Sebu8045-03 07-06

SEBU8045-03
July 2006
Operation and
Maintenance
Manual
330D Excavator
GBC1-Up (Machine)
GGE1-Up (Machine)
THJ1-Up (Machine)
ERN1-Up (Machine)
HAS1-Up (Machine)
RAS1-Up (Machine)
T2Y1-Up (Machine)
i01658146
Important Safety Information

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

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
Operations that may cause product damage are identified by “NOTICE” labels on the product and in
this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. If a tool,
procedure, work method or operating technique that is not specifically recommended by Caterpillar
is used, you must satisfy yourself that it is safe for you and for others. You should also ensure that
the product will not be damaged or be made unsafe by the operation, lubrication, maintenance or
repair procedures that you choose.
The information, specifications, and illustrations in this publication are on the basis of information that
was available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Caterpillar dealers have the most current information available.
When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.
Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
SEBU8045-03 3
Table of Contents
Table of Contents Engine Starting ................................................... 141
Operation ............................................................ 143

Foreword ................................................................. 4
Operating Techniques ......................................... 147
Safety Section Parking ................................................................ 160
Safety Messages .................................................... 6
Transportation Information .................................. 163
Additional Messages ............................................. 16
Towing Information .............................................. 167
General Hazard Information ................................. 19
Engine Starting (Alternate Methods) ................... 169
Crushing Prevention and Cutting Prevention ........ 21
Maintenance Section
Burn Prevention .................................................... 22
Maintenance Access ........................................... 172
Fire Prevention and Explosion Prevention ............ 22
Lubricant Viscosities and Refill Capacities ......... 173
Fire Extinguisher Location .................................... 24
Maintenance Support .......................................... 176
Track Information .................................................. 24
Maintenance Interval Schedule .......................... 177
Electrical Storm Injury Prevention ......................... 24
Reference Information Section
Before Starting Engine .......................................... 25
Reference Materials ............................................ 246
Engine Starting ..................................................... 25
Index Section
Before Operation .................................................. 25
Index ................................................................... 248
Work Tools ............................................................ 25
Operation .............................................................. 26
Engine Stopping ................................................... 27
Lifting Objects ....................................................... 27
Parking .................................................................. 27
Equipment Lowering with Engine Stopped ........... 28
Sound Information and Vibration Information ....... 28
Operator Station ................................................... 30
Guards (Operator Protection) ............................... 30
Product Information Section

General Information .............................................. 32
Identification Information ....................................... 83
Operation Section
Before Operation .................................................. 86
Machine Operation ............................................... 88

4 SEBU8045-03
Foreword
Foreword Maintenance
The maintenance section is a guide to equipment
Literature Information care. The Maintenance Interval Schedule (MIS) lists
the items to be maintained at a specific service
This manual should be stored in the operator’s interval. Items without specific intervals are listed
compartment in the literature holder or seat back under the "When Required" service interval. The
literature storage area. Maintenance Interval Schedule lists the page
number for the step-by-step instructions required to
This manual contains safety information, operation accomplish the scheduled maintenance. Use the
instructions, transportation information, lubrication Maintenance Interval Schedule as an index or "one
information and maintenance information. safe source" for all maintenance procedures.
Some photographs or illustrations in this publication
show details or attachments that can be different Maintenance Intervals
from your machine. Guards and covers might have
been removed for illustrative purposes. Use the service hour meter to determine servicing
intervals. Calendar intervals shown (daily, weekly,
Continuing improvement and advancement of monthly, etc.) can be used instead of service hour
product design might have caused changes to your meter intervals if they provide more convenient
machine which are not included in this publication. servicing schedules and approximate the indicated
Read, study and keep this manual with the machine. service hour meter reading. Recommended service
should always be performed at the interval that
Whenever a question arises regarding your machine, occurs first.
or this publication, please consult your Caterpillar
dealer for the latest available information. Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is
specified in the maintenance intervals chart might
Safety be necessary.
The safety section lists basic safety precautions. In Perform service on items at multiples of the original
addition, this section identifies the text and locations requirement. For example, at every 500 service
of warning signs and labels used on the machine. hours or 3 months, also service those items listed
under every 250 service hours or monthly and every
Read and understand the basic precautions listed 10 service hours or daily.
in the safety section before operating or performing
lubrication, maintenance and repair on this machine.
California Proposition 65 Warning
Operation Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
The operation section is a reference for the new birth defects, and other reproductive harm.
operator and a refresher for the experienced
operator. This section includes a discussion of Battery posts, terminals and related accessories
gauges, switches, machine controls, attachment contain lead and lead compounds. Wash hands
controls, transportation and towing information. after handling.
Photographs and illustrations guide the operator
through correct procedures of checking, starting, Certified Engine Maintenance
operating and stopping the machine.
Proper maintenance and repair is essential to keep
Operating techniques outlined in this publication are the engine and machine systems operating correctly.
basic. Skill and techniques develop as the operator As the heavy duty off-road diesel engine owner, you
gains knowledge of the machine and its capabilities. are responsible for the performance of the required
maintenance listed in the Owner Manual, Operation
and Maintenance Manual, and Service Manual.
SEBU8045-03 5
Foreword
It is prohibited for any person engaged in the 3. Check Character (character 9)

business of repairing, servicing, selling, leasing, or
trading engines or machines to remove, alter, or 4. Machine Indicator Section (MIS) or Product
render inoperative any emission related device or Sequence Number (characters 10-17). These were
element of design installed on or in an engine or previously referred to as the Serial Number.
machine that is in compliance with the regulations
(40 CFR Part 89). Certain elements of the machine Machines and generator sets produced before First
and engine such as the exhaust system, fuel system, Quarter 2001 will maintain their 8 character PIN
electrical system, intake air system and cooling format.
system may be emission related and should not be
altered unless approved by Caterpillar. Components such as engines, transmissions, axles,
etc. and work tools will continue to use an 8 character
Machine Capacity Serial Number (S/N).
Additional attachments or modifications may exceed

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

Number
Effective First Quarter 2001 the Caterpillar Product
Identification Number (PIN) has changed from 8 to 17
characters. In an effort to provide uniform equipment
identification, Caterpillar and other construction
equipment manufacturers are moving to comply
with the latest version of the product identification
numbering standard. Non-road machine PINs are
defined by ISO 10261. The new PIN format will apply
to all Caterpillar machines and generator sets. The
PIN plates and frame marking will display the 17
character PIN. The new format will look like the
following:
g00751314
Illustration 1
Where:
1. Caterpillar’s World Manufacturing Code

(characters 1-3)
2. Machine Descriptor (characters 4-8)

6 SEBU8045-03
Safety Section
Safety Messages
Safety Section
i02520165
Safety Messages
SMCS Code: 7000; 7405
There are several specific safety messages on this

machine. The exact location of the hazards and
the description of the hazards are reviewed in this
section. Please become familiarized with all safety
messages.
Make sure that all of the safety messages are legible.

Clean the safety messages or replace the safety
messages if you cannot read the words. Replace
the illustrations if the illustrations are not visible.
When you clean the safety messages, use a cloth,
water and soap. Do not use solvent, gasoline, or
other harsh chemicals to clean the safety messages.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety message. Loose
adhesive will allow the safety message to fall.
Replace any safety message that is damaged, or

missing. If a safety message is attached to a part
that is replaced, install a safety message on the
replacement part. Any Caterpillar dealer can provide
new safety messages.
SEBU8045-03 7
Safety Section
Safety Messages
g01234299
Illustration 2
View of the cab
8 SEBU8045-03
Safety Section
Safety Messages
g01234302
Illustration 3
Top view of machine
SEBU8045-03 9
Safety Section
Safety Messages
(1) Do Not Operate (3) Crushing Hazard

This safety message is located in the cab on the right
side window.
g01067551
Illustration 4
g00930652
This safety message is located in rear of the cab.
Do not operate or work on this machine unless Personal injury can result if the window is not
you have read and understand the instructions latched in the overhead position; ensure the au-
and warnings in the Operation and Maintenance to lock is engaged.
Manual. Failure to follow the instructions or heed
the warnings could result in injury or death. Con- Refer to Operation and Maintenance Manual,
tact any Caterpillar dealer for replacement manu- “Window (Front)” for further information.
als. Proper care is your responsibility.
(2) Crushing Hazard

side window.
g01141092
Crushing Hazard! Keep the work tool away from

the cab during operation. Personal injury or death
may result if the work tool contacts the cab during
operation.
10 SEBU8045-03
Safety Section
Safety Messages
(4) Product Link (If Equipped) (5) Crushing Injury (If Equipped)
g01089271 g01141097
Illustration 5 Illustration 6
This safety message is positioned in the cab on the This safety message is located in the cab on the right
left side door post. side window.
This machine is equipped with a Caterpillar Crush injury. Could cause serious injury or death.
Product Link radio communication device which Always confirm that the quick coupler is engaged
must be deactivated within 6.0 m (20 ft) of a blast onto the pins. Read the Operator’s Manual.
zone. Failure to do so could result in serious
injury or death. Refer to Operation and Maintenance Manual, “Quick
Coupler Operation” for further information.
Refer to Operation and Maintenance Manual ,
“Product Link” for further information. (6) Seat Belt
g01067563
Illustration 7

side window.
A seat belt should be worn at all times during ma-

chine operation to prevent serious injury or death
in the event of an accident or machine overturn.
Failure to wear a seat belt during machine opera-
tion may result in serious injury or death.
SEBU8045-03 11
Safety Section
Safety Messages
(7) Electrical Power Lines (8) Crushing Hazard

This safety message is located in the cab.
g01130693
Illustration 8
g01067566
side window.
Electrocution Hazard! Keep the machine and at-

tachments a safe distance from electrical power.
Stay clear 3 m (10 ft) plus twice the line insulator The impact from objects that strike the front of the
length. Read and understand the instructions and cab or the top of the cab could result in a crush-
warnings in the Operation and Maintenance Manu- ing hazard with the potential for personal injury or
al. Failure to follow the instructions and warnings death.
will cause serious injury or death
The front guard and the top guard should be in-
stalled on the cab for applications where the haz-
Refer to Operation and Maintenance Manual, ard of falling objects exist. Read the Operation and
“Specifications” for further information. Maintenance Manual.
Refer to Operation and Maintenance Manual,

“Guards” for further information.
12 SEBU8045-03
Safety Section
Safety Messages
(9) Joystick Controls Alternate (10) SmartBoom Mode

Patterns (If Equipped)
g00810639
Illustration 10
g01232432
Illustration 9
This message is located in the cab on the right side
window.
side window.
Do not elevate or lower the track when in the

Crush Hazard. Improper joystick setting could SmartBoom mode. Follow the operation proce-
dures for the SmartBoom in the Operation and
cause possible unexpected movement of the
Maintenance Manual. Failure to follow these in-
boom, stick, or worktool which could result in
serious injury or death. Confirm that the joy- structions can result in serious injury or death.
stick settings are properly configured before you
operate the machine. Read the Operation and
Maintenance Manual. (11) Crushing Hazard
This safety message is located on the rear of each
Refer to Operation and Maintenance Manual, side of the machine. This safety message is also
“Joystick Controls Alternate Patterns” for further located on each side of the counterweight.
information.
g01067376
Machine swings. Stay back. Crushing hazard

could cause serious injury or death.
SEBU8045-03 13
Safety Section
Safety Messages
(12) Pressurized System (13) Aerosol Starting Aid

This safety message is located inside the engine This safety message is positioned on the cover
compartment next to the cooling system filler cap. of the intake duct of the air cleaner. The following
information is not applicable to machines that are
equipped with an ether starting aid.
g01067344
g01067463
Pressurized system! Hot coolant can cause seri-

ous burns, injury or death. To open the cooling
system filler cap, stop the engine and wait until Explosion hazard! Do not use ether! This machine
the cooling system components are cool. Loosen is equipped with an air inlet heater. Using ether
the cooling system pressure cap slowly in order to can create explosions or fires that can cause per-
relieve the pressure. Read and understand the Op- sonal injury or death. Read and follow the starting
eration and Maintenance Manual before perform- procedure in the Operation and Maintenance Man-
ing any cooling system maintenance. ual.
Refer to Operation and Maintenance Manual, Refer to Operation and Maintenance Manual, “Engine
“Cooling System Coolant Level - Check” for further Starting” for the proper starting procedure.
information.
14 SEBU8045-03
Safety Section
Safety Messages
(14) Jump Start Cables (15) High Pressure Cylinder

This safety message is positioned on the circuit This safety message is positioned on the track
breaker panel. adjuster on both sides of the machine.
g01067366 g01076729
Explosion Hazard! Improper jumper cable connec- High Pressure Cylinder. Do not remove any parts
tions can cause an explosion resulting in serious from the cylinder until all of the pressure has been
injury or death. Batteries may be located in sep- relieved. This will prevent possible personal injury
arate compartments. Refer to the Operation and or death.
Maintenance Manual for the correct jump starting
procedure.
Refer to Operation and Maintenance Manual, “Track
Adjustment - Adjust” for the adjustment procedure.
“Engine Starting with Jump Start Cables” for further (16) High Pressure Gas
information.
This safety message is positioned on the accumulator.
g01055412
This system contains high pressure gas. Failure to

follow the instructions and warnings could cause
an explosion, resulting in possible injury or death.
Do not expose to fire. Do not weld. Do not drill.

Relieve pressure before discharging.
See Operation and Maintenance Manual for charg-

ing and discharging. See your Caterpillar Dealer
for tools and detailed information.

“Equipment Lowering with Engine Stopped” for
further information.
SEBU8045-03 15
Safety Section
Safety Messages
(17) Relieve Hydraulic Tank

Pressure
This safety message is located on top of the hydraulic
tank.
g01067344
HYDRAULIC TANK
RELIEVE TANK PRESSURE WITH ENGINE OFF BY

REMOVING CAP SLOWLY TO PREVENT BURNS
FROM HOT OIL.
16 SEBU8045-03
Safety Section
Additional Messages
i02477496
Additional Messages
SMCS Code: 7000; 7405
g00937179
Illustration 11
SEBU8045-03 17
Safety Section
Additional Messages
g01126552
Illustration 12
Radial Air Cleaner (1)
This message is located on the cover of the air

cleaner.
g00911166
Illustration 13
18 SEBU8045-03
Safety Section
Additional Messages
In order to avoid engine damage, replace old filters

with radial seal air filters. Other replacement filters
will not seal.
The location and design of the gasket for the radial

seal air filter is critical to the proper operation of the air
cleaner element. Use only Caterpillar replacements.
No Step (2)
This message is located on the engine cover on the

top of the machine.
g00939891
Illustration 16
If the Primary exits are blocked, pull the ring in order

to open the rear window. Exit the machine through
the window.
Machine Security System (5)
This message is located on the window on the right

side of the cab.
g00911158
Illustration 14
Do not step in this area.
Clean Glass (3)
This message is located on the upper window in the

cab.
g00951606
Illustration 17
This machine may be equipped with a security

system. Read the Operation and Maintenance
Manual before you operate the machine.
Key in Run Position (6)
This message is located on the window on the right

side of the cab.
g00911414
Illustration 15
NOTICE
Clean windows with a wet cloth or sponge. Dry cloth
or sponge may scratch window material.
Alternate Exit (4)
This message is located in the upper right corner of

the rear window.
SEBU8045-03 19
Safety Section
General Hazard Information
g00915002 g00702020
NOTICE Wear a hard hat, protective glasses, and other

Key must be in run position with engine running to protective equipment, as required.
maintain electrical and hydraulic functions and pre-
vent serious machine damage. Do not wear loose clothing or jewelry that can snag
on controls or on other parts of the equipment.
Make sure that all protective guards and all covers

i02443908
are secured in place on the equipment.
Keep the equipment free from foreign material.
SMCS Code: 7000 Remove debris, oil, tools, and other items from the
deck, from walkways, and from steps.
Secure all loose items such as lunch boxes, tools,

and other items that are not a part of the equipment.
Know the appropriate work site hand signals and

the personnel that are authorized to give the hand
signals. Accept hand signals from one person only.
Do not smoke when you service an air conditioner.

Also, do not smoke if refrigerant gas may be present.
Inhaling the fumes that are released from a flame that
contacts air conditioner refrigerant can cause bodily
harm or death. Inhaling gas from air conditioner
refrigerant through a lighted cigarette can cause
g00104545
Illustration 19 bodily harm or death.
Attach a “Do Not Operate” warning tag or a similar Never put maintenance fluids into glass containers.
warning tag to the start switch or to the controls Drain all liquids into a suitable container.
before you service the equipment or before you
repair the equipment. These warning tags (Special Obey all local regulations for the disposal of liquids.
Instruction, SEHS7332) are available from your
Caterpillar dealer. Use all cleaning solutions with care. Report all
necessary repairs.
Know the width of your equipment in order to maintain
proper clearance when you operate the equipment Do not allow unauthorized personnel on the
near fences or near boundary obstacles. equipment.
Be aware of high voltage power lines and power Unless you are instructed otherwise, perform
cables that are buried. If the machine comes in maintenance with the equipment in the servicing
contact with these hazards, serious injury or death position. Refer to Operation and Maintenance Manual
may occur from electrocution. for the procedure for placing the equipment in the
servicing position.
20 SEBU8045-03
Safety Section
Pressurized Air and Water Always use a board or cardboard when you check
for a leak. Leaking fluid that is under pressure can
Pressurized air and/or water can cause debris penetrate body tissue. Fluid penetration can cause
and/or hot water to be blown out. This could result in serious injury and possible death. A pin hole leak can
personal injury. cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
When pressurized air and/or pressurized water is from a doctor that is familiar with this type of injury.
used for cleaning, wear protective clothing, protective
shoes, and eye protection. Eye protection includes Containing Fluid Spillage
goggles or a protective face shield.
Care must be taken in order to ensure that fluids
The maximum air pressure for cleaning purposes are contained during performance of inspection,
must be reduced to 205 kPa (30 psi) when the maintenance, testing, adjusting and repair of the
nozzle is deadheaded and the nozzle is used with equipment. Prepare to collect the fluid with suitable
an effective chip deflector and personal protective containers before opening any compartment or
equipment. The maximum water pressure for disassembling any component that contains fluids.
cleaning purposes must be below 275 kPa (40 psi).
Refer to Special Publication, NENG2500, “Caterpillar
Trapped Pressure Dealer Service Tool Catalog” for the following items:
Pressure can be trapped in a hydraulic system. • Tools that are suitable for collecting fluids and
Releasing trapped pressure can cause sudden equipment that is suitable for collecting fluids
machine movement or attachment movement. Use
caution if you disconnect hydraulic lines or fittings. • Tools that are suitable for containing fluids and
High pressure oil that is released can cause a hose to equipment that is suitable for containing fluids
whip. High pressure oil that is released can cause oil
to spray. Fluid penetration can cause serious injury Obey all local regulations for the disposal of liquids.
and possible death.
Asbestos Information
Fluid Penetration
Pressure can be trapped in the hydraulic circuit long
after the engine has been stopped. The pressure can
cause hydraulic fluid or items such as pipe plugs to
escape rapidly if the pressure is not relieved correctly.
Do not remove any hydraulic components or parts

until pressure has been relieved or personal injury
may occur. Do not disassemble any hydraulic
components or parts until pressure has been relieved
or personal injury may occur. Refer to the Service
Manual for any procedures that are required to
relieve the hydraulic pressure.
g00702022
Illustration 22
Caterpillar equipment and replacement parts that are

shipped from Caterpillar are asbestos free. Caterpillar
recommends the use of only genuine Caterpillar
replacement parts. Use the following guidelines
when you handle any replacement parts that contain
asbestos or when you handle asbestos debris.
g00687600
Illustration 21
SEBU8045-03 21
Safety Section
Crushing Prevention and Cutting Prevention
Use caution. Avoid inhaling dust that might be Dispose of Waste Properly
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is usually
bound in a resin or sealed in some way. Normal
handling is not hazardous unless airborne dust that
contains asbestos is generated.
If dust that may contain asbestos is present, there

are several guidelines that should be followed:
• Never use compressed air for cleaning.

g00706404
• Avoid brushing materials that contain asbestos. Illustration 23
• Avoid grinding materials that contain asbestos. Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
• Use a wet method in order to clean up asbestos disposed of according to local regulations.
materials.
Always use leakproof containers when you drain
• A vacuum cleaner that is equipped with a high fluids. Do not pour waste onto the ground, down a
efficiency particulate air filter (HEPA) can also be drain, or into any source of water.
used.
i01359664
• Use exhaust ventilation on permanent machining
jobs. Crushing Prevention and
• Wear an approved respirator if there is no other Cutting Prevention
way to control the dust.
SMCS Code: 7000
• Comply with applicable rules and regulations
for the work place. In the United States, use Support the equipment properly before you perform
Occupational Safety and Health Administration any work or maintenance beneath that equipment.
(OSHA) requirements. These OSHA requirements Do not depend on the hydraulic cylinders to hold
can be found in “29 CFR 1910.1001”. up the equipment. Equipment can fall if a control is
moved, or if a hydraulic line breaks.
• Obey environmental regulations for the disposal
of asbestos. Do not work beneath the cab of the machine unless
the cab is properly supported.
• Stay away from areas that might have asbestos
particles in the air. Unless you are instructed otherwise, never attempt
adjustments while the machine is moving or while
the engine is running.
Never jump across the starter solenoid terminals

in order to start the engine. Unexpected machine
movement could result.
Whenever there are equipment control linkages the

clearance in the linkage area will change with the
movement of the equipment or the machine. Stay
clear of areas that may have a sudden change in
clearance with machine movement or equipment
movement.
Stay clear of all rotating and moving parts.

22 SEBU8045-03
Safety Section
Burn Prevention
If it is necessary to remove guards in order to perform Oils

maintenance, always install the guards after the
maintenance is performed. Hot oil and hot components can cause personal
injury. Do not allow hot oil to contact the skin. Also,
Keep objects away from moving fan blades. The fan do not allow hot components to contact the skin.
blade will throw objects or cut objects.
Remove the hydraulic tank filler cap only after the
Do not use a kinked wire cable or a frayed wire cable. engine has been stopped. The filler cap must be
Wear gloves when you handle wire cable. cool enough to touch with a bare hand. Follow the
standard procedure in this manual in order to remove
When you strike a retainer pin with force, the retainer the hydraulic tank filler cap.
pin can fly out. The loose retainer pin can injure
personnel. Make sure that the area is clear of people
when you strike a retainer pin. To avoid injury to
Batteries
your eyes, wear protective glasses when you strike
Electrolyte is an acid. Electrolyte can cause personal
a retainer pin.
injury. Do not allow electrolyte to contact the skin or
the eyes. Always wear protective glasses for servicing
Chips or other debris can fly off an object when you
batteries. Wash hands after touching the batteries
strike the object. Make sure that no one can be
and connectors. Use of gloves is recommended.
injured by flying debris before striking any object.
i01359795
i01329099
Burn Prevention Fire Prevention and Explosion

Prevention
SMCS Code: 7000
SMCS Code: 7000
Do not touch any part of an operating engine.
Allow the engine to cool before any maintenance is
performed on the engine. Relieve all pressure in the
air system, in the oil system, in the lubrication system,
in the fuel system, or in the cooling system before
any lines, fittings or related items are disconnected.
Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.
Any contact with hot coolant or with steam can cause Illustration 24
g00704000
severe burns. Allow cooling system components to
cool before the cooling system is drained. All fuels, most lubricants, and some coolant mixtures
are flammable.
Check the coolant level only after the engine has
been stopped. Flammable fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause
Ensure that the filler cap is cool before removing the a fire. Fire may cause personal injury and property
filler cap. The filler cap must be cool enough to touch damage.
with a bare hand. Remove the filler cap slowly in
order to relieve pressure. Remove all flammable materials such as fuel, oil, and
debris from the machine. Do not allow any flammable
Cooling system conditioner contains alkali. Alkali can materials to accumulate on the machine.
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth. Store fuels and lubricants in properly marked
containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials.
SEBU8045-03 23
Safety Section
Fire Prevention and Explosion Prevention
Do not operate the machine near any flame.
Exhaust shields (if equipped) protect hot exhaust

components from oil spray or fuel spray in case of
a break in a line, in a hose, or in a seal. Exhaust
shields must be installed correctly.
Do not weld on lines or on tanks that contain

flammable fluids. Do not flame cut lines or tanks
that contain flammable fluid. Clean any such lines or
tanks thoroughly with a nonflammable solvent prior
to welding or flame cutting.
Check all electrical wires daily. Repair any wires

that are loose or frayed before you operate the
machine. Clean all electrical connections and tighten
all electrical connections.
Dust that is generated from repairing nonmetallic

hoods or nonmetallic fenders can be flammable
and/or explosive. Repair such components in a well
ventilated area away from open flames or sparks. Illustration 26
g00704135
Inspect all lines and hoses for wear or for Gases from a battery can explode. Keep any open
deterioration. The hoses must be properly routed. flames or sparks away from the top of a battery. Do
The lines and the hoses must have adequate support not smoke in battery charging areas.
and secure clamps. Tighten all connections to the
recommended torque. Leaks can cause fires. Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or
a hydrometer.
Improper jumper cable connections can cause

an explosion that can result in injury. Refer to
the Operation Section of this manual for specific
instructions.
Do not charge a frozen battery. This may cause an

explosion.
Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.
Ether
g00704059
Illustration 25
Ether is flammable and poisonous.
Use caution when you are refueling a machine. Do
not smoke while you are refueling a machine. Do Use ether in well ventilated areas. Do not smoke
not refuel a machine near open flames or sparks. while you are replacing an ether cylinder or while you
Always stop the engine before refueling. Fill the fuel are using an ether spray.
tank outdoors.
Do not store ether cylinders in living areas or in the
operator compartment of a machine. Do not store
ether cylinders in direct sunlight or in temperatures
above 49 °C (120 °F). Keep ether cylinders away
from open flames or sparks.
24 SEBU8045-03
Safety Section
Fire Extinguisher Location
Dispose of used ether cylinders properly. Do not i01932259

puncture an ether cylinder. Keep ether cylinders
away from unauthorized personnel. Fire Extinguisher Location
Do not spray ether into an engine if the machine is SMCS Code: 7000; 7419
equipped with a thermal starting aid for cold weather
starting.
Lines, Tubes and Hoses

Do not bend high pressure lines. Do not strike high
pressure lines. Do not install any lines that are bent
or damaged.
Repair any lines that are loose or damaged. Leaks

can cause fires. Consult your Caterpillar dealer for
repair or for replacement parts.
Check lines, tubes and hoses carefully. Do not use

your bare hand to check for leaks. Use a board or Illustration 27
g01005330
cardboard to check for leaks. Tighten all connections
to the recommended torque. Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Replace the parts if any of the following conditions Inspect the fire extinguisher and service the fire
are present: extinguisher regularly. Obey the recommendations
on the instruction plate.
• End fittings are damaged or leaking.
The recommended location for mounting the fire
• Outer coverings are chafed or cut. extinguisher is in the storage box.
• Wires are exposed.

i01329108
• Outer coverings are ballooning. Track Information

• Flexible part of the hoses are kinked. SMCS Code: 4170; 7000
• Outer covers have embedded armoring. Track adjusting systems use either grease or oil
under high pressure to keep the track under tension.
• End fittings are displaced.
Grease or oil under high pressure coming out of the
Make sure that all clamps, guards, and heat shields
relief valve can penetrate the body causing injury or
are installed correctly. During machine operation, this
death. Do not watch the relief valve to see if grease
will help to prevent vibration, rubbing against other
or oil is escaping. Watch the track or track adjustment
parts, and excessive heat.
cylinder to see if the track is being loosened.
The pins and bushings in a dry track pin joint

can become very hot. It is possible to burn the
fingers if there is more than brief contact with these
components.
i01122596
Electrical Storm Injury

Prevention
SMCS Code: 7000
When lightning is striking in the vicinity of the

machine, the operator should never attempt the
following procedures:
SEBU8045-03 25
Safety Section
Before Starting Engine
• Mount the machine. i01340061
• Dismount the machine. Before Operation

If you are in the operator’s station during an electrical SMCS Code: 7000
storm, stay in the operator’s station. If you are on the
ground during an electrical storm, stay away from Clear all personnel from the machine and from the
the vicinity of the machine. area.
Clear all obstacles from the machine’s path. Beware

i00771840 of hazards (wires, ditches, etc).
Before Starting Engine Be sure that all windows are clean. Secure the doors
and the windows in the open position or in the shut
SMCS Code: 1000; 7000 position.
Start the engine only from the operator compartment. Adjust the rearview mirrors (if equipped) for the best
Never short across the starter terminals or across visibility close to the machine. Make sure that the
the batteries. Shorting could damage the electrical horn, the travel alarm (if equipped), and all other
system by bypassing the engine neutral start system. warning devices are working properly.
Inspect the condition of the seat belt and of the Fasten the seat belt securely.
mounting hardware. Replace any parts that are worn
or damaged. Regardless of appearance, replace the Warm up the engine and the hydraulic oil before
seat belt after three years of use. Do not use a seat operating the machine.
belt extension on a retractable seat belt.
Before moving the machine, check the position of the
Adjust the seat so that full pedal travel can be undercarriage. The normal travel position is with the
achieved with the operator’s back against the back idler wheels to the front under the cab and the drive
of the seat. sprockets to the rear. When the undercarriage is in
the reversed position, the directional controls must
Make sure that the machine is equipped with a be operated in opposite directions.
lighting system that is adequate for the job conditions.
Make sure that all machine lights are working
properly. i02568738
Before you start the engine and before you move the Work Tools
machine, make sure that no one is underneath the
machine, around the machine, or on the machine. SMCS Code: 6700
Make sure that the area is free of personnel.
Only use work tools that are recommended by
Caterpillar for use on Caterpillar machines.
i02346672
If you are in doubt about the compatibility of a
Engine Starting particular work tool with your machine, consult your
Caterpillar dealer.
SMCS Code: 1000; 7000
Make sure that all necessary guarding is in place on
If a warning tag is attached to the engine start switch the host machine and on the work tool.
or to the controls, do not start the engine. Also, do
not move any controls. Keep all windows and doors closed on the host
machine. A polycarbonate shield must be used when
Move all hydraulic controls to the HOLD position the host machine is not equipped with windows and
before you start the engine. Move the hydraulic when a work tool could throw debris.
lockout control to the LOCKED position. For further
details on this procedure, refer to Operation and Always wear protective glasses. Always wear the
Maintenance Manual, “Operator Controls”. protective equipment that is recommended in the
work tool’s operation manual. Wear any other
Diesel engine exhaust contains products of protective equipment that is required for the operating
combustion which can be harmful to your health. environment.
Always run the engine in a well ventilated area. If
you are in an enclosed area, vent the exhaust to the
outside.
26 SEBU8045-03
Safety Section
Operation
To prevent personnel from being struck by flying Be careful to avoid any ground condition which could
objects, ensure that all personnel are out of the work cause the machine to tip. Tipping can occur when
area. you work on hills, on banks, or on slopes. Tipping can
also occur when you cross ditches, ridges, or other
While you are performing any maintenance, any unexpected obstructions.
testing, or any adjustments to the work tool stay
clear of the following areas: cutting edges, pinching When possible, operate the machine up slopes and
surfaces, and crushing surfaces. down slopes. Avoid operating the machine across
the slope.
i02541203
Keep the machine under control. Do not overload the
Operation machine beyond capacity.
SMCS Code: 7000 Avoid changing the direction of travel on a slope. This
could result in tipping or side slipping of the machine.
Machine Operating Temperature Bring the load close to the machine before travelling
Range any distances.
The machine must function satisfactorily in the Bring the load close to the machine before swinging
anticipated ambient temperature limits that are the load.
encountered during operation. The standard
machine configuration is intended for use within Lifting capacity decreases as the load is moved
an ambient temperature range of −18 °C (0 °F) to further from the machine.
43 °C (109 °F). Special configurations for different
ambient temperatures may be available. Consult Make sure that the towing eyes and the towing
your Caterpillar dealer for additional information on devices are adequate for your needs.
special configurations of your machine.
Only connect trailing equipment to a drawbar or to a
hitch.
Machine Operation
Never straddle a wire cable. Never allow other
Only operate the machine while you are in a seat. personnel to straddle a wire cable.
The seat belt must be fastened while you operate the
machine. Only operate the controls while the engine When you maneuver in order to connect the
is running. equipment, make sure that no personnel are between
the machine and trailing equipment. Block up the
Check for proper operation of all controls and of all hitch of the trailing equipment in order to align the
protective devices while you operate the machine equipment with the drawbar.
slowly in an open area.
Check the local regulations, state codes, and/or
When the machine is moving watch the clearance directives of the job site for a specific minimum
of the boom. Uneven ground can cause the boom distance from obstacles.
to move in all directions.
Before you operate the machine, check with local
Make sure that no personnel will be endangered utilities for the locations of underground pipes and for
before you move the machine. Do not allow riders on the locations of buried cables.
the machine unless the machine has an additional
seat with a seat belt. Know the maximum dimensions of your machine.
Report any machine damage that was noted during Watch the load at all times.
machine operation. Make any necessary repairs.
Do not operate the machine without the
Hold attachments approximately 40 cm (15 inches) counterweight. The machine can tip when the boom
above ground level while you drive the machine. Do is over the side.
not drive the machine close to an overhang, to the
edge of a cliff, or to the edge of an excavation.
If the machine begins to sideslip on a grade,

immediately dump the load and turn the machine
downhill.
SEBU8045-03 27
Safety Section
Engine Stopping
The clamshell, the grapple, or the magnet can swing Machine movement that is sudden and unexpected
in all directions. Move the joysticks in a continuous will occur if any of the controls are moved. This can
motion. Failure to move the joysticks in a continuous cause personal injury or death.
motion can cause the clamshell, the grapple, or the
magnet to swing into the cab or into a person in the Always move the hydraulic lockout control to the
work area. This will result in personal injury. LOCKED position before you shut off the engine or
immediately after the engine stops running.
The boom and the stick linkage can allow the work
tool to contact the undercarriage and/or the cab. Be Park the machine on a level surface. If you must
aware of the position of the work tool. park the machine on a grade, chock the tracks of the
machine.
i01353516
Engine Stopping
SMCS Code: 1000; 7000
Do not stop the engine immediately after the

machine has been operated under load. This can
cause overheating and accelerated wear of engine
components.
After the machine is parked and the parking brake

is engaged, allow the engine to run for five minutes
before shutdown. This allows hot areas of the engine
to cool gradually. Illustration 28
g00100836
i00697030 Place the machine in the servicing position.
Lifting Objects Note: Make sure that all work tools are in the
recommended servicing position before servicing the
SMCS Code: 7000 machine.
There may be some local regulations and/or Move the hydraulic lockout control to the LOCKED
government regulations that govern the use of position.
excavators which lift heavy objects. Obey those
regulations. Stop the engine.
If this machine is used to lift objects within an Turn the engine start switch to the OFF position and
area that is controlled by the European Directive remove the engine start switch key.
“89/392/EEC”, the machine must be equipped with a
boom lowering control valve and an overload warning Turn the battery disconnect switch to the OFF
device. position. Remove the disconnect switch key if you
do not operate the machine for an extended period
of time. This will prevent drainage of the battery. A
i02252108
battery short circuit, any current draw from certain
Parking components, and vandalism can cause drainage of
the battery.
SMCS Code: 7000
The hydraulic system remains pressurized provided

that the accumulator is charged. This condition is true
even when the engine is not running. This pressure
should decrease in a short time (approximately
one minute). While the hydraulic system maintains
a charge, the hydraulic work tools and machine
controls remain functional.
28 SEBU8045-03
Safety Section
Equipment Lowering with Engine Stopped
i01329161 “The European Union Physical

Equipment Lowering with Agents (Vibration) Directive
Engine Stopped 2002/44/EC”
SMCS Code: 7000-II Vibration Data for Track Type Excavator
Before lowering any equipment with the engine Information Concerning Hand/Arm Vibration
stopped, clear the area around the equipment of Level
all personnel. The procedure to use will vary with
the type of equipment to be lowered. Keep in mind When the machine is operated according to the
most systems use a high pressure fluid or air to intended use, the hand/arm vibration of this machine
raise or lower equipment. The procedure will cause is below 2.5 meter per second squared.
high pressure air, hydraulic, or some other media
to be released in order to lower the equipment. Information Concerning Whole Body Vibration
Wear appropriate personal protective equipment and Level
follow the established procedure in the Operation
and Maintenance Manual, “Equipment Lowering with This section provides vibration data and a method
Engine Stopped” in the Operation Section of the for estimating the vibration level for track type
manual. excavators.
Note: Vibration levels are influenced by many

i02583825 different parameters. Many items are listed below.
Sound Information and • Operator training, behavior, mode, and stress
Vibration Information
• Job site organization, preparation, environment,
SMCS Code: 7000 weather, and material
Sound Level Information • Machine type, quality of the seat, quality of the
suspension system, attachments, and condition of
Hearing protection may be needed when the the equipment
machine is operated with an open operator station
and an open cab for extended periods or in a noisy It is not possible to get precise vibration levels for
environment. Hearing protection may be needed this machine. The expected vibration levels can be
when the machine is operated with a cab that is estimated with the information in Table 1 in order
not properly maintained or when the doors and to calculate the daily vibration exposure. A simple
windows are open for extended periods or in a noisy evaluation of the machine application can be used.
environment.
Estimate the vibration levels for the three vibration
directions. For typical operating conditions, use the
Sound Level Information for average vibration levels as the estimated level. With
Machines in European Union an experienced operator and smooth terrain, subtract
the Scenario Factors from the average vibration level
Countries and in Countries that in order to obtain the estimated vibration level. For
Adopt the “EU Directives” aggressive operations and severe terrain, add the
Scenario Factors to the average vibration level in
The operator sound pressure level that is measured order to obtain the estimated vibration level.
according to the static test procedure that is specified
in “ISO 6394:1998” is 76 dB(A) for an enclosed cab. Note: All vibration levels are in meter per second
The cab was properly installed and maintained. The squared.
test was conducted with the doors and the windows
closed.
The operator sound pressure level that is measured

according to the dynamic test procedure that is
specified in “ISO 6396:1992” is 78 dB(A) for an
enclosed cab. The cab was properly installed and
maintained. The test was conducted with the doors
and the windows closed.
SEBU8045-03 29
Safety Section
Sound Information and Vibration Information
Table 1
“ISO Reference Table A - Equivalent vibration levels of whole body vibration emission for earthmoving equipment.”
Machine Typical Operating Vibration Levels Scenario Factors

Type Activity X axis Y axis Z axis X axis Y axis Z axis
excavating 0,44 0,27 0,30 0,24 0,16 0,17
hydraulic breaker
Track Type 0,53 0,31 0,55 0,30 0,18 0,28
application
Excavator
mining application 0,65 0,42 0,61 0,21 0,15 0,32
transfer 0,48 0,32 0,79 0,19 0,20 0,23
Note: Refer to “ISO/TR 25398 Mechanical Vibration - 4. Use a seat that meets “ISO 7096”. Keep the seat
Guideline for the assessment of exposure to whole maintained and adjusted.
body vibration of ride on operated earthmoving
machines” for more information about vibration. a. Adjust the seat and suspension for the weight
This publication uses data that is measured and the size of the operator.
by international institutes, organizations and
manufacturers. This document provides information b. Inspect and maintain the seat suspension and
about the whole body exposure of operators of adjustment mechanisms.
earthmoving equipment. Refer to Operation and
Maintenance Manual, SEBU8257, “The European 5. Perform the following operations smoothly.
Union Physical Agents (Vibration) Directive
2002/44/EC” for more information about machine a. Steer
vibration levels.
b. Brake
The Caterpillar suspension seat meets the criteria of
“ISO 7096”. This represents vertical vibration level c. Accelerate.
under severe operating conditions.
d. Shift the gears.
Guidelines for Reducing Vibration Levels on
Earthmoving Equipment 6. Move the attachments smoothly.
Properly adjust machines. Properly maintain 7. Adjust the machine speed and the route in order
machines. Operate machines smoothly. Maintain the to minimize the vibration level.
conditions of the terrain. The following guidelines can
help reduce the whole body vibration level: a. Drive around obstacles and rough terrain.
1. Use the right type and size of machine, equipment, b. Slow down when it is necessary to go over
and attachments. rough terrain.
2. Maintain machines according to the 8. Minimize vibrations for a long work cycle or a long
manufacturer’s recommendations. travel distance.
a. Tire pressures a. Use machines that are equipped with

suspension systems.
b. Brake and steering systems
b. Use the ride control system on track type
c. Controls, hydraulic system and linkages excavators.
3. Keep the terrain in good condition. c. If no ride control system is available, reduce
speed in order to prevent bounce.
a. Remove any large rocks or obstacles.
d. Haul the machines between workplaces.
b. Fill any ditches and holes.
9. Less operator comfort may be caused by other risk
c. Provide machines and schedule time in order factors. The following guidelines can be effective
to maintain the conditions of the terrain. in order to provide better operator comfort:
30 SEBU8045-03
Safety Section
Operator Station
a. Adjust the seat and adjust the controls in order i01649970

to achieve good posture.
Operator Station
b. Adjust the mirrors in order to minimize twisted
posture. SMCS Code: 7300; 7301; 7325
c. Provide breaks in order to reduce long periods Any modifications to the inside of the operator
of sitting. station should not project into the operator space.
The addition of a radio, fire extinguisher, and other
d. Avoid jumping from the cab. equipment must be installed so that the defined
operator space is maintained. Any item that is brought
e. Minimize repeated handling of loads and lifting into the cab should not project into the defined
of loads. operator space. A lunch box or other loose items
must be secured. Objects must not pose an impact
f. Minimize any shocks and impacts during sports hazard in rough terrain or in the event of a rollover.
and leisure activities.
i01992325
Sources
Guards
The vibration information and calculation procedure (Operator Protection)
is based on “ISO/TR 25398 Mechanical Vibration
- Guideline for the assessment of exposure SMCS Code: 7000; 7150
to whole body vibration of ride on operated
earthmoving machines”. Harmonized data is There are different types of guards that are used to
measured by international institutes, organizations protect the operator. The machine and the machine
and manufacturers. application determines the type of guard that should
be used.
This literature provides information about assessing
the whole body vibration exposure of operators of A daily inspection of the guards is required in order to
earthmoving equipment. The method is based on check for structures that are bent, cracked or loose.
measured vibration emission under real working Never operate a machine with a damaged structure.
conditions for all machines.
The operator becomes exposed to a hazardous
You should check the original directive. This situation if the machine is used improperly or if poor
document summarizes part of the content of the operating techniques are used. This situation can
applicable law. This document is not meant to occur even though a machine is equipped with an
substitute the original sources. Other parts of these appropriate protective guard. Follow the established
documents are based on information from the United operating procedures that are recommended for your
Kingdom Health and Safety Executive. machine.
SEBU8257, “The European Union Physical
Agents (Vibration) Directive 2002/44/EC” for more
information about vibration.
Consult your local Caterpillar dealer for more

information about machine features that minimize
vibration levels. Consult your local Caterpillar dealer
about safe machine operation.
Use the following web site in order to find your local

dealer:
Caterpillar, Inc.
www.cat.com
SEBU8045-03 31
Safety Section
Guards
Rollover Protective Structure • Demolition applications

(ROPS), Falling Object Protective • Rock quarries
Structure (FOPS) or Tip Over
Protection Structure (TOPS) • Forestry products
The ROPS/FOPS Structure (if equipped) on your Additional guards may be required for specific
machine is specifically designed, tested and certified applications or work tools. The Operation and
for that machine. Excavators are not equipped Maintenance Manual for your machine or your
with ROPS structures. Any alteration or any work tool will provide specific requirements for the
modification to the ROPS/FOPS Structure could guards. Consult your Caterpillar dealer for additional
weaken the structure. This places the operator information.
into an unprotected environment. Modifications or
attachments that cause the machine to exceed the
weight that is stamped on the certification plate also
place the operator into an unprotected environment.
Excessive weight may inhibit the brake performance,
the steering performance and the ROPS. The
protection that is offered by the ROPS/FOPS
Structure will be impaired if the ROPS/FOPS
Structure has structural damage. Damage to the
structure can be caused by an overturn, a falling
object, a collision, etc.
Do not mount items (fire extinguishers, first aid

kits, work lights, etc) by welding brackets to the
ROPS/FOPS Structure or by drilling holes in the
ROPS/FOPS Structure. Welding brackets or drilling
holes in the ROPS/FOPS Structures can weaken
the structures. Consult your Caterpillar dealer for
mounting guidelines.
The Tip Over Protection Structure (TOPS) is

another type of guard that is used on mini hydraulic
excavators. This structure protects the operator in
the event of a tipover. The same guidelines for the
inspection, the maintenance and the modification of
the ROPS/FOPS Structure are required for the Tip
Over Protection Structure.
Other Guards (If Equipped)

Protection from flying objects and/or falling objects is
required for special applications. Logging applications
and demolition applications are two examples that
require special protection.
A front guard needs to be installed when a work

tool that creates flying objects is used. Mesh
front guards that are approved by Caterpillar or
polycarbonate front guards that are approved by
Caterpillar are available for machines with a cab or
an open canopy. On machines that are equipped with
cabs, the windshield should also be closed. Safety
glasses are recommended when flying hazards exist
for machines with cabs and machines with open
canopies.
If the work material extends above the cab, top

guards and front guards should be used. Typical
examples of this type of application are listed below:
32 SEBU8045-03
General Information
Product Information
Section
General Information
i02540478
Specifications
SMCS Code: 7000
g01166413
Illustration 29
Table 2 Table 3
330D Excavator(1) 330D L Excavator(1)
Approximate Weight 34500 kg (76060 lb) Approximate Weight 34500 kg- (76060 lb)
Overall Length (A) 11162 mm (36 ft 7 inch) Overall Length (A) 11132 mm (36 ft 6 inch)
Overall Height (B) 3619 mm (11 ft 10 inch) Overall Height (B) 3491 mm (11 ft 5 inch)
Tail Swing Radius (C) 3500 mm (11 ft 6 inch) Tail Swing Radius (C) 3500 mm (11 ft 6 inch)
Overall Width (D) 3440 mm (11 ft 3 inch) Overall Width (D) 3440 mm (11 ft 3 inch)
Track Shoe Width (E) 750 mm (2 ft 5.5 inch) Track Shoe Width (E) 750 mm (2 ft 5.5 inch)
Length to centers of Length to centers of
4040 mm (13 ft 3 inch) 4040 mm (13 ft 3 inch)
rollers (F) rollers (F)
Length of Track (G) 5020 mm (16 ft 6 inch) Length of Track (G) 5020 mm (16 ft 6 inch)
(1) These specifications are for a machine that has a 6.5 m (1) These specifications are for a machine that has a 6.5 m
(21 ft 4 inch) reach boom, a 3.9 m (12 ft 10 inch) stick, a 1.1 m3 (21 ft 4 inch) reach boom, a 3.2 m (10 ft 6 inch) stick, a 1.2 m3
(1.2 yd3) bucket, and a 10 percent full fuel tank. (1.3 yd3 ) bucket, and a 10 percent full fuel tank.
SEBU8045-03 33
General Information
Table 4 Table 7
330D L Excavator(1) 330D L Excavator(1)
Approximate Weight 35100 kg (77380 lb) Approximate Weight 40656 kg (89631 lb)
Overall Height (B) 3633 mm (11 ft 11 inch) Overall Height (B) 3667 mm (12 ft)
(1) These specifications are for a machine that has a 6.18 m (1) These specifications are for a machine that has a 6.18 m
(21 ft 4 inch) mass boom, a 2.55 m (8 ft 4 inch) stick, a 1.2 m3 (20 ft 3 inch) mass boom, a 2.15 m (7 ft 1 inch) stick, and a
(1.3 yd3 ) bucket, and a 10 percent full fuel tank. 10 percent full fuel tank.
Table 5 Table 8
330D L Excavator(1) 330D L Excavator(1)
Overall Height (B) 3602 mm (11 ft 9 inch) Overall Height (B) 3667 mm (12 ft)
(1) These specifications are for a machine that has a 6.5 m (1) These specifications are for a machine that has a VA boom, a
(21 ft 4 inch) reach boom, a 2.15 m (7 ft) stick, and a 10 percent 2.15 m (7 ft 1 inch) stick, and a 10 percent full fuel tank.
full fuel tank.
Table 9
Table 6
330D L Excavator(1)
330D L Excavator(1)
Approximate Weight 36890 kg (81328 lb)
Overall Length (A) 11232 mm (36 ft 10 inch)
Overall Height (B) 3633 mm (11 ft 11 inch)
Tail Swing Radius (C) 3500 mm (11 ft 6 inch)
Overall Width (D) 3440 mm (11 ft 3 inch)
Track Shoe Width (E) 750 mm (2 ft 5.5 inch)
Length to centers of
Length to centers of 4040 mm (13 ft 3 inch)
4040 mm (13 ft 3 inch) rollers (F)
rollers (F)
Length of Track (G) 5020 mm (16 ft 6 inch)
Length of Track (G) 5020 mm (16 ft 6 inch) (1) These specifications are for a machine that has a VA boom, a
(1) These specifications are for a machine that has a 6.5 m 2.8 m (9 ft 2 inch) stick, and a 10 percent full fuel tank.
(21 ft 4 inch) reach boom, a medium short stick, and a 10
percent full fuel tank.
34 SEBU8045-03
General Information
Table 10 Table 13
330D L Excavator(1) 330D L HW Excavator(1)
Overall Height (B) 3562 mm (11 ft 8 inch) Overall Height (B) 3639 mm (11 ft 11 inch)
(1) These specifications are for a machine that has a VA boom, a (1) These specifications are for a machine that has a 6.5 m
3.2 m (10 ft 6 inch) stick, and a 10 percent full fuel tank. (21 ft 4 inch) reach boom, a 2.8 m (9 ft 2 inch) stick, and a
10 percent full fuel tank.
Table 11
Table 14
330D L Excavator(1)
330D L HW Excavator(1)
4040 mm (13 ft 3 inch) Length to centers of
rollers (F) 4040 mm (13 ft 3 inch)
rollers (F)
(1)
These specifications are for a machine that has a VA boom, a
3.9 m (12 ft 10 inch) stick, and a 10 percent full fuel tank. (1) These specifications are for a machine that has a 6.5 m
(21 ft 4 inch) reach boom, a 3.2 m (10 ft 6 inch) stick, and a
Table 12 10 percent full fuel tank.
330D L HW Excavator(1) Table 15

