SEBU9190-12 (en-us)

July 2019

Operation and
Maintenance
Manual
6015B Hydraulic Mining Shovel
LWS 1-UP (6015B)
LWN 1-UP (6015B)
FKD 1-UP (6015B)
WSN 1-UP (6015B)
MKE 1-UP (6015B)
PZE 1-UP (6015B)
HLD 1-UP (6015B)
PWW 1-UP (6015B)
ZEN 1-UP (6015B)
HSE 1-UP (6015B)
HSF 1-UP (6015B)

Language: Original Instructions

PUBLICATIONS.CAT.COM
 i06558969

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.
SEBU9190-12 3
Table of Contents

Table of Contents Guards (Operator Protection) ......................... 41

Foreword ........................................................... 5 Product Information Section

General Information ........................................ 43

Safety Section
Identification Information ................................. 49
Safety Messages............................................... 7

Additional Messages ....................................... 20 Operation Section

General Hazard Information............................ 23 Before Operation ............................................. 53

Crushing Prevention and Cutting Prevention.. 25 Machine Operation .......................................... 55

Burn Prevention............................................... 26 Engine Starting.............................................. 107

Fire Prevention and Explosion Prevention...... 27 Operation........................................................110

Fire Safety ....................................................... 30 Operating Techniques ................................... 122

Fire Extinguisher Location............................... 31 Parking .......................................................... 143

Track Information ............................................ 31 Machine Cleanup .......................................... 146

High Pressure Fuel Lines ................................ 31 Transportation Information ............................ 147

Electrical Storm Injury Prevention ................... 32 Towing Information ........................................ 148

Before Starting Engine .................................... 32 Engine Starting (Alternate Methods)............. 151

Visibility Information ........................................ 32 Maintenance Section

Restricted Visibility .......................................... 33 Maintenance Access ..................................... 152

Engine Starting................................................ 33 Lubricant Viscosities and Refill Capacities ... 153

Before Operation ............................................. 34 Maintenance Support .................................... 159

Work Tools....................................................... 34 Maintenance Interval Schedule..................... 160

Operation......................................................... 34 Maintenance Interval Schedule..................... 163

Engine Stopping .............................................. 37 Warranty Section

Parking ............................................................ 38 Warranty Information..................................... 227

Equipment Lowering with Engine Stopped ..... 38 Reference Information Section

Sound Information and Vibration Information . 38 Reference Materials ...................................... 228

Operator Station .............................................. 41 Index Section

4 SEBU9190-12
Table of Contents

Index.............................................................. 229
SEBU9190-12
Foreword
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.
WARNING – This product can
expose you to chemicals
including ethylene glycol, which
is known to the State of California to
cause birth defects or other reproductive
harm. For more information go to:
www.P65Warnings.ca.gov
Do not ingest this chemical. Wash hands
after handling to avoid incidental
ingestion.
WARNING – This product can
expose you to chemicals
including lead and lead
compounds, which are known to the
State of California to cause cancer, birth
defects, or other reproductive harm. For
more information go to:
www.P65Warnings.ca.gov
Wash hands after handling components
that may contain lead.
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.
5
Foreword
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 the calendar intervals provide more
convenient servicing schedules and approximate the
indicated service hour meter reading. Perform the
recommended service at the interval that occurs first.
Under severe, dusty, or wet operating conditions,
more frequent lubrication than is specified in the
maintenance intervals chart might be necessary.
6 SEBU9190-12
Foreword

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.
Certified Engine Maintenance
Proper maintenance and repair are 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.
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,
and work tools will continue to use an 8 character
Serial Number (S/N).

It is prohibited for any person engaged in the

business of repairing, servicing, selling, leasing, or
trading engines or machines to remove, alter, or to
render inoperative, any emission-related device or
element of design installed on or in an engine or
machine that is in compliance with all applicable
regulations of the intended country to which it has
been shipped. 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.

Product Identification Number

Effective First Quarter 2001 the Product Identification
Number (PIN) has changed from 8 to 17 characters.
To provide uniform equipment identification,
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 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 g03891925

Where:
1. World Manufacturing Code (characters 1-3)
SEBU9190-12 7
Safety Section
Safety Messages

Safety Section
i05831679

Safety Messages
SMCS Code: 7000; 7405
There are several specific safety messages on this
machine. The exact location of the hazards and the
description of the hazards are reviewed in this
section. Please become familiarized with all safety
messages.
Make sure that all of the safety messages are legible.
Clean the safety messages or replace the safety
messages if you cannot read the words. Replace the
illustrations if the illustrations are not visible. When
you clean the safety messages, use a cloth, water,
and soap. Do not use solvent, gasoline, or other
harsh chemicals to clean the safety messages.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety message. Loose
adhesive will allow the safety message to fall.
Replace any safety message that is damaged, or
missing. If a safety message is attached to a part that
is replaced, install a safety message on the
replacement part. Any Cat dealer can provide new
safety messages.
8 SEBU9190-12
Safety Section
Safety Messages

Illustration 2 g03689008
SEBU9190-12 9
Safety Section
Safety Messages

Illustration 3 g03689039
10 SEBU9190-12
Safety Section
Safety Messages

Illustration 4 g03689066
SEBU9190-12 11
Safety Section
Safety Messages

Illustration 5 g03689187

Do Not Operate (1)

This safety message is located in the cab on the right
side window.
12
Safety Section
Safety Messages
Illustration 6 g01370904
Do not operate or work on this machine unless
you have read and understand the instructions
and warnings in the Operation and Maintenance
Manual. Failure to follow the instructions or heed
the warnings could result in injury or death. Con-
tact any Caterpillar dealer for replacement man-
uals. Proper care is your responsibility.
Product Link (2)
If equipped, this safety message is located in the cab
on the left side pillar.
SEBU9190-12
Illustration 7 g01370917
This machine is equipped with a Caterpillar Prod-
uct Link communication device. When electric
detonators are used, this communication device
should be deactivated within 12 m (40 ft) of a
blast site for satellite-based systems and within
3 m (10 ft) of a blast site for cellular based sys-
tems, or within the distance mandated under ap-
plicable legal requirements. Failure to do so
could cause interference with blasting operations
and result in serious injury or death.
In cases where the type of Product Link module
cannot be identified, Caterpillar recommends that
the device be disabled no less than 12 m (40 ft)
from the blast perimeter.
SEBU9190-12 13
Safety Section
Safety Messages

Refer to Operation and Maintenance Manual ,

“Product Link” for further information.

Do Not Weld or Drill on ROPS (3)

Illustration 9 g01374045

Electrocution Hazard! Keep the machine and

attachments a safe distance from electrical
power. Stay clear 3 m (10 ft) plus twice the line
insulator length. Read and understand the
instructions and warnings in the Operation and
Maintenance Manual. Failure to follow the
instructions and warnings will cause serious
injury or death
Illustration 8 g01970802

If equipped, this safety message is located in the cab Refer to Operation and Maintenance Manual,
“Specifications” for further information.
on the left side pillar.
Seat Belt (5)
This safety message is located in the cab on the right
Structural damage, an overturn, modification, al-
side window.
teration, or improper repair, can impair this struc-
ture's protective 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 plate. The maximum
mass of the machine, which includes the operator
and the attachments without a payload, should not
exceed the mass on the certification plate.
Refer to Operation and Maintenance Manual,
“Guards (Operator Protection)” for more information.

Electrical Power Lines (4)

This safety message is located in the cab on the right
side window.
14 SEBU9190-12
Safety Section
Safety Messages

Illustration 10 g01370908 Illustration 11 g02282255

A seat belt should be worn at all times during ma-
chine operation to prevent serious injury or death
in the event of an accident or machine overturn.
Failure to wear a seat belt during machine opera-
tion may result in serious injury or death.
Crushing Hazard (6)
If equipped, this safety message is located in the cab
on the right side window.
Crush Hazard! A machine may move unexpect-
edly and without warning resulting in personal in-
jury or death.
Before leaving the machine lower the work tool to
the ground, lock operator controls, shut off the
engine and remove the key.
Crushing Hazard (7)
This safety message is located in the cab above the
front window.
SEBU9190-12 15
Safety Section
Safety Messages

Refer to Operation and Maintenance Manual,

“Guards” for further information.

Crushing Hazard (9)

This safety message is located in the cab on the right
side window.

Illustration 12 g01373971

Crushing Hazard! Certain machine front linkage

combinations (boom, stick, quick coupler, work
tool) may require keeping the work tool away
from the cab during operation. Personal injury or Illustration 14 g02061339
death may result if the work tool contacts the cab
during operation.

Personal injury can result if the window is not

Crushing Hazard (8) latched in the overhead position; ensure the auto
lock is engaged.
This safety message is located in the cab on the right
side window.
Refer to Operation and Maintenance Manual,
“Window (Front)” for further information.

Fall Hazard (10)

This safety message is in ten locations on top of the
machine.

Illustration 13 g01374048

The impact from objects that strike the front of

the cab or the top of the cab could result in a
crushing hazard with the potential for personal
injury or death.
The front guard and the top guard should be in-
stalled on the cab for applications where the haz-
ard of falling objects exist. Read the Operation
and Maintenance Manual.
16 SEBU9190-12
Safety Section
Safety Messages

Illustration 16 g01407379

High Pressure Cylinder. Failure to read and follow

these instructions can cause rapidly discharging
Illustration 15 g01370910 gas and/or hydraulic fluid which can result in
death, personal injury and property damage.

Do not use this surface as a step or platform. This

Pressurized System (12)
surface may not support additional weight or may
be slippery. Serious injury or death could occur This safety message is located near the cooling
from a fall. system pressure cap.

Hydraulic Oil Under Pressure (11)

This safety message is located on top of the
hydraulic tank.

Illustration 17 g01371640

Pressurized system! Hot coolant can cause seri-

ous burns, injury or death. To open the cooling
system filler cap, stop the engine and wait until
the cooling system components are cool. Loosen
the cooling system pressure cap slowly in order
to relieve the pressure. Read and understand the
Operation and Maintenance Manual before per-
forming any cooling system maintenance.
SEBU9190-12 17
Safety Section
Safety Messages

Refer to Operation and Maintenance Manual,

“Cooling System Coolant Level - Check” for further
information.

Entanglement Hazard (13)

This safety message is located on the engine belt
guard.

Illustration 19 g01372254

Explosion hazard! Do not use ether! This ma-

chine is equipped with an air inlet heater. Using
ether can create explosions or fires that can
cause personal injury or death. Read and follow
Illustration 18 g03583264 the starting procedure in the Operation and Main-
tenance Manual.

Refer to Operation and Maintenance Manual,

Entanglement hazard exists. Entanglement could “Engine Starting” for the proper starting procedure.
cause serious injury or death. Keep hands away
from the engine while in operation. Shut off the Crushing Hazard (15)
engine and allow the engine to come to a stop be-
fore working on any equipment.
This safety message is located on both sides of the
stick.
Aerosol Starting Aid (14)
This safety message is positioned near the cover of
the intake duct of the air cleaner. The following
information is not applicable to machines that are
equipped with an ether starting aid.
18 SEBU9190-12
Safety Section
Safety Messages

Illustration 21 g01374060

Machine swings. Stay back. Crushing hazard

could cause serious injury or death.
Illustration 20 g01385579

High Pressure Gas (17)

A crushing hazard exists when the stick and This safety message is positioned on each
boom are in motion and when the machine is accumulator.
being used in object handling applications. Fail-
ure to stay clear of the stick and boom when the
machine is in operation can result in personal in-
jury or death. Stay clear of the stick and boom
when the machine is in operation.

Crushing Hazard (16)

This safety message is located on the front and rear
of each side of the machine.

Illustration 22 g01374065

This system contains high pressure gas. Failure

to follow the instructions and warnings could
cause an explosion, resulting in possible injury
or death.
Do not expose to fire. Do not weld. Do not drill.
Relieve pressure before discharging.
See Operation and Maintenance Manual for
charging and discharging. See your Caterpillar
Dealer for tools and detailed information.
SEBU9190-12 19
Safety Section
Safety Messages

Refer to Operation and Maintenance Manual,

“Equipment Lowering with Engine Stopped” for
further information.

Jump Start Cables (18)

This safety message is positioned near the batteries
and near the fuel heater.

Illustration 24 g03688638

Trip Point. Do not step within this area. Could

cause serious injury or death. See Operation and
Maintenance Manual.

Illustration 23 g01370909

Hot Surface (20)

This safety message is located in two locations, near
Explosion Hazard! Improper jumper cable con- each turbocharger.
nections can cause an explosion resulting in seri-
ous injury or death. Batteries may be located in
separate compartments. Refer to the Operation
and Maintenance Manual for the correct jump
starting procedure.

Refer to Operation and Maintenance Manual,

“Engine Starting with Jump Start Cables” for further
information.

Trip Hazard (19)

This safety message is in four location on the engine
cabinet.
20
Safety Section
Additional Messages
Illustration 25 g01372256
Engine hood and engine hood parts can be hot
while engine is running or immediately after en-
gine shutdown. Hot parts or hot components can
cause burns or personal injury. Do not allow
these parts to contact your skin, when engine is
running or immediately after engine shutdown.
Use protective clothing or protective equipment
to protect your skin.
Fall Hazard (21)
This safety message is located on the right side of
the machine near the handrail.
SEBU9190-12
Illustration 26 g01397286
Trip Point. Could cause serious injury or death.
See Operation and Maintenance Manual.
i05848152
Additional Messages
SMCS Code: 7000; 7405
There are several specific messages on this
machine. The exact location of the messages and the
description of the information are reviewed in this
section. Become familiar with all messages.
Make sure that all of the messages are legible. Clean
the messages or replace the messages if you cannot
read the words. Replace the illustrations if the
illustrations are not legible. When you clean the
messages, use a cloth, water, and soap. Do not use
solvent, gasoline, or other harsh chemicals to clean
the messages. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures the
messages. Loose adhesive will allow the messages
to fall.
Replace any message that is damaged, or missing. If
a message is attached to a part that is replaced,
install a message on the replacement part. Any Cat
dealer can provide new messages.
SEBU9190-12 21
Safety Section
Additional Messages

Illustration 27 g03701415

Cleaning Windows (1)

This message is located in the cab on the
polycarbonate windows.

Illustration 28 g01134495

NOTICE
Clean windows with a wet cloth or sponge. Dry cloth
or sponge may scratch window material.

Alternate Exit (2)

22 SEBU9190-12
Safety Section
Additional Messages

If equipped, this message is located on the roof

hatch.

Illustration 31 g01418953

Illustration 29 g02052833 The Product Link System is a satellite communication

If the Primary exits are blocked, exit the machine
through the opening.
For more information, refer to Operation and
Maintenance Manual, “Alternate Exit”.
Alternate Exit Lock/Unlock (3)
If equipped, this message is located on the roof
hatch.
device that transmits information regarding the
machine back to Caterpillar and Cat dealers and
customers. All logged events and diagnostic codes
that are available to the Cat Electronic Technician
(ET) on the Cat data link can be sent to the satellite.
Information can also be sent to the Product Link
System. The information is used to improve Cat
products and Cat services.
Refer to Operation and Maintenance Manual,
“Product Link” for more information.
Alternate Exit (5)
If equipped, this message is located on the right side
window of the cab.

Illustration 30 g02052873

NOTICE
Unlock alternate exit window during machine
operations. Illustration 32 g01069768

Break glass in order to exit.

Move the lever to the left to the UNLOCK position.
Move the lever to the right to the LOCK position. Exit
through the opening.
For more information, refer to Operation and
Maintenance Manual, “Alternate Exit”.
Data Privacy (4)
Refer to Operation and Maintenance Manual,
“Alternate Exit” for further information.
Alternate Exit (7)
If equipped, this message is located on the front
window of the cab in the upper left-hand corner.
SEBU9190-12
Illustration 33
Move the lever to the right in order to unlock the front
window. Raise the window into the storage position.
Exit through the opening.
Refer to Operation and Maintenance Manual,
“Alternate Exit” for further information.
Do not step in this area.
General Hazard Information
SMCS Code: 7000
Illustration 34
Typical example
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.
Warning tag SEHS7332 is available from your Cat
dealer.
23
Safety Section
General Hazard Information
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 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
g02052913 may occur from electrocution.
i07746355
Illustration 35 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.
g00104545
Know the appropriate work site hand signals and the
personnel that are authorized to give the hand
signals. Accept hand signals from one person only.
Do not smoke when you service an air conditioner.
Also, do not smoke if refrigerant gas may be present.
Inhaling the fumes that are released from a flame that
contacts air conditioner refrigerant can cause bodily
harm or death. Inhaling gas from air conditioner
refrigerant through a lighted cigarette can cause
bodily harm or death.
Never put maintenance fluids into glass containers.
Drain all liquids into a suitable container.
24 SEBU9190-12
Safety Section
General Hazard Information

Obey all local regulations for the disposal of liquids. Do not remove any hydraulic components or parts
until pressure has been relieved or personal injury
Use all cleaning solutions with care. Report all may occur. Do not disassemble any hydraulic
necessary repairs. components or parts until pressure has been relieved
or personal injury may occur. Refer to the Service
Do not allow unauthorized personnel on the Manual for any procedures that are required to
equipment. relieve the hydraulic pressure.
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.

Pressurized Air and Water

Pressurized air and/or water can cause debris and/or
hot water to be blown out. The debris and/or hot
water could result in personal injury.
When pressurized air and/or pressurized water is
used for cleaning, wear protective clothing, protective
shoes, and eye protection. Eye protection includes
goggles or a protective face shield.
The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the
nozzle is deadheaded and the nozzle is used with an
effective chip deflector and personal protective
equipment. The maximum water pressure for
cleaning purposes must be below 275 kPa (40 psi).
Avoid direct spraying of water on electrical
connectors, connections, and components. When
using air for cleaning, allow the machine to cool to
reduce the possibility of fine debris igniting when re-
deposited on hot surfaces.
Trapped Pressure
Illustration 36 g00687600
Always use a board or cardboard when you check for
a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak can
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury.
Containing Fluid Spillage
Care must be taken in order to ensure that fluids are
contained during performance of inspection,
maintenance, testing, adjusting, and repair of the
equipment. Prepare to collect the fluid with suitable
containers before opening any compartment or
disassembling any component that contains fluids.
Refer to Special Publication, NENG2500, “Cat dealer
Service Tool Catalog” for the following items:

Pressure can be trapped in a hydraulic system. • Tools that are suitable for collecting fluids and
Releasing trapped pressure can cause sudden equipment that is suitable for collecting fluids
machine movement or attachment movement. Use
caution if you disconnect hydraulic lines or fittings. • Tools that are suitable for containing fluids and
High-pressure oil that is released can cause a hose equipment that is suitable for containing fluids
to whip. High-pressure oil that is released can cause
oil to spray. Fluid penetration can cause serious
injury and possible death.

Fluid Penetration
Pressure can be trapped in the hydraulic circuit long
after the machine has been stopped. The pressure
can cause hydraulic fluid or items such as pipe plugs
to escape rapidly if the pressure is not relieved
correctly.
SEBU9190-12
Obey all local regulations for the disposal of liquids.
Inhalation
Illustration 37 g02159053
Exhaust
Use caution. Exhaust fumes can be hazardous to
your health. If you operate the machine in an
enclosed area, adequate ventilation is necessary.
Asbestos Information
Cat equipment and replacement parts that are
shipped from Caterpillar are asbestos free.
Caterpillar recommends the use of only genuine Cat
replacement parts. Use the following guidelines when
you handle any replacement parts that contain
asbestos or when you handle asbestos debris.
Use caution. Avoid inhaling dust that might be
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is bound
in a resin or sealed in some way. Normal handling is
not hazardous unless airborne dust that contains
asbestos is generated.
If dust that may contain asbestos is present, there
are several guidelines that should be followed:
• Never use compressed air for cleaning.
• Avoid brushing materials that contain asbestos.
• Avoid grinding materials that contain asbestos.
• Use a wet method in order to clean up asbestos
materials.
• A vacuum cleaner that is equipped with a high
efficiency particulate air filter (HEPA) can also be
used.
25
Safety Section
Crushing Prevention and Cutting Prevention
• Use exhaust ventilation on permanent machining
jobs.
• Wear an approved respirator if there is no other
way to control the dust.
• Comply with applicable rules and regulations for
the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”. In Japan,
use the requirements found in the “Ordinance on
Prevention of Health Impairment due to Asbestos”
in addition to the requirements of the Industrial
Safety and Health Act.
• Obey environmental regulations for the disposal of
asbestos.
• Stay away from areas that might have asbestos
particles in the air.
Dispose of Waste Properly
Illustration 38 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.
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.
26 SEBU9190-12
Safety Section
Burn Prevention

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.
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 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 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.

i07746334

Burn Prevention
SMCS Code: 7000
Do not touch any part of an operating engine. Allow
the engine to cool before any maintenance is
performed on the engine. Relieve all pressure in the
air system, in the oil system, in the lubrication
system, in the fuel system, or in the cooling system
before any lines, fittings, or related items are
disconnected.

Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.
Any contact with hot coolant or with steam can cause
severe burns. Allow cooling system components to
cool before the cooling system is drained.
SEBU9190-12 27
Safety Section
Fire Prevention and Explosion Prevention

Always wear protective glasses when you work with Keep the access doors to major machine
batteries. Wash hands after touching batteries. The compartments closed and access doors in working
use of gloves is recommended. condition in order to permit the use of fire
suppression equipment, in case a fire should occur.
i06179517
Clean all accumulations of flammable materials such
as fuel, oil, and debris from the machine.
Fire Prevention and Explosion
Do not operate the machine near any flame.
Prevention
Keep shields in place. Exhaust shields (if equipped)
SMCS Code: 7000
protect hot exhaust components from oil spray or fuel
spray in a break in a line, in a hose, or in a seal.
Exhaust shields must be installed correctly.
Do not weld or flame cut on tanks or lines that contain
flammable fluids or flammable material. Empty and
purge the lines and tanks. Then clean the lines and
tanks with a nonflammable solvent prior to welding or
flame cutting. Ensure that the components are
properly grounded in order to avoid unwanted arcs.
Dust that is generated from repairing nonmetallic
hoods or fenders may be flammable and/or
explosive. Repair such components in a ventilated
area away from open flames or sparks. Use suitable
Personal Protection Equipment (PPE).
Inspect all lines and hoses for wear or deterioration.
Illustration 39 g00704000 Replace damaged lines and hoses. The lines and the
hoses should have adequate support and secure
clamps. Tighten all connections to the recommended
Regeneration torque. Damage to the protective cover or insulation
may provide fuel for fires.
The exhaust gas temperatures during regeneration
will be elevated. Follow proper fire prevention Store fuels and lubricants in properly marked
instructions and use the disable regeneration containers away from unauthorized personnel. Store
function (if equipped) when appropriate. oily rags and flammable materials in protective
containers. Do not smoke in areas that are used for
General storing flammable materials.

All fuels, most lubricants, and some coolant mixtures

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.
28
Safety Section
Fire Prevention and Explosion Prevention
Illustration 40 g03839130
Use caution when you are fueling a machine. Do not
smoke while you are fueling a machine. Do not fuel a
machine near open flames or sparks. Do not use cell
phones or other electronic devices while you are
refueling. Always stop the engine before fueling. Fill
the fuel tank outdoors. Properly clean areas of
spillage.
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.
SEBU9190-12
Never store flammable fluids in the operator
compartment of the machine.
Battery and Battery Cables
Illustration 41 g03839133
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. Do not use cell
phones or other electronic devices in battery
charging areas.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter in
order to check the battery charge.
Daily inspect battery cables that are in areas that are
visible. Inspect cables, clips, straps, and other
restraints for damage. Replace any damaged parts.
Check for signs of the following, which can occur
over time due to use and environmental factors:
• Fraying
SEBU9190-12
• 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
contact 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.
• 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.
29
Safety Section
Fire Prevention and Explosion Prevention
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 42 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:
• 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.
30
Safety Section
Fire Safety
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
Diesel Particulate Filter (DPF) may result in the
accumulation of Ether in the DPF and an explo-
sion. 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.
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.
SEBU9190-12
Consider installation of an aftermarket Fire
Suppression System, if the application and working
conditions warrant the installation.
i07041871
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 are 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. 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.
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.
SEBU9190-12
• Remember that nearly all the fluids on the
machine are flammable, including coolant and oils.
Additionally, plastics, rubbers, fabrics, and resins
in fiberglass panels are also flammable.
i06931137
Fire Extinguisher Location
SMCS Code: 7000; 7419
Illustration 43 g06129430
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.
Mount the fire extinguisher to the guardrail support in
one of the locations shown in Illustration 43 .
Fire Suppression Canister
Location
If a fire suppression system is installed, ensure that
the agent canisters are mounted on the
counterweight only.
i01329108
Track Information
SMCS Code: 4170; 7000
Track adjusting systems use either grease or oil
under high pressure to keep the track under tension.
Grease or oil under high pressure coming out of the
relief valve can penetrate the body causing injury or
death. Do not watch the relief valve to see if grease
or oil is escaping. Watch the track or track adjustment
cylinder to see if the track is being loosened.
The pins and bushings in a dry track pin joint can
become very hot. It is possible to burn the fingers if
there is more than brief contact with these
components.
31
Safety Section
Fire Extinguisher Location
i02546320
High Pressure Fuel Lines
SMCS Code: 1000; 1274; 7000
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
structions may cause personal injury or death.
The high pressure fuel lines are the fuel lines that are
between the high pressure fuel pump and the high
pressure fuel manifold and the fuel lines that are
between the fuel manifold and cylinder head. These
fuel lines are different from fuel lines on other fuel
systems.
This is because of the following differences:
• The high pressure fuel lines are constantly
charged with high pressure.
• The internal pressures of the high pressure fuel
lines are higher than other types of fuel system.
• The high pressure fuel lines are formed to shape
and then strengthened by a special process.
Do not step on the high pressure fuel lines. Do not
deflect the high pressure fuel lines. Do not bend or
strike the high pressure fuel lines. Deformation or
damage of the high pressure fuel lines may cause a
point of weakness and potential failure.
Do not check the high pressure fuel lines with the
engine or the starting motor in operation. After the
engine has stopped allow 10 minutes to pass in order
to allow the pressure to be purged before any service
or repair is performed on the engine fuel lines.
Do not loosen the high pressure fuel lines in order to
remove air from the fuel system. This procedure is
not required.
Visually inspect the high pressure fuel lines before
the engine is started. This inspection should be each
day.
If you inspect the engine in operation, always use the
proper inspection procedure in order to avoid a fluid
penetration hazard. Refer to Operation and
Maintenance Manual, “General hazard Information”.
• Inspect the high pressure fuel lines for damage,
deformation, a nick, a cut, a crease, or a dent.
• Do not operate the engine with a fuel leak. If there
is a leak do not tighten the connection in order to
stop the leak. The connection must only be
tightened to the recommended torque. Refer to
Disassembly and Assembly for your engine.
32
Safety Section
Electrical Storm Injury Prevention
• If the high pressure fuel lines are torqued correctly
and the high pressure fuel lines are leaking the
high pressure fuel lines must be replaced.
• Ensure that all clips on the high pressure fuel lines
are in place. Do not operate the engine with clips
that are damaged, missing or loose.
• Do not attach any other item to the high pressure
fuel lines.
• Loosened high pressure fuel lines must be
replaced. Also removed high pressure fuel lines
must be replaced. Refer to Disassembly and
Assembly for your engine.
i01122596
Electrical Storm Injury
Prevention
SMCS Code: 7000
When lightning is striking in the vicinity of the
machine, the operator should never attempt the
following procedures:
• Mount the machine.
• Dismount the machine.
If you are in the operator's station during an electrical
storm, stay in the operator's station. If you are on the
ground during an electrical storm, stay away from the
vicinity of the machine.
i00771840
Before Starting Engine
SMCS Code: 1000; 7000
Start the engine only from the operator compartment.
Never short across the starter terminals or across the
batteries. Shorting could damage the electrical
system by bypassing the engine neutral start system.
Inspect the condition of the seat belt and of the
mounting hardware. Replace any parts that are worn
or damaged. Regardless of appearance, replace the
seat belt after three years of use. Do not use a seat
belt extension on a retractable seat belt.
Adjust the seat so that full pedal travel can be
achieved with the operator's back 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 machine lights are
working properly.
SEBU9190-12
Before you start the engine and before you move the
machine, make sure that no one is underneath the
machine, around the machine, or on the machine.
Make sure that the area is free of personnel.
i07746368
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:
• 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
SEBU9190-12 33
Safety Section
Restricted Visibility

Modifications of the machine configuration by the

user that result in a restriction of visibility shall be
evaluated.

i05830324

Restricted Visibility
SMCS Code: 7000
The size and the configuration of this machine may
result in areas that cannot be seen when the operator
is seated. Illustration 45 indicates areas of restricted
visibility near the machine in two locations. One
location is on a rectangular line 1.00 m (3.00 ft) from
the outside of the machine profile at a height of 1.5 m
(5.00 ft). The second location is on the ground level
at a radius of 12.00 m (40.00 ft) from the operator.
This machine may be equipped with optional visibility
aids that may provide visibility to some of the
restricted visibility areas. Refer to this Operation and
Maintenance Manual, “Mirror” for more information
on additional visibility. If your machine is equipped
with cameras, refer to this Operation and
Maintenance Manual, “Camera” for more information
on additional visibility. For areas that are not covered
by the optional visual aids, an appropriate job site
organization must be utilized to minimize hazards of
this restricted visibility. For more information
regarding job site organization refer to Operation and Illustration 45 g02547356
Maintenance Manual, “Visibility Information”.
Top view of the machine
When equipped with optional visual aids, the
machine visibility will meet the technical Note: The shaded areas indicate the approximate
requirements found in ISO5006:2006 location of areas with significant restricted visibility.
Restricted visibility is measured when the front i03562260
linkage of the machine is in the travel position.
Illustration 44 shows the machine in the travel
position. Engine Starting
SMCS Code: 1000; 7000
If a warning tag is attached to the engine start switch
or to the controls, do not start the engine. Also, do not
move any controls.
Make sure that you are seated before you start the
engine.
Move all hydraulic controls to the HOLD position
before you start the engine. Move the hydraulic
lockout control to the LOCKED position. For further
details on this procedure, refer to Operation and
Maintenance Manual, “Operator Controls”.
Diesel engine exhaust contains products of
Illustration 44 g02155813 combustion which can be harmful to your health.
(A) 1 m (3.0 ft) from the front of the machine to the bucket Always run the engine in a well ventilated area. If you
(B) 0.5 m (1.6 ft) from ground level are in an enclosed area, vent the exhaust to the
outside.
Note: This illustration does not show all areas of Briefly sound the horn before you start the engine.
restricted visibility that are inside the two locations.
This illustration does not show restricted visibility that
may exist at further distances from the machine.
34
Safety Section
Before Operation
i01340061
Before Operation
SMCS Code: 7000
Clear all personnel from the machine and from the
area.
Clear all obstacles from the machine's path. Beware
of hazards (wires, ditches, etc).
Be sure that all windows are clean. Secure the doors
and the windows in the open position or in the shut
position.
Adjust the rearview mirrors (if equipped) for the best
visibility close to the machine. Make sure that the
horn, the travel alarm (if equipped), and all other
warning devices are working properly.
Fasten the seat belt securely.
Warm up the engine and the hydraulic oil before
operating the machine.
Before moving the machine, check the position of the
undercarriage. The normal travel position is with the
idler wheels to the front under the cab and the drive
sprockets to the rear. When the undercarriage is in
the reversed position, the directional controls must be
operated in opposite directions.
i04159629
Work Tools
SMCS Code: 6700
Only use work tools that are recommended by
Caterpillar for use on Cat machines.
Use of work tools, including buckets, which are
outside of Caterpillar's recommendations or
specifications for weight, dimensions, flows,
pressures, and so on. may result in less-than-optimal
vehicle performance, including but not limited to
reductions in production, stability, reliability, and
component durability. Caterpillar recommends
appropriate work tools for our machines to maximize
the value our customers receive from our products.
Caterpillar understands that special circumstances
may lead a customer to use tools outside of our
specifications. In these cases, customers must be
aware that such choices can reduce vehicle
performance and will affect their ability to claim
warranty in the event of what a customer may
perceive as a premature failure.
Work tools and work tool control systems, that are
compatible with your Cat machine, are required for
safe machine operation and/or reliable machine
operation. If you are in doubt about the compatibility
of a particular work tool with your machine, consult
your Cat dealer.
SEBU9190-12
Make sure that all necessary guarding is in place on
the host machine and on the work tool.
Keep all windows and doors closed on the host
machine. A polycarbonate shield must be used when
the host machine is not equipped with windows and
when a work tool could throw debris.
Do not exceed the maximum operating weight that is
listed on the ROPS certification.
If your machine is equipped with an extendable stick,
install the transport pin when you are using the
following work tools: hydraulic hammers, augers and
compactors
Always wear protective glasses. Always wear the
protective equipment that is recommended in the
operation manual for the work tool. Wear any other
protective equipment that is required for the
operating environment.
To prevent personnel from being struck by flying
objects, ensure that all personnel are out of the work
area.
While you are performing any maintenance, any
testing, or any adjustments to the work tool stay clear
of the following areas: cutting edges, pinching
surfaces and crushing surfaces.
Never use the work tool for a work platform.
i07776501
Operation
SMCS Code: 7000
Machine Operating Temperature
Range
The machine must function satisfactorily in the
anticipated ambient temperature limits that are
encountered during operation. The standard machine
configuration is intended for use within an ambient
temperature range of −18 °C (0 °F) to 43 °C
(109 °F). Special configurations for different ambient
temperatures may be available. Consult your
Caterpillar dealer for additional information on special
configurations of your machine.
Limiting Conditions and Criteria
Limiting conditions are immediate issues with this
machine that must be addressed prior to continuing
operation.
The Operation and Maintenance Manual, Safety
Section describes limiting condition criteria for
replacing items such as safety messages, seat belt
and mounting hardware, lines, tubes, hoses, battery
cables and related parts, electrical wires, and
repairing any fluid leak.
SEBU9190-12 35
Safety Section
Operation

The Operation and Maintenance Manual,

Maintenance Interval Schedule describes limiting
condition criteria that require repair or replacement
for items (if equipped) such as alarms, horns, braking
system, steering system, and rollover protective
structures.
The Operation and Maintenance Manual, Monitoring
System (if equipped) provides information on limiting
condition criteria, including a Warning Category 3
that requires immediate shutdown of the engine.
The following table provides summary information on
several limiting conditions found in this Operation and
Maintenance Manual. The table provides criteria and
required action for the limiting conditions listed. Each
System or Component in this table, together with the
respective limiting condition, describes a potential
critical failure that must be addressed. Not
addressing limiting conditions with required actions
may, in conjunction with other factors or
circumstances, result in a risk of personal injury or
death. If an accident occurs, notify emergency
personnel and provide location and description of
accident.
Table 1
System or
Limiting Criteria for Required
Component
Condition Action Action
Name
End fittings are damaged or leak- Visible corrosion, loose, or Immediately repair any lines, tubes, or hoses that
ing. Outer coverings are chafed or damaged lines, tubes, or ho- are corroded, loose, or damaged. Immediately re-
cut. Wires are exposed. Outer ses. Visible fluid leaks. pair any leaks as these may provide fuel for fires.
Line, tubes, and coverings are swelling or balloon-
hoses ing. Flexible parts of the hoses
are kinked. Outer covers have ex-
posed embedded armoring. End
fittings are displaced.
Signs of fraying, abrasion, crack- Visible damage to electrical Immediately replace damaged wiring
Electrical Wiring ing, discoloration, cuts on the wiring
insulation
Signs of fraying, abrasion, crack- Visible damage to battery ca- Immediately replace damaged battery cables
ing, discoloration, cuts on the in- ble(s)
Battery cable(s) sulation of the cable, fouling,
corroded terminals, damaged ter-
minals, and loose terminals
Structures that are bent, cracked, Visible damage to structure. Do not operate machine with damaged structure or
Operator Protective or loose. Loose, missing, or dam- Loose, missing, or damaged loose, missing, or damaged bolts. Contact your Cat
Structure aged bolts. bolts. dealer for inspection and repair or replacement
options.
Worn or damaged seat belt or Visible wear or damage Immediately replace parts that are worn or
Seat Belt
mounting hardware damaged.
Age of seat belt Three years after date of Replace seat belt three years after date of
Seat Belt
installation installation
Appearance of safety message Damage to safety messages Replace the illustrations if illegible.
Safety Messages
making them illegible
Audible Warning De- Sound level of audible warning Reduced or no audible warn- Immediately repair or replace audible warning devi-
vice(s) (if equipped) ing present ces not working properly.
Camera(s) (if Dirt or debris on camera lens Dirt or debris obstructing cam- Clean camera before operating machine.
equipped) era view
Dirt, debris, or damaged windows Dirt or debris obstructing oper- Clean windows before operating machine. Repair
Cab Windows (if
ator visibility. Any damaged or replace damaged windows before operating
equipped)
windows. machine.

(continued)
36 SEBU9190-12
Safety Section
Operation

(Table 1, contd)
System or
Limiting Criteria for Required
Component
Condition Action Action
Name
Dirt, debris, or damaged mirror Dirt or debris obstructing oper- Clean mirrors before operating machine. Repair or
Mirrors (if equipped) ator visibility. Any damaged replace damaged mirrors before operating
mirrors. machine.
Inadequate braking performance System does not pass Braking Contact your Cat dealer to inspect and, if neces-
System - Test(s) included in sary, repair the brake system.
Braking System
Maintenance Section or in the
Testing and Adjusting Manual
The coolant temperature is too Monitoring System displays Stop the engine immediately. Check the coolant lev-
high. Warning Category 3 el and check the radiator for debris. Refer to Opera-
tion and Maintenance Manual, Cooling System
Cooling System Coolant Level - Check. Check the fan drive belts for
the water pump. Refer to Operation and Mainte-
nance Manual, Belts - Inspect/Adjust/ Replace.
Make any necessary repairs.
A problem has been detected with Monitoring System displays If the warning stays on during low idle, stop the en-
Engine Oil System the engine oil pressure. Warning Category 3 gine and check the engine oil level. Perform any
necessary repairs as soon as possible.
An engine fault has been detected Monitoring System displays Stop the engine immediately. Contact your Cat
Engine system
by the engine ECM. Warning Category 3 dealer for service.
A problem has been detected with Monitoring System displays Stop the engine. Determine the cause of the fault
Fuel System
the fuel system. Warning Category 3 and perform any necessary repairs.
The hydraulic oil temperature is Monitoring System displays Stop the engine immediately. Check the hydraulic
Hydraulic Oil System too high. Warning Category 3 oil level and check the hydraulic oil cooler for debris.
Perform any necessary repairs as soon as possible.
A problem has been detected with Monitoring System displays Move machine to a safe location and stop the en-
Steering System the steering system. (If equipped Warning Category 3 gine immediately. Contact your Cat dealer to in-
with steering system monitoring.) spect and, if necessary, repair the steering system.
Machine service is required. Monitoring System displays Stop the engine immediately. Contact your Cat
Overall Machine
Warning Category 3 dealer for service.

Machine Operation Hold attachments approximately 40 cm (15 inches)

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.
Check for proper operation of all controls and of all
protective devices while you operate the machine
slowly in an open area.
When the machine is moving watch the clearance of
the boom. Uneven ground can cause the boom to
move in all directions.
above ground level while you drive the machine. Do
not drive the machine close to an overhang, to the
edge of a cliff, or to the edge of an excavation.
If the machine begins to sideslip on a grade,
immediately dump the load and turn the machine
downhill.
Be careful to avoid any ground condition which could
cause the machine to tip. Tipping can occur when
you work on hills, on banks, or on slopes. Tipping can
also occur when you cross ditches, ridges, or other
unexpected obstructions.

Make sure that no personnel will be endangered
before you move the machine. Do not allow riders on
the machine unless the machine has an additional
seat with a seat belt.
During operation of the machine, flying debris could
be discharged from the tracks. Keep all personnel a
safe distance from the machine during operation.
Report any machine damage that was noted during
machine operation. Make any necessary repairs.
Never use the work tool for a work platform.
When possible, operate the machine up slopes and
down slopes with the final drive sprockets facing
down the slope. Avoid operating the machine across
the slope. Place the heaviest end of the machine
uphill when you are working on an incline.
To hold position on a slope, first use the joystick to
counter-swing and bring the superstructure to a stop.
Then quickly center the joystick to activate the swing
brake. To avoid brake damage, the brake will only
engage when the superstructure has come to a
complete stop.
Keep the machine under control. Do not overload the
machine beyond capacity.
SEBU9190-12 37
Safety Section
Engine Stopping

Avoid changing the direction of travel on a slope. Shut down the machine until damaged or non-
Changing the direction of travel on a slope could functioning visibility aids are repaired (if applicable)
result in tipping or side slipping of the machine. or until appropriate job site organization is used to
minimize hazards that are caused by any resulting
Bring the load close to the machine before traveling restricted visibility.
any distances.
Bring the load close to the machine before swinging Machine Operation when the
the load. Machine is not Completely
Lifting capacity decreases as the load is moved Assembled
further from the machine.
Make sure that the towing eyes and the towing
devices are adequate for your needs.
Only connect trailing equipment to a drawbar or to a
hitch.
Never straddle a wire cable. Never allow other
personnel to straddle a wire cable.
When you maneuver to connect the equipment,
make sure that no personnel are between the
machine and trailing equipment. Block up the hitch of
the trailing equipment to align the equipment with the
drawbar.
Check the local regulations, state codes, and/or
directives of the job site for a specific minimum
distance from obstacles.
Before you operate the machine, check with local
utilities for the locations of underground pipes and for
the locations of buried cables.
Know the maximum dimensions of your machine.
Illustration 46 g02202544
Watch the load at all times.
Attach the tag to the controls of the machine. When
Do not operate the machine without the the tag is attached to the controls, operate the
counterweight. The machine can tip when the boom machine as described below.
is over the side.
If the machine needs to be operated without the
Certain machine front linkage combinations (boom, boom, stick, and/or counterweight being installed, the
stick, quick coupler, work tool) can allow the work tool machine should be operated slowly on flat, stable
to contact the machine undercarriage, swing frame, ground or pavement by qualified operators. Avoid
boom, boom hydraulic cylinder and or the cab. Be any machine operations which could affect machine
aware of the position of the work tool while you stability, including the swing function. The ROPS
operate the machine. structural certification depends on the support of the
boom, stick, and counterweight in the event of a
machine tip over or a machine rollover incident.

i05864416

Engine Stopping
SMCS Code: 1000; 7000
Do not stop the engine immediately after the machine
has been operated under load. Stopping the engine
immediately can cause overheating and accelerated
wear of engine components.
After the machine is parked, allow the engine to run
for 5 minutes before shutdown. Running the engine
allows hot areas of the engine to cool gradually.
38
Safety Section
Parking
i05830314
Parking
SMCS Code: 7000
The hydraulic system controls remain pressurized if
the accumulator is charged. This condition is true
even when the engine is not running. The hydraulic
control system pressure should decrease in a short
time (approximately 1 minute). While the hydraulic
controls maintain a charge, the hydraulic work tools
and machine controls remain functional.
There can be residual pressure within the hydraulic
system even when the accumulator is empty. Refer
to this Operation and Maintenance Manual, “System
Pressure Relief” before any service is performed to
the hydraulic system.
Machine movement that is sudden and unexpected
will occur if any of the controls are moved. Machine
movement that is sudden and unexpected, can cause
personal injury or death.
Always move the hydraulic lockout control to the
LOCKED position before you shut off the engine or
immediately after the engine stops running.
Park the machine on a hard, level surface. If you
must park the machine on a grade, chock the tracks
of the machine.
Illustration 47 g00813422
Place the machine in the servicing position.
Note: Make sure that all work tools are in the
recommended servicing position before servicing the
machine.
Move the hydraulic lockout control to the LOCKED
position.
Stop the engine.
Turn the engine start switch to the OFF position and
remove the engine start switch key.
SEBU9190-12
Turn the battery disconnect switch to the OFF
position. Remove the disconnect switch key if you do
not operate the machine for an extended period.
Turning the battery disconnect switch to the OFF
position will prevent drainage of the battery. A battery
short circuit, any current draw from certain
components, and vandalism can cause drainage of
the battery.
Install barriers or lighting as required to prevent
interference in road traffic.
Select places free of danger by flooding and other
water damage.
i01329161
Equipment Lowering with
Engine Stopped
SMCS Code: 7000-II
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.
i07478286
Sound Information and
Vibration Information
SMCS Code: 7000
Sound Level Information
The dynamic operator sound pressure level is 71 dB
(A) when “ISO6396” is used to measure the value for
an enclosed cab. The cab was properly installed and
maintained. The test was conducted with the cab
doors and the cab windows closed.
The average exterior sound pressure level is 103 dB
(A) when the “ISO6395-Dynamic Test” procedure is
used to measure the value for the standard machine.
The declared sound levels listed above include both
measurement uncertainty and uncertainty due to
production variation.
SEBU9190-12
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.
Sound Level Information for
Machines in European Union
Countries and in Countries that
Adopt the “EU Directives”
The dynamic operator sound pressure level is 71 dB
(A) when “ISO6396” is used to measure the value for
an enclosed cab. The cab was properly installed and
maintained. The test was conducted with the cab
doors and the cab windows closed.
The average exterior sound pressure level is 103 dB
(A) when the “ISO6395-Dynamic Test” procedure is
used to measure the value for the standard machine.
The declared sound levels listed above include both
measurement uncertainty and uncertainty due to
production variation.
Sound Level Information for
Machines in Eurasian Economic
Union Countries
The dynamic operator sound pressure level is 71 dB
(A) when “ISO6396” is used to measure the value for
an enclosed cab. The cab was properly installed and
maintained. The test was conducted with the cab
doors and the cab windows closed.
The average exterior sound pressure level is 103 dB
(A) when the “ISO6395-Dynamic Test” procedure is
used to measure the value for the standard machine.
The declared sound levels listed above include both
measurement uncertainty and uncertainty due to
production variation.
“The European Union Physical
Agents (Vibration) Directive 2002/
44/EC”
Vibration Data for Track Type Excavator
Information Concerning Hand/Arm Vibration
Level
When the machine is operated according to the
intended use, the hand/arm vibration of this machine
is below 2.5 meter per second squared.
39
Safety Section
Sound Information and Vibration Information
Information Concerning Whole Body Vibration
Level
This section provides vibration data and a method for
estimating the vibration level for track type
excavators.
Note: Vibration levels are influenced by many
different parameters. Many items are listed below.
• Operator training, behavior, mode and stress
• Job site organization, preparation, environment,
weather and material
• Machine type, quality of the seat, quality of the
suspension system, attachments and condition of
the equipment
It is not possible to get precise vibration levels for this
machine. The expected vibration levels can be
estimated with the information in Table 2 in order to
calculate the daily vibration exposure. A simple
evaluation of the machine application can be used.
Estimate the vibration levels for the three vibration
directions. For typical operating conditions, use the
average vibration levels as the estimated level. With
an experienced operator and smooth terrain, subtract
the Scenario Factors from the average vibration level
in order to obtain the estimated vibration level. For
aggressive operations and severe terrain, add the
Scenario Factors to the average vibration level in
order to obtain the estimated vibration level.
Note: All vibration levels are in meter per second
squared.
40 SEBU9190-12
Safety Section
Sound Information and Vibration Information

Table 2
“ISO Reference Table A - Equivalent vibration levels of whole body vibration emission for earthmoving equipment.”

