SEBU7887-03

February 2007

Operation and
Maintenance
Manual
966H and 972H Wheel Loaders
A6D1-Up ( 966H)
A6G1-Up ( 966H)
A6J1-Up ( 966H)
A7D1-Up ( 972H)
A7G1-Up ( 972H)
A7J1-Up ( 972H)
 i01658146

Important Safety Information

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

The meaning of this safety alert symbol is as follows:

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

When replacement parts are required for this

product Caterpillar recommends using Caterpil-
lar replacement parts or parts with equivalent
specifications including, but not limited to, phys-
ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-

ture failures, product damage, personal injury or
death.
SEBU7887-03 3
Table of Contents

Table of Contents Transportation Information .................................... 87

Towing Information ................................................ 90

Foreword ................................................................. 4
Engine Starting (Alternate Methods) ..................... 92
Safety Section
Maintenance Section
Safety Messages .................................................... 6
Tire Inflation Information ....................................... 95
Additional Messages .............................................. 11
Lubricant Viscosities and Refill Capacities ........... 96
General Hazard Information ................................. 14
Maintenance Support .......................................... 101
Crushing Prevention and Cutting Prevention ........ 16
Maintenance Interval Schedule .......................... 102
Burn Prevention .................................................... 17
Reference Information Section
Fire Prevention and Explosion Prevention ............ 17
Reference Materials ............................................ 162
Fire Extinguisher Location .................................... 19
Index Section
Tire Information ..................................................... 19
Index ................................................................... 165
Electrical Storm Injury Prevention ......................... 20

Before Starting Engine .......................................... 20

Engine Starting ..................................................... 20

Before Operation .................................................. 20

Operation .............................................................. 21

Engine Stopping ................................................... 21

Parking .................................................................. 21

Work Tools ............................................................ 22

Equipment Lowering with Engine Stopped ........... 22

Sound Information and Vibration Information ....... 22

Operator Station ................................................... 25

Product Information Section

General Information .............................................. 26

Identification Information ....................................... 32

Operation Section
Before Operation .................................................. 36

Machine Operation ............................................... 38

Engine Starting ..................................................... 83

Parking .................................................................. 85
4 SEBU7887-03
Foreword

Foreword Maintenance
The maintenance section is a guide to equipment
Literature Information care. The Maintenance Interval Schedule (MIS) lists
the items to be maintained at a specific service
This manual should be stored in the operators interval. Items without specific intervals are listed
compartment in the literature holder or seat back under the "When Required" service interval. The
literature storage area. Maintenance Interval Schedule lists the page
number for the step-by-step instructions required to
This manual contains safety information, operation accomplish the scheduled maintenance. Use the
instructions, transportation information, lubrication Maintenance Interval Schedule as an index or "one
information and maintenance information. safe source" for all maintenance procedures.
Some photographs or illustrations in this publication
show details or attachments that can be different Maintenance Intervals
from your machine. Guards and covers might have
been removed for illustrative purposes. Use the service hour meter to determine servicing
intervals. Calendar intervals shown (daily, weekly,
Continuing improvement and advancement of monthly, etc.) can be used instead of service hour
product design might have caused changes to your meter intervals if they provide more convenient
machine which are not included in this publication. servicing schedules and approximate the indicated
Read, study and keep this manual with the machine. service hour meter reading. Recommended service
should always be performed at the interval that
Whenever a question arises regarding your machine, occurs first.
or this publication, please consult your Caterpillar
dealer for the latest available information. Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is
specified in the maintenance intervals chart might
Safety be necessary.
The safety section lists basic safety precautions. In Perform service on items at multiples of the original
addition, this section identifies the text and locations requirement. For example, at every 500 service
of warning signs and labels used on the machine. hours or 3 months, also service those items listed
under every 250 service hours or monthly and every
Read and understand the basic precautions listed 10 service hours or daily.
in the safety section before operating or performing
lubrication, maintenance and repair on this machine.
California Proposition 65 Warning
Operation Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
The operation section is a reference for the new birth defects, and other reproductive harm.
operator and a refresher for the experienced
operator. This section includes a discussion of Battery posts, terminals and related accessories
gauges, switches, machine controls, attachment contain lead and lead compounds. Wash hands
controls, transportation and towing information. after handling.
Photographs and illustrations guide the operator
through correct procedures of checking, starting, Certified Engine Maintenance
operating and stopping the machine.
Proper maintenance and repair is essential to keep
Operating techniques outlined in this publication are the engine and machine systems operating correctly.
basic. Skill and techniques develop as the operator As the heavy duty off-road diesel engine owner, you
gains knowledge of the machine and its capabilities. are responsible for the performance of the required
maintenance listed in the Owner Manual, Operation
and Maintenance Manual, and Service Manual.
SEBU7887-03 5
Foreword

It is prohibited for any person engaged in the 3. Check Character (character 9)

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

Additional attachments or modifications may exceed

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

Caterpillar Product Identification

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

g00751314
Illustration 1

Where:

1. Caterpillars World Manufacturing Code

(characters 1-3)

2. Machine Descriptor (characters 4-8)

6 SEBU7887-03
Safety Section
Safety Messages

Safety Section
i02428956

Safety Messages
SMCS Code: 7000

There are several specific safety messages on this

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

Make sure that all of the safety messages are legible.

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

Replace any safety message that is damaged, or

missing. If a safety message is attached to a part
that is replaced, install a safety message on the
replacement part. Any Caterpillar dealer can provide
new safety messages.
SEBU7887-03 7
Safety Section
Safety Messages

g01184504
Illustration 2
8 SEBU7887-03
Safety Section
Safety Messages

Do Not Operate (1) Pressurized System (3)

This warning label is located inside the cab of the This warning is located next to the hydraulic tank
machine on the front LH post. filler cap.

g01051165 g00930639

Do not operate or work on this machine unless At operating temperature, the hydraulic tank is hot
you have read and understand the instructions and under pressure.
and warnings in the Operation and Maintenance
manuals. Failure to follow the instructions or heed Hot oil and components can cause personal in-
the warnings could result in injury or death. Con- jury. Do not allow hot oil or components to contact
tact your authorized dealer for replacement man- skin.
uals. Proper care is your responsibility.
Remove the filler cap only when the engine is
stopped, and the filler cap is cool enough to
Operation Around A Blast Area (2) touch with your bare hand. Remove the filler cap
slowly to relieve pressure.
This warning label is located in the cab.

Rotating Fan (4)

This warning label is located on the radiator access
door on both sides of the machine.

g01213776

This machine is equipped with a Caterpillar g01065817

Product Link radio communication device which
must be deactivated within 6.0 m (20 ft) of a blast
zone. Failure to do so could result in serious
injury or death.
Keep hands clear of fan while engine is running.
May cause serious injury or death.
SEBU7887-03 9
Safety Section
Safety Messages

Pressurized System (5) Crush Hazard (7)

This warning label is located near the cooling system This warning is located on the side face of the loader
pressure cap. frame near the steering frame lock.

g01069675 g01069858

Pressurized system: Hot coolant can cause seri- Crushing Hazard. There is no clearance for a per-
ous burn. To open cap, stop engine, wait until ra- son in this area when the machine turns. Severe
diator is cool. Then loosen cap slowly to relieve injury or death from crushing could occur. Con-
the pressure. nect the steering frame lock between front and
rear frames before lifting, transporting, or servic-
ing the machine in the articulation area.
No Clearance (6)
Disconnect the steering lock and secure before
This warning is located on the side face of the loader resuming operation.
frame near the articulation hitch on both sides of the
machine.

g00930663

Stay back a safe distance. No clearance for a per-

son in this area when the machine turns. Severe
injury or death from crushing could occur.
10 SEBU7887-03
Safety Section
Safety Messages

Battery (8) Seat Belt (9)

This warning is located under the left ladder behind This warning is located inside the cab on the RH cab
the top step of the ladder. post.

g01069686

Explosion Hazard! Improper jumper cable connec-

tions can cause an explosion resulting in serious
injury or death. Batteries may be located in sep- g00930689
arate compartments. Refer to the Operation and
Maintenance Manual for the correct jump starting
procedure.
A seat belt should be worn at all times during ma-
Refer to Operation and Maintenance Manual, Engine chine operation to prevent serious injury or death
Starting with Jump Start Cables for more information. in the event of an accident or machine overturn.
Failure to wear a seat belt during machine opera-
tion may result in serious injury or death.
SEBU7887-03 11
Safety Section
Additional Messages

ROPS/FOPS Structure (10) High Pressure Cylinder (11)

This warning label is located above the platform on This warning is located on the accumulator in the
the right side of the cab to the left of the door. following three places: the service center on the right
side of the machine, the right control (accumulator) in
the right side of the non-engine end frame, and near
the main hydraulic control valve.

g01211890

g01123184

Structural damage, an overturn, modification, al-

teration, or improper repair can impair this struc-
tures protection capability thereby voiding this
certification. Do not weld on or drill holes in the Gas under pressure. Rapid discharge from dis-
structure. This will void the certification. Consult connecting or disassembly could cause personal
a Caterpillar dealer to determine this structures injury or death. See service manual before reliev-
limitations without voiding its certification. ing pressure or charging.

Certification for Rollover Protective Structure

i02428957
(ROPS) and for Falling Object Protective
Structure (FOPS) Additional Messages
When the ROPS or the FOPS is properly installed SMCS Code: 7000
on a machine which is not altered to exceed the
certification test mass, this structure meets the There are several specific messages on this
following standards at the time of installation: SAE machine. The exact location of the messages and
J394, SAE J1040 APR88, ISO 3471-1:1986, ISO the description of the messages are reviewed in
3471:1994, SAE J231 JAN 81, ISO 3449:1992 this section. Please become familiarized with all
LEVEL II. messages.

Make sure that all of the messages are legible.

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

Replace any message that is damaged, or missing.

If a message is attached to a part that is replaced,
install a message on the replacement part. Any
Caterpillar dealer can provide new messages.
12 SEBU7887-03
Safety Section
Additional Messages

g01213779
Illustration 3

Radial Seal Air Filter (1)

This message is located on the cover of the air

cleaner. The air cleaner is located inside the engine
compartment on the right side of the machine.

g01213780
Illustration 4
SEBU7887-03 13
Safety Section
Additional Messages

To avoid engine damage, use only Caterpillar radial If equipped,this message is located on the bracket
seal air filters as replacement filters. Refer to the assembly for the payload control system near the
following topics for correct replacement instructions: right hand door.

Operation and Maintenance Manual, Engine Air

Filter Primary Element - Clean/Replace

Operation and Maintenance Manual, Engine Air

Filter Secondary Element - Replace

Alternate Exit (2)

This message is located on the latch of the right side

window in the cab.

g01002993
Illustration 7

If the primary exit is blocked, exit the machine

through the door on the right side of the machine.