Approximate Weight 37625 kg (82949 lb) 330D L HW Excavator(1)
Overall Length (A) 11394 mm (37 ft 5 inch) Approximate Weight 37274 kg (82175 lb)
Overall Height (B) 3605 mm (11 ft 10 inch) Overall Length (A) 11163 mm (36 ft 7 inch)
Tail Swing Radius (C) 3500 mm (11 ft 6 inch) Overall Height (B) 3648 mm (11 ft 10 inch)
Overall Width (D) 3440 mm (11 ft 3 inch) Tail Swing Radius (C) 3500 mm (11 ft 6 inch)
Track Shoe Width (E) 750 mm (2 ft 5.5 inch) Overall Width (D) 3440 mm (11 ft 3 inch)
Length to centers of Track Shoe Width (E) 750 mm (2 ft 5.5 inch)
4040 mm (13 ft 3 inch)
rollers (F)
Length of Track (G) 5020 mm (16 ft 6 inch) 4040 mm (13 ft 3 inch)
rollers (F)
(1) These specifications are for a machine that has a 6.5 m Length of Track (G) 5020 mm (16 ft 6 inch)
10 percent full fuel tank. (1) These specifications are for a machine that has a 6.5 m
SEBU8045-03 35
General Information
Table 16
4040 mm (13 ft 3 inch)
rollers (F)
(1) These specifications are for a machine that has a 6.18 m
(20 ft 3 inch) mass boom, a 2.15 m (7 ft 1 inch) stick, and a
Table 17
4040 mm (13 ft 3 inch)
rollers (F)
(1) These specifications are for a machine that has a 6.18 m
(20 ft 3 inch) mass boom, a medium stick, and a 10 percent
full fuel tank.
36 SEBU8045-03
General Information
330D ES Stick R2.15TB
g01273010
Illustration 30
Table 18
330D ES Stick R2.15TB(1)

Maximum digging height 10009 mm
Maximum digging reach 10349 mm
Maximum digging depth -6376 mm
(1) These specs are for a machine that has a 6.5 m (21 ft 4 in)
reach boom, a 2.15 m (7 ft 1 in) short stick, and a 10 percent
full fuel tank.
SEBU8045-03 37
General Information
330D ES Stick R2.8DB
g01273011
Illustration 31
Table 19
330D ES Stick R2.8DB(1)

reach boom, a medium short stick, and a 10 percent full fuel
tank.
38 SEBU8045-03
General Information
g01273012
Illustration 32
Table 20

reach boom, a 3.2 m (10 ft 6 in) medium stick, and a 10 percent
full fuel tank.
SEBU8045-03 39
General Information
g01273013
Illustration 33
Table 21

reach boom, a 3.9 m (12 ft 10 in) long stick, and a 10 percent
full fuel tank.
40 SEBU8045-03
General Information
330D ES Stick M2.15TB
g01273014
Illustration 34
Table 22
330D ES Stick M2.15TB(1)

reach boom, a 2.15 m (7 ft 1 in) short stick, and a 10 percent
full fuel tank.
SEBU8045-03 41
General Information
330D ES Stick M2.55TB
g01273015
Illustration 35
Table 23
330D ES Stick M2.55TB(1)

reach boom, a medium stick, and a 10 percent full fuel tank.
42 SEBU8045-03
General Information
330D HW Stick R2.15TB
g01281370
Illustration 36
Table 24
330D HW Stick M2.15TB(1)

SEBU8045-03 43
General Information
330D HW Stick R2.8DB
g01281451
Illustration 37
Table 25
330D HW Stick R2.8DB(1)

reach boom, a medium short stick, and a 10 percent full fuel
tank.
44 SEBU8045-03
General Information
g01281610
Illustration 38
Table 26

reach boom, a 3.2 m (10 ft 6 in) medium stick, and a 10 percent
full fuel tank.
SEBU8045-03 45
General Information
g01281622
Illustration 39
Table 27

reach boom, a 3.9 m (12 ft 10 in) long stick, and a 10 percent
full fuel tank.
46 SEBU8045-03
General Information
330D HW Stick R2.15TB
g01281634
Illustration 40
Table 28
330D HW Stick M2.15TB(1)

SEBU8045-03 47
General Information
330D HW Stick M2.55TB
g01281656
Illustration 41
Table 29 i02355598
330D HW Stick M2.55TB(1) Boom/Stick/Bucket

Maximum digging height 10305 mm Combinations
SMCS Code: 6000; 6700
(1) These specs are for a machine that has a 6.18 m (20 ft 3 in) This machine can be equipped with a large variety of
reach boom, a medium stick, and a 10 percent full fuel tank. boom-stick-bucket combinations in order to meet the
needs of various applications.
48 SEBU8045-03
General Information
Buckets for the 330D and 330D L are grouped into

two different families. The names of the two families
of buckets are D and E. The capacity of the bucket is
used to differentiate between the two bucket families.
As a general rule, use a bucket with a smaller
capacity when you are using a longer stick and/or a
longer boom. Conversely, use a bucket with a larger
capacity when you are using a shorter stick and/or
a shorter boom. This rule ensures better machine
stability and protection against structural machine
damage.
Each stick is designed to match a specific family

of buckets. It is not possible to attach buckets of a
different family to a given stick.
The tables show various compatible

boom-stick-bucket combinations. Select an
optimum combination according to the working
conditions and according to the type of work that is
being done.
SEBU8045-03 49
General Information
Table 30
330D Excavators
Reach Boom 6.5 m (21 ft 4 inch)
3.9 m (12 3.2 m 2.8 m 2.2 m
SAE ft 10 inch) (10 ft 6 inch) (9 ft 2 inch) (7 ft 3 inch)
Capacity Width of Bucket Stick with D Stick with D Stick with Stick with
Application of Bucket Bucket Family Bucket Bucket D Bucket E Bucket
1345 mm
1.3 m3 (1) (1) (1)
(4 ft 5 inch)
1430 mm
1.4 m3 D (1) (1)
(4 ft 8 inch)
1500 mm
Excavation 1.5 m3 (2) (1)
(4 ft 11 inch)
1470 mm
1.7 m3 (1)
(4 ft 9 inch)
E
1600 mm
1.9 m 3 (2)
(5 ft 3 inch)
1520 mm
1.6 m3 (2)
(5 ft 0 inch)
D
1700 mm
Mass Excavation 1.9m3
(5 ft 7 inch)
1735 mm
2.1 m3 E
(5 ft 8 inch)
Mass Boom 6.2 m (20 ft 4 inch)
SAE
Capacity Width of Bucket 2.6 m (8 ft 6 inch) Stick 2.2 m (7 ft 3 inch) Stick
Application of Bucket Bucket Family with E Bucket with E Bucket
1345 mm
1.3 m3
(4 ft 5 inch)
1430 mm
1.4 m3 D
(4 ft 8 inch)
1500 mm
Excavation 1.5 m3
(4 ft 11 inch)
1470 mm
1.7 m3 (1) (1)
(4 ft 9 inch)
E
1600 mm
1.9 m 3 (2) (1)
(5 ft 3 inch)
1520 mm
1.6 m3
(5 ft 0 inch)
D
1700 mm
(5 ft 7 inch)
1735 mm
2.1 m3 E (2)
(5 ft 8 inch)
(1) Combination that is preferred
(2) Combination that is permissible
50 SEBU8045-03
General Information
Table 31
330D L Excavators
Reach Boom 6.5 m (21 ft 4 inch)
3.9 m (12 3.2 m 2.8 m 2.2 m
SAE ft 10 inch) (10 ft 6 inch) (9 ft 2 inch) (7 ft 3 inch)
Capacity Width of Bucket Stick with Stick with D Stick with Stick with E
Application of Bucket Bucket Family D Bucket Bucket D Bucket Bucket
1345 mm
1.3 m3 (1) (1) (1)
(4 ft 5 inch)
1430 mm
1.4 m3 D (2) (2)
(4 ft 8 inch)
1500 mm
Excavation 1.5 m3 (1) (1)
(4 ft 11 inch)
1470 mm
1.7 m3 (1)
(4 ft 9 inch)
E
1600 mm
1.9 m 3 (2)
(5 ft 3 inch)
1520 mm
1.6 m3
(5 ft 0 inch)
D
1700 mm
(5 ft 7 inch)
1735 mm
2.1 m3 E
(5 ft 8 inch)
Mass Boom 6.2 m (20 ft 4 inch)
SAE
Capacity Width of Bucket 2.6 m (8 ft 6 inch) Stick 2.2 m (7 ft 3 inch) Stick
Application of Bucket Bucket Family with E Bucket with E Bucket
1345 mm
1.3 m3
(4 ft 5 inch)
1430 mm
1.4 m3 D
(4 ft 8 inch)
1500 mm
Excavation 1.5 m3
(4 ft 11 inch)
1470 mm
1.7 m3 (1) (1)
(4 ft 9 inch)
E
1600 mm
1.9 m 3 (1) (1)
(5 ft 3 inch)
1520 mm
1.6 m3
(5 ft 0 inch)
D
1700 mm
(5 ft 7 inch)
1735 mm
2.1 m3 E (1)
(5 ft 8 inch)
(1) Combination that is preferred
(2) Combination that is permissible
Note: Never reverse the bucket in order to use the

bucket as a loader.
Note: The “Width of Bucket” indicates the maximum

width.
Consult your Caterpillar dealer for more information.

SEBU8045-03 51
General Information
i02539472
Lifting Capacities
SMCS Code: 7000
g00586902
Illustration 42
(H) Height (S) Lifting capacity over the side of the
(F) Lifting capacity over the front or rear of machine
the machine (R) Reach
Table 32
330D L and 330D LN Excavators with a 6.18 m (20 ft 4 in) reach boom, a 2.15 m (7 ft 1 inch)
stick, and 600 mm (2 ft 0 inch) triple grouser track shoes.(1)
All lifting capacities are in kilograms.
R
3.0 m 4.5 m 6.0 m 7.5 m Maximum Reach
H
F S F S F S F S F S m
7.5 m 8770(2) 8740(2) 6.7
6.0 m 9220(2) 8580(2) 8290 8560(2) 7980 7.66
4.5 m 13180(2) 10330(2) 8950(2) 8100 8580(2) 6930 8.24
3.0 m 16070(2) 11660(2) 10940 9560(2) 7820 8720(2) 6420 8.51
1.5 m 17740(2) 15970 12710(2) 10450 10090 7570 8930(2) 6280 8.51
0.0 m 17860(2) 15700 13120(2) 10180 10270(2) 7410 9180(2) 6500 8.24
−1.5 m 18000(2) 16890(2) 15740 12720(2) 10130 9750 7410 9420(2) 7200 7.67
−3.0 m 18800(2) 14760(2) 11140(2) 10310 9500(2) 8820 6.72
−4.5 m 10470(2) 8850 5.17
(1) “ISO 10567” “SAE J1097”
(2) Capacity is limited by hydraulics rather than by a tipping load. The loads do not exceed 87 percent of hydraulic lifting capacity or 75 percent
of tipping capacity. Weight of all lifting accessories must be subtracted from the lifting capacities.
52 SEBU8045-03
General Information
Table 33
330D L and 330D LN Excavators with a 6.18 m (20 ft 4 in) mass boom, a medium stick, a quick
coupler, and 700 mm (2 ft 6 inch) triple grouser track shoes.(1)
R
H
7.5 m 6370(2) 7.24
6.0 m 8640(2) 8060(2) 6150(2) 8.14
4.5 m 18620(2) 12280(2) 9800(2) 8540(2) 8150 6200(2) 8.68
3.0 m 15290(2) 11220(2) 11030 9230(2) 7850 6480(2) 5920 8.94
1.5 m 17360(2) 16130 12410(2) 10500 9870(2) 7570 7030(2) 5800 8.95
0.0 m 9420(2) 17920(2) 15720 13020(2) 10180 10190(2) 7380 7960(2) 5980 8.69
−1.5 m 17040(2) 17280(2) 15670 12860(2) 10070 9940(2) 7320 8830(2) 6540 8.15
−3.0 m 19050(2) 15500(2) 11660(2) 10180 8950(2) 7810 7.26
−4.5 m 15800(2) 11940(2) 8620(2) 5.86
(1) “ISO 10567” “SAE J1097”
Table 34
330D L and 330D LN Excavators with a 6.5 m (21 ft 4 in) mass boom, a medium stick, a quick
R
H
7.5 m 8130(2) 7.07
6.0 m 8880(2) 8120(2) 8030(2) 7400 7.99
4.5 m 13200(2) 10090(2) 8610(2) 8020 8080(2) 6470 8.54
3.0 m 16180(2) 11470(2) 10740 9290(2) 7710 8240(2) 6010 8.81
1.5 m 16810(2) 15610 12520(2) 10250 9870(2) 7440 8470(2) 5880 8.81
0.0 m 17600(2) 15430 12950(2) 9990 10140(2) 7280 8740(2) 6070 8.55
−1.5 m 15530(2) 15540(2) 16700(2) 15510 12650(2) 9950 9840(2) 7260 9020(2) 6670 8.0
−3.0 m 18820(2) 14880(2) 11410(2) 10110 9210(2) 8020 7.09
−4.5 m 11440(2) 8950(2) 5.65
(1) “ISO 10567” “SAE J1097”
SEBU8045-03 53
General Information
Table 35
330D L and 330D LN Excavators with a 6.5 m (21 ft 4 in) reach boom, a medium short stick, a quick
R
3.0 m 4.5 m 6.0 m
H
F S F S F S
9.0 m
7.5 m
6.0 m
4.5 m 12230(2) 9630(2)
3.0 m 15420(2) 11160(2) 11150
1.5 m 17550(2) 16270 12450(2) 10640
0.0 m 18150(2) 15890 13150(2) 10320
−1.5 m 12840(2) 17660(2) 15850 13140(2) 10210
−3.0 m 18300(2) 16220(2) 16010 12290(2) 10270
R
7.5 m 9.0 m Maximum Reach
H
F S F S F S m
9.0 m 7550(2) 6.63
7.5 m 7510(2) 6940(2) 7.9
6.0 m 7690(2) 6720(2) 6560 8.72
4.5 m 8320(2) 8290 7650(2) 6150 6760(2) 5870 9.24
3.0 m 9120(2) 7980 7980(2) 6010 7010(2) 5520 9.48
1.5 m 9850(2) 7700 8320(2) 5870 7510(2) 5420 9.48
0.0 m 10290 7500 8430(2) 5780 8160(2) 5570 9.24
−1.5 m 10250(2) 7420 8390 6020 8.74
−3.0 m 9380(2) 7490 8560(2) 6990 7.91
-4.5 m 8460(2) 6.66
(1) “ISO 10567” “SAE J1097”
54 SEBU8045-03
General Information
Table 36
330D L and 330D LN Excavators with a 6.5 m (21 ft 4 in) reach boom, a 3.2 m (10 ft 6 in) medium stick,
a quick coupler, and 600 mm (1 ft 11 inch) triple grouser track shoes.(1)
R
1.5 m 3.0 m 4.5 m
H
F S F S F S
9.0 m
7.5 m
6.0 m
4.5 m
3.0 m 14540(2)
1.5 m 17000(2)
0.0 m 7940(2) 18010(2) 15900
−1.5 m 9260(2) 13280(2) 17850(2) 15770
−3.0 m 14570(2) 18620(2) 16710(2) 15870
-4.5 m 19580(2) 14350(2)
R
6.0 m 7.5 m 9.0 m Maximum Reach
H
F S F S F S F S m
9.0 m 5900(2) 7.05
7.5 m 6970(2) 5500(2) 8.25
6.0 m 7250(2) 5680(2) 5370(2) 9.04
4.5 m 9080(2) 7930(2) 7300(2) 6190 5440(2) 9.54
3.0 m 10680(2) 8780(2) 8030 7710(2) 6030 5680(2) 5260 9.77
1.5 m 12090(2) 1070 9590(2) 7720 8120(2) 5870 6110(2) 5160 9.78
0.0 m 12960(2) 10330 10140 7490 8360(2) 5750 6820(2) 5280 9.54
−1.5 m 13150(2) 10160 10260(2) 7370 8180 5710 8000 5670 9.05
−3.0 m 12550(2) 10170 9690(2) 7400 8380(2) 6490 8.26
-4.5 m 10780(2) 13380 8510(2) 8260 7.07
(1) “ISO 10567” “SAE J1097”
SEBU8045-03 55
General Information
Table 37
R
1.5 m 3.0 m 4.5 m
H
F S F S F S
9.0 m
7.5 m
6.0 m
4.5 m
3.0 m 12880(2)
1.5 m 15820(2)
0.0 m 8260(2) 17480(2) 15970
−1.5 m 7740(2) 11900(2) 17910(2) 15660
−3.0 m 11940(2) 16790(2) 17290(2) 15640
-4.5 m 16950(2) 21140(2) 15580(2)
-6.0 m 16810(2) 12170(2)
R
H
F S F S F S F S m
9.0 m 4560(2) 8.02
7.5 m 4700(2) 4260(2) 9.09
6.0 m 6450(2) 6330(2) 4150(2) 9.81
4.5 m 7190(2) 6680(2) 6260 4180(2) 10.27
3.0 m 9730(2) 8120(2) 8110 7190(2) 6060 4320(2) 10.49
1.5 m 11330(2) 10820 9050(2) 7750 7710(2) 5860 4590(2) 4580 10.49
0.0 m 12490(2) 10350 9780 7470 8110(2) 5700 5040(2) 4660 10.28
−1.5 m 13010(2) 10090 10130(2) 7290 8230 5600 5750 4950 9.82
−3.0 m 12800(2) 10020 9940(2) 7240 7740(2) 5620(2) 6960(2) 5540 8.26
-4.5 m 11660(2) 10130 8800(2) 7360 7770(2) 6710 8.04
-6.0 m 8770(2) 7680(2) 6.46
(1) “ISO 10567” “SAE J1097”
56 SEBU8045-03
General Information
Table 38
330D L and 330D LN Excavators with a VA stub boom, a VA fore boom, a 2.15 m (7 ft 1 inch) short
stick, and 600 mm (2 ft 0 inch) triple grouser track shoes.(1)
R
H
9.0 m 9520(2) 9540(2) 5.49
7.5 m 12100(2) 10470(2) 9390 9580(2) 6800 7.02
6.0 m 19020(2) 14770(2) 14310 11630(2) 9250 9440(2) 6070 8980(2) 5260 7.98
4.5 m 21320(2) 16640(2) 13720 12530(2) 8920 9790(2) 6030 8090(2) 4460 8.57
3.0 m 22010(2) 18150(2) 13000 13190(2) 8480 9970(2) 5840 7470(2) 4040 8.87
1.5 m 18870(2) 18170(2) 12360 13300(2) 8100 9790 5530 7270(2) 3880 8.91
0.0 m 18810(2) 18270(2) 11500 13310(2) 7590 9630(2) 5200 7460(2) 3960 8.68
−1.5 m 19850(2) 18570(2) 11100 13540(2) 7260 9370 4970 6960(2) 4320 8.18
−3.0 m 23130(2) 21790 17700(2) 11120 11510(2) 7010 5600(2) 5160 7.34
−4.5 m 19120(2) 10620(2)
(1) “ISO 10567” “SAE J1097”
SEBU8045-03 57
General Information
Table 39
330D L and 330D LN Excavators with a VA stub boom, a VA fore boom, a medium short stick, a
quick coupler, and 600 mm (1 ft 11 inch) triple grouser track shoes.(1)
R
3.0 m 4.5 m 6.0 m
H
F S F S F S
10.5 m
9.0 m 8970(2)
7.5 m 10090(2) 9660
6.0 m 12560(2) 11160(2) 9530
4.5 m 22170 16040(2) 14100(2) 12230(2) 9200
3.0 m 22690(2) 18040(2) 13480 13180(2) 8830
1.5 m 22410(2) 18580(2) 12900 13600(2) 8410
0.0 m 20130(2) 18570(2) 12060 13540(2) 7940
−1.5 m 20790(2) 18780(2) 11510 13700(2) 7580
−3.0 m 23450(2) 22130 18570(2) 11340 13260(2) 7350
-4.5 m 21860(2) 15030(2) 11390 8680(2) 7310
R
H
F S F S F S m
10.5 m 10000(2) 4.35
9.0 m 8060(2) 7990 6.53
7.5 m 9060(2) 6370 7280(2) 5730 7.85
6.0 m 9110(2) 6540 6980(2) 5730 8.72
4.5 m 9540(2) 6460 7710(2) 4350 6940(2) 4050 9.26
3.0 m 10150(2) 6250 7620(2) 4260 6800(2) 3730 9.54
1.5 m 10000(2) 5960 7470(2) 4120 6650(2) 3610 9.58
0.0 m 9830 5620 7280(2) 3960 6800(2) 3670 9.37
−1.5 m 9710(2) 5300 6580(2) 3950 8.91
−3.0 m 8450(2) 5150 5500(2) 4570 8.14
-4.5 m
(1) “ISO 10567” “SAE J1097”
58 SEBU8045-03
General Information
Table 40
330D L and 330D LN Excavators with a VA stub boom, a VA fore boom, a medium short stick, a
R
3.0 m 4.5 m 6.0 m
H
F S F S F S
10.5 m
9.0 m 8960(2)
7.5 m 9940(2) 9770
6.0 m 10530(2) 10730(2) 9600(2)
4.5 m 22670 15330(2) 14190(2) 11720(2) 9300
3.0 m 23670(2) 17520(2) 13560 12900(2) 8910
1.5 m 24010(2) 18540(2) 12920 13490(2) 8450
0.0 m 21710(2) 18470(2) 12230 13480(2) 8020
−1.5 m 21690(2) 18620(2) 11560 13560(2) 7600
−3.0 m 26760(2) 22010 18720(2) 11290 13650(2) 7400
-4.5 m 25480(2) 22370 16670(2) 11340 10350(2) 7200
R
H
F S F S F S m
10.5 m 7570(2) 4.99
9.0 m 6270(2) 6.97
7.5 m 8630(2) 6570 5760(2) 5350 8.22
6.0 m 8800(2) 6680 5970(2) 4450 5570(2) 4390 9.05
4.5 m 9220(2) 6550 7640(2) 4470 5580(2) 3840 9.58
3.0 m 9880(2) 6310 7660(2) 4370 5760(2) 3540 9.85
1.5 m 9990(2) 6040 7520(2) 4180 6130(2) 3410 9.88
0.0 m 9820 5700 7320(2) 3990 6450(2) 3460 9.68
−1.5 m 9740(2) 5350 7170 3850 6590(2) 3690 9.23
−3.0 m 9450(2) 5120 5740(2) 4210 8.5
-4.5 m
(1) “ISO 10567” “SAE J1097”
SEBU8045-03 59
General Information
Table 41
330D L and 330D LN Excavators with a 3.1 m (10 ft) VA stub boom, a 3.5 m (10 ft 6 in) VA fore boom, a 3.9 m
(12 ft 10 in) long stick, a quick coupler, and 600 mm (1 ft 11 inch) triple grouser track shoes.(1)
R
3.0 m 4.5 m 6.0 m
H
F S F S F S
10.5 m 6710
9.0 m 7910(2)
7.5 m 7870(2)
6.0 m 8530(2)
4.5 m 10630(2) 10560 9420
3.0 m 25000 16410 13800 12270(2) 9010(2)
1.5 m 23890(2) 18110(2) 13050 13150(2) 8580(2)
0.0 m 25500(2) 23900 18330(2) 12560 13370(2) 8180
−1.5 m 23590(2) 22440 18360(2) 11690 13350(2) 7650
−3.0 m 24580(2) 21880 18650(2) 11240 13350(2) 7340
-4.5 m 27310(2) 21940 17980(2) 11160 12520(2) 7150
-6.0 m 21190(2) 12620(2) 11260
R
H
F S F S F S F S m
10.5 m 5660(2) 6.31
9.0 m 6470(2) 4850(2) 7.96
7.5 m 7770(2) 6840 4890(2) 4590 4480(2) 9.07
6.0 m 8270(2) 6810 7030(2) 4720 4320(2) 3770 9.83
4.5 m 8620(2) 6620 7200(2) 4700 4300(2) 3340 10.32
3.0 m 9310(2) 6380 7500(2) 4570 4920(2) 3140 4410(2) 3090 10.57
1.5 m 9970(2) 6120 7500(2) 4370 5440(2) 3050 4640(2) 2980 10.6
0.0 m 9800(2) 5780 7390 4100 5020(2) 3000 10.41
−1.5 m 9650(2) 5460 7200(2) 3890 5640(2) 3180 10.0
−3.0 m 9560 5140 6740(2) 3760 5430(2) 3560 9.32
-4.5 m 7880(2) 5030 4310(2) 8.33
-6.0 m 8770(2) 7680(2) 6.46
(1) “ISO 10567” “SAE J1097”
60 SEBU8045-03
General Information
Table 42
330D L and 330D LN Excavators with a 3.1 m (10 ft) VA stub boom, a 3.5 m (10 ft 6 in) VA fore boom, a 2.15
m (7 ft 1 in) short stick, a quick coupler, and 700 mm (2 ft 3 inch) triple grouser track shoes.(1)
R
H
9.0 m 9520(2) 9540(2) 5.49
7.5 m 12100 10470(2) 10140 9580(2) 7480 7.02
6.0 m 19020(2) 14770(2) 11630(2) 10050 9440(2) 6680 8980(2) 5820 7.98
4.5 m 21320(2) 16640(2) 14830 12530(2) 9670 9790(2) 6650 8190(2) 4970 8.57
3.0 m 22010(2) 18150(2) 14120 13190(2) 9280 10060(2) 6450 7560(2) 4520 8.87
1.5 m 18870(2) 18170(2) 13600 13300(2) 8870 9920 6130 7370(2) 4360 8.91
0.0 m 18810(2) 18270(2) 12880 13310(2) 8450 9760(2) 5810 7570(2) 4440 8.68
−1.5 m 19850(2) 18570(2) 12480 13540(2) 8100 9490 5570 6960(2) 4840 8.18
−3.0 m 23130(2) 17700(2) 12490 11510(2) 7840 5600(2) 7.34
−4.5 m 19120 10620(2)
(1) “ISO 10567” “SAE J1097”
SEBU8045-03 61
General Information
Table 43
330D L and 330D LN Excavators with a 3.1 m (10 ft) VA stub boom, a 3.5 m (10 ft 6 in) VA fore boom, a
medium short stick, a quick coupler, and 700 mm (2 ft 3 inch) triple grouser track shoes.(1)
R
3.0 m 4.5 m 6.0 m
H
F S F S F S
10.5 m
9.0 m 8970(2)
7.5 m 10090(2)
6.0 m 12560(2) 11160(2) 10280
4.5 m 22170(2) 16040(2) 15210 12230(2) 9960
3.0 m 22690 18040(2) 14650 13180(2) 9550
1.5 m 22410 18580(2) 14150 13600(2) 9190
0.0 m 20130 18570(2) 13460 13540(2) 8800
−1.5 m 20790(2) 18780(2) 12890 13700(2) 8420
−3.0 m 23450(2) 18570(2) 12710 13260(2) 8190
-4.5 m 21860(2) 15030(2) 12770 8680(2) 8150
R
H
F S F S F S m
10.5 m 10000(2) 4.35
9.0 m 8060(2) 6.53
7.5 m 9060(2) 6990 7280(2) 6310 7.85
6.0 m 9110(2) 7140 6980(2) 5140 8.72
4.5 m 9540(2) 7020 7790 4820 6940(2) 4500 9.26
3.0 m 10200(2) 6790 7720(2) 4730 6890(2) 4160 9.54
1.5 m 10110(2) 6580 7560(2) 4590 6740(2) 4040 9.58
0.0 m 9960 6230 7380(2) 4420 6900(2) 4110 9.37
−1.5 m 9840(2) 5900 6580 4420 8.91
−3.0 m 8450(2) 5750 5500(2) 5110 8.14
-4.5 m
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62 SEBU8045-03
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Table 44
(10 ft 4 in) medium stick, a quick coupler, and 700 mm (2 ft 3 inch) triple grouser track shoes.(1)
R
3.0 m 4.5 m 6.0 m
H
F S F S F S
10.5 m
9.0 m 8960(2)
7.5 m 9940(2)
6.0 m 10530(2) 10730(2) 10310
4.5 m 22670(2) 15330(2) 11720(2) 10050
3.0 m 23670(2) 17520(2) 14750 12900(2) 9640
1.5 m 24010 18540(2) 14120 13490(2) 9240
0.0 m 21710 18470(2) 13630 13480(2) 8800
−1.5 m 21690(2) 18620(2) 12950 13560(2) 8440
−3.0 m 23760(2) 18720(2) 12660 13560(2) 8250
-4.5 m 25480(2) 16670(2) 12720 10350(2) 8040
R
H
F S F S F S m
10.5 m 7570(2) 4.99
9.0 m 6270(2) 6.97
7.5 m 8630(2) 7160 5760(2) 8.22
6.0 m 8800(2) 7260 5970(2) 4920 5570(2) 4860 9.05
4.5 m 9220(2) 7100 7640 4940 5580(2) 4270 9.58
3.0 m 9880(2) 6850 7740(2) 4840 5760(2) 3950 9.85
1.5 m 10110(2) 6610 7620(2) 4650 6130(2) 3830 9.88
0.0 m 9950 6310 7420(2) 4450 6530(2) 3880 9.68
−1.5 m 9860(2) 5950 7270 4310 6590 4140 9.23
−3.0 m 9450(2) 5720 5740(2) 4720 8.5
-4.5 m
(1) “ISO 10567” “SAE J1097”
SEBU8045-03 63
General Information
Table 45
(12 ft 10 in) long stick, a quick coupler, and 700 mm (2 ft 4 inch) triple grouser track shoes.(1)
R
3.0 m 4.5 m 6.0 m
H
F S F S F S
10.5 m 6710(2)
9.0 m 7910(2)
7.5 m 7870
6.0 m 8530(2)
4.5 m 10630 10560(2) 10140
3.0 m 25000 16410(2) 14890(2) 12270(2) 9750(2)
1.5 m 23890(2) 18110(2) 14340 13150(2) 9300
0.0 m 25500 18330(2) 13820 13370(2) 8950
−1.5 m 23590(2) 18360(2) 13080 13350(2) 8500
−3.0 m 24580(2) 18650(2) 12610 13350(2) 8180
-4.5 m 27310(2) 25270 17980(2) 12540 12520(2) 7990
-6.0 m 21190(2) 12620(2)
R
H
F S F S F S F S m
10.5 m 5660(2) 6.31
9.0 m 6470(2) 4850(2) 7.96
7.5 m 7770(2) 7400 4890(2) 4480(2) 9.07
6.0 m 8270(2) 7380 7030(2) 5180 4320(2) 4190 9.83
4.5 m 8680(2) 7170 7200(2) 5160 4300(2) 3730 10.32
3.0 m 9310(2) 6910 7500(2) 5040 4620(2) 3520 4410(2) 3470 10.57
1.5 m 10060(2) 6630 7600(2) 4840 5440(2) 3430 4640(2) 3360 10.6
0.0 m 9880 6390 7460 4570 5020(2) 3390 10.41
−1.5 m 9770 6070 7300 4350 5640(2) 3580 10.0
−3.0 m 9680 5740 6740(2) 4220 5430(2) 4000 9.32
-4.5 m 7880(2) 5630 4310(2) 8.33
-6.0 m
(1) “ISO 10567” “SAE J1097”
64 SEBU8045-03
General Information
Table 46
330D L and 330D LN Excavators with a 3.1 m (10 ft) VA stub boom, a 3.5 m (10 ft 6 inch) VA fore boom, a 2.15
m (7 ft 1 inch) short stick, a quick coupler, and 700 mm (2 ft 3 inch) triple grouser track shoes.(1)
Mode: Heavy Lift
R
1.5 m 3.0 m 4.5 m
H
F S F S F S
9.0 m 9520(2)
7.5 m 12100(2)
6.0 m 19020(2) 14770(2)
4.5 m 21320(2) 16640(2) 14730
3.0 m 22010(2) 18150(2) 14110
1.5 m 18870(2) 18170(2) 13500
0.0 m 18810(2) 18270(2) 12790
−1.5 m 20650(2) 19850(2) 18570(2) 12380
−3.0 m 18820(2) 23130(2) 17700(2) 12400
-4.5 m 23160(2) 19120(2) 10620(2)
R
H
F S F S F S m
9.0 m 9540(2) 5.49
7.5 m 10470(2) 10100(2) 9580(2) 7420 7.02
6.0 m 11630(2) 9980 9440(2) 6630 8980(2) 5770 7.98
4.5 m 12530(2) 9600 9790(2) 6600 8130(2) 4920 8.57
3.0 m 13190(2) 9210 10020(2) 6400 7510(2) 4480 8.87
1.5 m 13300(2) 8830 9840(2) 6080 7310(2) 4320 8.91
0.0 m 13310 8380 9680(2) 5760 7500(2) 4400 8.68
−1.5 m 13540(2) 8030 9420 5520 6960(2) 4800 8.18
−3.0 m 11510(2) 7780 5600(2) 7.34
-4.5 m
(1) “ISO 10567” “SAE J1097”
SEBU8045-03 65
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Table 47
Mode: Heavy Lift
R
0.0 m 1.5 m 3.0 m 4.5 m
H
F S F S F S F S
10.5 m
9.0 m
7.5 m
6.0 m 12560(2)
4.5 m 22170(2) 16040 15120
3.0 m 22690 18040(2) 14560
1.5 m 22410 18580(2) 14060
0.0 m 12580 20130(2) 18570(2) 13370
−1.5 m 17900(2) 18120(2) 20790(2) 18780(2) 12800
−3.0 m 18080(2) 18780(2) 23450(2) 18570(2) 12620
-4.5 m 22160(2) 21860(2) 15030(2) 12670
R
H
F S F S F S F S m
10.5 m 10000(2) 4.35
9.0 m 8970 8060(2) 6.53
7.5 m 10090(2) 9060(2) 6940 7280(2) 6260 7.85
6.0 m 11160(2) 10220 9110(2) 7090 6330(2) 6980(2) 5100 8.72
4.5 m 12230 9890 9540(2) 6970 7730(2) 4780 6940(2) 4460 9.26
3.0 m 13180(2) 9490 10190(2) 6750(2) 7660(2) 4690 6830(2) 4130 9.54
1.5 m 13600(2) 9130 10050(2) 6530 7510(2) 4550 6690(2) 4000 9.58
0.0 m 13540(2) 8730 9880 6180 7320(2) 4380 6840(2) 4070 9.37
−1.5 m 13700(2) 8360 9760(2) 5850 6580(2) 4380 8.91
−3.0 m 13260(2) 8130 8450(2) 5700 5500(2) 5060 8.14
-4.5 m 8680(2) 8090
(1) “ISO 10567” “SAE J1097”
66 SEBU8045-03
General Information
Table 48
330D L and 330D LN Excavators with a 3.1 m (10 ft) VA stub boom, a 3.5 m (10 ft 6 inch) VA fore boom, a 3.2 m
(10 ft 6 inch) short stick, a quick coupler, and 700 mm (2 ft 3 inch) triple grouser track shoes.(1)
Mode: Heavy Lift
R
0.0 m 1.5 m 3.0 m 4.5 m
H
F S F S F S F S
10.5 m
9.0 m
7.5 m
6.0 m 10530(2)
4.5 m 22670(2) 15330 15300
3.0 m 23670 17520(2) 14650
1.5 m 24010 18540(2) 14020
0.0 m 12900(2) 21710(2) 18470(2) 13540
−1.5 m 16110(2) 18070(2) 21690(2) 18620(2) 12850
−3.0 m 18120(2) 19010(2) 23760(2) 18720(2) 12570
-4.5 m 21810(2) 25480(2) 16670(2) 12620
R
H
F S F S F S F S m
10.5 m 7570(2) 4.99
9.0 m 8960 6270(2) 6.97
7.5 m 9940(2) 8630(2) 7110 5760(2) 8.22
6.0 m 10730(2) 10290 8800(2) 7210 5970(2) 5570(2) 4820 9.05
4.5 m 11720 10000 9220(2) 7050 7640(2) 4900 5580(2) 4240 9.58
3.0 m 12900(2) 9570 9880(2) 6800(2) 7680(2) 4800 5760(2) 3920 9.85
1.5 m 13490(2) 9170 10040(2) 6560 7560(2) 4610 6130(2) 3790 9.88
0.0 m 13480(2) 8810 9870 6260 7360(2) 4410 6480(2) 3840 9.68
−1.5 m 13560(2) 8380 9790(2) 5900 7210 4270 6590(2) 4100 9.23
−3.0 m 13650(2) 8180 9450(2) 5670 5740(2) 4670 8.5
-4.5 m 10350(2) 7970
(1) “ISO 10567” “SAE J1097”
SEBU8045-03 67
General Information
Table 49
Mode: Heavy Lift
R
0.0 m 1.5 m 3.0 m 4.5 m
H
F S F S F S F S
10.5 m
9.0 m
7.5 m
6.0 m 10530(2)
4.5 m 10630(2)
3.0 m 25000 16410(2) 14820
1.5 m 10700 23890 18110(2) 14240
0.0 m 10040(2) 12040(2) 25500(2) 18330(2) 13720
−1.5 m 12830(2) 15770(2) 23590(2) 18360(2) 12980
−3.0 m 16190(2) 19520(2) 24580(2) 18650(2) 12520
-4.5 m 19070 21640(2) 27310(2) 25080 17980(2) 12440
-6.0 m 27190(2) 21190 12620 12540
R
H
10.5 m 6710(2) 5660(2) 6.31
9.0 m 7910 6470 4850(2) 7.96
7.5 m 7870(2) 7770(2) 7350 4890(2) 4480(2) 9.07
6.0 m 8530(2) 8270(2) 7330 7030(2) 5140 4320(2) 4160 9.83
4.5 m 10560 10070 8680(2) 7120 7200(2) 5120 4300(2) 3700 10.32
3.0 m 12270(2) 9710 9310(2) 6860(2) 7500(2) 5000 4920(2) 3490 4410(2) 3430 10.57
1.5 m 13150(2) 9240 9990(2) 6590 7540(2) 4800 5440(2) 3390 4640(2) 3320 10.6
0.0 m 13370(2) 8880 9850 6340 7420(2) 4530 5020(2) 3350 10.41
−1.5 m 13350(2) 8430 9700(2) 6020 7240 4310 5640(2) 3540 10.0
−3.0 m 13550(2) 8120 9610(2) 5690 6740(2) 4180 5430(2) 3960 9.32
-4.5 m 12520(2) 7920 7880(2) 5580 4310(2) 8.33
(1) “ISO 10567” “SAE J1097”
68 SEBU8045-03
General Information
Table 50
m (7 ft 1 inch) short stick, a quick coupler, and 600 mm (2 ft) triple grouser track shoes.(1)
Mode: Heavy Lift
R
1.5 m 3.0 m 4.5 m
H
F S F S F S
9.0 m 9520(2)
7.5 m 12100(2)
6.0 m 19020 14770(2) 14220
4.5 m 21320(2) 16640(2) 13630
3.0 m 22010(2) 18150(2) 12910
1.5 m 18870(2) 18170(2) 12270
0.0 m 18810(2) 18270(2) 11410
−1.5 m 20650(2) 19850(2) 18570(2) 11020
−3.0 m 18820(2) 23130(2) 21620 17700(2) 11030
-4.5 m 23160(2) 19120(2) 10620(2)
R
H
F S F S F S m
9.0 m 9540(2) 5.49
7.5 m 10470(2) 9330 9580(2) 6750 7.02
6.0 m 11630(2) 9200(2) 9440(2) 6020 8980(2) 5220 7.98
4.5 m 12530(2) 8860 9790(2) 5980 8020(2) 4420 8.57
3.0 m 13190(2) 8470 9900(2) 5790 7410(2) 4010 8.87
1.5 m 13300(2) 8040 9720(2) 5480 7210(2) 3850 8.91
0.0 m 13310 7530 9560(2) 5160 7400(2) 3920 8.68
−1.5 m 13540(2) 7190 9300 4930 6960 4270 8.18
−3.0 m 11510(2) 6950 5600(2) 5110 7.34
-4.5 m
(1) “ISO 10567” “SAE J1097”
SEBU8045-03 69
General Information
Table 51
330D L and 330D LN Excavators with a 3.1 m (10 ft) VA stub boom, a 3.5 m (10 ft 6 inch) VA fore boom, a
medium short stick, a quick coupler, and 600 mm (2 ft) triple grouser track shoes.(1)
Mode: Heavy Lift
R
0.0 m 1.5 m 3.0 m 4.5 m
H
F S F S F S F S
10.5 m
9.0 m
7.5 m
6.0 m 12560(2)
4.5 m 22170 16040(2) 14030
3.0 m 22690 18040(2) 13390
1.5 m 22410 18580(2) 12810
0.0 m 12580(2) 20130(2) 18570(2) 11980
−1.5 m 17900(2) 18120(2) 20790(2) 18780(2) 11420
−3.0 m 18080(2) 18780(2) 23450(2) 21970 18570(2) 11250
-4.5 m 22160(2) 21860(2) 15030(2) 11300
R
H
F S F S F S F S m
10.5 m 10000(2) 4.35
9.0 m 8970 8060(2) 7940 6.53
7.5 m 10090(2) 9630 9060(2) 6320 7280(2) 5690 7.85
6.0 m 11160(2) 9470 9110(2) 6490 7030(2) 6980(2) 4610 8.72
4.5 m 12230 9150 9540(2) 6410 7650(2) 4310 6940(2) 4020 9.26
3.0 m 13180(2) 8770 10100(2) 6210(2) 7570(2) 4230 6740(2) 3700 9.54
1.5 m 13600(2) 8350 9930(2) 5920 7410(2) 4080 6600(2) 3580 9.58
0.0 m 13540(2) 7880 9800 5580 7220(2) 3920 6750(2) 3640 9.37
−1.5 m 13700(2) 7510 9640(2) 5250 6580(2) 3910 8.91
−3.0 m 13260(2) 7290 8450(2) 5100 5500(2) 4530 8.14
-4.5 m 8680(2) 7250
(1) “ISO 10567” “SAE J1097”
70 SEBU8045-03
General Information
Table 52
330D L and 330D LN Excavators with a 3.1 m (10 ft) VA stub boom, a 3.5 m (10 ft 6 inch) VA fore boom, a
medium short stick, a quick coupler, and 600 mm (2 ft) triple grouser track shoes.(1)
Mode: Heavy Lift
R
0.0 m 1.5 m 3.0 m 4.5 m
H
F S F S F S F S
10.5 m
9.0 m
7.5 m
6.0 m 10530(2)
4.5 m 22670 15330(2) 14100
3.0 m 23670 17520(2) 13470
1.5 m 24010 18540(2) 12920
0.0 m 12900(2) 21710(2) 18470(2) 12140
−1.5 m 16110(2) 18070(2) 21690(2) 18620(2) 11470
−3.0 m 18120(2) 19010(2) 23760(2) 21840 18720(2) 11200
-4.5 m 21810(2) 25480(2) 22200 16670(2) 11250
R
H
F S F S F S F S m
10.5 m 7570(2) 4.99
9.0 m 8960 6270(2) 6.97
7.5 m 9940(2) 9710 8630(2) 6520 5760(2) 5310 8.22
6.0 m 10730(2) 9550 8800(2) 6640 5970(2) 4410 5570(2) 4350 9.05
4.5 m 11720 9240 9220(2) 6500 7640(2) 4430 5580(2) 3810 9.58
3.0 m 12900(2) 8840 9880(2) 6270(2) 7610(2) 4330 5760(2) 3510 9.85
1.5 m 13490(2) 8410 9950(2) 6000 7460(2) 4140 6130(2) 3380 9.88
0.0 m 13480(2) 7960 9750 5660 7260(2) 3950 6390(2) 3420 9.68
−1.5 m 13560(2) 7530 9660(2) 5300 7110 3810 6590(2) 3650 9.23
−3.0 m 13650(2) 7340 9440(2) 5070 5740(2) 4180 8.5
-4.5 m 10350(2) 7140
(1) “ISO 10567” “SAE J1097”
SEBU8045-03 71
General Information
Table 53
m (12 ft 10 inch) long stick, a quick coupler, and 600 mm (2 ft) triple grouser track shoes.(1)
Mode: Heavy Lift
R
0.0 m 1.5 m 3.0 m 4.5 m
H
F S F S F S F S
10.5 m
9.0 m
7.5 m
6.0 m
4.5 m 10630(2)
3.0 m 25000 16410(2) 13710
1.5 m 10700 23890 18110(2) 12960
0.0 m 10040(2) 12040(2) 25500(2) 23740 18330(2) 12470
−1.5 m 12830(2) 15770(2) 23590(2) 22280 18360(2) 11600
−3.0 m 16190(2) 19520(2) 24580(2) 21720 18650(2) 11150
-4.5 m 19070 21640(2) 27310(2) 21770 17980(2) 11070
-6.0 m 27190(2) 21190 12620 11170
R
H
10.5 m 6710(2) 5660(2) 6.31
9.0 m 7910 6470 4850(2) 7.96
7.5 m 7870(2) 7770(2) 6790 4890(2) 4550 4480(2) 4460 9.07
6.0 m 8530(2) 8270(2) 6790 7030(2) 4680 4320(2) 3740 9.83
4.5 m 10560 9350 8680(2) 6590 7200(2) 4670 4300(2) 3310 10.32
3.0 m 12270(2) 8970 9310(2) 6340(2) 7500(2) 4530 4920(2) 3110 4410(2) 3060 10.57
1.5 m 13150(2) 8540 9900(2) 6070 7460(2) 4330 5440(2) 3010 4640(2) 2950 10.6
0.0 m 13370(2) 8120 9720 5730 7330(2) 4070 5020(2) 2970 10.41
−1.5 m 13350(2) 7590 9570(2) 5420 7140 3850 5640(2) 3140 10.0
−3.0 m 13550(2) 7280 9480(2) 5090 6740(2) 3720 5430(2) 3520 9.32
-4.5 m 12520(2) 7090 7880(2) 4980 4310(2) 4270 8.33
-6.0 m
(1) “ISO 10567” “SAE J1097”
72 SEBU8045-03
General Information
330D High Wide Undercarriage

