................2-2 Cold Weather Starting
Truck Mount Cab Interior............................................2-3 Engine Pump Disconnect.........................................6-8
Bar Slasher/Delimber Cab Int....................................2-4 Warm-up Period.............................................................6-9
Feathering the Controls........................................... 6-10
03 - component terminology..................................3-1 Using Stabilizers.......................................................... 6-11
Landing Layout............................................................ 6-12
04 - controls and instruments.............................4-1
Heeling - Picking up Logs........................................ 6-12
Operator’s Cab ...............................................................4-1
Grapple Control........................................................... 6-13
Instrument Console ....................................................4-2
Stopping the Machine.............................................. 6-13
Engine Coolant Temp. Wrng. Ind..............................4-3
Getting off Machine................................................... 6-14
Low Coolant Warning Indicator................................4-3
Voltage Warning Indicator.........................................4-4
Hydraulic Oil Filter Warning Indicator....................4-4
Fuel Gauge.......................................................................4-5
569 1111
To the Operator
contents
07 - Break-In Period.........................................................7-1 Maintenance Details

After First 10 Hours.......................................................7-1 As Required.............................................................. 11-9
After First 100 Hours.....................................................7-2 Check Electrical System....................................... 11-9
Clean AC Condenser...........................................11-10
08 - Transporting.............................................................8-1 Clean/Replace Recirculation Air Filter..........11-10
09 - Fuels and Lubricants...........................................9-1 Fill Windsheild Washer Fluid Reservoir.........11-11
Clean Windsheild & Windows..........................11-11
Fuel 9-1
Check/Replace Polycarbonate Window . ...............
Engine Oil ........................................................................9-2
Skylight................................................................11-12
Hydraulic Oil....................................................................9-3
Adjust Slasher/Delimber Saw Bar Chain.................
Grease ............................................................................9-3
.......................................................................11-12
Grease for Swing Drive Bearing
Drain Replace Hydraulic Oil..............................11-13
and Swing Drive Motor.............................................9-4
Hazard Decals........................................................11-13
Lubricant for Pinion and
Swing Gear Teeth........................................................9-4 Daily or Every 10 Hours......................................11-14
Lubricant for Swing Drive Gear Box........................9-4 Daily Visual Inspection.......................................11-14
Cylinder Rod Corrosion Preventive.........................9-4 Lube Adapter Knuckle........................................11-14
Engine Coolant Specifications..................................9-4 Lube Stabilizer Pad & Pivot Points..................11-14
Storing Lubricants.........................................................9-5 Lube Stabilizer Cylinder Road Ends...............11-15
Lube Stablizer Arm Pivot Points......................11-15
10 - Maintenance Safety........................................... 10-1 LubeStablizer Cylinder Base Ends..................11-15
Before Maintenance.................................................. 10-1 LubeMain Boom Pivot Pins...............................11-15
Practice Safe Maintenance...................................... 10-1 Lube Main Boom Cylinder Base Ends...........11-16
Hydraulic Safety.......................................................... 10-2 LubeMain Boom Cylinder Rod Ends..............11-16
Protective Clothing.................................................... 10-2 Lube Main/Stick Pivot Pins................................11-16
Servicing Cotrol Valves, Cylinders, Pump s & . .......... Lube Stick Boom Cylinder Base Ends............11-16
Motors.................................................................... 10-3 Lube Stick Boom Cylinder Rod Ends.............11-17
Unauthorized Welding.............................................. 10-3 Lube Swing Bearing............................................11-17
During Maintenance.................................................. 10-4 Lube Pinion Gear..................................................11-17
Battery Safety............................................................... 10-4 Check Hydraulic Oil Reservoir Level..............11-18
Cooling Fan................................................................... 10-4 Fill Hydraulic Reservoir.......................................11-18
Diesel Exhaust.............................................................. 10-5 Prime the Pump....................................................11-20
Fluids Under Pressure............................................... 10-5 Air Cleaner Maintenance...................................11-20
Fuels & Lubricants...................................................... 10-6 Unloader Valve......................................................11-20
Pinch Points.................................................................. 10-6 Inlet Hood...............................................................11-20
Servicing Machine with Engine Running........... 10-6 Restriction Indicator............................................11-21
After Maintenance...................................................... 10-7 Cleaning Primary Element................................11-22
Disposing of Waste..................................................... 10-7 Check Fire Extinguisher.....................................11-23
Stroing of Flamable Materials................................ 10-7 Fill Fuel Tank...........................................................11-23
Inspect Cooling Fan.............................................11-23
11 - Scheduled/Periodic Maintenance . .................
Services................................................................................ 11-1 Inspect Belts...........................................................11-23
Drain Fuel Water Separator...............................11-24
Lubrication and Maintenance Intervals.............. 11-1
Check Engine Crankcase Oil Levle.................11-24
Lubrication Notice...................................................... 11-1
Check Radiator Coolant Level..........................11-25
Position Machine for Maintenance...................... 11-1
Inspect Eletrical Components.........................11-26
Maintenance Charts
Inspect Loader Mounting Bolts.......................11-26
As Required.............................................................. 11-2
Weekly or Every 50 Hours.................................11-27
Daily or Every 10 Hours........................................ 11-3
Weekly Inspection...............................................11-27
Weekly or Every 50 Hours................................... 11-5
Check Boom & Cylinder Attaching Pins.......11-28
Monthly or Every 250 Hours............................... 11-6
Check Stablizer Attaching Pins........................11-28
Every 500 Hours...................................................... 11-7
Check Hydraulic Oil Res. Hardware................11-28
Every 1000 Hours................................................... 11-8
Check Hydraulic Connections.........................11-29
569 vi 1111
To the Operator
contents
Clean Radiator & Oil Cooler..............................11-29 Seat ......................................................................... 13-6

Check Hydraulic Oil for Contaminants.........11-30 Electrical System......................................................... 13-6
Cehck Swing Drive Gear Box Lube Level Cleanliness of Hydraulic Components................ 13-7
.......................................................................11-30
14 - Specifications......................................................... 14-1
Monthly or Every 250 Hours.............................11-31
Machine Specs............................................................. 14-1
Change Engine Oil & Filters..............................11-31
Hydarulic Connection Torque Specs
Inspect Air Intake & Exhaust Connections
SAE 37 Deg Flare................................................ 14-3
.......................................................................11-32
Hydarulic Connection Torque Specs
Battery Service......................................................11-32
O-Ring Face Seal................................................. 14-4
Seat Maintanance................................................11-33
Torque Chart for Fasteners...................................... 14-5
Check Swing Drive Fasteners...........................11-34
Cylinder Torque Specs............................................... 14-6
Every 500 Hours....................................................11-35
Pressure Settings........................................................ 14-7
Replace Hydraulic Return Line Filter.............11-35
Check Cooling System........................................11-36 15 - Serial Numbers....................................................... 15-1
Replace Fuel Lift Pump Pre-Filter...................11-36
Replace Primary Fuel Filter/Watter Separator . .... 16 - Material Safety Data Sheets........................ 16-1
Element....................................................................11-37
Prime the Fuel System........................................11-37
Replace Pilot Filter...............................................11-38
Replace Pilot Return/Case Drain Filter..........11-39
Check Outer Swing Bearing Fastener Torque
.......................................................................11-39
Check Inner Swing Bearing Fastener Torque
.......................................................................11-40
Scheck Swivel Arm Fastener Torque..............11-40
Cehc Swivel Fastener Torque...........................11-40
Check Pinion Gear Fastener Torque...............11-40
Check Stationary Heel Fastneer Torque.......11-41
Replace Slasher/Delimber Return Line Filter
.......................................................................11-41
Every 1000 Hours.................................................11-42
Change Hydraulic Reservoir Oil......................11-42
Fill Hydraulic Reservoir.......................................11-42
Prime the Pump....................................................11-44
Replace Hydraulic Reservoir Breather Filter..........
.......................................................................11-44
Replace Pressure Vacume Relief Valve..........11-45
Flush & Fill Cooling System...............................11-45
Drain & Replace Swing Drive Gear Box Lube
.......................................................................11-47
Check Swing Drive Grease Level.....................11-47
Drain & Fill Swing Drive......................................11-48
Check/Clean Collector Ring..............................11-48
12 - Storage....................................................................... 12-1
Preparing Machine for Storage.............................. 12-1
Taking Machine Out of Storage............................. 12-2
13 - Troubleshooting................................................. 13-1
Hydraulic System........................................................ 13-1
Engine ......................................................................... 13-2
Flash Codes................................................................... 13-4
Event Codes.................................................................. 13-5
569 vii 1111
To the Operator
notes
569 viii 1111

general safety
general safety
WArNING Do not operate this machine without reading and understanding this operator’s
manual.
safety alert symbol

Read all safety messages.
To avoid personal injury and/or property damage, fol-
low safety messages.
operator preparation
Operator must be fully trained, qualified, and au-
thorized to operate this machine. Before operating
this machine, operator must know the location and
purpose of
• controls
• indicator lights
• instruments
• safety and instruction decals

(See Section 2, Safety Decals.)
avoid contact with stabilizers
WArNING Coming into contact with

stabilizers can cause serious personal injury or
death.
Clear all personnel from work area before raising or
lowering stabilizers.
g.043.03
569 1- 1111

general safety
battery safety
WArNING Batteries produce explo-

sive gases that can cause severe personal injury or
death.
Battery acid is poisonous and can cause severe
burns. If acid is taken internally, call a physician
immediately. If acid contacts skin or clothing, flush
with water immediately. Keep batteries away from
children.
Battery posts, terminals, and related accessories
contain lead and lead components, chemicals
known to the State of California to cause cancer
and reproductive harm. Wash hands after handling.
Keep sparks, flames, and cigarettes away from bat-
teries. Ventilate properly when charging or using
batteries in enclosed space. Always shield eyes
with goggles and wear a face shield when working
near batteries. Do not lean over batteries during
this operation. Always connect positive (+) to posi-
tive (+) and negative (-) to negative (-). For further
instructions, see Jump Starting Battery in Section
6, Operation. If battery acid contacts eyes, flush
them with water for 15 minutes and seek immedi-
ate medical attention.
Never charge a battery or jump start engine if bat-
tery is frozen. Warm battery to 60°F (16°C) or it may
explode. Be sure vent caps are tight. When jump
starting from another machine, be sure machines
do not touch. This machine has a 12-volt starting
system. Use equal voltage for jump starting.
control shut off lever
WArNING Accidental movement

of turntable or booms can cause serious personal
injury or death.
Before leaving cab, lift control shut off lever to disen-
gage hydraulic pilot circuit and to free door entry/exit
path.
569 1- 1111

general safety
electric lines
DANGer SERIOUS INJURY OR

DEATH WILL RESULT FROM CONTACT WITH ELEC-
TRIC LINES.
Never move any part of machine or load closer
than 10 feet plus twice the line insulator length to
electric lines. A line insulator is what connects an
electric line to an electric pole.
For example, if a line insulator is 6 inches long,
operator must stay at least 10 feet plus twice the
line insulator length (2x6 =12 inches or 1 foot) from
electric line, which means machine must stay at
least 11 feet from the electric line.
If machine touches an electric line, stay inside the
cab. Carefully move machine or load away from
electric line, without pulling the line down.
DO NOT allow anyone else to touch machine while
it is touching an electric line. If machine cannot be
moved away from the electric line without pulling
line down, have someone contact the utility com-
pany to disconnect power from line. If this is not
possible, or if machine begins to burn, jump away
from machine to the ground with both feet togeth-
er, in one smooth jump. Do not run or walk away
from machine. Jump with feet together (“bunny
hop”) away from machine. DO NOT touch machine
and ground at the same time or else electricity in
the line will go through your body. Get away from
machine after jumping.
Notify the utility company immediately. DO NOT
let anyone near the machine while it is touching an
electric line.
Electrical storm
WArNING Electrical storms (light-

ning) can cause severe personal injury or death.
When lightning is striking in the vicinity of the
machine, the operator should never attempt the
following procedures:
Mount the machine
Dismount the machine
If you are in the operator’s station during an electrical
storm, stay in the operator’s station. If you are on the
ground during an electrical storm, stay away from the
vicinity of the machine.
569 1- 1111

general safety
falling or swinging logs
WArNING Falling or swinging logs,

booms, or attachments can cause severe personal
injury or death.
Never operate the boom, attachment or load over or
near personnel.
fire prevention/First aid
CAUTION Fires can cause personal

injury and/or machine damage.
Keep machine clean. Forest debris, rags, and trash will
cause fires. Remove all debris, rags, and trash from
machine, especially around engine and hydraulic
components.
Repair all hydraulic and fuel leaks immediately. Do not
operate machine with hydraulic or fuel leaks.
Fire prevention beats fire fighting. Remove debris from
all compartments after every 8 hours of operation, or
more often, if warranted by working conditions.
Install a first-aid kit in the cab.
Properly maintain first-aid kit and fire extinguisher. Fol-
G.111.04 low instructions provided with them.
569 1- 1111

general safety
fluids under pressure
WArNING Fluids escaping under

pressure can penetrate skin and cause severe
personal injury or death. Wear eye and personal
protection equipment (PPE)!
Always use a board or cardboard when checking oil
hoses, lines, and fittings for leaks, cracks, or defects.
Be sure all clamps are in their proper position and
torqued as required and specified. Be sure hoses are
not twisted or touching parts.
DO NOT use hands to search for leaks. Escaping fluids
can penetrate skin and enter the bloodstream. Before
disconnecting lines, relieve all pressure.
DO NOT apply pressure to a damaged line, hose, or
fitting.
If ANY fluid is injected into the skin, seek medical at-
tention immediately. A serious infection or reaction
can result without proper medical treatment.
hand holds and steps
WArNING Slips and falls can cause

severe personal injury or death.
Use provided hand holds and steps while maintain-
ing at least 3 points of support (1 foot and 2 hands
or 2 feet and 1 hand) when getting on and off ma-
chine. Face machine when getting on and off of it.
Never use controls as hand holds. Never use steer-
ing wheel as a hand hold. Moving the steering
wheel from its center position will COMPLETELY
turn machine right or left.
DO NOT mount machine if hand rails or steps are
broken or missing. Get them repaired first.
DO NOT jump on or off machine unless it has
touched a live electrical wire and it must be exited.
Ensure firm foot position when getting on and off
machine. Be careful of slippery conditions on plat-
form, steps, and hand holds when getting on and
off machine.
Remove oil, grease, mud, ice, etc. before mounting
or dismounting machine.
To prevent slips and falls, replace skid-resistant ma-
terial if it is worn, damaged or missing.
569 1- 1111

general safety
hand signals
WArNING Accidents can cause se-

vere personal injury or death.
Know and use the hand signals required for particular
jobs.
Know who has the responsibility for signaling.
hoses and fittings
WArNING Mismatched brands or

types of hoses and fittings can blow apart and
cause severe personal injury or death.
DO NOT interchange brands or types of hoses
and fittings.
DO NOT install a fitting from one manufacturer on a
hose from a different manufacturer.
DO NOT install crimp fittings on hoses meant for reus-
able fittings.
Wear eye and personal protection equipment (PPE)!
hoses, lines, and fittings periodically for leaks, cracks or
defects. Be sure all clamps are in their proper position
and torqued as required and specified. Be sure hoses
are not twisted or touching parts.
569 1- 1111

general safety
no riders on machne
WArNING Machine riders can fall

from machine or be injured by movement of ma-
chinery, causing severe personal injury or death.
Do not allow riders on any machine that is operating
or moving.
operator safety
WArNING Flying debris, tree limbs,

and/or other material can cause severe personal
injury or death.
When operating machine:
1. Cab door must stay closed.
2. Window material and/or cab guarding MUST be in
place.
3. All cab openings (front, side, and rear) MUST be
covered with window material (no glass) and/or
protective screen.
4. Window guarding MUST be locked
in place.
569 1- 1111

general safety
practice safe maintenance

Understand service procedures before performing
maintenance. When performing maintenance, keep
area around machine clean and dry.
DO NOT service machine while it is moving. Keep away
from power-driven parts. Lower attachment to the
ground. Disengage power. Shut engine down. Move
controls in all directions to relieve hydraulic pressure.
Remove key from ignition. Allow machine to cool
down.
Support all raised equipment.
Keep all machine parts in good condition, and be sure
parts are properly installed. Repair damage immedi-
ately. Repair all hydraulic and fuel leaks immediately.
Replace worn or broken parts. Remove any buildup of
grease, oil, or debris.
Disconnect battery ground cable (-) before adjusting
the electrical system.
pressure settings
WArNING Excessive hydraulic pres-

sure can cause component or structural failure,
which may result in severe personal injury or
death.
DO NOT exceed factory-adjusted pressure settings.
569 1- 1111

general safety
protective clothing
Wear OSHA or local governing body-approved protec-
tive clothing when working on or near this machine,
such as
• ear protection • hard hat
• gloves • orange vest
• goggles • steel-toed shoes
Wear snug, protective clothing that is belted where

required.
Remove jewelry before working on or near this ma-
chine.
protective devices/equipment
WArNING Misuse, interference and

ignorance of protective equipment or devices can
Alarms, fire prevention equipment, ROPS/FOPS/OPS,
and other safety equipment is installed on machine for
your protection.
Never ignore, disconnect, disable or modify protection
equipment in any manner.
radiator cap
CAUTION Pressurized cooling sys-

tem can cause scalding burns.
Do not remove radiator cap unless engine is cool.
Allow system to cool. Remove cap slowly to relieve
pressure before removing completely.
569 1- 1111

general safety
refueling
WArNING Fires and explosions can

Handle fuel with care. It is highly flammable.
DO NOT refuel machine while smoking or when near
open flame or sparks.
Always stop engine before refueling. Fill fuel tank out-
doors. Prevent fires by keeping machine clean of trash,
grease, and debris. Always clean up spilled fuel.
starter circuitry
DANGer MACHINE will start in
gear if start circuitry is bypassed.
Do not attempt to start machine engine by shorting
starter circuit across starter terminals. Doing so may
cause unintended machine movement which could
result in severe personal injury or death and serious
machine and/or property damage.
unauthorized welding
WArNING Unauthorized welding

can cause structural failure and/or severe personal
injury or death.
DO NOT weld on any structural member.
Any unauthorized welding or repair will void
the warranty.
Once authorized, be sure to turn battery disconnect
master switch OFF and place welding ground (stinger)
as close to weld site as possible. Do not allow weld cur-
rent to pass through bearings or pivot points.
G.020.05
NOTICe Unauthorized welding can

cause damage to the electrical system.
569 1-10 1111

general safety
unstable platform
WArNING Unstable platform can

Lower all stabilizers before operating machine.
569 1-11 1111

general safety
569 1-12 1111

Safety decals
SAFETY DECALS
The following safety decals are located in positions on the machine as continual reminders of hazards. Serious
injury or property damage can occur if safety instructions are not followed.
Keep all safety decals clean and readable. Use soft cloth, water, and soap to clean decals if they are too dirty to
read. Do not clean safety decals with solvent. Solvent can damage them.
Replace safety decals immediately if they are damaged, missing, or hard to read. Contact an authorized dealer
for replacement safety decals. Authorized dealers will provide free replacement safety decals if you give them a
valid serial number for your machine.
NOTICe
If you replace a part that has a safety decal on it, apply a new safety decal to the replace-
ment part. Before putting a new decal on the machine or part, be sure the surface where the decal will be mounted is
clean and dry.
569 2- 1111

Safety decals
LOADER DECALS
CAutiON
tHis LiftiNg ROd tO Be
used fOR LiftiNg
COuNteRweigHt ONLy.
dO NOt use fOR LiftiNg
LOAdeR
wARNiNg
eXCessIVe HYDrAULIC
pressUre CAN CAUse
COMpONeNT Or sTrUCTUrAL
FAILUre, WHICH MAY resULT
IN seVere persONAL INjUrY
Or DeATH.
DO NOT eXCeeD
FACTOrY–ADjUsTeD
reLIeF pressUre seTTINGs.
1291 10004129
wARNiNg
eXpLODING GAses AND ACID
CAN CAUse seVere BUrNs.
DO NOT WOrK ON BATTerIes

