SEBU8906

August 2014

Operation and
Maintenance
Manual
AD30 Underground Articulated Truck
GXR 1-Up (Machine)

SAFETY.CAT.COM
 i05296198

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, including human factors
that can affect safety. 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 verify
that you are authorized to perform this work, and have read and understood the operation,
lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

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

When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts.
Failure to follow this warning may lead to pre-
mature failures, product damage, personal in-
jury or death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SEBU8906 3
Table of Contents

Table of Contents Product Information Section

Foreword.............................. ............................. 4 Model Views and Specifications........... .......... 34

Identification Information ................ ................ 36

Safety Section

Safety Messages....................... ....................... 6

Operation Section

Monitoring Systems and Operator Station

Additional Messages ................... ................... 13
Features............................ ............................ 38
General Hazard Information .............. ............. 18
Machine Controls and Operation.......... .......... 58
Crushing Prevention and Cutting Prevention . 21
Before Starting Engine ................. .................. 76
Burn Prevention....................... ....................... 21
Engine Starting ........................ ....................... 82
Fire Prevention and Explosion Prevention ... .. 22
Operating Techniques................... .................. 89
Fire Safety ........................... ........................... 25
Parking ............................. .............................. 93
Fire Extinguisher Location ............... ............... 25
Transportation Information............... ............... 95
Tire Information........................ ....................... 26
Jacking Location Information............. ............. 98
Electrical Storm Injury Prevention ......... ......... 27
Towing Information .................... ..................... 99
Mounting and Dismounting............... .............. 27
Maintenance Section
Before Starting Engine ................. .................. 27
Tire Inflation Information................ ............... 104
Engine Starting ........................ ....................... 28
Lubricant Viscosities and Refill Capacities.. . 105
Before Operation ...................... ...................... 28
Maintenance Locations................. .................111
Visibility Information.................... .................... 28
Maintenance Support .................. ..................115
Restricted Visibility .................... ..................... 29
Maintenance Interval Schedule .......... ...........117
Operation............................ ............................ 29
Reference Information Section
Engine Stopping ....................... ...................... 30
Reference Materials .................. ................... 187
Parking ............................. .............................. 30
Index Section
Slope Operation....................... ....................... 30
Index............................... .............................. 189
Equipment Lowering with Engine Stopped... .. 31

Sound Information and Vibration Information. 31

Operator Station ....................... ...................... 32

Guards (Operator Protection) ............. ............ 32

4 SEBU8906
Foreword
Foreword
Literature Information
This manual should be stored in the operator's
compartment in the literature holder or seat back
literature storage area.
This manual contains safety information, operation
instructions, transportation information, lubrication
information and maintenance information.
Some photographs or illustrations in this publication
show details or attachments that can be different from
your machine. Guards and covers might have been
removed for illustrative purposes.
Continuing improvement and advancement of
product design might have caused changes to your
machine which are not included in this publication.
Read, study and keep this manual with the machine.
Whenever a question arises regarding your machine,
or this publication, please consult your Cat dealer for
the latest available information.
Safety
The safety section lists basic safety precautions. In
addition, this section identifies the text and locations
of warning signs and labels used on the machine.
Read and understand the basic precautions listed in
the safety section before operating or performing
lubrication, maintenance and repair on this machine.
Operation
The operation section is a reference for the new
operator and a refresher for the experienced operator.
This section includes a discussion of gauges,
switches, machine controls, attachment controls,
transportation and towing information.
Photographs and illustrations guide the operator
through correct procedures of checking, starting,
operating and stopping the machine.
Operating techniques outlined in this publication are
basic. Skill and techniques develop as the operator
gains knowledge of the machine and its capabilities.
Maintenance
The maintenance section is a guide to equipment
care. The Maintenance Interval Schedule (MIS) lists
the items to be maintained at a specific service
interval. Items without specific intervals are listed
under the "When Required" service interval. The
Maintenance Interval Schedule lists the page number
for the step-by-step instructions required to
accomplish the scheduled maintenance. Use the
Maintenance Interval Schedule as an index or "one
safe source" for all maintenance procedures.
Maintenance Intervals
Use the service hour meter to determine servicing
intervals. Calendar intervals shown (daily, weekly,
monthly, etc.) can be used instead of service hour
meter intervals if they provide more convenient
servicing schedules and approximate the indicated
service hour meter reading. Recommended service
should always be performed at the interval that
occurs first.
Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is specified
in the maintenance intervals chart might be
necessary.
Perform service on items at multiples of the original
requirement. For example, at every 500 service hours
or 3 months, also service those items listed under
every 250 service hours or monthly and every 10
service hours or daily.
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm.
Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands after
handling.
Certified Engine Maintenance
Proper maintenance and repair is essential to keep
the engine and machine systems operating correctly.
As the heavy duty off-road diesel engine owner, you
are responsible for the performance of the required
maintenance listed in the Owner Manual, Operation
and Maintenance Manual, and Service Manual.
It is prohibited for any person engaged in the
business of repairing, servicing, selling, leasing, or
trading engines or machines to remove, alter, or
render inoperative any emission related device or
element of design installed on or in an engine or
machine that is in compliance with the regulations (40
CFR Part 89). Certain elements of the machine and
engine such as the exhaust system, fuel system,
electrical system, intake air system and cooling
system may be emission related and should not be
altered unless approved by Caterpillar.
Machine Capacity
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 Cat dealer for further information.
SEBU8906 5
Foreword

Cat Product Identification Number

Effective First Quarter 2001 the Cat 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 Cat machines and generator sets. The PIN
plates and frame marking will display the 17 character
PIN. The new format will look like the following:

Illustration 1 g00751314

Where:
1. Caterpillar's World Manufacturing Code (characters
1-3)
2. Machine Descriptor (characters 4-8)
3. Check Character (character 9)
4. Machine Indicator Section (MIS) or Product
Sequence Number (characters 10-17). These were
previously referred to as the Serial Number.
Machines and generator sets produced before First
Quarter 2001 will maintain their 8 character PIN
format.
Components such as engines, transmissions, axles,
etc. and work tools will continue to use an 8 character
Serial Number (S/N).
6 SEBU8906
Safety Section
Safety Messages

Safety Section
i05882997

Safety Messages
SMCS Code: 7000
There are several specific safety messages on this
machine. The exact location of the hazards and the
description of the hazards are reviewed in this
section. Please become familiarized with all safety
messages.
Make sure that all of the safety messages are legible.
Clean the safety messages or replace the safety
messages if you cannot read the words. Replace the
illustrations if the illustrations are not legible. When
you clean the safety messages, use a cloth, water,
and soap. Do not use solvent, gasoline, or other
harsh chemicals to clean the safety messages.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety message. Loose
adhesive will allow the safety message to fall.
Replace any safety message that is damaged, or
missing. If a safety message is attached to a part that
is replaced, install a safety message on the
replacement part. Any Caterpillar dealer can provide
new safety messages.
SEBU8906 7
Safety Section
Safety Messages

Illustration 2 g03709466

Illustration 3 g01952994
8 SEBU8906
Safety Section
Safety Messages

Illustration 4 g03709467

Illustration 5 g01952996
Additional safety message for ejector body machines
SEBU8906 9
Safety Section
Safety Messages

Do Not Weld or Drill the ROPS/

FOPS (1), (4)
This safety label is located inside the operator station
on the right front ROPS post.

Illustration 8 g01403066

Do not operate or work on this machine unless

Illustration 6 g01871221 you have read and understand the instructions
and warnings in the Operation and Maintenance
This safety label is located inside the operator station
on the rear of the ROPS structure. Manuals. Failure to follow the instructions or heed
the warnings could result in injury or death. Con-
tact your Cat dealer for replacement manuals.
Proper care is your responsibility.

Seat Belt (3)

This safety label is located inside the operator station.

Illustration 7 g03372605

Structural damage, an overturn, modification, al-

teration, or improper repair can impair this struc-
ture's protection capability thereby voiding this
certification. Do not weld on or drill holes in the Illustration 9 g01370908
structure. Consult a Caterpillar dealer to deter-
mine this structure's limitations without voiding
its certification.
A seat belt should be worn at all times during ma-
Rollover (ROPS) and Falling Object (FOPS) chine operation to prevent serious injury or death
Protective Structure Certification in the event of an accident or machine overturn.
Failure to wear a seat belt during machine opera-
This machine has been certified to the standards that tion may result in serious injury or death.
are listed on the certification film.

Do Not Operate (2)

This safety label is located in the operator station.
10 SEBU8906
Safety Section
Safety Messages

Batteries (5)
This safety label is located on the left side of the front
frame below the operator station.

Illustration 11 g01371644

Illustration 10 g01389332
Stay back a safe distance. No clearance for a per-
son in this area when the machine turns. Severe
injury or death from crushing could occur.

IMPROPER JUMPER CABLE CONNECTIONS CAN

CAUSE EXPLOSION RESULTING IN PERSONAL Crush Hazard (7)
INJURY.
This safety label is located on both sides of the
BATTERIES MAY BE LOCATED IN SEPARATE machine articulating hitch.
COMPARTMENTS. WHEN USING JUMPER CA-
BLES, ALWAYS CONNECT POSITIVE (+) CABLE
TO POSITIVE (+) TERMINAL OF BATTERY CON-
NECTED TO STARTER SOLENOID AND NEGA-
TIVE (-) CABLE FROM EXTERNAL SOURCE TO
STARTER NEGATIVE (-) TERMINAL (IF MACHINE
NOT EQUIPPED WITH STARTER NEGATIVE TER-
MINAL, CONNECT TO ENGINE BLOCK.) FOLLOW
PROCEDURE IN THE OPERATION MANUAL.

No Clearance (6)
This safety label is located on both sides of the
machine articulating hitch.

Illustration 12 g01389981

No clearance for person in this area when ma-

chine turns. Severe injury or death from crushing
could occur. Connect steering frame lock between
front and rear frames before lifting, transporting,
or servicing machine in articulation area. Discon-
nect lock and secure before resuming operation.

High Pressure Cylinder (Brake

Accumulator) (8), (9)
This safety label is located near the brake
accumulators.
SEBU8906 11
Safety Section
Safety Messages

Illustration 13 g01372252

Hydraulic accumulator contains gas and oil under

high pressure. Improper removal or repair proce-
dures could cause severe injury. To remove or re- Illustration 14 g01389331
pair, instructions in the service manual must be
followed. Special equipment is required for test-
ing and charging.
High Pressure Cylinder!
This safety label is located on the brake
accumulators. Do not remove any valve, hydraulic fitting, or
valve core, nor disassemble any parts until pres-
sure has been relieved, or personal injury may
occur.
To relieve pressure:

1. Refer to the Service Manual for the correct

method of dissipating hydraulic system
pressure.

2. Relieve gas pressure in the accumulator cylin-

der by opening the charging valve one turn
only.
Charge the cylinder with dry nitrogen gas.
See your Caterpillar dealer for tools and detailed
information required for charging cylinders.

Unit Injectors (10)

This safety label is located on the side of the engine
valve cover bases.
12 SEBU8906
Safety Section
Safety Messages

Illustration 15 g00907131

Do not operate or work on this equipment unless

you have read and understand the instructions
and warnings in the Operation and Maintenance
Manuals. Failure to follow the instructions or heed
the warnings could result in serious injury or
death.
Hot Surface (11)
This safety label is located on the exhaust cover.
Illustration 17 g01378799
PRESSURIZED SYSTEM: HOT COOLANT CAN
CAUSE SERIOUS BURN. TO OPEN CAP, STOP
ENGINE, WAIT UNTIL RADIATOR IS COOL. THEN
LOOSEN CAP SLOWLY TO RELIEVE THE
PRESSURE.

Tailgate (13)
This safety label is located on both sides of the
ejector body tailgate.

Illustration 16 g01403084

Avoid contact with hot surfaces. Exhaust piping

and engine components become hot during en-
gine operation and cool slowly after engine shut-
down. Any contact with hot surfaces can cause
severe burns.

Engine Coolant (12)

This safety label is located near the cooling system
pressure cap.
SEBU8906 13
Safety Section
Additional Messages

Illustration 18 g01389990

No clearance for person in this area when tailgate

lowers. Severe injury or death from crushing
could occur. Install tailgate safety pin before serv-
icing machine in tailgate area. Remove safety pin
and secure before resuming operation.

i05732011

Additional Messages
SMCS Code: 7000
There are several specific messages on this
machine. The exact location of the messages and the
description of the messages are reviewed in this
section. Become familiarized with all messages.
Make sure that all of the messages are legible. Clean
the messages or replace the messages if you cannot
read the words. Replace the illustrations if the
illustrations are not legible. When you clean the
messages, use a cloth, water, and soap. Do not use
solvent, gasoline, or other harsh chemicals to clean
the messages. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures the
messages. Loose adhesive will allow the messages
to fall.
Replace any message that is damaged, or missing. If
a message is attached to a part that is replaced,
install a message on the replacement part. Any
Caterpillar dealer can provide new messages.
14 SEBU8906
Safety Section
Additional Messages

Illustration 19 g01974238

Illustration 20 g03643196
SEBU8906 15
Safety Section
Additional Messages

Engine Coolant Fast Fill (1).This message is

located at the front of the radiator on the right side of
the machine.

Illustration 23 g01429855

This additional message identifies the location of the

Illustration 21 g01974234 fast fill connector for the hydraulic oil.

This additional message identifies the location of the
fast fill connector for the engine coolant.
Extended Life Coolant (2).This message is located
next to the cooling system pressure cap.
Alternate Exit (4)
This message is located on the outside of the right
side window and the front window.

Illustration 24 g00915912
Illustration 22 g01314339
Alternate Exit (4)
The cooling system is filled with ELC (Extended Life
Coolant) from the factory. This message is located on the right side window and
the front window.
Hydraulic Oil Fast Fill (3).This message is located
beside the hydraulic tank on the right side of the
machine.
16 SEBU8906
Safety Section
Additional Messages

Fire Suppression System (Foam) (If Equipped) (7).

This message is located on the left side of the
radiator guard and in the operator station.

Illustration 25 g01002993

Transmission Oil Fast Fill (5).This message is

located in the articulation area above the
transmission oil sight gauge on the right side of the
machine.
Illustration 28 g01547033
For more information on the foam fire suppression
system, refer to Operation and Maintenance Manual,
“Fire Suppression System (Foam)”.
Engine Oil (If Equipped) (8). This message is
located next to the engine oil fill tube on the right side
of the machine.

Illustration 26 g01974236

This additional message identifies the location of the

fast fill connector for the transmission oil.
Retarding Guidelines (6). This message is located
inside the cab. Illustration 29 g02448560

Cat DEO-ULS oils and oils that satisfy the “API CJ-
4”and/or “ACEA E9” requirements are required for
engines that are equipped with a Flow Through
Diesel Particulate Filter.
Refer to Operation and Maintenance Manual,
“Lubricant Viscosities” for more information about the
oil.
Fire Suppression System (Foam) (If Equipped) (9).
This message is located on the left side of the
radiator guard and in the operator station.

Illustration 27 g01978754

For more information on retarding, refer to Operation

and Maintenance Manual, “Retarding”.
SEBU8906
Illustration 30 g01959382
For more information on the foam fire suppression
system, refer to Operation and Maintenance Manual,
“Fire Suppression System (Foam)”.
Fire Suppression System (Dry Powder) (If
Equipped) (10). This message is located on the left
side of the radiator guard and in the operator station.
Illustration 31 g01431885
For more information on the dry powder fire
suppression system, refer to Operation and
Maintenance Manual, “Fire Suppression System (Dry
Powder)”.
Diesel Fuel Requirements (If Equipped) (11). This
additional message is located next to the fuel tank
filler cap.
17
Safety Section
Additional Messages
Illustration 32 g02399176
Note: This information is pertinent to the United
States of America (USA) and Canada.
If applicable, consult the federal, state, local, and
other governing authorities for guidance concerning
the fuel requirements in your area.
For more information about diesel fuels, refer to
Special Publication, SEBU6250, “Caterpillar Machine
Fluids Recommendations”.
Diesel Fuel Requirements (If Equipped) (11). This
additional message is located next to the fuel tank
filler cap.
Illustration 33 g02052934
Use Ultralow Sulfur Diesel(ULSD) fuel.
The United States (U.S.) Environmental Protection
Agency (EPA) defines Ultra-Low Sulfur Diesel (ULSD
- S15) as a U.S. diesel fuel with a sulfur content not to
exceed 15 parts per million (ppm(mg/kg)) or 0.0015
percent by weight. Engines equipped with exhaust
aftertreatment systems are designed to run on ULSD
only. Use of LSD or fuels higher than 15 ppm (mg/kg)
sulfur in these engines will reduce engine efficiency
and engine durability. Damage to the emissions
control systems will occur. Failures that result from
the use of fuels are not Caterpillar factory defects.
Therefore the cost of repairs would not be covered by
a Caterpillar warranty.
18
Safety Section
General Hazard Information
In Europe, ultra low sulfur diesel fuel will have a
maximum of 0.0010 percent (10 ppm(mg/kg)) sulfur
and is typically referred to as “sulfur-free”. This sulfur
level is defined in European Standard “EN
590:2004”.
Refer to Operation and Maintenance Manual,
“Lubricant Viscosities” for more information about the
fuel.
Also, refer to Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” for
more information about diesel fuels.
24 V Electrical System (12)
This message is located next to the jump-start
receptacle.
This machine is equipped with a 24 V electrical
system.
Illustration 34
General Hazard Information
SMCS Code: 7000
Illustration 35
Typical example
SEBU8906
Attach a “Do Not Operate” warning tag or a similar
warning tag to the start switch or to the controls.
Attach the warning tag before you service the
equipment or before you repair the equipment. These
warning tags (Special Instruction, SEHS7332) are
available from your Cat dealer.
Operating the machine while distracted can result
in the loss of machine control. Use extreme cau-
tion when using any device while operating the
machine. Operating the machine while distracted
can result in personal injury or death.
Know the width of your equipment in order to maintain
proper clearance when you operate the equipment
near fences or near boundary obstacles.
Be aware of high voltage power lines and power
cables that are buried. If the machine comes in
contact with these hazards, serious injury or death
may occur from electrocution.
g01126478
i05218279
Illustration 36 g00702020
Wear a hard hat, protective glasses, and other
protective equipment, as required.
Do not wear loose clothing or jewelry that can snag
on controls or on other parts of the equipment.
Make sure that all protective guards and all covers
are secured in place on the equipment.
Keep the equipment free from foreign material.
Remove debris, oil, tools, and other items from the
deck, from walkways, and from steps.
Secure all loose items such as lunch boxes, tools,
and other items that are not a part of the equipment.
Know the appropriate work site hand signals and the
personnel that are authorized to give the hand
g00104545
signals. Accept hand signals from one person only.
SEBU8906 19
Safety Section
General Hazard Information

Do not smoke when you service an air conditioner. Fluid Penetration

Also, do not smoke if refrigerant gas may be present.
Inhaling the fumes that are released from a flame that Pressure can be trapped in the hydraulic circuit long
contacts air conditioner refrigerant can cause bodily after the engine has been stopped. The pressure can
harm or death. Inhaling gas from air conditioner cause hydraulic fluid or items such as pipe plugs to
refrigerant through a lighted cigarette can cause escape rapidly if the pressure is not relieved correctly.
bodily harm or death.
Do not remove any hydraulic components or parts
Never put maintenance fluids into glass containers. until pressure has been relieved or personal injury
Drain all liquids into a suitable container. may occur. Do not disassemble any hydraulic
components or parts until pressure has been relieved
Obey all local regulations for the disposal of liquids. or personal injury may occur. Refer to the Service
Manual for any procedures that are required to relieve
Use all cleaning solutions with care. Report all the hydraulic pressure.
necessary repairs.
Do not allow unauthorized personnel on the
equipment.
Unless you are instructed otherwise, perform
maintenance with the equipment in the servicing
position. Refer to Operation and Maintenance Manual
for the procedure for placing the equipment in the
servicing position.
When you perform maintenance above ground level,
use appropriate devices such as ladders or man lift
machines. If equipped, use the machine anchorage
points and use approved fall arrest harnesses and
lanyards.
Illustration 37 g00687600
Pressurized Air and Water
Pressurized air and/or water can cause debris and/or Always use a board or cardboard when you check for
hot water to be blown out. The debris and/or hot a leak. Leaking fluid that is under pressure can
water could result in personal injury. penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak can
When pressurized air and/or pressurized water is cause severe injury. If fluid is injected into your skin,
used for cleaning, wear protective clothing, protective you must get treatment immediately. Seek treatment
shoes, and eye protection. Eye protection includes from a doctor that is familiar with this type of injury.
goggles or a protective face shield.
Containing Fluid Spillage
The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the nozzle Care must be taken in order to ensure that fluids are
is deadheaded and the nozzle is used with an contained during performance of inspection,
effective chip deflector and personal protective maintenance, testing, adjusting, and repair of the
equipment. The maximum water pressure for equipment. Prepare to collect the fluid with suitable
cleaning purposes must be below 275 kPa (40 psi). containers before opening any compartment or
disassembling any component that contains fluids.
Avoid direct spraying of water on electrical
connectors, connections, and components. When Refer to Special Publication, NENG2500, “Cat dealer
using air for cleaning, allow the machine to cool to Service Tool Catalog” for the following items:
reduce the possibility of fine debris igniting when re-
deposited on hot surfaces. • Tools that are suitable for collecting fluids and
equipment that is suitable for collecting fluids
Trapped Pressure
• Tools that are suitable for containing fluids and
Pressure can be trapped in a hydraulic system. equipment that is suitable for containing fluids
Releasing trapped pressure can cause sudden
machine movement or attachment movement. Use Obey all local regulations for the disposal of liquids.
caution if you disconnect hydraulic lines or fittings.
High-pressure oil that is released can cause a hose to
whip. High-pressure oil that is released can cause oil
to spray. Fluid penetration can cause serious injury
and possible death.
20 SEBU8906
Safety Section
General Hazard Information

Inhalation • Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos.

• Use a wet method in order to clean up asbestos
materials.

• A vacuum cleaner that is equipped with a high

efficiency particulate air filter (HEPA) can also be
used.
• Use exhaust ventilation on permanent machining
jobs.

• Wear an approved respirator if there is no other

way to control the dust.
Illustration 38 g02159053
• Comply with applicable rules and regulations for
Exhaust the work place. In the United States, use
Occupational Safety and Health Administration
Use caution. Exhaust fumes can be hazardous to (OSHA) requirements. These OSHA requirements
your health. If you operate the machine in an can be found in “29 CFR 1910.1001”. In Japan,
enclosed area, adequate ventilation is necessary. use the requirements found in the “Ordinance on
Prevention of Health Impairment due to Asbestos”
Asbestos Information in addition to the requirements of the Industrial
Safety and Health Act.
Cat equipment and replacement parts that are
shipped from Caterpillar are asbestos free. Caterpillar • Obey environmental regulations for the disposal of
recommends the use of only genuine Cat asbestos.
replacement parts. Use the following guidelines when
you handle any replacement parts that contain • Stay away from areas that might have asbestos
asbestos or when you handle asbestos debris. particles in the air.
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 bound
in a resin or sealed in some way. Normal handling is
not hazardous unless airborne dust that contains
asbestos is generated.
If dust that may contain asbestos is present, there are
several guidelines that should be followed:

Illustration 39 g00706404

Improperly disposing of waste can threaten the

environment. Potentially harmful fluids should be
disposed of according to local regulations.
Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
SEBU8906
i01359664
Crushing Prevention and
Cutting Prevention
SMCS Code: 7000
Support the equipment properly before you perform
any work or maintenance beneath that equipment. Do
not depend on the hydraulic cylinders to hold up the
equipment. Equipment can fall if a control is moved,
or if a hydraulic line breaks.
Do not work beneath the cab of the machine unless
the cab is properly supported.
Unless you are instructed otherwise, never attempt
adjustments while the machine is moving or while the
engine is running.
Never jump across the starter solenoid terminals in
order to start the engine. Unexpected machine
movement could result.
Whenever there are equipment control linkages the
clearance in the linkage area will change with the
movement of the equipment or the machine. Stay
clear of areas that may have a sudden change in
clearance with machine movement or equipment
movement.
Stay clear of all rotating and moving parts.
If it is necessary to remove guards in order to perform
maintenance, always install the guards after the
maintenance is performed.
Keep objects away from moving fan blades. The fan
blade will throw objects or cut objects.
Do not use a kinked wire cable or a frayed wire cable.
Wear gloves when you handle wire cable.
When you strike a retainer pin with force, the retainer
pin can fly out. The loose retainer pin can injure
personnel. Make sure that the area is clear of people
when you strike a retainer pin. To avoid injury to your
eyes, wear protective glasses when you strike a
retainer pin.
Chips or other debris can fly off an object when you
strike the object. Make sure that no one can be
injured by flying debris before striking any object.
i04760300
Burn Prevention
SMCS Code: 7000
Do not touch any part of an operating engine. Allow
the engine to cool before any maintenance is
performed on the engine. Relieve all pressure in the
air system, in the oil system, in the lubrication system,
in the fuel system, or in the cooling system before any
lines, fittings, or related items are disconnected.
21
Safety Section
Crushing Prevention and Cutting Prevention
Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.
Any contact with hot coolant or with steam can cause
severe burns. Allow cooling system components to
cool before the cooling system is drained.
Check the coolant level only after the engine has
been stopped.
Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to touch
with a bare hand. Remove the filler cap slowly in
order to relieve pressure.
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.
Oils
Hot oil and hot components can cause personal
injury. Do not allow hot oil to contact the skin. Also, do
not allow hot components to contact the skin.
Remove the hydraulic tank filler cap only after the
engine has been stopped. The filler cap must be cool
enough to touch with a bare hand. Follow the
standard procedure in this manual in order to remove
the hydraulic tank filler cap.
Batteries
The liquid in a battery is an electrolyte. Electrolyte is
an acid that can cause personal injury. Do not allow
electrolyte to contact the skin or the eyes.
Do not smoke while checking the battery electrolyte
levels. Batteries give off flammable fumes which can
explode.
Always wear protective glasses when you work with
batteries. Wash hands after touching batteries. The
use of gloves is recommended.
22 SEBU8906
Safety Section
Fire Prevention and Explosion Prevention

i05837959 Keep shields in place. Exhaust shields (if equipped)

protect hot exhaust components from oil spray or fuel
Fire Prevention and Explosion spray in case of a break in a line, in a hose, or in a
seal. Exhaust shields must be installed correctly.
Prevention
Do not weld or flame cut on tanks or lines that contain
SMCS Code: 7000 flammable fluids or flammable material. Empty and
purge the lines and tanks. Then clean the lines and
tanks with a nonflammable solvent prior to welding or
flame cutting. Ensure that the components are
properly grounded in order to avoid unwanted arcs.
Dust that is generated from repairing nonmetallic
hoods or fenders may be flammable and/or explosive.
Repair such components in a well ventilated area
away from open flames or sparks. Use suitable
Personal Protection Equipment (PPE).
Inspect all lines and hoses for wear or deterioration.
Replace damaged lines and hoses. The lines and the
hoses should have adequate support and secure
clamps. Tighten all connections to the recommended
torque. Damage to the protective cover or insulation
may provide fuel for fires.
Illustration 40 g00704000
Store fuels and lubricants in properly marked
containers away from unauthorized personnel. Store
General oily rags and flammable materials in protective
containers. Do not smoke in areas that are used for
All fuels, most lubricants, and some coolant mixtures storing flammable materials.
are flammable.
To minimize the risk of fire or explosion, Caterpillar
recommends the following actions.
Always perform a Walk-Around Inspection, which
may help you identify a fire hazard. Do not operate a
machine when a fire hazard exists. Contact your Cat
dealer for service.
Understand the use of the primary exit and alternative
exit on the machine. Refer to Operation and
Maintenance Manual, “Alternative Exit”.
Do not operate a machine with a fluid leak. Repair
leaks and clean up fluids before resuming machine
operation. Fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause a
fire. A fire may cause personal injury or death.
Remove flammable material such as leaves, twigs,
papers, trash, and so on. These items may
accumulate in the engine compartment or around
other hot areas and hot parts on the machine.
Illustration 41 g00704059
Keep the access doors to major machine
compartments closed and access doors in working
condition in order to permit the use of fire suppression Use caution when you are fueling a machine. Do not
equipment, in case a fire should occur. smoke while you are fueling a machine. Do not fuel a
machine near open flames or sparks. Always stop the
Clean all accumulations of flammable materials such engine before fueling. Fill the fuel tank outdoors.
as fuel, oil, and debris from the machine. Properly clean areas of spillage.
Do not operate the machine near any flame.
SEBU8906
Avoid static electricity risk when fueling. Ultra low
sulfur diesel (ULSD) poses a greater static ignition
hazard than earlier diesel formulations with a higher
sulfur content. Avoid death or serious injury from fire
or explosion. Consult with your fuel or fuel system
supplier to ensure that the delivery system is in
compliance with fueling standards for proper
grounding and bonding practices.
Never store flammable fluids in the operator
compartment of the machine.
Battery and Battery Cables
Illustration 42 g02298225
Caterpillar recommends the following in order to
minimize the risk of fire or an explosion related to the
battery.
Do not operate a machine if battery cables or related
parts show signs of wear or damage. Contact your
Cat dealer for service.
Follow safe procedures for engine starting with jump-
start cables. Improper jumper cable connections can
cause an explosion that may result in injury. Refer to
Operation and Maintenance Manual, “Engine Starting
with Jump Start Cables” for specific instructions.
Do not charge a frozen battery. This may cause an
explosion.
Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter in
order to check the battery charge.
23
Safety Section
Fire Prevention and Explosion Prevention
Daily inspect battery cables that are in areas that are
visible. Inspect cables, clips, straps, and other
restraints for damage. Replace any damaged parts.
Check for signs of the following, which can occur over
time due to use and environmental factors:
• Fraying
• Abrasion
• Cracking
• Discoloration
• Cuts on the insulation of the cable
• Fouling
• Corroded terminals, damaged terminals, and loose
terminals
Replace damaged battery cable(s) and replace any
related parts. Eliminate any fouling, which may have
caused insulation failure or related component
damage or wear. Ensure that all components are
reinstalled correctly.
An exposed wire on the battery cable may cause a
short to ground if the exposed area comes into
contact with a grounded surface. A battery cable
short produces heat from the battery current, which
may be a fire hazard.
An exposed wire on the ground cable between the
battery and the disconnect switch may cause the
disconnect switch to be bypassed if the exposed area
comes into contact with a grounded surface. This
may result in an unsafe condition for servicing the
machine. Repair components or replace components
before servicing the machine.
Fire on a machine can result in personal injury or
death. Exposed battery cables that come into con-
tact with a grounded connection can result in
fires. Replace cables and related parts that show
signs of wear or damage. Contact your Cat dealer.
Wiring
Check electrical wires daily. If any of the following
conditions exist, replace parts before you operate the
machine.
24
Safety Section
Fire Prevention and Explosion Prevention
• Fraying
• Signs of abrasion or wear
• Cracking
• Discoloration
• Cuts on insulation
• Other damage
Make sure that all clamps, guards, clips, and straps
are reinstalled correctly. This will help to prevent
vibration, rubbing against other parts, and excessive
heat during machine operation.
Attaching electrical wiring to hoses and tubes that
contain flammable fluids or combustible fluids should
be avoided.
Consult your Cat dealer for repair or for replacement
parts.
Keep wiring and electrical connections free of debris.
Lines, Tubes, and Hoses
Do not bend high-pressure lines. Do not strike high-
pressure lines. Do not install any lines that are bent or
damaged. Use the appropriate backup wrenches in
order to tighten all connections to the recommended
torque.
Illustration 43 g00687600
Check lines, tubes, and hoses carefully. Wear
Personal Protection Equipment (PPE) in order to
check for leaks. Always use a board or cardboard
when you check for a leak. Leaking fluid that is under
pressure can penetrate body tissue. Fluid penetration
can cause serious injury and possible death. A pin
hole leak can cause severe injury. If fluid is injected
into your skin, you must get treatment immediately.
Seek treatment from a doctor that is familiar with this
type of injury.
Replace the affected parts if any of the following
conditions are present:
SEBU8906
• End fittings are damaged or leaking.
• Outer coverings are chafed or cut.
• Wires are exposed.
• Outer coverings are swelling or ballooning.
• Flexible parts of the hoses are kinked.
• Outer covers have exposed embedded armoring.
• End fittings are displaced.
Make sure that all clamps, guards, and heat shields
are installed correctly. During machine operation, this
will help to prevent vibration, rubbing against other
parts, excessive heat, and failure of lines, tubes, and
hoses.
Do not operate a machine when a fire hazard exists.
Repair any lines that are corroded, loose, or
damaged. Leaks may provide fuel for fires. Consult
your Cat dealer for repair or for replacement parts.
Use genuine Cat parts or the equivalent, for
capabilities of both the pressure limit and temperature
limit.
Ether
Ether (if equipped) is commonly used in cold-weather
applications. Ether is flammable and poisonous.
Only use approved Ether canisters for the Ether
dispensing system fitted to your machine, do not
spray Ether manually into an engine, follow the
correct cold engine starting procedures. Refer to the
section in the Operation and Maintenance Manual
with the label “Engine Starting” .
Manually spraying Ether into an engine with a Die-
sel Particulate Filter (DPF) may result in the accu-
mulation of Ether in the DPF and an explosion.
This in conjunction with other factors may result
in an injury or death.
Use ether in ventilated areas. Do not smoke while
you are replacing an ether cylinder.
Do not store ether cylinders in living areas or in the
operator compartment of a machine. Do not store
ether cylinders in direct sunlight or in temperatures
above 49° C (120.2° F). Keep ether cylinders away
from open flames or sparks.
Dispose of used ether cylinders properly. Do not
puncture an ether cylinder. Keep ether cylinders away
from unauthorized personnel.
SEBU8906
Fire Extinguisher
As an additional safety measure, keep a fire
extinguisher on the machine.
Be familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Follow the recommendations
on the instruction plate.
Consider installation of an aftermarket Fire
Suppression System, if the application and working
conditions warrant the installation.
i04025591
Fire Safety
SMCS Code: 7000
Note: Locate secondary exits and how to use the
secondary exits before you operate the machine.
Note: Locate fire extinguishers and how to use a fire
extinguisher before you operate the machine.
If you find that you are involved in a machine fire, your
safety and that of others on site is the top priority. The
following actions should only be performed if the
actions do not present a danger or risk to you and any
nearby people. At all times you should assess the risk
of personal injury and move away to a safe distance
as soon as you feel unsafe.
Move the machine away from nearby combustible
material such as fuel/oil stations, structures, trash,
mulch and timber.
Lower any implements and turn off the engine as
soon as possible. If you leave the engine running, the
engine will continue to feed a fire. The fire will be fed
from any damaged hoses that are attached to the
engine or pumps.
If possible, turn the battery disconnect switch to the
OFF position. Disconnecting the battery will remove
the ignition source in the event of an electrical short.
Disconnecting the battery will eliminate a second
ignition source if electrical wiring is damaged by the
fire, resulting in a short circuit.
Notify emergency personnel of the fire and your
location.
If your machine is equipped with a fire suppression
system, follow the manufacturers procedure for
activating the system.
Note: Fire suppression systems need to be regularly
inspected by qualified personnel. You must be trained
to operate the fire suppression system.
Use the on-board fire extinguisher and use the
following procedure:
1. Pull the pin.
25
Safety Section
Fire Safety
2. Aim the extinguisher or nozzle at the base of the
fire.
3. Squeeze the handle and release the extinguishing
agent.
4. Sweep the extinguisher from side to side across
the base of the fire until the fire is out.
Remember, if you are unable to do anything else,
shut off the machine before exiting. By shutting off the
machine, fuels will not continue to be pumped into the
fire.
If the fire grows out of control, be aware of the
following risks:
• Tires on wheeled machines pose a risk of
explosion as tires burn. Hot shrapnel and debris
can be thrown great distances in an explosion.
• Tanks, accumulators, hoses, and fittings can
rupture in a fire, spraying fuels and shrapnel over a
large area.
• Remember that nearly all of the fluids on the
machine are flammable, including coolant and oils.
Additionally, plastics, rubbers, fabrics, and resins
in fiberglass panels are also flammable.
i05883000
Fire Extinguisher Location
SMCS Code: 7000; 7419
Make sure that a fire extinguisher is on the machine.
Make sure that you are familiar with the operation of
the fire extinguisher. Inspect the fire extinguisher and
service the fire extinguisher on a regular basis. Obey
the recommendations on the instruction plate.
Illustration 44 g00917681
If equipped, know how to use the machine fire
suppression system.
26
Safety Section
Tire Information
The recommended mounting location of the fire
extinguisher is behind the seat in the operator station.
Do not weld the ROPS in order to install the fire
extinguisher. Also, do not drill holes in the ROPS in
order to mount the fire extinguisher.
Illustration 45 g00917682
If more than one fire extinguisher is required, the
recommended place to mount a second fire
extinguisher is on the right side of the front frame,
beside the engine air cleaner.
Reference: For more information on mounting fire
extinguishers. Refer to Special Instruction,
“Procedure to Install Fire Extinguisher Mounting
Brackets to Certain Underground Articulated Trucks
and Load Haul Dumps”.
i04160129
Tire Information
SMCS Code: 7000
Explosions of air inflated tires have resulted from
heat-induced gas combustion inside the tires.
Explosions can be caused by heat that is generated
by welding, by heating rim components, by external
fire, or by excessive use of brakes.
A tire explosion is much more violent than a blowout.
The explosion can propel the tire, the rim
components, and the axle components from the
machine. Stay out of the trajectory path. Both the
force of the explosion and the flying debris can cause
property damage, personal injury, or death.
SEBU8906
Illustration 46 g02166933
Typical example of tire is shown
Do not approach a hot or an apparently damaged tire.
Caterpillar recommends against using water or
calcium as a ballast for the tires except in machines
designed for this additional mass. For those
applicable machines, the maintenance section will
contain instructions on the correct tire inflation and
filling procedures. Ballast, such as fluid in the tires,
increases overall machine weight and may affect
braking, steering, power train components, or the
certification of the protective structure such as the
ROPS. The use of tire/rim rust preventatives or other
liquid additives is not required.
Dry nitrogen gas is recommended for inflation of
tires. If the tires were originally inflated with air,
nitrogen is still preferred for adjusting the pressure.
Nitrogen mixes properly with air.
Nitrogen inflated tires reduce the potential of a tire
explosion because nitrogen does not aid combustion.
Nitrogen helps to prevent oxidation of the rubber,
deterioration of rubber, and corrosion of rim
components.
To avoid overinflation, proper nitrogen inflation
equipment and training in the usage of the equipment
are necessary. A tire blowout or a rim failure can
result from improper equipment or from misused
equipment.
When you inflate a tire, stand behind the tread and
use a self-attaching chuck.
Servicing tires and rims can be dangerous. Only
trained personnel that use proper tools and proper
procedures should perform this maintenance. If
correct procedures are not used for servicing tires
and rims, the assemblies could burst with explosive
force. This explosive force can cause serious
personal injury or death. Carefully obey the specific
instructions from your tire dealer.
SEBU8906 27
Safety Section
Electrical Storm Injury Prevention

i01122596 Do not carry tools or supplies when you mount the

machine or when you dismount the machine. Use a
Electrical Storm Injury hand line to raise and lower tools or supplies.
Prevention Do not use any controls as handholds when you enter
the operator compartment or when you exit the
SMCS Code: 7000 operator compartment.
When lightning is striking in the vicinity of the
machine, the operator should never attempt the Alternate Exit
following procedures: Machines that are equipped with cabs may have
alternate exits. For additional information on
• Mount the machine. machines that are equipped with alternate exits, see
Operation and Maintenance Manual, “Alternate Exit”.
• Dismount the machine.
If you are in the operator's station during an electrical i05883001
storm, stay in the operator's station. If you are on the
ground during an electrical storm, stay away from the
vicinity of the machine.
Before Starting Engine
SMCS Code: 1000; 7000
i01411864

Mounting and Dismounting

SMCS Code: 7000

Illustration 48 g03709474

Make sure that the steering frame lock is stored in the

Illustration 47 g00037860
Mount the machine and dismount the machine only at
locations that have steps and/or handholds. Before
you mount the machine, clean the steps and the
handholds. Inspect the steps and handholds. Make
any necessary repairs.
Face the machine whenever you mount the machine
and whenever you dismount the machine.
Maintain a three-point contact with the steps and with
the handholds.
Note: Three-point contact can be two feet and one
hand. Three-point contact can also be one foot and
two hands.
Never mount a moving machine. Never dismount a
moving machine. Never jump off the machine.
unlocked position, as shown. The steering frame lock
must be removed in order to steer the machine.
Note: Start the engine only from the operator station.
Never short across the starter terminals or across the
batteries. Shorting could bypass the engine neutral
start system. Shorting could also damage the
electrical system.
Before you mount the machine, perform a walk
around inspection. Look for any damaged
components and leaks. Report discrepancies and
make any necessary repairs before operating the
machine
Reference: For more information, refer to Operation
and Maintenance Manual, “Walk Around Inspection”
for the machine that is being serviced.
When you enter the operator station, Inspect the
condition of the seat belt and the condition of the
mounting hardware. Replace any parts that are worn
or damaged. Regardless of the appearance, replace
the seat belt after 3 years of use. Do not use a seat
belt extension on a retractable seat belt.
28
Safety Section
Engine Starting
Adjust the seat so that full pedal travel can be
achieved when the operator's back is against the
back of the seat.
Make sure that the machine is equipped with a
lighting system that is adequate for the job conditions.
Make sure that all lights are working properly.
Before you start the engine or before you move the
machine, make sure that no one is on the machine,
underneath the machine, or around the machine.
Make sure that there are no personnel in the area.
i03859832
Engine Starting
SMCS Code: 1000; 7000
Illustration 49 g00104545
If a warning tag is attached to the engine start switch
or to the machine controls, do not start the engine.
Also, do not move any machine controls.
For dump body machines, make sure that the dump
body is down. Put the hoist control in the FLOAT
position.
For ejector body machines, put the hoist control in the
HOLD position.
Move the transmission direction and speed control to
the NEUTRAL position.
Engage the parking brake control.
Diesel engine exhaust contains products of
combustion which can be harmful to your health.
Always start the engine in a well ventilated area.
Always operate the engine in a well ventilated area. If
you are in an enclosed area, vent the exhaust to the
outside.
Check for the presence of bystanders or maintenance
personnel. Ensure that all personnel are clear of the
machine.
Briefly sound the horn before you start the engine.
SEBU8906
i01794895
Before Operation
SMCS Code: 7000
Make sure that there are no personnel on the
machine or in the area around the machine.
Clear all obstacles from the path of the machine.
Beware of hazards such as wires, ditches, etc.
Make sure that all windows are clean. Secure the
door in the closed position.
Make sure that the horn, the backup alarm, the action
alarm, the dash indicator lamps and all other warning
devices are working properly.
Fasten the seat belt securely.
A person that occupies the companion seat must
wear the seat belt for the companion seat.
i04862936
Visibility Information
SMCS Code: 7000
Before you start the machine, perform a walk-around
inspection in order to ensure that there are no
hazards around the machine.
While the machine is in operation, constantly survey
the area around the machine in order to identify
potential hazards as hazards become visible around
the machine.
Your machine may be equipped with visual aids.
Some examples of visual aids are Closed Circuit
Television (CCTV) and mirrors. Before operating the
machine, ensure that the visual aids are in proper
working condition and that the visual aids are clean.
Adjust the visual aids using the procedures that are
located in this Operation and Maintenance Manual. If
equipped, the Work Area Vision System shall be
adjusted according to Operation and Maintenance
Manual, SEBU8157, “Work Area Vision System”. If
equipped, the Cat Detect Object Detection shall be
adjusted according to the Operation and Maintenance
Manual, “Cat Detect Object Detection” for your
machine.
It may not be possible to provide direct visibility on
large machines to all areas around the machine.
Appropriate job site organization is required in order
to minimize hazards that are caused by restricted
visibility. Job site organization is a collection of rules
and procedures that coordinates machines and
people that work together in the same area.
Examples of job site organization include the
following:
SEBU8906 29
Safety Section
Restricted Visibility

• Safety instructions
• Controlled patterns of machine movement and
vehicle movement
• Workers that direct safe movement of traffic
• Restricted areas

• Operator training
• Warning symbols or warning signs on machines or
on vehicles
• A system of communication

• Communication between workers and operators

prior to approaching the machine
Modifications of the machine configuration by the
user that result in a restriction of visibility shall be
evaluated.

i04388250

Restricted Visibility
SMCS Code: 7000
The size and the configuration of this machine may
result in areas that cannot be seen when the operator Illustration 50 g02554998
is seated. Illustration 50 provides an approximate
visual indication of the areas of significant restricted Note: The shaded areas indicate the approximate
visibility. Illustration 50 indicates restricted visibility location of areas with significant restricted visibility.
areas at the ground level inside a radius of 12.0 m
(39.37 ft) from the operator on a machine without the
use of visual aids. This illustration does not provide i05190872
areas of restricted visibility for distances outside a
radius of 12.0 m (39.37 ft). Operation
This machine may be equipped with visual aids that SMCS Code: 7000
may provide visibility to some of the restricted
visibility areas. For areas that are not covered by the Machine Operating Temperature
visual aids, job site organization must be utilized to
minimize hazards of this restricted visibility. For more Range
information regarding job site organization refer to
Operation and Maintenance Manual, “Visibility The standard machine configuration is intended for
Information”. use within an ambient temperature range of 0° + 45°C
(32° + 113°F). Special configurations for different
ambient temperatures may be available. Consult your
Caterpillar dealer for additional information on special
configurations of your machine.

