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SEBU7331-01
December 2003
Operation and
Maintenance
Manual
R1600G Load Haul Dump
9PP1-Up (Machine)
i01658146
3
Table of Contents
Table of Contents
Foreword ................................................................. 4
Safety Section
Safety Signs and Labels ......................................... 6
General Hazard Information ................................. 13
Crushing Prevention and Cutting Prevention ........ 15
Burn Prevention .................................................... 16
Fire Prevention and Explosion Prevention ............ 16
Fire Extinguisher Location .................................... 18
Tire Information ..................................................... 19
Electrical Storm Injury Prevention ......................... 19
Mounting and Dismounting ................................... 20
Before Starting Engine .......................................... 20
Engine Starting ..................................................... 21
Maintenance Section
Torque Specifications .......................................... 109
Tire Inflation Information ..................................... 112
Lubricant Viscosities and Refill Capacities ......... 113
Maintenance Locations ....................................... 116
Maintenance Interval Schedule .......................... 120
Index Section
Engine Stopping ................................................... 22
Index ................................................................... 190
Parking .................................................................. 22
Equipment Lowering with Engine Stopped ........... 22
Sound Information and Vibration Information ....... 22
Operator Station ................................................... 23
Guards (Operator Protection) ............................... 23
Operation Section
Monitoring Systems and Operator Station
Features .............................................................. 31
Machine Controls and Operation .......................... 50
Before Starting Engine .......................................... 69
4
Foreword
Foreword
Maintenance
Literature 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 Intervals
Use the service hour meter to determine servicing
intervals. Calendar intervals shown (daily, weekly,
monthly, etc.) can be used instead of service hour
meter intervals if they provide more convenient
servicing schedules and approximate the indicated
service hour meter reading. Recommended service
should always be performed at the interval that
occurs first.
Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is
specified in the maintenance intervals chart might
be necessary.
Perform service on items at multiples of the original
requirement. For example, at every 500 service
hours or 3 months, also service those items listed
under every 250 service hours or monthly and every
10 service hours or daily.
5
Foreword
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 Caterpillar dealer for further
information.
Illustration 1
Where:
1. Caterpillars World Manufacturing Code
(characters 1-3)
2. Machine Descriptor (characters 4-8)
g00751314
6
Safety Section
Safety Signs and Labels
Safety Section
i01946412
Illustration 3
g00891950
Do Not Operate
Illustration 4
g00891999
g00891937
7
Safety Section
Safety Signs and Labels
Illustration 5
g00892002
Structural damage, an overturn, modification, alteration, or improper repair can impair this structures protection capability thereby voiding this
certification. Do not weld on or drill holes in the
structure. Consult an Elphinstone dealer to determine this structures limitations without voiding
its certification.
Illustration 7
g00892055
No clearance for person in this area when machine turns. Severe injury or death from crushing
could occur. Connect steering frame lock between
front and rear frames before lifting, transporting,
or servicing machine in articulation area. Disconnect lock and secure before resuming operation.
No Clearance
Illustration 8
g00892141
Illustration 6
g00950489
8
Safety Section
Safety Signs and Labels
Illustration 9
g00892146
Illustration 11
g00892173
Illustration 10
g00892172
Illustration 12
g00892206
9
Safety Section
Safety Signs and Labels
Illustration 13
g00892207
Illustration 15
g00892335
No clearance for person in operators station access area when machine turns. Severe injury or
death from crushing could occur.
Install bucket control group safety pins before servicing machine in this area.
Illustration 14
g00950500
g00950492
10
Safety Section
Safety Signs and Labels
Illustration 17
g00892403
Illustration 19
g00892476
Illustration 18
Batteries
g01013182
Illustration 20
g00950499
11
Safety Section
Safety Signs and Labels
Unit Injectors
Illustration 22
g00950495
Illustration 21
g00892563
Illustration 23
g00892579
Engine Coolant
Illustration 24
g00950494
12
Safety Section
Safety Signs and Labels
Illustration 27
g00100414
Personal injury can result from spring force released when removing cap screws.
Internal spring force will be released when cylinder assembly cap screws are removed causing injury.
Always restrain cover as cap screws are loosened.
Illustration 25
g00892607
Recovery Hook
PRESSURIZED SYSTEM: HOT COOLANT CAN
CAUSE SERIOUS BURN. TO OPEN CAP, STOP
ENGINE, WAIT UNTIL RADIATOR IS COOL. THEN
LOOSEN CAP SLOWLY TO RELIEVE THE PRESSURE.
Compressed Spring
Illustration 28
g01014541
Illustration 26
g01014540
13
Safety Section
General Hazard Information
Illustration 29
g00946835
Illustration 31
i01426767
g00702020
Illustration 30
g00104545
14
Safety Section
General Hazard Information
Trapped Pressure
Pressure can be trapped in a hydraulic system.
Releasing trapped pressure can cause sudden
machine movement or attachment movement. Use
caution if you disconnect hydraulic lines or fittings.
High pressure oil that is released can cause a hose
to whip. High pressure oil that is released can
cause oil to spray. Fluid penetration can cause
serious injury and possible death.
Fluid Penetration
Pressure can be trapped in the hydraulic circuit
long after the engine has been stopped. The
pressure can cause hydraulic fluid or items such
as pipe plugs to escape rapidly if the pressure is
not relieved correctly.
Do not remove any hydraulic components or parts
until pressure has been relieved or personal injury
may occur. Do not disassemble any hydraulic
components or parts until pressure has been
relieved or personal injury may occur. Refer to the
Service Manual for any procedures that are required
to relieve the hydraulic pressure.
Illustration 32
g00687600
15
Safety Section
Crushing Prevention and Cutting Prevention
Asbestos Information
g00702022
Illustration 34
g00706404
16
Safety Section
Burn Prevention
Oils
Hot oil and hot components can cause personal
injury. Do not allow hot oil to contact the skin. Also,
do not allow hot components to contact the skin.
Remove the hydraulic tank filler cap only after the
engine has been stopped. The filler cap must be
cool enough to touch with a bare hand. Follow
the standard procedure in this manual in order to
remove the hydraulic tank filler cap.
Batteries
i01329099
i01359795
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.
Illustration 35
g00704000
17
Safety Section
Fire Prevention and Explosion Prevention
Illustration 36
g00704059
Illustration 37
g00704135
18
Safety Section
Fire Extinguisher Location
Fire Extinguisher
Ether
Ether is flammable and poisonous.
Use ether in well ventilated areas. Do not smoke
while you are replacing an ether cylinder or while
you are using an ether spray.
Do not store ether cylinders in living areas or in the
operator compartment of a machine. Do not store
ether cylinders in direct sunlight or in temperatures
above 49 C (120 F). Keep ether cylinders away
from open flames or sparks.
g00950479
19
Safety Section
Tire Information
Illustration 39
g00950480
Tire Information
SMCS Code: 7000
Explosions of air inflated tires have resulted from
heat-induced gas combustion inside the tires.
Explosions can be caused by heat that is generated
by welding, by heating rim components, by external
fire, or by excessive use of brakes.
A tire explosion is much more violent than a
blowout. The explosion can propel the tire, the rim
components, and the axle components as far as
500 m (1500 ft) or more from the machine. Both the
force of the explosion and the flying debris can
cause property damage, personal injury, or death.
Illustration 40
g00337832
20
Safety Section
Mounting and Dismounting
i02006130
i01829290
Illustration 41
g00037860
Illustration 42
g00950476
Alternate Exit
21
Safety Section
Engine Starting
Engine Starting
i01740624
i01740813
Operation
SMCS Code: 7000
Only operate the machine while you are sitting in
a seat. The seat belt must be fastened while you
operate the machine. Only operate the controls
while the engine is running.
Illustration 43
g00104545
Additional seat.
Additional seat belt.
Before Operation
22
Safety Section
Engine Stopping
Engine Stopping
SMCS Code: 1000; 7000
Do not stop the engine immediately after the
machine has been operated under load. This can
cause overheating and accelerated wear of engine
components.
After the machine is parked and the parking brake
is engaged, allow the engine to run for five minutes
before shutdown. This allows hot areas of the
engine to cool gradually.
i02006656
Parking
i01329161
Vibration Level
The hands and arms are exposed to a weighted root
mean square acceleration that is less than 1.7 m/s2.
The whole body is exposed to a maximum weighted
root mean square acceleration of 1.3 m/s2.
Measurements are obtained on a representative
machine using the procedures in the following
standards:
ISO 2631/1
ISO 5349
23
Safety Section
Operator Station
i01741439
Operator Station
SMCS Code: 7000; 7301; 7325
This Caterpillar machine is equipped with a factory
installed operator station that conforms to industry
standards. The standards specify the clearance that
is required in the operator station for the operator.
This machine complies with one or more of the
following standards:
ISO 3411
EN 474-1
EN 23411
Any modifications to the inside of the operator
station should not project into the defined space.