Table 54
330D L and 330D LN Excavators with a 6.18 m (20 ft 3 inch) boom, a 2.15 m (7 ft 1 in) short stick, a
R
H
7.5 m 8770(2) 8740(2) 6.72
6.0 m 9230(2) 8580(2) 7780 8560(2) 7470 7.67
4.5 m 13230(2) 10350(2) 8960(2) 7590 8590(2) 6470 8.24
3.0 m 16110(2) 15830 11680(2) 10260 9570(2) 7310 8500 5980 8.51
1.5 m 17750(2) 14980 12720(2) 9780 10090 7060 8360(2) 5850 8.51
0.0 m 17850(2) 14720 13120(2) 9510 9970(2) 6910 8690(2) 6050 8.24
−1.5 m 17990(2) 16860(2) 14760 12700(2) 9460 9730(2) 6910 9420(2) 6720 7.66
−3.0 m 18830(2) 14700(2) 11100(2) 9650 9500(2) 8290 6.7
−4.5 m 10360(2) 8820(2) 5.13
(1) “ISO 10567” “SAE J1097”
Table 55
330D L and 330D LN Excavators with a 6.18 m (20 ft 3 inch) mass boom, a medium stick, a quick
R
H
7.5 m 6370(2) 7.26
6.0 m 8650(2) 8070(2) 7860 6150(2) 8.15
4.5 m 18780(2) 12330(2) 9820(2) 8550(2) 7640 6210(2) 5930 8.69
3.0 m 15340(2) 11240(2) 10350 9250(2) 7340 6490(2) 5510 8.95
1.5 m 17380(2) 15140 12430(2) 9830 9880 7060 7040(2) 5390 8.94
0.0 m 9550(2) 17190(2) 14740 13030(2) 9510 9940(2) 6870 7980(2) 5560 8.68
−1.5 m 17190(2) 17260(2) 14690 12840(2) 9400 9880(2) 6820 8790(2) 6100 8.13
−3.0 m 19090(2) 15460(2) 14900 11630(2) 9510 8950(2) 7310 7.24
−4.5 m 15670(2) 15680(2) 11850(2) 8600(2) 5.83
(1) “ISO 10567” “SAE J1097”
SEBU8045-03 73
General Information
Table 56
330D L and 330D LN Excavators with a 6.5 m (21 ft 4 inch) reach boom, a 2.15 m (7 ft 1 inch) short
stick, a quick coupler, and 700 mm (2 ft 3 inch) triple grouser track shoes.(1)
R
H
7.5 m 8130(2) 7.09
6.0 m 8900(2) 8120(2) 7760 8020(2) 6920 8.0
4.5 m 13260(2) 10120(2) 8630(2) 7510 8090(2) 6030 8.55
3.0 m 16220(2) 15360 11490(2) 10060 9300(2) 7200 7980(2) 5590 8.81
1.5 m 16830(2) 14620 12540(2) 9570 9880(2) 6930 7840(2) 5470 8.81
0.0 m 17590(2) 14450 12950(2) 9320 9830(2) 6770 8130(2) 5640 8.54
−1.5 m 15720(2) 16680(2) 14530 12640(2) 9280 9810(2) 6760 8970(2) 6210 7.98
−3.0 m 18240(2) 14840(2) 14800 11380(2) 9450 9210(2) 7510 7.07
−4.5 m 11360(2) 8930(2) 5.61
(1) “ISO 10567” “SAE J1097”
74 SEBU8045-03
General Information
Table 57
330D L and 330D LN Excavators with a 6.5 m (21 ft 4 inch) reach boom, a medium short stick, a
R
3.0 m 4.5 m 6.0 m
H
F S F S F S
9.0 m
7.5 m
6.0 m
4.5 m 12290(2) 9660(2)
3.0 m 15470(2) 11190(2) 10480
1.5 m 17570(2) 15280 12470(2) 9970
0.0 m 18140(2) 14910 13160(2) 9650
−1.5 m 12980(2) 17640(2) 14870 13140(2) 9540
−3.0 m 18330(2) 16190(2) 15030 12270(2) 9600
-4.5 m 17760(2) 13370(2) 9660(2) 9890
R
H
F S F S F S m
9.0 m 7530(2) 6.66
7.5 m 7510(2) 6930(2) 7.92
6.0 m 7700(2) 6720(2) 6130 8.74
4.5 m 8330(2) 7780 7660(2) 5740 6760(2) 5470 9.24
3.0 m 9130(2) 7470 7910(2) 5600 7020(2) 5130 9.48
1.5 m 9860(2) 7190 7760(2) 5460 7160(2) 5040 9.48
0.0 m 10050 6990 7660(2) 5370 7380(2) 5180 9.23
−1.5 m 9960(2) 6920 8010 5610 8.72
−3.0 m 9350(2) 6990 8560(2) 6540 7.9
-4.5 m 8450(2) 6.63
(1) “ISO 10567” “SAE J1097”
SEBU8045-03 75
General Information
Table 58
R
1.5 m 3.0 m 4.5 m
H
F S F S F S
9.0 m
7.5 m
6.0 m
4.5 m
3.0 m 14590(2)
1.5 m 17030(2) 15430
0.0 m 8030(2) 18010(2) 14920
−1.5 m 9350(2) 13390(2) 17840(2) 14780
−3.0 m 14670(2) 18650(2) 16680(2) 14890
-4.5 m 19500(2) 14290(2)
R
H
F S F S F S F S m
9.0 m 5890(2) 7.07
7.5 m 6970(2) 5490(2) 8.27
6.0 m 7260(2) 5760(2) 5370(2) 9.05
4.5 m 9110(2) 7940(2) 7840 7310(2) 5780 5440(2) 5210 9.54
3.0 m 10700(2) 10590 8790(2) 7520 7720(2) 5620 5680(2) 4890 9.78
1.5 m 12110(2) 10030 9600(2) 7210 7760(2) 5460 6120(2) 4790 9.77
0.0 m 12970(2) 9660 10040 6980 7630(2) 5340 6840(2) 4900 9.54
−1.5 m 13150(2) 9490 9920(2) 6870 7600 5310 7550 5270 9.04
−3.0 m 12530(2) 9510 9670(2) 6890 8380(2) 6060 8.25
-4.5 m 10730(2) 9720 8510(2) 7760 7.04
(1) “ISO 10567” “SAE J1097”
76 SEBU8045-03
General Information
Table 59
330D L and 330D LN Excavators with a 6.5 m (21 ft 4 in) reach boom, a 3.9 m (12 ft 10 in) long stick,
R
1.5 m 3.0 m 4.5 m
H
F S F S F S
9.0 m
7.5 m
6.0 m
4.5 m
3.0 m 14590(2)
1.5 m 17030(2) 15430
0.0 m 8030(2) 18010(2) 14920
−1.5 m 9350(2) 13390(2) 17840(2) 14780
−3.0 m 14670(2) 18650(2) 16680(2) 14890
-4.5 m 19500(2) 14290(2)
R
H
F S F S F S F S m
9.0 m 5890(2) 7.07
7.5 m 6970(2) 5490(2) 8.27
6.0 m 7260(2) 5760(2) 5370(2) 9.05
4.5 m 9110(2) 7940(2) 7840 7310(2) 5780 5440(2) 5210 9.54
3.0 m 10700(2) 10590 8790(2) 7520 7720(2) 5620 5680(2) 4890 9.78
1.5 m 12110(2) 10030 9600(2) 7210 7760(2) 5460 6120(2) 4790 9.77
0.0 m 12970(2) 9660 10040 6980 7630(2) 5340 6840(2) 4900 9.54
−1.5 m 13150(2) 9490 9920(2) 6870 7600 5310 7550 5270 9.04
−3.0 m 12530(2) 9510 9670(2) 6890 8380(2) 6060 8.25
-4.5 m 10730(2) 9720 8510(2) 7760 7.04
(1) “ISO 10567” “SAE J1097”
SEBU8045-03 77
General Information
Table 60
330D L and 330D LN Excavators with a 6.5 m (21 ft 4 in) reach boom, a 3.9 m (12 ft 10 in) long stick,
R
1.5 m 3.0 m 4.5 m
H
F S F S F S
9.0 m
7.5 m
6.0 m
4.5 m
3.0 m 12940(2)
1.5 m 15860(2) 15740
0.0 m 8320(2) 17500(2) 14980
−1.5 m 7820(2) 11980(2) 17910(2) 14680
−3.0 m 12020(2) 16890(2) 17280(2) 14660
-4.5 m 17050 21190(2) 15540(2) 14880
-6.0 m 16680(2) 12090(2)
R
H
F S F S F S F S m
9.0 m 4550(2) 8.04
7.5 m 4770(2) 9.1
6.0 m 6460(2) 6340(2) 5990 4150(2) 9.83
4.5 m 7200(2) 6690(2) 5850 4180(2) 10.28
3.0 m 9760(2) 8140(2) 7600 7200(2) 5650 4320(2) 10.49
1.5 m 11360(2) 10140 9070(2) 7240 7720(2) 5450 4600(2) 4240 10.49
0.0 m 12500(2) 9680 9790(2) 6960 7590(2) 5290 5050(2) 4310 10.27
−1.5 m 13010(2) 9420 9840(2) 6790 7490 5200 5770 4590 9.81
−3.0 m 12790(2) 9350 9790(2) 6740 7510 5220 6980(2) 5150 9.09
-4.5 m 11630(2) 9460 8770(2) 6860 7770(2) 6280 8.01
-6.0 m 8680(2) 7670(2) 6.42
(1) “ISO 10567” “SAE J1097”
78 SEBU8045-03
General Information
Table 61
330D L and 330D LN Excavators with a 6.18 m (20 ft 3 inch) mass boom, a 2.15 m (7 ft 1 inch) short
Mode: Heavylift
R
H
7.5 m 9080(2) 9050(2) 6.72
6.0 m 9560(2) 8890(2) 7780 8870(2) 7470 7.67
4.5 m 13690(2) 10720(2) 9290(2) 7590 8910(2) 6470 8.24
3.0 m 16690(2) 15830 12100(2) 10260 9920(2) 7310 8500(2) 5980 8.51
1.5 m 18390(2) 14980 13180(2) 9780 10140(2) 7060 8360(2) 5850 8.51
0.0 m 18500(2) 14720 13600(2) 9510 9970(2) 6910 8690(2) 6050 8.24
−1.5 m 18510(2) 17480(2) 14760 13170(2) 9460 9970(2) 6910 9690(2) 6720 7.66
−3.0 m 19380(2) 15250(2) 15050 11520(2) 9650 9870(2) 8290 6.7
−4.5 m 10770(2) 9180(2) 5.13
(1) “ISO 10567” “SAE J1097”
Table 62
330D L and 330D LN Excavators with a 6.18 m (20 ft 3 inch) mass boom, a medium stick, a quick
Mode: Heavylift
R
H
7.5 m 6570(2) 7.26
6.0 m 8960(2) 8360(2) 7860 6350(2) 8.15
4.5 m 19420 12760(2) 10180(2) 8870(2) 7640 6410(2) 5930 8.69
3.0 m 15880(2) 11650(2) 10350 9590(2) 7340 6700(2) 5510 8.95
1.5 m 18000(2) 15140 12890(2) 9830 10140(2) 7060 7270(2) 5390 8.94
0.0 m 9850 18560(2) 14740 13510(2) 9510 9940(2) 6870 7990(2) 5560 8.68
−1.5 m 17690(2) 17700 17890(2) 14690 13320(2) 9400 9880(2) 6820 8790(2) 6100 8.13
−3.0 m 19640(2) 16030(2) 14900 12070(2) 9510 9300(2) 7310 7.24
−4.5 m 16290 12310(2) 8950(2) 5.83
(1) “ISO 10567” “SAE J1097”
SEBU8045-03 79
General Information
Table 63
330D L and 330D LN Excavators with a 6.5 m (21 ft 4 inch) mass boom, a 2.15 m (7 ft 1 inch) short
Mode: Heavylift
R
H
7.5 m 8430(2) 7.09
6.0 m 9220(2) 8420(2) 7760 8330(2) 6920 8.0
4.5 m 13730(2) 10480(2) 8950(2) 7510 8390(2) 6030 8.55
3.0 m 16810(2) 15360 11910(2) 10060 9650(2) 7200 7980(2) 5590 8.81
1.5 m 17320(2) 14620 13000(2) 9570 10000(2) 6930 7840(2) 5470 8.81
0.0 m 18240(2) 14450 13440(2) 9320 9830(2) 6770 8130(2) 5640 8.54
−1.5 m 16190(2) 17300(2) 14530 13110(2) 9280 9810(2) 6760 8970(2) 6210 7.98
−3.0 m 18760(2) 15400(2) 14800 11810(2) 9450 9570(2) 7510 7.07
−4.5 m 11810(2) 9290(2) 5.61
(1) “ISO 10567” “SAE J1097”
80 SEBU8045-03
General Information
Table 64
330D L and 330D LN Excavators with a 6.5 m (21 ft 4 inch) reach boom, a medium short stick, a
Mode: Heavylift
R
3.0 m 4.5 m 6.0 m
H
F S F S F S
9.0 m
7.5 m
6.0 m
4.5 m 12710(2) 10000(2)
3.0 m 16020(2) 11590(2) 10480
1.5 m 18200(2) 15280 12920(2) 9970
0.0 m 18790(2) 14910 13640(2) 9650
−1.5 m 13370(2) 18280(2) 14870 13620(2) 9540
−3.0 m 18860(2) 16780(2) 15030 12720(2) 9600
-4.5 m 18430(2) 13870(2) 10340(2) 9890
R
H
F S F S F S m
9.0 m 7770(2) 6.66
7.5 m 7780(2) 7150(2) 7.92
6.0 m 7980(2) 6940(2) 6130 8.74
4.5 m 8640(2) 7780 7940(2) 5740 6980(2) 5470 9.24
3.0 m 9470(2) 7470 7910(2) 5600 7240(2) 5130 9.48
1.5 m 10220(2) 7190 7760(2) 5460 7160(2) 5040 9.48
0.0 m 10050 6990 7660(2) 5370 7380(2) 5180 9.23
−1.5 m 9960(2) 6920 8010 5610 8.72
−3.0 m 9700(2) 6990 8890(2) 6540 7.9
-4.5 m 8790(2) 8610(2) 6.63
(1) “ISO 10567” “SAE J1097”
SEBU8045-03 81
General Information
Table 65
Mode: Heavylift
R
1.5 m 3.0 m 4.5 m
H
F S F S F S
9.0 m
7.5 m
6.0 m
4.5 m
3.0 m 15110(2)
1.5 m 17640(2) 15430
0.0 m 8280(2) 18660(2) 14920
−1.5 m 9640(2) 13790(2) 18480(2) 14780
−3.0 m 15110(2) 19190(2) 17290(2) 14890
-4.5 m 20220(2) 14820(2)
R
H
F S F S F S F S m
9.0 m 6080(2) 7.07
7.5 m 7220(2) 5670(2) 8.27
6.0 m 7530(2) 5950(2) 5880 5550(2) 9.05
4.5 m 9440(2) 8230(2) 7840 7580(2) 5780 5630(2) 5210 9.54
3.0 m 11090(2) 10590 9120(2) 7520 7940(2) 5620 5870(2) 4890 9.78
1.5 m 12550(2) 10030 9960(2) 7210 7760(2) 5460 6320(2) 4790 9.77
0.0 m 13440(2) 9660 10040 6980 7630(2) 5340 7010(2) 4900 9.54
−1.5 m 13630(2) 9490 9920(2) 6870 7600 5310 7550 5270 9.04
−3.0 m 13000(2) 9510 9940(2) 6890 8690(2) 6060 8.25
-4.5 m 11140(2) 9720 8840(2) 7760 7.04
(1) “ISO 10567” “SAE J1097”
82 SEBU8045-03
General Information
Table 66
Mode: Heavylift
R
1.5 m 3.0 m 4.5 m
H
F S F S F S
9.0 m
7.5 m
6.0 m
4.5 m
3.0 m 13400(2)
1.5 m 16430(2) 15740
0.0 m 8580(2) 18130(2) 14980
−1.5 m 8070(2) 12340(2) 18550(2) 14680
−3.0 m 12390(2) 17400(2) 17910(2) 14660
-4.5 m 17560 21800(2) 21810(2) 16120(2) 14880
-6.0 m 17330(2) 12560(2)
R
H
F S F S F S F S m
9.0 m 4710(2) 8.04
7.5 m 4930 4410(2) 9.1
6.0 m 6700(2) 6580(2) 5990 4300(2) 9.83
4.5 m 7480(2) 6950(2) 5850 4330(2) 10.28
3.0 m 10120(2) 8450(2) 7600 7480(2) 5650 4480(2) 4320 10.49
1.5 m 11780(2) 10140 9410(2) 7240 7760(2) 5450 4760(2) 4240 10.49
0.0 m 12970(2) 9680 10030 6960 7590(2) 5290 5230(2) 4310 10.27
−1.5 m 13490(2) 9420 9840(2) 6790 7490 5200 5970(2) 4590 9.81
−3.0 m 13270(2) 9350 9790(2) 6740 7510 5220 7220(2) 5150 9.09
-4.5 m 12070(2) 9460 9110 6860 8080(2) 6280 8.01
-6.0 m 9030(2) 7990(2) 6.42
(1) “ISO 10567” “SAE J1097”
SEBU8045-03 83
Identification Information
Identification Information • PIN__________________________________________________________

• Power (kW)_______________________________________________
i02346114
• Weight (kg)________________________________________________
Plate Locations and Film
Locations • Year of Manufacture_____________________________________
SMCS Code: 1000; 7000 Certification
The Product Identification Number (PIN) will be used
to identify a powered machine that is designed for
Machine Security System
an operator to ride.
If equipped, this message is used to verify the
certification of the Machine Security System as a
Caterpillar products such as engines, transmissions
RF transmitter. The following specifications are
and major attachments that are not designed for an
provided to aid in ensuring compliance with all local
operator to ride are identified by Serial Numbers.
regulations:
Product Identification Number Table 67
(PIN) and CE Plate Field strength(1) 16.12 dB micro-amp/meter

Operating frequency range 134.2 kHz
Note: The CE plate is only on machines that are
going into countries in the European Union. Operating time(2) 0.055 seconds (1/18
second)
(1) Field strength at 10 meters
(2) The operating time is measured after the key switch is first
activated.
This message is located on the control group for

the machine security system. The control group is
located in the engine compartment.
g01095268
Illustration 43
g00995393
Illustration 45
Consult your Caterpillar dealer with any questions

that concern the operation of the MSS in a specific
country.
g01048968
Illustration 44
This plate is positioned on the front of the machine,

close to the operator compartment.
• Model_______________________________________________________
84 SEBU8045-03
Sound A typical example is shown.
g00933634
Illustration 46
A typical example of this film is shown. Your machine may have a
different value.
If equipped, the certification film is used to verify the

environmental sound certification of the machine.
The value that is listed on the film indicates the
guaranteed sound power level. The guaranteed
sound power level is measured at the time of
manufacture. The guaranteed sound power level
is measured according to the conditions that are
specified in “2000/14/EC”.
Product Link
If equipped, this message is used to verify the
certification of the Product Link as a RF transmitter.
This message is located on the control group for the

product link.
g01040349
Illustration 47
i01830750
Emissions Certification Film

SMCS Code: 1000; 7000; 7405
Note: This information is pertinent in the United

States, in Canada and in Europe.
SEBU8045-03 85
g00776690
Illustration 48
86 SEBU8045-03
Operation Section
Before Operation
Operation Section i02208352
Daily Inspection
Before Operation SMCS Code: 1000; 6319; 6700; 7000
i02189821
Mounting and Dismounting

SMCS Code: 6700; 7000
g00102482
Illustration 50
For maximum service life of the machine, perform a

thorough walk-around inspection before you mount
the machine and before you start the engine.
Illustration 49
g00037860 First 100 Hours
Typical example
Daily, perform the procedures that are applicable to
your machine:
Mount the machine and dismount the machine only
at locations that have steps and/or handholds. Before
you mount the machine, clean the steps and the
• Operation and Maintenance Manual, “Boom and
Stick Linkage - Lubricate”
handholds. Inspect the steps and handholds. Make
all necessary repairs.
• Operation and Maintenance Manual, “ Bucket
Linkage - Lubricate”
Face the machine whenever you get on the machine
and whenever you get off the machine.
Severe Applications
Maintain a three-point contact with the steps and with
the handholds. Daily, perform the procedures that are applicable to
your machine:
Note: Three-point contact can be two feet and one
hand. Three-point contact can also be one foot and • Operation and Maintenance Manual, “Boom and
two hands. Stick Linkage - Lubricate”
Do not mount a moving machine. Do not dismount a • Operation and Maintenance Manual, “ Bucket
moving machine. Never jump off the machine. Do Linkage - Lubricate”
not carry tools or supplies when you try to mount the
machine or when you try to dismount the machine. Daily Basis
Use a hand line to pull equipment onto the platform.
Do not use any controls as handholds when you Daily, perform the procedures that are applicable to
enter the operator compartment or when you exit the your machine:
operator compartment.
• Operation and Maintenance Manual, “Cooling
Alternate Exit System Coolant Level - Check”
Machines that are equipped with cabs have alternate • Operation and Maintenance Manual, “Engine Oil
exits. For additional information, see Operation and Level - Check”
Maintenance Manual, “Alternate Exit”.
• Operation and Maintenance Manual, “Fuel System
Water Separator - Drain”
SEBU8045-03 87
Operation Section
Before Operation
• Operation and Maintenance Manual, “Fuel Tank

Water and Sediment - Drain”
• Operation and Maintenance Manual, “Hydraulic

System Oil Level - Check”
• Operation and Maintenance Manual, “Indicators

and Gauges - Test”
• Operation and Maintenance Manual, “Seat Belt -

Inspect”
• Operation and Maintenance Manual, “Track

Adjustment - Inspect”
• Operation and Maintenance Manual, “Travel Alarm

- Test”
• Operation and Maintenance Manual,

“Undercarriage - Check”
Look around the machine and under the machine.

Look for trash buildup, loose bolts, trash, oil leaks,
coolant leaks, broken parts, or worn parts.
Inspect the condition of the attachment and of the

hydraulic components.

“Maintenance Interval Schedule” for all maintenance
recommendations.
Check all oil levels, coolant levels, and fuel levels.

88 SEBU8045-03
Operation Section
Machine Operation
Machine Operation
i01698894
Alternate Exit
SMCS Code: 7310
g00874725
Illustration 51
Hammer
Alternate Exit – The rear window serves

as an alternate exit.
g01098275
Illustration 52
Break Glass – Perform the following The operator can adjust the seat position forward or
procedure in order to exit through the rear backward. The operator may also adjust the seat
window: The hammer is mounted on the back tilt. Select the desired position in order to allow
left side of the cab. Strike the rear window with the full pedal travel and full lever travel.
hammer in order to break the glass. Climb through
the opening in the rear window in order to exit the The seat and the consoles can also slide as one unit.
cab.
i02346674
Seat
SMCS Code: 5258-025; 7312-025; 7324; 7327
Put the hydraulic lockout control in the LOCKED

position. For further details on this procedure, refer
to Operation and Maintenance Manual, “Operator
Controls”. Do this procedure before you adjust the
seat and the console. This will prevent any possibility
of unexpected movement of the machine.
Adjust the seat at the beginning of each work period

and adjust the seat when you change operators.
Always use the seat belt when you operate the

machine. For further details on this procedure, refer
to Operation and Maintenance Manual, “Seat Belt”.
The seat should be adjusted so that full pedal travel

is allowed.
SEBU8045-03 89
Operation Section
Machine Operation
Use handle (4) in order to adjust the height of the

seat. Place the handle in the operating position.
Turning the handle clockwise increases the height
of the seat. Turning the handle counterclockwise
decreases the height of the seat. If your machine is
equipped with a lever, pull up the lever in order to
raise the height of the seat. Push down on the lever
in order to lower the seat. If the adjustment is correct,
indicator (3) will turn green. If the indicator shows
red, further adjustment is required.
To adjust the seat forward or backward, pull up lever

(5) and hold the lever. Move the seat to the desired
position. To lock the seat in the selected position,
release the lever.
g01120894
Illustration 53
To adjust the seat back tilt, move lever (1) and move
the seat back to the desired position.
Pull up lever (2) in order to change the angle of the

seat. Hold the seat in the desired position. Release
the lever.
g01120893
Illustration 55
To move the seat, the left console, and the right

console forward or backward as one unit, pull up
lever (6) and hold the lever. Hold the seat in the
desired position. Release the lever in order to lock
the seat, the left console, and the right console.
To adjust the angle of the armrest, operate dial (7).

A dial is on the bottom of each armrest. Place the
armrests in the upright position when you enter the
machine or when you exit the machine.
The lumbar support is located in the back of the seat.

Illustration 54
g01120901 Turn knob (8) (if equipped) counterclockwise in order
to increase the force of the lumbar support. In order
to decrease the lumbar support, continue to turn the
knob counterclockwise.
The height of the armrest can be adjusted. Squeeze

lever (9) in order to adjust the height of the armrest.
Move the armrest upward or move the armrest
downward. Release the lever when the armrest is in
the desired position.
90 SEBU8045-03
Operation Section
Machine Operation
The operator can adjust the height of headrest (if

equipped). To adjust the headrest, hold the headrest
with both hands. Move the headrest up and down.
Release the headrest when the desired position is
attained. The headrest will remain in the desired
position.
i01822242
Seat Belt
SMCS Code: 7327
Note: This machine was equipped with a seat belt

when the machine was shipped from Caterpillar. Illustration 57
g00932817
At the time of installation, the seat belt and the
instructions for installation of the seat belt meet the 2. To remove the slack in outer loop (1), rotate buckle
SAE J386 standards. See your Caterpillar dealer for (2). This will free the lock bar. This permits the
all replacement parts. seat belt to move through the buckle.
Always check the condition of the seat belt and 3. Remove the slack from the outer belt loop by
the condition of the mounting hardware before you pulling on the buckle.
operate the machine.
4. Loosen the other half of the seat belt in the same
Seat Belt Adjustment for manner. If the seat belt does not fit snugly with the
buckle in the center, readjust the seat belt.
Non-Retractable Seat Belts
Adjust both ends of the seat belt. The seat belt should Shortening the Seat Belt
be snug but comfortable.
Lengthening the Seat Belt
g00100713
Illustration 58
1. Fasten the seat belt. Pull out on the outer belt loop
g00100709 in order to tighten the seat belt.
Illustration 56
2. Adjust the other half of the seat belt in the same
1. Unfasten the seat belt. manner.
3. If the seat belt does not fit snugly with the buckle
in the center, readjust the seat belt.
SEBU8045-03 91
Operation Section
Machine Operation
Fastening The Seat Belt Seat Belt Adjustment for

Retractable Seat Belts
Fastening The Seat Belt
g00932818
Illustration 59
Fasten the seat belt catch (3) into the buckle (2).
Make sure that the seat belt is placed low across the g00867598
lap of the operator. Illustration 61
Pull seat belt (4) out of the retractor in a continuous

Releasing The Seat Belt motion.
Fasten seat belt catch (3) into buckle (2). Make sure
that the seat belt is placed low across the lap of the
operator.
The retractor will adjust the belt length and the

retractor will lock in place. The comfort ride sleeve
will allow the operator to have limited movement.
Releasing The Seat Belt
g00100717
Illustration 60
Pull up on the release lever. This will release the seat

belt.
g00039113
Illustration 62
Push the release button on the buckle in order to

release the seat belt. The seat belt will automatically
retract into the retractor.
92 SEBU8045-03
Operation Section
Machine Operation
Extension of the Seat Belt
When using retractable seat belts, do not use seat

belt extensions, or personal injury or death can
result.
The retractor system may or may not lock up de-

pending on the length of the extension and the
size of the person. If the retractor does not lock
up, the seat belt will not retain the person.
Longer, non-retractable seat belts and extensions for

the non-retractable seat belts are available.
Caterpillar requires only non-retractable seat belts to

be used with a seat belt extension.
Consult your Caterpillar dealer for longer seat belts

and for information on extending the seat belts.
i02574091
Operator Controls
SMCS Code: 7300; 7301; 7451
Note: Your machine may not be equipped with all of

the controls that are described in this topic.
SEBU8045-03 93
Operation Section
Machine Operation
g01164538
Illustration 63
(1) Hydraulic Lockout Control (5) Joystick Controls (9) Operator’s Seat
(2) Travel Controls (6) Engine Speed Control (10) Radio
(3) Service Hour Meter (7) Engine Start Switch (11) Backup Controls
(4) Monitor (8) Right Side Control Panel
94 SEBU8045-03
Operation Section
Machine Operation
g01164592
Illustration 64
(12) Travel Speed Control (19) Light Switch
(13) Automatic Engine Speed Control (AEC) (20) Quick Coupler Control
(14) Travel Alarm Switch (21) Seat Heater
(15) Work Tool Control (22) Fine Swing Control
(16) Heavy Lift Control (23) Overload Warning Device
(17) Window Washer (24) Smart Boom Control
(18) Window Wiper (25) Air Conditioning and Heating Control
Hydraulic Lockout Control (1) Travel Control (2)

The lever for the hydraulic lockout control is located
at the left side of the left console.
Locked – Move the travel levers/pedals

and move the joysticks to the HOLD
(center) position. Move the lever for the
hydraulic lockout control backward to the LOCKED
position. This makes all of the factory installed
hydraulic controls inoperable.
Note: Make sure that the lever for the hydraulic

lockout control is in the LOCKED position before
attempting to start the engine. If the lever is in the
UNLOCKED position, the engine start switch will not g00753277
Illustration 65
function.
Position for normal travel
Unlocked – Move the lever for the (A) Rear of machine
hydraulic lockout control forward to the (B) Final drive
(C) Idler
UNLOCKED position. This makes all of the
factory installed hydraulic controls operable.
When you travel, make sure that final drive sprockets
(B) are under the rear of the machine.
Stop – Release the travel levers/pedals in order

to stop the machine. When you release the
travel levers/pedals from any position, the travel
levers/pedals will return to the CENTER position.
This applies the travel brakes.
SEBU8045-03 95
Operation Section
Machine Operation
Move both of the travel levers or both of the travel

pedals equally in the same direction in order to travel
straight.
g00731478
Illustration 69
Pivot Left Turn (Reverse)
g00731542
Illustration 66
Forward Travel
g00731476
Illustration 70
Counterrotate Turn (Left)
g00731543
Illustration 67
Reverse Travel
g00731471
Illustration 71
Pivot Right Turn (Forward)
g00731472
Illustration 68
Pivot Left Turn (Forward)
96 SEBU8045-03
Operation Section
Machine Operation
Engine Speed Control (6)

Engine Speed – Turn the engine speed
dial in order to control the engine speed
(engine rpm). Select the desired position
from the ten available positions. The selected position
of the engine speed dial is indicated on the electronic
monitor panel.
Decrease – Turn the engine speed dial

counterclockwise in order to decrease the
engine speed (engine rpm).
Increase – Turn the engine speed dial

g00731479
Illustration 72 clockwise in order to increase the engine
Pivot Right Turn (Reverse) speed (engine rpm).
Backup Method for Controlling Engine

Speed
If the control system does not work due to a
malfunction and the engine speed cannot be adjusted
by the engine speed dial, the following method will
allow you to adjust the engine speed temporarily.
Make repairs as soon as possible.
Check the message display for any error messages.

If the error message “ECM ERROR” is displayed,
there is a problem in the electronic controller. See
“Backup Controls”.
g00731477
Illustration 73
Counterrotate Turn (Right) If the engine speed cannot be adjusted by the
engine speed dial and the indicator for the electronic
controller does not come on, see “Backup Controls”.
Service Hour Meter (3)
Note: Even if you cannot control the engine speed,
Service Hour Meter – This display you can turn the engine on and off with the engine
indicates the total operating hours of the start switch.
engine. Use the display to determine the
service hour maintenance intervals.
Engine Start Switch (7)
Monitor (4) NOTICE
The engine start switch must be in the ON position
The monitor is used in order to display various and the engine must be running in order to maintain
operating information of the machine. For more electrical functions and hydraulic functions. This pro-
information on the operation of the monitor, refer to cedure must be followed in order to prevent serious
Operation and Maintenance Manual, “Monitoring machine damage.
System”.
OFF – Insert the engine start switch key

Joystick Controls (5) only while the start switch is in the OFF
The joystick control is used to control the functions of position. Remove the engine start switch
key only while the engine start switch is in the OFF
the machine implements. For more information on the
position. Turn the engine start switch to the OFF
individual functions of the joysticks, refer to Operation
and Maintenance Manual, “Joystick Controls”. position before you attempt to restart the engine.
Turn the engine start switch to the OFF position in
order to stop the engine.
SEBU8045-03 97
Operation Section
Machine Operation
On – To activate the electrical circuits in Manual – If a problem occurs in the

the cab, turn the key clockwise to the ON electronic control system, move backup
position. switch (26) to this position in order to
disconnect the controller circuit of the electronic
Start – To start the tractor engine, turn the controller system. In this condition, the machine can
key clockwise to the START position. After be operated at a reduced ratio of pump output on
the engine starts, release the key. The key a temporary basis. “BACK UP SWITCH ON” will
will return to the ON position. appear on the message display.
Note: If the engine fails to start, return the engine Fast Engine Speed – Move backup switch
start switch key to the OFF position. This must be (27) to this position in order to increase the
done before you attempt to start the engine again. engine speed. This backup switch will not
operate if backup switch (26) is not in the MANUAL
position. When the switch is released the switch
Operator’s Seat (9) returns to the NEUTRAL position and the machine
will maintain the engine speed. This switch overrides
The operator’s seat and the console has a variety the function of the engine speed dial.
of adjustments in order to meet a wide range of
operators. For more information, refer to Operation
Slow Engine Speed – Move backup
and Maintenance Manual, “Seat”.
switch (27) to this position in order to
decrease the engine speed. This backup
Radio (10) switch will not operate if backup switch (26) is not in
the MANUAL position. When the switch is released
This machine may be equipped with a radio. For more the switch returns to the NEUTRAL position and the
information, refer to Operation and Maintenance machine will maintain the engine speed. This switch
Manual, “Radio”. overrides the function of the engine speed dial.
Backup Controls (11) Travel Speed Control (12)
Do not change the setting of the travel speed con-

trol switch while you travel. Machine stability may
be adversely affected.
Personal injury can result from sudden changes

in machine stability.
Travel Speed Control Switch – Press the

travel speed control switch in order to select
automatic travel speed or low travel speed.
Illustration 74
g01125955 When the engine start switch is on, the travel speed
control switch is always set at the LOW SPEED
The backup switches are located under the right position. Whenever the travel speed control switch is
armrest. pressed, the travel speed changes.
Engine Speed Control – By utilizing Low Speed – Select the LOW SPEED
these switches, the engine speed can be position if you travel on rough surfaces or
controlled manually by the operator or the on soft surfaces or if you require a great
engine speed can be controlled automatically by the drawbar pull. Also, select the LOW SPEED position if
electronic controller. you are loading a machine onto a trailer or you are
unloading a machine from a trailer.
Automatic – When the electronic control
system is functioning properly, backup Automatic – If you travel on a hard, level
switch (26) should be in this position. surface at a fast speed, select the AUTO
position.
98 SEBU8045-03
Operation Section
Machine Operation
Continuous driving at high speed should be limited The manual low idle allows the operator to easily
to two hours. If you need to continue driving at high reduce the rpm without touching the engine speed
speed for more than two hours, stop the machine dial. This is useful when the operator wants to reduce
for ten minutes. This will cool down the travel drives the engine speed in order to talk to someone or while
before you resume driving. the operator is waiting for a truck.
Automatic Engine Speed Control Operation of the automatic engine speed control
depends on the position of the AEC switch and of
(13) the switch for manual low idle. The engine rpm will
recover automatically to the setting of the engine
The Automatic Engine Speed Control (AEC) speed dial when any hydraulic function is activated.
automatically reduces engine speed when the
machine is inactive. The AEC system is designed to
reduce fuel consumption and noise. Lower engine
speeds can also increase engine life.
The AEC system will be inoperable while the backup

switch of the electronic controller system is in the
MAN position.
The engine rpm will recover automatically to the

setting of the engine speed dial when any hydraulic
function is activated. The AEC system operates in
three modes. Refer to Table 68 for a description of
each mode.
Automatic Engine Speed Control

(AEC) – The Automatic Engine Speed
Control switch is activated when the engine
start switch is turned to the ON position. The indicator
lamp will turn on. When you press the AEC switch,
the function of the AEC switch changes from ON to
OFF, and vice versa. The operator can choose from
three possible modes for automatic engine speed
control. Refer to Table 68 for more details.
g01077282
Illustration 75
The switch for manual low idle is on the right joystick.
Manual Low Idle – Activate the manual low idle in

order to reduce the engine speed to approximately
1020 rpm. Pressing the switch again will allow the
engine speed to return to the original setting of the
engine speed dial.
SEBU8045-03 99
Operation Section
Machine Operation
Table 68
Position of AEC Setting of Engine Position of Manual
AEC Mode Description of Mode
Switch Speed Dial Low Idle Switch
The electronic controller automatically
reduces engine speed by 100 rpm after
First stage OFF 5 to 10 OFF
there has been no hydraulic demand for
approximately three seconds.
The AEC system in the electronic controller
will automatically reduce the engine
Second
ON 5 to 10 OFF rpm to approximately 1300 rpm after
stage
there has been no hydraulic demand for
approximately three seconds.
Manual low The engine speed is reduced to
ON or OFF 3 to 10 ON
Idle approximately 1020 rpm.
Travel Alarm Cancel Switch (14) Window Wiper and Window Washer
Travel Alarm Cancel Switch – This
(17-18)
switch is used to stop the travel alarm from
Window Washer (17) – Push the switch in
sounding. Press the switch in order to stop order to activate the window washer. While
the alarm. The indicator lamp will turn on.
the switch is depressed, the indicator light
will come on and washer fluid will spray from the
Note: The travel alarm is located under the hydraulic nozzle. The window wiper will also operate while the
tank. The travel alarm will sound when the travel switch is depressed. After the switch is released for
lever or the travel pedal is activated. approximately three seconds, the window wiper will
stop.
Work Tool Control (15)
Window Wiper (18) – Push the switch
Work Tool Control (Switch) – Press this in order to activate the window wiper.
switch in order to display the selected work Whenever the switch is depressed, the
tool on the monitor display. Press the switch mode of the window wiper will change according to
repeatedly in order to change the selected work tool. the indicator light that is illuminated.
Six Second Delay – When the window wiper switch

Heavy Lift Control (16) is depressed one time, the first indicator light will turn
Push this button in order to activate heavy lift mode. on. The window wiper will operate intermittently at
six second intervals.
Also push this button in order to deactivate heavy
lift mode.
Three Second Delay – When the window wiper
switch is depressed two times, the second indicator
Heavy Lift Mode – This work mode
light will turn on. The window wiper will operate
increases the relief pressure in the hydraulic
circuit, which increases the hydraulic force intermittently at three second intervals.
that is available for lifting operations. The cylinder
Continuous Operation – When the window wiper
speed is slower when this mode is selected.
switch is depressed three times, the first indicator
light and the second indicator light will turn on. The
Note: During normal excavation work, the heavy lift window wiper will operate continuously.
control must be in the OFF position.
OFF – When the window wiper switch is depressed
four times, the indicator lights will turn off. The
window wiper stops.
NOTICE
If the wiper does not operate with the switch in the
ON position, turn the switch off immediately. Check
the cause. If the switch remains on, motor failure can
result.
100 SEBU8045-03
Operation Section
Machine Operation
Quick Coupler Control (20)

NOTICE
If the washer is used continuously for more than 20 LOCK – Move the switch to this position in
seconds or used when no washer solution comes out, order to retract the wedge. The wedge must
motor failure can result. be retracted in order to lock the work tool
in place.
Light Switch (19) UNLOCKED – Move the switch to this

position in order to extend the wedge. The
wedge must be extended in order to release
the work tool.
Note: An alarm will sound whenever the switch is in

the UNLOCKED position.
For further details, see Operation and Maintenance

Manual, “Quick Coupler Operation”.
Seat Heater (21)
g01172131
Illustration 76
Preexisting skin conditions can be aggravated by
Light Switch – Push the switch in order continued use of the seat heater. If skin condition
to turn on the work lights. worsens, discontinue use of the seat heater.
Seat Heater – In cold weather, the seat

Whenever you push the switch, you change the heater can be activated in order to improve
pattern of the work lights that are turned on. The operator comfort.
indicator lights in the cab indicate the pattern of the
work lights.
ON – Push down on the top of the seat
Pattern 1 – When you press the light switch once, heater switch in order to activate the seat
the first indicator light turns on. When the first heater.
indicator light is on, the following work lights are
turned on: work light (D), which is mounted on the OFF – Push down on the bottom of the
chassis, and work lights (F), which are mounted on seat heater switch in order to deactivate
the cab. the seat heater.
Pattern 2 – When you press the light switch twice,

NOTICE
the first indicator light and the second indicator light
Do not leave any heavy item or object with a sharp
turn on. When the first indicator light and the second
point on the seat.
indicator lights are on, the following work lights are
turned on: work light (D), which is mounted on the
Do not cover the seat or seat back with a blanket, seat
chassis,, work lights (F), which are mounted on the
cushion or any other similar covering. The seat heater
cab,, and work lights (E), which are mounted on the
can be over heated. Be sure to remove any spills on
boom.
the seat and thoroughly dry the spill.
OFF – When both of the indicator lights are off, all
of the work lights are off. Note: The thermostat in the seat heater deactivates
when the temperature in the cab is above 10°C
Note: Your machine may be equipped with a lighting (50°F). The seat heater will not operate when the
system that has a time delay. When this system thermostat is deactivated.
is installed, cab lights (F) will not turn off for a
predetermined amount of time after the engine start
key has been turned to the OFF position. The time
delay can vary from 0 seconds to 90 seconds. For
further details, consult your Caterpillar dealer.
SEBU8045-03 101
Operation Section
Machine Operation
Fine Swing Control (22)

OFF – Push the left side of the switch in
order to deactivate the overload warning
device.
The Fine Swing Control delays the engagement of
the swing parking brake. Smart Boom Control (24)
If the machine is operating on a slope with the Fine This machine may be equipped with SmartBoom
Swing Control in the ON position, the swing mo- Control. For more information, refer to Operation and
tion may become uncontrollable which could re- Maintenance Manual, “SmartBoom Control”.
sult in property damage, personal injury or death.
Turn the Fine Swing Control to the OFF position Air Conditioning and Heating
when the machine is operating on a slope. Control (25)
The heater/air conditioner provides comfort for the
Fine Swing Control – Push down on the
operator that is working under various temperature
top of the switch in order to activate the fine
conditions. For more information on the air
swing control.
conditioning and heater controls, refer to Operation
and Maintenance Manual, “Air Conditioning and
When the fine swing control is ON, the swing parking Heating Control”.
brake will not activate until 6.5 seconds after the
joystick control for the swing function returns to
the neutral position. This improves swing control i01039307
during deceleration of a swing because this will
allow the swing to drift instead of stopping the swing
Battery Disconnect Switch
abruptly. This combination of drift and the delay of
SMCS Code: 1411-B11
the engagement of the swing parking brake may be
helpful during certain types of lifting operations.
Push down on the bottom of the switch in order to

turn off the fine swing control. Operate the machine
with the fine swing control in the OFF position when
the machine is on a slope. Operate the machine with
the fine swing control in the OFF position when great
swing forces are required. For example, digging
on a sidewall requires great swing force. Operate
the machine with the fine swing control in the OFF
position in order to control the motion with the swing
brake.
Overload Warning Device (23) g00100862

Illustration 77
The switch for the overload warning device is located
on the right console. The battery disconnect switch is on the left side of
the machine behind the front access door.
Overload Warning Device – In lifting
applications, the overload warning device
informs the operator when an unstable load
condition exists by activating a buzzer. When this
occurs, the bucket load should be reduced or the
stick should be moved inward.
ON – Push the right side of the switch

in order to activate the overload warning
device.
102 SEBU8045-03
Operation Section
Machine Operation
i02360669
Product Link
(If Equipped)
SMCS Code: 7490; 7606
Product Link is a satellite communication device

that transmits information regarding the machine to
Caterpillar and to Caterpillar dealers and customers.
The device contains a Global Positioning System and
a satellite transmitter/receiver. All logged events and
diagnostic codes that are available to the Caterpillar
Electronic Technician (ET) on the CAT data link
Illustration 78
g00406959 can be sent to the satellite. Information can also
be sent to the Product Link from the satellite. The
ON – To activate the electrical system, information that is sent by the Product Link goes to
insert the disconnect switch key and turn the satellite, and then to the receiving station. The
the battery disconnect switch clockwise. receiving station transmits the data to Caterpillar. The
The battery disconnect switch must be turned to the information can then be sent to Caterpillar dealers
ON position before you start the engine. and customers.
Note: Product Link is automatically activated when

OFF – To deactivate the electrical the battery disconnect switch is in the ON position.
system, turn the battery disconnect switch
counterclockwise to the OFF position. The system consists of three main components:
The battery disconnect switch operates differently • Hardware, which includes the following, data
than the engine start switch. When the battery module, antenna, wiring, and additional mounting
disconnect switch is in the OFF position, the electrical hardware.
system is disabled. When the engine start switch is
turned to the OFF position and the battery disconnect • Satellite System and Caterpillar Network
switch is turned to the ON position, the battery
remains connected to the entire electrical system. • PC Software
Turn the battery disconnect switch to the OFF
position and remove the disconnect switch key
when you service the electrical system or other
components on the machine.
Turn the battery disconnect switch to the OFF

position and remove the disconnect switch key if you
do not operate the machine for an extended period
of a month or more. This will prevent drainage of
the battery.
NOTICE
Never move the battery disconnect switch to the OFF
position while the engine is operating. Serious dam- Illustration 79
g01131288
age to the electrical system could result. Typical location
This machine is equipped with a Caterpillar Prod-

uct Link communication device which must be de-
activated within 12 m (40 ft) of a blast zone. Failure
to do so could result in serious injury or death.
SEBU8045-03 103
Operation Section
Machine Operation
If the machine is required to work within 12 m i02516088

(40 ft) of a blast area, then the operator must take
one of the following precautions: Power Receptacle
(If Equipped)
• Disconnect the Product Link module from the
power source by disconnecting the wiring harness SMCS Code: 1436; 7451
at the Product Link module.
• Temporarily remove the Product Link module from

the machine.
• Install an ON/OFF switch in order to allow the

Product Link module to be turned off from the
inside of the cab.
This warning does not supersede the published

requirements or the regulations that are found in “Title
30 of the Code of Federal Regulations (CFR)”. Every
operation of a mine should conduct an assessment of
hazards that meets all of the requirements of “Title 30
of the Code of Federal Regulations (CFR)”. This will
ensure safe operation in the storage, transportation, Illustration 81
g01258930
loading, and blasting of explosive material. The
following specifications are provided in order to Power Receptacle – A twelve volt power receptacle
aid in conducting assessments of hazards. These is located on the right side console. This power
specifications are also provided in order to aid in receptacle can be used for powering automotive
ensuring compliance with all local regulations: electrical equipment or accessories. Remove the cap
before use. This machine can be equipped with one
• The power of the transmitter for the Product Link is power receptacle or with two power receptacles.
5 to 10 Watts.
• The operating frequency range for the Product Link i02248431

is 148 - 150 MHz.
Machine Security System
Refer to System Operation, Troubleshooting, (If Equipped)
Testing and Adjusting, RENR7911, “Product Link
121SR/321SR” for more information about this SMCS Code: 7631
service tool.
Operation Section
Regulatory Compliance
NOTICE
This machine is equipped with a Caterpillar Machine
Security System (MSS) and may not start under cer-
tain conditions. Read the following information and
know your machine’s settings. Your Caterpillar deal-
er can identify your machine settings.
Machine Security System (MSS) –

Machines that are equipped with a
Caterpillar Machine Security System (MSS)
can be identified by a decal in the operator station.
THE MSS is designed to be a theft deterrent or the
MSS will prevent the unauthorized operation of the
machine.
g01131982
Illustration 80
Consult your Caterpillar dealer with any questions

that concern the operation of the Product Link in a
specific country.
104 SEBU8045-03
Operation Section
Machine Operation
Basic Operation Spare keys are available from your dealer. Before a
key can operate the machine, the MSS must be set
MSS may be programmed to use a standard to accept that particular key. Contact your Caterpillar
Caterpillar key or an electronic key. The electronic dealer for information on additional features of the
key contains an electronic chip within the plastic MSS.
housing for the key. Each key emits a unique
signal to the MSS. The keys can be identified by a Regulatory Compliance Section
gray housing or a yellow housing. MSS may have
programmed settings that require an electronic key
for starting during certain periods of time. The MSS
may also have programmed settings that allow a
standard Caterpillar key to start the machine during
certain periods of time.
Note: Ensure that you have only one electronic

key near the exciter coil when you are attempting
to start the machine. If there is more than one
electronic key near the exciter coil the MSS may
not be able to read the key in the keyswitch and
the machine will not start.
When the key start switch of the machine is turned

to the ON position, the ECM will read the unique Illustration 82
g00832427
ID that is stored in the electronic key. The ECM
will then compare this ID to the list of authorized Consult your Caterpillar Dealer with any questions
keys. The status of the key will be displayed on the that concern the operation of the MSS in a specific
monitor. If the key is not authorized for the machine, country.
“UNAUTHORIZED KEY” will be displayed on the
monitor.
Note: MSS will not shut down the machine after the
machine has started.
Security Management
The MSS has the capability to allow you to program
the system to automatically activate at different time
periods with different keys. The MSS can also be
programmed to reject a specific electronic key after a
selected date and time. When you turn the key to the
OFF position and the MSS is active, you have a 30
second interval in order to restart the machine. Also
if the machine stalls, there is a 30 second interval
for restarting the machine. This 30 second interval is
counted from the time of turning the key to the OFF
position.
Note: Know your machine’s settings because the use

of an electronic key is no guarantee that the machine
can be restarted.
An expiration date can be set for each electronic key

that is contained in the list of keys for the machine.
The key will no longer start the machine when the
internal clock in the security system passes the
g00822256
expiration date. Each entry in the list of keys can Illustration 83
have a different expiration date.
SEBU8045-03 105
Operation Section
Machine Operation
i02540727
Fuel Level – This gauge indicates the
Monitoring System amount of fuel that is remaining in the fuel
tank. When the fuel gauge indicates that the
SMCS Code: 7451; 7490 fuel level is in the red range, add fuel immediately.
NOTICE Hydraulic Oil Temperature – This gauge

When the monitor provides a warning, immediately indicates the temperature of the hydraulic
check the monitor and perform the required action or oil. The normal operating range is the green
maintenance as indicated by the monitor. range. If the gauge reaches the red range, reduce
the load on the system. If the gauge stays in the red
The monitor indicator does not guarantee that the ma- range, stop the machine and investigate the cause
chine is in a good condition. Do not use the monitor of the problem.
panel as the only method of inspection. Maintenance
and inspection of the machine must be performed on
a regular basis. See the Maintenance Section of this Engine Coolant Temperature – This
Operation and Maintenance Manual. gauge indicates the temperature of the
engine coolant. The normal operating range
is the green range. If the gauge reaches the red
range, stop the machine and investigate the cause
of the problem.
g01105768
Illustration 85
Keypad
The keypad has eight keys that are used in order

to input information into the electronic monitoring
system.
Up Key – Press the up key in order to

move the cursor upward. Also press the up
key in order to increase values.
Down Key – Press the down key in order

to move the cursor downward. Also press
the down key in order to decrease values.
Illustration 84
g01105763 Left Key – Press the left key in order to
move the cursor to the left. Also press the
(1) Clock
(2) Alert indicator
down key in order to decrease values.
(3) Engine speed dial indicator
(4) Fuel level Right Key – Press the right key in order to
(5) Hydraulic oil temperature
(6) Engine coolant temperature move the cursor to the right. Also press the
(7) Keypad up key in order to increase values.
Engine Speed Dial Indicator – This digital display Home Key – Press the home key in order
indicates the current position of the engine speed to return to the default display at any time.
dial. For more information on the engine speed
dial, refer to Operation and Maintenance Manual,
“Operator Controls”.
Menu Key – Press the menu key in
order to access the main menu. For more
information, refer to “Main Menu”.
106 SEBU8045-03
Operation Section
Machine Operation
The service hours for the filters are checked first.

