® = se Bus983-04 ‘August 1986 Operation Maintenance Manual 950B Wheel Loader 31R1-UP 63R1-6053 65R1-3087 22Z1-3188Important Safety Information Most accidents involving product operation, maintenance and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs. A person must be alert to potential hazards. This person should also have the necessary training, sklls and tools to perform these functions property Improper operation, lubrication, maintenance or repair of this product can be dangerous and could result in injury or death. Do not operate or perform any lubrication, maintenance or repair on this product, until you have read and understood the operation, lubrication, maintenance and repair information. ‘Safety precautions and wamings are provided in this manual and on the product. If these hazard ‘wamings are not heeded, bodily injury or death could occur to you or other persons. ‘The hazards are identified by the “Safety Alert Symbol" and followed by a “Signal Word" such as "WARNING" as shown below. 7 SO ‘The meaning of this safety alert symbol is as follows: Attention! Become Alert! Your Safety is Involved. ‘The message that appears under the waming, explaining the hazard, can be either written or pictorialy presented, Operation that may cause product damage are identified by NOTICE labels on the product and in this, publication. Caterpilar cannot anticipate every possible circumstance that might involve a potential hazard. The ‘warning in this publication and on the product are therefore not all inclusive. Ifa tool, procedure, work method or operating technique not spectically recommended by Caterpilar is used, you must satisfy yourself that itis safe for you and others. You should also ensure that the product will not be damaged (or made unsafe by the operation, lubrication, maintenance or repair procedures you choose. The information, specications, and ilustrations in this pubication are on the basis of information avaiable at the time it was written. The specifications, torques, pressures, measurements, adjustments, ilustrations, and other items can change at any time. These changes can affect the service given to the product. Obtain the complete and mast current information before starting any job. Caterpillar ‘dealers have the most current information available. For a ist of the most current publication form numbers avallable, see the Service Manual Contents Microfiche, REG1 139F,Foreword This guide contains operation instructions and lubrication and maintenance information. The operation section is a reference for the new operator and a refresher for the experienced one. Read — study — and keep it handy. lustrations guide the operator through correct procedures of checking, starting, ‘operating and stopping the vehicle Operating techniques outlined in this Publication are basic. Skill and techniques develop as the operator gains knowledge of the vehicle. The maintenance section is a guide to equipment care. The illustrated, step-by-step instructions are grouped by servicing intervals. Topics without specific intervals are listed under “When Required.” Topics in the “Lubrication and Maintenance Chart” are referenced to detailed instructions that follow. Use the service meter to determine servicing intervals. Calendar intervals shown (daily, weekly, monthly, etc.) may be used instead of service meter intervals if they provide more convenient servicing schedules and approximate the indicated service meter reading Under extremely severe, dusty or wet operating conditions, more frequent lubrication than is specified in the “Lubrication and Maintenance Chart” may be necessary. Perform service on topics at multiples of the original requirement. For example, at Every 500 Service Hours or 3 Months, also service those topics listed under Every 250 Service Hours or Monthly, Every 50 Service Hours or Weekly and Every 10 Service Hours or Daily ‘Some photographs in this publication may show details or attachments that may be different from your vehicle. Some photographs show guards or covers removed for clear illustration, that need not be removed for routine lubrication and maintenance. Continuing improvement and advancement of product design may have caused changes to your vehicle which are not included in this publication. Each publication is reviewed and revised, as required, to update and include such changes in later editions. Whenever a question arises regarding your vehicle, or this publication, please consult your Caterpillar dealer for the latest available informationTable of Contents Safety Serial Number Locations Model Views Operation Section Operator's Compartment Vehicle Controls Implement Controls... Before Starting the Engine Starting the Engine After Starting the Engine Moving and Stopping the Vehicle Parking the Vehicle... Operating Adjustments Operating Tectiniques Towing Transporation Hints Tire Inflation Information . 18 19 8 42 50 51 56 59 61 72 74 7 Maintenance Section Maintenance Recommendations Coolant, Fuel and Lubricant Specifications Refill Capacities Recommended Lubricant Viscosities Lubrication and Maintenance Chart When Required Every 10 Service Hours or Daily Every 50 Service Hours or Weekly Every 100 Service Hours or 2 Weeks. Every 250 Service Hours or Monthly ... Every 500 Service Hours or 3 Months Every 1000 Service Hours or 6 Months Every 2000 Service Hours or 1 Year 78 BR 87 109 116 7 . 122 133 145 162Safety Warning Plates & Decals There are several specific warning signs ‘on your vehicle. Their exact location and description of the hazard are reviewed in this section. Please take the time to familiarize yourself with these signs. WARNING Do not operate this machine unless you have read and understand the instructions in the Operation Guide Improper machine operation is dangerous and could result in injury or death. The Operation Guide is in holder located in ‘operator's compartment or on seat back, Contact any Caterpillar dealer for a replacement guide. Proper operation is your responsibilty Located in the cab. WARNING Lubrication, maintenance or repair of this machine can be dangerous unless performed properly. Each person must satisfy himself that he has the necessary skill and information, proper tools and equipment, and that his work method is safe and correct. Caterpillar dealers are available to provide service and information. Located on the vehicle platform. WARNING: To avoid possible weakening of this ROPS, consult a Caterpillar dealer before altering this ROPS in any way. The protection offered by this ROPS will be impaired it it has been subjected to structural damage or has been involved in an overturn incident. Located on the ROPS.WARNING No clearance for man in this area when turning vehicle. When machine is to be lifted, transported on another vehicle or service work is being performed near center of machine: Connect safety rod between front and rear frames to keep machine in straight ahead Position. Before operation and when operating: Be sure safely rod, located near lower center of machine, is disconnected and pinned to retaining plates. Located on the vehicle at the center pivot. Caution should be used to avoid breathing dust that may be generated when handling ‘components containing asbestos fibers. If this, dust is inhaled, it can be hazardous to your health. Componenents in Caterpillar products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates and some gaskets. The asbestos used in these componenets is usually bound in a resin or sealed in some way. Normal handiing is not hazardous as long as airborne dust which contains asbestos is not generated. If dust which may contain asbestos is present, there are several common sense guidelines that should be folowed. 1. Never use compressed air for cleaning. 2. Use vacuum or wet methods for cleanup, 3. Use exhaust ventilation on permanent machining jobs. 4. Wear an approved respirator if there is no cother way to control the dust. 5. Follow environmental rules and regulations for disposal of asbestos. 6. Avoid areas where asbestos particles may be in the air ‘Wear a hard hat, protective glasses, and other protective equipment as required by job conditions. Do not wear loose clothing or jewelry that can catch on controls or other parts of the vehicle. Keep the vehicle, especially the deck and all steps, free of foreign material. Secure all loose items such as lunch boxes, tools, etc. Know the hand signals and who gives them. ‘Accept signals from one person only. Make sure that clearance flags, lights and other required warnings are on the vehicle when roading. Know your stopping distance at any given speed, Regulate the travel speed accordingly. Do not coast. Vehicle bounce affects the steering control. Slow down on rough roads. Road the vehicle in forward direction only, not in reverse,Cab Entrance Install the antipivot link before working in the center pivot area. Report all needed repairs immediately. Mounting and Dismounting ib on and off the vehicle only where steps and/or hand holds are provided. Use both hands, and face the vehicle when mounting and dismounting, Never get on or off a moving vehicle. Never jump off a vehicle Do not try to climb onto the vehicle while carrying tools or supplies. Use a hand line to pull equipment up onto the platform Always lower all equipment before dismounting. If the vehicle has a cab, enter through the left hand door only. The door on the right side of the cab serves as an emergency exit. Use it, if the left hand door is blocked. The emergency door, on the right hand side of the cab, can be opened from the inside only. Push the button to open the emergency door. The door opens to the outside only.Safety Preparing to Start the Engine Inspect the seat belt, the buckle and all mounting hardware. Replace the belt or any damaged hardware. Tighten any loose mounting hardware. Adjust the seat so that full brake pedal travel can be obtained with the operator's back against the seat back Make certain all protective guards and covers are secured in place. Make sure the vehicle is equipped with the proper lighting system, as required by conditions. Make sure all lights are working properly. Inspect the vehicle for potential hazards. Make sure no one is working on, underneath, or close to the vehicle before starting the engine or beginning to move the vehicle. Do not start the engine or move any of the controls, if there is a warning, DO NOT OPERATE" or similar tag attached to the controls or the starter switch. These tags, Form SEHS7332, are available from your Caterpillar dealer. Shift the transmission control lever to neutral and engage the parking brake before starting the engine.Lower all implements and move all controls to hold before starting the engine. Start and run the engine in a well ventilated area only. In an enclosed area, vent the engine exhaust to the outside. Preparing to Operate Clear all personnel from the vehicle and the area. Clear all obstacles from the path of the vehicle. Beware of hazards such as wires and ditches. Clean all windows. Secure the doors and windows in either the open or shut position, Adjust the rear view mirrors for best vision, Make sure the vehicle horn, the backup alarm, and all other warning devices are working properly Fasten the seat belt securely. Check for proper operation of all controls and protective devices while moving slowly in an open area, Test all controls before starting to work.Be sure that all brakes are operating properly. Test the right and left steering Operating Operate the controls only while seated, Operate the controls only with the engine running Do not allow riders on the vehicle unless an additional seat, a seat belt and rollover protection are provided The operator must satisfy himself that no ‘one will be endangered before moving the vehicle. Report any needed repairs, noted during operation, immediately. Stay a safe distance from the edge of cliffs, from overhangs, slide areas and from other vehicles. Carry the implements close to the ground, approximately 40 cm (15 inches) above ground level Be careful to avoid tipping when working on hills, banks or slopes, and when crossing ditches, ridges or other obstructions.Reduce the travel speed and use less Connect the trailing equipment to a steering angle to avoid tipping, when drawbar or hitch only. working on hills, banks or slopes. Personnel should not be between the Work up and down