Machine Operating Altitude Range

If the machine is used at elevations, higher than
3000 m (9843 ft) contact your Caterpillar dealer.

Machine Operation
Only operate the machine while you are in a seat.
The seat belt must be fastened while you operate the
machine. Only operate the controls while the engine
is running.
30
Safety Section
Engine Stopping
Before you move the machine, make sure that no one
will be endangered.
While you operate the machine slowly in an open
area, check for proper operation of all controls and all
protective devices.
Do not allow riders on the machine unless the
machine has the following equipment:
• Additional seat
• Additional seat belt
• Rollover Protective Structure (ROPS)
Never use the work tool for a platform.
Note any needed repairs during machine operation.
Report any needed repairs.
When the machine is on an upward slope, avoid
dumping the machine. The machine could tip
backward.
Avoid any conditions that can lead to tipping the
machine. The machine can tip when you work on
hills, on banks and on slopes. Also, the machine can
tip when you cross ditches, ridges, or other
unexpected obstacles.
Avoid operating the machine across the slope. When
possible, operate the machine up the slopes and
down the slopes.
Maintain control of the machine. Do not load the
machine beyond the machine capacity.
Never straddle a wire cable. Never allow other
personnel to straddle a wire cable.
Know the maximum dimensions of your machine.
Always keep the Rollover Protective Structure
(ROPS) installed during machine operation.
Always anticipate the grade and select the proper
gear range for the grade.
For dump body machines, lower the dump body
completely before travel. Keep the hoist control in the
FLOAT position during travel.
For ejector body machines, retract the ejector plate
completely and raise the tailgate completely before
travel. Keep the hoist control in the HOLD position
during travel.
When the machine is being loaded, stay in the
operator station of the machine.
Obey all road signs.
A signalman should be present, when you move the
machine in a building or out of a building.
SEBU8906
i05426630
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. Running the engine allows hot
areas of the engine to cool gradually.
i02228070
Parking
SMCS Code: 7000
Park the machine on a level surface. If you must park
on a grade, block the machine's wheels.
Apply the service brake in order to stop the machine.
Move the transmission control to the NEUTRAL
position. Move the throttle control to the LOW IDLE
position.
Engage the parking brake.
Stop the engine.
Turn the engine start switch to the OFF position and
remove the engine start switch key.
Turn the battery disconnect switch to the OFF
position. Remove the disconnect switch key if the
machine will not be operated for an extended period
of time. This will prevent any drainage of the battery.
A battery short circuit, any current draw from certain
components, and vandalism can cause drainage of
the battery.
i03745198
Slope Operation
SMCS Code: 7000
Machines that are operating safely in various
applications depend on these criteria: the machine
model, configuration, machine maintenance,
operating speed of the machine, conditions of the
terrain, fluid levels and tire inflation pressures. The
most important criteria are the skill and judgment of
the operator.
SEBU8906
A well trained operator that follows the instructions in
the Operation and Maintenance Manual has the
greatest impact on stability. Operator training
provides a person with the following abilities:
observation of working and environmental conditions,
feel for the machine, identification of potential
hazards and operating the machine safely by making
appropriate decisions.
When you work on side hills and when you work on
slopes, consider the following important points:
Speed of travel – At higher speeds, forces of inertia
tend to make the machine less stable.
Roughness of terrain or surface – The machine
may be less stable with uneven terrain.
Direction of travel – Avoid operating the machine
across the slope. When possible, operate the
machine up the slopes and operate the machine
down the slopes. Place the heaviest end of the
machine uphill when you are working on an incline.
Mounted equipment – Balance of the machine may
be impeded by the following components: equipment
that is mounted on the machine, machine
configuration, weights and counterweights.
Nature of surface – Ground that has been newly
filled with earth may collapse from the weight of the
machine.
Surface material – Rocks and moisture of the
surface material may drastically affect the machine's
traction and machine's stability. Rocky surfaces may
promote side slipping of the machine.
Slippage due to excessive loads – This may cause
downhill tracks or downhill tires to dig into the ground,
which will increase the angle of the machine.
Width of tracks or tires – Narrower tracks or
narrower tires further increase the digging into the
ground which causes the machine to be less stable.
Implements attached to the drawbar – This may
decrease the weight on the uphill tracks. This may
also decrease the weight on the uphill tires. The
decreased weight will cause the machine to be less
stable.
Height of the working load of the machine – When
the working loads are in higher positions, the stability
of the machine is reduced.
Operated equipment – Be aware of performance
features of the equipment in operation and the effects
on machine stability.
Operating techniques – Keep all attachments or
pulled loads low to the ground for optimum stability.
Machine systems have limitations on slopes –
Slopes can affect the proper function and operation of
the various machine systems. These machine
systems are needed for machine control.
31
Safety Section
Equipment Lowering with Engine Stopped
Note: Safe operation on steep slopes may require
special machine maintenance. Excellent skill of the
operator and proper equipment for specific
applications are also required. Consult the Operation
and Maintenance Manual sections for the proper fluid
level requirements and intended machine use.
i01329161
Equipment Lowering with
Engine Stopped
SMCS Code: 7000
Before lowering any equipment with the engine
stopped, clear the area around the equipment of all
personnel. The procedure to use will vary with the
type of equipment to be lowered. Keep in mind most
systems use a high pressure fluid or air to raise or
lower equipment. The procedure will cause high
pressure air, hydraulic, or some other media to be
released in order to lower the equipment. Wear
appropriate personal protective equipment and follow
the established procedure in the Operation and
Maintenance Manual, “Equipment Lowering with
Engine Stopped” in the Operation Section of the
manual.
i03769489
Sound Information and
Vibration Information
SMCS Code: 7000
The operator sound pressure level is 81 dB(A) when
measured on an enclosed cab using “ISO 6394:1998
Earth-moving machinery − Determination of emission
sound level pressure level at operator's position −
Stationary test conditions”. The cab was properly
installed and maintained. The test was conducted
with the cab doors and the cab window closed.
Hearing protection may be needed when the machine
is operated with an open operator station for
extended periods or in a noisy environment. Hearing
protection may be needed when the machine is
operated with a cab that is not properly maintained, or
when the doors and windows are open for extended
periods or in a noisy environment.
Vibration Level
The hands and arms are exposed to a weighted root
mean square acceleration that is 1.6 m/s2.
The whole body is exposed to a weighted root mean
square acceleration that is 1.7 m/s2.
Measurements are obtained on a representative
machine using the procedures in the following
standards:
32
Safety Section
Operator Station
• “ISO 2631/1”
• “ISO 5349”
i03634321
Operator Station
SMCS Code: 7000; 7301; 7325
Any modifications to the inside of the operator station
should not project into the operator space or into the
space for the companion seat (if equipped). The
addition of a radio, fire extinguisher, and other
equipment must be installed so that the defined
operator space and the space for the companion seat
(if equipped) is maintained. Any item that is brought
into the cab should not project into the defined
operator space or the space for the companion seat
(if equipped). A lunch box or other loose items must
be secured. Objects must not pose an impact hazard
in rough terrain or in the event of a rollover.
i03656846
Guards
(Operator Protection)
SMCS Code: 7000; 7150; 7325
There are different types of guards that are used to
protect the operator. The machine and the machine
application determines the type of guard that should
be used.
A daily inspection of the guards is required in order to
check for structures that are bent, cracked or loose.
Never operate a machine with a damaged structure.
The operator becomes exposed to a hazardous
situation if the machine is used improperly or if poor
operating techniques are used. This situation can
occur even though a machine is equipped with an
appropriate protective guard. Follow the established
operating procedures that are recommended for your
machine.
SEBU8906
Rollover Protective Structure
(ROPS), Falling Object Protective
Structure (FOPS) or Tip Over
Protection Structure (TOPS)
The ROPS/FOPS Structure (if equipped) on your
machine is specifically designed, tested and certified
for that machine. Any alteration or any modification to
the ROPS/FOPS Structure could weaken the
structure. This places the operator 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
windows 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:
SEBU8906 33
Safety Section
Guards

• Demolition applications
• Rock quarries

• Forestry products
Additional guards may be required for specific
applications or work tools. The Operation and
Maintenance Manual for your machine or your work
tool will provide specific requirements for the guards.
Consult your Caterpillar dealer for additional
information.
34 SEBU8906
Product Information Section
Model Views and Specifications

Product Information
Section

Model Views and

Specifications
i04494129

Model Views and

Specifications
SMCS Code: 7000 Illustration 53 g01803438
(12) Ejector body
(13) Tailgate
(14) Ejector cylinder

Basic machine operating specifications are listed in

the following tables.
Table 1
AD30 Underground Articulated Truck (Dump Body)
Empty Weight (approximate)(1) 28300 kg (62390 lb)

Length (maximum) 10160 mm (400 inch)

Width (maximum) 2840 mm (111.8 inch)

Height (top of empty body) 2722 mm (107.2 inch)

(1) The weight includes a full fuel tank, a 75 kg (165.3 lb) operator,
Illustration 51 g01803433 an enclosed operator station, and a standard dump body. If ad-
ditional attachments have been installed on your machine, the
(1) Fuel tank weight of your machine may vary.
(2) Engine air cleaner
(3) Hydraulic tank
(4) Engine Table 2
(5) Final drives AD30 Underground Articulated Truck (Dump Body -
Wide)
Empty Weight (approximate)(1) 28870 kg (63650 lb)

Length (maximum) 10455 mm (411.6 inch)

Width (maximum) 3040 mm (119.6 inch)

Height (top of empty body) 2547 mm (100.2 inch)

(1) The weight includes a full fuel tank, a 75 kg (165.3 lb) operator,
an enclosed operator station, and a wide dump body. If addition-
al attachments have been installed on your machine, the weight
of your machine may vary.

Illustration 52
(6) Radiator
(7) Operator station
(8) Dump body
(9) Battery compartment
(10) Steering frame lock
(11) Hoist cylinder
Table 3
AD30 Underground Articulated Truck (Ejector Body)
Empty Weight (approximate)(1) 32500 kg (71650 lb)
g01803437
Length (maximum) 10450 mm (411.4 inch)
(continued)
SEBU8906 35
Model Views and Specifications
Model Views and Specifications

(Table 3, contd) (Table 4, contd)

(1) There are many variables to consider when operating on a
AD30 Underground Articulated Truck (Ejector Body)
grade. For example: grades that can be partially side sloped
Width (maximum) 2880 mm (113.4 inch) and can be soft, hard, wet, dry, loose, firm, graded, not graded,
and frozen. Such variability will affect traction and rolling resist-
Height (top of empty body) 2941 mm (115.8 inch) ance and the individual circumstances must be considered be-
fore operating on any grade.
(1) The weight includes a full fuel tank, a 75 kg (165.3 lb) operator, (2) The listed restriction assumes that the brake components are

an enclosed operator station, and a standard ejector body. If ad-
ditional attachments have been installed on your machine, the
weight of your machine may vary.
Intended Use
The AD30 Underground Articulated Truck is a self-
propelled wheeled machine with an articulation frame
in order to steer. This machine has an open body that
is intended for the following applications under normal
conditions: transporting loose material and dumping
loose material.
within working specifications, the machine mass is at maximum
allowable, a graded ground surface, and a dry, firm underfoot.
The machine operator is responsible for evaluating the condition
of the machine, the environment, and using appropriate judg-
ment to maintain control of the machine.
(3) Dumping on a grade when the machine is articulated is not rec-
ommended. Dumping on a side grade is not recommended. Ma-
chines are designed to dump on level ground with some
variation in underfoot surface conditions. The center of gravity
of the machine can change rapidly during dumping on a grade
when the machine is articulated or during dumping on a side
grade.

Application and Configuration

Restrictions
The maximum approved operating weight of the
AD30 (including payload) is 60000 kg (132277 lb).
The operator station is ROPS certified to ISO
3471:1994 and up to 21070 kg (46,451 lb) tractor only
mass

General Operating Restrictions

Use only in a non-explosive gas environment.
Do not use to spread the load by raising the dump
body while the machine is moving.
Avoid conditions that can lead to tipping the machine.
The machine can tip when you work on hills, banks
and on upward and side slopes. The machine can tip
when you cross ditches, ridges, or other unexpected
obstacles.
Avoid operating the machine across a slope as there
are many factors that can adversely affect stability
and for that reason Caterpillar does not provide data
for such operations.

Reference: Refer to Operation and Maintenance

Manual, “Slope Operation” for more information.
Table 4
AD30 Operating Restrictions Grade
Maximum Working Grade(1) 20%

Parking Brake Holding Capability (2) 25%

Maximum Side Grade for Dumping (3) 0%

(continued)
36 SEBU8906
Identification Information
Plate Locations and Film Locations

Identification Information Service Information Plate (C)

Year of Manufacture Plate (D) (If Required)
i05750226
CE Plate (E) (If Required)
Plate Locations and Film Country of Origin Info Plate (F) (If Required)
Locations
Local regulation may require documentation of the
SMCS Code: 1000; 7000 Year of Manufacture in the Operation and
Maintenance Manual. Always comply with these
The Product Identification Number (PIN) will be used regulations.
to identify a powered machine that is designed for an
operator to ride.
Serial Number Plates (SN)
Caterpillar products such as engines, transmissions,
and major attachments that are not designed for an
operator to ride are identified by Serial Numbers.
For quick reference, record the identification numbers
in the spaces that are provided below the illustration.

Product Identification Number (PIN)

Illustration 56 g00929428

Engine Serial Number

Illustration 54 g03670180

The Product Identification Number (PIN) plate is

located on the left side of the rear frame. The PIN
plate may have the following information.

Illustration 57 g00929422

Transmission Serial Number

Illustration 55 g03670182

Model number (A)

Product Identification Number (B)
SEBU8906 37
Identification Information
Emissions Certification Film

Illustration 58 g00929423 Illustration 60 g01953246

Torque Converter Serial Number These films are located inside the cab.

i04019510

Emissions Certification Film

SMCS Code: 1000; 7000; 7405

Note: This information is pertinent in the United

States, in Canada and in Europe.
If applicable consult your Cat dealer for an Emission
Control Warranty Statement.
This label is located on the engine.

Illustration 59 g02161534
Typical example

Body Serial Number

Certification
ROPS/FOPS Plate

Structural damage, an overturn, modification, al-

teration, or improper repair can impair this struc-
ture's protection capability thereby voiding this
certification. Do not weld on or drill holes in the
structure. Consult a Caterpillar dealer to deter-
mine this structure's limitations without voiding
its certification.

This machine has been certified to the standards that

are listed on the certification film.
38
Operation Section
Battery Disconnect Switch
Operation Section
Monitoring Systems and
Operator Station Features
Battery Disconnect Switch
SMCS Code: 1411
Illustration 61
Illustration 62
Battery disconnect switch (1) is located on the left
front side of the machine.
Disconnect Switch ON – To activate the
electrical system, insert the battery
disconnect switch key and turn the key
clockwise. The battery disconnect switch must be
in the ON position before you start the engine.
Disconnect Switch OFF – To deactivate
the electrical system, turn the battery
disconnect switch key counterclockwise
to the OFF position.
SEBU8906
The battery disconnect switch and the engine start
switch perform different functions. The entire
electrical system is disabled when you turn off the
battery disconnect switch. The battery remains
connected to the electrical system when you turn off
the engine start switch key.
Turn the battery disconnect switch to the OFF
position and remove the key when you service the
i03460560 electrical system or any other machine components.
Turn the battery disconnect switch to the OFF
position and remove the key when the machine will
not be used for an extended period of a month or
more. This will help to prevent drainage of the battery.
NOTICE
Never move the battery disconnect switch to the OFF
position while the engine is operating. Serious dam-
age to the electrical system could result.
i02608118
Battery Isolation Control
(If Equipped)
SMCS Code: 1402; 1408
g01803440
Illustration 63 g01305620
g00926489
Use the battery isolation control in order to isolate the
electrical system. The battery isolation control is a
push-pull type switch.
Battery Isolation Control – Pull battery
isolation control knob outward to the
OFF position in order to isolate the
electrical system. Push the battery
isolation control knob inward to the ON
position in order to connect the
electrical system.
During normal operation, use the engine start switch
to stop the engine.
SEBU8906 39
Monitoring Systems and Operator Station Features
Engine Shutdown Switch

Note: Turn the battery disconnect switch to the OFF i05883002

position and remove the key when you service the
electrical system or any other machine components. Engine Start Switch
SMCS Code: 1416
i03460561

Engine Shutdown Switch

SMCS Code: 7418-ZS

Illustration 66 g03709476

Engine Start Switch (1) – The engine start switch (1)

is used to turn on the electrical system. The engine
start switch (1) is also used to start the engine.
Illustration 64 g01803442

OFF Position (2) – When you insert or

remove the engine start switch key, the
engine start switch (1) must be in the
OFF position. To disconnect the power to the
electrical circuits in the operators station, turn the
engine start switch (1) to the OFF position. Also,
turn the engine start switch (1) to the OFF
position in order to stop the engine.

ON Position (3) – To activate the

electrical circuits in the operators
station, turn the engine start switch key
clockwise to the ON position.
START POSITION(4) – To start the
Illustration 65 g01002796
engine, turn the engine start switch (1)
clockwise to the START position. When
The engine shutdown switch (1) is located on the left the engine start switch key is released, the engine
front side of the machine. start switch (1) will return to the ON position.

Engine Shutdown Switch (1) – Use Note: If the engine fails to start, return the engine
engine shutdown switch (1) in order to start switch (1) to the OFF position. Return the engine
stop the engine from the ground level. In start switch (1) to the OFF position must be done
order to use engine shutdown switch (1), push the before you attempt to start the engine again.
engine shutdown switch knob in to the OFF
position. This will stop the engine. After the i05883004
engine stops, turn the knob clockwise. This will
reset the engine shutdown switch to the ON
position.
Idle Timer Control (Engine
Shutdown)
During normal operation, use the engine start switch
to stop the engine. (If Equipped)
Note: The engine shutdown switch does not shut off
the electrical system of the machine.
40 SEBU8906
Monitoring Systems and Operator Station Features
Caterpillar Monitoring System

SMCS Code: 7418 i02223380

Caterpillar Monitoring System

SMCS Code: 7451; 7490

Illustration 67 g03709477

The function of the idle timer control is to provide a

timed period of idle (3 minutes) before engine
shutdown when the engine start switch is turned to
the OFF position.
Idle Timer On Indicator (1) – Indicates
that the idle timer has been activated.
When the engine start switch is turned to
the OFF position, the indicator will flash and the
engine will stop after 3 minutes.
Illustration 68 g01042550
The Caterpillar Monitoring System consists of gauge
display (1), speedometer/tachometer display (2), an
action alarm, action lamp (3), and monitoring system
display (4). Individual alert indicators (5) for each
machine system are located on the monitoring
system display.

Note: The idle timer will activate whenever the engine
start switch is turned from the ON position to the OFF
position.
The monitoring system is designed to alert the
operator of an immediate or an impending problem in
one or more of the machine systems.

Engine Shutdown Switch (2) – This

switch allows the engine to be stopped
immediately. Push down on the engine
shutdown switch in order to stop the engine.
To override the idle timer and stop the engine, turn
the engine start switch to the OFF position and push
the engine shutdown switch down.
Note: If the idle timer has been activated without
starting the engine, the idle timer can be deactivated
by pushing down engine shutdown switch (2).
Indicator (1) should stop flashing.

NOTICE
Never turn the battery disconnect switch to the OFF
position with the idle timer activated (engine running).
Electrical system damage could result.

Note: Certain machines may be equipped with a fire

suppression control (engine shutdown) in addition to
the idle time control. For more information on the
operation of the fire suppression control, refer to the
Operation and Maintenance Manual, “Fire
Suppression System (Foam)” for the machine that is
being serviced.
SEBU8906 41
Monitoring Systems and Operator Station Features
Caterpillar Monitoring System

Warning Operation
Table 5
Warning Operation

Warning Indications(1)

Warning Alert Indicator Required Action from the

Flashes(3) or a Action Lamp Possible Result(2)
Category The Action Alarm Operator
Gauge will Show in Flashes(4) Sounds
the Red Range

No immediate action is re-

No harmful effects or damag-
1 X quired. The system needs
ing effects will occur.
attention soon.
Change machine operation
Damage to machine compo-
2 X X or perform maintenance to
nents will occur.
the system.

Immediately change the Severe damage to

2-S X X X(5)
machine operation. components.

Injury to the operator or severe

Immediately perform a safe
3 X X X(6) damage to components will
engine shutdown.
occur.
(1) The active warning indications are marked with an X.
(2) If the required action is not carried out then the following results will occur.
(3) The alert indicator flashes at a 10 Hz rate.
(4) The action lamp flashes at a 1 Hz rate.
(5) The action alarm is on continuously.
(6) The action alarm will sound at a 1 Hz rate.

Warning Categories
The monitoring system provides three warning
categories. The first category requires only operator
awareness. The second warning category requires
the operation of the machine or the maintenance
procedure for the machine to be changed. The third
warning category requires immediate safe shutdown
of the machine.

Warning Category 1
In this category, only the appropriate alert indicators
will flash. The alert indicator informs the operator that
a machine system needs attention. The condition of
the machine system should not endanger the Illustration 69 g01041967
operator. Also, the condition of the machine system
should not damage the machine.
Air Filter Restriction (2) – Indicates the
engine air filters are plugged. If this
indicator comes on during operation,
service the filters that day.
Parking Brake (3) – This alert indicator
will be on when the transmission is in
neutral and the parking brake is
engaged. This alert indicator should come on
during start up. The alert indicator should go out
when the parking brake is disengaged.
If the alert indicator continues to flash after
disengaging the parking brake, determine the cause
before operating the machine.
42 SEBU8906
Monitoring Systems and Operator Station Features
Caterpillar Monitoring System

Charging System (4) – This alert

NOTICE
indicator will be on when the charging
system is malfunctioning. If the electrical Running out of fuel can cause engine damage. Do
not continue to operate the machine when critically
loads are high (e.g. air conditioning and/or
low on fuel.
lighting on) and the engine speed is low or near
idle, increase engine speed to high idle. This will
generate more output from the alternator. If the
charging system alert indicator turns off within Warning Category 2
about one minute, the electrical system is
probably operating normally but overloaded In this category, one of the following conditions will
during periods of low engine speeds. Modify occur:
operating cycle or reduce electrical loads to keep • An alert indicator and action lamp (1) will flash.
from overloading the electrical system and
discharging the batteries. • A gauge will show in the red range and the action
lamp will flash.
If engine speed is near operating speeds and if
electrical loads are light, and the lamp remains on, This warns the operator that a change of machine
pull to a convenient stop and investigate the cause operation is required to avoid possible damage to the
(loose/broken belt, defective batteries or alternator). indicated system. Move the machine to a convenient
Do not operate the machine until the cause has been place to park the machine and stop the engine.
corrected. Investigate the cause of the alert indicator or the
gauge and report the problem immediately.
Maintenance Required (5) – This alert
indicator will be on constantly when the
machine requires maintenance. The alert
indicator can be reset using the 4C-8195Control
Service Tool. The alert indicator can be reset and
the maintenance interval can be altered using
Electronic Technician (ET). For information on
resetting the maintenance indicator, refer to
Service Manual, “Caterpillar Monitoring System”,
for the machine that is being serviced.
Fuel Pressure (5) – This alert indicator
will flash if the fuel filter is blocked. If
this indicator flashes during operation,
service the fuel filter that day.
Illustration 71 g01042180

Brake Oil Temperature or Torque

Converter Oil Temperature (7) – This
alert indicator will be on when brake oil
temperature and/or torque converter oil
temperature is high. If the alert indicator comes
on, reduce the load on the machine or slow the
retarding speed. Move the machine to a
convenient location to park the machine. Keep
the engine running to cool the oil. Investigate the
cause. Do not operate the machine if the alert
indicator and action lamp remain on.

Illustration 70 g00926944

Fuel Level Gauge (6) – If the needle

enters the red range, this indicates low
fuel level (15 percent of the tank
capacity). Refuel the tank within the hour in order
to avoid running out of fuel.
SEBU8906
Illustration 72 g00926946
Engine Coolant Temperature (8) – When
the needle is in the red range, the
coolant temperature is high. Move the
machine to a convenient location to park the
machine and stop the engine. Investigate the
cause. Do not operate the machine if the action
lamp remains on.
Brake Oil Temperature (9) – When the
needle is in the red range, the brake oil
temperature is high. Reduce the load on
the machine or slow the retarding speed. Move
the machine to a convenient location to park the
machine. Keep the engine running to cool the oil.
Investigate the cause. Do not operate the machine
if the action lamp remains on.
Warning Category 2-S
The warning category 2-S includes a constant alarm.
Warning category 2-S includes all warnings in
category 2. The warning category 2-S is a severe
condition. The operator should immediately change
the operating procedures in order to prevent damage
to the machine. When the correct measures have
been taken, the alarm will stop. A category 2-S is
logged.
43
Monitoring Systems and Operator Station Features
Caterpillar Monitoring System
Illustration 73 g01132454
Parking Brake (10) – Indicates the
machine is not in neutral and the parking
brake is engaged. The action alarm will
continuously sound. If the alert indicator flashes
during operation and the alarm continuously
sounds, stop the machine immediately.
Investigate the cause of the fault.
Engine Overspeed (11) – This alert
indicator will be on when there is a
sensor problem or engine overspeed
(2500 rpm). Reduce engine speed immediately.
Investigate the cause of the fault.
Warning Category 3
In this category, one of the following conditions will
occur:
• The alert indicator will flash. Also, the action lamp
(1) will flash and the action alarm will sound.
• A gauge will show in the red range. Also, the
action lamp (1) will flash and the action alarm will
sound.
This category requires immediate shutdown of the
machine to prevent possible injury to the operator
and/or severe damage to the system and the
machine.
Do not operate the machine until the cause has been
corrected.
44 SEBU8906
Monitoring Systems and Operator Station Features
Gauges

NOTICE
If the transmission oil pressure indicator comes on,
the parking brake may engage. Cease operation,
quickly move the machine to a safe area and shut the
machine down. Inspect and rectify the cause of the
problem before recommencing operation.

Illustration 74 g01132455

Engine Oil Pressure (12) – This alert

indicator will be on when the engine oil
pressure is low. Immediately stop the
machine in a safe manner. Stop the engine and
investigate the cause. Do not operate the machine
until the cause has been corrected.
Illustration 75 g00926947
Charging System (13) – This alert
indicator will be on when there is a Engine Oil Pressure (17) – When the
serious malfunction in the charging needle is in the red range the engine oil
system. Immediately stop the machine in a safe pressure is low. Immediately stop the
manner. Stop the engine and investigate the machine in a safe manner. Stop the engine and
cause. Do not operate the machine until the cause investigate the cause. Do not operate the machine
has been corrected. until the cause has been corrected.
Brake Accumulator Oil Pressure (14) –
This alert indicator will be on when there i05794013
is low brake accumulator oil pressure. If
this alert indicator and the action lamp come on, Gauges
and the action alarm sounds during operation, SMCS Code: 7450
immediately stop the machine in a safe manner.
Stop the engine and investigate the cause. Do not
operate the machine until the cause has been
corrected.
Engine Coolant Level (15) – This alert
indicator will be on when the coolant
level in the radiator is low. If this
indicator comes on, immediately stop the
machine in a safe manner. Stop the engine. Check
the coolant level and investigate for leaks. Do not
operate the machine until the cause has been
corrected.

Transmission Oil Pressure (16) – This

alert indicator will be on when the
machine has low transmission oil
pressure (e.g. engine stalled). If the transmission
oil pressure further decreases, the parking brake
will automatically engage. Immediately stop the
machine in a safe manner. Stop the engine and
investigate the cause. Do not operate the machine
until the cause has been corrected.
Illustration 76 g03672125
Engine Coolant Temperature (1) –
Indicates the temperature of the engine
coolant. The normal operating range is
the white range. The needle will indicate in the red
range if the engine coolant temperature exceeds
107 °C (225 °F).
SEBU8906
Brake Oil Temperature (2) – Indicates the
temperature of the oil in the brake oil
cooling system. The normal operating
range is the white range. The needle will indicate
in the red range if the brake oil temperature
exceeds 124 °C (255 °F).
Tachometer (3) – The tachometer displays the
engine speed during machine operation.
Engine Oil Pressure (4) – Indicates the
pressure of the engine oil. The normal
operating range is the white range. The
needle will indicate in the red range if the engine
oil pressure is below 65 kPa (10 psi).
Fuel Level (5) – Indicates the amount of
fuel remaining in the fuel tank.
Speedometer (6) – The speedometer consists of
three digits. The speedometer shows the ground
speed of the machine in kilometers per hour or miles
per hour.
Actual Gear Indicator (7) – The actual gear indicator
consists of two digits. The two digits indicate the
actual transmission gear that is engaged. The left
digit is the actual gear. The right digit shows the
direction that was selected.
Illustration 77
Illustration 78
Front brake oil pressure
Front Brake Oil Pressure Gauge (8) (If Equipped) –
Shows the hydraulic pressure in the front braking
45
Monitoring Systems and Operator Station Features
Gauges
circuit when the service brakes are fully applied. The
front brake oil pressure should be 5860 ± 345 kPa
(850 ± 50 psi).
Illustration 79 g01000117
Rear brake oil pressure
Rear Brake Oil Pressure Gauge (9) (If Equipped) –
Shows the hydraulic pressure in the rear braking
circuit when the service brakes are fully applied. The
rear brake oil pressure should be 5860 ± 345 kPa
(850 ± 50 psi).
NOTICE
Loss of brake oil pressure may decrease the brake
application force. Also, loss of brake oil pressure may
cause the parking brake to engage. If low brake oil
pressure is indicated, stop the machine immediately.
Inspect the system for the cause of low brake oil pres-
sure. Repair the brake system before returning the
machine to operation.
g01000384
Illustration 80 g03672139
Display Window (10) – Indicates various machine
system conditions on a six-digit display.
Reference: For further information, refer to the
Operation and Maintenance Manual, “Caterpillar
Monitoring System” for the machine that is being
serviced.
g01000116
46
Monitoring Systems and Operator Station Features
Indicators
Indicators
SMCS Code: 7400; 7450
Illustration 81
Illustration 82
Alert Indicators
Action Lamp (4) – This indicator flashes
to indicate a Warning Category 2 or a
Warning Category 3 has been registered
by the Caterpillar Monitoring System. For more
information refer to Operation and Maintenance
Manual, “Caterpillar Monitoring System”.
Hydraulic Oil Level (12) – This indicator
will be on when the hydraulic oil level is
low. If this alert indicator flashes during
operation, stop the machine immediately and
engage the parking brake. Stop the engine and
investigate the cause.
Indicators
Left Turn (1) – This indicator will be on
when the external lights are signaling a
left turn.
SEBU8906
i05226276 Right Turn (2) – This indicator will be on
when the external lights are signaling a
right turn.
Body Up (3) – This indicator will be on
when the dump body is not down. When
the indicator is on, the transmission will
be limited to a programmed gear limit.
This indicator will also be on if the body position
sensor is out of calibration. Move the machine to a
convenient place to park the machine and stop the
engine. Find the cause immediately.
This indicator will be on for 3 seconds during powerup
in order to permit the operator to know that the
indicator is functioning properly. The operator must
inspect this indicator during powerup. If the indicator
does not come on, or glows dimly during powerup, or
if the indicator remains on and the body is down, find
the cause immediately.
g03672140 Tailgate Down (3) – This indicator will be
on when the tailgate is not up. When the
indicator is on, the transmission will be
limited to a programmed gear limit.
This indicator will be on for 3 seconds during powerup
in order to permit the operator to know that the
indicator is functioning properly. The operator must
inspect this indicator during powerup. If the indicator
does not come on, or glows dimly during powerup, or
if the indicator remains on and the tailgate is down,
find the cause immediately.
Transmission Reverse (5) – This
indicator will be on when the
transmission control is in the REVERSE
position, and the machine is in reverse gear. This
indicator will be on when the machine will be
g03339470 shifting into reverse gear when forward ground
speed drops.
Residual Brake Oil Pressure (6) – This
indicator will be on when there is oil
pressure in the wheel brakes. The lamp
will illuminate when the service brakes are
applied. The lamp should go out when the brakes
are released. If this indicator stays on, the brakes
are holding residual brake oil pressure. Stop the
machine and investigate the cause.
High Beam (7) – This indicator will be on
when the headlights are set on high
beam.
Retarder (8) – This indicator will be on
when the Automatic Retarder Control
(ARC) is on. The indicator will also be on
when you use the manual retarder.
SEBU8906 47
Monitoring Systems and Operator Station Features
Light Switches

When the ARC is on, this indicator will be on for 3 i05883005

seconds during powerup in order to permit the
operator to know that the indicator is functioning. The
operator must inspect this indicator during powerup. If
Light Switches
the indicator does not come on or glows dimly during SMCS Code: 1429-ZS; 7451
powerup, or if the indicator remains on, find the cause
immediately.
This indicator will also be on and flashes when there
is a fault with the retarder system. Move the machine
to a convenient place to park the machine and stop
the engine. Find the cause immediately.
Automatic Lubrication (9) (If Equipped) –
This indicator will be on when there is a
fault in the automatic lubrication system.
Report the fault to service personnel when
convenient.
This indicator will be on for 2 seconds after the engine
starts in order to alert the operator that the indicator is
functioning properly. The operator must inspect this
indicator after the engine starts. If the indicator does Illustration 83 g03709480
not come on or glows dimly after startup, or if the
indicator remains on, stop the engine, and find the
cause. Head Light Switch (1) – Push down on
the top half of the switch to turn on the
Exhaust Back Pressure (10) (If head lights. Push down on the bottom
Equipped) – This indicator will be on if half of the switch to turn off the head lights.
the exhaust back pressure is high. Have
the exhaust purifilter serviced. Rear Light/Backup Light Switch (2) –
Push down on the top half of the switch
Primary Steering (11) (If Equipped) – This to turn on the rear lights. Push down on
indicator will be on if there is a failure of the bottom half of the switch to activate the rear
the primary steering system. The lights in automatic mode. In automatic mode the
secondary steering system (if equipped) will rear lights turn on when reverse gear is selected.
automatically activate. Stop the machine and Move the switch to the center position to turn off
investigate the cause. the rear lights.

Note: The secondary steering system only operates
while the machine is moving.
NOTICE
If the primary steering indicator flashes, cease opera-
tion, quickly move the machine to a safe area and
shut the machine down. Inspect and rectify the cause
of the problem before recommencing operation.
Block Light/Rear Cab Flood Light Switch
(3) – The block light/rear cab flood light
switch is a three position switch. Push
down on the top half of the switch once to turn on
the block light. Push down on the top half of the
switch completely to turn on the block light and
the rear cab flood light. Push down on the bottom
half of the switch to turn off the block light and the
rear cab flood light.
48 SEBU8906
Monitoring Systems and Operator Station Features
Directional Turn Signal and Hazard Flasher Control

i05792726

Directional Turn Signal and

Hazard Flasher Control
SMCS Code: 1430

Illustration 84 g00926957

Dimmer Switch (4) – Push down switch

(4) in order to toggle the headlights
between high beam and low beam.

Illustration 86 g03670857

Directional Turn Signals – In order to

signal a right turn, move the handle
upward. After the right turn is complete,
return the handle to the center position. To signal
a turn left, move the handle downward. After the
left turn is complete, return the handle to the
center position.

Hazard Flashers – Pull out the handle in

order to turn on the hazard flashers.
Push the handle in order to turn off the
Illustration 85 g00926958 hazard flashers.

Dome Lamp Switch (5) – Switch (5) for

the interior lamp is located on the
interior lamp. Push the bottom half of
switch (5) to turn on the interior lamp. Push the
top half of switch (5) to turn off the interior lamp.
When the door is open, an automatic switch turns
on the interior lamp.
SEBU8906 49
Monitoring Systems and Operator Station Features
Operator Mode Scroll Switch

i05883006

Operator Mode Scroll Switch

SMCS Code: 7451

Illustration 89 g01405932

Odometer – In this mode, the six-digit display

window will show the total distance that has been
traveled by the machine. This measurement can be
displayed in miles or kilometers.
Illustration 87 g03709481

Operator Mode Scroll Switch (1) – Press

the top half of the switch to scroll
through the operator modes.

Illustration 90 g01405935

Digital Tachometer – In this mode, the engine rpm

will be displayed in the six-digit display window.
Illustration 88 g01405929

Service Meter – In this mode, the six-digit display

window will show the total number of machine
operating hours. The machine operating hours should
be used to determine maintenance intervals. Indicator
(3) will show that the display window is operating in
the service meter mode.

If there is an active fault, SERV CODE is displayed in

the upper right-hand corner of the display window. If
SERV CODE is displayed during normal operation,
an existing problem should be addressed.

Illustration 91 g01405936

Diagnostic Scrolling – In this mode, the display

window will show the faults that have been detected
by the Caterpillar Monitoring System. Faults cannot
be cleared in this mode. Also, faults may not be
50 SEBU8906
Monitoring Systems and Operator Station Features
Throttle Backup Switch

placed on hold. The service code will only be i05883008

displayed when the fault is active.
Window Wiper and Washer
i05883007
Control
SMCS Code: 7305; 7306
Throttle Backup Switch
SMCS Code: 1276

Illustration 93 g03709484

Rear Window Wiper and Washer Switch

Illustration 92 g03709482
(1) – The rear window wiper and washer
switch is a three position switch. Push
Throttle Backup Switch – If the signal
down on the top half of the switch once
from the throttle position sensor is
to turn on the rear window wiper. Push
invalid, the throttle backup switch will
down and hold the top half of the switch
allow the engine to accelerate to 1300 rpm. Push
to turn on the rear window wiper and the rear
and hold down the top half of the switch to
window washer. Push down on the bottom half of
activate the throttle backup function. Activating
the switch to turn off the rear window wiper and
the throttle backup function allows the machine to
the rear window washer.
be moved to a convenient location in order to
replace the throttle position sensor. Release the Front Window Wiper and Washer Switch
switch to deactivate the throttle backup function. (2) – The front window wiper and washer
switch is a three position switch. Turn
the knob clockwise to the FIRST speed position or
to the SECOND speed position to turn on the front
window wiper. Turn the knob counterclockwise to
turn off the front window wiper. Push the knob in
to activate the front window washer. The knob will
return when released.
SEBU8906 51
Monitoring Systems and Operator Station Features
Service Ports

i02304243 SMCS Code: 7601; 7610; 7620

Service Ports
SMCS Code: 0350

Illustration 95 g03701131
View under the seat in operator station

VIMS Service Port – This port allows service

Illustration 94 g00926485
personnel to connect a laptop computer using Vital
Information Management System (VIMSpc) software.
ET Service Port (1) – This service port allows for the The VIMS service port allows service personnel to
connection of a laptop computer using Electronic download and analyze data that is recorded by VIMS
Technician (ET) software. This will allow service on board memory. The data is used to analyze
personnel to diagnose the Caterpillar Monitoring current problems, examine machine history, and
System, the Electronic Control Module (ECM) for the identify potential problems.
engine, the Electronic Control Module (ECM) for the
power train/chassis.
Reference: For further information on using the
Service Tool Port (2) – This service port allows for
the connection of a Caterpillar 4C-8195 Control VIMSpc, refer to Systems Operation,
Service Tool to provide diagnostic access to the Troubleshooting, Testing and Adjusting, “VIMSpc
Caterpillar Monitoring System, the Electronic Control Software” for the machine that is being serviced.
Module (ECM) for the engine, the Electronic Control
Module (ECM) for the power train/chassis. This i05792727
service tool allows the technician to scroll through
display modes on the digital display window and clear
recorded faults as required. Horn
SMCS Code: 7402
Reference: For further information on using the
Electronic Technician and the Control Service Tool,
refer to Systems Operation, Troubleshooting, Testing
and Adjusting, “Caterpillar Monitoring System”.

i05864097

Vital Information Management

System (VIMS) Service Port
(If Equipped)

Illustration 96 g03670858

Horn – Push the horn button on the

steering wheel in order to sound the
horn. Use the horn button for alerting or
signaling personnel.
52
Monitoring Systems and Operator Station Features
Backup Alarm
Backup Alarm
SMCS Code: 7406
Illustration 97
Backup Alarm – The backup alarm will
sound when the transmission control is
in the REVERSE position. The backup
alarm warns personnel behind the machine that
the machine is backing up.
The backup alarm is located at the rear of the
machine behind the left rear light.
Illustration 98
A three position switch at the rear of the backup alarm
regulates the volume of the alarm.
The backup alarm is set at the highest sound level
when the machine is shipped from the factory. The
setting should remain on high, unless the job site
requires a lower level.
Air Conditioning and Heating
Control
(If Equipped)
SEBU8906
i02233008 SMCS Code: 7304; 7320; 7337
Illustration 99 g03605556
Temperature Control (1) – Use the
temperature control to regulate the
g00929418
temperature inside the operator station.
Turn the temperature control clockwise in order to
increase the temperature. Turn the temperature
control counterclockwise in order to decrease the
temperature.
Air Conditioner Switch (2) – Use the air
conditioner switch in order to turn the air
conditioner ON and OFF. Move the
switch to the upper position in order to turn ON
the air conditioner. Move the switch to the lower
position in order to turn OFF the air conditioner.
Fan Speed Switch (3) – Use the fan
speed switch in order to control the
speed of the blower fan. The fan speed
switch has five positions, OFF position, FIRST
speed, SECOND speed, THIRD speed, and
FOURTH speed. Turn the fan speed switch
clockwise in order to increase blower fan speed.
Turn the fan speed switch counterclockwise in
order to decrease blower fan speed.
OFF Position (4) – Turn the fan speed
switch fully counterclockwise in order to
g01124582 turn the blower fan to the OFF position.
Air Conditioning and Heating
System Operation
The air conditioning and heating system can perform
four functions:
Heating – Turn temperature control (1) clockwise in
order to increase the temperature. Turn fan speed
i05681873 switch (3) clockwise in order to obtain FIRST speed,
SECOND speed, THIRD speed, or FOURTH speed.
Cooling – Turn temperature control (1)
counterclockwise in order to decrease the
temperature. Move air conditioner switch (2) to the
SEBU8906 53
Monitoring Systems and Operator Station Features
Seat

ON position. Turn fan speed switch (3) clockwise in i05884032

order to obtain FIRST speed, SECOND speed,
THIRD speed, or FOURTH speed. Seat
SMCS Code: 7312
Pressurizing – Move air conditioner switch (2) to the
OFF position. Turn temperature control (1) to the Note: The operator seat that is provided with this
desired temperature. Turn fan speed switch (3) machine is in compliance with the appropriate class
clockwise in order to obtain FIRST speed, SECOND of ISO 7096.
speed, THIRD speed, or FOURTH speed. The speed
of the blower fan depends on the volume of air that is Adjust the seat in order to allow full travel of the
needed in order to keep out the dust. Pressure inside pedals. Make the seat adjustments when the operator
the operator station will help keep out the dust when is sitting against the back of the seat. In order to
heating or cooling is not desired. reduce fatigue, periodically readjust the seat and the
backrest for additional comfort.
Defogging – Move air conditioner switch (2) to the
ON position. Turn temperature control (1) clockwise
to the maximum heat position. Turn fan speed switch
(3) clockwise in order to obtain FIRST speed,
SECOND speed, THIRD speed, or FOURTH speed.
The speed of the blower fan depends on the volume
of air that is needed in order to remove moisture from
the air in the operator station. Once the windows are
free from moisture, adjust temperature control (1) to
the desired temperature.