OK Key – Press the OK key in order to Then, the service hours for the fluids are checked. If
select a menu option. Also press the OK a filter or a fluid is over the recommended change
key in order to set values. interval, “CHECK FLTR/FLUID INFO” appears on
the display. Refer to “Filter and Fluid Information” for
Back Key – Press the back key in order more information. This message will disappear after
to reject a menu option or a setting value. five seconds.
Also, press the back key in order to return
to the previous display. Machine Warnings
The monitoring system provides three warning
Prestart Monitoring Function categories.
Turn the engine start switch to the ON position. • The first warning category requires only operator
awareness. This type of warning will be indicated
by a message on the display screen.
• The second warning category requires a change

to the machine operation or a change to the
maintenance of the machine. This type of warning
will be indicated by a message on the display
screen and by a blinking of the Alert Indicator.
• The third warning category requires immediate

shutdown of the engine. This type of warning will
be indicated by a message on the display screen,
by a blinking of the Alert Indicator, and by a buzzer.
g00928810 If multiple warnings are present in the system, the

Illustration 86
most important problem is shown first. Press the
right key or press the left key in order to view all of
After approximately one second, Illustration 86 the warnings that are present in the machine. If no
appears in the display and the alert indicator turns on. keys are pressed within five seconds, the display will
return to the most important problem.
The coolant temperature, the hydraulic oil
temperature, the fuel level, and the position of the Note: The menu is still functional by pressing the
engine speed dial are now indicated. menu key.
The monitoring system checks the level of the engine
coolant, the engine oil, and the hydraulic oil before Warning Category 1
the engine starts.
In this category, only a warning will be shown in the
If the fluid level check detects a low fluid level, display screen. This category alerts the operator that
the appropriate message will be displayed and a the machine system needs attention. Failure of these
pictograph will be shown to indicate the fluid level systems will not endanger the operator. Failure of
that is low. these systems will not cause serious damage to the
machine components.
Note: If more than one fluid level is low, the symbols
for the right key and the left key are indicated in the “UNAUTHORIZED KEY” – This machine
bottom right area of warning message. Press the right is equipped with a Machine Security
key or the left key in order to check the other warning System. The key that is currently in the
message. The low fluid level indicators will disappear ignition switch is not an authorized key. Remove the
within five seconds after the engine is started. key and insert an authorized key.
Note: The machine cannot perform an accurate fluid “BATTERY VOLTAGE IRREGULAR” –
level check when the machine is on a slope. Perform The electrical charging system is
the fluid level check on level ground. malfunctioning. Check the electrical
components of the charging circuit immediately.
If the engine is started during the fluid level check, Perform any necessary repairs.
the monitor will cancel these checks.
SEBU8045-03 107
Operation Section
Machine Operation
“HYD RETURN FLTR PLUGGED” – The “AUTOLUBE ERROR” – The automatic

hydraulic return filter is restricted. This will lubrication system is malfunctioning. Stop
cause hydraulic components to malfunction. using the system and check the system for
Turn the engine start switch to the OFF position and the cause of the malfunction.
then turn the engine start switch to the ON position. If
the warning disappears the filter is good. Operate the
machine on flat ground for at least ten minutes. If the Warning Category 2
warning reappears, replace the return filter cartridge.
Refer to Operation and Maintenance Manual, “INLET AIR TEMP HIGH” – The inlet air
“Hydraulic System Oil Filter (Return) - Replace”. temperature is too high. Stop the machine
and investigate the cause of the fault.
Note: The warning for the restricted hydraulic return
filter will disappear from the display after three “COOLANT TEMP HIGH” – The coolant
minutes. temperature is too high. Stop operating
the machine and run the engine at low
“ATT FLTR PLUGGED” – The hydraulic idle until the coolant temperature decreases to the
filter is restricted. This will cause hydraulic correct level. If the warning stays on during low
components to malfunction. Turn the engine idle, stop the engine. Check the coolant level and
start switch to the OFF position and then turn the check the radiator for debris. Refer to Operation
engine start switch to the ON position. If the warning and Maintenance Manual, “Cooling System Coolant
disappears the filter is good. Operate the machine Level - Check”. Check the fan drive belts for the
on flat ground for at least ten minutes. If the warning water pump. Refer to Operation and Maintenance
reappears, replace the filter. Manual, “Belts - Inspect/Adjust/Replace”. Make any
necessary repairs.
“INTAKE AIR FLTR PLUGGED” – The
air filter is restricted. Engine output will “ENGINE SHUTDOWN ACTIVATING” –
be decreased. Immediately inspect the An error has occurred with the engine and
air filter. Clean the air filter. Inspect the condition the engine is shutting down. Contact your
of the air filter. Replace the air filter, if necessary. Caterpillar Dealer.
Perform any necessary repairs. Refer to Operation
and Maintenance Manual, “Engine Air Filter Primary “ENG OVERSPEED WARNING” –
Element - Clean/Replace”. The engine speed is too fast. Change
the operating technique. If the situation
“FUEL FLTR PLUGGED” – The fuel continues, contact your Caterpillar Dealer.
filter is restricted. Engine output will be
decreased. Immediately inspect the fuel “HYD OIL TEMP HIGH” – The hydraulic
filter. Replace the fuel filter, if necessary. Perform oil temperature is too high. Stop operating
any necessary repairs. Refer to Operation and the machine and run the engine at low idle
Maintenance Manual, “Fuel System Primary Filter until the hydraulic oil temperature decreases to the
(Water Separator) Element - Replace”. correct level. If the warning stays on during low idle,
stop the engine. Check the hydraulic oil level and
“WATER SEPARATOR FULL” – The check the hydraulic oil cooler for debris. Perform any
water separator is full. Drain the water from necessary repairs as soon as possible.
the water separator as soon as possible.
Refer to Operation and Maintenance Manual, “Fuel “HYD OIL TEMP HIGH (TOOL)” – The
System Water Separator - Drain”. hydraulic oil temperature is too high.
Stop operating the machine and run the
“FUEL LEVEL LOW” – The fuel in the engine at low idle until the hydraulic oil temperature
tank is low on fuel. Refill the fuel tank. decreases to the correct level. If the warning stays on
during low idle, stop the engine. Check the hydraulic
oil level and check the hydraulic oil cooler for debris.
Perform any necessary repairs as soon as possible.
“LUBE LEVEL LOW” – The reservoir for
the automatic lubrication system is low on
grease. Refill the reservoir. “FUEL PRESS HIGH” – The fuel pressure
is too high. Contact your Caterpillar Dealer.
108 SEBU8045-03
Operation Section
Machine Operation
“ECM ERROR” – The ECM has “CHECK FILTER FLUID INFO” – One
malfunctioned. Contact your Caterpillar of the machine’s filters has exceeded the
Dealer. recommended change interval. Replace the
filter and reset the hours for the filter.
“ENGINE ECM ERROR” – The engine
ECM has malfunctioned. Contact your Miscellaneous
Caterpillar Dealer.
“LUBE STARTING” – The automatic
“MONITOR ERROR” – The monitor has lubrication system is lubricating the
malfunctioned. Contact your Caterpillar machine’s bearings.
Dealer.
“LEVER IS NOT NEUTRAL” – The lever
“SERVICE REQUIRED” – The machine is not in the NEUTRAL position. Move the
has detected a malfunction. Contact your lever to the NEUTRAL position.
Caterpillar Dealer.
“COUNTERWEIGHT REMOVAL” – The
“TOOL CONTROL MALFUNCTION” – counterweight has been removed. Do not
The work tool has malfunctioned. Stop the operate the machine until the counterweight
machine and inspect the work tool. has been reinstalled.
Warning Category 3 “NOT CONFIGURED” – This is a general

warning that indicates that a machine
“LIFT OVERLOAD WARNING” – The load component needs to be configured.
on the machine is too heavy. The machine
is in danger of tipping. Reduce the load “NOT CALIBRATED” – This is a general
immediately. Refer to Operation and Maintenance warning that indicates that a machine
Manual, “Lifting Capacities” for more information. component needs to be calibrated.
“ENG OIL PRESS LOW” – The engine “CYCLE THE LOCK LEVER” – An error
oil pressure is too low. Stop the machine has occurred with the lock lever. Cycle the
immediately. Stop the engine and lock lever.
investigate the cause of the problem. Do not operate
the machine until the cause of the problem has been AIR INLET HEATER (If Equipped) – If
corrected. the engine coolant temperature is too low,
the air inlet heater will be activated. This
indicator will appear in the message display when the
Other Messages engine start switch is in the ON position. The engine
can be started after the indicator disappears from
Prestart the message display.
“COOLANT LEVEL LOW” – The
coolant level is too low. Stop the machine Adjusting the Monitor
immediately. Stop the engine and
investigate the cause of the fault. Follow this procedure in order to adjust the position
of the monitor.
“ENG OIL LEVEL LOW” – The engine
oil level is too low. Stop the machine
investigate the cause of the fault.
“HYD OIL LEVEL LOW” – The hydraulic

oil level is too low. Stop the machine
investigate the cause of the fault.
SEBU8045-03 109
Operation Section
Machine Operation
Setting
The “SETTING” menu allows the operator to change
the various machine settings.
1. Press the menu key.

Table 70
“MAIN MENU”
“SETTING”
g01105770
Illustration 87
1. Loosen the knob that is on the back of the monitor.
2. Adjust the monitor to the desired position.
3. Tighten the knob.

2. Press the right key or the left key in order to
Main Menu highlight the “SETTING” menu. Press the OK key.
Table 71
The “MAIN MENU” allows the operator to view
information concerning the machine. This menu also
allows the operator to change information concerning “SETTING”
the machine.
“DISPLAY SETUP”
1. Push the menu key when the default display is “WORK TOOL SELECT”
active.
Table 69
“MAIN MENU”
“SETTING”
3. The “SETTING” menu will be displayed with two
new menu options. For more information on these
menus, refer to the respective descriptions below.
4. Press the up key or the down key in order to

highlight the desired menu. Press the OK key in
order to open the desired menu.
2. The “MAIN MENU” will be displayed with four new Note: Press the home key in order to return to the
menu options: setting, maintenance information, default display.
performance, and service. For more information on
these menus, refer to the respective descriptions Maintenance Information
below.
The “MAINTENANCE INFO” menu allows the
3. Press the right key or the left key in order to operator to view the current hours of use and the
highlight the desired menu. Press the OK key in recommended change intervals for various system
order to open the desired menu. components.
Note: Press the back key or the home key in order to 1. Press the menu key.
exit this menu and return to the default display.
110 SEBU8045-03
Operation Section
Machine Operation
Table 72 Table 74
“MAIN MENU” “MAIN MENU”
“MAINTENANCE INFO” “PERFORMANCE”
2. Press the right key or the left key in order to 2. Press the right key or the left key in order to
highlight the “MAINTENANCE INFO” menu. Press highlight the “PERFORMANCE” menu. Press the
the OK key. OK key.
Table 73 Table 75
“MAINTENANCE INFO” “PERFORMANCE”

“COOLANT” “BATTERY VOLTAGE”
“100 / 12000 [HR]” “26.0 [V]”
“HYD OIL” “ENGINE SPEED”
“100 / 2000 [HR]” “1300 [RPM]”
“ENGINE OIL” “COOLANT TEMP”
“100 / 500 [HR]” “20 [°C]”
3. A list of system components will be displayed. 3. The “PERFORMANCE” menu will be displayed
Press the up key or the down key in order to with a list of system components and
scroll through the list. For each of the system measurements. Press the up key or the down key
components, the current hours of use will be in order to scroll through the list.
displayed. If the component has a recommended
change interval, the recommended interval will be Note: Press the home key in order to return to the
displayed to the right of the current hours of use. default display.
Note: Press the home key in order to return to the Service

default display.
The “SERVICE” menu allows the operator to change
Performance the password and the accumulated hours for the
machine’s filters and fluids.
The “PERFORMANCE” menu allows the operator to
view measurements of various system components. 1. Press the menu key.
The following components are a few examples of
the components that can be viewed through the
“PERFORMANCE” menu: battery voltage, engine
speed, and pump pressure.

SEBU8045-03 111
Operation Section
Machine Operation
Table 76 Table 78
“MAIN MENU” “PASSWORD”

“ENTER PASSWORD”
“SERVICE”
_ _ _ _
“< B C D E F 0 1 2 3 4 5 >”
2. Press the right key or the left key in order to 1. Press the right key or the left key in order to select
highlight the “SERVICE” menu. Press the OK key. the desired character.
Note: You will be prompted to enter a password. Note: The password is alphanumeric. You may
Refer to “Password Entry” for information on entering choose from “0” to “9”. You may also choose from
a password. “A” to “F”.
Table 77 Note: When the machine leaves the factory, the
password is initially set as 0001.
SERVICE
2. Press the OK key in order to enter the character.
“MAINTENANCE”
Note: Press the back key in order to delete the last
“PASSWORD CHANGE”
character that was entered.
3. After you enter 4 characters, the monitoring

system checks the password. If the password is
correct, you will have access to the menu.
Table 79
3. After the password has been entered successfully, “PASSWORD”

the “SERVICE” menu will be displayed with two “ENTER PASSWORD”
new menu options. For more information on these
menus, refer to the respective descriptions below.
* * * *
Note: Press the home key in order to return to the
default display.
“INVALID PASSWORD”
Password Entry
When you try to access certain menus, you will be
prompted to enter a password. Follow this procedure
in order to enter the password. 4. If the password is incorrect, “INVALID
PASSWORD” will be displayed. Press the OK key
in order to retry the password or press the back
key in order to return to the previous menu.
Note: Consult your Caterpillar dealer if you forget

your password.
Display Setup
The “DISPLAY SETUP” menu allows the operator to
change the various display settings of the monitor.
112 SEBU8045-03
Operation Section
Machine Operation
1. Press the menu key. 5. Press the up key or the down key in order to
highlight the desired menu. Press the OK key in
Table 80 order to open the desired menu.

“MAIN MENU”
default display.
“SETTING” Selecting the Work Tool

The “WORK TOOL SELECT” menu allows the
operator to change the settings for the work tool.
Note: Make sure that the hydraulic lockout control

is in the LOCKED position before you change the
settings for the work tool.
2. Press the right key or the left key in order to 1. Press the menu key.
highlight the “SETTING” menu. Press the OK key.
Table 83
Table 81
“MAIN MENU”
“SETTING”
“DISPLAY SETUP” “SETTING”
“WORK TOOL SELECT”

highlight the “DISPLAY SETUP” menu. Press the Table 84
OK key.
Table 82 “SETTING”
“DISPLAY SETUP”
“DISPLAY SETUP”
“CLOCK ADJUST”
“LANGUAGE SELECT”
“INDICATED ITEM”
“CONTRAST”
“BRIGHTNESS”
“BRIGHTNESS”
highlight the “WORK TOOL SELECT” menu.
Press the OK key.
4. The “DISPLAY SETUP” menu will be displayed
with various options for the monitor. For more
information on these menus, refer to the respective
descriptions below.
SEBU8045-03 113
Operation Section
Machine Operation
Table 85 Table 87
“WORK TOOL SELECT” “SETTING”

“TOOL #01” “DISPLAY SETUP”
“TOOL #02” “WORK TOOL SELECT”
“TOOL #03”
“TOOL #04”
Note: If the work tools have been configured through 3. Press the up key or press the down key in order
the Electronic Technician (ET), the names of the work to highlight the “DISPLAY SETUP” menu. Press
tools will be displayed instead of the numbers. the OK key.
Table 88
4. The “WORK TOOL SELECT” menu will be
displayed with the current options for work tools.
Press the up key or the down key in order to “DISPLAY SETUP”
highlight the desired work tool. Press the OK key
in order to select the new work tool. “CLOCK ADJUST”
default display. “INDICATED ITEM”
“CONTRAST”
Adjusting the Clock “BRIGHTNESS”
The “CLOCK ADJUST” menu allows the operator to “BRIGHTNESS”
change the time on the clock.

4. Press the up key or press the down key in order
Table 86 to highlight the “CLOCK ADJUST” menu. Press
the OK key.
“MAIN MENU” Table 89
“SETTING” “CLOCK ADJUST”
“12 : 00”
2. Press the right key or press the left key in order to

5. The “CLOCK ADJUST” menu will be displayed
with the current time. Press the left key or the right
key in order to select the hour or the minute. Press
the up key in order to increase the value. Press
the down key in order to decrease the value.
6. When the clock is set to the desired time, press the

OK key in order to save the new time in memory.
114 SEBU8045-03
Operation Section
Machine Operation
Note: Press the back key in order to return to the Table 92

previous display without saving.
Note: Press the home key in order to return to the “DISPLAY SETUP”
default display. “CLOCK ADJUST”
Language Selection
The “LANGUAGE SELECT” menu allows the “CONTRAST”
operator to change the language settings.
“BRIGHTNESS”
1. Press the menu key. “BRIGHTNESS”
Table 90
“MAIN MENU” 4. Press the up key or the down key in order to

highlight the “LANGUAGE SELECT” menu. Press
the OK key.
“SETTING”
Table 93
“ENGLISH”
“DANISH”
“FINNISH”
“ICELANDIC”
“NORWEGIAN”
Table 91
“SWEDISH”
“SETTING”
“DISPLAY SETUP” 5. The “LANGUAGE SELECT” menu will be
“WORK TOOL SELECT” displayed with a list of available languages. Press
the up key or the down key in order to scroll
through the available languages. Press the set
key in order to select the desired language.

default display.
Indicated Item
highlight the “DISPLAY SETUP” menu. Press the The “INDICATED ITEM” menu allows the operator to
OK key. display the name of the current work tool and/or the
service hours for the machine on the default display.
This procedure is also used to remove these items
from the default display.

SEBU8045-03 115
Operation Section
Machine Operation
Table 94 Table 97
“MAIN MENU” “INDICATED ITEM”

“TOOL NAME”
“SETTING” “SERVICE HR METER”
2. Press the right key or the left key in order to 5. The “INDICATED ITEM” menu will be displayed
highlight the “SETTING” menu. Press the OK key. with two items. Press the up key or the down key
in order to highlight the desired item. Press the
Table 95 OK key in order to enable the item. Also, press the
OK key in order to disable the item. By choosing
“SETTING”
to enable the item, that item will be shown on the
default display. By choosing to disable the item,
“DISPLAY SETUP” that item will be removed from the default display.
default display.
Adjusting the Contrast

The “CONTRAST” menu allows the operator to
change the contrast of the monitor.
3. Press the up key or the down key in order to 1. Press the menu key.
highlight the “DISPLAY SETUP” menu. Press the
Table 98
OK key.
Table 96
“MAIN MENU”
“DISPLAY SETUP”
“SETTING”
“CLOCK ADJUST”
“CONTRAST”
“BRIGHTNESS”
“BRIGHTNESS”

highlight the “INDICATED ITEM” menu. Press the
OK key.
Note: You will be prompted to enter a password.

Refer to “Password Entry” for information on entering
a password.
116 SEBU8045-03
Operation Section
Machine Operation
Table 99 Adjusting the Brightness

The “BRIGHTNESS” menu allows the operator to
“SETTING” change the brightness of the monitor.
“DISPLAY SETUP”
Table 102
“MAIN MENU”
“SETTING”

OK key.
Table 100
“DISPLAY SETUP” 2. Press the right key or the left key in order to
“CLOCK ADJUST”
“LANGUAGE SELECT” Table 103
“CONTRAST” “SETTING”
“BRIGHTNESS” “DISPLAY SETUP”
“BRIGHTNESS” “WORK TOOL SELECT”

highlight the “CONTRAST” menu. Press the OK
key.
Table 101
“CONTRAST”
OK key.
Table 104
“DISPLAY SETUP”
“5” “CLOCK ADJUST”

“CONTRAST”
5. The contrast can be set between 1 and 10. Press
“BRIGHTNESS”
the right key in order to increase the contrast.
Press the left key in order to decrease the contrast. “BRIGHTNESS”

default display.
SEBU8045-03 117
Operation Section
Machine Operation
4. Press the up key or the down key in order to Table 107

highlight the desired “BRIGHTNESS” menu. Press
the OK key.
SERVICE
Note: There are two “BRIGHTNESS” menus. The “MAINTENANCE”
first menu is used for machine operation during the
day. The second menu is used for machine operation “PASSWORD CHANGE”
at night.
Table 105
“BRIGHTNESS”
3. After the password has been entered successfully,

press the up key or the down key in order to
highlight the “MAINTENANCE” menu. Press the
OK key.
“5”
Table 108
“MAINTENANCE”
5. The brightness can be set between 1 and 10. “FLTR/FLUID INFO”
Press the right key in order to increase the
brightness. Press the left key in order to decrease
the brightness.

default display.
Maintenance
4. The “MAINTENANCE” menu will be displayed with
The “MAINTENANCE” menu allows the operator to two new menu options. For more information on
change the accumulated hours for the machine’s these menus, refer to the respective descriptions
filters and fluids. below.
1. Press the menu key. Note: Press the home key in order to return to the
default display.
Table 106
Changing the Password

“MAIN MENU”
The “PASSWORD CHANGE” menu allows the
operator to change the password.
“SERVICE”

highlight the “SERVICE” menu. Press the OK key.

a password.
118 SEBU8045-03
Operation Section
Machine Operation
Table 109 Note: The password is alphanumeric. You may

choose from “0” to “9”. You may also choose from
“A” to “F”.
“MAIN MENU”
Note: When the machine leaves the factory, the
password is initially set as 0001.
“SERVICE”
5. Press the OK key in order to enter the character.
Note: Press the back key in order to delete the last

character that was entered.
Table 112
2. Press the right key or the left key in order to “PASSWORD CHANGE”
highlight the “SERVICE” menu. Press the OK key. “ENTER NEW
PASSWORD”
a password. “* * * *”
Table 110
“ARE YOU SURE?”
“SERVICE”
“MAINTENANCE”
6. After you enter 4 characters, you will be asked to
confirm your selection. Press the OK key in order
to save the password in memory and return to the
“SERVICE” menu. Press the back key in order
to return to the “SERVICE” menu without saving
the password.

3. After the password has been entered successfully, default display.
highlight the “PASSWORD CHANGE” menu.
Press the OK key. Filter and Fluid Information
Table 111 The “FLTR/FLUID INFO” menu allows the operator
to change the accumulated hours for the machine’s
filters and fluids.
“ENTER NEW
PASSWORD”
“_ _ _ _”
“< B C D E F 0 1 2 3 4 5 >”
4. Press the right key or the left key in order to select

the desired character.
SEBU8045-03 119
Operation Section
Machine Operation
Table 113 Table 116
“MAIN MENU” “FLTR/FLUID INFO”

“ENGINE OIL FILTER”
“SERVICE” “00000 / 00000 [HR]”
“HYD OIL RET FILTER”
“00000 / 00000 [HR]”
“PILOT OIL FILTER”
“00000 / 00000 [HR]”
2. Press the right key or press the left key in order to

highlight the “SERVICE” menu. Press the OK key. 5. A list of filters and fluids will be displayed. For each
item, the current hours of use will be displayed on
Note: You will be prompted to enter a password. the left. The recommended change interval will
Refer to “Password Entry” for information on entering be displayed on the right. Press the up key or the
a password. down key in order to highlight the desired filter or
fluid. Press the OK key.
Table 114
6. Press the left key in order to reset the accumulated
hours for the selected item.
“SERVICE”
“MAINTENANCE” 7. Press the OK key in order to save the new hours
in memory.
Note: Press the back key in order to return to the
previous display without saving the value.

default display.
3. After the password has been entered successfully,

highlight the “MAINTENANCE” menu. Press the
OK key.
Table 115
“MAINTENANCE”
“FLTR/FLUID INFO”

highlight the “FLTR/FLUID INFO” menu. Press the
OK key.
120 SEBU8045-03
Operation Section
Machine Operation
i02163218 i02322732
Storage Box Storage and Literature

SMCS Code: 7268 Compartment
SMCS Code: 7268
Interior Storage Box
g01096952
Illustration 88
The storage box is used to store miscellaneous items

such as a first aid kit or a lunch box.
Exterior Storage Box Illustration 90

g01160959
A storage compartment is located inside the cab

on the left side. Use the compartment to store the
literature for the machine.
Note: Do not store tools in the storage compartment.

This could damage the compartment.
i02491515
Fuel Transfer Pump (Refueling)

(If Equipped)
SMCS Code: 1256
g01096953
Illustration 89
Use the following procedure to pump fuel and store
Open the storage box by pressing the push button. hose.
The storage box is used to store the refueling pump.
The storage box is also used to store miscellaneous
tools.
SEBU8045-03 121
Operation Section
Machine Operation
5. Make sure that excess fuel is drained from suction

hose (5) before storing the suction hose.
6. When you store suction hose (5), wind the hose

on the bar. Secure the hose end in place.
NOTICE
To prevent hose damage, do not coil the hose in a tight
radius.
7. Close the cover of the storage box.
Excavator with Demolition Cab (If

Equipped)
A special washer reservoir is installed when a
demolition cab is used.
g01245187
Illustration 91
Open the cover of the storage box that is located on

the right side in front of the fuel tank.
The electric refueling pump (1) pumps fuel into the g00464509
fuel tank. Illustration 92
When a machine is equipped with a refueling pump

NOTICE and a demolition cab, the refueling pump is relocated
Do not continuously operate the refueling pump for under the exterior storage box.
more than 30 minutes. Do not operate the refueling
pump more than a few seconds without fuel. Pump
damage can result.
On – Push switch (3) in order to activate

the refueling pump.
Off – Push switch (4) in order to deactivate

the refueling pump.
1. Remove cap (2) from the fuel tank.
2. Properly insert the free end of suction hose (5)

into a container of fuel.
3. Push switch (3) in order to supply the fuel to

the tank. When the tank is full, the pump stops
refueling.
4. After refueling, install cap (2) to the fuel tank.

122 SEBU8045-03
Operation Section
Machine Operation
i02376733
Radio
(If Equipped)
SMCS Code: 7338
g00729076
Illustration 93
(A) Display panel (3) Preset buttons (7) “Tune” button
(B) Display (Stereo) (4) “Tone” control (8) Volume control
(C) Display (Music) (5) Button for scan and auto memory (9) Volume control
(1) Power switch function
(2) AM/FM band selector (6) “Tune” button
Note: When the machine is in operation turn down (5) Scan and Auto Memory – Press button (5) for
the volume of the radio. less than 0.5 seconds in order to listen to 5 seconds
of each preset radio station. Press button (5) at least
Note: The radio can be used only when the battery 1.5 seconds in order to store the radio stations with
disconnect switch and the engine start switch are in the six strongest signals.
the ON position.
(6) and (7) “Tune” Buttons – Push the “tune”
Note: When a button is pushed a beep will occur. buttons in order to select a radio station. Pressing
“tune” button (7) will decrease the frequency.
(1) Power Switch – Push the power switch in order Pressing “tune” button (6) will increase the frequency.
to turn on the radio. Push the power switch again in Pressing the “tune” button for less than 0.5 seconds
order to turn off the radio. changes the radio station one at a time. Pressing the
“tune” buttons for more than 0.5 seconds will change
(2) AM/FM Band Selector – After you push the the frequency automatically until a radio station is
AM/FM band selector, the selected radio band found.
appears on display panel (A).
(8) and (9) Volume Control – Push the volume
(3) Preset Buttons – The circuitry in the memory control in order to control the volume. Push the
system allows you to preset six radio stations. upper volume control in order to increase the sound
To preset any of the “preset” buttons, follow the level and push the lower volume control in order to
“Presetting Radio Stations” procedure. decrease the sound level.
(4) Tone Control – Music is optimized by pressing

the tone control so that display (C) will show “MUSIC”.
SEBU8045-03 123
Operation Section
Machine Operation
Presetting Radio Stations
g00729101
Illustration 94
(E) Display (6) “Tune” button
(3) Preset buttons (7) “Tune” button
1. Turn on the radio. Select the AM band or the FM

band.
2. Select the first radio station by using tuning switch

(6) or tuning switch (7).
3. Depress one of preset buttons (3) for more than

1.5 seconds. The radio station is stored on display
(E).
4. Push preset button (3) in order to tune in the

radio station.
5. Repeat the same procedure for the remaining

preset switches.
Note: When the preset station is faint use the “tune”

buttons to locate a stronger signal.
124 SEBU8045-03
Operation Section
Machine Operation
Scan and Auto Memory
g00729102
Illustration 95
(D) Display (Frequency)
(F) Display (Scan)
(3) Preset buttons
(5) Button for scan and auto memory
function
Scan – Press button (5) for less than 0.5 seconds in Table 117
order to listen for 5 seconds to each of the preset Switch Position
radio stations. Press button (5) again in order to
stop scanning through the preset stations and keep AREA 1 2
listening to the current station. When this function is North America X
used “SCAN” is shown on the display. The frequency
of the radio station is also shown on the display. Middle and South America X
European Union X
Auto Memory – Press button (5) for more than 1.5
seconds in order to automatically store the radio Asia / Oceania X
stations that have the strongest signal. The radio
stations are stored in the six presets (3). Stations
that are already stored in the radio’s memory will
be erased.
Loss of Memory
The memory system is erased after a few days if the
battery is disconnected.
Radio Reception
Move the “area switch” according to the following
table:
SEBU8045-03 125
Operation Section
Machine Operation
g00729104 g01122088
(G) “Area switch” (A) Vent for upper body
(H) Selection table (B) Floor vent
(I) Protective film (C) Defroster vent
(J) Control panel (D) Defroster Vent
(E) Vent for upper body
(F) Control panel
Note: Remove the film from the radio. Remove the
vinyl from the operator’s seat. The film and vinyl may
cause noise interference in the radio. Redirect the louvers for air outlets (A), (C), (D), and
(E) by hand to the desired direction. The louvers for
air outlet (B) cannot be redirected.
i02189746
The climate control panel is located under the right
Air Conditioning and Heating window inside the cab:
Control
SMCS Code: 7304; 7320; 7337
All machines are equipped with a heater. Only certain

machines are equipped with an air conditioner.
Those machines that are not equipped with an air
conditioner also are not equipped with a compressor
switch.
g01106999
Illustration 98
(1) On/Off switch
(2) Automatic control switch
(3) Temperature switch
(4) LCD panel
(5) Fan switch
(6) Compressor switch
(7) Defrost mode
(8) Air inlet select switch
(9) Air outlet select switch
126 SEBU8045-03
Operation Section
Machine Operation
Main Power ON/OFF Switch (1) – Push Fan Switch (5) – The fan switch directly
the ON/OFF switch in order to power on controls the fan speed. If the climate control
the system. Push the switch again in order system is operating in the automatic mode,
to power off the system. pushing this switch overrides the automatically
selected fan speed.
Automatic Control Switch (2) – In order
to enter the full “AUT” mode for automatic Increase – Push this switch in order to
climate control, push this switch. However, increase the fan speed.
if you push the switch again, you cannot turn off the
air conditioning. When the system is in full “AUT”
mode, you can manually change specific functions Decrease – Push this switch in order to
by pushing another switch. If you manually change decrease the fan speed.
a specific function, “AUT” does not appear in the
display, but the unchanged functions will remain in
“AUT” mode. Even on a day that is sunny, a climate
control system with only a heater can cool the cab Compressor Switch (6) – Push the
in full “AUT” mode if the ambient temperature is no switch in order to turn on the compressor
more than 20 °C (68 °F). or push the switch in order to turn off the
compressor. In humid conditions, the compressor
may be used to remove moisture from the air in the
The climate control unit provides excellent operator cab. In cool weather, operate the compressor
comfort in the full “AUT” setting. Press the “AUT” weekly in order to prevent leakage of the
switch for full “AUT” mode. Push temperature switch refrigerant gas. This will also help to maintain the
(3) in order to set the desired temperature. The compressor in optimum working order.
temperature is only shown in metric values. All
other functions of climate control will be handled
automatically. Defrost (7) – Depressing this switch will
defog the windows. The air will also be
In order to take advantage of the full “AUT” setting of dehumidified while the compressor is
the climate control system, always keep the sunlight running. This selection directs air flow out of air outlet
sensor clean. Do not obstruct the sunlight sensor. If (C) and air outlet (D).
the climate control system is in the full “AUT” setting
at engine start-up and the temperature inside the Air Inlet Select Switch (8) – This switch selects the
cab is too warm or too cool, the damper for fresh air position of the air inlet.
ventilation may automatically close for a few minutes.
This will help to bring the air temperature to the Recirculate – When this position is
preset temperature more quickly. selected, the air inlet is closed. The air will
recirculate inside the cab.
Temperature Switch (3) – These switches
control the temperature of the air that Fresh Air – When this position is selected,
is coming from the air outlets in order the air inlet is open. Fresh air will circulate
to achieve the preset temperature. This preset into the cab.
temperature appears on display (6). If the heating
and air conditioning system is in the automatic
mode, pushing these switches changes the preset Air Outlet Select Switch (9) – This switch selects
temperature. the position of each air outlet. Each switch controls a
different air outlet.
Increase – Push this switch in order to Upper Body – Selecting this switch will
increase the temperature of the air that is open air outlet (A) and air outlet (D).
coming out of the air outlets or push this
switch in order to increase the preset temperature.
Upper Body and Floor – Selecting this
Decrease – Push this switch in order to switch will open air outlet (A), air outlet (B)
decrease the temperature of the air that is and air outlet (D).
coming out of the air outlets or push this
switch in order to decrease the preset temperature.
Floor – Selecting this switch will open air
outlet (B).
SEBU8045-03 127
Operation Section
Machine Operation
Floor and Defroster – Selecting this

switch will open air outlet (B) and air outlets
(C) and (D).
Consult with your Caterpillar dealer for periodic

maintenance of the heating and air conditioning
system.
English Versus Metric Toggle

In order to convert the temperature reading from
Degrees Celsius to Degrees Fahrenheit, depress
both keys of the fan switch at the same time for five
seconds. The same action is used for converting
the temperature reading from Degrees Fahrenheit
to Degrees Celsius.
i02491561
Window (Front) Illustration 99

g01245227
(1) Grip
SMCS Code: 7310-FR (2) Latch
Note: The sun visor (if equipped) must be down 1. Hold both grips (1) and squeeze both latches (2)
before the front window is raised. The front window in order to unlatch the window.
will not lock in the overhead storage position.
In order to provide full ventilation inside the cab, the

upper window and the lower window can be fully
opened.
When opening or closing the windshields, be ex-

tra careful to prevent any personal injury. Also,
the hydraulic activation control lever must be in
the LOCKED position to prevent any possibility of
sudden movement of machine due to inadvertent
contact with the hydraulic control(s).
g00107355
Illustration 100
Do not change the position of the window until the
following items have been done: 2. Lift the window upward until the window is
securely latched in the overhead position.
• Park the machine on a level surface.
Perform step 1 in order to close the upper
• Lower equipment to the ground. window.
• Move the hydraulic activation control lever to the 1. Hold both grips (1) and squeeze both latches (2)
LOCKED position. in order to unlatch the window. Lower the window
until the latches (2) engage. Once the latches
• Stop the engine. engage, the window is in the LOCKED position.
Perform step 1 through step 2 in order to open Perform step 1 through step 5 in order to open
the upper window. the lower window and close the lower window.
1. Raise the upper window into the locked position.

128 SEBU8045-03
Operation Section
Machine Operation
4. Store the lower window in the holder that is

located in the rear of the right side cab frame. In
order to store the lower window, locate one end of
the lower window into brackets (4). Secure the
opposite end of the lower window with catch (5).
5. In order to close the lower window, reverse the

procedure that is used for opening the window.
i01463761
Cab Visor
(If Equipped)
SMCS Code: 7301-ZZ
g01245266
Illustration 101
(3) Latch
2. Squeeze both latches (3) in order to unlock the

lower window.
g00681058
Illustration 104
Use the cab visor to control the amount of sunlight

through the roof hatch.
Insert your fingers into the openings that are located

in the cab visor in order to slide the cab visor into
the desired position.
g00103837
Illustration 102
3. Grasp the window and raise the lower window out

of the window frame.
g01245276
Illustration 103
SEBU8045-03 129
Operation Section
Machine Operation
i01463742
Roof Hatch
SMCS Code: 7303
g01095780
Illustration 107
In order to open the cab door from the inside of the

cab, push forward on the lever for the cab door latch.
g00681034
Illustration 105 For additional ventilation, open the cab door all the
(1) Grip way in order to engage the catch on the exterior wall
(2) Lock of the cab.
In order to open the roof hatch, release lock (2). Hold
grip (1) and push the roof hatch backward.
To close the roof hatch, hold grip (1) and pull the roof
hatch forward. Engage lock (2) securely.
i02325795
Cab Door
SMCS Code: 7308
g01121189
Illustration 108
In order to release the cab door from the catch, pull

downward on one of the two cab door release levers.
g01096558
Illustration 106
In order to open the cab door from the outside of the

cab, pull outward on the door handle.
g01096005
Illustration 109
In order to open a window, release the window latch,

and then slide the window to the desired position.
130 SEBU8045-03
Operation Section
Machine Operation
i01447292 Note: If the third pedal is depressed and a travel

pedal or a travel lever is operated, the machine will
Travel Control turn accordingly.
(Straight Travel Pedal (If
Equipped))
SMCS Code: 5462
With certain attachment combinations, the third

pedal can have different functions. Always check
for third pedal function before using the third ped-
al. Improper operation of the third pedal could re-
sult in serious injury or death.
g00555934
Illustration 112
(3) Lock pin
(4) Pin
(5) Notch
(A) LOCKED position
(B) UNLOCKED position (STORAGE position)
g00753277 When the machine is not operated with the third

Illustration 110
pedal, install lock pin (3) at the LOCKED position in
Position for normal travel order to prevent accidental operation.
(A) Rear of machine
(B) Final drive Note: To prevent lock pin (3) from being pulled out,
(C) Idler
insert pin (4) through notch (5) and turn lock pin (3)
counterclockwise by 1/4 turn.
When you travel, make sure that final drive sprockets
(B) are under the rear of the machine.
g00757775
Illustration 111
(1) Forward Travel
(2) Reverse Travel
The third pedal is to the right of the right travel pedal.

The third pedal controls the forward and backward
movement of the machine.
SEBU8045-03 131
Operation Section
Machine Operation
i02534001 Two functions may be performed at the same time by

moving a joystick diagonally.
Joystick Controls
SMCS Code: 5705 i02534073
Joystick Controls
(Medium Pressure (If
Equipped))
SMCS Code: 5705
g00731042
Illustration 113
(1) Stick Out
(2) Swing Right
(3) Stick In
(4) Swing Left
(5) Boom Lower
(6) Bucket Dump
(7) Boom Raise g00559405
(8) Bucket Close Illustration 114
(9) HOLD (1) Stick Out
(10) Seat (2) Swing Right
(3) Stick In
(4) Swing Left
(5) Boom Lower
(6) Tool Open
The Fine Swing Control delays the engagement of (7) Boom Raise
(8) Tool Close
the swing parking brake. (9) HOLD
If the machine is operating on a slope with the Fine

Swing Control in the ON position, the swing mo-
tion may become uncontrollable which could re-
sult in property damage, personal injury or death. The Fine Swing Control delays the engagement of
the swing parking brake.
Turn the Fine Swing Control to the OFF position
when the machine is operating on a slope. If the machine is operating on a slope with the Fine
Swing Control in the ON position, the swing mo-
tion may become uncontrollable which could re-
When you release the joysticks from any position, the sult in property damage, personal injury or death.
joysticks will return to HOLD position (9). Movement
of the upper structure will stop unless the fine swing Turn the Fine Swing Control to the OFF position
control (if equipped) is ON. When the fine swing when the machine is operating on a slope.
control is ON, the swing parking brake will not
activate until 6.5 seconds after the joystick control for
the swing function returns to the HOLD position. When you release the joysticks from any position, the
joysticks will return to HOLD position (9). Movement
The machine control pattern is initially set at the of the upper structure will stop unless the fine swing
factory to the SAE system, as shown. The pattern on control (if equipped) is ON. When the fine swing
the left pertains to the left joystick and the pattern on control is ON, the swing parking brake will not
the right pertains to the right joystick. activate until 6.5 seconds after the joystick control for
the swing function returns to the HOLD position.
The machine control pattern can be varied by
changing the hydraulic hose connections. See your
Caterpillar dealer for the procedure.
132 SEBU8045-03
Operation Section
Machine Operation
The machine control pattern is initially set at the i01429106

factory to the SAE system, as shown. The pattern on
the left pertains to the left joystick and the pattern on VA Boom Controls
the right pertains to the right joystick.
SMCS Code: 5461-VAR
The machine control pattern can be varied by
changing the hydraulic hose connections. See your The VA boom extends the working range of the
Caterpillar dealer for the procedure. machine by hydraulically increasing or reducing the
angle of the boom. The VA boom is equipped with
Two functions may be performed at the same time by a hydraulic check valve to prevent the boom from
moving a joystick diagonally. falling in case a hydraulic line breaks.
Rotating Tool Control
g00575819
Illustration 116
(1) Lock pin
(A) This position is not used.
g00875108
Illustration 115 (B) LOCKED position
(A) Left joystick (C) VA BOOM position
(B) Right joystick
(1) Medium pressure switch The VA boom pedal is located to the left of the travel
(2) Horn switch pedals.
(3) Medium pressure switch
(4) AEC switch
VA Boom Extend – Push down on the
Rotate Clockwise – Press the medium front of the pedal in order to extend the VA
pressure switch (1) on the left joystick in boom.
order to rotate the tool clockwise.
Horn – Press the horn switch (2) on the left

joystick in order to activate the horn.
VA Boom Retract – Push down on the rear
of the pedal in order to retract the VA boom.
Rotate Counterclockwise – Press
the medium pressure switch (3) on the
right joystick in order to rotate the tool
counterclockwise.
AEC Switch – Press the AEC switch (4)

on the right joystick in order to activate low
engine speed. Press the switch again in
order to activate high engine speed.
SEBU8045-03 133
Operation Section
Machine Operation
i01438945
(1) SmartBoom UP AND DOWN – Push
SmartBoom Control down on the top of the rocker switch in
(If Equipped) order to activate the SmartBoom UP AND
DOWN mode. When the boom control joystick is
SMCS Code: 5461-ZS; 7332 moved to the BOOM DOWN position, the boom will
lower by the weight of the boom. The boom can move
upward freely.
Personal injury or death can result from not fol- (2) SmartBoom DOWN – Push down on
lowing the proper procedures. the bottom of the rocker switch in order to
activate the SmartBoom DOWN mode. The
To avoid the possibility of injury or death, follow boom will lower by the weight of the boom when the
the established procedure. control lever is moved to the BOOM LOWER position.
This mode prevents the boom from moving upward.
In order to move the boom upward, the operator must
NOTICE use the boom control joystick to activate the BOOM
Always make sure that the boom control joystick UP mode.
is in the NEUTRAL position before activating the
SmartBoom. Note: When the rocker switch for the SmartBoom is
in the CENTER position, the SmartBoom is no longer
Do not select any SmartBoom mode, using the Smart- functional.
Boom selector switch located on the console, while
the tracks are elevated.
If any SmartBoom mode is active while the boom con-

trol joystick is in the Boom Down position (forward)
and the bucket or tool is on the ground, do not press
the disable button that is located on the front of the
right-hand joystick. Pressing the disable button could
cause a sudden Boom Down motion and tilt the ma-
chine upward.
While the machine is in any SmartBoom mode, do not

attempt to lift the tracks by using the disable button
and applying downward force with the BOOM LOWER
control. Releasing the disable button will immediately
g00753783
return the machine to the active SmartBoom mode. Illustration 118
This action could cause the machine to drop down Right Joystick
abruptly.
(3) SmartBoom Temporary Disable –
Press the trigger switch on the front of the
The switches for the SmartBoom are located on the
right joystick in order to temporarily override
right side instrument panel and on the right joystick.
the SmartBoom function. Release the trigger switch
in order to return to the selected SmartBoom function.
During operation of the SmartBoom, the operator

may wish to apply downward force to the boom.
When the rocker switch is in the SmartBoom DOWN
position or the rocker switch is in the SmartBoom UP
AND DOWN position, the operator can disable the
SmartBoom function temporarily with the SmartBoom
Disable switch. While the trigger switch is pressed,
BOOM RAISE and BOOM LOWER will operate in
the normal modes.
g00753781
Illustration 117
Right side instrument panel
134 SEBU8045-03
Operation Section
Machine Operation
i01781743 The work tool pedal can be located on either side

of the travel pedals. The work tool pedal allows the
Work Tool Control (One-Way operator to modulate the speed of the work tool.
Flow)
(If Equipped)
SMCS Code: 6700
The following information pertains to work tools that

require hydraulic oil flow in one direction. Hydraulic
hammers are an example of work tools that require
hydraulic oil flow in one direction.
Note: For information that pertains to work tools that

require hydraulic oil flow in two directions, refer to
Operation and Maintenance Manual, “Work Tool
Control (Two-Way Flow)”.
g00756717
Illustration 120
Joystick
Variable Speed – Push down on the front
of the pedal in order to activate the work
tool. Move the pedal further in order to
increase the speed of the work tool. Release the
pedal in order to turn off the work tool.
g00769298
Illustration 119
(A) Left joystick
(B) Right joystick
(1) Variable Speed – Move the variable g00291764

control downward in order to activate the Illustration 121
work tool. Move the variable control further (1) Lock pin
in order to increase the speed of the work tool. (A) UNLOCKED position
(B) LOCKED position
(2) On/Off – Push this switch in order to When you are not using the work tool, put the lock
activate the work tool at a constant rate. pin (1) in LOCKED position (B). This will lock the
Push this switch again in order to turn off work tool pedal in order to prevent any unexpected
the work tool. operation of the work tool.
Work Tool Pedal
With certain attachment combinations, the work

tool pedal can have different functions. Always
check for work tool pedal function before using
the work tool pedal. Improper operation of the
work tool pedal could result in serious injury or
death.
SEBU8045-03 135
Operation Section
Machine Operation
Joystick
g00291805
Illustration 122
(1) Lock pin g00731659
Illustration 123
(2) Pin
(3) Notch (A) Left joystick
(B) Right joystick
Note: To prevent lock pin (1) from being accidentally

(1) Rotate Clockwise – Move the variable
pulled out, insert pin (2) through notch (3) and turn
control upward in order to rotate the work
lock pin (1) counterclockwise by 1/4 turn.
tool clockwise.
i01781742 (2) Rotate Counterclockwise – Move the

variable control downward in order to rotate
Work Tool Control (Two-Way the work tool counterclockwise.
Flow)
(If Equipped) (3) Close – Move the variable control
upward in order to close the work tool.
SMCS Code: 6700
The following information pertains to work tools that (4) Open – Move the variable control
require hydraulic oil flow in two directions. These downward in order to open the work tool.
work tools can also be equipped with a rotate circuit.
Hydraulic shears, pulverizers, crushers, and grapples
are examples of work tools that require hydraulic oil
flow in two directions. Work Tool Pedal
Note: For information that pertains to hydraulic
hammers, refer to Operation and Maintenance
Manual, “Work Tool Control (One-Way)”. With certain attachment combinations, the work
tool pedal can have different functions. Always
check for work tool pedal function before using
the work tool pedal. Improper operation of the
work tool pedal could result in serious injury or
death.
The work tool pedal can be located on either side

of the travel pedals. The work tool pedal allows the
operator to vary the speed of the work tool.
136 SEBU8045-03
Operation Section
Machine Operation
g00756810 g00756811
(3) Lock pin
(1) Close – Push down on the front of the (4) Pin
pedal in order to close the work tool. (5) Notch
Note: To prevent lock pin (3) from being accidentally

pulled out, insert pin (4) through notch (5) and turn
(2) Open – Push down on the rear of the
lock pin (3) by 1/4 turn.
pedal in order to open the work tool.
i01288265
Joystick Controls Alternate

Patterns
SMCS Code: 5059; 5137
Changing Machine Control Pattern

By Four-Way Valve (If Equipped)
Whenever a change is made to the machine con-

g00756813 trol pattern, also exchange the pattern card in the
Illustration 125
(3) Lock pin cab to match the new pattern.
(A) LOCKED position
(B) UNLOCKED position Check the machine control pattern for confor-
mance to the pattern on the card in the cab. If
When you are not using the work tool, put the lock the pattern does not match, change the card to
pin (3) in LOCKED position (A). This will lock the match the machine control pattern before you
work tool pedal in order to prevent any unexpected operate the machine. Failure to do so could result
operation of the work tool. in personal injury.
If the machine is equipped with a four-way valve, the

machine control pattern can easily be changed. The
machine control pattern can be changed to the SAE
system, MHI system, KOB system or the former SCM
system by changing the four-way valve position. To
change the four-way valve position, use the following
procedure.
SEBU8045-03 137
Operation Section
Machine Operation
g00682736
Illustration 127
The four-way valve (if equipped) is located in front

of the radiator.
g00682737
Illustration 128
g00102959
(a) Bolt Illustration 129
(b) Lever (A) SAE machine control pattern
() MHI machine control pattern (B) MHI machine control pattern
(2) KOB machine control pattern (C) KOB machine control pattern
(3) SAE machine control pattern (D) Former SCM machine control pattern
(4) Former SCM machine control pattern
The patterns on the left side of the illustration show
1. Loosen bolt (a) and move lever (b) to the desired the possible configurations for the left control lever.
position. The lever can be moved to position (1), The patterns on the right side of the illustration show
(2), (3), or (4). the possible configurations for the right control lever.
Position (1) will change the machine control Stick Out (1) – Move the control lever
pattern to the MHI system. Position (2) will change to this position in order to move the stick
the machine control pattern to the KOB system. outward.
Position (3) will change the machine control
pattern to the SAE pattern. Position (4) will change
the machine control pattern to the former SCM Swing Right (2) – Move the control lever
pattern. to this position in order to swing the upper
structure to the right.
2. After the pattern is set, tighten the bolt in order
to secure the lever. Stick In (3) – Move the control lever to this
position in order to move the stick inward.
Swing Left (4) – Move the control lever

to this position in order to swing the upper
structure to the left.
138 SEBU8045-03
Operation Section
Machine Operation
Boom Lower (5) – Move the control lever

to this position in order to lower the boom.
Bucket Dump (6) – Move the control lever

to this position in order to dump the bucket.
Boom Raise (7) – Move the control lever

to this position in order to raise the boom.
Bucket Close (8) – Move the control lever

to this position in order to close the bucket. Illustration 130
g00102962
The two-way valve is located in the front of the

HOLD (9) – When the control lever is released from radiator.
any position, the control lever will return to the HOLD
position. Movement of the upper structure will stop.
Two functions may be performed at the same time by

moving a control lever diagonally.
If the machine is equipped with a hydraulic hammer,

the function of position (6) and of position (8) is
different.
Hydraulic Hammer Raise (6) – Move the control

lever to this position in order to raise the hydraulic
hammer.
Hydraulic Hammer Lower (8) – Move the control g00104103

lever to this position in order to lower the hydraulic Illustration 131
hammer. (a) Bolt
(b) Lever
Changing Machine Control Pattern 1. Loosen bolt (a) and move lever (b) to the SAE
by Two-Way Valve (If Equipped) position or to the BHL position.
Note: Illustration 131 shows that the two-way valve

is in the SAE position.
Whenever a change is made to the machine con- 2. After you set the machine control pattern, tighten
trol pattern, also exchange the pattern card in the bolt (a) in order to secure lever (b).
cab to match the new pattern.
Check the machine control pattern for confor-

mance to the pattern on the card in the cab. If
the pattern does not match, change the card to
match the machine control pattern before you
operate the machine. Failure to do so could result
in personal injury.
The machine control pattern can easily be changed

to the SAE system or to the standard backhoe loader
hydraulic system (BHL) by changing the position of
the two-way valve (if equipped). Use the following
procedure to change the position of the two-way
valve.
SEBU8045-03 139
Operation Section
Machine Operation
Bucket Close (8) – Move the control lever

to this position in order to close the bucket.
HOLD (9) – When the control lever is released from

any position, the control lever will return to the HOLD
position. Movement of the upper structure will stop.
Two functions may be performed at the same time by

moving a control lever diagonally.
If the machine is equipped with a hydraulic hammer,

the function of position (6) and of position (8) is
different.
Hydraulic Hammer Raise (6) – Move the control

lever to this position in order to raise the hydraulic
hammer.
Hydraulic Hammer Lower (8) – Move the control

g00102966 lever to this position in order to lower the hydraulic
Illustration 132
(A) SAE machine control pattern hammer.
(B) BHL machine control pattern for standard backhoe
The patterns on the left side of the illustration show

the possible configurations for the left control lever.
The patterns on the right side of the illustration show
the possible configurations for the right control lever.
Stick Out (1) – Move the control lever

to this position in order to move the stick
outward.
Swing Right (2) – Move the control lever

structure to the right.
Stick In (3) – Move the control lever to this

position in order to move the stick inward.
Swing Left (4) – Move the control lever

structure to the left.
Boom Lower (5) – Move the control lever

to this position in order to lower the boom.
Bucket Dump (6) – Move the control lever

to this position in order to dump the bucket.
Boom Raise (7) – Move the control lever

to this position in order to raise the boom.
140 SEBU8045-03
Operation Section
Machine Operation
i02115469
Fuel Tank Shutoff and Drain