Machine Security System (5)

If equipped, this message is located on the left side

of the instrument panel above the engine start switch.

g01213781
Illustration 5

If the primary exit is blocked, pull the pin from

the latch and release the latch. Push the window
outward. Exit the machine through the window.

Alternate Exit (3)

This message is located on the glass of the right

hand door just above the latch.

g01213785
Illustration 8

This machine is equipped with a security system.

Read the Operation and Maintenance Manual before
you operate the machine.

Air Conditioner (6)

This message is located inside the cab on the right

rear post.

g01213782
Illustration 6

If the primary exit is blocked, pull the pin from

the latch and release the latch. Push the window
outward. Exit the machine through the window.

Alternate Exit (4)

14 SEBU7887-03
Safety Section
General Hazard Information

g00990500 g00702020
Illustration 9 Illustration 11

Read the service manual before you perform any Wear a hard hat, protective glasses, and other
maintenance on the air conditioner. protective equipment, as required.

Do not wear loose clothing or jewelry that can snag

i02443908
on controls or on other parts of the equipment.
General Hazard Information Make sure that all protective guards and all covers
SMCS Code: 7000 are secured in place on the equipment.

Keep the equipment free from foreign material.

Remove debris, oil, tools, and other items from the
deck, from walkways, and from steps.

Secure all loose items such as lunch boxes, tools,

and other items that are not a part of the equipment.

Know the appropriate work site hand signals and

the personnel that are authorized to give the hand
signals. Accept hand signals from one person only.

Do not smoke when you service an air conditioner.

Also, do not smoke if refrigerant gas may be present.
Inhaling the fumes that are released from a flame that
Illustration 10
g00104545 contacts air conditioner refrigerant can cause bodily
harm or death. Inhaling gas from air conditioner
Attach a Do Not Operate warning tag or a similar refrigerant through a lighted cigarette can cause
warning tag to the start switch or to the controls bodily harm or death.
before you service the equipment or before you
repair the equipment. These warning tags (Special Never put maintenance fluids into glass containers.
Instruction, SEHS7332) are available from your Drain all liquids into a suitable container.
Caterpillar dealer.
Obey all local regulations for the disposal of liquids.
Know the width of your equipment in order to maintain
proper clearance when you operate the equipment Use all cleaning solutions with care. Report all
near fences or near boundary obstacles. necessary repairs.

Be aware of high voltage power lines and power Do not allow unauthorized personnel on the
cables that are buried. If the machine comes in equipment.
contact with these hazards, serious injury or death
may occur from electrocution. Unless you are instructed otherwise, perform
maintenance with the equipment in the servicing
position. Refer to Operation and Maintenance Manual
for the procedure for placing the equipment in the
servicing position.
SEBU7887-03 15
Safety Section
General Hazard Information

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

Pressure can be trapped in a hydraulic system. Tools that are suitable for collecting fluids and
Releasing trapped pressure can cause sudden equipment that is suitable for collecting fluids
machine movement or attachment movement. Use
caution if you disconnect hydraulic lines or fittings. Tools that are suitable for containing fluids and
High pressure oil that is released can cause a hose to equipment that is suitable for containing fluids
whip. High pressure oil that is released can cause oil
to spray. Fluid penetration can cause serious injury Obey all local regulations for the disposal of liquids.
and possible death.
Asbestos Information
Fluid Penetration
Pressure can be trapped in the hydraulic circuit long
after the engine has been stopped. The pressure can
cause hydraulic fluid or items such as pipe plugs to
escape rapidly if the pressure is not relieved correctly.

Do not remove any hydraulic components or parts

until pressure has been relieved or personal injury
may occur. Do not disassemble any hydraulic
components or parts until pressure has been relieved
or personal injury may occur. Refer to the Service
Manual for any procedures that are required to
relieve the hydraulic pressure.
g00702022
Illustration 13

Caterpillar equipment and replacement parts that are

shipped from Caterpillar are asbestos free. Caterpillar
recommends the use of only genuine Caterpillar
replacement parts. Use the following guidelines
when you handle any replacement parts that contain
asbestos or when you handle asbestos debris.

g00687600
Illustration 12
16 SEBU7887-03
Safety Section
Crushing Prevention and Cutting Prevention

Use caution. Avoid inhaling dust that might be Dispose of Waste Properly
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is usually
bound in a resin or sealed in some way. Normal
handling is not hazardous unless airborne dust that
contains asbestos is generated.

If dust that may contain asbestos is present, there

are several guidelines that should be followed:

Never use compressed air for cleaning.

g00706404
Avoid brushing materials that contain asbestos. Illustration 14

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

Never jump across the starter solenoid terminals

in order to start the engine. Unexpected machine
movement could result.

Whenever there are equipment control linkages the

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

Stay clear of all rotating and moving parts.

SEBU7887-03 17
Safety Section
Burn Prevention

If it is necessary to remove guards in order to perform Oils

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

i01359795
i01329099

Burn Prevention Fire Prevention and Explosion

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

Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.

Any contact with hot coolant or with steam can cause Illustration 15
g00704000
severe burns. Allow cooling system components to
cool before the cooling system is drained. All fuels, most lubricants, and some coolant mixtures
are flammable.
Check the coolant level only after the engine has
been stopped. Flammable fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause
Ensure that the filler cap is cool before removing the a fire. Fire may cause personal injury and property
filler cap. The filler cap must be cool enough to touch damage.
with a bare hand. Remove the filler cap slowly in
order to relieve pressure. Remove all flammable materials such as fuel, oil, and
debris from the machine. Do not allow any flammable
Cooling system conditioner contains alkali. Alkali can materials to accumulate on the machine.
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth. Store fuels and lubricants in properly marked
containers away from unauthorized persons. Store
oily rags and any flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials.
18 SEBU7887-03
Safety Section
Fire Prevention and Explosion Prevention

Do not operate the machine near any flame.

Exhaust shields (if equipped) protect hot exhaust

components from oil spray or fuel spray in case of
a break in a line, in a hose, or in a seal. Exhaust
shields must be installed correctly.

Do not weld on lines or on tanks that contain

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

Check all electrical wires daily. Repair any wires

that are loose or frayed before you operate the
machine. Clean all electrical connections and tighten
all electrical connections.

Dust that is generated from repairing nonmetallic

hoods or nonmetallic fenders can be flammable
and/or explosive. Repair such components in a well
ventilated area away from open flames or sparks. Illustration 17
g00704135

Inspect all lines and hoses for wear or for Gases from a battery can explode. Keep any open
deterioration. The hoses must be properly routed. flames or sparks away from the top of a battery. Do
The lines and the hoses must have adequate support not smoke in battery charging areas.
and secure clamps. Tighten all connections to the
recommended torque. Leaks can cause fires. Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or
a hydrometer.

Improper jumper cable connections can cause

an explosion that can result in injury. Refer to
the Operation Section of this manual for specific
instructions.

Do not charge a frozen battery. This may cause an

explosion.

Fire Extinguisher
Make sure that a fire extinguisher is available. Be
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations
on the instruction plate.

Ether
g00704059
Illustration 16
Ether is flammable and poisonous.
Use caution when you are refueling a machine. Do
not smoke while you are refueling a machine. Do Use ether in well ventilated areas. Do not smoke
not refuel a machine near open flames or sparks. while you are replacing an ether cylinder or while you
Always stop the engine before refueling. Fill the fuel are using an ether spray.
tank outdoors.
Do not store ether cylinders in living areas or in the
operator compartment of a machine. Do not store
ether cylinders in direct sunlight or in temperatures
above 49 C (120 F). Keep ether cylinders away
from open flames or sparks.
SEBU7887-03 19
Safety Section
Fire Extinguisher Location

Dispose of used ether cylinders properly. Do not If the fire extinguisher is mounted on the ROPS, strap
puncture an ether cylinder. Keep ether cylinders the mounting plate to a leg of the ROPS. If the weight
away from unauthorized personnel. of the fire extinguisher is more than 4.5 kg (10 lb),
mount the fire extinguisher as low as possible on one
Do not spray ether into an engine if the machine is leg. Do not mount the fire extinguisher on the upper
equipped with a thermal starting aid for cold weather one-third area of the leg.
starting.
Note: Do not weld the ROPS in order to install the
fire extinguisher. Also, do not drill holes in the ROPS
Lines, Tubes and Hoses in order to mount the fire extinguisher on the ROPS.
Do not bend high pressure lines. Do not strike high
pressure lines. Do not install any lines that are bent i01557411
or damaged.
Tire Information
Repair any lines that are loose or damaged. Leaks
can cause fires. Consult your Caterpillar dealer for SMCS Code: 7000
repair or for replacement parts.
Explosions of air inflated tires have resulted from
Check lines, tubes and hoses carefully. Do not use heat-induced gas combustion inside the tires.
your bare hand to check for leaks. Use a board or Explosions can be caused by heat that is generated
cardboard to check for leaks. Tighten all connections by welding, by heating rim components, by external
to the recommended torque. fire, or by excessive use of brakes.

Replace the parts if any of the following conditions A tire explosion is much more violent than a
are present: blowout. The explosion can propel the tire, the rim
components, and the axle components as far as
End fittings are damaged or leaking. 500 m (1500 ft) or more from the machine. Both the
force of the explosion and the flying debris can cause
Outer coverings are chafed or cut. property damage, personal injury, or death.

Wires are exposed.

Outer coverings are ballooning.
Flexible part of the hoses are kinked.
Outer covers have embedded armoring.
End fittings are displaced.
Make sure that all clamps, guards, and heat shields
are installed correctly. During machine operation, this
will help to prevent vibration, rubbing against other
parts, and excessive heat.
g00337832
Illustration 18
(A) At least 15 m (50 ft)
i00977136 (B) At least 500 m (1500 ft)

Fire Extinguisher Location Do not approach a warm tire. Maintain a minimum

distance, as shown. Stay outside the shaded area in
SMCS Code: 7000
Illustration 18.
Make sure that a fire extinguisher is on the machine.
Do not use water or calcium as a ballast for the tires.
Make sure that you are familiar with the operation of
Dry nitrogen gas is recommended for inflation of tires.
the fire extinguisher. Inspect the fire extinguisher and
If the tires were originally inflated with air, nitrogen
service the fire extinguisher on a regular basis. Obey
is still preferred for adjusting the pressure. Nitrogen
the recommendations on the instruction plate.
mixes properly with air.
The recommended location for mounting the fire
extinguisher is on the platform behind the cab.
20 SEBU7887-03
Safety Section
Electrical Storm Injury Prevention

Nitrogen inflated tires reduce the potential of Inspect the condition of the seat belt and the condition
a tire explosion because nitrogen does not aid of mounting hardware. Replace any parts that are
combustion. Nitrogen helps to prevent oxidation of worn or damaged. Regardless of the appearance,
the rubber, deterioration of rubber, and corrosion of replace the seat belt after three years of use. Do not
rim components. use a seat belt extension on a retractable seat belt.