Typical Operating Vibration Levels Scenario Factors

Machine Type
Activity X axis Y axis Z axis X axis Y axis Z axis
excavating 0,44 0,27 0,30 0,24 0,16 0,17

hydraulic breaker application 0,53 0,31 0,55 0,30 0,18 0,28

Track Type
Excavators mining application 0,65 0,42 0,61 0,21 0,15 0,32

transfer 0,48 0,32 0,79 0,19 0,20 0,23

Note: Refer to “ISO/TR 25398 Mechanical Vibration - b. Inspect and maintain the seat suspension and
Guideline for the assessment of exposure to whole adjustment mechanisms.
body vibration of ride on operated earthmoving
machines” for more information about vibration. This 5. Perform the following operations smoothly.
publication uses data that is measured by a. Steer
international institutes, organizations and
manufacturers. This document provides information b. Brake
about the whole body exposure of operators of
earthmoving equipment. Refer to Operation and c. Accelerate.
Maintenance Manual, SEBU8257, “The European d. Shift the gears.
Union Physical Agents (Vibration) Directive 2002/44/
EC” for more information about machine vibration 6. Move the attachments smoothly.
levels.
7. Adjust the machine speed and the route in order to
The Caterpillar suspension seat meets the criteria of minimize the vibration level.
“ISO 7096”. This represents vertical vibration level
under severe operating conditions. a. Drive around obstacles and rough terrain.

Guidelines for Reducing Vibration Levels on
Earthmoving Equipment
Properly adjust machines. Properly maintain
machines. Operate machines smoothly. Maintain the
conditions of the terrain. The following guidelines can
help reduce the whole body vibration level:
1. Use the right type and size of machine, equipment,
and attachments.
2. Maintain machines according to the
manufacturer's recommendations.
a. Tire pressures
b. Brake and steering systems
c. Controls, hydraulic system and linkages
3. Keep the terrain in good condition.
a. Remove any large rocks or obstacles.
b. Fill any ditches and holes.
c. Provide machines and schedule time in order to
maintain the conditions of the terrain.
4. Use a seat that meets “ISO 7096”. Keep the seat
maintained and adjusted.
a. Adjust the seat and suspension for the weight
and the size of the operator.
b. Slow down when it is necessary to go over
rough terrain.
8. Minimize vibrations for a long work cycle or a long
travel distance.
a. Use machines that are equipped with
suspension systems.
b. Use the ride control system on track type
excavators.
c. If no ride control system is available, reduce
speed in order to prevent bounce.
d. Haul the machines between workplaces.
9. Less operator comfort may be caused by other risk
factors. The following guidelines can be effective
in order to provide better operator comfort:
a. Adjust the seat and adjust the controls in order
to achieve good posture.
b. Adjust the mirrors in order to minimize twisted
posture.
c. Provide breaks in order to reduce long periods
of sitting.
d. Avoid jumping from the cab.
e. Minimize repeated handling of loads and lifting
of loads.
SEBU9190-12
f. Minimize any shocks and impacts during sports
and leisure activities.
Sources
The vibration information and the calculation
procedure is based on “ISO/TR 25398 Mechanical
Vibration - Guideline for the assessment of exposure
to whole body vibration of ride on operated
earthmoving machines”. Harmonized data is
measured by international institutes, organizations
and manufacturers.
This literature provides information about assessing
the whole body vibration exposure of operators of
earthmoving equipment. The method is based on
measured vibration emission under real working
conditions for all machines.
You should check the original directive. This
document summarizes part of the content of the
applicable law. This document is not meant to
substitute the original sources. Other parts of these
documents are based on information from the United
Kingdom Health and Safety Executive.
Refer to Operation and Maintenance Manual,
SEBU8257, “The European Union Physical Agents
(Vibration) Directive 2002/44/EC” for more
information about vibration.
Consult your local Caterpillar dealer for more
information about machine features that minimize
vibration levels. Consult your local Caterpillar dealer
about safe machine operation.
Use the following web site in order to find your local
dealer:
Caterpillar, Inc.
www.cat.com
i07746362
Operator Station
SMCS Code: 7300; 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.
41
Safety Section
Operator Station
i07746359
Guards
(Operator Protection)
SMCS Code: 7000; 7150
There are different types of guards that are used to
protect the operator. The machine and the machine
application determine 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.
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 Cat dealer for mounting
guidelines.
42 SEBU9190-12
Safety Section
Operator Protection

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:
• 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.
Refer to Operation Maintenance manual,
"Demolition" for additional information. Consult your
Cat dealer for additional information.
SEBU9190-12 43
Product Information Section
General Information

Product Information • Ensure that machine application conditions

comply with Caterpillar’s recommendations.
Section • Ensure that the operating weight does not exceed
limits set by manufacturer.
General Information
i07776511

Specifications
SMCS Code: 7000

Intended Use
The intended use of this machine is for excavating
with a bucket or working with approved work tools.
The machine should be operated with the
undercarriage in a stationary position since the upper
structure is normally capable of 360 degree swing
with mounted equipment. This machine can be used
in object handling applications that are within the lift
capacity of the machine. When this machine is used
in object handling applications, ensure that the
machine is properly configured and operated
properly. Obey any local governmental regulations
and regional governmental regulations. Only lift
objects from approved lifting points and with
approved lifting devices.

Expected Life
The expected life, defined as total machine hours, of
this machine is dependent upon many factors
including the machine owner’s desire to rebuild the
machine back to factory specifications. The expected
life interval of this machine is 12000 service hours.
The expected life interval corresponds to the service
hours to engine overhaul. Service hours to engine
overhaul may vary based on overall machine duty
cycle. At the expected life interval, remove the
machine from operation and consult your Cat dealer
for inspect, repair, rebuild, install remanufactured,
install new components, or disposal options and to
establish a new expected life interval. If a decision is
made to remove this machine from service, refer to
Operation and Maintenance Manual,
“Decommissioning and Disposal”.
The following items are required to obtain an
economical expected life of this machine:
• Perform regular preventive maintenance
procedures as described in the Operation and
Maintenance Manual.
• Perform machine inspections as described in the
Operation and Maintenance Manual and correct
any problems discovered.
• Perform system testing as described in the
Operation and Maintenance Manual and correct
any problems discovered.
44 SEBU9190-12
Product Information Section
Specifications

• Ensure that all frame cracks are identified,

inspected, and repaired to prevent further
development.

Application/Configuration
Restrictions
The maximum range of operation on a slope is 30
degrees and limited by engine lubrication.

Specification Data
SEBU9190-12 45
Product Information Section
Specifications

Illustration 48 g03688481

Table 3 (Table 3, contd)

6015B Shovel
Cab outside width (A)
Height over cab (B)
Track height over carrier rollers (C)
with a 700 mm
(27.56 inch) shoe
1096 mm (43.15 inch)
with a 900 mm
4207 mm (165.63 inch) Shoe width (D)
(35.43 inch) shoe
1793 mm (70.59 inch) with a 1000 mm
(39.37 inch) shoe

(continued)
(continued)
46 SEBU9190-12
Product Information Section
Specifications

(Table 3, contd)
Overall track length (E) 7000 mm (275.59 inch)

Idler to sprocket (F) 5532 mm (217.79 inch)

Gage (G) 4100 mm (161.42 inch)

with a 700 mm
4800 mm (188.98 inch)
(27.56 inch) shoe

Overall undercar- with a 900 mm

5000 mm (196.85 inch)
riage width (H) (35.43 inch) shoe

with a 1000 mm
5100 mm (200.79 inch)
(39.37 inch) shoe

Carbody clearance (I) 1077 mm (42.40 inch)

Counterweight clearance (J) 1936 mm (76.22 inch)

House width (K) 3650 mm (143.70 inch)

Width over walkways (L) 5689 mm (223.98 inch)

CL swing to rear (M) 5120 mm (201.57 inch)

Tail swing radius (N) 5179 mm (203.90 inch)

CL swing to boom pivot (O) 725 mm (28.54 inch)

Ground to boom pivot (P) 3537 mm (139.25 inch)

Boom length (Q) 7600 mm (299.21 inch)

Stick length (R) 3400 mm (133.86 inch)

Bucket tip radius (S) 2822 mm (111.10 inch)

(continued)
SEBU9190-12 47
Product Information Section
Specifications

(Table 3, contd)
18600 mm
Overall length at max reach (T)
(732.28 inch)

Overall height at max reach (U) 6280 mm (247.24 inch)

Working Ranges

Illustration 49 g03688559

Table 4 (Table 4, contd)

6015B Shovel Max depth (e) 7890 mm (310.63 inch)

Max reach at grade (a) 13550 mm (533.46 inch) Max dig height (f) 13160 mm (518.11 inch)

Max reach (d) 14020 mm (551.97 inch) Max dump height (g) 8700 mm (342.52 inch)

(continued) (continued)
48 SEBU9190-12
Product Information Section
Specifications

(Table 4, contd)
Minimum dump height (h) 4050 mm (159.45 inch)

Max bucket pin height (i) 11310 mm (445.27 inch)

Max vertical wall (j) 3070 mm (120.87 inch)

Minimum reach at grade (k) 700 mm (27.56 inch)

Minimum working swing radius 6000 mm (236.22 inch)

(l)

Minimum clean up at grade (m) 4600 mm (181.10 inch)

Max crowd length at grade (n) 4847 mm (190.83 inch)

SEBU9190-12 49
Product Information Section
Identification Information

Identification Information
i07478294

Plate Locations and Film

Locations
SMCS Code: 1000; 7000
The Product Information Number (PIN) will be used
to identify a powered machine that is designed for an
operator to ride.
Caterpillar products such as engines, transmissions,
and major attachments that are not designed for an
operator to ride are identified by Serial Numbers. Illustration 51 g06201159

The certification plate (CE) is used to verify that the Manufacturer Name and Address
product conforms to all the requirements that were
established by a country or a group of countries. The Model (A)
product is tested by a certified testing group to verify
conformance. Build (B)

For quick reference, record the identification Product Identification Number (C)
numbers in the spaces that are provided below the
illustration. Bar Code (D)
Month and Year of Manufacture Plate (If Required)
Product Identification Number (E)
(PIN) CE Plate (If Required) (F)
Address of Manufacturer (G)
Issue (H)
Country of Origin Info Plate (If Required) (I)
Local regulation may require documentation of the
month and/or year of manufacture in the Operation
and Maintenance Manual. Enter on line (E) above if
required.

Eurasian Economic Union

Illustration 50 g03689636
The Product Identification Number (PIN) plate is on
the front right corner of the machine. The plate may
have the following information:
For machines compliant to the Eurasian Economic
Union requirements, the EAC mark plate is
positioned near the Product Identification Number
(PIN) plate (see Product Information Section of the
machine Operation and Maintenance Manual). The
EAC mark plate is placed on machines certified to the
Eurasian Economic Union requirements effective at
the time of market entry.
50 SEBU9190-12
Product Information Section
Plate Locations and Film Locations

Illustration 52 g06094564 Illustration 53 g01212098

The Month and Year of Manufacture are on the PIN

plate.
Structural damage, an overturn, modification, al-
Manufacturer Information teration, or improper repair can impair this struc-
Manufacturer: ture's protection capability thereby voiding this
certification. Do not weld on or drill holes in the
structure. This will void the certification. Consult
Caterpillar Inc., your Cat dealer to determine this structure's limi-
100 N.E. Adams Street tations without voiding its certification.
Peoria, Illinois 61629, USA
Entity authorized by the manufacturer at the territory This machine has been certified to the standards that
of Eurasian Economic Union: are listed on the certification film. The maximum
mass of the machine, which includes the operator
Caterpillar Eurasia LLC and the attachments without a payload, should not
75, Sadovnicheskaya Emb. exceed the mass on the certification film.
Moscow 115035, Russia
Refer to Operation and Maintenance Manual,
“Guards (Operator Protection)” for more information.
Engine Serial Number
European Union
This label is on the engine.
Engine Serial Number

Certification
ROPS/FOPS Structure
This message is positioned on the ROPS on the left
side of the machine above the door.

Illustration 54 g01880193

This plate is positioned on the bottom left side of the

plate for the PIN.

Note: The CE plate is on machines that are certified

to the European Union requirements that were
effective at that time.
SEBU9190-12 51
Product Information Section
Emissions Certification Film

For machines compliant to 2006/42/EC, the following

information is stamped onto the CE plate. For quick
reference, record this information in the spaces that
are provided below.
• Engine Power Primary Engine (kW)

• Engine Power for Additional Engine (If Equipped)

• Typical Machine Operating Weight for European

Market (kg)
• Year of Construction

• Machine Type
Illustration 56 g01261742
Sound Certification

This machine is equipped with a Cat Product Link

radio communication device which must be deac-
tivated within 6.0 m (20 ft) of a blast zone. Failure
to do so could result in serious injury or death.

If the machine is required to work within 6 m (20 ft) of

a blast area, power to the Product Link module must
be disconnected.
Consult your Cat dealer with any questions that
concern the operation of the Product Link in a
specific country.

i07709181
Illustration 55 g00933634
A typical example of this film is shown. Your machine Emissions Certification Film
may have a different value.
SMCS Code: 1000; 7000; 7405
If equipped, the certification film is used to verify the
environmental sound certification of the machine. Note: This information is pertinent in the United
The value that is listed on the film indicates the States, in Canada and in Europe.
guaranteed sound power level. The guaranteed
sound power level is measured at the time of Consult your Cat dealer for an Emission Control
manufacture. The guaranteed sound power level is Warranty Statement.
measured according to the conditions that are
specified in “ISO 6394:1998”. This label is located on the engine.

Product Link
If equipped, this message is used to verify the
certification of the Product Link as an RF transmitter.
The following specifications are provided to aid in
ensuring compliance with all local regulations:
Table 5
Operating frequency range 148 to 150 MHz

Transmitter power 5W

This message is on the control group for the Product

Link. The control group is on the top of the cab.
52 SEBU9190-12
Product Information Section
Declaration of Conformity

Declaration of Conformity
SMCS Code: 1000; 7000

Table 6
An EC or EU Declaration of Conformity document was provided with the machine if it was manufactured to comply with specific requirements
for the European Union. In order to determine the details of the applicable Directives, review the complete EC or EU Declaration of Conformity
provided with the machine. The extract shown below from an EC or EU Declaration of Conformity for machines that are declared compliant to
“2006/42/EC” applies only to those machines originally “CE” marked by the manufacturer listed and which have not since been modified.

ORIGINAL EC or EU DECLARATION OF CONFORMITY

Manufacturer: Caterpillar Inc., 100 N.E. Adams Street, Peoria, Illinois 61629, USA

Person authorized to compile the Technical File and to communicate relevant part (s) of the Technical File to the Authorities of Euro-
pean Union Member States on request:

Standards & Regulations Manager,Caterpillar France SAS,

40 Avenue Leon-Blum 38000 Grenoble, France

I, the undersigned, _________, hereby certify that the construction equipment specified hereunder

Description: Generic Denomination: Earth-moving Equipment

Function: Hydraulic Excavator

Model/Type: 6015B

Serial Number:
Commercial Name: Caterpillar

Fulfills all the relevant provisions of the following Directives

Directives Notified Body Document No.

2000/14/EC amended by 2005/88/EC, Note (1)

2006/42/EC N/A
2004/108/EC N/A

Note (1) Annex -_____ Guaranteed Sound Power Level -_____dB (A)
Representative Equipment Type Sound Power Level - _____dB (A)
[Engine Power per ____-____ kW Rated engine speed - _____ rpm
Technical Documentation accessible through person listed above authorized to compile the Technical File

Done at: Signature

Date: Name/Position

Note: The above information was correct as of June 2014, but may be subject to change, please refer to the individual declaration of conformity
issued with the machine for exact details.
SEBU9190-12 53
Operation Section
Before Operation

Operation Section Machine Access System

Specifications
Before Operation The machine access system has been designed to
meet the intent of the technical requirements in “ISO
2867:2011 Earth-moving Machinery – Access
i07786730 Systems”. The access system provides for operator
access to the operator station and to conduct the
Mounting and Dismounting maintenance procedures described in Maintenance
section.
SMCS Code: 6700; 7000
Alternate Exit
Machines that are equipped with cabs have alternate
exits. For additional information, see Operation and
Maintenance Manual, “Alternate Exit”.

i06192431

Daily Inspection
SMCS Code: 1000; 6319; 6700; 7000
For maximum service life of the machine, perform a
thorough inspection before you mount the machine
and before you start the engine.
Test all engine stop switches. Refer to Operation and
Illustration 57 g00037860
Maintenance Manual, “Engine Stop Switches” for
Typical example additional information.

Mount the machine and dismount the machine only Look around the machine and under the machine for
at locations that have steps and/or handholds. Before any of the following items:
you mount the machine, clean the steps and the
handholds. Inspect the steps and handholds. Make • loose bolts
all necessary repairs.
• trash buildup
Face the machine whenever you get on or off the
machine. • oil leaks

Maintain a three-point contact with the steps and with • coolant leaks
the handholds.
• broken parts
Note: Three-point contact can be two feet and one
hand. Three-point contact can also be one foot and • worn parts
two hands.
Do not operate the machine until all necessary
Do not mount a moving machine. Do not dismount a repairs have been made.
moving machine. Never jump off the machine. Do not
carry tools or supplies when you try to mount the Inspect the condition of the work tool and of the
machine or when you try to dismount the machine. hydraulic components.
Use a hand line to pull equipment onto the platform. Check all oil levels, coolant levels, and fuel levels.
Do not use any controls as handholds when you Make sure that all joints that require lubrication have
enter the operator compartment or when you exit the been greased. Refer to the following procedures in
operator compartment. the Maintenance Section:

• Operation and Maintenance Manual, “Boom and

Stick Pins - Lubricate”
• Operation and Maintenance Manual, “Boom
Cylinder Pins - Lubricate”
• Operation and Maintenance Manual, “Bucket
Cylinder Pins - Lubricate”
54 SEBU9190-12
Operation Section
Daily Inspection

• Operation and Maintenance Manual, “Bucket Link

Pins - Lubricate”

• Operation and Maintenance Manual, “Cooling

System Coolant Level - Check”
• Operation and Maintenance Manual, “Diagnostic
Codes - Check”
• Operation and Maintenance Manual, “Engine Oil
Level - Check”

• Operation and Maintenance Manual, “Fuel System

Water Separator - Drain”

• Operation and Maintenance Manual, “Fuel Tank

Water and Sediment - Drain”
• Operation and Maintenance Manual, “Hydraulic
Oil Cooler Grate - Inspect”
• Operation and Maintenance Manual, “Hydraulic
System Oil Level - Check”

• Operation and Maintenance Manual, “Seat Belt -

Inspect”

• Operation and Maintenance Manual, “Stick

Cylinder Pins - Lubricate”
• Operation and Maintenance Manual, “Swing
Bearing - Lubricate”
• Operation and Maintenance Manual, “Swing Drive
Oil Level - Check”

• Operation and Maintenance Manual, “Travel

Alarm - Test”

• Operation and Maintenance Manual,

“Undercarriage - Check”
Refer to Operation and Maintenance Manual,
“Maintenance Interval Schedule” for all maintenance
recommendations.
SEBU9190-12
Machine Operation
i06893442
Stairway (Powered) Operation
(If Equipped)
SMCS Code: 7254
Crush Hazard! Stay back a safe distance from the
powered stairway when it is being raised or low-
ered. Failure to stay back may result in injury or
death.
NOTICE
Make sure that the area is free of obstacles before
raising or lowering the powered stairway.
Forward or reverse machine travel with the powered
stairway lowered could result in contact with the
ground or an obstacle resulting in damage to the
powered stairway.
The powered stairway is a set of electrohydraulic
controlled retractable steps that can be lowered close
to the ground level for mounting and dismounting the
machine.
The following rules apply when the stairway is in the
LOWERED position and the hydraulic lock switch is
UNLOCKED:
• Implement functions are available.
• Swing and travel functions are NOT available.
• Engine speed is limited to 1300 RPM.
• The action alarm will sound, and the action lamp
will flash.
• A warning is displayed on the Monitoring System.
Refer to Operation and Maintenance Manual,
Monitoring System for additional information.
55
Operation Section
Machine Operation
Lowering
Illustration 58 g03692851
To lower the powered stairway with one of the control
switches, perform the following steps:
1. Verify that the area around the powered stairway is
clear of people and obstacles before lowering the
powered stairway.
2. Hold control switch (1) in the DOWN position to
lower the powered stairway. Release the switch to
stop the powered stairway from moving.
Note: If the engine start switch is in the ON position,
then the hydraulic lockout control must be in the
Locked position to raise or lower the stairway.
Note: When the control switch is used continuously
to move the powered stairway, the powered stairway
will move from the fully raised position to the fully
lowered position in approximately 7 seconds.
3. Always place the powered stairway in the fully
lowered position before mounting and dismounting
the machine.
Manual Lowering
If necessary, the powered stairway can be lowered
with the use of manual lowering control (2).
The manual lowering control is on the handrail above
the platform for the powered stairway.
If the manual lowering control is used, the control
valve linkage will need to be reset before the control
switches can be used to move the powered stairway.
To lower the powered stairway with the manual
lowering control, perform the following steps:
56 SEBU9190-12
Operation Section
If Equipped

Crush Hazard! Stay back a safe distance from the

powered stairway when it is being raised or low-
ered. Failure to stay back may result in injury or
death.

NOTICE
Make sure that the area is free of obstacles before
raising or lowering the powered stairway.
Forward or reverse machine travel with the powered
stairway lowered could result in contact with the
ground or an obstacle resulting in damage to the
powered stairway.

1. Verify that the area around the powered stairway is

clear of people and obstacles before lowering the
powered stairway.
2. Depress manual lowering control (2) .
3. Push the stairway forward to lower the stairway
manually.

Note: When the manual lowering control is used to

move the powered stairway, the powered stairway
will move uncontrolled from the fully raised position to
the fully lowered position in approximately 3 seconds.

4. Perform the following steps to reset the control

valve linkage:

Illustration 60 g06002039

b. Remove spring pin (4) and allow the control

valve linkage to reset.
c. Reinstall the spring pin.

Raising
To raise the powered stairway with one of the control
switches, perform the following steps:
1. Verify that the area around the powered stairway is
clear of people and obstacles before raising the
Illustration 59 g03692863 powered stairway.
2. Hold control switch (1) in the UP position to raise
a. Remove tread plate (3) from the platform of the the powered stairway. Release the switch to stop
powered stairway. the powered stairway from moving.
3. Always place the powered stairway in the fully
raised position before operating the machine.

Locking the Powered Stairway

The powered stairway can be locked in the fully
raised position to prevent lowering.
SEBU9190-12 57
Operation Section
If Equipped

1. Move the powered stairway to the fully raised

position.

Illustration 62 g03692863

1. Remove tread plate (3) from the platform of the

Illustration 61 g03692889
powered stairway.
2. Retaining pin (5) is on the front of the platform for
the powered stairway. Remove the locking pin
from the end of retaining pin and remove the
retaining pin from the platform of the powered
stairway.
3. Align the retaining pin with hole (6) and fully insert
the retaining pin through the holes on each side of
the powered stairway.
4. Attach the locking pin to the end of the retaining
pin for the powered stairway.

Maintenance
Perform the following procedure if maintenance must Illustration 63 g06001251
be done on the powered stairway with the key in the
ON position. The following procedure is not
necessary if the key will be in the OFF position.
Failure to perform this procedure, and leaving the key
in the ON position, can result in unexpected
movement of the stairway.

Illustration 64 g06001258

2. Disconnect electrical connection (8) for the

pressure switch attached to accumulator (7).
3. Install tread plate (3).
58 SEBU9190-12
Operation Section
Alternate Exit

4. When the maintenance on the powered stairway is 4. Remove rope ladder (4) from the storage case
complete, reconnect the pressure switch located next to the operator seat.
connection.
5. Attach rope ladder (4) to hooks (5) using the
clasps on the ladder.
i06206978
6. Exit through the front window and climb down the
Alternate Exit rope ladder.
SMCS Code: 7310
Right Side Window
Front Window (If Equipped)
The front window serves as an alternate exit. Perform
the following procedure in order to remove the front
window and exit through the front window:

Illustration 67 g03852925
(6) Hammer (If Equipped)

Alternate Exit – The right side window

serves as an alternate exit.
Illustration 65 g03852904
(1) Lever
(2) Handle

1. Move lever (1) to the right.

2. Grab handles (2) and lift the window into the
overhead storage position.
3. Slide lower window (3) up in order to remove the
lower window.

Illustration 66 g03852901
(4) Rope ladder
(5) Rope ladder hooks
SEBU9190-12 59
Operation Section
Alternate Exit

Break Glass – Perform the following

procedure in order to exit through the
right side window. Hammer (6) is
mounted near the rear window of the cab. Strike
the right side window with the hammer in order to
break the glass. Climb through the opening of the
right side window in order to exit the cab.

Roof Hatch (If Equipped)

Illustration 69 g03852930

If equipped with gas springs (9), press gas spring

release (12) and remove gas spring shaft (11) in
order to open hatch wider.
Exit through the roof hatch.
Removing the Roof Hatch from the Outside

Illustration 68 g03852928
(7) Latch
(8) Grip
(9) Gas springs
(10) Lock mechanism

Note: Before operating the machine, make sure lock

mechanism (7) (if equipped) is unlocked.
Alternate Exit – The roof hatch serves as
an alternate exit.
Slide the visor cover back. If equipped, make sure
lock mechanism (10) is unlocked.
Release latch (7). Hold grip (8) and push the roof
hatch outward.
Illustration 70 g03852932
(13) Hinge pin release
If equipped with hinge pin release (13), the roof hatch
can also be removed from the outside of the cab.
Press hinge pin release (13) and slide backward. The
hinge pin should detach and allow the hatch to be
lifted. Exit through the roof hatch.
60 SEBU9190-12
Operation Section
Alternate Exit

Note: Lock mechanism (10) (if equipped) must be Top FOGS

unlocked in order to allow the hatch to be lifted.

Roof Hatch (If Equipped)

Illustration 72 g03852939

In order to exit through the roof hatch, the FOGS

guard is equipped with a release latch. Open the roof
hatch as stated above. As the roof hatch is being
pushed outward, the roof hatch will hit lever (15).
Lever (15) will allow the FOGS to lift upward. Exit
through the roof hatch.
In order to open the top FOGS from the outside of the
machine, reach under the FOGS and pull up on
Illustration 71 g03852938
release lever (15). Follow the directions for removing
the hatch from the outside.
Alternate Exit – The roof hatch serves as
an alternate exit.

Slide the visor cover back.

Remove knobs (14) and push the roof hatch outward.
Exit through the roof hatch.

FOGS (If Equipped)

Note: Some FOGS are fixed/bolted-on and others
can be opened. This information pertains to FOGS
that can be opened.
SEBU9190-12 61
Operation Section
Seat

Front FOGS i07186721

Seat
SMCS Code: 5258-025; 7312-025; 7324; 7327

Illustration 73 g03852940

In order to exit through the front window, the FOGS

guard is equipped with a release latch. Open the front
window as stated above and remove the lower
window. Press down on levers (16) in order to open
the front FOGS. Exit through the front window.

Illustration 74 g01636841
(1) Adjustment lever for the lumbar support
(2) Adjustment lever for reclining the seat
(3) Lever for the seat cushion adjustment
(4) Seat fore and aft adjustment.
(5) Seat height adjustment (if equipped)
(6) Fore and aft seat and console adjustment
(7) Console adjustment
(8) Indicator
(9) Seat angle lever
(10) Armrest
(11) Headrest

The lumbar support is located in the back of the seat.

Turn knob (1) (if equipped) counterclockwise to
increase the force of the lumbar support. To decrease
the lumbar support, continue to turn the knob
counterclockwise.
Pull up lever (2) to change the angle of the seat. Hold
the seat back in the desired position. Release the
lever.
Push in lever (3) to adjust the length of the cushion.
To adjust the seat forward or backward, pull up lever
(4) and hold the lever. Move the seat to the desired
position. To lock the seat in the selected position,
release the lever.
62 SEBU9190-12
Operation Section
Seat

Note: Before adjusting the seat forward or backward,

make sure that the lever for the seat height
adjustment (5) is in the downward position.
Turn lever (5) to adjust the seat and the console to
the desired height. To raise the seat height, pull the
grip downward and rotate the grip with the plus sign
outward. To lower the seat height, pull the grip
downward and rotate the grip with the minus sign
outward. Release grip to return to the original
position.
Pull lever (6) to adjust the seat and the console
forward and backward.
Use handle (7) to adjust the height of the console.
When the lever is pulled forward, a gear is released. Illustration 76 g02697124
The operator can rotate the lever freely. Release the
(13) Armrest height adjustment
lever to return to the original position.
Push the lever (9) to adjust the tilt angle of the seat. The height of the armrest can be adjusted. Unlatch
lever (13) to adjust the height of the armrest. Move
The operator can adjust the height of headrest (11). the armrest upward or move the armrest downward.
To adjust the headrest, hold the headrest with both Latch the lever when the armrest is in the desired
hands. Move the headrest up and down. Release the position.
headrest when the desired position is attained. The
headrest will remain in the desired position. Heated Seat and Ventilated Seat (If
Equipped)

Heat-induced burns can occur when some people

use a seat heater. Do not use the seat heater if
you have a reduced ability to sense temperature
changes, a reduced ability to feel pain, or have
sensitive skin.

Illustration 75 g01637296

If your machine is equipped with an air ride

suspension, the seat will be equipped with a lever
(12). Pull up the lever to raise the height of the seat.
Push down on the lever to lower the seat. If the
adjustment is correct, indicator (8) will turn green. If
the indicator shows red, further adjustment is
required.

Illustration 77 g02697116

Heated Seat Switch – If equipped with a heated

seat, press the top of rocker switch (14) to turn the
seat heater to the ON position. Press the bottom of
rocker switch (14) to turn the seat heater to the OFF
position.
Heated and Ventilated Seat Switch – If equipped
with a heated and ventilated seat, press the top of
rocker switch (14) for heat. Press the bottom of
SEBU9190-12 63
Operation Section
Seat Belt

rocker switch (14) for ventilation. The center switch

position is OFF.

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 79 g00932817
Always check the condition of the seat belt and the
condition of the mounting hardware before you 2. To remove the slack in outer loop (1), rotate buckle
operate the machine. (2). This will free the lock bar. This permits the
seat belt to move through the buckle.
Seat Belt Adjustment for Non-
3. Remove the slack from the outer belt loop by
Retractable Seat Belts pulling on the buckle.
Adjust both ends of the seat belt. The seat belt 4. Loosen the other half of the seat belt in the same
should be snug but comfortable. manner. If the seat belt does not fit snugly with the
buckle in the center, readjust the seat belt.
Lengthening the Seat Belt
Shortening the Seat Belt

Illustration 78 g00100709

Illustration 80 g00100713
1. Unfasten the seat belt.
1. Fasten the seat belt. Pull out on the outer belt loop
in order to tighten the seat belt.
2. Adjust the other half of the seat belt in the same
manner.
3. If the seat belt does not fit snugly with the buckle in
the center, readjust the seat belt.
64 SEBU9190-12
Operation Section
Seat Belt

Fastening The Seat Belt Releasing The Seat Belt

Illustration 81 g00932818 Illustration 82 g00100717

Fasten the seat belt catch (3) into the buckle (2). Pull up on the release lever. This will release the seat
Make sure that the seat belt is placed low across the belt.
lap of the operator.
Seat Belt Adjustment for
Retractable Seat Belts
Fastening The Seat Belt

Illustration 83 g00867598

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

motion.
Fasten seat belt catch (3) into buckle (2). Make sure
that the seat belt is placed low across the lap of the
operator.
The retractor will adjust the belt length and the
retractor will lock in place. The comfort ride sleeve
will allow the operator to have limited movement.
SEBU9190-12
Releasing The Seat Belt
Illustration 84 g00039113
Push the release button on the buckle in order to
release the seat belt. The seat belt will automatically
retract into the retractor.
Extension of the Seat Belt
When using retractable seat belts, do not use
seat 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.
i07618902
Engine Emissions Control
Warning System
SMCS Code: 1075; 1091; 7400
S/N: MKE1–Up
S/N: LWN1–Up
S/N: LWS1–Up
65
Operation Section
Engine Emissions Control Warning System
The engine and emissions control system shall be
operated, used, and maintained in accordance with
the instructions provided to the end user to maintain
the emissions performance of the engine within the
requirements applicable to the category of the
engine. No deliberate tampering with, or misuse of
the engine emissions control system should take
place. In particular regarding deactivating or not
maintaining an exhaust gas recirculation (EGR)
system.
The emissions control warning system will detect
conditions that result in an impeded EGR valve.
When those conditions are detected, the system will
provide warnings and will eventually impose
inducements if those conditions are not rectified.
Note: Code EID:60021 will be displayed when an
inducement occurs. An associated code will
supplement this inducement code for an emissions-
related fault. Refer to the Troubleshooting manual for
additional fault code information.
NOTICE
Stopping the engine immediately after the engine has
been working under load can result in overheating of
EGR components.
Refer to the Operation and Maintenance Manual,
“Engine Stopping” procedure to allow the engine to
cool and to prevent excessive temperatures in the
turbocharger housing.
NOTICE
Allow at least 2 minutes after shutting down the en-
gine before you turn the battery disconnect switch to
OFF.
Definitions
Observe the following definitions.
Self-correct – Fault condition no longer exists. An
active fault code will no longer be active.
Notification – Action taken by the system to alert the
operator of pending Inducement.
Inducement – Engine derates, vehicle speed limits,
or other actions intended to prompt the operator to
repair or maintain the emission control system.
First occurrence – When an escalating time
inducement fault code becomes active for the first
time.
Repeat occurrence – When any escalating time
inducement fault code becomes active again within
40 hours of the first occurrence. Engine must run for
40 hours without tripping any escalating time
inducement fault before returning get back to first
occurrence times.
66
Operation Section
Engine Emissions Control Warning System
Safe Harbor Mode (Worldwide) – Safe Harbor
Mode is a 30 minute engine run time period. During
the Safe Harbor Mode the engine can be operated
with full power after reaching a level 2 severe or level
3 inducement depending on inducement strategy
selected. Once in level 3 inducement, the operator
can perform a key cycle and the engine will enter
Safe Harbor Mode. Safe Harbor Mode can only be
implemented up to three times.
Impeded EGR Valve – Something preventing the
EGR valve from opening and closing normally.
NOTICE
Taking prompt action is essential to rectify any incor-
rect operation, use, or maintenance of the engine
emissions system in accordance with the rectification
measures indicated by the warnings listed on the fol-
lowing pages.
Inducement Strategy for Escalating
Time Inducement Faults
The following warnings and inducements are
triggered as a result of an impeded EGR valve.
Inducement Symbols
Fault Indicator Lamp – This lamp
indicates that a Level 1, Level 2, or Level
3 fault is active.
Emissions Malfunction Indicator Lamp –
This lamp activates for all inducement-
related faults that affect the engine.
Audible Alarm – The alarm sounds when
a Level 3 fault is active.
Refer to Operation and Maintenance Manual,
Monitoring System for additional information on
symbol locations.
Level 1 Inducement
Illustration 85 g06367818
Reduced Performance
SEBU9190-12
The emissions malfunction indicator lamp will
illuminate steady yellow on the top left of the display
for an inducement event. The fault indicator symbol
and code will also appear at the bottom of the
information display with a gray banner for any
inducement-related fault and a level 1 inducement
will occur for a duration of 36 hours. There is no
repeat occurrence for level 1 faults.
Reduced Time
The emissions malfunction indicator lamp will
illuminate steady yellow on the top left of the display
for an inducement event. The fault indicator symbol
and code will also appear at the bottom of the
information display with a gray banner for any
inducement-related fault and a level 1 inducement
will occur for a duration of 18 hours. There is no
repeat occurrence for level 1 faults.
Level 2 Inducement
Illustration 86 g06367818
Reduced Performance
If a fault condition exists for the entire duration of
inducement level 1, the strategy advances to
inducement level 2. The emissions malfunction
indicator lamp will illuminate steady yellow on the top
left of the display. In addition, on the information
display, the fault indicator symbol and code will have
a yellow banner. The engine will have a 50% derate.
The level 2 inducement occurs for a duration of 64
hours for first occurrence. For repeat occurrence, a
level 2 inducement fault will occur for a duration of 5
hours.
If the fault is not corrected before the inducement
duration ends, the engine will become 100% derated.
The engine will also be limited to 1000 rpm or low
idle, whichever is greater. No further inducements will
occur for “Reduced Performance” configuration. Safe
Harbor Mode is allowed for three key cycles.
Reduced Time
If a fault condition exists for the entire duration of
inducement level 1, the strategy advances to
inducement level 2. The emissions malfunction
indicator lamp will illuminate steady yellow on the top
left of the display. In addition, on the information
display, the fault indicator symbol and code will have
a yellow banner. The level 2 inducement occurs for a
duration of 18 hours for first occurrence. For repeat
occurrence, a level 2 inducement fault will occur for a
duration of 108 minutes.
SEBU9190-12 67
Operation Section
Operator Controls

Level 3 Inducement

Illustration 87 g06375348

Reduced Time
If configured to “Reduced Time” and a fault condition
exists for the entire duration of inducement level 2,
the strategy advances to inducement level 3. The
emissions malfunction indicator lamp will illuminate
steady yellow on the top left of the display. There will
also be a pulsing audible alarm. In addition, on the
information display, the fault indicator symbol and
code will have a red banner. The engine will have a
100% derate and be limited to 1000 rpm or low idle,
whichever is greater. If the final inducement action in
Cat ET is set to “Idle Down” , then engine will
continue to idle at derated condition. If set to
“Shutdown” , engine will shut down after 5 minutes. A
key cycle will allow safe harbor mode to initiate. Safe
harbor is allowed up to three times. After safe harbor,
the engine will be in level 3 final inducement. If set to
“Shutdown” , the engine may be restarted, but will
only run for 5 minutes at derated condition before
shutting down again. This action will continue until
the issue is resolved.

Note: Consult your Cat dealer for repairs if a fault

occurs.

Carbon Dioxide (CO2) Emissions

Statement
Emissions regulations require that the value of the
CO2 emissions be reported to the end user. For this
engine, 694.74 g/kWh was determined to be the CO2
value during the EU type approval process. This
value was recorded in EU type approval certificate.
This CO2 measurement results from testing over a
fixed test cycle, under laboratory conditions, with a
parent engine representative of the engine family.
This value shall not imply or express any guarantee
of the performance of a particular engine.

i05833318

Operator Controls
SMCS Code: 7300; 7301; 7451

Note: Your machine may not be equipped with all the

controls that are described in this topic.
68
Operation Section
Operator Controls
Operator Controls
Illustration 88
(1) Hydraulic lockout control
(2) Travel controls
(3) VIMS service port
(4) Monitor
SEBU9190-12
g03690611
(5) Stairway and hydraulic lockout indicator (9) Right side control panel
panel (10) Operator seat
(6) Fault indicator (11) Air conditioning and heating control
(7) Joystick controls (12) Radio
(8) Engine start switch
SEBU9190-12 69
Operation Section
Operator Controls

Illustration 89 g03690632
Right Side Control Panel (9)
(13) Engine speed control (18) Lower window washer (23) Lower window wiper
(14) Auto Lube Manual Operation (19) Work lights (24) Engine shutdown switch
(15) Travel speed control (20) Cab and boom lights (25) Ladder light
(16) Automatic engine speed control (AEC) (21) Window wiper (26) Heated mirrors (If Equipped)
(17) Travel alarm cancel (22) Window washer

Hydraulic Lockout Control (1) Unlocked – Move the lever for the
hydraulic lockout control forward to the
The lever for the hydraulic lockout control is on the UNLOCKED position. All the factory
left side of seat. installed hydraulic controls will become
operable.
Locked – Move the travel levers/pedals
and move the joysticks to the HOLD
(center) position. Move the lever for the
Travel Control (2)
hydraulic lockout control backward to the
LOCKED position. All the factory installed
hydraulic controls will become inoperable.

Note: Make sure that the lever for the hydraulic

lockout control is in the LOCKED position before
attempting to start the engine. If the lever is in the
UNLOCKED position, the engine start switch will not
function.

Illustration 90 g00753277
Position for normal travel
(A) Rear of machine
(B) Final drive
(C) Idler

When you travel, make sure that final drive sprockets

(B) are under the rear of the machine.
70 SEBU9190-12
Operation Section
Operator Controls

Stop – Release the travel levers/pedals to stop the

machine. When you release the travel levers/pedals
from any position, the travel levers/pedals will return
to the CENTER position. The travel brakes will be
applied.

Move both of the travel levers or both of the travel

pedals equally in the same direction to travel straight.

Illustration 93 g03690693
Pivot left turn (FORWARD)

Illustration 91 g03690707
FORWARD travel

Illustration 94 g03690694
Pivot Left Turn (REVERSE)

Illustration 92 g03690690
REVERSE travel

Illustration 95 g03690698
Counterrotate turn (LEFT)
SEBU9190-12 71
Operation Section
Operator Controls

Illustration 96 g03690702 Illustration 98 g03690704

Pivot right turn (FORWARD) Counterrotate turn (RIGHT)

VIMS Service Port (3)

Vital Information Management System
(VIMS) Service Port – This service port
allows service personnel to interface
with VIMS.

Monitor (4)
The monitor is used to display various operating
information of the machine. For more information on
the operation of the monitor, refer to Operation and
Maintenance Manual, “Monitoring System”.
Note: To prevent failure of the monitor bracket, do
Illustration 97 g03690703 not mount extra equipment, including fire
Pivot right turn (REVERSE) suppression controls, on the monitor. Also, do not
pull on the monitor when leaving the seat.