Control
SMCS Code: 1273
The fuel tank drain valve is located under the main

hydraulic pump. The fuel shutoff valve is located
underneath the fuel tank.
g01043694
Illustration 133
Fuel tank drain valve
g01043693
Illustration 134
Fuel shutoff valve
Fuel Tank Drain Valve – To drain the water and

sediment from the fuel tank, turn the fuel drain valve
counterclockwise. To close the fuel tank drain valve,
turn the drain valve clockwise.
Fuel Shutoff Valve – To shut off the fuel supply, turn

the fuel shutoff valve clockwise. To turn on the fuel
supply, turn the fuel shutoff valve counterclockwise.
Note: For more detailed information that pertains to

draining the water and sediment from the fuel tank,
refer to Operation and Maintenance Manual, “Fuel
Tank Water and Sediment - Drain”.
SEBU8045-03 141
Operation Section
Engine Starting
Engine Starting
i02565006
Engine Starting
SMCS Code: 1000; 1090; 1456; 7000
Explosion hazard! This machine is equipped with

an air inlet heater. Do not spray aerosol starting
aids such as ether manually into the intake. The
use of ether without an ether attachment could re- Illustration 136
g01075262
sult in an explosion or fires that could cause per-
sonal injury or death. 3. Move the hydraulic lockout control to the LOCKED
position.
NOTICE
The engine start switch must be in the ON position This machine is equipped with an engine neutral
and the engine must be running in order to maintain start system. The system only allows the engine
electrical functions and hydraulic functions. This pro- to start when the lever for the hydraulic lockout
cedure must be followed in order to prevent serious control is in the LOCKED position.
machine damage.
4. Move the joysticks to the HOLD position.
g00406959 g00682776
(1) Engine start switch
1. Turn the battery disconnect switch to the ON (2) Engine speed dial
position.
5. Turn engine start switch (1) to the ON position.
2. Make sure that the reset button for the circuit
breaker remains depressed. Refer to Operation 6. The monitoring system starts.
and Maintenance Manual, “Circuit Breakers -
Reset”. Note: For more information on the monitoring
system, refer to Operation and Maintenance Manual,
“Monitoring System”.
7. If the engine start switch is placed in the ON

position for two seconds or more, the prestart
check of the monitoring system will be activated. If
any fluid levels are low, the low fluid level will be
shown on the message display. Refer to Operation
and Maintenance Manual, “Monitoring System”
for more information on the prestart monitoring
function.
142 SEBU8045-03
Operation Section
Engine Starting
If the fluid level is too low, add the corresponding i02252001

fluid to the specified level. Add the fluid before you
start the engine. Engine and Machine Warm-Up
Note: An intake air heater is installed on the machine SMCS Code: 1000; 7000
as standard equipment. An ether starting aid may
also be installed on the machine. The selection of the NOTICE
intake air heater or of the ether starting aid is done Keep the engine speed slow until the indicator light for
automatically by the engine computer. This is based the engine oil pressure goes out.
on coolant temperature.
If the light does not go out within ten seconds, stop
8. Make sure that “INTAKE AIR HEATER ON” is not the engine and investigate the cause before starting
shown on the message display. If this message is the engine again. Failure to correct the problem can
shown on the message display, the temperature cause engine damage.
of the engine coolant is too low, and the engine
cannot start correctly. If “INTAKE AIR HEATER
ON” is shown on the message display, the Note: The hydraulic lockout control must be in the
intake air heater has activated. While the UNLOCKED position before the hydraulic controls
intake air heater is being activated, wait until will function.
the message “INTAKE AIR HEATER ON” is
no longer visible on the message display. 1. Allow the engine to warm up at low idle for at least
Proceed to step 9. five minutes. Engage the work tool controls and
disengage the work tool controls. This will speed
Note: Do not start the engine at this time. up the warm-up of the hydraulic components.
Note: If the ether starting aid is chosen by the engine When you idle the machine for warm-up, observe
computer, no message will be shown on the display. the following recommendations:
When the key is turned to START, a precise amount
of ether will be injected in order to allow the engine • If the temperature is greater than 0°C (32°F),
to start. warm up the engine for approximately 15
minutes.
9. Turn engine speed dial (2) to medium speed
position “5” or medium speed position “6”. • If the temperature is less than 0°C (32°F), warm
up the engine for approximately 30 minutes.
NOTICE • If the temperature is less than − 18°C (0°F) or
Do not crank the engine for more than 30 seconds. If if hydraulic functions are sluggish, additional
the engine does not start, allow the starter to cool for time may be required.
two minutes before cranking again. The engine start
switch must be turned to the OFF position before try- 2. To warm up the hydraulic oil, turn the engine
ing to restart. speed dial to the medium engine speed. Run
the engine for approximately five minutes and
10. Turn engine start switch (1) to the START position. move the joystick intermittently from the BUCKET
DUMP position to the HOLD position.
11. Release the engine start switch key after the
engine starts. 3. Turn the engine speed dial to the maximum
engine speed and repeat Step 2.
This machine’s engine with standard specifications
can start in areas that have temperatures as low as This allows the oil to attain relief pressure, which
−18°C (0°F). For areas that are cooler, a starting kit causes the oil to warm up more rapidly.
for cold weather is available.
4. Cycle all controls in order to circulate warm oil
through all hydraulic cylinders and through all
hydraulic lines.
5. Observe the gauges and the indicators frequently

during the operation.
SEBU8045-03 143
Operation Section
Operation
Operation
i02346395
Operation Information
SMCS Code: 7000
Note: Operating Temperature Range for the

Machine The machine must function satisfactorily
in the anticipated ambient temperature limits that
are encountered during operation. The standard
machine configuration is intended for use within
an ambient temperature range of −18 °C (0 °F) to
g00732198
43 °C (109 °F). Special configurations for different Illustration 138
ambient temperatures may be available. Consult
your Caterpillar dealer for additional information on 3. Turn the engine speed dial to the operating range.
special configurations of your machine.
4. Move the hydraulic lockout control to the
Make sure that no personnel are on the machine or UNLOCKED position.
near the machine in order to prevent any personal
injury. Keep the machine under control at all times
in order to prevent injury.
Reduce the engine speed when you maneuver the

machine in tight quarters and when you drive over
an incline.
Select the necessary travel speed range before you

drive downgrade. Do not change the travel speed
range while you drive downhill.
Use the same travel speed on a downgrade and on

an upgrade.
g00101463
When you travel for any distance, keep the stick Illustration 139
inward and carry the boom in a low position.
5. Raise the boom enough in order to provide
When you drive up a steep grade, keep the boom as sufficient ground clearance.
close to the ground as possible.
When you travel uphill or you travel downhill, keep

the boom on the uphill side of the machine.
1. Adjust the operator seat.
2. Fasten the seat belt.
g01113024
Illustration 140
6. Select the desired travel speed by operating the

travel speed control switch.
144 SEBU8045-03
Operation Section
Operation
7. Make sure that the position of the upper structure i00059294

and of the undercarriage is known before you
move the machine. The drive sprockets should be Frozen Ground Conditions
at the rear of the machine.
SMCS Code: 7000
Note: The directional steering controls will operate
normally if the drive sprockets are at the rear of the
machine and the idlers are at the front of the machine
and under the cab. When the sprockets are under the
cab, the travel controls will operate backward.
8. Turn the engine speed dial in order to increase the

engine speed (rpm) to the desired speed.
9. Push both travel levers forward at the same time

in order to travel forward. If both travel levers are
pushed farther, the travel speed at the selected
engine speed (rpm) will be faster.
Note: If the machine does not operate or if the g00101468

Illustration 141
machine does not travel in a straight line, consult
your Caterpillar dealer.
To free the tracks from frozen ground, swing the
boom to the front of the machine. Use boom down
10. See Operation and Maintenance Manual,
pressure to free the idler end of the machine.
“Operator Controls” for information about spot
turning and about pivot turns.
Swing the boom to the rear of the machine. Use
boom down pressure to free the sprocket end of the
11. When you make turns in soft material, travel in
machine.
a forward direction occasionally in order to clear
the tracks.
i02492602
12. Slowly move both of the travel levers or both of
the travel pedals to the CENTER position in order Equipment Lowering with
to stop the machine. Engine Stopped
SMCS Code: 7000
To lower the boom, place the hydraulic lockout lever

in the UNLOCKED position. Move the joystick to the
BOOM LOWER position. If the accumulator is still
charged, the boom will lower.
If the boom does not lower, the accumulator is empty.

Use one of the following methods to lower the boom.
Machine without a Boom Lowering

Control Valve
Be sure no one is under or near the work tools

before manually lowering the boom. Keep all per-
sonnel away from the boom drop area when low-
ering the boom with the engine stopped in order
to avoid possible personal injury.
When you must manually lower the boom due to

engine shutdown, use the following procedure.
SEBU8045-03 145
Operation Section
Operation
Note: Keep all personnel away from the boom when 5. Make sure that the work tool has lowered all the
you are lowering the boom. way to the ground. Tighten screw (6) to a torque
of 13 ± 2 N·m (9 ± 1 lb ft).
Relieve the pressure in the hydraulic system before
manually lowering the boom. Move the hydraulic Note: Refer to Operation and Maintenance Manual,
lockout lever to the UNLOCKED position. Move the “General Hazard Information” for information on
travel levers/pedals forward and backward in order to containing fluid spillage.
relieve the pressure.
6. Disconnect hose (5) from screw (6). Do not allow
1. Open the engine hood. the oil that is contained in hose (5) to spill.
7. Connect hose (5) to the original position on the

hydraulic tank and install fill/vent plug (4) securely.
8. Close the engine hood.
After completion of the manual boom lowering, make

necessary repairs before you operate the machine
again.
Note: For additional information, consult your

Caterpillar dealer.
Machine with a Boom Lowering

Illustration 142
g00831761
Control Valve
(1) Fill/vent plug
(2) Bolts
(3) Washers
(4) Cover
Boom load may cause cylinder oil pressure to
2. Slowly loosen fill/vent plug (1) on the top of reach relief pressure of the boom lowering control
the hydraulic tank until internal pressure in the device when the boom is supported by one cylin-
hydraulic tank has been completely relieved. der. Boom can lower suddenly, causing possible
Remove fill/vent plug (1). injury or death.
To avoid possible injury or death, be sure no one

is under or near the work tool before manually low-
ering the boom.
Keep all personnel away from the boom drop area

when lowering the boom with the engine stopped.
If the engine is shut down or the hydraulic system is

disabled, the operator can still lower the boom. Use
the following procedure if the machine is equipped
with a boom lowering control valve.
g01246296
Illustration 143
(5) Hose
(6) Screw
3. Connect an end of hose (5) to screw (6 ). Put the

other end of hose (5) into the filler plug opening.
4. Slowly loosen screw (6) by a maximum of 1/2 turn.

This allows the hydraulic oil in the boom circuit to
drain into the hydraulic tank. The boom will now
start to lower.
146 SEBU8045-03
Operation Section
Operation
Pressure Release of Auxiliary Lines
Personal injury can result from hot oil spray and

raised work tools.
Make sure all the work tools have been lowered,

the oil is cool and the pressure has been released
from the hydraulic system before removing any
components or lines.
Do not allow hot oil or components to contact

skin.
Note: Refer to Operation and Maintenance , “General

Hazard Information” for information on containing
fluid spillage.
Refer to the procedure below before any of the

g00754172
Illustration 144 following conditions.
(1) Locknut
(2) Check valve • The work tool is changed.
The boom lowering control valve (if equipped) is • The position of the ball valve is changed.
installed on each of the boom cylinders. The boom
lowering control valve allows the operator to manually 1. Turn the engine start switch to the OFF position.
lower the boom if the engine is stopped. The boom
lowering control valve also prevents the sudden 2. Place the hydraulic lockout lever to ON position.
descent of the boom if there is an oil leak in the
hydraulic line of the boom. 3. Release the pressure in the auxiliary lines by
pressing the auxiliary control buttons or the
1. Loosen locknut (1) of the boom lowering check auxiliary control pedal three times.
valve.
4. Place the hydraulic lockout lever in the OFF
2. Slowly turn check valve (2) counterclockwise until position.
the check valve stops. The boom will lower to the
ground. 5. Change the work tool.
3. Make sure that the work tool has been completely Note: There should be movement in the auxiliary
lowered onto the ground. Tighten check valve (2). hydraulic lines as the pressure is released. If there is
no movement in the auxiliary hydraulic lines, start the
4. Tighten locknut (1) to a torque of 2.25 ± 0.25 N·m engine and run the engine for 20 seconds. Repeat
(1.66 ± 0.18 lb ft). steps 1 to 5.
5. Before operating the machine, make any For additional information, consult your Caterpillar
necessary repairs. dealer.
For additional information, consult your Caterpillar

dealer.
SEBU8045-03 147
Operation Section
Operating Techniques
Operating Techniques Move the machine whenever the position for digging
is not efficient. The machine can be moved forward
or backward during the operating cycle.
i02515714
When you operate the machine in close places,
Operating Technique utilize the bucket or other work tools in order to
Information perform the following functions:
SMCS Code: 7000 • Pushing the machine

• Pulling the machine
• Lifting the tracks
Know the maximum height and the maximum
reach of your machine. Serious injury or death by Use a comfortable travel speed while you operate
electrocution can occur if the machine or the work the machine.
tools are not kept a safe distance from electrical
power lines. Keep a distance of at least 3000 mm Operating efficiency can be increased by using more
(118 inch) plus an additional 10 mm (0.4 inch) for than one machine control to perform a task.
each 1000 volts over 50000 volts.
Never swing a load over a truck cab or workers.
For safety, one of the following may require a greater
distance: Position the truck so that material can be loaded from
the rear of the truck or from the side of the truck.
• Local codes Load the truck evenly so that the rear axles are not
overloaded.
• State codes
An oversize bucket or a bucket that is equipped with
• Requirements of the job site side cutters should not be used in rocky material.
These types of buckets slow down the cycle. Damage
to the bucket and to other machine components
NOTICE could result.
When swinging into a ditch, do not use the ditch to stop
the swinging motion. Inspect the machine for damage
if the boom is swung into a bank or an object. Restricted Operation
Repeated stopping by an object can cause structural
damage if the boom is swung into a bank or an object.
With certain boom-stick-bucket combinations, the

bucket can hit the cab or front of the machine. Always
check for interference when first operating a new
work tool.
Whenever the tracks of the machine raise off the

ground while digging, lower the machine back to the
ground smoothly. DO NOT DROP OR CATCH IT
WITH THE HYDRAULICS. Damage to the machine
can result.
g00529436
Illustration 145
With certain combinations of work tools, the third
pedal can have different functions. Always check the Do not use the swing force to perform the following
function of the third pedal before you use the third operations:
pedal.
• Soil compaction
Know the location of any buried cables. Mark the
locations clearly before you dig. • Ground breaking
Consult your Caterpillar dealer for special bucket tips • Demolition
that are available for use in severe applications.
148 SEBU8045-03
Operation Section
Do not swing the machine while the bucket tips are in

the soil.
These operations will damage the boom, the stick

and the bucket and the operations will reduce the
life of the equipment.
g00529459
Illustration 148
While the bucket is in the ground, do not use the

travel force for any excavation. This operation will
cause excessive force on the rear of the machine.
g00529457
Illustration 146
Do not use the dropping force of the bucket as a

hammer. This will bring excessive force on the rear
of the machine. Possible damage to the machine
could result.
g00529460
Illustration 149
Do not use the dropping force of the rear of the

machine for excavation. This operation will damage
the machine.
g00529458
Operating Precaution
Illustration 147
If the cylinder is operated to the end of the stroke

during operations, excessive force will occur on the
stopper on the inside of the cylinder. This will reduce
the life of the cylinder. To avoid this problem, always
leave a small margin of play when the cylinder is
operated.
g01250228
Illustration 150
SEBU8045-03 149
Operation Section
NOTICE
Do not allow the machine to swing from the force of
traveling when you use the bucket , the stick, or the
boom to assist in travel. If the force from traveling
causes the machine to swing, damage may occur to
the swing motor and to the swing drive.
Do not use the force of the bucket, the stick or the

boom to assist in turning the machine while the
machine is traveling. This technique is referred to
as “jump steering”. This technique will damage the
swing motor and the swing brake.
g00807842
Illustration 152
Depth of water to the center of the track carrier roller
The following guidelines pertain to travel across

water and travel through mud, sand, or gravel.
The machine can travel across a river only under the

following conditions:
• The bed of the river is flat.

• The flow of the river is slow.
g00529462
• The machine dips into the water only to the center
Illustration 151 of the track carrier roller (dimension A).
When deep holes are dug, do not lower the boom so

that the bottom side of the boom touches the ground. NOTICE
Do not allow the fan on the engine to contact the water
When deep holes are dug, do not allow the boom to while the machine travels through the water. Do not
interfere with the tracks. allow the fan on the engine to contact the water during
a swing while the machine is in the water. Damage to
the fan may occur if the fan contacts the water.
i02508641
Travel in Water and Mud While you cross the river, carefully confirm the
depth of the water with the bucket. Do not move the
SMCS Code: 7000-V6 machine into an area that has a water depth that is
greater than Dimension A.
NOTICE
When working in or around any body of water, around The machine may sink gradually on soft ground.
a stream or river, or in conditions of heavy mud, be Therefore, you should frequently check the height of
careful that the swing bearing, the swing drive gear, the undercarriage from ground level and the depth
and the swivel joint do not dip into water, mud, sand, of water on the ground.
or gravel. If the swing bearing dips into water, mud,
sand, or gravel, immediately grease the swing bearing Check the swing gear by looking through the port for
until the used grease leaks from the outer circle of the inspection that is on the upper frame. If there is water
swing bearing. Failure to carry out this procedure may in the swing gear, contact your Caterpiller dealer for
cause premature wear in the swing bearing. the required maintenance on the swing gear.
After you travel through water, carefully clean the

machine in order to remove any salt, sand, or other
foreign matter.
150 SEBU8045-03
Operation Section
Procedure for Removing the

Machine from Water or Mud
NOTICE
Do not allow the machine to swing from the force of
traveling when you use the bucket , the stick, or the
boom to assist in travel. If the force from traveling
causes the machine to swing, damage may occur to
the swing motor and to the swing drive.
g00808152
Illustration 155
3. It may be impossible to travel because the bottom

of the frame comes into contact with the ground or
the undercarriage is clogged with mud or gravel.
In this case, operate the boom and the stick
together. Raise the track and rotate the track
forward and backward in order to remove the mud
and the gravel.
g00808148
Illustration 153 i00072842
1. You may not be able to move the machine by Boom, Stick and Bucket
using the travel controls only. In this case use both
the travel control levers/pedals and the stick to Operation
pull the machine out of the water or ground.
SMCS Code: 7000
Digging
g00808151
Illustration 154
2. The machine may slip because of a steep slope.

The procedure in Step 1 may not work. In this g00101523
Illustration 156
case, first rotate the upper structure by 180°. Then
use both the travel control levers/pedals and the 1. Position the stick at a 70 degree angle to the
stick to move the machine up the slope. ground.
SEBU8045-03 151
Operation Section
5. To apply the greatest force at the cutting edge,

decrease the down pressure as you move the
stick toward the cab.
6. Maintain a bucket attitude that ensures a

continuous flow of material into the bucket.
7. Continue the pass in a horizontal direction so that

material peels into the bucket.
g00101525
Illustration 157
2. Position the bucket cutting edge at a 120 degree

angle to the ground. Maximum breakout force can
now be exerted with the bucket.
g00101528
Illustration 160
8. Close the bucket and raise the boom when the

pass has been completed.
g00101526
Illustration 158
3. Move the stick toward the cab and keep the

bucket parallel to the ground.
g00101529
Illustration 161
9. Engage the swing control when the bucket is clear

of the excavation.
g00101527
Illustration 159
4. If the stick stops due to the load, raise the boom

and/or perform a curl in order to adjust the depth
of the cut.
152 SEBU8045-03
Operation Section
If the lifting bar is used, the connection must be made

with a sling or with a shackle.
g00101530
Illustration 162
10. To dump a load, move the stick outward and open Illustration 164
g00101532
the bucket in a smooth motion.
An unstable condition can exist if a load exceeds the
Lifting Objects machine load rating or if a heavy load is swung over
an end or over a side.
To prevent injury, do not exceed the rated load ca-

pacity of the machine. If the machine is not on lev-
el ground, load capacities will vary.
NOTICE
Damage to bucket cylinder, bucket or linkage could
result if slings are placed incorrectly.
Short slings will prevent excessive load swing.
Note: There may be local government regulations g00101533

Illustration 165
about the use of excavators for the lifting of heavy
objects. Please observe those regulations.
The most stable lifting position is over a corner of
the machine.
g00101531
Illustration 163
g00101534
Illustration 166
Use the lifting bar that is provided on the linkage to
lift objects. Lifting capacities are calculated from this For the best stability, carry a load close to the
point. Adjust to this capacity accordingly. machine and to the ground.
SEBU8045-03 153
Operation Section
The Caterpillar SmartBoom provides significant

advantages in the following operations:
Excavation and Loading

The operator should select the SmartBoom UP AND
DOWN mode for excavating operations and for
loading operations. This mode is effective during
the return cycle. The BOOM DOWN movement
is assisted by gravity, and the pump flow that is
normally required for the boom circuit is available for
faster STICK OUT and SWING functions. More work
is performed for the amount of hydraulic oil flow that
is provided by the pumps. This results in faster cycle
Illustration 167
g00101535 times and improved fuel efficiency.
Lift capacity decreases as the distance from the When the SmartBoom UP AND DOWN mode is
swing centerline is increased. active, no downward hydraulic force is applied to
the boom. The operator can intermittently apply
downward hydraulic force when the force is required
i01410435 for bucket penetration. A button on the right joystick
enables the operator to override the SmartBoom
SmartBoom Operation mode.
SMCS Code: 5461-ZS; 7332
Hammering
The operator should select the SmartBoom UP AND
DOWN mode for hammering operations, unless the
Personal injury or death can result from not fol- rock is extremely hard. In the SmartBoom UP AND
lowing the proper procedures. DOWN mode, the weight of the hammer plus the
boom and the stick provides sufficient downward
To avoid the possibility of injury or death, follow force for effective hammering in most rock and
the established procedure. concrete. This mode also reduces strain on the
machine structures.
NOTICE
For hammering in extremely hard rock, the operator
Always make sure that the boom control joystick
should select the SmartBoom DOWN mode. This
is in the NEUTRAL position before activating the
mode prevents the hammer from rebounding. The
SmartBoom.
boom follows the hammer downward freely as the
tool penetrates the rock.
Do not select any SmartBoom mode, using the Smart-
Boom selector switch located on the console, while
the tracks are elevated. Advantages
If any SmartBoom mode is active while the boom con- In hammering, the SmartBoom provides the following
trol joystick is in the Boom Down position (forward) advantages:
and the bucket or tool is on the ground, do not press
the disable button that is located on the front of the • The mode reduces shock in the cab.
right-hand joystick. Pressing the disable button could
cause a sudden Boom Down motion and tilt the ma- • The mode reduces strain on machine structures.
chine upward.
• The mode prevents blank shots.
While the machine is in any SmartBoom mode, do not
attempt to lift the tracks by using the disable button • The mode maintains optimum frequency.
and applying downward force with the BOOM LOWER
control. Releasing the disable button will immediately In rock cleaning, the SmartBoom provides the
return the machine to the active SmartBoom mode. following advantages:
This action could cause the machine to drop down
abruptly. • The mode reduces strain on machine structures.
154 SEBU8045-03
Operation Section
• The mode reduces wear on the bucket and the 2. Retract the bucket cylinder. Position the quick
teeth. coupler in alignment between the hinges of the
work tool.
• The mode maintains optimum frequency.
In a leveling operation, the SmartBoom eases the
operation. Only STICK IN actuation and bucket
actuation are required to level the surface.
In material handling, the SmartBoom reduces the

chance of damage below the material.
i02498620
Quick Coupler Operation

(Double Action (If Equipped))
SMCS Code: 6129; 6522; 7000
Securing the Work Tool
g00104708
Illustration 169
Inspect coupler wedge engagement before oper- (1) Lower bosses
ating the excavator. (2) Hinges
Serious injury or death may result from an improp- 3. Move the stick forward and raise the stick until
erly engaged coupler. the lower bosses (1) engage the hinges (2) of the
work tool.
Coupler wedge engagement can be inspected
from the cab by rotating the bucket inward or
rotating the work tool inward. Extend the bucket
cylinder in order to make the coupler actuator
visible and bring the stick in until the wedges are
visible.
g01220231
Illustration 170
4. Pull up on the switch and move the switch for the

quick coupler to the UNLOCKED position in order
to extend the wedge. The switch for the quick
coupler is located on the right side of the operator.
Note: Whenever the wedge is extended, a warning

alarm will sound. When the switch for the quick
coupler is moved to the LOCKED position in order to
retract the wedge, the warning alarm will stop.
g00104707
Illustration 168
1. Position the work tool on a level surface.

SEBU8045-03 155
Operation Section
g00104709 g01207244
(3) Center bosses
(4) Locking area 9. Verify that the quick coupler and the work tool are
locked together.
5. Extend the bucket cylinder in order to rotate the
quick coupler toward the work tool. a. Place the work tool on the ground.
Center bosses (3) must engage with the cut-out of b. Apply pressure to the work tool against the
the hinge. ground.
c. Drag the work tool backward.
Releasing the Work Tool
Place the work tool or bucket in a safe position

before disengaging the coupler. Disengaging the
coupler will release the work tool or bucket from
control of the operator.
Serious injury or death may result from disengag-

g01098797
ing the work tool or bucket when it is in an unsta-
Illustration 172 ble position or carrying a load.
6. Pull up on the switch and move the switch for the
quick coupler to the LOCKED position in order to
retract the wedge.
The springs in the quick coupler will move the

wedge into the locking area (4).
7. Retract the bucket cylinder. Make sure that the

wedge is engaged. Shake the work tool.
8. Visually check in order to ensure that the work

tool is properly locked.
156 SEBU8045-03
Operation Section
g00104711 g00104713
1. Level the bucket or level the work tool on the 3. Retract the bucket cylinder in order to move the
ground. quick coupler toward the machine.
4. Move the switch for the quick coupler to the

LOCKED position in order to retract the wedge.
g01220231
Illustration 175
2. Pull up on the switch and move the switch to

the UNLOCKED position in order to extend the
wedge. The switch for the quick coupler is located
on the right side of the operator.
Note: Whenever the wedge is extended, a warning

alarm will sound. When the switch for the quick
coupler is returned to the LOCKED position in order g00104714
Illustration 177
to retract the wedge, the warning alarm will stop.
5. Lower the stick and move the stick toward the
machine in order to disengage the quick coupler.
SEBU8045-03 157
Operation Section
i02282808 5. Remove retainer bolts (3). Move sliding wedges

(2) downward.
Work Tool Changing
6. Tighten four bolts (1) and reinstall retainer bolts
SMCS Code: 6129; 6522; 6700 (3).
Only certain machines are equipped with the
Versa-Link. i02459592
Position the stick in a VERTICAL position. Rotate Hammer Operation

the work tool so that the links and wedges are in a (If Equipped)
VERTICAL position. Lower the work tool close to the
ground but not touching the ground. SMCS Code: 5705-WTL
Once the positions have been found, perform the

following procedure.
g01012969
Illustration 180
g00103353
NOTICE
Illustration 178 Use only a Caterpillar recommended hydraulic ham-
(1) Bolts. (2) Sliding Wedge Locks. (3) Retainer Bolts. mer. The use of a hydraulic hammer not recommend-
ed by Caterpillar could damage your machine. Consult
1. Turn four bolts (1) in the counterclockwise your Caterpillar dealer for information on recommend-
direction until the bolts are loose. The bolts hold ed hydraulic hammers.
the sliding wedge locks (2) in place.
2. Remove retainer bolts (3). Only use the hydraulic hammer to break rocks,
concrete, and other hard objects. Before you start
3. Retract the sliding wedge locks (2) and reinstall hydraulic hammer operation, place the machine on a
the retainer bolts. level, stable surface.
4. Move the machine to the new work tool and Before you start hydraulic hammer operation, close
engage the new work tool. the front window. Caterpillar recommends the
installation of a window guard on the front windshield
for protection from flying debris.
NOTICE
In order to avoid structural damage to the host ma-
chine or the hydraulic hammer, comply with the fol-
lowing:
Do not attempt to break rocks or concrete by burying

the hammer tool completely into the rocks or concrete.
Do not apply a prying force to the hammer tool in order

to remove the hammer tool from the material.
g00103357
Illustration 179
(1) Bolts. (3) Retainer Bolts.
158 SEBU8045-03
Operation Section
Do not allow the hydraulic hammer to continuously

operate at one location and for more than 15
seconds. Change the location of the hydraulic
hammer and repeat the procedure. Failure to change
the location of the hydraulic hammer could cause the
hydraulic oil to overheat. Overheated hydraulic oil
could cause damage to the accumulator.
Stop the hydraulic hammer immediately if the jumper

lines are pulsating violently. This indicates that the
accumulator nitrogen charge is lost. Consult your
Caterpillar dealer for the necessary repair.
NOTICE
Do not use the dropping force of the hydraulic hammer Illustration 181
g00101503
to break rocks or other hard objects. This could cause (1) Incorrect working position
structural damage to the machine. (2) Correct working position
(3) Incorrect working position
Do not use the sides or back of the hydraulic hammer (4) Correct working position
to move rocks or other hard objects. Doing this could
cause damage not only to the hammer but to stick or
i01927702
boom cylinder.
Shear Operation
Do not operate the hydraulic hammer with any of the
cylinders fully retracted or extended. Doing this could (If Equipped)
cause structural damage to the machine, resulting in
reduced machine life. SMCS Code: 5705-WTL
Do not use the hydraulic hammer to lift an object.
Do not operate the hydraulic hammer while the stick

is vertical to the ground. This could allow the stick
cylinder to vibrate excessively.
Operate the attachment control levers carefully in

order to keep the hydraulic hammer’s tool from hitting
the boom.
Do not operate the hydraulic hammer under

water unless the hydraulic hammer is properly
equipped. Operating the hydraulic hammer under
water could cause serious damage to the machine
hydraulic system. Consult your Caterpillar dealer for
information on underwater operation.
Do not operate the hydraulic hammer with the upper

structure sideways to the undercarriage. Before
you start hydraulic hammer operation, place the g00763823
upper structure in the recommended positions that Illustration 182
are shown in illustration 181. Any other operating
positions could make the machine unstable. Any
other operating positions could place excessive loads
on the undercarriage.
Refer to the following for any additional questions

about the operation and care of your Caterpillar
hydraulic hammer: Operation and Maintenance
Manual, SEBU7346, “Hydraulic Hammers”, Operation
and Maintenance Manual, HEPU9000, “Hydraulic
Hammers”, and Decal, SMEU7397, “Hammer
Operation/Maintenance”.
SEBU8045-03 159
Operation Section
NOTICE
Do not operate or work on this work tool unless Using the demolition tool to level the work site or push
you have read and understand the instructions over standing structures may damage the machine or
and warnings in the Operation And Maintenance the demolition tool. Use appropriate equipment to do
Manual for both the work tool and the host ma- site preparation or maintenance operations.
chine.
Align the machine with the work area. Operate the
Failure to follow the instructions or heed the warn- hydraulic shear while you travel backward.
ings could result in injury or death.
Contact your Caterpillar dealer for replacement NOTICE

manuals. Proper care is your responsibility. To avoid structural damage to the machine, do not
break road surfaces by placing the cutting edge of the
hydraulic shear on the ground and moving the ma-
NOTICE chine.
Selection of a hydraulic shear must be done with extra
care. In order to peel the road surface with the hydraulic
shear, place the cutting edge of the stationary jaw
Use of a hydraulic shear not recommended by between the road surface and the road bed. Use the
Caterpillar could result in structural damage to the work tool cylinder to separate the road surface and
machine. the road bed.
Consult your Caterpillar dealer for hydraulic shear in-
formation. NOTICE
Operating the demolition tool with the cylinders fully
retracted or fully extended could cause structural dam-
Be sure that no one is near the work tool in order to age to the machine.
prevent injury. Keep the work tool under control at all
times in order to prevent injury. When a demolition
tool is used, all personnel should maintain a minimum NOTICE
distance of 10 m (33 ft). Using the machine hydraulic cylinders or the demoli-
tion tool rotating device to aid in the breaking or shear-
Close all windows. Make sure that all required ing process may damage the machine or the demoli-
guards are in place. Wear all required protective tion tool rotating device. Use only the arm hydraulic
equipment. Follow the instructions in the Operation cylinders to perform demolition operations.
and Maintenance Manual for the work tool.
NOTICE
Hitting the demolition tool against the ground or solid
object in order to dislodge an obstruction or free the
Serious injury or death could occur from the de- cutting arm may damage the demolition tool or the
molition of pipes, vessels, tanks or other contain- machine. Use a pry bar or cutting torch to free the
ers that may contain gas, flammable materials or cutting arm or dislodge the obstruction.
hazardous chemicals.
Always check the cutting edge alignment after the
Do not perform any demolition work on these jaws are working properly.
items until all of their contents have been re-
moved.
Follow all regulations for the removal and disposal

of these materials.
NOTICE
Cutting train or crane rails, engine crankshafts, welded
fabrications, bearings, shafts, and other hard metals
will increase the wear rate on the cutting edges and
the shear.
160 SEBU8045-03
Operation Section
Parking
Parking i01871055
Freezing Conditions
i02145838
SMCS Code: 7000
Stopping the Machine
If freezing temperatures are expected, remove the
SMCS Code: 7000 mud and the dirt from each track roller frame. Park
the machine on wood planks. Use the following
Park on a level surface. If it is necessary to park on a procedure to clean each track roller frame.
grade, chock the tracks securely.
Note: The swing parking brake is automatically

applied when the machine is stopped. The swing
parking brake is released when the engine is running
and the joystick is activated.
1. Turn the engine speed dial counterclockwise in

order to reduce engine speed.
g00101644
Illustration 184
1. Position the boom over one side of the machine.
2. Use boom down pressure in order to lift the track

on one side off the ground. Operate the track
in the forward direction. Then operate the track
in reverse. Continue this procedure until the
maximum amount of material is thrown off the
g00560313 track.
Illustration 183
2. Release the travel levers/pedals in order to stop 3. Lower the track onto the wood planks.
the machine.
4. Repeat the procedure for the other track.
3. Lower the work tool to the ground. Apply a slight
downward pressure. 5. Clean the area around the carrier rollers and
around the track rollers.
4. Move the hydraulic lockout control to the LOCKED
position. 6. Lower the work tool onto a wood plank in order to
prevent the work tool from touching the ground.
i02109135
Stopping the Engine

SMCS Code: 1000; 7000
NOTICE
Stopping the engine immediately after it has been
working under load can result in overheating and ac-
celerated wear of engine components.
Refer to the following procedure to allow the engine

to cool and to prevent excessive temperatures in the
turbocharger housing, which could cause oil coking
problems.
SEBU8045-03 161
Operation Section
Parking
1. Stop the machine and run the engine at low idle

for five minutes.
NOTICE
Never turn the battery disconnect switch to the OFF
position while the engine is running. Serious damage
to the electrical system may result.
g01048511
Illustration 187
2. Lift cover (1).
3. Push switch (2) upward. This should stop the

engine.
Note: Use the engine start switch to stop the engine

g00683306
Illustration 185 first. Use the engine stop control as an alternate
method to stop the engine.
2. Turn the engine start switch to the OFF position
and remove the engine start switch key. 4. Return the switch to the original position. The
engine will be enabled to start.
Engine Stop Control
Note: Do not operate the machine again until the
Turn the engine start switch to the OFF position. malfunction has been corrected.
If the engine does not stop, perform the following
procedure. 5. Use the method that follows if the previous steps
do not stop the engine.
Stop the Engine if an Electrical

Malfunction Occurs
Turn the engine start switch to the OFF position. If
the engine does not stop, perform the procedure that
follows.
g01073837
Illustration 186
1. The switch is located below the left side of the

operator seat.
g01043693
Illustration 188
The fuel shutoff valve is located under the fuel tank.
162 SEBU8045-03
Operation Section
Parking
Shut off the fuel supply by turning the fuel shutoff

valve clockwise. The engine will stop after consuming
the fuel in the fuel line. The engine may continue to
run for a few minutes.
Repair the engine before you restart the engine. The

fuel system may need to be primed. See Operation
and Maintenance Manual, “Fuel System - Prime” for
instructions.
i02443724
Leaving the Machine

SMCS Code: 7000 Illustration 190
g01221031
6. Remove the bolt that holds the vandalism guards

in place. Remove the vandalism guards from the
storage area.
g00037860
Illustration 189
1. Use the steps and the handholds when you

dismount. When you dismount, face the machine
and use both hands.
2. Inspect the engine compartment for debris. Clean

out any debris in order to avoid a fire hazard.
3. Remove all flammable debris from the front bottom

guard through the access doors in order to reduce
a fire hazard. Discard the debris properly. g00683466
Illustration 191
4. Turn the key for the battery disconnect switch to 7. Install the vandalism guards on the front window
the OFF position. When the machine is left for and on the cab door. An identification number is
an extended period of one month or longer, you stamped on each of the vandalism guards. Install
should remove the key. This will help to prevent the vandalism guards in the correct sequence.
a battery short circuit. Removing the key will also Use bolts (A) only for vandalism guard (3) and for
help to protect the battery from vandalism and vandalism guard (5).
from the current draw that is made by certain
components. Note: When you are storing the vandalism guards,
make sure that you place the guards in the storage
5. Lock all vandalism covers and all compartments. area in sequential order. The vandalism guards will
only fit in the storage area in this manner.
SEBU8045-03 163
Operation Section
Transportation Information
Transportation Information 4. Position the machine so that the machine can

drive straight up the loading ramps. The final
drives should be toward the rear of the machine.
i02540496 Do not operate the control levers while the
machine is on the loading ramps.
Shipping the Machine
5. When you drive over the loading ramp joint areas,
SMCS Code: 7000; 7500 maintain the balance point of the machine.
6. To prevent rolling of the machine or sudden

movement of the machine, perform the following
Automatic Engine Speed Control (AEC) will in- items:
crease engine speed automatically when you
operate the control levers and/or travel pedals • Chock both tracks.
with AEC switch on.
• Install sufficient tie-downs at several locations.
When loading and unloading the machine from
the truck or working in close quarters always turn • Fasten wire cables.
AEC switch off to prevent any possibility of sud-
den movement of machine, which could result in Note: Refer to Operation and Maintenance Manual,
serious injury or death. “Specifications”.
Set the travel speed control switch to LOW before i02540548

loading the machine. Never operate this switch
when loading the machine on a trailer. Securing the Machine
SMCS Code: 7000
Investigate the travel route for overpass clearances.
Make sure that there will be adequate clearance for
the machine. NOTICE
Never transport the machine with the engine running.
Remove ice, snow, or other slippery material from the If the fine swing control is left ON with the engine run-
loading dock and from the truck bed before you load ning, the swing parking brake will stay disengaged.
the machine onto the transport machine. Removing
ice, snow, or other slippery material will help to Comply with any laws that govern the characteristics
prevent the machine from slipping in transit. of a load (length, width, height, and weight).
Note: Obey all laws that govern the characteristics of
a load (height, weight, width, and length). Observe all
regulations that govern wide loads.
Choose the flattest ground when you load the

machine or when you unload the machine.
1. Before you load the machine, chock the trailer

wheels or the rail car wheels.
2. When you use loading ramps, make sure that the

loading ramps have adequate length, adequate
width, adequate strength, and an adequate slope.
3. Maintain the slope of the loading ramps within 15 Illustration 192

g01075262
degrees of the ground.
Note: It is necessary to use two trailers to ship the position.
ultrahigh demolition configuration. The fore boom
and the boom nose can be shipped with the stick and 2. Turn the engine start switch to the OFF position
the linkage. The machine and the boom foot will be in order to stop the engine. Remove the engine
shipped on a separate trailer. start switch key.
164 SEBU8045-03
Operation Section
3. Turn the battery disconnect switch to the OFF i01438164

position and remove the disconnect switch key.
Mirror Installation
4. Lock the door and the access covers. Attach any
vandalism protection. SMCS Code: 7319
g00683723
g00102439 Illustration 194
Illustration 193
(1) Bar
(A) Working position
5. Chock the tracks and secure the machine with (B) Position for transportation
tie-downs. Make sure that you use the proper
rated wire cable. Note: Before you transport the machine, move the
rearview mirror inward.
Use the front towing eyes on the lower frame, the
rear towing eyes on the lower frame, and the rear
towing eye that is on the upper frame.
Securely fasten all loose parts and all removed

parts to the trailer or to the rail car.
When the engine is stopped, the swing parking brake

is automatically applied. This prevents the upper
structure from swinging.
NOTICE
In freezing weather, protect the cooling system with
antifreeze, to the lowest outside expected tempera-
ture on the travel route. Or, drain the cooling system g00683724
completely. Illustration 195
(2) Rearview mirror
After you transport the machine, return the rearview

mirror to the proper position.
SEBU8045-03 165
Operation Section
i01953326 Lifting the Machine Segments

Lifting and Tying Down the Bucket
Machine
(Spreader Bar)
SMCS Code: 7000; 7500
g00115251
Illustration 197
(1) Pin
(2) Sleeve
(3) Bolts
(4) Nuts
g00683762
Illustration 196
Install pin (1) and install sleeve (2) in the brackets
NOTICE of the bucket. Illustration 197 shows the way to
Improper lifting and improper tie-downs can allow the secure pin (1) with bolts (3) and nuts (4). Fasten two
load to shift and cause injury or damage. correctly rated wire cables to pin (1).
The weight and the instructions that are given i02251869

here describe the machine as the machine is
manufactured by Caterpillar.
Lifting and Tying Down the
Machine
Refer to the Operation and Maintenance Manual,
“Specifications” for specific weight information. (Rear Eyes and Front Eyes)
1. Use correctly rated cables and slings for lifting. SMCS Code: 7000; 7500
The crane should be positioned so that the
machine is lifted parallel to the ground.
2. To prevent contact with the machine, lifting cables

should have sufficient length.
3. The width of the spreader bar and the strength of

the spreader bar should be sufficient to prevent
contact with the machine.
When the wire cables are lifted the wire cables

should slide to front track rollers and to the rear
track rollers.
4. Move the lever for the hydraulic lockout control to g00683756

Illustration 198
the LOCKED position.
NOTICE
Improper lifting and improper tie-downs can allow the
load to shift and cause injury or damage.
166 SEBU8045-03
Operation Section
Note: The shipping weight that is listed is the weight

of the most common configuration of the machine. If
attachments have been installed on your machine,
the weight of your machine and the center of gravity
of your machine may vary.

“Specifications” for specific weight information.
1. Use correctly rated cables and slings for lifting.

The crane should be positioned so that the
machine is lifted parallel to the ground.
2. To prevent contact with the machine, lifting cables

should have sufficient length.
3. Use the rear eyes and the front eyes that are
provided on the lower frame to fasten tie-downs.
Use corner protectors for sharp corners.
4. Move the lever for the hydraulic lockout control to

the LOCKED position.
Lifting the Machine Segments

Bucket
g00115251
Illustration 199
(1) Pin
(2) Sleeve
(3) Bolts
(4) Nuts
Install pin (1) and install sleeve (2) in the brackets

of the bucket. Illustration 199 shows the method for
securing pin (1) with bolts (3) and nuts (4). Fasten
two correctly rated wire cables to pin (1).
SEBU8045-03 167
Operation Section
Towing Information
Towing Information Before you tow the machine, make sure that the tow
line or the tow bar is in good condition. Make sure that
the tow line or the tow bar has enough strength for
i00779118 the towing procedure that is involved. The strength of
the tow line or of the tow bar should be at least 150
Towing the Machine percent of the gross weight of the towing machine.
This requirement is for a disabled machine that is
SMCS Code: 7000 stuck in the mud and for towing on a grade.
Attach the cable to the towing eye on the front of

the machine if you are towing the machine forward.
Personal injury or death could result when towing Attach the cable to the drawbar pin on the rear of the
a disabled machine incorrectly. machine if you are towing the machine backward.
Block the machine to prevent movement before fi- Do not use a chain for pulling a disabled machine. A
nal drives are disengaged. The machine can roll chain link can break. This may cause personal injury.
free if it is not blocked. With final drives disen- Use a wire rope cable with ends that have loops or
gaged, the machine cannot be stopped or steered. rings. Put an observer in a safe position in order to
watch the pulling procedure. The observer can stop
Follow the recommendations below, to properly the procedure if the wire rope cable starts to break.
perform the towing procedure. Stop pulling whenever the towing machine moves
without moving the towed machine.
Relieve the hydraulic tank and line pressure be-
fore any disassembly. Operate the travel levers/ Keep the tow line angle to a minimum. Do not exceed
pedals back and forth with the engine stopped to a 30 degree angle from the straight ahead position.
relieve pressure.
Quick machine movement could overload the tow
Removing the plugs from the brake cover of the line or the tow bar. This could cause the tow line
travel motor without first relieving the internal or the tow bar to break. Gradual, steady machine
pressure will cause hydraulic oil to squirt out. movement will be more effective.
Even after the machine has been turned off, the Normally, the towing machine should be as large
hydraulic oil can still be hot enough to burn. Allow as the disabled machine. Make sure that the towing
the hydraulic oil to cool before draining. machine has enough brake capacity, enough weight,
and enough power. The towing machine must be
able to control both machines for the grade that is
NOTICE involved and for the distance that is involved.
To tow the machine, both final drives must be disen-
gaged. You must provide sufficient control and sufficient
braking when you are moving a disabled machine
Do not operate the travel motors with the final drives downhill. This may require a larger towing machine or
disengaged. Damage could result. additional machines that are connected to the rear of
the disabled machine. This will prevent the machine
from rolling away out of control.
These towing instructions are for moving a disabled
machine for a short distance at low speed. Move All situation requirements cannot be listed. Minimal
the machine at a speed of 2 km/h (1.2 mph) or less towing machine capacity is required on smooth, level
to a convenient location for repair. Always haul the surfaces. On inclines or on surfaces in poor condition,
machine if long distance moving is required. maximum towing machine capacity is required.
Shields must be provided on both machines. This Do not tow a loaded machine.
will protect the operator if the tow line or the tow bar
breaks. Consult your Caterpillar dealer for the equipment that
is necessary for towing a disabled machine.
Do not allow an operator to be on the machine that
is being towed.
168 SEBU8045-03
Operation Section
Towing Information
i01440776 8. Remove remaining two cover bolts (2) and final

drive cover (4).
Final Drive Ring Gear Removal
9. Remove twelve bolts (3) and ring gear (5) from
SMCS Code: 4050 final drive cover (4).
10. Install final drive cover (4) and all cover bolts (2).
11. Fill the final drive with new oil. See Operation and
Maintenance Manual, “Final Drive Oil - Change”
for the procedure.
12. Repeat this procedure for the other final drive.
13. Refer to the Service Manual for information on

the installation of the final drive ring gear.
g00754624
Illustration 200
(1) Ring Gear. (2) Cover Bolts. (3) Bolts. (4) Final Drive Cover.
(5) Ring Gear.
Without the ring gear in place, the brakes are inef-

fective. Personal injury or death could result. Pro-
vide other means to hold or stop the machine.
1. Thoroughly clean the area around the final drive.

Make sure that you also clean the track shoes that
are positioned above the final drive.
Note: Refer to Operation and Maintenance Manual,

“General Hazard Information” for information that
pertains to Containing Fluid Spillage.
2. Drain the final drive oil into a suitable container.