To avoid overinflation, proper nitrogen inflation Adjust the seat so that there is full pedal travel while
equipment and training in the usage of the equipment the operators back is against the back of the seat.
are necessary. A tire blowout or a rim failure can
result from improper equipment or from misused Make sure that the machine is equipped with a
equipment. lighting system that is adequate for the job conditions.
Make sure that all lights are working properly.
When you inflate a tire, stand behind the tread and
use a self-attaching chuck. Before you start the engine or before you move the
machine, make sure that no one is on the machine,
Servicing tires and rims can be dangerous. Only underneath the machine, or around the machine.
trained personnel that use proper tools and proper Make sure that there are no personnel in the area.
procedures should perform this maintenance. If
correct procedures are not used for servicing tires
i01019869
and rims, the assemblies could burst with explosive
force. This explosive force can cause serious
personal injury or death. Carefully obey the specific
Engine Starting
instructions from your tire dealer. SMCS Code: 1000; 7000

i01122596 If a warning tag is attached to the engine start switch

or to the controls, do not start the engine and do not
Electrical Storm Injury move any controls.
Prevention Move all hydraulic controls to the HOLD position
before you start the engine.
SMCS Code: 7000
Move the transmission control to the NEUTRAL
When lightning is striking in the vicinity of the position.
machine, the operator should never attempt the
following procedures: Engage the parking brake.
Mount the machine. Diesel engine exhaust contains products of
combustion which can be harmful to your health.
Dismount the machine. Always operate the engine in a well ventilated area.
If you are in an enclosed area, vent the exhaust to
If you are in the operators station during an electrical the outside.
storm, stay in the operators station. If you are on the
ground during an electrical storm, stay away from
the vicinity of the machine. i01943255

Before Operation
i00934890
SMCS Code: 7000
Before Starting Engine
Make sure that there are no personnel on the
SMCS Code: 1000; 7000 machine or in the area around the machine.
The steering frame lock must be in the unlocked Clear all obstacles from the path of the machine.
position in order to steer the machine. Beware of hazards such as wires, ditches, etc.
Start the engine only from the operator compartment. Make sure that all windows are clean. Secure the
Never short across the starter terminals or across doors and the windows in the open position or in the
the batteries. Shorting could bypass the engine shut position.
neutral start system. Shorting could also damage the
electrical system. Adjust the rear view mirrors (if equipped) for the best
vision of the area near the machine.
SEBU7887-03 21
Safety Section
Operation

Ensure that the horn, the backup alarm (if equipped), Before you maneuver the machine, make sure that
and all other warning devices are working properly. no personnel are between the machine and the
trailing equipment. Block up the hitch of the trailing
Fasten the seat belt securely. equipment in order to align the hitch with the drawbar.
Maneuver the machine. Connect the machine to the
trailing equipment.
i01353266

Operation Know the maximum dimensions of your machine.

SMCS Code: 7000 i02624835

Only operate the machine while you are sitting in Engine Stopping
a seat. The seat belt must be fastened while you
operate the machine. Only operate the controls while SMCS Code: 1000; 7000
the engine is running.
Do not stop the engine immediately after the
While you operate the machine slowly in an open machine has been operated under load. This can
area, check for proper operation of all controls and all cause overheating and accelerated wear of engine
protective devices. components.

Before you move the machine, make sure that no After the machine is parked and the parking brake
one will be endangered. is engaged, allow the engine to run for two minutes
before shutdown. This allows hot areas of the engine
Do not allow riders on the machine unless the to cool gradually.
machine has an additional seat with a seat belt.
i01353455
Note any needed repairs during machine operation.
Report any needed repairs. Parking
Carry work tools at approximately 40 cm (15 inches) SMCS Code: 7000
above ground level.
Park the machine on a level surface. If you must park
Do not go close to the edge of a cliff, an excavation, the machine on a downgrade, block the tires.
or an overhang.
Apply the service brake in order to stop the machine.
Avoid operating the machine across the slope. When Move the transmission control to the NEUTRAL
possible, operate the machine up the slopes and position.
down the slopes. If the machine begins to sideslip
on a downgrade, immediately remove the load and Engage the parking brake.
turn the machine downhill.
Lower all work tools to the ground. Activate any
Avoid any conditions that can lead to tipping the control locks.
machine. The machine can tip when you work on
hills, on banks and on slopes. Also, the machine Stop the engine.
can tip when you cross ditches, ridges or other
unexpected obstructions. Turn the engine start switch to the OFF position and
remove the key.
Maintain control of the machine. Do not overload the
machine beyond the machine capacity. Turn the battery disconnect switch to the OFF
position. If the machine will not be operated for an
Make sure that the hitches and the towing devices extended period of time, remove the key in order to
are adequate. Only connect trailing equipment to a avoid battery discharge that may be caused by a
drawbar or to a hitch. battery short circuit, by the current draw via certain
components, or by vandalism.
Never straddle a wire cable. Never allow other
personnel to straddle a wire cable.
22 SEBU7887-03
Safety Section
Work Tools

i02706013 i01329161

Work Tools Equipment Lowering with

SMCS Code: 6700 Engine Stopped
SMCS Code: 7000
Only use work tools that are recommended by
Caterpillar for use on Caterpillar machines.
Before lowering any equipment with the engine
stopped, clear the area around the equipment of
If you are in doubt about the compatibility of a
particular work tool with your machine, consult your all personnel. The procedure to use will vary with
the type of equipment to be lowered. Keep in mind
Caterpillar dealer.
most systems use a high pressure fluid or air to
Make sure that all necessary guarding is in place on raise or lower equipment. The procedure will cause
high pressure air, hydraulic, or some other media
the host machine and on the work tool.
to be released in order to lower the equipment.
Keep all windows and doors closed on the host Wear appropriate personal protective equipment and
follow the established procedure in the Operation
machine. A polycarbonate shield must be used when
and Maintenance Manual, Equipment Lowering with
the host machine is not equipped with windows and
when a work tool could throw debris. Engine Stopped in the Operation Section of the
manual.
Do not exceed the maximum operating weight that is
listed on the ROPS certification. i02498157

If your machine is equipped with an extendable stick, Sound Information and

install the transport pin when you are using the
following work tools: hydraulic hammers, augers, and
Vibration Information
compactors SMCS Code: 7000
Always wear protective glasses. Always wear the
protective equipment that is recommended in the Sound Level Information
work tools operation manual. Wear any other
protective equipment that is required for the operating The operator Equivalent Sound Pressure Level
environment. (Leq) is 75 dB(A) when ANSI/SAE J1166 OCT 98
is used to measure the value for an enclosed cab.
To prevent personnel from being struck by flying This is a work cycle sound exposure level. The cab
objects, ensure that all personnel are out of the work was properly installed and maintained. The test was
area. conducted with the cab doors and the cab windows
closed.
While you are performing any maintenance, any
testing, or any adjustments to the work tool stay Hearing protection may be needed when the
clear of the following areas: cutting edges, pinching machine is operated with an open operator station for
surfaces, and crushing surfaces. extended periods or in a noisy environment. Hearing
protection may be needed when the machine is
operated with a cab that is not properly maintained.

The average exterior sound pressure level is 75

dB(A) when the SAE J88Apr95 - Constant Speed
Moving Test procedure is used to measure the value
for the standard machine. The measurement was
conducted under the following conditions: distance of
15 m (49.2 ft) and the machine moving forward in an
intermediate gear ratio.
SEBU7887-03 23
Safety Section
Sound Information and Vibration Information

Sound Level Information for Note: All vibration levels are in meter per second
squared.
Machines in European Union
Countries and in Countries that
Adopt the EU Directives
The dynamic operator sound pressure level is 75
dB(A) when ISO 6394:1998 is used to measure the
value for an enclosed cab. The cab was properly
installed and maintained. The test was conducted
with the cab doors and the cab windows closed.

The European Union Physical

Agents (Vibration) Directive
2002/44/EC
Vibration Data for Wheel Loaders
Information Concerning Hand/Arm Vibration
Level

When the machine is operated according to the

intended use, the hand/arm vibration of this machine
is below 2.5 meter per second squared.

Information Concerning Whole Body Vibration

Level

This section provides vibration data and a method for

estimating the vibration level for wheel loaders.

Note: Vibration levels are influenced by many

different parameters. Many items are listed below.

Operator training, behavior, mode, and stress

Job site organization, preparation, environment,
weather, and material

Machine type, quality of the seat, quality of the

suspension system, attachments, and condition of
the equipment

It is not possible to get precise vibration levels for

this machine. The expected vibration levels can be
estimated with the information in Table 1 in order
to calculate the daily vibration exposure. A simple
evaluation of the machine application can be used.

Estimate the vibration levels for the three vibration

directions. For typical operating conditions, use the
average vibration levels as the estimated level. With
an experienced operator and smooth terrain, subtract
the Scenario Factors from the average vibration level
in order to obtain the estimated vibration level. For
aggressive operations and severe terrain, add the
Scenario Factors to the average vibration level in
order to obtain the estimated vibration level.
24 SEBU7887-03
Safety Section
Sound Information and Vibration Information

Table 1
ISO Reference Table A - Equivalent vibration levels of whole body vibration emission for earthmoving equipment.

Machine Typical Operating Vibration Levels Scenario Factors

Type Activity X axis Y axis Z axis X axis Y axis Z axis
load and carry motion 0,84 0,81 0,52 0,23 0,20 0,14

Wheel mining application(1) 1,27 0,97 0,81 0,47 0,31 0,47

Loader transfer(2) 0,76 0,91 0,49 0,33 0,35 0,17
V-shape motion(3) 0,99 0,84 0,54 0,29 0,32 0,14
(1) Loading at the face
(2) Travel at high speed on the job site or on public roads
(3) Loading a truck in short cycles

Note: Refer to ISO/TR 25398 Mechanical Vibration - a. Remove any large rocks or obstacles.
Guideline for the assessment of exposure to whole
body vibration of ride on operated earthmoving b. Fill any ditches and holes.
machines for more information about vibration.
This publication uses data that is measured c. Provide machines and schedule time in order
by international institutes, organizations and to maintain the conditions of the terrain.
manufacturers. This document provides information
about the whole body exposure of operators of 4. Use a seat that meets ISO 7096. Keep the seat
earthmoving equipment. Refer to Operation and maintained and adjusted.
Maintenance Manual Supplement , SEBU8257 for
more information about machine vibration levels. a. Adjust the seat and suspension for the weight
and the size of the operator.
The Caterpillar suspension seat meets the criteria of
ISO 7096. This represents vertical vibration level b. Inspect and maintain the seat suspension and
under severe operating conditions. This seat is tested adjustment mechanisms.
with the input spectral class EM3. The seat has a
transmissibility factor of SEAT<1.0. 5. Perform the following operations smoothly.