Louvers

Illustration 101 g03709977

Illustration 100 g03710658
(1) Headrest
Four louvers are located on the air conditioning and (2) Seat with Lumbar Support
heating control (3) Lumbar Adjustment
(4) Seat Height Firmness
Adjust the louvers in order to circulate air around the (5) Air Suspension Switch
operator station. (6) Fore and Aft Adjustment
(7) Seat Backrest Angle Adjustment
Adjustments are made by the following.
Headrest (1) – Pull up on the headrest in
• rotating the louvers clockwise order to remove extension. The headrest
can be pulled forward to support the
• rotating the louvers counterclockwise head at an angle. Pull fully forward in order to
return to the original position.
• Moving the louvers forward
Lumbar Support (3) – Rotate knob in
• Moving the louvers backward
order to adjust the lumbar support.
54 SEBU8906
Monitoring Systems and Operator Station Features
Seat Belt

Seat Firmness (4) – Pull the lever upward Lengthening the Seat Belt
in order to increase the firmness. Push
the lever down in order to decrease the
firmness.
Air Suspension Switch Raise (5) – Push
the left side of the switch in order to
raise the height of the seat.
Air Suspension Switch Lower (5) – Push
the right side of the switch in order to
lower the height of the seat.
Fore and Aft Position (6) – Pull the lever
upward. Hold the lever upward and slide
the seat forward or backward to the
desired position. Release the lever in
order to lock the seat into position.
Illustration 102 g00100709

Seat Backrest Angle Adjustment (7) –

Pull the lever upward. Hold the lever 1. Unfasten the seat belt.
upward and adjust the backrest to the
desired angle. Release the lever in order to lock
the backrest into position.

i04200349

Seat Belt
SMCS Code: 7327

Note: This machine was equipped with a seat belt

when the machine was shipped from Caterpillar . At
the time of installation, the seat belt and the
instructions for installation of the seat belt meet the
SAE J386 and ISO 6683 standards. Consult your Cat
dealer for all replacement parts.
Illustration 103 g00932817
Always check the condition of the seat belt and the
condition of the mounting hardware before you
operate the machine. 2. To remove the slack in outer loop (1), rotate buckle
(2). This will free the lock bar. This permits the seat
Seat Belt Adjustment for Non- belt to move through the buckle.
Retractable Seat Belts 3. Remove the slack from the outer belt loop by
Adjust both ends of the seat belt. The seat belt should pulling on the buckle.
be snug but comfortable.
4. Loosen the other half of the seat belt in the same
manner. If the seat belt does not fit snugly with the
buckle in the center, readjust the seat belt.
SEBU8906 55
Monitoring Systems and Operator Station Features
Seat Belt

Shortening the Seat Belt Releasing The Seat Belt

Illustration 104 g00100713 Illustration 106 g00100717

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

1. Fasten the seat belt. Pull out on the outer belt loop belt.
in order to tighten the seat belt.

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

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

Fastening The Seat Belt

Illustration 107 g00867598

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

Illustration 105 g00932818 motion.
Fasten seat belt catch (3) into buckle (2). Make sure
Fasten the seat belt catch (3) into the buckle (2). that the seat belt is placed low across the lap of the
Make sure that the seat belt is placed low across the operator.
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.
56 SEBU8906
Monitoring Systems and Operator Station Features
Mirror

Releasing The Seat Belt i03460580

Mirror
SMCS Code: 7319

Illustration 108 g00039113

Push the release button on the buckle in order to

release the seat belt. The seat belt will automatically
retract into the retractor. Illustration 109 g01803445

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 Cat dealer for longer seat belts and for
information on extending the seat belts.
Illustration 110 g01803446
Adjust the rear view mirrors for best operator vision.
Adjust the rear view mirrors before you operate the
machine. Also, adjust the rear view mirrors after you
change operators.

i05884038

Alternate Exit
SMCS Code: 7310

Incorrect window sealing (beading) may obstruct

window removal and may cause inability to use al-
ternate exit. Personal injury can result.
Use the correct method of sealing (beading) to se-
cure the operator's station windows. Contact your
Caterpillar dealer for the correct sealing (beading)
method.
SEBU8906 57
Monitoring Systems and Operator Station Features
Alternate Exit

In order to exit the operator station through the side

window or front window. Exert outwards pressure on
the window until the window separates from the
operator station frame.

Illustration 111 g03709981

Illustration 112 g01136961

In order to remove the side window or front window

from outside the operator station. Pull on the locking
strip tab to remove the locking strip. Exert inwards
pressure on the window until the window separates
from the operator station frame.
In order to install the window and seal, contact your
Cat dealer for the correct sealing method.
58
Machine Controls and Operation
Braking
Machine Controls and
Operation
i05346889
Braking
SMCS Code: 4250; 4251; 4267; 4278; 4284
Parking Brake
This machine is equipped with spring applied parking
brakes. The spring force engages the brakes on all
four wheels. Hydraulic pressure is used to disengage
the brakes. If the hydraulic pressure is unavailable,
the brakes will remain engaged.
If hydraulic pressure is unavailable and the machine
must be towed, use the 212-6102 Portable
Hydraulic Pump in order to release the parking brake.
Reference: For further information on towing an
inoperable machine, consult your Cat dealer or refer
to Operation and Maintenance Manual, “Towing
Information” for the machine that is being serviced.
Personal injury could result from the sudden stop
of the machine. The parking brake is automati-
cally engaged when brake oil pressure drops be-
low an adequate operating pressure.
If the brake system oil pressure drops below nor-
mal operating pressure, the action alarm will
sound. The brake oil pressure indicator and the
action lamp will start flashing.
If the pressure drops further, the parking brake
will engage automatically, the parking brake indi-
cator on the operator's panel will come on and the
transmission will shift to neutral.
Be prepared for a sudden stop. Correct the reason
for the loss of brake oil pressure. Do not move the
machine without normal brake oil pressure.
SEBU8906
Illustration 113 g03709498
Loss of service brake oil pressure will cause the
action alarm to sound, action lamp (1) and brake
accumulator oil pressure indicator (3) to flash. Further
loss of oil pressure will cause parking brake indicator
(2) to come on and the parking brake will
automatically engage to stop the machine.
Also the parking brake will engage when the operator
present strategy conditions are not met.
Reference: For further information on the operator
present strategy conditions, refer to Operation and
Maintenance Manual, “Hauling”.
Note: If the machine was started with the parking
brake control in the OFF position, move the parking
brake control to the ON position and then to the OFF
position to disengage the parking brake
NOTICE
Do not engage the parking brake while the machine is
moving unless the service brakes fail. The use of the
parking brake as a service brake in regular operation
will cause severe damage to the parking brake.
NOTICE
The standard parking brake control is a pull-to-en-
gage type. When the knob is pulled OUT, the parking
brake will be engaged.
Certain mining regulations require machines to be
equipped with a push-to-engage parking brake con-
trol. When the knob is pushed IN, the parking brake is
engaged.
Before operating the machine, ensure you are familiar
with the operation of the parking brake control.
SEBU8906
Standard Pull-to-Engage Type
Parking Brake Control
Illustration 114 g03709499
Use the parking brake control to engage or disengage
the parking brake when you park the machine. The
parking brake control is a push-pull type switch.
Parking Brake Control – Push the
parking brake control knob inward to the
OFF position in order to disengage the
parking brake. Pull the parking brake
control knob outward to the ON position
in order to engage the parking brake.
Optional Push-to-Engage Type
Parking Brake Control
Illustration 115 g03709500
Use the parking brake control to engage or disengage
the parking brake when you park the machine. The
parking brake control is a push-pull type switch.
Parking Brake Control – Pull the parking
brake control knob outward to the OFF
position in order to disengage the
parking brake. Push the parking brake
control knob inward to the ON position
in order to engage the parking brake.
59
Machine Controls and Operation
Braking
Service Brake
Illustration 116 g00926943
During normal machine operation, depress the
service brake pedal to slow or stop the machine.
The service brake pedal applies all four-wheel
brakes. The pedal is fully variable. The amount of
braking force depends on the position of the brake
pedal.
Secondary Brake
Personal injury or death can result from a brake
system malfunction.
If the secondary brake is required in order to stop
the machine, the machine stopping distance will
be increased.
Personal injury could result from the sudden stop
of the machine. Be prepared for a sudden stop.
If the secondary brake system is required in order
to stop the machine, do not operate the machine
until the entire braking system has been checked.
Do not operate the machine until all necessary re-
pairs have been made.
Note: The machine is equipped with a secondary
brake system. A category 3 warning can provide an
indication of a failure in the brake system.
Depress the service brake to bring the machine to a
complete stop. The distance required to bring the
machine to a complete stop will be increased.
To obtain the maximum available braking force to the
machine in an emergency stop condition, apply the
parking brake. Applying the parking brake can bring
the machine to a sudden stop.
60
Machine Controls and Operation
Retarding
i05886149
Retarding
SMCS Code: 1000; 3121
Retarder Control
Aggressive application of retarder capacity in
slippery conditions may cause loss of operator
control and/or power train damage. Apply the re-
tarder gradually in slippery conditions. Serious in-
jury or death may occur if the retarder is applied
too aggressively in slippery conditions.
NOTICE
Do not use the retarder control as a parking
brake.
Do not use the retarder control to stop the
machine.
Illustration 117 g03709501
The retarder system allows the machine to maintain a
constant speed on long downgrades.
The retarder will not apply all of the normal braking
capacity.
Retarder Control (Lever) (1) – Move
retarder lever (1) downward in order to
apply the retarder. Move lever (1) upward
in order to release the retarder. The
position of lever (1) determines the
amount of retarding force. As you move
lever (1) downward, retarding force will
increase.
SEBU8906
Automatic Retarder Control (ARC)
Illustration 118 g03709502
When the proper gear is selected during Automatic
Retarder Control (ARC) operation and the throttle
control pedal is at less than 60 percent of the pedal
travel, machine speed and engine speed will be
automatically regulated. When the transmission shifts
to the selected gear and the engine rpm increases to
2100 rpm, the ARC will apply the retarder in order to
maintain the engine speed at 2300 ± 50 rpm. Use
retarder lever (1) to apply additional retarding force
during operation of the ARC.
Note: If the throttle control pedal is at more than 60
percent of the pedal travel, the Automatic Retarder
Control function will not activate.
When the transmission control is in the DRIVE
position and the transmission is in the third gear,
move the transmission control to the THIRD GEAR
position in order to prevent an upshift to a higher
gear. The transmission will remain in the third gear
and the ARC will maintain the engine speed at 2300 ±
50 rpm. The transmission will not downshift until the
proper ground speed is achieved.
Automatic Retarder Control (ARC)
Switch (2) – Push the top half of switch
(2) in order to select the ON position for
the ARC. Push the bottom half of the switch in
order to select the OFF position for the ARC.
Retarder indicator (3) is illuminated for 3 seconds
after switch (2) is moved to the ON position.
Switch (2) for the ARC should remain in the ON
position during all normal operation. When you place
switch (2) in the OFF position, the ARC will not
control the engine speed during normal operation.
However, the ARC will override switch (2) if the
engine speed is too high. Refer to Operation and
Maintenance Manual, “Changing Direction and
Speed” in order to learn more about the engine
overspeed protection.
SEBU8906
Manual Retarding
Travel at a constant machine speed. Do not speed up
immediately before you use the retarder. Do not try to
do all the retarding at the bottom of a hill. Keep the
retarding steady and keep the machine speed under
control.
Never coast down a grade in neutral. Always keep
the transmission in gear. When the machine speed is
greater than 5 km/h (3 mph), the Power Train/
Chassis ECM will not allow you to shift from forward
gear into neutral or into reverse.
1. Make sure that switch (2) for the ARC is in the ON
position during all normal operation.
Illustration 119 g00926952
2. Select the proper gear on transmission control (4)
before you start down the grade. The actual gear
should also match the selected gear before you
start down the grade.
Note: Determine the proper gear for the conditions,
the load, and the downgrade. If you do not know the
proper gear, use the common practice of selecting the
gear that is required to go up the grade when the
machine is loaded.
3. Maintain a constant machine speed.
Aggressive application of retarder capacity in
slippery conditions may cause loss of operator
control and/or power train damage. Apply the re-
tarder gradually in slippery conditions. Serious in-
jury or death may occur if the retarder is applied
too aggressively in slippery conditions.
4. If the machine builds up excessive speed during
retarding, the engine can overspeed. Use the
retarder control lever in order to reduce the
machine speed.
61
Machine Controls and Operation
Secondary Steering
Note: The machine is equipped with automatic
overspeed protection. Refer to Operation and
Maintenance Manual, “Changing Speed and
Direction” for further information on the operation of
the overspeed protection.
a. Adjust lever (1) in order to maintain a proper
rpm and a constant speed. If skidding is
experienced, ease off lever (1).
b. Avoid repeated engaging and disengaging of
lever (1).
c. If braking is needed, depress the service brake
pedal.
Illustration 120 g03672141
5. Frequently observe the brake oil temperature
gauge (5). Keep the brake oil temperature in the
normal range.
6. If the brake oil temperature is high after traveling
down the grade, select a lower gear when you
travel down that grade again.
7. If the needle enters the red range on the gauge, the
oil cooler capacity has been exceeded. Reduce
the load on the machine or slow the machine
speed.
i05768917
Secondary Steering
(If Equipped)
62
Machine Controls and Operation
Changing Direction and Speed
SMCS Code: 7000
Illustration 121 g03709505
The activation of the primary steering indicator
indicates a failure of the primary steering system. If
this indicator comes on during operation, steer the
machine to a convenient location and immediately
stop the machine. Stop the engine and investigate the
cause of the problem.
Note: The secondary steering system only works
while the machine is in motion.
Complete any necessary repairs before you return
the machine to operation.
i01801906
Changing Direction and Speed
SMCS Code: 3030; 7300; 7451
NOTICE
To avoid striking adits, overpasses, electrical power
lines and obstructions, always lower the dump body
before moving the machine.
NOTICE
The machine must be stopped and engine at low idle
before changing directions.
After moving the transmission control, do not acceler-
ate until after hearing or feeling the transmission
clutches engage.
The transmission has four forward gears and one
reverse gear. The transmission gear speed that is
currently in use is displayed on the instrument panel.
SEBU8906
Illustration 122 g00926959
Use transmission control (1) to select forward,
neutral, or reverse transmission speeds. When the
transmission control is in the NEUTRAL position,
plunger (2) prevents the transmission control from
being accidently moved into a gear position.
Lift plunger (2), and move the transmission control in
order to select the following gears.
R – Reverse gear
N – Neutral
D – Drive
3 – Third gear
2 – Second gear
1 – First gear
If you select first speed, second gear, third gear, the
transmission will upshift through the gears. The
transmission will not upshift higher than the gear that
has been selected. If drive is selected, the
transmission will automatically shift between forward
gears according to conditions.
Make sure that the machine is stopped and that the
engine is at low idle when you change direction
between forward and reverse, or between reverse
and forward.
When you move transmission control (1) from the
NEUTRAL position to any forward speed, first gear is
engaged. Below a ground speed of approximately
5 km/h (3 mph), the machine will be in torque
converter drive.
When the engine accelerates and the ground speed
increases, the transmission automatically upshifts.
Above a ground speed of approximately 5 km/h
(3 mph) and during other forward gears, the lockup
clutch will be engaged. When the lockup clutch is
engaged the machine is in direct drive. During shifts,
the machine will be in torque converter drive.
SEBU8906
While the machine is in motion, moving transmission
control (1) to a higher gear will not force an upshift.
Shifting of the transmission is governed by ground
speed.
When the ground speed and the engine speed are
reduced by an increased load or by deceleration, the
transmission automatically downshifts. The
transmission downshifts one gear at a time in order to
select the correct gear.
A downshift inhibitor prevents the machine from
forcing a downshift. When the machine is in motion
and transmission control (1) is moved to a lower gear,
the transmission will not force a sudden downshift.
The transmission will not downshift until the proper
ground speed is achieved.
Shift Inhibiting
The Power Train/Chassis Electronic Control Module
(ECM) performs most of the transmission control and
torque converter lockup functions. The Power Train/
Chassis ECM receives input signals that describe the
position of the dump body or the tailgate and the
position of the transmission control. These input
signals are sent to the Power Train/Chassis ECM.
The input signals are used to control the shifting of
the transmission and torque converter lockup.
Shifting is limited in the following situations: starting in
neutral, coasting in neutral, management of
directional shifts, limiting top gear, limiting ground
speed, reverse neutralizer, limiting body up and body
float gear and limiting tailgate down gear.
Reference: For additional information, refer to
Systems Operation, Testing and Adjusting, “Power
Train Electronic Control System” for the machine that
is being serviced.
Starting in Neutral
The machine will not start unless the following
conditions exist:
• The transmission control is in the NEUTRAL
position.
• The parking brake is engaged.
Coasting in Neutral
The transmission will not shift into neutral if the
machine speed is above 5 km/h (3 mph).
If the transmission is in neutral and the machine
speed is greater than 12 km/h (7.5 mph) for more
than 2.5 seconds, the Power Train/Chassis ECM will
apply the retarder brakes to reduce the speed of the
machine. Also, the engine speed will increase to
1300 rpm in order to maintain pressure oil to the
transmission.
63
Machine Controls and Operation
Changing Direction and Speed
Management of Directional Shifts
If the transmission is in a forward gear and the
transmission control is moved into the REVERSE
position, the transmission will remain in forward gear
until the machine speed is below 5 km/h (3 mph).
Then, the transmission will shift into neutral. The
transmission will not shift from neutral into reverse
until the machine speed is below 5 km/h (3 mph).
Limiting Top Gear
The transmission will not shift to a gear above the
selected top gear limit. The machine comes from the
factory with the top gear limit programmed to
customer requirements. Use the Electronic
Technician (ET) to change the top gear limit.
Limiting Ground Speed
The machine ground speed will not increase above
the selected ground speed limit. The machine comes
from the factory with the ground speed programmed
to customer requirements. Use the Electronic
Technician (ET) to change the ground speed limit.
When a particular ground speed limit is selected, the
top gear will be limited. Also, the engine speed will be
limited in the top gear. The transmission will not shift
to a gear above the top gear limit.
Reverse Neutralizer
If the hoist control is in the RAISE/EJECT position
and the transmission is in reverse, the transmission
will shift into neutral. Also, when the hoist control is in
the RAISE/EJECT position, the transmission will not
shift into reverse until the hoist control is moved out of
the RAISE/EJECT position and until the transmission
control is moved into the NEUTRAL position and then
into the REVERSE position.
The reverse neutralizer has no effect on forward
gears. If necessary, the forward gears can be
engaged from either neutral or reverse gear.
Limiting Body Up and Body Float Gear
(Dump Body Machines)
This function limits the gear of the machine while the
dump body is up and/or the hoist control is not in the
FLOAT position. The gear is limited until the body
position sensor tells the Power Train/Chassis ECM
that the dump body is down. The gear is also limited
until the hoist control position sensor tells the Power
Train/Chassis ECM that the hoist control is in the
FLOAT position. The Power Train/Chassis ECM
prevents upshifting to any gear higher than the stored
value. The value of the gear limit is programmable by
the service personnel. Use the ET service tool. The
allowed range for this gear limit is first gear to third
gear. The value of the factory setting for the gear limit
is first gear.
64 SEBU8906
Machine Controls and Operation
Throttle Control

Limiting Tailgate Down Gear (Ejector Releasing the Throttle Control – Release
the throttle pedal in order to decrease
Body Machines) the engine speed.
This function limits the gear of the machine while the
tailgate is down. The gear is limited until the tailgate i01802289
switch tells the Power Train/Chassis ECM that the
tailgate is up. The Power Train/Chassis ECM
prevents upshifting to any gear higher than the stored
Steering Column Tilt Control
value. The value of the gear limit is programmable by SMCS Code: 4310; 4338
the service personnel. Use the ET service tool. The
allowed range for this gear limit is first gear to third
gear. The value of the factory setting for the gear limit
is first gear.

Engine Overspeed Protection

If the machine is travelling down a grade and the
engine speed reaches 2400 rpm the retarder alert
indicator will activate and the Automatic Retarder
Control (ARC) will automatically begin to apply the
wheel brakes. The Automatic Retarder Control (ARC)
will maintain the engine speed at 2450 rpm down the
grade. If the engine speed reaches 2500 rpm, the
engine overspeed alert indicator and the action lamp
of the Caterpillar Monitoring System will activate.

NOTICE Illustration 124 g00928260

Do not exceed 2500 rpm or engine damage can
result. Steering Column Tilt – To adjust the steering
column position, pull the steering column tilt control.
Move the steering column to the desired position.
When the steering column tilt control is released, the
i01802287 steering column will lock in the desired position.

Throttle Control Steering Column Telescope – To adjust the

distance between the operator and the steering
SMCS Code: 1276 wheel, push the steering column tilt control. Move the
steering wheel to the desired position. When the
steering column tilt control is released, the steering
wheel will lock in the desired position.

i02242601

Hoist Control
SMCS Code: 5136

Dump Body Machines

Illustration 123
The throttle pedal is located on the floor of the
operator station.
Depressing the Throttle Control –
Depress the throttle pedal in order to
increase the engine speed.
Note: The machine's hoist control lever functions will
be disabled when the parking brake is engaged and
the engine speed is less than 1500 rpm.
g00926960
NOTICE
The body must be lowered and in the FLOAT position
when operating the machine. This will help prevent
damage to the body, caused by vibrations from the
haul road.
SEBU8906
Illustration 125 g00926961
LOWER Position (1) – Hold the hoist
control lever completely forward in order
to lower the dump body. When the hoist
control lever is released, the hoist control lever
will return to the FLOAT position.
FLOAT Position (2) – When the hoist
control lever is in the FLOAT position,
the dump body will seek a level. The
hoist control lever will stay in this position until
the hoist control lever is manually moved.
HOLD Position (3) – When the hoist
control lever is in the HOLD position, the
dump body will not move. The hoist
control lever will stay in this position until the
hoist control lever is manually moved.
RAISE Position (4) – Hold the hoist
control lever completely backward in
order to raise the dump body and empty
the load. When the hoist control lever is released,
the hoist control lever will return to the HOLD
position.
NOTICE
Do not use the hoist control when the body retaining
pins are installed. Damage to the dump body may
occur.
Ejector Body Machines
Note: The machine's hoist control lever functions will
be disabled when the parking brake is engaged and
the engine speed is less than 1500 rpm.
65
Machine Controls and Operation
Truck Payload Measurement System (TPMS)
Illustration 126 g00942088
RETRACT Position (1) – Hold the hoist
control lever completely forward in order
to retract the ejector plate. When the
hoist control lever is released, the hoist control
lever will return to the HOLD position.
HOLD Position (2) – When the hoist
control lever is in the HOLD position the
ejector plate will not move. The hoist
control lever will stay in this position until the
hoist control lever is manually moved.
EJECT Position (3) – Hold the hoist
control lever completely backward in
order to eject the ejector plate and empty
the load. When the hoist control lever is released,
the hoist control lever will return to the HOLD
position.
NOTICE
Do not use the hoist control when the tailgate retain-
ing pin is installed. Damage to the ejector body may
occur.
i05384751
Truck Payload Measurement
System (TPMS)
(If Equipped)
SMCS Code: 7494
The Truck Payload Measurement System (TPMS)
records load cycle information automatically. The
TPMS also provides real-time data on loading to the
operator.
Autoweigh
The TPMS will automatically weigh a load in the truck
body immediately before a load is dumped. The load
will be weighed and recorded in memory if the
following conditions are met:
66
Machine Controls and Operation
Truck Payload Measurement System (TPMS)
• The body up indicator is off.
• The hoist control has been in the FLOAT position
for 10 seconds or more before the hoist control is
moved to the RAISE position.
A load will be recorded each time these conditions
are met.
Payload Operator Display
Illustration 127 g01032563
Payload Indicator (1) – This liquid crystal display
(LCD) indicates the weight of the material that is
located in the truck. The weight is displayed in
kilograms or pounds. Refer to Service Manual,
RENR4725, “Truck Payload Measurement System”
for information on changing the units.
A fault code will be displayed if a malfunction is
detected in the system. If a malfunction is indicated, a
fault code such as “ChX TRA.FAULT” will be
displayed. The fault code informs the operator that a
machine system requires attention. The problem
should be reported in order to allow maintenance to
take appropriate action.
SEBU8906
Load Indicator Lights
Illustration 128 g01132457
Typical example
Illustration 129 g01132459
Typical example
External Load Indicator Lights (2) – External load
indicator lights (2) are the external red lights and the
external green lights that are located on each side of
the truck.
These indicator lights inform the operator of the
loader and the operator of the truck when the load
has reached target payload weight. External lights (2)
are only active during loading.
During loading the green lights will turn on when the
preset lower target weight has been reached or
exceeded. The green light signals the loader operator
to continue loading at a reduced rate.
The red lights will turn on when the preset upper
target weight has been reached or exceeded. The
loader operator should stop loading when the red
lights remain on.
Refer to Service Manual, RENR4725, “Truck Payload
Measurement System” for information on changing
the values for the lower target weight and the upper
target weight.
SEBU8906
TPMS Switches
Illustration 130 g01127222
Typical Example
TPMS Switch (3) – Push down on the
bottom half of the switch in order to
activate the TPMS. Push down on the top
half of the switch in order to deactivate the TPMS.
Auxiliary Switch (4) – If required, depress the
auxiliary switch to record the current load.
Cycle Data
Throughout the trucks load cycle, several conditions
are monitored. The data that is collected during each
load cycle is stored into the memory. Later, the data
may be downloaded through the ET service port by
using a laptop computer. For more information, refer
to Service Manual, RENR4725, “Truck Payload
Measurement System”.
The memory can contain the data that is collected for
1000 load cycles.
Download load cycle data before the memory limits
are reached. If the memory limits are exceeded,
some of the memory space will be cleared
automatically. The oldest load cycle will be deleted in
order to clear the memory space, allowing new load
cycle data to be stored. Data will be retained for the
most recent 1000 load cycles.
Clear Totals
When you use the TPMS downloading software, the
load cycle count will reset and the total weight will be
reset to zero.
This can be done at the beginning of every shift or at
any other time.
67
Machine Controls and Operation
Fire Suppression System (Foam)
ET Service Port
Illustration 131 g01132797
Typical Example
ET Service Port (5) – ET service port (5) is used to
connect a laptop computer in order to download the
load cycle data. This procedure is described in the
Service Manual, RENR4725, “Truck Payload
Measurement System”. The ET service port is located
on the left side of the instrument panel.
Note: A 247-2042 Data Download Harness is used
to connect a laptop computer to the ET service port.
i05883034
Fire Suppression System
(Foam)
(If Equipped)
SMCS Code: 7401
This section contains basic operating procedures for
the foam fire suppression system. The foam fire
suppression system may be activated automatically
or manually. The foam fire suppression system may
also include an engine shutdown control.
For more complete information, refer to the fire
suppression system manufacturers information.
Fire Suppression Control (Manual)
Manual actuation of the fire suppression system
will result in immediate system discharge which
may obscure vision and affect the operator's abil-
ity to control the machine. This may result in per-
sonal injury or death. Make certain the machine is
stopped safely before manually actuating the sys-
tem. Manual actuation will bypass all auxiliary
shutdown and alarm functions.
68
Machine Controls and Operation
Fire Suppression System (Foam)
Illustration 132
Illustration 133
There are two manual actuators on the machine.
Manual actuator (1) is located in the operator station
of the machine. Manual actuator (3) is located on the
left side of the radiator guard.
Activate the fire suppression system by turning
handle (2) or (4) counterclockwise.
SEBU8906
Fire Suppression Control (Engine
Shutdown)
g00927423
Illustration 134 g03709508
Engine shutdown control for fire suppression
g00929440
Illustration 135 g03709509
Engine shutdown control for fire suppression and idle
timer
The function of the fire suppression control is to
cause a delayed engine shutdown when the fire
suppression system is activated.
Fire System Activated (1) – Fire system
activated indicator (1) indicates that the
fire suppression system has been
activated. When this indicator flashes, an alarm
will sound and the engine will shut down after a
six second delay.
Engine Shutdown Switch (2) – Engine
Shutdown switch (2) allows the engine to
be shut down immediately. Push and
hold engine shutdown switch (2) down to shut
down the engine.
Note: During normal operation use the engine start
switch to shut down the engine.
SEBU8906
System Reset Button (3) – System reset
button (3) is used to override the fire
suppression control so that the machine
can be moved after discharge of the fire
suppression system and loss of system pressure.
The “SYSTEM RESET” button must be held in for
the engine to operate. Upon release, the engine will
shut down after 6 seconds.
Note: The override function should only be used in an
extreme emergency. Restarting the machine before
the fire suppression system has been recharged can
reignite the fire that had been previously suppressed,
without a means of extinguishment.
Idle Timer Function
Certain machines may be equipped with an idle timer
control (engine shutdown) in addition to the fire
suppression control.
The function of the idle timer control is to provide a
timed period of idle (3 minutes) before engine
shutdown when the engine start switch is turned to
the OFF position.
Idle Timer On Indicator (4) – Indicates
that the idle timer has been activated.
When the engine start switch is turned to
the OFF position, the indicator will flash and the
engine will stop after 3 minutes.
Note: The idle timer will activate whenever the engine
start switch is turned from the ON position to the OFF
position.
Note: To override the idle timer and stop the engine,
turn the engine start switch to the OFF position and
push engine shutdown switch (2) down.
Note: If the idle timer has been activated without
starting the engine. The idle timer can be deactivated
by pushing down engine shutdown switch (2).
Indicator (1) should stop flashing.
NOTICE
Never turn the battery disconnect switch to the OFF
position with the idle timer activated (engine running).
Electrical system damage could result.
In Case of Fire
In case of fire, evacuate the area to reduce the risk
of injury from flames, heat, hazardous vapors, ex-
plosions, or any other hazards that may be
created.
69
Machine Controls and Operation
Fire Suppression System (Dry Powder)
The following procedure should be read and
performed in accordance with the current mine site
practices.
In case of fire perform the following procedure:
1. When a fire is detected or when the system alarm
(if equipped) sounds, bring the machine to a safe
controlled stop.
2. Stop the engine.
3. Engage the parking brake.
4. If not automatically activated, manually activate the
fire suppression system by turning the handle on
the manual fire suppression control
counterclockwise.
5. Evacuate the machine.
6. If possible, turn the battery disconnect switch to the
OFF position.
7. Notify the appropriate mine personnel.
8. Stand by (at a safe distance) with a portable fire
extinguisher.
Note: Stand by with a portable fire extinguisher to
guard against any fire that may reignite after the fire
suppression system has discharged. Remain alert
until the possibility of reignition is past.
NOTICE
If the fire suppression system has been activated, the
system must be flushed and recharged. Have the ma-
chine cleaned, inspected and repaired before return-
ing the machine to operation.
i01802301
Fire Suppression System (Dry
Powder)
(If Equipped)
SMCS Code: 7401
This section contains basic operating procedures for
the dry powder fire suppression system. The dry
powder fire suppression system may be activated
automatically or manually.
Reference: For more complete information, refer to
the fire suppression system manufacturer's
information.
70 SEBU8906
Machine Controls and Operation
Fire Suppression System (Dry Powder)

Fire Suppression Control Release Fault (Yellow) (6) – This indicator and the
audio sounder will pulse once every ten seconds
(Automatic) when a fault condition is detected in the release
circuit. The fire suppression control will return to
normal when the fault condition is cleared. The
indicator will also pulse after the system has
completed a discharge cycle. The fault signal in this
condition is used to indicate that a recharge of the fire
suppression system is necessary.
Delay Button (7) – Push and release the DELAY
button to restart the delay period for the shutdown of
the engine after a fire has been detected. Push and
hold the DELAY button to indefinitely delay the
shutdown of the engine after a fire has been
detected.
Reset Button (8) – Push and hold the RESET button
to override the fire suppression control so that the
machine can be restarted after discharge of the fire
suppression system.

The RESET button must be held in for the engine to

operate. Upon release, the engine will shutdown after
three seconds.

Note: The override function should only be used in an

extreme emergency. Restarting the machine before
the fire suppression system has been recharged, can
reignite the fire that had been previously suppressed,
without a means of extinguishment.
The RESET button is also used to reset the fire
suppression control after the fire suppression system
Illustration 136 g00899222
has been charged. When depressed, it provides an
indication that all the indicators and the audio
The fire suppression control is located in the operator sounder are functional. When the RESET button is
station. pressed, three short audio and visual indications will
acknowledge that the system has been reset.
Audio Sounder (1) – The audio sounder gives the
audio indication for all alarm and fault outputs. The
sounder will pulse at the same rate as the Fire Suppression Control (Manual)
corresponding indicator.
Battery Fault (Yellow) (2) – This indicator and the
audio sounder will pulse once every ten seconds to
indicate a low power condition. Manual actuation of the fire suppression system
will result in immediate system discharge which
Power Normal (Green) (3) – This indicator pulses may obscure vision and affect the operator's abil-
once every three seconds to indicate normal battery ity to control the machine. This may result in per-
power. The indicator will be off to indicate a loss of sonal injury or death. Make certain the machine is
power or a low power condition.
stopped safely before manually actuating the sys-
Alarm (Red) (4) – This indicator and the audio tem. Manual actuation will bypass all auxiliary
sounder will pulse at two times per second if an alarm shutdown and alarm functions.
condition exists. An alarm condition is caused by the
detection of a fire or by the operation of a manual
actuator. The indicator and the audio sounder will
pulse until the source of the alarm is removed and the
fire suppression control is reset.
Detection Fault (Yellow) (5) – This indicator and the
audio sounder will pulse once every ten seconds
when the fire suppression control detects a fault in
the detection circuit. The fire suppression control will
return to normal when the fault condition is cleared.
SEBU8906
Illustration 137 g00997217
Illustration 138 g00997218
There are two manual actuators on the machine.
Manual actuator (2) is located in the operator station
of the machine. Manual actuator (4) is located on the
left side of the radiator guard.
Activate the fire suppression system by pulling the
ring pin on manual actuator (2) or (4) and striking red
button (1) or (3).
In Case of Fire
In case of fire, evacuate the area to reduce the risk
of injury from flames, heat, hazardous vapors, ex-
plosions, or any other hazards that may be
created.
The following procedure should be read and
performed in accordance with the current mine site
practices.
In case of fire perform the following procedure:
1. When the system alarm sounds, bring the machine
to a safe controlled stop.
71
Machine Controls and Operation
Fuel Shutoff Valve
2. Stop the engine.
3. Engage the parking brake.
4. If not automatically activated, manually activate the
fire suppression system by pulling the ring pin on
the manual actuator and striking the red button.
5. Evacuate the machine.
6. If possible, turn the battery disconnect switch to the
OFF position.
7. Notify the appropriate mine personnel.
8. Stand by (at a safe distance) with a portable fire
extinguisher.
Note: Stand by with a portable fire extinguisher to
guard against any fire that may reignite after the fire
suppression system has discharged. Remain alert
until the possibility of reignition is past.
NOTICE
If the fire suppression system has been activated, the
system must be flushed and recharged. Have the ma-
chine cleaned, inspected and repaired before return-
ing the machine to operation.
i02262541
Fuel Shutoff Valve
SMCS Code: 1329
Illustration 139 g01136261
The shutoff valves for the fuel lines are located on the
right side of the machine at the bottom of the fuel
tank. Shutoff valve (1) is for the supply line. Shutoff
valve (2) is for the return line.
72 SEBU8906
Machine Controls and Operation
Steering Frame Lock

i05883038

Steering Frame Lock

SMCS Code: 7506

Connection Procedure

Personal injury or death can result from machine

articulation or movement.
Machine frames can move and a person can be
crushed.
Connect the steering frame lock link between the Illustration 140 g03709510
front and rear frames before working on machine.
Secure clevis pin with locking pin. 3. Remove locking pin (3) and pin (1).
Before operating the machine, fasten the steering 4. Remove retaining pin (4 ) and pin (2).
frame lock link into the stored position and secure
the clevis pin with locking pin.
Failure to lock into the stored position before op-
erating can result in loss of steering.

Failure to follow the instruction below for the in-

stallation of the steering frame lock pin may result
in personal injury. Special care must be taken if
more than one person is installing the steering
frame lock pin.
Confirm the verbal communication and the hand
signals that will be used during the installation.
Illustration 141 g00994592
Be alert for the sudden movement of the machine
frames or the steering frame lock pin. 5. Move the steering frame lock link (5) in position to
Do not insert fingers into the steering frame lock rear frame.
bores when the bores are being aligned.
6. Check that the bores in steering frame lock link (5)
Do not hold the pin in the steering frame lock and the rear frame are aligned.
bores when the bores are being aligned.
7. Install pin (2), ensure pin (2) passes through the
Do not stand within 1 m (3.28 ft) of the machine three bores.
while the steering control is moved to align the
steering lock bores. 8. Install retaining pin (4).

9. Install pin (1) and locking pin (3).

1. Move the machine to a hard, level surface. Park
the machine in the straight ahead position and
engage the parking brake.

2. Stop the engine.

SEBU8906 73
Machine Controls and Operation
Steering Frame Lock

Illustration 142 g02223473 Illustration 143 g02223474

Typical example Typical example

19. Realign the pin bores if pin (2) cannot be

Machine frames can move and the steering frame
lock pin can be expelled if the steering frame lock
pin is only partially installed, or the pin bevel is in
contact with the upper edge of the steering frame
lock link.
Personal injury can result from machine articula-
tion or movement.
Ensure that the steering frame lock pin is installed
through the machine frame bore before moving
the steering control.
10. If pin (2) is only partially installed in steering frame
lock link (5) or pin bevel (6) stops pin (2) from
entering steering frame lock link (5), perform Step
11 through Step 18.
removed. Perform Step 20 through Step 27.
20. Remove all personnel apart from the operator
from within 1.0 m (3.28 ft) of the machine.
21. Start the engine.
22. Disengage the parking brake.
23. Slowly move the steering control in one direction
and then in the opposite direction until pin (2)
moves through the three frame bores.
24. Engage the parking brake.
25. Stop the engine.
26. Install retaining pin (4).

11. Remove pin (2). 27. Install pin (1) and locking pin (3).

12. Start the engine. Separation Procedure

13. Disengage the parking brake.

14. Realign the bores in steering frame lock link (5)

and the rear frame. Personal injury or death can result from machine
articulation or movement.
15. Engage the parking brake.
Machine frames can move and a person can be
16. Stop the engine. crushed.

17. Place pin (2) in the installed position and ensure
pin (2) passes through the three bores.
18. Install retaining pin (4).
Connect the steering frame lock link between the
front and rear frames before working on machine.
Secure clevis pin with locking pin.
Before operating the machine, fasten the steering
frame lock link into the stored position and secure
the clevis pin with locking pin.
Failure to lock into the stored position before op-
erating can result in loss of steering.
74
Machine Controls and Operation
Body Retaining Pin
Illustration 144 g00994592
1. Remove locking pin (3) and pin (1).
2. Remove retaining pin (4) and pin (2)
Illustration 145 g03709510
3. Move steering frame lock link (5) to the stored
position. Install pin (1) and locking pin (3).
4. Install pin (2) and retaining pin (4)
5. If pin (2) cannot be removed perform Step 6
through Step 11.
Machine frames can move and the steering frame
lock pin can be expelled if the steering frame lock
pin is only partially installed or the pin bevel is in
contact with the upper edge of the steering frame
lock link.
Personal injury can result from machine articula-
tion or movement.
Ensure that the engine is stopped before remov-
ing the steering frame lock pin.
SEBU8906
6. Start the engine.
7. Disengage the parking brake.
8. Slowly move the steering control in one direction.
9. Engage the parking brake.
10. Stop the engine.
11. Remove pin (2).
12. Move steering frame lock link (5) to the stored
position. Install pin (1) and locking pin (3).
13. Install pin (2) and retaining pin (4).
14. If the steering lock pin cannot be removed,
perform Step 6 through Step 11 but move the
steering control in the opposite direction.
i01803697
Body Retaining Pin
SMCS Code: 7424
Dump Body
To prevent personal injury or death, do not work
under the truck with the body (bed) raised.
When it is necessary to work under the truck with
the body (bed) raised, install the body (bed) re-
taining pins through the pin holes in the frame
and body.
Illustration 146 g00929432
1. Pull rod (1) and remove retaining pin (2) from the
stored position.
2. Repeat Step 1 for the other retaining pin.
SEBU8906 75
Machine Controls and Operation
Tailgate Retaining Pin

3. Raise the dump body to the fully raised position.

Illustration 148 g03670859

1. Pull rod (1) and remove retaining pin (2) from the
Illustration 147 g00929433 stored position.

4. Install retaining pin (2) through the pin holes in the

frame and dump body, as shown.