Stairway and Hydraulic Lockout

Indicator Panel (5)
Stairway Indicator – When the stairway
indicator is illuminated, the powered
stairway (if equipped) is in the
LOWERED position.
Hydraulic Lockout Indicator – When the
hydraulic lockout indicator is
illuminated, the hydraulic lockout is in
the LOCKED position.
72
Operation Section
Operator Controls
Note: Make sure that the lever for the hydraulic
lockout control is in the LOCKED position before
attempting to start the engine. If the lever is in the
UNLOCKED position, the engine start switch will not
function.
Fault Indicator (6)
Fault Indicator – If a system malfunction
occurs, the red fault indicator will flash.
Joystick Controls (7)
The joystick control is used to control the functions of
the machine implements. For more information on
the individual functions of the joysticks, refer to
Operation and Maintenance Manual, “Joystick
Controls”.
Engine Start Switch (8)
NOTICE
The engine start switch must be in the ON position
and the engine must be running in order to maintain
electrical functions and hydraulic functions. This pro-
cedure must be followed in order to prevent serious
machine damage.
Engine Stop (Shutdown) – Turn the key
to this position to disable the delayed
engine shutdown (DES). The engine will
be shutdown immediately.
Note: Shutting down the engine using this method is
considered a hard shutdown which disables the DES.
Note: A warning message and/or Audible alarm will
be initiated. A fault code will be logged for improper
engine shutdown if exhaust temperature is above
limit.
Note: Overriding delayed engine shutdown may
reduce engine and machine system component life.
OFF – Insert the engine start switch key
only when the start switch is in the OFF
position. Remove the engine start
switch key only when the engine start switch is in
the OFF position. Turn the engine start switch to
the OFF position before you attempt to restart the
engine. Turn the engine start switch to the OFF
position to stop the engine.
ON – To activate the electrical circuits in
the cab, turn the key clockwise to the
ON position.
SEBU9190-12
START – To start the tractor engine, turn
the key clockwise to the START
position. After the engine starts, release
the key. The key will return to the ON position.
Note: If the engine fails to start, return the engine
start switch key to the OFF position. Return the key
to the start position before you attempt to start the
engine again.
Engine Idle Shutdown
This function shuts down the engine after the
operator is not operating the machine for aperiodof
time. This function does notshutdown other systems,
such as the AC, which can run down the battery after
idle shutdown. This function comes disabled from the
factory but can be enabled and adjusted in the
monitoring system. Refer to Operation and
Maintenance Manual, “Monitoring System”
Note: Engine Idle Shutdown may be required for
local regulations.
The Engine Idle Shutdown (EIS) shuts down the
engine if the following conditions are met:
• The control lever is in neutral.
• The engine coolant temperature is greater than
70° C (158° F).
• The battery voltage is greater than 24.5V
• The engine speed is less than 2000 rpm.
• The ambient temperature range is between 0° C
(32° F) and 30° C (86° F).
• The Back Pressure Valve (BPV) is not working.
Note: If any service tests or calibrations are running,
the machine will not enter into engine idle shutdown.
Engine Idle Shut down – The action
lamp will illuminate and the monitor will
display a message 20 seconds before
the engine shuts down. An operator can cancel
the shutdown by moving one of the controls.
Operator Seat (10)
The operator seat and the console have various
adjustments to meet a wide range of operators. For
more information, refer to Operation and
Maintenance Manual, “Seat”.
Air Conditioning and Heating
Control (11)
If equipped, the switch for the air conditioning and
heating control is on the right console.
SEBU9190-12
The heater/air conditioner provides comfort for the
operator that is working under various temperature
conditions. For more information on the air
conditioning and heater controls, refer to Operation
and Maintenance Manual, “Air Conditioning and
Heating Control”.
Radio (12)
This machine may be equipped with a radio. For
more information, refer to Operation and
Maintenance Manual, “Radio”.
Engine Speed Control (13)
Engine Speed – Turn the engine speed
dial to control the engine speed (engine
rpm). Select the desired position from
the ten available positions. The selected position
of the engine speed dial is indicated on the
electronic monitor panel.
Decrease – Turn the engine speed dial
counterclockwise to decrease the
engine speed (engine rpm).
Increase – Turn the engine speed dial
clockwise to increase the engine speed
(engine rpm).
Note: If there is a failure of the communication
system, the engine will default to 1300 RPM to allow
limited operation.
Auto Lube Manual Operation (14)
Auto Lube Manual Operation – The auto
lube manual operation switch allows for
manual testing of the automatic
lubrication system.
Travel Speed Control (15)
Do not change the setting of the travel speed con-
trol switch while you travel. Machine stability may
be adversely affected.
Personal injury can result from sudden changes
in machine stability.
Travel Speed Control Switch – Press the
travel speed control switch to select
high travel speed or low travel speed.
When the engine start switch is on, the travel
speed control switch is always set at the LOW
SPEED position. Whenever the travel speed
control switch is pressed, the travel speed
changes.
73
Operation Section
Operator Controls
LOW SPEED – Select the LOW SPEED
position if you travel on rough surfaces
or on soft surfaces or if you require a
great drawbar pull. Also, select the LOW SPEED
position if you are loading a machine onto a
trailer or you are unloading a machine from a
trailer.
Note: When traveling in LOW SPEED, if the
hydraulic oil temperature is greater than 86° C
(187° F) a warning will be shown on the Monitoring
System.
HIGH SPEED – If you travel on a hard,
level surface at a fast speed, select the
HIGH SPEED position.
Note: When traveling in HIGH SPEED, if the
hydraulic oil temperature is greater than 79° C
(174° F) a warning will be shown on the Monitoring
System, and the travel speed will be automatically
switched to LOW SPEED.
Continuous driving at high speed should be limited to
2 hours. If you need to continue driving at high speed
for more than 2 hours, stop the machine for 10
minutes. This process will cool down the travel drives
before you resume driving.
Automatic Engine Speed Control
(16)
The Automatic Engine Speed Control (AEC)
automatically reduces engine speed when the
machine is inactive. The AEC system is designed to
reduce fuel consumption and noise. Lower engine
speeds can also increase engine life.
The engine rpm will recover automatically to the
setting of the engine speed dial when any hydraulic
function is activated. The AEC system operates in
three modes. Refer to Table 7 for a description of
each mode.
Automatic Engine Speed Control (AEC)
– The Automatic Engine Speed Control
switch is activated when the engine
start switch is turned to the ON position. The
indicator lamp will turn on. When you press the
AEC switch, the function of the AEC switch
changes from ON to OFF. The operator can
choose from three possible modes for automatic
engine speed control. Refer to Table 7 for more
details.
The switch for manual low idle is on the right joystick.
74 SEBU9190-12
Operation Section
Operator Controls

Table 7
Position of AEC Setting of Engine Position of Manual
AEC Mode Description of Mode
Switch Speed Dial Low Idle Switch

First stage OFF 5 to 10 OFF The electronic controller does not reduce engine speed.

The AEC system in the electronic controller will automati-

cally reduce the engine rpm to approximately 1300 rpm
Second stage ON 5 to 10 OFF
after there has been no hydraulic demand for approxi-
mately 20 seconds.

Travel Alarm Cancel (17) NOTICE

If the washer is used continuously for more than 20
Travel Alarm Cancel – This switch is seconds or used when no washer solution comes
used to stop the travel alarm from out, motor failure can result.
sounding. Press the switch to stop the
alarm. The indicator lamp will turn on.
Note: The travel alarm is located under the hydraulic Work Lights (19)
tank. The travel alarm will sound when the travel
lever or the travel pedal is activated. Work Lights – Push the switch to turn on
the work lights.
Note: The travel alarm cannot be canceled for the
first 10 seconds of travel.
Cab and Boom Lights (20)
Lower Window Washer (18)
Lower Window Washer (27) – Push
down on the top of the switch and keep
the switch depressed to activate the
lower window washer. When the switch is
depressed, the washer fluid will spray from the
nozzle.

Illustration 99 g03690902

Light Switch – Push the switch to turn

on the cab and boom lights.

Whenever you push the switch, you change the

pattern of the work lights that are turned on. The
indicator lights in the cab indicate the pattern of the
work lights.
Pattern 1 – When you press the light switch once,
the first indicator light turns on. When the first
indicator light is on, the following work lights are
turned on: work light (D), which is mounted on the
chassis, and work lights (F), which are mounted on
the cab.

Pattern 2 – When you press the light switch twice,

the first indicator light and the second indicator light
turn on. When the first indicator light and the second
indicator lights are on, the following work lights are
SEBU9190-12 75
Operation Section
Operator Controls

turned on: work light (D), which is mounted on the

chassis, work lights (F), which are mounted on the NOTICE
If the washer is used continuously for more than 20
cab, and work lights (E), which are mounted on the seconds or used when no washer solution comes
boom. out, motor failure can result.

OFF – When both of the indicator lights are off, all the
work lights are off.
Window Wiper (21)
Window Wiper – Push the switch to
activate the window wiper. Whenever
the switch is depressed, the mode of the
window wiper will change according to the
indicator light that is illuminated.
6 Second Delay – When the window wiper switch is
depressed one time, the first indicator light will turn
on. The window wiper will operate intermittently at six
second intervals.
3 Second Delay – When the window wiper switch is
depressed two times, the second indicator light will
turn on. The window wiper will operate intermittently
at three second intervals.
Continuous Operation – When the window wiper
switch is depressed three times, the first indicator
light and the second indicator light will turn on. The
window wiper will operate continuously.
OFF – When the window wiper switch is depressed
four times, the indicator lights will turn off. The
window wiper stops.
Lower Window Wiper (23)
Lower Window Wiper – Push down on
the top of the switch to turn on the lower
window wiper. Push down the bottom
portion of the switch to turn off the lower window
wiper.
NOTICE
If the wiper does not operate with the switch in the
ON position, turn the switch off immediately. Check
the cause. If the switch remains on, motor failure can
result.
Engine Shutdown Switch (24)
Engine Shutdown Switch – To stop the
engine, push the button downward. To
start the engine after the engine
shutdown switch has been pressed, the engine
start switch must be cycled.

NOTICE
If the wiper does not operate with the switch in the
ON position, turn the switch off immediately. Check
the cause. If the switch remains on, motor failure can
result.

Window Washer (22)

Window Washer – Push the switch to
activate the window washer. When the
switch is depressed, the indicator light
will come on and washer fluid will spray from the
nozzle. The window wiper will also operate when
the switch is depressed. After the switch is
released for approximately 3 seconds, the
window wiper will stop.
76 SEBU9190-12
Operation Section
Battery Disconnect Switch

Refer to Operation and Maintenance Manual, Contact your Cat dealer for additional information.
“Engine Shutdown Switch” for more information.
i05832441
Ladder Light (25)
Battery Disconnect Switch
Ladder Light – Push down on the top of
the switch to turn on the ladder light. SMCS Code: 1411-B11
Push down on the bottom of the switch
to turn off the ladder light.

Heated Mirrors (26) (If Equipped)

Heated Mirrors – Press the top of the
switch to turn ON the heated mirrors.
Press the bottom of the switch to turn
OFF the heated mirrors.

Service Port

Illustration 101 g03689679

The battery disconnect switch is located in the rear

right side of the machine at ground level in the swing
frame.

Illustration 100 g03320855

Electronic Technician service port

An Electronic Technician (ET) service port is located

inside the cab behind the seat. This service port
allows service personnel to connect a laptop
computer that is equipped with Electronic Technician.
Service personnel can use electronic technician to
diagnose machine and engine systems. Illustration 102 g00406959

ON – To activate the electrical system,

insert the disconnect switch key and
turn the battery disconnect switch
clockwise. The battery disconnect switch must
be turned to the ON position before you start the
engine.

OFF – To deactivate the electrical

system, turn the battery disconnect
switch counterclockwise to the OFF
position.
SEBU9190-12 77
Operation Section
Product Link

The battery disconnect switch and the engine start
switch perform different functions. The entire
electrical system is disabled when you turn the
battery disconnect switch to the OFF position. The
battery remains connected to the electrical system
when you turn the engine start switch to the OFF
position.
Turn the battery disconnect switch to the OFF
position and remove the key when you service the
electrical system or any other machine components.
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.
Data Broadcasts
Data concerning this machine, the condition of the
machine, and the operation of the machine is being
transmitted by Cat Product Link to Caterpillar and/or
Cat dealers. The data is used to serve the customer
better and to improve upon Cat products and
services. The information transmitted may include:
machine serial number, machine location, and
operational data, including but not limited to: fault
codes, emissions data, fuel usage, service meter
hours, software, and hardware version numbers and
installed attachments.
Caterpillar and/or Cat dealers may use this
information for various purposes. Refer to the
following list for possible uses:

• Providing services to the customer and/or the

To ensure that no damage to the engine occurs,
verify that the engine is fully operational before machine
cranking the engine. Do not crank an engine that is
• Checking or maintaining Cat Product Link
not fully operational.
equipment
Perform the following procedure in order to check the
battery disconnect switch for proper operation: • Monitoring the health of the machine or
performance
1. With the battery disconnect switch in the ON
position, verify that electrical components in the • Helping maintain the machine and/or improve the
operator compartment are functioning. Verify that efficiency of the machine
the engine will crank. • Evaluating or improving Cat products and
2. Turn the battery disconnect switch to the OFF services
position.
• Complying with legal requirements and valid court
3. Verify that the following items are not functioning: orders
electrical components in the operator
• Performing market research
compartment and engine cranking. If any of the
items continue to function with the battery • Offering the customer new products and services
disconnect switch in the OFF position, consult
your Caterpillar dealer.

i07742538

Product Link
SMCS Code: 7490; 7606

Note: Your machine may be equipped with the Cat ®

Product Link™ system.
The Cat Product Link communication device utilizes
cellular and/or satellite technology to communicate
equipment information. This information is
communicated to Caterpillar, Cat dealers, and
Caterpillar customers. The Cat Product Link
communication device uses Global Positioning
System (GPS) satellite receivers.
The capability of two-way communication between
the equipment and a remote user is available with the
Cat Product Link communication device. The remote
user can be a dealer or a customer.
78 SEBU9190-12
Operation Section
Power Receptacle

Caterpillar may share some or all the collected • Special Instruction, REHS9111, “Installation
information with Caterpillar affiliated companies, Procedure for the Pro Product Link PL641 and
dealers, and authorized representatives. Caterpillar PL631 Systems”
will not sell or rent collected information to any other
third party and will exercise reasonable efforts to i03903396
keep the information secure. Caterpillar recognizes
and respects customer privacy. For more information,
please contact your local Cat dealer. Power Receptacle
(If Equipped)
Operation in a Blast Site for SMCS Code: 1436; 7451
Product Link Radios

This equipment is equipped with a Cat® Product

Link communication device. When electric deto-
nators are being used for blasting operations, ra-
dio frequency devices can cause interference
with electric detonators for blasting operations
which can result in serious injury or death. The
Product Link communication device should be
deactivated within the distance mandated under
all applicable national or local regulatory require-
ments. In the absence of any regulatory require-
ments Caterpillar recommends the end user
perform their own risk assessment to determine
safe operating distance.
Illustration 103 g02145563
Refer to your products Operation and Maintenance
Manual Supplement, “Regulatory Compliance Power Receptacle – Two 12 volt power receptacles
Information” for more information. are located on the right side console. These power
receptacles can be used for powering automotive
For information regarding the methods to disable the electrical equipment or accessories. Remove the cap
Cat Product Link communication device, please refer before use.
to your specific Cat Product Link manual listed below:

• Operation and Maintenance Manual, SEBU8142, i05864967

“Product Link - PL121, PL321, PL522, and PL523”

• Operation and Maintenance Manual, SEBU8832,

Engine Shutdown Switch
“Product Link PLE702, PLE602, PLE601, PL641, SMCS Code: 1259; 7418-ZS; 7418
PL631, PL542, PL240, PL241, PL141, PL131,
PL161, and PL042 Systems” There are four engine shutdown switches on the
machine. The engine shutdown switches are in the
Note: If no radio disable switch is installed and the following locations:
equipment will be operating near a blast zone, a
Product Link radio disable switch may be installed on • Cab
the equipment. The switch will allow the Cat Product
• Ground Level
Link communication device to be shut off by the
operator from the equipment control panel. For more • Pump Room
details and installation procedures, refer to the
following: • Engine Room
• Special Instruction, REHS7339, “Installation Cycle the engine shutdown switches before starting
Procedure for Product Link PLE640 Systems” the engine at the beginning of every shift in order to
verify operation.
• Special Instruction, REHS8850, “Installation
Procedure for the Elite Product Link PLE601,
PLE641, and PLE631 Systems”
• Special Instruction, SEHS0377, “Installation
Procedure for the Product Link PL131, PL141, and
PL161 Systems”
SEBU9190-12 79
Operation Section
Engine Shutdown Switch

Cab Note: The engine shutdown switch does not shut off
the electrical system of the machine.

Ground Level

Illustration 104 g03702016

There is an engine shutdown switch located in the

cab, on the right side.
Illustration 105 g03702027

Engine Shutdown Switch – Use the

There is an engine shutdown switch located at
engine shutdown switch located in the ground level on the left side of the machine.
cab in order to stop the engine from the
cab. In order to use the engine shutdown switch,
push the engine shutdown switch knob in to the
OFF position. The engine will stop. After the
engine stops, turn the knob clockwise. Turning
the knob clockwise will reset the engine
shutdown switch to the ON position.
During normal operation, use the engine start switch
to stop the engine.
80
Operation Section
Engine Shutdown Switch
Engine Shutdown Switch – Use the
engine shutdown switch located at
ground level in order to stop the engine
from ground level. In order to use the engine
shutdown switch, push the engine shutdown
switch knob in to the OFF position. The engine
will stop. After the engine stops, turn the knob
clockwise. Turning the knob clockwise will reset
the engine shutdown switch to the ON position.
Pump Compartment
Illustration 106 g03702086
There is an engine shutdown switch located in the
pump compartment next to the door, on the right side
of the machine.
SEBU9190-12
Engine Shutdown Switch – Use the
engine shutdown switch located in the
pump compartment in order to stop the
engine. In order to use the engine shutdown
switch, push the engine shutdown switch knob in
to the OFF position. The engine will stop. After
the engine stops, turn the knob clockwise.
Turning the knob clockwise will reset the engine
shutdown switch to the ON position.
Engine Compartment
Illustration 107 g03702107
There is an engine shutdown switch located in the
back of the engine compartment, mounted on the
frame around the radiator.
SEBU9190-12 81
Operation Section
Camera

Engine Shutdown Switch – Use the
engine shutdown switch located in the
engine compartment in order to stop the
engine. In order to use the engine shutdown
switch, push the engine shutdown switch knob in
to the OFF position. The engine will stop. After
the engine stops, turn the knob clockwise.
Turning the knob clockwise will reset the engine
shutdown switch to the ON position.
i05864500
Note: The right side view camera system has been
set up by the factory or by a Caterpillar dealer in
order to provide views which comply with specified
guidelines. Consult your Caterpillar dealer before any
adjustments are made to the system.
i07618909
Monitoring System
SMCS Code: 7451; 7490

Camera
SMCS Code: 7347; 7348

Rear View Camera (If Equipped)

The rear view camera system consists of a camera
that is located in the middle of the top of the
counterweight and a “VIDEO MODE SETTING”
menu on the monitor.
Note: The rear view camera system has been set up
by the factory or by a Caterpillar dealer in order to
provide views which comply with specified
guidelines. Consult your Caterpillar dealer before any
adjustments are made to the system. Illustration 108 g03690934
Monitoring system
For more information refer to Operation and
Maintenance Manual, “Monitoring System”.
Startup
Right Side View Camera (If
Equipped)
The right side view camera system consists of a
camera that is located on the right side of the
machine and an additional monitor mounted above
the primary monitoring system.

Illustration 109 g03690954

At startup theCat splash page will appear

momentarily.
82 SEBU9190-12
Operation Section
Monitoring System

Hydraulic Oil Temperature

Engine Coolant Temperature

Machine System Voltage

Fuel Level

Illustration 110 g03690956 Top Level Navigation

The fluid levels screen will appear after the splash
page. Press the OK button to proceed to the
performance page.
Performance Page
Right Side Navigation Buttons
The Information Display has five buttons that act as
the principle navigation. The Display buttons have an
icon and are on the right side of the Display. The right
side buttons are considered the categories for
navigation.
Display – Press the display button to
view the display menu.

Machine – Press the machine button to

view the machine menu.

Totals – Press the totals button to view

the totals menu.

Service – Press the service button to

view the service menu.
Illustration 111 g03690944
Performance Page Camera – Press the camera button to
show the rear view camera view (If
The performance pages on the monitoring system Equipped).
are the main introductory pages. Real-time machine
status information is displayed on the performance Menu Navigation Buttons
page.
At the selection of a category, a menu appears and
Categories for the navigation buttons are displayed the right side buttons change to navigation buttons.
on the right-hand side and left-hand side of the While in the submenus, the right buttons are
performance page. displayed as the navigation keys for the category
The following machine information gauges are shown selected.
on the performance page:
Up – The Up navigation button navigates
Engine Speed lists and menus in the upward direction.

OK – The OK button selects a

highlighted item, and confirms an
Engine Oil Pressure
action.

Down – The Down navigation button

navigates lists and menus in the
downward direction.
SEBU9190-12
Back – The Back button navigates to the
previous screen, and cancels an action.
Home – The Home button navigates to
the default screen from anywhere within
the Display.
Reset – Press the Reset button to reset
the selected value.
Menu Buttons and Menu Button
Groups
Navigation through menu lists and submenus is
possible by using the menu button groups. Menu
buttons do not show a pressed state. Instead, menu
buttons highlight in yellow when the operator selects
an item. A menu button group is accessible by
directly touching a single button within the group, or
by using the navigation buttons along the right side.
To select the highlighted item, press or touch the
“OK” button. On certain machines, if more than four
options are available and appear in a menu button
group, a non-interactive scroll bar will appear.
Scroll Bar
Illustration 112 g03377932
A three page scroll bar on page 1.
Illustration 113 g03377990
A three page scroll bar on page 2.
83
Operation Section
Monitoring System
The scroll bar object is used to navigate between the
main performance pages. The scroll bar is
distinguished from the non-interactive scroll bar by
using an image to show the button characteristic in
yellow. The scroll bar slider is also visually wider and
has an expanded activation zone to reduce activation
error. This scroll bar slider brings the next page into
view with either a touch above or below the slider or a
directional drag of the slider. Arrows appear on the
slider bar when more pages are available above or
below.
Incremental Bars
Incremental Bar
Illustration 114 g03378002
Increase a number by pressing the “+” button on the
right end of the incremental bar.
Decrease a number by pressing the “-” button on the
left end of the incremental bar.
Incremental Bar with Value
Illustration 115 g03378008
Increase a number by pressing the “+” button on the
right end of the incremental bar.
Decrease a number by pressing the “-” button on the
left end of the incremental bar.
When the desired number appears on the bar, press
the “OK” button to highlight that number in yellow and
set the number.
84 SEBU9190-12
Operation Section
Monitoring System

The newly set number appears in white text. These icons show the pages that have been visited,
or the path taken, to arrive at the current page.
Navigation Path
Lower Information Banner

Illustration 117 g03691008

The lower information banner displays the machine

hours, and an indicator for a snoozed diagnostic
message or event.

Illustration 116 g03690986 Camera (If Equipped)

The navigation path that has been followed is shown
in the top portion of the screen.

Illustration 118 g03691018

Illustration 119 g03691025

Camera – Press the camera button to

show the rear view camera view (If
Equipped).
SEBU9190-12 85
Operation Section
Monitoring System

The camera image will be shown for 3 seconds at

startup. This image will appear after the splash
screen, but before the fluid level check screen.

Display Settings

Illustration 122 g03691041

Day and Night mode are determined by the state of

the work lights. If any work light is ON, the Display
will be in Night mode. When all work lights are OFF,
the Display will be in Day Mode. When in day mode,
the brightness bar modifies the brightness only for
Illustration 120 g03691031 the day mode. When in night mode, the brightness
bar modifies the brightness only for the night mode.
Display – To view and adjust the display
settings, press the Display button on the The brightness of the display is adjustable by
top right side of the display. The Display pressing either end of the incremental bar. Press the
page will appear. “+” button and “-” button to adjust the brightness of
the display. Press the “OK” button to set the
The following menu items are available in the display brightness.
settings:
Language
• Screen Brightness

• Language
• Units
• Software License Info

Screen Brightness

Illustration 123 g03691044

Language – Press the language button.

The button will highlight in yellow, then
the language screen will appear.

Illustration 121 g03691034

Screen Brightness – Press the screen

brightness button. The button will
highlight in yellow, then the screen
brightness screen will appear.
86 SEBU9190-12
Operation Section
Monitoring System

Illustration 124 g03691061 Illustration 126 g03691074

Press the Up and Down arrows to scroll through the
language list. Press the desired language, the button
will highlight in yellow. Press “OK” to set the desired
language. The display will adjust to the new language
setting.
Units
Selection of preferred units is limited to English and
Metric. The display will convert the system values to
the selected measurement and add the appropriate
unit abbreviation for each value.
Press the desired unit selection button, the selection
will highlight in yellow. Press the “OK” button to set
the units.

Software License Info

Illustration 125 g03691070

Units – Press the units button. The Illustration 127 g03691102

button will highlight in yellow, then the
units screen will appear. Software License Info – Press the
View parameter values in the preferred units by software license info button. The button
changing the units setting. will highlight in yellow, then the
software license info screen will appear.
SEBU9190-12 87
Operation Section
Monitoring System

Parameters

Illustration 128 g03691108

Press the Up and Down arrows to read the pages of Illustration 130 g03691204
the license agreement.
Parameters – Press the parameters
Machine button. The button will highlight in
yellow, then the parameters screen will
appear.
The following menu items are available in the
parameters screen:

• Engine
• Hydraulic

• Autolube
Engine

Illustration 129 g03691157

Machine – Press the machine button to

view the machine menu.

The following menu items are available in the

machine screen:

• Parameters

Illustration 131 g03691217

Engine – Press the engine button to

view the engine parameters.
88 SEBU9190-12
Operation Section
Monitoring System

Autolube

Illustration 132 g03691220

Note: Parameter listings may vary. Illustration 135 g03691281

Hydraulic Autolube – Press the autolube button to

view the autolube parameters.

Illustration 133 g03691226

Hydraulic – Press the hydraulic button

to view the hydraulic parameters.

Illustration 134 g03691258

Note: Parameter listings may vary.

SEBU9190-12 89
Operation Section
Monitoring System

Lifetime Totals

Illustration 136 g03691306

Note: Parameter listings may vary. Illustration 138 g03691594

Totals Lifetime Totals – Press the lifetime totals

button to view the lifetime totals screen.

Illustration 137 g03691588

Illustration 139 g03691617

Totals – Press the totals button to view
the totals menu.
Note: Lifetime totals cannot be reset.

The following menu items are available in the totals

screen:
• Lifetime Totals

• Resettable Totals
90 SEBU9190-12
Operation Section
Monitoring System

Resettable Totals

Illustration 142 g03691679

Illustration 140 g03691619 When the reset button is pressed, a dialog box will
appear. Press the OK button to reset the value to
Resettable Totals – Press the resettable zero. Press the Back button to exit the screen without
resetting the value.
totals button to view the resettable
totals screen.
Service

Illustration 141 g03691659

Illustration 143 g03691690
Press the Up or Down arrows to scroll through the list
of items. Each item will highlight in yellow when the Service – Press the service button to
arrow button is pressed. Press the reset button to view the service menu.
reset the highlighted item.
The following menu items are available in the service
screen:
• Diagnostics

• ECM Summary
• Service Mode

• Preventive Maintenance
SEBU9190-12 91
Operation Section
Monitoring System

Diagnostics ECM Summary

Illustration 144 g03691696 Illustration 146 g03691791

Diagnostics – Press the diagnostics ECM Summary – Press the ECM

button to view the diagnostics screen. Summary button to view the ECM
Summary screen.
ECM summary information is available for the
following systems:

• Engine
• Implement

• Display
• Chassis
• Telematics

Preventive Maintenance

Illustration 145 g03691730

The diagnostic screen shows a list of events. Press

the Up or Down arrows to scroll through the list of
events. Each event will highlight in yellow when the
arrow button is pressed. Press the OK button to view
the details of the highlighted event.

Illustration 147 g03691814

Preventive Maintenance – Press the

preventive maintenance button to view
the preventive maintenance screen.
92 SEBU9190-12
Operation Section
Monitoring System

Refer to Operation and Maintenance Manual, Engine

Emissions Control Warning System for additional
information.

Pop-Up Messages

Illustration 150 g03383856

Illustration 148 g03691837

Pop up messages within the monitoring system

Engine Emissions inform the operator of a pending or immediate
machine condition. These messages are abbreviated
to relate the machine condition when the machine is
in operation. The messages are restricted to a
dedicated area of the display to minimize conflicts
with productivity and safety information.
The pop-up message box is formatted to provide
required information in a condensed, understandable
condition for the operator. Pop-up messages are
used for various information conditions and
severities.

Illustration 149 g06376104
Emissions Malfunction Indicator Lamp –
This lamp activates for all inducement-
related faults that affect the engine.
Information Pop-Ups
Information pop-ups provide non-safety critical
messages to the operator. Text within the messages
appears in complete words, allowing for greater
understanding. If multiple information pop-ups are
active, an arrow will appear and indicate so. Press
the arrow to scroll through all active pop-ups. If the
arrow is not pressed for 5 seconds, the display
automatically pages through active information pop-
ups, provided no warnings are active. If any warnings
are active, and not snoozed, the information pop-ups
will not display.

Warnings

Illustration 151 g03383856

There are three levels of warnings, and each level

appears as a different color. The following colors are
associated with each warning level:
Level 1 – Gray
Level 2 – Yellow
SEBU9190-12 93
Operation Section
Monitoring System

If the arrow is not pressed for 5 seconds, the display

Level 3 – Red automatically pages through the active Level 3
Warnings only.
Level 1 Warning
Stairway (Powered) Lowered
A Level 1 Warning supersedes any active information
pop-up.
Warning
If multiple warnings are active, an arrow will appear
and indicate so. Press the arrow to scroll through all
active pop-ups. The numbers above the arrow
indicate the index of the currently displayed pop-up
and the total number of active and unsnoozed pop-
ups that can be accessed using the arrow.
If the arrow is not pressed for 5 seconds, the display
automatically pages through the active Level 1
Warnings, provided no Level 2 or Level 3 Warnings
are active.
These warnings may be snoozed, after which time,
the warnings will reappear if the event generating the
warning remains active.
Level 2 Warning Illustration 152 g06158153

A Level 2 Warning supersedes any active information
pop-up, and any Level 1 Warning.
If multiple warnings are active, an arrow will appear
and indicate so. Press the arrow to scroll through all
active pop-ups. The numbers above the arrow
indicate the index of the currently displayed pop-up
and the total number of active and unsnoozed pop-
ups that can be accessed using the arrow.
If the arrow is not pressed for 5 seconds, the display
automatically pages through the active Level 2
Warnings, provided no Level 3 Warnings are active.
These warnings may be snoozed, depending on the
condition. If the warnings are an event, the warning
will reappear if the event generating the warning
remains active.
Level 3 Warning
The powered stairway interlock feature disables
machine travel and swing movement when the
stairway is not stowed or in case of a failed stow
switch. The stairway lowered warning screen, shown
in Illustration 152 , is activated any time the stairway
is in the not stowed position and the hydraulic lock
switch is in the unlocked position. Boom, bucket, and
stick movement are allowed when the stairway
lowered interlock is active.
Pressing the “OK” button overrides the interlock and
allows machine travel and swing movement even
with the ladder in the lowered position. Pressing the
back button hides the stairway lowered warning
screen while keeping the interlock active. To bring
back the warning screen, the hydraulic lock switch,
ladder stow switch, or key switch must be cycled.

Level 3 Warnings are the highest priority. A Level 3

Warning always supersedes an active Level 2, or
lower, pop-up.
If multiple warnings are active, an arrow will appear
and indicate so. Press the arrow to scroll through all
active pop-ups. The numbers above the arrow
indicate the index of the currently displayed pop-up
and the total number of active and unsnoozed pop-
ups that can be accessed using the arrow.
94 SEBU9190-12
Operation Section
Storage Box

A level 2S event with action lamp and action alarm

will be active any time the stairway lowered warning
screen is active.

i05832516

Storage Box
SMCS Code: 7268

Exterior Storage Box

Illustration 153 g03689752

The storage box is used to store miscellaneous tools.

i03912100

Radio
(If Equipped)
SMCS Code: 7338

Illustration 154 g02117159

(1) Power switch (2) Volume control

SEBU9190-12 95
Operation Section
If Equipped

(3) Volume control (7) “Tune” button (10) “Tone” control

(4) “AM/FM/AUX” selector (8) “Tune” button (11) Preset buttons
(5) Auxiliary plug (9) Button for scan and auto memory
(6) Display panel function

Note: When the machine is in operation, turn down

the volume of the radio.

Note: The radio can be used only when the battery

disconnect switch and the engine start switch are in
the ON position.

Note: When a button is pushed, a beep will occur.

(1) Power Switch – Push the power switch in order
to turn on the radio. Push the power switch again in
order to turn off the radio.
(2) and (3) Volume Control – Push the volume
control in order to control the volume. Push the upper
volume control in order to increase the sound level
and push the lower volume control in order to
decrease the sound level.
(4) “ AM/FM/AUX”” Selector – After you push the
“AM/FM/AUX” selector, the selected radio band
appears on display panel (6). This button is also used
to activate the auxiliary function.
(5) Auxiliary Plug – The front auxiliary plug allows
for the connection of a portable audio device.
(6) Display – The display shows various functions
such as the station frequency, band, and the volume
level.
(7) and (8) “ Tune”” Buttons – Push the “tune” buttons
in order to select a radio station. Pressing “tune”
button (7) will decrease the frequency. Pressing
“tune” button (6) will increase the frequency. Pressing
the “tune” button for less than 0.5 seconds changes
the radio station one at a time. Pressing the “tune”
buttons for more than 0.5 seconds will change the
frequency automatically until a radio station is found.
(9) Scan and Auto Memory – Press button (5) for
less than 0.5 seconds in order to listen to 5 seconds
of each preset radio station. Press button (5) at least
1.5 seconds in order to store the radio stations with
the six strongest signals.
(10) Tone Control – Music is optimized by pressing
the tone control so that display (C) will show “MUSIC”
.
(11) Preset Buttons – The circuitry in the memory
system allows you to preset six radio stations. To
preset any of the “preset” buttons, follow the
“Presetting Radio Stations” procedure.
96 SEBU9190-12
Operation Section
If Equipped

Presetting Radio Stations

Illustration 155 g02117163

(6) Display (8) “Tune” button

(7) “Tune” button (11) Preset buttons

1. Turn on the radio. Select the AM band or the FM

band.
2. Select the first radio station by using tuning switch
(7) or tuning switch (8).
3. Depress one of preset buttons (11) for more than
1.5 seconds. The radio station will be stored in the
memory for the selected preset.
4. Push preset button (11) in order to tune in the
radio station.
5. Repeat the same procedure for the remaining
preset switches.
SEBU9190-12 97
Operation Section
If Equipped

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

buttons to locate a stronger signal.

Scan and Auto Memory

Illustration 156 g02117175

(6) Display (Frequency) (9) Button for scan and auto memory (11) Preset buttons
function

Scan – Press button (9) for less than 0.5 seconds in Table 8
order to listen for 5 seconds to each of the preset
Display Setting
radio stations. Press button (9) again in order to stop
scanning through the preset stations and keep AREA EU US
listening to the current station. When this function is
used “SCAN” is shown on display (6). The frequency North America X
of the radio station is also shown on the display. Central and South America X
Auto Memory – Press button (9) for more than 1.5 European Union X
seconds in order to store the radio stations that have
the strongest signal. The radio stations are stored in Asia / Oceania X
the six presets (11). Stations that are already stored
in the memory will be erased. Use the following procedure in order to set the
desired area.
Loss of Memory 1. Turn off the radio.
2. Press preset button “1” , preset button “4” and
The memory system is erased after a few days if the
battery is disconnected. button (9) at the same time. Hold until “EU” or “US”
is displayed on the display panel.
Radio Reception
Note: The radio must be connected to a power
source in order to set the area of reception.
Set the area of reception according to the following
table:
98 SEBU9190-12
Operation Section
Air Conditioning and Heating Control

Note: Remove the film from the radio. Remove the

vinyl from the operator seat. The film and vinyl may
cause noise interference in the radio.

i03767393

Air Conditioning and Heating

Control
SMCS Code: 7304; 7320; 7337

Illustration 157 g02117176

(12) Protective film
(13) Control panel
(14) Method of selection

Illustration 158 g02031354

(A) Vent for upper body
(B) Floor vent
(C) Defroster vent
(D) Defroster Vent
(E) Vent for upper body
(F) Control panel

Redirect the louvers for air outlets (A), (C), (D), and
(E) by hand to the desired direction. The louvers for
air outlet (B) cannot be redirected.
The climate control panel is located under the right
window inside the cab:
SEBU9190-12
Illustration 159 g02031355
(1) On/Off switch
(2) Automatic control switch
(3) Temperature switch
(4) LCD panel
(5) Fan switch
(6) Compressor switch
(7) Defrost mode
(8) Air inlet select switch
(9) Air outlet select switch
Main Power ON/OFF Switch (1) – Push
the ON/OFF switch in order to power on
the system. Push the switch again in
order to power off the system.
Automatic Control Switch (2) – In order
to enter the full “ AUT”” mode for
automatic climate control, push this
switch. However, if you push the switch again,
you cannot turn off the air conditioning. When
the system is in full “ AUT”” mode, you can
manually change specific functions by pushing
another switch. If you manually change a specific
function, “ AUT”” does not appear in the display,
but the unchanged functions will remain in “ AUT””
mode. Even on a day that is sunny, a climate
control system with only a heater can cool the
cab in full “ AUT”” mode if the ambient temperature
is no more than 20 °C (68 °F).
The climate control unit provides excellent operator
comfort in the full “AUT” setting. Press the “AUT”
switch for full “AUT” mode. Push temperature switch
(3) in order to set the desired temperature. The
temperature is only shown in metric values. All other
functions of climate control will be handled
automatically.
In order to take advantage of the full “AUT” setting of
the climate control system, always keep the sunlight
sensor clean. Do not obstruct the sunlight sensor. If
the climate control system is in the full “AUT” setting
at engine start-up and the temperature inside the cab
is too warm or too cool, the damper for fresh air
ventilation may automatically close for a few minutes.
This will help to bring the air temperature to the
preset temperature more quickly.
99
Operation Section
Air Conditioning and Heating Control
Temperature Switch (3) – These
switches control the temperature of the
air that is coming from the air outlets in
order to achieve the preset temperature. This
preset temperature appears on LCD panel (4). If
the heating and air conditioning system is in the
automatic mode, pushing these switches
changes the preset temperature.
Increase – Push this switch in order to
increase the temperature of the air that
is coming out of the air outlets or push
this switch in order to increase the preset
temperature.
Decrease – Push this switch in order to
decrease the temperature of the air that
is coming out of the air outlets or push
this switch in order to decrease the preset
temperature.
Fan Switch (5) – The fan switch directly
controls the fan speed. If the climate
control system is operating in the
automatic mode, pushing this switch overrides
the automatically selected fan speed.
Increase – Push this switch in order to
increase the fan speed.
Decrease – Push this switch in order to
decrease the fan speed.
Compressor Switch (6) – Push the
switch in order to turn on the
compressor or push the switch in order
to turn off the compressor. In humid conditions,
the compressor may be used to remove moisture
from the air in the cab. In cool weather, operate
the compressor weekly in order to prevent
leakage of the refrigerant gas. This will also help
to maintain the compressor in optimum working
order.
Defrost (7) – Depressing this switch will
defog the windows. The air will also be
dehumidified while the compressor is
running. This selection directs air flow out of air
outlet (C) and air outlet (D).
Air Inlet Select Switch (8) – This switch selects the
position of the air inlet.
Recirculate – When this position is
selected, the air inlet is closed. The air
will recirculate inside the cab.
Fresh Air – When this position is
selected, the air inlet is open. Fresh air
will circulate into the cab.
100 SEBU9190-12
Operation Section
Mirror

Air Outlet Select Switch (9) – This switch selects
the position of each air outlet. Each switch controls a
different air outlet.
Upper Body – Selecting this switch will
open air outlet (A) and air outlet (D).
Upper Body and Floor – Selecting this
switch will open air outlet (A), air outlet
(B) and air outlet (D).
Floor – Selecting this switch will open
air outlet (B).
Floor and Defroster – Selecting this
switch will open air outlet (B) and air
outlets (C) and (D).
Consult with your Caterpillar dealer for periodic
maintenance of the heating and air conditioning
system.
English Versus Metric Toggle
Mirrors provide additional visibility around your
machine. Make sure that the mirrors are in proper
working condition and that the mirrors are clean.
Adjust all mirrors at the beginning of each work
period and adjust the mirrors when you change
operators.
Modified Machines or machines that have additional
equipment or attachments may influence your
visibility.
Mirror Adjustment
• Park the machine on a level surface.
• Stop the engine.
• Adjust rear view mirrors in order to provide
visibility behind the machine at a maximum
distance of 30 m (98 ft) from the rear corners of
the machine.
Note: Hand tools may be needed in order to adjust
the mirrors. Refer to Specifications, SENR3130,
“Torque Specifications” for the recommended torque.

In order to convert the temperature reading from

Degrees Celsius to Degrees Fahrenheit, depress
both keys of the fan switch at the same time for five
seconds. The same action is used for converting the
temperature reading from Degrees Fahrenheit to
Degrees Celsius.

i05837983

Mirror
SMCS Code: 7319

Adjust all mirrors as specified in the Operation

and Maintenance Manual. Failure to heed this
warning can lead to personal injury or death.

Slips and falls can result in personal injury. Use

the machine's access systems when adjusting
the mirrors. If the mirrors cannot be reached us-
ing the machine access systems follow the in-
structions found within the Operation and
Maintenance Manual, “Mirror” in order to access
the mirrors.

Note: Your machine may not be equipped with all of

the mirrors that are described in this topic.
SEBU9190-12 101
Operation Section
Window (Front)

• See an object on the ground at a distance of 30 m

(98 ft) from the rear corner of the machine.

Left Side Rear View Mirror (2)

Illustration 160 g03692433

Right Side Rear View Mirror (1)

Illustration 162 g03692542

Adjust the left side rear view mirror (3) so that the left
side of the machine can be seen. Also adjust the left
side rear view mirror in order to see the following:

• A view of at least 1 m (3.3 ft) from the side of the

machine can be seen from the operator seat.

• See an object on the ground at a distance of 30 m

(98 ft) from the rear corner of the machine.

i06932588

Illustration 161 g03692541

Adjust the right side rear view mirror (2) so that the
right side of the machine can be seen. Also adjust the
right side rear view mirror in order to see the
following:
• A view of at least 1 m (3.3 ft) from the side of the
machine can be seen from the operator seat.
Window (Front)
SMCS Code: 7310-FR
Note: The cab visor (if equipped) must be down
before the front window is raised. The front window
will not lock in the overhead storage position with the
cab visor in the raised position.
To provide full ventilation inside the cab, the upper
window and the lower window can be fully opened.

When opening or closing the windows, be extra

careful to prevent any personal injury. The hy-
draulic lockout control must be in the LOCKED
position in order to prevent any possibility of
sudden movement of the machine due to inadver-
tent contact with the hydraulic control(s).

Do not change the position of the window until the

following items have been done:

• Park the machine on a level surface.

• Lower the work tool to the ground.
102 SEBU9190-12
Operation Section
Window (Front)

• Move the hydraulic lockout control to the LOCKED
position.
• Stop the engine.
Perform Step 1 through Step 3 to open the upper
window.
Note: If equipped, the Cat Grade Control monitor
may interfere with the window when opening. Ensure
that the monitor is adjusted out of the way before
opening the window.
Note: If equipped, the Cat Grade Control monitor
may interfere with the window when closing. Ensure
that the monitor is adjusted out of the way before
closing the window.
4. Move the lever of the auto-lock latch (1) in the
direction of the arrow to release the auto-lock
latch.
5. Reverse Steps 1 through 3 to close the upper
window.
Perform Steps 6 through 8 to open the lower
window and close the lower window.

Illustration 163 g02028981

(1) Lever
Illustration 165 g00103837

1. Release the auto-lock latch by moving lever (1) to

the right. 6. Raise the lower window out of the window frame.

2. Hold both grips that are on the window frame. Pull

the window upward.

Illustration 166 g00680500

Illustration 164 g02028982
(2) Auto-lock latch
3. Hold both grips that are provided on the window
frame and move the window into the STORAGE
position until auto-lock latch (2) is engaged.
Perform Steps 4 through 5 to close the upper
window.
(3) Brackets
(4) Catch
7. Store the lower window in the holder that is located
in the rear of the left side cab frame. To store the
lower window, locate one end of the lower window
into brackets (3). Secure the opposite end of the
lower window with catch (4).
8. To close the lower window, reverse the procedure
that is used for opening the lower window.
SEBU9190-12 103
Operation Section
Cab Visor

Note: The lower window is curved. The lower window i02500596

can only be positioned one way in the holders.
Sun Screen
i01523337
(If Equipped)
Cab Visor SMCS Code: 7165-ZZ
(If Equipped)
SMCS Code: 7301-ZZ

Illustration 167 g00681071

The cab visor is used to shade the sunlight that is

coming in through the sun roof or coming in through
Illustration 168 g01250563
the front windshields. Attach the cab visor to the top
of the front windshield and tilt the cab visor to the
desired angle. Pull out the sun screen (1). Hook the sun screen to
the bracket (2). The sun screen may be positioned in
Note: The cab visor cannot be attached to a power 3 different places.
window.
i01463742

Roof Hatch
SMCS Code: 7303

Illustration 169 g00681034

(1) Grip
(2) Lock

In order to open the roof hatch, release lock (2). Hold

grip (1) and push the roof hatch backward.
104 SEBU9190-12
Operation Section
Cab Door

To close the roof hatch, hold grip (1) and pull the roof
hatch forward. Engage lock (2) securely.

i05832528

Cab Door
SMCS Code: 7308

Illustration 172 g01121189

In order to release the cab door from the catch, pull

downward on one of the two cab door release levers.