The whole body vibration level of the machine varies. a. Steer

There is a range of values. The low value is 0.5
meter per second squared. The machine meets the b. Brake
short term level for the design of the seat in ISO
7096. The value is 1.13 meter per second squared c. Accelerate.
for this machine.
d. Shift the gears.
Guidelines for Reducing Vibration Levels on
Earthmoving Equipment 6. Move the attachments smoothly.

Properly adjust machines. Properly maintain 7. Adjust the machine speed and the route in order
machines. Operate machines smoothly. Maintain the to minimize the vibration level.
conditions of the terrain. The following guidelines can
help reduce the whole body vibration level: a. Drive around obstacles and rough terrain.

1. Use the right type and size of machine, equipment, b. Slow down when it is necessary to go over
and attachments. rough terrain.

2. Maintain machines according to the 8. Minimize vibrations for a long work cycle or a long
manufacturers recommendations. travel distance.

a. Tire pressures a. Use machines that are equipped with

suspension systems.
b. Brake and steering systems
b. Use the ride control system on wheel loaders.
c. Controls, hydraulic system and linkages
c. If no ride control system is available, reduce
3. Keep the terrain in good condition. speed in order to prevent bounce.
SEBU7887-03 25
Safety Section
Operator Station

d. Haul the machines between workplaces. i01649970

9. Less operator comfort may be caused by other risk Operator Station

factors. The following guidelines can be effective
in order to provide better operator comfort: SMCS Code: 7000

a. Adjust the seat and adjust the controls in order Any modifications to the inside of the operator
to achieve good posture. station should not project into the operator space.
The addition of a radio, fire extinguisher, and other
b. Adjust the mirrors in order to minimize twisted equipment must be installed so that the defined
posture. operator space is maintained. Any item that is brought
into the cab should not project into the defined
c. Provide breaks in order to reduce long periods operator space. A lunch box or other loose items
of sitting. must be secured. Objects must not pose an impact
hazard in rough terrain or in the event of a rollover.
d. Avoid jumping from the cab.

e. Minimize repeated handling of loads and lifting

of loads.

f. Minimize any shocks and impacts during sports

and leisure activities.

Sources
The vibration information and calculation procedure
is based on ISO/TR 25398 Mechanical Vibration
- Guideline for the assessment of exposure
to whole body vibration of ride on operated
earthmoving machines. Harmonized data is
measured by international institutes, organizations
and manufacturers.

This literature provides information about assessing

the whole body vibration exposure of operators of
earthmoving equipment. The method is based on
measured vibration emission under real working
conditions for all machines.

You should check the original directive. This

document summarizes part of the content of the
applicable law. This document is not meant to
substitute the original sources. Other parts of these
documents are based on information from the United
Kingdom Health and Safety Executive.

Refer to Operation and Maintenance Manual

Supplement , SEBU8257 for more information about
vibration.

Consult your local Caterpillar dealer for more

information about machine features that minimize
vibration levels. Consult your local Caterpillar dealer
about safe machine operation.

Use the following web site in order to find your local

dealer:

Caterpillar, Inc.
www.cat.com
26 SEBU7887-03
Product Information Section
General Information

Product Information Configurations for the Hydraulic

Section Controls

General Information
i02168718

Machine Configuration
SMCS Code: 7000

Your machine has one of four configurations.

Conventional steering and command control steering
are available steering configurations. Control levers
g01098824
and joystick control are available for the hydraulic Illustration 21
controls. Joystick Control and Console

Steering Configurations

g01126066
Illustration 22
Control Levers and Console
g00751039
Illustration 19
Full Steering Wheel (Conventional Steering) i02498156

Specifications
SMCS Code: 7000

Intended Use
This machine is classified as a Wheel Loader as
described in ISO 6165:2001. This machine normally
has a front mounted bucket for the principal intended
functions of digging, loading, lifting, carrying, and
moving material such as earth, crushed rock or
gravel. Additional work tools allow this machine to
perform other specific tasks.
g00751045
Illustration 20
Half-circle Steering Wheel (Command Control Steering) Application/Configuration
Restrictions
Steering with command control steering will be more
responsive and less effort will be required for turning Refer to Machine Data below for information about
the steering wheel. maximum machine weight.
SEBU7887-03 27
Product Information Section
General Information

Lift arm height restrictions will be found in the Note: Rated loads should be used as a guide.
Operation and Maintenance Manual for the Attachments, uneven ground conditions, soft ground
appropriate work tool. conditions, or poor ground conditions have effects on
rated loads. The operator is responsible for being
The maximum fore and aft slope for proper lubrication aware of these effects.
is 25 degrees continuous and 35 degrees intermittent.
Rated loads are based upon a standard machine with
This machine is approved for use in environments the following conditions:
with no explosive gases.
proper lubricants
Machine Data
full fuel tank
The 966H machines are equipped with a C11 Engine.
The 972H machines are equipped with a C13 Engine. enclosed ROPS

Basic machine specifications are listed in the 80 kg (176 lb) operator

following tables.
26.5R25 L3 (20 Ply) tires or equivalent
Table 2
Rated loads will vary for different attachments.
966H Wheel Loader Consult your Caterpillar dealer about the rated load
Shipping Weight 22861 kg (50400 lb) for specific attachments.
Maximum Length 9008 mm (355 inch) The rated operating load is defined by SAE J818
Width Across Tires 2950 mm (116 inch) (May 1987) and by the ISO 5998 (1986) as 50% of
the full turn static tipping load.
Height to Top of ROPS 3580 mm (141 inch)
Counterweight (Standard) 1142 kg (2518 lb) For North America, the rated operating load is
defined by SAE J1197 (February 1991) as 50% of
the full turn static tipping load.
Table 3
972H Wheel Loader
Rated Load for the Bucket
Shipping Weight 25187 kg (55531 lb)
Maximum Length 9420 mm (371 inch)
Width Across Tires 3031 mm (119 inch)
Height to Top of ROPS 3580 mm (141 inch)
Counterweight (Standard) 2653 kg (5849 lb)

i02622968

Rated Load
SMCS Code: 6700
g01098826
Illustration 23

The dump clearance and the reach are given for each
Failure to comply to the rated load can cause pos-
bucket at maximum lift height and at a 45 degree
sible personal injury or property damage. Review
dumping angle. Dump clearance (A) is measured
the rated load of a particular work tool before per-
from the ground to the bucket edge. Reach (B) is
forming any operation. Make adjustments to the
measured from the front of the front tire to the bucket
rated load as necessary for non-standard config-
edge.
urations.
The following tables provide the rated operating loads
for the standard machine configuration with a bucket.
28 SEBU7887-03
Product Information Section
General Information

Table 4
Rated Load (966H Buckets)
Part Number Ground Engaging Rated Operating Dump Clearance Reach
Rated Volume
(Bucket) Tools Load A B
General Purpose 2912 mm 1356 mm
3.6 m3 (4.75 yd3) 6460 kg (14242 lb)
With Teeth (115 inch) (53.4 inch)
General Purpose
2912 mm 1356 mm
With Teeth and 3.8 m3 (5 yd3) 6460 kg (14242 lb)
133-1667 (115 inch) (53.4 inch)
Segments
General Purpose
3040 mm
With a Bolt-On 3.8 m3 (5 yd3) 6460 kg (14242 lb) 1228 mm (48.3 ft)
(120 inch)
Cutting Edge
General Purpose 2942 mm 1323 mm
3.5 m3 (4.6 yd3) 6460 kg (14242 lb)
With Teeth (116 inch) (52.1 inch)
General Purpose
2942 mm 1323 mm
With Teeth and 3.6 m3 (4.75 yd3) 6460 kg (14242 lb)
133-1668 (116 inch) (52.1 inch)
Segments
General Purpose
3070 mm 1197 mm
With a Bolt-On 3.6 m3 (4.75 yd3) 6460 kg (14242 lb)
(121 inch) (47.1 inch)
Cutting Edge
General Purpose 2970 mm 1297 mm
3.3 m3 (4.25 yd3) 6460 kg (14242 lb)
With Teeth (117 inch) (51.1 inch)
General Purpose
2970 mm 1297 mm
With Teeth and 3.5 m3 (4.5 yd3) 6460 kg (14242 lb)
133-1669 (117 inch) (51.1 inch)
Segments
General Purpose
3098 mm 1170 mm
With a Bolt-On 3.5 m3 (4.5 yd3) 6460 kg (14242 lb)
(122 inch) (46.1 inch)
Cutting Edge
Material Handler 3147 mm 1318 mm
3.6 m 3 (4.75 yd3) 6460 kg (14242 lb)
With Teeth (124 inch) (51.9 inch)
Material Handler
3147 mm 1318 mm
With Teeth and 4 m3 (5.25 yd3) 6460 kg (14242 lb)
133-1670 (124 inch) (51.9 inch)
Segments
Material Handler
3077 mm 1190 mm
With a Bolt-On 4 m3 (5.2 yd3) 6460 kg (14242 lb)
(121 inch) (46.8 inch)
Cutting Edge
Material Handler 2839 mm 1361 mm
3.8 m3 (5 yd3) 6460 kg (14242 lb)
With Teeth (112 inch) (53.6 inch)
Material Handler
2839 mm 1361 mm
With Teeth and 4 m3 (5.25 yd3) 6460 kg (14242 lb)
133-1691 (112 inch) (53.6 inch)
Segments
Material Handler
3035 mm 1233 mm
With a Bolt-On 4 m3 (5.25 yd3) 6460 kg (14242 lb)
(119 inch) (48.5 inch)
Cutting Edge
Spade Rock With a
2965 mm 1302 mm
148-6899 Bolt-On Cutting 3.5 m3 (4.5 yd3) 6460 kg (14242 lb)
(117 inch) (51.3 inch)
Edge
Spade Rock
2814 mm 1453 mm
148-6901 With Teeth and 3.5 m3 (4.5 yd3) 6460 kg (14242 lb)
(111 inch) (57.2 inch)
Segments
(continued)
SEBU7887-03 29
Product Information Section
General Information