slopes, rather than vehicle and the trailing equipment while sideways, whenever possible. maneuvering to connect. Block tongue or hitch of trailing equipment to align it with the Hf your vehicle begins to side-slip on a drawbar or hitch grade, immediately dispose of the load and turn the vehicle downhill : Park on a level surface. If it is necessary to park on a grade, block the wheels Keep the vehicle under control — do not securely. try to work it over its capacity Stop the vehicle frequently at night — walk around and inspect the vehicle — stay alert Be sure all hitch points and the tow cable are adequate.Safety Lower all equipment to the ground and Turn the starting switch to OFF and apply slight down pressure. remove the key. Move the transmission control lever to When parking the vehicle for an extended neutral. period (overnight, etc.), turn off the disconnect switch and remove the key. Engage the transmission control lock. Apply the parking brake. To minimize vandalism and theft, lock all doors and compartments 10Fire or Explosion Prevention In the event of a vehicle fire or tire bead seat overheating, air inflated tires can explode and blow tire and rim parts over 500 m (1500 ft) Park the vehicle immediately. Dismount and move at least 500 m (1500 ft) from it, Do not allow personnel within 500 m (1800 ft) of the vehicle until the tire cools, Four to eight hours may be required to cool the tire, Know how to use a fire extinguisher. Loose or damaged fuel or oil lines, tubes Service the fire extinguisher according to or hoses can leak and cause fires. recommendations on the extinguisher plate. Do not bend or strike high pressure lines. Do not install bent or damaged lines, tubes Do not carry any flammable liquids, such and hoses. as starting fluid (ether), gasoline or fuel on the vehicle in loose containers. Before operating, remove all trash. Have oil and fuel leaks, which can cause a fire, repaired. See the topic “Walk-Around Inspection.” — A) Inspect all lines, tubes and hoses carefully. Tighten all connections to the recommended torque. Replace any bent or damaged lines, tubes or hoses. Be sure the parking brake is released before operating, Heat from a vehicle fire can cause a tire explosion. Death or serious injury can occur if a tire explodes while you are attempting to put out a fire. If smoke, excessive heat, ‘smell of burning rubber or hot brakes or other indications of tire bead burning are noticed, move the vehicle to a remote area. "Make sure that all clamps, guards and heat shields are installed correctly to prevent vibration or excessive heat during operation. Shields, which protect hot exhaust components from oil or fuel spray in the event of a line, tube or seal failure, must be installed correctly. Accumulated grease and oil on a vehicle is a fire hazard. Remove this debris with steam cleaning or high pressure water at least every 1000 service hours or anytime a significant quantity of oil is spilled on the vehicle. Have jobsite fuel tanks protected by an embankment, or steel post, so tanks are not struck by equipment when fueling Inspect the engine compartment for any debris. Clean out the engine compartment, the radiator and any accumulated debris thoroughly. This is particularly important to help prevent fires and engine and hydraulic system overheating, Clean and tighten all electrical connections, Check daily for loose or frayed electrical wires. Have all loose or frayed electrical wires tightened, repaired or replaced before operating the vehicle. Inspect the driveline and the brakes daily for accumulated debris. Clean out all debris. Park the vehicle in a cleared area and a sate distance from other equipment. 12Whenever draining a lubricant, extreme caution should be used; the lubricant may be hot and can be a fire hazard Tire Inflation Explosions of air-inflated earthmoving tires have resulted from heat-induced gas combustion inside the tires. The heat, generated by welding or heating rim components, external fire, or excessive use of brakes can cause gaseous combustion. A tire explosion is much more violent than a blowout. The explosion can propel the tire, rim and final drive 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 personal injury or death, and property damage. Do not approach a tire closer than the outside of the area represented by the shaded area in the above drawing, Proper nitrogen inflation equipment and training in its use are necessary to avoid overinfiation. A tire blowout or rim failure can result from improper or misused equipment. Stand behind the tread when inflating a tire. Servicing and changing tires and rims can be dangerous and should be done only by trained personnel using proper tools and procedures. If correct procedures are not followed while servicing tires and rims, the assemblies could burst with explosive force and cause serious personal injury or death. Follow carefully the specific information provided by your tire or rim servicing man or dealer. 13To prevent personal injury, always lower all equipment, stop the engine, set the Parking brake and block or restrain the machine before servicing it, unless otherwise specified. Read and understand all warning and caution information provided on the machine. Follow servicing instructions carefully Do not attempt adjustments while the machine is moving or the engine is running, Do not allow unauthorized personnel on the machine while it is being serviced. 14 Use the proper tools. Repair or replace broken or damaged equipment. Always inspect the cooling system with the engine stopped and cool. Remove the radiator cap slowly to relieve pressure. Steam can cause personal injury. Cooling system conditioner contains alkali, avoid contact with the skin and eyes. Store all oly rags and other combustible material in a container in a safe place.zi Do not smoke when observing the battery . electrolyte level. Batteries give off flammable ‘ : fumes. 5 Electrolyte solution is an acid. Do not allow the electrolyte solution to contact the skin or eyes Turn the disconnect switch OFF and remove the key before servicing the electrical system. Diesel fuel and all lubricants are flammable. Do not weld or flame cut on pipes or tubes that contain oil. Clean them thoroughly with nonflammable solvent before welding or flame cutting. Engage the parking brake, block the tires and attach warning tags to the controls while servicing the machine. Do not smoke when refueling. Use caution when removing the radiator cap or any drain plugs, grease fittings or Pressure taps, Connect frames with the antipivot link before servicing the machine center area. Do not attempt any repairs you do not When using pressure air, wear protective understand glasses and protective clothing, 15Whenever draining a lubricant, extreme caution If the engine is not running, do not release the should be used: the lubricant may be hot and ‘emergency or parking brake systems unless the ‘can cause personal injury. machine is blocked or restrained. Hot oil and components can cause personal injury. Do not allow hot oil or components to contact the skin. Collect drained oil and wipe up spills when draining oil Hot hydraulic oil can cause personal injury. Remove the hydraulic tank fill cap slowly to relieve the tank pressure. Allow the oil to cool before draining the tank. 16‘When starting with a boost, make sure all battery Attach the ground cable from the boost source vent caps are firmly in place. Attach the ground to the starter ground terminal or the disconnect cable last, and remove it first, to prevent sparks switch terminal on the machine to be started. from occurring near the battery, which could explode battery vapors. This machine has a 24 volt starting system. Use only the same voltage (24 Volt) for boost starting. The use of a welder or higher voltage will damage the electrical system. 7Serial Number Locations For quick reference, record your machine's serial numbers in the spaces Provided below the photographs. Engine Serial Number Bucket Serial Number 18Model Views 950B Wheel Loader Engine Air Cleaner Operator's Compartment Bucket Positioner Bucket Engine Compartment Hydraulic Tank Lift Kickout Engine Compartment Radiator Cap Drawbar Fuel Tank Bumper Anti-Pivot Link 19Operator’s Compartment Operator Panel 1. service Meter — Indicates the total operating hours of the engine. It should be used to determine service intervals. 2. starting Aid — Depress the utton when starting aid is required juring cold weather. This releases a premeasured amount of ether into the air intake. 3. Power Switch — OFF — no electrical power to the cab ON — all circuits in the cab are operational START — starts the engine, key returns to the ON position when eleased. Light Switches 1. Panel Lights — Move the switch to the center position to turn on the panel lights. Running Lights — Move the panel lights switch @) to the right Position to turn on the running lights (front and rear). 2. Flood Lights — Move the switch to the right position to turn on the flood lights for illumination of the work area. 3. Auxiliary — Two additional locations are available for installation of additional switches for optional lighting (auxiliary flood lights, rotating beacon, etc.)Electronic Monitoring System (EMS) Windshield Wiper /Washer Fs is Ae cate 1, Front Windshield — Turn the snob clockwise to turn on the ;ndshield wiper. Pull the knob to activate the windshield washer. Spring force will return the knob when released, 2. Rear Windshield (if Equipped) — Operates the same as lescribed above. consists of a fault alarm, a fault light a monitoring panel with individual indicators @ for each vehicle system listed on the panel. The Electronic Monitoring System cvs) and The Electronic Monitoring System is designed to alert the operator of an immediate or impending problem in one or more of the vehicle systems covered. EMS Functional Test To ensure the proper operation of the EMS, check the system daily 21Operator’s Compartment (ee TD he disconnect switch @ must e ON to supply electrical power fo the operator's compartment for the EMS to function. vi Panel Test Switch — With the engine stopped, move the test switch @) UP. All indicators should flash and the fault light should blink. Alll lights should stay on until the switch is released. Release the switch. It will return to the off position. If any of the indicators or the fault light do not light up, have the electrical system checked and all necessary repairs made before starting the engine. If all the indicators and the fault light did light up, start the engine. Repeat the panel test with the engine running. All indicators and the fault light should light up again. The fault alarm should also sound. It any of the indicators or the fault light do not light up or the fault alarm does not sound, stop the engine. Have the electrical system and any vehicle system, for which the indicator did not light up, inspected. Have all necessary repairs made before starting the engine again. EMS Warning Levels The EMS provides three warning levels. The first level requires only operator awareness. The second warning level needs operator response. The third warning level requires immediate shutdown of the vehicle. The following topic groups the vehicle systems by EMS warning levels. 22Warning Level 1 At this level, only the indicator will ight up. It requires that the operator is aware, that a vehicle system needs attention Failure of these systems will not endanger the operator or cause serious damage to vehicle components. 7 1. Parking Brake — indicates (©) parking brake is engaged and transmisison is in NEUTRAL. The indicator, should light up during start-up. It should go out when the parking brake is released. 2. Aiternator — Indicates alternator is malfunctioning. if the indicator lights up, pull to a convenient stop. Investigate the cause (loose or broken belt, etc.). Do not operate the vehicle until the cause has been corrected, . Fuel Level — The indicator il ight up when the fue! level reaches 10% of tank capacity. ‘0 avoid being stranded without fuel, refuel as soon as possible within the hour. 23 Warning Level 2 At this level, the indicator and the fault light will ight up. It requires a change in vehicle operation to reduce excessive temperature in one or more of the systems. 