5. Repeat Step 4 for the other retaining pin.

Note: The following steps are for the removal of the

body retaining pins.
6. Raise the dump body to the fully raised position.

7. Remove retaining pin (2).

8. Repeat Step 7 for the other retaining pin.

9. Lower the dump body.

10. Pull rod (1) and install retaining pin (2) in the Illustration 149 g03670860

stored position.
2. Fully retract the ejector plate and raise the tailgate
11. Repeat Step 10 for the other retaining pin. until the pin bore on the body aligns with the pin
bore on the tailgate.
i05792729
3. Place retaining pin (2) in position as shown.
Tailgate Retaining Pin
Note: The following steps are for the removal of the
SMCS Code: 7271-PN
retaining pin.
4. Raise the tailgate to release any tension.
Ejector Body
5. Remove retaining pin (2).

6. Pull rod (1) and replace retaining pin (2) in the

The tailgate may move suddenly and without stored position. Release rod (1) to hold the
warning, resulting in personal injury or death. retaining pin in the stored position.

When it is necessary to work under the tailgate

with the tailgate raised, install the tailgate retain-
ing pins through the pin bores in the tailgate and
body.
76 SEBU8906
Before Starting Engine
Walk-Around Inspection

Before Starting Engine

i04023199

Walk-Around Inspection
SMCS Code: 1000; 7000
For maximum service life of the machine, make a
thorough walk around inspection before you operate
the machine. Make a complete clockwise circle of the
machine.
Ensure that the machine is parked on a hard level
surface in the straight ahead position with the parking
brake engaged. Check for the presence of warning
tags attached to any machine controls.
Look around the machine and under the machine.
Inspect the condition of all major components. Check
all grease fittings. Look for the following
discrepancies:

• Loose bolts
• Trash buildup

• Oil, coolant, or fuel leaks

• Broken parts or worn parts

• Cracks in the frame

• Make sure that the handrails are secure
Remove any trash and any debris. Report any
abnormalities to your service personnel. Make any
necessary repairs before you operate the machine.

Note: If the machine has not been operated for more

than 48 hours, qualified personnel should complete a
service inspection before you operate the machine.
Refer to Operation and Maintenance Manual,
“Service Inspection” for further information.
SEBU8906 77
Before Starting Engine
Walk-Around Inspection

Illustration 150 g00929044

Inspection points for the walk around inspection
(A) Ground level controls (I) Power train (Q) Automatic lubricant reservoir (if
(B) Front lights (J) Right steering cylinder equipped)
(C) Radiator (K) Right hoist cylinder (R) Left steering cylinder
(D) Engine (L) Right rear tire (S) Steering frame lock
(E) Hydraulic tank (M) Rear axle (T) Left front tire
(F) Air cleaner (N) Frame and body (U) Windows
(G) Right front tire (O) Left rear tire
(H) Fuel tank (P) Left hoist cylinder
78 SEBU8906
Before Starting Engine
Walk-Around Inspection

Illustration 151 g01803454 Illustration 153 g01803456

(A) Inspect the ground level controls. Make sure that (E) Inspect the hydraulic tank. Check the oil level in
engine shutdown switch (1) and battery disconnect the hydraulic tank sight gauge (4). Inspect the tank for
switch (2) are in the ON position. leaks and for damage. Make sure that the filler cap is
installed.
(B) Inspect the front operating lights for damage.
(C) Inspect the radiator. Check for leaks. Remove any
debris that could block air flow. Check the coolant
level in the radiator sight gauge.

Illustration 154 g01803457

(F) Inspect air cleaner (5). Remove debris that may

obstruct the air cleaner.
Illustration 152 g01803455 (G) Inspect the right front tire. Check the tire inflation.
Inspect the tire treads for damage. Check the wheel
(D) Inspect the engine. Use dipstick (3) to check the for bolts that are loose or missing. Check the final
oil level in the crankcase of the engine. Check for oil drive for oil leaks.
leaks and coolant leaks.
Note: Rust behind a bolt may indicate that the bolt is
loose. Shiny metal areas around a bolt may indicate
that the bolt is loose.
(H) Inspect the fuel tank. Make sure that the filler cap
is installed correctly. Look for any leaks or damage to
the fuel tank.
SEBU8906
Illustration 155 g01125863
(I) Inspect the power train. Check the transmission oil
level in sight gauge (6). Check for leaks from the
torque converter and from the transmission.
(J) Inspect the right steering cylinder. Look for leaks,
cracking, or marks on the chrome. Inspect the
articulating hitch, the oscillating hitch, and the center
drive shaft.
(K) Inspect the right hoist cylinder. Look for leaks,
cracking, or marks on the chrome.
(L) Repeat procedure (G) for the right rear tire.
(M) Inspect the rear axle. Inspect the rear lights for
damage. Inspect the dump body pivot points. If
equipped with an ejector body, inspect the tailgate
pivot points.
Illustration 156 g01803458
(N) Inspect frame (8) and dump body (7) for cracks or
damage. If equipped with an ejector body, inspect the
ejector body and the tailgate for cracks or damage.
(O) Repeat procedure (G) for the rear left tire.
(P) Repeat procedure (K) for the left hoist cylinder.
(Q) Inspect the automatic lubricant reservoir (if
equipped) for leaks.
(R) Repeat procedure (J) for the left steering cylinder.
79
Before Starting Engine
Mounting and Dismounting
(S) Check that the steering frame lock is not installed.
The machine will not steer if the steering frame lock is
installed.
(T) Repeat procedure (G) for the front left tire.
(U) Make sure that all the windows are clean. Make
sure that the operators vision is not impaired by dust,
mud, or other foreign materials. Adjust the mirrors for
proper vision.
For service information refer to the Maintenance
Section in Operation and Maintenance Manual,
“Service Inspection” for the machine that is being
serviced.
i04027420
Mounting and Dismounting
SMCS Code: 7000
Illustration 157 g00037860
Use steps and handholds whenever you mount the
machine. Use steps and handholds whenever you
dismount the machine. Before you mount the
machine, clean the step and the handholds. Inspect
the step and handholds. Make all necessary repairs.
Face the machine whenever you mount the machine
and whenever you dismount the machine. Maintain a
three-point contact with the step and with handholds.
Note: Three-point contact can be two feet and one
hand. Three-point contact can also be one foot and
two hands.
Do not mount a moving machine. Do not dismount a
moving machine. Never jump off the machine. Do not
try to mount the machine when you carry tools or
supplies. Do not try to dismount the machine when
you are carrying tools or supplies. Use a hand line to
pull equipment onto the platform. Do not use any
controls as handholds when you enter the operator
compartment or when you exit the operator
compartment.
80
Before Starting Engine
Seat Adjustment and Seat Belt Inspection
Machine Access System
Specifications
The machine access system has been designed to
meet the intent of the technical requirements in “ISO
2867 Earth-moving Machinery – Access Systems”.
The access system provides for operator access to
the operator station and to conduct the maintenance
procedures described in Maintenance section.
i05886155
Seat Adjustment and Seat Belt
Inspection
SMCS Code: 7312; 7327
Illustration 158 g03711196
Note: Adjust the seat at the beginning of each shift or
adjust the seat when there is a change of operators.
When the operator is seated against the back of the
seat, adjust the seat in order to allow full pedal travel.
The operator may adjust the seat forward or
backward.
Inspect the belt mounting hardware. If the hardware is
damaged or worn, replace the hardware. Keep the
mounting bolts tight.
Fasten the seat belt before you start the engine.
Reference: For further information on the seat and
the seat belt, refer to the Operation and Maintenance
Manual, “Seat, Seat Belt” for the machine that is
being serviced.
SEBU8906
i05792749
Caterpillar Monitoring System -
Self Test
SMCS Code: 7490
Illustration 159 g03709511
Caterpillar Monitoring System
(1) Action lamp
(2) Alert indicators
(3) Display window
(4) Engine start switch
The Caterpillar Monitoring System will perform an
automatic self test at startup whenever the engine
start switch is turned to the ON position. Observe the
self test when engine start switch (4) is turned from
the OFF position to the ON position.
Observe the monitoring system display and the
gauge display to determine if the Caterpillar
Monitoring System is operating properly as follows:
1. All alert indicators (2) flash for approximately 3
seconds to permit the operator to know that the
indicators are functioning properly. Certain
diagnostics are not possible with the use of LED
lamps. Visually inspect the lamps during starting. If
an indicator glows dimly or if an indicator does not
light, find the cause immediately.
2. Display window (3) shows the following readouts
for approximately 3 seconds:
• All units indicators (Degree C, kPa, miles,
kilometers, rpm, and liters).
• "x 10".
• Service meter symbol.
• "888.8.8.8" in the six-digit window.
SEBU8906 81
Before Starting Engine
Caterpillar Monitoring System - Self Test

Illustration 160 g03670877

Caterpillar Monitoring System
(5) Gauge cluster
(6) Tachometer
(7) Digital Speedometer
(8) Actual gear indicator

3. The gauges in gauge cluster (5) and tachometer

(6) will be calibrated. The gauges will sweep to half
scale, back to zero, then sweep to full scale. After
reaching full scale, the tachometer and gauges
return to showing current machine values.

4. The digital speedometer (7) activates every

segment of the display which will produce the
following readout: "188", "MPH" and "km/h".

5. Actual gear indicator (8) for the transmission

activates every segment of the readout. You will
see a "0" with an "X" and a "+" sign laid on top of
the "0". There should be two of these symbols.

6. The action lamp (1) illuminates.

7. The action alarm sounds once.

If the alert indicators, action lamp or digital readouts
do not appear, or if the gauges do not sweep, the
electrical system must be inspected. Perform all the
necessary repairs before the engine is started again.
If the above test is completed, turn the engine start
switch to the START position.
After you start the engine, observe the gauge display
and the monitoring system display. If any alert
indicators or the action alarm remain on or if the
action alarm sounds, stop the engine. Inspect the
electrical system and any of the machine systems
which were indicated. Perform all necessary repairs
before the engine is started again.
82 SEBU8906
Engine Starting
Starting the Engine

Engine Starting
i05883048

Starting the Engine

SMCS Code: 1000; 7000

Diesel engine exhaust contains products of com-

bustion which may cause personal injury.
Always start and operate the engine in a well ven-
tilated area, and, if in an enclosed area, vent the
exhaust to the outside. Illustration 162 g00927810

6. For dump body machines the dump body should

1. Make sure that no one is on the machine, be down and the hoist control should be in FLOAT
underneath the machine or around the machine. position (3).
Make sure that there are no personnel in the area.

2. Close the operator station door.

3. Adjust the operators seat.

4. Fasten the seat belt.

Note: Before you start the engine, wait for the self
test of the Caterpillar Monitoring System. The self test
will activate when the engine start switch is turned to
the ON position. Refer to the Operation and
Maintenance Manual, “Caterpillar Monitoring System
- Self Test” in this section for further information.

Illustration 163 g01000709

7. For ejector body machines the tailgate should be

up and the hoist control should be in HOLD
position (4).

8. Sound the horn.

Illustration 161 g00927809

5. Move transmission control (2) to the NEUTRAL

position. Engage parking brake control (1).
SEBU8906 83
Engine Starting
Engine Cold Mode

Operator Present Strategy

If the parking brake has engaged and the engine
stops after 3 to 4 seconds the operator present
strategy has applied, repeat Step 5 through Step 10
of in order to restart the engine.

Reference: For more information on the operator

present strategy refer to Operation and Maintenance
Manual, “Hauling”.

i01798868

Engine Cold Mode

SMCS Code: 1000; 7000
Illustration 164 g03709513

Elevated Low Idle

Illustration 165 g00927811

9. Turn the engine start switch to START position (5).

10. Release the engine start switch when the engine

starts.

NOTICE Illustration 166 g00921507

Do not crank the engine for more than 30 seconds. Al-
low the starter to cool for two minutes before cranking
again. Turbocharger damage can result if the engine
rpm is not kept low until the oil gauge display verifies
that the oil pressure is sufficient.
Note: For starting below −18 °C (0.0 °F), use of
additional cold weather starting aids is
recommended. A coolant heater, a fuel heater, or
some extra battery capacity may be required. At
temperatures below −23 °C (−10.0 °F), consult your
Caterpillar dealer or refer to Operation and
Maintenance Manual, SEBU5898, “Cold Weather
Recommendations”.
For coolant temperatures less than 18 °C (64 °F),
engine idle speed is raised to 1000 RPM. For coolant
temperatures that are greater than 18 °C (64 °F), the
elevated idle is disabled. When the elevated idle is
disabled, the engine speed returns to the factory set,
low idle speed of 700 RPM.
Activated
The following items must be present before elevated
low idle will activate:
• The transmission control is in the NEUTRAL
position.
• The parking brake control is in the ON position.

Deactivated
The following actions will deactivate elevated low idle:
84
Engine Starting
Engine Starting with Jump Start Cables
• The throttle pedal is depressed by more than 25
percent of the pedal's travel.
• The transmission is moved into gear.
• The parking brake is disengaged.
• The throttle backup switch is moved on the ON
position.
Note: If the transmission is in the NEUTRAL position
and the parking brake is in the ON position, elevated
low idle will activate again after 10 minutes.
i02905297
Engine Starting with Jump
Start Cables
SMCS Code: 1000; 1401; 7000
Never "hotwire" or short across the starter termi-
nals! Hotwiring or shorting across the starter ter-
minals could bypass the engine neutral start
system, damage the electrical system, and result
in unexpected machine motion or behavior. This
could cause personal injury or death.
SEBU8906
Failure to properly service the batteries may
cause personal injury.
Prevent sparks near the batteries. They could
cause vapors to explode. Do not allow the jump
start cable ends to contact each other or the
machine.
Do not smoke when checking battery electrolyte
levels.
Electrolyte is an acid and can cause personal in-
jury if it contacts the skin or eyes.
Always wear eye protection when starting a ma-
chine with jump start cables.
Improper jump start procedures can cause an ex-
plosion resulting in personal injury.
When using jumper cables, always connect the
positive (+) jumper cable to the positive (+) battery
terminal first. Next, connect the negative (-) jump-
er cable to the frame away from the batteries. Fol-
low the procedure in the Operation and
Maintenance Manual.
Jump start only with an energy source of the
same voltage as the stalled machine.
Turn off all lights and accessories on the stalled
machine. Otherwise, they will operate when the
energy source is connected.
NOTICE
When starting from another machine, make sure that
the machines do not touch. This could prevent dam-
age to engine bearings and electrical circuits.
Turn on (close) the battery disconnect switch prior to
the boost connection to prevent damage to electrical
components on the stalled machine.
Severely discharged maintenance free batteries do
not fully recharge from the alternator after jump start-
ing. The batteries must be charged to proper voltage
with a battery charger. Many batteries thought to be
unusable are still rechargeable.
This machine has a 24 volt starting system. Use only
the same voltage for jump starting. Use of a higher
voltage damages the electrical system.
Use of Jump Start Cables
If the machine is equipped with an auxiliary start
receptacle, use the auxiliary start receptacle. When
the auxiliary start receptacle is not available, use the
following procedure.
SEBU8906
Reference: For more information concerning the
auxiliary start receptacle, refer to the Operation and
Maintenance Manual, “Engine Starting with Auxiliary
Start Receptacle” in this publication.
1. Determine the cause of the failure of the engine to
start.
Reference: Refer to Special Instruction, REHS0354,
“Charging System - Troubleshooting” for further
information.
2. Move the transmission control to the NEUTRAL
position on the stalled machine. Engage the
parking brake. For dump body machines move the
hoist control to the FLOAT position.For ejector
body machines move the hoist control to the HOLD
position.
3. On the stalled machine, turn the engine start switch
to the OFF position. Turn off all accessories.
4. On the stalled machine, turn the battery disconnect
switch to the ON position.
5. Move the machines together in order for the cables
to reach. DO NOT ALLOW THE MACHINES TO
CONTACT EACH OTHER.
6. Stop the engine on the machine that is being used
as the electrical source. If you are using an
auxiliary power source, turn off the charging
system.
Illustration 167 g00928267
7. Check the battery caps for correct placement and
for correct tightness. Make these checks on both
machines. Make sure the batteries in the stalled
machine are not frozen. Check the batteries for low
electrolyte.
85
Engine Starting
Engine Starting with Jump Start Cables
8. Connect the positive jump start cable to the
positive cable terminal of the discharged battery.
Do not allow positive cable clamps to touch any
metal except for battery terminals.
9. Batteries in series may be in separate
compartments. Use the terminal that is connected
to the starter solenoid. This battery is normally on
the same side of the machine as the starter.
10. Connect the positive jump start cable to the
positive terminal of the electrical source. Use the
procedure from Step 9 to determine the correct
terminal.
11. Connect one end of the negative jump start cable
to the negative terminal of the electrical source.
12. Make the final connection. Connect the negative
cable to the frame of the stalled machine. Make
this connection away from the battery, the fuel, the
hydraulic lines, or moving parts.
13. Start the engine on the machine that is the
electrical source. Also, you can energize the
charging system on the auxiliary power source.
14. Allow the electrical source to charge the batteries
for two minutes.
15. Attempt to start the stalled engine.
Reference: For more information on starting the
engine, refer to the Operation and Maintenance
Manual, “Engine Starting” for the machine that is
being serviced.
16. Immediately after the stalled engine starts,
disconnect the jump start cables in reverse order.
17. Conclude with a failure analysis on the starting/
charging system. Check the stalled machine, as
required. Check the machine when the engine is
running and the charging system is in operation.
86
Engine Starting
Engine Starting with Auxiliary Start Receptacle
i02905299
Engine Starting with Auxiliary
Start Receptacle
SMCS Code: 1450; 1463
Illustration 168 g00928269
The auxiliary start receptacle is located on the left
side of the machine, in the battery compartment.
Some Caterpillar products may be equipped with
auxiliary start receptacles as standard. All other
machines can be equipped with a receptacle from
parts service. Then, a permanent receptacle is
always available for jump starting.
There are two cable assemblies that can be used to
jump start the stalled machine. You can jump the
machine from another machine that is equipped with
this receptacle or an auxiliary power pack. Your
Caterpillar dealer can provide the correct cable
lengths for your application.
1. Determine the cause of the failure of the engine to
start.
Reference: Refer to Special Instruction, REHS0354,
“Charging System - Troubleshooting” for further
information.
2. Move the transmission control to the NEUTRAL
position on the stalled machine. Engage the
parking brake. For dump body machines move the
hoist control to the FLOAT position. For ejector
body machines move the hoist control to the HOLD
position.
3. On the stalled machine, turn the engine start switch
to the OFF position. Turn off all accessories.
4. On the stalled machine, turn the battery disconnect
switch to the ON position.
SEBU8906
5. Move the machines together in order for the cables
to reach. DO NOT ALLOW THE MACHINES TO
CONTACT EACH OTHER.
6. Stop the engine on the machine that is being used
as the electrical source. If you are using an
auxiliary power source, turn off the charging
system.
7. On the stalled machine, connect the appropriate
jump start cable to the auxiliary start receptacle.
8. Connect the other end of this cable to the electrical
source. You must connect the cable to the auxiliary
start receptacle.
9. Start the engine on the machine that is the
electrical source. Also, you can energize the
charging system on the auxiliary power source.
10. Allow the electrical source to charge the batteries
for two minutes.
11. Attempt to start the stalled engine.
Reference: For more information on starting the
engine, refer to the Operation and Maintenance
Manual, “Engine Starting” for the machine that is
being serviced.
12. Immediately after the stalled engine starts,
disconnect the jump start cable from the electrical
source.
13. Disconnect the other end of this cable from the
stalled machine.
14. Conclude with a failure analysis on the starting/
charging system. Check the stalled machine, as
required. Check the machine when the engine is
running and the charging system is in operation.
i05886151
Engine and Machine Warm-Up
SMCS Code: 1000; 7000
NOTICE
With the engine above low idle, the oil pressure indi-
cator should go off within 15 seconds. If not, stop the
engine immediately and investigate the cause.
SEBU8906 87
Engine Starting
Engine and Machine Warm-Up

6. Adjust the operators seat. Adjust the mirrors.

7. Fasten the seat belt.

Do not allow a companion to ride on the machine

Illustration 169 g03672627
1. Before you operate the machine, observe action
lamp (1) and alert indicators (2) of the Caterpillar
Monitoring System. Take action on any lamp or
alert indicator that remains illuminated.
unless the companion is seated within the Roll-
over Protective Structure (ROPS) or Falling Object
Protection Structure (FOPS) with the seat belt fas-
tened. The companion must have the seat belt
fastened while the machine is in operation. The
operator of the machine is responsible for the
safety of the companion. Personal injury or death
may occur if the companion is not restrained and
protected.

Note: In order to provide maximum sound

suppression, keep all doors closed and keep all
windows closed.
2. With the engine at low idle and with the oil at
normal operating temperature, check the oil levels
of the following systems: engine, transmission, and
hydraulic. Refer to the "Maintenance Section" for
information on checking the oil levels.

3. Check the horn. Check the backup alarm. Check

any other warning devices on the machine.
4. Check the operation of the steering and the brakes.
Do not operate the machine if any discrepancies
are found.
Illustration 171 g00928258
8. For dump body machines lower the dump body.
Move the hoist control to FLOAT position (4).

Illustration 170 g03672143 Illustration 172 g01000710

5. Frequently observe warnings, alert indicators, and 9. For ejector body machines raise the tailgate. Move
gauges. All gauges (3) should be at normal the hoist control to HOLD position (5).
operating range. The alert indicators, the action
lamp, and the action alarm should be off.
88 SEBU8906
Engine Starting
Engine and Machine Warm-Up

Note: Only operate the controls if the engine is

running.

12. Release service brake pedal (10) and depress

throttle pedal (11).

Machine Warm-up
When the oil is allowed to warm up gradually, the
bearing components maintain optimum operating
positions. High speeds during a cold start-up may
decrease the durability of the bearing components.
If the outside temperature is above 0.0 °C (32 °F), a
warm-up time of 5 minutes is recommended. When
the temperature is below 0.0 °C (32 °F), additional
Illustration 173 g03711179 warm-up time is recommended.

10. Retarder control lever (7) should be in the UP Differential Warm-up

position and switch (6) for the ARC should be in
the ON position.
Operate the machine in fourth gear or lower, after
startup, until the oil is at operating temperature.
Providing a gradual warm-up period allows bearing
components to maintain optimum operating settings.
Operating at high speeds from a cold start causes
high temperature gradients between rotating and
stationary bearing components. High temperature
gradients within the bearing may result in degradation
of bearing components durability.

Preparing to Operate the Machine

1. Before the machine operates at a high speed,
check the operation of the brake system and of the
steering system. These systems should be
checked while the machine maintains a low speed.

2. Make sure that the Automatic Retarder Control

Illustration 174 g00928262 (ARC) operates properly before you travel down a
grade with a machine that is loaded. Test the ARC
on a short grade before the machine is loaded.

3. In order to prevent injury, make sure that no one is

working on the machine or near the machine. Keep
the machine under control at all times in order to
prevent injury.

4. Reduce engine speed when you are maneuvering

in tight quarters or when you are driving over a
rise.

Reference: For further operating information, See

Operation and Maintenance Manual, “Loading”,
Operation and Maintenance Manual, “Hauling”, and
Operation and Maintenance Manual, “Dumping”.
Illustration 175 g00928263

11. Depress service brake pedal (10). Disengage

parking brake control (8). Move transmission
control (9) to the desired direction and the desired
speed.
SEBU8906
Operating Techniques
i01801438
Loading
SMCS Code: 7000
Positioning
Take care when you drive into the loading area.
Maintain a safe distance from the machine in front of
your machine.
Avoid hitting sharp rocks and overflow.
Park the machine on level ground. For the
recommended procedure, refer to Operation and
Maintenance Manual, “Stopping the Machine” for the
machine that is being serviced.
Loading
The operator of the machine should stay in the
operator station while the machine is being loaded.
Note: For dump body machines keep the hoist
control in the FLOAT position during the loading of the
machine. Also, keep the hoist control in the FLOAT
position when the machine travels.
Note: For ejector body machines keep the hoist
control in the HOLD position during the loading of the
machine. Also, keep the hoist control in the HOLD
position when the machine travels.
i05884029
Hauling
SMCS Code: 7000
NOTICE
Do not use the retarder control as a parking
brake.
Do not use the retarder control to stop the
machine.
Pay attention to your surroundings. Keep a safe
distance from any machines in front of your machine.
Do not drive over unprotected power cables. Do not
drive under low-power cables.
Know the maximum height of the machine. Know the
maximum width of the machine. Maintain proper
clearances.
For dump body machines always travel with the hoist
control in the FLOAT position. For ejector body
machines always travel with the hoist control in the
HOLD position.
89
Operating Techniques
Loading
Shift to the top speed that is anticipated. All further
shifts will be automatic.
During normal operation, use the service brake for all
normal braking.
Roads can be slick from being wet. Reduce the
speed of the machine in order to compensate for poor
ground conditions.
Operator Present Strategy
When operating the machine you must perform one
of the following actions within 4 seconds or the
parking brake will engage, the implement and
steering functions will neutralize and the engine will
stop.
• Apply the service brake
• Maintain engine speed above 750 rpm
• Maintain ground speed above 5 km/h (3.1 mph)
When the machine is stopped, perform one of the
following actions within 4 seconds or the parking
brake will engage, the implement and steering
functions will neutralize and the engine will stop.
• Apply the service brake
• Maintain engine speed above 750 rpm
• Engage the parking brake
Also, to operate the steering and implement functions
with the parking brake engaged, perform the following
action.
• Maintain engine speed above 1500 rpm.
Note: The operator present function engine stop can
be configured using Caterpillar Electronic Technician
(ET) service tool. The engine will stop when
ENABLED. The engine will not stop when
DISABLED. Refer to Systems Operation,
Troubleshooting, Testing and Adjusting, Power Train
Electronic Control System, “Configuration”.
If the operator present strategy stops the engine, refer
to Operation and Maintenance Manual, “Starting the
Engine”.
Maneuvering in Tight Quarters
When maneuvering the machine at less than 5 km/h
(3.1 mph), slightly depress the service brake pedal in
order to prevent the operator present strategy from
engaging the parking brake and stopping the engine.
90
Operating Techniques
Dumping
Traveling Down a Grade
Never coast down a grade in neutral. Always keep
the transmission in gear. When the machine speed is
greater than 5 km/h (3.1 mph), the power train/
chassis ECM will not allow you to shift from forward
gear into neutral or into reverse.
Illustration 176 g03709973
When you approach a downgrade that is long or
steep, Automatic Retarder Control (ARC) switch (1)
should be in the ON position. Select the desired gear
before you start the downgrade The actual gear of the
transmission should also match the selected gear
before you start the downgrade.
Determine the proper gear for the conditions, the
load, and the downgrade. If you do not know the
proper gear, use the common practice of selecting the
gear that is required to go up the grade when the
machine is loaded.
For further information, refer to Operation and
Maintenance Manual, “Retarding” for the machine
that is being serviced.
Preventing Overspeed
Illustration 177 g03709975
If the machine builds up excessive speed, use
retarder control (2) in order to reduce the machine
speed. If braking force is needed, use the service
brake.
SEBU8906
Note: If the engine reaches 2565 rpm in any
programmed top gear, the torque converter lockup
clutch will disengage.
NOTICE
Do not shift into the NEUTRAL position and freewheel
down grade.
If the brake oil temperature gauge registers in the red
range, reduce the travel speed or stop the machine
until the oil cools to prevent damage to the brake
components.
i01801898
Dumping
(Dump Body Machines)
SMCS Code: 7000
Personal injury or death can occur when backing
the machine over soft edges. Use care when back-
ing into the dump area. Stay clear of soft edges
that could collapse under the machine.
If the load is frozen in the machine bed and dump-
ing is attempted on a slope, the machine can tip
over causing personal injury or death.
Inspect the dump area before you bring in a loaded
machine.
Take care when you drive into the dump area.
Maintain a safe distance from other machines.
Avoid hitting sharp rocks.
Be certain that no personnel are near the dump area.
Park the machine on level ground. For the
recommended procedure, refer to Operation and
Maintenance Manual, “Stopping the Machine” for the
machine that is being serviced.
SEBU8906 91
Operating Techniques
Dumping

Dumping Note: This machine is equipped with an automatic

snub feature that activates just before the dump body
is completely lowered. This reduces the float speed in
order to prevent the dump body from contacting the
frame too hard. Leave the hoist control in FLOAT
position (2) until the dump body is completely lowered
in order to allow the snub feature to soften the impact
of the dump body.
Completely lower the dump body before you pull out
for the return trip. This will prevent the dump body
from hitting power lines or overhead obstructions.

Note: Gears will be limited to a programmed gear

limit if the dump body is up and/or the hoist control is
not in the FLOAT position.

Illustration 178 g00926961 Reverse Neutralizer

The machine will not shift into reverse while the dump
body is being raised or the hoist control is in RAISE
position (4) or in LOWER position (1).
When the transmission is in the REVERSE position
and the hoist control is moved to RAISE position (4)
or to LOWER position (1), the transmission will
promptly shift to the NEUTRAL position. If the
machine is on a slope, apply the brakes in order to
stop the machine from moving. If the reverse
neutralizer must be bypassed, refer to “Shifting into
Reverse with the Body Raised” for the procedure.
The reverse neutralizer has no effect on the forward
gears. If the situation is required, the forward gears
can be engaged from the NEUTRAL position or the
REVERSE position.
Illustration 179 g00927815

Before you move the hoist control to RAISE position Shifting into Reverse with the Body
(4), make sure that the machine is at the location to Raised
dump. Also, move parking brake control (5) to the ON
position and move transmission control (6) to the When the dump body is raised, perform the following
NEUTRAL position. steps to return transmission control (6) to the
REVERSE position:
Note: If the parking brake is not engaged or if the
service brake is not applied, the machine may roll 1. Move the hoist control to HOLD position (3).
backward.
2. Move transmission control (6) to the NEUTRAL
With the hoist control in the RAISE position, depress
the throttle pedal to increase the engine speed. As position.
the hoist cylinders approach full extension, reduce
the engine speed. Reduce hand pressure on the hoist 3. Pause for three seconds.
control in order to slow the movement of the dump 4. Move the transmission control (6) to the REVERSE
body. This may avoid damage to the hoist cylinders.
position.
Move the hoist control to FLOAT position (2) in order
to lower the dump body. Leave the hoist control in i01923464
FLOAT position (2) until the dump body is completely
lowered.
Dumping
(Ejector Body Machines)
92
Operating Techniques
Dumping
SMCS Code: 7000
Use care when backing into the dump area.
Stay clear of soft edges that could collapse under
the machine.
Inspect the dump area before you bring in a loaded
machine.
Take care when you drive into the dump area.
Maintain a safe distance from other machines.
Avoid hitting sharp rocks.
Be certain that no personnel are near the dump area.
Park the machine on level ground. For the
recommended procedure, refer to Operation and
Maintenance Manual, “Stopping the Machine” for the
machine that is being serviced.
Ejecting
Illustration 180 g00942088
Before you move the hoist control to EJECT position
(3), make sure that the machine is at the location to
dump. Also, move the parking brake control to the ON
position and move the transmission control to the
NEUTRAL position.
Note: If the parking brake is not engaged or if the
service brake is not applied, the machine may roll
backward.
With the hoist control in the EJECT position, wait until
the tailgate is completely down before depressing the
throttle pedal to increase the engine speed. As the
ejector cylinders approach full extension, reduce the
engine speed. Reduce hand pressure on the hoist
control in order to slow the movement of the ejector
plate. This may avoid damage to the ejector
cylinders.
SEBU8906
When the body is empty move the hoist control to
RETRACT position (1) in order to retract the ejector
plate and raise the tailgate. Depress the throttle pedal
to increase the engine speed. As the ejector cylinders
fully retract, reduce the engine speed. Reduce hand
pressure on the hoist control in order to slow the
movement of the ejector plate and the tailgate.
Completely raise the tailgate before you pull out for
the return trip.
Note: Gears will be limited to a programmed gear
limit if the tailgate is down and/or the hoist control is
not in the HOLD position.
Reverse Neutralizer
The machine will not shift into reverse while the
tailgate is down or the hoist control is in EJECT
position (3) or in RETRACT position (1).
When the transmission is in reverse and the hoist
control is moved to EJECT position (3) or to
RETRACT position (1), the transmission will promptly
shift to neutral. If the machine is on a slope, apply the
brakes in order to stop the machine from moving. If
the reverse neutralizer must be bypassed, refer to
“Shifting into Reverse with the Tailgate Down” for the
procedure.
The reverse neutralizer has no effect on the forward
gears. If the situation is required, the forward gears
can be engaged from the NEUTRAL position or the
REVERSE position.
Shifting into Reverse with the Tailgate
Down
When the tailgate is down, perform the following
steps to return the transmission control to the
REVERSE position:
1. Move the hoist control to HOLD position (2).
2. Move the transmission control to the NEUTRAL
position.
3. Pause for three seconds.
4. Move the transmission control to the REVERSE
position.
SEBU8906
Parking
i01802282
Stopping the Machine
SMCS Code: 7000
Personal injury or death can result from not en-
gaging the parking brake.
If the parking brake is not engaged, the machine
may roll while personnel are on or near the
machine.
Always engage the parking brake before leaving
the machine.
NOTICE
Do not engage the parking brake while the machine is
moving unless the service brakes fail. The use of the
parking brake as a service brake in regular operation
will cause severe damage to the parking brake.
1. Park the machine on a level surface. If it is
necessary to park on a grade, block the wheels.
Illustration 181 g00927812
2. Release throttle pedal (2). Depress service brake
pedal (1) in order to stop the machine.
93
Parking
Stopping the Machine
Illustration 182 g00927813
3. After the machine is stopped, move transmission
control (4) to the NEUTRAL position.
4. Move parking brake control (3) to the ON position
in order to engage the parking brake.
Note: Do not use the retarder as a parking brake.
i05884037
Stopping the Engine
SMCS Code: 1000; 7000
1. Park the machine on level ground. For the
recommended procedure, refer to the Operation
and Maintenance Manual, “Stopping the Machine”
for the machine that is being serviced.
NOTICE
Stopping the engine immediately after it has been
working under load can result in overheating and ac-
celerated wear of the engine components.
If the engine has been operating at high rpm and/or
high loads, run at low idle for at least three minutes to
reduce and stabilize internal engine temperature be-
fore stopping the engine.
Avoiding hot engine shutdowns will maximize turbo-
charger shaft and bearing life.
2. In order to allow the engine to cool, operate the
engine at low idle for 3 minutes.
94 SEBU8906
Parking
Stopping the Engine if an Electrical Malfunction Occurs

Note: Do not operate the machine again until the

problem has been corrected.

i01761975

Leaving the Machine

SMCS Code: 7000

Illustration 183 g03709979

3. Turn engine start switch key (1) to the OFF position

in order to stop the engine.

NOTICE
Never turn the battery disconnect switch key to OFF
with the engine running. Electrical system damage
Illustration 185 g00901356
could result.

1. Use the steps and the handholds when you get off
4. If the machine is parked, block the wheels. the machine. Make sure the steps are clear of
debris before dismounting. Face the machine and
i01802288 maintain a three-point contact with the steps and
with the handholds.
Stopping the Engine if an
Note: Three-point contact can be two feet and one
Electrical Malfunction Occurs hand. Three-point contact can also be one foot and
SMCS Code: 1000; 7000 two hands.
2. Inspect the engine compartment for debris. Clean
out any debris and paper in order to avoid a fire.

3. Turn the battery disconnect switch to the OFF

position. Remove the battery disconnect switch
key. This will help to prevent a battery short circuit.
This will also help to protect the battery from any
possible current draw by components over
extended time periods.

NOTICE
Never turn the battery disconnect switch key to OFF
with the engine running. Electrical system damage
could result.
Illustration 184 g00927808

If the engine start switch is in the OFF position but the

engine does not stop, use the engine shutdown
switch to stop the engine.
Reference: For further information, refer to the
Operation and Maintenance Manual, “Engine
Shutdown Switch” for the machine that is being
serviced.
SEBU8906
Transportation Information
i01819249
Shipping the Machine
SMCS Code: 7000; 7500
Consult your Caterpillar dealer for shipping
instructions for your machine.
Investigate the travel route for overpass clearances.
Make sure that there is adequate clearance for the
machine that is being transported.
In order to prevent the machine from slipping during
loading or shifting in transit, remove ice, snow or
other slippery material. Remove these materials from
the loading dock and the area of the transport.
NOTICE
Obey all state and local laws governing the weight,
width and length of a load.
Make sure the cooling system has proper antifreeze if
moving machine to a colder climate.
Observe all regulations governing wide loads.
Illustration 186 g00901921
1. Block the trailer wheels or rail car wheels before
you load the machine (trailer shown).
2. After the machine is positioned, install the steering
frame lock in order to hold the front frame and the
rear frame in place.
3. Move the transmission control to the NEUTRAL
position.
4. Engage the parking brake.
5. Turn the engine start switch to the OFF position.
Remove the engine start switch key.
95
Transportation Information
Shipping the Machine
6. Turn the battery disconnect switch to the OFF
position. Remove the battery disconnect switch
key.
7. Lock the door and the access covers. Attach any
vandalism protection.
8. Secure the machine, any equipment and any tools
with adequate tie-downs in order to prevent
movement during shipping.
9. Cover the exhaust opening. The turbocharger
should not rotate when the engine is not operating.
Damage to the turbocharger can result.
i01762989
Roading the Machine
SMCS Code: 7000; 7500
Before you road a machine, consult your tire dealer
for recommended tire pressures and for speed
limitations.
Limitations for TON-kilometer per hour (TON-mile per
hour) must be obeyed. Consult your tire dealer for the
speed limit of the tires that are used.
When you travel for long distances, schedule stops in
order to allow the tires and the components to cool.
Stop for 30 minutes after every 40 km (25 miles) or
after every hour.
Perform a Walk-Around Inspection and measure the
fluid levels in each of the compartments.
Bring the engine coolant, the crankcase oil, and the
transmission oil up to the correct levels.
Inflate the tires to the correct pressure.
Use a self-attaching inflation chuck in order to inflate
the tire. Stand behind the tire tread while you inflate
the tires.
Reference: For information on tire inflation, refer to
the Operation and Maintenance Manual, “Tire
Inflation Information” for the machine that is being
serviced.
Check with the proper officials in order to obtain the
required licenses and other similar items.
Travel at a moderate speed. Observe all speed
limitations when you road the machine.
96 SEBU8906
Transportation Information
Lifting and Tying Down the Machine

i04004853

Lifting and Tying Down the Machine

SMCS Code: 7000; 7500

Illustration 187 g01972975

SEBU8906
A machine may shift if improper procedures or
equipment are used for lifting and tying down for
transport. Ensure that proper equipment and pro-
cedures are used for lifting and tying machines
down for transport. If a machine shifts it could
cause personal injury or death.
NOTICE
Improper lifting or tie-downs can allow the load to shift
and cause injury or damage. Install the steering frame
lock link before lifting.
Note: The machine shipping weights listed are the
weight of the most common configuration of the
machine. If additional attachments have been
installed on your machine, the weight of your machine
and the center of gravity of your machine may vary.
Reference: Refer to the Operation and Maintenance
Manual, “Model Views and Specifications” for the
dimensions of the machines.
Lift and Tie Down Messages
Lifting Point – This message is located
on points that are used to attach lifting
devices.
Tie Down Point – This message is
located on points that are used to attach
tie-downs.
Lifting the Machine
Each machine is equipped with lifting points. Install
the lifting lines to the designated lifting points.
For lifting objects, use properly rated lifting lines
(cables, chains, and straps) and use properly rated
lifting devices (tooling, spreader bars, slings, and
hardware). Position the crane for a level machine lift.
1. Park the machine on a level surface in the straight
ahead position, engage the parking brake, and
stop the engine.
2. Connect the steering frame lock.
3. Attach two lifting lines to the front lifting points.
There is a lifting point on each side of the front
bumper.
4. Attach two lifting lines to the rear lifting points if the
body is attached. If the body is not attached wrap a
sling or suitable tooling underneath the rear axle.
97
Transportation Information
Lifting and Tying Down the Machine
5. Connect the lifting lines to spreader bars or suitable
tooling in order to keep the lifting lines vertical
during lifting. The spreader bars must be centered
over the machine. The width of the spreader bar
should be sufficient to prevent the lifting lines from
contacting the machine.
6. Lift the machine.
Tying Down the Machine
Each machine is equipped with tie-down points.
Install the tie-downs to the designated tie-down
points.
1. Place the machine on the load platform. Engage
the parking brake and stop the engine.
2. Connect the steering frame lock.
3. Install wheel blocks or chocks to the front and rear
wheels, when possible. Place blocks under the
front wheels and under the rear wheels. If not
possible due to the design of the load platform,
place blocks or chocks in suitable locations in
order to prevent machine movement during
transportation.
4. Install tie-downs to the two tie-down points that are
located on the front bumper.
5. Install a tie-down over the top of the front axle on
each side of the machine.
6. Install a tie-down over the top of the rear axle on
each side of the machine.
7. Install two tie-downs to the rear tow point. Install
each tie-down at a different angle.
8. Check the appropriate laws that govern the weight
of the load, width of the load, length of the load,
and height of the load. If necessary, install
additional tie-downs in order to secure the machine
to a specific mode of transportation.
98 SEBU8906
Jacking Location Information
Jacking Locations

Jacking Location Note: Refer to Disassembly and Assembly, “Tire and

Rim - Remove and Install” for suitable stands and
Information their locations.
The stands should be placed on level ground. The
i01854847 stands should provide a large base for support. Only
use stands that will support the weight of the
Jacking Locations machine.
SMCS Code: 7000 Once the stands are in place, lower the jack until the
machine is fully supported by the stands.
Jacking Locations Make sure that the machine is stable before you
proceed to work on the machine.
Park the machine on level ground. Engage the
parking brake. Stop the engine. Refer to Operation
and Maintenance Manual, “Machine Parking” for
further information.
Note: Empty the body before you jack up the
machine.

Raising with a Jack and Supporting with

Stands
Place the jack in a location that will sustain the weight
of the machine such as a frame member. The frame
member should be parallel to the ground. The head of
the jack should be against a flat surface. Use a jack
which will support the weight of the machine.