The addition of a radio, fire extinguisher, and other
equipment must be installed so that the defined
space is maintained. Any item that is brought into
the operator station should not project into the
defined space. 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 machine
rollover.
i01992325
Guards
(Operator Protection)
SMCS Code: 7000; 7150; 7325
There are different types of guards that are used to
protect the operator. The machine and the machine
application determines the type of guard that should
be used.
24
Safety Section
Guards
Demolition applications
Rock quarries
Forestry products
Additional guards may be required for specific
applications or work tools. The Operation and
Maintenance Manual for your machine or your
work tool will provide specific requirements for the
guards. Consult your Caterpillar dealer for additional
information.
25
Product Information Section
General Information
Product Information
Section
General Information
i01774750
26
Product Information Section
Model Views and Specifications
g00950439
Illustration 46
(9) Final drives
(10) Bucket control group safety pin
(11) Steering frame lock pin
(12) Operators station
Illustration 44
(1)
(2)
(3)
(4)
g00950437
Engine compartment
Hydraulic tank
Tilt cylinder
Bucket
g00950440
Illustration 47
(13) Engine air cleaner
(14) Radiator
Illustration 45
(5)
(6)
(7)
(8)
Fuel tank
Battery compartment
Transmission compartment
Lift arm
g00950438
Approximate Weight
Length (maximum)
Width (maximum)
27
Product Information Section
Model Views and Specifications
i01829373
Failure to comply to the rated load can cause possible personal injury or property damage. Review
the rated load of a particular work tool before performing any operation. Make adjustments to the
rated load as necessary for non-standard configurations.
Note: Rated loads should be used as a guide.
Work tools, uneven ground conditions, soft ground
conditions, or poor ground conditions have effects
on rated loads. The operator is responsible for
being aware of these effects.
Rated loads are based upon a standard machine
with the following conditions:
proper lubricants
full fuel tank
enclosed ROPS
75 kg (165 lb) operator
18.00x25 28PR L-5 tires or equivalent
Rated loads will vary for different work tools. Consult
your Caterpillar dealer about the rated load for
specific work tools.
The rated operating load is defined by the ISO
5998 (1986) standard as 50 percent of the full turn
static tipping load.
28
Product Information Section
Model Views and Specifications
g00950426
Illustration 48
Rated Load
Ground Engaging
Tools
Rated Volume
Rated Operating
Load
Dump Clearance A
Reach B
29
Product Information Section
Identification Information
Identification Information
i01829382
Illustration 50
g00950457
Illustration 51
g00950458
Illustration 49
g00950454
g00950462
30
Product Information Section
Identification Information
Illustration 53
g00950463
31
Operation Section
Monitoring Systems and Operator Station Features
Operation Section
Monitoring Systems and
Operator Station Features
i01829387
Illustration 54
g00942168
Illustration 55
g00942167
32
Operation Section
Monitoring Systems and Operator Station Features
i01829388
i01829389
Illustration 56
g00942203
Illustration 58
g00941148
Illustration 57
g00942206
33
Operation Section
Monitoring Systems and Operator Station Features
i01847695
Illustration 59
g00941150
Illustration 60
g00941181
34
Operation Section
Monitoring Systems and Operator Station Features
Warning Operation
Table 3
Warning Operation
Warning
Warning
Category
(1)
(2)
(3)
(4)
(5)
(6)
Alert Indicator
Flashes(3) or
a Gauge will
Show in the
Red Range
Indications(1)
Action Lamp
Flashes(4)
The Action
Alarm Sounds
Possible Result(2)
No immediate action is
required. The system
needs attention soon.
No harmful effects
or damaging effects
will occur.
2-S
X(5)
Immediately change
the machine operation.
Severe damage to
components.
X(6)
Immediately perform a
safe engine shutdown.
Change machine
operation or perform
maintenance to the
system.
Damage to machine
components will occur.
Warning Categories
The monitoring system provides three warning
categories. The first category requires only operator
awareness. The second warning category requires
the operation of the machine or the maintenance
procedure for the machine to be changed. The
third warning category requires immediate safe
shutdown of the machine.
Warning Category 1
In this category, only the appropriate alert indicators
will flash. The alert indicator informs the operator
that a machine system needs attention. The
condition of the machine system should not
endanger the operator. Also, the condition of the
machine system should not damage the machine.
Illustration 61
g01014543
35
Operation Section
Monitoring Systems and Operator Station Features
Illustration 62
g00896050
Warning Category 2
In this category, one of the following conditions will
occur:
is on.
Illustration 63
g00941184
36
Operation Section
Monitoring Systems and Operator Station Features
Illustration 65
g01015560
Warning Category 3
In this category, the alert indicator and the action
lamp will flash and the action alarm will sound. This
category requires immediate safe shutdown of the
machine in order to prevent possible injury to the
operator and/or severe damage to the system and
the machine.
Do not operate the machine until the cause has
been corrected.
Illustration 64
g01013387
Illustration 66
g01013389
37
Operation Section
Monitoring Systems and Operator Station Features
i01847773
Gauges
SMCS Code: 7450
Illustration 68
Illustration 67
g00988294
g00911576
38
Operation Section
Monitoring Systems and Operator Station Features
Illustration 69
g00937414
Illustration 70
g00937415
Indicators
SMCS Code: 7400; 7450
g00941292
Illustration 71
g00941265
39
Operation Section
Monitoring Systems and Operator Station Features
i01848095
Light Switches
SMCS Code: 1429-ZS; 7451
Illustration 73
g00941328
Illustration 74
g00896696
40
Operation Section
Monitoring Systems and Operator Station Features
i01753118
i01848319
Illustration 75
g00896705
Illustration 76
g00941366
41
Operation Section
Monitoring Systems and Operator Station Features
i01848377
i01848472
Ride Control
(If Equipped)
SMCS Code: 5004; 7451
Travel at high speeds over rough terrain causes
bucket movement and a swinging motion. The
ride control system acts as a shock absorber by
dampening forces from the bucket. This helps to
stabilize the entire machine.
Illustration 77
g00941377
g00941484
42
Operation Section
Monitoring Systems and Operator Station Features
i01943870
Illustration 81
Illustration 79
g01013394
g00996574
Operator Modes
Illustration 82
g00996575
Illustration 80
g00996573
Illustration 83
g00996576
43
Operation Section
Monitoring Systems and Operator Station Features
i01753593
Service Ports
SMCS Code: 0350
i01848525
Illustration 85
Illustration 84
g00941534
g00896933
44
Operation Section
Monitoring Systems and Operator Station Features
i01753566
i01944239
Horn
Backup Alarm
Illustration 86
g00896916
Illustration 87
g01012239
Illustration 88
g00896957
45
Operation Section
Monitoring Systems and Operator Station Features
i01946415
Illustration 89
g00897007
Seat
SMCS Code: 7312
Adjust the seat in order to allow full travel of the
pedals. Make the seat adjustments when the
operator is sitting against the back of the seat. In
order to reduce fatigue, periodically readjust the
seat and the backrest for additional comfort.
Illustration 90
g00897046
46
Operation Section
Monitoring Systems and Operator Station Features
Illustration 91
g00100709
i01822242
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 standards. See your Caterpillar dealer
for all replacement parts.
Always check the condition of the seat belt and
the condition of the mounting hardware before you
operate the machine.
g00932817
47
Operation Section
Monitoring Systems and Operator Station Features
Illustration 93
g00100713
Illustration 95
g00100717
3. If the seat belt does not fit snugly with the buckle
in the center, readjust the seat belt.
Illustration 96
Illustration 94
g00932818
Fasten the seat belt catch (3) into the buckle (2).
Make sure that the seat belt is placed low across
the lap of the operator.
g00867598
48
Operation Section
Monitoring Systems and Operator Station Features
i01848698
Alternate Exit
SMCS Code: 7310
Illustration 97
g00039113
Use the correct method of sealing (beading) to secure the operators station windows. Contact your
Caterpillar dealer for the correct sealing (beading)
method.
In order to exit the operators station through the
front window, side window or rear window, exert
outwards pressure on the window until the window
separates from the operators station frame.
Illustration 98
g00941616
Illustration 99
g00941617
49
Operation Section
Monitoring Systems and Operator Station Features
50
Operation Section
Machine Controls and Operation
Braking
SMCS Code: 4250; 4251; 4267; 4278; 4284
Parking Brake
This machine is equipped with spring applied
parking brakes. The spring force engages the
brakes on all four wheels. Hydraulic pressure is
used to disengage the brakes. If the hydraulic
pressure is unavailable, the brakes will remain
engaged.
If hydraulic pressure is unavailable and the machine
must be towed, use the 1DE-3048 Portable
Hydraulic Pump in order to release the parking
brake.
Reference: For further information on towing an
inoperable machine, consult your Caterpillar dealer
or refer to Operation and Maintenance Manual,
Towing Information for the machine that is being
serviced.
Illustration 100
g00941647
51
Operation Section
Machine Controls and Operation
g00941650
Illustration 103
g00897567
Illustration 102
g00941661
g00897569
52
Operation Section
Machine Controls and Operation
Inspect the parking brake system and make any necessary repairs before returning the machine to operation.
Service Brake
No clearance for person in operators station access area when machine turns. Severe injury or
death from crushing could occur.