See Operation and Maintenance Manual, “Final
Drive Oil - Change” for the procedure.
3. Remove fourteen of sixteen cover bolts (2) from

final drive cover (4). Do not leave a bolt in the top
hole of the cover.
4. Insert an alignment dowel through the top hole of

the cover and into the threads in the final drive
housing. This is necessary in order to support ring
gear (1) while you are removing the final drive
cover.
5. Remove one track shoe in order to allow access

to the face between final drive cover (4) and ring
gear (1).
6. Loosen remaining two cover bolts (2).
7. Use a hammer and a wedge to separate final drive

cover (4) and ring gear (1). Make sure that ring
gear (1) stays in place.
SEBU8045-03 169
Operation Section
Engine Starting (Alternate Methods)
Engine Starting (Alternate

NOTICE
Methods) To prevent damage to engine bearings and to elec-
trical circuits when you jump start a machine, do not
allow the stalled machine to touch the machine that is
i02457337 used as the electrical source.
Engine Starting with Jump Turn on (close) the battery disconnect switch prior to
Start Cables the boost connection to prevent damage to electrical
components on the stalled machine.
SMCS Code: 1000; 7000
Use only equal voltage for starting. Check the battery
and starter voltage rating of your machine. Use only
the same voltage for jump starting. Use of a welder or
higher voltage will damage the electrical system.
Failure to properly service the batteries may cause
peronal injury.
Severely discharged maintenance free batteries do
not fully recharge from the alternator after jump start-
Prevent sparks near the batteries. They could
ing. The batteries must be charged to proper voltage
cause vapors to explode. Do not allow the jump
with a battery charger. Many batteries thought to be
start cable ends to contact each other or the
unusable are still rechargeable.
machine.
Refer to Special Instruction, SEHS7633, “Battery Test
Do not smoke when checking battery electrolyte
Procedure” for complete testing and charging informa-
levels.
tion. This publication is available from your Caterpillar
dealer.
Electrolyte is an acid and can cause personal in-
jury if it contacts skin or eyes.
When the auxiliary start receptacles are not available,
Always wear eye protection when starting a ma- use the following procedure.
chine with jump start cables.
1. Lower the equipment to the ground. Move all
Improper jump start procedures can cause an ex- controls to the HOLD position. Move the hydraulic
plosion resulting in personal injury. lockout control to the LOCKED position.
Always connect the battery positive (+) to battery 2. Turn the start switch on the stalled machine to the
positive (+) and the battery negative (−) to battery OFF position. Turn off all accessories.
negative (−).
3. Turn the battery disconnect switch on the stalled
Jump start only with an energy source with the machine to the ON position.
same voltage as the stalled machine.
4. Move the machine that is being used as an
Turn off all lights and accessories on the stalled electrical source near the stalled machine so that
machine. Otherwise, they will operate when the the jump start cables reach the stalled machine.
energy source is connected. Do not allow the machines to contact each
other.
5. Stop the engine of the machine that is being

used as an electrical source. If you are using
an auxiliary power source, turn off the charging
system.
6. Ensure that battery caps on both machines are

tight and correctly placed. Ensure that batteries in
the stalled machine are not frozen. Make sure that
the batteries have enough electrolyte.
170 SEBU8045-03
Operation Section
Note: The positive terminal of the 24 volt system 10. Finally, connect the other negative end of the
of the source and the negative terminal of the 24 jump start cable to the frame of the stalled
volt system of the source must be identified correctly machine. Do not connect the jump start cable
before the jumper cables are connected. The positive to the battery post. Do not allow the jump start
terminal of the 24 volt system of the discharged cables to contact the battery cables, the fuel lines,
battery must be identified correctly before the jumper the hydraulic lines, or any moving parts.
cables are connected.
11. Start the engine of the machine that is being used
7. The positive ends of the jump start cable are red. as an electrical source or energize the charging
Connect one positive end of the jump start cable system on the auxiliary power source.
to the positive cable terminal of the discharged
battery. Some machines have battery sets. 12. Wait at least two minutes before you attempt
to start the stalled machine. This will allow the
Note: Batteries that are in series may be in separate batteries in the stalled machine to partially charge.
compartments. Use the terminal that is connected
to the starter solenoid. This battery or battery set is 13. Attempt to start the stalled engine. See Operation
normally on the same side of the machine as the and Maintenance Manual, “Engine Starting” for
starter. the correct starting procedure.
Do not allow the positive cable clamps to contact 14. Immediately after you start the stalled engine,
any metal except for the battery terminals. disconnect the jump start cables in reverse order.
i02225711
Engine Starting with Auxiliary

Start Receptacle
SMCS Code: 1000; 7000
g01226420
Illustration 201
Typical example of the location of the batteries in an excavator g01122769
Illustration 202
(1) Red positive post to starter Typical location
(2) The black negative post connects to the battery disconnect
switch.
(3) Do not use these two connections for jump starting. The red Some Caterpillar products may be equipped with
positive post is connected in series to the black negative post. an auxiliary start receptacle as a standard part. If
(4) Cover your machine is not equipped with an auxiliary start
receptacle, the machine can be equipped with an
8. Connect the other positive end of the jump start auxiliary start receptacle from parts service. This
cable to the positive cable terminal of the electrical will ensure that a permanent receptacle is always
source. available in order to jump start the machine.
9. Connect one negative end of the jump start cable There are two cable assemblies that can be used to
to the negative cable terminal of the electrical jump start the stalled machine. You can jump start
source. the stalled machine from another machine that is
equipped with an auxiliary start receptacle or with
an auxiliary power pack. Your Caterpillar dealer can
provide the correct cable lengths for your application.
SEBU8045-03 171
Operation Section
1. Determine the reason that the engine will not start.
Reference: Refer to Special Instruction,

SEHS7633, “Battery Test Procedure” for more
information.
2. Move the transmission direction control lever on

the stalled machine to NEUTRAL. Engage the
hydraulic lockout control. Engage the parking
brake. Lower all work tools to the ground. Move all
controls to HOLD.
3. Turn the engine start switch key on the stalled

machine to the OFF position. Turn off all
accessories.
4. Turn the battery disconnect switch on the stalled

machine to ON.
5. Move the machine that is being used as a power

source close to the stalled machine. The jump
start cables should reach the batteries on both
machines. DO NOT ALLOW THE MACHINES TO
CONTACT EACH OTHER.
6. Stop the engine on the machine that is being used

as a power source. If you use an auxiliary power
source, turn off the charging system.
7. Connect the appropriate jump start cable to the

auxiliary start receptacle on the stalled machine.
8. Connect the other end of the jump start cable to

the auxiliary start receptacle of the machine that is
being used as a power source.
9. Start the engine on the machine that is being

used as a power source or energize the charging
system on the auxiliary power source.
10. Wait for a minimum of two minutes while the

batteries in the stalled machine partially charge.
11. Attempt to start the stalled engine.
12. Immediately after the stalled engine starts,

disconnect the jump start cable from the power
source.
13. Disconnect the other end of the jump start cable

from the stalled machine.
14. Conclude the failure analysis on the starting

charging system of the stalled machine, as
required. Check the machine while the engine is
running and the charging system is in operation.
172 SEBU8045-03
Maintenance Section
Maintenance Access
Maintenance Section Left Front Access Door
Maintenance Access
i01440847
Access Door and Cover

Locations
SMCS Code: 726A-CH
Engine Hood
g00101423
Illustration 205
Right Access Door
g00754693
Illustration 203
Left Rear Access Door

g00101497
Illustration 206
g00101813
Illustration 204
SEBU8045-03 173
Maintenance Section
Lubricant Viscosities and Refill Capacities
Lubricant Viscosities and

Refill Capacities
i02416349
Lubricant Viscosities
SMCS Code: 7581
Table 118
Lubricant Viscosities for Ambient Temperatures
°C °F
Compartment or System Oil Type and Classification Oil Viscosities
Min Max Min Max
SAE 0W-20 −40 10 −40 50
SAE 0W-30 −40 30 −40 86
SAE 0W-40 −40 40 −40 104
Cat DEO Multigrade
Cat DEO SYN SAE 5W-30 −30 30 −22 86
Engine Crankcase(1)(2) Cat Arctic DEO SYN(3)
Cat ECF-1(4) SAE 5W-40 −30 50 −22 122
API CG-4 Multigrade(5)
SAE 10W-30(6) −18 40 0 104
SAE 10W-40 −18 50 0 122
SAE 15W-40 −9.5 50 15 122
SAE 0W-20(7) -40 0 -40 32
SAE 0W-30(8) -40 10 -40 50
Cat TDTO SAE 5W-30(8) -30 10 -22 50

Final Drives and Swing Cat TDTO-TMS
SAE 10W −30 0 -22 32
Drives Cat Arctic TDTO SYN
commercial TO-4 SAE 30 −25 25 −13 77
SAE 50 -15 50 5 122
Cat TDTO-TMS(9) −30 25 -22 77
SAE 0W-20 −40 40 −40 104
Cat HYDO SAE 0W-30 −40 40 −40 104

Cat DEO
SAE 5W-30 −30 40 −22 104
Cat MTO
Cat TDTO SAE 5W-40 −30 40 −22 104
Cat TDTO-TMS
Cat DEO SYN SAE 10W −20 40 −4 104
Cat Arctic DEO SYN
Hydraulic System SAE 30 10 50 50 122
Cat Arctic TDTO SYN
Cat ECF-1 SAE 10W-30 −20 40 −4 104
Cat BIO HYDO (HEES)
API CG-4 SAE 15W-40 −15 50 5 122
API CF
Cat MTO −25 40 −13 104
commercial TO-4
commercial BF-1(10)(11) Cat BIO HYDO (HEES)(10)(11) −40 43 −40 110
Cat TDTO-TMS(9) −20 50 −4 122
(continued)
174 SEBU8045-03
Maintenance Section
(Table 118, contd)

Lubricant Viscosities for Ambient Temperatures
°C °F
Compartment or System Oil Type and Classification Oil Viscosities
Min Max Min Max
SAE 0W-20(7) −40 0 −40 32
SAE 0W-30(8) −40 10 −40 50
SAE 5W-30(8) −35 0 −31 32
Cat TDTO
Track Roller Frame Recoil SAE 10W −30 0 −22 32
Cat TDTO-TMS
Spring and Pivot Shaft
Cat Arctic TDTO SYN SAE 30 −20 25 −4 77
Bearings
commercial TO-4
SAE 40 −10 40 14 104
SAE 50 0 50 32 122
Cat TDTO-TMS(9) −25 25 −13 77
Cat DEO SAE 30 −20 25 −4 77
Cat DEO SYN
Track Idlers and Track SAE 40 −10 40 14 104
Cat ECF-1
Rollers
API CG-4
API CF SAE 5W-40 −35 40 −31 104
(1) Supplemental heat is recommended for cold soaked starts below the minimum ambient temperature. Supplemental heat may be required
for cold soaked starts that are above the minimum temperature that is stated, depending on the parasitic load and other factors. Cold
soaked starts occur when the engine has not been operated for a period of time. This allows the oil to become more viscous due to
cooler ambient temperatures.
(2) API CF oils are not recommended for Caterpillar 3500 Series and smaller Direct Injection (DI) diesel engines. API CF-4 oils are not
recommended for Caterpillar diesel engines.
(3) Cat Arctic DEO SYN is an SAE 0W-30 viscosity grade oil.
(4) API CI-4, API CI-4 PLUS, and API CH-4 oils are acceptable if the requirements of Caterpillar’s ECF-1 (Engine Crankcase Fluid specification
- 1) are met. API CI-4, API CI-4 PLUS, and API CH-4 oils that have not met the requirements of Caterpillar’s ECF-1 specification may cause
reduced engine life.
(5) API CG-4 oils are acceptable for use in all Caterpillar machines with diesel engines. When API CG-4 oil is used, the oil change interval
should not exceed 250 hours. API CG-4 oils that also meet API CI-4, API CI-4 PLUS, or APICH-4 must also meet the requirements
of the Caterpillar ECF-1 specification.
(6) SAE 10W-30 is the preferred viscosity grade for the 3116, 3126, C7, C-9 and the C9 diesel engines when the ambient temperature is
between -18° C (0° F) and 40° C (104° F).
(7) First Choice: Cat Arctic TDTO SYN - SAE 0W-20 Second Choice: Oils of full synthetic base stock without viscosity index improvers that
meet the performance requirements of the TO-4 specification for the SAE 30 viscosity grade. Typical lubricant viscosity grades are SAE
0W-20, SAE 0W-30, and SAE 5W-30. Third Choice: Oils that contain a TO-4 additive package and a lubricant viscosity grade of SAE
0W-20, SAE 0W-30, or SAE 5W-30
(8) First Choice: Oils of full synthetic base stock without viscosity index improvers that meet the performance requirements of the TO-4
specification for the SAE 30 viscosity grade. Typical lubricant viscosity grades are SAE 0W-20, SAE 0W-30, and SAE 5W-30. Second
Choice: Oils that contain a TO-4 additive package and a lubricant viscosity grade of SAE 0W-20, SAE 0W-30, or SAE 5W-30.
(9) Cat TDTO-TMS (Transmission Multi-Season) (synthetic blend that exceeds the TO-4M multigrade specification requirements).
(10) Commercial biodegradable hydraulic oil (HEES) must meet the Caterpillar BF-1 specification. The listed ambient temperature range is for
the current Cat BIO HYDO (HEES), not for commercial BF-1 oil.
(11) Contact your local Caterpillar dealer before using Cat BIO HYDO (HEES) or commercial BF-1 oil. Your machine may not be compatible with
biodegradable hydraulic oil.
Note: For more information, refer to Special

Publication, SEBU6250, “Caterpillar Machine Fluids
Recommendations”.
SEBU8045-03 175
Maintenance Section
i02254226
Capacities (Refill)
SMCS Code: 1000; 7000
Table 119
Approximate Refill Capacities
Component or System Liters US gal Imp gal Recommended Type
Cooling System 35 9.2 7.7
Caterpillar Extended Life Coolant (ELC)
Coolant Reservoir 1.5 0.4 0.3
Fuel Tank 618 163 136 No. 1 Diesel Fuel or No. 2 Diesel Fuel
Engine Crankcase with Filter 35.5 9.4 7.8
Hydraulic System(1) 194 51.2 42.7 Refer to Operation and Maintenance Manual,
Swing Drive 19 5.0 4.18 “Lubricant Viscosities”.
Each Final Drive 8 2.1 1.8

Swing Gear 29 7.7 6.4 Multipurpose Lithium Grease NLGI Grade 2
(1) The amount of hydraulic fluid that is needed to refill the hydraulic system after performing Operation and Maintenance Manual, “Hydraulic
System Oil - Change”
i01822901
S·O·S Information
SMCS Code: 1000; 1348; 3080; 4050; 5050; 7000;
7542-008
S·O·S Services is a highly recommended process

for Caterpillar customers to use in order to minimize
owning and operating cost. Customers provide
oil samples, coolant samples, and other machine
information. The dealer uses the data in order to
provide the customer with recommendations for
management of the equipment. In addition, S·O·S
Services can help determine the cause of an existing
product problem.
Refer to Special Publication, SEBU6250, “Caterpillar

Machine Fluid Recommendations” for detailed
information concerning S·O·S Services.

“Maintenance Interval Schedule” for a specific
sampling location and a service hour maintenance
interval.
Consult your Caterpillar dealer for complete

information and assistance in establishing an S·O·S
program for your equipment.
176 SEBU8045-03
Maintenance Section
Maintenance Support
Maintenance Support
i02000840
Welding on Machines and

Engines with Electronic
Controls
SMCS Code: 1000; 7000
Proper welding procedures are necessary in order to

avoid damage to the electronic controls and to the
bearings. When possible, remove the component
that must be welded from the machine or the engine
and then weld the component. If you must weld near
an electronic control on the machine or the engine,
temporarily remove the electronic control in order to
prevent heat related damage. The following steps
should be followed in order to weld on a machine or
an engine with electronic controls.
1. Turn off the engine. Place the engine start switch

in the OFF position.
2. If equipped, turn the battery disconnect switch to

the OFF position. If there is no battery disconnect
switch, remove the negative battery cable at the
battery.
NOTICE
Do NOT use electrical components (ECM or ECM sen-
sors) or electronic component grounding points for
grounding the welder.
3. Clamp the ground cable from the welder to the

component that will be welded. Place the clamp
as close as possible to the weld. Make sure that
the electrical path from the ground cable to the
component does not go through any bearing. Use
this procedure in order to reduce the possibility of
damage to the following components:
• Bearings of the drive train

• Hydraulic components
• Electrical components
• Other components of the machine
4. Protect any wiring harnesses from the debris
which is created from welding. Protect any wiring
harnesses from the splatter which is created from
welding.
5. Use standard welding procedures in order to weld

the materials together.
SEBU8045-03 177
Maintenance Section
Maintenance Interval Schedule
i02583591 Every 10 Service Hours or Daily

Maintenance Interval Schedule Cooling System Coolant Level - Check .............. 195
Engine Oil Level - Check .................................... 201
SMCS Code: 7000 Fuel System Water Separator - Drain .................. 211
Fuel Tank Water and Sediment - Drain ............... 212
Ensure that all safety information, warnings and Hydraulic System Oil Level - Check ................... 230
instructions are read and understood before any Indicators and Gauges - Test .............................. 234
operation or any maintenance procedures are Seat Belt - Inspect .............................................. 236
performed. Track Adjustment - Inspect ................................. 243
Travel Alarm - Test .............................................. 243
The user is responsible for the performance of Undercarriage - Check ........................................ 244
maintenance, including all adjustments, the use of
proper lubricants, fluids, filters, and the replacement Every 10 Service Hours or Daily for Machines
of components due to normal wear and aging. Failure Used in Severe Applications
to adhere to proper maintenance intervals and
procedures may result in diminished performance of Bucket Linkage - Lubricate ................................. 182
the product and/or accelerated wear of components.
Every 50 Service Hours or Weekly
Use mileage, fuel consumption, service hours, or
calendar time, WHICH EVER OCCURS FIRST, Bucket Linkage - Lubricate ................................. 182
in order to determine the maintenance intervals. Quick Coupler - Lubricate ................................... 235
Products that operate in severe operating conditions
may require more frequent maintenance. Every 50 Service Hours or Weekly After Initial
500 Hours
Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be Hydraulic System Biodegradable Oil Filter Pressure
performed. Gauge - Inspect ................................................ 217
Hydraulic System Pressure Gauge (Fine Filtration
When Required Filter) - Inspect .................................................. 231
Air Conditioner/Cab Heater Filter (Recirculation) - Every 100 Service Hours or 2 Weeks for
Inspect/Replace ................................................ 179 Machines Used in Severe Applications
Battery - Recycle ................................................ 179
Battery or Battery Cable - Inspect/Replace ........ 179 Boom and Stick Linkage - Lubricate ................... 180
Bucket Linkage - Inspect/Adjust ......................... 181
Bucket Tips - Inspect/Replace ............................ 183 Initial 250 Service Hours
Bucket Tips - Inspect/Replace ............................ 185
Bucket Tips - Inspect/Replace ............................ 188 Engine Valve Lash - Check ................................. 207
Final Drive Oil - Change ..................................... 207
Cab Air Filter (Fresh Air) - Clean/Replace .......... 191
Hydraulic System Filter Element (Fine Filtration) -
Circuit Breakers - Reset ...................................... 191
Engine Air Filter Primary Element - Replace ............................................................. 218
Hydraulic System Oil Filter (Case Drain) -
Clean/Replace .................................................. 197
Replace ............................................................. 223
Engine Air Filter Secondary Element - Replace .. 200
Fuel System - Prime ........................................... 208 Hydraulic System Oil Filter (Pilot) - Replace ....... 225
Hydraulic System Oil Filter (Return) - Replace ... 226
Fuses - Replace .................................................. 213
Swing Drive Oil - Change ................................... 237
Fuses - Replace .................................................. 214
High Intensity Discharge Lamp (HID) - Replace .. 216
Hydraulic System Biodegradable Oil Filter Element - Every 250 Service Hours
Replace ............................................................. 216 Cooling System Coolant Sample (Level 1) -
Oil Filter - Inspect ................................................ 234 Obtain ............................................................... 196
Radiator Core - Clean ......................................... 235 Engine Oil Sample - Obtain ................................ 202
Track Adjustment - Adjust ................................... 241 Final Drive Oil Sample - Obtain .......................... 208
Window Washer Reservoir - Fill .......................... 244
Window Wiper - Inspect/Replace ........................ 244
Every 250 Service Hours or Monthly
Windows - Clean ................................................. 244
Belt - Inspect/Adjust/Replace .............................. 180
Every 10 Service Hours or Daily for First 100 Condenser (Refrigerant) - Clean ........................ 192
Hours Final Drive Oil Level - Check .............................. 207
Swing Bearing - Lubricate ................................... 237
Boom and Stick Linkage - Lubricate ................... 180 Swing Drive Oil Level - Check ............................ 239
Bucket Linkage - Lubricate ................................. 182
178 SEBU8045-03
Maintenance Section
Maintenance Interval Schedule
Every 250 Service Hours or Monthly Before Refrigerant Dryer - Replace ................................ 236
Initial 500 Hours Swing Gear - Lubricate ....................................... 240
Hydraulic System Biodegradable Oil Filter Pressure Every Year

Gauge - Inspect ................................................ 217
Cooling System Coolant Sample (Level 2) -
Every 250 Service Hours of Partial Hammer Obtain ............................................................... 197
Use (50% of Service Hours)
Every 3 Years After Date of Installation or
Hydraulic System Oil Filter (Case Drain) - Every 5 Years After Date of Manufacture
Replace ............................................................. 223
Hydraulic System Oil Filter (Pilot) - Replace ....... 225 Seat Belt - Replace ............................................. 237
Initial 500 Hours (for New Systems, Refilled Every 5000 Service Hours or 3 Years
Systems, and Converted Systems)
Hydraulic System Oil (If Equipped with Fine Filtration
Cooling System Coolant Sample (Level 2) - Filter) - Change ................................................. 218
Obtain ............................................................... 197
Every 6000 Service Hours or 3 Years
Every 500 Service Hours
Cooling System Coolant Extender (ELC) - Add .. 194
Hydraulic System Oil Sample - Obtain ............... 231
Swing Drive Oil Sample - Obtain ........................ 239 Every 12 000 Service Hours or 6 Years
Every 500 Service Hours or 3 Months Cooling System Coolant (ELC) - Change ........... 192
Engine Crankcase Breather - Clean ................... 200

Engine Oil and Filter - Change ........................... 202
Fuel System Primary Filter (Water Separator)
Element - Replace ............................................ 210
Fuel System Secondary Filter - Replace ............. 211
Fuel Tank Cap and Strainer - Clean ................... 212
Hydraulic System Filter Element (Fine Filtration) -
Replace ............................................................. 218
Every 500 Service Hours of Partial Hammer

Every 1000 Service Hours or 6 Months

Battery - Clean .................................................... 179
Battery Hold-Down - Tighten ............................... 179
Boom and Stick Linkage - Lubricate ................... 180
Engine Valve Lash - Check ................................. 207
Final Drive Oil Level - Check .............................. 207
Hydraulic System Oil Filter (Case Drain) -
Replace ............................................................. 223
Hydraulic System Oil Filter (Pilot) - Replace ....... 225
Swing Drive Oil - Change ................................... 237
Every 1000 Service Hours of Partial Hammer

Hydraulic System Oil - Change ........................... 219
Every 2000 Service Hours or 1 Year

Final Drive Oil - Change ..................................... 207
Hydraulic System Oil - Change ........................... 219
Hydraulic Tank Screen - Clean ........................... 232
SEBU8045-03 179
Maintenance Section
Air Conditioner/Cab Heater Filter (Recirculation) - Inspect/Replace
i02459073 i00993589
Air Conditioner/Cab Heater Battery - Recycle

Filter (Recirculation) - SMCS Code: 1401-561
Inspect/Replace
Always recycle a battery. Never discard a battery.
SMCS Code: 1054-040-A/C; 1054-510-A/C
Always return used batteries to one of the following
NOTICE locations:
An air recirculation filter element plugged with dust will
result in decreased performance and service life to the • A battery supplier
air conditioner or cab heater.
• An authorized battery collection facility
To prevent decreased performance, clean the filter el-
ement, as required. • Recycling facility
i00934872
Battery Hold-Down - Tighten

SMCS Code: 7257
Tighten the hold-downs for the battery in order to

prevent the batteries from moving during machine
operation.
i01913589
Battery or Battery Cable -

Illustration 207
g01100988 Inspect/Replace
SMCS Code: 1401-040; 1401-510; 1401-561; 1401;
The air conditioner filter is located on the lower left
1402-040; 1402-510
side of the cab behind the seat.
1. Slide the operator seat forward.
2. Slide the filter element upward. Personal injury can result from battery fumes or
explosion.
3. Tap the air filter in order to remove the dirt. Do not
use compressed air to clean the filter. Batteries give off flammable fumes that can ex-
plode. Electrolyte is an acid and can cause per-
4. After you clean the filter element, inspect the filter sonal injury if it contacts the skin or eyes.
element. If the filter element is damaged or badly
contaminated, use a new filter element. Make sure Prevent sparks near the batteries. Sparks could
that the filter element is dry. cause vapors to explode. Do not allow jumper ca-
ble ends to contact each other or the engine. Im-
5. Install the filter element. proper jumper cable connections can cause an ex-
plosion.
i00934864
Always wear protective glasses when working
Battery - Clean with batteries.
SMCS Code: 1401-070 1. Turn the engine start switch key to the OFF
position. Turn all of the switches to the OFF
Clean the battery surface with a clean cloth. Keep the position.
terminals clean and keep the terminals coated with
petroleum jelly. Install the post cover after you coat 2. Turn the battery disconnect switch to the OFF
the terminal post with petroleum jelly. position. Remove the key.
180 SEBU8045-03
Maintenance Section
Belt - Inspect/Adjust/Replace
3. Disconnect the negative battery cable at the c. Install a new belt.

battery.
i01933858
4. Disconnect the positive battery cable at the
battery. Boom and Stick Linkage -
5. Disconnect the battery cables at the battery Lubricate
disconnect switch. The battery disconnect switch
is connected to the machine frame. SMCS Code: 6501-086; 6502-086
6. Make necessary repairs or replace the battery. Note: Caterpillar recommends the use of 5%
molybdenum grease for lubricating the boom,
7. Connect the battery cable at the battery disconnect stick and bucket control linkage. Refer to Special
switch. Publication, SEBU6250, “Caterpillar Machine
Fluids Recommendations” for more information on
8. Connect the positive battery cable of the battery. molybdenum grease.
9. Connect the negative battery cable of the battery. Apply lubricant through all fittings after operation
under water.
10. Install the key and turn the battery disconnect
switch to the ON position. Wipe all fittings before you apply lubricant.
i01606285
Belt - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510;
1397-025; 1397-040; 1397-510
Note: This engine is equipped with a belt tightener

that automatically adjusts the belt to the correct
tension.
1. Unlatch the engine hood and raise the engine

hood.
g00685797
Illustration 209
2. Inspect the belt for wear and for cracking.
1. Apply lubricant through the fitting at the base of
3. If the belt requires replacement, perform Step 3.a
each boom cylinder.
through Step 3.c.
g00685798
g00832096 Illustration 210
Illustration 208
2. The fittings are at the base of the boom. The

a. Turn the belt tensioner in order to release the
fittings can be serviced from the platform on top
tension from the belt.
of the storage box. To lubricate the lower boom
bearings, apply lubricant through fittings (1) and
b. Remove the belt.
(2).
SEBU8045-03 181
Maintenance Section
Bucket Linkage - Inspect/Adjust
3. Apply lubricant through fittings (3) and (4) for the i02168785
boom cylinder rod.
Bucket Linkage -
4. Apply lubricant through fitting (5) for the stick
cylinder head.
Inspect/Adjust
SMCS Code: 6513-025; 6513-040
Note: To ensure proper lubrication of the lower
boom bearings and of the boom cylinder rod end
bearings, lubricant should be applied through fittings
(1), (2), (3), and (4). Apply lubricant first when the
boom is raised and any attachment is suspended. Unexpected machine movement can cause injury
Then apply lubricant when the boom is lowered and or death.
the attachment is rested on the ground with a slight
downward pressure. To avoid possible machine movement, move the
hydraulic lockout control to the locked position
and attach a Special Instruction, SEHS7332, “Do
Not Operate” or similar warning tag to the hy-
draulic lockout control.
NOTICE
Improperly adjusted bucket clearance could cause
galling on the contact surfaces of the bucket and
stick, resulting in excessive noise and/or damaged
O-ring seals.
g00685799
Illustration 211
5. Apply lubricant through fitting (6). Fitting (6) is at

the connection point of the boom and of the stick.
g00101687
Illustration 213
(1) No gap
(2) Stick boss
(3) Bucket clearance
(4) Shims
(5) Pin
(6) Plate
(7) Bolts
(8) Washers
g00685800 (9) Location
Illustration 212
(10) Flange
(11) Bucket boss
6. Apply lubricant through fitting (7) on the stick
cylinder rod, fitting (8) at the connection point of The clearance of the bucket control linkage on
the boom and of the stick, and fitting (9) at the
this machine can be adjusted by shimming. If the
bucket cylinder head end. gap between the bucket and the stick becomes
excessive, adjust bucket clearance (3) to 0.5 to 1 mm
(.02 to .04 inch).
Two shims of different thickness are used at location

(9). The thicknesses of the shims are 0.5 mm
(0.02 inch ) and 1.0 mm (0.04 inch).
182 SEBU8045-03
Maintenance Section
Bucket Linkage - Lubricate
i01936491
Bucket Linkage - Lubricate

SMCS Code: 6513-086
Note: Caterpillar recommends the use of 5%

molybdenum grease for lubricating the boom,
stick and bucket control linkage. Refer to Special
Publication, SEBU6250, “Caterpillar Machine
molybdenum grease.
Wipe all fittings before you apply lubricant.

g00102146
Illustration 214
Area for linkage adjustment
1. Position the machine on a level surface and lower

the bucket to the ground.
2. Slowly operate the swing control lever until stick

boss (2) and the bucket boss (11) are in full face
contact at no gap (1). This will help to determine
the total clearance of the connection point of the
stick and of the bucket.
3. Place the hydraulic lockout control in the LOCKED

position and stop the engine. g00750605
Illustration 215
4. Measure bucket clearance (3), which is the
existing total clearance. Note: Completely fill all cavities of the bucket control
linkage with grease when you initially install a bucket.
5. Determine the number of shims that need to be
removed from shims (4) by using the following 1. Apply lubricant through fittings for the linkages (1),
calculation: (2), (3), and (4).
Subtract 0.5 mm (0.02 inch ) or 1.0 mm (0.04 inch) 2. Apply lubricant through fittings for the bucket (5),
from bucket clearance (3). (6), and (7). Continue to fill with grease until the
grease is visible on both sides of the power link.
6. Remove the appropriate number of shims at
location (9) in order to meet the above thickness. Note: Service the above fittings after you operate
Make sure that you use a minimum of three the bucket under water.
0.5 mm (0.02 inch) shims. To remove the shims,
remove bolts (7), washers (8), and plate (6). Installation of the Bucket
7. After the correct number of shims has been Use the procedure that follows when a bucket is
removed and pin (5) is aligned with the pin changed. Use the procedure that follows when a new
hole, install plate (6), washers (8), and bolts (7). pin is installed. Use the procedure that follows when
Tighten bolts (7) to a torque of 240 ± 40 N·m new bearings are installed.
(175 ± 30 lb ft).
Note: Fill the cavity of the stick nose with grease
8. After installation, make sure that bucket clearance before you install the pin.
(3) is still correct.
1. Insert the pin into the stick nose.
2. Secure the bucket to the stick.

SEBU8045-03 183
Maintenance Section
Bucket Tips - Inspect/Replace
g00840339 g00101352
(5) Fitting (1) Usable
(8) Plug (2) Removal Procedure
(3) Removal Procedure
3. Remove plug (8).
Check the bucket tips for wear. If the bucket tip has a
4. Apply grease through fitting (5). hole, replace the bucket tip.
5. Fill until grease flows out of plug (8). Removal

6. Install plug (8) and tighten plug (8).
7. Continue to fill with grease until the grease is

visible on both sides of stick nose.
8. Apply lubricant through fittings for the bucket

(6), and (7). Continue to fill with grease until the
grease is visible on both sides of power link.
i02420403

SMCS Code: 6805-040; 6805-510 g01124847
Illustration 218
(1) Bucket tip
(2) Retainer
(3) Adapter
Personal injury or death can result from the bucket
falling. Note: Retainers are often damaged during the
removal process. Caterpillar recommends the
Block the bucket before changing bucket tips. installation of a new retainer when bucket tips are
rotated or replaced.
Note: In order to maximize the life of the bucket tip
and the penetration of the bucket tip, the bucket tip
can be rotated.
184 SEBU8045-03
Maintenance Section
Side Cutters
g01175361
Illustration 219
g01092808
Illustration 221
1. Use a pry bar in order to disengage retainer (2). Bucket with side cutters
(A) Side cutters
2. Use the pry bar in order to remove retainer (2)
from bucket tip (1). 1. Remove the mounting bolts and the side cutters.
3. Remove bucket tip (1) from adapter (3) with a 2. Clean the mounting surface of the side plate on
slight counterclockwise rotation. the bucket and of the side cutter. Remove any
burrs or protrusions on the mating surfaces.
4. Clean adapter (3).
Installation
1. Clean the adapter and the area around the latch,
if necessary.
2. Install the new bucket tip onto the adapter with a

slight clockwise rotation.
g01092810
Illustration 222
(A) Side cutter
Note: Some side cutters may be rotated for additional

wear.
3. Install the side cutter.
Note: Certain bolts may require thread compound.

g01124736
Illustration 220
4. Hand tighten the bolts.
3. Install the retainer. Make sure that the retainer’s
latch catches under the tip pocket.
4. Make sure that the latch is properly seated by

trying to remove the bucket tip.
SEBU8045-03 185
Maintenance Section
g01092812 g01055179
Section B-B From Illustration 222 Acceptable wear
(A) Side cutter
(C) Shear ledge on a side cutter
(D) Side plate on a bucket
(E) 0.0 mm (0.0 inch)
5. Make sure that there is not a gap between the

side plate on the bucket and the shear ledge on
the side cutter.
6. Torque the mounting bolts to the correct

specification.
i02420541
Bucket Tips - Inspect/Replace g01055196

Illustration 225
(Drive-through System) Replace this bucket tip.
SMCS Code: 6805-040; 6805-510

hole, replace the bucket tip.
Personal injury or death can result from bucket

falling.
Block the bucket before changing bucket tips or

side cutters.
Bucket Tips
Note: In order to maximize the life of the bucket tip
and the penetration of the bucket tip, the bucket tip
can be rotated.
g01053737
Illustration 226
(1) Bucket tip
(2) Retainer
(3) Adapter
186 SEBU8045-03
Maintenance Section
Removal Procedure 2. Remove the bucket tip from the adapter with a
slight counterclockwise rotation.
Note: Retainers are often damaged during the
removal process. Caterpillar recommends the Installation Procedure
installation of a new retainer when bucket tips are
rotated or replaced. 1. Clean the adapter, if necessary.
2. Install the new bucket tip or the rotated bucket tip

onto the adapter with a slight clockwise rotation.
g01054386
Illustration 227
Internal view
1. The retainer can be removed from the top of the g01053732

Illustration 229
bucket tip or from the bottom of the bucket tip. Use Proper location for installing the retainer
one of the following methods in order to remove
the retainer from the bucket tip:
• Use a hammer and a punch in order to drive out

the retainer.
• Use a pin removal tool. Follow step 1.a through

step 1.b for the procedure.
g01053731
Illustration 230
Internal View
The latch of the retainer is properly seated in the recess of the
bucket tip.
3. The retainer can be installed from the top of the

bucket tip or from the bottom of the bucket tip. Use
g01055210 one of the following methods in order to install the
Illustration 228
retainer into the bucket tip:
Pin removal tool
• Use a hammer in order to drive the retainer into
Note: Carefully follow all safety instructions that are the bucket tip. A punch may be necessary in
provided with the pin removal tool. order to ensure that the latch of the retainer is
properly seated into the recess of the bucket tip.
a. Use a hammer and the short punch of the pin
removal tool in order to unseat the retainer. • Use a pin removal tool. Follow step 3.a through
step 3.b for the procedure.
b. Use a hammer and the long punch of the pin
removal tool in order to completely remove the a. Use a hammer in order to drive the retainer
retainer from the bucket tip. into the bucket tip.
SEBU8045-03 187
Maintenance Section
b. Use a hammer and the short punch of the pin

removal tool in order to ensure that the latch of
the retainer is properly seated into the recess
of the bucket tip.
g01092810
Illustration 233
(A) Side cutter

g01054753
Illustration 231 wear.
A properly installed retainer does not extend beyond the ear of
the bucket tip. 3. Install the side cutter.
4. The retainer is properly seated if the retainer can Note: Certain bolts may require thread compound.
be moved slightly by the technician’s hand. If the
retainer cannot be moved, use the punch or the 4. Hand tighten the bolts.
pin removal tool in order to adjust the retainer,
as needed. The ends of the retainer should not
extend beyond the ear of the bucket tip.
Side Cutters
g01092812
Illustration 234
Section B-B From Illustration 233
(A) Side cutter
(C) Shear ledge on a side cutter
g01092808 (E) 0.0 mm (0.0 inch)
Illustration 232
Bucket with side cutters 5. Make sure that there is not a gap between the
(A) Side cutters side plate on the bucket and the shear ledge on
the side cutter.
1. Remove the mounting bolts and the side cutters.
2. Clean the mounting surface of the side plate on specification.
the bucket and of the side cutter. Remove any
188 SEBU8045-03
Maintenance Section
i02420545

SMCS Code: 6805-040; 6805-510
Block the bucket before changing the bucket

teeth.
To prevent possible injury to the eyes, wear a pro-

tective face shield when striking the pin.
The pin, when struck, can fly out and cause injury Illustration 236
g00590670
to nearby personnel.
(4) Back of Pin-Master
(5) Extractor
Bucket Tips a. Place the Pin-Master on the bucket tip.
b. Align extractor (5) with the pin.
c. Strike the Pin-Master at the back of the tool

(4) and remove the pin.
Note: Discard the old pin and the retainer assembly.

When you change tips, use a new pin and a new
retainer assembly. Refer to the appropriate parts
manual for your machine.
g00101352
Illustration 235
(1) Usable
(2) Replace this bucket tip.
(3) Overworn
hole, replace the bucket tip.
1. Remove the pin from the bucket tip. The pin can
be removed by one of the following methods.
g01194448
Illustration 237
• Use a hammer and a punch from the retainer
side of the bucket to drive out the pin. (6) Retainer assembly
(7) Adapter
• Use a Pin-Master. Follow Step 1.a through Step 2. Clean the adapter and the pin.
1.c for the procedure.
3. Fit retainer assembly (6) into the counterbore that
is in the side of adapter (7). Make sure that the
face of the retainer assembly with the marking
“OUTSIDE” is visible.
SEBU8045-03 189
Maintenance Section
g00101359 g01209140
(4) Back of Pin-Master
4. Install the new bucket tip onto the adapter. (9) Pin holder
(10) Pin setter
Note: The bucket tips can be rotated by 180 degrees
in order to allow the tip to wear evenly. You may also b. Place the Pin-Master over the bucket tips so
move the tips from the outside teeth to the inside that the pin will fit into the counterbore of the
teeth. Check the tips often. If wear is present on the pin holder (9).
tips, rotate the tips. The outside teeth generate the
most wear. c. Strike the Pin-Master with a hammer at the
back of the tool (4) in order to insert the pin.
5. Drive the pin through the bucket tip. The pin can
be installed by using one of the following methods: d. Slide pin holder (9) away from the pin and
rotate the tool slightly in order to align pin setter
• From the same side of the retainer, drive the pin (10) with the pin.
through the bucket tip, the retainer assembly,
and the adapter.
• Use a Pin-Master. Follow Step 5.a through Step

5.e for the procedure.
g01209159
Illustration 241
Final assembly of pin into bucket tip.
e. Strike the end of the tool until the pin is fully

inserted.
g01209166
Illustration 239
(8) Pin
a. Insert pin (8) through the bucket tip.

190 SEBU8045-03
Maintenance Section
Side Cutters
g01092812
Illustration 244
g01092808
Illustration 242 Section B-B From Illustration 243
Bucket With Side Cutters (A) Side cutter
(A) Side cutters (C) Shear ledge on a side cutter
(E) 0.0 mm (0.0 inch)
1. Remove the mounting bolts and the side cutters.
5. Make sure that there is not a gap between the
2. Clean the mounting surface of the side plate on side plate on the bucket and the shear ledge on
the bucket and of the side cutter. Remove any the side cutter.
specification.
Side Protectors
Inspect the wear of the side protector. When too
much wear is present, replace the protector.
g01092810
Illustration 243
(A) Side cutter

wear.
3. Install the side cutter.

g00851494
Illustration 245
Note: Certain bolts may require thread compound.
4. Hand tighten the bolts.

SEBU8045-03 191
Maintenance Section
Cab Air Filter (Fresh Air) - Clean/Replace
The cab air filter is behind the cab.
1. Loosen bolt (1) and open filter cover (2).
g00851496
Illustration 246
(11) Side protector
(12) Pin
(13) Retainer g00730032
Illustration 248
(14) side plate
(2) Filter cover
(3) Air filter
1. Hit pin (12) from the retainer side of the bucket
in order to remove side protector (11) from side
plate (14). 2. Remove air filter (3) from filter cover (2).
2. Clean side protector (11), pin (12), retainer (13) 3. Clean the air filter with a maximum of 200 kPa
and side plate (14) before installation. (30 psi) pressure air.
3. Put retainer (13) in side plate (14). 4. After you clean the air filter, inspect the air filter.
If the air filter is damaged or badly contaminated,
4. Align two pin holes of the new protector and the use a new air filter.
side plate. Hit the pin from the side of the bucket
without the retainer. 5. Install the air filter and the filter cover.
Note: If the pin and/or the retainer are worn, replace Note: Make sure that the arrow on top of the air filter
the pin and/or the retainer. is facing forward.
i02221264
i01547055
Cab Air Filter (Fresh Air) - Circuit Breakers - Reset

Clean/Replace SMCS Code: 1420-529
SMCS Code: 7342-070; 7342-510 Open the access door on the left side of the machine.
g00730030 g01120975
(1) Bolt
(2) Filter cover
192 SEBU8045-03
Maintenance Section
Condenser (Refrigerant) - Clean
Main Breaker (1) – This circuit breaker is designed 3. Use clean water to wash off all dust and dirt from
to protect the electrical system. The circuit breaker the condenser.
has a capacity of 80 Amp.
4. Close the access door.
Air Inlet Heater Circuit (2) – This circuit breaker is
designed to protect the air inlet heater. The circuit
i02582005
breaker has a capacity of 120 Amp.
Alternator Circuit (3) – This circuit breaker is

Cooling System Coolant (ELC)
designed to protect the alternator. If the batteries are - Change
installed with reversed polarity, the circuit breaker
would prevent the alternator from damaging the SMCS Code: 1350-044
rectifier. The circuit breaker has a capacity of 80 Amp.
Circuit Breaker Reset – Push in the button in order

to reset the circuit breaker. If the electrical system is Personal injury can result from hot coolant, steam
working properly, the button will remain depressed. and alkali.
If the button does not remain depressed, check the
appropriate electrical circuit. Repair the electrical At operating temperature, engine coolant is hot
circuit, if necessary. and under pressure. The radiator and all lines
to heaters or the engine contain hot coolant or
i01606351
steam. Any contact can cause severe burns.
Condenser (Refrigerant) - Remove cooling system pressure cap slowly to

relieve pressure only when engine is stopped and
Clean cooling system pressure cap is cool enough to
touch with your bare hand.
SMCS Code: 1805-070
Do not attempt to tighten hose connections when
NOTICE the coolant is hot, the hose can come off causing
If excessively dirty, clean condenser with a brush. To burns.
prevent damage or bending of the fins, do not use a
stiff brush. Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
Repair the fins if found defective.
NOTICE
1. Open the front access door on the left side of the Do not change the coolant until you read and under-
machine. The condenser and the oil cooler are stand the cooling system information in Special Pub-
located behind the cab. lication, SEBU6250, “Caterpillar Machine Fluids Rec-
ommendations”.
Failure to do so could result in damage to the cooling

system components.
NOTICE
Mixing ELC with other products will reduce the effec-
tiveness of the coolant.
This could result in damage to cooling system compo-

nents.
If Caterpillar products are not available and com-

g00537515 mercial products must be used, make sure they
Illustration 250
have passed the Caterpillar EC-1 specification for
Typical example pre-mixed or concentrate coolants and Caterpillar
Extender.
2. Inspect the condenser for debris. Clean the
condenser, if necessary.
Note: This machine was filled at the factory with
Caterpillar Extended Life Coolant.
SEBU8045-03 193
Maintenance Section
Cooling System Coolant (ELC) - Change
If the coolant in the machine is changed to Extended b. Fill the cooling system with clean water.
Life Coolant from another type of coolant, see Special
Publication, SEBU6250, “Caterpillar Machine Fluids c. Install the pressure cap.
Recommendations”.
d. Start the engine and run the engine until the
1. Unlatch the engine hood and raise the engine engine reaches operating temperature.
hood.
e. Stop the engine and allow the engine to cool.
f. Loosen the pressure cap slowly in order to

relieve any pressure in the cooling system.
g. Open the drain valve that is underneath the

radiator and allow the coolant to drain into a
suitable container.
h. Flush the radiator with clean water until the

draining water is transparent.
7. Close the drain valve and install the access cover

underneath the radiator.
g00544510
Illustration 251 8. Add the Extended Life Coolant. Refer to the
following topics:
2. Slowly loosen the pressure cap that is on the
radiator in order to release pressure from the • Special Publication, SEBU6250, “Caterpillar
cooling system. Machine Fluids Recommendations”
3. Remove the pressure cap. • Operation and Maintenance Manual,
“Capacities (Refill)”
9. Start the engine. Operate the engine without

the cooling system pressure cap until the water
temperature regulator opens and the coolant level
stabilizes.
10. Maintain the coolant level within 13 mm (.5 inches)

of the bottom of the filler pipe.
11. Inspect the gasket of the cooling system pressure

cap. If the gasket is damaged, replace the
pressure cap.
g00544378 12. Install the cooling system pressure cap.

Illustration 252
13. Stop the engine.
“General Hazard Information” for information that 14. Open the left access door.
pertains to containing fluid spillage.
4. Remove the access cover that is underneath the

radiator.
5. Open the drain valve and allow the coolant to

drain into a suitable container. The drain valve is
located on the bottom of the radiator.
6. Flush the cooling system. Follow Step 6.a through

Step 6.h in order to properly flush the cooling
system.
a. Close the drain valve.

194 SEBU8045-03
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
Use Caterpillar Extended Life Coolant (ELC) when

you add coolant to the cooling system. See Special
Fluids Recommendations” for all cooling system
requirements.
Use a Coolant Conditioner Test Kit in order to check

the concentration of the coolant.
NOTICE
Mixing ELC with other products will reduce the effec-
tiveness of the coolant.
This could result in damage to cooling system compo-

Illustration 253
g00545226 nents.
(1) “FULL”
(2) “LOW”
If Caterpillar products are not available and com-
mercial products must be used, make sure they
15. Check the coolant reservoir. Maintain the coolant have passed the Caterpillar EC-1 specification for
level between “FULL” mark (1) and “LOW” mark pre-mixed or concentrate coolants and Caterpillar
(2). Extender.
16. If additional coolant is necessary, remove the Note: This machine was filled at the factory with
reservoir cap and add the appropriate coolant Caterpillar Extended Life Coolant.
solution.
1. Park the machine on level ground.
17. Install the reservoir cap.
2. Stop the engine.
18. Close the engine hood and latch the engine hood.
Close the left access door. 3. Unlatch the engine hood and raise the engine
hood.
i02580027
Cooling System Coolant

Extender (ELC) - Add
SMCS Code: 1352; 1353; 1395
Personal injury can result from hot coolant, steam

and alkali.
At operating temperature, engine coolant is hot

and under pressure. The radiator and all lines Illustration 254
g00544510
steam. Any contact can cause severe burns. 4. Make sure that the cooling system has cooled
down. Loosen the cooling system pressure
Remove cooling system pressure cap slowly to cap slowly in order to relieve system pressure.
relieve pressure only when engine is stopped and Remove the pressure cap.
cooling system pressure cap is cool enough to
touch with your bare hand. Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information on
Do not attempt to tighten hose connections when containing fluid spillage.
the coolant is hot, the hose can come off causing
burns. 5. It may be necessary to drain some coolant from
the radiator so that Caterpillar Extender can be
Cooling System Coolant Additive contains alkali. added to the cooling system.
Avoid contact with skin and eyes.
SEBU8045-03 195
Maintenance Section
Cooling System Coolant Level - Check
Note: Always discard drained fluids according to

local regulations.
6. AddCaterpillar Extended Life Coolant (ELC) to the

cooling system. Refer to the following topics for
the proper amount of Caterpillar Extender:
• Special Publication, SEBU6250, “Caterpillar

Machine Fluids Recommendations”

7. Inspect the gasket of the cooling system pressure

cap. If the gasket is damaged, replace the g00545226
pressure cap. Illustration 255
(1) “FULL” level
8. Install the cooling system pressure cap. (2) “LOW” level
9. Close the engine hood and latch the engine hood. 2. Check the coolant level of the coolant reservoir.
Maintain the coolant level between the “FULL”
mark and the “LOW” mark. If the coolant reservoir
i02580035 is empty, follow Steps 2.a through 2.i.
Cooling System Coolant Level a. Unlatch the engine hood and raise the engine
- Check hood.
SMCS Code: 1350-040; 1350-535-FLV;

1395-535-FLV
Personal injury can result from hot coolant, steam

and alkali.
At operating temperature, engine coolant is hot

and under pressure. The radiator and all lines
steam. Any contact can cause severe burns.
Remove cooling system pressure cap slowly to g00544510

Illustration 256
relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to b. Slowly loosen the cooling system pressure cap
touch with your bare hand. in order to relieve system pressure. Remove
the pressure cap.
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing Note: Refer to Operation and Maintenance Manual,
burns. “General Hazard Information” for information on
containing fluid spillage.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes. c. Add the appropriate coolant solution to the
cooling system. Refer to the following topics:
1. Open the left rear access door.
• Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations”

196 SEBU8045-03
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
d. Start the engine. Operate the engine without

the cooling system pressure cap until the water NOTICE
temperature regulator opens and the coolant Always use a designated pump for oil sampling, and
level stabilizes. use a separate designated pump for coolant sampling.
Using the same pump for both types of samples may
e. Maintain the coolant level within 13 mm contaminate the samples that are being drawn. This
(0.5 inch) of the bottom of the filler pipe. contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
f. Inspect the condition of the gasket on the dealers and customers.
pressure cap. If the gasket is damaged, replace
the pressure cap.
NOTICE
g. Install the cooling system pressure cap. Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
h. Stop the engine. ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
i. Close the engine hood and latch the engine ing any compartment or disassembling any compo-
hood. nent containing fluids.
Note: Refer to Operation and Maintenance Manual, Refer to Special Publication, NENG2500, “Caterpillar
“General Hazard Information” for information on Tools and Shop Products Guide” for tools and supplies
containing fluid spillage. suitable to collect and contain fluids on Caterpillar
products.
3. If additional coolant is necessary, remove the
reservoir cap and add the appropriate coolant Dispose of all fluids according to local regulations and
solution. mandates.
4. Install the reservoir cap. Note: Level 1 results may indicate a need for
Level 2 Analysis.
5. Close the left access door.
i02282048
Cooling System Coolant

Sample (Level 1) - Obtain
SMCS Code: 1395-008; 1395-554; 7542
Note: It is not necessary to obtain a Coolant

Sample (Level 1) if the cooling system is filled
with Cat ELC (Extended Life Coolant). Cooling
systems that are filled with Cat ELC should have
a Coolant Sample (Level 2) that is obtained at
the recommended interval that is stated in the Illustration 257
g00832064
Maintenance Interval Schedule. The coolant sampling valve is located near the cooling system
hose.
Note: Obtain a Coolant Sample (Level 1) if the
cooling system is filled with any other coolant Obtain the sample of the coolant as close as possible
instead of Cat ELC. This includes the following to the recommended sampling interval. In order
types of coolants. to receive the full effect of S·O·S analysis, you
must establish a consistent trend of data. In order
• Commercial long life coolants that meet the to establish a pertinent history of data, perform
Caterpillar Engine Coolant Specification -1 consistent samplings that are evenly spaced.
(Caterpillar EC-1) Supplies for collecting samples can be obtained from
your Caterpillar dealer.
• Cat Diesel Engine Antifreeze/Coolant (DEAC)
Use the following guidelines for proper sampling of
• Commercial heavy-duty coolant/antifreeze the coolant:
SEBU8045-03 197
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
• Complete the information on the label for the i02530911

sampling bottle before you begin to take the
samples. Engine Air Filter Primary
Element - Clean/Replace
• Keep the unused sampling bottles stored in plastic
bags. SMCS Code: 1054-070; 1054-510
• Obtain coolant samples directly from the coolant If a warning and a pictograph is displayed on the
sample port. You should not obtain the samples message display or if the exhaust is black, check the
from any other location. primary filter.
• Keep the lids on empty sampling bottles until you 1. Open both access doors on the left side of the
are ready to collect the sample. machine.
• Place the sample in the mailing tube immediately

after obtaining the sample in order to avoid
contamination.
• Never collect samples from expansion bottles.