4. Coolant Temperature — Indicates excessive coolant temperature. If the indicator comes on, pull the vehicle to a convenient stop. Investigate the cause. Do not operate the vehicle if the indicator is lit, and the fault light flashes. 5. Hydraulic Oil Temperature — Indicates excessive hydraulic oil temperature. If the indicator lights up, reduce the load on the system. If the indicator stays lit, pull the vehicle to a convenient stop. Investigate the cause. Do not operate the vehicle if the indicator stays lit and the fault light flashes. 6. Transmission Oil Temperature — Indicates excessive transmission oil temperature. If the indicator lights up, reduce the load on the vehicle. If the indicator stays lit, pull to a convenient stop. Investigate the cause. Do not operate the vehicle if the indicator stays lit and the fault light flashes.Operator’s Compartment Warning Level 3 At this level, the indicator and the fault light will light up and the fault alarm will sound. It requires immediate shutdown of operation to prevent injury to the operator and/or severe damage to the system and/or vehicle, 7. Brake Oil Pressure — Indicates low oil pressure to the brakes. If the indicator lights up, stop the vehicle immediately. Apply the parking brake and stop the engine. Investigate the cause. Do not operate the vehicle until the cause has been corrected. 8. Engine Oil Pressure — Indicates low oil pressure. If the indicator lights up, stop the vehicle immediately. Stop the engine. Investigate the cause. Do not ‘operate the vehicle until the cause has been corrected. 9. Brake Air Pressure — Indicates low air pressure to the brakes. If the indicator lights up, stop the vehicle immediately. Apply the parking brake and stop the engine. Investigate the cause. Do not operate the vehicle until the cause has been corrected. 10. Parking Brake — Indicates parking brake is engaged. If the indicator lights up during operation, stop the vehicle immediately. Stop the engine. Investigate the cause. Do not operate the vehicle until the cause has been corrected. If the parking brake is applied and the transmission is engaged during engine start- up, the indicator will ight up, the fault light will flash and the fault alarm will sound. Shift the transmission lever to NEUTRAL to stop the fault alarm 24Operator Comfort Features 4, Right Cab Door — The cab J ) door on the right side serves as an emergency exit. it can be opened from the inside only. Push the button and open the door. 1. Lighter — Push the lighter in and release. The lighter will pop ‘out when ready for use. 2. Ashtray — Pull the ashtray open to use. Shut it when not in use. The door can be secured in the open position with a brace. Open the door as far as desired, then tighten the knob, 3. Cab Lights (it Equipped) — This will eliminate cab pressurization. The cab lights are located on the rear post of the cab. One on each post Lights are individually operated by the switch at the bottom of each light 25Operator’s Compartment The coat hook is next to the cab light on A storage pouch is in the left cab door. the left side of the cab (if equipped). Another storage compartment is under the left control console. is The literature compartment is in the back } \ of the seat backrest. A storage compartment is on the left front under the dashPositioning Seat of the seat belt and the Replace any defective Inspect condi mounting hardw components. Always wear the seat belt when opers the machine. Adjust the seat at the beginning of shift or when operators chang Replace the seat belt at least every 3 years, regardless of appearance. ‘L. Raise the backrest @ up and move it to the desired position. Lower it to lock it into position. - Push down on the seat height level lever @ to release the lock. Press the seat to the desired height. Release the lever to lock the seat 3. Pull up the fore-att lever ©, Slide the seat forward or back to the desired position. Release the lever to lock the seat. 27Operator’s Compartment ce the seat belt or mounting hard- e if it is damaged. Replace the belt at t every 3 years. Adjust and fasten the seat belt before operating the machine. 4. Pull up the seat angle lever @. Adjust the seat cushion to the desired angle. Release the lever to lock the seat cushion . Turn the knob © clockwise to increase or counterclockwise to decrease the stiffness of the suspension until the yellow rod in the indicator © is just visible, }. Adjust the seat belt buckle to fit the operator. See the topic, “Seat Belt.” Check for worn or damaged buckle or anticreep slide on each half of the belt. Replace the belt, buckle, or slides if they are worn or damaged. 28Inspect the belt mounting hardware. Replace any damaged or worn hardware. Keep the mounting bolts tight. To Lengthen the Belt: 1. With the belt unfastened, move the anticreep slide toward the buckle. 2. To remove the slack in the outer loop , rotate the buckle @ to tree the lock bar. This permits the belt to move through the buckle. 3. Pull on the buckle until the slack is removed from the outer belt loop. 4, Loosen the other half of the belt in the same manner. Readjust the belt if it does not fit snugly with the buckle in the center.Operator’s Compartment To Shorten the Belt: Se 1. with the belt fastened, pull on the ‘outer loop to tighten the belt. 4, Readjust the belt if it does not fit snugly with the buckle in the center 2. Move the anticreep slide toward the anchor end of the belt to take up the slack jin the outer loop. 3. Adjust the other half of the belt in the same manner.Heating and Air Conditioning — If Equipped with Cab 1. Fan Control — This switch controls the air flow speed. HI — Move the switch to the right to run the fan at high speed. Oz — Move the switch to the center to turn the fan off. LO — Move the switch to the left to run the fan at low speed 2. Air Conditioning Control — OFF = turn the knob all the way to the left (counterclockwise). ON — tum the knob to ON to activate the air conditioning control system. cool — turn the knob to the right (clockwise towards COLD) until the desired amount of cooling is achieved ©O©@ The knob can be set at any position ) to obtain the desired amount of cooling: 3. Heating Control — OFF — tum the knob all the way to the left (counterclockwise). warm — turn the knob to the right (clockwise towards HOT) until the desired amount of heating is achieved. S© The knob can be set at any position ) to obtain the desired amount of heating.Operator’s Compartment Speman? Air Conditioning System The heating and cooling system can perform four functions. Heati Turn the cooling control OFF. Push the blower fan switch to LOW or HIGH speed. Adjust the heating control for the desired temperature. Adjust the air flow louvers in the dash and in the seat base for the desired air flow pattern. Cooling: Tur the heating control OFF. Push the blower fan switch to LOW or HIGH speed. Adjust the cooling control for the desired temperature. Adjust the air flow louvers. Pressurizing: Pressure inside the cab will help keep dust out when heating or cooling is not desired, Tur the heating and air conditioning controls to OFF. Tum the fan switch to either LOW or HIGH speed, as needed to keep out dust. Adjust the air flow with the louvers. Defogging: Turn on the fan. Adjust the heating and cooling controls until the moisture level is lowered, and the temperature is comfortable, Adjust the air flow with the louvers,Vehicle Controls CAUTION Do not apply the parking/emergency brake while the machine is moving. unless an emer- gency exists. The use of the parking brake as a service brake in regular operation will cause severe damage to the parking brake system. 1. Parking / Emergency Brake — Pull the knob up to apply the brake. When the brake is applied, the ( transmission is in NEUTRAL. Push the knob down to release the brake. g Release the brake before moving the machine, 2. Transmission Control Lock — Engaged (pushed in) — The transmission control is locked in ow NEUTRAL. aa Released (pulled out) — The transmission control lever can be moved to the FORWARD or REVERSE position 1. Brake Pedal — The left brake pedal disengages the transmission and brakes the machine. This permits higher engine speed for better hydraulic Depress the left brake pedal when positioning and raising the bucket at the same time. Release the pedal to re-engage the transmission and to release the brake 2. Brake Pedal — Depress the right brake pedal for normal machine braking. response. Release the pedal to release the brake. increase the engine speed Release to decrease the engine speed. 8 3. Accelerator — Depress to The accelerator pedal can be used to shut off the engine by pulling the pedal back past the detentVehicle Controls ‘Transmission Control Lever CAUTION ‘Apply the service brake before moving the transmission control lever. ‘Speed Selector: Rotate the transmission control lever to the desired gear speed: 1 - First Speed Direction Selector: 2 - Second Speed 3 - Third Speed 1. Forward — Push the 4 - Fourth Speed transmission lever forward. The machine will move forward. should not move when lever is in neutral 3. Reverse — Pull the transmission lever towards the operator. The machine will move in reverse (N):: Neutral — The machineDisconnect Switch Lift the latch to RELEASE the steering Disconnect Switch — Insert the column. Move the column to the desired key, and turn it to the right, to turn Position. Release the latch to LOCK the ON the electrical system. steering column, Horn Button Turn the key to the left to turn OFF the electrical system, Remove the key when leaving the machine. Also, remove it when servicing the electrical system. CAUTION Never turn the disconnect key off with the en- gine running. Horn Button — Depress the horn button to sound the horn. The horn is used to warn or signal personnel.Implement Controls Bucket Lift Lever 1. Bucket Float Position — Push the lever all the way forward into detent for FLOAT. The bucket will lower to the ground and follow ground contour. 4 cS) The lever will remain in FLOAT until pulled out of detent. The lever will then return to HOLD when released CAUTION NEVER use FLOAT position to lower a load- ed bucket. 2. Bucket Lower Position Push the lever forward from HOLD position to LOWER the bucket. The lever will return to HOLD when released. 3. Bucket Hold Position — The lever will return to HOLD when released from either RAISE or LOWER. The bucket will remain in the position it is in. 4. Bucket Raise Position — Pull the lever back to RAISE the bucket. Release the lever to stop lifting the bucket. The lever will return to HOLD when released. The lever is detented in the full raise position. It will stay in detent until the bucket reaches height set by the lift kickout. Then it returns to HOLD. 36 Bucket Tilt Lever 1. Bucket Tit — Dump Position Push the lever forward to DUMP the bucket 2. Bucket Tilt — Hold Position — Release the tit lever. The bucket will remain in the position it is in. 3. Bucket Tit — Tilt Back Position — Pull the lever back to tit the bucket back1. Fork Float Position — Push the lever all the way forward into detent for fork FLOAT. The fork will lower to the ground and move up and down, following Ground contour The lever will remain in float until pulled out of detent. The lever will then return to HOLD when it is released, CAUTION NEVER use FLOAT position to lower a load- ed fork. 2. Fork — Lower Position — Push the lever forward to LOWER the fork. When the lever is released it will return to HOLD 3. Fork — Hold Position — The lever will return to HOLD when it is released from either RAISE or LOWER, The fork will remain in the position it is in. 4. Fork — Raise Position — Pull the lever back to RAISE the fork. Release the lever to stop lifting the fork. Lever will return to HOLD when released 37 1. Fork Tilt Forward Position — Push the lever forward to tit the fork FORWARD. The lever will return to HOLD when released will remain in the position it is in The fork 2. Fork Tilt Hold Position — Release the tlt lever, and the fork will remain in the position it is in. 3. Fork — Tilt Back Position — Pull the lever back to tit the fork BACK. Release the lever and it will return to HOLD. The fork will remain in the position it is inImplement Controls Top Clamp Lever 1. clamp Close Position — Push the lever forward to CLOSE the clamp. Release the lever and it will return to HOLD. 2. clamp Hold Position — Release the tilt lever. The clamp will remain in the position it is in, 3. clamp Open Position — Pull the lever back and the clamp will OPEN. Release the lever and it will return to HOLD. NOTE: On machines equipped with a Lumber Fork with Top Clamp, the Controls and their operation are identical to the controls for the Log Fork and Top Clamp and their operation. Side Dump Bucket Lift Lever 1. side Dump Bucket Float Position — Push the lever all the way forward into the detent, for side dump bucket FLOAT. The side dump bucket will lower to the ground, and move up and down, following the ground contour CAUTION NEVER use the FLOAT position to lower a loaded side dump bucket. 