Engage transmission/primary steering lock before
leaving the operators station.
Illustration 105
g00897634
Illustration 106
g00897677
53
Operation Section
Machine Controls and Operation
i01754771
Illustration 108
g00897738
Illustration 107
g00897679
54
Operation Section
Machine Controls and Operation
i01754787
Transmission Control
SMCS Code: 3065; 3168; 4800
Direction Selection
Illustration 111
Illustration 109
g00897780
g00897771
Speed Selection
Illustration 110
g00897776
g00897930
55
Operation Section
Machine Controls and Operation
Illustration 113
g00918520
Illustration 114
Illustration 115
g00941794
Illustration 116
g00941795
g00897762
3 Third Speed
4 Fourth Speed (If Equipped)
Note: When the parking brake is engaged, the
transmission cannot be shifted into the first gear
speed (unless the parking brake drive through
feature is activated). For further information on the
Parking Brake Drive Through feature, refer to the
Operation and Maintenance Manual, Braking for
the machine that is being serviced.
56
Operation Section
Machine Controls and Operation
Illustration 117
g00941805
Illustration 118
g00941806
57
Operation Section
Machine Controls and Operation
i01755584
Throttle Control
SMCS Code: 1276
Illustration 119
g00898242
i01755662
Steering Control
SMCS Code: 4309; 4343
Remove the steering frame lock and store it in the
unlocked position. The steering frame lock must
be in the unlocked position in order to steer the
machine.
Reference: For information on the steering frame
lock, refer to Operation and Maintenance Manual,
Steering Frame Lock for the machine that is being
serviced.
Illustration 120
g00898294
g00898292
58
Operation Section
Machine Controls and Operation
g00988644
i01849063
Joystick Control
NOTICE
Never use the FLOAT position to lower a loaded bucket.
59
Operation Section
Machine Controls and Operation
Illustration 123
g00988645
i01930895
60
Operation Section
Machine Controls and Operation
g00905299
key.
61
Operation Section
Machine Controls and Operation
The bucket and bucket control group operate automatically. A safe operating distance must be maintained between the machine and other personnel.
Operating the machine within an unsafe distance
can be dangerous and could result in severe injury
or death.
Under no circumstances should any service work or
testing and adjusting be carried out on the machine
while the machine is operating on Autodig.
Autodig Controls
Illustration 125
g00942000
Additional Features
Reference: More complete information is available
from your Caterpillar dealer. Refer to the Operation
and Maintenance Manual, SEBU7012, Payload
Control System for additional features.
i01849196
Autodig System
(If Equipped)
62
Operation Section
Machine Controls and Operation
Autodig Operation
Autodig Operation from the Operators
Station
Illustration 128
Illustration 126
g00942000
g00942004
Illustration 127
g00942003
63
Operation Section
Machine Controls and Operation
Illustration 131
g00898881
g00898889
Illustration 130
g00942007
64
Operation Section
Machine Controls and Operation
Illustration 134
g00898996
Illustration 132
g00898990
Illustration 133
g00942246
65
Operation Section
Machine Controls and Operation
In Case of Fire
i01849785
NOTICE
If the fire suppression system has been activated, the
system must be flushed and recharged. Have the machine cleaned, inspected and repaired before returning the machine to operation.
g00899222
66
Operation Section
Machine Controls and Operation
g00899282
Illustration 137
g00942326
67
Operation Section
Machine Controls and Operation
In Case of Fire
i01850016
Illustration 138
g00942345
NOTICE
If the fire suppression system has been activated, the
system must be flushed and recharged. Have the machine cleaned, inspected and repaired before returning the machine to operation.
Illustration 139
g00942346
68
Operation Section
Machine Controls and Operation
Illustration 141
g00942389
Illustration 140
g00942373
3. Raise lift arm (1) until the safety pin bore can be
aligned with the front frame tower.
69
Operation Section
Before Starting Engine
Walk-Around Inspection
SMCS Code: 1000; 7000
For maximum service life of the machine, make a
thorough walk-around inspection before you mount
the machine.
Look around the machine and under the machine.
Inspect the condition of all major components.
Check all grease fittings. Look for the following
discrepancies:
loose bolts
trash buildup
oil, coolant, or fuel leaks
broken parts or worn parts
cracks in the frames
Remove any trash and any debris. Report any
abnormalities to the shop. Make any necessary
repairs before you operate the machine.
Note: If the machine has not been operated for
more than 48 hours, qualified personnel should
complete a service inspection before you operate
the machine.
Reference: Refer to the Operation and Maintenance
Manual, Service Inspection for further information.
70
Operation Section
Before Starting Engine
g01013673
Illustration 142
Inspection points for the walk-around inspection
(A) Left steering cylinder
(B) Steering frame lock
(C) Frame
(D) Left front tire
(E) Front lights
(F) Bucket and linkage
(G) Right front tire
Illustration 143
g01013444
71
Operation Section
Before Starting Engine
g01013412
Illustration 144
g01013413
Illustration 147
g01013411
Illustration 145
g01013414
72
Operation Section
Before Starting Engine
i01618562
Illustration 148
g01013410
Illustration 149
73
Operation Section
Before Starting Engine
i01758396
i01850114
Illustration 151
g00942425
Gauge cluster
Tachometer
Digital speedometer
Actual gear indicator
g00918640
g00942438
74
Operation Section
Before Starting Engine
"X 10".
Symbol for the service hour meter.
"888.8.8.8" in the six digit display area.
The self test will also activate the gauge panel to
show the following:
75
Operation Section
Engine Starting
Engine Starting
i01850252
Diesel engine exhaust contains products of combustion which may cause personal injury.
Always start and operate the engine in a well ventilated area, and, if in an enclosed area, vent the
exhaust to the outside.
1. Make sure that no one is on the machine,
underneath the machine or around the machine.
Make sure that there are no personnel in the
area.
Illustration 154
g00899762
Illustration 153
Illustration 155
g00899766
g00899776
Illustration 156
g00942511
76
Operation Section
Engine Starting
i01850254
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
Note: For starting below 18 C (0 F), use
of additional cold weather starting aids is
recommended. A coolant heater, a fuel heater or
some extra battery capacity may be required. At
temperatures below 23 C (10 F), consult your
Caterpillar dealer or refer to the Operation and
Maintenance Manual, SEBU5898, Cold Weather
Recommendations for the machine that is being
serviced.
77
Operation Section
Engine Starting
NOTICE
When starting from another machine, make sure that
the machines do not touch. This could prevent damage to engine bearings and electrical circuits.
g00942542
78
Operation Section
Engine Starting
i01850324
Illustration 158
g00942553
79
Operation Section
Engine Starting
i01850374
if the temperature
More time may be required
is less than 18 C (0 F). More time may
also be required if the hydraulic functions are
sluggish.
g00942566
NOTICE
Keep engine speed low until the engine oil pressure
alert indicator goes out. If the alert indicator does not
go out within ten seconds, stop the engine and investigate the cause before starting again. Failure to do so
can cause engine damage.
1. Allow a cold engine to warm up at low idle
for at least five minutes. To help the hydraulic
components to warm up faster, engage and
disengage the hydraulic controls to help speed
warm up of the hydraulic oil and components.
The hydraulic oil will warm up faster if the joystick
control is held in the full TILT BACK position for
short periods of ten seconds or less. This will
allow the hydraulic oil to reach relief pressure,
which causes the hydraulic oil to warm more
rapidly.
Cycle all hydraulic controls in order to allow warm
hydraulic oil to circulate through all hydraulic
cylinders and through all hydraulic lines.
2. Look at the alert indicators and the gauges
frequently during operation.
When you idle the engine in order to warm up the
engine, observe the following recommendations:
80
Operation Section
Operation
Operation
i01850553
g00900169
Illustration 162
g00900168
Illustration 160
g00942629
g00900171
81
Operation Section
Operation
Downhill Operation
Maintain a ground speed that is slow enough for
the conditions. Before you operate the machine
down a hill, select the proper gear before you start
down the grade. The proper gear should allow the
machine to maintain the appropriate speed on the
down grade. The throttle control should be at high
idle and the engine should not overspeed. In most
situations, the proper gear will be the same gear
that is required to drive up the grade.
If the machine builds up excessive speed, the
engine can overspeed. This can result in damage to
the engine. Use the service brake in order to slow
the machine until a lower gear can be selected.
Select the lower gear and proceed with the throttle
control at high idle.
Use the service brakes for stopping the machine.
Using the service brakes in order to control the
travel speed of the machine or using the service
brakes for stopping from high speeds can cause
the axle oil to overheat. This will result in significant
wear and/or damage to the service brakes and the
axle components.