WITHOUT prOper INsTrUCTION
dANgeR KeeP CLeAR

AND TrAINING.
see OperATOrs MANUAL.
10042434 10008930
CONTACT WITH FAN

COULD CAUse persONAL INjUrY.
DO NOT pLACe HANDs NeAr FAN

WHeN sTArTING Or rUNNING
eNGINe.
ALWAYs repLACe sHrOUD DOOrs
AFTer WOrKING ON eNGINe.
531147
CAutiON
pressUrIZeD COOLING
sYsTeM
CAN CAUse
sCALDING BUrNs.
ALLOW sYsTeM TO COOL

reMOVe CAp sLOWLY
WITH GLOVes ON.
10008922
CAutiON
serVICING THIs MACHINe
CAN CAUse INjUrY Or
MACHINe DAMAGe IF DONe
IMprOperLY.
Use prOper TOOLs AND

eQUIpMeNT.
reFer TO OperATOrs
MANUAL FOr INsTrUCTIONs.
wARNiNg
eXCessIVe HYDrAULIC
pressUre CAN CAUse
COMpONeNT Or sTrUCTUrAL
FAILUre, WHICH MAY resULT
IN seVere persONAL INjUrY
Or DeATH.
DO NOT eXCeeD
FACTOrY–ADjUsTeD
reLIeF pressUre seTTINGs.
1291 10004129
DO NOT eXCeeD reLIeF seTTING

reFer TO OperATION & MAINTeNANCe MANUAL
FOr COrreCT reLIeF pressUre seTTINGs
0189
569 2- 1111

Safety decals
CAB DECALS
569 2- 1111

Safety decals
TMS trailer DECALS
Tire Malfunction
This warning is located on each side of the machine
trailer.
WArNING Do not exceed speeds of

50 mph when transporting machine. Tire malfunc-
tion can occur resulting in serious personal injury
or death.
569 2- 0511

1111
Component Terminology
COMPONENT TERMINOLOGY
Loader
1. Subframe assembly 10. Cab

2. Stabilizer 11. Main boom cylinder
3. Swing bearing 12. Main boom
4. Swing motor 13. Stick boom cylinder
5. Upper frame assembly 14. Stick boom
6. Hydraulic pump assembly 15. Grapple
7. Hydraulic oil reservoir 16. Grapple knuckle
8. Hydraulic oil filter 17. Stationary heel (option)
9. Oil cooler 18. Operator protection guard
19. Turntable assembly
569 3- 1108

Component Terminology
Loader
1. SAP Chassis 9. Control Valves

2. Subframe 10. Swing Motor (other side)
3. Turntable 11. Main Boom
4. Operator’s Cab 12. Main Boom Cylinder
5. Engine Compartment 13. Stick Boom
6. Hydraulic Pump & Drive 14. Stick Boom Cylinder
7. Hydraulic Oil Reservoir 15. Tilt Cylinder
8. Fuel Tank 16. Grapple
17. Grapple Tilt Cylinder
18. Grapple Head
569 3- 1108

controls and instruments
Operator’s cab
7
4 3
8
9
14
1 10
2
11
12
13
G.023.03
1. Operator’s Seat 8. Error Code Indicator Lights

2. Engine Throttle Control 9. Stabilizer Switches
3. Right Hand Joystick Control 10. Power Supply
4. Left Hand Joystick Control 11. Washer/Wiper and Light Switches
5. Pilot Pressure Shutoff Lever 12. A/C Heat/Defrost Switches
6. Foot Control - Swing Pedal 13. Heat Control Lever
7. Instrument Console 14. Ignition
569 4- 1111

joysticks with pipe handle attachment
1
2
1. Left hand Control - Stick, Swing & Jib

2. Rear Right Hand Control - Grapple
3. Front Right Hand Control - Steer &
Drive, Switch for Brake Control
569 4- 1111

instrument console
Engine Coolant Temp Engine Oil Pressure
Engine Coolant Level Air Cleaner Filter
Voltage Hydraulic Oil Temperature
Hydraulic Oil Filter Hydraulic Oil Level
Fuel Level Alarm
img.2414.
(SEE PHOTO
ABOVE)
STABILIZER AUX. POWER

SWITCHES OUTLET
12
V TEMP CONTROL
WARM
ERROR CODE
LIGHTS
THROTTLE
IGNITION
SWITCH
TEMP CONTROL
COOL
g.024.03
569 4- 1111

engine coolant temperature warning indicator
NOTICe Failure to reduce load with

engine coolant temperature warning indicator lit could
cause premature engine failure or damage.
If the engine coolant temperature reaches 210°F
(99°C), a warning indicator will light and an alarm will
sound. When this happens, shut engine down and
check for loose belts, coolant leakage, or a plugged
radiator.
low coolant warning indicator
The low coolant warning indicator will light and an

alarm will sound when the coolant in the radiator is
low by approximately 1.25 gallons (4.72 L) from the
FULL level.
When the indicator lights, immediately shut engine
down, fill radiator with coolant (50 percent mixture or
clean, distilled water and ethylene glycol antifreeze),
and check for leaks and/or damage.
569 4- 1111

voltage warning idicator
NOTICe DO NOT operate engine if

voltage warning indicator is lit. Operating with voltage
too high or too low can cause electrical system damage.
If voltage is too high or too low, the voltage warning
indicator will light. Immediately shut engine down,
turn key to OFF position, and check electrical system
for improper charging.
hydraulic oil filter warning indicator

The hydraulic oil filter warning indicator will light if
any of the hydraulic system filters become restricted or
plugged. Once filters are serviced, indicator light will
go off.
The indicator will light at initial start up until hydraulic
oil reaches normal operating temperature.
If indicator remains lit, oil is bypassing the return line
filter and going directly into the tank without being
filtered.
The filters should be changed immediately to prevent
damage to hydraulic components. See Scheduled/Pe-
riodic Maintenance Services Section, for filter replace-
ment instructions.
569 4- 1111

fuel gauge
The fuel gauge indicates the amount of fuel in the fuel
tank. A warning indicator will light if fuel level drops
below .17 percent capacity.
NOTICe . DO NOT allow a diesel

engine to run out of fuel. Doing so will cause engine dam-
age.
engine oil pressure warning indicator
NOTICe . If no oil pressure is indicated

within 10 to 15 seconds at start up, stop engine and
check the lubricating oil system. Oil pressure does not
guarantee a sufficient amount of oil in the engine oil pan.
Check engine oil level by observing level on the engine oil
dipstick.
The engine oil pressure warning indicator will light
if engine oil pressure drops below 15 psi (103 kPa).
When this happens, shut engine down and check for
leaks. Refer to the engine operator’s manual for more
information.
569 4- 1111

air cleaner warning indicator

The air filter warning indicator will light when the
engine air filter is plugged and requires cleaning or
replacement. Once air filter is serviced, indicator light
will go off.
In high humidity conditions, indicator may register a
false reading.
See Scheduled/Periodic Maintenance Services Section
or proper air filter maintenance.
AIR CLEANER FILTER

G.038.03
hydraulic oil temperature warning indicator
NOTICe . Possible pump or hydraulic

system damage can occur if operating for an extended
period of time when hydraulic oil temperature warning
indicator is lit.
A warning indicator will light and an alarm will sound
if the hydraulic oil temperature reaches 200°F (93°C).
If this happens, shut engine down immediately and
check for a plugged oil cooler or leaks.
low hydraulic oil warning indicator
The low hydraulic oil warning indicator will light when

the hydraulic oil level becomes too low.
Fill reservoir immediately to prevent damage to hy-
draulic components.
To fill hydraulic reservoir, refer to Scheduled/Periodic
Maintenance Services Section.
569 4- 1111

switch panel
horn switch
Press switch to sound horn.
work light switch

Press switch to turn on work lights.
windshield washer switch

Press switch to dispense windshield wiper fluid. Wipers
will operate as long as switch is depressed.
windshield wiper switch

Two-position switch controls speed of wiper motor.
Top position is OFF; middle position is low speed; bot-
tom position is high speed.
Defroster fan switch

Press switch to start defroster fan.
heater/ac fan speed switch

Two-position switch controls speed of fan motor. Top
position is OFF, middle position is low speed; bottom
position is high speed.
heat/ac mode switch

Two-position switch controls heat/AC mode. Top posi-
tion is heat mode; middle position is OFF, and bottom
position is AC.
569 4- 1111

ignition switch
Turn key in ignition switch (A) to ACC for power to the
electrical components.
Turn key to ON position for power to the starter and
electrical components.
Turn key OFF to shut engine down.
NOTICe Before leaving machine, be

A sure key is in OFF position to prevent battery drain.
Remove key so machine cannot be accidentally
started, or started by unauthorized personnel.
dome light
Press the button (B) to turn the dome light ON or OFF.
img.2432
error code indicator lights
The error code indicator lights (C and D) will flash

when engine problems exists. For specific information
on errors, refer to Operation Section.
D C
569 4- 1111

circuit breakers
Circuit breakers protect an electrical circuit from cur-
rent overload.
If an overload should occur, the circuit breaker will trip,
thus breaking the flow of current and prventing dam-
age to the circuit.
To reset the circuit breaker, press the tripped breaker
to its original position.
NOTICe If circuit breakers trip fre-

quently, consult an authorized dealer for assistance.
img.2490
heat control lever
Temperature in the cab is regulated by adjusting the

position of the heat control lever. For more heat, move
the lever toward the side labeled WARM.
For less heat, move the lever toward the side labeled
COOL.
569 4-10 1111

pilot pressure shut off

The cab is equipped with a lever to shut off pilot pres-
sure to the joystick and foot pedal controls when the
operator exits the cab.
WArNING Accidental movement

of turntable or booms can cause serious personal
A injury. Before leaving cab, always push hydraulic
power shut off lever up and forward to disengage
hydraulic pilot circuit, and to free the door entry/
exit path.
pilot pressure disengaged (A)

When the pilot shut off lever is in the UP position (A),
the pilot controls (joystick and foot pedal functions)
are disabled. Before exiting cab, always push the pilot
shut off lever up and forward to disable the pilot con-
trols and to free the entry/exit path.
img.2576
pilot pressure engaged (B)

When the pilot shut off lever is in the DOWN position
(B), pilot controls are operational. When down, the
b lever blocks the cab door. The lever must be down to
operate the machine.
img.2577
battery disconnect master switch

The battery disconnect master switch, located behind
the cab near the diesel fuel fill cap, is designed to pre-
vent accidental starting of the engine during servicing,
to prevent accidental battery drain, and to help as a
vandal deterrent.
Turn switch OFF to shut off electrical system.
Turn switch ON to connect electrical system.
All systems will shut down if battery disconnect master
switch is turned OFF.
img.2385
569 4-11 1111

throttle
Operate engine at FULL throttle.
Engine must run at full throttle because doing so
ensures
• proper cooling of engine and hydraulic system,
• proper volume and pressure of oil to hydrostatic
components; and,
• full oil flow to hydraulic circuits.
A The throttle (A) controls governed engine speed from
low idle to full governed speed as follows:
Low idle rpm 900
Full load governed rpm 2400
increasing engine speed

Turn knob clockwise to increase engine speed.
decreasing engine speed

Turn knob counterclockwise to decrease engine speed.
NOTICe To return to IDLE, push

throttle knob in.
swing pedal
Control the upper frame swing as follows:

Press LEFT side of pedal (B) to swing upper frame to
c the left.
Press RIGHT side of pedal (C) to swing upper frame to
the right.
b
001.03
569 4-12 1111

left joystick
left hand joystick

The left hand joystick (A) operates the main boom,
stick boom, and grapple as follows:
Push joystick lever forward (B) to lower main boom.
Push joystick lever back (C) to raise main boom.
Push joystick lever left (D) to open grapple jaws.
A Push joystick lever right (E) to close grapple jaws.
g.077.03
d e
c
g.086.03
569 4-13 1111

right joystick
right hand joystick

The right hand joystick (A) operates the stick boom
and grapple rotation as follows:
Push joystick lever forward (B) to lower stick boom.
Pull joystick lever back (C) to raise stick boom.
A Push joystick lever left (D) to rotate grapple counter-

clockwise.
Push joystick lever right (E) to rotate grapple clockwise.
g.077.03
d e
c
g.087.03
569 4-14 1111

right joystick rocker switch

The rocker switch on top of the right joystick (A)
activates the saw bar in and out of its storage housing,
and activates saw function.
Press the rocker switch LEFT to start the saw chain and
to activate saw bar function.
Press the rocker switch RIGHT to stop the saw chain
and to return the saw bar to storage housing.
A
g.089.03
stabilizer controls
Press top of switch to raise stabilizer. Press bottom of

switch to lower stabilizer.
B. Left stabilizer
C. Front/Rear stabilizer
b D. Right Stabilizer
c d
img.2423a
hourmeter
The hourmeter shows hours of machine operation

in full hours and tenths hours. Use the hourmeter as
a guide for maintenance intervals throughout this
manual.
The hourmeter is located on the engine housing, be-
hind the operator’s cab.
img.2364
569 4-15 1111

operator’s seat
Adjust operator’s seat using the following guidelines.
control carrier
The armrest and joystick (A) can be swung up and back
to allow easier access to the operator’s seat.
011.03
seat front and rear position

Lift lever (B) UP and hold.
Slide seat to desired position.
Release lever.
569 4-16 1111

operator’s seat, continued
seat height
Firmly lift up and hold adjustment lever (A) until lever
releases.
While holding lever in the UP position, adjust seat to
desired height by adding or removing body weight to
the front or rear of seat cushion.
Firmly push DOWN on lever until seat locks (a click will
be heard).
seat suspension
While seated, rotate handwheel (B) until seat cushion
is level.
b
021.03
backrest
c
Rotate control knob (C) to select desired backrest posi-
tion.
armrest
Rotate control knob (D) to select desired armrest
angle.
d Pivot armrest up and parallel with backrest when not
in use.
010.03
569 4-17 1111

am/fm stereo cassette radio
G.050.03
1. on-off switch/volume control both weak and strong FM signal areas. For normal reception condi-
Rotate knob to the right to turn unit ON. Continue rotation until tions, and when receiving a wide range of signals including weak or
desired volume level is obtained. distant stations, switch should be set to the IN position, which will
allow maximum signal to the receiver. When in an extremely strong
2. tone control (local) signal area, set switch to local setting (OUT position). This will
Turn knob to right or left to adjust bass and treble levels. eliminate weak signals and suppress overly strong signals to avoid
overloading receiver input. When moving out of strong signal area,
3. balance return switch to the distant (IN) setting.
Rotate knob left or right to obtain desired balance between left and
right speakers. NOTE: The Local/Distant selector affects only FM signals.
4. selecting a band 9. cassette door

Press button to change radio band from AM to FM. FM broadcasts Hold cassette with exposed tap edge to the right and insert it into
will be received with the switch in the IN position, and AM broad- the cassette door. Depress fully until cassette is engaged and begins
casts will be received with the switch in the OUT position. playing.
5. manual tuning NOTE: Observe cassette operation cautions in the Care and Mainte-
nance section of the radio operation manual.
Rotate knob left or right to select desired radio station. When tuning
in a station, always adjust the control so full signal is received. If 10. Fast Forward/Eject button
radio is off frequency, noise and reception problems will occur. The This button performs two functions.
dial pointer will move along the dial to indicate the frequency.
To eject a cassette, depress button fully, then release. Cassette will
6. FM stereo indicator eject and radio operation will resume.
Indicator will illuminate during reception of FM stereo broadcasts. If To fast forward a tape, depress button halfway into the locked posi-
indicator flickers or goes on and off as machine moves, stereo signal tion. To stop fast forwarding, resume normal tape playback, depress
may be too weak to reproduce clearly. button slightly then release. Do not press fully in or the cassette will
be ejected.
7. antenna trimmer
It is important to adjust the antenna trimmer for optimum AM NOTE: Never leave a cassette engaged in player when not in use. Do-
reception. The antenna trimmer is located at the back of the tap slot. ing so can cause damage to the cassette and/or mechanism of the
Adjust following these instructions: unit. Always press eject button and remove cassette when leaving a
vehicle.
• Tune in a weak station around 1400 KHz on the AM band.
• Using a small screwdriver, slowly adjust trimmer for maximum
radio output.
8. FM local/distant selector
This selector switch is incorporated to allow maximum reception in
569 4-18 1111

Pre-start Inspection
PRE-START INSPECTION
WArNING Do not use this machine until you read, study, and understand this manual to
learn how to properly operate this machine. Operating this machine without reading, studying, and un-
derstanding this manual could result in severe personal injury or death.
Failure to perform a daily inspection of the loader could result in machine damage
WArNING and severe personal injury.
pre-start checks: on the ground
Check for protective clothing (wear it) and safety equipment (know where it is).
Check entire machine by performing a thorough walk-around inspection.
Check for loose or missing parts. Tighten loose parts. Replace any missing parts.
Check for leaks in hydraulic hoses and/or lines (replace defective hoses and/or lines).
Check hydraulic hoses and lines for wear and/or damage. Replace any defective
hoses and/or lines.
Check that machine has been properly lubricated as spelled out in the Scheduled/
Periodic Maintenance Services section of this manual.
Check shields and guards. They must be in place and undamaged.
Check that safety decals are on machine and that they are readable.
Check that shut-off valves are open (if so equipped).
Check for dirt and grime on all hydraulic components. Clean away dirt and grime to
help prevent overheating.
Check for ice, snow, mud, oil, and grease on ladders and walkways. Clear away ice, snow, mud
oil, and grease to prevent slips and falls.
Check for any loose skid-resistant mats. Replace mats if they are loose.
Add hydraulic oil to reservoir if necessary.
Check for combustible or flammable materials. Remove them from machine if you find them.
Check mounting hardware for tightness.
Check that machine will not be near electrical wires. See Operation section later in
this manual.
Check swing bearing for loose or missing fasteners. Tighten loose fasteners. Replace
missing fasteners per maintenance instructions.
Check booms for damage, cracks, debris, mounting pin retention, and other problems.
Immediately report any structural problems (cracks) to an authorized dealer for diagnosis and
repair or replacement.
Check that truck/trailer is on firm level, ground and that the parking brake is set.
Check that upper frame and engine area are free of leaves, twigs, branches and other debris.
Check electrical system for worn insulation or frayed wires and loose connections.
NOTICe You can copy the pages in this section. Check off each inspection item before operating the
machine, and file the copy as a record of inspection as required per OSHA or local governing body.
569 5- 1111
pre-start checks: on platform


off machine.
terial if it is worn, damaged or missing.
Check hydraulic hoses in platform/boom end area for wear and/or damage. Replace any
defective hoses and/or lines.
Check safety decals. They must be present and readable.
Check control levers/pedals for free movement.
Check booms for damage, cracks, debris, mounting pin retention, and other problems.
Immediately report any structural problems (cracks) to an authorized dealer for diagnosis
and repair or replacement.

Check fuel tank (fill tank at end of shift to reduce water condensation).