(Table 4, contd)
Rated Load (966H Buckets)
Part Number Ground Engaging Rated Operating Dump Clearance Reach
Rated Volume
(Bucket) Tools Load A B
Heavy-Duty Rock
2965 mm 1302 mm
148-6898 With a Bolt-On 3.5 m3 (4.5 yd3) 6460 kg (14242 lb)
(117 inch) (51.3 inch)
Cutting Edge
Heavy-Duty Rock
2814 mm 1453 mm
148-6900 With Teeth and 3.5 m3 (4.5 yd3) 6460 kg (14242 lb)
(111 inch) (57.2 inch)
Segments
30 SEBU7887-03
Product Information Section
General Information

Table 5
Rated Load (972H Buckets)
Part Number Ground Engaging Rated Operating Dump Clearance Reach
Rated Volume
(Bucket) Tools Load A B
General Purpose 2997 mm 1364 mm
4.5 m3 (5.75 yd3) 7310 kg (16115 lb)
With Teeth (118 inch) (53.7 inch)
General Purpose
2997 mm 1364 mm
With Teeth and 4.7 m3 (6 yd3) 7310 kg (16115 lb)
133-1690 (118 inch) (53.7 inch)
Segments
General Purpose
3144 mm 1255 mm
With a Bolt-On 4.7 m3 (6 yd3) 7310 kg (16115 lb)
(123.8 inch) (49.4 inch)
Cutting Edge
General Purpose 3074 mm 1401 mm
4 m3 (5.25 yd3) 7310 kg (16115 lb)
With Teeth (121 inch) (55.2 inch)
General Purpose
3074 mm 1401 mm
With Teeth and 4.3 m3 (5.5 yd3) 7310 kg (16115 lb)
133-1693 (121 inch) (55.2 inch)
Segments
General Purpose
3221 mm 1281 mm
With a Bolt-On 4.3 m3 (5.5 yd3) 7310 kg (16115 lb)
(126.8 inch) (50.4 inch)
Cutting Edge
Material Handler 3074 mm 1401 mm
3.8 m3 (5 yd3) 7310 kg (16115 lb)
With Teeth (121 inch) (55.2 inch)
Material Handler
3074 mm 1401 mm
With Teeth and 4 m3 (5.25 yd3) 7310 kg (16115 lb)
133-1671 (121 inch) (55.2 inch)
Segments
Material Handler
3221 mm 1281 mm
With a Bolt-On 4 m3 (5.25 yd3) 7310 kg (16115 lb)
(126.8 inch) (50.4 inch)
Cutting Edge
Material Handler 3061 mm 1301 mm
4 m3 (5.25 yd3) 7310 kg (16115 lb)
With Teeth (120.5 inch) (51.2 inch)
Material Handler
3061 mm 1301 mm
With Teeth and 4.3 m3 (5.5 yd3) 7310 kg (16115 lb)
133-1689 (120.5 inch) (51.2 inch)
Segments
Material Handler
3208 mm 1192 mm
With a Bolt-On 4.3 m3 (5.5 yd3) 7310 kg (16115 lb)
(126.3 inch) (46.9 inch)
Cutting Edge
Spade Rock With a
3099 mm 1458 mm
148-6903 Bolt-On Cutting 4 m3 (5.25 yd3) 7310 kg (16115 lb)
(122 inch) (57.4 inch)
Edge
Spade Rock
2904 mm 1588 mm
148-6905 With Teeth and 4 m3 (5.25 yd3) 7310 kg (16115 lb)
(114.3 inch) (62.5 inch)
Segments
Heavy-Duty Rock
3099 mm 1458 mm
148-6902 With a Bolt-On 4 m3 (5.25 yd3) 7310 kg (16115 lb)
(122 inch) (57.4 inch)
Cutting Edge
Heavy-Duty Rock
2904 mm 1588 mm
148-6904 With Teeth and 4 m3 (5.25 yd3) 7310 kg (16115 lb)
(114.3 inch) (62.5 inch)
Segments
SEBU7887-03 31
Product Information Section
General Information

Rated Load for the Logging Fork

g00885703
Illustration 24

The discharge clearance and the reach are given for

each implement at the maximum lift height and at the
maximum discharge angle. Discharge clearance (A)
is measured from the ground to the bottom edge of
the implement. Reach (B) is measured from the front
of the front tire to the front edge of the implement.

The following table provides the rated operating

loads for the standard machine (North American
configuration).

Reference: Refer to Special Publication, GELQ0149,

Wheel Loader Fork Application Guide for the rated
loads of other machine configurations.

For Europe, the rated operating load is defined by

CEN 474-3 as 60% of the full turn static tipping load.

Table 6
Rated Load for the 966H Wheel Loader
Part Number (Logging Additional Rated Operating Discharge Clearance Reach
Fork) Counterweight Load A B
143-7211
1225 kg (2700 lb) 6000 kg (13200 lb) 1894 mm (75 inch) 1386 mm (64 inch)
Logging Fork
166-8575 Millyard Fork 1225 kg (2700 lb) 6000 kg (13200 lb) 1894 mm (75 inch) 1386 mm (64 inch)
32 SEBU7887-03
Product Information Section
Identification Information

Identification Information
i02375041

Plate Locations and Film

Locations
SMCS Code: 1000; 7000; 7405

The Product Identification Number (PIN) will be used

to identify a powered machine that is designed for
an operator to ride.

Caterpillar products such as engines, transmissions g00904964

Illustration 26
and major attachments that are not designed for an
operator to ride are identified by Serial Numbers.
This plate is located on the transfer gear case.
For quick reference, record the identification numbers
Transmission Serial Number_____________________________
in the spaces that are provided below the illustration.

g00883938
Illustration 25

This plate is located on the left side of the front loader

frame.

Machine PIN_________________________________________________
g01099084
Illustration 27
SIN_____________________________________________________________
This plate is located on the upper left side of the
If the machine is equipped with the certification plate engine block.
for the European Union, this plate will be attached to
the PIN plate. The certification plate will contain the Engine Serial Number_____________________________________
following information:
Certification
Power (kW) _______________________________________________
Weight (kg) _______________________________________________ ROPS/FOPS Plate

Year of Manufacture This message is located on the triangular panel in

front of the door on the left side of the cab.
SEBU7887-03 33
Product Information Section
Identification Information

Sound

g01185189
Illustration 28
g00933634
Illustration 30
A typical example of this film is shown. Your machine may have a
different value.

If equipped, the certification film is used to verify the

environmental sound certification of the machine to
the requirements of the European Union. The value
that is listed on the label indicates the guaranteed
exterior sound power level LWA at the time of
manufacture for the conditions that are specified in
2000/14/EC.

Italian Roading Homologation

Illustration 29
g00902324 This plate is located on the right side of the machine
behind the front tire.

Structural damage, an overturn, modification, al-

teration, or improper repair can impair this struc-
tures protection capability thereby voiding this
certification. Do not weld on or drill holes in the
structure. This will void the certification. Consult
a Caterpillar dealer to determine this structures
limitations without voiding its certification.

This machine has been certified to the standards that

are listed on the certification plate. The maximum
mass of the machine, which includes the operator
and the attachments without a payload, should not Illustration 31
g00937218
exceed the mass on the certification plate.
The following information is stamped on the
TUV/homologation plate:

Model ____________________________________________________
Homologation number _______________________________
PIN _______________________________________________________
Allowed total weight __________________________________
Allowed front axle weight ____________________________
34 SEBU7887-03
Product Information Section
Identification Information

Allowed rear axle weight ____________________________

Permissible towable mass __________________________
Unbraked towable mass _____________________________
Independently-braked towable mass _____________
Inertia-braked towable mass _______________________
Towable mass fitted with an assisted braking
system (hydraulic or pneumatic)____________________

Machine Security System

This message is located on the control group for
the machine security system. The control group is
located in the engine compartment.

g00995393
Illustration 32

Consult your Caterpillar dealer with any questions

that concern the operation of the MSS in a specific
country.

i01830750

Emissions Certification Film

SMCS Code: 1000; 7000; 7405

Note: This information is pertinent in the United

States, in Canada and in Europe.

A typical example is shown.

SEBU7887-03 35
Product Information Section
Identification Information

g00776690
Illustration 33
36 SEBU7887-03
Operation Section
Before Operation

Operation Section i02163915

Daily Inspection
Before Operation SMCS Code: 1000; 7000

For a maximum service life of the machine, complete

i02189821 a thorough walk-around inspection before you mount
the machine and before you start the engine.
Mounting and Dismounting
Inspect the area around the machine and under the
SMCS Code: 7000 machine. Look for loose bolts, trash buildup, oil,
coolant leakage, broken parts, or worn parts.

Note: Watch closely for leaks. If you observe a leak,

find the source of the leak and correct the leak. If you
suspect a leak or you observe a leak, check the fluid
levels more frequently.

Inspect the condition of the equipment and of the

hydraulic components.

Check the condition of the tires. Adjust the inflation

pressure, if necessary.

Check all of the oil levels, all of the coolant levels,

g00037860 and all of the fuel levels.
Illustration 34
Typical example Remove any trash buildup and debris. Make all
necessary repairs before you operate the machine.
Mount the machine and dismount the machine only
at locations that have steps and/or handholds. Before Make sure that all covers and guards are securely
you mount the machine, clean the steps and the attached.
handholds. Inspect the steps and handholds. Make
all necessary repairs. Adjust the mirrors for the correct rear view of the
machine.
Face the machine whenever you get on the machine
and whenever you get off the machine. Grease all of the fittings that need to be serviced on
a daily basis.
Maintain a three-point contact with the steps and with
the handholds. Daily, perform the procedures that are applicable to
your machine:
Note: Three-point contact can be two feet and one
hand. Three-point contact can also be one foot and Operation and Maintenance Manual, Backup
two hands. Alarm - Test
Do not mount a moving machine. Do not dismount a Operation and Maintenance Manual, Bucket
moving machine. Never jump off the machine. Do Cutting Edges - Inspect/Replace
not carry tools or supplies when you try to mount the
machine or when you try to dismount the machine. Operation and Maintenance Manual, Bucket Tips
Use a hand line to pull equipment onto the platform. - Inspect/Replace
Do not use any controls as handholds when you
enter the operator compartment or when you exit the Operation and Maintenance Manual, Cooling
operator compartment. System Coolant Level - Check

Alternate Exit Operation and Maintenance Manual, Engine Oil

Level - Check
Machines that are equipped with cabs have alternate
exits. For additional information, see Operation and Operation and Maintenance Manual, Fuel System
Maintenance Manual, Alternate Exit. Primary Filter (Water Separator) - Drain
SEBU7887-03 37
Operation Section
Before Operation

Operation and Maintenance Manual, Fuel Tank

Water and Sediment - Drain

Operation and Maintenance Manual, Hydraulic

System Oil Level - Check

Operation and Maintenance Manual, Seat Belt -

Inspect

Operation and Maintenance Manual, Transmission

Oil Level - Check

Operation and Maintenance Manual, Windows -

Clean
g01063175
Illustration 36
i02163933 Steering frame lock in the unlocked position

Steering Frame Lock Separate steering frame lock (1) before the machine
is operated.
SMCS Code: 7506
Move the steering frame lock into the unlocked
position and install pin (2).