2. side Dump Bucket — Lower Position — Push the lever forward to LOWER the side dump bucket When the lever is released it will re- turn to HOLD. 3. side Dump Bucket — Hold Po- sition — The lever will return to HOLD when it is released from either RAISE or LOWER. The side dump bucket will remain in the position it is in 4, side Dump Bucket — Raise Po- sition — Pull the lever back to RAISE the side dump bucket, Re- lease the lever to stop lifting the bucket. Lever will return to HOLD when released.Side Dump Bucket Tilt Lever Side Dump Lever 1. Bucket Tiit-Dump Position — Push the lever forward to tilt the side dump bucket FORWARD. The lever will return to HOLD when released. The side dump bucket will remain in the position it is in. 2. Bucket Tilt-Hold Position — Release the tilt lever and the side dump bucket will remain in the Position it is in. 3. Bucket Tit-Titt Back Position — Pull the lever back to fit the side dump bucket BACK Release the lever and it will return to HOLD. The side dump bucket will remain in the position it is in 1. Bucket Side Dump Position — Push the lever forward to SIDE DUMP the bucket. Release the lever and it will return to HOLD 2. Bucket Hold Position — Release the tit lever. The bucket will remain in the position it is in. 3. Bucket Return Position — Pull thé lever back and the bucket will RETURN. Release the lover and it will return to HOLD.Implement Controls Multipurpose Bucket Lift Lever 1. Multipurpose Bucket Float m — Push the lever all the way forward into detent for bucket FLOAT. The bucket will lower to the ground and move up and down, following ground contour. The lever will remain in float until pulled out of detent. The lever will then return to HOLD when it is released. CAUTION NEVER use FLOAT position to lower a load- ‘ed multipurpose bucket. 2. Multipurpose Bucket — Lower Position — Push the lever forward to LOWER the bucket. When the lever is released, it will return to HOLD. 3. Multipurpose Bucket — Hold Position — The lever will return to HOLD when it is released from either RAISE or LOWER, The bucket wil remain in the position it is in. 4. Muttipurpose Bucket — Raise Position — Pull the lever back to RAISE the bucket Release the lever to stop lifting the bucket. Lever will return to HOLD when released, Multipurpose Bucket Tilt Lever 1. Bucket Tit-Dump Position — Push the lever forward to tit the bucket FORWARD. The lever will return to HOLD when released. The bucket will remain in the position it is in 2. Bucket TitHold Position — Release the tit lever and the bucket will remain in the position it is in. 3. Bucket Tilt-Back Position — Pull the lever back to tit the bucket BACK. Release the lever and it will return to HOLD. The bucket will remain in the position it is in.Multipurpose Bucket Bow! Lever Hydraulic Control Lever Lock 1. Bow! Close Position — Push the lever forward to CLOSE the bowl. Release the lever and it will return to HOLD. 2. Bow! Hold Position — Release the tit lever. The bow! will remain in the position it is in. 3. Bow! Open Position — Pull the lever back and the bow will OPEN. Release the lever and it will return to HOLD. 4 1. Released Position — Push the knob away from the operator to extend the lock rod and release the hydraulic control levers. 2. Locked Position — Pull the knob towards the operator to retract the lock rod and lock the hydraulic control levers. 3. The end of the lock rod has an eye to accept a padlock. This helps against vandalism and unauthorized use.Before Starting the Engine Walk-Around Inspection For your own safety and maximum service life of the vehicle, make a thorough walk- around inspection before mounting the machine to start the engine. Look around and under the machine for such items as loose or missing bolts, trash buildup, cil, coolant or fuel leaks Inspect the condition and inflation of the tires, condition of the bucket, and the bucket linkage Remove any trash and debris. Adjust tire inflation as needed. Have any necessary repairs made, loose connections and parts tightented to their specified torque and any missing parts replaced, before starting the engine or operating the machine. 1. Bucket Inspect for damage or excessive wear. 2. Bucket Control Linkage Inspect for damage or excessive wear. 3. Lights Inspect for broken bulbs and lenses. Check for loose or frayed wires. 4. Radiator Guard Inspect for trash buildup. 5. Cooling System Inspect for leaks — trash buildup. 6. Engine Precieaner Inspect for dirt buildup. 7. Engine Compartment Inspect for leaks — trash buildup. 8. steps and Grab Irons Inspect their condition and cleanliness. 9. Differentials (front and rear) Inspect under machine for leaks.10. Hydraulic System Inspect for leaks. Check for loose hose connections. Check for frayed hoses. 11. Final Drives (front and rear) Inspect for leaks. 12. Covers and Guards Be sure they are firmiy in place. Inspect for damage 13. Transmission Inspect for leaks. 14, Tires (front and rear) Inspect for damage and proper inflation. 15. Operator’s Compartment Inspect for cleanliness. 16. instrument Panel Inspect for broken gauges and indicator lights.Before Starting the Engine Measure the crankcase oil level. The level should be above the ADD mark on the ENGINE STOPPED side of the dipstick. pe Observe the hydraulic system oil level. Maintain the oil level above the ADD mark in the sight gauge. Inspect the precleaner. Empty the precleaner cup, when dirt reaches the indicator mark. Measure the transmission oil level. Oil must show on the dipstick. coolant within 1 om (1/2 inch) of the bottom of the leasure the tire pressure. See the topic Tire Inflation Information."”Measure the fuel level. Fill the fuel tank after each day of operation to help prevent condensation in the tank. Inspect the wheel brakes for oil leaks.Starting the Engine 4, Move the transmission control to 1. Be sure the antipivot link is in carry NEUTRAL position. 2. 1 the disconnect switch was turned 5. Push in the knob to engage the off, turn it on. transmission control lock 3. Pull up the knob to apply the parking 6. Move all hydraulic control levers to brake. HOLD.Starting the Engine Above 0°C (32°F) 1. Depress the accelerator pedal just past the detent 2. Turn the start switch to START to crank the engine. Release the switch when the engine starts The low air pressure buzzer should sound until air pressure is normal and the parking brake is released, or until the transmission is shifted into NEUTRAL. CAUTION Do not crank the engine for more than 30 se- conds. Allow the starter to cool for 2 minutes before cranking again. Between 16°C (60°F) and 0°C (32°F), no starting aid should be needed. If a starting aid is required, see the next topic, "Below 0°C (32°F). 47 Below 0°C (32°F) 1. Repeat steps 1 and 2 as outlined in the topic, “Above 0°C (32°F).” 2. alter cranking begins, push the starting aid button. Repeat every 2 seconds until the engine starts 3. when the engine starts, push the starting aid button about every 2 seconds until the engine runs smoothly. CAUTION Do not use the starting aid excessively during starting or when the engine is running. Do not use starting aid when the engine is warm and running. For starting below -18°C (°F), the use of additional optional starting aids is recommended. Heating of the coolant and/or use of extra battery capacity may be required. At starting temperatures below —23°C (= 10°F), consult your Caterpillar dealer or refer to the “Cold Weather Operation Guide,” Caterpillar Form SEBUS898.Starting the Engine Starting With A Boost When starting from another machine, make sure the machines do not touch. This prevents sparks near the battery, which could ignite the hydrogen gas given off by the battery, causing the battery to explode. Always wear eye protection when sti a machine with a boost. To prevent poss personal injury, use care when removing the cables from the machine that has been started. Do not al low the cable ends to contact each other or the machine. Electrolyte is an acid and can cause per- sonal injury if it contacts skin or eee The machine to be started should be parked on level ground with all equipment lowered If this is not possible, the wheels must be blocked securely, so that the machine cannot move. CAUTION These machines have a 24 Volt starting system. Use only the same voltage (24 Volt) for boost starting. Use of a welder or higher voltage will damage the electrical system. Starting Kit ‘An emergency starting kit helps when starting with a boost. It provides a permanent receptacle (4V3445) on the machine to plug in a booster cable. Two different cable assemblies are available for boost starting. For starting from an ‘operating machine, use 983664. For starting from an auxiliary power pack, use 882632. The boost starting cable assembly must be attached to the boost source (operating machine or auxiliary power pack) first. Insert the plug in the receptacle of the machine to be started. Start the engine. After the engine starts, remove the plug from the receptacle.Boost Cables Connect the batteries in parallel: POSITIVE (+) to POSITIVE (+) and NEGATIVE (—) to NEGATIVE (—). Attach the positive boost cable, from the positive post of the boost battery to th positive post of the battery of the machine to be started. Attach the negative boost cable from the negative post of the boost battery to the starter ground terminal or to the discon- nect switch ground terminal of the vehicle to be started. Disconnect the ground cable first when re- moving the booster cables. This will prevent sparks near the battery. 1. Attach one cable to the POSITIVE (+) terminal of the battery on the left side of the machine to be started 2. attach the opposite end of the cable to the POSITIVE (+) terminal of the boost source. 3. Attach the second cable to the NEGATIVE (-) terminal of the boost source. 49 4, Attach the remaining cable end to the disconnect switch terminal of the machine to be started. 5. start the engine. See the topic “Starting the Engine."" 6. Aiter the engine starts, remove the cable from the disconnect switch terminal first. 7. Remove the opposite end of the negative cable from the boost source 8. Remove the remaining cable trom the POSITIVE (+) terminal of the battery of the machine that was started. Remove the opposite end of that cable from the boost sourceAfter Starting |. Keep the engine speed low until the oil pressure light goes out. If the oil pressure light does not go out within 10 seconds, stop the engine and investigate 2. Push the panel test switch to the test Position to test the indicator lights. 3. if the lights do not come on, make any necessary repairs. 4. it any of the indicator lights stay on, have any necessary repairs made before operating the machine. 5. Look at the operator's pane! frequently during operation. If any of the indicator lights come on, stop the machine, if necessary, and investigate.Moving and Stopping the Vehicle 1. Make sure the antipivot link is in the carry position. 