Check hydraulic reservoir fluid level. Add hydraulic oil to reservoir if necessary.
Check engine oil level. Add engine oil if necessary.
Check radiator coolant level and make sure radiator fins are clean. Add proper coolant
mixture if necessary. Clean radiator of all debris.
Check that all cab windows are clean and clear. Replace any damaged polycarbonate
window material.
Check for mud and debris on cab floor (clean away mud and debris).
Check air cleaner. Clean or replace air filter if necessary.
NOTICe You can copy the pages in this section. Check off each inspection item before operating
the machine, and file the copy as a record of inspection as required per OSHA or local governing body.
569 5- 1111

pre-start checks: in the cab


off machine.
To prevent slips and falls, replace skid-resistant
material if it is worn, damaged or missing.
Check that there is no mud or debris on cab floor (clean away mud and debris).
Check for free movement of controls.
Check and review safety decals, that all are present and can be clearly read.
Check that all cab window material is clean and clear. Replace any damaged polycarbonate
window material.
Check that fire extinguisher is adequately charged.
Check instrument panel for broken gauges and/or broken indicator lights. Have
gauges and/or indicator lights repaired if necessary.
Check fuel gauge to be sure machine has enough fuel. Refuel machine if necessary.
Check window emergency exits.
Check cab operator protection structure for damage. Have structure repaired if necessary.
Check that all items in cab that are not part of the machine, such as lunch boxes or
tools, are secured.
NOTICe You can copy the pages in this section. Check off each inspection item before operating the
machine, and file the copy as a record of inspection as required per OSHA or local governing body.
569 5- 1111
fire prevention
CAUTION Fires can cause personal

injury or machine damage.
Keep machine clean. Remove debris, especially from
heat sources. Fire prevention beats fire fighting. Hourly
or daily inspections can reduce the possibility of fires.
CAUTION Forest debris can collect on the machine and cause a fire. When forest debris mixes
with flammable fluids in a hot, confined space, the risk of a fire starting greatly increases. KEEP THE MACHINE
CLEAN.
Check machine daily for fire hazards. Remove debris from areas of the machine that create heat and that are
potential fire start points. Depending on machine model, check for flammable debris in the following locations:
• Engine block • Turbocharger • Electrical connections
• Exhaust manifold • Battery • Control valves
Fire needs fuel. Remove combustible material (fuel for fire) from heat sources. Keep the machine clean. Remove
the following materials, and other combustible materials from areas of the machine that create heat:
• Pine needles • Twigs • Debris
• Shop rags • Oil spills • Coolant mixture
• Leaves • Sticks • Sawdust
• Grease • Bark • Diesel fuel
CAUTION Keep the machine clean. Risk of fire increases if combustible materials and flam-
mable materials build up on machine. This machine is not designed to house or store combustible materials.
Regularly remove flammable materials (such as diesel fuel, engine oil, hydraulic oil, and grease) from all areas of
the machine. Clean up after working. Keep the fuel and hydraulic systems in good repair.
Check hydraulic hoses, fuel lines, and fittings for leaks. Tighten loose fittings. If hoses or lines are bent, kinked, or
show signs of wear, install new parts. Check electrical connections to be sure they are clean and secure.
Frayed, damaged or worn insulation on battery cables or other wires may lead to electrical fires. Check cables
and wires and replace if insulation is frayed, worn, or damaged.
NOTICe At the end of each shift ALWAYS stay with the machine for 30 minutes after shutting down
the engine to ensure there is no forest debris/trash fire start up. Keep a fire extinguisher ready during this 30 minute
cool down.
569 5- 1111

operation
operation
general guidelines
WArNING Only a trained, qualified, and authorized operator shall be allowed to operate
this machine. Only use this machine after carefully reading this manual and learning how to safely oper-
ate and maintain this machine. Unsafe operation can cause severe personal injury or death.
operator preparation
Operator must be fully trained, qualified, and
authorized to operate this machine.
Before running this machine, operator must know the
location and purpose of
• controls
• indicator lights
• instruments
• local operating safety rules and procedures
• safety and instruction decals (see Safety Decals

Section)
Operators must be at least 18 years old to operate this machine (Code of Federal Regulations: Labor).
Never operate this machine while under the influence of drugs or alcohol. Use of prescription or over-the-
counter drugs or medications requires advice from a medical practitioner on whether or not machine can be
safely operated.
Operators may not run this machine if subject to dizziness, seizures, or motion disturbance.
Do not operate this machine unless it is properly mounted to a truck or trailer for stability.
Never operate this machine with stabilizers in raised position.
No riders are allowed on this machine. Machine riders can fall from machine or be injured by movement of
machinery, causing severe personal injury or death. Do not allow riders on a machine that is operating or
moving.
Follow all safety operating instructions and practices. (See General Safety section.)
Keep machine away from power lines.
If this manual is lost, contact an authorized dealer for a new manual. Keep manual in the manual storage pouch
in the cab.
Report any noticeable machine problems to people who can repair the problems before machine is used.
Be sure cab windows are clean before operating machine. Cab windows must be clear of ice and frost. Replace
windows that are cracked, yellow, and/or hazy.
Remember, operators are key to the safe operation of this machine.
569 6- 1111

operation
electrocution danger
DANGer contacting electric

lines with boom, line, or load will cause
severe injury or death. Watch for over-
head power lines. treat any line as live
and dangerous. if at all possible, have the
power line disconnected before starting
work.
Never move any part of machine or load closer than
10 feet plus twice the line insulator length to electric
lines. A line insulator is what connects an electric line
to an electric pole.
For example, if a line insulator is 6 inches long, stay at
least 10 feet plus twice the line insulator length (2x6
=12 inches or 1 foot) from electric line, which means
machine must stay at least 11 feet from this electric
line.
If machine touches an electric line, stay inside the cab.
Carefully move machine or load away from electric
line, without pulling the line down.
DO NOT allow anyone else to touch machine while
it is touching an electric line. If machine cannot be
moved away from the electric line without pulling line
down, have someone contact the utility company to
disconnect power from line. If this is not possible, or
if machine begins to burn, jump away from machine
to the ground with both feet together, in one smooth
jump. DO NOT touch machine and ground at the same
time or else electricity in the line will go through the
body. Get away from machine after jumping.
Notify utility company immediately. DO NOT let any-
one near machine while it is touching an electric line.
overhead loads
WArNING Falling or swinging logs or

booms can cause severe injury or death.
The loader operator is responsible for ensuring that
booms or loads are never suspended over or near
personnel.
• Always know where other people are working at
the job site in relation to the loader.
• Maintain good communication with everyone on
the job.
• Stop operations if someone on the ground ap-
proaches the machine.
g.027.03
569 6- 1111

operation
getting on machine

off machine.
terial if it is worn, damaged or missing
machine start up
1. Perform a pre-start inspection (refer to

Pre-Start Inspection Section.)
2. Before start up, walk completely around machine
and make sure no obstacles or personnel are in
the area.
3. Sound horn before operation.
g.048.03
4. Check all controls for proper function and re-
sponse before starting work (refer to
Controls and Instruments Section).
5. Maintain adequate distance between machine
and other equipment and personnel.
569 6- 1111

operation
starting the engine
a NOTICe Pressing starter button while

engine is running can damage starter.
1. Make sure battery disconnect master switch (A) is
ON.
1. Insert key in ignition switch (B).
2. Turn key to the right (ON position). Verify that
the error code indicator light (C) is not lit. If the
error code indicator light is lit, see Cold Weather
Starting Procedure later in this section. If the wait-
img.2385
to-start indicator is not lit, turn key all the way to
the right and hold until engine starts. Release key
when engine starts. If engine fails to start after 30
seconds, allow starter to cool a few minutes. Try
starting engine again. If engine still will not start,
see engine operator’s manual and Starting with a
Booster Battery later in this section.
4. Turn throttle knob (D) clockwise about 1/3 turn to
increase engine speed.
5. Run engine at partial-throttle and no load for
B approximately five minutes to allow machine to
warm up.
NOTICe If ambient (outside) air tem-

perature is below 32°F (0°C), and starter aid is necessary,
refer to the engine operator’s manual.
569 6- 1111

operation
starting machine with a booster battery

battery safety
WArNING Batteries produce explo-

sive gases.
Keep sparks, flames, and cigarettes away from batter-
ies. Ventilate properly when charging or using batteries
in enclosed space. Always shield eyes with goggles and
wear a face shield when working near batteries. Do not
lean over batteries during this operation. Always connect
positive (+) to positive (+) and negative (-) to negative
(-). For further instructions, see Jump Starting Battery in
Operation Section. If battery acid contacts eyes, flush
them with water for 15 minutes and seek immediate
medical attention.
Battery acid is poisonous and can cause severe burns. If
acid is taken internally, call a physician immediately. If
acid contacts skin or clothing, flush with water immedi-
ately. Keep batteries away from children.
Battery posts, terminals, and related accessories contain
lead and lead components, chemicals known to the State
of California to cause cancer and reproductive harm.
Wash hands after handling.
Never charge a battery or jump start engine if battery is
frozen. Warm battery to 60°F (16°C) or it may explode.
Be sure vent caps are tight. When jump starting from
another machine, be sure machines do not touch. This
machine has a 12-volt starting system. Use equal voltage
for jump starting.
Jump starting procedure

1. Turn battery disconnect master switch OFF. Re-
move key from ignition switch.
A
D 2. Clamp one end of first booster cable to positive
terminal of discharged battery (A) (terminal con-
nected to starter or solenoid).
Machine 3. Clamp other end of first booster cable to positive
Battery terminal of booster battery (B).
4. Clamp one end of second booster cable to nega-
tive terminal of booster battery (C).
C 5. Clamp other end of second booster cable to en-
B gine block or frame of machine (D) (to keep sparks
away from either battery).
6. Insert key in ignition switch. Turn battery discon-
nect master switch ON.
7. After starting engine, remove booster cables
Booster in reverse order from how they were put on. To
Battery prevent sparks, keep booster cable clamps from
g.060.02 touching.
569 6- 1111

operation
indicator lamp checks

Following are the sequences of indicator lamp error
codes:
when starting engine
Red error code indicator (A) and yellow error code
A B indicator (B) will both illuminate for 2 seconds at start
up.
starting engine with cold start aid opera-
tion
indicator (B) will both illuminate until operation is
complete at start up.
error detected at start up (e.g. lack of
lubrication oil pressure after start delay
exceeded)
Red error code indicator (A) will remain illuminated
after the 2 second delay.
569 6- 1111

operation
indicator lamp checks, continued
when starting engine
Following are the sequences of error code indicator
error codes:
If engine fails to start
A B no detected faults
indicator (B) will both not be illuminated.
Electrical Fault Warning
The yellow error code indicator (B) will be illuminated.
Stop Engine
Red error code indicator (A) will flash. Fault has been
detected that prevented start of engine.
after starting engine
No Detected Faults
indicator (B) will both not be illuminated.
oil pressure low
The red error code indicator will be illuminated.
coolant/air intake temperature high
Yellow error code indicator (B) will flash.
stop engine fault/de-rate conditions
The red error code indicator (A) will be flashing.
electrical fault warning
Yellow error code indicator (B) will be illuminated.
oil pressure low and electrical fault
indicator (B) will both be illuminated after start up.
stop engine fault/de-rate conditions and
electrical fault
The red error code indicator (A) will be flashing and
yellow error code indicator (B) will be illuminated.
oil pressure low and coolant/air intake
temperature high
The red error code indicator (A) will be illuminated and
yellow error code indicator (B) will be flashing.
569 6- 1111

operation
cold weather starting - engine/pump disconnect (optional)

1. Locate clutch disconnect lever (outside rear of cab
between rear of cab and hydraulic oil reservoir).
2. Push lever away (A) from engine to disconnect
hydraulic pumps.
3. Start engine (see procedures on Page 6-4).
4. Allow engine to warm up for approximately ten
minutes.
WArNING DO NOT engage pumps

with engine running. Engaging pumps with engine
running may cause machine to move unexpectedly,
which may lead to serious personal injury or death.
5. Shut engine down.
6. Engage pumps by slowly pulling the dicsonnect
-A- g.052.03
lever toward (B) the engine.
7. Start engine.
Side panel and top panel removed
from illustration for clarity. NOTICe These instructions apply
to optional controls and instruments available from an
authorized dealer.
-B- g.053.03
569 6- 1111

operation
warm up period
1. Be sure area is clear of personnel.

2. Close cab door.
3. Pull down control shut off lever (A) to engage
control system.
It is important to allow the

hydraulic system to reach operating temperature
g.048.03
before beginning operation. Cold and thick oil can-
not flow fast enough to the pump to meet output
demand. Cavitation and extreme damage may be
caused by operating the machine when the hydraulic
a oil is too cold to flow easily.
4. Warm up the hydraulic system by
• engaging and disengaging controls to help speed
warm up of hydraulic components, and;
• cycling all controls to allow warm oil to circulate
through all cylinders and lines.
img.2577 Do not idle engine for exces-

sively long periods. Long periods of idling (more
than 10 minutes) can damage an engine because
combustion chamber temperatures drop so low the
fuel will not burn completely.
569 6- 1111

operation
feathering the controls
g.031.03
g.030.03
Rough operation can be dangerous, hard on the machine, and hard on the operator.
DO NOT jerk control levers to full speed, or from one direction to another.
Feather controls this way:
1. Move joystick control gently from neutral to start motion.
2. After a slow, smooth start, move joystick control to desired speed position.
3. Just before stopping movement, move joystick control gently back to neutral.
This method of carefully manipulating the controls is called feathering. Work can done more efficiently by feath-
ering controls than by jerking controls.
There is a rhythm to operating this machine. Feathering the controls will help the operator find and take advan-
tage of this rhythm.
569 6-10 1111

operation
using stabilizers
WArNING Unstable platform can

cause severe personal injury or machine damage.
Lower all stabilizers before operating machine.
WArNING Coming into contact with

stabilizers can cause serious personal injury or
death. Clear all personnel from work area before
lowering stabilizers.
It is the responsibility of the operator to make sure all
personnel are clear of the stabilizers before lowering
them. When setting the stabilizers, make sure they are
sitting on firm, solid ground.
DO NOT set stabilizers on rocks, stumps, curbs, edge of
paving, etc. or on soft or unstable ground.
1. Position loader on firm, level ground with stabiliz-
ers down to ensure stability while operating.
2. Double check to ensure no persons are close to
truck and/or loader.
3. Clear ice and snow from the area where the
g.132.03
stabilizer pads will be lowered. Do not operate or
position loader on slippery surfaces.
4. Lower stabilizer legs to raise truck or trailer tires
about 1-1/2 to 2 inches off the ground. The entire
loader should rest firmly on the stabilizer pads.
5. Follow these stabilizer operating guidelines:
• Never allow another person to be on the
loader or in and around the truck when lower-
ing or raising stabilizers.
g.043.03
• Lift boom from transport position and make
a test lift to check ground conditions under
stabilizers.
• Never operate machine with stabilizers in
raised position.
c stabilizer control switches

A Left Stabilizer (A)
Top Position: Raise stabilizer
Bottom Position: Lower stabilizer
Front/Rear Stabilizer (B)
Top Position: Rear stabilizer
b Bottom Position: Front stabilizer
Right Stabilizer (C)
img.2423a
Top Position: Raise stabilizer
Bottom Position: Lower stabilizer
569 6-11 1111

operation
landing layout
• The loader operator is in one of the best positions

on the work site to notice a problem and warn
others by sounding the horn. The loader opera-
tor is responsible for the safety of people on the
ground.
• All landings (decks) should provide an area clear
of suspended loads for landing personnel (deck
hands) to work. Remember, logs can roll or be
thrown a considerable distance.
• If clearance of suspended loads cannot be pro-
vided, STOP loading operations and lower grapple
while deck hands are working on the landing.
• All obstructing trees should be removed to ensure
clearance for loading.
• Never locate landing near overhead electrical
g.034.03
lines. See Electrocution Dangers in this section for
instructions.
heeling - picking up logs or poles

• Never operate this machine with tires touching
the ground. Lower stabilizers to the ground, and
raise tires slightly off the ground.
• Always lift and heel long logs from butt end of log
(larger end). Place grapple on log as illustrated so
the log will not hit the stick boom cylinder.
• Never pinch a log. Always make sure the grapple
wraps around the log.
g.046.03
WArNING Always place logs in heel

on opposite side of boom, away from cab. This can
reduce the risk of a log flying toward the cab if a
log slips in the grapple.
• Never heel logs from the center — this puts the
ends of the logs too close to the boom cylinders
and the cab when drag loading.
• Never swing load or grapple over truck cab being
loaded.
• Make sure truck driver and other personnel are
away from truck and loader when operating
loader.
• On booms without heels, pick up logs toward the
butt end. When lifting logs at their balance point,
take care when rotating logs to make sure they
clear the loader and other obstructions.
569 6-12 1111

operation
grapple control
Study and learn the grapple control functions (see

Controls and Instruments Section). Improper rotation
of grapple or accidental opening of grapple will cause
loss of control of the load.
• Do not change function arrangement.
• Use proper grapple to match application.
g.048.03
• For log handling always use a log bypass, or com-
bination bypass/pulp grapple.
• For short wood handling, use a log bypass, combi-
nation bypass or butt-style pulpwood grapple.
• Never swing and load a single log or branch by
pinching the sides of the log or stem with the
grapple jaw tips. Always clamp the log or branch
within the grapple jaws.
stopping the machine
1. Bring machine to a complete stop.

2. Lower attachment to ground with the main and
stick booms fully extended. The grapple should
be open with the jaw tips on the ground. For
extra stability on unfrozen ground, jaw tips can be
closed slightly so that they dig into the ground.
g.048.03
3. Slow engine to LOW IDLE. Run engine at low idle
for at least 2 minutes to cool engine.
4. Turn key switch to OFF to stop the engine.
5. Remove key from ignition switch.
569 6-13 1111

operation
getting off machine

off machine.
terial if it is worn, damaged or missing
569 6-14 1111

break-in period
break-in period
loader
2 1
3
4
5
g.055.03
after first 10 hours of operation
KEY COMPONENT SERVICE SPECIFICATION

1. Hydraulic Reservoir Check fluid level - 65 gallons (246 L) Full mark. Use
Premium A.S. Hydraulic Fluid
2. Fuel Tank Check fuel level - 89 gallons (337 L) Full mark
3. Loader (not shown) Visually check for any loose hardware
or fluid leaks.
4. Outer Swing Bearing Fasteners Check Tighten to 600 ft-lbs (814 N•m)
5. Inner Swing Bearing Fasteners Check Tighten to 600 ft-lbs (814 N•m)
NOTICe The above fluid capacities are WArNING Loose outer bolts or in-
approximate values. Be sure to check levels after filling. ner capscrews on the swing bearing can cause the
DO NOT OVERFILL. upper and lower frame to separate, causing severe
injury or death. Read and follow all torque instruc-
tions in this manual.
During the first 100 hours of operation

1. Use seasonal viscosity grade oil as specified in Fuels and Lubricants Section.
2. Avoid excessive engine idling.
3. Check all accessible hardware for tightness.
4. Check engine oil level regularly.
5. Check hydraulic fluid regularly.
569 7- 1111

break-in period
10
6
11 3
1
5 2
4
12
7
8
9
g.055.03
after first 100 hours of operation
KEY COMPONENT SERVICE SPECIFICATION

1. Engine Oil and Filter Drain and Replace See Fuels and
Lubricants section
2. Case Drain Filter Replace Use Genuine parts
3. Hydraulic Reservoir Replace Use Genuine parts
Return Line Filter
4. Fuel Filters Replace Use Cat parts
5. Pinion Gear Fastener Check tightness, torque if necessary 420 ft-lbs (569 N•m)
6. Swing Drive Fasteners Check tightness, torque if necessary 437-483 ft-lbs (593-655 N•m)
7. Outer Swing Bearing Check tightness, torque if necessary 600 ft-lbs (814 N•m)
Fasteners
8. Inner Swing Bearing Check tightness, torque if necessary 600 ft-lbs (814 N•m)
Fasteners
9. Heel Fasteners (opt) Check tightness, torque if necessary 162-178 ft-lbs (220-241 N•m)
10. Swivel Torque Arm Fast. Check tightness, torque if necessary 76 - 84 ft-lbs. (103-114 N•m)
11. Swivel Fasteners Check tightness, torque if necessary 266-294 ft-lbs. (360-399 N•m)
12. Engine Refer to engine operator’s manual
to tighten a loose bolt or capscrew

WArNING Loose outer bolts or in- 1. Torque the bolt or capscrew to recommended ft-
ner capscrews on the swing bearing can cause the lbs. Recheck every 10 hours until torque stabilizes.
upper and lower frame to separate, causing severe
injury or death. Read and follow all torque instruc- 2. Check the two adjacent bolts (on either side of
tions in this manual. loose bolt) for proper torque and recheck every 10
hours until torque stabilizes.
3. If any of these bolts or capscrews do not take
the torque, or come loose again, they must be
replaced, including adjacent bolts/capscrews.
Replace with factory-approved parts.
569 7- 0209

1111
transporting
transporting
WArNING Failure to follow these important safety rules could result in seri-
ous personal injury or death.
• Remove any obstacles from trailer floor.
• Load and unload machine on level ground.
• Always use a ramp of proper height, loading angle, and strength.
• Engage trailer and truck brakes, and place wooden blocks around wheels.
TRAILER MOUNT
TRUCK MOUNT
13' 6" MAX.