No clearance for person in this area when machine

turns. Severe injury or death from crushing could
occur.

The steering frame lock is located on the left side

of the machine.

g01063282
Illustration 35
Steering frame lock in the locked position

Connect steering frame lock (1) when the machine

is being lifted and when the machine is being
transported. Also connect the steering frame lock if
you are performing service work near the articulation
joint. Install pin (2) in order to secure the steering
frame lock.
38 SEBU7887-03
Operation Section
Machine Operation

Machine Operation
i01612239

Alternate Exit
SMCS Code: 7310

g00886240
Illustration 38
g00738852
Illustration 37
Backrest (1) Pull up on the backrest in
The right side cab window can be used as an order to remove extension (1).
alternate exit. The window can only be opened from
the inside of the cab.
Lumbar Support (2) Rotate the knob
Pull latch (2) backward and push the latch outward clockwise in order to increase support
in order to open the window to the partial open to the lower back. Rotate the knob
position. Remove pin (1) from the window and push counterclockwise in order to decrease support to the
the window to the fully open position. lower back.

i02163386
Rotate knob (3) in order to adjust the angle of the
armrest in the operating position.
Seat
Seat Backrest Angle Adjustment (4)
SMCS Code: 7312 Pull the lever upward. Hold the lever
upward and adjust the backrest to the
Note: The operators seat that is provided with this desired angle. Release the lever in order to lock the
machine is in compliance with the appropriate class backrest into position.
of ISO 7096.
Fore and Aft Position (5) Pull the lever
Adjust the seat in order to allow full travel of the upward. Hold the lever upward and slide
pedals. Make the seat adjustments when the operator the seat forward or backward to the desired
is sitting against the back of the seat. position. Release the lever in order to lock the seat
into position.

Mechanical Suspension
Seat Height (6) Pull the lever upward.
Hold the lever upward and move the seat
to the desired height. Release the lever in
order to lock the seat into position.
SEBU7887-03 39
Operation Section
Machine Operation

Air Suspension (If Equipped) Seat Belt Adjustment for

Seat Height (6) Push in on air valve knob
Non-Retractable Seat Belts
(6) in order to raise the height of the seat.
Adjust both ends of the seat belt. The seat belt should
Pull out on the air valve knob (6) in order to
be snug but comfortable.
lower the height of the seat.
Lengthening the Seat Belt

g00100709
Illustration 40

1. Unfasten the seat belt.

g01105067
Illustration 39

Cushion Angle Adjustment (7) In order

to raise the angle of the seat, pull upward
on the front of the seat and push the seat
rearward. In order to lower the angle of the seat, pull
upward and pull forward. Illustration 41
g00932817

2. To remove the slack in outer loop (1), rotate buckle

i02707449 (2). This will free the lock bar. This permits the
seat belt to move through the buckle.
Seat Belt
3. Remove the slack from the outer belt loop by
SMCS Code: 7327
pulling on the buckle.
Note: This machine was equipped with a seat belt
4. Loosen the other half of the seat belt in the same
when the machine was shipped from Caterpillar.
manner. If the seat belt does not fit snugly with the
At the time of installation, the seat belt and the
buckle in the center, readjust the seat belt.
instructions for installation of the seat belt meet the
SAE J386 standards. See your Caterpillar dealer for
all replacement parts.

Always check the condition of the seat belt and

the condition of the mounting hardware before you
operate the machine.
40 SEBU7887-03
Operation Section
Machine Operation

Shortening the Seat Belt Releasing The Seat Belt

g00100713 g00100717
Illustration 42 Illustration 44

1. Fasten the seat belt. Pull out on the outer belt loop Pull up on the release lever. This will release the seat
in order to tighten the seat belt. belt.

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

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

g00867598
Illustration 45

g00932818 Pull seat belt (4) out of the retractor in a continuous

Illustration 43
motion.
Fasten the seat belt catch (3) into the buckle (2).
Make sure that the seat belt is placed low across the Fasten seat belt catch (3) into buckle (2). Make sure
lap of the operator. that the seat belt is placed low across the lap of the
operator.

The retractor will adjust the belt length and the

retractor will lock in place. The comfort ride sleeve
will allow the operator to have limited movement.
SEBU7887-03 41
Operation Section
Machine Operation

Releasing The Seat Belt

g00039113
Illustration 46

Push the release button on the buckle in order to

release the seat belt. The seat belt will automatically
retract into the retractor.

Extension of the Seat Belt

When using retractable seat belts, do not use seat

belt extensions, or personal injury or death can
result.

The retractor system may or may not lock up de-

pending on the length of the extension and the
size of the person. If the retractor does not lock
up, the seat belt will not retain the person.

Longer, non-retractable seat belts and extensions for

the non-retractable seat belts are available.

Caterpillar requires only non-retractable seat belts to

be used with a seat belt extension.

Consult your Caterpillar dealer for longer seat belts

and for information on extending the seat belts.
42 SEBU7887-03
Operation Section
Machine Operation

i02710322

Operator Controls
SMCS Code: 7300; 7301; 7451

g01126052
Illustration 47
Conventional steering
(1) Steering Control (4) Transmission Control (7) Governor Control
(2) Horn (5) Tilt Control for the Steering Wheel (9) Hydraulic Control Support
(3) Seat (6) Service Brake Controls
SEBU7887-03 43
Operation Section
Machine Operation

g01123709
Illustration 48
Command Control Steering
(1) Steering Control (4) Transmission Control (7) Governor Control
(2) Horn (5) Tilt Control for the Steering Wheel (8) Telescopic Control for the Steering Wheel
(3) Seat (6) Service Brake Controls (9) Hydraulic Control Support
44 SEBU7887-03
Operation Section
Machine Operation

g01132241
Illustration 49
Conventional Steering with Joystick
(1) Steering Control (4) Transmission Control (7) Governor Control
(2) Horn (5) Tilt Control for the Steering Wheel (9) Hydraulic Control Support
(3) Seat (6) Service Brake Controls
SEBU7887-03 45
Operation Section
Machine Operation

g01126054
Illustration 50
Command Control Steering with Joystick
(1) Steering Control (4) Transmission Control (7) Governor Control
(2) Horn (5) Tilt Control for the Steering Wheel (8) Telescopic Control for the Steering Wheel
(3) Seat (6) Service Brake Controls (9) Hydraulic Control Support
46 SEBU7887-03
Operation Section
Machine Operation

g01112235 g01131323
Illustration 51 Illustration 53
(10) Lighter (34) Fine Modulation
(11) Light switch (35) Hydraulic Lockout
(12) HID Lights (If Equipped) (36) Implement Function (If Equipped)
(13) Continuous Flow Control (If Equipped) (37) Auxiliary Control (If Equipped)
(14) Parking brake control (38) Lift Control
(15) Beacon Switch (If Equipped) (39) Tilt Control
(16) Hazard Switch (40) Autodig Trigger Switch (If Equipped)
(17) Engine Start Switch (41) Transmission Downshift Switch
(18) 12 Volt Power Receptacle

g01122973
Illustration 52
(19) Variable Shift Control
(20) Autodig System (If Equipped)
(21) Quick Coupler (If Equipped)
(22) Bucket Kickout Set Switch
(23) Front Windshield Wiper/Washer Switch
(24) Rear Windshield Wiper/Washer Switch
(25) Heating and Air Conditioning Control
(26) Autoshift Control
(27) Ride Control (If Equipped)
(28) Transmission Neutralizer Override Switch
(29) Secondary Steering (If Equipped)
(30) Fan Reversing (If Equipped)
(31) Heated Mirror (If Equipped)
(32) Switch for the Display Module
(33) Payload Control System (If Equipped)
SEBU7887-03 47
Operation Section
Machine Operation

g01115219
Illustration 54
Machines that are Equipped with Command Control Steering and Joystick
(34) Fine Modulation (37) Auxiliary Control (If Equipped) (40) Autodig Trigger Switch (If Equipped)
(35) Hydraulic Lockout (38) Lift Control
(36) Implement Function (If Equipped) (39) Tilt Control

Horn (2)
Press the center of the steering wheel in order to
sound the horn.

Also, you can press button (2) in order to sound the

horn.

Seat (3)
For information regarding the adjustment of the seat
and the features of the seat, refer to Operation and
Maintenance Manual, Seat.

g01131337
Illustration 55
(41) Transmission Downshift Switch

Steering Control (1)

Your machine may be equipped with conventional
steering or command control steering. Command
control steering will be more responsive than
conventional steering.

The steering wheel will self-center as you release the

wheel on machines that are equipped with command
control steering. However, the machine will not
straighten as the steering wheel moves to the center
position. You must steer the machine in the opposite
direction in order to straighten the machine.
48 SEBU7887-03
Operation Section
Machine Operation

Transmission Control (4) The direction for machines that are equipped with
command control steering is determined by the
Direction Selection position of the select switch that is located on the left
side of the steering wheel.

(4A) FORWARD Push the switch to the left in order

to place the transmission in FORWARD.

(4B) NEUTRAL Push the switch to the middle

position in order to place the transmission in
NEUTRAL.

(4C) REVERSE Push the switch to the right in

order to place the transmission in REVERSE.

Forward/Neutral/Reverse Switch (If Equipped)

g00999329
Illustration 56
Conventional steering

g01131344
Illustration 59
Machines that are Equipped with Forward/Neutral/Reverse Switch

g01131342
Illustration 57
Conventional steering

g01117221
Illustration 60
Machines that are Equipped with Joystick and Forward/Neutral/
Reverse Switch

Illustration 58
g00999332 Once the machine is started, the NEUTRAL
lamp should be on. The machine may be placed
Command control steering
into gear either by using the shifter or the
forward/neutral/reverse switch. In order to use the
The direction for machines that are equipped with
shifter, ensure that the forward/neutral/reverse switch
conventional steering is determined by the position of
the lever that is located on the left side of the steering is in the NEUTRAL position. Use the shifter to select
the direction. The appropriate direction indicator
column or by the forward/neutral/reverse switch that
should illuminate.
is located next to the bucket controls.
SEBU7887-03 49
Operation Section
Machine Operation

In order to use the forward/neutral/reverse switch,

place the shifter in the NEUTRAL position.
Select the direction that is desired by using the
forward/neutral/reverse switch. The appropriate
direction indicator should illuminate.