Illustration 170 g03689766

In order to open the cab door from the outside of the

cab, pull outward on the door handle.

Illustration 173 g01096005

In order to open a window, release the window latch,

and then slide the window to the desired position.

Illustration 171 g01095780

In order to open the cab door from the inside of the

cab, push forward on the lever for the cab door latch.
For additional ventilation, open the cab door all the
way in order to engage the catch on the exterior wall
of the cab.
SEBU9190-12 105
Operation Section
Joystick Controls

i05864512 i05832542

Joystick Controls Fuel Tank Shutoff and Drain

SMCS Code: 5705 Control
SMCS Code: 1273

Illustration 174 g02233473

(1) STICK OUT Illustration 175 g03689795
(2) SWING RIGHT
(3) STICK IN
(4) SWING LEFT
(5) BOOM LOWER
(6) BUCKET DUMP
(7) BOOM RAISE
(8) BUCKET CURL
(9) HOLD
(9a) HORN (IF EQUIPPED)
(9b) MANUAL LOW IDLE SWITCH (IF EQUIPPED)
(10) Seat

When you release the joysticks from any position, the

joysticks will return to HOLD position (9). Movement
of the upper structure will stop, and the swing brake
will engage. To avoid brake damage, the brake will
only engage when the superstructure has come to a
complete stop.
Two functions may be performed at the same time by Illustration 176 g03689792
moving a joystick diagonally.
The fuel tank drain valve is located under the
The machine control pattern is initially set at the machine on the left side.
factory to the SAE system, as shown. The pattern on
the left pertains to the left joystick and the pattern on Fuel Tank Drain Valve (1) – To drain the water and
the right pertains to the right joystick. sediment from the fuel tank, turn the fuel drain valve
counterclockwise. To close the fuel tank drain valve,
turn the drain valve clockwise.
106 SEBU9190-12
Operation Section
Fuel Tank Shutoff and Drain Control

Illustration 177 g03689796

The fuel tank shutoff valves are located behind the

fuel tank.
Fuel Shutoff Valves (2) – To shut off the fuel supply,
turn the fuel shutoff valves clockwise. To turn on the
fuel supply, turn the fuel shutoff valves
counterclockwise.

Note: For more detailed information that pertains to

draining the water and sediment from the fuel tank,
refer to Operation and Maintenance Manual, “Fuel
Tank Water and Sediment - Drain”.
SEBU9190-12 107
Operation Section
Engine Starting

Engine Starting
i05836374

Engine Starting
SMCS Code: 1000; 1090; 1456; 7000

NOTICE
The engine start switch must be in the ON position
and the engine must be running in order to maintain
electrical functions and hydraulic functions. This pro-
cedure must be followed in order to prevent serious
machine damage.
Illustration 179 g03701716

7. Turn engine start switch to the ON position. The

monitoring system will start and an indicator
message will appear on the monitor display screen
for the glow plugs.
Note: Leave the engine start switch in the ON
position until the glow plug indicator disappears.
Note: For more information on the monitoring
system, refer to Operation and Maintenance Manual,
“Monitoring System”.

8. If the engine start switch is placed in the ON

position, the fluid level check screen of the
Illustration 178 g00406959 monitoring system will be activated. If any fluid
levels are low, the low fluid level will be shown on
1. Turn the battery disconnect switch to the ON the message display. Refer to Operation and
position. Maintenance Manual, “Monitoring System” for
2. Make sure that the reset button for the circuit more information.
breaker remains depressed. Refer to Operation If the fluid level is too low, add the corresponding
and Maintenance Manual, “Circuit Breakers - fluid to the specified level. Add the fluid before you
Reset”. start the engine.
3. Make sure that all engine shutdown switches are
disengaged.
4. Move the hydraulic lockout control to the LOCKED
position.
This machine is equipped with an engine neutral
start system. The system only allows the engine to
start when the lever for the hydraulic lockout
control is in the LOCKED position.
5. Move the joysticks to the HOLD position.
6. Before you start the engine, check for the
presence of bystanders or maintenance
personnel. Ensure that all personnel are clear of
the machine. Briefly sound the horn before you Illustration 180 g03691850
start the engine.
9. Turn the engine speed dial to speed position “One”
.
108
Operation Section
Engine and Machine Warm-Up
NOTICE
Do not crank the engine for more than 30 seconds. If
the engine does not start, allow the starter to cool for
two minutes before cranking again. The engine start
switch must be turned to the OFF position before try-
ing to restart.
10. Turn the engine start switch to the START
position.
Note: The operating period of the glow plug indicator
will change due to the temperature of the engine.
11. Release the engine start switch after the engine
starts.
This machines engine with standard specifications
can start in areas that have temperatures as low as
−18°C (0°F). For areas that are cooler, a starting kit
for cold weather is available.
i05864644
Engine and Machine Warm-Up
SMCS Code: 1000; 7000
NOTICE
Keep engine speed low until the engine oil pressure
registers on the gauge. If it does not register within
ten seconds, stop the engine and investigate the
cause before starting again. Failure to do so, can
cause engine damage.
NOTICE
Always run the engine at low idle for at least ten mi-
nutes before performing any other operations in cold
conditions in order to protect your engine and hy-
draulic components.
NOTICE
Depending on the ambient temperature, in order to
prevent the machine operation with high speed with-
out sufficient lubrication at the turbo bearing, the en-
gine speed may be set at dial 1 and the hydraulic
power minimized for a pre-determined time after the
engine starts. Refer to turbo protection feature.
The engine may automatically change speeds when
the machine is stationary and idling in cold ambient
temperature for an extended time. The engine will
change speeds in order to:
• Maintain desired coolant temperature.
• Maintain desired operation of engine systems.
• Maintain desired operation of the regeneration
system.
SEBU9190-12
During extended idling in cold ambient conditions,
engine speed may be limited to 700 rpm.
Hydraulic System
When you cycle the machine controls, the ma-
chine can move suddenly. Contact between the
machine and external objects or ground person-
nel can result in serious injury or death. Before
you cycle the machine controls, the machine
should be located in an unobstructed, hazard-
free work area that is away from external objects
and ground personnel.
1. Make sure that the area is clear of personnel and
equipment.
Note: The hydraulic lockout control must be in the
UNLOCKED position before the hydraulic controls
will function.
2. Allow the engine to warm up at low idle for at least
5 minutes. Engage the work tool controls and
disengage the work tool controls. Engaging the
work tool will speed up the warm-up of the
hydraulic components.
When you idle the machine for warm-up, observe
the following recommendations:
• If the temperature is greater than 0°C (32°F),
warm up the engine for approximately 15
minutes.
• If the temperature is less than 0°C (32°F),
warm up the engine for approximately 30
minutes.
• If the temperature is less than − 18°C (0°F) or
if hydraulic functions are sluggish, additional
time may be required.
3. To warm up the hydraulic oil, turn the engine speed
dial to the medium engine speed. Run the engine
for approximately 5 minutes and move the joystick
intermittently from the BUCKET DUMP position to
the HOLD position. Do not hold the joystick in the
BUCKET DUMP position with the bucket cylinder
fully extended for more than 10 seconds.
This procedure allows the oil to attain relief
pressure, which causes the oil to warm up more
rapidly.
4. Turn the engine speed dial to the maximum engine
speed and repeat Step 3.
SEBU9190-12 109
Operation Section
Engine and Machine Warm-Up

5. Cycle all controls in order to circulate warm oil

through all hydraulic cylinders and all hydraulic
lines, and through the swing motor and travel
motors.
6. Observe the gauges and the indicators frequently
during the operation.
110
Operation Section
Operation
Operation
i07775983
Operation Information
SMCS Code: 7000
Working Operation
Safety
Personnel
Any work with the machine must be executed only by
reliable, skilled, and well trained personnel in good
healthy condition. Statutory minimum age limits must
be observed.
Never operate the machine while impaired with drugs
or alcohol.
Refer to the Safety Section of this Operation and
Maintenance Manual for additional safety
information.
Observe all job site safety requirements.
State of the Site
Inspect the site for underground gas, power, and
water lines before starting work. Any damage to such
lines is a risk to life!
Clear all obstacles from the path of the machine.
Sound the horn to warn persons in the immediate
vicinity before starting work.
Stop work if anyone is in the hazard range of the
machine. Make sure that all persons have left the
hazard range before resuming work.
Machine Stability
Never operate the machine unless the machine is
standing on a reasonably horizontal, flat surface. The
stability of the machine is otherwise at risk.
When working or traveling on a slope is required, do
not exceed the maximum machine inclination for
working operation and for traveling. Refer to
Operation and Maintenance Manual, Maximum
Operating Grade for additional information.
Ensure that the attachment has adequate clearance
below overhead power lines and structures.
Trenches and working faces may give way. Keep well
clear of them.
SEBU9190-12
As travel brakes are deactivated, the machine could
slightly move in direction of excavating during
operation. Whenever loading operation is interrupted,
stand attachment on the ground. This position avoids
slight movement of the machine and possible
consequential damage of lowered ladder, in case
ignition remains engaged.
State of the Operator Workplace
Inspect and fasten your seat belts.
Adjust the operator seat for comfortable reach all
controls and pedals. Adjust for operator height and
weight.
Keep your workplace clean. Remove all unsecured
items like tools and other supplies from the cab.
Clean off any earth, mud, snow, ice, grease, and oil
adhering to your working footwear before operating
the machine. There is otherwise a risk of slipping off
the pedals and initiating inadvertent movements.
Clean and secure all windows and doors.
Clean and adjust all mirrors for optimum vision.
Start the engines only from the operator
compartment.
Operate the machine only while sitting on the
operator seat.
State of the Machine
Operate the machine only if all protective and safety-
oriented devices, such as removable safety devices,
emergency shut-off equipment, soundproofing
elements and exhausters, are in place and fully
functional.
Do not operate the machine:
• when several track rollers or upper rollers have
been removed
• when one or several swing gearboxes have failed
or been removed
• when one or several teeth on the backhoe or on
the shovel are worn or missing
• when parts of the hardfacing layer on the backhoe
or on the shovel are worn or missing
Working under these circumstances results in heavy
wear and possibly in severe damage and thus in high
repair costs.
Such circumstances are considered an "abusive
utilization".
Caterpillar refuses to assume the guarantee for
damage and consequential damage caused by an
abusive utilization of the machine.
SEBU9190-12
Before Staring Work
Perform a machine walk around inspection. Report
any obvious damage and defects, including changes
in the machine working behavior to your supervisor.
In the event of malfunctions, stop the machine
immediately and lock the machine.
Prior to initial commissioning and after repairs on the
central lubricating system or the hydraulic cylinders,
move the unloaded equipment for about 5 minutes.
This action is required to ensure an adequate supply
of grease to the cylinder bearings when the work
starts.
Prior to each shift perform a complete 360° swing
movement of the upper structure. Performing this
action ensures proper distribution of grease and
brings all the bearing rollers inside the swing ring to
new positions.
Machine Operating Temperature
The machine must function satisfactorily in the
anticipated ambient temperature limits that are
encountered during operation. The standard machine
configuration is intended for use within an ambient
temperature range of −20° C (−4° F) to 55° C
(131° F). Special configurations for different ambient
temperatures may be available. For use at
temperatures below−10° C (14° F), the machine can
be equipped with a cold-weather package. Consult
your Cat dealer for additional information on special
configurations of your machine.
Warming Up the Hydraulic System
At low outside temperatures from 0° C (32° F)−20° C
(−4° F) to run the hydraulic system nearly up to
operating temperature is necessary. The outside
temperatures at which warming up is necessary
depends on the type of hydraulic fluid used. Refer to
Operation and Maintenance Manual, Lubricant
Viscosities for the proper lubricants.
Refer to Operation and Maintenance Manual, Engine
and Machine Warm-Up for the proper warm-up
procedure.
If the monitoring system indicates problems with the
cooling liquid temperature, engine oil pressure,
coolant level, alternator or hydraulic fluid filter control
(with hydraulic fluid at service temperature):
• Lower the attachment to the ground and shut off
the engine.
• Report the problem.
111
Operation Section
Operation Information
Working on Level Ground
Operating the machine on level and stable ground is
recommended. Doing so ensures maximum
productivity and prevents machine components from
premature wear.
Working on Slopes or on Rough Terrain
Clean and level rough terrain before moving into the
bank. A clean, level pit floor is necessary for safe and
stable machine operation and prevents the tracks
and other components of the undercarriage from
being damaged.
When working or traveling on a slope is required, do
not exceed the maximum machine inclination for
working operation and for traveling. Refer to
Operation and Maintenance Manual, Maximum
Operating Grade for additional information.
If the machine begins to sideslip on a slope,
immediately lower the attachment and the load to the
ground and turn the machine facing downhill.
Operate the machine slowly, accelerate, and
decelerate attachment movements gently. Sudden
movements with full speed and filled bucket are a
huge strain for the structure which could tip the
machine over.
When working on a slope, always operate the
hydraulic shovel with the attachment positioned uphill
or downhill, never sideways.
When traveling up and down a slope, or when
traveling over rough terrain, reduce travel speed
mode to slow. Refer to the Traveling section of this
article.
Joystick Controls
Refer to Operation and Maintenance Manual,
Joystick Controls for information on using the
joysticks to swing and brake the machine, and to
control the boom, stick, and bucket.
Traveling Operation
Safety
Personnel
Any work with the machine must be executed only by
reliable, skilled, and well trained personnel in good
healthy condition. Statutory minimum age limits must
be observed.
Avoid aggressive operating practices and never
operate the machine while impaired with drugs or
alcohol.
Do not overload the machine.
112
Operation Section
Operation Information
State of the Operator Workplace
Inspect and fasten your seat belts.
Adjust the operator seat for comfortable reach all
controls and pedals. Adjust for operator height and
weight.
Keep your workplace clean. Remove all unsecured
items like tools and other supplies from the cab.
Clean off any earth, mud, snow, ice, grease, and oil
adhering to your working footwear before operating
the machine. There is otherwise a risk of slipping off
the pedals and initiating inadvertent movements.
Clean and secure all windows and doors.
Clean and adjust all mirrors for optimum vision.
Travel the machine only while sitting on the operator
seat.
State of the Machine
The engines must be at operating temperature before
being subjected to full load.
If the machine is to be driven a longer distance, the
upper structure must be secured against turning with
the upper structure holding brake.
Sound the horn to warn persons in the immediate
vicinity before starting traveling.
Sound the horn and allow adequate time for
bystanders to clear the area before moving the
machine into a restricted visibility area. Follow local
practices for your machine application. For more
information refer to Operation and Maintenance
Manual, Restricted Visibility.
Clear the Hazard Range of the Machine
Flying Debris Hazard! During operation of the ma-
chine, flying debris could be discharged from the
tracks which could result in personal injury or
death. Keep a safe distance from the machine
during operation.
Check the surrounding area around the machine (the
hazard range of the machine):
• No personnel around the machine
• No personnel on the machine outside the cab
State of the Site and Machine Stability
Before starting traveling, inspect the condition of the
ground you want to travel on. The machine may sink
on soft ground.
SEBU9190-12
Do not travel into a water surface without knowing
how deep the water is and how stable the
underground is. The underground may be sludgy and
with insufficient bearing capacity. The machine may
sink.
Do not travel through water or mud that is deeper
than the breather valves of the final drives. Refer to
Operation and Maintenance Manual, Operating
Technique Information.
Ground that has been newly filled with earth / gravel
may collapse from the weight of the machine.
Rocks and moisture of the surface material may
drastically affect the machine traction and machine
stability. Rocky surfaces may promote side slipping of
the machine.
The machine may be less stable when traveling on
uneven ground.
Have the attachment raised only so far as to permit
the machine to be driven under overhead power lines
without any risk.
Do not exceed the maximum machine inclination.
Refer to Operation and Maintenance Manual,
Maximum Operating Grade for additional information.
Do not travel across slopes. Always travel 90° to the
slope face (upwards and downwards). Place the
heaviest end of the machine uphill when you are
traveling on an incline.
Do not drive the machine close to an overhang, to the
edge of a cliff, or to the edge of an excavation.
Take the utmost care on slippery, greasy ground.
If the upper structure is turned by more than 90° from
the basic position, the hydraulic shovel travels in the
opposite direction to that selected.
If the position of the upper structure in relation to the
undercarriage is not exactly known, touch the travel
pedals lightly to see which direction the machine
takes, before initiating the full traveling movement.
Safe operation on steep slopes may require special
machine configuration. Excellent skill of the operator
and proper attachment for specific applications are
also required.
Before Starting to Travel
• Read and observe all notes given in the "Safety"
section of this article.
• Lift the hydraulic access ladder.
• Lift attachment up to the traveling position.
• Activate the signal horn.
• Release the travel brake switch (if applied).
SEBU9190-12 113
Operation Section
Operation Information

• Watch the mirrors and the camera monitor (if

equipped).

• Start traveling.

Basic Position of the Upper Structure

Illustration 182 g06335224

If the upper structure is swung out of the basic

position by more than 90°, the shovel moves in a
direction opposite to the expected movement when
the travel pedals are actuated.
If the operator is not sure of the position of the upper
Illustration 181 g03721959 structure, the pedals should be depressed slightly to
(1) Cab find out which way the shovel moves, before initiating
(2) Idler the full traveling movement.
(3) Counterweight
(4) Final drive
Basic Travel Movements
Travel only with the upper structure in the basic
position. Refer to Operation and Maintenance Manual,
Operator Controls for information on using the travel
The drive sprockets should be at the rear of the pedals.
machine.
Traveling movement is controlled by the travel
Before moving the machine, check the position of the pedals. The travel pedals return automatically to the
undercarriage. neutral positions when released.

Travel direction and sense of actuation of the travel
pedals are identical only when the hydraulic shovel is
in the basic position. For more information on the
travel pedals, refer to Operation and Maintenance
Manual, Operator Controls.
In this basic position the counterweight (3) is
positioned above the final drives (4). The operator
cab (1) is above the left idler (2).
Forwards means: Machine movement in direction of
the idlers.
Backwards means: Machine movement in direction
of the final drives.
During traveling, an acoustic warning signal sounds
(Travel Alarm).
All instructions regarding travel direction control are
applicable only as long as the crawler tracks have
sufficient grip and do not slip.
The information given in this section is applicable
when traveling on level ground and also when
traveling the machine on moderate inclinations, for
example on haul roads. For additional information
about traveling on steep ramps and steep slopes
refer to Operation and Maintenance Manual,
Operating Technique Information.
Accelerate and decelerate travel movements gently.
Sudden acceleration and abrupt braking from full
speed are a huge strain for the machine. Avoid
aggressive traveling practices.

Turning
When turning, select the slow speed level.
Change the position of the undercarriage only by
turning forwards/backwards.
114 SEBU9190-12
Operation Section
Operation Information

Illustration 183 g06335232

Turning to the left:

1. Move forward from position 1 to position 2.
2. Move backwards from position 2 to position 3.
3. Move forwards from position 3 to position 4.

Illustration 184 g06335233

The same procedure should be adopted if the

hydraulic shovel is to be driven out of depressions:
1. Turn to the left from position 1 to position 2.
2. Turn to the right from position 2 to position 3.

Travel Speed
All instructions regarding traveling speed regulation
are applicable only as long as the crawler tracks have
sufficient grip and do not slip.
For information on adjusting the travel speed refer to
Operation and Maintenance Manual, Operator
Controls.
Change speed level only when the hydraulic shovel
is stationary.
SEBU9190-12 115
Operation Section
Operation Information

Table 9
Travel Speed Recommendations

Travel Situation Travel Speed

Adjusting machine position while loading trucks Slow

Traveling rearwards Slow

Traveling long distances on flat or slight ramps and slopes Slow or Fast

Turning Slow

Traveling uphill / downhill on ramps and steep slopes Slow

Traveling on soft or inconsistent material Slow

Traveling on rough terrain Slow

Loading machine onto a trailer Slow

Track Parking Brakes Traveling Uphill and Downhill

The hydraulic shovel is equipped with four traveling
gear brakes which are integrated in the travel drives.
The traveling gear brakes are parking brakes. The
protect the hydraulic shovel from rolling forwards or
backwards. When the machine is parked, travel
brakes are activated automatically. The brakes are
deactivated when the travel pedals are activated
allowing the machine to travel.
As travel brakes are deactivated, the machine could
slightly move in direction of excavating during
operation.
Whenever loading operation is interrupted, rest the
attachment on the ground. This position avoids slight
movement of the machine and possible
Illustration 185 g06335472
consequential damage of lowered ladder, in case
ignition remains engaged.

Swing Brake
The hydraulic shovel is equipped with swing brakes
which are integrated in the swing gearboxes. The
swing brakes lock the upper structure with respect to
the undercarriage.
The gearbox brakes are holding brakes only.
For more information on the swing brake controls (if
equipped) refer to Operation and Maintenance
Manual, Operator Controls.
Apply the swing brake:

• When the hydraulic shovel is parked Illustration 186 g06335505

• When traveling longer distances When traveling uphill or downhill on ramps and steep
slopes, the travel drives (1) must always face
downhill. Otherwise track tension loss may occur.
116 SEBU9190-12
Operation Section
Operation Information

Do not exceed the maximum machine inclination

when traveling uphill or downhill. Refer to Operation
and Maintenance Manual, Maximum Operating
Grade for additional information.
When traveling on ramps and slopes, select slow
speed level, depress the travel pedals fully to the limit
stop, and regulate the travel speed only with the
engine speed control switch. Refer to Operation and
Maintenance Manual, Operator Controls for more
information on speed and travel controls.
When traveling downhill, the travel retarder valve
acts as a speed limiter.
If the traveling speed becomes too high when
traveling downhill, release the travel pedals to stop
Illustration 187 g06222919
the shovel.
Backhoe traveling position
Avoid changing the direction of travel on a slope.
Changing the direction of travel on a slope could Recommended position of the backhoe bucket
result in tipping or side slipping of the machine. attachment:
Be extremely careful on slippery and greasy ground. • Fully extend the boom cylinder
The machine may slip.
• Extend backhoe cylinder
Do not travel across slopes.
• Extend stick cylinder
Keep the working attachment close to the ground.
• Extend backhoe cylinder and stick cylinder to such
Be careful to avoid any ground condition which could an extent as to reach the position of the
cause the machine to tip. Tipping can occur when attachment shown in Illustration 187 .
you travel on hills, on banks or on slopes.
If the machine begins to sideslip on a grade, NOTICE
immediately dump the load and turn the machine If non-OEM buckets are installed, be careful to avoid
uphill. contact between bucket and machine.

Traveling Over Long Distances If the attachment position must be changed:

Travel only forwards with the hydraulic shovel in the • Stop the hydraulic shovel
basic position. Traveling backwards over longer
distances could wear out or damage parts of the • Change the position
undercarriage.
• Continue to travel
Read and observe all notes given in the "Safety"
section of this article.
Track Roller Temperature Check
Do not exceed the maximum machine inclination.
Refer to Operation and Maintenance Manual, After traveling for 15 minutes without interruption,
Maximum Operating Grade for additional information. stop the hydraulic shovel and check the temperature
of the track rollers.
When traveling, pay attention for sufficient headroom
when going under bridges or power lines. Lower the An infrared thermometer can be used to measure the
attachment when traveling underneath obstacles. temperature from a distance.

Keep the bucket close to the ground. For a more If the temperature is below 70° C (158° F):
uniform loading of the tracks, the attachment must,
however, be kept at a steep angle. • Continue traveling

Set the swing brake. If the temperature is between 70° C (158° F) and
90° C (194° F):
• Monitor the temperature of the track rollers

• Continue traveling but check temperature in short

intervals
SEBU9190-12 117
Operation Section
Maximum Operating Grade

If temperatures are above 90° C (194° F):

• Stop traveling

• Resume traveling only after the track rollers have

cooled down to approximately 40° C (104° F)
Note: Do not walk beside the machine and try to cool
down track rollers by hand with a bucket of water or
with a water hose.
In principle, the use of a water truck to spray water on
the track rollers from a safe distance is possible. This
water spray will rapidly cool down the track rollers.

i05914220

Maximum Operating Grade

SMCS Code: 1000; 7000

S/N: HSE1–Up
S/N: MKE1–Up
S/N: PZE1–Up
S/N: HSF1–Up
S/N: ZEN1–Up
The machine must not exceed the inclinations
indicated for working, traveling, servicing operations
and during downtimes. The values specified in the
tables below are valid for all types of working
equipment.
If the maximum inclinations are exceeded, there is a
risk of severe damage to the engine due to
insufficient lubrication. In the event of extreme
inclinations the machine can topple over.
The working performance of the machine is more
efficient when the machine stands on firm and level
ground.
A loss of performance and higher wear must be
accepted when the machine works in an inclined
position.
For the building of ramps, the maximum inclinations
during working operations may be exceeded. In this
case, however, a reduced service life of the
components can be expected.
During downtimes, the machine must be parked in
such a way that the inclination does not exceed 3° /
5.2%.
118 SEBU9190-12
Operation Section
Maximum Operating Grade

Illustration 188 g03721833

Table 10
Forward Inclination Rearward Inclination Side Inclination
Maximum machine inclinations during:
(A) (B) (C)

Working Operations 10° / 17.6% 10° / 17.6% 10° / 17.6%

Traveling 20° / 36.4% 20° / 36.4% 20° / 36.4%

Maintenance Operations 2° / 3.4% 2° / 3.4% 2° / 3.4%

i07527580 For the building of ramps, the maximum inclinations

during working operations may be exceeded. In this
Maximum Operating Grade case, however, a reduced service life of the
components can be expected.
SMCS Code: 1000; 7000
During downtimes, the machine must be parked in
S/N: FKD1–Up such a way that the inclination does not exceed 3° /
5.2%.
S/N: HLD1–Up
S/N: LWN1–Up
S/N: WSN1–Up
S/N: LWS1–Up
S/N: PWW1–Up
The machine must not exceed the inclinations
indicated for working, traveling, servicing operations
and during downtimes. The values specified in the
tables below are valid for all types of working
equipment.
If the maximum inclinations are exceeded, there is a
risk of severe damage to the engine due to
insufficient lubrication. In the event of extreme
inclinations the machine can topple over.
The working performance of the machine is more
efficient when the machine stands on firm and level
ground.
A loss of performance and higher wear must be
accepted when the machine works in an inclined
position.
SEBU9190-12 119
Operation Section
Frozen Ground Conditions

Illustration 189 g03721833

Table 11
Forward Inclination Rearward Inclination Side Inclination
Maximum machine inclinations during:
(A) (B) (C)

Working Operations 10° / 17.6% 10° / 17.6% 10° / 17.6%

Traveling 23° / 42% 23° / 42% 23° / 42%

Maintenance Operations 2° / 3.4% 2° / 3.4% 2° / 3.4%

i06186862

Frozen Ground Conditions

SMCS Code: 7000

Frozen Tracks

Illustration 190 g00101468

To free the tracks from frozen ground, swing the

boom to the front of the machine. Use boom down
pressure to free the idler end of the machine.
120 SEBU9190-12
Operation Section
Equipment Lowering with Engine Stopped

Swing the boom to the rear of the machine. Use Manual Boom Lowering
boom down pressure to free the sprocket end of the
machine.

Moving the Machine Personal injury or death may occur from failure
to adhere to the following warnings.
The boom can fall if a control is moved or if a hy-
draulic component fails.
Do not rely on a hydraulic cylinder to hold the
boom.
Support the boom during all service procedures.

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the machine.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
Illustration 191 g00101644 bling any component containing fluids.

If the tracks have been frozen, turn the upper
structure 90 degrees so that the boom is positioned
over the side of the tracks. If the machine is moved
without turning the upper structure during frozen
ground conditions, damage to the catwalk, ladder or
fast fill areas can occur. Drive the machine
backwards, away from the idlers, initially. Then drive
the machine forwards and backwards a few times in
order to break free any material that is stuck to the
tracks. If any areas of buildup remain, use heat or
tools for further cleanup.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide”, for tools and sup-
plies suitable to collect and contain fluids.
Dispose of all fluids according to local regulations
and mandates.
This procedure requires two people. One person
must perform the procedure and the other person
must ensure that the area under the boom is clear.

i06816723

Equipment Lowering with

Engine Stopped
SMCS Code: 7000
To lower the boom, turn the engine start switch to the
ON position. Place the hydraulic lockout control
(lever) in the UNLOCKED position. Move the joystick
control (lever) to the BOOM LOWER position. If the
accumulator is still charged, the boom will lower. Turn
the engine start switch to the OFF position.
If the boom does not lower, the accumulator is empty.
Use the following method to lower the boom.

Illustration 192 g00880479

Implement and travel control valve
Location of purging screw (1)
SEBU9190-12 121
Operation Section
Equipment Lowering with Engine Stopped

1. Purging screw (1) is on the left side near the top of

the implement and travel control valve. Slowly
loosen the purging screw until the hydraulic oil
begins to flow. The purging screw allows the
hydraulic oil to flow from the head ends of the
boom cylinders through the implement and travel
control valve and back to the tank.
2. The boom will start to lower slowly.
3. Make sure that the front implement has been
completely lowered onto the ground. Tighten
purging screw (1).
4. Make all necessary repairs before you operate the
machine.
For additional information, consult your Caterpillar
dealer.
122 SEBU9190-12
Operation Section
Operating Techniques

Operating Techniques When you operate the machine in close places,

i07505978
Operating Technique
Information
SMCS Code: 7000
Know the maximum height and the maximum
reach of your machine. Serious injury or death by
electrocution can occur if the machine or the
work tools are not kept a safe distance from elec-
trical power lines. Keep a distance of at least
3000 mm (118 inch) plus an additional 10 mm
(0.4 inch) for each 1000 volts over 50000 volts.
For safety, one of the following may require a greater
distance:
• Local codes
• State codes
utilize the bucket or the other work tool to perform the
following functions:
• Pushing the machine
• Pulling the machine
• Lifting the tracks
Use a comfortable travel speed while you operate the
machine.
Operating efficiency can be increased by using more
than one machine control to perform a task.
Never swing a load over a truck cab or workers.
Position the truck so that material can be loaded from
the rear of the truck or from the side of the truck.
Load the truck evenly so that the rear axles are not
overloaded.
An oversize bucket or a bucket that is equipped with
side cutters should not be used in rocky material.
These types of buckets slow down the cycle.
Damage to the bucket and to other machine
components could result.

• Requirements of the job site Machine Operation with Backhoe

NOTICE
Attachment
When swinging into a ditch, do not use the ditch to
stop the swinging motion. Inspect the machine for Machine Stability
damage if the boom is swung into a bank or an
object.
Repeated stopping by an object can cause structural
damage if the boom is swung into a bank or an
object.
With certain boom-stick-bucket combinations, the
bucket or worktool can hit the cab and/or the front
structure of the machine. Always check for interfer-
ence when first operating a new bucket or a new work
tool. Keep the bucket or work tool away from the cab
and away from the front structure during operation.
Whenever the tracks of the machine raise off the
ground while digging, lower the machine back to the
ground smoothly. DO NOT DROP OR CATCH IT
WITH THE HYDRAULICS. Damage to the machine
can result. Illustration 193 g06299017

The hydraulic shovel must always be operated in a

Know the location of any buried cables. Mark the way, that stability of the shovel is always ensured,
locations clearly before you dig. and the danger of tipping over is avoided.

Consult your Caterpillar dealer for special work tool Machine stability is greater when the bucket is
tips that are available for use in severe applications. parallel with the tracks.

Move the machine whenever the position for
operating the machine is not efficient. The machine
can be moved forward or backward during the
operating cycle.
When working with the bucket parallel to the tracks,
the final drives should be in the rear position, for the
following reasons:
• The travel motors and final drives are protected
from falling rocks and other objects.
SEBU9190-12 123
Operation Section
Operating Technique Information

• When the hydraulic shovel is operated on muddy • Easily penetrable material. All loose, free flowing
ground and the tracks are covered with mud, the material and all materials which can be excavated
sprocket runs on a clean track when backing up. without blasting.
When working with the attachment in a cross • Difficult to penetrate material. Blasted or unblasted
direction to the tracks, be sure that the track is not material containing large chunks, wet clayey soil
raised off the ground. This action can cause the track and overburden.
to set-off from the rollers when the track is lowered
down on the ground. Material flow:
The flanges of the track rollers and the track shoes • Free flowing / loose.
can be bent by the excessive load. Refer to
Operation and Maintenance Manual, Operating • Sticky / in situ.
Technique Information for additional information.
Conditions favorable to hydraulic backhoes:
Do not overfill / overload the bucket, the machine
may tip over. • Low to moderate bench heights
When working or traveling on a slope is required , do • Truck spotted either on top of bench or on the floor
not exceed the maximum machine inclination for below the backhoe
working operation and for traveling. Refer to
Operation and Maintenance Manual, Maximum • Tight load area
Operating Grade for additional information.
Do not operate the shovel on rain slicked, slippery • Short swing - 60 degrees
slopes. The shovel may slip. • Well-shot material
Clean and level the pit floor before moving into the Conditions unfavorable to hydraulic backhoes:
bank. A clean, level pit floor is necessary for safe and
stable machine operation and prevents the tracks • High benches
and other components of the undercarriage from
being damaged. • Excessive tramming
Position the hydraulic shovel on level, consistent, • Multiple benches
firm, and stable ground. The hydraulic shovel may
gradually sink on soft and yielding ground. Always re- • Unstable benches
enforce soft and yielding ground with firm material.
• Low angle of repose
If working on soft and yielding ground is unavoidable,
operate the machine at reduced bucket loads to • No cleanup support
avoid tipping of the machine.
When working on high-density and coarse material,
operate the machine at reduced bucket loads to
avoid overloading and damaging components of the
machine.
Stand attachment down to the ground during breaks
in working operation.
Do not operate the hydraulic shovel in water or in
mud deeper than the breather valves of the final
drives. Refer to Operation and Maintenance Manual,
Operating Technique Information for additional
information.

Know the Situation on Site

To maximize productivity of the machine, the
operator must understand the characteristics of the
material and how to adjust the operating style
accordingly.
Material penetrability:
124 SEBU9190-12
Operation Section
Operating Technique Information

Bench Climbing and Leaving Bench Heights

Climbing Onto a Bench Insufficient Bench Height

Illustration 194 g03722222 Illustration 196 g06299107

Do not exceed the maximum machine inclination for A too low bench does not allow good bucket fills and
working. Refer to Operation and Maintenance involves the risk to pull material against the tracks.
Manual, “Maximum Operating Grade” for more
information.
Build the ramp. Travel up the ramp onto a bench with
idlers first, keep the bucket close to the ground.
If necessary, engage the bucket into the ground and
move working equipment towards the machine. This
procedure supports the machine while climbing the
steep ramp.
Leaving a Bench

Illustration 197 g06299109

Insufficient height increases the danger of collision

between excavator and truck under certain
circumstances.
Sufficient Bench Height

A sufficient bench height is essential for efficient and

Illustration 195 g03722223
Build the ramp. If the bench is steep, bring the shovel
down the bench with the final drive first. Keep the
bucket close to the ground.
Keep the bucket close to the ground.
safe operation.
The ideal bench height is equal to the stick length or
equal to the truck body rail height.
Note: This is a rule of thumb and is valid only if the
material allows this bench height and only for
standard truck match.
Loading Setups
The following setups are used for digging and loading
with the hydraulic shovel:
SEBU9190-12
• Hydraulic shovel on top of the bench, and truck
below (This is the typical application).
• Hydraulic shovel and truck on the same level.
Illustration 198 g06299117
Working with the hydraulic shovel on a proper bench
height and the truck below offers the following
improvements:
• 15-20% more production.
• Clear separation of loading and hauling
equipment.
• Less risk of collision.
• Excellent operator view into the truck body.
• Potential for short swing angles.
• Shortest attachment lifting distance possible.
• Various options for truck positioning with loading
through the body gate or over the side wall.
Productivity increases:
• 10 – 15% higher productivity when bench is
correct height versus too high or too low.
• 15 – 20% higher productivity when trucks are
spotted on the floor below the excavator versus on
top of bench.
• 5% higher productivity when excavator swings 60
degrees versus 90 degrees.
• Higher productivity when positioned as close to
the edge as safely possible.
125
Operation Section
Operating Technique Information
Truck on Lower Level (Drive-by Loading)
Illustration 199 g06300695
Working with the truck on a lower level offers the
following advantages:
• Truck spotting time is eliminated, for the highest
productivity, because the next truck does not need
to reverse for positioning.
Working with the truck on a lower level has the
following disadvantages:
• More than 90 degree swing angle.
• Loading through the gate could be more difficult
due to limited space for dumping.
Truck on Upper Level (Top Loading)
Illustration 200 g06300701
This working technique is best applied for drop cuts
and in difficult to access or wet areas at the pit
bottom.
Working with the hydraulic shovel and the truck on
the same level offers the following advantages:
• Loading over side walls offers reduced swing
angles.
126 SEBU9190-12
Operation Section
Operating Technique Information

• Loading over tail offers reduced lifting effort for

faster cycles.
Working with the hydraulic shovel and the truck on
the same level has the following disadvantages:

• Increased lifting effort and larger swing angle

requires longer cycle time.
• Productivity is approximately 15 to 20% lower.
SEBU9190-12 127
Operation Section
Operating Technique Information

Bench Height Recommendations

Table 12

Stick Length Truck Body Loading Edge at 4 Recommended Bench Height

Model
to 5 Pass Match
3.6 m (11 ft 9.7 inch) / 4.1 m 3 m (9 ft 10.1 inch) to 4 m
6015B 3.7 m (12 ft 1.7inch) (775G)
(13 ft 5.4 inch) (13 ft 1.5inch)

3.5 m (11 ft 5.8inch) to 4.5 m

6020B 3.9 m (12 ft 9.5 inch) 4.4 m (14 ft 5.2 inch) (777G)
(14 ft 9.2inch)

Digging and Loading
Perform the following actions when loading a truck:
• Start at "key cut" and work toward the truck.
• Always work over the idler and swing no more
than 60 degrees to the truck.
• Prepare the next cuts in advance.
• General digging advance is backwards.
• Maintain a proper bench height.
• Position the truck close enough to the machine for
effective loading, but not too close so that the
machine cannot hit and damage the truck.
• Only a bucket with a complete set of teeth and
cutting edges in good condition ensures efficient
performance.
• Loosen hard material and rocks with the bucket,
not with the stick crowding thrust.
• Avoid digging with corner tooth to avoid torsional
forces into attachments.
• Avoid contacting mechanical stops and cylinders
end of stroke.

• Most productive work is performed with the truck

on a lower level.
• Swing the attachment at a sufficient height over
the loading platform.
• Distribute material evenly on the truck bed.

• Remove sticky material from the bucket.

• Always keep the shovel as close as possible to the Illustration 201 g03722150
work area. Keeping the shovel close minimizes
short stick and boom movements - high efficiency.
• Correct bucket size and properly adjusted
equipment prevents overloading and ensures
maximum operating efficiency of the hydraulic
shovel.
Do not perform the following actions when loading a
truck:
• Do not swing the attachment over unprotected
driver cabs.

• Do not overload the truck.

• When turning into a pit, the swing motion must not
be stopped by the walls of the pit. Doing so can Illustration 202 g06341901
cause structural damage to the attachment. Use
the machine hydraulic system to stop the swing Use the following guidelines when digging and
motion. loading a truck:
128 SEBU9190-12
Operation Section
Operating Technique Information

• Position the stick at an angle to the ground. Rules for Double Benching
• Position the bucket cutting edge at an angle to the
ground. This position allows maximum breakout
force to be exerted throughout the dig cycle.
• Move the stick towards the cab and keep the
bucket parallel to the ground.
• If the stick stops due to the load, raise the boom
and / or perform a curl to adjust the depth of the
cut.
• To apply the greatest force at the cutting edge,
decrease the down pressure as you move the
stick toward the cab.
• Maintain a bucket attitude that ensures a
continuous flow of material into the bucket. Illustration 203 g06339138

• Continue the pass in a horizontal direction so that

material peels into the bucket.

• Curl in the bucket and raise the boom when the

pass has been completed.

• Swing the load from the rear of the truck or from

the side of the truck. Never swing a load over a
truck cab or personnel.

• To dump a load, move the stick outward and open

the bucket in a smooth motion.
• Load trucks evenly. This loading will help to avoid
overloading the rear axle.
• When bucket is empty, swing the upper structure Illustration 204 g06301997
back and begin the next loading cycle.
Material:
Double Benching • Loose, well blasted and easy to dig material is
essential for Double Benching.
Double Benching is an operation method which could
be productive but also be harmful to component life. • Boom down function should be used in float
This method should be used only by well trained and position only to pull down material from the wall.
experienced operators in accordance with the
following rules. • Do not use the “Power boom down” - function.

• Always maintain a proper distance to the highwall

to avoid operating at the limits of the cylinders.

Note: Digging poorly blasted material with great

boulders or too tough material is a great stress for the
steel structure and could result in serious damages.
Bench Height:
• A high bench is split up into two segments, 1/3 of
the bench is below the excavator and 2/3 is above
the excavator.
• The ideal upper bench height is when the bucket
could lay flat on the top of the bench (1).
SEBU9190-12 129
Operation Section
Operating Technique Information

• The ideal lower bench height is equal to the length • Operate the stick-retract function while slowly
of the stick or equal to the truck body side wall raising the boom. When the stick moves past the
edge. vertical position, slowly lower the boom to allow
the bucket to maintain a smooth surface.
Note: Too low lower benches can cause collisions of
the counterweight and the truck body. Park the Machine
Working direction:
• While digging the upper bench, the cab must be
on the opposite side of the high wall, swing
direction is to the truck / cabin side. Dig forward.
• While digging the lower bench, the cab must be on
the opposite side of the high wall, swing direction
is to the truck / cabin side. Dig backwards.
Working method:

• Dig the upper bench first, progressing from right to

left, by digging down material from the face.

• Dig the lower bench on the way back in standard

setup from left to right.
Illustration 206 g06302011

• Dig a trench in front of the machine and along the

high wall (2).
• Leave this trench along the dig face
(approximately 1.5 m (5 ft)) while digging forward.
• If any spillage falls out, the spillage is collected in
the trench and will not damage the excavator.
• The hole in front of the machine also eases bucket
fill.
Grading the Pit Floor
Park the machine in a location that is smooth, stable,
level, and hard. The location should also be dry and
free of debris and not endangered by falling.
Position the attachment using the following
guidelines:
• Half extend the boom cylinders.
• Bring the stick in a vertical position.
• Lower the boom until the bucket is on the ground.

Illustration 205 g06302006

The described grading function can be performed

precisely by simultaneously use of the boom, stick,
and bucket function.
• Position the stick slightly forward of the vertical
position with the bucket in the dumped position.
130 SEBU9190-12
Operation Section
Operating Technique Information

Note: Other positions of the attachment are not Restricted Operation with Backhoe
allowed when parking the machine.
Attachment

Illustration 207 g06335076

Illustration 208 g06335078

Illustration 209 g06335080

SEBU9190-12 131
Operation Section
Operating Technique Information

Avoid extreme positions of the attachment. Parts of

the attachment may damage the machine if they are
moved too close to the machine.

Illustration 211 g06335086

Illustration 210 g06335082

Do not operate the machine when:

• One or several teeth are worn or missing

• Lip shrouds or side shrouds are worn or missing

• Other parts of the bucket are worn or missing
Working under these conditions reduces digging
performance, results in heavy wear, potential
damage, and high repair costs.

Illustration 212 g06335088

Do not operate cylinders to the end of stroke during

operation, excessive force will occur on the inside of
the cylinder.
This will reduce the life of the cylinder and structures.
To avoid this issue, always leave around 10% of the
cylinder stroke unused when the cylinder is operated.
If cylinders must be operated to the end of stroke,
extend or retract speed must be reduced to 10%.
132
Operation Section
Operating Technique Information
Illustration 213 g06335125
Do not use the dropping force of the bucket as a
hammer, breaker, or pile driver. This will bring
excessive force on the machine and possible
damage to the machine could result.
Illustration 214 g06335128
If the stick IN function is operated at high speed to
the end of the cylinder stroke, excessive force will be
applied to the stick cylinder, stick, and boom. To
avoid this problem, always operate a stick In function
with moderate speed and stop motion prior to
reaching the end of cylinder stroke.
SEBU9190-12
Illustration 215 g06335130
Do not use the bucket to lever rocks out. If the back
of the bucket contacts the rock behind, the lever
action will cause excessive force on the attachment.
Use only the force of the stick and bucket to carry out
digging operations. When the force of the stick and
the bucket are used for digging, hydraulic relief
valves protect the attachment from excessive force.
Illustration 216 g06335131
Do not operate the machine in unsuitable material for
digging.
Ensure that material is blasted or has appropriate
penetrability and material fragmentation.
Operating the machine in inappropriate conditions
will reduce durability, productivity, and increase cost
of ownership.
If material conditions cannot improve, the bucket or
working tool may need to be exchanged. Consult
your dealer for machine bucket and/or work tool
options and recommended operational/maintenance
techniques in severe applications.
SEBU9190-12 133
Operation Section
Operating Technique Information

If the tracks rise off the ground while digging, lower

the machine back to the ground smoothly.