13' 6" MAX.
0
loading procedure
1. Before transporting, investigate road width, bridges, road and traffic conditions of
planned route, as well as governing laws and regulations. Obtain required permits and/or
authorization from appropriate agencies.
2. Mount loader as if for operation (see Operation section).
3. Swing upper frame clear of obstacles until it centers with grapple carrier.
4. Lower booms. Lower grapple until it rests in grapple carrier.
5. Raise stabilizers.
6. Shut engine down. Remove key from ignition.
7. Turn master battery disconnect switch to OFF.
8. Close and lock cab door.
9. Cover intake and exhaust openings to prevent damage to turbocharger and prevent water
and dust from entering engine.
10. Secure grapple to grapple carrier with chain.
11. Secure any attachment(s) with chain.
12. Before transporting, make sure no part of the machine exceeds 13’6” from the ground, or
special height permits may be required.
NOTICe DO NOT wrap chains around machined surfaces. Travel vibration can cause
chain hammering.
569 8- 1111

transporting
NOTES
569 8- 1111

fuels and lubricants
Fuel
fuel tank refueling
WArNING Fuel leaked or spilled

onto hot surfaces or electrical components can
cause a fire, which can result in severe personal
injury or death. To help prevent possible injury,
turn the ignition switch OFF when changing fuel
filters or water separator elements. Clean up fuel
spills immediately.
CAUTION Prevent fire! Handle fuel

carefully!
• DO NOT fill fuel tank while engine is running.
• DO NOT smoke while filling or working on the fuel
system.
• DO check fuel tank vent. Clean if dirty or plugged.

• DO fill fuel tank at the end of each day.
• DO drain fuel tank of water once a week.
• DO clean up all spills immediately.
fuel specifications
WArNING DO NOT mix gasoline or

alcohol with diesel fuel. This mixture can cause an
explosion.
Refer to engine operator’s manual for recommended
diesel fuel grades.
storing fuels
• Keep fuel containers in a protected area.
• Remove water and sediment before transporting.
• DO NOT use deicers to remove water from fuel.

• DO NOT depend on filters to remove water.
• DO install water separators at storage tank outlets.
• KEEP FUEL CLEAN.
569 9- 1111

fuels and Lubricants
engine oil
lubrication, oil performance and viscosity recommendations
Use of a quality engine lubricating oil combined with
Engine Oil Viscosity appropriate oil and filter change intervals are critical
Caterpillar DEO Ambient Temperature factors in maintaining engine performance and
Multigrade durability. When changing or adding engine oil, use
EMA LRG-1 recommended engine oil. For more information, refer
API CH-4 Minimum Maximum to the engine operator’s manual.
API CG-4 and
API CF-4 NOTICe When adding lubricants, do
Viscosity Grade not mix different brands or grade weights. Manufacturers’
additives are not always compatible.
SAE 0W20 -40°F (-40°C) 50°F (10°C)
SAE 0W30 -40°F (-40°C) 86°F (30°C) Caterpillar recommends the use a of a multigrade
lubricating oil due to its effectiveness in maintaining
SAE 0W40 -40°F (-40°C) 104°F (40°C)
low oil consumption and low levels of piston
SAE 5W30 -22°F (-30°C) 86°F (30°C) deposits. See the Caterpillar Oil Viscosity Chart (left)
SAE 5W40 -22°F (-30°C) 104°F (40°C) for recommended engine oil specifications. The use
SAE 10W30 -4°F (-20°C) 104°F (40°C of single-grade lubricating oil is not recommended
SAE 15W40 5°F (-15°C) 122°F (50°C) except for synthetic oils used in arctic conditions.
Caterpillar SAE Oil engine break-in oils

Viscosity Recommendations Do not use special “break-in” lubricating oils for new
or rebuilt Caterpillar engines. Use the same type of
oil during the break-in period as will be used during
normal operations.
arctic operation
If an engine is operated in ambient temperatures
consistently below -10°F (-23°C), and there are no
plans to keep the engine warm when it is NOT in
operation, use a synthetic CD/SF engine oil with
adequate low temperature properties such as
5W-20 or 5W-30.
NOTICe The use of synthetic-

based oil does not justify extended oil change intervals.
Extended oil change intervals can decrease engine life
due to factors such as engine corrosion, deposits and
wear.
569 9- 1111

hydraulic oil
Hydraulic systems have been filled from the factory with Premium All-Season Hydraulic Oil 46.
Use the following hydraulic oils in this machine.
ambient temp ambient temp ambient temp

-25°F to 80°F -10°F to 95°F 0°F to 105°F
(-32°C to 27°C) (-23°C to 35°C) (-18°C to 41°C)
Premium All-Season Premium All-Season Premium All-Season
Hydraulic Oil 32 Hydraulic Oil 46 Hydraulic Oil 68
NOTICe Check with an authorized

dealer for hydraulic fluid recommendations and
compatibilities.
BE SURE hydraulic fluid selection is compatible with
the hydraulic system.
BE SURE hydraulic fluid selection assistance is from a
reputable supplier.
BE SURE hydraulic specifications meet or exceed the
Premium All Season Hydraulic Oil specifications. See
an authorized machine dealer.
BE SURE to use a mineral-base hydraulic oil.
grease
Most lubricated fittings require Premium Moly-Lith EP

#2 Grease. However, there are special requirements for
the swing bearing and swing drive motor (see Grease
for Swing Bearing and Swing Drive Motor in this
section).
569 9- 1111

lubricant for pinion and swing gear teeth
When lubricating the pinion gear and swing gear teeth, use moly-lith open gear lubricant.
When the gear path becomes contaminated, clean with solvent to remove contamination. Relubricate gear with
moly-lith open gear lubricant, available from an authorized dealer.
cylinder rod CORROSION PREVENTIve
NOTICe If machine will be stored for an extended period, or stored in a corrosive environment
(such as salt air or industrial pollution), apply Chrome Kote Corrosion Preventive on all portions exposed to air.
See Storage section for more information.
ENGINE COOLANT SPECIFICATIONS

Engine coolant must meet or exceed the following specifications:
• SAE J1941
• ASTM 4985
• GM 6038M
• TMC RP 302B
The engine coolant must contain low silicate (less than .1% anhydrous metasilicate) ethylene glycol base. The
supplemental coolant additive (SCA) should be Fleetgard DCA4 or equivalent.
When preparing engine coolant, follow these steps:
1. Thoroughly mix ethylene glycol base coolant with SCA in this ratio: 93% coolant to 7% additive.
2. Mix coolant/additive compound with distilled water in this ratio: 50% coolant/additive compound to 50%
distilled water.
569 9- 1111

storing lubricants
Store lubricants in a clean area that will keep them protected from water, dirt, or other contamination.
Always use clean containers when handling lubricants.
Storing lubricant drums or other containers outdoors is poor practice. To minimize the harmful effect of
unavoidable outdoor storage, a few simple precautions and procedures can be very helpful.
1. Generally, lubricants in containers smaller than

WATER drums (55-, 30-, and 16-gallon oil drums, and
400- and 120-pound grease drums) should never
be stored outdoors. When drums must be stored
outdoors, a temporary shelter or lean-to, or a
waterproof tarp will protect them from rain or
snow.
2. Drums should be placed on their sides with the
bungs approximately horizontal. In this position,
bungs are below the level of the contents so that
breathing of water or moisture is greatly reduced
and water cannot collect inside chine (ridge of
drum). For maximum protection, drums should
be stood on end with bung end down on a well-
drained and contained surface. Where all of these
approaches are not practical, drum covers may
be used. Drum covers are available in metal and
plastic.
G.121.05 3. When drums must be stored outdoors with bung
end up, they should be blocked up with bungs
NO WATER AROUND BUNG TO parallel to the block to keep water away from the
BE DRAWN INTO DRUM bung openings.
4. Drums that have a bung on the side should be
stored either on end or on their side with the
bung down. Regardless of their position, drums
should always be placed on blocks or racks several
inches off the ground to avoid moisture damage.
CORRECT
G.122.05 dispose of used fluids properly.
NOTICe If machine will be stored

for an extended period, or stored in a corrosive
WATER AROUND BUNG MAY BE environment (such as salt air or industrial pollution),
DRAWN INTO DRUM using a sponge, apply Chrome Kote Corrosion
Preventive to portions exposed to air. See Storage
section for more information.
WRONG
G.123.05
569 9- 1111

notes
569 9- 1111

maintenance safety
maintenance safety
before maintenance
WArNING Maintaining this machine improperly could result in severe personal injury or
death. Read this manual before doing maintenance. Follow all safety instructions.
1. Read all safety and maintenance instructions in

this operator’s manual.
2. Position equipment on firm, level ground.
3. Lower attachment to the ground.
5. Move controls in all directions to relieve hydraulic
pressure.
6. Remove key from ignition.
practice safe maintenance

Read maintenance manuals and understand service
procedures before performing service/maintenance.
Understand service procedures before performing
maintenance. When performing maintenance, keep
area around machine clean and dry.
DO NOT service machine while it is moving. Keep away
from power-driven parts. Lower attachment to the
ground. Disengage power. Shut engine down. Move
controls in all directions to relieve hydraulic pressure.
Remove key from ignition. Allow machine to cool
down.
Support all raised equipment.
Keep all machine parts in good condition, and be
sure parts are properly installed. Repair damage
immediately. Repair all hydraulic and fuel leaks
immediately. Replace worn or broken parts. Remove
any buildup of grease, oil or debris.
Disconnect battery ground cable (-) before working on
the electrical system.
Lower stabilizers to the ground. Do not support
machine weight on stabilizers.
569 10- 1111

maintenance safety
before maintenance
protective clothing
Wear OHSA-approved protective clothing when
working on or near this machine, such as
• ear protection • gloves
• goggles • hard hat
• orange vest • steel-toed boots
Wear snug, protective clothing that is belted where
required.
Remove jewelry before working on or near this
machine.
hydraulic safety

protection equipment (PPE).
If ANY fluid is injected into the skin, seek
medical attention immediately. A serious
infection or reaction can result without proper medical
treatment.
Before working on the hydraulic system,
1. Lower boom and grapple to the ground.
2. Raise stabilizers so loader rests on carrier tires.
Then lower stabilizers to they touch the ground
without raising the loader.
4. Move joysticks in all directions to relieve hydraulic
pressure on boom.
5. Disengage pilot controls by moving pilot shut off
lever UP.
7. Purge air from hydraulic reservoir by depressing
relief valve button.
CAUTION Hot hydraulic oil can
cause severe burns. DO NOT work on hydraulic
system if oil temperature exceeds 120°F (49°C).
Wear eye and personal protection equipment
(PPE)!
hoses, lines, and fittings periodically for leaks, cracks or
defects. Be sure all clamps are in their proper position
and torqued as required and specified. Be sure hoses
are not twisted or touching parts.
569 10- 1111

maintenance safety
before maintenance
boom safety
WArNING Falling boom or

attachment can cause severe personal injury or
death.
DO NOT enter danger area under or around boom if
either of the following conditions apply:
1. Attachment is off the ground; or,
2. Engine is running.
Before ANY work is done in this area,
1. Lower attachment to the ground.
3. Move joysticks until pressure is released,
4. Remove key from ignition to prevent accidental
start up.
servicing control valves, cylinders,

pumps, and motors
Increasing relief valve settings could cause
machine or component failure resulting in severe
personal injury or death. Do not change pressure
settings. Do not switch lines from one valve to
another.
Special tools and training are required to service
control valves, cylinders, pumps, and motors. If these
parts need service, see an authorized dealer.
unauthorized welding
WArNING Unauthorized welding

injury or death.
the warranty.
Once authorized, be sure to turn battery disconnect
master switch OFF.
NOTICe Unauthorized welding can

cause damage to the electrical system.
569 10- 1111

maintenance safety
during maintenance
battery safEty
WArNING Batteries produce

explosive gases that can cause severe personal
injury or death.
children.
Keep sparks, flames, and cigarettes away from
batteries. Ventilate properly when charging or
using batteries in enclosed space. Always shield
eyes with goggles and wear a face shield when
working near batteries. Do not lean over batteries
during this operation. Always connect positive (+)
to positive (+) and negative (-) to negative (-). For
further instructions, see Jump Starting Battery in
Operation section. If battery acid contacts eyes,
flush them with water for 15 minutes and seek
immediate medical attention.
Never charge a battery or jump start engine if
battery is frozen. Warm battery to 60°F (16°C) or
it may explode. Be sure vent caps are tight. When
jump starting from another machine, be sure
machines do not touch. This machine has a 12-
volt starting system. Use equal voltage for jump
starting.
cooling fAn
WArNING Rotating fan can cause

severe personal injury or death. Cooling fan can
start at any time, even with motor off. Keep away
from fan at all times.
569 10- 1111

maintenance safety
during maintenance, continued
diesel exhaust
WArNING Diesel exhaust fumes

contain elements that are hazardous to health.
Always run engine in a well ventilated area. If in an
enclosed area, vent exhaust outside.
Fluids under presure

protection equipment (PPE)!
DO NOT use hands to search for leaks. Always use a
board or cardboard when checking oil hoses, lines,
and fittings for leaks, cracks, or defects. Be sure all
clamps are in their proper position and torqued as
required and specified. Be sure hoses are not twisted
or touching parts.
Escaping fluids can penetrate skin and enter the
bloodstream. Before disconnecting lines, relieve all
pressure.
DO NOT apply pressure to a damaged line, hose, or
fitting.
If any fluid is injected into the skin, seek medical
attention immediately. A serious infection or reaction
can result without proper medical treatment.
WArNING Fires and explosions can

• Handle fuels and lubricants carefully.
• DO NOT smoke when fueling or working with or

around fuel.
• Clean up, and properly dispose of all spilled

lubricants, grease and solvents.
• Use proper tools and procedures for making

repairs.
• Wear approved eye and personal protection

equipment (PPE).
569 10- 1111

maintenance safety
during maintenance, continued
pinch points
WArNING Placing hands or any

portion of the body where the machine moves can
cause severe personal injury or death. Never place
hands or any portion of the body where injury
could occur if machine moves. Never check pin hole
alignments with fingers.
Servicing Machine with Engine Running
WArNING Servicing machine with

engine running can cause severe injury or death.
When maintenance procedure requires engine be
running, ONLY qualified service technicians should
service machine.
569 10- 1111

maintenance safety
after maintenance
disposing of waste
Follow local, state, federal, and international
regulations when disposing of waste. Waste may
include, but is not limited to oil, fuel, coolant, brake
fluid, filters, and batteries.
Use leakproof containers when draining fluids. Do not
use food or beverage containers. Do not pour waste
on the ground, down a drain, or into any water source.
Clean up all spilled fuel, oil, grease, etc. and dispose of
per local, state, federal, or international regulations.
storing flammable materials

• Do not smoke where flammable materials are
stored.
• Store fuels and lubricants in properly marked
containers.
• Store oily rags and other flammable materials in
protective containers.
569 10- 1111

maintenance
notes safety
569 10- 1111

scheduled and periodic maintenance services
scheduled and periodic
maintenance services
lubrication and maintenance intervals
Maintenance requirements for lubrication, adjust-
ments and checks are shown on the maintenance
charts in this section.
Intervals of maintenance are based on normal operat-
ing conditions. If operating under more demanding
conditions, observe a shorter time interval between
maintenance.
Demanding conditions include but are not limited to:
• Hilly terrain
• Working in or passing through deep water or mud
• Dry work area with heavy blowing dust
• Extreme cold, -20°F (-6°C) and below
• Extreme heat, 100°F ( °C) and above
Use the hourmeter to help determine proper mainte-
nance intervals.
LUBRICATION notice
Listed maintenance intervals are for normal use applications. When greasing lubrication fittings, if grease is not forced
out the bushing ends with the recommended shots, increase number of shots used until grease is forced out. If grease
cannot be forced out, check for blocked grease passageways.
If the lubricating areas are dry at the end of a normal operating day, increase the frequency of lubricating time periods
instead of increasing the amount of grease used at one lubrication period.
position machine for maintenance
WArNING To avoid serious personal

injury or property damage, follow the steps below
before performing any maintenance on this ma-
chine.
1. Park machine on level ground.
2. Lower boom and grapple to ground.
3. Raise stabilizers so loader rests on carrier tires.
Then lower stabilizers so they touch the ground
without raising the loader.
pressure on boom.
6. Disengage controls by moving control shut off
lever up.
569 11- 1111

6 8
5
3
4
MAINTENANCE CHART USAGE

Use the KEY # and COMPONENT for locating the proper service and maintenance procedures in this section.
AS REQUIRED
KEY COMPONENT SERVICE SPECIFICATION MATERIAL USED
1. Electrical System* Check Reset breakers or replace fuses
2. A/C Condenser Clean Compressed air
3. Recirculation Air Filter Clean/replace New filter Use Genuine parts
4. Windshield Washer Reservoir Check Fill washer fluid
5. Windshield and Windows Clean Detergent and water
6. Polycarbonate Skylight Replace Polycarbonate material Use Genuine parts
7. Slasher/Delimber Saw* Adjust bar chain See details in section and
(if equipped) slasher/delimber manual
8. Hydraulic Oil Drain/replace Seasonally AS Hyd. Oil
9. Safety Decals* Clean/replace Use Genuine parts
10. Slip Resistant Mats* Clean/replace Use Genuine parts
* Not shown
NOTICe Be sure to refer to the engine

operation and maintenance manual for additional en-
gine maintenance recommendations and procedures.
569 11- 1111

19 17 16
21
20 15
18
13
12
14
11
22

DAILY OR EVERY 10 HOURS

*DAILY VISUAL INSPECTION** Inspect Inspect loader for damage, see detail
11. Adapter Knuckle Lubricate Lubricate until grease is forced out Prem. Grease
12. Stabilizer Pad Pivot Pin Lubricate Lubricate until grease is forced out Prem. Grease
13. Stabillizer Cylinder Rod End Lubricate Lubricate until grease is forced out Prem. Grease
14. Stabilizer Arm Pivot Pin Lubricate Lubricate until grease is forced out Prem. Grease
15. Stabilizer Cylinder Base End Lubricate Lubricate until grease is forced out Prem. Grease
16. Main Boom Pivot Pin Lubricate Lubricate until grease is forced out Prem. Grease
17. Main Boom Cylinder Base End Lubricate Lubricate until grease is forced out Prem. Grease
18. Main Boom Cylinder Rod End Lubricate Lubricate until grease is forced out Prem. Grease
19. Main/Stick Pivot Pin Lubricate Lubricate until grease is forced out Prem. Grease
10. Stick Boom Cylinder Base End Lubricate Lubricate until grease is forced out Prem. Grease
21. Stick Boom Cylinder Rod End Lubricate Lubricate until grease is forced out Prem. Grease
22. Swing Bearing Lubricate Lubricate while rotating 2 complete Prem. Grease
revolutions
* - Not shown
NOTICe ** WArNING Do not weld on structures.