The transmission will be placed in the

NEUTRAL position if both the shifter and the
forward/neutral/reverse switch indicate a state
that is not NEUTRAL during operation. The
NEUTRAL lamp will be OFF. Both the shifter and
the forward/neutral/reverse switch must be placed in
the NEUTRAL position before normal operation can
resume.
g00999339
Illustration 63
Speed Selection
Command control steering

The speed of the machines that are equipped with

command control steering is selected by using switch
(4D) that is located on the left side of the steering
wheel. Press the top of switch (4D) in order to
increase the transmission speed. Press the bottom
of switch (4D) in order to decrease the speed of the
transmission. The transmission has four speeds.

Note: The transmission can shift automatically or the

transmission can shift manually.

Reference: Refer to Autoshift Control for more

information.
g00884219
Illustration 61
The transmission can also be downshifted by using
The speed of the machine will be displayed on the the left service brake pedal.
front dash.
Reference: Refer to Service Brake Control for more
information.

Tilt Control for the Steering Wheel

(5)
To adjust the steering column, pull up on steering
column tilt lever (5) and move the steering column to
the desired position. Release lever (5) in order to lock
the steering column in the desired position.

Service Brake Control (Pedals) (6)

Illustration 62
g00884220 Right Service Brake Pedal
Conventional steering
The right service brake pedal is used to slow down
the machines ground speed when the operator
The speed of the machines that are equipped with does not wish to have the transmission downshift
conventional steering is selected by rotating the aggressively.
switch that is located on the left side of the steering
column. Rotate the switch forward or backward The right service brake pedal is normally used for
in order to increase or decrease the speed of the braking when the autoshift transmission control is
transmission. downshifting adequately.
50 SEBU7887-03
Operation Section
Machine Operation

Left Service Brake Pedal Initial travel (X) of the left brake pedal will cause
the transmission to aggressively downshift. The
The left service brake pedal provides three braking transmission will downshift to the lowest available
functions: speed. The lowest available speed depends on
the position of the autoshift switch. Refer to Table
Aggressive automatic downshifting of the 7 or Table 8 for the lowest available speed. Each
transmission downshift of the transmission will reduce the speed
of the machine. The transmission will downshift at
Neutralization of the transmission higher speeds than the normal automatic downshift
speeds. The transmission will only downshift if an
Conventional braking engine overspeed will not occur. The transmission will
not upshift until the left brake pedal is fully released.
The left brake pedal is used to initiate automatic
downshifting of the transmission at higher ground The transmission will be engaged again after the left
speeds than the standard automatic downshifting. brake pedal is released four degrees from maximum
pedal position (6C). This will only happen if the
When the left service brake pedal is depressed transmission was neutralized. The service brakes will
to a certain point, automatic downshifting and still be applied. This will allow the transmission to be
neutralization of the transmission will occur for all engaged when the brakes are applied. This will help
positions of the autoshift switch. The automatic to prevent unwanted movement while you are on a
downshifting and the neutralizing of the transmission slope.
saves wear on the service brakes, axles, and
components of the power train. Note: You should wait for at least one second after
you release the left brake pedal for four degrees
Use the left brake pedal for most conditions when before you completely release the pedal. This will
adequate traction is available. allow the transmission to fully engage.

Left Brake Pedal Operation Depressing the left pedal will neutralize the
transmission again.
The functions of the left brake pedal depend on the
position of the left brake pedal and on the position of When the left brake pedal is fully released, the
the autoshift switch. transmission will return to normal operation. The
transmission will remain in the current speed if the
autoshift switch is in MANUAL (6E).

Note: The left brake pedal requires calibration if

the pedal was replaced. The neutralization of the
transmission can also be adjusted.

Reference: For more information on calibration of

the left brake pedal, refer to Power Train Testing and
Adjusting, RENR8846, Position Sensor (Left Brake
Pedal) Calibrate.

g00999344
Illustration 64
(X) Initial travel
(Y) Downshifting and service brake application
(Z) Additional travel (application of service brakes)
(6A) Calibrated initial brake pressure point
(6B) Set point for neutralization
(6C) Pedal position for stopping the machine
(6D) Maximum pedal travel (full application of service brakes)
SEBU7887-03 51
Operation Section
Machine Operation

Command Control Steering

g01069119
Illustration 65
Command Control Steering

Table 7

Modes of Operation for the Transmission Neutralizer

Autoshift Switch Manual Mode (6E) 4 3 2 1-4

4th-3rd-2nd-
Shift Pattern 4th-3rd-2nd 4th-3rd-2nd 3rd-2nd None
1st
Lowest Available Speed 2nd 2nd 2nd 2nd 1st

Conventional Steering

g01069112
Illustration 66
Conventional Steering

Table 8
Modes of Operation for the Transmission Neutralizer
Autoshift Switch Manual Mode 2-4 1-4
Shift Pattern 4th-3rd-2nd 4th-3rd-2nd 4th-3rd-2nd-1st
Lowest Available Speed 2nd 2nd 1st

Governor Control (7)

Depress pedal (7) in order to increase the speed of
the engine. Release pedal (7) in order to allow the
speed of the engine to decrease.
52 SEBU7887-03
Operation Section
Machine Operation

Telescopic Control for the Steering Light Switch (11)

(8)
This control is available on machines which are
equipped with command control steering.

Rotate lever (8) counterclockwise in order to move

the steering wheel to the desired height. Rotate lever
(8) clockwise in order to lock the steering wheel in
the desired position.

Hydraulic Control Support (9)

g00999380
Illustration 69

OFF (11A) Turn the knob to the OFF

position in order to shut off all of the lights.

Parking Lights and Cab Interior Lights

(11B) Turn the knob to position (11B) in
order to turn on both the parking lights and
the interior cab lights.

Illustration 67
g01131346 Roading Lights (11C) Turn the knob
to position (11C) in order to turn on the
roading lights.

Front Floodlights (11D) Turn the knob

to position (11D) in order to turn on the front
floodlights.

Rear Floodlights (11E) Turn the knob

to position (11E) in order to turn on the rear
floodlights.

HID Lights (12)

g01115222 Press the top of the switch in order to turn on the
Illustration 68
front and rear HID lights.
Joystick control
Place the switch into the middle position in order to
Control lever (9C) allows fore and aft movement of turn on the front HID lights only.
entire armrest (9A). Control knobs (9D) and (9E)
allow tilt and vertical movement of hydraulic control Press the bottom of the switch in order to turn off the
support (9A). Control knob (9F) allows vertical lights.
movement of support (9B).

Lighter (10)
Lighter The lighter can be used as a 12V
power receptacle. This power receptacle
can be used to power automotive electrical
equipment or accessories. Remove the lighter before
use.
SEBU7887-03 53
Operation Section
Machine Operation

Continuous Flow Control (13) (If

Equipped)
Continuous Flow The continuous flow
control supplies continuous flow of hydraulic
fluid to the auxiliary hydraulic circuit without
continuously holding the auxiliary hydraulic control.
Move the lever or the thumb wheel for the auxiliary
control to the desired flow rate. Press the continuous
flow switch and release the continuous flow switch.
Immediately release the auxiliary control lever or
the thumb wheel after you release the continuous
flow switch. The continuous flow function will not
be activated if the operator does not release the
auxiliary control lever or the thumb wheel within one Illustration 70
g01124161
second of releasing the continuous flow switch. Move
the auxiliary control lever, the thumb wheel, or the If the brakes lose oil pressure, an alert indicator for
continuous flow switch in order to stop the flow to the the brakes will flash and an action alarm will sound.
auxiliary hydraulic circuit.
Anticipate a sudden stop. Correct the cause of the
loss of oil pressure. Do not operate the machine
Parking Brake Control (14) without normal brake oil pressure.

NOTICE The action light will also flash when the lights on the
Do not engage the parking brake while the machine is monitoring system flash.
moving unless the service brake fails. The use of the
parking brake as a service brake in regular operation NOTICE
will cause severe damage to the parking brake. Moving the machine with the parking brake engaged
can cause excessive wear or damage to the brake.
Parking Brake Knob (14) is located to
the left of the steering column. Use the If necessary, have the brake repaired before operating
parking brake after the machine has been the machine.
stopped.
Beacon Switch (15) (If Equipped)
Pull knob (14) outward in order to engage the parking
brake. Push knob (14) inward in order to disengage Rotating Beacon (15) Press the top of
the parking brake. switch (15) in order to turn on the rotating
beacon. Press the bottom of switch (15) in
Parking Brake Operation order to turn off the rotating beacon.

Hazard Switch (16)

Personal injury could result from the sudden stop Hazard Flasher Press switch (16) for the
of the machine. The parking brake is automatically hazard flashers. Both turn signal lights will
engaged when brake oil pressure drops below an flash simultaneously.
adequate operating pressure.
54 SEBU7887-03
Operation Section
Machine Operation

12 Volt Power Receptacle (18)

Power receptacle The 12V power
receptacle can be used to power
automotive electrical equipment or
accessories. Remove the cap before use.

Variable Shift Control (19) (If

Equipped)

g01112303
Illustration 71

Indicator light (16A) on the front dash panel will flash

when the hazard flasher is activated.

Engine Start Switch (17)

g01123828
Illustration 73

The variable shift control is located on the switch

panel. The variable shift control will change the
transmissions characteristic of the shift points.
The transmission can be set to shift sooner as the
machine is accelerating. The transmission can be set
to shift later as the machine is accelerating.

Rotate the switch clockwise into economy mode

(19C). The transmission will shift at a lower rpm.
g01123822
Illustration 72 This position is the most fuel efficient position. This
position will provide the most comfort for the operator.
OFF (17A) When you insert the engine
start switch key and when you remove the Rotate the switch counterclockwise to standard mode
engine start switch key, the engine start (19A). The rpm of the engine will now be higher when
switch must be in the OFF position. To disconnect the transmission shifts.
the power to the electrical circuits in the cab, turn the
engine start switch to the OFF position. Also, turn An intermediate position (19B) is also available . As
the engine start switch to the OFF position in order the switch is rotated clockwise, the transmission will
to stop the engine. continue to shift at a lower rpm.

ON (17B) To activate the electrical Autodig Control (20) (If Equipped)

circuits in the cab, turn the engine start
switch key clockwise to the ON position. For more information regarding the Autodig System,
refer to Operation and Maintenance Manual,
START (17C) To start the engine, turn Aggregate Autodig.
the engine start switch clockwise to the
START position. When the engine start
switch key is released, the engine start switch will
return to the ON position.