Illustration 188 g00945878

Suitable places (1) and (2) for jacking up the machine

are shown in Illustration 188 . These locations are
part of the front frame and the rear frame. A jack with
a lifting capacity of 25000 kg (55120 lb) is required to
lift the machine in position (1). A jack with a lifting
capacity of 15000 kg (33070 lb) is required to lift the
machine in position (2).
Jack up the machine to the required height. Place
stands at suitable locations under the machine.
SEBU8906
Towing Information
i01807168
Towing the Machine
SMCS Code: 7000
Personal injury or death could result when towing
a disabled machine incorrectly.
Block the machine to prevent movement before
releasing the brakes. The machine can roll free if
it is not blocked.
This machine is equipped with a spring engaged oil
pressure disengaged parking brake. If the engine
cannot be run, the oil pump will be inoperable and this
will prevent the disengaging of the parking brake with
the parking brake control that is located in the
operator station.
The parking brake can be disengaged manually in the
event of insufficient oil pressure in the system. For
additional information, refer to Operation and
Maintenance Manual, “Parking Brake Manual
Release” for the machine that is being serviced.
These towing instructions are for moving a disabled
machine for a short distance at low speed. Move the
machine at a speed of 2 km/h (1.2 mph) or less to a
convenient location for repair. Always haul the
machine if long distance moving is required.
Shields must be provided on both machines. This will
protect the operator if either the tow line or the bar
breaks.
Do not allow an operator to be on the machine that is
being towed unless the operator can control the
steering and/or braking.
Before towing, make sure that the tow line or the bar
is in good condition. Make sure that the tow line or the
bar has enough strength for the towing procedure that
is involved. The strength of the towing line or bar
should be at least 150 percent of the gross weight of
the towing machine. This is true for a disabled
machine that is stuck in the mud and for towing on a
grade.
When you tow the machine from the front, only attach
the tow line to the front tow pin. When you tow the
machine from the rear, only attach the tow line to the
rear tow pin.
99
Towing Information
Towing the Machine
Do not use a chain for pulling a disabled machine. A
chain link can break. This may cause possible
personal injury. Use a wire cable with ends that have
loops or rings. Put an observer in a safe position in
order to watch the pulling procedure. The observer
can stop the procedure, if necessary. The procedure
should be stopped if the cable starts to break. Also,
stop the procedure if the cable starts to unravel. Stop
pulling whenever the towing machine moves without
moving the towed machine.
Keep the tow line angle to a minimum. Do not exceed
a 30 degree angle from the straight ahead position.
When you tow the machine from an angle, always
steer the tires of the machine that is being towed in
the direction that it is being towed.
Quick machine movement could overload the tow line
or the bar. This could cause the tow line or the bar to
break. Gradual, steady machine movement will be
more effective.
Normally, the towing machine should be as large as
the disabled machine. Make sure that the towing
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 involved
and for the distance that is involved.
You must provide sufficient control and sufficient
braking when you are moving a disabled machine
downhill. This may require a larger towing machine or
additional machines that are connected to the rear.
This will prevent the machine from rolling away out of
control.
All situation requirements cannot be listed. Minimal
towing machine capacity is required on smooth level
surfaces. Maximum towing machine capacity is
required on inclines and on surfaces in poor
condition.
Consult your Caterpillar dealer for additional details
about towing a disabled machine.
Note: If possible, dump the load before you attempt
to move the machine. When any towed machine is
loaded, ensure that the brake system of that machine
is operable before starting towing.
Towing with an Inoperable Engine
NOTICE
Certain Caterpillar machines may be equipped with
an optional secondary steering system.
The secondary steering system provides emergency
steering only while the machine is in motion.
If your machine is equipped with secondary steering,
do not reverse the hydraulic steering hoses. The sec-
ondary steering system can be used to safely steer
the machine while it is being towed.
Perform the following steps before you tow the
machine.
100
Towing Information
Towing the Machine
Illustration 189 g00995243
(A) Head end (upper connection), rod end (lower connection)
1. Block the wheels. Reverse the hydraulic steering
hose connections for one cylinder only. This will
allow the steering cylinders to move freely.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and sup-
plies suitable to collect and contain fluids on Caterpil-
lar products.
Dispose of all fluids according to local regulations and
mandates.
NOTICE
Be sure the cylinder hoses are connected correctly
before operating the machine. With the hoses re-
versed, the steering system will not function.
2. If failure of the internal transmission or of the drive
line is suspected, remove the axle shafts.
Note: Removing the axle shafts will disable the
secondary steering system if equipped.
Reference: For information on removing the axle
shafts, refer to the Power Train, Disassembly and
Assembly, “Axle Shafts - Remove” for the machine
that is being serviced.
3. If possible, dump the load.
4. Fasten the tow line.
SEBU8906
5. Manually release the parking brake.
Reference: For information about the manual
release of the parking brake, refer to the Operation
and Maintenance Manual, “Parking Brake Manual
Release” for the machine that is being serviced.
NOTICE
Release the parking brake to prevent excessive wear
and damage to the parking brake system when tow-
ing the machine.
6. Remove the wheel blocks. Tow the machine slowly.
Do not exceed 2 km/h (1.2 mph).
Personal injury or death can occur from a brake
malfunction.
Make sure all necessary repairs and adjustments
have been made before a machine that has been
towed to a service area is put back into operation.
Towing with an Operable Engine
If the engine can be run during towing and there is no
fault with the steering system, an operator can steer
the disabled machine.
An operator can use the brakes to slow down the
machine during towing, if there are no faults in the
braking system.
Failure of a final drive, differential or transmission will
require machine towing. In order to allow the machine
to be towed, remove the corresponding axle shaft.
Reference: For information on removing the axle
shafts refer to Power Train, Disassembly and
Assembly, “Axle Shafts - Remove” for the machine
that is being serviced.
NOTICE
If the power train and steering system are operable
and the engine is running, the machine can be towed
a short distance, pulled out of mud or to the side of
the road.
The operator on the towed machine must steer in the
direction of the tow line.
Inspect the machine thoroughly, repair any damage
before returning the machine to operation.
SEBU8906 101
Towing Information
Equipment Lowering with Engine Stopped

i02228974

Equipment Lowering with

Engine Stopped
SMCS Code: 7000
If a fault has occurred on the machine and the engine
has stopped, the dump body may need to be lowered.
Note: Before you lower the dump body, make sure
that the area around the machine is clear of all
personnel.

1. Engage the parking brake.

Illustration 191 g00996879
2. Install the steering frame lock. Block the wheels.
3. Loosen nut (1).

4. Turn valve assembly (2) counterclockwise until the

valve assembly contacts the stop.

Note: To stop lowering the dump body turn valve

assembly (2) clockwise.
5. If the dump body lowers go to Step 7. If the dump
body does not lower go to Step 6.

Illustration 190 g00996872

Location of the lowering control valve

Note: The lowering control valve is a part of the hoist

control valve. The hoist control valve is located in the
transmission compartment.

NOTICE
Do not access the lowering control valve by opening
the rear transmission cover. If the machine is fully ar-
ticulated, damage to the rear transmission cover may Illustration 192 g00997190
occur when the dump body lowers. Access the lower-
ing control valve by opening the center transmission 6. Have an assistant position a suitable lifting jack (4)
cover.
under dump body (3). Raise the jack until it
touches the dump body. Raise the jack an
additional 100 mm (4 inch) or until the dump body
begins to lower.

7. When the dump body has fully lowered turn valve

assembly (2) clockwise until the valve assembly
stops. Tighten nut (1) to a torque of 50 ± 7 N·m
(37 ± 5 lb ft).

8. Remove the steering frame lock. Remove the

blocks from the wheels.
102 SEBU8906
Towing Information
Parking Brake Manual Release

i05884039 2. Depress the service brake pedal at least 80 times

to release the oil pressure from the brake hydraulic
Parking Brake Manual Release system.
SMCS Code: 4267; 7000
3. Press and hold the breaker relief valve to release
any pressure in the hydraulic tank.

Personal injury or death can result from a brake

malfunction. Do not operate the machine if the
brake was applied due to a malfunction of the oil
system or the brake.
Correct any problem before attempting to operate
the machine.

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem- Illustration 194 g00993367
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products.
Dispose of all fluids according to local regulations and
mandates.

Illustration 195 g03709983

4. Remove the caps from quick connect couplers (2)

and (3). Connect the hydraulic hoses from the
portable hydraulic pump to quick connect couplers
(2) and (3).

Illustration 193 g00943687 5. Turn the battery disconnect switch to the ON

Portable hydraulic pump position.

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

1. Connect plug (1) of the 212-6102 Portable
Hydraulic Pump to the machine's 24 V DC power
supply.
Note: The machine batteries must be fully charged
for the operation of the portable hydraulic pump. If
battery charge is low, connect to an external 24 V DC
power supply.
7. Connect a 4C-8195 Control Service Tool and a
257-8717 Cable Adapter to the service tool port.
Reference: For information on using the 4C-8195
Control Service Tool, refer to the Service Manual,
"Caterpillar Monitoring System" for the machine that
is being serviced.
SEBU8906
Illustration 196 g00993369
8. Use the control service tool to access Mode 7.7
(Transmission Pressure Override) on the
Caterpillar Monitoring System display window (7).
The default display window reading is "PO-OFF".
9. Operate the clear switch on the control service tool
to change the display window reading to "PO-ON".
Note: Leave the Caterpillar Monitoring System in
Mode 7.7 until the procedure has been completed.
Changing to another mode will cause the Caterpillar
Monitoring System to revert to the default setting and
the parking brake will not disengage.
Illustration 197 g00943691
10. Position switch (8) (from the portable hydraulic
pump) inside the operator station.
103
Towing Information
Parking Brake Manual Release
11. Press and hold switch (8) in the ON position to
activate the portable hydraulic pump. Brake
accumulator oil pressure indicator (4) will go out
when the braking system has full oil pressure.
Note: Operation of the switch should only take place
from inside the operator station. Observe brake
indicators and gauges (if equipped) while operating
the portable hydraulic pump.
12. When the braking system has full oil pressure,
move parking brake control (6) to the OFF position
to disengage the parking brake. Hold switch (8) in
the ON position until parking brake indicator (5) on
the Caterpillar Monitoring System panel goes out.
The parking brake is now disengaged.
Note: The service brakes can be used to stop the
machine when the machine has brake oil pressure.
Use the service brakes to control the machine when
the machine is being towed.
Note: Using the service brakes will cause the braking
system oil pressure to decrease. If brake accumulator
oil pressure indicator (4) comes on, operate the
portable hydraulic pump to increase the braking
system pressure. Ensure that the braking system
pressure is maintained for the duration of the towing.
NOTICE
Operating the portable hydraulic pump for extended
periods of time may cause overheating and possible
damage of the electric motor. If overheating is ob-
served, stop operating the portable hydraulic pump
and allow it time to cool before towing is continued.
13. To steer the machine while being towed, press
and hold switch (8) to ensure that the system oil
pressure is maintained for the duration of the
towing.
Note: For the removal of the portable hydraulic pump
from the machine, refer to Steps 14 through 17.
Note: Turning the engine start switch to the OFF
position will change the Caterpillar Monitoring
System Mode 7.7 to the default setting.
14. Turn the engine start switch to the OFF position.
15. Repeat Steps 2 through 3.
16. Disconnect and remove the portable hydraulic
pump from the machine.
17. Install the caps on the quick connect couplers.
104 SEBU8906
Maintenance Section
Tire Inflation with Nitrogen

Maintenance Section i05884040

Tire Shipping Pressure

Tire Inflation Information SMCS Code: 4203-PX; 7500
The following table contains the cold tire shipping
i01763544 pressures.
Table 6
Tire Inflation with Nitrogen Shipping Pressure
Ply Rating or
SMCS Code: 4203-PX; 7500 Tire Size
Strength Index
Front Rear
Caterpillar recomends the use of dry nitrogen gas for 650 kPa 650 kPa
Bridgestone Multi
tire inflation and for tire pressure adjustments. This 26.5-R25
(94 psi) (94 psi)
Star
includes all machines with rubber tires. Nitrogen is an
inert gas that will not aid combustion inside the tire. Bridgestone Two 650 kPa 650 kPa
26.5-R25
Star (94 psi) (94 psi)

Note: The "R" in the tire size signifies radial

Proper nitrogen inflation equipment, and training
in using the equipment, are necessary to avoid
over inflation. A tire blowout or rim failure can re-
sult from improper or misused equipment and
personal injury or death can occur.
A tire blowout and/or rim failure can occur if the
inflation equipment is not used correctly, due to
the fact that a fully charged nitrogen cylinder's
pressure is approximately 15000 kPa (2200 psi).
There are other benefits to using nitrogen in addition
to reducing the risk of an explosion. The use of
nitrogen for tire inflation lessens the slow oxidation of
the rubber. Use of nitrogen also slows gradual tire
deterioration. This is especially important for tires that
are expected to have a long service life of at least
four years. Nitrogen reduces the corrosion of rim
components. Nitrogen also reduces problems that
result from disassembly.
A tire blowout or a rim failure can cause personal
injury.
Use a self-attaching inflation chuck and stand be-
hind the tread when inflating a tire, to prevent per-
sonal injury.
construction.
The tire inflation pressure is based on the weight of a
ready-to-work machine without attachments, at rated
payload, and in average operating conditions. The
tire pressures for each application may vary. Always
obtain the proper pressures from your tire supplier.
i01763687
Tire Inflation Pressure
Adjustment
SMCS Code: 4203-025-PX; 7500
The tire pressure in a warm shop area 18° to 21°C
(65° to 70°F) will significantly change when you move
the machine into freezing temperatures. If you inflate
the tire to the correct pressure in a warm shop, the
tire will be underinflated in freezing temperatures.
Low pressure shortens the life of a tire.
Reference: When you operate the machine in
freezing temperatures, refer to Operation and
Maintenance Manual, SEBU5898, “Cold Weather
Recommendations” in order to adjust tire inflation
pressures.

Note: Do not set the tire inflation equipment regulator

higher than 140 kPa (20 psi) over the recommended
tire pressure.
Use 6V-4040 Inflation Group or an equivalent
inflation group to inflate tires with a nitrogen gas
cylinder. Refer to Special Instruction, SMHS7867 for
tire inflation instructions.
For nitrogen inflation, use the same tire pressures
that are used for air inflation. Consult your tire dealer
for operating pressures.
SEBU8906
Lubricant Viscosities and
Refill Capacities
i05271850
Lubricant Viscosities
SMCS Code: 1000; 7000; 7581
The oil viscosities shown in bold type in the following
table are the standard oils used in Caterpillar AD30
machines. If the ambient temperatures you operate in
do not fall within the standard oil temperature range,
choose an oil that meets the required ambient
temperature range.
General Information for Lubricants
When you are operating the machine in temperatures
below −20°C (−4°F), refer to Operation and
Maintenance Manual, SEBU5898, “Cold Weather
Recommendations”. This publication is available from
your Cat dealer.
Refer to the “Lubricant Information” section in the
latest revision of the Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” for a
list of Cat engine oils and for detailed information.
This manual may be found on the Web at Safety.Cat.
com.
The footnotes are a key part of the tables. Read ALL
footnotes that pertain to the machine compartment in
question.
Selecting the Viscosity
In order to select the proper oil for each machine
compartment, refer to the “Lubricant Viscosity for
Ambient Temperature” table. Use the oil type AND oil
viscosity for the specific compartment at the proper
ambient temperature.
The proper oil viscosity grade is determined by the
minimum ambient temperature (the air in the
immediate vicinity of the machine). Measure the
temperature when the machine is started and while
the machine is operated. In order to determine the
proper oil viscosity grade, refer to the “Min” column in
the table. This information reflects the coldest
ambient temperature condition for starting a cold
machine and for operating a cold machine. Refer to
the “Max” column in the table for operating the
machine at the highest temperature that is
anticipated. Unless specified otherwise in the
“Lubricant Viscosities for Ambient Temperatures”
tables, use the highest oil viscosity that is allowed for
the ambient temperature.
105
Lubricant Viscosities and Refill Capacities
Lubricant Viscosities
Machines that are operated continuously should use
oils that have the higher oil viscosity in the final drives
and in the differentials. The oils that have the higher
oil viscosity will maintain the highest possible oil film
thickness. Refer to “General Information for
Lubricants” article, “Lubricant Viscosities” tables, and
any associated footnotes. Consult your Cat dealer if
additional information is needed.
NOTICE
Not following the recommendations found in this man-
ual can lead to reduced performance and compart-
ment failure.
Engine Oil
Cat oils have been developed and tested in order to
provide the full performance and life that has been
designed and built into Cat engines.
Cat DEO-ULS or oils that meet the Cat ECF-3
specification and the API CJ-4 are required for use in
the applications listed below. Cat DEO-ULS and oils
meeting Cat ECF-3 specification and the API CJ-4
and ACEA E9 oil categories have been developed
with limited sulfated ash, phosphorus, and sulfur.
These chemical limits are designed to maintain the
expected aftertreatment devices life, performance,
and service interval. If oils meeting the Cat ECF-3
specification and the API CJ-4 specifications are not
available, oils meeting ACEA E9 may be used. ACEA
E9 oils meet the chemical limits designed to maintain
aftertreatment device life. ACEA E9 oils are validated
using some but not all ECF-3 and API CJ-4 standard
engine performance tests. Consult your oil supplier
when considering use of an oil that is not Cat ECF-3
or API CJ-4 qualified.
Failure to meet the listed requirements will damage
after-treatment-equipped engines and can negatively
impact the performance of the after-treatment
devices.
Typical after-treatment systems include the following:
• Flow Through Diesel Particulate Filter (FTDPF)
• Diesel Particulate Filters (DPF)
• Diesel Oxidation Catalysts (DOC)
• Selective Catalytic Reduction (SCR)
• Lean NOx Traps (LNT)
Other systems may apply.
106 SEBU8906
Lubricant Viscosities and Refill Capacities
Lubricant Viscosities

Table 7
Lubricant Viscosities for Ambient Temperatures

°C °F
Compartment or System Oil Type and Classification Oil Viscosities
Min Max Min Max
Cat DEO-ULS Cold Weather(1) SAE 0W-40 −40 22 −40 72

Cat DEO-ULS SYN(1)

SAE 5W-40 −30 50 −22 122
Cat DEO SYN
Engine Crankcase
Cat DEO-ULS(1)
SAE 10W-30 −18 40 0 104
Cat DEO
Cat DEO-ULS(1)
SAE 15W-40 −9.5 50 15 122
Cat DEO
(1) Cat DEO-ULS or commercial oils meeting Cat ECF-3 specification are recommended for use in diesel engines that are equipped with Diesel
Particulate Filters (DPF) and other aftertreatment devices.

When fuels of sulfur level of 0.1 percent (1000 ppm)

or higher are used, Cat DEO-ULS may be used if
S·O·S oil analysis program is followed. Base the oil
change interval on the oil analysis.

Note: Failure to follow oil analysis recommended oil

change interval may result in reduced engine
component life.

Transmission
Refer to the “Lubricant Information” section in the
latest revision of the Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” for
detailed information. This manual may be found on
the Web at Safety.Cat.com.
When you are operating the machine in temperatures
below −20°C (−4°F), refer to Special Publication,
SEBU5898, “Cold Weather Recommendations”. This
publication is available from your Cat dealer.
Table 8
Lubricant Viscosities for Ambient Temperatures

°C °F
Compartment or System Oil Type and Classification Oil Viscosities
Min Max Min Max
SAE 0W20(1) −40 22 −40 72

SAE 0W30(1) −40 30 −40 86

SAE 5W30(1) −30 30 −22 86

Caterpillar TDTO
Transmission Caterpillar TDTO-TMS SAE 10W −20 22 −4 72
commercial TO-4
SAE 30 10 50 50 122
SAE 50(2) 30 50 86 122

TDTO-TMS (3) 10 50 50 122

(1) First Choice: Oils of full synthetic base stock without viscosity index improvers that meet the performance requirements of the TO-4 specifica-
tion for the SAE 30 viscosity grade. Typical lubricant viscosity grades are SAE 0W20, SAE 0W30, and SAE 5W30. Second Choice: Oils that
contain a TO-4 additive package and a lubricant viscosity grade of SAE 0W20, SAE 0W30 and SAE 5W30.
(2) SAE 50 is the preferred viscosity grade for machines operating with a high load factor and constant ambient temperature conditions above
30 °C (86 °F).
(3) TDTO-TMS Transmission Multi-Season (exceeds the TO-4/TO-4M multigrade specification requirements).
SEBU8906 107
Lubricant Viscosities and Refill Capacities
Lubricant Viscosities

Hydraulic Systems
Refer to the “Lubricant Information” section in the
latest revision of the Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” for
detailed information. This manual may be found on
the Web at Safety.Cat.com.
The following are the preferred oils for use in most
Cat machine hydraulic systems:
Table 9
Lubricant Viscosities for Ambient Temperatures

°C °F
Compartment or System Oil Type and Classification Oil Viscosities
Min Max Min Max
SAE 0W20(1) -40 40 -40 104
Caterpillar TDTO
Hydraulic Systems SAE 10W -20 50 -4 122
commercial TO-4
SAE 30 −15 50 5 122
(1) First Choice: Oils of full synthetic base stock without viscosity index improvers that meet the performance requirements of the TO-4 specifica-
tion for the SAE 30 viscosity grade. Typical lubricant viscosity grades are SAE 0W20, SAE 0W30, and SAE 5W30. Second Choice: Oils that
contain a TO-4 additive package and a lubricant viscosity grade of SAE 0W20, SAE 0W30 and SAE 5W30.

Differential and Final Drive

Refer to the “Lubricant Information” section in the
latest revision of the Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” for
detailed information. This manual may be found on
the Web at Safety.Cat.com.
When you are operating the machine in temperatures
below −20°C (−4°F), refer to Special Publication,
SEBU5898, “Cold Weather Recommendations”. This
publication is available from your Cat dealer.
Table 10
Lubricant Viscosities for Ambient Temperatures

°C °F
Compartment or System Oil Type and Classification Oil Viscosities
Min Max Min Max
SAE 10W −25 0 −13 32
SAE 30 −20 20 −4 68
Caterpillar FDAO
Differentials and Final Drives Caterpillar TDTO-TMS SAE 50 -10 43 14 110
commercial TO-4
SAE 60 -5 50 23 122
TDTO-TMS(1) -5 50 23 122
(1) SAE 50 is the preferred viscosity grade for machines operating with a high load factor and constant ambient temperature conditions above
30 °C (86 °F).

Special Lubricants
Grease
In order to use a non-Cat grease, the supplier must
certify that the lubricant is compatible with Cat
grease.
Each pin should be flushed with the new grease.
Ensure that all old grease is removed. Failure to meet
this requirement may lead to failure of a pin joint.
108 SEBU8906
Lubricant Viscosities and Refill Capacities
Lubricant Viscosities

Table 11
Recommended Grease for Ambient Temperatures

°C °F
Compartment or System GreaseType NLGI Grade
Min Max Min Max
Cat Advanced 3Moly NLGI Grade 2 −20 40 −4 104

NLGI Grade 2 −30 50 −22 122

Cat Ultra 5Moly NLGI Grade 1 −35 40 −31 104
External Lubrication Points
NLGI Grade 0 −40 35 −40 95
Cat Arctic Platinum NLGI Grade 0 −50 20 −58 68
Cat Desert Gold NLGI Grade 2 −20 60 −4 140
Cat Multipurpose Grease NLGI Grade 2 −30 40 −22 104
Drive Shaft Universal Joints(1)
Drive Shaft Support Bearing
Hand Rail Pivots Exxon Mobil Mobilith SHC
NLGI Grade 2 -20 55 -4 131
220
Cat High Speed Bearing
Fan Drive Bearings NLGI Grade 2 -20 40 -4 104
Grease
(1) Use lithium complex grease. The use of molybdenum disulphide additives in the drive shaft universal joints can reduce expected service life.

Grease for the Autolube System

The grease used with the automatic lubrication
system must not contain any graphite or PTFE.

Note: Pumpability is based on “US Steel Mobility and

Lincoln Ventmeter Tests”. Performance may vary
depending on lubrication equipment and the length of
the lines.
Reference: Refer to Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” for
additional information about grease. This manual may
be found on the Web at Safety.Cat.com.
Table 12
Recommended Grease for the Autolube System

°C °F
Compartment or System GreaseType NLGI Grade
Min Min
Cat Advanced 3Moly NLGI Grade 2 −18 0

NLGI Grade 2 −7 20
Cat Ultra 5Moly NLGI Grade 1 −18 0
Autolube System
NLGI Grade 0 −29 −20
Cat Arctic Platinum NLGI Grade 0 −43 −45
Cat Desert Gold NLGI Grade 0 2 35
SEBU8906
Diesel Fuel Recommendations
Diesel fuel must meet Caterpillar Specification for
Distillate Fuel and the latest revisions of “ASTM
D975-09a” and “EN 590” in order to ensure optimum
engine performance. Refer to Special Publication,
SEBU6250, “Caterpillar Machine Fluids
Recommendations” for the latest fuel information and
for Cat fuel specification. This manual may be found
on the Web at Safety.Cat.com.
Illustration 198 g02052934
Misfueling with fuels of higher sulfur level can have
the following negative effects:
• Adversely impact the performance and life of
aftertreatment devices (cause loss of
performance)
• Reduce regeneration intervals of aftertreatment
devices
• Reduce engine efficiency and durability.
• Increase the wear.
• Increase the corrosion.
• Increase the deposits.
• Lower fuel economy
• Shorten the time period between oil drain intervals
(more frequent oil drain intervals).
• Increase overall operating costs.
Failures that result for the use of improper fuels are
not Caterpillar factory defects. Therefore, the cost of
repairs would not be covered by a Caterpillar
warranty.
Caterpillar does not require the use of ULSD in non-
road and machine applications that are not Tier 4/
Stage IIIB/ Stage IV certified engines and are not
equipped with aftertreatment devices. Always follow
operating instructions and fuel tank inlet labels to
insure the correct fuels are used.
109
Lubricant Viscosities and Refill Capacities
Lubricant Viscosities
Refer to Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” for more details
about fuels, lubricants. This manual may be found on
the Web at Safety.Cat.com.
Fuel Additives
Cat Diesel Fuel Conditioner and Cat Fuel System
Cleaner are available for use when needed. These
products are applicable to diesel and biodiesel fuels.
Consult your Cat dealer for availability.
Biodiesel
Biodiesel is a fuel that can be made from various
renewable resources that include vegetable oils,
animal fat, and waste cooking oil. Soybean oil and
rapeseed oil are the primary vegetable oil sources. In
order to use any of these oils or fats as fuel, the oils or
fats are chemically processed (esterified). The water
and contaminants are removed.
U.S. distillate diesel fuel specification “ASTM D975-
09a” includes up to B5 (5 percent) biodiesel.
Currently, any diesel fuel in the U.S. may contain up
to B5 biodiesel fuel.
European distillate diesel fuel specification “EN 590”
includes up to B5 (5 percent) and in some regions up
to B7 (7 percent) biodiesel. Any diesel fuel in Europe
may contain up to B5 or in some regions up to B7
biodiesel fuel.
Note: Up to B20 biodiesel blend level is acceptable
for use in Underground Articulated Truck engines.
When biodiesel fuel is used, certain guidelines must
be followed. Biodiesel fuel can influence the engine
oil, aftertreatment devices, non-metallic, fuel system
components, and others. Biodiesel fuel has limited
storage life and has limited oxidation stability. Follow
the guidelines and requirements for engines that are
seasonally operated and for standby power
generation engines.
In order to reduce the risks associated with the use of
biodiesel, the final biodiesel blend and the biodiesel
fuel used must meet specific blending requirements.
All the guidelines and requirements are provided in
the latest revision of Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations”. This
manual may be found on the Web at Safety.Cat.com.
Coolant Information
The information provided in this “Coolant
Recommendation” section should be used with the
“Lubricants Information” provided in the latest revision
of Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations”. This manual
may be found on the Web at Safety.Cat.com.
The following two types of coolants may be used in
Cat diesel engines:
Preferred – Cat ELC (Extended Life Coolant)
110 SEBU8906
Lubricant Viscosities and Refill Capacities
Capacities (Refill)

Acceptable – Cat DEAC (Diesel Engine Antifreeze/

Coolant)

NOTICE
Never use water alone as a coolant. Water alone is
corrosive at engine operating temperatures. In addi-
tion, water alone does not provide adequate protec-
tion against boiling or freezing.

i05703189

Capacities (Refill)
SMCS Code: 7560
Table 13
Approximate Refill Capacities

Compartment or US Imperial
System Liters Gallons Gallons
Engine Crankcase with
38 10 8.4
Filter
Transmission 67 17.7 14.7
Hydraulic Tank 210 55.5 46.2

Cooling System 76 20 16.7

Front Differential and Final

56 14.8 12.3
Drives
Rear Differential and Final
56 14.8 12.3
Drives
Fuel Tank 500 132 109
SEBU8906
Maintenance Locations
Filter and Screen Locations
SMCS Code: 1000; 1050; 3000; 4000; 4250; 4300;
5050; 7000
Illustration 199
(1) Engine oil filter
(2) Brake oil cooler screen
(3) Breaker relief valve
(4) Hydraulic tank screens
(5) Engine air filters
(6) Steering system oil filters
(7) Front axle breather
i01851117
(8) Transmission breather
(9) Rear axle breather
(10) Primary fuel filter
(11) Secondary fuel filter
(12) Cab pressurizer filter
(13) Transmission magnetic screen
(14) Torque converter sump screen
111
Maintenance Locations
Filter and Screen Locations
g00942949
(15) Transmission oil filters
(16) Hydraulic system pilot oil filters
(17) Automatic lubrication system inline filter
(if equipped)
(18) Automatic lubrication system filler filter
(if equipped)
112 SEBU8906
Maintenance Locations
Sampling Interval and Location of Sampling Valve

i05792771 Location of Sampling Valves

Sampling Interval and Location
of Sampling Valve
SMCS Code: 1000; 1318; 1348; 3080; 4070; 4250;
4300; 5050; 7000; 7542

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Dealer Illustration 200 g03670897
Service Tool Catalog” for tools and supplies suitable Sampling valve for the engine oil
to collect and contain fluids on Cat products.
Dispose of all fluids according to local regulations and The sampling valve for the engine oil is located on the
mandates. right side of the engine above the engine oil filter.

Take the oil samples as close as possible to the

standard intervals. To receive the full value from the
S·O·S oil analysis, establish a consistent trend of
data. To establish a pertinent history of data, perform
consistent oil samplings at set intervals.
Operate the machine for a few minutes before
obtaining the oil sample. Operating the machine will
thoroughly mix the oil for a more accurate sample.

Reference: Refer to Special Publication, PEHP6001,

“How to Take a Good Oil Sample” for more
information about obtaining an oil sample.
Table 14
Illustration 201 g00942953
Change Sampling Sampling
Type of Fluid Sampling valve for the transmission and torque
Interval Interval Valve
converter oil
Engine Oil 250 Hours 250 Hours Yes(1)
The sampling valve for the transmission and torque
Transmission Oil 1000 Hours 500 Hours Yes(1) converter oil is located on the manifold mounted to
Hydraulic Oil Yes(1)
the front of the transmission housing.
1000 Hours 500 Hours

Differential and Fi-

2000 Hours 500 Hours No
nal Drive Oil
Coolant 6000 Hours 500 Hours No
(1) Machines may be equipped with optional sampling valves

Consult your Cat dealer for complete information and

for assistance in establishing an S·O·S program for
your equipment.

Illustration 202 g00942954

Sampling valve for the hydraulic system oil
SEBU8906 113
Maintenance Locations
Sampling Interval and Location of Sampling Valve

The sampling valve for the hydraulic system oil is

located on the manifold mounted to the right side of
the transmission compartment.

Illustration 206 g03670898

The cooling system is not equipped with a sampling

Illustration 203
Sampling port for the final drive oil
g00942959 valve. Obtaining a sample of the coolant will require a
vacuum pump or an equivalent. Lift the lever on the
pressure cap to relieve the cooling system pressure.
Remove the pressure cap and withdraw the coolant
through the filler opening.

More Frequent S·O·S Sampling

Improves Life Cycle Management
Traditionally, the suggested S·O·S sampling intervals
have been at each oil change (250 hours for engines
and every 500 hours for all other compartments).
However, more frequent oil sampling is
recommended in severe applications. If the machine
is operated under a high load and/or in high
temperature conditions, sample all compartments at
every 250 hour interval.

Illustration 204
Sampling port for the front differential oil
Application
g00942960
Studies reveal that obtaining oil samples at every 500
hours intervals is too great in some applications in
order to predict potential failure modes. A sampling
interval at every 250 hours provides more data
between oil change intervals. More data increases
the chance for detecting a potential failure.

Determining Optimum Oil Change

Illustration 205
Sampling port for the rear differential oil
Intervals
Sampling the compartments at every 250 hours
provides information for oil condition and for oil
performance. This information is used to determine
the optimum usable life of a particular oil. Also, more
points of data will allow closer monitoring of
component wear rates. Close monitoring also allows
you to obtain the maximum use of the oil. For detailed
g00943247 information about extending oil change intervals,
consult your Cat dealer.
114 SEBU8906
Maintenance Locations
Sampling Interval and Location of Sampling Valve

Optimizing the Component Life Cycle

An increase in the number of oil samples provides a
better definition of the trends in data between oil
change intervals. More oil samples will allow you to
monitor wear patterns of components. This action will
ensure that a prolonged service life of the
components is achieved.
The standard interval that is used between S·O·S oil
samples is 250 hours for all Caterpillar engines. While
500 hour oil sample intervals remain acceptable for
non-engine compartments, these intervals are not
necessarily optimum. If the machine is operated
under a high load and/or high temperature condition,
sample all compartments at the 250 hour interval.
SEBU8906 115
Maintenance Support
Welding on Machines and Engines with Electronic Controls

Maintenance Support 5. Use standard welding procedures in order to weld

the materials together.
i03636245
i04807435

Welding on Machines and Severe Service Application

Engines with Electronic SMCS Code: 1000; 7000
Controls
An engine which operates outside of normal
SMCS Code: 1000; 7000 conditions is operating in a severe service
application.
Do not weld on any protective structure. If it is
necessary to repair a protective structure, contact An engine that operates in a severe service
your Caterpillar dealer. application may need more frequent maintenance
intervals in order to maximize the following
Proper welding procedures are necessary in order to conditions:
avoid damage to the electronic controls and to the
bearings. When possible, remove the component that • Reliability
must be welded from the machine or the engine and
then weld the component. If you must weld near an • Service life
electronic control on the machine or the engine,
temporarily remove the electronic control in order to The number of individual applications cause the
prevent heat related damage. The following steps impossibility of identifying all of the factors which may
should be followed in order to weld on a machine or contribute to severe service operation. Consult your
an engine with electronic controls. Caterpillar dealer for the unique maintenance that
may be necessary for your engine.
1. Turn off the engine. Place the engine start switch in
the OFF position. An application is a severe service application if any of
the following conditions apply:
2. If equipped, turn the battery disconnect switch to
the OFF position. If there is no battery disconnect Severe Environmental Factors
switch, remove the negative battery cable at the
• Frequent operation in dirty air
battery.
• Frequent operation at an altitude which is above
1525 m (5000 ft)
NOTICE
Do NOT use electrical components (ECM or sensors) • Frequent operation in ambient temperatures which
or electronic component grounding points for ground- are above 32° C (90° F)
ing the welder.
• Frequent operation in ambient temperatures which
are below 0° C (32° F)
3. Clamp the ground cable from the welder to the
component that will be welded. Place the clamp as
close as possible to the weld. Make sure that the
electrical path from the ground cable to the
component does not go through any bearing. Use
this procedure in order to reduce the possibility of
damage to the following components:

• Bearings of the drive train

• Hydraulic components

• Electrical components

• Other components of the machine

4. Protect any wiring harnesses and components

from the debris and the spatter which is created
from welding.
116
Maintenance Support
Severe Service Application
Severe Operating Conditions
• Frequent operation with inlet air which has a
corrosive content
• Operation with inlet air which has a combustible
content
• Operation which is outside of the intended
application
• Operation with a plugged fuel filter
• Extended operation at low idle (more than 20% of
hours)
• Frequent cold starts at temperatures below 0° C
(32° F)
• Frequent dry starts (starting after more than 72
hours of shutdown)
• Frequent hot shutdowns (shutting down the engine
without the minimum of 2 minutes to 5 minutes of
cool down time)
• Operation above the engine rated speed
• Operation below the peak torque speed
• Operating with fuel which does not meet the
standards for distillate diesel fuel as stated in
Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations”, “Distillate
Diesel Fuel”
• Operating with a blend of distillate fuel which
contains more than 20 percent biodiesel
SEBU8906
Improper Maintenance Procedures
(Maintenance Procedures Which
May Contribute to a Severe Service
Application)
• Inadequate maintenance of fuel storage tanks from
causes such as excessive water, sediment, and
microorganism growth.
• Extending maintenance intervals beyond the
recommended intervals
• Using fluids which are not recommended in
Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations”
• Extending maintenance intervals for changing the
engine oil and engine coolant without S·O·S
validation
• Extending maintenance intervals for changing air
filters, oil filters, and fuel filters
• Failure to use a water separator
• Using filters which are not recommended by
Special Publication, PEWJ0074, “2008 Cat Filter
and Fluid Application Guide”
• Storing the engine for more than 3 months but less
than 1 yr (For information about engine storage,
refer to Special Publication, SEHS9031, “Storage
Procedure for Caterpillar Products”)
SEBU8906
i05698889
Maintenance Interval Schedule
SMCS Code: 1000; 7000
Ensure that all safety information, warnings, and
instructions are read and understood before any
operation or any maintenance procedures are
performed.
The user is responsible for the performance of
maintenance, including all adjustments. The user is
responsible for the use of proper lubricants, fluids,
filters, and the replacement of components due to
normal wear and aging. Failure to adhere to proper
maintenance intervals and procedures may result in
diminished performance of the product and/or
accelerated wear of components.
Use mileage, fuel consumption, service hours, or
calendar time, WHICH EVER OCCURS FIRST, in
order to determine the maintenance intervals.
Products that operate in severe operating conditions
may require more frequent maintenance.
Before each consecutive interval is performed, all
maintenance from the previous interval must be
performed.
When Required
“Battery - Recycle” ................................................ 120
“Battery, Battery Cable or Battery Disconnect Switch -
Replace” ............................................................... 121
“Brake Discs - Check”........................................... 123
“Brake Oil Cooler Screen - Clean”........................ 124
“Circuit Breakers - Reset” ..................................... 127
“Diesel Particulate Filter - Inspect” ....................... 135
“Engine Air Filter Secondary Element - Replace”. 141
“Fuel System - Prime”........................................... 150
“Fuses - Replace” ................................................. 156
“Hydraulic Tank Screen - Clean”........................... 162
“Oil Filter - Inspect” ............................................... 165
“Radiator Core - Clean” ........................................ 168
“Rim - Inspect” ...................................................... 169
“Screen (Torque Converter) - Clean” .................... 170
“Window Washer Bottle - Fill” ............................... 186
“Window Wiper - Inspect/Replace”....................... 186
Every 10 Service Hours or Daily
“Automatic Lubrication Grease Tank - Fill” ............119
117
Maintenance Support
Maintenance Interval Schedule
“Backup Alarm - Test” ........................................... 120
“Body Pivot Bearings - Lubricate”......................... 123
“Braking System - Test” ........................................ 124
“Cooling System Level - Check” ........................... 133
“Ejector Cylinder Bearing - Lubricate” .................. 139
“Engine Air Filter Primary Element - Clean/
Replace” ............................................................... 140
“Engine Oil Level - Check”.................................... 143
“Fire Suppression System - Check” ..................... 148
“Fuel Tank Water and Sediment - Drain” .............. 155
“Hoist Cylinder Bearings - Lubricate”.................... 156
“Hydraulic System Oil Level - Check ”.................. 161
“Indicators and Gauges - Test” ............................. 164
“Oscillating Hitch - Lubricate” ............................... 166
“Seat Belt - Inspect” .............................................. 171
“Service Inspection”.............................................. 172
“Steering Cylinder Bearings - Lubricate” .............. 177
“Tailgate and Tailgate Cylinder Bearings -
Lubricate”.............................................................. 179
“Transmission Oil Level - Check” ......................... 184
“Window - Clean” .................................................. 185
Every 50 Service Hours or Weekly
“Automatic Lubrication Filler Filter - Clean” ...........119
“Cab Air Filter - Clean/Replace” ........................... 127
“Fuel System Primary Filter (Water Separator) -
Drain” .................................................................... 151
“Hoses and Clamps - Inspect/Replace”................ 157
“Tire Inflation - Check” .......................................... 180
Initial 250 Service Hours (or at first
oil change)
“Engine Valve Lash - Check/Adjust”..................... 145
“Oscillating Hitch - Adjust” .................................... 165
Every 250 Service Hours or Monthly
“Articulation Chassis Cable - Inspect/Replace”.....118
“Battery Electrolyte Level - Check” ....................... 120
“Belts - Inspect/Adjust/Replace”........................... 122
118 SEBU8906
Maintenance Support
Articulation Chassis Cable - Inspect/Replace

“Differential and Final Drive Oil Level - Check” .... 138 Every 3000 Service Hours or 2
“Drive Shaft Universal Joints, Splines and Bearings - Years
Inspect/Lubricate”................................................. 139
“Cooling System Coolant Extender (ELC) - Add” . 131
“Engine Oil and Filter - Change”........................... 144
“Cooling System Pressure Cap - Clean/Replace” 134
“Exhaust Purifier - Inspect/Clean”......................... 147
Every 3 Years After Date of
“Fan Drive Bearing - Lubricate” ............................ 147
Installation or Every 5 Years After
“Frame and Body - Inspect”.................................. 148 Date of Manufacture
“Fuel System Primary Filter (Water Separator) - “Seat Belt - Replace” ............................................172
Replace” ............................................................... 152
“Fuel System Secondary Filter - Replace” ........... 153
Every 6000 Service Hours or 4
Years
“Pressure Sensor (Transmission Oil) - Test” ........ 167
“Cooling System Coolant (ELC) - Change” .......... 130
“Steering Stop - Check” ........................................ 178
“Cooling System Water Temperature Regulator -
“Wheel Bolt Torque - Check” ................................ 185 Replace” ............................................................... 134

Every 500 Service Hours or 3 “Engine Water Pump - Inspect” ............................ 147
Months i04594229
“Fuel Tank Breather - Replace” ............................ 154
“Fuel Tank Cap and Strainer - Clean”................... 154
Articulation Chassis Cable -
Inspect/Replace
“Hydraulic System Oil Filter (Pilot) - Replace”...... 159
SMCS Code: 1408-040; 1408-510
“Steering System Oil Filter - Replace” .................. 178
“Transmission Oil Filter - Replace” ....................... 182

Every 1000 Service Hours or 6 Crushing Hazard. Ensure that the engine start
switch is in the OFF position, and that the parking
Months brake is engaged before entering the articulation
“Brake Accumulator - Check” ............................... 123 area. Failure to do so could result in serious injury
or death.
“Frame and Body Support Pads - Clean/Inspect” 149
“Hydraulic System Oil - Change” .......................... 158
“Hydraulic Tank Breaker Relief Valve - Clean” ..... 162
“Oscillating Hitch - Adjust” .................................... 165
“Rollover Protective Structure (ROPS) - Inspect”. 170
“Transmission Oil - Change”................................. 180

Every 2000 Service Hours or 1 Year

“Differential and Final Drive Oil - Change”............ 136
“Engine Mounts - Inspect” .................................... 142
“Engine Valve Lash - Check/Adjust”..................... 145
Illustration 207 g02747316
“Engine Valve Rotators - Inspect”......................... 146 Location of the chassis cable for articulation
“Refrigerant Dryer - Replace” ............................... 169
“Turbocharger - Inspect” ....................................... 185
SEBU8906 119
Maintenance Support
Automatic Lubrication Filler Filter - Clean

Reference: For information on cleaning the

automatic lubrication system filler filter, refer to
Systems Operation, Testing and Adjusting,
“Automatic Lubrication System, Hydraulic Type” for
the machine that is being serviced

i05884043

Automatic Lubrication Grease

Tank - Fill
(If Equipped)
SMCS Code: 7540-544-HR

Illustration 208 g02747317

Location of the chassis cable for oscillation

1. Inspect each chassis cable for the following

conditions:

• Worn or frayed

• Corrosion

• Loose connections
2. Replace chassis cables if required.

i05884041
Illustration 210 g03709985

Automatic Lubrication Filler Note: The lubricant tank should be refilled at regular
Filter - Clean intervals. Refills should be performed daily to prevent
emptying the system.
(If Equipped)
SMCS Code: 7540-070-HR 1. Use a manual lubricant gun or pump to fill the
reservoir through filler fitting (2) in the pump body.
Fill the reservoir until lubricant appears at overflow
relief valve (1).