Note: The left pedal should not be used for downhill
braking.
i01759577
82
Operation Section
Operation
i01850573
Parking Brake
i01850577
Secondary Steering
(If Equipped)
Illustration 165
Illustration 164
g00942656
g00942658
83
Operation Section
Operating Techniques
Operating Techniques
i01850605
Operating Technique
Information
SMCS Code: 7000
Illustration 168
g00942665
Illustration 166
g00942662
g00942667
g00942663
Illustration 170
g00942706
84
Operation Section
Operating Techniques
Illustration 174
Illustration 171
g00942662
g00900427
Illustration 172
g00942707
g00900487
Illustration 173
g00900430
85
Operation Section
Operating Techniques
i01850617
Illustration 176
g00900491
Illustration 178
g00942731
Illustration 177
g00942712
Illustration 179
g00900737
86
Operation Section
Operating Techniques
Illustration 180
g00942733
Illustration 181
g00900711
87
Operation Section
Parking
Parking
i01850807
Personal injury or death can result from not engaging the parking brake.
If the parking brake is not engaged, the machine
may roll while personnel are on or near the machine.
Always engage the parking brake before leaving
the machine.
Illustration 183
g00901282
No clearance for person in operators station access area when machine turns. Severe injury or
death from crushing could occur.
Engage transmission/primary steering lock before
leaving the operators station.
NOTICE
Do not engage the parking brake while the machine is
moving unless the service brakes fail. The use of the
parking brake as a service brake in regular operation
will cause severe damage to the parking brake.
1. Park the machine on a level surface. If it is
necessary to park on a grade, block the wheels.
Illustration 182
Illustration 184
g00901283
g00901281
Illustration 185
g00942759
88
Operation Section
Parking
i01850822
Illustration 187
g00942776
Illustration 186
g00901297
89
Operation Section
Parking
i01761975
Illustration 188
g00901356
90
Operation Section
Remote Control System
Transmitter Controls
g00901539
Illustration 189
g00901537
91
Operation Section
Remote Control System
Illustration 191
g00901395
Illustration 193
g00901401
Illustration 192
g00901399
92
Operation Section
Remote Control System
g00901467
93
Operation Section
Remote Control System
Illustration 195
Illustration 197
g00942813
g00901739
g00901748
Illustration 196
g00942812
94
Operation Section
Remote Control System
i01850922
Illustration 199
g00901819
Illustration 200
g00942831
NOTICE
Do not crank the engine continuously for more than
30 seconds. Allow the starting motor to cool for two
minutes before cranking the engine again.
NOTICE
Do not operate the machine if the amber light remains
ON. This indicates the machine has either low brake
oil pressure or the brakes are applied. Driving the machine with the brakes applied for an extended period
can cause severe damage to the braking system.
i01850959
Illustration 201
g00901851
95
Operation Section
Remote Control System
Illustration 202
g00942849
NOTICE
If the machine is not going to be operated by remote
control for an extended period of time, remove the receiver from the machine and store it in a dry, secure
place. This will prevent accidental damage to the receiver.
96
Operation Section
Remote Control System
i01778443
i02009352
Illustration 203
g00909412
Personal injury or death can result from attempting repairs on a machine while it is in a stope or
dangerous area.
The machine must be recovered by a machine operated by remote control and moved to a safe location for repairs.
Note: If the machine is equipped with a brake
release system, this system can be used to release
the brakes for towing. For more information, refer
to the Operation and Maintenance Manual, Brake
Release (If Equipped) for the machine that is being
serviced.
97
Operation Section
Transportation Information
Transportation Information
i01762987
Illustration 204
g00901921
98
Operation Section
Transportation Information
i01762989
99
Operation Section
Transportation Information
Illustration 205
g00942862
100
Operation Section
Towing Information
Towing Information
i01851088
101
Operation Section
Towing Information
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
NOTICE
Be sure the cylinder hoses are connected correctly before operating the machine. With the hoses reversed,
the steering system will not function.
2. If failure of the internal transmission or of the
drive line is suspected, remove the axle shafts.
Reference: For information on removing the
axle shafts, refer to Power Train, Disassembly
and Assembly, Axle Shafts - Remove for the
machine that is being serviced.
Illustration 206
g00942975
102
Operation Section
Towing Information
NOTICE
Release the parking brake to prevent excessive wear
and damage to the parking brake system when towing
the machine.
6. Remove the wheel blocks. Tow the machine
slowly. Do not exceed 2 km/h (1.2 mph).
i01951817
Illustration 207
g00942987
Illustration 208
g00909742
103
Operation Section
Towing Information
Illustration 211
g00909759
Illustration 209
g00942989
Illustration 212
Illustration 210
g00942993
g00942998
104
Operation Section
Towing Information
i02007662
Brake Release
(If Equipped)
SMCS Code: 4267
Certain Caterpillar machines fitted with remote
controls may be equipped with an optional brake
release system. The brake release system is used to
recover a machine from a stope or dangerous area.
If the parking brake is engaged due to a machine
fault, or if the machine becomes partially buried in
a rock fall, the brake release system can be used to
disengage the parking brake to enable the machine
to be towed.
If the recovery machine is equipped with a recovery
bar, the recovery bar can be used to activate the
brake release system. If the disabled machine is
equipped with a recovery hook, the recovery hook
can be used to activate the brake release system.
The machine may be equipped with the optional
steering release system. The steering release
system is activated when the brake release system
is activated. When the steering release system is
activated the oil in the rod end and the head end of
the steering cylinders is open to the hydraulic tank.
The machine will articulate freely.
Illustration 213
g00943005
105
Operation Section
Towing Information
Illustration 214
g00901945
Illustration 216
g00902000
Illustration 215
g00901998
Recovery bar
Weld-on adapter plate
Bucket lower lip
Bolts
Illustration 217
g00902004
106
Operation Section
Towing Information
Once the towing brake release system is activated, the machine can roll freely.
Personal injury or death could result when towing
a disabled machine incorrectly.
Illustration 218
g00943055
107
Operation Section
Adjustments
Adjustments
i01851265
Illustration 220
g00943077
Illustration 221
Illustration 219
g00943076
g00943079
108
Operation Section
Adjustments
Illustration 222
g00902144
109
Maintenance Section
Torque Specifications
Maintenance Section
i01763381
Torque Specifications
g00280501
Illustration 223
Table 5
Width of Clamp
Width of Clamp
Reassembly or Retightening
Torque
i01763383
i01763380
BOLT SIZE
INCH
(1)
RECOMMENDED TORQUE
(1)
Nm
lb ft
5/8
270 40
200 30
3/4
475 60
350 45
7/8
750 90
550 65
1150 150
850 110
1 1/4
2300 300
1700 220
These values are only for Caterpillar bolts for cutting edges.
110
Maintenance Section
Torque Specifications
i01763384
Illustration 224
Thread Size
Inch
Standard Torque
1/4
12 3 Nm (9 2 lb ft)
5/16
25 6 Nm (18 4 lb ft)
g00735086
3/8
47 9 Nm (35 7 lb ft)
7/16
70 15 Nm (50 11 lb ft)
1/2
9/16
5/8
3/4
7/8
1 1/8
1 1/4
1 3/8
1 1/2
Table 7
Standard Torque
1/4
8 3 Nm (6 2 lb ft)
5/16
17 5 Nm (13 4 lb ft)
3/8
35 5 Nm (26 4 lb ft)
7/16
45 10 Nm (33 7 lb ft)
1/2
65 10 Nm (48 7 lb ft)
5/8
3/4
7/8
1 1/8
1 1/4
1 3/8
1 1/2
111
Maintenance Section
Torque Specifications
i01763388
Standard Torque
M6
12 3 Nm (9 2 lb ft)
M8
28 7 Nm (21 5 lb ft)
M10
55 10 Nm (41 7 lb ft)
M12
M14
M16
M20
M24
M30
M36
Table 9
Standard Torque
M6
8 3 Nm (6 2 lb ft)
M8
17 5 Nm (13 4 lb ft)
M10
35 5 Nm (26 4 lb ft)
M12
65 10 Nm (48 7 lb ft)
M16
M20
M24
M30
M36
112
Maintenance Section
Tire Inflation Information
i01946416
Tire Size
Ply Rating or
Strength Index
18.0-25
Shipping Pressure
Front
Rear
Bridgestone 28
690 kPa
(100 psi)
415 kPa
(60 psi)
18.0-25
Goodyear 28
655 kPa
(95 psi)
450 kPa
(65 psi)
18.0-R25
Bridgestone Two
Star
690 kPa
(100 psi)
415 kPa
(60 psi)
18.0-R25
690 kPa
(100 psi)
480 kPa
(70 psi)
113
Maintenance Section
Lubricant Viscosities and Refill Capacities
Lubricant Viscosities
SMCS Code: 1000; 7000; 7581
The oil viscosities shown in bold type in the
following table are the standard oils used in
Caterpillar R1600G machines. If the ambient
temperatures you operate in do not fall within the
standard oil temperature range, choose an oil that
meets the required ambient temperature range.