Illustration 217 g06335134

Avoid working in materials having higher density than
appropriate for bucket or work tool. If unavoidable,
operate the machine at reduced bucket loads to
avoid overloading, tipping, and reducing machine
durability.
Illustration 220 g06335140
Do not use the dropping force weight of the machine
to pry material in the bank or for excavation.
Doing so may damage the machine and the
attachment.
If the tracks rise off the ground while digging, lower
the machine back to the ground smoothly.

Illustration 218 g06335137

Do not suspend a loaded bucket for more than 5

minutes. Ground the bucket.
Illustration 221 g06335141

Machine stability is greater when the load is

positioned parallel with the tracks and over the front.

Illustration 219 g06335138

Do not overload the attachment and do not allow the

tracks to rise off the ground.
134 SEBU9190-12
Operation Section
Operating Technique Information

Illustration 222 g06335143 Illustration 224 g06335147

Machine stability is reduced when the load is swung Do not propel the machine while the bucket is
to the side and when operating the attachment engaged in the material. This operation will
perpendicular to the tracks potentially damage components of the attachment.
Sudden stopping of the attachment movement can
result in the tipping of the machine, especially when
the attachment is perpendicular to the tracks. Never
overload the attachment.

Illustration 223 g06335145

Do not drag the bucket down or swing the upper Illustration 225 g06335148
structure when digging hard rock if the bucket teeth
will not penetrate the rock. Do not allow the boom to hit the ground when
excavating below grade.
The teeth will slip on the rock surface and cause
excessive vibration of the machine that will damage
the attachment or frame.
SEBU9190-12 135
Operation Section
Operating Technique Information

Illustration 226 g06335152 Illustration 228 g06335158

Do not swing the machine while the bucket is Do not swing a load over a truck cab or over
engaged in the material. personnel.
Do not stop swinging by contacting an object such as
a bank or ditch.
Do not sweep the pit floor.
Do not start swinging until the bucket is completely
removed from the bank.
Do not begin digging before the swing motion is
stopped.

Illustration 229 g06335163

Do not attempt to travel on slopes with the bucket

Illustration 227 g06335154
Do not allow rocks or other material build-up between
the H-link and the gooseneck or between stick and
bucket.
Serious damage of attachment components will
occur while:
• Retracting or extending the curl cylinders with
rocks in the H-link / gooseneck region
• curling the bucket with rocks between stick and
bucket
loaded or any load suspended from the bucket.
Never attempt to ascend or descend steep slopes.
Refer to Operation and Maintenance Manual,
Maximum Operating Grade for additional information.
Keep the bucket pointed in the direction of travel,
approximately 0.5 m (1 ft 7.7 inch) to 1 m
(3 ft 3.4 inch) above the ground.
If the machine starts to skid or becomes unstable,
lower the bucket immediately to the ground. Avoid
swinging the upper carriage on slopes. Never attempt
to swing the upper structure downhill. The machine
may tip over.
If swinging uphill is unavoidable, carefully operate the
upper structure and boom at slow speed. If the
engine stalls on a slope, immediately lower the
bucket to the ground. Return joysticks to neutral.
Then, restart engine. Be sure to thoroughly warm-up
the machine before ascending steep slopes. If the
hydraulic oil has not warmed-up sufficiently,
performance may be effected.
136 SEBU9190-12
Operation Section
Operating Technique Information

Illustration 230 g06334789 Illustration 232 g06335165

Do not exceed the maximum machine inclination for

working operation. Refer to Operation and
Maintenance Manual, Maximum Operating Grade for
additional information.

Illustration 231 g06334791

Always ascend the slope at a 90 degree angle.

Driving across the face of a slope or steering on a
slope may cause the machine to slide or tip over.
If the direction must be changed, move the machine
to level ground, then, change the direction to ensure
safe operation.
Illustration 233 g06335169
Do not use the force of the bucket, the stick, or the
boom to assist in turning the machine while the
machine is traveling.
This technique is referred to as “jump steering.” The
force applied to the swing motors and swing drives by
this method may cause damage to the swing motors
and swing drives. For proper turning procedures refer
to Operation and Maintenance Manual, Operation
Information.
SEBU9190-12 137
Operation Section
Operating Technique Information

Illustration 234 g06335172 Illustration 237 g06335185

Do not contact the ground with the heal of the bucket. When initiating material penetration with the bucket,
Doing so could apply excessive force to the bucket do not contact material at high speeds. High-speed
linkage and bucket cylinder as well as potentially contacts will reduce machine life.
damaging the bucket.

Illustration 238 g06335187

Illustration 235 g06335174
Do not park the machine with the stick cylinder and
Do not operate the machine with the final drives the bucket curl cylinder fully retracted.
facing the attachment. Risk of damaging components
of the gearboxes and sprockets and hydraulics.

Illustration 236 g06335177

Do not operate the machine on uneven, rough

ground. Doing so is extremely detrimental to
undercarriage component life.
138 SEBU9190-12
Operation Section
Operating Technique Information

Illustration 239 g06335192 Illustration 241 g06335243

Do not park the machine with the stick cylinder and
the bucket curl cylinder fully extended, so that
gooseneck and H-link contact the ground.
Traveling
When crossing the sharp edge of a steep bench
upwards or downwards, travel very slowly and let the
machine tip over the edge very carefully. Doing so
prevents the machine from being damaged when
impact on the ground.

Best Practices

Illustration 242 g06304282

When working in any body of water or mud, be

Illustration 240 g06335237
When traveling down from a steep bench, lower the
bucket so that the distance to ground is about 0.5 m
(1.6 ft) to 1 m (3.3 ft). Travel slowly and in the lower
gear mode. In case the machine tends to tip to the
front, lower the attachment to ground and protect the
machine from tipping over.
careful that the level of water or mud is not higher
than the breather valves on top of the final drives.
Water or mud could enter the gearboxes and cause
serious damages.
While you cross any body of water or mud, carefully
confirm the depth of the water or mud with the
bucket. Do not move the machine into an area that
has a water or mud depth that is higher than the
breather valves of the final drives.
SEBU9190-12 139
Operation Section
Operating Technique Information

Restricted Operations The weight of the machine will force the stick
cylinders and the bucket curl cylinders over the relief
valves causing the cylinders to extend into the end
stops. The weight and inertia of the machine pressing
the cylinder can lead to overstressing cylinder clevis
bolts.
Do not travel too steep ramps. Doing so can exceed
the hydraulic capability of the machine. This action
can cause an uncontrolled state and damage to the
machine. Refer to Operation and Maintenance
Manual, Maximum Operating Grade for information
about maximum inclinations.

Illustration 243 g06334780

Do not travel the machine longer than 5 minutes with

the final drives to the front.
This will reduce the durability of the undercarriage
and the travel system components.

Illustration 246 g06334789

Illustration 244 g06334783

Do not travel with a filled bucket.

Illustration 247 g06334791

Always ascend the slope at a 90 degree angle.

Driving across the face of a slope or steering on a
slope may cause the machine to slide or tip over.
If the direction must be changed, move the machine
to level ground, then, change the direction to ensure
safe operation.

Illustration 245 g06334786

If traveling down from a steep bench, do not place

the bucket on the ground to prevent the machine
from slipping or tipping.
140 SEBU9190-12
Operation Section
Operating Technique Information

Illustration 248 g06334794 Illustration 250 g06334798

Do not travel through loose gravel material which Do not travel over large rocks or unblasted material.
could penetrate between rollers and track. This Large rocks can damage components of the
action could result in damaging components of the undercarriage.
under carriage.
Tracks may point load on rocks making the machine
less stable.

Illustration 251 g06334802

Do not use the force of the bucket, the stick, or the

boom to lift and assist in turning the machine while
Illustration 249 g06334796 the machine is traveling.

Do not operate the machine in FAST travel speed This technique is referred to as “jump steering”.
unless in appropriate situations. Doing so creates the risk of high stress and damage
to:

• Swing ring and mounting bolts.

• Bucket or shovel front clam and back wall.
SEBU9190-12
• Undercarriage components.
i05915078
Travel in Water and Mud
SMCS Code: 7000-V6
NOTICE
When working in or around any body of water, around
a stream or river, or in conditions of heavy mud, be
careful that the swing bearing, the swing drive gear,
and the swivel joint do not dip into water, mud, sand,
or gravel. If the swing bearing dips into water, mud,
sand, or gravel, immediately grease the swing bear-
ing until the used grease leaks from the outer circle of
the swing bearing. Failure to carry out this procedure
may cause premature wear in the swing bearing.
Illustration 252 g03722481
Depth of water to the center of the track carrier roller
The following guidelines pertain to travel across
water and travel through mud, sand, or gravel.
The machine can travel across a river only under the
following conditions:
• The bed of the river is flat.
• The flow of the river is slow.
• The machine dips into the water only to the center
of the track carrier roller (dimension A).
NOTICE
Do not allow the fan on the engine to contact the
water while the machine travels through the water.
Do not allow the fan on the engine to contact the
water during a swing while the machine is in the
water. Damage to the fan may occur if the fan con-
tacts the water.
141
Operation Section
Travel in Water and Mud
While you cross the river, carefully confirm the depth
of the water with the bucket. Do not move the
machine into an area that has a water depth that is
greater than Dimension A.
The machine may sink gradually on soft ground.
Therefore, you should frequently check the height of
the undercarriage from ground level and the depth of
water on the ground.
Check the swing gear by looking through the port for
inspection that is on the upper frame. If there is water
in the swing gear, contact your Cat dealer for the
required maintenance on the swing gear.
After you travel through water, carefully clean the
machine in order to remove any salt, sand, or other
foreign matter.
Procedure for Removing the
Machine from Water or Mud
NOTICE
Do not allow the machine to swing from the force of
traveling when you use the bucket , the stick, or the
boom to assist in travel. If the force from traveling
causes the machine to swing, damage may occur to
the swing motor and to the swing drive.
Illustration 253 g00808148
1. You may not be able to move the machine by using
the travel controls only. In this case use both the
travel control levers/pedals and the stick to pull the
machine out of the water or ground.
142 SEBU9190-12
Operation Section
Travel in Water and Mud

Illustration 254 g00808151

2. The machine may slip because of a steep slope.

The procedure in Step 1 may not work. In this
case, first rotate the upper structure by 180°. Then
use both the travel control levers/pedals and the
stick to move the machine up the slope.

Illustration 255 g00808152

3. It may be impossible to travel because the bottom

of the frame comes into contact with the ground or
the undercarriage is clogged with mud or gravel. In
this case, operate the boom and the stick together.
Raise the track and rotate the track forward and
backward in order to remove the mud and the
gravel.
SEBU9190-12
Parking
i05837046
Stopping the Machine
SMCS Code: 7000
Leaving the machine unattended when the engine
is running may result in personal injury or death.
Before leaving the machine operator station, neu-
tralize the travel controls, lower the work tools to
the ground and deactivate all work tools, and
place the lever for the hydraulic lockout control
in the LOCKED position.
Note: There may be regulations that define the
requirements for the operator and/or support
personnel to be present when the engine is running.
Park on a level surface. If the machine must be
parked on a grade, chock the tracks securely.
Note: The swing parking brake is automatically
applied when the machine is stopped. The swing
parking brake is released when the engine is running
and the joystick is activated.
1. Turn the engine speed dial counterclockwise in
order to reduce engine speed.
Illustration 256 g03692136
2. Release the travel pedals in order to stop the
machine.
3. Lower the work tool to the ground. Apply a slight
downward pressure.
4. Move the hydraulic lockout control to the LOCKED
position.
143
Operation Section
Parking
i01871055
Freezing Conditions
SMCS Code: 7000
If freezing temperatures are expected, remove the
mud and the dirt from each track roller frame. Park
the machine on wood planks. Use the following
procedure to clean each track roller frame.
Illustration 257 g00101644
1. Position the boom over one side of the machine.
2. Use boom down pressure in order to lift the track
on one side off the ground. Operate the track in
the forward direction. Then operate the track in
reverse. Continue this procedure until the
maximum amount of material is thrown off the
track.
3. Lower the track onto the wood planks.
4. Repeat the procedure for the other track.
5. Clean the area around the carrier rollers and
around the track rollers.
6. Lower the work tool onto a wood plank in order to
prevent the work tool from touching the ground.
i05837111
Stopping the Engine
SMCS Code: 1000; 7000
NOTICE
Stopping the engine immediately after it has been
working under load can result in overheating and ac-
celerated wear of engine components.
Refer to the following procedure to allow the engine
to cool and to prevent excessive temperatures in the
turbocharger housing, which could cause oil coking
problems.
144
Operation Section
Stopping the Engine
NOTICE
Never turn the battery disconnect switch to the OFF
position while the engine is running. Serious damage
to the electrical system may result.
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.
Illustration 258 g03391658
Engine start switch positions
(1) STOP
(2) OFF
(3) ON
1. Park the machine on level ground in preparation to
stop the engine. See Operation and Maintenance
Manual, “Stopping the Machine” for the
recommended procedure.
2. Operate the engine for 5 minutes at low idle. This
procedure allows the engine to cool gradually.
3. Turn the engine start switch to OFF position (2),
and remove the key. The engine may continue to
run because the delayed engine shutdown feature
is active.
SEBU9190-12
Delayed Engine Shutdown
Delayed engine shutdown (if enabled) allows the
engine to run for a time after the engine start switch is
turned to the OFF position. This feature allows the
engine and other machine system components to
cool gradually. When the engine start switch is
moved to the OFF position after machine operation,
the delayed engine shutdown will automatically
activate. The engine start switch key may be
removed during delayed engine shutdown. At any
time during a delayed engine shutdown, the engine
start switch may be turned to ON position (3).
Delayed engine shutdown enable/disable and
delayed engine shutdown maximum delay time can
be programmed through ET.
Note: There may be regulations that define the
requirements for the operator and/or support
personnel to be present when the engine is running.
Leaving the machine unattended when the engine
is running may result in personal injury or death.
Before leaving the machine operator station, neu-
tralize the travel controls, lower the work tools to
the ground, deactivate all work tools, place the
switch for the implement lockout in the LOCKED
position and ensure the Park Brake is activated.
Note: Leaving the engine unattended while running
may result in property damage in the event of a
malfunction.
Delayed engine shutdown will run for a minimum of
30 seconds and will continue to run until the engine
and system components are cooled. The maximum
run time is 10 minutes,
Immediate Engine Shutdown
To override delayed engine shutdown and stop the
engine, turn the engine start switch to STOP position
(1). Overriding delayed engine shutdown may reduce
engine and system component life. A warning
message and/or audible alarm will be initiated and a
fault code will be logged for improper engine
shutdown.
For more information on the engine start switch, refer
to Operation and Maintenance Manual, “Operator
Controls”.
Stop the Engine if an Electrical
Malfunction Occurs
Turn the engine start switch to the OFF position. If
the engine does not stop, perform the following
procedure.
SEBU9190-12
Illustration 259 g03692161
The fuel shutoff valves are located behind the fuel
tank.
Shut off the fuel supply by turning the fuel shutoff
valves clockwise. The engine will stop after
consuming the fuel in the fuel line. The engine may
continue to run for a few minutes.
Repair the engine before you restart the engine. The
fuel system may need to be primed. See Operation
and Maintenance Manual, “Fuel System - Prime” for
instructions.
i05837221
Leaving the Machine
SMCS Code: 7000
Illustration 260 g00037860
1. Use the steps and the handholds when you
dismount. When you dismount, face the machine
and use both hands.
2. Inspect the engine compartment for debris. Clean
out any debris in order to avoid a fire hazard.
3. Remove all flammable debris from the front bottom
guard through the access doors in order to reduce
a fire hazard. Discard the debris properly.
145
Operation Section
Leaving the Machine
4. Always turn the battery disconnect switch to the
OFF position before leaving the machine.
5. If the machine will not be operated for a month or
more, remove the battery disconnect switch key.
6. Lock all compartments and all vandalism covers (if
equipped).
i07735116
Machine Storage and
Specified Storage Period
SMCS Code: 7000
Machine Storage
The Safety Section of this Operation and
Maintenance Manual contains storage information for
fuels, lubricants, and ether (if equipped).
The Operation Section of this Operation and
Maintenance Manual contains information for short-
term storage of this machine, including engine
shutdown, parking, and instructions for leaving the
machine.
For detailed steps on long-term storage refer to
Special Instruction, SEHS9031, “Storage Procedure
for Caterpillar Products”.
Specified Storage Period
The specified storage period of this machine is 1
year.
After the specified storage period has expired,
consult your Cat dealer for inspect, repair, rebuild,
install remanufactured, or install new components,
and disposal options, and to establish a new
specified storage period.
If a decision is made to remove the machine from
service, refer to Decommissioning and Disposal for
further information.
146 SEBU9190-12
Operation Section
Machine Cleanup

Machine Cleanup
i06154481

Machine Cleanup Procedure

SMCS Code: 7000-070; 7000

Undercarriage Cleanup

Illustration 261 g00101644

Turn the upper structure 90 degrees so that the boom

is positioned over the side of the tracks. If the
machine is moved without turning the upper
structure, damage to the catwalk, ladder or fast fill
areas can occur. Drive the machine backwards, away
from the idlers, initially. Drive the machine 45 m
(150 ft) in reverse and again forward before shutting
the machine down. This movement is meant to
dislodge as much material as possible before the
material can solidify or freeze.
For additional information when freezing conditions
are present, refer to Operation and Maintenance
Manual, “Freezing Conditions” and Operation and
Maintenance Manual, “Frozen Ground Conditions”.
SEBU9190-12 147
Operation Section
Transportation Information

Transportation Information
i01466642

Shipping the Machine

SMCS Code: 7000; 7500

NOTICE
Obey all state and local laws governing the weight,
width and length of a load.
Remove the starting aid (ether) cylinder, if equipped.
Make sure the cooling system has proper antifreeze
if moving machine to a colder climate.
Observe all regulations governing wide loads.
If you must ship the machine, you must disassemble
the machine. Refer to the Special Instruction for your
machine and follow the assembly procedures in
reverse order. Consult your Caterpillar dealer for
disassembly instructions and for shipping instructions
for your machine.
148
Operation Section
Towing Information
Towing Information
i06611754
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
final drive brakes are disengaged. The machine
can roll free if it is not blocked. With final drive
brakes disengaged, the machine cannot be
stopped or steered.
Follow the recommendations below, to properly
perform the towing procedure.
Relieve the hydraulic tank and line pressure be-
fore any disassembly. Operate the travel levers/
pedals back and forth with the engine stopped to
relieve pressure.
Opening any system without first relieving the in-
ternal pressure will cause fluid to squirt out.
Even after the machine has been turned off, the
hydraulic oil can still be hot enough to burn. Al-
low the hydraulic oil to cool before draining.
NOTICE
Before towing the machine, the travel motors must be
removed.
Do not operate the travel motors while the final drives
are disengaged. Damage to the machine can result.
This machine is equipped with hydraulic brakes that
are spring applied. If the engine is inoperable, the
brakes are engaged and the machine cannot be
moved until the two input shafts behind the travel
motors are removed. Refer to “Removing the Input
Shafts Behind the Travel Motors” for information on
removing the shafts behind the travel motors.
These towing instructions are for moving a disabled
machine for a short distance at low speed. Move the
machine at a speed of 1.5 km/h (0.9 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. The
shields will protect the operator if the tow line or the
tow bar breaks.
Do not allow an operator to be on the machine that is
being towed.
SEBU9190-12
Before you tow the machine, make sure that the tow
line or the tow bar is in good condition. Make sure
that the tow line or the tow bar has enough strength
for the towing procedure that is involved. The
strength of the tow line or of the tow bar should be at
least 150 percent of the gross weight of the towing
machine. This requirement is for a disabled machine
that is stuck in the mud and for towing on a grade.
Attach the cable to the tow eyes on the carbody only.
Do not use a chain for pulling a disabled machine. A
chain link can break. A chain link break may cause
personal injury. Use a wire cable with ends that have
loops or rings. Put an observer at an adequate
distance from the machines to watch the pulling
procedure. The observer can stop the procedure if
the wire cable starts to break. 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.
Quick machine movement could overload the tow line
or tow bar. Overloading could cause the tow line or
tow 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.
Sufficient control and sufficient braking must be
provided when you are moving a disabled machine
downhill. Providing sufficient control and braking may
require a larger towing machine or more machines
that are connected to the rear of the disabled
machine. Providing sufficient control and braking will
prevent the machine from rolling away out of control.
All situation requirements cannot be listed. Minimum
towing machine capacity is required on smooth, level
surfaces. On inclines in poor condition or on surfaces
in poor condition, maximum towing machine capacity
is required.
Do not tow a loaded machine.
Consult your Caterpillar dealer for the equipment that
is necessary for towing a disabled machine.
Removing the Input Shafts Behind
the Travel Motors
Refer to the following procedure to remove the shafts
behind the travel motors.
SEBU9190-12 149
Operation Section
Towing 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 machine.
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, “Caterpillar
Tools and Shop Products Guide”, for tools and sup-
plies suitable to collect and contain fluids in Caterpil-
lar machines.
Dispose of all fluids according to local regulations
and mandates.

Illustration 263 g03692219

Personal injury can result from removing hoses

or fittings in a system under pressure.
Failure to relieve pressure can cause personal
injury.
Do not remove or disconnect hoses or fittings un-
til all pressure in the hydraulic system has been
relieved.

2. Disconnect tube (4).

Illustration 262 g03692203
1. Attach a hoist and a suitable lifting sling to guard
assembly (2). Remove five bolts(1) and the
washers. Remove guard assembly (2) from the
machine. The weight of travel motor (4) is
approximately 154 kg (340 lb).
3. Fasten a hoist and a suitable lifting sling to travel
motor (4). Remove four twelve point head bolts
(5). Remove travel motor (3) from the machine.
The weight of travel motor (4) is approximately
90 kg (200 lb).

Illustration 264 g03692221

4. Remove shaft (6) from final drive (7).

5. Use four twelve point head bolts (5) to install travel
motor (3) on the machine.
6. Connect tube (4).
150 SEBU9190-12
Operation Section
Towing the Machine

7. Repeat Step 1 through Step 6 to remove the other

shaft behind the other travel motor.

Installing the Input Shafts Behind

the Travel Motors
Refer to the following procedure to install the input
shafts behind the travel motors.

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the machine.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids. Illustration 266 g03692221

Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide”, for tools and sup-
plies suitable to collect and contain fluids in Caterpil-
lar machines.
Dispose of all fluids according to local regulations
and mandates.
3. Install shaft (6) in final drive (7).
4. Use four twelve point head bolts (5) to install travel
motor (3) on the machine.
5. Connect tube (4).

Illustration 267 g03692203

Illustration 265 g03692219

6. Attach a hoist and a suitable lifting sling to guard
assembly (2). Position guard assembly (2) on the
1. Disconnect tube (4).
track roller frame. Install five bolts(1) and the
2. Fasten a hoist and a suitable lifting sling to travel washers. The weight of guard assembly (2) is
motor (3). Remove four twelve point head bolts approximately 154 kg (340 lb).
(5). Remove travel motor (3) from the machine.
7. Repeat Step 1 through Step 6 to install the other
The weight of travel motor (3) is approximately
shaft behind the other travel motor.
90 kg (200 lb).
SEBU9190-12 151
Operation Section
Engine Starting (Alternate Methods)

Engine Starting (Alternate
Methods)
i05837859
Engine Starting with Auxiliary
Start Receptacle
(If Equipped)
SMCS Code: 1000; 7000
Illustration 268 g03689679
Some Caterpillar products may be equipped with an
auxiliary start receptacle as a standard part. If your
machine is not equipped with an auxiliary start
receptacle, the machine can be equipped with an
auxiliary start receptacle from parts service. This will
ensure that a permanent receptacle is always
available in order to jump-start the machine.
There are two cable assemblies that can be used to
jump-start the stalled machine. You can jump-start
the stalled machine from another machine that is
equipped with an auxiliary start receptacle or with an
auxiliary power pack. Your Caterpillar dealer can
provide the correct cable lengths for your application.
1. Determine the reason that the engine will not start.
5. Move the machine that is being used as a power
source close to the stalled machine. The jump-
start cables should reach the batteries on both
machines. DO NOT ALLOW THE MACHINES TO
CONTACT EACH OTHER.
6. Stop the engine on the machine that is being used
as a power source. If you use an auxiliary power
source, turn off the charging system.
7. Connect the appropriate jump-start cable to the
auxiliary start receptacle on the stalled machine.
8. Connect the other end of the jump-start cable to
the auxiliary start receptacle of the machine that is
being used as a power source.
9. Start the engine on the machine that is being used
as a power source or energize the charging
system on the auxiliary power source.
10. Wait for a minimum of 2 minutes while the
batteries in the stalled machine partially charge.
11. Attempt to start the stalled engine.
12. Immediately after the stalled engine starts,
disconnect the jump-start cable from the power
source.
13. Disconnect the other end of the jump-start cable
from the stalled machine.
14. Conclude the failure analysis on the starting
charging system of the stalled machine, as
required. Check the machine while the engine is
running and the charging system is in operation.

Reference: Refer to Special Instruction, SEHS7633,

“Battery Test Procedure” for more information.
2. Ensure that the travel control levers on the stalled
machine are in the CENTER position. Engage the
hydraulic lockout control. Engage the parking
brake. Lower all work tools to the ground. Move all
controls to HOLD.
3. Turn the engine start switch key on the stalled
machine to the OFF position. Turn off all
accessories.
4. Turn the battery disconnect switch on the stalled
machine to ON.
152 SEBU9190-12
Maintenance Section
Maintenance Access

Maintenance Section

Maintenance Access
i05848086

Access Door and Cover

Locations
SMCS Code: 726A-CH

Illustration 271 g03696283

(6) Front engine compartment access door

Illustration 269 g03696252

(1) Rear engine compartment access door
(2) Right side front engine compartment access door
(3) Right side access door

Illustration 270 g03696250

(4) Automatic lubrication and storage access door
(5) Left side access door
SEBU9190-12 153
Maintenance Section
Lubricant Viscosities and Refill Capacities

Lubricant Viscosities and NOTICE

Not following the recommendations found in this
Refill Capacities manual can lead to reduced performance and com-
partment failure.
i07748229

Lubricant Viscosities Engine Oil

(Fluids Recommendations) Cat oils have been developed and tested to provide
SMCS Code: 7581 the full performance and life that has been designed
and built into Cat engines.
General Information for Lubricants Cat DEO-ULS or oils that meet the Cat ECF-3
specification, API CJ-4, and the newer API CK-4, are
When you are operating the machine in temperatures required for use in the applications listed below. Cat
below −20°C (−4°F), refer to Special Publication, DEO-ULS and oils meeting Cat ECF-3 specification,
SEBU5898, “Cold-Weather Recommendations”. This API CJ-4, the newer API CK-4, and ACEA E9 oil
publication is available from your Cat dealer. categories have been developed with limited sulfated
ash, phosphorus, and sulfur. These chemical limits
For cold-weather applications where transmission oil are designed to maintain the expected aftertreatment
SAE 0W-20 is recommended, Cat TDTO Cold devices life, performance, and service interval. If oils
Weather is recommended. meeting the Cat ECF-3 specification, API CJ-4, the
newer API CK-4 specifications are not available, oils
Refer to the “Lubricant Information” section in the meeting ACEA E9 may be used. ACEA E9 oils meet
latest revision of the Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” for a the chemical limits designed to maintain
list of Cat engine oils and for detailed information. aftertreatment device life. ACEA E9 oils are validated
using some but not all ECF-3 and API CJ-4 standard
This manual may be found on the Web at Safety.Cat. engine performance tests. Consult your oil supplier
com.
when considering use of an oil that is not Cat ECF-3,
The footnotes are a key part of the tables. Read ALL API CJ-4, or the newer API CK-4 qualified.
footnotes that pertain to the machine compartment in
question. Failure to meet the listed requirements will damage
aftertreatment-equipped engines and can negatively
impact the performance of the aftertreatment
Selecting the Viscosity devices.
To select the proper oil for each machine Oils that are per API CI-4 or prior categories are not
compartment, refer to the "Lubricant Viscosity for allowed. These oils have high ash and are not
Ambient Temperature" table. Use the oil type AND oil appropriate for use in engines with aftertreatment
viscosity for the specific compartment at the proper devices.
ambient temperature.
The proper lubricant viscosity grade is determined by
the minimum outside temperature when the machine
is started. The proper lubricant viscosity grade is also
determined by the maximum outside temperature
while the machine is operated. Use the column on
the table that is designated “Min” to determine the
lubricant viscosity grade that is required when you
start a cold machine and when you operate a cold
machine. Use the column on the table that is
designated “Max” to select the lubricant viscosity
grade when you operate the machine at the highest
temperature that is anticipated. When you start the
machine, use the oil with the highest lubricant
viscosity that is allowed for the temperature.
Machines that are continuously operated should use
the oils with a higher viscosity in the final drives and
differentials to 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.
154 SEBU9190-12
Maintenance Section
Fluids Recommendations

Table 13
Cat Diesel Engines Lubricant Viscosities for Ambient Temperatures(1)(2)

Oil Type and Performance °C °F

Compartment or System Oil Viscosities
Requirements Min Max Min Max
Cat DEO Cold Weather (API CK-4) SAE 0W-40 −40 40 −40 104

Engine Crankcase for all Direct In- Cat DEO-ULS SYN (API CK-4) SAE 5W-40 −30 50 −22 122
jection (DI) Engines
Cat DEO-ULS (API CK-4) SAE 10W-30 −18 40 0 104
Cat DEO (API CI-4/CI-4 PLUS) SAE 15W-40 −10 50 14 122
(1) Refer to Special Publication, SEBU6250, “Engine Oil” for information on the recommended and required engine oils for Tier 4 emissions certi-
fied engines.
(2) Commercial oils of viscosity grades that are not included in this table may be used if the oils are per Cat ECF specifications. Refer to Special
Publication, SEBU6250, “Engine Oil” for more information. Commercial oils are second choice.

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 hydraulic system oils:
• Cat HYDO Advanced 10 SAE 10W

• Cat HYDO Advanced 20 SAE 20W

• Cat HYDO Advanced 30 SAE 30
Cat HYDO Advanced fluids have a 50% increase
in the standard oil drain interval for machine
hydraulic systems over second and third choice oils
when you follow the maintenance interval schedule
for oil filter changes and for oil sampling that is stated
in the Operation and Maintenance Manual for your
particular machine. 10000-hour oil drain intervals are
possible when using S·O·S Services oil analysis.
Consult your Cat dealer for details. When switching
to Cat HYDO Advanced fluids, cross contamination
with the previous oil should be kept to less than 10%.
Note: Verify compatibility with the current oil in the
machine before switching oil brands. Consult your
Cat dealer for additional information.
Table 14
Lubricant Viscosities for Ambient Temperatures

Oil Type and Performance °C °F

Compartment or System Oil Viscosities
Requirements Min Max Min Max
SAE 10W −15 45 5 113
Hydraulic System Cat HYDO Advanced SAE 20W −7 55 19 131
SAE 30 5 55 41 131
SEBU9190-12 155
Maintenance Section
Fluids Recommendations

Other Applications
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.
Cat HYDO Advanced fluids are the preferred oils for
use in Cat machines hydraulic systems.
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 15
Hydraulic Shovels Fluid Recommendations for Ambient Temperatures

Oil Type and Performance °C °F

Compartment or System Oil Viscosities
Requirements Min Max Min Max
Final Drive and Swing Gearbox Cat Compactor Oil Synthetic, ISO 220 -35 50 -31 122

Idlers, Track Rollers, and Support API CF

Cat DEO
Rollers(1) SAE 40

Cat TDTO SAE 10W(2) 0 50 32 122

Powered Stairway Cat TDTO Cold-Weather SAE 0W-20 0 50 32 122
MIL-H-5606A MIL-H-5606A -40 40 -40 104
(1) Components are pre-lubricated at the factory with a lifetime lubricant. For inquiries on recommended fluid in the event of a component re-
build, consult your local Cat dealer.
(2) Factory fill oil for standard configuration machines.

Grease Applications
To use a non-Cat grease, the supplier must certify
that the lubricant is compatible with Cat grease, and
contains 5% Molybdenum disulfide (MoS2 or “Moly”).
Each pin joint 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 and
slew ring.
Table 16
Recommended Grease
°C °F
Compartment or System Grease Type NLGI Grade
Min Max Min Max

Cat Extreme Application NLGI Grade 2 −15 140 5 284

Central Lubrication System (Bear- Grease NLGI Grade 1 −20 140 −4 284
ings, Slew Rings, Track System)
External Lubrication Points Cat Extreme Application
NLGI Grade 0.5 −50 130 −58 266
Grease - Arctic
Electric Drive Motor Bearings Cat Utility Grease NLGI 2 -30 40 -22 104

The grease used with the automatic lubrication Note: Pumpability is based on “US Steel Mobility and
system must not contain any graphite or PTFE. Lincoln Ventmeter Tests”. Performance may vary
depending on lubrication equipment and the length of
the lines.
156
Maintenance Section
Fluids Recommendations
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.
Diesel Fuel Recommendations
Illustration 272 g02157153
NACD Film
Illustration 273 g02052934
EAME Film
Diesel fuel must meet “Cat Specification for Distillate
Fuel” and the latest versions of “ASTM D975” or “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.
SEBU9190-12
NOTICE
Ultra Low Sulfur Diesel (ULSD) fuel 0.0015 percent
(≤15 ppm (mg/kg)) sulfur is required by regulation for
use in engines certified to nonroad Tier 4 standards
(U.S. EPA Tier 4 certified) and that are equipped with
exhaust aftertreatment systems.
European ULSD 0.0010 percent (≤10ppm (mg/kg))
sulfur fuel is required by regulation for use in engines
certified to European Stage V type-approved nonroad
engines. Additionally, the Cetane number should not
be less than 45, and the biodiesel content should not
be greater than 20% volume/volume.
Misfueling with fuels of higher sulfur level will
invalidate the warranty and have the following
negative effects:
• Shorten the time interval between
aftertreatment device service intervals (cause
the need for more frequent service intervals)
• Adversely impact the performance and life of
aftertreatment devices (cause loss of
performance)
• 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 from the use of improper fuels
are not Cat factory defects. Therefore the cost of
repairs would not be covered by a Cat warranty.
Caterpillar does not require the use of ULSD in off
road and machine applications that are not Tier 4/
Stage IIIB certified engines. ULSD is not required in
engines that are not equipped with after treatment
devices. For Tier 4/Stage IIIB/Stage IV certified
engines always follow operating instructions. Fuel
tank inlet labels are installed in order to ensure that
the correct fuels are used.
SEBU9190-12 157
Maintenance Section
Fluids Recommendations

Refer to Special Publication, SEBU6250, “Caterpillar Preferred – Cat ELC (Extended Life Coolant)
Machine Fluids Recommendations” for more details
about fuels, lubricants, and Tier 4 requirements. This Acceptable – Cat DEAC (Diesel Engine Antifreeze/
manual may be found on the Web at Safety.Cat.com. Coolant)

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
D7467”includes up to B20 (20 percent) biodiesel. Any
diesel fuel in the U.S. may contain up to B20
biodiesel fuel. European distillate diesel fuel
specification “EN16709:2015”includes up to B20 (20
percent) biodiesel. Any diesel fuel in Europe may
contain up to B20.

Note: The diesel portion used in the biodiesel blend

must be Ultra Low Sulfur Diesel (15 ppm sulfur or
less, per “ASTM D975”). In Europe the diesel fuel
portion used in the biodiesel blend must be sulfur free
diesel (10 ppm sulfur or less, per “EN 590”). The final
blend must have 15 ppm sulfur or less.
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.
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:
158 SEBU9190-12
Maintenance Section
Capacities (Refill)

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.

i07680915

Capacities (Refill)
SMCS Code: 1000; 7000

Table 17
Approximate Capacities (Refill)

Component or System Liters US gal Recommended Type

Cooling System(1) 165 43.6

Engine Crankcase with Filter 80 23.0

Each Final Drive 20 5.3

Refer to Operation and Maintenance Manual,
Fuel Tank 1703 450
“Lubricant Viscosities”.
Hydraulic Tank 956 252.5

Both Swing Drives and Reservoir 38 10

Powered Stairway 1.7 0.45

Swing Gear 274 72 NLGI Grade 2

kg lbs

Refrigerant(2) 2.2 4.85 R-134a

mL oz

Refrigerant Oil(2) 165 5.58 Polyalkylene Glycol (PAG) Oil

(1) Combine 67.8 L (17.9 US gal) of Caterpillar ELC concentrate with 45.2 L (11.9 US gal) of water in order to make the 113 L (29.8 US gal) sol-
ution for the cooling system.
(2) Refer to Service Manual, “Air Conditioning and Heating R-134a for All Caterpillar Machines” for additional information

i07445339 Refer to the Operation and Maintenance Manual,

“Maintenance Interval Schedule” for a specific
S·O·S Information sampling location and a service hour maintenance
interval.
SMCS Code: 1000; 1348; 3080; 4050; 5050; 7000;
7542-008 Consult your Cat dealer for complete information and
assistance in establishing an S·O·S program for your
S·O·S Services is a highly recommended process for equipment.
Cat customers to use in order to minimize owning
and operating cost. Customers provide oil samples,
coolant samples, and other machine information. The
dealer uses the data in order to provide the customer
with recommendations for management of the
equipment. In addition, S·O·S Services can help
determine the cause of an existing product problem.
Refer to Special Publication, SEBU6250, “Caterpillar
Machine Fluid Recommendations” for detailed
information concerning S·O·S Services.
The effectiveness of S·O·S Services is dependent on
timely submission of the sample to the laboratory at
recommended intervals.
SEBU9190-12
Maintenance Support
i05839959
System Pressure Release
SMCS Code: 1250-553-PX; 1300-553-PX; 1350-
553-PX; 5050-553-PX; 6700-553-PX; 7540-553-PX
Personal injury or death can result from sudden
machine movement.
Sudden movement of the machine can cause in-
jury to persons on or near the machine.
To prevent injury or death, make sure that the
area around the machine is clear of personnel
and obstructions before operating the machine.
Coolant System
Pressurized system: Hot coolant can cause seri-
ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve
the pressure.
To relieve the pressure from the coolant system, turn
off the machine. Allow the cooling system pressure
cap to cool. Remove the cooling system pressure
cap slowly in order to relieve pressure.
Hydraulic System
Personal injury can result from hydraulic oil pres-
sure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Seri-
ous injury can be caused if this pressure is not
released before any service is done on the hy-
draulic system.
Make sure all of the attachments have been low-
ered, oil is cool before removing any components
or lines. Remove the oil filler cap only when the
engine is stopped, and the filler cap is cool
enough to touch with your bare hand.
1. Shut off the engine.
2. Slowly loosen the filler cap in order to release the
pressure in the hydraulic tank.
3. Tighten the filler cap.
159
Maintenance Section
Maintenance Support
4. The pressure in the hydraulic system has been
released. Lines and components can be removed.
i07746333
Welding on Machines and
Engines with Electronic
Controls
SMCS Code: 1000; 7000
Do not weld on any protective structure. If it is
necessary to repair a protective structure, contact
your Cat dealer.
Proper welding procedures are necessary to avoid
damage to the electronic controls and to the
bearings. When possible, remove the component
that must be welded from the machine or the engine
and then weld the component. If you must weld near
an electronic control on the machine or the engine,
temporarily remove the electronic control to prevent
heat related damage. The following steps should be
followed to weld on a machine or an engine with
electronic controls.
1. Turn off the engine. Place the engine start switch
in the OFF position.
2. If equipped, turn the battery disconnect switch to
the OFF position. If there is no battery disconnect
switch, remove the negative battery cable at the
battery.
NOTICE
Do NOT use electrical components (ECM or sensors)
or electronic component grounding points for ground-
ing the welder.
3. Clamp the ground cable from the welder to the
component that will be welded. Place the clamp as
close as possible to the weld. Make sure that the
electrical path from the ground cable to the
component does not go through any bearing. Use
this procedure to reduce the possibility of damage
to the following components:
• Bearings of the drive train
• Hydraulic components
• Electrical components
• Other components of the machine
4. Protect any wiring harnesses and components
from the debris and the spatter which is created
from welding.
5. Use standard welding procedures to weld the
materials together.
160 SEBU9190-12
Maintenance Section
Maintenance Interval Schedule

i07832100 “ Circuit Breakers - Reset” . . . . . . . . . . . . . . . . . . . 179

“ Engine Air Filter Primary Element - Replace” . . 185
Maintenance Interval Schedule
SMCS Code: 7000 “ Engine Air Filter Secondary Element -
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
S/N: FKD1–Up
“ Engine Air Precleaner - Clean” . . . . . . . . . . . . . . 187
S/N: HLD1–Up
“ Ether Starting Aid Cylinder - Replace” . . . . . . . . 196
S/N: HSE1–Up
“ Film (Product Identification) - Clean” . . . . . . . . . 197
S/N: PZE1–Up
“ Fuel System - Prime” . . . . . . . . . . . . . . . . . . . . . . 199
S/N: HSF1–Up
“ Fuses - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 205
S/N: WSN1–Up
“ Hydraulic System Oil Cooler Core - Clean” . . . . 210
S/N: ZEN1–Up
S/N: PWW1–Up “ Oil Filter - Inspect” . . . . . . . . . . . . . . . . . . . . . . . . 216

Ensure that all safety information, warnings, and “ Radiator Core - Clean” . . . . . . . . . . . . . . . . . . . . 217
instructions are read and understood before any
operation or any maintenance procedures are “ Window - Check” . . . . . . . . . . . . . . . . . . . . . . . . . 225
performed. “ Window Washer Reservoir - Fill” . . . . . . . . . . . . 225
The user is responsible for the performance of “ Window Wiper - Inspect/Replace” . . . . . . . . . . . 225
maintenance. All adjustments, the use of proper
lubricants, fluids, filters, and the replacement of “ Windows - Clean”. . . . . . . . . . . . . . . . . . . . . . . . . 225
components due to normal wear and aging are
included. Failure to adhere to proper maintenance
intervals and procedures may result in diminished
Every 10 Service Hours or Daily
performance of the product and/or accelerated wear
of components. “ Bucket Linkage - Lubricate” . . . . . . . . . . . . . . . . 174

Use mileage, fuel consumption, service hours, or
calendar time, WHICH EVER OCCURS FIRST, to
determine the maintenance intervals. Products that
operate in severe operating conditions may require
more frequent maintenance. Refer to the
maintenance procedure for any other exceptions that
may change the maintenance intervals.
Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be
performed.
Use the service hour meter for the machine or
machine system to determine when maintenance
should be performed.
When Required
“ Air Conditioner/Cab Heater Filter (Recirculation) -
Inspect/Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . 167
“ Cooling System Coolant Level - Check”. . . . . . . 183
“ Engine Oil Level - Check” . . . . . . . . . . . . . . . . . . 191
“ Fuel System Primary Filter (Water Separator) -
Check/Drain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
“ Fuel Tank Water and Sediment - Drain” . . . . . . . 205
“ Hydraulic System Oil Level - Check ” . . . . . . . . . 214
“ Indicators and Gauges - Test” . . . . . . . . . . . . . . . 215
“ Seat Belt - Inspect” . . . . . . . . . . . . . . . . . . . . . . . 217
“ Swing Drive Oil Level - Check” . . . . . . . . . . . . . . 221
“ Track Adjustment - Inspect” . . . . . . . . . . . . . . . . 224
“ Travel Alarm - Test” . . . . . . . . . . . . . . . . . . . . . . . 224
“ Undercarriage - Check” . . . . . . . . . . . . . . . . . . . . 225

“ Automatic Lubrication System Grease - Add” . . 168
“ Battery - Recycle” . . . . . . . . . . . . . . . . . . . . . . . . 169
“ Bucket Linkage - Inspect/Adjust” . . . . . . . . . . . . 171
“ Bucket Tips - Inspect/Replace” . . . . . . . . . . . . . . 174
“ Cab Air Filter (Fresh Air) - Clean/Replace” . . . . 178
Initial 250 Service Hours
“ Engine Oil and Filter - Change”. . . . . . . . . . . . . . 192
“ Final Drive Oil - Change” . . . . . . . . . . . . . . . . . . . 198
“ Hydraulic System High Pressure Screen - Check/
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