2. Check all lubricant lines for leakage.

3. Check hydraulic lines for leakage.

4. Check for worn or damaged hoses.

5. Check that all lubricant injectors are operative.

Check all bearings that are lubricated by the
automatic lubrication system for signs of
lubrication.
6. Inspect the electrical system for worn or frayed
Illustration 209 g03709984 wiring, damaged connectors, or a tripped circuit
breaker.
Clean the filler filter every 50 Service Hours or
Weekly. Reference: For more information on the automatic
lubrication system, refer to the Systems Operation,
Testing and Adjusting, “Automatic Lubrication
System, Hydraulic Type” for the machine that is being
serviced.
120 SEBU8906
Maintenance Support
Backup Alarm - Test

i02231984 i00993589

Backup Alarm - Test Battery - Recycle

SMCS Code: 7406-081 SMCS Code: 1401-561
Make sure that the parking brake is engaged. Always recycle a battery. Never discard a battery.
Turn the engine start switch to the ON position to Always return used batteries to one of the following
perform the test. locations:
Make sure that the area behind the machine is clear • A battery supplier
of personnel and clear of obstacles.
• An authorized battery collection facility
Apply the service brake. Move the transmission
control to the REVERSE position. • Recycling facility
The backup alarm should start to sound immediately.
The backup alarm should continue to sound until the i03460622
transmission control is moved to the NEUTRAL
position or to the FORWARD position. Battery Electrolyte Level -
Check
SMCS Code: 1401-535-ESG
Table 15
Battery Electrolyte Level

Battery Interval
Conventional 100 Hours
Low Maintenance 250 Hours
Maintenance Free No Interval

Tighten the battery retainers on all of the batteries.

Illustration 211 g00929418 Tighten the battery retainers at every 1000 hours.

The backup alarm is located at the rear of the Check the following areas at a minimum interval of
machine behind the left rear light. 1000 hours. Check the following areas more
frequently during adverse conditions:

Illustration 212 g01124582

A three position switch at the rear of the backup alarm Illustration 213 g01803460
regulates the volume of the alarm.
1. The battery compartment is located on the right
To adjust the sound level, move the switch to the side of the machine below the operator station
required setting. The setting should remain on high,
unless the job site requires a lower sound level. door.
SEBU8906 121
Maintenance Support
Battery, Battery Cable or Battery Disconnect Switch - Replace

• In extreme temperatures, check the water in the

cells weekly. Cell water usage could be higher
in extreme temperatures.

i01852801

Battery, Battery Cable or

Battery Disconnect Switch -
Replace
SMCS Code: 1401-510; 1402-510; 1411-510

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

Illustration 214 g00943693 2. Turn all switches to the OFF position.

2. Clean the battery surface with a clean cloth.

3. Disconnect all battery cables from the batteries.

Reference: To disconnect the battery cables, refer to

the Operation and Maintenance Manual, “Battery,
Battery Cable or Battery Disconnect Switch -
Replace” for the machine that is being serviced.

4. Clean the battery cables and the battery posts.

Coat the battery posts with 1P-0808 Multipurpose
Grease or petroleum jelly.

5. Connect the battery cables to the batteries.

Reference: To connect the battery cables, refer to

the Operation and Maintenance Manual, “Battery,
Battery Cable or Battery Disconnect Switch -
Replace” for the machine that is being serviced.
6. Coat the terminals with 1P-0808 Multipurpose
Grease or petroleum jelly. Then install the post
cover.
Illustration 215 g00944173
3. Turn the battery disconnect switch to the OFF
position and remove the key.
4. Disconnect the negative end (-) of the battery cable
from the frame near the battery disconnect switch.

7. For conventional batteries and batteries of low Note: Do not allow the disconnected battery cable to
maintenance, follow these additional instructions: contact the battery disconnect switch.

• Inspect the battery electrolyte level in each
battery cell. A maintenance free battery does
not require inspection.
• Maintain the level of the distilled water to the
bottom of the filler openings. If distilled water is
not available, use clean drinking water.
• A battery should not require more than 30 cc
(1.8306 in3 (1 ounce)) of water per cell per
week. This requirement should exist with the
proper charging rate and with a moderate
climate.
5. Disconnect the negative end (-) of the battery cable
from the battery.
6. Disconnect the positive end (+) of the battery cable
from the battery.
7. Replace the battery or make all necessary repairs
to the battery.
8. Connect the positive end (+) of the battery cable to
the battery.
9. Connect the negative end (-) of the battery cable to
the battery.

10. Connect the negative end (-) of the battery cable

to the frame near the battery disconnect switch.
122 SEBU8906
Maintenance Support
Belts - Inspect/Adjust/Replace

11. Install the key. Turn the battery disconnect switch Adjust the Air Conditioning
to the ON position. Compressor Belt (If Equipped)
i01852838

Belts - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510
The engine is equipped with a belt that drives the fan
and the alternator.

Note: The engine is equipped with a belt tensioner

that automatically adjusts the belt that drives the fan
and the alternator to the correct tension.
1. Park the machine on a level surface. Engage the
parking brake. Stop the engine.
Illustration 217 g00908664
2. Inspect drive belt (1). Check the belt for wear,
fraying or cracking. If the belt is damaged, replace To check the belt tension, apply 110 N (25 lb) of force
the belt. midway between the pulleys. Correctly adjusted belts
will deflect 17 ± 3 mm (0.67 ± 0.12 inch).
If a new belt is installed, check belt adjustment again
after 30 minutes of operation.

Illustration 216 g00993769

3. If belt (1) requires replacement, insert a square

drive into the hole in tensioner (5) and turn Illustration 218 g00993770

counterclockwise in order to release the tension

from the belt. 1. Loosen mounting bolts (1) and (5).

4. Remove the belt from the engine. 2. Loosen bracket bolt (2) and locknut (3).

5. In order to install a new belt, insert a square drive
into the hole in tensioner (5) and turn
counterclockwise.
6. Install belt (1) in the following order: drive pulley
(6), fan pulley (4), lower idler pulley (7), tensioner
(5), alternator pulley (2) and top idler pulley (3).
3. Turn adjusting nut (4) until the correct belt tension
is reached. Tighten locknut (3) to 150 ± 20 N·m
(110 ± 15 lb ft).
4. Tighten bracket bolt (2), mounting bolts (1) and (5)
to 105 ± 20 N·m (75 ± 15 lb ft).
5. Check the belt deflection. If the amount of
deflection is incorrect repeat steps 1 to 4.
SEBU8906 123
Maintenance Support
Body Pivot Bearings - Lubricate

i01901270 i01853350

Body Pivot Bearings - Brake Accumulator - Check

Lubricate SMCS Code: 4263-535
SMCS Code: 7258-086-BD

NOTICE
Check that the lines attached to all the remote grease
fittings are undamaged. If the grease lines are split,
grease will not reach the components that require lu-
bricating. Machine damage will result.

Wipe off the fittings before any lubricant is applied.

Illustration 220 g00944540

Correct brake accumulator charge pressure is

necessary for efficient hydraulic brake operation.
Special tools and equipment are required to test the
accumulator.

Reference: For the correct testing and charging

procedures for the brake accumulator, refer to
Systems Operation, Testing and Adjusting, “Brake
Illustration 219 g00989208
Accumulator - Test and Charge” for the machine that
Left side view is being serviced, or consult your Caterpillar dealer.

1. Apply lubricant through remote mounted fitting (1)

i01853415
for the right body pivot bearing.

2. Apply lubricant through remote mounted fitting (2) Brake Discs - Check
for the left body pivot bearing. SMCS Code: 4251-535; 4267-535

Illustration 221 g00944572

It is necessary to monitor brake disc wear to maintain

an efficient braking system and to prevent
unnecessary wear to braking system components.
The brake disc wear can be checked without having
to remove the wheel brake assembly.
124 SEBU8906
Maintenance Support
Brake Oil Cooler Screen - Clean

Reference: For information on checking brake disc 3. Remove the screen. Clean the screen and the plug
wear, refer to Systems Operation, Testing and with clean, nonflammable solvent.
Adjusting, “Brake Disc Wear - Check” for the machine
that is being serviced. 4. Install the screen in the oil cooler.
5. Inspect the seal on plug (2). Replace the seal if
i05794084
damaged.
Brake Oil Cooler Screen - 6. Install the plug.
Clean 7. Start the engine and operate the engine at low idle.
SMCS Code: 4257-070; 4295-070 Check for leaks and make any necessary repairs.

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact the skin.

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Dealer Illustration 223 g01803474
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products. 8. For machines equipped with a dump body check
the oil level with the body fully lowered. For
Dispose of all fluids according to local regulations and
mandates. machines equipped with an ejector body check the
oil level with the ejector plate fully retracted and the
tailgate fully raised. With the oil cold maintain the
Clean the brake oil cooler screen whenever there is a hydraulic oil level to the “FULL COLD” mark in
failure of the brake hydraulic system.
sight gauge (3). With the oil at operating
temperature, maintain the hydraulic oil level to the
“FULL WARM” mark in sight gauge (3).

9. Remove hydraulic tank filler cap (4) and add

hydraulic oil, if necessary.

i05884044

Braking System - Test

SMCS Code: 4250-081; 4251-081; 4267-081
Be sure that the area around the machine is clear of
personnel and obstructions. Be sure that the steering
frame lock is in the stored position.
Illustration 222 g03672144
Test the brakes on a dry, level surface. Fasten the
seat belt before testing the brakes.
1. Remove drain plug (1) from the oil cooler. Drain the
oil into a suitable container. Clean and install the
plug.

2. Remove plug (2) from the end of the oil cooler.

SEBU8906 125
Maintenance Support
Braking System - Test

The following tests are to determine if the parking

brake and the service brakes are functional. These
tests are not intended to measure the maximum
brake holding effort. Brake holding effort required to
hold a machine at a specific engine rpm will vary from
machine to machine. These differences are due to
engine settings, power train efficiency, as well as
differences in brake holding ability.
Engine rpm at beginning of machine movement, with
the brake applied, should be compared against the
engine rpm on a prior test. This test will indicate
system deterioration.
To carry out the brake test, first start the engine and
let the brake oil pressure build up to the operating
range. The parking brake will stay engaged until
operating oil pressure has been reached and the Illustration 225 g03709499
parking brake control is moved to the OFF position.
As soon as operating oil pressure has been reached 3. Disengage the parking brake by moving the
a test of the braking system can be commenced. parking brake control to the OFF position.
Service Brake Holding Ability Test 4. Move the transmission control to the FIRST
SPEED FORWARD position.

5. Gradually increase the engine speed to 1600 rpm.

Personal injury can result if the machine moves The machine should not move.
while testing.
6. Reduce the engine speed to low idle. Move the
If the machine begins to move during test, reduce transmission control to the NEUTRAL position.
the engine speed immediately and engage the Engage the parking brake. Stop the engine.
parking brake.
NOTICE
If the machine moved while testing the brakes, con-
1. Move the transmission control to the NEUTRAL
tact your Caterpillar dealer.
position. Start the engine.
Have the dealer inspect and, if necessary, repair the
service brake before returning the machine to
operation.

Parking Brake Holding Ability Test

Illustration 224
2. Depress the service brake pedal.
NOTICE
The standard parking brake control is a pull-to-en-
gage type. When the knob is pulled OUT, the parking
brake will be engaged.
Certain mining regulations require machines to be
equipped with a push-to-engage parking brake con-
trol. When the knob is pushed IN, the parking brake is
engaged.
g00926943
Before operating the machine, ensure you are familiar
with the operation of the parking brake control.
126
Maintenance Support
Braking System - Test
Standard Pull-to-Engage Type
Personal injury can result if the machine moves
while testing the parking brake.
If the machine begins to move during the test, re-
duce the engine speed immediately and apply the
service brakes.
1. Move the transmission control to the NEUTRAL
position. Start the engine.
Illustration 226 g03709499
2. Engage the parking brake by pulling the parking
brake control knob out to the ON position.
3. Move the transmission control to the FIRST
SPEED FORWARD position.
Note: The parking brake indicator and the action
lamp should illuminate. The action alarm should
sound.
4. Gradually increase the engine speed to 1400 rpm.
The machine should not move.
5. Reduce the engine speed to low idle. Move the
transmission control to the NEUTRAL position.
Stop the engine.
NOTICE
If the machine moved while testing the brakes, con-
tact your Caterpillar dealer.
Have the dealer inspect and, if necessary, repair the
parking brakes before returning the machine to
operation.
SEBU8906
Optional Push-to-Engage Type
Personal injury can result if the machine moves
while testing the parking brake.
If the machine begins to move during the test, re-
duce the engine speed immediately and apply the
service brakes.
1. Move the transmission control to the NEUTRAL
position. Start the engine.
Illustration 227 g03709500
2. Engage the parking brake by pushing the parking
brake control in to the ON position.
3. Move the transmission control to the FIRST
SPEED FORWARD position.
Note: The parking brake indicator and the action
lamp should illuminate. The action alarm should
sound.
4. Gradually increase the engine speed to 1400 rpm.
The machine should not move.
5. Reduce the engine speed to low idle. Move the
transmission control to the NEUTRAL position.
Stop the engine.
NOTICE
If the machine moved while testing the brakes, con-
tact your Caterpillar dealer.
Have the dealer inspect and, if necessary, repair the
parking brakes before returning the machine to
operation.
SEBU8906 127
Maintenance Support
Cab Air Filter - Clean/Replace

i05685130 Cab Pressurizer Filter

Cab Air Filter - Clean/Replace
(If Equipped)
SMCS Code: 7342-070; 7342-510
Clean the cab air filter frequently in dusty conditions.
Replace the cab air filter if the following conditions are
noted.

• Rips or tears in the filter

• A reduction of air circulation in the operator station

Return Air Filter

Illustration 229 g03608877

1. Remove two screws (1) and cover (2).

2. Remove the wing nut on the filter element. Remove

Illustration 228 g03608856
Seat removed
1. Remove two screws (1), cover (2), and the return
air filter from the air conditioning unit.
2. Clean the return air filter using pressure air. When
using pressure air, the maximum air pressure
should not exceed 205 kPa (30 psi).
3. Install the return air filter, cover (2), and two screws
(1) to the air conditioning unit.
the filter element.
3. Clean the filter element with pressure air or wash
the element in warm water and a nonsudsing
household detergent. When using pressure air, the
maximum air pressure should not exceed 205 kPa
(30 psi). When using pressure water, the maximum
water pressure should not exceed 280 kPa
(40 psi).
4. If washed, rinse the element in clean water and air
dry thoroughly.
5. Install the filter element and the wing nut. Tighten
the wing nut finger tight, do not use a tool to tighten
the wing nut.
6. Install cover (2) and two screws (1). Tighten two
screws (1) finger tight, do not use a tool to tighten
the screws.
i02231988

Circuit Breakers - Reset

SMCS Code: 1420-529

NOTICE
Replace circuit breakers with the same type and size
only. Otherwise, electrical damage can result.
If it is necessary to reset circuit breakers frequently,
an electrical problem may exist. Contact your Cater-
pillar dealer.
128 SEBU8906
Maintenance Support
Circuit Breakers - Reset

Circuit Breaker/Reset – Push in the (3) Right Tail Light –

button in order to reset the circuit
breaker. If the electrical system is
working properly, the button will remain (3) Right Backup Light –
depressed. If the button does not remain
depressed, check the appropriate electrical
circuit. Repair the electrical circuit, if necessary.
(4) Keyswitch – 15 Amp

(4) Engine Electronic Control Module

(ECM) –

(4) Engine Idle Timer –

(4) Fire Suppression System (Foam

Type) –

(5) Horn – 15 Amp

Illustration 230 g01125879

(5) Dome Lamp –

(5) Flasher –

(5) 24V to 12V Converter –

(5) Spare –

(6) Backup Alarm – 15 Amp

Illustration 231 g01126234

(1) Power Train/Chassis Electronic

Control Module (ECM) – 15 Amp (6) Brake Release Pump (If Equipped) –

(2) Left Headlight – 30 Amp (Automatic)

(7) Rear Cab Flood Light – 15 Amp

(2) Left Tail Light –

(7) Instrument Illumination –

(2) Left Backup Light –

(8) Front Window Washer and Wiper –
15 Amp
(3) Right Headlight – 30 Amp
(Automatic) (8) Rear Window Washer and Wiper –
SEBU8906 129
Maintenance Support
Circuit Breakers - Reset

(9) Air Conditioner – 15 Amp

(10) Automatic Lubrication System (If

Eqipped) – 15 Amp

(11) Caterpillar Monitoring System – 15

Amp

(11) Body Position Sensor –

(11) Fuel Level Buffer –

Illustration 232 g01161061

(16) Alternator - 105 Amp

(11) Retarder Indicator Lamp –

(12) Engine Electronic Control Module

(ECM) – 15 Amp

(12) Engine Electronic Control Module

(ECM) Service Port –

(13) Transmission Gear Position Sensor

– 15 Amp

(13) Hoist Control Position Sensor –

Illustration 233 g01161062

(17) Main - 80 Amp

(13) Retarder Lever Switch –

(14) Payload – 15 Amp

(15) Residual Brake Oil Pressure – 15

Amp

(15) 24V to 12V Converter –

(15) Stop Light –

(15) Monitor, Telemetry Port, Electronic

Access Module (EAM) –

(15) Cassette –
130 SEBU8906
Maintenance Support
Cooling System Coolant (ELC) - Change

i04496449
Cooling System Coolant (ELC)
- Change
SMCS Code: 1352-044-NL; 1395-044-NL
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 to
heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove the cooling system pressure cap only
when the engine is stopped and is cool enough to
touch with your bare hand. Lift the lever on the
pressure cap to relieve the cooling system pres-
sure before removing the pressure cap.
Do not attempt to tighten hose connections when
the coolant is hot because the hose can come off
which could result in burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
NOTICE
Mixing ELC with other products reduces the effective-
ness of the coolant and shortens coolant life. Use only
Caterpillar products or commercial products that
have passed the Caterpillar EC-1 specifications for
premixed or concentrate coolants. Use only Caterpil-
lar Extender with Caterpillar ELC. Failure to follow
these recommendations could result in the damage to
cooling systems components.
If ELC cooling system contamination occurs see the
topic Extended Life Coolant (ELC) in the Special Pub-
lication, SEBU6250, “Caterpillar Machine Fluids
Recommendations”.
Note: This procedure pertains to machines using
Extended Life Coolant (ELC) only.
If the coolant is dirty or if you observe any foaming in
the cooling system, drain the coolant before the
recommended interval.

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Dealer Illustration 234 g03670898
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products. 1. Lift the lever on the pressure cap to relieve the
Dispose of all fluids according to local regulations and cooling system pressure. Remove the pressure
mandates. cap.

NOTICE
Do not change the coolant until you read and under-
stand the cooling system information in Special Publi-
cation, SEBU6250, “Caterpillar Machine Fluids
Recommendations”.
Failure to do so could result in damage to the cooling
system components.
SEBU8906
Illustration 235 g03670902
2. Open the drain valve for the engine cooling
system. Drain the coolant into a suitable container.
The drain valve is located on the bottom radiator
tube.
3. Flush the cooling system with clean water until the
draining water is clear. Close the drain valve.
4. Replace the water temperature regulator.
Reference: Refer to the Operation and Maintenance
Manual, “Cooling System Water Temperature
Regulator - Replace” for the machine that is being
serviced.
5. Add the coolant solution. Add coolant slowly to
help avoid air locks, 20 L (5 US gal) per minute.
Reference: For information on the cooling system
capacity, refer to the Operation and Maintenance
Manual, “Lubricant Viscosities and Refill Capacities”
for the machine that is being serviced.
6. Start the engine. Run the engine with the cooling
system pressure cap removed. Run the engine
until the water temperature regulator opens and
the coolant level stabilizes.
131
Maintenance Support
Cooling System Coolant Extender (ELC) - Add
Illustration 236 g00946138
7. Maintain the coolant level to within 13 mm
(0.50 inch) of the bottom of the filler pipe or to the
proper level in the sight gauge.
8. Install the cooling system pressure cap.
9. Stop the engine.
i04496489
Cooling System Coolant
Extender (ELC) - Add
SMCS Code: 1352-538-NL; 1395-538-NL
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 to
heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove the cooling system pressure cap only
when the engine is stopped and is cool enough to
touch with your bare hand. Lift the lever on the
pressure cap to relieve the cooling system pres-
sure before removing the pressure cap.
Do not attempt to tighten hose connections when
the coolant is hot because the hose can come off
which could result in burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
132 SEBU8906
Maintenance Support
Cooling System Coolant Extender (ELC) - Add

The amount of extender is determined by the cooling

NOTICE
Adding coolant to an overheated engine could result
in damage to the engine. Allow the engine to cool be-
fore adding coolant.
If the machine is to be stored in, or shipped to, an
area with freezing temperatures, the cooling system
must be protected to the lowest outside (ambient)
temperature.
The engine cooling system is normally protected to a
minimum of −29° C (−20° F) with Caterpillar Anti-
freeze, when shipped from the factory unless special
requirements are defined.
system capacity.
Reference: For information on the cooling system
capacity, refer to the Operation and Maintenance
Manual, “Lubricant Viscosities and Refill Capacities”
for the machine that is being serviced.
Reference: For all cooling system requirements,
refer to Caterpillar Machine Fluids
Recommendations, SEBU6250 or consult your Cat
dealer.

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products.
Dispose of all fluids according to local regulations and Illustration 237 g03670898
mandates.
1. Lift the lever on the pressure cap to relieve the
NOTICE cooling system pressure. Remove the pressure
Excessive additive (greater than the recommended cap.
6% initial fill) together with concentrations of anti-
freeze greater than 60% cause deposits to form and 2. If necessary, drain enough coolant from the
can result in radiator tube blockage and overheating. radiator to allow for the addition of the liquid
coolant extender.
Note: Make sure that the coolant is drained into a
NOTICE
suitable container.
Mixing ELC with other products reduces the effective-
ness of the coolant and shortens coolant life. Use only 3. Add the recommended amount of ELC Extender to
Caterpillar products or commercial products that the cooling system.
have passed the Caterpillar EC-1 specifications for
premixed or concentrate coolants. Use only Caterpil- 4. Clean the pressure cap and inspect the pressure
lar Extender with Caterpillar ELC. Failure to follow cap. Install the pressure cap.
these recommendations could result in the damage to
cooling systems components. 5. Start the engine and check for leaks. Allow the
coolant level to stabilize.
If ELC cooling system contamination occurs see the
topic Extended Life Coolant (ELC) in the Special Pub- 6. If necessary, add premixed coolant in order to bring
lication, SEBU6250, “Caterpillar Machine Fluids
Recommendations”. the coolant to the proper level in the sight gauge.

When a Caterpillar Extended Life Coolant (ELC) is

used, an Extender must be added to the cooling
system.
Reference: For the proper service interval, refer to
the Operation and Maintenance Manual,
“Maintenance Interval Schedule” for the machine that
is being serviced.
SEBU8906 133
Maintenance Support
Cooling System Level - Check

i04496490

Cooling System Level - Check

SMCS Code: 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 to
heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove the cooling system pressure cap only Illustration 238 g03670908
when the engine is stopped and is cool enough to
touch with your bare hand. Lift the lever on the 1. Maintain the coolant level in the sight gauge
pressure cap to relieve the cooling system pres- located on the right side of the machine. If adding
sure before removing the pressure cap.
coolant daily, check for leaks.
Do not attempt to tighten hose connections when
the coolant is hot because the hose can come off 2. Inspect the radiator core for debris. Clean the
which could result in burns. radiator core, if necessary.
Cooling System Coolant Additive contains alkali. Reference: For information on cleaning the radiator
Avoid contact with skin and eyes. core, refer to the Operation and Maintenance Manual,
“Radiator Core - Clean” for the machine that is being
serviced.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products.
Dispose of all fluids according to local regulations and
mandates.

Illustration 239 g03670898

3. If coolant level is low, lift the lever on the pressure

cap to relieve the cooling system pressure.
Remove the pressure cap. Add coolant as required
to within 13 mm (0.50 inch) of the bottom of the
filler pipe or to the proper level in the sight gauge.

4. Inspect the pressure cap and cap seal for damage,

deposits, or foreign material. Clean the pressure
cap with a clean cloth or replace the cap if
damaged.

5. Install the cooling system pressure cap.

134
Maintenance Support
Cooling System Pressure Cap - Clean/Replace
i04496509
Cooling System Pressure Cap -
Clean/Replace
SMCS Code: 1382-070; 1382-510
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 to
heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove the cooling system pressure cap only
when the engine is stopped and is cool enough to
touch with your bare hand. Lift the lever on the
pressure cap to relieve the cooling system pres-
sure before removing the pressure cap.
Do not attempt to tighten hose connections when
the coolant is hot because the hose can come off
which could result in burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
Illustration 240 g03670898
1. Lift the lever on the pressure cap in order to relieve
the cooling system pressure. Remove the pressure
cap.
2. Inspect the pressure cap for damage, foreign
material and for deposits.
3. Inspect the condition of the pressure cap seal.
Replace the pressure cap if damaged. If the seal is
not damaged, use a 9S-8140 Pressurizing Pump
to pressure test the pressure cap. The correct cap
relief pressure is stamped on the radiator cap. If
the pressure cap does not hold the correct
pressure, install a new cap.
SEBU8906
4. Install the pressure cap.
i04528041
Cooling System Water
Temperature Regulator -
Replace
SMCS Code: 1355-510
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 to
heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove the cooling system pressure cap only
when the engine is stopped and is cool enough to
touch with your bare hand. Lift the lever on the
pressure cap to relieve the cooling system pres-
sure before removing the pressure cap.
Do not attempt to tighten hose connections when
the coolant is hot because the hose can come off
which could result in burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
Replace the water temperature regulator on a regular
basis in order to reduce the chance of unscheduled
downtime and of problems with the cooling system.
The water temperature regulator should be replaced
after the cooling system has been cleaned. Replace
the water temperature regulator while the cooling
system is drained, or at a level where the water is
below the water temperature regulator housing.
NOTICE
Failure to replace the engine's water temperature reg-
ulator on a regularly scheduled basis could cause se-
vere engine damage.
Note: If you are only replacing a water temperature
regulator, drain the cooling system coolant to a level
that is below the water temperature regulator
housing.
SEBU8906
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products.
Dispose of all fluids according to local regulations and
mandates.
Illustration 241 g00947344
1. Remove water temperature regulator housing.
2. Remove the gasket, the water temperature
regulator, and the seal from the water temperature
regulator housing.
NOTICE
Former water temperature regulators may be used, if
they meet the test specifications and are not dam-
aged or have excessive buildup or deposits.
135
Maintenance Support
Diesel Particulate Filter - Inspect
NOTICE
Since Caterpillar engines incorporate a shunt design
cooling system, it is mandatory to always operate the
engine with a water temperature regulator.
Depending on load, failure to operate with a water
temperature regulator could result in either an over-
heating or an overcooling condition.
NOTICE
If the water temperature regulator is installed incor-
rectly, it will cause the engine to overheat.
3. Install a new seal in the water temperature
regulator housing. Install a new water temperature
regulator and a new gasket. Install the water
temperature regulator housing and the hose.
4. Refill the cooling system.
Reference: For all cooling system requirements,
refer to the Operation and Maintenance Manual,
SEBU6250, “Caterpillar Machine Fluids
Recommendations”.
Reference: For information on the cooling system
capacity, refer to the Operation and Maintenance
Manual, “Lubricant Viscosities and Refill Capacities”
for the machine that is being serviced.
i05757210
Diesel Particulate Filter -
Inspect
SMCS Code: 1061-040; 1089-040
Illustration 242 g01803479
Remove the diesel particulate filter covers. Inspect
the diesel particulate filter for damage and for leaks. If
necessary, make repairs. If the diesel particulate filter
is damaged, consult your Cat dealer.
136 SEBU8906
Maintenance Support
Differential and Final Drive Oil - Change

i01858534

Differential and Final Drive Oil -

Change
SMCS Code: 3258-044; 4050-044

Note: The oil change interval for the differential and

for the final drives can be monitored with the S·O·S
(Scheduled Oil Sampling) program. The oil change
interval is based on the condition of the oil. If
scheduled oil sampling program is not used, the oil
change interval for the differential and final drives is at
2000 service hours.

Illustration 243 g00947352

Hot oil and hot components can cause personal 1. Position the wheels so that the final drive drain
injury. Do not allow hot oil or hot components to plugs are facing downward. Remove the final drive
contact the skin. drain plugs and allow the oil to drain into a suitable
container.

NOTICE 2. Clean the drain plug and install the drain plug.
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and sup-
plies suitable to collect and contain fluids on Caterpil-
lar products.
Dispose of all fluids according to local regulations and
mandates.

Wipe covers and surfaces around openings before

checking or adding oil. Park on a level surface. Illustration 244 g00947354
View of front differential

Illustration 245 g00947357

View of rear differential
SEBU8906 137
Maintenance Support
Differential and Final Drive Oil - Change

3. Remove differential drain plugs (2) and allow the oil

to drain into a suitable container.
4. Clean the drain plugs and install the drain plugs.

5. Remove the differential filler plugs (1). Fill the

differential to the bottom of the filler plug opening.
Reference: For information on lubricants and refill
capacities, refer to Operation and Maintenance
Manual, “Lubricant Viscosities and Refill Capacities”
for the machine that is being serviced.

6. Clean the filler plug and install the filler plug.

Illustration 247 g01000386

Location of the front differential breather

Illustration 246 g00955069

7. Position the wheels so that the filler plugs are even

with the center line of the wheel. Remove the filler
Illustration 248 g01000387
plugs.
Location of the rear differential breather
8. Fill the final drives slowly to the bottom of the filler
openings. 13. Remove the front and rear differential breathers.

Reference: For information on lubricants and refill 14. Install new front and rear differential breathers.
capacities, refer to Operation and Maintenance
Manual, “Lubricant Viscosities and Refill Capacities”
for the machine that is being serviced.

9. Clean the filler plugs and install the filler plugs.

10. If the specified amount of oil will not fit in the final
drives, install the final drive filler plugs. Operate the
machine on level ground for a few minutes in order
to equalize the oil level in the axles.

11. Remove the filler plugs and add the remaining oil.

12. Operate the machine for a few minutes and

recheck the oil level. The oil level should reach the
bottom of the filler plug opening.
Note: If the oil level is higher than the filler plug
opening, do not allow the oil to drain to the level of the
filler plug opening. Install the filler plug.
138 SEBU8906
Maintenance Support
Differential and Final Drive Oil Level - Check

i02230384
3. Clean the filler plugs and install the filler plugs.
Differential and Final Drive Oil
Level - Check
SMCS Code: 3258-535-FLV; 4050-535-FLV

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and sup-
plies suitable to collect and contain fluids on Caterpil-
lar products. Illustration 250 g00955072
Location of the front differential filler plug
Dispose of all fluids according to local regulations and
mandates.

Wipe covers and surfaces around openings before

checking or adding oil. Park on a level surface.
Note: Perform Steps 1 through 3 to the final drive on
each wheel.

Illustration 251 g00955100

Location of the rear differential filler plug

4. Remove the differential filler plugs. The oil level

should be at the bottom of the filler plug openings.
Add oil, if necessary.

Illustration 249 g00955069 Reference: For information on lubricants, refer to the

Operation and Maintenance Manual, “Lubricant
1. Position the wheels so that the final drive filler Viscosities and Refill Capacities” for the machine that
plugs are even with the center line of the wheel. is being serviced.
Note: If the oil level is higher than the filler plug
2. Remove the oil filler plugs. The oil level should be
opening, do not allow the oil to drain to the level of the
at the bottom of the filler plug openings. Add oil, if filler plug opening.
necessary.
5. Clean the filler plugs and install the filler plugs.
Reference: For information on lubricants, refer to the
Operation and Maintenance Manual, “Lubricant
Viscosities and Refill Capacities” for the machine that
is being serviced.
Note: If the oil level is higher than the filler plug
opening, do not allow the oil to drain to the level of the
filler plug opening.
SEBU8906 139
Maintenance Support
Drive Shaft Universal Joints, Splines and Bearings - Inspect/Lubricate

i04872909

Drive Shaft Universal Joints,

Splines and Bearings - Inspect/
Lubricate
SMCS Code: 3251-040; 3251-086; 3253-040-SN;
3253-086-SN; 3267-040-BD; 3267-086-BD

Crushing Hazard. Ensure that the engine start

switch is in the OFF position, and that the parking
brake is engaged before entering the articulation
area. Failure to do so could result in serious injury Illustration 253 g00988860
or death.
2. Apply lubricant through two fittings for the slip joint
splines.
NOTICE
Check that the lines attached to all the remote grease i01900742
fittings are undamaged. If the grease lines are split,
grease will not reach the components that require lu- Ejector Cylinder Bearing -
bricating. Machine damage will result.
Lubricate
Inspect the drive shaft universal joints for wear, loose SMCS Code: 5305-086-BD
bolts, or missing bolts. Tighten loose bolts and
replace missing bolts. Inspect the drive shaft splines
and bearings for wear. Replace worn components. NOTICE
Check that the lines attached to all the remote grease
Wipe off the fittings before any lubricant is applied. fittings are undamaged. If the grease lines are split,
grease will not reach the components that require lu-
bricating. Machine damage will result.

Wipe off the fittings before any lubricant is applied.

Illustration 252 g00988851

1. Apply lubricant through eight fittings in universal

joints.
Illustration 254 g00988865

1. Apply lubricant through two fittings (1) (one on

each side of the machine) for the bearing at the rod
end of the ejector cylinder.
140 SEBU8906
Maintenance Support
Engine Air Filter Primary Element - Clean/Replace

2. Apply lubricant through two fittings (2) (one on

each side of the machine) for the bearing at the rod
end of the ejector cylinder.
NOTICE
This machine uses radial seal type air cleaners. To
avoid engine damage, use only radial seal replace-
ment filters. Others will not seal.
Radial seal filter gasket design and location are crit-
ical to proper air cleaner operation. Use only Caterpil-
lar replacements.

Illustration 255 g00989169

3. With the ejector plate in the fully ejected position

apply lubricant through two fittings (3) (one on
each side of the machine) for the bearing at the
head end of the ejector cylinder. Illustration 257 g03671496

i05793481 1. Remove the cover from the air cleaner housing.

Engine Air Filter Primary

Element - Clean/Replace
SMCS Code: 1054-070-PY; 1054-510-PY

Illustration 258 g03671497

2. Remove the primary filter element from the air

cleaner housing.

Illustration 256 g03713906 3. Clean the inside of the air cleaner housing.
Service the air cleaner daily or if the air filter 4. Inspect the primary element. If the pleats, the
restriction indicator located on the dash panel comes gaskets or the seals are damaged, discard the
on. Stop the engine.
primary element. Replace a damaged primary
element with a clean primary element.
NOTICE
Service the air cleaner only with the engine stopped.
Engine damage could result if the air cleaner is serv-
iced while the engine is running.
SEBU8906
NOTICE
Do not clean the primary elements by bumping or tap-
ping them. Do not use primary elements with dam-
aged pleats, gaskets or seals. Engine damage can
result.
Make sure the cleaned primary elements are com-
pletely dry before installing them into the filter hous-
ing. Water remaining in the elements can cause false
indications of contamination in S·O·S Analysis test
results.
5. If the primary element is not damaged, clean the
primary element. The primary element can be
cleaned by using the following methods:
• Pressure air
• Pressure water
• Detergent washing
When using pressure air, the maximum air
pressure is 205 kPa (30 psi). When using
pressure water, the maximum water pressure is
280 kPa (40 psi).
Illustration 259 g00905242
6. When cleaning the inside pleats and the outside
pleats, direct the air along the pleats or direct the
water along the pleats.
The primary element can be washed in a solution
that consists of warm water and of nonsudsing
household detergent. Fully rinse the pleats. Allow
the primary element to air dry completely.
7. Inspect the primary element after cleaning the
primary element. Do not use a primary element if
the pleats, the gasket, or the seals are damaged.
8. Cover the clean primary element. Store the primary
element in a clean, dry location.
141
Maintenance Support
Engine Air Filter Secondary Element - Replace
A primary element may be cleaned for a maximum
of six times. Also replace the primary element if the
primary element has been in service for 1 year.
9. Install a clean primary element. Clean and install
the cover.
Note: Make sure that the primary filter element is
properly seated and sealed.
Note: If the air filter restriction indicator remains on
after starting the engine, or the exhaust smoke is still
black after installing a clean primary element, install a
new primary filter element. If the indicator remains on
after installing a new primary filter element, replace
the secondary filter element.
Reference: For the correct procedure to replace the
secondary filter element, refer to the Operation and
Maintenance Manual, “Engine Air Filter Secondary
Element - Replace” for the machine that is being
serviced.
i01901734
Engine Air Filter Secondary
Element - Replace
SMCS Code: 1054-510-SE
NOTICE
Service the air cleaner only with the engine stopped.
Engine damage could result.
NOTICE
Always replace the secondary element. Do not at-
tempt to reuse it by cleaning. Engine damage could
result.
Replace the engine air filter secondary element under
the following conditions:
• A clean primary element has been installed and a
warning for the air filter still occurs.
• The engine air filter primary element is serviced for
the third time.
• The exhaust smoke remains black and a clean
primary element has been installed.
1. Remove the primary element.
Reference: For additional information, refer to the
Operation and Maintenance Manual, “Engine Air
Filter Primary Element - Clean/Replace” for the
machine that is being serviced.
142 SEBU8906
Maintenance Support
Engine Mounts - Inspect

i05884045

Engine Mounts - Inspect

SMCS Code: 1152-040

Illustration 260 g00989517

2. Remove the secondary element.

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

air cleaner housing. Illustration 261 g03709987
Location of the front engine mounts
NOTICE
This machine uses radial seal type air cleaners. To
avoid engine damage, use only radial seal replace-
ment filters. Others will not seal.
Radial seal filter gasket design and location are crit-
ical to proper air cleaner operation. Use only Caterpil-
lar replacements.

4. Uncover the air inlet opening. Install a new

secondary element.

5. Install a clean primary element and install the cover

on the air cleaner housing.
SEBU8906
Illustration 262 g00990228
Illustration 263 g00990230
Caterpillar recommends inspecting the engine
mounts for deterioration and for proper bolt torque.
Inspecting the engine mounts for deterioration and for
proper bolt torque will help to prevent excessive
engine vibration that is caused by improper mounting.
Reference: For the proper bolt torques for the
engine mounts, refer to Specifications Supplement,
“AD30 Engine” for the machine that is being serviced.
i03460625
Engine Oil Level - Check
SMCS Code: 1000-535-FLV
NOTICE
Do not underfill or overfill the engine crankcase with
oil. Either condition can cause engine damage.
143
Maintenance Support
Engine Oil Level - Check
Illustration 264 g01803475
Check the engine oil level with the machine level and
the parking brake engaged.
The dipstick is located on the right side of the engine.
Illustration 265 g01803476
1. Before starting the engine, the oil level must be in
the hatched area on the SAFE STARTING RANGE
ENGINE STOPPED side of dipstick (2).
2. With the engine running and the oil warm, maintain
the oil level in the hatched area on the SAFE
OPERATING RANGE ENGINE RUNNING side of
dipstick (2).
3. Remove filler cap (1) and add oil if necessary.
4. Clean the filler cap and install the filler cap.
144 SEBU8906
Maintenance Support
Engine Oil and Filter - Change

i03460640

Engine Oil and Filter - Change

SMCS Code: 1318-044

Note: Some commercial oils that meet API

specifications may require shorter oil change
intervals. The oil change intervals are determined by
close monitoring of the oil condition and engine wear
metals. Caterpillar prefers scheduled oil sampling as
the proper method of checking engine wear metals.
Consult your Caterpillar dealer for the latest oil
recommendations.

Illustration 266 g00991038

Hot oil and hot components can cause personal 1. Open the crankcase drain valve and allow the oil to
injury. Do not allow hot oil or hot components to drain into a suitable container. Close the
contact the skin. crankcase drain valve.