114
Maintenance Section
Lubricant Viscosities and Refill Capacities
Table 11
Engine Crankcase
Hydraulic Systems
Drive Axles
Caterpillar TDTO
Commercial TO-4
Caterpillar TDTO-TMS
Caterpillar Biodegradable
Hydraulic Oil (HEES)
Caterpillar HYDO
Caterpillar DEO
Caterpillar TDTO
Caterpillar MTO
API CG-4
API CF-4
API CF
Commercial TO-4
Caterpillar TO-4M
Caterpillar TDTO-TMS
API CH-4
Commercial BF-1(4)
Global DHD-1
Caterpillar TDTO
Commercial TO-4
Caterpillar TDTO-TMS
(2)
(3)
(4)
F
Min
Max
Min
Max
SAE 0W20
40
+10
40
+50
SAE 0W30
40
+30
40
+86
SAE 0W40
40
+40
40
+104
SAE 5W30
30
+30
22
+86
SAE 5W40
30
+40
22
+104
SAE 10W30
20
+40
+104
SAE 10W40
20
+50
+122
SAE 15W40
15
+50
+5
+122
SAE 0W20
(2)
40
+10
40
+50
SAE 0W30
(2)
40
+20
40
+68
SAE 5W30
(2)
30
+20
22
+68
20
+10
+50
SAE 30
+35
+32
+95
SAE 50
+10
+50
+50
+122
TDTO-TMS (3)
10
+43
+14
+110
SAE 0W20
(2)
40
+40
40
+104
SAE 0W30
(2)
40
+40
40
+104
SAE 5W30
(2)
30
+40
22
+104
SAE 5W40
30
+40
22
+104
SAE 10W
20
+40
+104
SAE 30
+10
+50
+50
+122
SAE 10W30
20
+40
+104
SAE 15W40
15
+50
+5
+122
Caterpillar MTO
25
+40
13
+104
Cat Biodegradable
Hydraulic Oil (HEES)
40
+43
40
+110
TDTO-TMS (3)
20
+50
-4
+122
SAE 30
20
+20
+68
SAE 50
-10
+43
+23
+122
SAE 60
+50
+23
+122
25
+22
13
+72
SAE 10W
(4)
TDTO-TMS
(1)
C
Oil Viscosities
(3)
When you are operating the machine in temperatures below 20C (4F), refer to Operation and Maintenance Manual, SEBU5898, Cold
Weather Recommendations. This is available from your Caterpillar dealer.
First Choice: Oils of full synthetic base stock without viscosity index improvers that meet the performance requirements of the TO-4
specification for the SAE 30 viscosity grade. Typical lubricant viscosity grades are SAE 0W-20, SAE 0W-30, and SAE 5W-30. Second
Choice: Oils that contain a TO-4 additive package and a lubricant viscosity grade of SAE 0W-20, SAE 0W-30, or SAE 5W-30.
TDTO-TMS Transmission Multi-Season (exceeds the TO-4/TO-4M multigrade specification requirements).
Commercial Biodegradable Hydraulic Oil (HEES) must meet the Caterpillar BF-1 specification. The listed ambient temperature range is for
the current Caterpillar Biodegradable Hydraulic Oil (HEES), not for commercial BF-1 oil.
115
Maintenance Section
Lubricant Viscosities and Refill Capacities
i01851555
Capacities (Refill)
SMCS Code: 7560
Table 12
Liters
US
Gallons
Imperial
Gallons
36.1
9.5
7.9
Transmission
36
9.5
7.9
Hydraulic Tank
125
33
27.5
Cooling System
53
14
11.7
70
18.5
15.4
70
18.5
15.4
80
21.1
17.6
80
21.1
17.6
Fuel Tank
400
105.7
88
330
87.2
72.6
Engine Crankcase
116
Maintenance Section
Maintenance Locations
Maintenance Locations
i01851578
g00943272
Illustration 225
(1) Front axle breather
(2) Hydraulic tank oil filler screen
(3) Hydraulic system oil filters
(4) Transmission magnetic screen
(5) Rear axle suction screen (if equipped
with axle oil cooler)
(6) Rear axle breather
(7) Torque converter suction screen
(8) Secondary fuel filter
(9) Engine crankcase breather
117
Maintenance Section
Maintenance Locations
i01851732
Illustration 226
g00943399
Illustration 227
g00943401
Type of Fluid
Change
Interval
Sampling
Interval
Sampling
Valve
Engine Oil
250 Hours
250 Hours
Yes(1)
Transmission
Oil
1000 Hours
500 Hours
Yes(1)
Hydraulic Oil
2000 Hours
500 Hours
Yes(1)
Differential
and Final
Drive Oil
1000 Hours
500 Hours
No
Coolant
6000 Hours
500 Hours
No
(1)
g00943406
118
Maintenance Section
Maintenance Locations
Illustration 232
Illustration 229
g00943418
g00943423
Illustration 230
g00943419
Application
Studies have revealed that obtaining oil samples at
every 500 hours is too long a time interval in some
applications in order to predict potential failure
modes. A sampling interval at every 250 hours
provides more data between oil change intervals.
More data increases the chance for detecting a
potential failure.
g00943420
119
Maintenance Section
Maintenance Locations
120
Maintenance Section
Maintenance Interval Schedule
i02013181
When Required
Battery - Recycle ................................................ 125
Battery, Battery Cable or Battery Disconnect Switch Replace ............................................................. 126
Circuit Breakers - Reset ...................................... 133
Engine Air Filter Secondary Element - Replace .. 155
Engine Air Precleaner - Clean ............................ 155
Exhaust Purifier - Inspect/Clean ......................... 160
Fuel System - Prime ........................................... 161
Fuses - Replace .................................................. 165
Oil Filter - Inspect ................................................ 172
Radiator Core - Clean ......................................... 173
Window Washer Bottle - Fill ................................ 187
Window Wiper - Inspect/Replace ........................ 187
124
131
163
182
156
164
167
184
121
Maintenance Section
Maintenance Interval Schedule
152
158
159
166
169
186
135
139
141
142
153
Every 3 Years
Seat Belt - Replace ............................................. 176
122
Maintenance Section
Articulated Hitch Bearings - Inspect
i01900687
No clearance for a man in this area when the machine turns. Severe injury or death from crushing
could occur.
Install the steering frame lock pin into the locked
position before lifting the machine, transporting
the machine on another vehicle, or performing service near the center of the machine.
Disengage the steering lock pin from articulation
joint and store in retainer before resuming operation or the machine will not steer.
Illustration 233
g00943466
Illustration 234
g01013399
123
Maintenance Section
Automatic Brake Application System (Low Transmission Oil Pressure) - Test
i01851992
Illustration 236
g00943611
Illustration 235
g00943606
NOTICE
If the parking brake disengaged and the machine
moved while testing the Automatic Brake Application
(ABA) system, have the system inspected and repaired immediately before returning the machine to
operation. Contact your Caterpillar dealer or refer to
the Braking Section of the machine Service Manual.
Operating the machine with a defective ABA system
may result in serious personal injury or death.
9. Remove the plug from the manifold on the
transmission and install transmission oil pressure
switch (2). Connect the switch to the transmission
wiring harness at connector (1).
124
Maintenance Section
Automatic Lubrication Filler Filter - Clean
i01851889
Illustration 237
g00943521
i01851888
i01851872
Illustration 239
g00943517
Illustration 238
g00943482
125
Maintenance Section
Backup Alarm - Test
i01944979
Battery - Recycle
SMCS Code: 1401-561
Always recycle a battery. Never discard a battery.
Always return used batteries to one of the following
locations:
A battery supplier
An authorized battery collection facility
Recycling facility
i01829468
Illustration 240
Battery
Interval
Conventional
100 Hours
Low Maintenance
250 Hours
Maintenance Free
No Interval
g01012239
Illustration 241
g00896957
126
Maintenance Section
Battery, Battery Cable or Battery Disconnect Switch - Replace
Illustration 242
g00943586
g00943587
Illustration 244
g00943627
127
Maintenance Section
Belts - Inspect/Adjust
Belts - Inspect/Adjust
SMCS Code: 1357-025; 1357-040
For maximum engine performance and utilization
of your engine, inspect the belts for wear and for
cracking. Check and adjust the belt tension to
minimize belt slippage which will decrease belt life
and cause poor performance of the alternator and
any driven equipment.
1. Inspect the condition of the belts.
2. Inspect the tension of the alternator belt and air
conditioning compressor belts.
3. Check the belt tightener for wear/alignment and
that it is maintaining correct belt tension.
Illustration 246
g00908703
Illustration 245
g00908664
128
Maintenance Section
Brake Accumulator - Check
Illustration 247
g00908701
Illustration 249
g00943652
i01943872
Illustration 248
g00943640
Illustration 250
g00950168
129
Maintenance Section
Braking System - Test
Illustration 251
g00903126
Illustration 252
g00943668
130
Maintenance Section
Braking System - Test
If the machine begins to move during the test, reduce the engine speed immediately and apply the
service brakes.
1. Move the transmission direction and speed
control to the NEUTRAL position. Start the
engine. Raise the bucket slightly.