Lubricate with Premium
Immediately report structural problems (cracks) to an
Moly-Lith EP #2 Grease.
authorized dealer for diagnosis and repair or replac-
ment.
569 11- 1111

27 25 28
24
29
30
31
32
26
23
34

DAILY OR EVERY 10 HOURS, continued

23. Pinion Gear Lubricate Lubricate gear with open gear lube Open gear lube
24. Hydraulic Oil Reservoir Check level Add hydraulic oil if necessary Hyd. Oil
25. Air Cleaner Maintenance Clean or replace element Use Genuine parts
26. Fire Extinguisher Check charge Recharge or replace
27. Fuel Tank Check level Add fuel if necessary Diesel fuel
28. Cooling Fan Inspect Replace if damaged Use Genuine parts
29. Belts Inspect Replace if damaged Use Genuine parts
30. Fuel-water Separator Drain Drain until clear fuel drains
31. Engine Crankcase Oil Check level Add engine oil if necessary Prem. Eng. Oil
32. Radiator Coolant Check level Add coolant if necessary Water/antifreeze
33. Electrical Components* Inspect Check for fraying, loose connections See details in section
34. Loader Mounting Bolts Inspect Check for stability of loader position

* - Not shown
WArNING Do not weld on struc-
NOTICe Lubricate with Premium tures. Immediately report structural problems
Moly-Lith EP #2 Grease. (cracks) to an authorized dealer for diagnosis and
repair or replacment.
569 11- 1111

37
40
35
39
35
36
41

WEEKLY OR EVERY 50 HOURS

*. WEEKLY INSPECTION Inspect Check for damage, see detail
35. Boom / Cylinder Attaching Pins Check Tighten Wrench
36. Stabilizer Attaching Pins Check Tighten Wrench
37. Oil Reservoir Hardware Check Tighten Wrench
38. Hydraulic connections* Inspect Tighten Wrench
39. Radiator and Oil Cooler Clean Remove debris Water
40. Hydraulic Oil Reservoir Check oil If contaminated, replace Prem AS Hyd Oil
41. Swing Drive Gear Box Check lube level Add lubricant, if necessary GL-5 Gear Lube
* Not shown
NOTICe Be sure to refer to the engine ** WArNING Do not weld on struc-

operation and maintenance manual for additional en- tures. Immediately report structural problems
gine maintenance recommendations and procedures. (cracks) to an authorized dealer for diagnosis and
569 11- 1111

43
44 42
46
45

MONTHLY OR EVERY 250 HOURS

42. Engine Oil and Filter Change Drain and replace Oil and filter
43. Air Intake and Exhaust Inspect Check connections Wrench
44. Battery Check Check connections, electrolyte level Clean, distilled
water
45. Seat Inspect/Lube Silicone spray
46. Swing Drive Fasteners Check Tighten to 437-483 ft-lbs* (593-655 N•m) Torque wrench
*Use with Loc-Tite® or equivalent
NOTICe Be sure to refer to the engine ** WArNING Do not weld on struc-

operation and maintenance manual for additional en- tures. Immediately report structural problems
gine maintenance recommendations and procedures. (cracks) to an authorized dealer for diagnosis and
569 11- 0209

1111
56 60 48
57 47
49
58
50
51
54 52
55 53
59

EVERY 500 HOURS

47. Hydraulic Oil Return Line Filter Install new* Replacement filter Use Genuine parts
48. Cooling System Check Check for leaks, sample conditioner Water conditioner
49. Fuel Lift Pump Pre-filter Install new** Replacement filter Use Cat parts
50. Primary Fuel Filter Install new** New filter Use Cat parts
51. Fuel System Prime See engine operator’s manual
52. Pilot Supply Filter Install new* New filter Use Genuine parts
53. Pilot Return/Case Drain Filter Install new* New filter Use Genuine parts
54. Outer Swing Bearing Fasteners Check Tighten to 600 ft-lbs (813 N•m) Torque wrench
55. Inner Swing Bearing Fasteners Check Tighten to 600 ft-lbs (813 N•m) Torque wrench
56. Swivel Torque Arm Fasteners Check Tighten to 76-84 ft-lbs (103-114 N•m) Torque wrench
57. Swivel Fasteners Check Tighten to 266-294 ft-lbs (360-399 N•m) Torque wrench
58. Pinion Gear Fastener (if equipped) Check Tighten to 420 ft-lbs (529 N•m) Torque wrench
59. Stationary Heel Fasteners Check*** Tighten to 162-178 ft-lbs (220-241 N•m) Torque wrench
60. Slasher/Delimber Return Line Filter Install new* New filter Use Genuine parts
* Change interval can vary depending on operating conditions

** Change interval can vary depending on cleanliness of fuel
*** Tighten head of bolt while holding nut

569 11- 1111

0209
61
62
63 64
65
66
67
68

EVERY 1000 HOURS

61. Hydraulic Oil Drain/replace See details in section Premium AS Oil
62. Hydraulic Oil Reservoir Breather Replace Install new breather element Use Genuine parts
Filter
63. Pressure Vacuum Relief Valve Replace Install new relief valve Use Genuine parts
64. Cooling System Flush and fill Replace coolant See engine manual
65. Swing Drive Gear Box Lube Drain/replace Replace with 0.9 gal (3.4 L) lubricant GL-5
Gearlube
66. Swing Drive Check level Add grease if necessary Prem.
Grease
67. Swing Drive Drain and fill See details within section Mobilgear 630
68. Collector Ring Check/clean Spray contacts, check brushes Contact cleaner
and wire connections

569 11- 1111

as required
1. check electrical system

Check circuit breakers.
Circuit breakers protect an electrical circuit from cur-
rent overload.
If an overload occurs, the circuit breaker will trip, ex-
posing the white reset button, and breaking the flow
of current. This will prevent damage to the circuit.
To reset a circuit breaker, depress the tripped circuit
breaker to its original position.
If breakers will not reset, replace the circuit breaker
and/or have an authorized dealer diagnose and repair
the problem.
img.2490
569 11- 1111

as required
a 2. clean a/c condenser
If the air conditioner is not cooling properly, the con-
denser cooling fins may require cleaning to remove
debris and dirt.
1. Gain access to condenser by removing cap screws
from the access door (A).
Cleaning with compressed

air release debris and flying particles that
can cause serious personal injury. Wear a face
img.2453 shield and protective clothing.
2. With a maximum of 30 psi (210 kPa) compressed
air, clean condenser cooling fins. If fins cannot
be cleaned with compressed air, wash them with
water.
3. Secure access door with cap screws removed in
Step 1.
3. clean/replace recirculation air

filter
1. The recirculating air filter is located beneath the
operator’s seat inside the cab. Loosen retaining
knobs and remove filter cover.
2. Remove, and clean filter (B) using one of the fol-
lowing methods.
b Cleaning with compressed

air release debris and flying particles that
img.2458
can cause serious personal injury. Wear a face
shield and protective clothing.
a. Lightly tap filter on flat surface, dirty side
down.
b. Direct 30 psi (210 kPa) maximum compressed
air through filter from the opposite direction
of air flow.
c. Wash filter with mild soap and water. Rinse
until clean with water from hose having a
maximum pressure of 30 psi (210 kPa). Lightly
shake excess water from filter and allow to dry
before installing.
3. Reinstall filter. If filter is damaged, replace with
new.
569 11-10 1111

as required
4. fill windshield washer fluid

reservoir
The washer reservoir (A) is located inside the cab, on
the left side of the seat.
Add commercial windshield washer fluid as necessary.
img.2429
5. clean windshield and windows

The cab windshield and windows are made of tinted
safety glass. The skylight is polycarbonate window
material.
Do not use abrasive or highly alkaline cleaner.
Do not scrape window with a metal scraper or sharp
object.
Do not use benzene, gasoline, acetone or carbon tetra-
chloride to clean polycarbonate windows.
img.2400
Do not clean polycarbonate window material skylight
in hot sun or at elevated temperatures.
Fresh paint, grease and tree sap can be removed be-
fore drying by rubbing lightly with naptha, isopropyl
alcohol, or butyl cellosolve (2-butoxy ethanol). Then
wash with a mild soap or detergent solution. Rinse
thoroughly with clean water.
Scratches and abrasions can be removed or minimized
by using a mild automobile wax. Test a small area of
the polycarbonate window material with the product
used to be sure it does not scratch or cloud the win-
dow.
1. Open front window guard.
2. Flush away as much loose dirt and dust as pos-
sible.
3. Wash windshield and windows and skylight with a
mild soap or detergent and lukewarm water. Use a
clean sponge or soft cloth. Rinse with clean water.
Dry with a soft cloth or chamois to prevent water
spots.
Falling or swinging
logs can cause severe personal injury or death.
Never operate the machine without the cab guard
securely in place and undamaged.
4. Close front window guard and secure into place.
569 11-11 1111

as required
6. check/replace polycarbonate
window skylight
To prevent serious person-

al injury or death from objects breaking through
polycarbonate window material, replace them
when they
• are yellow or hazed;
• are scratched on either side with scratches that
img.2557b
can be felt with a fingernail (.0003 inch or greater);
• have small cracks coming from edges or mounting
holes; or,
• have contacted fluids that have caused cloudiness.
When any of the above conditions exist, the polycar-
bonate windows have lost enough of their strength
that they will no longer protect the operator as
designed.
7. adjust slasher/delimber saw

bar chain
1. Remove personnel from saw area.
2. Activate saw function, and run saw bar to halfway
down from the saw box (as shown), then release
button. This will stop the saw chain from rotating,
and will position the saw bar for chain adjustment.
3. Shut engine down and remove key.
4. Adjust chain following instruction in the slasher/
delimber operator’s manual.
5. After chain is adjusted, remove personnel from
Slasher saw bar position for saw area.
chain adjustment
6. Start engine.
7. Activate saw function, and return the bar to the
saw box.
Delimber saw bar position for

chain adjustment
569 11-12 1111

as required
8. drain and replace hydraulic oil
Hydraulic oil must be changed based on the ambient
(outside) air temperature. Certain grades of hydraulic
oil work best in certain temperature ranges.
Follow Caterpillar’s hydraulic oil specifications. If oil
is not changed seasonally, as required, the hydraulic
system can be damaged.
Refer to Fuels and Lubricants section for hydraulic oil
recommendations.
Procedures for changing hydraulic oil can be found
later in this section.
Hydraulic oil capacity is 65 gallons (246 L).
DO NOT mismatch brands

or weights of hydraulic oil.
9. hazard decals
Inspect safety decals and replace as needed when
damaged or unreadable.
Decals will not adhere to

dirty or wet surfaces. Thoroughly clean and dry any area
where a decal or slip resistant mat is to be placed.
10. slip resistant mats

Inspect and clean resistant mats. Replace any slip resis-
tant mat that has been damaged or has come loose.
Decals will not adhere to

dirty or wet surfaces. Thoroughly clean and dry any area
where a decal or slip resistant mat is to be placed.
569 11-13 1111

daily or every 10 hours

perform a daily visual inspection
Failure to perform a daily

inspection of machine can result in machine dam-
age and severe personal injury or death.
In addition to the required daily inspection outlined in
Pre-Start Inspection section perform a daily inspection
g.048.03
of the following components:
• Structures • Swing bearing
• Booms • Load-bearing items
• Cylinders • All mountings
• Turntable
Unauthorized welding
injury or death.
the warranty.
Once authorized, turn battery disconnect master
switch OFF and place welding ground (stinger) as close
to the weld site as possible. Do not allow weld current
to pass through bearings, bushings or pivot points.
Welding can cause damage

to the electrical system.
11. lubricate adapter knuckle

Lubricate adapter knuckle (A) with Premium Moly-Lith
EP #2 until grease is forced out.
a
img.2560
12. lubricate stabilizer pad pivot

pins
Lubricate stabilizer pad pivot pins (B) with Premium
b Moly-Lith EP #2 until grease is forced out.
img.2470
569 11-14 1111

13. lubricate stabilizer cylinder
rod ends
Lubricate stabilizer cylinder rod ends (A) with Premium
Moly-Lith EP #2 until grease is forced out.
img.2557a
14. Lubricate stabilizer arm pivot

b pins
Lubricate stabilizer arm pivot pins (B) with Premium
045.03
15. lubricate stabilizer cylinder

base ends
c
Lubricate stabilizer cylinder base ends (C) with Pre-
mium Moly-Lith EP #2 until grease is forced out.
img.2469
16. lubricate main boom pivot pins

Lubricate main boom pivot pins (D) with Premium
d
047.03
569 11-15 1111

17. lubricate main boom cylinder
base ends
a
Lubricate main boom cylinder base ends (A) with Pre-
img.2464
18. lubricate main boom cylinder

b rod ends
Lubricate main boom cylinder rod ends (B) with Pre-
img 2466
19. Lubricate main/stick pivot pins

Lubricate main/stick pivot pins (C) with Premium Moly-
Lith EP #2 until grease is forced out.
c
img.2479
20. Lubricate stick boom cylinder

base ends
Lubricate stick boom cylinder base ends (D) with Pre-
img.2473
569 11-16 1111

21. Lubricate stick boom cylinder
rod ends
Lubricate stick boom cylinder rod ends (A) with Pre-
052.03
22. Lubricate swing bearing

b Lubricate swing bearing with Premium Moly-Lith EP #2
while rotating loader 2 complete revolutions.
There are 3 grease fittings (B) located on the floor of
the right side of the cab that can be reached with a
grease gun from the operator’s seat.
Rotate turntable slowly.

Boom can strike people or property, which can cause
personal injury or property damage. Be sure loader
img.2571
is clear of obstructions, remove personnel, and make
sure those not performing maintenance are clear of
the machine.
23. Lubricate pinion gear

c Coat gear teeth (C) with Heavy Duty Open Gear Lube
to prevent bare metal contact. Spray lubricant through
access hole (D) .
054.03
pinion lube.tif
569 11-17 1111

24. check hydraulic oil reservoir
level
1. Position loader properly for an accurate reading.
Booms should be horizontal, and grapple should
be closed. Lower stabilizers so they touch the
ground without raising the loader.
2. Shut engine down and move joysticks in all direc-
a tions to relieve hydraulic pressure.
lever UP (A).
4. Visually check the oil level by observing the sight
gauge (B) on the hydraulic reservoir while oil is
warm. Sight gauge is located in hydraulic filter
compartment, accessed through the top of the
engine compartment.
5. Add clean, filtered oil, if necessary (refer to Fill
Hydraulic Reservoir below).
img.2576
img.2500
fill hydraulic reservoir

c 1. Gain access to hydraulic reservoir hand fill pump
(C) on the loader.
2. Uncoil fill hose (D).
d
img.2349
569 11-18 1111

fill hydraulic reservoir, continued
a 3. Clean fill hose end.
4. Remove cap from fill hose end (A).
5. Insert hose into oil supply container.
057.03
6. Purge air from hydraulic reservoir.

If loader is equipped with a relief valve breather,
refer to Step A below.
b
If loader is equipped with a breather element,
refer to Step B below.
a. Press relief valve button (B) to purge air from
hydraulic reservoir.
b. Slowly turn breather element (C) counter-
clockwise until pressure is released. DO NOT
img.2330
completely remove breather element.
7. Use hand pump to fill reservoir.
059.03
8. Fill reservoir until oil reaches the FULL mark on the

hydraulic reservoir sight gauge (D). Hydraulic oil
capacity is 65 gallons (246 L)
9. Clean and replace fill hose end cap.
10. Recoil fill hose onto bracket.
11. Tighten breather element (if equipped).
img.2500
569 11-19 1111

fill hydraulic reservoir, continued
a
prime the pump
If the hand pump fails to

pump hydraulic oil into the reservoir, the pump requires
priming. Use the following procedure for priming the
hand pump.
1. Gain access to hydraulic reservoir fill hose.
2. Clean fill hose end (A).
057.03
3. Remove cap from fill hose end.

4. While holding hose, fill it with the type of hydrau-
lic oil being used in the loader. See Fuels and
Lubricants section for specifications.
5. While holding the hose in the highest position,
b operate the hand pump (B) for 10 to 15 strokes or
until all air is removed from the pump. This is indi-
cated by feeling a higher resistance on the handle
of the pump.
It may be necessary to refill

img.2349 the hose with hydraulic oil.
If, while pumping the hand pump, the resistance on
the handle become so great the handle cannot be
moved, the pump should be replaced.
25. Air cleaner maintenance
unloader valve
Squeeze dust unloader valve (C) to release any trapped
c dirt particles. If the sealing tip of the valve is damaged,
life of the air filter elements will be greatly reduced.
Replace sealing tip if damaged.
img.2371
inlet hood
Clean debris from air cleaner inlet hood (D).
img.2365
569 11-20 1111

servicing air cleaner, continued
restriction indicator
To prevent over- or under- servicing of the air cleaner
elements, an air filter restriction indicator (A) has been
installed in the air intake system.
a When air flow is restricted to 25-inch vacuum, a red
band indicates that the filter elements require servic-
ing.
To reset the indicator, press the reset button on the
indicator.
022.03
If the filter elements require servicing, use the follow-
ing procedures.
servicing air cleaner

1. Gain access to the air cleaner.
b
2. Release clips holding filter cover (B) in place.
3. Thoroughly clean filter cover with a clean, damp
cloth.
4. Remove primary element (C) carefully. Bumping
element against housing may contaminate the
clean side of the filter housing with dirt and dust.
If the element can be cleaned, do so following
instructions in Cleaning Primary Element (following
img.2365
pages).
5. Thoroughly clean out the inside of filter hous-
ing with a clean, damp cloth. Dirt left in the filter
housing will shorten the life of the filters.
Clean all dirt and dust from

filter housing BEFORE removing secondary element.
Engine damage will result if dirt enters the engine.
NEVER clean the secondary element.
6. Remove secondary element (D).
c Replace secondary element

at least every third primary element cleaning/
img. 2367 change, or if the element requires replacement.
7. Immediately install new secondary element to
prevent dirt from entering the engine air intake.
8. Install cleaned/new primary elemet.
d DO NOT operate engine

without air cleaner cover in place. Air filter life will
be quickly shortened due to reduced turbo cleaning
action of the air filter.
11. Install air filter cover; snap clips in place.
12. Reset air cleaner restriction indicator.
img. 2369
569 11-21 1111

servicing air cleaner, continued
cleaning primary filter element with com-

pressed air.
Do not clean any filter ele-

ments with filter element cleaners. DO NOT tap element
against a hard surface. An element that is dented or torn
must be replaced.
1. Rotate element and tap with palm of hand. Care
must be taken to prevent removed dirt from get-
092.02
ting deposited on inside of filter during cleaning
procedure.
Cleaning with com-

pressed air releases debris and flying particles
that can cause serious personal injury. Wear a face
2. If tapping does not remove dust, use compressed
air under 30 psi (207 kPa). Direct air up and down
through filter pleats. Keep nozzle at least 1 inch
from pleated paper. Move air from inside to out-
side of element ONLY. Be careful to not damage
element.
093.02
Always inspect element after
cleaning.
3. Inspect primary element after cleaning by put-
ting a bright light inside element. Rotate element
slowly. If any rupture, hole, or a damaged gasket is
found, replace with NEW element. Failure to do so
could cause engine damage.
094.02
569 11-22 1111

26. Check fire extinguisher charge
Inspect fire extinguisher (A) for proper charge. If gauge
on fire extinguisher indicates a recharge is required,
have an authorized service center recharge unit.
RECHARGE FIRE EXTINGUISHER IMMEDIATELY AFTER
a ANY USE!
img.2430
27. Fill fuel tank

b
Diesel fuel is flammable.
Fires and explosions can cause severe personal
injury or death. Handle with extreme care.
1. Check the fuel level indicator (B) to determine the
amount of fuel in the tank.
2. Fill the fuel tank with diesel fuel at the end of each
shift to prevent condensation in the tank.
Do not overfill. Tank overflow can occur when fuel gets
img.2414
warm.
Fuel tank capacity for the 569 is 89 gallons
(337L).
c 28. Inspect cooling fan

d With engine off and key removed, check fan (C) for
cracked, bent, or loose blades. Check fan to make sure
it is properly mounted. Replace damaged fan and/or
fan guard.
29. Inspect belts

Visually inspect the belts (D) for cracking, fraying, or
pieces of material missing. Replace belts as needed.
See the engine operator’s manual for replacement
068.03 information.
569 11-23 1111

30. drain fuel-water separator
Drain the water and sediment from the fuel/water
separator (A) daily.
a
2. Turn valve on the separator counterclockwise ap-
proximately 2 turns until draining occurs.
3. Drain until clear fuel is visible in catch pan. Clean
up spill.
DO NOT overtighten the

valve. Doing so will damage the threads.
4. Close valve by turning clockwise.
Fuel water separator is under

suction during normal engine operation. Ensure drain
valve is tightened securely to prevent air from entering
the fuel system.
31. check engine crankcase oil

level
a 1. With loader on level ground. Stop the engine and
remove key.
2. Wait 15 minutes for oil to drain.
3. Gain access to oil dipstick (A).
4. Check oil level on dipstick. Oil level should be to
b the FULL mark on the dipstick.
DO NOT run the engine if

oil level is below the bottom mark on the dipstick.
5. Clean area around filler cap (B) and remove the
filler cap.
6. Add engine oil as necessary to bring oil level to
FULL or top mark on disptick. DO NOT OVERFILL.
Engine oil capacity is 17.2 quarts (16.2 L).
Refer to Fuels and Lubricants section for engine oil
specification.
7. Replace filler cap.
569 11-24 1111