4, Pull out the knob to release the transmission control lock. It is possible to start the engine when the transmission control lever is in FORWARD or REVERSE, but the machine will not move. Should this happen, move the lever to NEUTRAL, then to the desired speed and direction eres anneena Be sure the area is clear of personnel and 2. Raise the bucket to the carry position obstructions. approximately 40 cm (15 inches) above the ground 5. Move the transmission control to the 3. Push the knob down to release the desired travel direction. Rotate the control parking brake. to the desired speed 51Moving and Stopping the Vehicle 6. Depress the accelerator pedal Drive the machine forward for best visibility and control. CAUTION For operator safety and comfort and maxi- mum service life of power train components, deceleration and/or braking is recommended before any directional shifts are made. Emergency Brake System If the brake system air pressure drops be- low normal operating pressure, a warning horn will sound. The low brake pressure and the parking brake indicators on the operator’s panel will light up. The fault light will start flashing. If the pressure drops further, the parkin- g/emergency brake ill apply automatically and the transmission will shift to neutral. Be prepared for a sudden stop. Correct the reason for the loss of air pressure. Do not move the machine without normal ai pressure. In an emergency, the machine can be moved with the parking/emergency brake applied, with the engine running, by holding the shift lever in 1st speed. The lever and transmission will return to NEUTRAL immediately when the lever is released. CAUTION Moving the machine with the parking /emer- gency brake applied can cause excessive wear or damage to the brake. If necessary, have the brake repaired before operating the machine. Loss of brake oil or air pressure will cause the brake indicators on the operator Panel to light up. The emergency brake will automatically engage and stop the machine. The fault light will also flash when the monitor system lights go on.Test Emergency Braking System: Be sure that the area around the machine is clear of personnel and obstructions. Be sure the antipivot link is in the carry position. Test the brakes on a dry, level surface. Fasten the seat belt before testing the brakes. Start the engine and raise the bucket slightly, 2. With the parking brake applied, shift the transmission to 2nd gear reverse. The backup alarm should sound as soon as the lever is moved to reverse It will be necessary to hold the lever in reverse or the lever will move to NEUTRAL 53 3. Gradually increase the engine speed to high idle. The machine must not move. If the machine begins to move, reduce the engine speed immediately and apply the The parking brake light must come on.Moving and Stopping the Vehicle Manual Release of Emergency Brake Do not the machine if the brake was applied due to a malfunction of the air system or the brake. Correct any problem before attempting to operate the machi Block the wheels securely so that the ma- chine cannot move. The main fault light must flash and the warning horn must sound CAUTION If the machine moved while testing, have your Caterpillar dealer inspect the brake. If neces- sary, repair the parking brake before returning the machine to operation. ¥ 4, Reduce engine speed, shift the transmission to NEUTRAL, lower the bucket to the ground, and stop the engine. 1. Connect the antipivot link 542. Loosen the locknut @. Move the locknut as far as possible towards the rod end @ 3. Turn the nut © as far as possible counterclockwise to release the emergency brake The machine can be moved a short dis- tance only. Have the brake system icy brake linkage adjusted before the machine is operated. Supplemental Steering (If Equipped) It the supplemental steering warning light comes on, steer the machine IMMEDIATE- LY to a safe location and stop. Have any necessary repairs made before returning the machine to ope Supplemental steering works only while the machine is in motion. If the machine is equipped with supplemental steering and the standard steering malfunctions or the engine stops, the indicator light will go on 55Parking the Vehicle Stopping the Machine CAUTION Park on a level surface. If it is necessary to Park on a grade, block the wheels seourely. Do not apply the parking brake while machine is moving unless an emergency exists. 3. Push the knob in to engage the transmission control lock. 1. Apply the service brakes to stop the machine. 4, Pull the knob up to engage the parking brake. 2. Move the transmission control to NEUTRAL, 5. Lower the bucket to the ground and apply slight down pressure.Stopping the Engine 1. with the machine stopped, run the 4. Use the ladder and grab irons, use engine for 5 minutes at low idle. both hands and face the machine, when dismounting, 2. Tur off the starter key to stop the engine. Remove the key. Moe 5. Drain the moisture from the air tank daily 3. It, for any reason, the key switch does not turn off the’ engine, pull the accelerator pedal back past the detent 87Parking the Vehicle Bie Install all vandalism protection locks and 6. inspect the engine compartment for eaves paper and debris. Clean out any debris and paper to avoid a fire. If the machine is being parked for an extended period (overnight, etc.), turn off the disconnect switch and remove the key.Operating Adjustments Bucket Positioner — Tilt Adjustment Stop the engine. Lower the equipment. Apply the parking brake. Block the tires. 1. Lower the bucket to the ground 2. Position the bucket at the desired angle to the ground, Stop the engine and turn the key to ON. Move the tit control to TILT BACK detent 3. Loosen two bracket boits @. Move the tube assembly @) toward the bucket. When the switch aligns with the magnet the tit lever should move from the TILT BACK to the HOLD position 59 4. To test the adjustment, start the engine. Raise and dump the bucket. Move the tit control lever to TILT BACK detent 5. when the pre-set bucket angle is reached, the tit control lever should return to HOLD.Operating Adjustments Bucket Lift Kickout Use caution to avoid possible personal jury when adjusting the bucket lift kickout. Keep personnel off the machine. Clear the area when working under or around the bucket linkage. With the bucket raised, proper support must be provided for the bucket and/or 4. Move the magnet away from the the linkage. switch to increase, or toward the switch to ee decrease the bucket lift kickout height. 1. start the engine. Raise the bucket to 5. ee the desired height and stop the engine. cee 2. Block the bucket and the linkage. 6. start the engine and move the bucket lift control to the RAISE detent. 3. Loosen the plate clamp bolts. Align the plate and the magnet with the switch 7. At the pre-set lift height, the control assembly. lever should return to HOLD.Operating Techniques General For good operator vision and loader When working in hard material, use stability, carry the loaded bucket low, bucket teeth, or “half-arrow” bolt-on cutting approximately 40 cm (15 inches) above the ground, edges To control dumping, move the tit control lever to the DUMP position. Then return to the HOLD position. Repeat until the bucket is empty, Utilize wait time to clean and level the work area. Ee a aa To keep dust away from the engine and Maintain traction by avoiding excessive maintain visibility, dump with the wind to down pressure on the bucket your back 61Operating Techniques Dumping Be certain that the bucket used is Use the bucket stops for maximum appropriate for the work performed. dumping angle. Exceeding the machine limits will reduce the service lite of the machine. CAUTION Dozing Striking the stops unnecessarily and repetiti- vely can result in accelerated wear and high CAUTION maintenance cost of the loader linkage. Do not bulldoze with the bucket in the dump Loading from a Stockpi position. 1. Position the bucket parallel to, and When bulldozing, keep the bucket bottom just skimming, the ground. Drive the bucket parallel to the ground straight into the pile 62Move the control to the RAISE detent position as forward movement slows. Return to the HOLD position for additional crowding power. 5. When the tit control lever is released to the HOLD position, the bucket will rise. 6. Raise the bucket high enough to clear the material being loaded. Shift the transmission control to REVERSE. To pump in a heaped load, work the tilt control lever back and forth. 4, wnen the bucket is loaded, move the tilt contro! to the TILT BACK position 7. Carry the loaded bucket approximately 40 om (16 inches) above the ground levelOperating Techniques When reaching the dump area, move 3. Position the loader to dump the load the lift control to the RAISE detent. The lift in the center of the hauler body. If the kickout will automatically return the lift hauler body is two bucket widths or more control to HOLD. in length, dump from the front to the rear. Loading Hauling Units A. To reduce the loader turning and 4, Push the tilt lever forward to dump the travel, position the hauling unit at an angle bucket to the material being loaded 5. shake the bucket to loosen sticky 2. The travel distance should be long material. Move the tilt lever back and forth enough for the bucket to reach the lift auickly, allowing the tit arms to strike the height without slowing loader movement. stops.6. Put the tit lever in the TILT BACK detent Before lowering the bucket, make sure the hauling unit is out from under the bucket 7. Lower the bucket while positioning the loader for the next load Loading from a Bank Remove any overhang and watch for slid- ing material. Start to load at the base of the bank and follow up the face. 2. Raise the bucket slightly and move away from the bank Excavating 1. Lower the bucket to the ground and Position for a slight digging angle. 2. Apply down pressure to the bucket as the loader starts forward, Return the lift control to HOLD when sufficient penetration is obtained.Operating Techniques Loading Rock in a Quarry Stay at a safe distance during blasting, and until the face is clear. Make absolutely sure that the loading area is safe before entering. Remove any overhang and watch for si ing mat If falling rock is encountered, quickly move as far away from the quarry face at possible. 3. Maintain level cuts, while moving forward, by raising and lowering the bucket. working in a quarry. 4. nen the bucket is loaded, tlt it back against the stops. Carry the loaded bucket approximately 40 om (15 inches) above the ground when moving to the dump area e 3 ce 1. start loading at the base of the rockpile. Very large boulders may have to be loaded individually2. Remove any overhang and watch for sliding material. 3. Load the fine material into the truck first. This will help minimize any damage to the truck. 4. To reduce the dump shock on the hauling unit, dump from the lowest height possible Loading Hoppers eT ‘1. Load the bucket (see “Loading from a Stockpile” steps 1 through 8) 2. when the lift kickout height is reached, dump the load into the hopper. If possible, dump with the wind to your back, Log Fork with Top Clamp 1. Position the fork in the center of the load, with the top clamp open. 67Operating Techniques 2. Close the top clamp and tilt the fork back to hold the load against the fork uprights. 3. For best operator vision and loader stabilty, carry the load as low as possible. 4. Position the load over the stacking area. Tilt the fork down and raise the clamp to release the load. Lumber Fork with Top Clamp 1. Position the fork in the center of the load, with the top clamp open 2. Move the machine forward and move the fork tines under the load. 3. Close the top clamp and tit the fork back to hold the load against the fork uprights.4. For best operator vision and load stability, carry the load as low as possible. ‘© 5. Position the load over the stacking area. Tilt the fork forward. 