Illustration 254
Illustration 253
g00943668
g00943668
131
Maintenance Section
Bucket Pivot Bearings - Lubricate
i01765442
Illustration 257
g00903297
Illustration 255
g00943670
Illustration 256
g00943673
Illustration 258
g00918813
132
Maintenance Section
Central Lubrication System - Lubricate
Illustration 259
g00943791
10. Install end cap (4). Tighten clamp bolt (3) finger
tight. Do not use a tool to tighten the clamp bolt.
i01852412
133
Maintenance Section
Circuit Breakers - Reset
i01944981
Illustration 260
g00943793
Illustration 261
g01012251
Illustration 262
g01012253
134
Maintenance Section
Collet Pin Bolt Torque - Check
Illustration 264
g01012266
Illustration 263
g01012260
Illustration 265
g00943679
135
Maintenance Section
Cooling System Coolant (DEAC) - Change
i01852427
Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve
the pressure.
Illustration 266
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
g00943423
Illustration 267
g00943802
136
Maintenance Section
Cooling System Coolant (ELC) - Change
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
NOTICE
Do not change the coolant until you read and understand the cooling system information in Special Publication, SEBU6250, Caterpillar Machine Fluids Recommendations.
Failure to do so could result in damage to the cooling
system components.
Illustration 268
g00943804
NOTICE
Mixing ELC with other products reduces the effectiveness of the coolant and shortens coolant life. Use only Caterpillar products or commercial products that
have passed the Caterpillar EC-1 specifications for
premixed or concentrate coolants. Use only Caterpillar
Extender with Caterpillar ELC. Failure to follow these
recommendations could result in the damage to cooling systems components.
Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve
the pressure.
137
Maintenance Section
Cooling System Coolant Additive (DEAC) - Add
Illustration 269
g00943423
g00943804
Illustration 270
g00943802
138
Maintenance Section
Cooling System Coolant Additive (DEAC) - Add
Illustration 272
g00943423
139
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
i01852492
Illustration 273
g00988945
140
Maintenance Section
Cooling System Level - Check
NOTICE
Excessive additive (greater than the recommended
6% initial fill) together with concentrations of antifreeze
greater than 60% cause deposits to form and can result in radiator tube blockage and overheating.
NOTICE
Mixing ELC with other products reduces the effectiveness of the coolant and shortens coolant life. Use only Caterpillar products or commercial products that
have passed the Caterpillar EC-1 specifications for
premixed or concentrate coolants. Use only Caterpillar
Extender with Caterpillar ELC. Failure to follow these
recommendations could result in the damage to cooling systems components.
If ELC cooling system contamination occurs see the
topic Extended Life Coolant (ELC) in the Operation
and Maintenance Manual, SEBU6250, Caterpillar
Machine Fluids Recommendations.
When a Caterpillar Extended Life Coolant (ELC) is
used, an Extender must be added to the cooling
system.
Reference: For the proper service interval, refer
to the Operation and Maintenance Manual,
Maintenance Interval Schedule for the machine
that is being serviced.
The amount of extender is determined by the
cooling system capacity.
Reference: For information on the cooling system
capacity, refer to the Operation and Maintenance
Manual, Lubricant Viscosities and Refill Capacities
for the machine that is being serviced.
Reference: For all cooling system requirements, refer
to Caterpillar Machine Fluids Recommendations,
SEBU6250 or consult your Caterpillar dealer.
Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve
the pressure.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
Illustration 274
g00943423
141
Maintenance Section
Cooling System Pressure Cap - Clean/Replace
i01852520
Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve
the pressure.
Illustration 275
g00943804
g00943423
Illustration 276
g00943423
142
Maintenance Section
Cooling System Water Temperature Regulator - Replace
i01852525
Pressurized system: Hot coolant can cause serious burn. To open cap, stop engine, wait until radiator is cool. Then loosen cap slowly to relieve
the pressure.
Illustration 278
g00943880
NOTICE
Failure to replace the engines water temperature regulator on a regularly scheduled basis could cause severe engine damage.
Note: If you are only replacing a water temperature
regulator, drain the cooling system coolant to a
level that is below the water temperature regulator
housing.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
NOTICE
Former water temperature regulators may be used, if
they meet the test specifications and are not damaged
or have excessive buildup or deposits.
NOTICE
Since Caterpillar engines incorporate a shunt design
cooling system, it is mandatory to always operate the
engine with a water temperature regulator.
Depending on load, failure to operate with a water temperature regulator could result in either an overheating
or an overcooling condition.
NOTICE
If the water temperature regulator is installed incorrectly, it will cause the engine to overheat.
4. Install a new seal in the water temperature
regulator housing. Install a new water temperature
regulator and a new gasket. Install the water
temperature regulator housing and the hose.
5. Refill the cooling system.
Reference: For all cooling system requirements,
refer to the Operation and Maintenance
Manual, SEBU6250, Caterpillar Machine Fluids
Recommendations.
143
Maintenance Section
Crankshaft Vibration Damper - Inspect
Illustration 279
g00943973
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
crankshaft.
144
Maintenance Section
Differential and Final Drive Oil (With Axle Oil Cooler) - Change
Illustration 280
g00944014
Illustration 283
g00944022
Illustration 281
g00944015
Illustration 284
g00904075
g00944021
145
Maintenance Section
Differential and Final Drive Oil (With Axle Oil Cooler) - Change
Illustration 285
g00944029
Illustration 287
g00944039
Illustration 286
g00944036
12. Clean the filler plug and install the filler plug.
g00944042
146
Maintenance Section
Differential and Final Drive Oil (With Axle Oil Cooler) - Change
Illustration 291
g00944086
g00944014
Illustration 292
g00904075
g00944085
147
Maintenance Section
Differential and Final Drive Oil (With Axle Oil Cooler) - Change
Illustration 293
g00944091
Illustration 295
g00944039
Illustration 294
g00950868
Illustration 296
g00950999
148
Maintenance Section
Differential and Final Drive Oil (Without Axle Oil Cooler) - Change
Illustration 298
g00950683
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
Wipe covers and surfaces around openings before
checking or adding oil. Park on a level surface.
Illustration 297
g00950912
Illustration 299
g00950684
Illustration 300
Location of the front differential filler plug
g00950689
149
Maintenance Section
Differential and Final Drive Oil (Without Axle Oil Cooler) - Change
Illustration 301
g00950690
g00950702
Illustration 302
g00950691
Illustration 304
g00950703
150
Maintenance Section
Differential and Final Drive Oil Level (With Axle Oil Cooler) - Check
i01852623
Illustration 306
g00950867
Illustration 307
g00950868
Illustration 305
g00944039
151
Maintenance Section
Differential and Final Drive Oil Level (Without Axle Oil Cooler) - Check
i01852626
Illustration 309
g00950867
Illustration 310
g00950868
Illustration 308
g00944039
152
Maintenance Section
Drive Shaft Universal Joints, Splines and Bearings - Inspect/Lubricate
i01864402
Illustration 312
g00904968
Illustration 311
g00950525
g00950528
i01770342
153
Maintenance Section
Engine Aftercooler - Check
i01859598
Illustration 315
g00947932
Illustration 314
g00947911
NOTICE
Service the air cleaner only with the engine stopped.
Engine damage could result if the air cleaner is serviced while the engine is running.
NOTICE
This machine uses radial seal type air cleaners. To
avoid engine damage, use only radial seal replacement filters. Others will not seal.
Radial seal filter gasket design and location are critical
to proper air cleaner operation. Use only Caterpillar
replacements.
Illustration 316
g00947934
154
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
Illustration 317
g00947943
Illustration 318
g00905242
Pressure air.
Pressure water.
Detergent washing.
When you use pressure air, the maximum air
pressure is 205 kPa (30 psi). When you use
pressure water, the maximum water pressure is
280 kPa (40 psi).
155
Maintenance Section
Engine Air Filter Secondary Element - Replace
i01859607
NOTICE
This machine uses radial seal type air cleaners. To
avoid engine damage, use only radial seal replacement filters. Others will not seal.
Illustration 320
g00947964
Illustration 319
g00947959
156
Maintenance Section
Engine Crankcase Breather - Clean
i01859719
i01859721
Illustration 321
Illustration 322
g00948098
Illustration 323
g00948100
g00947967
157
Maintenance Section
Engine Oil Level - Check
i01859888
i01859895
NOTICE
Do not underfill or overfill the engine crankcase with
oil. Either condition can cause engine damage.
Illustration 324
g00948124
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
Illustration 325
g00948125
Illustration 326
g00948153
158
Maintenance Section
Engine Valve Lash - Check/Adjust
Illustration 327
g00948155
Illustration 329
g00948169
Illustration 328
g00948166
159
Maintenance Section
Engine Valve Rotators - Inspect
NOTICE
Only qualified service personnel should perform this
maintenance. Refer to the Service Manual or your
Caterpillar dealer for the complete valve lash adjustment procedure.
Operation of Caterpillar engines with improper valve
adjustments can reduce engine efficiency. This reduced efficiency could result in excessive fuel usage
and/or shortened engine component life.
i01770623
Illustration 330
g00905744
i01860088
NOTICE
A valve rotator which does not operate properly will
accelerate valve face wear and valve seat wear and
shorten valve life. If a damaged rotator is not replaced,
valve face guttering could result and cause pieces of
the valve to fall into the cylinder. This can cause piston
and cylinder head damage.
Valve rotators cause the valve to rotate when the
engine runs. This helps to prevent deposits from
building up on the valve and the valve seats.