“ Camera - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . 178

SEBU9190-12
“ Hydraulic System Oil Filter (Charge Pump) -
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
“ Hydraulic System Oil Filter (Pilot) - Replace”. . . 212
“ Hydraulic System Oil Filter (Return) -
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
“ Swing Drive Oil - Change”. . . . . . . . . . . . . . . . . . 220
Every 250 Service Hours
“ Final Drive Oil Sample - Obtain” . . . . . . . . . . . . . 199
“ Swing Drive Oil Sample - Obtain” . . . . . . . . . . . . 221
Every 250 Service Hours or
Monthly
“ Engine Oil Sample - Obtain” . . . . . . . . . . . . . . . . 191
“ Final Drive Oil Level - Check” . . . . . . . . . . . . . . . 198
Initial 500 Service Hours
“ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . 195
“ Engine Valve Rotators - Inspect” . . . . . . . . . . . . 195
“ Swing Bearing Bolts - Check” . . . . . . . . . . . . . . . 220
Initial 500 Hours (for New Systems,
Refilled Systems, and Converted
Systems)
“Cooling System Coolant Sample (Level 2) -
Obtain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Every 500 Service Hours
“ Accumulator - Check” . . . . . . . . . . . . . . . . . . . . . 166
“ Hydraulic System Oil Filter (Charge Pump) -
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
“ Hydraulic System Oil Filter (Pilot) - Replace”. . . 212
“ Hydraulic System Oil Sample - Obtain” . . . . . . . 215
Every 500 Service Hours or 3
Months
“ Belt - Inspect/Replace” . . . . . . . . . . . . . . . . . . . . 169
“Cooling System Coolant Sample (Level 1) -
Obtain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
“ Engine Oil and Filter - Change”. . . . . . . . . . . . . . 192
“ Fuel System Primary Filter (Water Separator)
Element - Replace” . . . . . . . . . . . . . . . . . . . . . . . . 201
161
Maintenance Section
Maintenance Interval Schedule
“ Fuel System Secondary Filter - Replace”. . . . . . 203
“ Fuel Tank Strainer - Clean” . . . . . . . . . . . . . . . . . 204
“ Hydraulic System High Pressure Screen - Check/
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
“ Strainer (Hydraulic Tank) - Clean” . . . . . . . . . . . 219
Every 1000 Service Hours
“ Hydraulic System Oil Filter (Return) -
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Every 1000 Service Hours or 6
Months
“ Battery - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . 169
“ Battery Hold-Down - Tighten” . . . . . . . . . . . . . . . 169
“ Bearing (Swing Drive) - Lubricate” . . . . . . . . . . . 169
“ Fuel Tank Cap Filter - Replace” . . . . . . . . . . . . . 204
“ Swing Drive Oil - Change”. . . . . . . . . . . . . . . . . . 220
“ Powered Stairway - Lubricate” . . . . . . . . . . . . . . 216
Every 2000 Service Hours or 1 Year
“ Final Drive Oil - Change” . . . . . . . . . . . . . . . . . . . 198
“ Receiver Dryer (Refrigerant) - Replace”. . . . . . . 217
“ Swing Gear Grease - Check” . . . . . . . . . . . . . . . 222
Every 1500 Service Hours
“ Machine Structure - Inspect” . . . . . . . . . . . . . . . . 216
Every 2500 Service Hours or 6
Months
“ Swing Bearing Bolts - Check” . . . . . . . . . . . . . . . 220
Every Year
“Cooling System Coolant Sample (Level 2) -
Obtain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Every 3000 Service Hours or 2
Years
“ Engine Mounts - Inspect” . . . . . . . . . . . . . . . . . . 190
“ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . 195
162 SEBU9190-12
Maintenance Section
Maintenance Interval Schedule

“ Engine Valve Rotators - Inspect” . . . . . . . . . . . . 195

Every 3 Years
“ Seat Belt - Replace”. . . . . . . . . . . . . . . . . . . . . . . 218

Every 5000 Service Hours

“ Hydraulic System High Pressure Screen - Check/
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
“ Hydraulic System Oil - Change” . . . . . . . . . . . . . 208

Every 6000 Service Hours or 3

Years
“ Cooling System Coolant Extender (ELC) -
Add” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
“ Cooling System Water Temperature Regulator -
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Every 6000 Service Hours or 4

Years
“ Engine Water Pump - Inspect” . . . . . . . . . . . . . . 195

Every 10 000 Service Hours or 6

Years
“ Swing Gear Grease - Replace”. . . . . . . . . . . . . . 223

Every 12 000 Service Hours or 6

Years
“ Cooling System Coolant (ELC) - Change” . . . . . 180

Every 850 000 L (225 000 US Gal) of

Fuel
“ Engine Components - Clean/Inspect, Rebuild/Install
Reman, Install New”. . . . . . . . . . . . . . . . . . . . . . . . 187

Every 1 703 435 L (450 000 US gal)

of Fuel
“ Engine Components - Clean/Inspect, Rebuild/Install
Reman, Install New”. . . . . . . . . . . . . . . . . . . . . . . . 189
SEBU9190-12 163
Maintenance Section
Maintenance Interval Schedule

i07832119 “ Engine Air Filter Primary Element - Replace” . . 185

Maintenance Interval Schedule “ Engine Air Filter Secondary Element -

Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
SMCS Code: 7000
“ Engine Air Precleaner - Clean” . . . . . . . . . . . . . . 187
S/N: MKE1–Up
“ Ether Starting Aid Cylinder - Replace” . . . . . . . . 196
S/N: LWN1–Up
“ Film (Product Identification) - Clean” . . . . . . . . . 197
S/N: LWS1–Up
“ Fuel System - Prime” . . . . . . . . . . . . . . . . . . . . . . 199
Ensure that all safety information, warnings, and
instructions are read and understood before any “ Fuses - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 205
operation or any maintenance procedures are
performed. “ Hydraulic System Oil Cooler Core - Clean” . . . . 210
The user is responsible for the performance of “ Oil Filter - Inspect” . . . . . . . . . . . . . . . . . . . . . . . . 216
maintenance. All adjustments, the use of proper
lubricants, fluids, filters, and the replacement of “ Radiator Core - Clean” . . . . . . . . . . . . . . . . . . . . 217
components due to normal wear and aging are
included. Failure to adhere to proper maintenance “ Window - Check” . . . . . . . . . . . . . . . . . . . . . . . . . 225
intervals and procedures may result in diminished “ Window Washer Reservoir - Fill” . . . . . . . . . . . . 225
performance of the product and/or accelerated wear
of components. “ Window Wiper - Inspect/Replace” . . . . . . . . . . . 225
Use mileage, fuel consumption, service hours, or “ Windows - Clean”. . . . . . . . . . . . . . . . . . . . . . . . . 225
calendar time, WHICH EVER OCCURS FIRST, to
determine the maintenance intervals. Products that
operate in severe operating conditions may require Every 10 Service Hours or Daily
more frequent maintenance. Refer to the
maintenance procedure for any other exceptions that “ Bucket Linkage - Lubricate” . . . . . . . . . . . . . . . . 174
may change the maintenance intervals.
“ Cooling System Coolant Level - Check”. . . . . . . 183
Note: The aftertreatment system can be expected to
function properly for the useful life of the engine “ Engine Oil Level - Check” . . . . . . . . . . . . . . . . . . 191
(emissions durability period), as defined by
regulation. All prescribed maintenance requirements “ Fuel System Primary Filter (Water Separator) -
Check/Drain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
must be followed.
“ Fuel Tank Water and Sediment - Drain” . . . . . . . 205
Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be “ Hydraulic System Oil Level - Check ” . . . . . . . . . 214
performed.
“ Indicators and Gauges - Test” . . . . . . . . . . . . . . . 215
Use the service hour meter for the machine or
machine system to determine when maintenance “ Seat Belt - Inspect” . . . . . . . . . . . . . . . . . . . . . . . 217
should be performed.
“ Swing Drive Oil Level - Check” . . . . . . . . . . . . . . 221
When Required “ Track Adjustment - Inspect” . . . . . . . . . . . . . . . . 224
“ Air Conditioner/Cab Heater Filter (Recirculation) - “ Travel Alarm - Test” . . . . . . . . . . . . . . . . . . . . . . . 224
Inspect/Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . 167
“ Undercarriage - Check” . . . . . . . . . . . . . . . . . . . . 225
“ Automatic Lubrication System Grease - Add” . . 168
“ Battery - Recycle” . . . . . . . . . . . . . . . . . . . . . . . . 169
Initial 250 Service Hours
“ Engine Oil and Filter - Change”. . . . . . . . . . . . . . 192
“ Bucket Linkage - Inspect/Adjust” . . . . . . . . . . . . 171
“ Final Drive Oil - Change” . . . . . . . . . . . . . . . . . . . 198
“ Bucket Tips - Inspect/Replace” . . . . . . . . . . . . . . 174
“ Hydraulic System High Pressure Screen - Check/
“ Cab Air Filter (Fresh Air) - Clean/Replace” . . . . 178 Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
“ Camera - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . 178 “ Hydraulic System Oil Filter (Charge Pump) -
“ Circuit Breakers - Reset” . . . . . . . . . . . . . . . . . . . 179 Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
164 SEBU9190-12
Maintenance Section
Maintenance Interval Schedule

“ Hydraulic System Oil Filter (Pilot) - Replace”. . . 212
“ Hydraulic System Oil Filter (Return) -
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
“ Swing Drive Oil - Change”. . . . . . . . . . . . . . . . . . 220
Every 250 Service Hours
“ Final Drive Oil Sample - Obtain” . . . . . . . . . . . . . 199
“ Swing Drive Oil Sample - Obtain” . . . . . . . . . . . . 221
Every 250 Service Hours or
Monthly
“ Engine Oil Sample - Obtain” . . . . . . . . . . . . . . . . 191
“ Final Drive Oil Level - Check” . . . . . . . . . . . . . . . 198
Initial 500 Service Hours
“ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . 195
“ Engine Valve Rotators - Inspect” . . . . . . . . . . . . 195
“ Swing Bearing Bolts - Check” . . . . . . . . . . . . . . . 220
Initial 500 Hours (for New Systems,
Refilled Systems, and Converted
Systems)
“Cooling System Coolant Sample (Level 2) -
Obtain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Every 500 Service Hours
“ Hydraulic System High Pressure Screen - Check/
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
“ Strainer (Hydraulic Tank) - Clean” . . . . . . . . . . . 219
Every 1000 Service Hours
“ Hydraulic System Oil Filter (Return) -
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Every 1000 Service Hours or 6
Months
“ Battery - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . 169
“ Battery Hold-Down - Tighten” . . . . . . . . . . . . . . . 169
“ Bearing (Swing Drive) - Lubricate” . . . . . . . . . . . 169
“ Fuel Tank Cap Filter - Replace” . . . . . . . . . . . . . 204
“ Powered Stairway - Lubricate” . . . . . . . . . . . . . . 216
“ Swing Drive Oil - Change”. . . . . . . . . . . . . . . . . . 220
Every 1500 Service Hours
“ Engine Crankcase Breather - Clean” . . . . . . . . . 190
“ Machine Structure - Inspect” . . . . . . . . . . . . . . . . 216
Every 2000 Service Hours or 1 Year
“ Final Drive Oil - Change” . . . . . . . . . . . . . . . . . . . 198
“ Receiver Dryer (Refrigerant) - Replace”. . . . . . . 217
“ Swing Gear Grease - Check” . . . . . . . . . . . . . . . 222

“ Accumulator - Check” . . . . . . . . . . . . . . . . . . . . . 166 Every 2500 Service Hours or 6

“ Hydraulic System Oil Filter (Charge Pump) - Months
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
“ Swing Bearing Bolts - Check” . . . . . . . . . . . . . . . 220
“ Hydraulic System Oil Filter (Pilot) - Replace”. . . 212
“ Hydraulic System Oil Sample - Obtain” . . . . . . . 215 Every Year
Every 500 Service Hours or 3 “Cooling System Coolant Sample (Level 2) -
Obtain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Months
“ Belt - Inspect/Replace” . . . . . . . . . . . . . . . . . . . . 169
Every 3000 Service Hours or 2
Years
“Cooling System Coolant Sample (Level 1) -
Obtain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 “ Engine Mounts - Inspect” . . . . . . . . . . . . . . . . . . 190
“ Engine Oil and Filter - Change”. . . . . . . . . . . . . . 192 “ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . 195
“ Fuel System Primary Filter (Water Separator)
Element - Replace” . . . . . . . . . . . . . . . . . . . . . . . . 201
“ Fuel System Secondary Filter - Replace”. . . . . . 203
“ Fuel Tank Strainer - Clean” . . . . . . . . . . . . . . . . . 204
SEBU9190-12 165
Maintenance Section
Maintenance Interval Schedule

“ Engine Valve Rotators - Inspect” . . . . . . . . . . . . 195

Every 3 Years
“ Seat Belt - Replace”. . . . . . . . . . . . . . . . . . . . . . . 218

Every 5000 Service Hours

“ Hydraulic System High Pressure Screen - Check/
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
“ Hydraulic System Oil - Change” . . . . . . . . . . . . . 208

Every 6000 Service Hours or 3

Years
“ Cooling System Coolant Extender (ELC) -
Add” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
“ Cooling System Water Temperature Regulator -
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Every 6000 Service Hours or 4

Years
“ Engine Water Pump - Inspect” . . . . . . . . . . . . . . 195

Every 10 000 Service Hours or 6

Years
“ Swing Gear Grease - Replace”. . . . . . . . . . . . . . 223

Every 12 000 Service Hours or 6

Years
“ Cooling System Coolant (ELC) - Change” . . . . . 180

Every 850 000 L (225 000 US Gal) of

Fuel
“ Engine Components - Clean/Inspect, Rebuild/Install
Reman, Install New”. . . . . . . . . . . . . . . . . . . . . . . . 188

Every 1 703 435 L (450 000 US gal)

of Fuel
“ Engine Components - Clean/Inspect, Rebuild/Install
Reman, Install New”. . . . . . . . . . . . . . . . . . . . . . . . 189
166 SEBU9190-12
Maintenance Section
Accumulator - Check

i06555800 Visually inspect pilot accumulators for leaks. Make

any necessary repairs. If the accumulator requires
Accumulator - Check any service work, refer to Testing and Adjusting,
“Accumulator (Pilot) - Test and Charge”.
SMCS Code: 5077-PLT; 5077
Track Tension Accumulators

Pressurized System!
Hydraulic accumulators contain gas and oil
under high pressure. DO NOT disconnect lines or
disassemble any component of a pressurized ac-
cumulator. All gas pre-charge must be removed
from the accumulator as instructed by the service
manual before servicing or disposing of the accu-
mulator or any accumulator component.
Failure to follow the instructions and warnings
could result in personal injury or death.
Only use dry nitrogen gas to recharge accumula-
tors. See your Cat dealer for special equipment
and detailed information for accumulator service Illustration 275 g03830962
and charging.
There is one accumulator in each track roller frame.
Remove the access panels to inspect the
Pilot Accumulator accumulators.

Illustration 274 g03830942

The pilot accumulator is on the side of the fuel tank.

SEBU9190-12 167
Maintenance Section
Air Conditioner/Cab Heater Filter (Recirculation) - Inspect/Replace

Visually inspect pilot accumulators for leaks. Make

any necessary repairs.

HOC Accumulator

Illustration 276 g03830964

The track tension accumulator can be inspected

through the access panel in the track roller frame.
Visually inspect the track tension accumulators for
leaks. Make any necessary repairs. If the
accumulator requires any service work, Refer to Illustration 278 g06022097
Testing and Adjusting, “Accumulator (Track Tension)
- Test and Charge”. The HOC accumulator is on the hydraulic tank.
Visually inspect pilot accumulators for leaks. Make
Swing Charge Accumulator any necessary repairs.

i07574123

Air Conditioner/Cab Heater

Filter (Recirculation) - Inspect/
Replace
SMCS Code: 1054-510-A/C; 1054-040-A/C

NOTICE
An air recirculation filter element plugged with dust
will result in decreased performance and service life
to the air conditioner or cab heater.
To prevent decreased performance, clean the filter el-
Illustration 277 g06022096 ement, as required.

The swing charge accumulator is in the pump

compartment.
168 SEBU9190-12
Maintenance Section
Automatic Lubrication System Grease - Add

The lines and the pipes in the automatic lubrica-

tion system are under extremely high pressure.
Do not loosen any joints or plugs while the pump
is operating.
Serious injury can result from high pressure
grease spraying out suddenly.

1. Inspect the level of the reservoir when a message

appears on the display which indicates that the
level of grease in the grease reservoir is low.

Illustration 279 g06365505

The air conditioner filter is on the lower left side of the

cab behind the seat.
1. Slide the operator seat forward.
2. Remove filter cover (1).
3. Remove filter element (2).
4. Tap the filter to remove the dirt. Do not use
compressed air to clean the filter.
5. After you clean the filter element, inspect the filter
element. If the filter element is damaged or badly
contaminated, use a new filter element. Make sure
that the filter element is dry.
6. Install the filter element.
7. Install the filter cover.
NOTICE
Failure to reinstall the filter element for the air condi-
tioning system will contaminate and damage the sys-
tem components.
Illustration 280 g03693285
2. Place switch (3) in the center position in order to
test the bulb in light (2). Place switch (3) in the ON
position in order to activate the level indicator. Add
grease to the reservoir at fitting (1) until the level of
grease is to the “MAX” level. When the reservoir is
full, light (2) will illuminate. Place switch (3) in the
OFF position.
Note: Make sure that the grease level does not fall
below the “MIN” level in the reservoir. The operation
of the automatic lubrication system with the grease
level below “MIN” will damage the front pins and the
swing bearing because not enough grease will be
supplied to these areas.

i05840731 Note: Any foreign material that enters the grease

reservoir could restrict the lubrication lines or the
Automatic Lubrication System foreign material could damage the valves. Prior to
adding the grease to the reservoir, be sure to wipe
Grease - Add any potential contaminants from the grease fitting
(If Equipped) and from the grease gun nozzle.

SMCS Code: 7540-538
The reservoir for the grease is behind the cab.
Note: When you add grease to the grease reservoir,
never add the grease beyond the “MAX” level. If you
add grease above this level, the cover of the grease
reservoir could come off during operation. The
capacity of the grease reservoir is 61 L (16 US gal).
SEBU9190-12 169
Maintenance Section
Battery - Clean

Refer to Operation and Maintenance Manual,

“Lubricant Viscosities” for information about the
correct type of grease.

i00934864

Battery - Clean
SMCS Code: 1401-070
Clean the battery surface with a clean cloth. Keep the
terminals clean and keep the terminals coated with
petroleum jelly. Install the post cover after you coat
the terminal post with petroleum jelly.

i07746330
Illustration 281 g03830875

Battery - Recycle Clean the fittings before you lubricate the fittings.
SMCS Code: 1401-561 Apply lubricant through both fittings with a grease
gun. Use “NLGI Grade 2” grease with molybdenum
Always recycle a battery. Never discard a battery. for machines that are used in normal operating
temperatures.
Always return used batteries to one of the following
locations: i07291537

• A battery supplier
Belt - Inspect/Replace
• An authorized battery collection facility SMCS Code: 1357-040; 1357-510; 1397-040; 1397-
510
• Recycling facility
Note: The alternator and the refrigerant compressor
i00934872 are driven by a single serpentine belt.

Battery Hold-Down - Tighten Inspect

SMCS Code: 7257
1. Park the machine on level ground. Lower the
Tighten the hold-downs for the battery in order to bucket to the ground. Move the transmission
prevent the batteries from moving during machine control switch to the NEUTRAL position and
operation.
engage the parking brake. Shut off the engine.
i06153765

Bearing (Swing Drive) -

Lubricate
SMCS Code: 5459-086
The remote grease fittings are located near the oil
reservoir for the swing drives.
170 SEBU9190-12
Maintenance Section
Belt - Inspect/Replace

Illustration 283 g06276190

Illustration 282 g06276196

Engine guard assembly location

2. Open the door assemblies on the right side of the

machine and remove the engine guard assembly Illustration 284 g06114636

(1) to gain access to the belt. (A) New belt

(B) Worn belt

3. Inspect the condition of the serpentine belt (2).

Over time the belt ribs will lose material (C). The
space between the ribs will increase (D). The loss
of material will cause the pulley sheave to contact
the belt valley. This will lead to belt slippage and
accelerated wear (E). Replace the belt if the belt is
worn or frayed.

Note: If a new belt is installed, recheck the belt

adjustment after 30 minutes of operation.
Note: This machine is equipped with a belt tensioner
(3). The belt tensioner automatically adjusts the belt
to the correct position.
SEBU9190-12
4. Install the engine guard assembly (1) and close the
door assemblies.
Replace
Note: Belts that have more than 15,000 hours have
exceeded the intended life target for most
applications and should be replaced. Extension of life
is possible for some applications through regular belt
inspections.
1. Replace the belt if any of the following conditions
exist:
• Excessive cracking
• Excessive wear
• Excessive damage
2. Park the machine on level ground. Lower the
bucket to the ground. Move the transmission
control switch to the NEUTRAL position and
engage the parking brake. Shut off the engine.
3. The battery disconnect switch is on the control
panel on the left side of the rear bumper. Turn the
battery disconnect switch to the OFF position.
4. Open the door assemblies on the right side of the
machine.
5. Remove the engine guard assembly (1) to gain
access to the belt.
6. Release the tension on the serpentine belt (2).
Insert a ratchet into the square hole in the belt
tensioner (3) and rotate the belt tensioner in a
clockwise direction.
7. Remove the belt.
Illustration 285 g06276208
Belt routing
8. Install a new belt.
171
Maintenance Section
Bucket Linkage - Inspect/Adjust
9. When you release the tension off the belt
tensioner, the belt will automatically adjust to the
correct position. Recheck the belt tension.
10. Turn the battery disconnect switch to the ON
position.
11. Install the engine guard assembly (1) and close
the door assemblies.
i06816819
Bucket Linkage - Inspect/
Adjust
SMCS Code: 6513-040; 6513-025
When performing this adjustment, put the hy-
draulic controls lockout lever in the LOCKED po-
sition and stop the engine.
NOTICE
Improperly adjusted bucket clearance could cause
galling on the contact surfaces of the bucket and
stick, resulting in excessive noise and/or damaged O-
ring seals.
Note: To access the areas required to perform this
procedure, a portable access system (ladder, stair
assembly, man lift, or other portable access system)
that is suitable and compliant to local regulations may
be necessary.
The lateral clearance of the bucket control linkage on
this machine can be adjusted by shimming four
different pins. If the gap between the bucket and the
stick becomes excessive, adjust the clearance to
0.5 to 1 mm (0.02 to 0.04 inch). If the gap between
the power link and the idler link becomes excessive,
adjust the clearance to 0.5 to 1 mm
(0.02 to 0.04 inch). If the gap between the idler link
and the stick becomes excessive, adjust the
clearance to 0.5 to 1 mm (0.02 to 0.04 inch). If the
gap between the bucket cylinder and the stick
becomes excessive, adjust the clearance to a
maximum of 1 mm (0.04 inch).
172 SEBU9190-12
Maintenance Section
Bucket Linkage - Inspect/Adjust

Illustration 286 g00880867

1. Position the machine on a level surface and lower

the bucket to the ground.
SEBU9190-12 173
Maintenance Section
Bucket Linkage - Inspect/Adjust

Illustration 287 g00880899

2. Slowly operate the swing control lever until the 5. Start the engine and place the hydraulic lockout
bucket cylinder and the stick are in full face control (lever) in the UNLOCKED position.
contact at location (1).
6. Slowly operate the swing control lever until the
3. Place the hydraulic lockout control (lever) in the power link and the idler link are in full face contact
LOCKED position and stop the engine. at location (4).
4. Measure the clearance at location (2). If the 7. Place the hydraulic lockout control (lever) in the
clearance is greater than 1 mm (0.04 inch), install LOCKED position and stop the engine.
more shims at location (1) to reduce the clearance
to a maximum of 1 mm (0.04 inch). Refer to
Disassembly and Assembly, “Bucket Cylinder -
Remove” and Disassembly and Assembly, “Bucket
Cylinder - Install” to remove the pin for the bucket
cylinder.
174 SEBU9190-12
Maintenance Section
Bucket Linkage - Lubricate

8. Measure the clearance at location (3). If the

clearance is greater than 1 mm (0.04 inch), install
more shims at location (4) to reduce the clearance
to 0.75 ± 0.25 mm (0.03 ± 0.01 inch). Refer to
Disassembly and Assembly, “Bucket Cylinder -
Remove” and Disassembly and Assembly, “Bucket
Cylinder - Install” to remove the pin for the bucket
cylinder.
9. Start the engine and place the hydraulic lockout
control (lever) in the UNLOCKED position.
10. Slowly operate the swing control lever until the
stick boss and the bucket boss are in full face
contact at location (5).
Illustration 288 g06085912
11. Place the hydraulic lockout control (lever) in the
LOCKED position and stop the engine. Note: Completely fill all cavities of the bucket control
linkage with grease when you initially install a bucket.
12. Measure the clearance at location (6). If the
clearance is greater than 1 mm (0.04 inch), install Apply lubricant through the six fittings for the
more shims at location (5) to reduce the clearance linkages.
to 0.75 ± 0.25 mm (0.03 ± 0.01 inch). Refer to
Note: Service the above fittings after you operate the
Disassembly and Assembly, “Bucket - Remove
bucket under water.
and Install” to remove the pin for the bucket.
13. Start the engine and place the hydraulic lockout i03574842
control (lever) in the UNLOCKED position.
Bucket Tips - Inspect/Replace
14. Slowly operate the swing control lever until the
stick boss and the idler link are in full face contact SMCS Code: 6805-510; 6805-040
at location (7).
15. Place the hydraulic lockout control (lever) in the
LOCKED position and stop the engine. Block the bucket before changing the bucket
teeth.
16. Measure the clearance at location (8). If the
clearance is greater than 1 mm (0.04 inch), install To prevent possible injury to the eyes, wear a pro-
more shims at location (7) to reduce the clearance tective face shield when striking the pin.
to 0.75 ± 0.25 mm (0.03 ± 0.01 inch). Refer to
The pin, when struck, can fly out and cause injury
Disassembly and Assembly, “Stick - Remove and to nearby personnel.
Install” to remove the pin for the idler link.

i06710211

Bucket Linkage - Lubricate

SMCS Code: 6513-086

Note: Caterpillar recommends the use of 5%

molybdenum grease for lubricating the bucket
linkage. Refer to Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” for
more information on grease.
Wipe all fittings before you apply lubricant.
SEBU9190-12 175
Maintenance Section
Bucket Tips - Inspect/Replace

Bucket Tips c. Strike the Pin-Master at the back of the tool (4)
and remove the pin.
Note: Discard the old pin and the retainer
assembly. When you change tips, use a new pin
and a new retainer assembly. Refer to the
appropriate parts manual for your machine.

Illustration 289 g01577934

(1) Usable tip
(2) Replaceable bucket tip
(3) Overworn tip

Check the bucket tips for wear. If the bucket tip has a
hole, replace the bucket tip. Illustration 291 g01577913
1. Remove the pin from the bucket tip. The pin can be (6) Retainer assembly
removed by one of the following methods. (7) Adapter

• Use a hammer and a punch from the retainer
side of the bucket to drive out the pin.
• Use a Pin-Master. Follow Step 1a through Step
1c for the procedure.
2. Clean the adapter and the pin.
3. Fit retainer assembly (6) into the counterbore that
is in the side of adapter (7). Make sure that the
face of the retainer assembly with the marking
“OUTSIDE” is visible.

Illustration 292 g00101359

4. Install the new bucket tip onto the adapter.

Note: The bucket tips can be rotated by 180 degrees

Illustration 290 g01577993 in order to allow the tip to wear evenly. You may also
move the tips from the outside teeth to the inside
(4) Back of Pin-Master
(5) Extractor teeth. Check the tips often. If wear is present on the
tips, rotate the tips. The outside teeth generate the
a. Place the Pin-Master on the bucket tip. most wear.

b. Align extractor (5) with the pin.

176 SEBU9190-12
Maintenance Section
Bucket Tips - Inspect/Replace

5. Drive the pin through the bucket tip. The pin can be
installed by using one of the following methods:

• From the same side of the retainer, drive the

pin through the bucket tip, the retainer
assembly, and the adapter.

• Use a Pin-Master. Follow Step 5a through Step

5e for the procedure.

Illustration 295 g01209159

Final assembly of pin into bucket tip

e. Strike the end of the tool until the pin is fully

inserted.

Side Cutters

Illustration 293 g01578233

(8) Pin

a. Insert pin (8) through the bucket tip.

Illustration 296 g01579693

Bucket With Side Cutters

1. Remove the mounting bolts and the side cutters

(11).
Illustration 294 g01578342 2. Clean the mounting surface of the side plate on the
bucket and of the side cutter. Remove any burrs or
b. Place the Pin-Master over the bucket tips so protrusions on the mating surfaces.
that the pin will fit into the counterbore of the pin
holder (9).
c. Strike the Pin-Master with a hammer at the
back of the tool (4) in order to insert the pin.
d. Slide pin holder (9) away from the pin and
rotate the tool slightly in order to align pin setter
(10) with the pin.
SEBU9190-12 177
Maintenance Section
Bucket Tips - Inspect/Replace

Illustration 298 g01592996

Illustration 297 g01579713

(12) Shear ledge on a side cutter
(13) Side plate on a bucket
(B) 0.0 mm (0.0 inch)

Note: Some side cutters may be rotated for

additional wear.

3. Install the side cutter.

Note: Certain bolts may require thread compound.

Illustration 299 g01903678
4. Hand tighten the bolts. (14) Side plate
(15) Retainer
5. Make sure that there is not a gap between the side (16) Side protector
plate on the bucket and the shear ledge on the (17) Pin
side cutter. (18) Shim

6. Torque the mounting bolts to the correct
specification.
Side Protectors (If Equipped)
Inspect the wear of the side protector. When too
much wear is present, replace the protector.
1. Hit pin (17) from the side of the bucket without the
retainer in order to remove side protector (16) from
side plate (14).
2. Clean side protector (16), pin (17), retainer (15)
and side plate (14) before installation.
Note: Lateral clearance between the side plate and
the side protector should not exceed 1 mm
(0.04 inch). Shims (18) may be required in order to
decrease the lateral clearance which will decrease
movement. Install the shims (18) between the side
plate and the side protector on the opposite side of
the retainer.

3. Put retainer (15) in side plate (14).

178 SEBU9190-12
Maintenance Section
Cab Air Filter (Fresh Air) - Clean/Replace

4. Align two pin holes of the new protector and the 5. Install the air filter and the filter cover.
side plate. Hit the pin from the retainer side of the
bucket. i05841237

Note: If the pin and/or the retainer are worn, replace Camera - Clean
the pin and/or the retainer.
SMCS Code: 7348-070
i03901495

Cab Air Filter (Fresh Air) - Failure to use an appropriate external ladder or
Clean/Replace an appropriate platform for direct access to the
rear view camera could result in slipping and fall-
SMCS Code: 7342-510; 7342-070 ing which could result in personal injury or death.
Be sure to use an appropriate external ladder or
an appropriate platform for direct access to the
rear view camera.
The machine's counterweight and the engine
hood are not approved as a maintenance
platforms.

Unexpected machine movement can cause injury

or death.
In order to avoid possible machine movement,
move the hydraulic lockout control to the
LOCKED position and attach a Special Instruc-
Illustration 300 g01973174 tion, SEHS7332, “Do Not Operate” or similar
warning tag to the hydraulic lockout control.
The cab air filter is located on the left side of the cab.
1. Use the ignition key in order to open the access
Note: When you access the cameras for cleaning, be
panel.
sure to observe safe procedures for access. Maintain
a three-point contact and/or use a body harness.

Illustration 301 g02144326

(1) Air filter Illustration 302 g03693380

2. Remove air filter (1).
3. Clean the air filter with a maximum of 200 kPa
(30 psi) pressure air.
4. After you clean the air filter, inspect the air filter. If
the air filter is damaged or badly contaminated,
use a new air filter.
The rear view camera is located on top of the
counterweight.
If necessary, use a damp cloth in order to clean the
glass of the camera. The camera is sealed. The
camera is not affected by a wash with high-pressure
spray.
SEBU9190-12 179
Maintenance Section
Circuit Breakers - Reset

Note: Alternatively, cameras may be cleaned from

ground level by using a wash with a high-pressure
spray or a damp rag on a wand.

i05841412

Circuit Breakers - Reset

SMCS Code: 1420-529

Circuit Breaker Reset – Push in the

button in order to reset the circuit
breaker. If the electrical system is
working properly, the button will remain
depressed. If the button does not remain
depressed, check the appropriate electrical Illustration 304 g03693525
circuit. Repair the circuit, if necessary.

Illustration 303 g03693520

This circuit breaker panel is located below the center

of the engine.
(1) Powered Stairway – 80 Amp
Illustration 305 g03693530

(2) Main Circuit – 105 Amp This circuit breaker panel is located inside the cab.

(3) Engine ECM – 15 Amp

(4) Engine ECM – 15 Amp

(5) Powered Stairway – 10 Amp

(6) HVAC Blower Motor – 15 Amp

(7) Lower Wiper/Washer – 10 Amp

180 SEBU9190-12
Maintenance Section
Cooling System Coolant (ELC) - Change

(8) Condenser – 15 Amp
(9) Upper Wiper/Washer – 10 Amp
Note: This machine was filled at the factory with Cat
Extended Life Coolant.
If the coolant in the machine is changed to Extended
Life Coolant from another type of coolant, see
Special Publication, SEBU6250, “Caterpillar Machine
Fluids Recommendations”.

i05842136
Procedure for Changing the
Cooling System Coolant (ELC) Coolant
- Change Note: The pressure must be removed from the
SMCS Code: 1350-044 system before service can be performed. Refer to
this Operation and Maintenance Manual, “System
Pressure Release”.

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 cooling system pressure cap slowly to
relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
touch with your bare hand.
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns.
Illustration 306 g03693918
Cooling System Coolant Additive contains alkali.
(1) Cooling system pressure cap
Avoid contact with skin and eyes. (2) Cooling system sight gauge

1. Open the cooling system pressure cap access

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.
door that is located on the top of the engine
compartment. Slowly remove cooling system
pressure cap (1).
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information that
pertains to containing fluid spillage.

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, PERJ1017, “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.
SEBU9190-12
Illustration 307 g03693968
(3) Cooling system drain valve hose
2. Position a suitable container beneath cooling
system drain valve hose (3). The cooling system
drain valve hose is located under the rear of the
machine.
Illustration 308 g03694002
(4) Cooling system drain valve
3. Open cooling system drain valve (4) and allow the
coolant to drain into the container that was
positioned in step 2.
4. Flush the cooling system. Follow step 4a through
Step 4h in order to flush the cooling system.
a. Close the cooling system drain valve.
b. Fill the cooling system with clean water.
c. Install the cooling system pressure cap.
d. Start the engine and run the engine until the
engine reaches operating temperature.
e. Stop the engine and allow the engine to cool.
f. Loosen the cooling system pressure cap slowly
in order to relieve any pressure in the cooling
system.
181
Maintenance Section
Cooling System Coolant (ELC) - Change
g. Open the cooling system drain valve and allow
the coolant to drain into a suitable container.
h. Flush the cooling system with clean water until
the draining water is transparent.
5. Close the cooling system drain valve.
6. Replace the water temperature regulators.
Reference: Refer to Operation and Maintenance
Manual, “Cooling System Water Temperature
Regulator - Replace” for the correct procedure.
7. Add the Extended Life Coolant. Refer to the
following topics:
• Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations”
• Operation and Maintenance Manual,
“Capacities (Refill)”
8. After the cooling system has been filled, perform
the following procedures during initial start-up:
a. Start the engine without the cooling system
pressure cap installed.
b. Run the engine at low idle for 10 minutes.
c. Then, increase the engine speed to a high idle
until the water temperature regulators are open
and the coolant level is stabilized.
d. Observe cooling system sight gauge (2) and
maintain the coolant at the proper level. Refer
to Operation and Maintenance Manual,
“Cooling System Coolant Level - Check”.
9. Install the cooling system pressure cap and close
the access door on top of the engine
compartment.
182
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
10. Stop the engine.
i05842328
Cooling System Coolant
Extender (ELC) - Add
SMCS Code: 1352; 1353; 1395
Personal injury can result from hot coolant,
steam and alkali.
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines to
heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove cooling system pressure cap slowly to
relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
touch with your bare hand.
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
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, PERJ1017, “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.
Use Caterpillar Extended Life Coolant (ELC) when
you add coolant to the cooling system. See Special
Publication, SEBU6250, “Caterpillar Machine Fluids
Recommendations” for all cooling system
requirements. When a Caterpillar Extended Life
Coolant (ELC) is used, an extender must be added to
the cooling system.
Use a Coolant Conditioner Test Kit in order to check
the concentration of the coolant.
1. Park the machine on level ground.
2. Stop the engine and allow the engine to cool.
SEBU9190-12
Note: The pressure must be removed from the
system before service can be performed. Refer to
this Operation and Maintenance Manual, “System
Pressure Release”.
Illustration 309 g03693918
(1) Cooling system pressure cap
(2) Coolant level sight gauge
3. Open the cooling system pressure cap access
door that is located on the top of the engine
compartment. Slowly remove cooling system
pressure cap (2).
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information on
containing fluid spillage.
4. It may be necessary to drain some coolant from
the radiator so that Cat Extender can be added to
the cooling system.
Reference: Refer to Operation and Maintenance
Manual, “Cooling System Coolant (ELC) - Change”
for information on how to drain coolant from the
cooling system.
Note: Always discard drained fluids according to
local regulations.
5. Add Caterpillar Extended Life Coolant (ELC) to the
cooling system. Refer to the following topics for
the proper amount of Caterpillar Extender:
• Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations”
• Operation and Maintenance Manual,
“Capacities (Refill)”
6. Observe cooling system sight gauge (3) and
maintain the coolant at the proper level. Refer to
Operation and Maintenance Manual, “Cooling
System Coolant Level - Check”.
SEBU9190-12
7. Install the cooling system pressure cap and close
the access door on top of the engine
compartment.
i05842338
Cooling System Coolant Level
- Check
SMCS Code: 1350-535-FLV; 1350-040; 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 cooling system pressure cap slowly to
relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
touch with your bare hand.
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
Illustration 310 g03693918
(1) Cooling system pressure cap
(2) Coolant level sight gauge
1. Observe coolant level sight gauge (2) in order to
maintain the coolant level within the view of the
sight gauge.
2. If additional coolant is necessary, open the cooling
system pressure cap access door that is located
on the top of the engine compartment. Slowly
remove cooling system pressure cap (1).
183
Maintenance Section
Cooling System Coolant Level - Check
Note: The pressure must be removed from the
system before service can be performed. Refer to
this Operation and Maintenance Manual, “System
Pressure Release”.
3. Add the appropriate amount of Extended Life
Coolant and install the cooling system pressure
cap. Refer to the following topics:
• Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations”
• Operation and Maintenance Manual,
“Capacities (Refill)”
4. Install the cooling system pressure cap. Close the
access door to the cooling system pressure cap.
i06906751
Cooling System Coolant
Sample (Level 1) - Obtain
SMCS Code: 1395-554; 1395-008; 7542
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sam-
pling. Using the same pump for both types of sam-
ples may contaminate the samples that are being
drawn. This contaminate may cause a false analysis
and an incorrect interpretation that could lead to con-
cerns by both dealers and customers.
Note: Level 1 results may indicate a need for
Level 2 Analysis.
184
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
Illustration 311 g06163000
The sampling port for the coolant (1) (if equipped) is
located behind the engine oil filters.
Illustration 312 g06163002
For machines that are not equipped with a sampling
port, use a vacuum pump to obtain a sample of the
coolant. Withdraw the coolant through filler cap (2) on
the top of the radiator.
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. To receive
the full effect of S·O·S analysis, you must establish a
consistent trend of data. To establish a pertinent
history of data, perform consistent samplings that are
evenly spaced. Supplies for collecting samples can
be obtained from your Caterpillar dealer.
SEBU9190-12
Use the following guidelines for proper sampling of
the coolant:
• Complete the information on the label for the
sampling bottle before you begin to take the
samples.
• Keep the unused sampling bottles stored in plastic
bags.
• Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples
from any other location.
• Keep the lids on empty sampling bottles until you
are ready to collect the sample.
• Place the sample in the mailing tube immediately
after obtaining the sample to avoid contamination.
• Never collect samples from expansion bottles.
• Never collect samples from the drain for a system.
Submit the sample for Level 1 analysis.
For additional information about coolant analysis, see
Special Publication, SEBU6250, “Caterpillar Machine
Fluids Recommendations” or consult your Caterpillar
dealer.
i07349178
Cooling System Coolant
Sample (Level 2) - Obtain
SMCS Code: 1395-554; 1395-008; 7542
Reference: Refer to Operation and Maintenance
Manual, “Cooling System Coolant Sample (Level 1) -
Obtain” for the guidelines for proper sampling of the
coolant.
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. Supplies for
collecting samples can be obtained from your Cat
dealer.
Submit the sample for Level 2 analysis.
Reference: For additional information about coolant
analysis, refer to Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” or
consult your Cat dealer.
SEBU9190-12 185
Maintenance Section
Cooling System Water Temperature Regulator - Replace

i05842365 i07493310

Cooling System Water Engine Air Filter Primary

Temperature Regulator - Element - Replace
Replace SMCS Code: 1054-510-PY; 1054-510
SMCS Code: 1355-510
NOTICE
Service the air cleaner only with the engine stopped.
Engine damage could result.
Personal injury can result from hot coolant, Service the air cleaner filter elements when the
steam and alkali. engine fault indicator is activated. The engine fault
indicator is located inside the cab. The engine fault
At operating temperature, engine coolant is hot indicator will activate when there is an inlet air
and under pressure. The radiator and all lines to restriction, and the Advisor display will provide a
heaters or the engine contain hot coolant or message regarding the specific problem. Operation
steam. Any contact can cause severe burns. and Maintenance Manual, “Monitoring System” for
further information.
Remove cooling system pressure cap slowly to
relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
touch with your bare hand.
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.

Replace the cooling system water temperature

regulators on a regular basis. Replace the regulators
to reduce the chance of unscheduled downtime and
of problems with the cooling system.
Note: The water temperature regulators should be
replaced after the cooling system has been cleaned.
Replace the water temperature regulators while the
cooling system is drained or while the coolant is
drained to a level that is below the water temperature
regulator housing.
Note: Refer to Operation and Maintenance Manual,
“Cooling System Coolant (ELC) - Change” for
additional information on how to drain and dispose of
coolant.
NOTICE
Failure to replace the engine water temperature regu-
lator on a regularly scheduled basis could cause se-
vere engine damage.
Replace the water temperature regulators and the
regulator housing gasket while the cooling system is
being cleaned. If you only need to replace the water
temperature regulators, drain the cooling system
coolant to a level that is below the regulator housing.
Reference: Refer to the Disassembly and Assembly
Manual for the correct procedure for replacing the
water temperature regulators.
Illustration 313 g03694110
The engine air filter assemblies are on each side of
the engine.
(1) Engine air filter assemblies
NOTICE
Service the engine air filter elements only when the
alert indicator for the intake air filter is flashing. Do
not open the filter compartment unless service is indi-
cated. Opening the filter compartment can cause dirt
to get into the clean side of the filter housing.
NOTICE
Short air filter life can result if the precleaner system
malfunctions. If air filter life is drastically reduced from
typical for the operating conditions, consult you Cat
dealer.
NOTICE
Service the engine air filters with the engine stopped.
Engine damage could result.
186
Maintenance Section
Engine Air Filter Secondary Element - Replace
NOTICE
Do not use the air filter elements for longer than 1
year.
1. Park the machine on a level surface. Stop the
engine and engage the parking brake.
2. Open the engine access doors to service engine
air filter assemblies (1).
Illustration 314 g03694112
Components of each engine air filter assembly.
(2) Engine air filter assembly housing
(3) Secondary engine air filter element
(4) Primary engine air filter element
(5) Engine air filter assembly housing cover
3. Release the latches that secure engine air filter
assembly housing cover (5). Remove the cover.
4. Grasp the handle that is molded into primary
engine air filter element (4) and pull the element
from engine air filter housing (2).
5. Carefully remove secondary air filter element (3)
by pulling out on the element with a circular
motion.
Note: Removal of the secondary air filter element
allows for more complete cleaning of the engine air
filter housing than is possible by removing only the
primary engine air filter element.
6. Set the secondary air filter element aside in a
clean and safe location if the secondary element
will be reinstalled after replacing the primary air
filter element.
7. Cover the engine air filter assembly housing outlet.
This outlet is revealed when the secondary air
filter element is removed.
8. Clean the inside of the air filter assembly housing.
SEBU9190-12
Note: Thorough cleaning of the housing is necessary
so that the primary engine air filter element and the
secondary air filter element can be installed correctly.
9. Uncover the engine air filter assembly housing
outlet that was covered in step 7.
10. Inspect the secondary air filter element that was
removed in step 5. If damage or contamination of
the secondary air filter element is found, dispose
of the element properly and replace with a new
secondary air filter element.
NOTICE
Always replace the primary and secondary air filter el-
ements. Do not clean the air filter elements. Do not
wash the air filter elements. Do not use air filter ele-
ments with damaged pleats, gaskets, or seals.
11. Install the secondary air filter element into the air
filter housing. Push the end of the secondary
element firmly, but carefully, to position the
element into the air filter housing properly.
12. Write the date of installation on the secondary air
filter element.
13. Install a new primary air filter element. Push the
element firmly toproperly seat the element. Write
the date of installation on the element.
14. Install the air filter housing cover and secure the
latches that clamp the cover to the air filter
housing.
15. Repeat the preceding procedure to replace the
other engine air filter primary element.
16. Close the access doors.
i05277583
Engine Air Filter Secondary
Element - Replace
SMCS Code: 1054-510
NOTICE
Service the air filter only with the engine stopped. En-
gine damage could result.
NOTICE
Always replace the secondary element. Do not at-
tempt to reuse it by cleaning. Engine damage could
result.
SEBU9190-12 187
Maintenance Section
Engine Air Precleaner - Clean

Note: Replace the engine air filter secondary 5. Uncover the air inlet openings. Install the new
elements when you service the engine air filter secondary filter elements.
primary elements for the third time. Replace the
secondary filter elements if the exhaust smoke 6. Install the primary filter elements and install the air
remains black and the clean primary filter elements filter covers.
have been installed.
i05842468
Park the machine on a level surface. Stop the engine
and engage the parking brake. Engine Air Precleaner - Clean
Reference: Refer to Operation and Maintenance SMCS Code: 1055-070-DJ
Manual, “Engine Air Filter Primary Element -
Replace” for information about how to access the
engine air filter assemblies.