32. check radiator coolant level
Cooling system is under

pressure. HOT engine coolant can cause severe
burns. DO NOT remove radiator filter cap unless
engine is cool. Slowly release all pressure before
cap (A) removing.
Never use water alone with-

out Supplemental Coolant Additives (SCA) or without
inhibited coolant. Water alone is corrosive at engine
operating temperatures. Water alone does not provide
adequate protection against boiling or freezing.
Wear eye and personal protection equip-

ment (PPE)!
2. Gain access to the radiator cap (A). The radiator
cap can be accessed through the cover on top of
the engine shroud.
3. Rotate radiator cap 1/4 turn to relieve pressure.
a Remove radiator cap slowly. Do not stand with
face over cap when removing.
Do not pour cold liquid into

a hot engine. Allow the engine to cool below 120°F (50°C)
before adding coolant.
4. Coolant level should be at the bottom of the fill
img.2359 neck. If necessary, fill with coolant. For the proper
coolant mixture, refer to Engine Coolant Specifica-
tions in Fuels and Lubricants section.
During filling, air must be vented from engine coolant
passages. Refer to the engine operator’s manual for
cooling system maintenance.
569 11-25 1111

33. Inspect Electrical components
Loose, frayed, or worn

electrical components may result in electrical shock
or fire, causing severe personal injury or death.
Check all electrical wires daily. Wiring must be kept in
good condition. All electrical wires must be properly
routed and securely attached. Repair any wires that are
loose or frayed before starting the engine. Clean and
tighten all electrical connections.
Arcing or sparking could cause a fire. Securing connec-
tions and maintaining recommended wiring will help
to prevent arcing or sparking.
34. Inspect loader mounting bolts

Inspect and tighten loader mounting bolts, ensuring
loader position has not moved.
g.062.03
569 11-26 1111

weekly or every 50 hours
perform a weekly inspection using the fol-

lowing guidelines
1. Clean the structure thoroughly. Remove all dirt,
mud, grease, oil, debris, and snow.
2. Look for rust lines in the paint, and missing or
cracked paint. These are indications of crack sites.
g.048.03
3. Inspect all welds and adjacent areas on booms,
cylinders, turntable, swing gear mounting, and
grapple for signs of cracks.
4. Inspect the grapple around cylinder and jaw
mountings, the jaws, the rotator mounting, and
frame.
5. Check all boom cylinders and pin keeper retain-
ers for broken fasteners. If broken or damaged,
replace with new fasteners.
6. Check swing mounting fasteners for correct tight-
ness. If any fastener will not torque to the specifi-
cation, remove it and the two on either side of it.
Replace all three fasteners (and washers, if used)
with new ones.
7. Check the mounting to the truck or trailer frame.
Ensure that the fasteners are tight and any spacers
are in good condition and in their correct loca-
tions.
8. Check the sub-frame and stabilizers. Check the
areas around the swing bearing mounting, the
stabilizer, and their mounting ears, and the stabi-
lizer cylinders and their mounting
Unauthorized welding
injury or death.
the warranty.
Once authorized, turn battery disconnect master
switch OFF and place welding ground (stinger) as close
to the weld site as possible. Do not allow weld current
to pass through bearings, bushings or pivot points.
Welding can cause damage

to the electrical system.
9. Inspect safety decals and replace as needed when
damaged or unreadable.
10. Inspect slip resistant mats. Replace any slip

resistant mat that has been damaged or has come
loose.
569 11-27 1111

35. Check boom and cylinder

a attaching pins
Inspect and tighten all boom and cylinder attaching
pins (A and B).
img.2556
36. Check stabilizer attaching pins

Inspect and tighten all stabilizer attaching pins (C).
g.060.03
37. check hydraulic oil reservoir

hardware
Inspect and tighten hydraulic oil reservoir hardware. If
damaged, replace with new.
569 11-28 1111

38. check hydraulic connections
Inspect and tighten all hydraulic connections.
074.03
39. clean radiator and oil cooler

a 1. Shut engine down. Remove key.
2. Gain access to the radiator and oil cooler by re-
moving the guard cap screws (A).
Cleaning with com-

pressed air releases debris and flying particles
that can cause serious personal injury. Wear a face
3. Using a maximum air pressure of 30 psi
img.2557
(210 kPa), clean debris from cooling units with
compressed air. Direct air from inside to outside
the cooling units.
4. Reinstall and secure guard with cap screws re-
moved in Step 2.
569 11-29 1111

40. Check hydraulic oil reservoir

for contaminants
1. Loosen drain plug (A) on bottom of hydraulic
reservoir.
2. Using a catch pan to collect hydraulic oil, visually
inspect hydraulic oil for contamination.
a
If contamination such
as water is visible, the hydraulic oil reservoir must be
077.03
drained, cleaned, and filters replaced. For procedures
on changing the hydraulic oil, see Changing Hydraulic
Reservoir Oil in this section.
3. Tighten drain plug.
4. Dispose of used hydraulic oil properly.
41. check swing drive gear box lu-

b bricant level
1. Clean area around dipstick (B) and oil fill plug.
2. Remove dipstick. Lubricant should be to the FULL
mark on the dipstick.
3. If necessary, add Premium GL-5 gear lube through
fill plug to bring lubricant level to FULL or top
mark on dipstick. DO NOT OVERFILL.
4. Clean and replace plug and dipstick.
078.03
569 11-30 1111

monthly or every 250 hours
a 42. change engine oil and filter

1. Run engine approximately 5 minutes to warm up
oil. Shut engine down and remove key.
2. Remove drain plug (A) and drain oil. Use properly
sized catch pan.
3. Install drain plug.
4. Clean and dry area around the oil filter (B).
5. Remove oil filter and clean filter mounting pad.
img.2402
Dispose of filter properly.
6. Lubricate gasket on new filter with clean oil.
7. Fill filter with new clean engine oil.
8. Install new filter and hand tighten according to
b values printed on filter element. DO NOT over-
tighten filter element.
9. Clean area around fill cap (C). Remove fill cap.
c 10. Fill engine with engine oil specified in
Fuels and Lubricants section.
Oil capacity is 17.2 quarts (16.3 L).
11. Install fill cap. Hold and screw cap handle to
tighten.
12. Start engine and run until warm and check for
leaks.
13. Shut down engine. Wait approximately 5 minutes
to let the oil drain from the upper portion of the
engine. Check oil level. Oil level should be on up-
per mark of dipstick.
569 11-31 1111

43. inspect air intake, exhaust and
charged air cooler
Fan-shaped dirt tracks at an air intake connection indi-
cate a leak. Have connections repaired.
1. Inspect air intake connections. Replace defective
parts.
2. Inspect exhaust connections. Replace defective
parts.
3. Inspect charged air cooler connections. Replace
defective parts.
s9066
44. battery service
Batteries produce explo-

sive gases.
Keep sparks, flames, and cigarettes away from bat-
teries. Ventilate properly when charging or using
batteries in enclosed space. Always shield eyes with
goggles and wear a face shield when working near
batteries. Do not lean over batteries during this op-
eration. Always connect positive (+) to positive (+)
and negative (-) to negative (-). For further instruc-
tions, see Jump Starting Battery in Operation sec-
tion. If battery acid contacts eyes, flush them with
water for 15 minutes and seek immediate medical
attention.
children.
Never charge a battery or jump start engine if bat-
tery is frozen. Warm battery to 60°F (16°C) or it may
explode. Be sure vent caps are tight. When jump
starting from another machine, be sure machines
do not touch. This machine has a 12-volt starting
system. Use equal voltage for jump starting.
1. Turn battery disconnect master switch (A) to OFF
position.
2. Gain access to battery (B).
569 11-32 1111

battery service, continued
3. Check electrolyte level. Fill each cell with clean wa-

a ter to the bottom of the filler check. Avoid overfill-
ing, doing so will cause electrolyte loss.
4. Check terminals and connections. Clean or replace
if they are damaged. Use a wire brush to remove
corrosion on terminals and on battery carrier.
After cleaning apply a coat of petroleum jelly to
the terminals and cable clamps to prevent further
corrosion.
img.2385
b 5. Check battery (C) for external damage. A broken

case or cracked cell cover will result in battery
failure. Battery hold down clamps should be tight
enough to hold the battery securely yet not so
tight as to warp the case.
6. Remove cables to clean top of battery. Clean top
of battery by using a baking soda solution of 1
pound soda per quart of water. DO NOT allow bak-
ing soda solution to enter battery.
img.2350 7. Reconnect the cable from starter to the positive
(+) battery post.
8. Reconnect the ground cable to the negative (-)
battery post. Always connect the negative battery
cable last.
c 9. Replace battery cover.
10. Turn battery disconnect master switch ON.
Unauthorized welding can

cause damge to the electrical system.
img.2350
569 11-33 1111

45. seat maintenance
1. Inspect the rollers and bushings in the seat sus-
pension for excessive wear. If damaged, replace
with new.
2. Grease the inside section of suspension frame
rails.
NOTICe Do not grease the actual rail

surface that rollers roll on. If these rails are greased, rollers
will begin to slide rather than roll, causing premature
wear on both surfaces.
46. check swing drive fasteners

Check that the swing drive fasteners (A) are tightened
to 437-483 ft-lbs (593-655 N•m) torque.
a 083.03
569 11-34 0209

1111
every 500 hours
47. replace hydraulic return line

filter
a
1. Lower boom and grapple to ground. Shut engine
down and remove key.
pressure.
lever UP.
4. Purge air from hydraulic reservoir by pressing
img.2330
relief valve button (A).
5. Gain access to filter assembly (B) on top of the
engine compartment.
6. Clean and dry area around filter head assembly.
b 7. Remove mounting cap screws and washers.
8. Remove filter head assembly (C).
9. Inspect sealing ring for nicks or cuts. Replace if
damaged.
10. Carefully remove hydraulic filter (D). DO NOT
damage the filter during removal. DO NOT knock
img.2500
the filter against the side of the canister during
removal.
11. Install new filter. Be careful not to contaminate
hydraulic reservoir while installing new filter.
12. Install filter head and tighten mounting cap
screws and washers to 25 ft-lbs (34 N•m) torque.
13. Cut old filter body and examine pleats. A preven-
tative maintenance check will be required if metal
particles such as brass or aluminum are found.
Contact an authorized dealer for preventative
maintenance procedures.
c
085.03
086.03
569 11-35 1111

every 500 hours
48. check cooling system
Cooling system is under

pressure. HOT engine coolant can cause severe burns.
DO NOT remove radiator filler cap unless engine is
cool. Slowly release all pressure before cap removal.
1. Check entire cooling system for leaks. Tighten all
clamps securely.
2. Inspect all cooling system hoses. Replace hoses
when hard, flimsy, or cracked.
3. Rotate radiator cap (A) 1/4 turn to relieve pressure.
SLOWLY remove the radiator cap. DO NOT stand
with face over cap when removing.
4. Take coolant conditioner sample to check anti-
freeze concentrations.
Blended coolant must meet the following specifica-
tions:
50% Distilled Water
50% Coolant Mixture
Refer to Fuels and Lubricants section for detailed addi-
tive specifications.
DO NOT pour cold liquid into

a hot engine. Allow the engine to cool below 120°F (50° C)
a before adding coolant. During filling, air must be vented
from the engine coolant passages. Refer to the engine
operator’s manual for proper filling procedure.
img.2359
5. If necessary, add cooling system conditioner.
A cooling system conditioner will help prevent rust
and scale, and lubricate the water pump.
49. replace fuel lift pump pre-filter

1. Clean area around filter head.
2. Remove filter and dispose of properly.
3. Clean gasket surface of filter head.
b 4. Replace o-ring.
5. Fill new fuel filter with clean fuel.
6. Lubricate the new o-ring seal with clean lubricat-
ing oil.
7. Install new fuel lift pump filter (B) and hand-tight-
en according to instructions on the filter element.
569 11-36 1111

every 500 hours
50. replace primary fuel filter/wa-
ter separator element
1. Clean area around the filter head.
2. Remove filter (A) and dispose of properly.
3. Clean gasket surface of filter head.
a 4. Replace o-ring.
5. Fill new fuel filter with clean fuel.
6. Lubricate o-ring seal with clean lubricating oil.
7. Install new filter. Hand-tighten according to in-
structions on the filter element.
8. After fuel filter is replaced, prime the fuel system.
Refer Prime the Fuel System, below.
Fuel leaked or spilled onto

hot surfaces or electrical components can cause a
fire resulting in serious personal injury or damage
to the machine. To help prevent possible injury,
turn ignition switch OFF when changing fuel filters
or water separator elements. Clean up fuel spills
immediately.
Do not allow dirt to enter the

fuel system. Thoroughly clean area around a fuel system
component that will be disconnected. Fit a suitable cover
over any disconnected fuel system component.
51. Prime the fuel system

If the fuel system requires manual priming, see the
engine operation and maintenance manual for the
proper procedure.
Prime the fuel system if:
• Fuel filter has been replaced
• High pressure fuel lines are replaced
• Initial engine start up or start up after an extended
period of no operation has occurred
• Fuel tank has run empty
569 11-37 1111

every 500 hours
52. replace pilot filter
a
pressure.
lever UP.
relief valve button (A).
5. Gain access to the pilot filter (B).
img.2330
6. Clean and dry area around pilot filter.
7. Remove and retain end plug (C).
8. Discard o-ring (D).
9. Inspect spring (E) for damage. If damaged, replace
with new.
b
10. Discard filter (F) and gasket (G).
11. Reinstall new gasket, filter, spring, and o-ring, and
secure with end plug.
img.2503
g
f
e
d
c
569 11-38 1111

every 500 hours
53. replace pilot return/case drain
filter
a
pressure.
lever UP.
relieve valve button (A).
img.2330
5. Gain access to pilot return/case drain filter (B).
6. Clean area around filter.
7. Remove filter element and seal. Dispose of used
b filter properly.
8. Apply a small amount of lubricant to the canister
seal.
9. Install the new canister and hand-tighten.
091.03
54. CHECK OUTER SWING BEARING

C FASTENER TORQUE
Check that the outer swing bearing fasteners (C) are
torqued at 600 ft-lbs (813 N•m) torque.
If fasteners are damaged, replace with new.
If a fastener will not tighten to the specified torque, re-
place with a new fastener. Also remove and replace the
two fasteners on either side of the damaged (replaced)
fastener.
g.068.03
569 11-39 1111

every 500 hours
55. CHECK INNER SWING BEARING
FASTENER TORQUE
Check that all inner swing bearing fasteners (A) are
tightened to 600 ft-lbs (813 N•m) torque.
a If a fastener will not tighten to the specified torque,
replace with a new fastener. Also, remove and replace
the two fasteners on either side of the damaged (re-
placed) fastener.
g.069.03
56. check swivel arm fastener

torque
b Check that swivel arm fasteners (B) are torqued to 76-
84 ft-lbs (103-114 N•m).
57. check swivel fastener torque

Check that the swivel fasteners are torqued at
266-294 ft-lbs (360-399 N•m) torque.
093.03
58. check pinion gear fastener

torque (if equipped)
Check that the pinion gear fastener (C) is torqued
between 420 ft-lbs (569 N•m) torque.
If fastener is damaged, replace with new.
054.03
569 11-40 0209

1111
every 500 hours
59. Check stationary heel fastener
torque
a Check that the stationary heel fasteners (A) are
tightened to 162-178 ft-lbs (220-241 N•m) torque by
tightening head of bolt while holding nut.
g.070.03
60. replace slasher/delimber

b return line filter (slasher/
delimber models only)
pressure.
lever UP.
img.2330
relief valve button (B).
5. Gain access to filter, and clean around filter.
6. Remove filter element (C) and seal. Properly dis-
pose of these parts.
7. Apply a small amount of lubricant to the canister
seal.
8. Install the new canister and hand-tighten.
094.03
569 11-41 1111

every 1000 hours
61. change hydraulic reservoir oil

1. Position the machine on level ground. The boom
should be horizontal and the grapple should be
open.
a 3. Move joysticks in all directions to relieve hydraulic
pressure.
lever (A) UP.
5. Purge air from hydraulic reservoir by pressing but-
ton on relief valve.
6. Gain access to the hydraulic drain plug (B).
7. Clean around drain plug on bottom of hydraulic
reservoir.
8. Remove the drain plug and drain hydraulic oil into
properly-sized catch pan. Dispose of oil properly.
9. Reinstall drain plug.
img.2576
077.03
fill hydraulic reservoir

1. Gain access to hydraulic reservoir hand fill pump
(C) and fill hose/tube on the loader.
img.2349
569 11-42 1111

every 1000 hours
change hydraulic reservoir oil, cont.
a 2. Clean fill hose/tube end (A).
3. Remove cap from fill hose/tube end.
057.03
4. Insert hose/tub into oil supply container (B).

relief valve button.
b
095.03
c 6. Use hand pump (C) to fill reservoir
NOTICe To make hydraulic reservoir

oil filling easier, periodically relieve hydraulic reservoir
pressure by pressing relief valve button.
096.03
7. Fill until oil reaches the FULL mark on the hydrau-

lic oil sight gauge (D). Hydraulic oil capacity is 65
gallons (246 L).
img.2500
569 11-43 1111

every 1000 hours
change hydraulic reservoir oil, cont.
prime the pump
NOTICe If the hand pump fails to

pump hydraulic oil into reservoir, the pump requires prim-
ing. Use the following procedure for priming the hand
pump.
a 1. Gain access to hydraulic reservoir fill hose (A).
2. Clean fill hose end.
057.03
3. Remove cap from fill hose end.

4. While holding the hose, fill it with the type of hy-
draulic oil being used in the loader. See Fuels and
Lubricants section for hydraulic oil specifications.
5. While holding the hose in the highest most posi-
tion, operate the hand pump for 10 to 15 strokes
or until the air is removed from the pump. This
b is indicated by feeling a higher resistance on the
handle of the pump.
NOTICe It may be necessary to refill

the hose with hydraulic oil.
img.2349 If, while pumping the hand pump, the resistance on
the handle becomes so great that the handle cannot
be moved the pump should be replaced.
62. replace hydraulic reservoir

breather filter (if equipped)
c 1. Clean area around the breather filter (C).
2. Slowly remove breather element to purge air from
reservoir.
3. Completely remove breather element and replace
with a new element.
059.03
569 11-44 1111

every 1000 hours
63. replace pressure vacuum relief
a valve
1. Lower boom and grapple to ground. Shut engine
down; remove key.
2. Move joysticks in all direction to relieve hydraulic
pressure.
lever UP.
img.2330 relief valve button (A).
5. Clean and dry area around pressure vacuum relief
valve assembly. Remove and discard.
6. Install new pressure vacuum relief valve assembly.
Hand-tighten.
64. flush and fill cooling system
CAUTION Cooling system is under

pressure. Hot engine coolant can cause severe burns.
DO NOT remove radiator filler cap unless the engine
is cool. Slowly release all pressure before cap re-
moval!
Flush cooling system. If more information is needed,
refer to engine operator’s manual.
1. Remove radiator cap.
2. Open radiator drain cock (B).
img.2605
569 11-45 1111

every 1000 hours
flush and fill cooling system, cont.
3. Remove engine plug(s) (see engine operator’s
manual).
4. Drain cooling system into an adequately sized
a catch pan. Dispose of used coolant properly.
5. Close drain cock (A) and replace engine plug(s).
NOTICe NEVER add coolant to a hot

engine. Doing so will damage the engine.
img.2605 6. Refill cooling system with soft, clean water.
7. Start engine and operate for 15 minutes to thor-
oughly circulate water.
8. Shut engine down. Drain cooling system before
rust or sediment settles. Continue flushing system
until scale deposits, rust, and sediment are com-
pletely removed.
NOTICe Cooling system cleaners

may need to be used to remove scale formation. See an
authorized dealer.
9. Close drain cock and replace engine plug(s).
10. Fill system with a 50% mixture of clean, soft
water and ethylene glycol antifreeze. Also add
SCA (Supplement Coolant Additive) according to
instructions in engine operator’s manual.
See engine operator’s manual for coolant capacities
11. Wait one minute and top off cooling system with
coolant.
12. Start engine and operate it for 5 minutes to circu-
late water/coolant/SCA mixture.
14. SLOWLY remove radiator cap.
15. Check radiator coolant level and fill as needed.
16. Repeat Steps 10 through 14 until coolant level
stabilizes in radiator.
569 11-46 1111

every 1000 hours
65. drain and replace swing drive
gear box lubricant
1. Remove drain plug (A).
2. Drain lubricant into catch pan and dispose of
properly.
3. Replace drain plug.
a 4. Clean area around fill plug and remove plug.