• Never collect samples from the drain for a system.
Submit the sample for Level 1 analysis.
For additional information about coolant analysis, see

Special Publication, SEBU6250, “Caterpillar Machine
Fluids Recommendations” or consult your Caterpillar
dealer.
g01266485
Illustration 258
i02049802
2. Squeeze the outlet tube (1) slightly in order to
Cooling System Coolant purge the dirt from the outlet tube.
Sample (Level 2) - Obtain

SMCS Code: 1395-008; 1395-554; 7542
Reference: Refer to Operation and Maintenance

Manual, “Cooling System Coolant Sample (Level 1)
- Obtain” for the guidelines for proper sampling of
the coolant.
Obtain the sample of the coolant as close as possible

to the recommended sampling interval. Supplies
for collecting samples can be obtained from your
Caterpillar dealer.
g01266486
Submit the sample for Level 2 analysis. Illustration 259
Reference: For additional information about coolant 3. Loosen the cover latches (2) and remove the air
analysis, refer to Special Publication, SEBU6250, cleaner cover.
“Caterpillar Machine Fluids Recommendations” or
consult your Caterpillar dealer.
198 SEBU8045-03
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
10. Close the access doors.
Cleaning Primary Air Filter

Elements
NOTICE
Caterpillar recommends certified air filter cleaning ser-
vices available at participating Caterpillar dealers. The
Caterpillar cleaning process uses proven procedures
to assure consistent quality and sufficient filter life.
Observe the following guidelines if you attempt to

clean the filter element:
g00101415
Illustration 260
Do not tap or strike the filter element in order to re-
move dust.
4. Remove the primary filter element from the air
cleaner housing.
Do not wash the filter element.
5. Clean the air cleaner cover and the inside of the
Use low pressure compressed air in order to remove
air cleaner housing.
the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
6. Inspect the O-ring seal on the air cleaner cover.
pleats and down the pleats from the inside of the filter
Replace the O-ring seal if the O-ring seal is worn
element. Take extreme care in order to avoid damage
or damaged.
to the pleats.
7. Install the clean primary filter.
Do not use air filters with damaged pleats, gaskets, or
seals. Dirt entering the engine will cause damage to
Note: Refer to “Cleaning Primary Air Filter Elements”.
engine components.
8. Install the air cleaner cover and close the latches
securely. When the primary air filter element is cleaned, check
for rips or tears in the filter material. Replace the
primary air filter element after the primary air filter
element has been cleaned six times. The primary air
filter element should be replaced at least one time
per year. This replacement should be performed
regardless of the number of cleanings.
NOTICE
Do not clean the air filter elements by bumping or tap-
ping. This could damage the seals. Do not use ele-
ments with damaged pleats, gaskets, or seals. Dam-
aged elements will allow dirt to pass through. Engine
damage could result.
g00101416
Illustration 261 Visually inspect the primary air filter elements before
cleaning. Inspect the air filter elements for damage
Note: Install the air cleaner cover properly. The to the seal, the gaskets, and the outer cover. Discard
arrows must point upward. any damaged air filter elements.
9. Change the filter if any of the following conditions There are two common methods that are used to
occurs: clean primary air filter elements:
• Restricted Air Filter indicator on the monitor • Pressurized air

panel still comes on.
• Vacuum cleaning
• Exhaust smoke is still black after the installation
of a primary filter.
SEBU8045-03 199
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
Pressurized Air Inspecting the Primary Air Filter

Pressurized air can be used to clean primary air filter
Elements
elements that have not been cleaned more than two
times. Pressurized air will not remove deposits of
carbon and oil. Use filtered, dry air with a maximum
pressure of 207 kPa (30 psi).
g00281693
Illustration 263
Inspect the clean, dry primary air filter element. Use

a 60 watt blue light in a dark room or in a similar
g00281692
facility. Place the blue light in the primary air filter
Illustration 262 element. Rotate the primary air filter element. Inspect
the primary air filter element for tears and/or holes.
Note: When the primary air filter elements are Inspect the primary air filter element for light that may
cleaned, always begin with the clean side (inside) show through the filter material. If it is necessary in
in order to force dirt particles toward the dirty side order to confirm the result, compare the primary air
(outside). filter element to a new primary air filter element that
has the same part number.
Aim the hose so that the air flows inside the element
along the length of the filter in order to help prevent Do not use a primary air filter element that has any
damage to the paper pleats. Do not aim the stream of tears and/or holes in the filter material. Do not use
air directly at the primary air filter element. Dirt could a primary air filter element with damaged pleats,
be forced further into the pleats. gaskets or seals. Discard damaged primary air filter
elements.
Vacuum Cleaning
Storing Primary Air Filter Elements
Vacuum cleaning is another method for cleaning
primary air filter elements which require daily cleaning If a primary air filter element that passes inspection
because of a dry, dusty environment. Cleaning with will not be used, the primary air filter element can
pressurized air is recommended prior to vacuum be stored for future use.
cleaning. Vacuum cleaning will not remove deposits
of carbon and oil.
g00281694
Illustration 264
200 SEBU8045-03
Maintenance Section
Engine Air Filter Secondary Element - Replace
Do not use paint, a waterproof cover, or plastic as a

protective covering for storage. An air flow restriction
may result. To protect against dirt and damage, wrap
the primary air filter elements in Volatile Corrosion
Inhibited (VCI) paper.
Place the primary air filter element into a box for

storage. For identification, mark the outside of the
box and mark the primary air filter element. Include
the following information:
• Date of cleaning
• Number of cleanings
g00101451
Store the box in a dry location. Illustration 265
3. Remove the secondary filter element.

i01430699
4. Cover the air inlet opening. Clean the inside of
Engine Air Filter Secondary the air cleaner housing.
Element - Replace
5. Remove the cover from the air inlet opening.
SMCS Code: 1054-510
6. Install the new secondary filter element.
NOTICE
7. Install the primary filter element.
Always replace the secondary filter element. Never at-
tempt to reuse the secondary filter element by clean-
8. Install the air cleaner cover and close the latches
ing the element.
securely.
When the primary filter element is replaced, the sec-
ondary filter element should be replaced.
The secondary filter element should also be replaced i01724662

if the air filter restriction warning appears on the mes-
sage display after the installation of a clean primary Engine Crankcase Breather -
filter element or if exhaust smoke is still black. Clean
1. Open the access door on the front left side of the SMCS Code: 1317-070-DJ
machine.
NOTICE
2. See Operation and Maintenance Manual, “Engine Perform this maintenance with the engine stopped.
Air Filter Primary Element - Clean/Replace”.
Remove the air cleaner cover from the air cleaner
housing. Remove the primary filter element from NOTICE
the air cleaner housing. If the crankcase breather is not maintained on a regu-
lar basis, it can become plugged. A plugged breather
will cause excessive crankcase pressure that may
cause crankshaft seal leakage.
SEBU8045-03 201
Maintenance Section
Engine Oil Level - Check
NOTICE
Do not overfill the crankcase. Engine damage can re-
sult.
Note: This machine is equipped with both an

automated function for checking fluid levels and
a dipstick. Refer to Operation and Maintenance
Manual, “Monitoring System” regarding the
automated system. If the machine is on an incline or
the engine has been stopped only for a short time,
then the engine oil does not return to the crankcase
and the fluid level cannot be properly checked by
either method. Park the machine on level ground and
check the oil level after the engine has been stopped
for at least 30 minutes.
Check the oil level while the engine is stopped. Do

not check the oil level while the engine is running.
g00768439 1. Open the engine hood.

Illustration 266
(1) Breather assembly
(2) Bolt
(3) Hose clamp
(4) Hose
1. Loosen hose clamp (3) and remove hose (4) from

breather assembly (1).
2. Remove bolt (2) and the washer. Remove the

breather assembly (1) and the seal.
3. Wash the breather element in solvent that is clean

and nonflammable. Allow the breather element to
dry before installation.
g01172396
Illustration 267
4. Install a breather element that is clean and dry.
Install breather assembly (1) and the seal.
2. Remove the dipstick. Wipe the oil off the dipstick
5. Install bolt (2) and the washer. Refer and reinsert the dipstick.
to Specifications, SENR3130, “Torque
Specifications” for the correct torque.
6. Install hose (4) on breather assembly (1).

Tighten hose clamp (3). Refer to Specifications,
SENR3130, “Torque Specifications” for the correct
torques.
i02582000
Engine Oil Level - Check

SMCS Code: 1000-535
g00832222
Illustration 268
Hot oil and hot components can cause personal 3. Remove the dipstick and check the dipstick. The
injury. Do not allow hot oil or hot components to oil level should be between the “FULL” mark and
contact skin. the “ADD” mark.
202 SEBU8045-03
Maintenance Section
Engine Oil Sample - Obtain
i01920440
NOTICE
Do not fill above the “FULL” mark on the dipstick.
Engine Oil Sample - Obtain
SMCS Code: 1000-008; 1000; 1348-008;
If the oil level is above the “FULL” Mark, the crankshaft
1348-554-SM; 7542-008; 7542-554-OC, SM
might dip into the oil during engine operation. This will
lead to excessively high oil temperatures. High oil tem-
peratures can reduce the lubricating characteristics of
oil.
g00831837
Illustration 270
Obtain a sample of the engine oil from the engine oil

g01172400
sampling valve that is located on the engine oil filter
Illustration 269 housing. Refer to Special Publication, SEBU6250,
“S·O·S Oil Analysis” for information that pertains to
Note: Refer to Operation and Maintenance Manual, obtaining a sample of the engine oil. Refer to Special
“General Hazard Information” for information on Publication, PEHP6001, “How To Take A Good Oil
Containing Fluid Spillage. Sample” for more information about obtaining a
sample of the engine oil.
4. Remove the oil filler plug in order to add oil, if
necessary. See Operation and Maintenance
Manual, “Lubricant Viscosities”. i02581978
Note: If the oil is deteriorated or badly contaminated, Engine Oil and Filter - Change
change the oil regardless of the maintenance interval.
SMCS Code: 1318-510
5. Clean the oil filler plug. Install the oil filler plug.
Selection of the Oil Change Interval
6. Close the engine hood.
NOTICE
A 500 hour engine oil change interval is available, pro-
vided that the operating conditions and recommend-
ed multigrade oil types are met. When these require-
ments are not met, shorten the oil change interval
to 250 hours, or use an S·O·S Services oil sampling
and analysis program to determine an acceptable oil
change interval.
If you select an interval for oil and filter change that is

too long, you may damage the engine.
Caterpillar oil filters are recommended.
Recommended multigrade oil types are listed in Table

120. Do not use single grade oils.
SEBU8045-03 203
Maintenance Section
Engine Oil and Filter - Change
Abnormally harsh operating cycles or harsh Table 120

environments can shorten the service life of Engine Oil Change Interval(1)
the engine oil. Arctic temperatures, corrosive
environments, or extremely dusty conditions may Operating Conditions
require a reduction in engine oil change intervals Severe
from the recommendations in Table 120. Also refer
to Operation and Maintenance Manual, SEBU5898, Normal(2) High Fuel Altitude
“Cold Weather Recommendations for all Caterpillar Load Sulfur above
Machines”. Poor maintenance of air filters or of fuel Multigrade Factor(3) from 1830 m
Oil Type above 0.3% to (6000 ft)
filters requires reduced oil change intervals. See your
Caterpillar dealer for more information if this product 37.8 L 0.5%
(9.8 US
will experience abnormally harsh operating cycles or gal) per
(4)
harsh environments. hr of
fuel
Cat DEO
500 hr 500 hr 500 hr 250 hr(6)
Preferred
Cat ECF-1
11.0
minimum 500 hr 500 hr 500 hr 250 hr(6)
TBN(4)
Preferred
Cat ECF-1
TBN(4) 500 hr 500 hr 250 hr(5) 250 hr(6)
below 11.0
API CG-4 250 hr 250 hr(5) 250 hr(5) 250 hr(6)
(1) The traditional oil change interval for engines is 250 hours. The
standard oil change interval in this machine is 500 hours, if the
operating conditions and recommended oil types that are listed
in this table are met. Improvements in the engine allow this
engine oil change interval. This new standard interval is not
permitted for other machines. Refer to the applicable Operation
and Maintenance Manuals for the other machines.
(2) Normal conditions include these factors: Fuel sulfur below
0.3%, altitude below 1830 m (6000 ft), and good air filter and
fuel filter maintenance. Normal conditions do not include high
load factor, harsh operating cycles, or harsh environments.
(3) High load factors can shorten the service life of your engine oil.
Continuous heavy load cycles and very little idle time result
in increased fuel consumption and oil contamination. These
factors deplete the oil additives more rapidly. If the average fuel
consumption of your machine exceeds 37.8 L (9.8 US gal)
per hour, follow the “High Load Factor” recommendations in
Table 120. To determine average fuel consumption, measure
average fuel consumption for a period of 50 to 100 hours. If
the application of the machine is changed, the average fuel
consumption may change.
(4) For sulfur content above 0.5%, refer to Operation and
Maintenance Manual, SEBU6250, “Caterpillar Machine Fluids
Recommendations”, “Total Base Number (TBN) and Fuel Sulfur
Levels for Direct Injection (DI) Diesel Engines”.
(5) In order to verify an oil change interval of 500 hours, refer to
“Program A” below.
(6) Use “Program B” below to determine an appropriate interval.
Adjustment of the Oil Change Interval

Note: Your Caterpillar dealer has additional
information on these programs.
Program A
Verification for an Oil Change Interval of 500 Hours

204 SEBU8045-03
Maintenance Section
This program consists of three oil change intervals of The Oil Grade Plugs are used on the C9 engine to
500 hours. Oil sampling and analysis is done at 250 enhance start-up in cold weather conditions. When
hours and 500 hours for each of the three intervals changing oil grades, the operator must ensure that
for a total of six oil samples. The analysis includes the corresponding plug is inserted into the wiring
oil viscosity and infrared (IR) analysis of the oil. If harness. The oil grade plugs can be recognized by
all of the results are satisfactory, the 500 hour oil either the identification tags or by the color of the
change interval is acceptable for the machine in that wires.
application. Repeat Program A if you change the
application of the machine. The following plugs are used to inform the ECM when
a particular grade of oil is being used.
If a sample does not pass the oil analysis, take one
of these actions:
• Shorten the oil change interval to 250 hours.

• Proceed to Program B.
• Change to a preferred oil type in Table 120.
Program B
Optimizing Oil Change Intervals
Begin with a 250 hour oil change interval. The oil

change intervals are adjusted by increments. Each
interval is adjusted an additional 50 hours. Periodic oil
sampling and analysis is done during each interval.
The analysis includes oil viscosity and infrared (IR)
analysis of the oil. Repeat Program B if you change
the application of the machine.
If an oil sample does not pass the analysis, shorten g00852969

Illustration 272
the oil change interval, or change to a preferred
multigrade oil type in the listing above. Oil grade plugs being shipped with the engine.
(1) Identification tag for 10W30 oil grade plug
For additional information, see Special Publication, (2) Identification tag for 15W40 oil grade plug
SEBU6250, “Caterpillar Machine Fluids
Recommendations” or consult your Caterpillar dealer.
Oil Grade Plug
g00821713
Illustration 271
Location of the Oil Grade Plug
SEBU8045-03 205
Maintenance Section
Park the machine on a level surface. Stop the engine.
Note: Drain the crankcase while the oil is warm. This

allows waste particles that are suspended in the oil to
drain. As the oil cools, the waste particles will settle
to the bottom of the crankcase. The particles will not
be removed by draining the oil and the particles will
recirculate in the engine lubrication system with the
new oil.
g00852892
Illustration 273
Repair Kit
(3) 10W30 oil grade plug (Green wire) g00101627
Illustration 274
(4) 15W40 oil grade plug (Red wire)
(5) 0W20 oil grade plug (Black wire)
1. The drain valve for the engine crankcase oil is
located under the rear of the upper structure.
10W30 and 15W40 oil grade plugs are shipped with
the engine. The 0W20 oil grade plug can be ordered
from the parts manual. Order the repair kit. The
0W20 oil grade plug can be made from a connector
Containing Fluid Spillage.
repair kit. For the correct pin connections, refer to the
Electrical Schematic or refer to Table 121.
Table 121
OIL GRADE PLUGS
Oil Pin
Plug Wire Color
Grade Connections
3 10W30 Green B-C
4 15W40 Red A-C
5 0W20 Black A-B-C
g00832244
Illustration 275
Procedure for Changing Engine Oil
2. Open the crankcase drain valve. Allow the oil to
and Filter drain into a suitable container.
Note: Discard any drained fluids according to local

regulations.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to 3. Close the drain valve.
contact skin.
4. Open the access door at the right side of the
machine.
Note: If the sulfur content in the fuel is greater than
1.5 percent by weight, use an oil that has a TBN of Refer to Operation and Maintenance Manual,
30 and reduce the oil change interval by one-half. “Access door and Cover Locations”.
206 SEBU8045-03
Maintenance Section
g00832246 g00832234
5. Remove the oil filter with a strap type wrench. See 11. Remove the oil filler plug . Fill the crankcase
Operation and Maintenance Manual, “Oil Filter - with new oil. See Operation and Maintenance
Inspect”. Dispose of the used filter according to Manual, “Capacities (Refill)” and Operation and
local regulations. Maintenance Manual, “Lubricant Viscosities”.
Clean the oil filler plug and install the oil filler plug.
6. Clean the filter housing base. All of the seal
material must be removed. NOTICE
Do not under fill or overfill engine crankcase with oil.
Either condition can cause engine damage.
12. Start the engine and allow the oil to warm. Check
the engine for leaks. Stop the engine.
g00101502
Illustration 277
7. Apply a thin coat of engine oil to the new filter seal.
8. Install the new oil filter by hand.
Instructions for the installation of the filter are Illustration 279

g00832222
printed on the side of each Caterpillar spin-on
filter. For non-Caterpillar filters, refer to the 13. Wait for 30 minutes in order to allow the oil to
installation instructions that are provided by the drain back into the crankcase. Check the oil
supplier of the filter. level with the dipstick. Maintain the oil between
the “FULL” and “ADD” marks on the dipstick. If
9. Close the access door. necessary, add oil.
10. Unlatch the engine hood and raise the engine 14. Close the engine hood and latch the engine hood.
hood.

“Access door and Cover Locations”.
SEBU8045-03 207
Maintenance Section
Engine Valve Lash - Check
i01747875 5. Fill the final drive to the bottom of the opening on

level plug (1). See Operation and Maintenance
Engine Valve Lash - Check Manual, “Lubricant Viscosities” and Operation and
Maintenance Manual, “Capacities (Refill) ”.
SMCS Code: 1102-082; 1102-535; 1102; 1105-025;
1105-535; 1121-535; 1209-082; 1209-535; 1209; 6. Install level plug (1).
7527
7. Perform Step 1 to Step 6 on the other final drive.
Refer to Engine Systems Operation/Testing and Use a different container for the oil so that the oil
Adjusting in order to perform the complete procedure samples from the final drives will be separate.
for the valve lash adjustment.
8. Completely remove the oil that has spilled onto
i02580062
surfaces.
Final Drive Oil - Change 9. Start the engine and allow the final drives to run
through several cycles.
SMCS Code: 4050-044-FLV
10. Stop the engine. Check the oil level.
11. Check the drained oil for metal chips or for

particles. If there are any chips or particles,
consult your Caterpillar dealer.
injury. Do not allow hot oil or hot components to
contact skin.
12. Properly dispose of the drained material. Obey
local regulations for the disposal of the material.
i02580064
Final Drive Oil Level - Check


contact skin.
g00822278
Illustration 280
(1) Oil level plug
(2) Oil drain plug
1. Position one final drive so that oil drain plug (2) is

at the bottom.

Containing Fluid Spillage.
2. Remove drain plug (2) and level plug (1). Allow

the oil to drain into a suitable container.
3. Clean the plugs and inspect the O-ring seals. If Illustration 281
g00822278
wear or damage is evident, replace the drain plug,
(1) Oil level plug
the level plug, and/or the O-ring seals. (2) Oil drain plug
4. Install drain plug (2). 1. Position one final drive so that oil drain plug (2) is
at the bottom.
208 SEBU8045-03
Maintenance Section
Final Drive Oil Sample - Obtain
Note: Refer to Operation and Maintenance Manual, i02531076

Containing Fluid Spillage. Fuel System - Prime
2. Remove oil level plug (1). SMCS Code: 1250-548
3. Check the oil level. The oil should be near the

bottom of the level plug opening.
Fuel leaked or spilled onto hot surfaces or elec-
4. Add oil through the level plug opening, if trical components can cause a fire. To help pre-
necessary. See Operation and Maintenance, vent possible injury, turn the start switch off when
“Lubricant Viscosities”. changing fuel filters or water separator elements.
Clean up fuel spills immediately.
Note: Overfilling the final drive will cause the seals on
the travel motor to allow hydraulic oil or water to enter
the final drive. This may contaminate the final drive. NOTICE
Care must be taken to ensure that fluids are contained
5. Clean oil level plug (1). Inspect the O-ring seal. during performance of inspection, maintenance, test-
Replace the O-ring seal if the O-ring seal is worn ing, adjusting and repair of the product. Be prepared to
or damaged. collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
6. Install oil level plug (1). nent containing fluids.
7. Repeat the procedure for the other final drive. Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
i01920502 products.
Final Drive Oil Sample - Obtain Dispose of all fluids according to local regulations and
mandates.
SMCS Code: 4011-008; 4050-008; 4050-SM;
7542-008
NOTICE
Do not loosen the fuel lines at the fuel manifold. The
fittings may be damaged and/or a loss of priming pres-
sure may occur when the fuel lines are loosened.
Prime the fuel system in order to fill the fuel filter, and
prime the fuel system in order to purge trapped air.
The fuel system should be primed under the following
conditions:
• The fuel tank is running low.

• The machine has been stored.
g00564732
Illustration 282 • The fuel filter is being replaced.
Obtain an oil sample of the final drive oil by removing
the filler plug and taking the sample directly from
Machines with a Mechanical
the final drive housing. Refer to Special Publication, Priming Pump
SEBU6250, “S·O·S Oil Analysis” for information
that pertains to obtaining an oil sample from the 1. Open the access door on the left rear of the
final drive housing. Refer to Special Publication, machine.
PEHP6001, “How To Take A Good Oil Sample” for
more information about obtaining an oil sample from
the final drive housing.
SEBU8045-03 209
Maintenance Section
Fuel System - Prime
Machines with an Electrical Priming

Pump
g01172525
Illustration 283
Priming Pump Plunger
2. Turn the priming pump plunger counterclockwise

in order to unlock the priming pump plunger.
Operate the priming pump plunger until a strong
pressure is felt. This procedure will require
considerable strokes.
3. Push in the priming pump plunger and tighten the Illustration 284
g01247728
priming pump plunger by hand. (1) Switch for the fuel priming pump
(2) Primary fuel filter/water separator
NOTICE
Do not crank the engine continuously for more than The switch for the fuel priming pump is located by the
30 seconds. Allow the starting motor to cool for two primary fuel filter/water separator.
minutes before cranking the engine again.
1. Open the access door on the left rear of the
machine.
4. Crank the engine. If the engine does not start or if
the engine misfires, additional priming is required. 2. Hold the switch for the fuel priming pump in the
Also if the engine emits smoke, additional priming ON position. Allow the fuel priming pump to run for
is required. several seconds.
5. If the engine starts but the engine runs rough, 3. Return the switch for the fuel priming pump to the
continue to run the engine at low idle. Run the OFF position.
engine at low idle until the engine runs properly.
NOTICE
6. Check the fuel system for leaks. Stop the engine.
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
4. Start the engine. If you cannot start the engine,

the engine needs more priming. If the engine
continues to misfire or to smoke, more priming
is necessary.
Note: The fuel priming pump will only operate if the

engine start switch key is in the OFF position. Shut
off the engine before any additional priming.
5. Run the engine at the LOW IDLE position until the

engine runs smoothly.
6. Check the fuel system for leaks. Stop the engine.

210 SEBU8045-03
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
7. Close the access door. 2. Turn drain valve (3) counterclockwise in order to
open. The drain valve is located on the bottom
Note: Do not activate the fuel priming pump while of the water separator.
you crank the engine.
“General Hazard Information” that pertains to
i02540566
Fuel System Primary Filter 3. Drain the water and sediment into a suitable
(Water Separator) Element - container.
Replace Note: Dispose of drained fluids and used filters
according to local regulations.
SMCS Code: 1263-510-FQ
4. Close drain valve (3).
5. Hold the bottom of the filter (1) while you loosen

Personal injury or death may result from failure to bowl (2).
adhere to the following procedures.
6. Remove bowl (2).
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire. 7. Remove filter (1). Discard filter(1).
Clean up all leaked or spilled fuel. Do not smoke 8. Clean the inside surface of the filter head and of
while working on the fuel system. bowl (2).
Turn the disconnect switch OFF or disconnect the 9. Inspect the O-ring on bowl (2). Also inspect the
battery when changing fuel filters. seal on the filter head. Replace these seals if the
seals are worn or damaged.
NOTICE 10. Lubricate the seal of the new element with clean
Do not fill the fuel filters with fuel before installing the diesel fuel.
fuel filters. The fuel will not be filtered and could be
contaminated. Contaminated fuel will cause acceler- 11. Install the new filter by hand.
ated wear to fuel system parts.
Instructions for the installation of the filter are
The primary filter/water separator is located behind printed on the side of each Caterpillar spin-on
the left rear access door. filter. For non-Caterpillar filters, refer to the
installation instructions that are provided by the
1. Open the rear access door on the left side of the supplier of the filter.
machine.
12. Install bowl (2).
13. Prime the fuel system. See Operation and

Maintenance Manual, “Fuel System - Prime” for
instructions.
g01102123
Illustration 285
(1) Filter
(2) Bowl
(3) Drain valve
SEBU8045-03 211
Maintenance Section
Fuel System Secondary Filter - Replace
i02540553
Fuel System Secondary Filter -

Replace
SMCS Code: 1261-510
Personal injury or death can result from a fire.
Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire.
g00101318
Clean up all leaked or spilled fuel. Do not smoke Illustration 287
while working on the fuel system.
5. Apply a thin coat of clean diesel fuel to the sealing
Turn the disconnect switch OFF or disconnect the surface of the new fuel filter.
battery when changing fuel filters.
6. Install the new filter by hand.
NOTICE Instructions for the installation of the filter are
Do not fill fuel filters with fuel before installing them. printed on the side of each Caterpillar spin-on
Contaminated fuel will cause accelerated wear to fuel filter. For non-Caterpillar filters, refer to the
system parts. installation instructions that are provided by the
supplier of the filter.
1. Open the access door on the left side of the
machine. 7. Prime the fuel system. See Operation and
Maintenance Manual, “Fuel System - Prime” for
instructions.
8. Close the access door on the left side of the

machine.
i02529331
Fuel System Water Separator

- Drain
SMCS Code: 1263
1. Open the rear access door on the left side of the

Illustration 286
g01251033 machine.
Note: Refer to Operation and Maintenance Manual, 2. Provide a suitable container for used fluid.
containing fluid spillage. Note: Refer to Operation and Maintenance Manual,
2. Remove the fuel filter. Containing Fluid Spillage.
Note: The fuel filter has not been drained. The filter
contains fuel. When you remove the filter, use caution
in order to avoid spilling the fuel.
3. Inspect the fuel filter for debris by cutting the fuel

filter open.
4. Clean the mounting base of the fuel filter. Make

sure that all of the old seal is removed from the
mounting base.
212 SEBU8045-03
Maintenance Section
Fuel Tank Cap and Strainer - Clean
g00751973 g00824196
(1) Drain valve
(2) Bowl Note: Refer to Operation and Maintenance Manual,
3. Check bowl (2) in the bottom of the water Containing Fluid Spillage.
separator. Open drain valve (1). Drain the water
and sediment in the bowl. 4. Remove the strainer that is located in the filler
opening.
Note: Dispose of used fluids according to local
regulations. 5. Wash the strainer and the fuel tank cap in a clean,
nonflammable solvent.
4. Close drain valve (1).
6. Install a new cap filter kit. Install the gaskets, drain
5. Close the rear access door. valve (3), filter assembly (2), and screws (1).
7. Install the strainer into the filler opening.

i01589598
Fuel Tank Cap and Strainer - 8. Install the fuel tank cap.
Clean
i02115478
SMCS Code: 1273-070-STR

Fuel Tank Water and Sediment
- Drain
SMCS Code: 1273-543
The fuel tank drain valve is located underneath the

main hydraulic pump.
g00824193
Illustration 289
1. Remove the fuel cap.
2. Inspect seal (4) for damage. Replace the seal, if

necessary.
3. Remove screws (1), filter assembly (2), drain Illustration 291

g01043694
valve (3) and the gaskets.
SEBU8045-03 213
Maintenance Section
Fuses - Replace

1. Open the drain valve by turning the valve

counterclockwise. Allow the water and the
sediment to drain into a suitable container.
Note: Dispose of drained fluids according to local

regulations.
2. Close the drain valve by turning the valve

clockwise.
i02355623
Fuses - Replace
SMCS Code: 1417-510
Fuses – Fuses protect the electrical

system from damage that is caused by
overloaded circuits. Change a fuse if the
element separates. If the element of a new fuse
separates, check the circuit and/or repair the circuit.
NOTICE
Always replace fuses with the same type and capacity
fuse that was removed. Otherwise, electrical damage
could result.
NOTICE
If it is necessary to replace fuses frequently, an elec- g01163543
trical problem may exist. Illustration 292
Contact your Caterpillar dealer. (1) Air Conditioner – 15 Amp
(2) Automatic Engine Speed Control (AEC) – 5

To replace a fuse, use the puller that is stored in the Amp
fuse panel. Two fuses of 5 Amperes, three fuses of
10 Amperes, two fuses of 15 Amperes, and one fuse (3) Chassis Light – 10 Amp
of 30 Amperes are contained in the fuse panel as
spare fuses. (4) Cigar Lighter – 10 Amp
The following list identifies the circuits that are (5) 12 Volt 7 Amp Converter 1 – 10 Amp
protected by each fuse. The amperage for each fuse
is included with each circuit. (6) Radio – 5 Amp
(7) Attachment Solenoid – 10 Amp
(8) Seat Heater – 5 Amp
(9) Upper Window Washer and Upper Window

Wiper – 10 Amp
(10) Lower Window Washer and Lower Window

Wiper – 10 Amp
(11) Cab Lamp – 10 Amp

214 SEBU8045-03
Maintenance Section
Fuses - Replace
(12) 12 Volt 7 Amp Converter 1 – 10 Amp i02505439
(13) Beacon Light – 10 Amp Fuses - Replace

(14) Auxiliary Circuit – 10 Amp SMCS Code: 1417-510
(15) Boom Float – 5 Amp
(16) Spare – 5 Amp
(21) Air Conditioner Blower – 15 Amp

g01101038
Illustration 293
(22) Product Link – 5 Amp
The fuse panel is located on the left side of the
(23) Boom Light – 10 Amp
interior storage box. Remove the cover in order to
access the fuses.
(24) Air Conditioner Blower – 10 Amp
Fuses – Fuses protect the electrical
(25) Cab Lamp – 10 Amp
system from damage that is caused by
overloaded circuits. Change a fuse if the
(26) Dome Lamp and Radio – 10 Amp
element separates. If the element of a new fuse
separates, check the circuit and/or repair the circuit.
(27) Engine Start Switch – 10 Amp
(28) Horn – 10 Amp NOTICE

Always replace fuses with the same type and capacity
(29) Machine Control Module – 15 Amp fuse that was removed. Otherwise, electrical damage
could result.
(30) Engine Controller – 15 Amp
(31) Auxiliary Circuit – 10 Amp NOTICE

If it is necessary to replace fuses frequently, an elec-
(32) Auxiliary Circuit – 10 Amp trical problem may exist.
(33) Electric Refueling Pump – 30 Amp Contact your Caterpillar dealer.
(34) Spare – 5 Amp To replace a fuse, use the puller that is stored in the
fuse panel. Three fuses of 5 Amperes, six fuses of 10
(35) Spare – 10 Amp Amperes, two fuses of 15 Amperes, and one fuse
of 30 Amperes are contained in the fuse panel as
(36) Spare – 10 Amp spare fuses.
(37) Spare – 10 Amp The following list identifies the circuits that are
protected by each fuse. The amperage for each fuse
(38) Spare – 10 Amp is included with each circuit.

SEBU8045-03 215
Maintenance Section
Fuses - Replace
(13) Beacon – 10 Amp
(14) Inspection Lamp 1 – 10 Amp
(15) Boom Float – 5 Amp
(16) spare – 5 Amp
(21) Heater and Air Conditioner Blower Fan – 15

Amp
(22) Product Link – 5 Amp
(23) Boom Light – 10 Amp
(24) Air Conditioner Condenser Blower – 10 Amp
(25) Cab Light – 10 Amp
(26) Cab Dome Light and Radio Memory – 10 Amp
(27) Engine Start Switch – 10 Amp
(28) Horn – 10 Amp
(29) Machine Control Module – 25 Amp

g01254332
Illustration 294
(30) Engine Control Module (ECM) – 15 Amp
(1) Air Conditioner – 15 Amp
(31) Inspection Lamp 2 – 10 Amp
(2) Automatic Engine Speed Control (AEC) – 5
Amp (32) Inspection Lamp 3 – 10 Amp
(3) Chassis Light – 10 Amp (33) Electric Refueling Pump – 30 Amp
(4) Cigar Lighter – 10 Amp (34) Spare – 5 Amp
(5) 12 Volt 7 Amp Converter – 10 Amp (35) Spare – 25 Amp
(6) Switch Panel And Radio – 5 Amp (36) Spare – 25 Amp
(7) Attachment Solenoid – 10 Amp (37) Spare – 10 Amp
(8) Seat Heater – 5 Amp (38) Spare – 10 Amp
(9) Window Wiper And Window Washer – 10 Amp (39) Spare – 15 Amp
(10) Lower Window Wiper and Lower Window (40) Spare – 30 Amp
Washer – 10 Amp
(11) Air Suspension Seat – 10 Amp
(12) 12 Volt 7 Amp Converter – 10 Amp

216 SEBU8045-03
Maintenance Section
High Intensity Discharge Lamp (HID) - Replace
i02245859 6. Reattach the electrical power to the HID lamp.

High Intensity Discharge Lamp 7. Check the HID lamp for proper operation.
(HID) - Replace Note: Consult your Caterpillar dealer for additional
(If Equipped) information on HID lamps.
SMCS Code: 1434-510

i02492329
Hydraulic System
HID lamps operate at very high voltages. To avoid Biodegradable Oil Filter
electrical shock and personal injury, disconnect Element - Replace
power before servicing HID lamps.
(If Equipped)
SMCS Code: 5068-510
HID bulbs become very hot during operation.

Before servicing, remove power from lamp for at
least five minutes to ensure lamp is cool.
NOTICE
Although HID bulb materials may change over time,
HID bulbs produced at the time of the printing of this
manual contain mercury. When disposing of this com-
ponent, or any waste that contains mercury, please
use caution and comply with any applicable laws.
1. Remove the electrical power from the high

intensity discharge lamp (HID). The electrical Illustration 295
g00101508
power must be removed from the HID lamp for at
least five minutes, in order to ensure that the bulb 1. Place the machine in the servicing position.
is cool.
2. Disassemble the housing for the HID lamp in order position. Stop the engine.
to have access to the bulb.
Note: On some HID lamps, the bulb is an integral

part of the lens assembly. The bulb is not removed
separately from the lens assembly. Replace the
entire lens assembly on these HID lamps.
3. Remove the bulb from the HID lamp.
4. Install the replacement bulb in the HID lamp.
If the bulb is an integral part of the lens assembly,

install the replacement lens assembly in the HID
lamp.
Note: In order to avoid failure to the bulb that is g01208340

Illustration 296
premature, avoid touching the bulb’s surface with
your bare hands. Clean any fingerprints from the bulb 3. Slowly loosen the filler plug in order to relieve any
with alcohol prior to operation. pressure.
5. Reassemble the housing for the HID lamp. Ensure 4. Tighten the filler plug after the pressure is relieved.
that any printing on the lens is oriented correctly
with respect to the HID lamp’s mounting position 5. Open the access door on the right side of the
on the machine. machine.
SEBU8045-03 217
Maintenance Section
Hydraulic System Biodegradable Oil Filter Pressure Gauge - Inspect
g01090728 g01208340
6. Remove four bolts (1) and cover (2) from the BIO 3. Slowly loosen the filler plug in order to relieve any
filter. pressure.
7. Remove BIO filter element (3) from the filter 4. Tighten the filler plug after the pressure is relieved.
assembly.
5. Place the joysticks in the HOLD position.
8. Install a new filter element.
6. Start the engine and turn the engine speed dial to
9. Close the access door. the high idle position “10”. DO NOT MOVE ANY
CONTROL.
i02491781
7. Open the access door on the right side of the
Hydraulic System machine.
Biodegradable Oil Filter

Pressure Gauge - Inspect
(If Equipped)
SMCS Code: 5068-040
g01087411
Illustration 300
8. Install the pressure gauge on the pressure nipple

on top of the filter and read the value.
If the pressure is between “1 bar” and “3 bars”, the

BIO filter element is clean.
g00101508
Illustration 298
If the pressure is more than “3 bars”, the BIO filter
1. Place the machine in the servicing position. element is clogged. If this occurs, replace the BIO
filter element. Refer to Operation and Maintenance
2. Move the hydraulic lockout control to the LOCKED Manual, “Hydraulic System Biodegradable Oil
position. Stop the engine. Filter Element - Replace” for information on
replacing the BIO filter element.

218 SEBU8045-03
Maintenance Section
Hydraulic System Filter Element (Fine Filtration) - Replace
i02582966
Hydraulic System Filter

Element (Fine Filtration) -
Replace
(If Equipped)
SMCS Code: 5068-510

g01090728
contact skin. Illustration 303
6. Remove four bolts (1) and cover (2) from the fine
filtration filter.
7. Remove element (3) from the filter assembly.
8. Install a new filter element.
i01990521
Hydraulic System Oil (If

Equipped with Fine Filtration
Illustration 301
g00101508
Filter) - Change
1. Place the machine in the servicing position. SMCS Code: 5056-044

position. Stop the engine.
5000 Hour Oil Change Interval
A 5000 hour maintenance interval for hydraulic
oil (change) is available. The extended interval
requires S·O·S monitoring of the hydraulic oil. The
interval for S·O·S monitoring is every 500 hours. The
maintenance interval for the hydraulic oil filter is not
changed. If S·O·S monitoring is not performed, the
2000 hour maintenance interval must be used.
Machines with hammers are not included in the

5000 hour maintenance interval. Machines with
hammers must use the intervals that are listed in
the Maintenance Interval Schedule. Machines that
are used in severe conditions are not included in the
5000 hour maintenance interval. Machines that are
Illustration 302
g01208340 used in severe conditions must use the interval in the
Maintenance Interval Schedule.
3. Slowly loosen the filler plug in order to relieve any
pressure. Lubricants
4. Tighten the filler plug after the pressure is relieved. Approved hydraulic oil must be used to obtain the
5000 hour hydraulic oil change. Refer to the list that
5. Open the access door on the right side of the follows for approved oils.
machine.
SEBU8045-03 219
Maintenance Section
Hydraulic System Oil - Change
Caterpillar Hydraulic Oils Machines with hammers are not included in the
4000 hour maintenance interval. Machines with
• Cat HYDO hammers must use the intervals that are listed in
the Maintenance Interval Schedule. Machines that
• TDTO are used in severe conditions are not included in the
4000 hour maintenance interval. Machines that are
• TDTO (TMS) used in severe conditions must use the interval in the
Maintenance Interval Schedule.
• DEO
Lubricants
• Biodegradable Hydraulic Oil (HEES)
Approved hydraulic oil must be used to obtain the
• MTO 4000 hour hydraulic oil change. Refer to the list that
follows for approved oils.
Commercial Oils
Caterpillar Hydraulic Oils
Diesel engine oils (Heavy Duty) with a minimum
zinc content of 900 ppm can be used. Acceptable • Cat HYDO
commercial oils are identified by the American
Petroleum Institute trademark (API) . Refer to the list • Cat TDTO
that follows for acceptable types of hydraulic oils.
• Cat TDTO-TMS
• CF
• Cat DEO
• CF-4
• Cat BIO HYDO (HEES) (Biodegradable Hydraulic
• CG-4 Oil)
• CH-4 • Cat MTO

Note: Industrial hydraulic oils are not recommended Commercial Oils
for the hydraulic systems of Caterpillar machines.
Industrial hydraulic oils are more likely to allow Diesel engine oils (Heavy Duty) with a minimum
corrosion and Industrial hydraulic oils are more likely zinc content of 900 ppm can be used. Acceptable
to allow excessive wear. commercial oils are identified by the American
Petroleum Institute trademark (API) . Refer to the list
Oil Change that follows for acceptable types of hydraulic oils.
Refer to Operation and Maintenance Manual, • Engine oils that meet the Cat ECF-1 specification
“Hydraulic System Oil - Change” for the procedure to
change the hydraulic oil. • API CG-4
• API CF
i02581938
Hydraulic System Oil - Change • TO-4

Note: Industrial hydraulic oils are not recommended
SMCS Code: 5056-044 for the hydraulic systems of Caterpillar machines.
Industrial hydraulic oils are more likely to allow
4000 Hour Oil Change Interval corrosion and Industrial hydraulic oils are more likely
to allow excessive wear.
A 4000 hour maintenance interval for hydraulic
oil (change) is available. The extended interval
requires S·O·S monitoring of the hydraulic oil. The
interval for S·O·S monitoring is every 500 hours. The
maintenance interval for the hydraulic oil filter is not
changed. If S·O·S monitoring is not performed, the
2000 hour maintenance interval must be used.
220 SEBU8045-03
Maintenance Section
Procedure to Change the Hydraulic

Oil

contact skin.
g01121188
Illustration 306
4. Clean the area thoroughly in order to keep dirt out

of the screen cover. Clean the area thoroughly in
order to keep dirt out of the fill/vent plug.
5. Relieve the internal pressure from the hydraulic

tank by loosening the fill/vent plug. After the
pressure is relieved, remove the fill/vent plug.
g00101435
Illustration 304
1. Park the machine on level ground. Lower the

bucket to the ground so that the stick is vertical.
2. Open the engine access cover.
g00101446
Illustration 307
The oil drain valve is located under the hydraulic tank.
6. Remove the hydraulic tank access cover that is

located under the upper structure. This will allow
access to the drain valve.
g01121186
Illustration 305
3. Remove bolts (1), washers (2), and cover (3) from

the top of the hydraulic tank.
g00687273
Illustration 308
(4) Plug
SEBU8045-03 221
Maintenance Section

“General Hazard Information” for information that
pertains to containing fluid spillage.
7. Remove plug (4).
g01121218
Illustration 310
16. Remove the plug from the tube. Allow the oil to
drain into a container.
Note: Dispose of used filters and used fluids

17. Inspect the O-ring. Replace the O-ring if wear or

damage is evident.
g00687274
18. Clean the plug. Install the plug and the O-ring into
Illustration 309 the drain port.
(5) Pipe Nipple
(6) Hose
(7) Drain plug
8. Replace plug (4) with a 3B-7271 Pipe Nipple (5)

and hose (6).
9. Loosen drain plug (7) in order to drain the oil.
10. Drain the oil into a suitable container.
11. After the oil has been drained, tighten drain plug
(7) to a torque of 110 ± 15 N·m (81 ± 11 lb ft).
12. Remove Pipe Nipple (5) and hose (6).
13. Clean plug (4) and install the plug. Tighten the
plug to a torque of 75 ± 5 N·m (55 ± 48 lb ft).

machine.
g01121224
15. Clean the pump, the hydraulic lines, and the Illustration 311
hydraulic tank. (8) Bolts
(9) Washers
(10) Cover
(11) Spring
(12) Screen
19. Remove bolts (8), washers (9) and cover (10).
Note: Dispose of used filters and used fluids

222 SEBU8045-03
Maintenance Section
Note: Do not allow spring (11) to fall back into the

tank.
20. Remove spring (11) and screen (12).

21. Wash the screen in a clean nonflammable solvent.

Allow the screen to dry. Inspect the screen.
Replace the screen, if the screen is damaged.
g01121239
Illustration 313
27. Inspect the O-ring seal on the filler plug for

damage. Replace the O-ring, if necessary. Clean
the filler plug. Install the filler plug.
g00687278
Illustration 312
(13) O-ring seal
(14) O-ring seal
22. Remove O-ring seal (13) from the screen.
23. Inspect O-ring seals (13) and (14). Replace the

O-ring seals if wear or damage is evident. g01121430
Illustration 314
24. Install O-ring seal (13) on screen (12). (15) Drain hose
(16) Connector
(17) Seal
25. Install screen (12) and spring (11). Then install (18) Negative flow control hose
cover (10), washers (9), and bolts (8).
Note: Make no attempt to start the engine until the
Note: Make sure that the O-ring seals and the spring pump has been filled with hydraulic oil. Serious
are properly positioned during installation. damage to the hydraulic components can result.
26. Fill the hydraulic system oil tank. Refer to 28. When the hydraulic oil has been replaced, the air
Operation and Maintenance Manual, “Capacities must be removed from the hydraulic oil system.
(Refill)”. To remove the air from the hydraulic oil system,
follow Step 28.a through Step 28.g.
a. While the engine is stopped, remove drain

hose (15), connector (16) and seal (17) from
the top of the pump. Add hydraulic oil through
the opening.
b. Check the condition of seal (17). If the seal is

damaged, replace the seal.
c. After the pump has been filled with oil, install

drain hose (15), connector (16) and seal (17) to
the original locations.
SEBU8045-03 223
Maintenance Section
Hydraulic System Oil Filter (Case Drain) - Replace
d. Start the engine. When the engine is at low Reference: For the correct procedure, refer to
idle, fully raise the boom. Hold the boom in Operation and Maintenance Manual, “Hydraulic
this position. System Oil Level - Check”.
e. Slowly loosen negative flow control hose (18) 32. Close the access door.
until the air has been released from the pump.
f. Tighten negative flow control hose (18).
i02581934
g. Stop the engine. Slowly lower the boom until
the bucket is on the ground. This pressurizes
the hydraulic tank.
Hydraulic System Oil Filter
(Case Drain) - Replace
SMCS Code: 5068-510; 5091-510

contact skin.
g01121273
Illustration 315
(19) Fitting
h. Slowly loosen fitting (19) until the hydraulic oil

flows out of the opening. This indicates that the
air has been released from the pump.
i. Tighten fitting (19).
29. Start the engine. Operate the engine at idling g00101435

Illustration 317
speed for five minutes.
1. Park the machine on level ground. Lower the

UNLOCKED position.
3. Turn the engine start switch to the ON position.
4. Move the joysticks and the travel levers/pedals

to the full stroke positions in order to relieve the
pressure in the pilot lines.

and return the lever for the hydraulic lockout
Illustration 316
g00101435 control to the LOCKED position.
30. Operate the joysticks in order to circulate the

hydraulic oil. Lower the bucket to the ground so
that the stick is vertical to the ground. Stop the
engine.
31. Check the hydraulic oil level.

224 SEBU8045-03
Maintenance Section
Hydraulic System Oil Filter (Case Drain) - Replace

10. Remove the used case drain filter from the filter
base.
Note: Used filters should always be disposed of

11. Clean the filter base.
g01208340
Illustration 318
6. Slowly loosen the fill/vent plug on top of the

hydraulic tank in order to relieve the internal
pressure of the hydraulic tank.
7. After the pressure is relieved, tighten the fill/vent

plug.
g00101502
Illustration 321
12. Coat the seal of a new case drain filter with clean
hydraulic oil.

printed on the side of each Caterpillar spin-on
filter. For non-Caterpillar filters, refer to the
installation instructions that are provided by the
g00101497
Illustration 319
14. Start the engine and operate the machine slowly
8. Open the access door on the right side of the for 10 to 15 minutes. Move each cylinder evenly
machine. through several cycles.
g01121031
g00101508
The case drain filter is located near the pilot oil filter.
15. Return the machine to the position that is shown
9. Clean the area in order to keep dirt out of the filter in Illustration 322. Check the machine for oil leaks.
base.
SEBU8045-03 225
Maintenance Section
Hydraulic System Oil Filter (Pilot) - Replace
16. Stop the engine.
17. Check the hydraulic oil level.
Reference: For the correct procedure, refer to

Operation and Maintenance Manual, “Hydraulic
System Oil Level - Check”.
i02581929

(Pilot) - Replace g01208340
Illustration 324
SMCS Code: 5068-510-PS; 5068-510; 5092-510
6. Slowly loosen the fill/vent plug on top of the
hydraulic tank in order to relieve the internal
pressure of the hydraulic tank.
Hot oil and hot components can cause personal 7. After the pressure is relieved, tighten the fill/vent
injury. Do not allow hot oil or hot components to plug.
contact skin.
g00101497
Illustration 325
g00101435
Illustration 323
1. Park the machine on level ground. Lower the machine.