Illustration 317 g03694117

Illustration 315 g02604996
1. There are six latches (1) that hold filter cover (3)
onto the filter housing. Release the latches and
remove the filter cover from each filter housing.
2. Remove primary filter element (2) from each air
filter housings.
Engine air precleaners
1. Use the following procedure to clean each one of
the two engine air precleaners on this machine.
2. Inspect the precleaner screen for dirt
accumulation.
3. Loosen the retainer and remove the screen.
4. Clean the screen with compressed air or water.
5. Clean the precleaner tube with compressed air if
the precleaner tube is dirty.
6. Replace the screen.

i07569296

Engine Components - Clean/

Inspect, Rebuild/Install
Reman, Install New
(Every 850 000 L (225 000 US
gal) of Fuel)
Illustration 316 g02605696
SMCS Code: 1000; 1000-012-NW; 1000-012-IC;
3. Remove secondary filter elements (4) and properly 1000-022-MC; 1000-571-IC; 1800-022
discard the secondary elements. S/N: FKD1–Up
4. Cover the air inlet openings. Clean the inside of S/N: HLD1–Up
the air cleaner housings.
S/N: HSE1–Up
188 SEBU9190-12
Maintenance Section
Engine Components - Clean/Inspect, Rebuild/Install Reman, Install New

S/N: PZE1–Up • Fuel priming pump

S/N: HSF1–Up • Gear train bushings, bearings, and thrust plates
S/N: WSN1–Up • Heat shields
S/N: ZEN1–Up
• Main bearings, rod bearings, and crankshaft thrust
S/N: PWW1–Up plates
Caterpillar recommends this additional maintenance • Piston rings
for the following engine components. Consult your
Cat dealer for further information. • Updated engine software

Clean Components and Inspect • Wiring harness

Components for Reusability i07569297

• Aftercooler core
Engine Components - Clean/
• Camshaft Inspect, Rebuild/Install
• Connecting rods Reman, Install New
• Crankshaft (Every 850 000 L (225 000 US
• Cylinder block gal) of Fuel)
SMCS Code: 1000; 1000-012-NW; 1000-012-IC;
• Cylinder liners 1000-022-MC; 1000-571-IC; 1800-022
• Damper S/N: MKE1–Up
• Gear train S/N: LWN1–Up
• Pistons S/N: LWS1–Up
• Piston pins Caterpillar recommends this additional maintenance
for the following engine components. Consult your
• Rocker arm assemblies Cat dealer for further information.

• Rocker arm shaft Clean Components and Inspect

• Spacer plates (head) Components for Reusability
Rebuild Components and/or Install • Aftercooler core
Remanufactured Components • Camshaft

• Cylinder heads • Connecting rods

• Oil coolers (if equipped) • Crankshaft

• Oil pump • Cylinder block

• Scavenge oil pump (if equipped) • Cylinder liners

• Damper
Install New Components
• Gear train
• All seals, gaskets, and O-rings
• NOx Reduction System (NRS) venturi
• Camshaft bearings
• Pistons
• Engine mounts
• Piston pins
• Fuel pressure regulating valve
• Rocker arm assemblies
SEBU9190-12 189
Maintenance Section
Engine Components - Clean/Inspect, Rebuild/Install Reman, Install New

• Rocker arm shaft S/N: HSE1–Up

• Spacer plates (head) S/N: PZE1–Up
S/N: HSF1–Up
Rebuild Components and/or Install
S/N: WSN1–Up
Remanufactured Components
S/N: ZEN1–Up
• Cylinder heads
S/N: PWW1–Up
• NOx Reduction System (NRS) control valve Caterpillar recommends this additional maintenance
for the following engine components. Consult your
• Oil coolers (if equipped) Cat dealer for further information.
• Oil pump
Clean Components and Inspect
• Scavenge oil pump (if equipped)
Components for Reusability
Install New Components • Heat shields
• All seals, gaskets, and O-rings
Rebuild Components and/or Install
• Camshaft bearings Remanufactured Components
• Diesel Oxidation Catalyst (DOC) • Fuel transfer pump
• Engine mounts • Injectors
• Fuel pressure regulating valve • Turbochargers
• Fuel priming pump • Water pump
• Gear train bushings, bearings, and thrust plates
Install New Components
• Heat shields
• Water temperature regulators
• Main bearings, rod bearings, and crankshaft thrust
plates i07569304

• NRS coolers and bellows

Engine Components - Clean/
• Piston rings Inspect, Rebuild/Install
• Updated engine software Reman, Install New
• Wiring harness (Every 1 703 435 L (450 000 US
i07569303
gal) of Fuel)
SMCS Code: 1000; 1000-012-NW; 1000-012-IC;
Engine Components - Clean/ 1000-022-MC; 1000-571-IC; 1800-022
Inspect, Rebuild/Install S/N: MKE1–Up
Reman, Install New S/N: LWN1–Up
(Every 1 703 435 L (450 000 US S/N: LWS1–Up
gal) of Fuel) Caterpillar recommends this additional maintenance
SMCS Code: 1000; 1000-012-NW; 1000-012-IC; for the following engine components. Consult your
Cat dealer for further information.
1000-022-MC; 1000-571-IC; 1800-022

S/N: FKD1–Up
S/N: HLD1–Up
190 SEBU9190-12
Maintenance Section
Engine Crankcase Breather - Clean

Clean Components and Inspect

Components for Reusability
• Heat shields

Rebuild Components and/or Install

Remanufactured Components
• Fuel transfer pump
• Injectors

• Turbochargers
• Water pump

Install New Components

• Diesel Oxidation Catalyst (DOC Bellows)

• Rubber NRS hoses

• Water temperature regulators

i07597220

Engine Crankcase Breather -

Clean Illustration 318 g02713306

(Emission Related Component) The engine in this machine is equipped with two
engine crankcase breathers (1). One breather is on
SMCS Code: 1317-070-DJ the valve cover on the right side and one breather is
on the valve cover on the left side.
S/N: MKE1–Up
1. Park the machine on a level surface and stop the
S/N: LWN1–Up engine. Make sure that the transmission control is
S/N: LWS1–Up in the PARK position.
2. Loosen the clamps.
3. Remove the hoses from the breathers. Remove
the breathers from the valve covers.
4. Wash the breathers in clean nonflammable
solvent.
5. Install the breathers on the valve covers. Install the
hoses and clamps on the breathers.
6. Tighten all of the clamps.

i02164781

Engine Mounts - Inspect

SMCS Code: 1152; 1152-040
Caterpillar recommends checking the engine mounts
for deterioration and for proper bolt torque. This will
help to prevent excessive engine vibration that is
caused by improper mounting.
SEBU9190-12 191
Maintenance Section
Engine Oil Level - Check

i05842884

Engine Oil Level - Check

SMCS Code: 1000-535

Hot oil and components can cause personal

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

NOTICE
Do not under fill or overfill engine crankcase with oil.
Either condition can cause engine damage.
Illustration 320 g03694179
2. Check the engine oil level gauge. Maintain the
engine oil level in the shaded area (A) of the
engine oil level gauge when the engine is stopped
and the oil is cold. Maintain the engine oil level in
the shaded area (B) of when the engine is running
at low idle and the oil is warm.
3. If necessary, remove the engine oil filler cap and
add oil through the engine oil filler tube.

i05843058

Engine Oil Sample - Obtain

SMCS Code: 1000; 1000-008; 1348-554-SM; 1348-
008; 7542-554-SM; 7542-554-OC; 7542-008
Illustration 319 g03694167
(1) Engine oil filler cap
(2) Engine oil level gauge
Hot oil and hot components can cause personal
1. Engine oil filler cap (1) and engine oil level gauge injury. Do not allow hot oil or hot components to
contact the skin.
(2) are located inside the front engine access door.

Obtain the Sample and the

Analysis
In addition to a good preventive maintenance
program, Caterpillar recommends using S·O·S oil
analysis at regular scheduled intervals in order to
monitor the condition of the engine and the
maintenance requirements of the engine.
Each oil sample should be taken when the oil is warm
and when the oil is mixed well. This oil sampling
procedure is used to ensure that the sample is
representative of the oil that is in the crankcase.
192 SEBU9190-12
Maintenance Section
Engine Oil and Filter - Change

Obtain the S·O·S Sample Abnormally harsh operating cycles or harsh

environments can shorten the service life of the
engine oil. Arctic temperatures, corrosive
environments, or extremely dusty conditions may
require a reduction in engine oil change intervals.
Also refer to Special Publication, SEBU5898, “Cold
Weather Recommendations for All Caterpillar
Machines”. Poor maintenance of air filters or of fuel
filters requires reduced oil change intervals. Consult
your Caterpillar dealer for more information if this
product will experience abnormally harsh operating
cycles or harsh environments.

Illustration 321 g03694197

Engine oil sampling port.

The sampling port for the engine oil is located inside

the front engine access door. The port is located on
the base of the engine oil filters.
Refer to Special Publication, SEBU6250, “S·O·S
Services Oil Analysis” for information that pertains to
obtaining a sample of the engine oil. Refer to Special
Publication, PEHP6001, “How To Take A Good Oil
Sample” for more information about obtaining a
sample of the engine oil.

i07680936

Engine Oil and Filter - Change

SMCS Code: 1318-510

Selection of the Oil Change Interval

NOTICE
A 500 hour engine oil change interval is achievable if
normal operating conditions are met, recommended
multigrade oil types are used, and an S·O·S oil sam-
pling analysis program is utilized. Normal operating
conditions include load factors below 40%, idle time
below 40%, fuel sulfur levels below 0.3%, and alti-
tude below 1830 m (6000 ft). When these require-
ments are not met, shorten the oil change interval
and use an S·O·S Services oil sampling and analysis
program to determine an acceptable change interval.
For assistance with optimizing oil change intervals,
contact your local Cat dealer.
For sulfur content above 0.1 % refer to Special Publi-
cation, SEBU6250, “Caterpillar Machine Fluids
Recommendations”.

The normal engine oil change interval is listed in this

Operation and Maintenance Manual, “Maintenance
Interval Schedule”.
SEBU9190-12 193
Maintenance Section
Engine Oil and Filter - Change

Table 18
Engine Oil Change Interval

Operating Conditions

Multigrade Oil Type Severe

Initial Normal Load Factor Idle Time above Fuel Sulfur Altitude above
above 75% 40% above 0.3% 1830 m (6000 ft)

Cat DEO
Preferred
250 hr 500 hr 250 hr 250 hr 250 hr 250 hr
ECF-2
Preferred
ECF-1-a 250 hr 250 hr 125 hr 125 hr 125 hr 125 hr

Adjustment of the Oil Change Interval References

Note: Your Caterpillar dealer has additional
information on these programs.
Cat oil filters are recommended.
Program A
Verification for an Oil Change Interval of 500 Hours
This program consists of three oil change intervals of
500 hours. Oil sampling and analysis are done at 250
hours and 500 hours for each of the three intervals
for a total of six oil samples. The analysis includes oil
viscosity and infrared (IR) analysis of the oil. If all of
the results are satisfactory, the 500 hour oil change
interval is acceptable for the machine in that
application. Repeat Program A if you change the
application of the machine.
If a sample does not pass the oil analysis, take one of
these actions:
Reference: Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations”
Reference: Special Publication, SEBU5898, “Cold
Weather Recommendations for All Caterpillar
Machines”
Reference: Special Publication, PEDP7035,
“Optimizing Oil Change Intervals”
Reference: Special Publication, PEDP7036, “S·O·S
Fluid Analysis”
Reference: Special Publication, PEDP7076,
“Understanding the S·O·S Oil Analysis Tests”
Procedure for Changing the Engine
Oil and Filter

• Shorten the oil change interval to 250 hours.

Hot oil and components can cause personal
• Proceed to Program B. injury.
• Change to a preferred oil type in the “Lubricant Do not allow hot oil or components to contact
Viscosities for Ambient Temperatures” Table in this skin.
Operation and Maintenance Manual

Program B
Optimizing Oil Change Intervals
Begin with a 250 hour oil change interval. The oil
change intervals are adjusted by increments. Each
increment is an additional 50 hours. Periodic oil
sampling and analysis are done during each interval.
The analysis includes oil viscosity and infrared (IR)
analysis of the oil. Repeat Program B if you change
the application of the machine.
If an oil sample does not pass the analysis, shorten
the oil change interval, or change to a preferred
multigrade oil type.
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, PERJ1017, “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.
The engine oil drain valve is positioned on the right-
hand side of the engine oil pan behind the rear axle.
194 SEBU9190-12
Maintenance Section
Engine Oil and Filter - Change

Illustration 322 g03694206 Illustration 324 g03694219

Bottom view of the rear of the machine. (3) Engine oil filler cap
(1) Engine oil drain valve hose (4) Engine oil level gauge
(5) Engine oil filters

1. Position a suitable container below engine oil drain

5. Use a strap type wrench to remove engine oil
valve hose (1) to collect the used engine oil.
filters (5). Dispose of the used filters properly.
6. Clean the filter mounting bases. Make sure that
used seal material is removed completely from
each mounting base.

Illustration 323 g03353473

(2) Engine oil drain valve

2. Open engine oil drain valve (2) and allow the oil to
drain into the container. Illustration 325 g00101318

3. Close the engine oil drain valve.
4. Open the engine access door on the front of the
engine compartment.
7. Apply a thin film of clean engine oil to the seal on
each of the new filter elements. Install each of the
new engine oil filters hand tight until the seal of the
engine oil filter contacts the base. Note the
position of the index marks on the filter in relation
to a fixed point on the filter base.

Note: There are rotation index marks on the engine

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

8. Tighten the filters according to the instructions that

are printed on the filter. Use the index marks as a
guide. For non-Cat filters, use the instructions that
are provided with the filter.
SEBU9190-12 195
Maintenance Section
Engine Valve Lash - Check

Note: You may need to use a Cat strap wrench, or Note: A qualified mechanic should adjust the engine
another suitable tool, to turn the filter to the amount valve lash because special tools and training are
that is required for final installation. Make sure that required.
the installation tool does not damage the filter.
i07187396
9. Remove engine oil filler cap (3) and fill the engine
crankcase with oil. Engine Valve Rotators -
Reference: Refer to Operation and Maintenance Inspect
Manual, “Capacities (Refill)” for the proper amount of
SMCS Code: 1109-040
oil.

When inspecting the valve rotators, protective

glasses or face shield and protective clothing
must be worn, to prevent being burned by hot oil
or spray.
Caterpillar recommends replacing valve rotators that
are operating improperly. An improperly operating
valve rotator will shorten valve life because of
accelerated wear on the valves and valve stems.
Also, metal particles produced by a damaged valve
or rotator could lead to lubrication system
contamination and deposit debris into the cylinder.
Damage to the piston head and to the cylinder head
may result.
Illustration 326 g06395028
(A) Rear of the oil pan
(B) Front of the oil pan

Note: When the standard oil change procedure is

followed, 4.5 L (1.2 US gal) of oil will remain in the
front of the oil pan (B). If the access plate on the front
of the oil pan is removed, then additional oil must be
added when filling the engine crankcase.

10. Clean the oil filler cap and install the oil filler cap.
11. Start the engine and allow the oil to circulate.
Check for leaks.
12. Stop the engine and check the engine oil level by Illustration 327 g00882731
using engine oil level gauge (4).
Start the engine and run the engine at low idle. Watch
Reference: Refer to Operation and Maintenance the top surface of each valve rotator. Whenever an
Manual, “Engine Oil Level - Check” for the correct inlet valve closes or an exhaust valve closes, each
procedure. valve rotator should turn.
If a valve rotator fails to turn, consult your Cat dealer
i04538255
for service.
Engine Valve Lash - Check i01394313
SMCS Code: 1102-082; 1102-535; 1102; 1105-025;
1105-535; 1121-535; 1209-082; 1209; 1209-535; Engine Water Pump - Inspect
7527
SMCS Code: 1361-040; 1361
In order to perform the valve lash adjustment, refer to
Systems Operation, Testing and Adjusting, “Engine Failure of the engine water pump may cause severe
Valve Lash - Inspect/Adjust”. engine overheating problems such as cracks in the
cylinder head or piston seizure.
196 SEBU9190-12
Maintenance Section
Ether Starting Aid Cylinder - Replace

Visually inspect the water pump for leaks. If you find

leaks, all of the seals on the water pump must be
replaced.
Note: For more information, refer to the appropriate
Disassembly and Assembly manual for your
machine's engine.

i05843110

Ether Starting Aid Cylinder -

Replace
(If Equipped)
SMCS Code: 1456-510-CD Illustration 328 g00751767

1. Loosen the cylinder retaining clamp.

Breathing ether vapors or repeated contact of 2. Unscrew the empty ether starting aid cylinder and
ether with skin can cause personal injury. Per- remove the empty ether starting aid cylinder.
sonal injury may occur from failure to adhere to
the following procedures.
Use ether only in well ventilated areas.
Do not smoke while changing ether cylinders.
Use ether with care to avoid fires.
Do not store replacement ether cylinders in living
areas or in the operator's compartment.
Do not store ether cylinders in direct sunlight or
at temperatures above 49 °C (120 °F).
Discard cylinders in a safe place. Do not puncture
or burn cylinders.
Keep ether cylinders out of the reach of unauthor- Illustration 329 g00751769
ized personnel.
3. Remove the used gasket.
The ether cylinder is located in the rear left corner of
the engine compartment. 4. Install a new gasket.
Refer to Operation and Maintenance, “Fire Note: A new gasket is provided with each new ether
Prevention and Explosion Prevention” before you starting aid cylinder.
replace the ether cylinder.
5. Install the new ether starting aid cylinder.
6. Tighten the ether starting aid cylinder hand tight.
7. Tighten the cylinder retaining clamp securely.
SEBU9190-12 197
Maintenance Section
Film (Product Identification) - Clean

i07681009 Cleaning of the Films

Film (Product Identification) - Make sure that all of the product identification films
are legible. Make sure that the recommended
Clean procedures are used in order to clean the product
SMCS Code: 7405-070; 7557-070 identification films. Ensure that all the product
identification films are not damaged or missing.
Clean the product identification films or replace the
films.

Hand Washing
Use a wet solution with no abrasive material that
contains no solvents and no alcohol. Use a wet
solution with a “pH” value between 3 and 11. Use a
soft brush, a rag, or a sponge in order to clean the
product identification films. Avoid wearing down the
surface of the product identification films with
unnecessary scrubbing. Ensure that the surface of
the product identification films is flushed with clean
water and allow the product identification films to air
dry.

Illustration 330 g02174985 Power Washing

Power washing or washing with pressure may be
used in order to clean product identification films.
However, aggressive washing can damage the
product identification films.
Excessive pressure during power washing can
damage the product identification films by forcing
water underneath the product identification films.
Water lessens the adhesion of the product
identification film to the product, allowing the product
identification film to lift or curl. These problems are
magnified by wind. These problems are critical for the
perforated film on windows.
To avoid lifting of the edge or other damage to the
product identification films, follow these important
Illustration 331 g02175297
steps:

• Use a spray nozzle with a wide spray pattern.

• A maximum pressure of 83 bar (1200 psi)
• A maximum water temperature of 50° C (120° F)

• Hold the nozzle perpendicular to the product

identification film at a minimum distance of
305 mm (12 inch).

Illustration 332 g06394021

Typical example of the Product Identification Films.
198
Maintenance Section
Final Drive Oil - Change
• Do not direct a stream of water at a sharp angle to
the edge of the product identification film.
i05843879
Final Drive Oil - Change
SMCS Code: 4050-044-FLV
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact skin.
Illustration 333 g03694501
(1) Oil fill plug
(2) Oil level plug
(3) Oil drain plug
1. Position one final drive so that oil drain plug (3) is
at the bottom.
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information on
Containing Fluid Spillage.
2. Remove drain plug (3), level plug (2), and fill plug
(1). Allow the oil to drain into a suitable container.
3. Clean the plugs and inspect the O-ring seals. If
wear or damage is evident, replace the drain plug,
the level plug, the fill plug, and/or the O-ring seals.
4. Install drain plug (3).
5. Fill the final drive through the opening of fill plug (1)
to the bottom of the opening on level plug (2). See
Operation and Maintenance Manual, “Lubricant
Viscosities” and Operation and Maintenance
Manual, “Capacities (Refill) ”.
Note: If the oil fills slowly, the fill hole may be blocked
by the planetary gear. Rotate the final drive in order
to move the planetary gear away from the fill hole.
SEBU9190-12
Note: Overfilling the final drive will cause the seals
on the travel motor to allow hydraulic oil or water to
enter the final drive. The final drive may become
contaminated.
6. Install fill plug (1) and level plug (2).
7. Perform Step 1 to Step 6 on the other final drive.
Use a different container for the oil so that the oil
samples from the final drives will be separate.
8. Completely remove the oil that has spilled onto
surfaces.
9. Start the engine and allow the final drives to run
through several cycles.
10. Stop the engine. Check the oil level.
11. Check the drained oil for metal chips or for
particles. If there are any chips or particles,
consult your Caterpillar dealer.
12. Properly dispose of the drained material. Obey
local regulations for the disposal of the material.
i05843983
Final Drive Oil Level - Check
SMCS Code: 4050-535-FLV
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact skin.
Illustration 334 g03694501
(1) Oil fill plug
(2) Oil level plug
(3) Oil drain plug
1. Position one final drive so that oil drain plug (3) is
at the bottom.
SEBU9190-12
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information on
Containing Fluid Spillage.
2. Remove oil level plug (2).
3. Check the oil level. The oil should be near the
bottom of the level plug opening.
4. Add oil through the fill plug opening, if necessary.
See Operation and Maintenance, “Lubricant
Viscosities”.
Note: If the oil fills slowly, the fill hole may be blocked
by the planetary gear. Rotate the final drive in order
to move the planetary gear away from the fill hole.
Note: Overfilling the final drive will cause the seals
on the travel motor to allow hydraulic oil or water to
enter the final drive. The final drive may become
contaminated.
5. Clean oil level plug (2). Inspect the O-ring seal.
Replace the O-ring seal if the O-ring seal is worn
or damaged.
6. Install oil level plug (2).
7. Repeat the procedure for the other final drive.
i05844002
Final Drive Oil Sample - Obtain
SMCS Code: 4011-008; 4050-008; 4050-SM; 7542-
008
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact skin.
Illustration 335 g03694501
(1) Oil fill plug
(2) Oil level plug
(3) Oil drain plug
199
Maintenance Section
Final Drive Oil Sample - Obtain
1. Position the final drive so that oil drain plug (3) is at
the bottom.
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information on
Containing Fluid Spillage.
2. Remove oil level plug (2).
3. Obtain a sample of the final drive oil through the
hole for the oil level plug.
4. Install oil level plug (2).
Refer to Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” “S·O·S Oil
Analysis” for more information on obtaining a sample
of the final drive oil. For additional information about
taking an oil sample, refer to Special Publication,
PEGJ0047, “How To Take A Good Oil Sample”.
i05844023
Fuel System - Prime
SMCS Code: 1250-548
Personal injury or death may result from failure
to adhere to the following procedures.
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire.
Clean up all leaked or spilled fuel. Do not smoke
while working on the fuel system.
Turn the disconnect switch OFF or disconnect
the battery when changing fuel filters.
Prime the fuel system in order to purge trapped air
and in order to fill the fuel filter.
Illustration 336 g03694560
Fuel system primary filter (water separator)
200 SEBU9190-12
Maintenance Section
Fuel System Primary Filter (Water Separator) - Check/Drain

i05844075

Fuel System Primary Filter

(Water Separator) - Check/
Drain
SMCS Code: 1263-535; 1263-543

Fuel leaked or spilled onto hot surfaces or electri-

cal components can cause a fire. To help prevent
possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Illustration 337 g03694556 Clean up fuel spills immediately.
Fuel system priming pump switch

The switch for the fuel system priming pump is NOTICE

located on the fuel system primary filter (water Care must be taken to ensure that fluids are con-
separator). Open the left side access door in order to tained during performance of inspection, mainte-
operate the fuel system priming pump switch. nance, testing, adjusting, and repair of the machine.
Be prepared to collect the fluid with suitable contain-
Note: The engine start switch must be in the OFF ers before opening any compartment or disassem-
position in order to prime the fuel system. bling any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
1. Hold the priming pump switch upward in order to
Tools and Shop Products Guide”for tools and sup-
activate the electric fuel priming pump. The plies to collect and contain fluids in Caterpillar
priming pump will fill the engine fuel lines and the machines.
fuel filters with fuel.
Dispose of all fluids according to local regulations.
2. As the air is purged from the fuel system, fuel
pressure will increase.
3. 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.
4. If the engine starts but the engine runs rough,
continue to run the engine at low idle until the
engine runs smoothly.
5. If the engine does not start after several attempts,
consult your Cat dealer.

Illustration 338 g03694560

1. Locate the primary fuel filter (water separator). The

primary fuel filter (water separator) is mounted on
the side of the fuel tank.
SEBU9190-12
Fuel System Primary Filter (Water Separator) Element - Replace
Illustration 339 g03694570
(1) Primary fuel filter
(2) Water separator bowl
(3) Water separator drain valve
(4) Water separator drain hose
2. The water separator is located on the bottom of
primary fuel filter (1). Direct water separator drain
hose (4) into a suitable container.
3. Open water separator drain valve (3) on the
bottom of water separator bowl (2). Allow the
water and other contaminants to drain into the
suitable container.
4. After the water separator is drained, close the
drain by hand pressure only. Properly dispose of
the drained fluid.
i05844105
Fuel System Primary Filter
(Water Separator) Element -
Replace
SMCS Code: 1263-510-FQ
Personal injury or death can result from a fire.
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire.
Clean up all leaked or spilled fuel. Do not smoke
while working on the fuel system.
Turn the disconnect switch OFF or disconnect
the battery when changing fuel filters.
201
Maintenance Section
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, PERJ1017, “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 ac-
celerated wear to fuel system parts. The fuel sys-
tem should be primed prior to starting the engine.
Note: In order to reduce contamination in the system,
do not remove the primary fuel filter and the
secondary fuel filter simultaneously. Perform these
operations separately.
Note: After the engine has stopped, you must wait for
60 seconds in order to allow the fuel pressure to be
purged from the high-pressure fuel lines before any
service or repair is performed on the engine fuel
lines.
1. Locate the fuel supply shutoff valves. The fuel
supply shutoff valves are mounted on the inboard
vertical surface of the fuel tank above the left-hand
steering cylinder.
Illustration 340 g03694583
(1) Rear fuel supply shutoff valve
(2) Front fuel supply shutoff valve
2. Turn handles of rear fuel supply shutoff valve (1)
and front fuel supply shutoff valve (2) to the OFF
position.
202
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
Illustration 341 g03694560
3. Locate the primary fuel filter (water separator). The
primary fuel filter(water separator) is mounted on
the side of the fuel tank.
4. Place a suitable container under the primary fuel
filter/water separator in order to catch any fuel that
might spill. Clean up any spilled fuel. Clean the
outside of the water separator.
Illustration 342 g03694592
(3) Primary fuel filter
(4) Water separator bowl
(5) Water separator drain valve
(6) Water separator drain hose
5. Water separator bowl (4) is located on the bottom
of primary fuel filter (3). Direct water separator
drain hose (6) into a suitable container.
6. Open water separator drain valve (5) on the
bottom of the water separator bowl. Allow the
water, fuel, and other contents to drain into the
suitable container.
7. Tighten the drain valve by hand pressure only.
8. Unscrew the water separator bowl from the
primary fuel filter.
SEBU9190-12
Note: The water separator bowl is reusable. Do not
discard the water separator bowl.
9. Use a Cat strap wrench in order to remove the
filter. Discard the old seals and the old fuel filter in
a safe place.
10. Clean the water separator bowl.
11. Install a new primary fuel filter.
a. Apply clean diesel fuel or a thin coat of clean
engine oil to the seal on the new filter.
b. Install the 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 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.
c. Tighten the filter according to the instructions
that are printed on the filter. Use the index
marks as a guide. For non-Cat filters, use the
instructions that are provided with the filter.
Note: You may need to use a Cat 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.
12. Lubricate the new water separator bowl seal with
clean diesel fuel or with clean engine oil. Place the
new seal in the water separator bowl.
13. Screw the water separator bowl onto the primary
fuel filter.
14. Turn the fuel supply valve to the ON position after
you perform this maintenance.
15. Be sure to dispose of the fuel and other contents
that were drained from the used primary fuel filter/
water separator in a safe place.
16. Prime the fuel system. Refer to Operation and
Maintenance Manual, “Fuel System - Prime” for
more information.
SEBU9190-12 203
Maintenance Section
Fuel System Secondary Filter - Replace

i05844150

Fuel System Secondary Filter -

Replace
SMCS Code: 1261-510

Personal injury or death can result from a fire.

Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire.
Clean up all leaked or spilled fuel. Do not smoke
while working on the fuel system. Illustration 343 g03694656

Turn the disconnect switch OFF or disconnect

the battery when changing fuel filters.

NOTICE
Do not fill fuel filters with fuel before installing them.
Contaminated fuel will cause accelerated wear to fuel
system parts.

NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.
The two secondary fuel filters are located behind the
engine access door on the right-hand side of the Illustration 344 g06126350
machine.
3. Locate the secondary fuel filters. The secondary
Note: The pressure must be removed from the fuel filters are located in the engine compartment
system before service can be performed. Refer to
on the left-hand side of the machine.
this Operation and Maintenance Manual, “System
Pressure Release”. 4. Remove the two secondary fuel filters. Dispose of
the used filters properly.
1. Turn the fuel supply shutoff valves to the OFF
position. Refer to Operation and Maintenance Note: The filters contain fuel. When you remove the
Manual, “Fuel System Primary Filter (Water filters, use caution to avoid spilling the fuel.
Separator) Element - Replace” for information on
how to operate the fuel supply shutoff valves on Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information on
this machine.
containing fluid spillage.
2. Open the engine access door on the front of the
engine compartment. 5. Clean the mounting base of the fuel filters. Make
sure that all the old seal material is removed from
the mounting base.
204 SEBU9190-12
Maintenance Section
Fuel Tank Cap Filter - Replace

i04421489

Fuel Tank Cap Filter - Replace

SMCS Code: 1273-510-FI; 1273-510-Z2

Illustration 345 g00101318

6. Apply a thin coat of clean diesel fuel to the sealing

surface of each new fuel filter.
7. Install the new filters by hand.
Illustration 346 g02612539
Instructions for the installation of the filter are
printed on the side of each Cat spin-on filter. For 1. Remove the fuel cap.
non-Cat filters, refer to the installation instructions 2. Remove filter element screws (2) from the
that are provided by the supplier of the filter. underside of the fuel cap and remove old filter
Note: You may need to use a Cat strap wrench, or element (1).
another suitable tool, to turn the filter to the amount 3. Wash the fuel tank cap in a clean, nonflammable
that is required for final installation. Make sure that solvent.
the installation tool does not damage the filter.
4. Install a new fuel cap filter element.
8. Turn the fuel supply shutoff valves to the ON
position. 5. Install filter element screws (2) in order to secure
filter element (1) to the fuel cap.
9. Prime the fuel system. See Operation and
Maintenance Manual, “Fuel System - Prime” for 6. Install the fuel tank cap
instructions.
i04462462
10. Close the engine access door on the right-hand
side of the machine. Fuel Tank Strainer - Clean
SMCS Code: 1273-070-STR

Illustration 347 g02609604

1. Remove fuel tank cap (1).

SEBU9190-12 205
Maintenance Section
Fuel Tank Water and Sediment - Drain

2. Remove strainer (2) from the filler opening.

3. Wash the strainer in a clean, nonflammable
solvent.
4. Install the strainer into the filler opening.
5. Install the fuel tank cap.

i05844280

Fuel Tank Water and Sediment

- Drain
SMCS Code: 1273-543
Refer to this Operation and Maintenance Manual,
“Fuel Tank Shutoff and Drain Control” for the exact
location of the fuel tank drain valve
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information on
containing fluid spillage.
Illustration 349 g03694687
1. Open the drain valve by turning the valve
counterclockwise. Allow the water and the
sediment to drain into a suitable container.
Note: Dispose of drained fluids according to local
regulations.

2. Close the drain valve by turning the valve

clockwise.

i05841534

Fuses - Replace
SMCS Code: 1417-510

Illustration 348 g03689795

Location of the fuel tank drain valve.

Illustration 350 g03693525

The fuse panel is located on the left side of the

interior storage box. Remove the cover in order to
access the fuses.
Fuses – Fuses protect the electrical
system from damage that is caused by
overloaded circuits. Change a fuse if the
element separates. If the element of a new fuse
separates, check the circuit and/or repair the
circuit.
206 SEBU9190-12
Maintenance Section
Fuses - Replace

(F9) Mid Precision GPS – 10 Amp

NOTICE
Always replace fuses with the same type and ca- (F10) 12V Converter – 10 Amp
pacity fuse that was removed. Otherwise, electrical
damage could result. (F11) Automatic Lubrication – 15 Amp
(F12) Powered Stairway – 10 Amp
NOTICE (F13) Air Conditioner – 10 Amp
If it is necessary to replace fuses frequently, an elec-
trical problem may exist. (F14) Heated Mirrors – 15 Amp
Contact your Cat dealer. (F15) Fuel Gauge – 10 Amp
(F16) Seat – 10 Amp
To replace a fuse, use the puller that is stored in the
fuse panel. (F17) Heated Seat – 10 Amp

The following list identifies the circuits that are (F18) Spare – 10 Amp
protected by each fuse. The amperage for each fuse (F19) Beacon – 10 Amp
is included with each circuit.
(F20) Alarm – 10 Amp
(F21) Engine ECM – 15 Amp
(F22) Engine ECM – 15 Amp
(F23) Powered Stairway – 10 Amp
(F24) Work Lights – 15 Amp
(F25) Work Lights – 15 Amp
(F26) Ladder Lights – 15 Amp
(F27) Monitoring System – 10 Amp
(F28) Work Lights – 15 Amp
(F29) Engine Enclosure Lights – 15 Amp
(F30) Spare – 15 Amp
(F31) Display – 10 Amp
(F32) Switch Panel Module – 10 Amp
(F33) Primer (Start Aid) – 15 Amp
(F34) Horn – 10 Amp
(F35) Keyswitch – 10 Amp
(F36) Hydraulic ECM – 15 Amp

Illustration 351 g03693599

(F37) Machine ECM – 15 Amp
(F38) Starter Motor – 10 Amp
(F1) HVAC – 15 Amp
(F39) Work Lights – 15 Amp
(F2) Lower Window Wiper and Washer – 10 Amp
(F40) 12V Converter – 10 Amp
(F3) Condenser – 15 Amp
(F4) Upper Window Wiper and Washer – 10 Amp
(F5) Empty – N/A
(F6) Empty – N/A
(F7) WAVS Display – 10 Amp
(F8) Swing Pump Displacement Sensor – 10 Amp
SEBU9190-12 207
Maintenance Section
Hydraulic System High Pressure Screen - Check/Replace

Relays
i07576343

Hydraulic System High

Pressure Screen - Check/
Replace
SMCS Code: 5068-040

Hot oil and hot components can cause personal

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

If a hydraulic system becomes contaminated or if a

major failure occurs, clean the screen. If a screen is
damaged, replace the screen.
Check the screen and clean the screen at "Every 500
Service Hours or 3 Months". Replace the screen at
"Every 5000 Service Hours".

Illustration 352 g03693634

(R1) Primer (Start Aid) – Relay

(R2) Alarm – Relay
(R3) Work Light – Relay
(R4) Work Light – Relay
(R5) Work Light – Relay
Illustration 353 g00880867
(R6) Work Light – Relay
1. Put the machine in the servicing position.
(R7) Automatic Lubrication – Relay
2. Move the hydraulic lockout control (lever) to the
(R8) Lower Window Wiper – Relay
LOCKED position.
(R9) Starter Motor – Relay
(R10) Lower Window Washer – Relay
208 SEBU9190-12
Maintenance Section
Hydraulic System Oil - Change

Illustration 354 g03831089 Illustration 356 g03695752

3. Press the button on the breaker valve to release
the hydraulic tank pressure. The breaker valve is
on the hydraulic tank by the filler pipe.
5. Remove the plug from the bottom of the cartridge
that holds screen (2) to allow the oil to drain.
Remove screen (2) from the cartridge.
6. Wash the screen and the plug in a nonflammable
solvent. Dry the parts.
7. Carefully insert the screen back into the cartridge.
8. Tighten the plug and install the cartridge on the
machine.
9. Use the same procedure for the other high-
pressure screen (3).
10. Close the access door.

i06614154

Hydraulic System Oil - Change

Illustration 355 g03695751
SMCS Code: 5056-044
4. Open access door (1) on the right side of the 1. Operate the machine until the hydraulic oil is
machine. warm.
SEBU9190-12 209
Maintenance Section
Hydraulic System Oil - Change

3. Breaker valve (2) is located next to filler cap (1).

Press the button on breaker valve (2) to relieve the
tank pressure before you remove filler cap (1).

NOTICE
Never remove the hydraulic tank filler cap from the
hydraulic tank if the oil is hot.
Air can enter the system which can cause pump
damage.

4. Remove filler cap (1).

5. Remove the filler strainer and clean the strainer.
Install the strainer.
Illustration 357 g00880867

2. Park the machine on level ground. Lower the

bucket to the ground so that the stick is vertical.
Stop the engine.

At operating temperature, the hydraulic tank is

hot and under pressure.
Hot oil and components can cause personal in-
jury. Do not allow hot oil or components to con-
tact skin.
Before removing the filler cap, press the valve re-
lief button on the hydraulic tank in order to re- Illustration 359 g03695836
lieve the tank pressure.
Remove the filler cap only when the engine is
stopped and the filler cap is cool enough to touch
with your bare hand. Remove the filler cap slowly
in order to relieve any remaining pressure.

Illustration 360 g03695837

6. Remove drain plug (4) that is located in the bottom

of the hydraulic tank.

Illustration 358 g03695832

(1) Filler cap
(2) Breaker valve
(3) Sight gauge
210 SEBU9190-12
Maintenance Section
Hydraulic System Oil Cooler Core - Clean

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

NOTICE
Care must be taken to ensure that fluids are con- present in the oil, air is entering the hydraulic system.
tained during performance of inspection, mainte- Inspect the suction hoses and inspect the clamps.
nance, testing, adjusting and repair of the machine.
Be prepared to collect the fluid with suitable contain- 15. Stop the engine.
ers before opening any compartment or disassem-
bling any component containing fluids. 16. If necessary, tighten any loose clamps and
connections. Replace any damaged hoses.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide”, for tools and sup- i05845862
plies suitable to collect and contain fluids in Caterpil-
lar machines. Hydraulic System Oil Cooler
Dispose of all fluids according to local regulations
and mandates.
Core - Clean
SMCS Code: 1374-070-KO
7. Install an NPT pipe nipple that is 25 mm (1 inch) in
diameter and 100 mm (4 inch) long to open the
internal drain valve. Drain the oil into a suitable
container.

Note: Tighten the NPT pipe nipple by hand. Do not

use tools.
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information on
containing fluid spillage.

8. Remove the NPT pipe nipple. Install drain plug (4).

9. Change the hydraulic system filters. Refer to
Operation and Maintenance Manual, “Hydraulic
Illustration 361 g03695847
Oil Tank Filters - Replace” and Operation and
Maintenance Manual, “Hydraulic System Oil Filter Inspect hydraulic oil cooler core (1) for debris. If
(Pilot) - Replace” for information on changing the necessary, clean the core. Compressed air is
hydraulic system filters. preferred, but high-pressure water or steam can also
be used to remove dust, leaves, and general debris
10. Fill the hydraulic system oil tank by adding oil from the core.
through the filler tube. Refer to Operation and
Maintenance Manual, “Lubricant Viscosities” to
determine the correct type of oil. Refer to
Operation and Maintenance Manual, “Capacities
(Refill)” to determine the correct amount of oil.
11. Check the O-ring seal of filler cap (2). Replace
the O-ring seal if the seal is damaged.
12. Clean the filler cap and install the filler cap.
13. Start the engine and run the engine for a few
minutes.
14. With the linkage in the service position, check the
oil level on sight gauge (3). Maintain the oil level
above the “ADD” mark.
Refer to Operation and Maintenance Manual,
“Hydraulic System Oil Level - Check” for
information on checking the oil level and adding
oil.
SEBU9190-12 211
Maintenance Section
Hydraulic System Oil Filter (Charge Pump) - Replace

i06154378

Hydraulic System Oil Filter

(Charge Pump) - Replace
SMCS Code: 3204-510; 5068-510

Illustration 364 g03695751

4. Open access door (1) on the right side of the

machine.

Illustration 362 g00880867

1. Put the machine in the servicing position.

2. Move the hydraulic lockout control (lever) to the
LOCKED position.

Illustration 365 g03831092

5. Use a strap type wrench in order to remove swing

oil filter (2).
6. Inspect the oil filter. Refer to Operation and
Maintenance Manual, “Oil Filter - Inspect” for
information on inspecting the oil filter.

Illustration 363 g03831089
3. Press the button on the breaker valve in order to
release the hydraulic tank pressure. The breaker
valve is located on the hydraulic tank by the filler
pipe.
7. Clean the filter housing base. Make sure that all of
the old filter seal is removed.
8. Lubricate the seal of the new filter with a light coat
of hydraulic oil.
9. Install the new filter by hand. Additionally tighten
the filter by 3/4 turn after the seal contacts the filter
base.
10. Close access door (1).
212 SEBU9190-12
Maintenance Section
Hydraulic System Oil Filter (Pilot) - Replace

i05845739

Hydraulic System Oil Filter

(Pilot) - Replace
SMCS Code: 5068-510; 5068-510-PS; 5092-510

Hydraulic oil pressure can remain in the hydraulic

oil system on this machine after the engine and
pump have been stopped. Personal injury can be
caused if this pressure is not released before any
service is done on the hydraulic systems. To pre-
vent personal injury, refer to the procedure in
Testing and Adjusting Manual, “Release of Pres-
sure in the Hydraulic System”.
When possible, the bucket must always be low-
ered to the ground with the cutting edge rotated
to the ground before service is started. When it is
necessary for the boom to be in the raised posi-
tion while tests or adjustments are done, be sure
that the boom, stick and bucket have correct
support.
Be sure the swing parking brakes and the travel
parking brakes are on and the brake release lines
are disconnected and plugged.
Always move the machine to a location away
from the travel of other machines. Be sure that
other personnel are not near the machine when
the engine is running and tests or adjustments
are being made.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
Illustration 366 g03695770
Pilot manifold
(1) Pressure tap for low-pressure pilot circuit
5. Check the pilot pressure at pressure tap (1) for the
low-pressure pilot circuit on the pilot manifold
under the cab.
6. Put the hydraulic lockout control (lever) in the
UNLOCK position. Turn the engine start key to the
ON position. Do not start the engine.
7. Move the control levers for the boom, the stick, the
bucket, and swing to each of the FULL STROKE
positions. Actuate both the trigger switches for the
front shovel bucket bottom dump controls. This
actuation should release any pressure that might
be present in the main implement system.
Disconnect the auxiliary pump unit (if used) and
install the pressure gauge at the test port.
Continue to move the control levers until the pilot
system pressure is released. Use a pressure
gauge to verify that the pilot system pressure is
released.

Before the pilot oil filter for the hydraulic system can
be replaced, the pressure in the hydraulic system
must be released.
1. Fully retract the rod in the stick cylinder.
2. Adjust the position of the bucket as the boom is
lowered. The bucket must rest flat on the ground.
3. Lower the boom until the bucket is flat on the
ground.
4. Shut off the engine.