6. Raise the top clamp. Back the machine out, until the fork tines clear the stack ‘Side Dump Bucket 1. The bucket is loaded the same as the General Purpose Bucket (see “Loading from a Stockpile” steps 1 through 8) 2. when loading a hauling unit, the side dump bucket can be used like a General Purpose Bucket for unloading 3. or can be dumped to the left, which is helpful in restricted loading space or when a side approach can reduce loader cycle time.Operating Techniques 4. The Side Dump Bucket also allows even distribution of loading material in the hauling unit body. 5. Raise the bucket and side dump as the loader moves alongside the hauling unit. 6. The Side Dump Bucket can also be used for backfiling or windowing, 7. Side dump the bucket slowly to deposit backfill or windrow material 8. Distribute or doze the material the same as with a General Purpose Bucket. Multipurpose Bucket SIR a ma 1. Bucket used as a clamp. Open the bow! and lower the open bucket over the loading material 705. Use the bucket as a scraper for leveling, stripping or spreading fill 6. when loaded, close the bowl and tit the bucket back 3. Bucket used for dozing. Open the bow! to use the blade for dozing 7.. For maximum dumping height or when unloading sticky material, position the bucket over the dump area. Open the bowl to dump the load. 4. Maintain a level cut with the bucket lift control m1ing a disabled machine incorrectly. Block the machine to prevent movement be- fore releasing the brakes. The machine can roll free if it is not blocked. Follow the recommendations below, to proper- ly perform the towing procedure. This machine is equipped with spring applied, air pressure released brakes. If the engine or the pressure air system are inoperable, the brakes are applied and the machine cannot be moved. ‘These towing instructions are for moving a disabled machine a short distance, only a few feet at low speed, no faster than 2 km/h (1.2 mph), to a convenient location for repair. These instructions are for emergencies only. Always haul the machine if long distance moving is required. Shielding must be provided on the towing machine, to protect the operator if the tow line or bar should break. Do not allow riders on the machine being towed, unless the operator can control the steering and/or braking, Before towing, make sure the tow line or bar is in good condition and has enough strength for the towing situation involved. Use a towing line or bar with a strength of at least 1.5 times the gross weight of the towing machine, for a disabled machine stuck in mud or when towing on a grade. Keep the tow line angle to a minimum. Do not exceed a 30° angle from the straight ahead position. Quick machine movement could overload the tow line or bar and cause it to break. Gradual and ‘smooth machine movement will work better. Normally, the towing machine should be as large as the disabled machine. Satisfy yourself that the towing machine has enough brake capacity, ‘weight and power, to control both machines for the grade and distance involved, To provide sufficient control and braking when moving a disabled machine downhill, a larger towing machine or additional machines connected to the rear could be required. This will prevent it from rolling uncontrolled. The different situation requirements cannot be given, as minimal towing machine capacity is required on smooth level surfaces to maximum on. inclines or poor surface conditions. Consult your Caterpillar dealer for towing a disabled machine. Engine Running: CAUTION If the power train and the steering system are operable, and the engine is running, the machine can be towed a SHORT DISTANCE, pulled out ‘of mud or to the side of the road. ‘The operator on the towed machine MUST steer in the direction of the tow line. Make certain, that all instructions outlined in this, topic “Towing” are carefully and exactly followed. 72Engine Stopped: Perform the following steps before towing the machine with the engine stopped. ROD END Jae HEAD END 1. Reverse the hydraulic steering hose connections ON ONE CYLINDER ONLY, so the steering cylinders can move freely CAUTION Be sure the cylinder hoses are connected cor- rectly before operating the machine. With the hoses reversed, the steering system will not function 2. 1 internal transmission or drive line failure is suspected, remove the axle shafts. When the axle shafts are removed, the ma- chine has NO brakes. Block the wheels securely so that the ma- chine cannot move. The towing connection must be rigid, or tow- ing must be done by two machines of the same size or larger than the towed machine, ‘one on each end. CAUTION Release the parking brake manually to prevent excessive wear and damage to the parking brake system, when towing without brake air pressure. The procedure for manual release of the emergency brake is outlined under “Manual Release of Emergency Brake" in the section titled “Moving the Machine® in this guide 3. Release the parking brake. 4. inspect the machine for power train damage. Remove all four axle shafts if damage is suspected. 5. Fasten the tow bar. 6. Remove the wheel blocks. 7. Tow the machine slowly. Do not tow any faster than 2 km/h (1.2 mph). 73Transportation Hints Shipping Investigate the travel route for overpass clearances. Make sure there will be ade- quate clearance if the machine being transported is equipped with a ROPS, cab or canopy. To prevent the machine from slipping while loading or shift ice, snow or other slippery material from the loading dock and the truck bed before loading. 2. After the machine is in position, connect the antipivot link to hold the articulated frame rigid, CAUTION Obey all state and local laws governing the weight, width and length of a load, Observe all regulations governing wide loads. 3. Lower the bucket and shift the transmission to NEUTRAL. before loading, 4. Engage the transmission control lock 748. Block the tires and secure the machine with tie-downs (rail car), 6. Tum off the engine. Remove the starter key, 9. Cover the exhaust opening or secure the rain cap to prevent the turbocharger from “windmilling” in transit. 7. Tum the disconnect switch off and remove the key. 75Transportation Hints Roading CAUTION When roading a machine, consult your tie dealer for recommended pressures and speed limitations. Use a self-attaching inflation chuck and stand behind the tire tread while inflating the tire. See “Tire Inflation Information.” 76 -. 1 AR Bring the engine coolant, the crankcase oil and the transmission oil up to the correct levels. Check with the proper officials to obtain the required permits, etc. Travel at a moderate speed. Observe all speed limitations when roading the machine, Stop every 25 miles or 1 hour for 30 minutes to allow the tires and components to cool. Perform a "Walk-Around Inspection" and measure the fluid levels in the various compartments.Tire Inflation Information Dry nitrogen (Nz) gas is recommended for inflation of tires. If the tires were originally inflated with air, nitrogen is still preferred for adjusting the pressure. Nitrogen mixes properly with air. Nitrogen inflated tires reduce the potential of a tire explosion, because nitrogen does not support combustion. Also, nitrogen helps prevent oxidation and the resulting deterioration of rubber and corrosion of rim ‘components. 7 A tire inflated in an enclosed shop area at a temperature of 18° to 21°C (65° to 70°F), will be underinflated if the machine works in freezing temperatures. Low pressure shortens the life of a tire. When operating in freezing temperatures, consult the Cold Weather Operation Guide, Form SEBUS5898, for adjusted inflation pressures. CAUTION The following chart is for shipping pressures ‘only. Consult your tire dealer for operating pressures. Shipping Pressures Ship Type | Breseure size nating [kPa | pei D8x 2 348] 60 2 8x28 wae | oo 18 205 x28 20 wo | 6s leaning 205 x28 30 | radial WER 20 | 2Maintenance Recommendations Cooling System CAUTION Never add coolant to an overheated engine; ak low the engine to cool first. Check the specific gravity of the antifreeze so- lution frequently in cold weather to ensure adequate protection. If the machine is to be stored in, or shipped to, an area with below freezing temperatures; the cooling system must be protected against freezing to the lowest expected ambient temperature. All water is corrosive at engine operating tem- perature. The cooling system should be protected with a 3% to 6% concentration of cooling system conditioner at all times regard- less of the concentration of antifreeze. Do not use Caterpillar Cooling System Condi- tioner or Coolant Conditioner Elements with Dowtherm 209 Full-Fill coolant. Follow the in- structions provided with the Dowtherm 209 FullFill Coolant. Coolant should be drained and replaced “Every 2000 Service Hours or 1 Year.” However, when Cooling System Conditioner additions are made every 250 service hours as recommended, the drain period can be extended to “4000 Service Hours or 2 Years." ‘A 3% to 6% concentration of Caterpillar Cooling System Conditioner can be maintained by adding conditioner as follows. When Filing Complete System 2 liter (2 at.) Every 250 Service Hours 1/2 titer (1 pty Premix antifreeze solution to provide protection to the lowest expected ambient temperature. Pure undiluted antifreeze will freeze at -23°C (-10°F), 78 Use clean water that is low in scale forming mineral. Do not use softened water. Filing at over 20 liters (5 U.S. gallons) per minute can cause air pockets in the cooling system. After draining and refilling the cooling system, run the engine with the filer cap off until the coolant level stabilizes. Add coolant as necessary to fill the system. The engine cooling system is protected to -28°C (-20°F), with permanent type antifreeze, when shipped from the factory. Operate with a thermostat in the cooling system year-round. Cooling system problems can arise without a thermostat. Fuel System a Fill the fuel tank at the end of each day of operation to drive out moist air and to prevent condensation. Do not fil the tank to the top. The fuel expands as it gets warm and may overfiow. Do not fil fuel fiters with fuel before instaling them. Contaminated fuel will cause accelerated wear to fuel system parts. Check the fuel level with the dipstick in the filler opening, Drain the fuel tank of water and sediment as required by prevailing conditions. Water and sediment should be drained from the fuel tank at the start of a shift or after the fuel tank has been filled and allowed to stand for 5 to 10 minutes. After changing fuel filters, always bleed the fuel system to remove air bubbles from system.Maintenance Recommenda‘ ns Drain water and sediment from any fuel storage tank weekly, and before the tank is refilled. This will help prevent water or sediment from being pumped from the storage tank into the machine fuel tank, Use only fuel as recommended in the “Fuel, Coolant and Lubricant Specifications” of this Guide. Hydraulic System CAUTION Scheduled Oil Sampling Use scheduled oil sampling to monitor machine condition and maintenance Tequirements. Each oil sample should be taken when the oil is hot and well mixed, to ensure the sample is representative of the oil in the compartment, ‘Sampling Interval Chart Make-up oil added to the hydraulic system must mix with the oil already in the tank. Use only petroleum products unless the system is ‘equipped for use with special products. Water or air can cause pump failure. If hydrau- lic oil becomes cloudy, then water or air is entering the system. Drain fluid, retighten hy- raulic suction line clamps, purge and refill the system. Consult your Caterpillar dealer for Purging instructions. Air Intake System Check precleaner cup daily for accumulation of dust and debris. Service air cleaner when the indicator piston locks in the RED position. The indicator is marked in 5 inch of Hg. increments to show the amount of air cleaner restriction at all times. The primary element can be cleaned up to 6 times before replacement. The element, when cleaned, should be thoroughly checked for rips or tears in the filter material, Replace the primary element every year even though it has not been cleaned 6 times. The secondary filter element has a tab on the outer end of the element to keep a record of when the secondary element should be changed. A section of the tab should be pulled off each time a primary element is serviced. At the time of the third change of a primary element, the secondary element must be replaced. Compartment Interval [Engine Crankcase 7250 Service Hours. Transmission ‘500 Service Hours: Final Drives: ‘500 Service Hours: [Hydraulic System 500 Service Hours Consult your Caterpillar dealer for complete information and assistance in establishing a scheduled oil sampling program for your equipment. General CAUTION ‘Accumulated grease and oll on @ machine is a fire hazard. Remove this debris with steam cleaning or high pressure water every 1000 reach time any significant quantity of Drain moisture and sediment from the air reservoir at the beginning of each day of operation. 