UNLOCKED position.
3. Turn the engine start switch to the ON position.
4. Move the joysticks and the travel levers/pedals

to the full stroke positions in order to relieve the
pressure in the pilot lines.

and return the lever for the hydraulic lockout
control to the LOCKED position.
g01121062
Illustration 326
9. Clean the area in order to keep dirt out of the filter

base.
226 SEBU8045-03
Maintenance Section
Hydraulic System Oil Filter (Return) - Replace
Note: Refer to Operation and Maintenance Manual, The return filter is a cartridge type filter. The amount
“General Hazard Information” for information on of foreign material that enters the hydraulic system is
containing fluid spillage. reduced when the filter element is replaced.
10. Remove the used pilot filter element from the Two different filters are available for the return filter.
filter base. One filter is used for standard applications such as
digging and normal use of a hammer. The second
Note: Used filters should always be disposed of filter is used for an application such as demolishing a
according to local regulations. ceiling in a tunnel with a hammer.
11. Clean the filter base. Note: If the message display shows that the hydraulic
return filter is plugged, turn off the machine. After you
make sure that the warning has disappeared, start
the machine and run the machine on level ground for
approximately 10 minutes. If the warning still appears
in the message display, inspect the filter and replace
the filter, if necessary.
g00101502
Illustration 327
12. Coat the seal of a new pilot filter with clean

hydraulic oil.

g01220269
Illustration 328
printed on the side of each Caterpillar spin-on 1. Loosen the fill/vent plug in order to relieve the
filter. For non-Caterpillar filters, refer to the hydraulic tank pressure. Tighten the fill/vent plug
installation instructions that are provided by the after the hydraulic tank pressure is relieved.
Note: The return filter cartridge is located on the side
14. Check the hydraulic oil level. of the hydraulic tank.
Reference: For the correct procedure, refer to 2. Remove the filter cartridge. Perform Step 2.a
Operation and Maintenance Manual, “Hydraulic through Step 2.f in order to remove the filter
System Oil Level - Check”. cartridge.
i02580552

(Return) - Replace
SMCS Code: 5068-510-RJ

contact skin.
SEBU8045-03 227
Maintenance Section
g00102211 g00102214
(1) Bolts
(2) Washers d. Turn the filter cartridge counterclockwise by
(3) Cover 180 degrees in order to align the projection of
(4) Plug
the filter cartridge with the notch of the filter
(5) Filter cartridge
case. Pull out the filter cartridge.
a. Remove bolts (1), washers (2), and cover (3).

b. Remove plug (4) in order to release the

pressure in filter cartridge (5).
Note: When plug (4) is removed the oil level in the

return filter drops to the level of the hydraulic tank.
g00102219
Illustration 332
(7) O-ring
e. Inspect the cover and O-ring (7). If either part

is damaged, replace the part.
f. Inspect the filter cartridge for debris and

for damage. If necessary, replace the filter
cartridge.
3. Remove the filter element. Perform Step 3.a

Illustration 330
g00102212 through Step 3.f in order to remove the filter
element.
(5) Filter cartridge
(6) Filter case
(A) Guide
c. Pull up the handle at the top of filter cartridge

(5) until the filter cartridge contacts guide (A)
on filter case (6).
228 SEBU8045-03
Maintenance Section
c. Hold the filter cartridge with one hand. Grasp

the grip of plate (8) with your other hand. Lift
plate (8) in order to separate plate (8) from the
filter cartridge.
d. Remove O-ring (11) from plate (8).
e. Lift filter element (12) from shell (10).
f. Pour the remaining oil into a suitable container.
Note: Dispose of used oil according to local

regulations.
g00104507
g. Repeat Step 3.a through Step 3.f for the other
Illustration 333 filter groups.
(4) Plug
(8) Plate 4. Clean the shell of the filter cartridge. Perform Step
(18) O-ring
4.a through Step 4.d in order to clean the shell of
the filter cartridge.
a. Make sure that plug (4) is removed. Make sure
that all of O-ring (18) is removed from plate (8).
g00104511
Illustration 336
Illustration 334
g00918893 (13) Slide plate
(14) Pads
(8) Plate (15) Screws
(9) Spiral retaining ring (19) Port
b. Remove spiral retaining ring (9). a. Turn shell (10) upside-down.
b. Remove screws (15).
c. Remove Pads (14) from slide plate (13).
d. Wash the following parts in a clean

nonflammable solvent: plug (4), plate (8), spiral
retaining ring (9), shell (10), and Pads (14). Dry
the parts.
5. Install the filter elements. Perform Step 5.a through

Step 5.k in order to install the filter elements.
Note: Consult a Caterpillar dealer for the Service Kit

g00104510
that is needed to install the filter element and the
Illustration 335 filter cartridge.
(8) Plate
(10) Shell a. Apply spray type oil to the inside of shell (10) in
(11) O-ring
(12) Filter element
order to prevent rust.
SEBU8045-03 229
Maintenance Section
b. Apply grease to a new O-ring (11).
c. Plate (8) will contact the inside of shell (10).

Apply grease to this point.
d. Apply grease to O-rings inside ports (19) at the

bottom of shell (10).
e. Install new Pads (14). Tighten the screws to a

torque of 0.4 N·m (3.5 lb in).
f. Apply spray type oil into the clearance between

shell (10) and slide plate (13).
g00102220
Illustration 338
(B) Port
(C) Slide plate
a. Check that ports (B) at the bottom of the filter

case are closed.
Note: If the ports are open, rotate slide plate (C)

counterclockwise to the stopper in order to fully
close the ports. When the ports are fully closed, any
remaining oil in the filter case should be completely
removed.
g00104512
Illustration 337
(8) Plate
(10) Shell
(16) Boss
(17) Notch
g. Turn over shell (10). Apply grease to the two

O-rings on new element (12). Install element
(12) into shell (10).
h. Move boss (16) in alignment with notch (17).

Install plate (8) into shell (10).
i. Install spiral retaining ring (9) into the groove

g00102221
in shell (10). Illustration 339
(E) Slide plate
j. Apply grease to new O-ring (18). Install O-ring (D) Port
(18) on plug (4).
b. Check that ports (D) of the filter cartridge are
k. Install plug (4) into plate (8). fully closed.
6. Install the filter cartridge. Perform Step 6.a through Note: The filter cartridge cannot be installed unless
Step 6.e in order to install the filter cartridge. the ports are fully closed. If the ports are open, rotate
slide plate (E) counterclockwise to the stopper in
order to fully close the ports.
230 SEBU8045-03
Maintenance Section
Hydraulic System Oil Level - Check
i02581923
Hydraulic System Oil Level -

Check
SMCS Code: 5050-535

contact skin.
Illustration 340
g00102222 NOTICE
(F) O-rings
Never remove the fill/vent plug from the hydraulic tank
if the oil is hot.
c. Check that O-rings (F) have been installed and
that oil has been applied to O-rings (F). Air can enter the system and cause pump damage.
g00102225 g00102817
(1) Bolts The hydraulic oil tank is on the right side of the machine.
d. Install the filter cartridge into the filter case. 1. Park the machine on level ground. Lower the
Turn the filter cartridge clockwise by 180 bucket to the ground with the stick in a vertical
degrees and push down the filter cartridge position, as shown.
when the filter cartridge contacts guide (A).
e. Install plug (4), cover (3), washers (2), and bolts

(1). Tighten bolts (1) to a torque of 29 ± 5 N·m
(22 ± 4 lb ft).
7. Check the hydraulic system oil level.
Reference: For the correct procedure, refer to

Operation and Maintenance Manual, “Hydraulic
System Oil Level - Check”.
g00102818
Illustration 343

machine.
SEBU8045-03 231
Maintenance Section
Hydraulic System Oil Sample - Obtain
i01920531
Hydraulic System Oil Sample

- Obtain
SMCS Code: 5050-008-OC; 5095-008; 5095-SM;
7542-008; 7542
g01121278
Illustration 344
(A) High temperature range
(B) Low temperature range
3. For a cold machine, maintain the hydraulic oil level

in the low temperature range (B). For a machine
that is at normal operating temperature, maintain
the hydraulic oil level in the high temperature Illustration 346
g00843816
range (A).
The hydraulic oil sampling valve is near the pilot filter.
4. Close the access door. Obtain a sample of the hydraulic oil from the hydraulic
oil sampling valve that is located on the hydraulic
oil filter housing. Refer to Special Publication,
SEBU6250, “S·O·S Oil Analysis” for information that
pertains to obtaining a sample of the hydraulic oil.
Refer to Special Publication, PEHP6001, “How To
Take A Good Oil Sample” for more information about
obtaining a sample of the hydraulic oil.
i02492334
Hydraulic System Pressure

Gauge (Fine Filtration Filter) -
g01208340
Inspect
Illustration 345
(If Equipped)
“General Hazard Information” for information that SMCS Code: 7475-040
Note: Perform Step 5 through Step 7 if the oil level

is low.
5. Slowly loosen the fill/vent plug in order to relieve

any pressure. Add oil, if necessary. See Operation
and Maintenance, “Lubricant Viscosities”.
6. Check the O-ring seal of the fill/vent plug. Replace

the O-ring seal if the O-ring seal is damaged.
7. Clean the fill/vent plug and install the fill/vent plug.
g00101508
Illustration 347
1. Place the machine in the servicing position.

232 SEBU8045-03
Maintenance Section
Hydraulic Tank Screen - Clean
2. Move the hydraulic lockout control to the 9. Close the access door.
ENABLED position. Stop the engine.
i02581915

SMCS Code: 5056-070-Z3

contact skin.
g01208340
Illustration 348
3. Slowly loosen the filler plug in order to relieve any

pressure.
4. Tighten the filler plug after the pressure is relieved.
5. Place the joysticks in the HOLD position.
6. Start the engine and turn the engine speed dial to

the high idle position “10”. DO NOT MOVE ANY
CONTROL.
g00101435
Illustration 350
machine. 1. Park the machine on level ground. Lower the
2. Unlatch the engine hood and raise the engine

hood.
g01087411
Illustration 349
8. Install the pressure gauge on the pressure nipple

on top of the fine filtration filter and read the value.
g01121186
Illustration 351
If the pressure is between “1 bar” and “3 bars”, the (1) Bolts
element for the fine filtration filter is clean. (2) Washers
(3) Cover
If the pressure is more than “3 bars”, the element
is clogged. If this occurs, replace the element for 3. Remove bolts (1), washers (2) and cover (3) from
the fine filtration filter. Refer to Operation and the top of the hydraulic tank.
Maintenance Manual, “Hydraulic System Filter
Element (Fine Filtration) - Replace” for information
on replacing the element for the fine filtration filter.
SEBU8045-03 233
Maintenance Section
8. Wash the screen in a clean nonflammable solvent.

Allow the screen to dry. Inspect the screen.
Replace the screen, if the screen is damaged.
g01121188
Illustration 352
4. Clean the area thoroughly in order to keep dirt out

of the screen cover. Clean the area thoroughly in Illustration 354
g00691204
order to keep dirt out of the fill/vent plug. (9) O-ring seal
(10) O-ring seal
5. Relieve the internal pressure from the hydraulic
tank by loosening the fill/vent plug. After the 9. Remove O-ring seal (9) from screen (12).
pressure is relieved, remove the fill/vent plug.
10. Inspect O-ring seals (9) and (10). Replace the
O-ring seals if wear or damage is evident.
11. Install O-ring seal (9) on screen (12).
12. Install screen (8) and spring (7). Then install

cover (6), washers (5), and bolts (4).
Note: Make sure that the O-ring seals and the spring
are properly positioned during installation.
13. Inspect the O-ring seal on the filler plug for

damage. Replace the O-ring, if necessary. Clean
the filler plug. Install the filler plug.
14. Install cover (3) with bolts (1) and washers (2).
g01121280
Illustration 353
(4) Bolts
(5) Washers
(6) Cover
(7) Spring
(8) Screen
6. Remove bolts (4), washers (5) and cover (6).
Note: Do not allow spring (7) to fall into the tank.
7. Remove spring (7) and screen (8).
Note: Refer to Operation and Maintenance, “General

Hazard Information” for information on containing
fluid spillage.
234 SEBU8045-03
Maintenance Section
Indicators and Gauges - Test
i02116248 i02106227
Indicators and Gauges - Test Oil Filter - Inspect

SMCS Code: 7450-081; 7490-081 SMCS Code: 1308-507; 5068-507
Inspect a Used Filter for Debris
g01077750
Illustration 355
1. Look for broken lenses on the gauges, broken g00100013

Illustration 356
indicator lights, broken switches, and other broken
components in the cab. The element is shown with debris.
2. Start the engine. Use a filter cutter to cut the filter element open.
Spread apart the pleats and inspect the element for
3. Look for inoperative gauges. metal and for other debris. An excessive amount of
debris in the filter element can indicate a possible
4. Turn on all machine lights. Check for proper failure.
operation.
If metals are found in the filter element, a magnet can
5. Move the machine forward. Release the travel be used to differentiate between ferrous metals and
levers and the travel pedals. The machine should nonferrous metals.
stop.
Ferrous metals can indicate wear on steel parts and
6. Stop the engine. on cast iron parts.
7. Make any repairs that are required before Nonferrous metals can indicate wear on the
operating the machine. aluminum parts of the engine such as main bearings,
rod bearings, or turbocharger bearings.
Small amounts of debris may be found in the filter

element. This could be caused by friction and by
normal wear. Consult your Caterpillar dealer in order
to arrange for further analysis if an excessive amount
of debris is found.
Using an oil filter element that is not recommended

by Caterpillar can result in severe engine damage
to engine bearings, to the crankshaft, and to other
parts. This can result in larger particles in unfiltered
oil. The particles could enter the lubricating system
and the particles could cause damage.
SEBU8045-03 235
Maintenance Section
Quick Coupler - Lubricate
i02461929
Quick Coupler - Lubricate

(If Equipped)
SMCS Code: 6129-086
Note: Caterpillar recommends the use of

5% molybdenum grease. Refer to Special
molybdenum grease.
Wipe all fittings before you apply lubricant.
g01197146
Illustration 358
2. Locate the radiator (1).
3. Check all of the core fins for debris.
4. Remove dust and debris from all of the core fins

and from the screens.
g00104878
Illustration 357
Typical Example Compressed air is preferred, but high pressure
water or steam can be used to remove dust and
Apply lubricant through the four fittings on the quick general debris from a core.
coupler. The quick coupler has two fittings on each
side. See Special Publication, SEBD0518, “Know Your
Cooling System” for more detailed information
Note: Do not lubricate the wedge and the wear about cleaning core fins.
plates. Friction is needed in order to hold the wedge
in place during backfilling. 5. Close the access doors.
i02581905
Radiator Core - Clean

SMCS Code: 1353-070
Personal injury can result from air pressure.
Personal injury can result without following prop-

er procedure. When using pressure air, wear a pro-
tective face shield and protective clothing.
Maximum air pressure at the nozzle must be less

than 205 kPa (30 psi) for cleaning purposes.
1. Open the access doors on the left side of the

machine.
236 SEBU8045-03
Maintenance Section
Refrigerant Dryer - Replace
i02252730 i02429589
Refrigerant Dryer - Replace Seat Belt - Inspect

SMCS Code: 7322-510 SMCS Code: 7327-040
Always check the condition of the seat belt and the

condition of the seat belt mounting hardware before
Personal injury can result from contact with refrig- you operate the machine. Replace any parts that are
erant. damaged or worn before you operate the machine.
Contact with refrigerant can cause frost bite. Keep

face and hands away to help prevent injury.
Protective goggles must always be worn when re-

frigerant lines are opened, even if the gauges in-
dicate the system is empty of refrigerant.
Always use precaution when a fitting is removed.

Slowly loosen the fitting. If the system is still un-
der pressure, release it slowly in a well ventilated
area.
Personal injury or death can result from inhaling

refrigerant through a lit cigarette. g00932801
Illustration 359
Inhaling air conditioner refrigerant gas through a Typical example

lit cigarette or other smoking method or inhaling
fumes released from a flame contacting air con- Check the seat belt mounting hardware (1) for wear
ditioner refrigerant gas, can cause bodily harm or or for damage. Replace any mounting hardware that
death. is worn or damaged. Make sure that the mounting
bolts are tight.
Do not smoke when servicing air conditioners or
wherever refrigerant gas may be present. Check buckle (2) for wear or for damage. If the buckle
is worn or damaged, replace the seat belt.
Use a certified recovery and recycling cart to prop-
erly remove the refrigerant from the air condition- Inspect the seat belt (3) for webbing that is worn or
ing system. frayed. Replace the seat belt if the seat belt is worn
or frayed.
NOTICE Consult your Caterpillar dealer for the replacement of

If the refrigerant system has been open to the outside the seat belt and the mounting hardware.
air (without being plugged) for more than 30 minutes,
the receiver-dryer must be replaced. Moisture will en- Note: Within three years of the date of installation or
ter an open refrigerant system and cause corrosion within five years of the date of manufacture, replace
which will lead to component failure. the seat belt. Replace the seat belt at the date which
occurs first. A date label for determining the age of
the seat belt is attached to the seat belt, the seat belt
Refer to Service Manual, SENR5664, “Air buckle, and the seat belt retractor.
Conditioning and Heating System with R-134a
Refrigerant for All Caterpillar Machines” for the proper If your machine is equipped with a seat belt
procedure to change the receiver-dryer assembly extension, also perform this inspection procedure for
and for the procedure to reclaim the refrigerant gas. the seat belt extension.
SEBU8045-03 237
Maintenance Section
Seat Belt - Replace
i02429594
Seat Belt - Replace

SMCS Code: 7327-510
Within three years of the date of installation or within

five years of the date of manufacture, replace the
seat belt . Replace the seat belt at the date which
occurs first. A date label for determining the age of
the seat belt is attached to the seat belt, the seat belt
buckle, and the seat belt retractor.
g00101569
Illustration 361
The swing bearing is under the base of the boom.
g01152685
Illustration 360
(1) Date of installation (retractor)
(2) Date of installation (buckle)
(3) Date of manufacture (tag) (fully extended web)
(4) Date of manufacture (underside) (buckle)
Consult your Caterpillar dealer for the replacement of

the seat belt and the mounting hardware.
g00834905
Illustration 362
If your machine is equipped with a seat belt
extension, also perform this replacement procedure Apply lubricant through the fittings until the lubricant
for the seat belt extension. overflows the bearing seals.
i02379418 i02581851
Swing Bearing - Lubricate Swing Drive Oil - Change

SMCS Code: 7063-086 SMCS Code: 5459-044

“Lubricant Viscosities” for more information on the
types of grease to use. Hot oil and hot components can cause personal
Note: Do not overgrease the swing bearings. Do not contact skin.
grease more than the recommended maintenance
interval. Refer to Operation and Maintenance
Manual, “Maintenance Interval Schedule” for more
information.
Wipe the fittings before you lubricate the swing

bearing.
238 SEBU8045-03
Maintenance Section
Swing Drive Oil - Change
g00101586 g00834927
4. Tighten the drain valve. Hook the drain hose (2)

to the holder (1). Make sure that the end of the
hose is facing upward.
g00834920
Illustration 364
1. Remove the access cover that is located below

the swing drives.
g00834933
Illustration 366
“General Hazard Information” for information that 5. Remove dipstick (4).
6. Add the specified quantity of oil through the
2. Remove drain hose (2) from holder (1) on the dipstick tube. See Operation and Maintenance,
upper frame. Face the end of the hose toward the “Capacities (Refill)”.
container.
3. Use a universal joint with a socket extension to

loosen the drain valve in hole (3). Drain the oil into
a suitable container.
Note: Drained fluids should always be disposed of

g01049757
Illustration 367
7. Maintain the oil level between the tip of the dipstick

and the mark on the dipstick (4).
SEBU8045-03 239
Maintenance Section
Swing Drive Oil Level - Check
8. Check the oil that has been drained for metal chips
or metal particles. Consult your Caterpillar dealer
if any metal chips or metal particles are found.
9. Drained materials should always be disposed of

i02581849
Swing Drive Oil Level - Check

g01049757
Illustration 370
injury. Do not allow hot oil or hot components to Note: Refer to Operation and Maintenance Manual,
contact skin. “General Hazard Information” for information that
2. Check the dipstick. Maintain the oil level between

the tip of the dipstick and the mark on the dipstick.
Add oil through the dipstick tube, if necessary. See
Operation and Maintenance Manual, “Lubricant
Viscosities”.
3. Insert the dipstick.
i01874006
Swing Drive Oil Sample -

Obtain
g00101622
Illustration 368
SMCS Code: 5459-008; 5459-008-OC;
5459-554-OC; 5459-OC; 7542-008
The dipstick for the swing drive oil is on the swing
drive at the rear base of the boom.
g00831846
Illustration 371
g00831846
Illustration 369
Obtain an oil sample of the swing drive oil through the
1. Remove the dipstick. opening for the dipstick. Refer to Special Publication,
SEBU6250, “S·O·S Oil Analysis” for information
that pertains to obtaining an oil sample from the
swing drive housing. Refer to Special Publication,
PEHP6001, “How To Take A Good Oil Sample” for
more information about obtaining an oil sample from
the swing drive housing.
240 SEBU8045-03
Maintenance Section
Swing Gear - Lubricate
i01727115
Swing Gear - Lubricate

SMCS Code: 7063-086
NOTICE
Improper lubrication can cause damage to machine
components.
To avoid damage, make sure that the proper amount

of grease is applied to the swing drive.
When the amount of grease in the compartment be-

comes too large, the agitation loss becomes large, g00834993
thereby accelerating grease deterioration. Illustration 373
(1) Bolts
Grease deterioration can cause damage to the pinion (2) Washers
(3) Cover
gear of the swing drive and swing internal gear. (4) Gasket
Not enough grease will result in poor gear lubrication. 1. Remove bolts (1) and washers (2). Remove cover
(3) and gasket (4).
“Lubricant Viscosities” for more information on the
types of grease to use.
g00688058
Illustration 374
(3) Cover
(4) Gasket
g00834990
Illustration 372
2. Inspect gasket (4). Replace the gasket if there is
Remove the inspection cover that is located near the damage.
boom base. Inspect the grease.
3. Check the level of the grease. The grease should
be evenly distributed on the floor of the pan.

“Capacities (Refill)” for the size of the pan.
Add grease, as needed. Remove grease, as

needed. Too much grease will result in the
deterioration of the grease because of excessive
movement of the grease. Too little grease will
result in poor lubrication of the swing gear.
SEBU8045-03 241
Maintenance Section
Track Adjustment - Adjust
i02255665

SMCS Code: 4170-025
Personal injury or death can result from grease

under pressure.
Grease coming out of the relief valve under pres-

sure can penetrate the body causing injury or
death.
g00688063
Illustration 375
Do not watch the relief valve to see if grease is es-
(5) Bolts caping. Watch the track or track adjustment cylin-
(6) Washers
(7) Cover
der to see if the track is being loosened.
(8) Gasket
Loosen the relief valve one turn only.
4. Check for contamination and for discolored
grease. If track does not loosen, close the relief valve and
contact your Caterpillar dealer.
5. If the grease is contaminated or discolored with
water, change the grease. Remove bolts (5),
washers (6), cover (7), and gasket (8) in order to NOTICE
allow the water to drain. When you reinstall cover Keeping the track properly adjusted will increase the
(7), inspect gasket (8). Replace the gasket if there service life of the track and drive components.
is damage.
Note: The track tension must be adjusted according
to the current operating conditions. Keep the track as
slack as possible if the soil is heavy.
Measuring Track Tension

1. Operate the machine in the direction of the idlers.
g00101644
Illustration 376
6. Raise the boom and turn the upper structure by

1/4 turn. Lower the bucket to the ground.
7. Repeat Step 6 at every 1/4 turn in four places.

Add grease, as needed.
g01103855
Illustration 377
8. Install gasket (4), cover (3), washers (2), and bolts
(1).
2. Stop with one track pin directly over the front
carrier roller. Park the machine and turn off the
engine.
242 SEBU8045-03
Maintenance Section
Tightening the Track
g00101752
Illustration 378
g01091134
Illustration 380
3. Place a straight edge on top of the track grousers
(1) Grease fitting
between the front carrier roller and the idler. The (2) Relief valve
straight edge should be long enough to reach from
the front carrier roller to the idler. Wipe the fitting before you add grease.
4. Measure the maximum amount of sag in the track. 1. Add grease through grease fitting (1) until the
The sag is measured from the highest point of the correct track tension is reached.
track grouser to the bottom of the straight edge. A
track that is properly adjusted will have a sag of 2. Operate the machine back and forth in order to
40.0 to 55.0 mm (1.57 to 2.17 inch). equalize the pressure.
5. If the track is too tight, or if the track is too 3. Check the amount of sag. Adjust the track, as
loose, adjust the track tension according to the needed.
appropriate procedure below.
Loosening the Track
g00270405
Illustration 379
The track adjuster is located on the track frame. g01091134
Illustration 381
(1) Grease fitting
(2) Relief valve
1. Loosen relief valve (2) carefully until the track

begins to loosen. One turn should be the
maximum.
2. Tighten relief valve (2) to 34 ± 5 N·m (25 ± 4 lb ft)

when the desired track tension is reached.
3. Operate the machine back and forth in order to

equalize the pressure.
SEBU8045-03 243
Maintenance Section
Track Adjustment - Inspect
4. Check the amount of sag. Adjust the track, as

needed.
If the correct adjustment cannot be achieved, consult

your Caterpillar Dealer.
i01590290
Track Adjustment - Inspect

SMCS Code: 4170-040
g00560313
Illustration 383
3. Use the travel levers or the travel pedals to move

the machine forward. The travel alarm should
sound.
4. Release the travel levers and the travel pedals in

order to stop the machine.
5. Use the travel levers and the travel pedals to

move the machine backward. The travel alarm
Illustration 382
g00824541 should sound.
Check the track adjustment. Check the track for wear

and for excessive dirt buildup.
If the track appears to be too tight or too loose,

refer to Operation and Maintenance Manual, “Track
Adjustment - Adjust”.
i02232929
Travel Alarm - Test

(If Equipped)
SMCS Code: 7429-081 Illustration 384
g01126167
You must move the machine in order to test the travel 6. Push the alarm cancel switch. The travel alarm
alarm. should shut off.
1. Start the engine. Move the hydraulic lockout 7. Stop the machine. Lower the work tool to the
control to the UNLOCKED position. ground. Move the Hydraulic lockout control to the
LOCKED position. Stop the engine.
2. Raise the work tool in order to avoid any obstacles.
Make sure that there is adequate overhead
clearance.
244 SEBU8045-03
Maintenance Section
Undercarriage - Check
i00059532
Undercarriage - Check
SMCS Code: 4150-535
g00688996
Illustration 386
2. Remove the filler cap.
g00101898
3. Fill the window washer reservoir with washer fluid
Illustration 385 through the filler opening.
1. Check the carrier rollers, the track rollers, and the 4. Install the filler cap.
idler wheels for possible leakage.
2. Check the surface of the track, the carrier rollers,
the track rollers, the idler wheels, the track shoes,
and the drive sprockets. Look for signs of wear i01258249
and loose mounting bolts.
Window Wiper -
3. Listen for any abnormal noises while you are Inspect/Replace
moving slowly in an open area.
SMCS Code: 7305-040; 7305-510
4. If abnormal wear exists or abnormal noises or
leaks are found, consult your Caterpillar dealer. Inspect the condition of the wiper blades. Replace
the wiper blades if the wiper blades are worn or
damaged or if streaking occurs.
i01458697
Window Washer Reservoir - i01077829

Fill Windows - Clean
SMCS Code: 7306-544-KE
SMCS Code: 7310-070; 7340-070
NOTICE Use commercially available window cleaning
When operating in freezing temperatures, use solutions in order to clean the windows. Clean the
Caterpillar or any commercially available nonfreezing outside of the windows from the ground, unless
window washer solvent. handholds are available.
1. Open the access door on the left side of the

machine.
SEBU8045-03 245
Maintenance Section
Windows - Clean
g00566124
Illustration 387
Typical example
Use a pole with a squeegee in order to reach the high

areas of the window.
Cleaning Methods
Aircraft Windshield Cleaner
Apply the cleaner with a soft cloth. Rub the window
with moderate pressure until all the dirt is removed.
Allow the cleaner to dry. Wipe off the cleaner with a
clean soft cloth.
Soap and Water

Use a clean sponge or a soft cloth. Wash the windows
with a mild soap or with a mild detergent. Also
use plenty of lukewarm water. Rinse the windows
thoroughly. Dry the windows with a moist chamois or
with a moist cellulose sponge.
Stubborn Dirt and Grease

Wash the windows with a good grade of naphtha, of
isopropyl alcohol, or of Butyl Cellosolve. Then, wash
the windows with soap and with water.
246 SEBU8045-03
Reference Materials
Reference Information Special Instruction, SEHS7633, “Battery Test

Procedure”
Section
Special Instruction, SEHS9031, “Storage Procedure
for Caterpillar Products”
Reference Materials Special Instruction, SEHS7332, “Warning Tag -

Danger Do Not Operate”
i02364677
Specifications, SENR3130, “Torque Specifications”
Reference Material Systems Operation, Troubleshooting, Testing and
SMCS Code: 1000; 7000 Adjusting, RENR5885, “Product Link 151/201”
System Operation, Troubleshooting, Testing and

Caterpillar Reference Material Adjusting, RENR7911, “Product Link 121SR/321SR”
The following literature can be obtained from any Service Parts, PECP9067, “One Safe Source”
Caterpillar dealer:
Service Magazine, SEHS6929, “Inspection,
Special Publication, PEHP6001, “How to Take a Maintenance and Repair of ROPS and Attachment
Good Oil Sample” Installation Guidelines”
Special Publication, SEBD0640, “Oil and Your Service Manual, SENR5664, “Air Conditioning and
Engine” Heating R-134a for All Caterpillar Machines”
Special Publication, PEHP7076, “Understanding Operation and Maintenance Manual, SEBU7346,
S·O·S Services Test” “Hydraulic Hammer”
Special Publication, PEHP7057, “S·O·S Coolant Operation and Maintenance Manual, HEPU9000,
Analysis” “Hydraulic Hammer”
Special Publication, PEEP5027, “Extended Life Operation and Maintenance Decal, SMEU7397,
Coolant/Antifreeze Label” “Hydraulic Hammer”
Special Publication, SEBD0518, “Know Your Cooling Operation and Maintenance Manuals are available
System” in other languages. Consult your Caterpillar dealer
for information about obtaining these Operation and
Special Publication, SEBD0970, “Coolant and Your Maintenance Manuals.
Engine”
Special Publication, SEBD0717, “Diesel Fuels and Additional Reference Material

Your Engine”
ASTM D2896, “TBN Measurements” This can
Special Publication, SEBU5898, “Cold Weather normally be obtained from your local technological
Recommendations for all Caterpillar Machines” society, from your local library, or from your local
college.
Special Publication, SEBU6250, “Caterpillar Machine
Fluids Recommendations” SAE J183, “Classification” This can normally be
found in the SAE handbook.
Special Publication, PEWJ0074, “Caterpillar Filter
and Fluid Application Guide” SAE J313, “Diesel Fuels” This publication can be
found in the SAE handbook. This publication can also
Special Publication, SEBD0400, “Dictionary of be obtained from your local technological society,
Pictograph Symbols” from your local library, or from your local college.
Special Publication, SMBU6981, “Emissions Control SAE J754, “Nomenclature” This can normally be
Warranty Information for US, Canada, and California” found in the SAE handbook.
Special Publication, NENG2500, “Caterpillar Dealer Engine Manufacturers Association, “Engine Fluids
Service Tool Catalog” Data Book”
SEBU8045-03 247
Reference Materials
Engine Manufacturers Association

Two North LaSalle Street, Suite 2200
Chicago, IL, USA 60602
E-mail: ema@enginemanufacturers.org
(312) 827-8700
Facsimile: (312) 827-8737
i00852444
Decommissioning and
Disposal
SMCS Code: 1000; 7000
Decommissioning and disposal will vary with local

regulations. Consult the nearest Caterpillar dealer
for additional information.
248 SEBU8045-03
Index Section
Index
A Cooling System Coolant Extender (ELC) - Add... 194
Cooling System Coolant Level - Check ............... 195
Access Door and Cover Locations ...................... 172 Cooling System Coolant Sample (Level 1) -
Engine Hood .................................................... 172 Obtain ................................................................ 196
Left Front Access Door .................................... 172 Cooling System Coolant Sample (Level 2) -
Left Rear Access Door..................................... 172 Obtain ................................................................ 197
Right Access Door ........................................... 172 Crushing Prevention and Cutting Prevention ........ 21
Additional Messages ............................................. 16
Air Conditioner/Cab Heater Filter (Recirculation) -
Inspect/Replace ................................................. 179 D
Air Conditioning and Heating Control .................. 125
English Versus Metric Toggle........................... 127 Daily Inspection ..................................................... 86
Alternate Exit ......................................................... 88 Daily Basis ......................................................... 86
First 100 Hours .................................................. 86
Severe Applications ........................................... 86
B Decommissioning and Disposal .......................... 247
Battery - Clean..................................................... 179

Battery - Recycle ................................................. 179 E
Battery Disconnect Switch................................... 101
Battery Hold-Down - Tighten ............................... 179 Electrical Storm Injury Prevention ......................... 24
Battery or Battery Cable - Inspect/Replace ......... 179 Emissions Certification Film .................................. 84
Before Operation ............................................. 25, 86 Engine Air Filter Primary Element -
Before Starting Engine .......................................... 25 Clean/Replace ................................................... 197
Belt - Inspect/Adjust/Replace .............................. 180 Cleaning Primary Air Filter Elements ............... 198
Boom and Stick Linkage - Lubricate.................... 180 Inspecting the Primary Air Filter Elements....... 199
Boom, Stick and Bucket Operation...................... 150 Engine Air Filter Secondary Element - Replace .. 200
Digging............................................................. 150 Engine and Machine Warm-Up ........................... 142
Lifting Objects .................................................. 152 Engine Crankcase Breather - Clean.................... 200
Boom/Stick/Bucket Combinations ......................... 47 Engine Oil and Filter - Change ............................ 202
Bucket Linkage - Inspect/Adjust .......................... 181 Oil Grade Plug ................................................. 204
Bucket Linkage - Lubricate .................................. 182 Procedure for Changing Engine Oil and Filter.. 205
Installation of the Bucket.................................. 182 Selection of the Oil Change Interval ................ 202
Bucket Tips - Inspect/Replace..................... 183, 188 Engine Oil Level - Check ..................................... 201
Bucket Tips ...................................................... 188 Engine Oil Sample - Obtain ................................. 202
Installation........................................................ 184 Engine Starting .............................................. 25, 141
Removal........................................................... 183 Engine Starting (Alternate Methods) ................... 169
Side Cutters ............................................. 184, 190 Engine Starting with Auxiliary Start Receptacle .. 170
Side Protectors ................................................ 190 Engine Starting with Jump Start Cables .............. 169
Bucket Tips - Inspect/Replace (Drive-through Engine Stopping .................................................... 27
System).............................................................. 185 Engine Valve Lash - Check ................................. 207
Bucket Tips ...................................................... 185 Equipment Lowering with Engine Stopped.... 28, 144
Side Cutters ..................................................... 187 Machine with a Boom Lowering Control Valve.. 145
Burn Prevention..................................................... 22 Machine without a Boom Lowering Control
Batteries............................................................. 22 Valve .............................................................. 144
Coolant............................................................... 22 Pressure Release of Auxiliary Lines ................ 146
Oils..................................................................... 22
F
C
Final Drive Oil - Change ...................................... 207
Cab Air Filter (Fresh Air) - Clean/Replace........... 191 Final Drive Oil Level - Check ............................... 207
Cab Door ............................................................. 129 Final Drive Oil Sample - Obtain ........................... 208
Cab Visor (If Equipped) ....................................... 128 Final Drive Ring Gear Removal........................... 168
Capacities (Refill) ................................................ 175 Fire Extinguisher Location ..................................... 24
Circuit Breakers - Reset ...................................... 191
Condenser (Refrigerant) - Clean ......................... 192
Cooling System Coolant (ELC) - Change............ 192
SEBU8045-03 249
Index Section
Fire Prevention and Explosion Prevention ............ 22 Hydraulic System Oil (If Equipped with Fine Filtration
Ether .................................................................. 23 Filter) - Change.................................................. 218
Fire Extinguisher ................................................ 23 5000 Hour Oil Change Interval ........................ 218
Lines, Tubes and Hoses .................................... 24 Oil Change ....................................................... 219
Foreword ................................................................. 5 Hydraulic System Oil Filter (Case Drain) -
California Proposition 65 Warning ....................... 4 Replace.............................................................. 223
Caterpillar Product Identification Number ............ 5 Hydraulic System Oil Filter (Pilot) - Replace ....... 225
Certified Engine Maintenance.............................. 4 Hydraulic System Oil Filter (Return) - Replace.... 226
Literature Information........................................... 4 Hydraulic System Oil Level - Check .................... 230
Machine Capacity ................................................ 5 Hydraulic System Oil Sample - Obtain ................ 231
Maintenance ........................................................ 4 Hydraulic System Pressure Gauge (Fine Filtration
Operation ............................................................. 4 Filter) - Inspect (If Equipped) ............................. 231
Safety................................................................... 4 Hydraulic Tank Screen - Clean ............................ 232
Freezing Conditions............................................. 160
Frozen Ground Conditions .................................. 144
Fuel System - Prime ............................................ 208 I
Machines with a Mechanical Priming Pump .... 208
Machines with an Electrical Priming Pump ...... 209 Identification Information ....................................... 83
Fuel System Primary Filter (Water Separator) Important Safety Information ................................... 2
Element - Replace ............................................. 210 Indicators and Gauges - Test............................... 234
Fuel System Secondary Filter - Replace .............. 211
Fuel System Water Separator - Drain .................. 211
Fuel Tank Cap and Strainer - Clean .................... 212 J
Fuel Tank Shutoff and Drain Control ................... 140
Fuel Tank Water and Sediment - Drain ............... 212 Joystick Controls ................................................. 131
Fuel Transfer Pump (Refueling) (If Equipped)..... 120 Joystick Controls (Medium Pressure (If
Excavator with Demolition Cab (If Equipped) .. 121 Equipped)) ......................................................... 131
Fuses - Replace .......................................... 213–214 Rotating Tool Control ....................................... 132
Joystick Controls Alternate Patterns.................... 136
Changing Machine Control Pattern By Four-Way
G Valve (If Equipped)......................................... 136
Changing Machine Control Pattern by Two-Way
General Hazard Information .................................. 19 Valve (If Equipped)......................................... 138
Asbestos Information ......................................... 20
Containing Fluid Spillage ................................... 20
Dispose of Waste Properly ................................ 21 L
Fluid Penetration................................................ 20
Pressurized Air and Water ................................. 20 Leaving the Machine ........................................... 162
Trapped Pressure .............................................. 20 Lifting and Tying Down the Machine (Rear Eyes and
General Information............................................... 32 Front Eyes) ........................................................ 165
Guards (Operator Protection) ................................ 30 Lifting the Machine Segments.......................... 166
Other Guards (If Equipped)................................ 31 Lifting and Tying Down the Machine (Spreader
Rollover Protective Structure (ROPS), Falling Bar) .................................................................... 165
Object Protective Structure (FOPS) or Tip Over Lifting the Machine Segments.......................... 165
Protection Structure (TOPS) ............................ 31 Lifting Capacities ................................................... 51
330D High Wide Undercarriage ......................... 72
Lifting Objects........................................................ 27
H Lubricant Viscosities............................................ 173
Lubricant Viscosities and Refill Capacities .......... 173
Hammer Operation (If Equipped) ........................ 157
High Intensity Discharge Lamp (HID) - Replace (If
Equipped) .......................................................... 216 M
Hydraulic System Biodegradable Oil Filter Element -
Replace (If Equipped) ........................................ 216 Machine Operation ................................................ 88
Hydraulic System Biodegradable Oil Filter Pressure Machine Security System (If Equipped) .............. 103
Gauge - Inspect (If Equipped)............................ 217 Basic Operation ............................................... 104
Hydraulic System Filter Element (Fine Filtration) - Operation Section ............................................ 103
Replace (If Equipped) ........................................ 218 Regulatory Compliance Section....................... 104
Hydraulic System Oil - Change ........................... 219 Security Management ...................................... 104
4000 Hour Oil Change Interval ........................ 219 Maintenance Access ........................................... 172
Procedure to Change the Hydraulic Oil ........... 220 Maintenance Interval Schedule ........................... 177
250 SEBU8045-03
Index Section
Maintenance Section ........................................... 172 Operator Controls .................................................. 92

Maintenance Support .......................................... 176 Air Conditioning and Heating Control (25) ....... 101
Mirror Installation ................................................. 164 Automatic Engine Speed Control (13) ............... 98
Monitoring System............................................... 105 Backup Controls (11) ......................................... 97
Adjusting the Brightness ................................... 116 Engine Speed Control (6) .................................. 96
Adjusting the Clock ........................................... 113 Engine Start Switch (7) ...................................... 96
Adjusting the Contrast....................................... 115 Fine Swing Control (22) ................................... 101
Adjusting the Monitor ....................................... 108 Heavy Lift Control (16) ....................................... 99
Changing the Password.................................... 117 Hydraulic Lockout Control (1) ............................ 94
Display Setup.................................................... 111 Joystick Controls (5) .......................................... 96
Filter and Fluid Information ............................... 118 Light Switch (19) .............................................. 100
Indicated Item ................................................... 114 Monitor (4).......................................................... 96
Language Selection .......................................... 114 Operator’s Seat (9) ............................................ 97
Machine Warnings ........................................... 106 Overload Warning Device (23)......................... 101
Main Menu ....................................................... 109 Quick Coupler Control (20) .............................. 100
Maintenance ..................................................... 117 Radio (10) .......................................................... 97
Maintenance Information ................................. 109 Seat Heater (21) .............................................. 100
Other Messages............................................... 108 Service Hour Meter (3)....................................... 96
Password Entry................................................. 111 Smart Boom Control (24) ................................. 101
Performance ..................................................... 110 Travel Alarm Cancel Switch (14) ....................... 99
Prestart Monitoring Function............................ 106 Travel Control (2) ............................................... 94
Selecting the Work Tool .................................... 112 Travel Speed Control (12).................................. 97
Service .............................................................. 110 Window Wiper and Window Washer (17-18) ..... 99
Setting.............................................................. 109 Work Tool Control (15) ....................................... 99
Mounting and Dismounting.................................... 86 Operator Station .................................................... 30
Alternate Exit...................................................... 86
P
O
Parking .......................................................... 27, 160
Oil Filter - Inspect ................................................ 234 Plate Locations and Film Locations....................... 83
Inspect a Used Filter for Debris ....................... 234 Certification ........................................................ 83
Operating Technique Information ........................ 147 Product Identification Number (PIN) and CE
Operating Precaution ....................................... 148 Plate ................................................................. 83
Restricted Operation ........................................ 147 Power Receptacle (If Equipped).......................... 103
Operating Techniques.......................................... 147 Product Information Section .................................. 32
Operation....................................................... 26, 143 Product Link (If Equipped) ................................... 102
Machine Operating Temperature Range............ 26 Regulatory Compliance.................................... 103
Machine Operation............................................. 26
Operation Information.......................................... 143
Operation Section.................................................. 86 Q
Quick Coupler - Lubricate (If Equipped) .............. 235

Quick Coupler Operation (Double Action (If
Equipped)) ......................................................... 154
Releasing the Work Tool .................................. 155
Securing the Work Tool.................................... 154
Radiator Core - Clean.......................................... 235

Radio (If Equipped).............................................. 122
Loss of Memory ............................................... 124
Presetting Radio Stations ................................ 123
Radio Reception .............................................. 124
Scan and Auto Memory ................................... 124
Reference Information Section ............................ 246
Reference Material .............................................. 246
Additional Reference Material.......................... 246
Caterpillar Reference Material ......................... 246
SEBU8045-03 251
Index Section
Reference Materials ............................................ 246 T

Refrigerant Dryer - Replace................................. 236
Roof Hatch........................................................... 129 Table of Contents..................................................... 3
Towing Information .............................................. 167
Towing the Machine............................................. 167
S Track Adjustment - Adjust ................................... 241
Loosening the Track ........................................ 242
S·O·S Information ................................................ 175 Measuring Track Tension................................. 241
Safety Messages ..................................................... 6 Tightening the Track ....................................... 242
Safety Section ......................................................... 6 Track Adjustment - Inspect.................................. 243
Seat ....................................................................... 88 Track Information................................................... 24
Seat Belt ................................................................ 90 Transportation Information .................................. 163
Extension of the Seat Belt ................................. 92 Travel Alarm - Test (If Equipped)......................... 243
Seat Belt Adjustment for Non-Retractable Seat Travel Control (Straight Travel Pedal (If
Belts ................................................................. 90 Equipped)) ......................................................... 130
Seat Belt Adjustment for Retractable Seat Travel in Water and Mud ..................................... 149
Belts ................................................................. 91 Procedure for Removing the Machine from Water
Seat Belt - Inspect ............................................... 236 or Mud ............................................................ 150
Seat Belt - Replace.............................................. 237
Securing the Machine.......................................... 163
Shear Operation (If Equipped)............................. 158 U
Shipping the Machine .......................................... 163
SmartBoom Control (If Equipped) ....................... 133 Undercarriage - Check ........................................ 244
SmartBoom Operation......................................... 153
Advantages ...................................................... 153
Excavation and Loading................................... 153 V
Hammering ...................................................... 153
Sound Information and Vibration Information ........ 28 VA Boom Controls ............................................... 132
Sound Level Information .................................... 28
Sound Level Information for Machines in European
Union Countries and in Countries that Adopt the W
“EU Directives” ................................................. 28
Sources.............................................................. 30 Welding on Machines and Engines with Electronic
“The European Union Physical Agents (Vibration) Controls ............................................................. 176
Directive 2002/44/EC” ...................................... 28 Window (Front) .................................................... 127
Specifications ........................................................ 32 Window Washer Reservoir - Fill .......................... 244
330D ES Stick M2.15TB .................................... 40 Window Wiper - Inspect/Replace ........................ 244
330D ES Stick M2.55TB .................................... 41 Windows - Clean ................................................. 244
330D ES Stick R2.15TB..................................... 36 Cleaning Methods ............................................ 245
330D ES Stick R2.8DB ...................................... 37 Work Tool Changing ............................................ 157
330D ES Stick R3.2DB ...................................... 38 Work Tool Control (One-Way Flow) (If
330D ES Stick R3.9DB ...................................... 39 Equipped) .......................................................... 134
330D HW Stick M2.55TB ................................... 47 Joystick ............................................................ 134
330D HW Stick R2.15TB ............................. 42, 46 Work Tool Pedal............................................... 134
330D HW Stick R2.8DB ..................................... 43 Work Tool Control (Two-Way Flow) (If
330D HW Stick R3.2DB ..................................... 44 Equipped) .......................................................... 135
330D HW Stick R3.9DB ..................................... 45 Joystick ............................................................ 135
Stopping the Engine ............................................ 160 Work Tool Pedal............................................... 135
Engine Stop Control......................................... 161 Work Tools............................................................. 25
Stop the Engine if an Electrical Malfunction
Occurs............................................................ 161
Stopping the Machine.......................................... 160
Storage and Literature Compartment .................. 120
Storage Box......................................................... 120
Exterior Storage Box........................................ 120
Interior Storage Box ......................................... 120
Swing Bearing - Lubricate ................................... 237
Swing Drive Oil - Change .................................... 237
Swing Drive Oil Level - Check ............................. 239
Swing Drive Oil Sample - Obtain ......................... 239
Swing Gear - Lubricate........................................ 240
252 SEBU8045-03
Index Section
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.
Delivery Date:
Product Information
Model:
Product Identification Number:
Engine Serial Number:
Transmission Serial Number:
Generator Serial Number:
Attachment Serial Numbers:
Attachment Information:
Customer Equipment Number:
Dealer Equipment Number:
Dealer Information
Name: Branch:
Address:
Dealer Contact Phone Number Hours
Sales:
Parts:
Service:
©2006 Caterpillar
All Rights Reserved Printed in U.S.A.

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SEBU8045-03

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Failure to heed this warning can lead to prema-

Table of Contents Engine Starting ................................................... 141

Operation ............................................................ 143

Engine Stopping ................................................... 27

Lifting Objects ....................................................... 27

Equipment Lowering with Engine Stopped ........... 28

Sound Information and Vibration Information ....... 28

Operator Station ................................................... 30

Guards (Operator Protection) ............................... 30

Product Information Section

Identification Information ....................................... 83

Machine Operation ............................................... 88

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

Additional attachments or modifications may exceed

Caterpillar Product Identification

1. Caterpillar’s World Manufacturing Code

2. Machine Descriptor (characters 4-8)

There are several specific safety messages on this

Make sure that all of the safety messages are legible.

Replace any safety message that is damaged, or

(1) Do Not Operate (3) Crushing Hazard

(2) Crushing Hazard

Crushing Hazard! Keep the work tool away from

This safety message is located in the cab on the right

A seat belt should be worn at all times during ma-

(7) Electrical Power Lines (8) Crushing Hazard

Electrocution Hazard! Keep the machine and at-

Refer to Operation and Maintenance Manual,

(9) Joystick Controls Alternate (10) SmartBoom Mode

Do not elevate or lower the track when in the

Machine swings. Stay back. Crushing hazard

(12) Pressurized System (13) Aerosol Starting Aid

Pressurized system! Hot coolant can cause seri-

(14) Jump Start Cables (15) High Pressure Cylinder

This system contains high pressure gas. Failure to

Do not expose to fire. Do not weld. Do not drill.

See Operation and Maintenance Manual for charg-

Refer to Operation and Maintenance Manual,

(17) Relieve Hydraulic Tank

RELIEVE TANK PRESSURE WITH ENGINE OFF BY

Radial Air Cleaner (1)

This message is located on the cover of the air

In order to avoid engine damage, replace old filters

The location and design of the gasket for the radial

This message is located on the engine cover on the

If the Primary exits are blocked, pull the ring in order

Machine Security System (5)

This message is located on the window on the right

Do not step in this area.

Clean Glass (3)

This message is located on the upper window in the

This machine may be equipped with a security

Key in Run Position (6)

This message is located on the window on the right

Alternate Exit (4)

This message is located in the upper right corner of

NOTICE Wear a hard hat, protective glasses, and other

Make sure that all protective guards and all covers

Secure all loose items such as lunch boxes, tools,