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
Illustration 267 g01803477

The machine must be level and the parking brake
engaged. The oil must be warm and the engine
stopped.
2. Use a strap type wrench to remove the filter
element. Dispose of the used filter properly.
3. Clean the filter housing base. Ensure that all of the
old seal is removed from the filter base.
SEBU8906
Illustration 268 g00101502
4. Apply a thin film of clean engine oil to the new filter
element seal.
5. Install the new filter element hand tight until the
seal of the filter contacts the base. Note the
position of the index marks on the filter in relation
to a fixed point on the filter base.
Note: There are rotation index marks on the filter that
are spaced 90 degrees or 1/4 of a turn away from
each other. When you tighten the filter, use the
rotation index marks as a guide.
6. Tighten the filter according to the instructions that
are printed on the filter. Use the index marks as a
guide. For non-Caterpillar filters, use the
instructions that are provided with the filter.
Note: You may need to use a Caterpillar strap
wrench, or another suitable tool, in order to turn the
filter to the amount that is required for final
installation. Make sure that the installation tool does
not damage the filter.
145
Maintenance Support
Engine Valve Lash - Check/Adjust
Illustration 269 g01803476
7. Remove engine oil filler cap (1). Fill the engine
crankcase with new oil. Clean the filler cap and
install the filler cap.
Reference: For information on lubricants and refill
capacities, refer to the Operation and Maintenance
Manual, “Lubricant Viscosities and Refill Capacities”
for the machine that is being serviced.
8. Start the engine and run the engine at low idle for
five minutes. Inspect the engine oil filter for leaks.
9. Maintain the oil level in the hatched area on the
SAFE OPERATING RANGE ENGINE RUNNING
side of dipstick (2). Add oil, if necessary.
10. Stop the engine.
i05884047
Engine Valve Lash - Check/
Adjust
SMCS Code: 1102-025; 1102-535
Ensure that the engine cannot be started while
this maintenance is being performed. To help pre-
vent possible injury, do not use the starting motor
to turn the flywheel.
Hot engine components can cause burns. Allow
additional time for the engine to cool before meas-
uring/adjusting valve lash clearance.
146 SEBU8906
Maintenance Support
Engine Valve Rotators - Inspect

NOTICE NOTICE
Only qualified service personnel should perform this A valve rotator which does not operate properly will
maintenance. Refer to the Systems Operation/Testing accelerate valve face wear and valve seat wear and
and Adjusting Manual, “Valve Lash and Valve Bridge shorten valve life. If a damaged rotator is not re-
Adjustment” article or consult your Caterpillar dealer placed, valve face guttering could result and cause
for the complete valve lash adjustment procedure. pieces of the valve to fall into the cylinder. This can
cause piston and cylinder head damage.
Operation of Caterpillar engines with improper valve
adjustments can reduce engine efficiency. This re-
duced efficiency could result in excessive fuel usage Valve rotators cause the valve to rotate when the
and/or shortened engine component life. engine runs. This helps to prevent deposits from
building up on the valve and the valve seats.
The initial valve lash adjustment on new engines,
rebuilt engines, or remanufactured engines is
recommended at the first scheduled oil change. The
initial adjustment is necessary due to initial wear of
the valve train components and seating of the valve
train components.
This maintenance is recommended by Caterpillar as
part of a lubrication and preventative maintenance
schedule in order to help provide maximum engine
life.

Reference: For more information on adjusting the

engine valve lash, refer to Testing and Adjusting,
“Engine Valve Lash - Inspect/Adjust”
Illustration 270 g00905744
Adjustment of the Electronic Unit
Perform the following steps after the valve lash is set,
Injectors but before the valve covers are installed:
Adjust the electronic unit injector preload at the same 1. Start the engine. Operate the engine at low idle
interval as the valve lash adjustment. The operation
of Caterpillar engines with improper valve adjustment 2. Observe the top surface of each valve rotator. The
and with improper adjustments of the electronic unit
injector can reduce engine efficiency. This reduced valve rotators should turn slightly when the valves
efficiency could result in excessive fuel usage and/or close.
shortened engine component life.
If the valve fails to rotate, contact your Caterpillar
Reference: For more information on adjusting the dealer.
electronic unit injectors, refer to Testing and
Adjusting, “Electronic Unit Injectors - Adjust”

i01770623

Engine Valve Rotators - Inspect

SMCS Code: 1109-040

When inspecting the valve rotators, protective

glasses or face shield and protective clothing
must be worn, to help prevent being burned by
hot oil or spray.
SEBU8906 147
Maintenance Support
Engine Water Pump - Inspect

i02358781 i03460641

Engine Water Pump - Inspect Exhaust Purifier - Inspect/

SMCS Code: 1361-040 Clean
SMCS Code: 1089-040; 1089-070

Illustration 272 g01803479

Remove the catalytic purifier cover. Inspect the

Illustration 271
A water pump that has failed may cause severe
engine overheating problems. The engine
overheating problems could result in the following
problems:
catalytic purifier for damage and for leaks. If
necessary, make repairs. If the catalytic purifier is
damaged, consult your Caterpillar dealer.
If the engine has low power, the catalytic purifier may
be blocked. Clean the catalytic purifier.
Reference: For information on cleaning the catalytic
purifier, refer to the Systems Operation,
Troubleshooting, Testing and Adjusting, “Emission
g01038881
Control Systems for Caterpillar Underground
Machines”.
i02230387

• Cracks in the cylinder head.

Fan Drive Bearing - Lubricate
SMCS Code: 1359-086-BD
• Piston seizure.

• Other potential engine damage. NOTICE

Visually inspect the water pump for leaks. If leaks are
found, all of the seals on the water pump must be
replaced.
Note: For further information, refer to Disassembly
and Assembly, “C15 Engine”.
Check that the lines attached to all the remote grease
fittings are undamaged. If the grease lines are split,
grease will not reach the components that require lu-
bricating. Machine damage will result.
Wipe off the fitting before any lubricant is applied.
148 SEBU8906
Maintenance Support
Fire Suppression System - Check

Illustration 273 g00989174 Illustration 275 g03710638

Dry powder type fire suppression system
1. Apply lubricant through the remote mounted fitting
for the fan drive bearing. Perform fire suppression system checks and service
procedures in accordance with the fire suppression
Note: To avoid seal damage do not over lubricate the system manufacturers service information.
fan drive bearing.
i05793488
i05885030
Frame and Body - Inspect
Fire Suppression System - SMCS Code: 7051-040; 7258-040
Check
(If Equipped) Dump Body
SMCS Code: 7401-535

Reference: For detailed information on the fire

suppression system service procedures, refer to the
fire system manufacturers service information.
The body (bed) may fall unexpectedly and without
warning resulting in personal injury or death.
When it is necessary to work under the truck with
the body (bed) raised, install the body (bed) re-
taining pins through the pin bores in the frame
and body.

Illustration 274 g00991011

Foam type fire suppression system

Illustration 276 g00991029

1. Raise the dump body until the pin bores on the

dump body align with the pin bores on the frame.
Install the two body retaining pins.
SEBU8906
Illustration 277 g01804773
2. Inspect the dump body. If the dump body is
damaged or worn, repair the dump body.
3. Clean the frame with a wire brush or a scraper. If
you find cracks or damage, contact your Caterpillar
dealer for the specific repair procedures.
4. Remove the body retaining pins. If the pins cannot
be removed, raise the dump body to release the
tension. After lowering the dump body, place the
pins in the stored position in the dump body.
Ejector Body
The tailgate may move suddenly and without
warning, resulting in personal injury or death.
When it is necessary to work under the tailgate
with the tailgate raised, install the tailgate retain-
ing pins through the pin bores in the tailgate and
body.
Illustration 278 g03671500
149
Maintenance Support
Frame and Body Support Pads - Clean/Inspect
1. Fully retract the ejector plate and raise the tailgate
until the pin bore on the body aligns with the pin
bore on the tailgate. Install the tailgate retaining
pin.
Illustration 279 g01804798
2. Clean the ejector body with a wire brush or a
scraper. Inspect the ejector body. If the body is
damaged or worn, repair the body. If you find
cracks, contact your Caterpillar dealer for the
specific repair procedure.
3. Remove the tailgate retaining pin. If the pin cannot
be removed, raise the tailgate to release the
tension. Place the pin in the stored position in the
ejector body.
i03462061
Frame and Body Support Pads
- Clean/Inspect
SMCS Code: 7051-040; 7051-070; 7258-040; 7258-
070
Dump Body
The body (bed) may fall unexpectedly and without
warning resulting in personal injury or death.
When it is necessary to work under the truck with
the body (bed) raised, install the body (bed) re-
taining pins through the pin bores in the frame
and body.
150
Maintenance Support
Fuel System - Prime
Illustration 280 g00991037
1. Raise the dump body until the retaining bores on
the dump body align with the retaining bores on the
frame. Install the two retaining pins.
Illustration 281 g01804818
2. Clean the body support pads with high pressure
water or steam. If damage is found, contact your
Caterpillar dealer for the specific repair
procedure.
3. Visually inspect each of the body support pads.
Look for uneven wear of the body support pads.
Look for gaps between the body support pads and
the mating surfaces. If problems are found contact
your Caterpillar dealer for additional information.
4. Remove the body retaining pins. If the pins cannot
be removed, raise the dump body to release the
tension. After lowering the dump body, place the
pins in the stored position in the dump body.
Ejector Body
SEBU8906
Illustration 282 g00992142
1. Clean the ejector body support pads with high
pressure water or steam. If damage is found,
contact your Caterpillar dealer for the specific
repair procedure.
2. Visually inspect each of the ejector body support
pads. Look for uneven wear of the ejector body
support pads. Look for gaps between the ejector
body support pads and the mating surfaces. If
problems are found contact your Caterpillar
dealer for additional information.
i05793491
Fuel System - Prime
SMCS Code: 1250-548
After changing the fuel filters or if the engine fuel
system is run dry, the fuel system must be primed
(purged). Priming (Purging) the fuel system will fill the
fuel filters and remove air bubbles from the system.
NOTICE
Do not loosen the fuel lines at the fuel manifold. The
engine components may be damaged.
Do not remove the fitting in the fuel filter base in order
to release air from the fuel system while priming the
engine. Periodic removal of the fitting will result in in-
creased wear of the threads in the fuel filter base and
will lead to fuel leakage.
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around any fuel system component
that will be disconnected. Fit a suitable cover over
any disconnected fuel system component in order to
protect it from dirt and debris.
SEBU8906
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products.
Dispose of all fluids according to local regulations and
mandates.
Illustration 283 g02849376
Location of the electric fuel priming pump
Illustration 284 g03671503
(1) Switch for the Electric Fuel Priming Pump
Note: The engine start switch must be in the OFF
position in order to prime the fuel system.
1. Hold switch (1) upward in order to activate the
electric fuel priming pump. The priming pump will
fill the engine fuel lines and the fuel filters with fuel.
151
Maintenance Support
Fuel System Primary Filter (Water Separator) - Drain
2. As the air is purged from the fuel system, fuel
pressure will increase. Listen for the electric fuel
priming pump to come under load. Do not continue
priming the fuel system after the priming pump is
under load. Do not operate the priming pump for
more than 2 minutes.
3. Crank the engine promptly after pressurizing the
fuel system. The engine should start within 15
seconds.
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
4. If the engine will not start, allow the starter motor 2
minutes to cool. Repeat Step 1 through Step 3.
5. If the engine starts, but runs rough, or once started
continues to misfire or smoke, further priming is
necessary. Continue to run the engine at low idle
until fuel flows free without pockets of air in the fuel
lines and the engine runs smoothly.
i05750227
Fuel System Primary Filter
(Water Separator) - Drain
SMCS Code: 1261-543; 1263-543
Personal injury or death can result if spilled fuel
ignites. Fuel leaked or spilled onto hot surfaces or
electrical components can cause a fire.
To help prevent possible injury, turn the battery
disconnect switch to the OFF position when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products.
Dispose of all fluids according to local regulations and
mandates.
152 SEBU8906
Maintenance Support
Fuel System Primary Filter (Water Separator) - Replace

NOTICE
Do not fill fuel filters with fuel before installing
them. The fuel will not be filtered and could be
contaminated. Contaminated fuel will cause accel-
erated wear to fuel system parts. The fuel system
should be primed prior to starting the engine.

Illustration 285 g03671501

1. Open the drain valve a 1/4 turn and allow the water
and sediment to drain into a suitable container.
2. Close the drain valve.

Illustration 286 g02849376

i05793495

Location of the primary fuel filter.

Fuel System Primary Filter
(Water Separator) - Replace
SMCS Code: 1261-510; 1263-510
Replace the primary element when the engine has a
loss of power or when the exhaust smoke is black.

Personal injury or death can result if spilled fuel

ignites. Fuel leaked or spilled onto hot surfaces or
electrical components can cause a fire.
To help prevent possible injury, turn the battery
disconnect switch to the OFF position when
changing fuel filters or water separator elements.
Clean up fuel spills immediately. Illustration 287 g03671505

1. In order to drain the primary filter, open drain valve

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
(2) a 1/4 turn. Catch the fuel in a suitable container.
2. Remove primary filter (1) with a strap-type wrench.
3. Remove and retain metal drain valve (2) for
installation purposes. Dispose of the used filter
properly

Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products.
Dispose of all fluids according to local regulations and
mandates.
4. Remove and discard the plastic drain valve from
the new filter. Retain the new drain valve seal from
the plastic drain valve.
5. Clean metal drain valve (2).

6. Apply clean diesel fuel to the new drain valve seal

and place onto to metal drain valve (2).
SEBU8906
7. Install metal drain valve (2) onto the new filter by
hand.
Illustration 288 g00101502
8. Lubricate the sealing surface of new primary filter
(1) with clean diesel fuel.
9. Install the new filter hand tight until the seal of the
filter contacts the filter mounting base. Note the
position of the index marks on the filter in relation
to a fixed point on the filter mounting base.
Note: There are rotation index marks on the filter that
are spaced 90 degrees or 1/4 of a turn away from
each other. When you tighten the filter, use the
rotation index marks as a guide.
10. Tighten the filter according to the instructions that
are printed on the filter. Use the index marks as a
guide for tightening the filter. For non-Caterpillar
filters, use the instructions that are provided with
the filter.
Note: A Caterpillar strap wrench, or another suitable
tool maybe required in order to turn the filter to the
amount that is required for final installation. Make
sure that the installation tool does not damage the
filter.
11. Prime the fuel system. Refer to Operation and
Maintenance Manual, “Fuel System - Prime”.
Note: The secondary fuel filter should also be
changed at this time. Refer to Operation and
Maintenance Manual, “Fuel System Secondary Filter
- Replace”.
12. Start the engine and check for leaks. Make any
necessary repairs.
153
Maintenance Support
Fuel System Secondary Filter - Replace
i05750228
Fuel System Secondary Filter -
Replace
SMCS Code: 1261-510-SE
Personal injury or death can result if spilled fuel
ignites. Fuel leaked or spilled onto hot surfaces or
electrical components can cause a fire.
To help prevent possible injury, turn the battery
disconnect switch to the OFF position when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products.
Dispose of all fluids according to local regulations and
mandates.
NOTICE
Do not fill fuel filters with fuel before installing
them. The fuel will not be filtered and could be
contaminated. Contaminated fuel will cause accel-
erated wear to fuel system parts. The fuel system
should be primed prior to starting the engine.
Illustration 289 g03671504
154 SEBU8906
Maintenance Support
Fuel Tank Breather - Replace

1. Remove the fuel filter element with a strap-type i02934292

wrench. Discard the used filter.
Fuel Tank Breather - Replace
2. Clean the filter housing base. Make sure that all of
the old seal is removed. SMCS Code: 1273-510-BRE

3. Lubricate the sealing surface of the new filter

element with clean diesel fuel.
4. Install a new filter hand tight until the seal of the
filter contacts the base. Note the position of the
index marks on the filter in relation to a fixed point
on the filter base.

Note: There are rotation index marks on the

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

5. Tighten the filter according to the instructions that

are printed on the filter. Use the index marks as a Illustration 290 g01455243
guide. For non-Caterpillar filters, use the Fast fill only
instructions that are provided with the filter.
1. Remove cover (1).
Note: Use a Caterpillar strap wrench, or another
suitable tool, in order to turn the filter to the amount 2. Remove the fuel tank breather. Properly discard
that is required for final installation. Make sure that
the used breather.
the installation tool does not damage the filter.
3. Install the new breather by hand.
6. Prime the fuel system.
4. Install cover (1).
Reference: For information on priming the fuel
system, refer to the Operation and Maintenance
Manual, “Fuel System - Prime” for the machine that is i05885029
being serviced.
Fuel Tank Cap and Strainer -
7. Start the engine and inspect the filter for leaks.
Make any necessary repairs.
Clean
SMCS Code: 1273-070-STR; 1273-070-Z2

Note: Machines equipped with an optional fast-fill fuel

system do not contain a breather filter element in the
fuel cap. Perform Steps 3 and 5 only to standard
machines without the fast-fill fuel system.
SEBU8906
Illustration 291
The fuel tank cap is located on the right side of the
machine.
Illustration 292
1. Lift lever (5) and turn the lever counterclockwise
until the lever stops. Lift the cap straight up to
remove the cap.
2. Inspect seal (4) for damage. Replace the seal, if
necessary.
3. Remove screws (1), filter assembly (2), valve (3)
and gaskets.
4. Wash the cap in a clean, nonflammable solvent.
5. Install a new filter kit in the cap. Install the
components in reverse order.
155
Maintenance Support
Fuel Tank Water and Sediment - Drain
g03710636 Illustration 293 g03710637
6. Remove the strainer from the filler opening.
7. Wash the strainer in a clean, nonflammable
solvent.
8. Install the strainer in the filler opening.
9. Install the fuel tank cap.
i01904466
Fuel Tank Water and Sediment
- Drain
SMCS Code: 1273-543-M&S
g00906284
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and sup-
plies suitable to collect and contain fluids on Caterpil-
lar products.
Dispose of all fluids according to local regulations and
mandates.
156 SEBU8906
Maintenance Support
Fuses - Replace

NOTICE
Replace the fuses with the same type and size only.
Otherwise, electrical damage can result.
If it is necessary to replace fuses frequently, an elec-
trical problem may exist. Contact your Caterpillar
dealer

Illustration 294 g00991356

The drain valve is located on the right side of the

machine under the fuel tank.

Illustration 296 g01165532

View of the battery compartment

(1) 500 Amp - Fuse.

i01901268

Hoist Cylinder Bearings -

Lubricate
Illustration 295 g00991652
SMCS Code: 7551-086-CD
1. Open (turn counterclockwise) drain valve (1) and
allow the water and sediment to drain out of NOTICE
opening (2) into a suitable container. Check that the lines attached to all the remote grease
fittings are undamaged. If the grease lines are split,
2. Close drain valve (1). grease will not reach the components that require lu-
bricating. Machine damage will result.
i02334758
Wipe off the fittings before any lubricant is applied.
Fuses - Replace
SMCS Code: 1417-510

Fuses – Fuses protect the electrical

system from damage caused by
overloaded circuits. Replace the fuse if
the element separates. If the element of a new
fuse separates, check the circuit. Repair the
circuit, if necessary.
SEBU8906
Illustration 297 g00989204
Left side view
1. Apply lubricant through remote mounted fitting (1)
for the left lower hoist cylinder bearing.
2. Apply lubricant through remote mounted fitting (2)
for the right lower hoist cylinder bearing.
3. Apply lubricant through remote mounted fitting (3)
for the right upper hoist cylinder bearing.
4. Apply lubricant through remote mounted fitting (4)
for the left upper hoist cylinder bearing.
i05898431
Hoses and Clamps - Inspect/
Replace
SMCS Code: 1000; 7554-040; 7554-510
Hoses and clamps must be inspected periodically in
order to ensure safe operation and continuous
operation of the machine. Take proper safety
precautions before inspecting or replacing hoses and
clamps.
Note: Always use a board or cardboard when
components are checked for leaks. Leaking fluid that
is under pressure can cause serious injury or
possible death. Leaks that are the size of a pin hole
are included. Refer to Operation and Maintenance
Manual, “General Hazard Information” for more
information.
Inspect the Hoses and the Clamps
Inspect all hoses for leaks that are caused by the
following conditions. Replace any hose which exhibits
any of the following conditions. Failure to replace a
hose which exhibits any of the following conditions
may result in a hazardous situation.
157
Maintenance Support
Hoses and Clamps - Inspect/Replace
• Hoses which are cracked
• Hoses which are soft
• Outer covering that is chafed or cut
• Exposed wire that is used for reinforcement
• Outer covering that is ballooning locally
• Flexible part of the hose that is kinked or crushed
• Armoring that is embedded in the outer covering
• Hoses which exhibit signs of leakage which are not
the result of loose couplings or clamps
Inspect all clamps for the following conditions.
Replace any clamp which exhibits signs of any of the
following conditions.
• Cracking
• Looseness
• Damage
Inspect all couplings for leaks. Replace any coupling
which exhibits signs of leaks.
Each installation application can be different. The
differences depend on the following factors:
• Type of hose
• Type of fitting material
• Anticipated expansion and contraction of the hose
• Anticipated expansion and contraction of the
fittings
Due to extreme temperature changes, the hose will
heat set. Heat setting causes hose clamps to loosen
which can result in leaks. A constant torque hose
clamp will help to prevent loose hose clamps.
Replace hoses that are cracked or soft. Replace
hoses that show signs of leakage. Replace hoses
that show signs of damage. Replace hose clamps
that are cracked or damaged. Tighten or replace hose
clamps which are loose.
Replacing Hoses and Clamps
At operating temperature, engine coolant is hot
and under pressure. Hot coolant and hot compo-
nents can cause severe burns. Do not allow hot
coolant or hot components to contact the skin.
158 SEBU8906
Maintenance Support
Hydraulic System Oil - Change

i05793512

Hot oil and hot components can cause personal Hydraulic System Oil - Change
injury. Do not allow hot oil or hot components to SMCS Code: 5050-044
contact the skin.

Hot oil and hot components can cause personal

Personal injury can result from removing hoses
or fittings in a pressure system.
Failure to relieve pressure can cause personal
injury.
Do not disconnect or remove hoses or fittings un-
til all pressure in the system has been relieved.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
fluids on Cat products.
Dispose of all fluids according to local regulations and
mandates.
injury. Do not allow hot oil or hot components to
contact the skin.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
Operate the machine for a few minutes in order to
warm the hydraulic system oil.
Park the machine on level ground. Engage the
parking brake and stop the engine.

1. If a coolant hose needs to be replaced, drain the

coolant to a level that is below the hose. Drain the
coolant into a suitable clean container. The coolant
can be reused.
2. Replace any damaged hoses. Replace any
damaged clamps.

Note: Refer to Specifications, SENR3130, “Torque

Specifications”, “Hose Clamps” for information about
selecting and installing the proper hose clamps.

3. Fill the affected system to the proper fluid level.

Illustration 298 g03671517
4. Start the engine and operate the engine at low idle.
Check for leaks and make necessary repairs. 1. Relieve the hydraulic tank pressure by pushing top
of breaker relief valve (1) before removing the oil
filler cap.
SEBU8906
Illustration 299 g01804993
2. Remove oil filler cap (3) slowly to relieve any
remaining pressure.
Illustration 300 g00991355
Note: Hand tighten the NPT pipe nipple. Do not use
tools.
3. Remove hydraulic tank drain plug (6). Install a 1
inch NPT pipe nipple, 88 mm (3.50 inch) long, in
the bottom of the tank, to open the internal drain
valve. Drain the oil into a suitable container.
4. Remove the pipe nipple. Clean the drain plug and
install the drain plug.
5. Change the hydraulic system pilot oil filters.
Reference: For the correct procedure, refer to the
Operation and Maintenance Manual, “Hydraulic
System Oil Filter (Pilot) - Replace” for the machine
that is being serviced.
6. Remove the strainer from the hydraulic oil filler
tube.
7. Wash the oil filler cap and the strainer in clean,
nonflammable solvent. Allow the oil filler cap and
the strainer to dry.
159
Maintenance Support
Hydraulic System Oil Filter (Pilot) - Replace
8. Inspect the oil filler cap gasket. Use a new gasket if
the used gasket is damaged. Install the strainer in
the filler tube.
9. Fill the hydraulic tank with clean oil.
Reference: For information on lubricants and refill
capacities, refer to the Operation and Maintenance
Manual, “Lubricant Viscosities and Refill Capacities”
for the machine that is being serviced.
10. When the dump body is fully raised, ensure that
the hydraulic oil level is in the “SAFE START
BODY RAISED” range of lower sight gauge (5).
11. Start the engine and run the engine at low idle.
Check for leaks.
12. For machines equipped with a dump body check
the oil level with the body fully lowered. For
machines equipped with an ejector body check the
oil level with the ejector plate fully retracted and the
tailgate fully raised. With the oil cold maintain the
hydraulic oil level to the “FULL COLD” mark in
sight gauge (2). With the oil at operating
temperature, maintain the hydraulic oil level to the
“FULL WARM” mark in sight gauge (2). Add more
oil, if necessary through filler tube (4).
Note: The oil must be free of bubbles. If bubbles are
present in the oil, air is entering the hydraulic system.
Inspect the hydraulic suction line hoses and the hose
clamps.
13. Stop the engine.
14. If necessary, tighten any loose clamps or any
loose connections. Replace any damaged hoses.
i05793515
Hydraulic System Oil Filter
(Pilot) - Replace
SMCS Code: 5092-510
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
160 SEBU8906
Maintenance Support
Hydraulic System Oil Filter (Pilot) - Replace

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
Illustration 303 g00991719

3. Use a strap type wrench to remove the filter

elements. Dispose of the used filters properly.

4. Clean the filter mounting base. Ensure all of the old

seal is removed.

Illustration 301 g01370458

1. Relieve the hydraulic tank pressure by pushing the

top of breaker relief valve (1) before removing the
oil filler cap.

Illustration 304 g00101502

5. Lubricate the sealing surface of the new filter

elements with clean hydraulic oil.

6. Install the new filter elements hand tight until the

seal of the filter contacts the base. Note the
position of the index marks on the filter in relation
to a fixed point on the filter base.

Note: There are rotation index marks on the filter that

are spaced 90 degrees or 1/4 of a turn away from
each other. When you tighten the filter, use the
rotation index marks as a guide.
Illustration 302 g01804994
7. Tighten the filter according to the instructions that
are printed on the filter. Use the index marks as a
2. Remove oil filler cap (2) slowly to relieve any
guide. For non-Caterpillar filters, use the
remaining pressure.
instructions that are provided with the filter.
SEBU8906
Note: Use a Caterpillar strap wrench, or another
suitable tool, in order to turn the filter to the amount
that is required for final installation. Make sure that
the installation tool does not damage the filter.
8. Start the engine and run the engine at low idle.
Check for leaks.
Illustration 305 g01804995
9. For machines equipped with a dump body check
the oil level with the body fully lowered. For
machines equipped with an ejector body check the
oil level with the ejector plate fully retracted and the
tailgate fully raised. With the oil cold maintain the
hydraulic oil level to the “FULL COLD” mark in
sight gauge (3). With the oil at operating
temperature, maintain the hydraulic oil level to the
“FULL WARM” mark in sight gauge (3). Add more
oil, if necessary through filler tube (4).
10. Stop the engine.
161
Maintenance Support
Hydraulic System Oil Level - Check
i05793518
Hydraulic System Oil Level -
Check
SMCS Code: 5050-535-FLV
Illustration 306 g01804996
The hydraulic oil tank is located on the right side of
the machine.
Check the hydraulic oil level with the machine on a
level surface and the parking brake engaged. The
engine must be at low idle.
1. For machines equipped with a dump body check
the oil level with the body fully lowered. For
machines equipped with an ejector body check the
oil level with the ejector plate fully retracted and the
tailgate fully raised. With the oil cold maintain the
hydraulic oil level to the “FULL COLD” mark in
sight gauge (1). With the oil at operating
temperature, maintain the hydraulic oil level to the
“FULL WARM” mark in sight gauge (1).
162 SEBU8906
Maintenance Support
Hydraulic Tank Breaker Relief Valve - Clean

4. Install the breaker relief valve.

i02732803

Hydraulic Tank Screen - Clean

SMCS Code: 5056-070-Z3

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact the skin.
Illustration 307 g03671518

NOTICE
2. Relieve the hydraulic tank pressure by pushing the Care must be taken to ensure that fluids are con-
top of breaker relief valve (3) before removing the tained during performance of inspection, mainte-
oil filler cap. nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
3. Remove oil filler cap (2) slowly to relieve any before opening any compartment or disassembling
remaining pressure. Add oil, if necessary, through any component containing fluids.
the filler tube.
Refer to Special Publication, NENG2500, “Caterpillar
4. Clean the oil filler cap and install the oil filler cap. Tools and Shop Products Guide” for tools and sup-
plies suitable to collect and contain fluids on Caterpil-
lar products.
i05793519
Dispose of all fluids according to local regulations and
Hydraulic Tank Breaker Relief mandates.
Valve - Clean
There is one suction screen in the hydraulic tank.
SMCS Code: 5118-070
There is one return screen in the hydraulic tank.
Clean both screens whenever there is a failure of the
brake system, hoist system or another hydraulic
component that uses oil from the hydraulic tank.
Clean the screens in order to remove the debris.

Illustration 308 g03671519

1. Depress the button on the top of the breaker relief

valve in order to relieve any pressure in the
Illustration 309 g01370458
hydraulic tank.

2. Remove the breaker relief valve.
3. Clean the breaker relief valve in a clean,
nonflammable solvent. Shake the breaker relief
valve dry or use pressure air.
1. Relieve the hydraulic tank pressure by pushing on
top of breaker relief valve (1) before removing the
oil filler cap.
SEBU8906 163
Maintenance Support
Hydraulic Tank Screen - Clean

Illustration 310 g01370447 Illustration 312 g01370451

2. Remove oil filler cap (3) slowly to relieve any 4. Remove bolt (7), return tube (8) and cover (9).
remaining pressure.
5. Remove the valve and return screen assembly.

6. Wash the valve and return screen assembly in

clean, nonflammable solvent.

7. Install the valve and return screen, cover (9), return

tube (8) and bolt (7).

Illustration 311 g01370450

Note: Hand tighten the NPT pipe nipple. Do not use

tools.
3. Remove hydraulic tank drain plug (6). Install a 1
inch NPT pipe nipple, 88 mm (3.50 inch) long, in
the bottom of the tank, to open the internal drain
Illustration 313 g00993359
valve. Drain the oil into a suitable container.
8. Remove suction tube (10).

9. Remove the suction screen from the hydraulic

tank.
10. Wash the suction screen in clean, nonflammable
solvent.
11. Install the clean suction screen, the suction tube
and the retaining bolts.
164 SEBU8906
Maintenance Support
Indicators and Gauges - Test

i05884050

Indicators and Gauges - Test

SMCS Code: 7000-081; 7450-081

Illustration 314 g01370454

12. Remove guard (11).

13. Remove front cover (12) from the hydraulic tank.

14. Clean the debris from the bottom of the hydraulic
tank.
15. Clean the cover for the front of the hydraulic tank
in clean, nonflammable solvent. Install a new
gasket.
16. Install cover (12) to the front of the tank.
17. Install guard (11).
18. Fill the hydraulic tank with clean oil. Refer to
Operation and Maintenance Manual, “Lubricant
Viscosities and Refill Capacities”.
19. When the dump body is fully raised ensure the
hydraulic oil level is in the “SAFE START BODY
RAISED” range of lower sight gauge (5).
20. Start the engine and run the engine at low idle.
Check for leaks.
21. For machines equipped with a dump body check
the oil level with the body fully lowered. For
machines equipped with an ejector body check the
oil level with the ejector plate fully retracted and the
tailgate fully raised. With the oil cold maintain the
hydraulic oil level to the “FULL COLD” mark in
sight gauge (2). With the oil at operating
temperature, maintain the hydraulic oil level to the
“FULL WARM” mark in sight gauge (2). Add more
oil, if necessary through filler tube (4).
Illustration 315 g03710597
Before you operate the machine, perform the
following checks and make any necessary repairs:
• Look for broken lenses on the gauges. Also, look
for broken indicator lights, broken switches, and
other broken components in the operators station.
• Move the engine start switch key to the ON
position and check the Caterpillar Monitoring
System self test.
Reference: For information on the Caterpillar
Monitoring System self test, refer to the Operation
and Maintenance Manual, “Caterpillar Monitoring
System - Self Test” for the machine that is being
serviced.
• Make sure that the parking brake is engaged. Start
the engine.
• Check for oil leaks. Repair any oil leaks around the
covers or around the hoses.
• Look for inoperative gauges.
• Turn on all machine lights. Check for proper
operation.
• Sound the horn.
• Stop the engine.

Note: The oil must be free of bubbles. If bubbles are

present in the oil, air is entering the hydraulic system.
Inspect the hydraulic suction tubes and the hose
clamps.

22. Stop the engine.

SEBU8906 165
Maintenance Support
Oil Filter - Inspect

i01773398 i05898432

Oil Filter - Inspect Oscillating Hitch - Adjust

SMCS Code: 1308-507; 3067-507; 5068-507 SMCS Code: 7113-025

Inspect a Used Filter for Debris

Personal injury or death can result from machine
articulation or movement.
Machine frames can move and a person can be
crushed.
Connect the steering frame lock link between the
front and rear frames before working on machine.
Secure clevis pin with locking pin.
Before operating the machine, fasten the steering
frame lock link into the stored position and secure
the clevis pin with locking pin.
Failure to lock into the stored position before op-
erating can result in loss of steering.
Illustration 316 g00907074
The Element is Shown with Debris 1. Park the machine on a level surface.
Use a 4C-5084 Filter Cutter to cut the filter element 2. Relieve the tension from the oscillating hitch. Place
open. Spread apart the pleats and inspect the a large block of timber behind the rear wheels of
element for metal and for other debris. An excessive
amount of debris in the filter element can indicate a the machine and reverse the machine against the
possible failure. block.
If metals are found in the filter element, a magnet can 3. Engage the parking brake and stop the engine.
be used to differentiate between ferrous and
nonferrous metals.
Ferrous metals can indicate wear on steel parts and
on cast iron parts.
Nonferrous metals can indicate wear on the
aluminium 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 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. Illustration 317 g00992525
This can result in larger particles in unfiltered oil. The
particles could enter the lubricating system and the 4. Remove three bolts (1) and remove locking plate
particles could cause damage.
(2).
166 SEBU8906
Maintenance Support
Oscillating Hitch - Lubricate

If regular lubrication is carried out at the

recommended interval. The fittings for the articulating
hitch bearings should only take one or two shots of
grease. As many as 20 shots of grease, may be used
in order to lubricate the bearings for the oscillating
hitch.
Wipe off the fittings before any lubricant is applied.

Illustration 318 g00992526

5. Reposition locking plate (2) so that hole (5) is

outside of the circumference of thrust flange (3).

6. Insert a 3/4 inch square drive through hole (5) so

that the square drive contacts the outside of thrust
flange (3). The square drive will prevent locking Illustration 319 g00989499
plate (2) from rotating clockwise.
1. Apply lubricant through remote mounted fitting (1)
7. Use a suitable wrench on the square drive in order for the upper hitch bearing.
to turn thrust flange (3) clockwise until all end play
has been removed. 2. Apply lubricant through remote mounted fitting (2)
for the lower hitch bearing.
8. If necessary, turn the thrust flange
counterclockwise in order to line up the holes.
Insert the square drive into hole (4) in order to
rotate the thrust flange counterclockwise. Rotate
the thrust flange as far as the first correct hole
alignment.

9. Remove the square drive and reposition locking

plate (2) and bolts (1).

i04872910

Oscillating Hitch - Lubricate

SMCS Code: 7113-086

Illustration 320 g01000113

Crushing Hazard. Ensure that the engine start
switch is in the OFF position, and that the parking
brake is engaged before entering the articulation
area. Failure to do so could result in serious injury
or death.
Left side view of dump body machine
3. Apply lubricant through remote mounted fitting (3)
for the front oscillation bearing.
4. Apply lubricant through remote mounted fitting (4)
for the rear oscillation bearing.

NOTICE
Check that the lines attached to all the remote grease
fittings are undamaged. If the grease lines are split,
grease will not reach the components that require lu-
bricating. Machine damage will result.
SEBU8906 167
Maintenance Support
Pressure Sensor (Transmission Oil) - Test

Illustration 321 g01000114 Illustration 322 g03709998

Left side view of ejector body machine
4. Move the parking brake control to the OFF position
5. Apply lubricant through remote mounted fitting (5) in order to disengage the parking brake.
for the front oscillation bearing.

6. Apply lubricant through remote mounted fitting (6)

for the rear oscillation bearing.

i05884051

Pressure Sensor
(Transmission Oil) - Test
SMCS Code: 1408-081-PXS
Perform the following test to check that the pressure
sensor is functioning correctly.

Note: Before testing the operation of the pressure

sensor, test the holding ability of the machine parking Illustration 323 g00991722
brake.
5. Move the engine shutdown switch to the OFF
Reference: For more information on testing the position. The engine will stop.
parking brake holding ability, refer to the Operation
and Maintenance Manual, “Braking System - Test” for
the machine that is being serviced.

1. Be sure that the area around the machine is clear

of personnel and obstructions.

2. Block the wheels.

3. Start the engine.

Illustration 324 g03710000

6. Parking brake indicator (1) will come on and flash.

Transmission oil pressure indicator (2) will come
on and flash.
168 SEBU8906
Maintenance Support
Radiator Core - Clean

7. If the transmission oil pressure indicator or the

parking brake indicator did not come on,
investigate the cause or consult your Caterpillar
dealer.

i03462200

Radiator Core - Clean

SMCS Code: 1353-070-KO
To access the radiator for cleaning, perform the
following procedure.

Illustration 327 g00907092

2. You can use compressed air, high pressure water

or steam to remove dust and other debris from the
radiator core. However, the use of compressed air
is preferred.

Note: Care must be taken when you are using high

pressure water. High pressure water can cause
damage to the radiator. Using a water spray nozzle
on the pressure washer which will disperse the water
pressure is preferred.

3. Close the grille.

Illustration 325 g01805013 Reference: For the complete procedure for cleaning
(1) Latch the radiator core, refer to Special Publication,
SEBD0518, “Know Your Cooling System” for the
1. Release latch (1) and open the grille at the front of machine that is being serviced.
the machine.

Illustration 326 g01805014

(2) Radiator core
(3) Air conditioning condenser
SEBU8906
i02660498
Refrigerant Dryer - Replace
SMCS Code: 1808-510; 1808; 7322-510; 7322-535;
7322-710
Personal injury can result from contact with
refrigerant.
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 indi-
cate the system is empty of refrigerant.
Always use precaution when a fitting is removed.
Slowly loosen the fitting. If the system is still
under pressure, release it slowly in a well venti-
lated area.
Personal injury or death can result from inhaling
refrigerant through a lit cigarette.
Inhaling air conditioner refrigerant gas through a
lit cigarette or other smoking method or inhaling
fumes released from a flame contacting air condi-
tioner refrigerant gas, can cause bodily harm or
death.
Do not smoke when servicing air conditioners or
wherever refrigerant gas may be present.
Use a certified recovery and recycling cart to
properly remove the refrigerant from the air condi-
tioning system.
Illustration 328 g01337150
The refrigerant dryer is located on the front frame
behind the radiator grill. The dryer contains the
desiccant that dries the liquid refrigerant.
169
Maintenance Support
Refrigerant Dryer - Replace
The moisture indicator is located on the dryer. The
indicator should be checked at the end of each shift. If
the color is blue, the system is dry. If the color is pink,
the system contains moisture. The dryer must be
changed.
Note: The “R-134a” refrigerant dryer should be
replaced annually. Extremely humid operating
conditions may require more frequent replacement of
the dryer. The dryer should also be replaced if the air
conditioning system has been leaking or if the system
has been opened for service repair.
Note: The dryer should be changed once per year
even though the indicator remains blue.
Reference: Refer to Service Manual, SENR5664,
“Air Conditioning and Heating R-134a” for the correct
procedure.
i03462201
Rim - Inspect
SMCS Code: 4209-040
Illustration 329 g01805015
The interval for inspection of the rim and the rim
components is determined by the work-site conditions
and machine usage. The work-site conditions and
machine usage may include but are not limited to:
• Ground conditions
• Corrosive environments
• Operating cycles
Harsh operating cycles or harsh environments can
shorten the service life of the rim and the rim
components. Reduce the interval for inspection in
harsh operating cycles or in harsh environments.
Inspect the rim and the rim components for damage,
cracks and wear. Replace any rims or rim
components that are damaged. Replace any rims or
rim components that are cracked. Replace any rims
or rim components that are worn.
170
Maintenance Support
Rollover Protective Structure (ROPS) - Inspect
For further information, consult your Caterpillar
dealer.
i01904833
Rollover Protective Structure
(ROPS) - Inspect
SMCS Code: 7325-040
NOTICE
Do not attempt to straighten the ROPS structure. Do
not repair the ROPS by welding reinforcement plates
to the structure.
If there are any cracks in the welds, in the castings, or
in any metal section of the ROPS, consult your Cater-
pillar dealer for repairs.
Illustration 330 g01000115
Inspect the ROPS for bolts that are loose or
damaged. Use original equipment parts only to
replace bolts that are damaged or missing. Tighten
the mounting bolts to the correct torque.
Reference: For the correct bolt torques, refer to the
Power Train Specifications, “Cab Mounting” for the
machine that is being serviced.
Note: Apply thread lubricant to all ROPS bolt threads
before installation. Failure to apply lubricant can
result in improper bolt torque.
Replace ROPS mounting supports if the ROPS
rattles or makes a noise when the machine is
operated on a rough surface.
Do not repair the ROPS by welding reinforcement
plates to the ROPS. Consult your Caterpillar dealer
for repair of cracks in any welds, in any castings, or
any metal section of the ROPS.
Ensure any certification labels are firmly fixed and
legible.
SEBU8906
i04872913
Screen (Torque Converter) -
Clean
SMCS Code: 3101-070-Z3
Personal injury or death can result from machine
articulation or movement.
Machine frames can move and a person can be
crushed.
Connect the steering frame lock link between the
front and rear frames before working on machine.
Secure clevis pin with locking pin.
Before operating the machine, fasten the steering
frame lock link into the stored position and secure
the clevis pin with locking pin.
Failure to lock into the stored position before op-
erating can result in loss of steering.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products.
Dispose of all fluids according to local regulations and
mandates.
Clean the screen whenever there is a failure of the
torque converter.
1. Park the machine on a level surface. Engage the
parking brake. Stop the engine.
SEBU8906 171
Maintenance Support
Seat Belt - Inspect

Illustration 331 g00989509 Illustration 332 g01125794

Note: Hand tighten the NPT pipe nipple. Do not use
tools.
2. Remove torque converter drain plug (5). Open the
drain valve by installing a 1 inch NPT pipe nipple,
100 mm (4 inch). Drain the oil into a suitable
container.
3. Remove the pipe nipple and install the drain plug.
Tighten the drain plug to 68 ± 7 N·m (50 ± 5 lb ft).
10. While the engine is running and at operating
temperature, maintain the oil level between two
marks (9) in sight gauge (7).
Note: The oil level varies significantly when the
engine is stopped. The oil level should be above mark
(8) before the engine is started.
11. Remove filler cap (6) and add oil if necessary.

4. Remove bolts (2) from cover assembly (1). 12. Stop the engine.
Remove the cover assembly.
i04423622
5. Remove screen (3).

6. Wash the screen in clean, nonflammable solvent.

Seat Belt - Inspect
Do not crush the screen. SMCS Code: 7327-040

7. Inspect cover gasket (4) for damage. If damaged, Always inspect the condition of the seat belt and the
use a new gasket. condition of the seat belt mounting hardware before
you operate the machine. Replace any parts that are
8. Install the screen. Install the cover. damaged or worn before you operate the machine.

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

Inspect for leaks.