79Maintenance Recommendations Wipe all fittings, caps and plugs before servicing, 1 newton-meter (N-m) is approximately equal to 0.1 mkg 1 kilopascal (kPa) is approximately equal to 0.01 bar (kg/cm?) Bolt Torque for Ground Engaging Tools Bolt Size | Recommended Torque™ Inch Nem Ibat 5/8 265 = 35 | 195 + 25 3/4 475 = 70__| 350 + 50 778 765 = 116 | 565% 85 1 7220 = 150] 900 = 110 “These values are applicable only to Caterpillar cutting ‘edge bolts.Fuel, Coolant and Lubricant Specifications Fuel Specifications Caterpillar Diesel Engines have the ability to burn a wide variety of fuels. These fuels are divided into two general groups, preferred and permissible. Types of Fuel The preferred fuels provide maximum engine service life and performance. They are distillate fuels. They are commonly called fuel oil, furnace oil, diesel fuel, gas oil, or kerosene. The permissible fuels are crude oils or blended fuels. Use of these fuels can result in higher maintenance costs and reduced engine service life. See Caterpillar Form Number SEHS7067, “Fuels for Caterpillar Diesel Engines," for a detailed summary of preferred and permissible fuels and their specifications. Cetane Requirement The minimum cetane number recommended for the engine is 40. Fuel Cloud Point Fuel waxing can plug the fuel fiters in cold weather. The fuel cloud point must be below the temperature of the surrounding air to prevent filter waxing and power loss. Fuel heating attachments are available from your Caterpillar dealer to minimize fuel filter waxing Fuel Sulphur Content The percentage of sulfur in the fuel will affect the engine oil recommendations (see “Engine Oils” Under “Lubricant Specifications), Fuel sulfur is chemically changed during ‘combustion to form sulfuric acid, The acid chemically attacks metal surfaces and causes corrosive wear. Higher engine oil Total Base Number (TBN) values are essential to minimize corrosive wear. Periodically request fuel sulfur content information from your fuel supplier. Fuel sulfur content can change with each bulk delivery. 81 Coolant Specifications Use a mixture of fill water and antifreeze, and Cooling System Conditioner. Caterpillar Form Number SEBD0518 titled, "Know Your Cooling System,” can provide more detailed specifications. Fill Water Always add conditioner to water. Never use plain water only. Acceptable water for use in the ethylene glycol-type antifreeze and water mixture is shown on the chart below: ‘Acceptable Water ‘50% Antifreeze | _ Without Water Content | 50% Water | Antifreeze 100 ppm 50 ppm rod or less or less 100 ppm 50 ppm | ues or less orless | Hardness as | 200 ppm 700 ppm CaCO, orless | _orless. '500 ppm 250 ppm Dissolved Solids} 500 pon 50 pen pH 635 or higher | 65 or higher ppm = parts per million Antifreeze Use ethylene glycol-type antifreeze. Use the correct amount to provide freeze protection to the lowest expected outside temperature. Conditioner Use Caterpillar Cooling System Conditioner or equivalent. Follow the instructions on the container. Cooling System Conditioner Size Part Number 172 Pint | 0.24 iter eva542 1 Quart 0.96 liter | _aP2044 55 Gallon | _ 208 iter ‘5P2907Fuel, Coolant and Lubricant Specifications Lubricant Specifications The abbreviations listed below follow S.A.E. J754 nomenclature. The classifications follow SAE. J189 classifications. The MIL specifications are U.S.A. Military Specifications. These definitions will be of assistance in purchasing lubricants. The recommended oil viscosities are found on the “Recommended Lubricant Viscosities” chart. ‘The prefix "SPC" is a general abbreviation used by Caterpillar to identify special oils such as synthetic, or semi-synthetic oils Engine Oils (CD or CD/TO-2) Use oils that meet the Engine Service Classification CD (MIL-L-2104D) or oils that have satisfactory performance in the Caterpillar Oil Test Number TO-2. These oils are referred to as Service Classification CD/TO-2. Consult the "EMA Lubricating Oils Data Book," Form SEBUS5939, for a listing of CD oil brands. The percentage of sulfur in the fuel will affect the engine oil recommendations. If the fuel has over 0.5% sulfur content, the CD engine oil must have a Total Base Number (TBN) of 20 times the percentage of fuel sulfur (TBN as measured by the ‘ASTM D-2896 methode). If the sulfur content is. greater than 1.5% by weight, use an oil with a TBN of 30 and reduce the oil change interval by ‘one half. Consult your Caterpillar dealer for correct engine oil recommendations. Higher TEN values are essential to retard the corrosive damage to metal engine parts. Your oil supplier should be able to furnish the correct oils. Transmission and Clutch Oils (CD/TO-2) Use Service Classification CD oils that have satisfactory performance in the Caterpillar Oil Test No. TO-2: Referred to as Service Class CD/TO-2 ail 82 Hydraulic Oils (HYDO) Use Engine Service Classification CC (MIL-L: 21048), or MIL-L-46162), CD, or industrial-type hydraulic oils that are certified by the supplier as having antiwear, antifoam, antirust, and antioxidation additive properties for heavy duty use. Lubricating Grease (MPGM) Use Multipurpose type Grease (MPGM) which contains 3% to 5% molybdenum disulfied. NLGI No. 2 Grade is suitable for most temperatures. Use NUGI No, 1 or No. 0 Grade for extremely low temperatures, Hydraulic Brake Fluid (BF) Use heavy duty hydraulic brake fluid meeting the requirements of SAE 17031 Refill Capacities (Approximate) Compartment us. or ‘System Gallons Front Differential & Final Drives 33 85 Rear Differential & Final Drives 38 10 Transmission 34 9 Hydraulic Tank 3 2 Engine Crankcase 22 6 Cooling System 34 9 Fuel Tank 222 60Recommended Lubricant Viscosities or Temperature Ranges F and" egres F Degrees € Corsten ee Timm [Maximum | — Minima | Maxim Sa awa FO) “ze +0 =o 70 SAE 5W20 = 50 8 #0 Engin Canto SAE TOW = <0 20 0 @ SAE 10030 = ce 20 oa coffo2 SAE 15-40 3s wz = +0 sae 20 08 3 340 sae 40 A ra 250 SAEEW20 SPO) 250 “30 70 SAE Sw.20 132 5 0 SAE TOW 50 =20 39 Lg SAE 10W-30| 750) =20) +10) sae 151-40 a7 = oa SAE0 oa 08 3 0 sae-40 si wee 5 30 SAE SW20(5O) =z ioe 30 70 SAE Sw.20 =a +0 a5 #0 ‘Seem SAE Tow = 08 20 +40 "D0 SAE 100739, = 08 20 +40 SAE T5W40 ra wee = +0 SAESO 750 Hite 0 30 SAE SW20 SPO) = = = 3 ites ae 108 = 3B 20 0 nates SAE 20 = oT 20 a cores SAE «0 m4 08 =0 40 SAES0 1 a2 2 +50 ome SAE J1704 “2 we “20 0 “When operating Below 80°C (-20°F) refer to the Gold Weather Recommendation Operation and Maintenance Guide, Form SEBUS®S8, ‘avalable from your Caterpillar dealer. 83Lubrication and Maintenance Chart Item Service Lube. [Page| When Required Dilerentas and Fal ves Tnpoct brant Tove eakage develops] GDITO2 | 87 crs tuected, Engine Aa ia Sion Sorvie when indeator ook RED post ® ie Engine Ai Precoorer ‘Gar procbaner ~ peal axial oa w rectors at Sean? raed emus oe wore Coaing Sten Drain and clean when engine overheats or e Soha ey. Cheek lvoe Feat Tank ranwalerandsedment wien enghari 10 fre. Fost Sion ‘Chango irandlan pivary or uoghivor power ice sonre’ Negra al Meek eatetralssonSeniceroarser eine Teraior Bais Fast oF e608 Ba when Baa ry eames Sonat Tain Inspec conden ~ replace worn or ar oi Se Gating Ege Change before wear Gocurson 6298 p> 72 a Seat Bas inspedt — repace damaged, Seat bat 708 (Bee reas a ht SeryS game Fuses opace mas loner re Botan io 7 Cordtonar Clean condersercl- wash itr eons 105 IPeow sors oxprntoa har Sarg Ad Tt change oloporeriy anova ar 706 Sindee nda Wiper and Waser Inspect conor of wiper Bade aveak= 7) ing develops ~ refill washer reservoit. 84Lubrication and Maintenance Chart Item Service Lube. [Page| Every 10 Service Hours or Daily Wak-Around Inspection inapect machine. 709 Engine Crankcase ‘Measure ol level Ger [an 0/02 © Radiator inspect coolant level 12 [Q Ere Air Precleaner Ciean if necessary” 113) © Air Reservoir Drain moisture and sediment. 113 [© indicator Lights Test for proper funtion. 14 ‘© Transmission Check ol eve coro2 | na [@ Hydraulic System ‘Check oll evel yoo | 114 Service tem © in very dusty conditions, Every 50 Service Hours or Weekly Bucket Lower Pivot Pins Lubricate 2 fittings. wpGm | 115, © Tres ‘Measure inflation pressure ~ inspect for 115 damage. © Gab hir System Clean fiter elements 16 Every 100 Service Hours or 2 Weeks Rear Axle Trunnion Bearings Lubricate 2 fitings MeGM_[ 115 © Steering Cylinder Bearings Lubricate 4 fitings. Mec [117 Bucket Upper Pivot Pin Lubricate + iting ecm | 118 Bucket Control Cylinder and Linkage Lubricate 10 fitings wecm [118 [© Logging Fork Ciamp Lbriato 6 fitings. ecm _| 120 (© Batteries Measure electrolyte level 120 Serve tem @® on new & reconditioned machines Every 250 Service Hours or Monthly @ Engine Crankcase ‘Change oil and filters. Dor | 122 cpjTo-2 | @ Brake Fd Reservors Observe fui evel BF | 728 @ Service Brakes Determine holding ability. 125; @ Parking Brake Determine holding ablty ~ test warring 128 light and horn for function © Deve Shait Spine Lubricate 1 fing wean | 126 | @ Fan and Alternator Belts Inspect - adust or replace, necessary 729) © Air Conditioner Inspect compressor belt ~ adjust or re 130 place, i necessary. Fan Bearing Lubricate 1 iting wpcu_| 131 Coating System ‘Ad cooling system conditioner. 34Lubrication and Maintenance Chart tem | service Lube. |Page| Every 500 Service Hours or 3 Months @ Fuel Tank Cap and Fil Screen Wash tank cap and fl sereen 73 Hyaraule System Change filter elements. HYDO_| 194 Transmission Change filter element. cn/r0-2 | 138, @ Fuel System Clean primary filter ~ change final filter ~ 140 prime fuel system. [@ Engine Crankcase Breather Wash breather element. 144 Every 1000 Service Hours or 6 Months ® Transmission Change ot, wash suation screen and mag | CD/TO-2 | 145 nets and change breather. ‘© Drive Shaft Support Bearing Lubricate 1 iting. pam | 149 ‘© Drive Shaft Universal Joints Lubricate 5 ftings. mpam_| 149 Frame Upper and Lower Pivot Bearings Lirica 2 fittings. mpcm_| 150 [Fors an roe Sn rn ei i Every 2000 Service Hours or 1 Year Front and Rear Differentials and Final Drives ‘Change lubricant, (0/t0-2 | 182 [S tronas sen Sa a SR RTORIOT | WO | @ Cooing System ‘Change coolant soiton 7 [G9 Engine Valve Lash Measure — adjust if necessary. 160)When Required Front and Rear Differentials and Final Drives Hot oil and components can cause Do not allow hot oil or components to con tact the skin. Operate the machine for a few minutes to allow the lubricant to reach a common level, before measuring the lubricant level 87 1. Park the machine on level ground. Lower the bucket with slight down pressure, Apply the parking brake. Stop the engineWhen Required 2. Remove the fill plug from the front axle 4. Remove the rear differential fil plug slowly housing from the rear axle housing Porat mapa lhatiea Levels epovest esa 5. Maintain the oil level to the bottom ofthe fill plug opening, do not drain the lubricant to the bottom of the fill plug opening, Install the fill plug, lug openings. Clean and install both fill plugs. 3. it the lubricant level is below the fill plug opening, add lubricant to bring the lubricant level to the bottom of the fill plug opening, 88Air Intake System Primary Element CAUTION Never service the air cleaner when the engine is running. 1. Remove the cover and the primary element. Clean and inspect the element. See the topic “Cleaning Air Cleaner Elements." CAUTION Always inspect the primary element before and after cleaning with a light bulb inside the element. Discard the element, if any tears, rips or damage are evident. Service the filter elements when the indicator piston locks in the RED position. 89When Required It the indicator locks again in the RED Position shortly after the installation of a primary element, which has been cleaned 6 times, change to another clean element. The primary element should be replaced after being cleaned a maximum of 6 times. Replace the element once a year, even though it has not been cleaned 6 times. It the indicator locks again in the RED Position, shortly after the installation of a clean primary element, change the secondary element. 2. Clean the inside of the air cleaner housing and the cover. Install a clean element and the cover Replace the secondary element at the time the primary element is cleaned for the third time. Secondary Element CAUTION Tighten the cover screws finger tight to 4 N.m (3 Ib ft) torque maximum. Do not use a tool to tighten them. 1. Remove the cover and the primary element.2. Remove the bolts. Remove the secondary element. Discard the secondary element. 3. Cover the air inlet opening. 4, Clean the entire air cleaner, including the precieaner, if necessary. 5. Uncover the air inlet opening. 6. inspect the gasket between the filter housing and the engine air inlet. Replace the gasket, if it is damaged. CAUTION ‘Always replace the secondary element. Do not attempt to reuse it by cleaning. 