Illustration 331
g00948218
160
Maintenance Section
Exhaust Purifier - Inspect/Clean
g00948239
Illustration 332
g00948231
g00948684
161
Maintenance Section
Fuel System - Prime
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Illustration 335
g00948686
NOTICE
Do not loosen the fuel lines at the fuel manifold. The
engine components may be damaged.
Do not remove the fitting in the fuel filter base in order
to release air from the fuel system while priming the
engine. Periodic removal of the fitting will result in increased wear of the threads in the fuel filter base and
will lead to fuel leakage.
Do not allow dirt to enter the fuel system. Thoroughly clean the area around any fuel system component
that will be disconnected. Fit a suitable cover over any
disconnected fuel system component in order to protect it from dirt and debris.
g00948524
162
Maintenance Section
Fuel System Primary Filter - Clean/Replace
Illustration 337
g00948638
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
163
Maintenance Section
Fuel System Secondary Filter - Replace
i01860588
Illustration 338
g00948663
164
Maintenance Section
Fuel Tank Cap and Strainer - Clean
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
Illustration 340
g00948818
Illustration 339
g00948703
Illustration 341
g00906284
165
Maintenance Section
Fuel Tank Water and Sediment - Drain
Illustration 342
g00948815
Illustration 343
g00948863
Illustration 344
g00948866
Fuses - Replace
SMCS Code: 1417-510
166
Maintenance Section
Hydraulic System Oil - Change
Illustration 345
g00948903
Illustration 346
g00949076
Illustration 347
g01012273
Illustration 348
g00949090
167
Maintenance Section
Hydraulic System Oil Filter - Replace
i01944989
Illustration 349
g01012274
11. With the oil cold, maintain the hydraulic oil level
to the FULL COLD mark in sight gauge (5).
With the oil at operating temperature, maintain
the oil level to the FULL WARM mark in sight
gauge (5). Add more oil, if necessary through
filler tube (4).
Illustration 350
g00949076
168
Maintenance Section
Hydraulic System Oil Filter - Replace
Illustration 351
g01012276
Illustration 353
g01013189
Illustration 354
Illustration 352
g01012590
g01012588
13. With the oil cold, maintain the hydraulic oil level
to the FULL COLD mark in sight gauge (6).
With the oil at operating temperature, maintain
the oil level to the FULL WARM mark in sight
gauge (6). Add more oil, if necessary through
filler tube (7).
14. Install the oil filler cap.
169
Maintenance Section
Hydraulic System Oil Level - Check
i01945618
Illustration 357
g01012595
Illustration 355
g01012591
Illustration 356
g01012593
Illustration 358
g00949230
170
Maintenance Section
Implement and Steering Lockout (STIC Steering) - Test
NOTICE
If the machine moved while testing the steering mechanical lockout system, contact your Caterpillar dealer. Have the dealer inspect and repair the steering mechanical lockout before returning the machine to operation.
Illustration 359
g00906651
NOTICE
If the bucket or the machine moved while testing the
implement and steering hydraulic lockout system, contact your Caterpillar dealer. Have the dealer inspect
and repair the implement and steering hydraulic lockout before returning the machine to operation.
171
Maintenance Section
Implement and Steering Lockout (Wheel Steering) - Test
i01860941
i01860942
Illustration 360
g00949296
NOTICE
If the bucket or the machine moved while testing the implement and steering secondary lockout
system, contact your Caterpillar dealer. Have the
dealer inspect and repair the implement and steering
secondary lockout before returning the machine to
operation.
the engine.
the covers or around the hoses.
172
Maintenance Section
Lift Arm and Cylinder Bearings - Lubricate
i01860948
i01773398
NOTICE
Check that the lines attached to all the remote grease
fittings are undamaged. If the grease lines are split,
grease will not reach the components that require lubricating. Machine damage will result.
Wipe off the fittings before any lubricant is applied.
The fittings are located on the right side of the
machine articulation area.
Illustration 362
g00907074
Illustration 361
g00989104
173
Maintenance Section
Radiator Core - Clean
i01860952
Illustration 366
Illustration 363
g00949343
g00907092
Illustration 364
g00949340
i01773405
Illustration 365
g00949339
174
Maintenance Section
Rear Axle Trunnion Bearings - Lubricate
i01946617
i01945622
Illustration 369
g01012600
g00949461
Illustration 368
g01013381
175
Maintenance Section
Rollover Protective Structure (ROPS) and Falling Object Protective Structure (FOPS) - Inspect
i01862533
i01773416
g00907536
Illustration 370
g00949688
Illustration 372
g00907537
176
Maintenance Section
Seat Belt - Replace
i01773427
Illustration 373
g00907536
Service Inspection
SMCS Code: 7000
For maximum service life of the machine, make
a thorough service inspection when you perform
lubrication and maintenance work. Look around
the machine and under the machine. Inspect the
condition of all major components. Check all grease
fittings. Look for the following discrepancies:
loose bolts
trash buildup
oil, coolant, or fuel leaks
broken parts or worn parts
cracks in the frames
Remove any trash and any debris. As needed,
adjust the tire inflation. Make any necessary repairs.
Make sure that all loose connections and all parts
are tightened to the specified torques. Replace any
missing parts before starting the engine or before
operating the machine.
177
Maintenance Section
Service Inspection
g00949495
Illustration 374
Inspection points for the service inspection
(A) Steering hydraulic system
(B) Frame
(C) Tires
(D) Front lights
(E) Bucket and linkage
(F) Hydraulic system
(G) Window washer reservoirs
(H) Power train
(I) Handholds and steps
(J) Engine
178
Maintenance Section
Service Inspection
Illustration 375
g00949525
Illustration 376
g01013198
Illustration 377
g01013201
179
Maintenance Section
Service Inspection
g00949532
Illustration 380
g00949535
Illustration 379
g00949534
180
Maintenance Section
Steering Cylinder Bearings - Lubricate
i01946619
i01863098
Illustration 383
g00949853
g00949829
i01864387
Illustration 382
g01013382
g00950515
181
Maintenance Section
Tilt Cylinder and Tilt Lever Bearings - Lubricate
g00950021
g00950019
Illustration 386
Illustration 388
g00950150
Illustration 389
g00950153
g00950020
182
Maintenance Section
Tire Inflation - Check
Illustration 392
g00950188
g00950161
g01011996
183
Maintenance Section
Transmission Oil - Change
NOTICE
Do not drop or rap the magnets against any hard objects. Replace any damaged magnets.
10. Clean the cover. Inspect the cover seal. Replace
the seal if it is damaged.
11. Insert the magnets in the screen.
12. Insert the screen, tube and magnets in the
transfer case housing.
13. Install the seal, the cover and the four bolts.
14. Clean the transmission drain plug and install the
drain plug.
Illustration 393
g00950234
g00950300
Illustration 394
g00950233
184
Maintenance Section
Transmission Oil Filter - Replace
23. Remove oil filler cap (8) and fill the transmission
with oil.
Reference: For information on lubricants and
refill capacities, refer to the Operation and
Maintenance Manual, Lubricant Viscosities and
Refill Capacities for the machine that is being
serviced.
24. Start and run the engine at low idle. Inspect the
machine for leaks.
25. Apply the service brakes. Use the right brake
pedal only.
Illustration 396
g00950269
g01011998
Illustration 398
g01012000
185
Maintenance Section
Transmission Oil Filter - Replace
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
Illustration 399
g00950328
Illustration 401
g01012007
g00950329
186
Maintenance Section
Transmission Oil Level - Check
i01944249
i01863148
Turbocharger - Inspect
Illustration 402
g01012008
Engine smoke.
Speeding up of the engine with no load.
Note: For specifications used to check the
turbocharger, refer to Specifications, 3176C
Engine for the machine that is being serviced.
Illustration 403
g00908561
187
Maintenance Section
Window - Clean
i01863165
Window - Clean
(If Equipped)
i01863168
Illustration 404
g00950407
Illustration 405
g00950411
Illustration 406
g00950412
188
Reference Information Section
Reference Materials
Reference Information
Section
Reference Materials
Reference Material
SMCS Code: 1000; 7000
189
Reference Information Section
Reference Materials
Decommissioning and
Disposal
SMCS Code: 1000; 7000
Disposal of your machine will vary with local
regulations. Consult your nearest Caterpillar dealer
for additional information on disposal.