Illustration 367 g03695782

Location of button (2) on the breaker valve
SEBU9190-12
8. Press button (2) on the breaker valve in order to
release the hydraulic tank pressure. The breaker
valve is located on the hydraulic tank by the filler
pipe.
9. The pressure in the system has been released and
the pilot oil filter can be replaced.
Illustration 368 g03695788
10. Open hydraulic pump compartment door (3) on
the first level of the operator platform.
Illustration 369 g03695789
11. Use a strap type wrench in order to remove pilot
oil filter (4).
12. Inspect the oil filter. Refer to Operation and
Maintenance Manual, “Oil Filter - Inspect” for
information on inspecting the oil filter.
13. Clean the filter housing base. Make sure that all
of the old filter seal is removed.
14. Lubricate the seal of the new filter with a light coat
of hydraulic oil.
15. Install the new filter by hand. Additionally tighten
the filter by 3/4 turn after the seal contacts the filter
base.
213
Maintenance Section
Hydraulic System Oil Filter (Return) - Replace
16. Close pump compartment door (3).
i06816875
Hydraulic System Oil Filter
(Return) - Replace
SMCS Code: 5068-510-RJ
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
Note: To access the areas required to perform this
procedure, a portable access system (ladder, stair
assembly, man lift, or other portable access system)
that is suitable and compliant to local regulations may
be necessary.
Illustration 370 g03831065
(1) Kidney loop (return) filter cover
(2) Return filter covers
(3) Breaker valve
(4) Sight gauge
The hydraulic tank filter elements are located under
filter covers on top of the hydraulic tank.
1. Press the button on breaker valve (3) to relieve the
pressure in the hydraulic tank.
2. Remove kidney loop (return) filter cover (1), and
the two return filter covers (2).
3. Inspect the seals in the filter covers and replace
the seals, if necessary.
4. Remove the filter elements and discard the filter
elements according to local regulations.
5. Install new filter elements.
6. Install kidney loop (return) filter cover (1), and the
two return filter covers (2).
214 SEBU9190-12
Maintenance Section
Hydraulic System Oil Level - Check

7. Check the oil level on sight gauge (4).

For a cold machine, the hydraulic oil should
completely fill the sight gauge. For a machine that
is at normal operating temperature, the hydraulic
oil should be above the “ADD” mark.
Refer to Operation and Maintenance Manual,
“Hydraulic System Oil Level - Check” for
information on checking the oil level and adding
oil.

i05845969

Hydraulic System Oil Level -

Illustration 371 g00880867
Check
SMCS Code: 5050-535 1. Park the machine on level ground. Place the
machine in the servicing position.
The hydraulic oil tank is on the right side of the
machine.
At operating temperature, the hydraulic tank is
hot and under pressure.
Hot oil and components can cause personal in-
jury. Do not allow hot oil or components to con-
tact skin.
Before removing the filler cap, press the valve re-
lief button on the hydraulic tank in order to re-
lieve the tank pressure.
Remove the filler cap only when the engine is
stopped and the filler cap is cool enough to touch
with your bare hand. Remove the filler cap slowly
in order to relieve any remaining pressure.

NOTICE
Never remove the hydraulic tank filler cap from the Illustration 372 g03695832
hydraulic tank if the oil is hot.
Air can enter the system which can cause pump
damage.

Illustration 373 g03695882

Sight gauge (3)
SEBU9190-12 215
Maintenance Section
Hydraulic System Oil Sample - Obtain

2. For a cold machine, maintain the hydraulic oil level

in the low temperature range (B) on sight gauge
(3). For a machine that is at normal operating
temperature, maintain the hydraulic oil level in the
high temperature range (A) on sight gauge (3).

Note: Refer to Operation and Maintenance Manual,

“General Hazard Information” for information on
containing fluid spillage.

3. Press the button on breaker valve (2) in order to

release the pressure in the hydraulic tank.
4. Slowly loosen filler cap (1) in order to relieve any
remaining pressure. Add oil, if necessary.
5. Check the O-ring seal of the filler cap. Replace the
O-ring seal if the O-ring seal is damaged.
6. Clean the filler cap and install the filler cap.

i06906512

Hydraulic System Oil Sample -

Obtain
SMCS Code: 5050-008-OC; 5095-SM; 5095-008;
7542; 7542-008
Relieve the hydraulic oil pressure before obtaining
the hydraulic system oil sample. Refer to Operation
and Maintenance Manual, System Pressure Release
for information on relieving the hydraulic oil pressure.
Illustration 374 g06162832
The sampling port for the hydraulic oil is located
above the hydraulic system charge pump oil filter.
Refer to Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” and refer to
Special Publication, PEGJ0047, “How To Take A
Good Oil Sample” for more information about
obtaining an oil sample. Consult your Caterpillar
dealer for complete information.

i03753191

Indicators and Gauges - Test

SMCS Code: 7450-081; 7490-081

1. Look for broken lenses on the gauges, broken

indicator lights, broken switches, and other broken
components in the cab.
2. Start the engine.
3. Look for inoperative gauges.
4. Turn on all machine lights. Check for proper
operation.
5. Move the machine forward. Release the travel
levers and the travel pedals. The machine should
stop.
6. Stop the engine.
216 SEBU9190-12
Maintenance Section
Machine Structure - Inspect

7. Make any repairs that are required before
operating the machine.
i07735166
Machine Structure - Inspect
SMCS Code: 7000-040; 7050-040
A full structural inspection of the machine must be
completed every 1500 service hours. If the machine
is equipped with a hydraulic hammer, then a full
structural inspection must be completed every 500
service hours.
Refer to General Service Information, EM029412,
“6015B: Structural Inspection” for the inspection
procedure.
The structural inspection manual contains
inspections for the following sections:
• Undercarriage
• Superstructure
• Attachment
To reduce downtime, for the standard structural
inspection Caterpillar recommends inspecting one
section every 500 service hours. If the machine is
equipped with a hydraulic hammer, then all three
sections must be performed every 500 service hours.
i02106227
Use a filter cutter to cut the filter element open.
Spread apart the pleats and inspect the element for
metal and for other debris. An excessive amount of
debris in the filter element can indicate a possible
failure.
If metals are found in the filter element, a magnet can
be used to differentiate between ferrous metals and
nonferrous metals.
Ferrous metals can indicate wear on steel parts and
on cast iron parts.
Nonferrous metals can indicate wear on the
aluminum parts of the engine such as main bearings,
rod bearings, or turbocharger bearings.
Small amounts of debris may be found in the filter
element. This could be caused by friction and by
normal wear. Consult your Caterpillar dealer in order
to arrange for further analysis if an excessive amount
of debris is found.
Using an oil filter element that is not recommended
by Caterpillar can result in severe engine damage to
engine bearings, to the crankshaft, and to other
parts. This can result in larger particles in unfiltered
oil. The particles could enter the lubricating system
and the particles could cause damage.
i06507480
Powered Stairway - Lubricate
SMCS Code: 0634-086-PWR

Note: Refer to Special Publication, SEBU6250,

Oil Filter - Inspect “Caterpillar Machine Fluids Recommendations” for
SMCS Code: 1308-507; 5068-507 more information on grease.
Wipe all fittings before you apply lubricant.
Inspect a Used Filter for Debris

Illustration 376 g06001883

Illustration 375 g00100013 There are four grease fittings for the powered
The element is shown with debris. stairway. Remove the tread plate to access the
fittings. Lubricate all four fittings.
SEBU9190-12
i06805012
Radiator Core - Clean
SMCS Code: 1353-070
Illustration 377 g03695884
Radiator core (1) is located on the left side of the
machine in front of the counterweight.
1. Check both sides of the coolers for debris. Debris
is most likely to build up on the fan side of radiator
due to the direction of air flow.
Note: Air flows from the fan, through the radiator and
into the engine compartment.
2. Remove dust and debris from the radiator core.
Compressed air is the preferred method of
cleaning, but high-pressure water or steam can be
used to remove dust and general debris from a
radiator.
Refer to Operation and Maintenance Manual,
“General Hazard Information” for the proper safety
precautions that should be followed before
compressed air is used.
Refer to Special Publication, SEBD0518, “Know
Your Cooling System” for more detailed
information about cleaning the radiator core.
217
Maintenance Section
Radiator Core - Clean
i05805860
Receiver Dryer (Refrigerant) -
Replace
SMCS Code: 7322-510; 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 in-
dicate the system is empty of refrigerant.
Always use precaution when a fitting is removed.
Slowly loosen the fitting. If the system is still
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 con-
ditioning system.
NOTICE
If the refrigerant system has been open to the outside
air (without being plugged) for more than 30 minutes,
the receiver-dryer must be replaced. Moisture will en-
ter an open refrigerant system and cause corrosion
which will lead to component failure.
Refer to Service Manual, “Air Conditioning and
Heating R-134a for All Caterpillar Machines” for the
proper procedure to change the receiver-dryer
assembly and for the procedure to reclaim the
refrigerant gas.
i04423622
Seat Belt - Inspect
SMCS Code: 7327-040
Always inspect the condition of the seat belt and the
condition of the seat belt mounting hardware before
you operate the machine. Replace any parts that are
damaged or worn before you operate the machine.
218 SEBU9190-12
Maintenance Section
Seat Belt - Replace

Illustration 379 g01152685

Illustration 378 g02620101

Typical example
Inspect buckle (1) for wear or for damage. If the
buckle is worn or damaged, replace the seat belt.
Inspect seat belt (2) for webbing that is worn or
frayed. Replace the seat belt if the webbing is worn
or frayed.
Inspect all seat belt mounting hardware for wear or
for damage. Replace any mounting hardware that is
worn or damaged. Make sure that the mounting bolts
are tight.
If your machine is equipped with a seat belt
extension, also perform this inspection procedure for
the seat belt extension.
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)
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.
Complete seat belt system should be installed with
new mounting hardware.
Date of installation labels should be marked and
affixed to the seat belt retractor and buckle.

Contact your Cat dealer for the replacement of the
seat belt and the mounting hardware.
Note: 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
tags (non-retractable belts).
Note: Date of installation labels should be
permanently marked by punch (retractable belt) or
stamp (non-retractable belt).
If your machine is equipped with a seat belt
extension, also perform this replacement procedure
for the seat belt extension.

i06891605

Seat Belt - Replace

SMCS Code: 7327-510
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
tags (non-retractable belts).
SEBU9190-12 219
Maintenance Section
Strainer (Hydraulic Tank) - Clean

i05844401

Strainer (Hydraulic Tank) -

Clean
SMCS Code: 5068

At operating temperature, the hydraulic tank is

hot and under pressure.
Hot oil and components can cause personal in-
jury. Do not allow hot oil or components to con-
tact skin.
Before removing the filler cap, press the valve re-
lief button on the hydraulic tank in order to re-
lieve the tank pressure.
Remove the filler cap only when the engine is
stopped and the filler cap is cool enough to touch
with your bare hand. Remove the filler cap slowly
in order to relieve any remaining pressure. Illustration 381 g00754730

3. Remove lock ring (3). Remove strainer assembly

(4) from the hydraulic tank.
4. Wash the strainer assembly in a clean,
nonflammable solvent.
5. Position the strainer assembly (4) into the
hydraulic tank. Install lock ring (3).

Illustration 380 g03694870

(1) Location of the breaker valve
(2) Location of the filler cap

1. Breaker valve (1) is located next to filler cap (2).

Press the button on breaker valve (1) in order to
relieve the tank pressure before you remove filler
cap (2).

NOTICE
Never remove the hydraulic tank filler cap from the
hydraulic tank if the oil is hot.
Air can enter the system which can cause pump
damage.

2. Remove filler cap (2).

220
Maintenance Section
Swing Bearing Bolts - Check
i07291679
Swing Bearing Bolts - Check
SMCS Code: 7063-535; 7063-535-BC
Illustration 382 g06276266
Typical inner and outer swing bearing bolts location
Check all the mounting bolts that join the swing
bearing to the swing frame. Also check all the
mounting bolts that join the swing bearing to the
carbody. Ensure that none of the bolts are loose.
Refer to and use the procedures and torques called
out for the 6015B listed within the Special Instruction,
REHS1012, “Procedure for Periodic Static Torque
Inspection of the Bolts for the Swing Bearing”.
SEBU9190-12
i07196571
Swing Drive Oil - Change
SMCS Code: 5459-044
The rear swing drive motor is located between the
swivel joint and the implement and travel control
valve. The front swing drive motor is located in front
of the swivel. Perform the same procedure for both of
the swing drives.
1. Operate the swing function for a duration of one to
two minutes.
Illustration 383 g03694895
(1) coupler for rear swing drive
(2) coupler for front swing drive
2. Coupler (1) and coupler (2) are located between
the pins for the boom pivot. Connect a hose that is
equipped with a 9S-9273 Coupler to the coupler
for the swing drive. Place the end of the hose into
a suitable oil container.
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 machine.
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, “Caterpillar
Tools and Shop Products Guide”, for tools and sup-
plies suitable to collect and contain fluids in Caterpil-
lar machines.
Dispose of all fluids according to local regulations
and mandates.
SEBU9190-12 221
Maintenance Section
Swing Drive Oil Level - Check

Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information on
containing fluid spillage.
3. Remove the oil drain hose and clean the hose.
4. Check the oil level of the swing drive motor. Refer
to Operation and Maintenance Manual, “Swing
Drive Oil Level - Check” for information on
checking the oil level.
5. Caterpillar recommends flushing the swing drive at
this time. To flush the swing drive, operate the
swing function for a duration of one to two
minutes. Drain the swing drive. Fill the swing drive
with oil.
6. Repeat Step 1 through 2 for the other swing drive
motor.
i05844476
Swing Drive Oil Level - Check
SMCS Code: 5459-535-FLV
The oil level in the two swing drives is monitored by
the Caterpillar Monitoring System. When the alert
indicator activates, the level of the swing drive oil is
low.
Oil that is badly contaminated or deteriorated
should always be replaced. This can occur more
frequently than the recommended maintenance
interval. Refer to Operation and Maintenance
Manual, “Swing Drive Oil - Change” in order to
change the oil.
i06906570
Swing Drive Oil Sample -
Obtain
SMCS Code: 5459-554-OC; 5459-008-OC; 5459-
OC; 5459-008; 7542-008
The swing drive oil must be sampled from the
following three locations:
• Swing drive oil reservoir
• Rear swing drive oil drain
• Front swing drive oil drain
Refer to Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” and refer to
Special Publication, PEGJ0047, “How To Take A
Good Oil Sample” for more information about
obtaining an oil sample. Consult your Caterpillar
dealer for complete information.

Illustration 384 g03694904

Manually check the oil level by looking at swing motor

tank (1) that is located on the fuel tank.
Note: The rear swing drive is located between the
swivel joint and the main control valve. The front
swing drive is located in front of the swivel. Perform
the same procedure for both of the swing drives.

Note: Refer to Operation and Maintenance Manual,

“General Hazard Information” for information on
containing fluid spillage.

1. Check the tank. Maintain the oil level between the

marks on the tank. Add oil through the filler cap, if
necessary.
222 SEBU9190-12
Maintenance Section
Swing Gear Grease - Check

Swing Drive Oil Reservoir After collecting the samples , check the swing drive
oil level. Add oil if necessary.

i06153519

Swing Gear Grease - Check

SMCS Code: 7063-535

Illustration 385 g06162974
The swing drive oil reservoir is not equipped with a
sampling valve. Use a vacuum pump to obtain a
sample of the oil. Withdraw the oil through the filler
cap on the swing drive oil reservoir.
NOTICE
Improper lubrication can cause damage to machine
components.
To avoid damage, make sure that the proper amount
of grease is applied to the swing drive.
When the amount of grease in the compartment be-
comes too large, the agitation loss becomes large,
thereby accelerating grease deterioration.
Grease deterioration can cause damage to the pinion
gear of the swing drive and swing internal gear.
Not enough grease will result in poor gear lubrication.

Swing Drive Drains

Illustration 387 g03830786

Illustration 386 g06162979
Operate the drives prior to collecting the samples.
Drain 0.6 L (0.16 US gal) of oil prior to collecting the
sample. Use a hose equipped with the appropriate
coupler to obtain a sample of the oil from the rear
swing drive oil drain (1) and from the front swing drive
oil drain (2).
The access cover for the swing gear is located
behind the cab.
1. Remove the ten bolts and the washers.
2. Remove the cover and the gasket.
3. Check the level of the grease. The grease must be
distributed evenly on the floor of the pan.
Add grease or remove grease, as needed. Too
little grease will result in poor lubrication of the
swing gear. Too much grease will result in the
deterioration of the grease that is caused by
excessive movement of the grease. Use “NLGI
Grade 2” grease with molybdenum for machines
that are used in normal operating temperatures.
4. Check for contamination and for discolored
grease.
SEBU9190-12 223
Maintenance Section
Swing Gear Grease - Replace

5. If the grease is contaminated or discolored with

water, change the grease. If the grease needs to
be replaced, refer to Operation and Maintenance
Manual, “Swing Gear Grease - Replace”.

i06153655

Swing Gear Grease - Replace

SMCS Code: 7063-510

NOTICE
Improper lubrication can cause damage to machine
components.
To avoid damage, make sure that the proper amount Illustration 389 g00685717
of grease is applied to the swing drive.
3. Raise the bucket. Swing the boom by 90 degrees.
When the amount of grease in the compartment be-
comes too large, the agitation loss becomes large, Lower the bucket. Remove grease from the
thereby accelerating grease deterioration. compartment. Repeat this step until all the grease
has been removed.
Grease deterioration can cause damage to the pinion
gear of the swing drive and swing internal gear.
Not enough grease will result in poor gear lubrication.

Illustration 390 g03830855

4. The swing gear drain plug can be removed to drain

water from the compartment. The swing gear drain
Illustration 388 g03830786 plug is located below the swing gear.
5. Fill the compartment with new grease. Use “NLGI
1. The access cover for the swing gear is located Grade 2” grease with molybdenum for machines
behind the cab. Remove the ten bolts and the that are used in normal operating temperatures.
washers. Remove the cover and the gasket. Refer to Operation and Maintenance Manual,
2. Remove grease from the compartment. “Refill Capacities” for the capacity of the swing
gear.
6. Position the gasket and cover on the swing gear.
Install the ten bolts and the washers.
224 SEBU9190-12
Maintenance Section
Track Adjustment - Inspect

i06188271

Track Adjustment - Inspect

SMCS Code: 4170-040

Illustration 392 g03692136

3. Use the travel levers or the travel pedals to move

the machine forward. The travel alarm should
sound.
Illustration 391 g00824541
4. Release the travel levers and the travel pedals in
Check the track adjustment. Check the track for wear order to stop the machine.
and for excessive dirt buildup.
5. Use the travel levers and the travel pedals to move
If the track appears to be too tight or too loose, the machine backward. The travel alarm should
consult your Cat dealer. sound.

i05844367

Travel Alarm - Test

(If Equipped)
SMCS Code: 7429-081
Move the machine in order to test the travel alarm.
1. Start the engine. Move the hydraulic lockout
control to the UNLOCKED position.
2. Raise the work tool in order to avoid any obstacles.
Make sure that there is adequate overhead
clearance.
Illustration 393 g03694851

6. Push the alarm cancel switch. The travel alarm

should shut off.
7. Stop the machine. Lower the work tool to the
ground. Move the hydraulic lockout control to the
LOCKED position. Stop the engine.
SEBU9190-12 225
Maintenance Section
Undercarriage - Check

i05844359 i05844342

Undercarriage - Check Window Washer Reservoir -

SMCS Code: 4150-535 Fill
SMCS Code: 7306-544-KE

NOTICE
When operating in freezing temperatures, use Cater-
pillar or any commercially available nonfreezing win-
dow washer solvent.

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

machine.

Illustration 394 g03694841

1. Check the carrier rollers, the track rollers, and the

idler wheels for possible leakage.
2. Check the surface of the track, the carrier rollers,
the track rollers, the idler wheels, the track shoes,
and the drive sprockets. Look for signs of wear
and loose mounting bolts.
3. Listen for any abnormal noises while you are
Illustration 395 g03694791
moving slowly in an open area.
4. If abnormal wear exists or abnormal noises or 2. Remove the filler cap.
leaks are found, consult your Caterpillar dealer.
3. Fill the window washer reservoir with washer fluid
through the filler opening.
i03898951
4. Install the filler cap.
Window - Check 5. Close the access door.
SMCS Code: 7310-535
i01258249
Check the polycarbonate windows of the cab for the
following conditions.
Window Wiper - Inspect/
• yellow or haze Replace
• scratches on either side of the window that can be SMCS Code: 7305-040; 7305-510
felt with a fingernail
Inspect the condition of the wiper blades. Replace
• small cracks that come from the edges or the wiper blades if the wiper blades are worn or
mounting holes damaged or if streaking occurs.

• contact with fluids that result in haze or clouds on i05867976

the window such as brake fluid
When any of the above conditions exist, contact your Windows - Clean
Caterpillar dealer for replacement. SMCS Code: 7310-070; 7340-070
Clean the outside of the windows from the ground,
unless handholds are available.
226 SEBU9190-12
Maintenance Section
Windows - Clean

Note: Do not use abrasive, or highly alkaline

cleaners. Do not use sharp instruments, such as
squeegees or razor blades on polycarbonate
windows. Do not clean polycarbonate windows in the
hot sun or at elevated temperatures.

Illustration 396 g00566124

Typical example

Cleaning Methods
Aircraft Window Cleaner
Apply the cleaner with a soft cloth. Rub the window
with moderate pressure until all the dirt is removed.
Allow the cleaner to dry. Wipe off the cleaner with a
clean soft cloth.

Soap and Water

Use a clean sponge or a soft cloth. Wash the
windows with a mild soap or with a mild detergent.
Also use plenty of lukewarm water. Rinse the
windows thoroughly. Dry the windows with a moist
chamois or with a moist cellulose sponge.

Stubborn Dirt and Grease

Wash the windows with a good grade of naphtha, of
isopropyl alcohol, or of Butyl Cellosolve. Then, wash
the windows with soap and with water.

Polycarbonate Windows (If

equipped)
Special care is needed in order to clean
polycarbonate windows.
Wash polycarbonate windows with mild soap and
warm water that does not exceed 50° C (122° F).
Use a soft sponge, or damp cloth. Never use a dry
cloth or paper towels on polycarbonate windows.
Rinse the windows with a sufficient amount of clean
cold water.
Note: Naphtha or kerosene can be used in order to
remove labels, films, paint, or marking pen from
polycarbonate windows.
SEBU9190-12 227
Warranty Section
Warranty Information

Warranty Section 3. New non-road diesel engines installed in

construction machines conforming to the South
Korean regulations for construction machines
Warranty Information manufactured after January 1, 2015, and operated
and serviced in South Korea, including all parts of
their emission control systems (“emission related
i06044323 components”), are:
Emissions Warranty a. Designed, built, and equipped so as to conform,
at the time of sale, with applicable emission
Information standards prescribed in the Enforcement Rule
SMCS Code: 1000 of the Clean Air Conservation Act promulgated
by South Korea MOE.
The certifying engine manufacturer warrants to the
ultimate purchaser and each subsequent purchaser b. Free from defects in materials and
that: workmanship in emission-related components
1. New non-road diesel engines and stationary diesel that can cause the engine to fail to conform to
engines less than 10 liters per cylinder (including applicable emission standards for the warranty
Tier 1 and Tier 2 marine engines < 37 kW, but period.
excluding locomotive and other marine engines) The aftertreatment system can be expected to
operated and serviced in the United States and function properly for the lifetime of the engine
Canada, including all parts of their emission (emissions durability period) subject to prescribed
control systems (“emission related components”), maintenance requirements being followed.
are:
A detailed explanation of the Emission Control
a. Designed, built, and equipped so as to conform, Warranty that is applicable to new non-road and
at the time of sale, with applicable emission stationary diesel engines, including the components
standards prescribed by the United States covered and the warranty period, is found in a
supplemental Special Publication. Consult your
Environmental Protection Agency (EPA) by way authorized Cat dealer to determine if your engine is
of regulation. subject to an Emission Control Warranty and to
obtain a copy of the applicable Special Publication.
b. Free from defects in materials and
workmanship in emission-related components
that can cause the engine to fail to conform to
applicable emission standards for the warranty
period.
2. New non-road diesel engines (including Tier 1 and
Tier 2 marine propulsion engines < 37 kW and Tier
1 through Tier 4 marine auxiliary engines < 37 kW,
but excluding locomotive and other marine
engines) operated and serviced in the state of
California, including all parts of their emission
control systems (“emission related components”),
are:
a. Designed, built, and equipped so as to conform,
at the time of sale, to all applicable regulations
adopted by the California Air Resources Board
(ARB).
b. Free from defects in materials and
workmanship which cause the failure of an
emission-related component to be identical in
all material respects to the component as
described in the engine manufacturer's
application for certification for the warranty
period.
228 SEBU9190-12
Reference Information Section
Reference Materials

Reference Information
Section

Reference Materials
i07422648

Reference Material
SMCS Code: 1000; 7000
Additional literature regarding your product may be
purchased from your local Cat dealer or by visiting
publications.cat.com. Use the product name, sales
model, and serial number to obtain the correct
information for your product.
publications.cat.com

i07743978

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.
Improperly disposing of waste can threaten the
environment. Obey all local regulations for the
decommissioning and disposal of materials.
Utilize appropriate personal protective equipment
when decommissioning and disposing product.
Consult the nearest Cat dealer for additional
information. Including information for component
remanufacturing and recycling options.
SEBU9190-12
Index
A Rear View Camera (If Equipped)................. 81
Access Door and Cover Locations................ 152
Accumulator - Check ..................................... 166
HOC Accumulator...................................... 167
Pilot Accumulator....................................... 166
Swing Charge Accumulator ....................... 167
Track Tension Accumulators ..................... 166
Additional Messages ....................................... 20
Air Conditioner/Cab Heater Filter
(Recirculation) - Inspect/Replace ................ 167
Air Conditioning and Heating Control.............. 98
English Versus Metric Toggle .................... 100
Alternate Exit ................................................... 58
FOGS (If Equipped) ..................................... 60
Front Window (If Equipped)......................... 58
Right Side Window ...................................... 58
Roof Hatch (If Equipped) ....................... 59–60
Automatic Lubrication System Grease -
Add (If Equipped)......................................... 168
B Declaration of Conformity................................ 52
Battery - Clean............................................... 169
Battery - Recycle ........................................... 169
Battery Disconnect Switch .............................. 76
Battery Hold-Down - Tighten ......................... 169
Bearing (Swing Drive) - Lubricate ................. 169
Before Operation ....................................... 34, 53
Before Starting Engine .................................... 32
Belt - Inspect/Replace ................................... 169
Inspect ....................................................... 169
Replace...................................................... 171
Bucket Linkage - Inspect/Adjust.................... 171
Bucket Linkage - Lubricate............................ 174
Bucket Tips - Inspect/Replace ...................... 174
Bucket Tips ................................................ 175
Side Cutters ............................................... 176
Side Protectors (If Equipped) .................... 177
Burn Prevention............................................... 26
Batteries....................................................... 26
Coolant ........................................................ 26
Oils............................................................... 26
C Engine Components - Clean/Inspect,
Cab Air Filter (Fresh Air) - Clean/Replace .... 178
Cab Door ....................................................... 104
Cab Visor (If Equipped) ................................. 103
Camera............................................................ 81
229
Index Section
Right Side View Camera (If Equipped)........ 81
Camera - Clean ............................................. 178
Capacities (Refill) .......................................... 158
Circuit Breakers - Reset ................................ 179
Cooling System Coolant (ELC) - Change ..... 180
Procedure for Changing the Coolant......... 180
Cooling System Coolant Extender (ELC) -
Add .............................................................. 182
Cooling System Coolant Level - Check......... 183
Cooling System Coolant Sample (Level 1) -
Obtain .......................................................... 183
Cooling System Coolant Sample (Level 2) -
Obtain .......................................................... 184
Cooling System Water Temperature
Regulator - Replace..................................... 185
Crushing Prevention and Cutting Prevention.. 25
D
Daily Inspection ............................................... 53
Decommissioning and Disposal.................... 228
E
Electrical Storm Injury Prevention ................... 32
Emissions Certification Film ............................ 51
Emissions Warranty Information ................... 227
Engine Air Filter Primary Element -
Replace ....................................................... 185
Engine Air Filter Secondary Element -
Replace ....................................................... 186
Engine Air Precleaner - Clean....................... 187
Engine and Machine Warm-Up ..................... 108
Hydraulic System....................................... 108
Engine Components - Clean/Inspect,
Rebuild/Install Reman, Install New (Every
1 703 435 L (450 000 US gal) of Fuel) ........ 189
Clean Components and Inspect Components
for Reusability .......................................... 190
Install New Components............................ 190
Rebuild Components and/or Install
Remanufactured Components ................ 190
Rebuild/Install Reman, Install New (Every
1 703 435 L (450 000 US gal) of Fuel) ........ 189
Clean Components and Inspect Components
for Reusability .......................................... 189
230
Index Section
Install New Components............................ 189
Rebuild Components and/or Install
Remanufactured Components ................ 189
Engine Components - Clean/Inspect,
Rebuild/Install Reman, Install New (Every
850 000 L (225 000 US gal) of Fuel) ........... 188
Clean Components and Inspect Components
for Reusability .......................................... 188
Install New Components............................ 189
Rebuild Components and/or Install
Remanufactured Components ................ 189
Engine Components - Clean/Inspect,
Rebuild/Install Reman, Install New (Every
850 000 L (225 000 US gal) of Fuel) ........... 187
Clean Components and Inspect Components
for Reusability .......................................... 188
Install New Components............................ 188
Rebuild Components and/or Install
Remanufactured Components ................ 188
Engine Crankcase Breather - Clean
(Emission Related Component) .................. 190
Engine Emissions Control Warning System ... 65
Carbon Dioxide (CO2) Emissions
Statement................................................... 67
Definitions .................................................... 65
Inducement Strategy for Escalating Time
Inducement Faults ..................................... 66
Engine Mounts - Inspect................................ 190
Engine Oil and Filter - Change ...................... 192
Procedure for Changing the Engine Oil and
Filter ......................................................... 193
Selection of the Oil Change Interval .......... 192
Engine Oil Level - Check............................... 191
Engine Oil Sample - Obtain........................... 191
Obtain the Sample and the Analysis ......... 191
Engine Shutdown Switch ................................ 78
Cab .............................................................. 79
Engine Compartment................................... 80
Ground Level ............................................... 79
Pump Compartment .................................... 80
Engine Starting........................................ 33, 107
Engine Starting (Alternate Methods)............. 151
Engine Starting with Auxiliary Start
Receptacle (If Equipped)............................. 151
Engine Stopping .............................................. 37
Engine Valve Lash - Check ........................... 195
Engine Valve Rotators - Inspect .................... 195
Engine Water Pump - Inspect ....................... 195
Equipment Lowering with Engine Stopped .... 38,
120
Manual Boom Lowering............................. 120
SEBU9190-12
Ether Starting Aid Cylinder - Replace (If
Equipped) .................................................... 196
F
Film (Product Identification) - Clean.............. 197
Cleaning of the Films ................................. 197
Final Drive Oil - Change ................................ 198
Final Drive Oil Level - Check......................... 198
Final Drive Oil Sample - Obtain..................... 199
Fire Extinguisher Location............................... 31
Fire Suppression Canister Location ............ 31
Fire Prevention and Explosion Prevention...... 27
Battery and Battery Cables.......................... 28
Ether ............................................................ 30
Fire Extinguisher.......................................... 30
General ........................................................ 27
Lines, Tubes, and Hoses ............................. 29
Regeneration ............................................... 27
Wiring........................................................... 29
Fire Safety ....................................................... 30
Foreword ........................................................... 5
California Proposition 65 Warning ................. 5
Certified Engine Maintenance ....................... 6
Literature Information .................................... 5
Machine Capacity .......................................... 6
Maintenance .................................................. 5
Operation ....................................................... 5
Product Identification Number ....................... 6
Safety............................................................. 5
Freezing Conditions ...................................... 143
Frozen Ground Conditions .............................119
Frozen Tracks .............................................119
Moving the Machine .................................. 120
Fuel System - Prime...................................... 199
Fuel System Primary Filter (Water
Separator) - Check/Drain ............................ 200
Fuel System Primary Filter (Water
Separator) Element - Replace..................... 201
Fuel System Secondary Filter - Replace ...... 203
Fuel Tank Cap Filter - Replace...................... 204
Fuel Tank Shutoff and Drain Control ............. 105
Fuel Tank Strainer - Clean............................. 204
Fuel Tank Water and Sediment - Drain ......... 205
Fuses - Replace ............................................ 205
Relays ........................................................ 207
G
General Hazard Information............................ 23
Containing Fluid Spillage............................. 24
Dispose of Waste Properly .......................... 25
SEBU9190-12
Fluid Penetration ......................................... 24
Inhalation ..................................................... 25
Pressurized Air and Water........................... 24
Trapped Pressure ........................................ 24
General Information ........................................ 43
Guards............................................................. 41
Guards (Operator Protection)
Other Guards (If Equipped) ......................... 42
Rollover Protective Structure (ROPS), Falling
Object Protective Structure (FOPS) or Tip
Over Protection Structure (TOPS)............. 41
H
High Pressure Fuel Lines ................................ 31
Hydraulic System High Pressure Screen -
Check/Replace ............................................ 207
Hydraulic System Oil - Change ..................... 208
Hydraulic System Oil Cooler Core - Clean.... 210
Hydraulic System Oil Filter (Charge Pump)
- Replace ......................................................211
Hydraulic System Oil Filter (Pilot) -
Replace ....................................................... 212
Hydraulic System Oil Filter (Return) -
Replace ....................................................... 213
Hydraulic System Oil Level - Check.............. 214
Hydraulic System Oil Sample - Obtain.......... 215
I 164
Identification Information ................................. 49
Important Safety Information............................. 2
Indicators and Gauges - Test ........................ 215
J Every 3 Years..................................... 162, 165
Joystick Controls ........................................... 105
L Every 500 Service Hours or 3 Months...... 161,
Leaving the Machine ..................................... 145
Lubricant Viscosities (Fluids
Recommendations) ..................................... 153
Biodiesel .................................................... 157
Coolant Information ................................... 157
Diesel Fuel Recommendations ................. 156
Engine Oil .................................................. 153
Fuel Additives ............................................ 157
General Information for Lubricants............ 153
Grease Applications .................................. 155
Hydraulic Systems..................................... 154
Other Applications ..................................... 155
231
Index Section
Selecting the Viscosity............................... 153
Lubricant Viscosities and Refill Capacities ... 153
M
Machine Cleanup .......................................... 146
Machine Cleanup Procedure......................... 146
Undercarriage Cleanup ............................. 146
Machine Operation .......................................... 55
Machine Storage and Specified Storage
Period .......................................................... 145
Machine Storage ....................................... 145
Specified Storage Period........................... 145
Machine Structure - Inspect .......................... 216
Maintenance Access ..................................... 152
Maintenance Interval Schedule............. 160, 163
Every 1 703 435 L (450 000 US gal) of
Fuel .................................................. 162, 165
Every 10 000 Service Hours or 6 Years.... 162,
165
Every 10 Service Hours or Daily........ 160, 163
Every 1000 Service Hours................. 161, 164
Every 1000 Service Hours or 6 Months.... 161,
164
Every 12 000 Service Hours or 6 Years.... 162,
165
Every 1500 Service Hours................. 161, 164
Every 2000 Service Hours or 1 Year ........ 161,
Every 250 Service Hours ................... 161, 164
Every 250 Service Hours or Monthly ........ 161,
164
Every 2500 Service Hours or 6 Months.... 161,
164
Every 3000 Service Hours or 2 Years ...... 161,
164
Every 500 Service Hours ................... 161, 164
164
Every 5000 Service Hours................. 162, 165
Every 6000 Service Hours or 3 Years ...... 162,
165
Every 6000 Service Hours or 4 Years ...... 162,
165
Every 850 000 L (225 000 US Gal) of
Fuel .................................................. 162, 165
Every Year ......................................... 161, 164
Initial 250 Service Hours.................... 160, 163
Initial 500 Hours (for New Systems, Refilled
Systems, and Converted Systems) ........ 161,
164
232
Index Section
Initial 500 Service Hours.................... 161, 164
When Required.................................. 160, 163
Maintenance Section..................................... 152
Maintenance Support .................................... 159
Maximum Operating Grade....................117–118
Mirror ............................................................. 100
Left Side Rear View Mirror (2) ................... 101
Mirror Adjustment ...................................... 100
Right Side Rear View Mirror (1)................. 101
Monitoring System........................................... 81
Camera (If Equipped) .................................. 84
Display Settings ........................................... 85
Engine Emissions ........................................ 92
Incremental Bars ......................................... 83
Lower Information Banner ........................... 84
Machine ....................................................... 87
Menu Buttons and Menu Button Groups ..... 83
Navigation Path ........................................... 84
Performance Page....................................... 82
Pop-Up Messages ....................................... 92
Scroll Bar ..................................................... 83
Service ......................................................... 90
Stairway (Powered) Lowered Warning........ 93
Startup ......................................................... 81
Top Level Navigation ................................... 82
Totals............................................................ 89
Mounting and Dismounting ............................. 53
Alternate Exit ............................................... 53
Machine Access System Specifications...... 53
O
Oil Filter - Inspect .......................................... 216
Inspect a Used Filter for Debris ................. 216
Operating Technique Information.................. 122
Machine Operation with Backhoe
Attachment............................................... 122
Restricted Operation with Backhoe
Attachment............................................... 130
Traveling .................................................... 138
Operating Techniques ................................... 122
Operation..................................................34, 110
Limiting Conditions and Criteria .................. 34
Machine Operating Temperature Range ..... 34
Machine Operation ...................................... 36
Machine Operation when the Machine is not
Completely Assembled .............................. 37
Operation Information ....................................110
Traveling Operation .................................... 111
Working Operation......................................110
Operation Section............................................ 53
Operator Controls............................................ 67
SEBU9190-12
Air Conditioning and Heating Control (11)... 72
Auto Lube Manual Operation (14) ............... 73
Automatic Engine Speed Control (16)......... 73
Cab and Boom Lights (20)........................... 74
Engine Idle Shutdown.................................. 72
Engine Shutdown Switch (24) ..................... 75
Engine Speed Control (13) .......................... 73
Engine Start Switch (8) ................................ 72
Fault Indicator (6)......................................... 72
Heated Mirrors (26) (If Equipped)................ 76
Hydraulic Lockout Control (1) ...................... 69
Joystick Controls (7) .................................... 72
Ladder Light (25) ......................................... 76
Lower Window Washer (18) ........................ 74
Lower Window Wiper (23) ........................... 75
Monitor (4) ................................................... 71
Operator Controls ........................................ 68
Operator Seat (10)....................................... 72
Radio (12) .................................................... 73
Service Port ................................................. 76
Stairway and Hydraulic Lockout Indicator
Panel (5) .................................................... 71
Travel Alarm Cancel (17)............................. 74
Travel Control (2) ......................................... 69
Travel Speed Control (15) ........................... 73
VIMS Service Port (3) .................................. 71
Window Washer (22) ................................... 75
Window Wiper (21) ...................................... 75
Work Lights (19) .......................................... 74
Operator Station .............................................. 41
P
Parking .................................................... 38, 143
Plate Locations and Film Locations ................ 49
Certification.................................................. 50
Engine Serial Number ................................. 50
Eurasian Economic Union ........................... 49
Manufacturer Information ............................ 50
Product Identification Number (PIN)............ 49
Power Receptacle (If Equipped) ..................... 78
Powered Stairway - Lubricate ....................... 216
Product Information Section............................ 43
Product Link .................................................... 77
Data Broadcasts .......................................... 77
Operation in a Blast Site for Product Link
Radios ........................................................ 78
R
Radiator Core - Clean ................................... 217
Radio (If Equipped) ......................................... 94
SEBU9190-12
Loss of Memory ........................................... 97
Presetting Radio Stations ............................ 96
Radio Reception .......................................... 97
Scan and Auto Memory ............................... 97
Receiver Dryer (Refrigerant) - Replace ........ 217
Reference Information Section ..................... 228
Reference Material ........................................ 228
Reference Materials ...................................... 228
Restricted Visibility .......................................... 33
Roof Hatch..................................................... 103
S Intended Use ............................................... 43
S·O·S Information ......................................... 158
Safety Messages............................................... 7
Aerosol Starting Aid (14) ............................. 17
Crushing Hazard (15) .................................. 17
Crushing Hazard (16) .................................. 18
Crushing Hazard (6) .................................... 14
Crushing Hazard (7) .................................... 14
Crushing Hazard (8) .................................... 15
Crushing Hazard (9) .................................... 15
Do Not Operate (1) .......................................11
Do Not Weld or Drill on ROPS (3) ............... 13
Electrical Power Lines (4)............................ 13
Entanglement Hazard (13) .......................... 17
Fall Hazard (10) ........................................... 15
Fall Hazard (21) ........................................... 20
High Pressure Gas (17) ............................... 18
Hot Surface (20) .......................................... 19
Hydraulic Oil Under Pressure (11)............... 16
Jump Start Cables (18)................................ 19
Pressurized System (12) ............................. 16
Product Link (2) ........................................... 12
Seat Belt (5) ................................................. 13
Trip Hazard (19)........................................... 19
Safety Section ................................................... 7
Seat ................................................................. 61
Heated Seat and Ventilated Seat (If
Equipped)................................................... 62
Seat Belt .......................................................... 63
Extension of the Seat Belt ........................... 65
Seat Belt Adjustment for Non-Retractable
Seat Belts................................................... 63
Seat Belt Adjustment for Retractable Seat
Belts ........................................................... 64
Seat Belt - Inspect ......................................... 217
Seat Belt - Replace ....................................... 218
Shipping the Machine.................................... 147
Sound Information and Vibration
Information..................................................... 38
Sound Level Information.............................. 38
233
Index Section
Sound Level Information for Machines in
Eurasian Economic Union Countries......... 39
Sound Level Information for Machines in
European Union Countries and in Countries
that Adopt the “EU Directives” ................... 39
Sources........................................................ 41
“The European Union Physical Agents
(Vibration) Directive 2002/44/EC”.............. 39
Specifications .................................................. 43
Application/Configuration Restrictions ........ 44
Expected Life ............................................... 43
Specification Data........................................ 44
Working Ranges .......................................... 47
Stairway (Powered) Operation (If Equipped) .. 55
Locking the Powered Stairway .................... 56
Lowering ...................................................... 55
Maintenance ................................................ 57
Raising ......................................................... 56
Stopping the Engine ...................................... 143
Delayed Engine Shutdown ........................ 144
Immediate Engine Shutdown .................... 144
Stop the Engine if an Electrical Malfunction
Occurs...................................................... 144
Stopping the Machine.................................... 143
Storage Box..................................................... 94
Exterior Storage Box ................................... 94
Strainer (Hydraulic Tank) - Clean .................. 219
Sun Screen (If Equipped) .............................. 103
Swing Bearing Bolts - Check......................... 220
Swing Drive Oil - Change .............................. 220
Swing Drive Oil Level - Check....................... 221
Swing Drive Oil Sample - Obtain................... 221
Swing Drive Drains .................................... 222
Swing Drive Oil Reservoir.......................... 222
Swing Gear Grease - Check ......................... 222
Swing Gear Grease - Replace ...................... 223
System Pressure Release............................. 159
Coolant System ......................................... 159
Hydraulic System....................................... 159
T
Table of Contents .............................................. 3
Towing Information ........................................ 148
Towing the Machine....................................... 148
Installing the Input Shafts Behind the Travel
Motors ...................................................... 150
Removing the Input Shafts Behind the Travel
Motors ...................................................... 148
Track Adjustment - Inspect............................ 224
Track Information ............................................ 31
234 SEBU9190-12
Index Section

Transportation Information ............................ 147

Travel Alarm - Test (If Equipped)................... 224
Travel in Water and Mud ............................... 141
Procedure for Removing the Machine from
Water or Mud ........................................... 141

U
Undercarriage - Check .................................. 225

V
Visibility Information ........................................ 32

W
Warranty Information..................................... 227
Warranty Section........................................... 227
Welding on Machines and Engines with
Electronic Controls ...................................... 159
Window - Check ............................................ 225
Window (Front).............................................. 101
Window Washer Reservoir - Fill .................... 225
Window Wiper - Inspect/Replace .................. 225
Windows - Clean ........................................... 225
Cleaning Methods...................................... 226
Polycarbonate Windows (If equipped) ...... 226
Work Tools....................................................... 34
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.

Delivery Date:

Product Information
Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information
Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:
SEBU9190 CAT, CATERPILLAR, LET’S DO THE WORK, their respective logos, “Caterpillar Yellow”, the
©2019 Caterpillar “Power Edge” and Cat “Modern Hex” trade dress as well as corporate and product identity used
All Rights Reserved herein, are trademarks of Caterpillar and may not be used without permission.

236 July 2019