7. install a new secondary element. Torque the element nuts to 27 + 7 Nm (20 + 5 bb tt) Install a clean primary element and the cover. Tighten the cover screws. Q. Tighten the cover screws finger tight to 4 N.m (3 Ib ft) torque maximum. Do not use a tool to tighten them.When Required Cleaning Air Cleaner Elements When using pressure air wear a protective face shield and protective clothing. The maximum air pressure must be below 205 kPa (30 psi) for cleaning purposes. CAUTION Do not clean any elements by bumping or tapping. Do not use elements with damaged pleats, gaskets or seals. Have spare elements on hand to use while cleaning used elements. Pressure Air — 205 kPa (30 psi) Maximum 1. Direct the air inside the element along the length of the pleats. 92 2. Direct the air outside the element along the length of the pleats. Direct the air inside the element along the length of the pleats. Inspect the element Water — 280 kPa (40 psi) Maximum 1. Direct the water inside the element along the length of the pleats. 2. Direct the water outside the element along the length of the pleats. Rinse and air dry thoroughly Inspect the elementDetergent Inspecting Element 1. Wash the element in warm water and 1. Insert a light inside each clean and a nonsudsing household detergent. dry element and inspect. Discard the element if rips or tears are found. Rinse with clean water. See preceding 2. wrap and store all good elements in topic. a clean, dry place. 3. Air dry thoroughly. Inspect the element,‘When Required Engine Air Precleaner 1. inspect visually. The cup should be emptied whenever dirt reaches the indicator mark 4, install the cup and the cap. Tighten the wing nut finger tight only. Do not use a tool. 2. Loosen the wing nut on top of the cap and remove the cap. 5. Periodically remove the precleaner cup and the cap and wash them in water. . Remove and empty the cup. Wipe the cup clean.Cooling System — Cleaning At operating temperature, engine coolant is hot and under pressure. Steam can cause personal injury. Check coolant level ONLY when engine is stopped and radiator filler cap is cool en- ough to touch with your hand. Remove filler cap slowly to reli Pressure. Cooling System Conditioner contains al- kali. Avoid contact with skin and eyes to prevent personal injury. Use all cleaning solutions with c: CAUTION if the machine is to be stored in, or shipped to, an area with freezing temper- atures, the cooling system must either be protected to the lowest expected ambient temperature or drained completely. Use clean water that is low in scale- forming minerals — not softened water. Measure specific gravity of antifreeze solution frequently in cold weather to assure adequate protection, Note: Most commercial cooling system cleaners may be used. 95 The machine must be level, the bucket lowered with slight down pressure, the engine stopped and cool. 2. Tur the radiator cap slowly to relieve any pressure, then remove the cap.When Required 3. Open the drain valve and drain the coolant. + Remove the drain plug from the gine block. Drain the coolant. 5. Remove the drain plug from the torque converter oil cooler. Drain the coolant. 6. Close the drain valve. Clean and install all drain plugs. Fill the system with a cleaning solution. Any commercial cooling system cleaner can be used, or mix 1 kg Sodium Bisulfate (NaHSO.) per 40 liters of water (2 lb per 10 gal). 7. Start and run the engine for 1/2 hour. Stop the engine and drain the cleaning solution. 8. Flush the system with clean water until the draining water is clean, Do not run the engine while flushing. 9. Close the drain valve. Fill the system with a neutralizing solution. Any commercial cooling system neutralizer can be used, or mix 250 g of Sodium Carbonate Crystals (NazCOs «10H2O) per 40 liters of water (1/2 Ib per 10 gal). 10. start and run the engine for 10 minutes. Stop the engine and drain the neutralizing solutionSI 11. Flush the system with clean water until the draining water is clean. Do not run the engine while flushing. 12. Close the drain valve and install all drain plugs. Fill the system with clean water. Start and run the engine for 5 minutes. Stop the engine and drain the cooling system. Repeat this procedure, until the drained water is clean. 13. Mix the antifreeze solution to provide protection to the lowest expected outside temperature. Add 2 liters (2 quarts) of Caterpillar Cooling System Conditioner or equivalent. 14, close the drain valve. Add the coolant slowly, 20 liters (5 U.S. gallons) per minute or less, to the proper level. See “Refill Capacities.” Adding the coolant too fast will produce air pockets in the system, 15. Run the engine with the radiator cap off until the coolant level stabilizes.‘When Required Cooling System Relief Valve At operating temperature is hot and under pressure. engine coolant ‘Steam can cause personal injury. Check coolant level ONLY when engine is stopped and radiator filler cap is cool or ough to touch with your hand, Remove filler cap slowly to relieve ressure. I necessary, add more coolant until the Le level is within 1 cm (1/2 inch) of the bottom Cooling System Condition of the fill pipe. contains kali. Avoid contact with skin and eyes prevent personal injury. Us II cleaning solutions with care. With the engine stopped and cool! 16. inspect the radiator cap gasket. Replace the gasket if it is damaged 1. Remove the radiator cap slowly to relieve any pressure in the system 17. install the radiator cap. 982. inspect the valve for damage, 4. inspect the coolant level. Maintain the deposits or foreign material coolant level to within 1. cm (1/2 inch) of the bottom of the fill pipe. 3. Clean the pressure relief valve with a clean cloth, or replace the radiator cap, it necessary. 5. install the radiator cap.When Required Fuel Tank Escaping fuel is flammable. Do not smoke while draining moisture and sediment from the fuel tank. ‘Open the fuel tank drain valve. Drain moisture and sediment. Close the drain valve. Alternator Belts Eon If the alternator warning light on the indicator panel in the operator's compartment comes on while the engine is running, inspect the alternator belts. Tighten the alternator belts as shown in the topic "Fan and Alternator Belts" under “Every 250 Service Hours or Monthly.” Replace the alternator belts, if they are worn or damaged. CAUTION Replace belts in sets only, even if only one of them is worn or damaged, 100Bucket Teeth - Replace Tips Block the bucket before changing the bucket teeth. To prevent possible injury to the eyes, wear a protective face shield when striking the pin. The pin, when struck, can fly out and cause injury to nearby personnel. 3. Instat! a new tip over the retainer in either the runner or the digger position. 4. install the pin through the bucket tooth and: retainer. 5. Repeat steps 2 through 4 for the remaining bucket teeth. 1. Drive the pin out of the tip from the retainer side of the tip. Remove the tip and the retainer. 2. Clean the adapter, the pin and the retainer. Install the retainer in the groove in the side of the adapter 101‘When Required Cutting Edge Block the bucket bet bucket cutting edg changing the 3. Use the opposite side of the cutting edge if itis not worn. Use @ new section if both edges are worn. vat 1. Raise and block the bucket. Stop the engine. 4, install all bolts and tighten them to the specified torque. See the “Bolt Torque for Ground Engaging Tools” chart in the "Maintenance Recommendations" section 2. Remove the cutting edge. Clean all contact surfaces 102Seat Belt Inspect the condition of the seat belt and all mounting hardware frequently. Replace the seat belt or any part of the mounting hardware, if it is damaged. Replace the seat belt every 3 years regard- less of its condition or appearance. 5. start the engine, raise the bucket slightly and remove the blocks. 6. After a few hours of operation retighten all bolts to the proper torque. 103When Required Fuses 1. The fuse panel is located behind the cab air intake cover on the right side of the operator's platform. 2. Open the access panel on the right side of the cab. 104 3. Remove and inspect the fuses. Replace any fuse if the element is broken. CAUTION If it is necessary to replace fuses fre- quently, consult your Caterpillar dealer.Air Conditioner — If Equipped PCy When using pressure face shield and protective clothing. The maximum air pressure must be below 205 kPa (30 psi) for cleaning purpose: Clean the filter elements. See the topic “Cab Air System’ under “ Every 50 Service Hours or Weekly.” Changing Elements 1. Open the cover behind the operator's seat 2. Remove the filter elements. Install clean elements. Close the cover 105 Cleaning Condenser Coil 1. Open the access door on the right side of the cab. 2. Clean the condenser coil. Use a vacuum cleaner, if necessary. Close the access door.When Required Ether Starting Aid — Ether Cylinder Ether ‘a poison and is flammable. Do not smoke while installing or changing Use ether only in well ventilated areas. Use ether with care to avoid fires. Do not store replacement cylinders in ing areas or in the operator’s compartment. Ke el ether cylinders out of the reach of Avoid breathing of the vapors or repeated contact of ether with the skin. Do not store cylinde above 49°C (120°F). Do not store cy! sunlight. at temperatures ders in direct Do not puncture or burn cylinders. Discard empty cylinders in a safe The ether cylinder valve is located in the service compartment behind the operator's compartment 106 ‘1. Remove the protective plug @ from the ether cylinder valve. Store the plug in the threaded holder @ 3. screw the ether cylinder @ into the valve hand tight. Do not use any tools to tighten it. Fasten the cylinder clamp @ securely around the cylinder.Changing (typical procedure shown) Temporary Removal (typical procedure shown) Observe all safety precautions to store partially filled cylinders for future u: 1. Loosen the cylinder clamp. Unscrew and remove the cylinder 2. Remove the used gasket. Install the new gasket, provided with the new cylinder. 2. Remove the cylinder and the gasket Store the cylinder and the gasket in a safe place. 3. install a new cylinder. Tighten the oylinder hand tight. Refasten the cylinder clamp securely around the cylinder. 107When Required 3. Remove the protective plug from the threaded holder. Screw it finger fight into the cylinder valve. Windshield Wiper and Washer — If Equipped 1. inspect the windshield wiper blades. Replace them if they are worn or damaged, or if streaking occurs. CAUTION When operating in freezing temperatures, use a nonfreezing window washer solvent. Any commercially available nontreezing window washer solvent can be used. 2. Fil the windshield washer bottle, located in the operator's seat baseEvery 10 Service Hours or Daily @ Walk-Around Inspection For your own safety, and maximum service life of the vehicle, make a thorough walk- around inspection before mounting the machine to start the engine. Look around and under the machine for such items as loose or missing bolts, trash buildup, oil, coolant or fuel leaks, condition and inflation of tires, condition of bucket and linkage. Inspect for trash buildup. 5. Cooling System Inspect for leaks — trash buildup. 6. Engine Precleaner Inspect for dirt buildup. 1. Bucket Inspect for damage, or excessive wear. 2. Bucket Control Linkage Inspect for damage or excessive wear. 3. Lights Inspect for broken bulbs and lenses. 7. Engine Compartment Inspect for leaks — trash buildup. 8. Steps and Grab Irons Inspect their condition and cleanliness 9. Ditterentials (front and rear) Inspect under machine for leaks. 109Every 10 Service Hours or Daily WT 8 10. Hydraulic System 15. Operator's Compartment Inspect for leaks. Inspect for cleanliness. 11. Final Drives (front and rear) 16. instrument Panel Inspect for leaks. Inspect for broken gauges and indicator lights. 12. Covers and Guards Be sure they are firmly in place. Inspect for damage. 13. Transmission Inspect for leaks. 14. Tires (front and rear) Inspect for damage and proper inflation. 110@Engine Crankcase 1. Measure oil level with the machine level. Lower the bucket with slight down pressure and apply the parking brake. 4, with the engine running, the oil level should be between the FULL and the ADD OIL mark on the ENGINE IDLING side of the dipstick. 2. The level can be measured with the engine stopped or the engine running and the oil warm. 5. Add oil, if necessary, to bring the oil level to the specified level 3. with the engine stopped, the oil level should be above the ADD OIL mark on the ENGINE STOPPED side of the dipstick. W4