Illustration 333 g02620101

Typical example

Inspect buckle (1) for wear or for damage. If the

buckle is worn or damaged, replace the seat belt.
172 SEBU8906
Maintenance Support
Seat Belt - Replace

Inspect seat belt (2) for webbing that is worn or Complete seat belt system should be installed with
frayed. Replace the seat belt if the webbing is worn or new mounting hardware.
frayed.
Date of installation labels should be marked and
Inspect all seat belt mounting hardware for wear or for affixed to the seat belt retractor and buckle.
damage. Replace any mounting hardware that is
worn or damaged. Make sure that the mounting bolts Note: Date of installation labels should be
are tight. permanently marked by punch (retractable belt) or
stamp (non-retractable belt).
If your machine is equipped with a seat belt
extension, also perform this inspection procedure for If your machine is equipped with a seat belt
the seat belt extension. extension, also perform this replacement procedure
for the seat belt extension.
Contact your Cat dealer for the replacement of the
seat belt and the mounting hardware.
i04872914
Note: The seat belt should be replaced within 3 years
of the date of installation. A date of installation label is Service Inspection
attached to the seat belt retractor and buckle. If the
SMCS Code: 7000
date of installation label is missing, replace belt within
3 years from the year of manufacture as indicated on
belt webbing label, buckle housing, or installation
tags (non-retractable belts).
The body (bed) may fall unexpectedly and without
warning resulting in personal injury or death.
i04421974
When it is necessary to work under the truck with
Seat Belt - Replace the body (bed) raised, install the body (bed) re-
taining pins through the pin bores in the frame
SMCS Code: 7327-510 and body.
The seat belt should be replaced within 3 years of the
date of installation. A date of installation label is
attached to the seat belt retractor and buckle. If the
date of installation label is missing, replace belt within
3 years from the year of manufacture as indicated on
belt webbing label, buckle housing, or installation No clearance for person in this area when tailgate
tags (non-retractable belts). lowers. Severe injury or death from crushing
could occur. Install tailgate safety pin before serv-
icing machine in tailgate area. Remove safety pin
and secure before resuming operation.

Crushing Hazard. Ensure that the engine start

switch is in the OFF position, and that the parking
brake is engaged before entering the articulation
area. Failure to do so could result in serious injury
or death.

Illustration 334
Typical Example
(1) Date of installation (retractor)
(2) Date of installation (buckle)
(3) Year of manufacture (tag) (fully extended Web)
(4) Year of manufacture (underside) (buckle)
g01152685 For maximum service life of the machine, make a
thorough service inspection when you perform
lubrication and maintenance work. Look around the
machine and under the machine. Inspect the
condition of all major components. Check all grease
fittings. Look for the following discrepancies:

Consult your Cat dealer for the replacement of the

seat belt and the mounting hardware.
Determine age of new seat belt before installing on
seat. A manufacture label is on belt webbing and
imprinted on belt buckle. Do not exceed install by
date on label.
SEBU8906 173
Maintenance Support
Service Inspection

• loose bolts
• trash buildup

• oil, coolant, or fuel leaks

• broken parts or worn parts

• cracks in the frames

Remove any trash and any debris. As needed, adjust
the tire inflation. Make any necessary repairs. Make
sure that all loose connections and all parts are
tightened to the specified torques. Replace any
missing parts before starting the engine or before
operating the machine.
Inspect the machine for leaks. If leaks are observed,
find the source of the leak and correct the leak. If
leaks are suspected, check the fluid levels more
frequently than the recommended intervals.
174 SEBU8906
Maintenance Support
Service Inspection

Illustration 335 g00992046

Inspection points for the service inspection
(A) Ground level controls (G) Fuel tank (M) Automatic lubricant reservoir (if
(B) Front lights (H) Power train hydraulic system equipped)
(C) Cooling system (I) Steering hydraulic system (N) Tires
(D) Engine (J) Articulating hitch and oscillating hitch (O) Rollover Protective Structure
(E) Hydraulic system (K) Rear axle
(F) Air cleaner (L) Frame and body
SEBU8906
Illustration 336 g01805016
(A) Inspect the ground level controls for proper
operation. Replace a damaged or worn engine
shutdown switch (1). Replace a damaged or worn
battery disconnect switch (2).
(B) Inspect the lights for broken lamps, lenses, and
proper operation. Replace broken lamps and lenses.
(C) Inspect the cooling system for leaks, worn hoses,
and debris. Repair any leaks and damaged hoses.
Remove any debris that could block the air flow
through the radiator.
Illustration 337 g03671520
(D) Inspect the engine. Use dipstick (3) to check the
engine oil level. Check for oil leaks, coolant leaks,
and exhaust leaks. Check the belts of the engine for
proper tension and for good condition.
175
Maintenance Support
Service Inspection
Illustration 338 g01805019
(E) Inspect the hydraulic system. Check for leaks,
worn hoses, and damaged lines. Repair any leaks,
worn hoses, and damaged lines.
Check the level in hydraulic tank (4). Make sure that
the filler cap is installed. Inspect the tank covers for
damaged bolts, loose bolts, or missing bolts. Tighten
loose bolts and replace missing bolts. Check the
welds and mounting brackets for the hydraulic tank.
Inspect the tank for leaks or for damage. If necessary,
make repairs.
Illustration 339 g01805020
(F) Check engine air cleaner hood (5) for
accumulated debris. If necessary, clean engine air
cleaner hood (5).
(G) Inspect the fuel tank. Make sure that the filler cap
is installed correctly. Check the welds and mounting
brackets for the fuel tank. Look for any leaks or
damage to the fuel tank.
176
Maintenance Support
Service Inspection
Illustration 340 g00992118
(H) Inspect the hydraulic system for torque converter
and transmission (6). Check for leaks from the torque
converter and from the transmission. Check for worn
hoses and for damaged lines. Repair any leaks, worn
hoses, and damaged lines.
Illustration 341 g00992119
(I) Inspect the steering hydraulic system for leaks,
worn hoses, and damaged lines. If necessary repair
leaks, worn hoses and damaged lines. Inspect the
steering cylinders (7).
(J) Inspect the articulating hitch and the oscillating
hitch for wear, damage, and loose or missing bolts.
Have the necessary repairs made.
(K) Inspect the rear axle for leaks. Inspect the rear
lights for damage.
SEBU8906
Illustration 342 g01805021
(L) Inspect the frame and body. Check frame (9) for
cracks or damage. Inspect body (8) for damage,
wear, or distortion. Check for uneven wear of the
body support pads. If equipped with an ejector body,
check the ejector body and the tailgate for damage,
wear and distortion.
Illustration 343 g03710006
(M) Inspect the automatic lubrication system (if
equipped). Inspect tank (10) for leaks. Fill tank (10)
with lubricant. For the correct procedure, refer to the
Operation and Maintenance Manual, “Automatic
Lubrication Grease Tank - Fill” for the machine that is
being serviced. Check all of the grease fittings.
(N) Inspect tires for cuts, gouges, and proper inflation.
Remove large rocks from the treads. Look for
abnormal wear or uneven wear that may indicate
mechanical problems elsewhere. Make sure that you
check the inside of the tire for damage or for wear.
Inspect the tire treads for damage. If necessary,
repair the tires.
Look for damaged rims. Replace any missing valve
caps. Check the wheels for bolts that are loose or
missing.
Note: Rust behind a bolt may indicate that the bolt is
loose. Shiny metal areas around a bolt may indicate
that the bolt is loose.
SEBU8906 177
Maintenance Support
Steering Cylinder Bearings - Lubricate

Illustration 344 g01805022 Illustration 345 g00989502

(O) Inspect the Rollover Protective Structure (ROPS)

(11) for cracks in welds, castings, or any metal
section on the ROPS. Check the mounting bolts and
the mounting pads for damage. Consult your Cat
dealer for necessary repairs. Inspect the operator
station. Check the level in the washer fluid bottle.
Check the Caterpillar Monitoring System for
diagnostic codes. Correct any discrepancies.
1. Apply lubricant through remote mounted fitting (1)
for the bearing in the head end of the left steering
cylinder.
2. Apply lubricant through remote mounted fitting (2)
for the bearing in the head end of the right steering
cylinder.

i04872929

Steering Cylinder Bearings -

Lubricate
SMCS Code: 4303-086-BD

Crushing Hazard. Ensure that the engine start

switch is in the OFF position, and that the parking
brake is engaged before entering the articulation
area. Failure to do so could result in serious injury
or death.
Illustration 346 g00989506

NOTICE
3. Apply lubricant through remote mounted fitting (3)
Check that the lines attached to all the remote grease
fittings are undamaged. If the grease lines are split, for the bearing in the rod end of the right steering
grease will not reach the components that require lu- cylinder.
bricating. Machine damage will result.
4. Apply lubricant through remote mounted fitting (4)
for the bearing in the rod end of the left steering
Wipe off the fittings before any lubricant is applied. cylinder.
178 SEBU8906
Maintenance Support
Steering Stop - Check

i02230393 The machine must be level, the parking brake

engaged, and the engine stopped.
Steering Stop - Check
SMCS Code: 7188-535

Illustration 348 g03671521

Illustration 347 g00992509

1. Relieve the hydraulic tank pressure by pushing the
top of breaker relief valve (1).
Check the clearance between the front frame and the
rear frame steering stops.
Reference: For the correct procedure, refer to
Steering System, Systems Operation, Testing and
Adjusting, “Neutralizer Valve” for the machine that is
being serviced.

i05793526

Steering System Oil Filter -

Replace
SMCS Code: 431F-510; 5068-510

Illustration 349 g00992515

Hot oil and hot components can cause personal 2. Use a strap type wrench to remove the filter
injury. Do not allow hot oil or hot components to elements. Dispose of the used filters properly.
contact the skin.
3. Clean the filter mounting base. Ensure all of the old
seal is removed.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
SEBU8906
Illustration 350 g00101502
4. Lubricate the sealing surface of the new filter
elements with clean hydraulic oil.
5. Install the new filter elements hand tight until the
seal of the filter contacts the base. Note the
position of the index marks on the filter in relation
to a fixed point on the filter base.
Note: There are rotation index marks on the filter that
are spaced 90 degrees or 1/4 of a turn away from
each other. When you tighten the filter, use the
rotation index marks as a guide.
6. Tighten the filter according to the instructions that
are printed on the filter. Use the index marks as a
guide. For non-Caterpillar filters, use the
instructions that are provided with the filter.
Note: Use a Caterpillar strap wrench, or another
suitable tool, in order to turn the filter to the amount
that is required for final installation. Make sure that
the installation tool does not damage the filter.
7. Start the engine and run the engine at low idle.
Check for leaks.
179
Maintenance Support
Tailgate and Tailgate Cylinder Bearings - Lubricate
Illustration 351 g01805023
8. For machines equipped with a dump body check
the oil level with the body fully lowered. For
machines equipped with an ejector body check the
oil level with the ejector plate fully retracted and the
tailgate fully raised. With the oil cold maintain the
hydraulic oil level to the “FULL COLD” mark in
sight gauge (2). With the oil at operating
temperature, maintain the hydraulic oil level to the
“FULL WARM” mark in sight gauge (2). Add more
oil, if necessary through filler tube (3).
9. Stop the engine.
i01905913
Tailgate and Tailgate Cylinder
Bearings - Lubricate
SMCS Code: 5107-086-BD; 7271-086-BD
NOTICE
Check that the lines attached to all the remote grease
fittings are undamaged. If the grease lines are split,
grease will not reach the components that require lu-
bricating. Machine damage will result.
Wipe off the fittings before any lubricant is applied.
180
Maintenance Support
Tire Inflation - Check
Illustration 352 g00992520
Left side view
1. Apply lubricant through remote mounted fitting (1)
for the left tailgate pivot bearing.
2. Apply lubricant through remote mounted fitting (2)
for the left tailgate cylinder head end bearing.
3. Apply lubricant through remote mounted fitting (3)
for the left tailgate cylinder rod end bearing.
4. Apply lubricant through remote mounted fitting (4)
for the right tailgate pivot bearing.
5. Apply lubricant through remote mounted fitting (5)
for the right tailgate cylinder head end bearing.
6. Apply lubricant through remote mounted fitting (6)
for the right tailgate cylinder rod end bearing.
SEBU8906
i03462221
Tire Inflation - Check
SMCS Code: 4203-535-AI; 4203-535-PX
Illustration 353 g01805024
Measure the tire pressure on each tire. Consult your
Caterpillar dealer for correct load rating and for the
correct operating pressures.
Inflate the tires, if necessary.
Reference: For additional information about tire
inflation, tire pressures, and tire inflation pressure
adjustment, refer to the Operation and Maintenance
Manual, “Tire Inflation Information” for the machine
that is being serviced.
i04872931
Transmission Oil - Change
SMCS Code: 3030-044
Personal injury or death can result from machine
articulation or movement.
Machine frames can move and a person can be
crushed.
Connect the steering frame lock link between the
front and rear frames before working on machine.
Secure clevis pin with locking pin.
Before operating the machine, fasten the steering
frame lock link into the stored position and secure
the clevis pin with locking pin.
Failure to lock into the stored position before op-
erating can result in loss of steering.
SEBU8906 181
Maintenance Support
Transmission Oil - Change

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact the skin.

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Dealer Illustration 355 g00990227
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products. Note: Hand tighten the NPT pipe nipple. Do not use
tools.
Dispose of all fluids according to local regulations and 5. Remove converter drain plug (4). Open the drain
mandates.
valve by installing a 1 inch NPT pipe nipple,
100 mm (4 inch). Drain the oil into a suitable
1. Operate the machine for a few minutes in order to container.
warm the transmission oil.
6. Remove the pipe nipple and install the drain plug.
2. Park the machine on a level surface. Engage the Tighten the drain plug to 68 ± 7 N·m (50 ± 5 lb ft).
parking brake. Stop the engine.
7. Remove cover (3) and the magnetic tube and
screen assembly from housing (2).

Illustration 354 g00990231

Note: Hand tighten the NPT pipe nipple. Do not use Illustration 356 g00947579
tools.
3. Remove transmission drain plug (1). Open the 8. Remove the magnetic tube from the screen.
drain valve by installing a 1 inch NPT pipe nipple,
100 mm (4 inch). Drain the oil into a suitable 9. Wash the magnetic tube and the screen in a clean,
container. nonflammable solvent.

4. Remove the pipe nipple and install the drain plug. 10. Clean the magnets with a cloth, stiff bristle brush,
Tighten the drain plug to 68 ± 7 N·m (50 ± 5 lb ft). or pressure air.

NOTICE
Do not drop or rap the magnets against any hard ob-
jects. Replace any damaged magnets.
182
Maintenance Support
Transmission Oil Filter - Replace
11. Clean the cover. Inspect the cover seal. Replace
the seal if damaged.
12. Insert the magnetic tube in the screen.
13. Insert the screen and the magnetic tube in the
housing.
14. Install the seal, the cover, and the cover bolts.
15. Change the transmission oil filter element.
Reference: For the correct procedure, refer to the
Operation and Maintenance Manual, “Transmission
Oil Filter - Replace”.
Illustration 357 g00990243
16. Remove transmission breather (5). Wash the
transmission breather in clean, nonflammable
solvent. Install the breather.
Illustration 358 g01125794
17. Remove oil filler cap (6) and fill the transmission
with oil.
Reference: For information on lubricants and refill
capacities, refer to the Operation and Maintenance
Manual, “Lubricant Viscosities and Refill Capacities”.
SEBU8906
18. Start and run the engine at low idle. Inspect the
transmission for leaks.
19. Operate the transmission control to circulate oil in
the transmission.
20. While the engine is running and at operating
temperature, maintain the oil level between two
marks (9) in sight gauge (7).
Note: The oil level varies significantly when the
engine is stopped. The oil level should be above mark
(8) before the engine is started.
21. Stop the engine.
i04872932
Transmission Oil Filter -
Replace
SMCS Code: 3067-510
Personal injury or death can result from machine
articulation or movement.
Machine frames can move and a person can be
crushed.
Connect the steering frame lock link between the
front and rear frames before working on machine.
Secure clevis pin with locking pin.
Before operating the machine, fasten the steering
frame lock link into the stored position and secure
the clevis pin with locking pin.
Failure to lock into the stored position before op-
erating can result in loss of steering.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
SEBU8906
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products.
Dispose of all fluids according to local regulations and
mandates.
Park the machine on a level surface. Engage the
parking brake. Stop the engine.
Illustration 359 g01805033
The transmission oil filter is located under the
transmission access cover.
Illustration 360 g00990659
1. Use a strap-type wrench in order to remove the
filter elements. Dispose of the used filter elements
properly.
2. Clean the filter mounting base. Be sure all of the
old seal is removed.
183
Maintenance Support
Transmission Oil Filter - Replace
3. Lubricate the sealing surface of the new filter
elements with clean hydraulic oil.
4. Install a new filter hand tight until the seal of the
filter contacts the base. Note the position of the
index marks on the filter in relation to a fixed point
on the filter base.
Note: There are rotation index marks on the
secondary fuel filter that are spaced 90 degrees or 1/
4 of a turn away from each other. When you tighten
the primary fuel filter, use the rotation index marks as
a guide.
5. Tighten the filter according to the instructions that
are printed on the filter. Use the index marks as a
guide. For non-Caterpillar filters, use the
instructions that are provided with the filter.
Note: Use a Caterpillar strap wrench, or another
suitable tool, in order to turn the filter to the amount
that is required for final installation. Make sure that
the installation tool does not damage the filter.
6. Start and run the engine at low idle. Inspect for
leaks.
7. Operate the transmission control to circulate oil in
the transmission.
Illustration 361 g01125847
8. While the engine is running and at operating
temperature, maintain the oil level between two
marks (4) in sight gauge (2).
Note: The oil level varies significantly when the
engine is stopped. The oil level should be above mark
(3) before the engine is started.
9. Remove oil filler cap (1) and add oil, if necessary.
Reference: For information on lubricants and refill
capacities, refer to the Operation and Maintenance
Manual, “Lubricant Viscosities and Refill Capacities”.
184 SEBU8906
Maintenance Support
Transmission Oil Level - Check

10. Clean and install the oil filler cap.

11. Stop the engine.

i04872933

Transmission Oil Level - Check

SMCS Code: 3030-535-FLV

Personal injury or death can result from machine

articulation or movement.
Machine frames can move and a person can be Illustration 362 g01125858
crushed.
Connect the steering frame lock link between the
front and rear frames before working on machine.
Secure clevis pin with locking pin.
Before operating the machine, fasten the steering
frame lock link into the stored position and secure
the clevis pin with locking pin.
Failure to lock into the stored position before op-
erating can result in loss of steering.

The sight gauge for the transmission is located on the

right side of the machine near the articulating hitch.
Check the transmission oil level with the machine on
a level surface and the parking brake engaged.

Illustration 363 g01125859

1. While the engine is running and at operating

temperature, maintain the oil level between two
marks (4) in sight gauge (2).

Note: The oil level varies significantly when the

engine is stopped. The oil level should be above mark
(3) before the engine is started.

2. If necessary, remove oil filler cap (1) and add oil.

Clean the filler cap and install the filler cap.
SEBU8906 185
Maintenance Support
Turbocharger - Inspect

Reference: For information on lubricants and refill i01906356

capacities, refer to the Operation and Maintenance
Manual, “Lubricant Viscosities and Refill Capacities” Wheel Bolt Torque - Check
for the machine that is being serviced.
SMCS Code: 4210-535
i02358785

Turbocharger - Inspect
SMCS Code: 1052-040
If the turbocharger fails during engine operation,
severe damage to the turbocharger compressor
wheel can result. If the turbocharger fails during
engine operation, severe damage to the engine can
also result.
For example, damage to the turbocharger
compressor wheel could cause parts from the
turbocharger compressor wheel to enter the engine
cylinder. These parts from the compressor wheel can
cause additional damage to the following engine
components: pistons, intake valves, exhaust valves Illustration 364 g00992869
and cylinder head.
Check the wheel bolt torque at each wheel. Continue
Note: Turbocharger failure can cause large quantities to check the torque on new wheels and rebuilt
of oil to enter the intake and exhaust systems. Loss of wheels. Check the torque until the torque remains at
engine lubricant can result in serious engine damage the specified amount.

If no turbocharger bearing failure has occurred, minor Reference: For the correct wheel bolt torque, refer to
leakage of a turbocharger housing during an Power Train, Specifications, “Rim Mounting” for the
extended period of operation at low idle will not cause machine that is being serviced.
problems.
i03462240
Do not continue to operate the engine when a
turbocharger bearing failure is accompanied by a
significant loss of engine performance. One of the Window - Clean
following characteristics will be present with a loss of SMCS Code: 7310-070; 7340-070
engine performance;

• Engine smoke.
• Speeding up of the engine with no load.

Note: For specifications used to check the

turbocharger, refer to Specifications, “C15 Engine”.

Illustration 365 g01805053

Use commercially available window cleaning

solutions to clean the windows. Only clean the
outside windows from the ground unless handholds
are available. Use a mop or use a similar device with
a long handle to clean the windows from the ground.
186 SEBU8906
Maintenance Support
Window Washer Bottle - Fill

i05793496 i03462241

Window Washer Bottle - Fill Window Wiper - Inspect/

SMCS Code: 7306-544-KE Replace
SMCS Code: 7305-040; 7305-070
NOTICE
When operating in freezing temperatures, use Cater-
pillar nonfreezing window washer solvent or equiva-
lent. System damage can result from freezing.

Illustration 367 g01805054

Inspect the condition of the wiper blades on the front

and rear windows. Replace the wiper blades if the
wiper blades are worn or damaged. If the wiper
Illustration 366 g03671506 blades streak the window, replace the wiper blades.
The window washer bottle is located in front of the
operator station.
Remove the cap and fill the window washer bottle.
Refit the cap.
SEBU8906 187
Reference Information Section
Reference Material

Reference Information Special Publication, PEHP7506, “Product Data Sheet

for Caterpillar Transmission/Drive Train Oil (TDTO)”
Section Special Publication, PEHJ0007, “Product Data Sheet
for Caterpillar Arctic TDTO (SAE 0W-20) (synthetic
blend)”
Reference Materials Special Publication, PEHP7506, “Product Data Sheet
for Caterpillar TDTO (SAE 10W, SAE 30, SAE 50)”
i05703149

Miscellaneous Publications
Reference Material
Systems Operation, Testing and Adjusting,
SMCS Code: 1000; 7000 RENR8598, “Emission Control System”

Cooling System Service Manual, RENR8595, “Machining and

Special Publication, PMEP5027, “Label - ELC
Radiator Label”
Special Publication, PEHJ0067, “Product Data Sheet
for Caterpillar ELC”
Special Publication, SEBD0518, “Know Your Cooling
System”
Special Publication, SEBD0970, “Coolant and Your
Engine”
Grease
Data Sheet, NEHP6010, “Cat Ultra 5Moly Grease
(NLGI grade 1 and grade 2)”
Data Sheet, NEHP6011, “Cat Arctic Platinum Grease
(NLGI grade 0)”
Data Sheet, NEHP6012, “Cat Desert Gold Grease
(NLGI grade 2)”
Data Sheet, NEHP6015, “Cat High Speed Ball
Bearing Grease (NLGI grade 2)”
Special Publication, PEGJ0035, “Grease Selection
Guide”
Data Sheet, PEHJ0088, “Cat Multipurpose Grease
(NLGI grade 2)”
Data Sheet, PEHP0002, “Cat Advanced 3Moly
Grease (NLGI grade 2)”
Special Publication, PEHP0003, “Caterpillar Fluids -
Lithium Grease Data Sheet”
Systems Operation, Testing and Adjusting,
RENR4503, “Automatic Lubrication System - Electric
Control”
Systems Operation, Testing and Adjusting,
RENR4671, “Automatic Lubrication System -
Hydraulic Type”
Hydraulic Oil
Special Publication, PEGP6028, “Caterpillar
Hydraulic Systems Management Guide”
Welding Information”
Service Manual, SENR5664, “R-134a Air
Conditioning & Heating System”
Operation and Maintenance Manual, SEBU5898,
“Cold Weather Recommendations”
Maintenance Manual, SEBU6250, “Caterpillar
Machine Fluids”
Service Sheet, UENR4823, “AD30 Underground
Articulated Truck - 10 Hours/Daily to 6000 Hours/4
Years”
Special Publication, SEBD0717, “Diesel Fuels and
Your Engine”
Operation and Maintenance Manual, SEBU5898,
“Cold Weather Recommendations”
Special Instruction, SEHS7332, “Do not Operate
Warning Tag”
Operation and Maintenance Manual, SEBU6250,
“Caterpillar Machine Fluids Recommendations”
Special Instruction, SEHS7663, “Battery Test
Procedure”
Special Instruction, SMHS7867, “Use of 6V-4040
Nitrogen Tire Inflation Group”
Special Instruction, SEHS9031, “Storage Procedure
for Caterpillar Products”
Operation and Maintenance Manuals are available in
other languages. Consult your Caterpillar dealer
about obtaining these Operation and Maintenance
Manuals.
Oil
Special Publication, PEHP6001, “How to Take a
Good Oil Sample”
Special Publication, SEBD0640, “Oil and Your
Engine”
Special Publication, PEHJ0008, “Product Data Sheet
for Caterpillar Arctic DEO (SAE 0W-30)”
188 SEBU8906
Reference Materials
Decommissioning and Disposal

Special Publication, PEHJ0059, “Product Data Sheet SAE J754, “Nomenclature” which can normally be
for Caterpillar DEO (SAE 10W-30)” found in the SAE handbook.
Special Publication, PEHP7062, “Product Data Sheet SAE J183, “Classification” which can normally be
for Caterpillar DEO Synthetic (SAE 5W-40)” found in the SAE handbook.

Special Publication, PEHP7506, “Product Data Sheet Engine Manufacturers Association, “Engine Fluids
for Caterpillar Transmission/Drive Train Oil (TDTO)” Data Book”

Special Publication, PEHJ0007, “Product Data Sheet Engine Manufacturers Association

for Caterpillar Arctic TDTO (SAE 0W-20) (synthetic
blend)”
Special Publication, PEHP7506, “Product Data Sheet
for Caterpillar TDTO (SAE 10W, SAE 30, SAE 50)”
Special Publication, PEHP8035, “Product Data Sheet
for TDTO Transmission Multi-Season (TMS)”
Special Publication, PEHP9530, “Product Data Sheet
for Caterpillar FDAO (SAE 60)”
Special Publication, PEHP9570, “Product Data Sheet
for Caterpillar FDAO Synthetic (Multigrade)”
Parts and Service Manuals
Service Manual, UENR4806, “AD30 Underground
Articulated Truck”GXR1–Up
Parts Manual, SEBP6408, “AD30 Underground
Articulated Truck”GXR1–Up
Two North LaSalle Street, Suite 2200
Chicago, Illinois, USA 60602
E-mail: ema@enginemanufacturers.org
i03989612
Decommissioning and
Disposal
SMCS Code: 1000; 7000
When the product is removed from service, local
regulations for the product decommissioning will vary.
Disposal of the product will vary with local
regulations. Consult the nearest Cat dealer for
additional information.

S·O·S Information
Special Publication, PEDP7036, “S·O·S Services”
Special Publication, PEHP7052, “Making the Most of
S·O·S Services”
Special Publication, PEHP7057, “S·O·S Coolant
Analysis”
Special Publication, PEHP7076, “Understanding
S·O·S Services Tests”

Specifications Manuals
Specifications Manual, SENR3130, “Torque
Specifications”

Tools
Special Publication, NENG2500, “Caterpillar Dealer
Service Tool Catalog”

Additional Reference Material

ASTM D2896, “TBN Measurements” which can
normally be obtained from your local technological
society, from your local library, or from your local
college.
SAE J313, “Diesel Fuels” which can be found in the
SAE handbook. Also, this publication can be obtained
from your local technological society, from your local
library, or from your local college.
SEBU8906
Index
A Coolant......................................................... 21
Additional Messages ....................................... 13
Air Conditioning and Heating Control (If
Equipped) ...................................................... 52
Air Conditioning and Heating System
Operation ................................................... 52
Alternate Exit ................................................... 56
Articulation Chassis Cable - Inspect/
Replace.........................................................118
Automatic Lubrication Filler Filter - Clean (If
Equipped) .....................................................119
Automatic Lubrication Grease Tank - Fill (If
Equipped) .....................................................119
B Shift Inhibiting .............................................. 63
Backup Alarm .................................................. 52
Backup Alarm - Test....................................... 120
Battery - Recycle ........................................... 120
Battery Disconnect Switch............................... 38
Battery Electrolyte Level - Check .................. 120
Battery Isolation Control (If Equipped)............. 38
Battery, Battery Cable or Battery
Disconnect Switch - Replace....................... 121
Before Operation ............................................. 28
Before Starting Engine ...............................27, 76
Belts - Inspect/Adjust/Replace....................... 122
Adjust the Air Conditioning Compressor Belt (If
Equipped)................................................. 122
Body Pivot Bearings - Lubricate .................... 123
Body Retaining Pin .......................................... 74
Dump Body .................................................. 74
Brake Accumulator - Check........................... 123
Brake Discs - Check ...................................... 123
Brake Oil Cooler Screen - Clean ................... 124
Braking ............................................................ 58
Optional Push-to-Engage Type Parking Brake
Control........................................................ 59
Parking Brake .............................................. 58
Secondary Brake ......................................... 59
Service Brake............................................... 59
Standard Pull-to-Engage Type Parking Brake
Control........................................................ 59
Braking System - Test.................................... 124
Parking Brake Holding Ability Test ............. 125
Service Brake Holding Ability Test ............. 125
Burn Prevention............................................... 21
Batteries....................................................... 21
189
Index Section
Oils............................................................... 21
C
Cab Air Filter - Clean/Replace (If Equipped) . 127
Cab Pressurizer Filter ................................ 127
Return Air Filter .......................................... 127
Capacities (Refill) ...........................................110
Caterpillar Monitoring System ......................... 40
Warning Categories ..................................... 41
Warning Operation....................................... 41
Caterpillar Monitoring System - Self Test......... 80
Changing Direction and Speed........................ 62
Engine Overspeed Protection...................... 64
Circuit Breakers - Reset................................. 127
Cooling System Coolant (ELC) - Change...... 130
Cooling System Coolant Extender (ELC) -
Add .............................................................. 131
Cooling System Level - Check ...................... 133
Cooling System Pressure Cap - Clean/
Replace........................................................ 134
Cooling System Water Temperature
Regulator - Replace..................................... 134
Crushing Prevention and Cutting Prevention .. 21
D
Decommissioning and Disposal .................... 188
Diesel Particulate Filter - Inspect ................... 135
Differential and Final Drive Oil - Change ....... 136
Differential and Final Drive Oil Level -
Check........................................................... 138
Directional Turn Signal and Hazard Flasher
Control ........................................................... 48
Drive Shaft Universal Joints, Splines and
Bearings - Inspect/Lubricate ........................ 139
Dumping (Dump Body Machines).................... 90
Dumping....................................................... 91
Reverse Neutralizer ..................................... 91
Dumping (Ejector Body Machines).................. 91
Ejecting ........................................................ 92
Reverse Neutralizer ..................................... 92
E
Ejector Cylinder Bearing - Lubricate.............. 139
190
Index Section
Electrical Storm Injury Prevention ................... 27
Emissions Certification Film ............................ 37
Engine Air Filter Primary Element - Clean/
Replace........................................................ 140
Engine Air Filter Secondary Element -
Replace........................................................ 141
Engine and Machine Warm-Up........................ 86
Differential Warm-up .................................... 88
Machine Warm-up........................................ 88
Preparing to Operate the Machine............... 88
Engine Cold Mode ........................................... 83
Elevated Low Idle......................................... 83
Engine Mounts - Inspect................................ 142
Engine Oil and Filter - Change ...................... 144
Engine Oil Level - Check ............................... 143
Engine Shutdown Switch................................. 39
Engine Start Switch ......................................... 39
Engine Starting ...........................................28, 82
Engine Starting with Auxiliary Start
Receptacle..................................................... 86
Engine Starting with Jump Start Cables .......... 84
Use of Jump Start Cables ............................ 84
Engine Stopping .............................................. 30
Engine Valve Lash - Check/Adjust ................ 145
Adjustment of the Electronic Unit Injectors
................................................................. 146
Engine Valve Rotators - Inspect .................... 146
Engine Water Pump - Inspect........................ 147
Equipment Lowering with Engine Stopped..... 31,
101
Exhaust Purifier - Inspect/Clean.................... 147
F Fuses - Replace............................................. 156
Fan Drive Bearing - Lubricate........................ 147
Filter and Screen Locations............................ 111
Fire Extinguisher Location ............................... 25
Fire Prevention and Explosion Prevention ...... 22
Battery and Battery Cables .......................... 23
Ether ............................................................ 24
Fire Extinguisher.......................................... 25
General ........................................................ 22
Lines, Tubes, and Hoses ............................. 24
Wiring........................................................... 23
Fire Safety ....................................................... 25
Fire Suppression System - Check (If
Equipped) .................................................... 148
Fire Suppression System (Dry Powder) (If
Equipped) ...................................................... 69
Fire Suppression Control (Automatic).......... 70
Fire Suppression Control (Manual).............. 70
SEBU8906
In Case of Fire.............................................. 71
Fire Suppression System (Foam) (If
Equipped) ...................................................... 67
Fire Suppression Control (Engine Shutdown)
................................................................... 68
Fire Suppression Control (Manual).............. 67
In Case of Fire.............................................. 69
Foreword............................................................ 4
California Proposition 65 Warning ................. 4
Cat Product Identification Number ................. 5
Certified Engine Maintenance........................ 4
Literature Information..................................... 4
Machine Capacity .......................................... 4
Maintenance .................................................. 4
Operation ....................................................... 4
Safety............................................................. 4
Frame and Body - Inspect ............................. 148
Dump Body ................................................ 148
Ejector Body............................................... 149
Frame and Body Support Pads - Clean/
Inspect ......................................................... 149
Dump Body ................................................ 149
Ejector Body............................................... 150
Fuel Shutoff Valve............................................ 71
Fuel System - Prime ...................................... 150
Fuel System Primary Filter (Water
Separator) - Drain ........................................ 151
Fuel System Primary Filter (Water
Separator) - Replace.................................... 152
Fuel System Secondary Filter - Replace ....... 153
Fuel Tank Breather - Replace........................ 154
Fuel Tank Cap and Strainer - Clean .............. 154
Fuel Tank Water and Sediment - Drain.......... 155
G
Gauges ............................................................ 44
General Hazard Information ............................ 18
Containing Fluid Spillage ............................. 19
Dispose of Waste Properly........................... 20
Fluid Penetration.......................................... 19
Inhalation ..................................................... 20
Pressurized Air and Water ........................... 19
Trapped Pressure ........................................ 19
Guards (Operator Protection) .......................... 32
Other Guards (If Equipped).......................... 32
Rollover Protective Structure (ROPS), Falling
Object Protective Structure (FOPS) or Tip
Over Protection Structure (TOPS) ............. 32
SEBU8906 191
Index Section

H Coolant Information.................................... 109

Diesel Fuel Recommendations.................. 109
Hauling ............................................................ 89
Differential and Final Drive......................... 107
Operator Present Strategy........................... 89
Engine Oil .................................................. 105
Preventing Overspeed ................................. 90
Fuel Additives ............................................ 109
Traveling Down a Grade .............................. 90
General Information for Lubricants ............ 105
Hoist Control.................................................... 64
Hydraulic Systems ..................................... 107
Dump Body Machines.................................. 64
Selecting the Viscosity ............................... 105
Ejector Body Machines ................................ 65
Special Lubricants...................................... 107
Hoist Cylinder Bearings - Lubricate ............... 156
Transmission.............................................. 106
Horn................................................................. 51
Lubricant Viscosities and Refill Capacities.... 105
Hoses and Clamps - Inspect/Replace ........... 157
Inspect the Hoses and the Clamps ............ 157
Replacing Hoses and Clamps ................... 157 M
Hydraulic System Oil - Change...................... 158
Hydraulic System Oil Filter (Pilot) - Replace.. 159 Machine Controls and Operation..................... 58
Hydraulic System Oil Level - Check .............. 161 Maintenance Interval Schedule ......................117
Hydraulic Tank Breaker Relief Valve - Clean Every 10 Service Hours or Daily .................117
..................................................................... 162 Every 1000 Service Hours or 6 Months ......118
Hydraulic Tank Screen - Clean ...................... 162 Every 2000 Service Hours or 1 Year...........118
Every 250 Service Hours or Monthly ..........117
Every 3 Years After Date of Installation or
I Every 5 Years After Date of Manufacture
..................................................................118
Identification Information ................................. 36
Every 3000 Service Hours or 2 Years .........118
Idle Timer Control (Engine Shutdown) (If
Every 50 Service Hours or Weekly .............117
Equipped) ...................................................... 39
Every 500 Service Hours or 3 Months ........118
Important Safety Information ............................. 2
Every 6000 Service Hours or 4 Years .........118
Indicators ......................................................... 46
Initial 250 Service Hours (or at first oil change)
Alert Indicators ............................................. 46
..................................................................117
Indicators ..................................................... 46
When Required...........................................117
Indicators and Gauges - Test......................... 164
Maintenance Locations................................... 111
Maintenance Section..................................... 104
J Maintenance Support .....................................115
Mirror ............................................................... 56
Jacking Location Information........................... 98
Model Views and Specifications...................... 34
Jacking Locations............................................ 98
General Operating Restrictions.................... 35
Jacking Locations ........................................ 98
Intended Use................................................ 35
Monitoring Systems and Operator Station
L Features......................................................... 38
Mounting and Dismounting.........................27, 79
Leaving the Machine ....................................... 94 Alternate Exit................................................ 27
Lifting and Tying Down the Machine................ 96 Machine Access System Specifications ...... 80
Lift and Tie Down Messages........................ 97
Lifting the Machine....................................... 97
Tying Down the Machine.............................. 97 O
Light Switches ................................................. 47
Oil Filter - Inspect........................................... 165
Loading............................................................ 89
Inspect a Used Filter for Debris.................. 165
Loading ........................................................ 89
Operating Techniques...................................... 89
Positioning ................................................... 89
Operation......................................................... 29
Lubricant Viscosities...................................... 105
Machine Operating Altitude Range.............. 29
Biodiesel .................................................... 109
192
Index Section
Machine Operating Temperature Range...... 29
Machine Operation....................................... 29
Operation Section............................................ 38
Operator Mode Scroll Switch........................... 49
Operator Station .............................................. 32
Oscillating Hitch - Adjust................................ 165
Oscillating Hitch - Lubricate........................... 166
P Seat Belt (3) ................................................... 9
Parking .......................................................30, 93
Parking Brake Manual Release ..................... 102
Plate Locations and Film Locations................. 36
Certification.................................................. 37
Product Identification Number (PIN) ............ 36
Serial Number Plates (SN)........................... 36
Pressure Sensor (Transmission Oil) - Test .... 167
Product Information Section ............................ 34
R Seat Adjustment and Seat Belt Inspection ...... 80
Radiator Core - Clean.................................... 168
Reference Information Section ...................... 187
Reference Material ........................................ 187
Additional Reference Material.................... 188
Cooling System.......................................... 187
Grease ....................................................... 187
Hydraulic Oil............................................... 187
Miscellaneous Publications........................ 187
Oil............................................................... 187
Parts and Service Manuals ........................ 188
S·O·S Information...................................... 188
Specifications Manuals .............................. 188
Tools........................................................... 188
Reference Materials ...................................... 187
Refrigerant Dryer - Replace........................... 169
Restricted Visibility .......................................... 29
Retarding ......................................................... 60
Automatic Retarder Control (ARC) .............. 60
Manual Retarding......................................... 61
Retarder Control .......................................... 60
Rim - Inspect.................................................. 169
Roading the Machine....................................... 95
Rollover Protective Structure (ROPS) -
Inspect ......................................................... 170
S Steering Frame Lock ....................................... 72
Safety Messages............................................... 6
Batteries (5).................................................. 10
SEBU8906
Crush Hazard (7).......................................... 10
Do Not Operate (2)......................................... 9
Do Not Weld or Drill the ROPS/FOPS (1), (4)
..................................................................... 9
Engine Coolant (12) ..................................... 12
High Pressure Cylinder (Brake Accumulator)
(8), (9)......................................................... 10
Hot Surface (11) ........................................... 12
No Clearance (6).......................................... 10
Tailgate (13) ................................................. 12
Unit Injectors (10)..........................................11
Safety Section ................................................... 6
Sampling Interval and Location of Sampling
Valve .............................................................112
Location of Sampling Valves.......................112
More Frequent S·O·S Sampling Improves Life
Cycle Management...................................113
Screen (Torque Converter) - Clean................ 170
Seat ................................................................. 53
Seat Belt .......................................................... 54
Extension of the Seat Belt............................ 56
Seat Belt Adjustment for Non-Retractable Seat
Belts ........................................................... 54
Seat Belt Adjustment for Retractable Seat
Belts ........................................................... 55
Seat Belt - Inspect ......................................... 171
Seat Belt - Replace........................................ 172
Secondary Steering (If Equipped) ................... 61
Service Inspection ......................................... 172
Service Ports ................................................... 51
Severe Service Application.............................115
Improper Maintenance Procedures
(Maintenance Procedures Which May
Contribute to a Severe Service Application)
..................................................................116
Severe Environmental Factors ...................115
Severe Operating Conditions......................116
Shipping the Machine ...................................... 95
Slope Operation............................................... 30
Sound Information and Vibration Information.. 31
Vibration Level ............................................. 31
Starting the Engine .......................................... 82
Operator Present Strategy........................... 83
Steering Column Tilt Control............................ 64
Steering Cylinder Bearings - Lubricate.......... 177
Connection Procedure ................................. 72
Separation Procedure.................................. 73
Steering Stop - Check.................................... 178
SEBU8906 193
Index Section

Steering System Oil Filter - Replace.............. 178
Stopping the Engine ........................................ 93
Stopping the Engine if an Electrical
Malfunction Occurs ........................................ 94
Stopping the Machine...................................... 93
Wheel Bolt Torque - Check ............................ 185
Window - Clean ............................................. 185
Window Washer Bottle - Fill........................... 186
Window Wiper - Inspect/Replace .................. 186
Window Wiper and Washer Control................. 50

T
Table of Contents............................................... 3
Tailgate and Tailgate Cylinder Bearings -
Lubricate ...................................................... 179
Tailgate Retaining Pin...................................... 75
Ejector Body................................................. 75
Throttle Backup Switch.................................... 50
Throttle Control................................................ 64
Tire Inflation - Check...................................... 180
Tire Inflation Information................................ 104
Tire Inflation Pressure Adjustment................. 104
Tire Inflation with Nitrogen ............................. 104
Tire Information................................................ 26
Tire Shipping Pressure .................................. 104
Towing Information .......................................... 99
Towing the Machine......................................... 99
Towing with an Inoperable Engine ............... 99
Towing with an Operable Engine ............... 100
Transmission Oil - Change ............................ 180
Transmission Oil Filter - Replace................... 182
Transmission Oil Level - Check ..................... 184
Transportation Information............................... 95
Truck Payload Measurement System
(TPMS) (If Equipped)..................................... 65
Autoweigh .................................................... 65
Cycle Data ................................................... 67
ET Service Port............................................ 67
Load Indicator Lights.................................... 66
Payload Operator Display ............................ 66
TPMS Switches............................................ 67
Turbocharger - Inspect .................................. 185

V
Visibility Information......................................... 28
Vital Information Management System
(VIMS) Service Port (If Equipped).................. 51

W
Walk-Around Inspection .................................. 76
Welding on Machines and Engines with
Electronic Controls........................................115
194 SEBU8906
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 Phone Hours

Contact Number

Sales:

Parts:

Service:
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