190
Index Section
Index
A
Adjustments......................................................... 107
Air Conditioning and Heating Control .................... 45
Air Conditioning and Heating System
Operation ......................................................... 45
Alternate Exit ......................................................... 48
Articulated Hitch Bearings - Inspect .................... 122
Articulated Hitch Bearings - Lubricate ................. 122
Autodig System (If Equipped)................................ 61
Autodig Controls ................................................ 61
Autodig Operation .............................................. 62
Automatic Brake Application System (Low
Transmission Oil Pressure) - Test (If Equipped).. 123
Automatic Lubrication Filler Filter - Clean (If
Equipped) .......................................................... 124
Automatic Lubrication Grease Tank - Fill (If
Equipped) .......................................................... 124
Automatic Lubrication Inline Filter - Clean (If
Equipped) .......................................................... 124
Autoshift Control (STIC Steering) .......................... 55
Autoshift Control (Wheel Steering) ........................ 56
B
Backup Alarm ........................................................ 44
Backup Alarm - Test ............................................ 125
Battery - Recycle ................................................. 125
Battery Disconnect Switch..................................... 31
Battery Electrolyte Level - Check ........................ 125
Battery, Battery Cable or Battery Disconnect Switch Replace.............................................................. 126
Before Operation ................................................... 21
Before Operation (Remote Control)....................... 92
Before Starting Engine .................................... 20, 69
Belts - Inspect/Adjust........................................... 127
Adjust the Air Conditioning Compressor Belt (If
Equipped)....................................................... 128
Adjust the Alternator Belt ................................. 127
Brake Accumulator - Check ................................. 128
Brake Discs - Check ............................................ 128
Brake Release (If Equipped) ............................... 104
Brake Release with the Recovery Bar ............. 104
Brake Release with the Recovery Hook .......... 106
Brake Release System - Test (If Equipped)......... 128
Braking .................................................................. 50
Optional Push-to-Engage Type Parking Brake
Control.............................................................. 51
Parking Brake..................................................... 50
Parking Brake Drive Through............................. 51
Service Brake..................................................... 52
Standard Pull-to-Engage Type Parking Brake
Control.............................................................. 51
Braking System - Test.......................................... 129
Parking Brake Holding Ability Test ................... 130
Service Brake Holding Ability Test ................... 129
Bucket Control Group Safety Pins ......................... 68
191
Index Section
E
Electrical Storm Injury Prevention ......................... 19
Electronic Unit Injector - Inspect/Adjust............... 152
Emergency Stopping (Remote Control)................. 96
Engine Aftercooler - Check.................................. 153
Engine Air Filter Primary Element Clean/Replace ................................................... 153
Engine Air Filter Secondary Element - Replace .. 155
Engine Air Precleaner - Clean ............................. 155
Engine and Machine Warm-Up ............................. 79
Preparing to Operate the Machine..................... 79
Engine Crankcase Breather - Clean.................... 156
Engine Mounts - Inspect...................................... 156
Engine Oil and Filter - Change ............................ 157
Engine Oil Level - Check ..................................... 157
Engine Shutdown Switch....................................... 32
Engine Start Switch ............................................... 32
Engine Starting................................................ 21, 75
Engine Starting with Auxiliary Start Receptacle .... 78
Engine Starting with Jump Start Cables................ 76
Use of Jump Start Cables .................................. 77
Engine Stopping .................................................... 22
Engine Valve Lash - Check/Adjust....................... 158
Adjustment of the Electronic Unit Injectors ...... 158
Engine Valve Rotators - Inspect .......................... 159
Engine Water Pump - Inspect.............................. 159
Equipment Lowering with Engine Stopped...... 22, 88
Exhaust Purifier - Inspect/Clean .......................... 160
F
Fan Drive Bearing - Lubricate.............................. 160
Filter and Screen Locations................................. 116
Fire Extinguisher Location ..................................... 18
Fire Prevention and Explosion Prevention............. 16
Ether .................................................................. 18
Fire Extinguisher ................................................ 18
Lines, Tubes and Hoses..................................... 18
Fire Suppression System - Check (If Equipped).. 160
Fire Suppression System (Dry Powder) (If
Equipped) ............................................................ 65
Fire Suppression Control (Automatic)................ 65
Fire Suppression Control (Manual) .................... 66
In Case of Fire ................................................... 67
Fire Suppression System (Foam) (If Equipped) .... 63
Fire Suppression Control (Engine Shutdown).... 64
Fire Suppression Control (Manual) .................... 64
In Case of Fire ................................................... 65
Forced Shutdown of Machine (Remote Control) ... 96
Foreword.................................................................. 5
California Proposition 65 Warning ....................... 4
Caterpillar Product Identification Number ............ 5
Certified Engine Maintenance.............................. 4
Literature Information........................................... 4
Machine Capacity ................................................ 5
Maintenance ........................................................ 4
Operation ............................................................. 4
Safety................................................................... 4
Fuel System - Prime............................................ 161
162
163
163
164
165
165
G
Gauges .................................................................. 37
General Hazard Information .................................. 13
Asbestos Information ......................................... 15
Containing Fluid Spillage ................................... 14
Dispose of Waste Properly ................................ 15
Fluid Penetration ................................................ 14
Pressure Air and Water...................................... 14
Trapped Pressure............................................... 14
General Information............................................... 25
General Information (Remote Control) .................. 90
General Torque Information................................. 109
Guards (Operator Protection) ................................ 23
Other Guards (If Equipped)................................ 23
Rollover Protective Structure (ROPS), Falling
Object Protective Structure (FOPS) or Tip Over
Protection Structure (TOPS) ............................ 23
H
Horn....................................................................... 44
Hydraulic System Oil - Change ........................... 166
Hydraulic System Oil Filter - Replace.................. 167
Hydraulic System Oil Level - Check .................... 169
Hydraulic Tank Breaker Relief Valve - Clean ....... 169
I
Identification Information ....................................... 29
Idle Timer Control (Engine Shutdown) (If
Equipped) ............................................................ 33
Implement and Steering Lockout (STIC Steering) Test .................................................................... 170
Implement and Steering Hydraulic Lockout ..... 170
Steering Mechanical Lockout........................... 170
Implement and Steering Lockout (Wheel Steering) Test .................................................................... 171
Important Safety Information ................................... 2
Indicators ............................................................... 38
Indicators and Gauges - Test............................... 171
J
Joystick Control ..................................................... 58
Joystick Control Lever - Optional Type............... 59
Joystick Control Lever - Standard Type.............. 58
192
Index Section
M
Machine Controls and Operation........................... 50
Machine Operation Information ............................. 80
Downhill Operation............................................. 81
Maintenance Interval Schedule ........................... 120
Maintenance Locations........................................ 116
Maintenance Section ........................................... 109
Model Views and Specifications ............................ 26
Monitoring Systems and Operator Station
Features............................................................... 31
Mounting and Dismounting.............................. 20, 72
Alternate Exit ..................................................... 20
O
Oil Filter - Inspect ................................................ 172
Inspect a Used Filter for Debris ....................... 172
Operating Technique Information .......................... 83
Operating Techniques............................................ 83
Operation......................................................... 21, 80
Operation (Remote Control) .................................. 94
Operation Section.................................................. 31
Operator Mode Scroll Switch................................. 42
Operator Modes ................................................. 42
Operator Station .................................................... 23
P
Parking ............................................................ 22, 87
Parking (Remote Control)...................................... 94
Parking Brake ........................................................ 82
Parking Brake Manual Release ........................... 102
Payload Control System (PCS) (If Equipped)........ 59
Additional Features ............................................ 61
General Operations of the Keypad..................... 60
Measuring the Load of a Bucket in the Stationary
Position ............................................................ 60
Measuring the Load of a Bucket on the Go ....... 60
Using the EXC Key .......................................... 61
Using the REW Key ......................................... 60
Plate Locations and Film Locations....................... 29
Certification Plate (CE) ...................................... 30
Product Identification Number (PIN) .................. 29
Serial Number Plates (SN) ................................ 29
Product Information Section .................................. 25
S
Safety Section ......................................................... 6
Safety Signs and Labels.......................................... 6
Batteries............................................................. 10
Bucket Control Group .......................................... 9
Compressed Spring ........................................... 12
Do Not Operate.................................................... 6
Do Not Weld the ROPS/FOPS............................. 6
Engine Coolant .................................................. 11
High Pressure Cylinder (Brake Accumulator) ...... 9
High Pressure Cylinder (Ride Control)............... 10
No Clearance ....................................................... 7
Operator Station Access ...................................... 8
Recovery Hook .................................................. 12
STIC Steering Control.......................................... 7
Unit Injectors ...................................................... 11
Wheel Steering Control........................................ 8
Sampling Interval and Location of Sampling
Valve .................................................................. 117
Location of Sampling Valves ............................ 117
More Frequent SOS Sampling Improves Life
Cycle Management ........................................ 118
Seat ....................................................................... 45
Seat Adjustment and Seat Belt Inspection ............ 73
Seat Belt ................................................................ 46
Extension of the Seat Belt ................................. 48
Seat Belt Adjustment for Non-Retractable Seat
Belts ................................................................. 46
Seat Belt Adjustment for Retractable Seat
Belts ................................................................. 47
Seat Belt - Inspect ............................................... 175
Seat Belt - Replace.............................................. 176
Secondary Steering (If Equipped) ......................... 82
Service Inspection ............................................... 176
Service Ports ......................................................... 43
Shipping the Machine............................................ 97
Sound Information and Vibration Information ........ 22
Vibration Level ................................................... 22
Standard Torque for Constant Torque Hose
Clamps............................................................... 109
Standard Torque for Inch Fasteners .................... 110
193
Index Section
194
Index Section
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
Sales:
Parts:
Service:
Phone Number
Hours
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