5. Add 0.9 gal (3.4 L) of Premium Gearlube GL-5 80W-
90 when adding or changing lubricant.
6. Remove dipstick (B). Lubricant should reach the
100.03 FULL or top mark on dipstick. DO NOT overfill.
7. Replace dipstick and fill plug.
101.03
66. check swing drive grease level

1. Clean area around grease plugs (A and B), and
remove plugs. Plug (C) is located 180 degrees from
plug (D).
2. Fill grease into plug holes with Premium Moly-lith
EP#2 or EP#1 until grease is forced out of plug. See
Fuels and Lubricants section for grease specifica-
c tions.
3. Replace grease plugs.
100.03
102.03
569 11-47 1111

every 1000 hours
67. drain and fill swing drive
NOTICe This step should be per-

formed when oil is fully warmed up and sediments are
suspended in the oil.
b
2. Clean around drain plug (A). Remove drain plug.
Allow oil to drain into a properly sized container.
A
3. Clean around fill plug (B). Remove fill plug. Flush
with hydraulic oil to remove any sediment. Dis-
pose of used oil in compliance with local, state,
and federal regulations.
4. Clean and install drain plug.
5. Fill housing with fresh Mobil Gear 630 or Mobil
SCH630 Synthetic Oil to bottom of fill plug open-
g.065.03
ing. Capacity is approximately 1.1 gallons (4.2 L).
6. Clean and install fill plug.
68. check/clean collector ring

c
2. Gain acces to collector (C).
3. Remove collector cover (D).
4. Spray collector with a quality contact cleaner.
5. Check wire connections and brushes. If necessary,
replace.
6. Replace collector cover.
103.03
img.2494
569 11-48 1111

storage
storage
preparing machine for storage

NOTICe If possible, store machine under cover and out of weather, in a well-ventilated
area. Store attachment on firm, level ground. Block tires to prevent accidental machine movement. See engine
operator’s manual for proper engine storage.
NOTICe If machine will be stored for an extended period, or stored in a corrosive environment
(such as salt air or industrial pollution), using a sponge, apply Chrome Kote Corrosion Preventive to portions
exposed to air. Also apply Chrome Kote Corrosion Preventive to radiator, oil cooler fins, and all wiring
connections. Reapply Chrome Kote Corrosion Preventive every 3 months while machine remains in storage.
1. Operate machine long enough to warm fluids. Check for leaks after machine warms up.
3. Drain engine oil, replace filters. Refill engine with lightest viscosity oil normally used in engine.
4. Drain and flush radiator. Refill radiator with 50/50 mixture of ethylene glycol antifreeze and distilled water.
Dispose of used coolant properly.
5. Drain water and sediment from fuel system. Properly dispose of water and sediment.
6. Change fuel filters.
7. Add proper fuel stabilizer for a full tank.
8. Fill fuel tank completely.
9. Drain hydraulic oil, flush oil reservoir.
10. Change hydraulic filters, refill hydraulic tank.
11. Repair worn or damaged parts. Install new parts, if necessary.
12. Clean air cleaner.
13. Grease machine thoroughly. Lubricate all grease points. Grease threads on bolts used for adjustments. Coat
exposed cylinder rods with Chrome Kote Corrosion Preventive to
retard rusting.
14. Restart engine and operate machine long enough to warm oil. Check for leaks after machine
warms up.
16. Loosen all belts.
17. Clean inside of cab.
18. Close and lock cab windows and doors. Do not leave rags in cab.
19. Thoroughly wash machine and attachments.
20. Repaint machine where necessary.
21. Remove battery (negative cables first) and store in a cool, dry place. Remove corrosion from cables and
battery case. Use baking soda to neutralize acid. Place battery on wood (not concrete) and connect a small
trickle charger to maintain charge, OR charge battery every 30 days while stored, if necessary.
22. Seal all engine openings with moisture-resistant tape to prevent animals and insects from building nests
inside machine.
23. Wipe up lube spills.
24. Dispose of rags and trash. Dispose of used fluids properly.
569 12- 1111

storage
taking the machine out of storage
1. Clean machine and attachments thoroughly.

2. Remove sealing tape from engine openings.
3. Charge battery (if necessary); install.
4. Check all oil levels. If low, check for leaks; add oil as required.
5. Check coolant level. If low, check for leaks; add coolant as required.
6. Adjust belt tension.
7. Check tire inflation.
8. See engine operator’s manual for information on restoring engine to service.
9. Cycle all hydraulic functions several times.
10. Check condition of all hoses and connections.
11. Review this operator’s manual.
Chrome Kote Corrosion Preventive is compatible with hydraulic oil and seal materials. It does not have to be
removed before when taking machine out of storage. When using a different brand of corrosion preventive, be
sure to check manufacturer’s recommendations on whether it should be removed prior to operation.
569 12- 1111

troubleshooting
troubleshooting
hydraulic system
PROBLEM POSSIBLE CAUSE SOLUTION

Hydraulic system does not work. Low hydraulic oil level. Add hydraulic fluid.
Control shut off lever disengaged. Engage control shut off lever.
Plugged suction line. See an authorized dealer.

Defective pump drive. See an authorized dealer.
Hydraulic system is noisy, vibrating. Air in system. Check fluid level and see an authorized
dealer if problem persists.
Cylinder “settle.” Leaking piston seals. See an authorized dealer.

Controls slow and/or lack power. Lack of hydraulic oil. Check/add hydraulic oil (see
Fuels and Lubricants section for
recommended hydraulic oils).
Aeration in suction lines. Tighten hose fittings.
Improper adjustment of relief valves. See an authorized dealer.
Cylinder functions poorly and/or lacks Cold oil. Warm up system.

power.
Wrong hydraulic oil. Replace hydraulic oil (see
Fuels and Lubricants section for
recommended hydraulic oil).
Damage to cylinder seals. Replace seals.
Aeration in cylinders. Bleed air from line.
Malfunctioning control valve. Repair or replace control valve.
Swing is slow or impossible to move. Obstruction under swing pedal. Remove obstruction.
Control valve problem. Repair or replace control valve.
Swing motor problem. Repair or replace swing motor.

Damage to swing gears. Repair or replace swing gears.
Damage to swing bearing. Repair or replace swing bearing.
Hydraulic fluid is foaming. Suction line air leak. Repair or replace suction line.
Low hydraulic oil leak. Add hydraulic oil.
Water in hydraulic fluid. Replace hydraulic fluid and filters.
Switches and/or lights in cab Tripped circuit breaker. Reset circuit breaker for the function
do not work. that is not working.
Loose wire connections. Tighten wire connections.
Stabilizer pad does not move freely. Lack of lubrication. Lubricate stabilizer pad with 30W oil.
569 13- 1111

troubleshooting
engine

Starter will not crank engine. Battery disconnect master switch turned OFF. Turn switch ON.
Loose or corroded connections. Tighten or repair connections.
Defective switch. Replace switch.
Low battery voltage. Charge and test battery or replace.
Crankcase oil viscosity too high. Change oil.
Pressure buildup in hydraulics. Hand and foot controllers must be in
neutral position.
Cold weather. Use cold weather starting procedure.
If starter still will not function properly,
see an authorized dealer.
Engine hard to start or will not start. Defective starter/internal seizure. Replace starter.
No fuel, or improper fuel, engine flooded. Use fuel specified.
Crankcase oil viscosity too high. Change oil.
Water, dirt or air in diesel fuel system. Bleed fuel system.
Clogged strainer or fuel filter. Replace with new.
Dirty or defective injection nozzles. See engine manual or contact dealer.
Resistance in starting circuit. Clean and tighten connections.
Low compression. See engine manual or contact dealer.
Cold weather. Use cold weather starting procedure.
If engine still will not start properly,
Engine runs irregularly, stalls Wrong fuel. Use fuel specified.
frequently, or knocks.
Clogged fuel filter(s) or strainer. Replace filters and/or strainer.
Insufficient crankcase oil. Add oil to proper level.
Low coolant temperature. Defective thermostat or incorrect
thermostat.
Dirty or defective injection nozzles. See engine dealer.
Clogged air intake system. Clean air intake and replace air
filters.
If engine still will not function properly,
Engine overheats (under normal Low coolant level. Add and check coolant level.
operating conditions).
Dirty or plugged radiator (external). Clean radiator.
Dirty or plugged side panels. Clean side panels.
Loose fan belts. Check belt tensioner.
Defective thermostat. Replace with new.
Defective radiator cap. Replace radiator cap.
Cooling system passages limed or plugged. Contact dealer.
Defective temperature gauge. Repair or replace.
Plugged exhaust system. Contact engine dealer.
If engine still overheats, see an authorized dealer.
Engine operating temperature Defective thermostat. Replace thermostat

is below normal.
Defective temperature gauge. Repair or replace.
If engine operating temperature is still below
normal, see an authorized dealer.
569 13- 1111

troubleshooting
engine, continued

Engine lacks power. Air intake restriction or plugged filter. Check air intake and replace air filters.
Clogged fuel filter(s) or strainers. Change fuel filters and/or strainer.
Faulty injection system. See engine dealer.
Fast idle speed too slow. See engine dealer.
Engine overheating. See problem ‘Engine Overheats’.
Wrong valve clearance. See engine dealer.
Crankcase oil viscosity too high or over full. Change engine oil.
Faulty relief valve in hydraulic system. See an authorized dealer.
If engine still will not function properly,
Low engine oil pressure. Crankcase oil level is low. Add oil as needed.
Engine oil viscosity too low. Change engine oil.
If engine oil pressure is still low, see an
authorized dealer.
High oil consumption. Crankcase oil viscosity too low. Use correct oil.
Leaking oil. Check drain plug.
Check engine gaskets.
See engine dealer.
Dirty or plugged air cleaner. Clean air cleaner and replace air filters.
If there is still a high oil consumption,
High fuel consumption. Clogged or dirty air intake system. Clean air intake and replace air filters.
Dirty or defective injection nozzles. See engine manual or contact dealer.
Faulty relief valve in hydraulic system. See an authorized dealer.
If there is still a high fuel consumption,
Engine exhaust emits black or Dirty or plugged air cleaner. Clean air cleaner and replace air filters.
gray smoke.
Dirty or defective injection nozzles. See engine dealer.
If there is still black or gray smoke,
Engine emits white smoke. Cold engine. Allow engine to warm up.
Defective thermostat or incorrect thermostat. Replace thermostat or see engine
dealer.
If there is still white smoke,
Control panel displays error code. Refer to FLASH/EVENT reference charts. See engine dealer.

569 13- 1111

troubleshooting
flash codes
569 13- 1111

troubleshooting
event codes
569 13- 1111

troubleshooting
seat

Seat rides too stiff; tends to push or Adjustment knob has been tightened (turned See height adjustment procedures in
throw operator forward CCW) too much. This typically happens because Operation section.
the operator is trying to use additional ride adjustment
rather than the yellow height adjustment lever to
raise the seat. Operator is riding seat in low height
position setting.
Seat rides too soft or bottoms out; Seat ride adjustment knob has not been tightened See height adjustment procedures in
pinches operator’s backside. (turned CCW) enough. Insufficient ride adjustment Operation section.
exaggerates the action movement of seat. This
usually happens because the operator is trying to
lower the seat by decreasing the amount of ride
adjustment instead of using height adjustment lever.
Seat too high or too low. Multiple causes See height adjustment procedures in
Operation section and adjust
seat to desired position.
Operator’s legs fall asleep in seat. Seat is adjusted too high, and ride adjustment knob See height adjustment procedures in
has not been tightened (turned CCW) enough, Operation section.
resulting in operator sitting in “bucket.”
Seat armrests too low. Multiple causes Find armrest adjustment knob on back
of each armrest. Rotate knob to the
right (CW) to raise the armrest.
Rotate knob to the left (CCW) to
lower armrest.
ELECTRICAL SYSTEM

Battery will not charge. Loose or corroded connection. Clean and tighten battery connections.
Battery worn out. Install new battery.
Loose alternator belts. Check belt tensioner.
Alternator or voltage regulator defective. See an authorized dealer.
If battery still will not charge,
Lights will not work. Tripped circuit breaker switch. Reset breaker.
If lights still will not work,
569 13- 1111

troubleshooting
cleanliness of hydraulic components
Cleanliness in hydraulics is essential. Be sure to keep contaminants out of the machine’s hydraulic system.
Maintain the loader properly to reduce the risk of contaminating hydraulic components.
Clearances in hydraulic components can be very small. Many hydraulic systems have clearances of less than 25
microns, or .001 inch. Abrasive particles can enter the space between moving parts and honed surfaces to wider
clearances. Increased clearance decreases the efficiency of pumps, motors, and cylinders. This damage wastes
horsepower and generates potentially damaging system heat.
The following figure lists the sizes of different common particles in inches and microns to show how even very
small particles can contaminate hydraulic components.
NOTE: Contaminant particle size is measured in microns. One micron equals one millionth of a meter,
or .000039 inch.
inches microns
130
.005
120
110 Table salt
.004 100
90
80
200 Mesh screen
.003
70 Human hair
60 Pollen
.002 50 Fog
40 Visibility limit
30
.001 White blood cells
20
10 Talcum
Red blood cells
2 Bacteria
569 13- 1111

troubleshooting
notes
569 13- 1111

SPECIFICATIONS
SPECIFICATIONS
Caterpillar Loader Specifications
519 529 559 569 579
Engines & Drive Line
CAT 3056 DITA-160HP Tier-II Compliant S S S
CAT C6.6-160HP Tier-III Compliant S S
CAT C6.6-173HP Tier-III Compliant O
Engine RPM Full Load Governed 2100 2100 2100 2100 2100
Electrical 12 V System S S S S S
Circuit Breaker Protection S S S S S
Master Electrical Disconnect Switch S S S S
Electronic Monitoring System S S
2 Cab Mounted Work Lights S S S S S
Boom Lights O O O S S
Pump Drive Direct S S S S S
29.2 cm (11 1/2”) Manual Clutch O O
Operators Station
97.8 cm x 142.2 cm (38.5” x 56”) right side mounted with isolation pads S S S
94.0 cm x 127 cm (37” x 50”) left side mounted with isolation pads S S
Tinted Safety Glass Windows, Lexan Skylight, Sun Visor S S S S S
Fully adjustable Seat with Fold-up armrests S S S S S
Operator protection Guard S S S S S
Pressurized Cab with Heater S
Pressurized Cab with Heat/Air Conditioning O S S S S
Integral Heat/AC Ductwork S S S S S
Analog Gauges S S S
Electronic Gauges S S
Tachometer S S S S S
Windshield Wiper/Washer S S S S S
Horn S S S S S
Defroster Fan S S S S S
Lighter S S S S S
Dome Light S S S S S
Fire Extinguisher S S S S S
Swing Open Door with Sliding Window S S S S S
Sliding Cab Window S S S S S
AM/FM Cassette Radio O S S S S
Hydraulic System
3 in-line gear pumps, Pilot Pump S S S
Two Variable Displacement Axial Piston Pumps, Pilot Pump S S
Flows GPM @ 2200 RPM 44,33,22 51,42,33 110 57,41,33 104
LPM @ 2200 RPM 166,124,83 193,158,124 416 215,155,124 393
System Pressure PSI 2,250 2,750 3,500 2,500 3,500
KPA 15513 18960 24131 17236 24131
Swing Pressure PSI 2,400 2,650 3,100 2,500 3,500
KPA 16547 18271 21373 17236 24131
Swing Motor Radial Piston Motor S
Axial Piston Motor S S S S
Swing Speed RPM 8 8 11 7 9
Controls Pilot Joysticks, Electric Stabilizer Controls S S S S S
Dual Swing Pedals S
Single Rocker Type Swing Pedal S S S S
Filtration Single Element Return Filter S S S
Two Single Element Return Filters S S
Case Drain Filters S S S
Saw Return Filters S S S
Swivel Steel Barrel with Durabar Core S S S S S
Serviceability Diagnostic nipples on pumps S S S S S
Hand Hydraulic Oil Fill Pump S S S S
6 S = Standard
O = Optional
569 14- 1111

SPECIFICATIONS
519 529 559 569 579
Auxiliary Hydraulics Bar Slasher/Hydraulics O S S O O

Delimber Hydraulics S S O O
Circle Saw Hydraulics O O O
Carrier Hydraulics O O O
Delimber/Carrier/Bar Slasher Hydraulic Pkg O
Cylinders Bore x Rod
Main (2) 15.2x10.2cm 12.7x7.6cm 12.7x7.6cm 15.2x10.2cm 12.7x7.6cm
6”x4” 5”x3” 5”x3” 6”x4” 5”x3”
Stick (1) 15.2x10.2cm 15.2x10.2cm 15.2x10.2cm 17.8x10.2cm 15.2x10.2cm
6”x4” 6”x4” 6”x4” 7”x4” 6”x4”
Live Heel 15.2x10.2cm 15.2x10.2cm 15.2x10.2cm 15.2x10.2cm
6”x4” 6”x4” 6”x4” 6”x4”
Stabilizer (4) 15.2x10.2cm 15.2x10.2cm 16.5x10.2cm 15.2x10.2cm 15.2x10.2cm
6”x4” 6”x4” 6.5”x4” 6”x4” 6”x4”
Structural
Upper Frame 48.3 cm (19”) Fixed Mount Cab Riser
(3.6 m (12’) Eye Level) S S
91.4 cm (36”) Hydraulic Cab Riser
(4.1 m (13’5”) Eye Level) O O
139.7 cm (55”) Fixed Mount Cab Riser
(4.6 m (15’) Eye Level) O O
Counterweight kg 498.9 1496.8 635.0 1392.5 1392.5
lbs 1,100 3,300 1,400 3,070 3,070
Tailswing with counterweight 259 cm 248.9 cm 252.7 cm 248.9 cm 248.9 cm
(102”) (98”) (99.5”) (98”) (98”)
Booms 8.2 m (27’) Knuckleboom S
8.8 m (29’) Knuckleboom S
9.1 m (30’) Knuckleboom O
9.1 m (30’) Tuckaway Live Heel Boom O
9.8 m (32’) Knuckleboom S
9.8 m (32’) Live Heel Boom O
9.9 m (32’6”) Knuckleboom S S
10.2 m (33’6”) Live Heel Boom O O
11.0 m (36’) Knuckleboom O O
Heels Single “V” Heel O O O O O
Double “VV” Heel O O O O O
Grapple Mounting Knuckle 22.9 cm (9”) Length S S S S S
30.5 cm (12”) Length (use w/live heel booms) O O O
Swing Bearing Diameter 109.2 cm 109.2 cm 129.5 cm 137.2 cm 137.2 cm
43” OD 43” OD 51” OD 54” OD 54” OD
Gearing External External External External External
Lower Frame Bolt-on Skid Resistant Fenders S S S S S
Two Wide Tread Ladders S S S S S
Turntable Mounting Centered Turntable S S S S S
58.4 cm (23”) Rear Oﬀset O
Stabilizers (4) Pad Size 55.8x66 cm 55.8x55 cm 55.8x71 cm 55.8x66 cm 55.8x66 cm
22”x26” 22”x23” 22”x28” 22”x26” 22”x26”
Installation Kit Standard Heavy Duty Kit S S S S S
Stationary Electric Mount O O
Capacities
Fuel Liters (Gallons) 268.8 (71) 276.3 (73) 276.3 (73) 336.9 (89) 336.9 (89)
Hydraulic Liters (Gallons) 132.5 (35) 295.3 (78) 302.8 (80) 246.0 (65) 246.0 (65)
Unit Weight
Wet, with standard boom, less options, carrier and grapplekg 8663 12655 14605 15422 15422
lbs 19,099 27,900 32,200 34,000 34,000
S = Standard 7
O = Optional
519, 529, 559, 569, 579 Knuckleboom Loaders
specifications
569 14- 1111

SPECIFICATIONS
Basic Dimensions for 519, 529 and 559 Knuckleboom Loaders
C
Maximum
Tailswing
B
I
J
G
E F
H* D K
A J L
519 529 559 569 579

A 1127.8 cm 444.00" 1219.2 cm 480.00" 1219.2 cm 480.00" 1219.2 cm 480.00" 1219.2 cm 480.00"
B 401.3 cm 158.00" 404.5 cm 159.25" 401.6 cm 158.10" 398.8 cm 157.00" 398.8 cm 157.00"
C 256.5 cm 101.00" 248.9 cm 98.00" 252.7 cm 99.50" 248.9 cm 98.00" 248.9 cm 98.00"
D 228.6 cm 90.00" 232.0 cm 91.34" 227.8 cm 89.70" 238.1 cm 93.75" 238.1 cm 93.75"
E 137.2 cm 54.00" 152.4 cm 60.00" 152.4 cm 60.00" 152.4 cm 60.00" 152.4 cm 60.00"
F 137.2 cm 54.00" 152.4 cm 60.00" 152.4 cm 60.00" 152.4 cm 60.00" 152.4 cm 60.00"
G 99.1 cm 39.00" 99.1 cm 39.00" 99.1 cm 39.00" 99.1 cm 39.00" 99.1 cm 39.00"
H* 10.2 cm 4.00" 24.1 cm 9.50" 7.6 cm 3.00" 27.3 cm 10.75" 27.3 cm 10.75"
I 238.8 cm 94.00" 246.4 cm 97.00" 246.4 cm 97.00" 269.2 cm 106.00" 269.2 cm 106.00"
J 35.6 cm 14.00" 36.0 cm 14.18" 41.9 cm 16.50" 39.4 cm 15.50" 39.4 cm 15.50"
K 416.6 cm 164.00" 392.0 cm 154.35" 425.4 cm 167.47" 454.7 cm 179.00" 454.7 cm 179.00"
L 457.2 cm 180.00" 447.0 cm 176" 495.3 cm 195.70" 495.3 cm 195.00" 495.3 cm 195.00"
* Add for counterweight
Basic Dimensions 569 and 579 Knuckleboom Loader

C
Maximum
Tailswing
I
J
G
F E H*
A K
D J L
569 14- 1111

SPECIFICATIONS
Lift Charts
Notes 3. Lift capacities are based on the machine standing on firm,
Do not attempt to lift or hold any load that is greater than the uniform supporting surface. User must make allowances for
rated values over the end or side. The weight of the grapple job site conditions.
and all lifting accessories must be deducted from lift capacities 4. Operator should be fully acquainted with the
shown. Operator’s Manual and all safety instructions furnished
by Caterpillar, Inc. prior to operating the machine.
1. The over end capacities and over side capacities do not 5. Lift capacities are in compliance with SAE J2417, “Lift
exceed 87% of hydraulic limited capacity or 75% of stability Capacity Calculation Method--Knuckleboom Log Loaders
limited capacity. and Certain Forestry Equipment”.
— Stability limited capacities are indicated with an asterisk (*).
2. The lift point is located at the grapple knuckle pin.
8.2 m (27') Boom 9.1 m (30') Boom 9.8 m (32') Boom 9.9 m (32'6") Boom 9.9 m (32'6") Boom
8.2 m (27’) Knuckleboom – 519 Model

3m (10') 4.6m (15’) 6.1m (20') 7.6m (25’) Max Reach
kg. lbs. kg. lbs. kg. lbs. kg. lbs. kg. lbs.
30’/9.1m 4574.6 10085 100% Hyd
3979.9 8774 Over End
3979.9 8774 Over Side
25’/7.6m 5208.7 11483 4076.5 8978 100% Hyd
4531.5 9990 3543.1 7811 Over End
4531.5 9990 3543.1 7811 Over Side
20’/6.1m 5246.8 11567 4611.3 10166 100% Hyd
4564.6 10063 4011.6 8844 Over End
4564.6 10063 4011.6 8844 Over Side
15’/4.6m 5673.2 12507 4742.4 10455 3954.5 8718 1850.2 4079 100% Hyd
4935.6 10881 4125.9 9096 3440.5 7585 1609.8 3549 Over End
4935.6 10881 4125.9 9096 3215.1 7088* 1609.8 3549 Over Side
10’/3m 6305.5 13901 5545.7 12226 3920.5 8643 1776.5 3917 100% Hyd
5485.8 12094 4824.9 10637 3410.6 7519 1545.9 3408 Over End
5485.8 12094 4582.7 10103* 3188.3 7029* 1545.9 3408 Over Side
5’/1.5m 8720.0 19224* 6520.5 14375 4068.3 8969 1771.3 3905 100% Hyd
7586.5 16725* 5672.7 12506 3539.4 7803 1540.9 3397 Over End
7369.7 16247* 4106.9 9054* 3152.5 6950* 1540.9 3397 Over Side
0 0.0 4373.2 9641 8341.2 18389* 6061.9 13364 3553 7833 100% Hyd
3804.8 8388 7256.7 15998* 5274 11627 3091.3 6815 Over End
3804.8 8388 7186.4 15843* 4395.4 9690* 3091.3 6815 Over Side
-5’/-1.5m 6371.3 14046 6789.5 14968 4688.8 10337 100% Hyd
5543 12220 5906.8 13022 4079.2 8993 Over End
5543 12220 5906.8 13022 4079.2 8993 Over Side
-10’/-3m 4980.1 10979 3743.6 8253 1100 2425 100% Hyd
4332.8 9552 3256.8 7180 957.1 2110 Over End
4332.8 9552 3256.8 7180 957.1 2110 Over Side
519, 529, 559, 569, 579 Knuckleboom Loaders

specifications
569 14- 1111

SPECIFICATIONS
Lift Charts
3m (10’) 4.6m (15’) 6.1m (20’) 7.6m (25’) Max Reach
kg. lbs. kg. lbs. kg. lbs. kg. lbs. kg. lbs.
30’/9.1m 5591.9 12328 100% Hyd
4864.8 10725 Over End
4864.8 10725 Over Side
25’/7.6m 5854.1 12906 5136.6 11324 100% Hyd
5093.1 11228 4468.8 9852 Over End
5093.1 11228 4468.8 9852 Over Side
20’/6.1m 5896.7 13000 5481.7 12085 4159.5 9170 100% Hyd
5130.2 11310 4769.2 10514 3618.8 7978 Over End
5130.2 11310 4769.2 10514 3618.8 7978 Over Side
15’/4.6m 6384.8 14076 5641.8 12438 4650.8 10253 2379.5 5246 100% Hyd
5554.7 12246 4908.4 10821 4046.1 8920 2070.2 4564 Over End
5554.7 12246 4908.4 10821 4046.1 8920 2070.2 4564 Over Side
10’/3m 7557.4 16661 6542.2 14423 5072.6 11183 2344.2 5168 100% Hyd
6574.8 14495 5691.7 12548 4413.1 9729 2039.4 4496 Over End
6574.8 14495 5691.7 12548 4413.1 9729 2039.4 4496 Over Side
5’/1.5m 8857.8 19528 6573.1 14491 4963.7 10943 2355.9 5194 100% Hyd
7706.2 16989 5718.5 12607 4318.2 9520 2049.8 4519 Over End
7706.2 16989 5718.5 12607 4318.2 9520 2049.8 4519 Over Side
0 0.0 6924.5 15266 8425.6 18575 6101.3 13451 4259.8 9391 100% Hyd
6024.2 13281 7330.2 16160 5308.1 11702 3705.9 8170 Over End
6024.2 13281 7330.2 16160 5308.1 11702 3705.9 8170 Over Side
-5’/-1.5m 7980.1 17593 6807.2 15007 4782.3 10543 100% Hyd
6942.8 15306 5922.2 13056 4160.4 9172 Over End
6942.8 15306 5922.2 13056 4160.4 9172 Over Side

3m (10’) 4.6m (15’) 6.1m (20’) 7.6m (25’) 9.1m (30’) 9.8m (32’)
kg. lbs. kg. lbs. kg. lbs. kg. lbs. kg. lbs. kg. lbs.
35’/10.6m 5687.1 12538 100% Hyd
4947.8 10908 Over End
4947.8 10908 Over Side
30’/9.1m 5398.7 11902 100% Hyd
4696.9 10355 Over End
4696.9 10355 Over Side
25’/7.6m 5630.9 12414 4732.4 10433 100% Hyd
4898.8 10800 4117.3 9077 Over End
4898.8 10800 4117.3 9077 Over Side
20’/6.1m 5751.1 12679 5133.3 11317 100% Hyd
5003.6 11031 4466.1 9846 Over End
5003.6 11031 4466.1 9846 Over Side
15’/4.6m 7265.2 16017 6594.8 14539 5594.2 12333 4182.6 9221 2665.8 5877 100% Hyd
6320.8 13935 5737.5 12649 4867.1 10730 3638.7 8022 2319.2 5113 Over End
6320.8 13935 5737.5 12649 4867.1 10730 3631.9 8007* 2319.2 5113 Over Side
10’/3m 9105.9 20075 7195.8 15864 5946.1 13109 4455.2 9822 2691.2 5933 100% Hyd
7921.9 17465 6260.5 13802 5173.6 11405 3875.9 8522 2341.4 5162 Over End
7921.9 17465 6260.5 13802 5173.6 10851* 3582.2 7897 2341.4 5162 Over Side
5’/1.5m 10155.1 22300 7591.8 16737 6015.5 13262 4253.4 9377 2797.8 6168 100% Hyd
8800.2 19401 6604.8 14561 5233.5 11538 3700.5 8158 2433.9 5366 Over End
8800.2 19401 6604.8 14561 4776.4 10530* 3526.7 7775* 2433.9 5366 Over Side
0 0.0 8249.5 18187 10288.4 22682 7553.7 16653 5758.4 12695 3705.9 8170 100% Hyd
7177.2 15823 8950.8 19733 6571.7 14488 5009.9 11045 3224.2 7108 Over End
7177.2 15823 8950.8 19733 6571.7 14488 4667.5 10290* 3224.2 7108 Over Side
-5’/-1.5m 8217.3 18116 9281.9 20463 6782.6 14953 4870.2 10737 100% Hyd
7149.1 15761 8075.4 17803 5900.8 13009 4237 9341 Over End
7149.1 15761 8075.4 17803 5900.8 13009 4237 9341 Over Side
10
569 14- 1111

SPECIFICATIONS
ENGINE COOLANT SPECIFICATIONS
Engine coolant must meet or exceed the following specifications:
SAE J1941
ASTM 4985
GM 6038M
TMC RP 302B
The engine coolant must contain low silicate (less than .1% anhydrous metasilicate) ethylene glycol base. The
supplemental coolant additive (SCA) should be Fleetgard DCA4 or equivalent.
When preparing engine coolant, follow these steps:
1. Thoroughly mix ethylene glycol base coolant with SCA in this ratio: 93% coolant to 7% additive.
2. Mix coolant/additive compound with distilled water in this ratio: 50% coolant/additive compound to 50%
distilled water.
569 14- 1111

SPECIFICATIONS
MACHINE FUNCTION W/CORRESPONDING PRESSURE SETTING (PSI)
Caterpillar Models
519
529
559
569
579
519
529
559
569
579
EXCEEDING STATED PRESSURE SETTINGS WILL VOID WARRANTY
569 14- 1111

SPECIFICATIONS
Hydraulic Connection Torque Specifications

SAE 37° FLARE CONNECTION
How connection works: This connection seals on two mating 37° seats.
How to tighten connection: Use a torque wrench to rotate and tighten nut. Turn nut to value shown in
table below.
Torque
Dash size (or tube size) Thread size Inch–lbs. Newton–Meters

–3 3
/8–24 95–105 11–12
–4 /16–20
7
135–145 15–16
–5 1
/2–20 170–190 19–21
–6 /16–18
9
215–245 25–27
–8 3
/4–16 430–470 49–53
–10 7
/8–14 680–750 77–84
–12 1 /16–12
1
950–1050 108–118
–14 1 3/16–12 1000–1100 113–124
–16 1 /16–12
5
1300–1360 147–153
–20 1 5/8–12 1520–1600 172–180
–24 1 7/8–12 1900–2000 215–225
–32 2 1/2–12 2940–3100 332–350
The above torque values are good for:

• machined adapters and hose fittings
• flared tubes (with sleeve and nut)
• universal radius flared tubes.
569 14- 1111

SPECIFICATIONS
Hydraulic Connection Torque Specifications

O–RING FACE SEAL CONNECTION
How connection works: This connection seals with an O–Ring on the male against a flat surface.
How to tighten connection: Use a torque wrench to rotate and tighten nut. Turn nut to value shown in
table below.
Torque
Dash size (or tube size) Thread size Inch–lbs. Newton–Meters

–4 9
/16–18 120–144 14–16
–6 11
/16–16 216–240 24–27
–8 13
/16–16 384–420 43–47
–10 1–14 552–600 62–68
–12 1 3/16–12 780–840 88–95
–16 1 7/16–12 1104–1200 125–136
–20 1 11/16–12 1500–1680 170–190
–24 2–12 1800–1980 204–224
Make sure the O–Ring does not fall out of the male end before connection is made. Proper lubrication helps.
569 14- 1111

SPECIFICATIONS
Torque Chart for Fasteners
This torque chart applies to lubricated threads for bolts, cap screws, and studs.
These specifications do not apply to self–locking nuts or cap screws. To obtain proper torque, do not use lockwashers.
Hardened flat washers recommended.
GRADE 8 FASTENERS
COARSE THREAD FINE THREAD

Nominal Size Torque (ft. lbs.) Torque (N•m) Nominal Size Torque (ft. lbs.) Torque (N•m)
1
/4–20 8–9 11–12 1
/4–28 9–10 12–14
5
/16–18 17–19 23–26 /16–24
5
19–21 26–28
3
/8–16 33–36 45–49 3
/8–24 34–37 46–50
7
/16–14 52–57 71–77 /16–20
7
53–58 72–79
1
/2–13 76–84 103–114 1
/2–20 86–94 117–128
9
/16–12 105–115 142–156 /16–18
9
124–136 168–184
5
/8–11 162–178 220–241 5
/8–18 171–189 232–256
3
/4–10 266–294 361–399 3
/4–16 304–336 412–456
/8–9
7
437–483 593–655 7
/8–14 475–525 644–712
1–8 646–714 876–968 1–12 703–777 953–1054
1 1/8–7 912–1008 1237–1367 1 1/8–12 979–1081 1328–1466
1 /4–7
1
1292–1428 1752–1936 1 /4–12
1
1425–1575 1932–2136
1 1/2–6 2242–2478 3040–3360 1 1/2–12 2527–2793 3427–3787
1 3/4–5 3048–3688 4133–5001 1 3/4–12 4004–4424 5429–5999
2 –4 1/2 4610–5096 6251–6910 2–12 6116–6760 8293–9167
Use these torque values unless otherwise specified. Exceptions are noted where applicable. SAE Grade 8
fasteners (A.S.T.M. A354, Grade BD) are made from quenched and tempered medium carbon steel. Grade 8 fasteners
have six (6) equally spaced radial lines embossed on the head of the fastener (see illustration below).
Examples of Grade 8 Fastener Heads
569 14-10 1111

SPECIFICATIONS
cylinder torque specifications

C Y L IN D E R T O R Q U E S P E C IF IC A T IO N S
G r a d e 8 Z i n c – p l a te d H e x H e a d C a p S c r e w s , D r y
Da s h S iz e T orque
ft. lbs . N•m

7
/16– 1 4 U N C 76– 84 103– 114
1
/2– 1 3 U N C 105– 115 142– 156
G r a d e 8 E l a s ti c L o c k N u ts , P h o s . a n d O i l F i n i s h , L u b r i c a te d T h r e a d s
Da s h S iz e T orque
ft. lbs . N•m
1– 14 U N F 540 732
1 1/4– 1 2 U N F 750 1017
1 3/8– 1 2 U N F 1000 1356
1 1/2– 1 2 U N F 1200 1627
1 3/4– 1 2 U N F 1500 2034
2 1/4– 1 2 U N F 2500 3390
569 14-11 1111

SPECIFICATIONS
569 14-12 1111

SERIAL NUMBERS
PR
EN
TI
CE
SERIAL NUMBERS
384
Machine Serial Number

R
CLEA
KEEP
Pump Serial Number
Part Number
Swing Drive Serial Number
Part Number
569 15- 1111

SERIAL NUMBERS
Main Boom Part Number
Stick Boom Part Number
Main Boom Cylinder Part Number

and Date of Manufacture
569 15- 1111

SERIAL NUMBERS
Stick Boom Cylinder Part Number

Stabilizer Cylinder Part Number

Swivel Part Number

Hydraulic Oil Reservoir Return Line Filter Identifi-

cation Number
569 15- 1111

SERIAL NUMBERS
NOTES
569 15- 1111

material safety data sheets
(MSDS)
Federal Occupational Safety and Health Administration (OSHA) Standard 29 CFR 1910.1200, and in some cases
state and local right–to–know laws, may require specific material safety data sheets (MSDS) be made available
to employees before operating this equipment. This may include information on substances contained in this
equipment such as antifreeze, brake fluid, battery acid, hydraulic fluid, and R–134 A refrigerant (if machine is
equipped with an air conditioner).
Caterpillar Forest Products, Inc. will provide, free of charge, MSDS that apply to the machine. Simply request
them from an authorized dealer.
To ensure a prompt response, include return address (including zip or postal code) and the machine’s model
number and serial number with the request.
569 16- 1111

notes
569 16- 1111

CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of
its constituents are known to the
State of California to cause cancer,
birth defects, and other reproduc-
tive harm.
Battery post terminals and related

accessories contain lead and lead
components, chemicals known
to the State of California to cause
cancer and reproductive harm. Wash
hands after handling.
CAT, CATERPILLAR, their respective logos and "Caterpillar Yellow," and the POWER EDGE trade dress as well as
corporate and product identity used herein, are trademarks of Caterpillar and may not be used without permis-
sion.
©
2008 Caterpillar
All Rights Reserved Printed in the U.S.A.

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Part No.

569 - 569PH Knuckleboom Loader

Capacity at maximum reach: per sae j2417

569 iii 1111

SAFETY ALERT SYMBOL

Means: ATTENTION. BE ALERT. YOUR SAFETY IS

This safety symbol is used for important safety messages.

DANGER identifies the hazard or

DANGer unsafe practice that will result in severe

WARNING identifies the hazard or unsafe practice

WArNING that could result in severe personal injury or death.

CAUTION CAUTION identifies the hazard or unsafe practice

NOTICe NOTICE identifies important installation, operation, or

07 - Break-In Period.........................................................7-1 Maintenance Details

Clean Radiator & Oil Cooler..............................11-29 Seat ......................................................................... 13-6

569 viii 1111

safety alert symbol

• safety and instruction decals

avoid contact with stabilizers

WArNING Coming into contact with

569 1- 1111

WArNING Batteries produce explo-

control shut off lever

WArNING Accidental movement

569 1- 1111

DANGer SERIOUS INJURY OR

WArNING Electrical storms (light-

569 1- 1111

falling or swinging logs

WArNING Falling or swinging logs,

fire prevention/First aid

CAUTION Fires can cause personal

569 1- 1111

fluids under pressure

WArNING Fluids escaping under

hand holds and steps

WArNING Slips and falls can cause

569 1- 1111

WArNING Accidents can cause se-

hoses and fittings

WArNING Mismatched brands or

569 1- 1111

WArNING Machine riders can fall

WArNING Flying debris, tree limbs,

569 1- 1111

practice safe maintenance

WArNING Excessive hydraulic pres-

569 1- 1111

Wear snug, protective clothing that is belted where

WArNING Misuse, interference and

CAUTION Pressurized cooling sys-

569 1- 1111

WArNING Fires and explosions can

WArNING Unauthorized welding

NOTICe Unauthorized welding can

569 1-10 1111

WArNING Unstable platform can

569 1-11 1111

569 1-12 1111

569 2- 1111

DO NOT WOrK ON BATTerIes

dANgeR KeeP CLeAR

see OperATOrs MANUAL.

569 1- 1111

569 1- 1111

569 1- 1111

569 1- 1111

569 1- 1111

569 1- 1111

569 1- 1111

569 1- 1111

569 1- 1111

569 2- 1111

569 2- 1111

569 2- 1111

569 2- 0511

569 3- 1108

569 3- 1108

569 4- 1111

569 4- 1111

569 4- 1111

569 4- 1111

569 4- 1111

569 4- 1111

569 4- 1111

569 4- 1111

569 4- 1111