Note: If the engine fails to start, return the engine

start switch to the OFF position. This must be done
before you attempt to start the engine again.
SEBU7887-03 55
Operation Section
Machine Operation

Quick Coupler (21) (If Equipped) To set the lower kickout, lower the bucket to the
desired position below the midway point. Then
depress the top of switch (22). The boom will return
to the programmed position when the float detent is
activated and the boom is at least a foot above the
Improper engagement of work tools could result kickout position.
in injury or death.
Note: If the boom is 305 mm (12 inch) or less above
Do not operate this machine until you have pos- the lower kickout position, placing the lift control lever
itive indication that the coupler pins are fully en- in the float detent will cause the bucket to float and
gaged. the bucket will hit the ground.

To set the rotation of the tiltback for the work tool,

depress the bottom of switch (22).

Front Windshield Wiper/Washer

Switch (23)
Turn the knob in order to turn on the window wiper.
Push the knob in order to activate the window washer.

Note: The machine is equipped with intermittent front

wipers. There are several positions that will affect
the wipers.
g00767990 Turn knob (23) clockwise from the OFF position
Illustration 74
for the desired setting (INTERMITTENT, LOW
Move the diverter valve lever to the coupler position or HIGH). The delay speed of the wipers can be
in order to provide flow to the coupler. adjusted by turning the knob clockwise through the
INTERMITTENT position.
Engage Press the bottom of the switch in order
to engage the coupler pins. The switch will remain Rear Windshield Wiper/Washer
in the engaged position.
Switch (24)
Disengage Press the bottom of the switch in order
to release the switch. The top of the switch can then Turn the knob in order to turn on the window wiper.
be pressed in order to disengage the coupler pins. Push the knob in order to activate the window washer.

To make sure that the coupler pins are fully engaged Turn knob (24) clockwise from the OFF position for
into the attachment, tilt the attachment downward the desired setting (LOW or HIGH).
onto the ground and apply slight downward pressure.
Then, back up the machine. If there is movement Heating and Air Conditioning
between the attachment and the coupler pins, the
attachment is not installed properly. Controls (25)
Note: Operating instructions for specific attachments
are not provided. The function of the control lever
is dependent upon the installation of an Auxiliary
Equipment Manufacturers attachment.

Bucket Kickout Set Switch (22)

Lift Kickout Position and Lower Kickout
Position To set the lift kickout, raise the
bucket to the desired position above the
midway point. Then depress the top of switch (22).
The boom will return to the programmed position
when the raise detent is activated and the boom is
below the kickout position. Illustration 75
g01123833
56 SEBU7887-03
Operation Section
Machine Operation

The heating and air conditioning controls are located Autoshift Control (26)
on the switch panel in the upper right side of the cab.

Heater Press the top of switch (25B) in

order to turn on the heater.

Air Conditioner Press the bottom of

switch (25B) in order to turn on the air
conditioner.

Place switch (25B) into the middle position in order to

turn off the heater and air conditioner.

Fan Speed Switch (25C) The switch

controls the speed of the blower fan motor
for the heating and air conditioning system.

LOW Press in the bottom of switch (25C) in order

to turn on the fan blower at the lowest speed.

MEDIUM Place switch (25C) into the middle g01185236

position in order to turn on the fan blower at the Illustration 76
medium speed.
Reference: Refer to Operation and Maintenance
HIGH Press in the top of switch (25C) in order to Manual, Autoshift Control for more information
turn on the fan blower at the highest speed. about autoshift control (26).

Temperature Control Temperature Ride Control (27) (If Equipped)

control knob (25A) is a rotary switch. Turn
knob (25A) clockwise for warmer air. Turn
knob (25A) counterclockwise for cooler air.

Defrost Press the bottom of switch

(25B) in order to turn on the air conditioner.
Set fan speed switch (25C) to the desired
speed. Adjust temperature control knob (25A) so that
the windows remain free of moisture.

g01112310
Illustration 77

Travel at high speeds over rough terrain causes

bucket movement and a swinging motion. The
ride control system acts as a shock absorber by
dampening forces from the bucket. This helps to
stabilize the entire machine.

Ride control switch (27) is located on the switch

panel.

Manual Ride Control Press the bottom

of switch (27) (lower half) in order to turn on
the ride control system at all travel speeds.
Indicator (27A) will be illuminated.
SEBU7887-03 57
Operation Section
Machine Operation

Depress the transmission neutralizer override switch

Automatic Ride Control Press the again in order to enable the transmission neutralizer.
top of switch (27) (upper half) in order to The NEUTRAL LOCK light in the dash will not be
activate the automatic ride control system. illuminated. Depressing the left service brake pedal
The ride control system will automatically turn on if will neutralize the transmission while applying the
the ground speed exceeds 9.6 km/h (6 mph). The service brakes. This will allow the operator to press
ride control system will automatically turn off if the the accelerator pedal in order to increase engine
ground speed is less than 9.6 km/h (6 mph) and if speed for better hydraulic response.
the bucket is being operated. Indicator (27A) will be
illuminated only when the ride control system is on. Secondary Steering (29) (If
The activation speed for the automatic ride control
can be adjusted by a qualified service technician. Equipped)
Reference: Refer to Operation and Maintenance
Place switch (27) into the middle position in order to
turn off the ride control system completely. Manual, Secondary Steering for more information.

The ride control system should be in the automatic Fan Reversing (30) (If Equipped)
mode or in the off position during loading operations.
The auto reversing fan automatically reverses the
Reference: Refer to Hydraulic System, RENR4395, hydraulic fan for 25 seconds after every 20 minute
Ride Control System for more information. interval. Then, the hydraulic fan returns the air flow to
the normal direction. Switch (30) provides a manual
Transmission Neutralizer Override override control that will initiate the purge cycle.
Then, the cycle will reset the timer for the automatic
Switch (28) purge cycle.

The transmission neutralizer override switch is

located on the switch panel on the upper right side of
Heated Mirror (31) (If Equipped)
the cab. The transmission neutralizer override switch
If equipped, heated mirror switch (31) is used in order
is a momentary contact switch.
to activate the heated mirrors.

Switch for the Display Module (32)

Switch (31) is used to scroll through different
categories in the display window of the Caterpillar
Monitoring System. Refer to Operation and
Maintenance Manual, Monitoring System for more
information.

Payload Control System (33) (If

Equipped)
For more information on the Payload Control
g01112345
Illustration 78 System, refer to Operation and Maintenance Manual,
Payload Control System (PCS).
The transmission neutralizer is always enabled
whenever the machine is started. Depress the Fine Modulation (34) (If Equipped)
transmission neutralizer override switch in order to
disable the transmission neutralizer. The NEUTRAL Machines may be equipped with a switch for fine
LOCK light in the dash will be illuminated. modulation. This switch controls the shift speed of
Depressing the left service brake pedal will not the main hydraulic spool. Activating this switch will
neutralize the transmission. If the machine is allow better control in certain applications.
shutdown, the transmission neutralizer override
switch must be pressed again in order to disable the Press the front of the switch in order to enable fine
transmission neutralizer. modulation. Press the rear of the switch in order to
disable fine modulation.
58 SEBU7887-03
Operation Section
Machine Operation

Hydraulic Lockout (35) Side Dump Bucket Control

Press the front of the switch in order to lock the DUMP Move the lever to position 1 in order to
hydraulic bucket controls. The switch is located on dump the bucket.
the right side of the right armrest. Press the rear of
the switch in order to unlock the bucket controls. HOLD The lever will return to position 2 when the
lever is released from position 1 or from position 3.
The attachment will remain in the selected position.
Implement Function (36) (If
Equipped) RETURN Move the lever to position 3 in order to
lower the bucket.
The implement function select switch is located on
the hydraulic control support. The implement function Auxiliary Control
select switch allows the operator to select one of two
functions for the auxiliary control. Left auxiliary hydraulic line Move the lever to
position 1 in order to pressurize the left supply line.
Auxiliary Control (37) (If Equipped)
HOLD The lever will return to position 2 when the
This lever is used for the following implements (if lever is released from position 1 or from position 3.
equipped): The left supply line and the right supply line will not
be pressurized when the lever is in position 2.
Multipurpose bucket
Right auxiliary hydraulic line Move the lever to
Side dump bucket position 3 in order to pressurize the right supply line.

Auxiliary hydraulics Note: Operating instructions for specific attachments

are not provided. The function of the control lever
Logging fork clamp is dependent upon the installation of an Auxiliary
Equipment Manufacturers attachment.

Logging Fork Clamp Control

CLOSE Move the lever to position 1 in order to
close the logging fork clamp.

HOLD The lever will return to position 2 when the

lever is released from position 1 or from position 3.
The attachment will remain in the selected position.

OPEN Move the lever to position 3 in order to open

the logging fork clamp.

Illustration 79
g01131352 Auxiliary Control with Joystick (37)
Machines that are not Equipped with a Joystick (If Equipped)
Multipurpose Bucket Control This thumb wheel is used for the following implements
(if equipped):
CLOSE Move the lever to position 1 in order to
close the bucket. Multipurpose bucket

HOLD The lever will return to position 2 when the Side dump bucket
lever is released from position 1 or from position 3.
The attachment will remain in the selected position. Auxiliary hydraulics

OPEN Move the lever to position 3 in order to open Logging fork clamp
the bucket.
SEBU7887-03 59
Operation Section
Machine Operation

Logging Fork Clamp Control

CLOSE Move the thumb wheel forward in order to
close the logging fork clamp.

HOLD The thumb wheel will return when the

thumb wheel is released. The attachment will remain
in the selected position.

OPEN Move the thumb wheel backward in order to

open the logging fork clamp.

Lift Control (38)

g01113517
Illustration 80

Multipurpose Bucket Control

CLOSE Move the thumb wheel forward in order
to close the bucket.

HOLD The thumb wheel will return when the

thumb wheel is released. The attachment will remain
in the selected position.

OPEN Move the thumb wheel backward in order

to open the bucket.
g01131358
Illustration 81
Side Dump Bucket Control
Float (1) Push the lever forward into the
DUMP Move the thumb wheel forward in order to soft detent. The attachment will follow along
close the bucket. the contour of the ground.

HOLD The thumb wheel will return when the

The lever will return to the HOLD position when the
thumb wheel is released. The attachment will remain
lever is released. The attachment will remain in the
in the selected position.
FLOAT position until the lever is moved at least 6
from the HOLD position.
RETURN Move the thumb wheel backward in
order to lower the bucket.
Note: If the attachment is greater than 305 mm
(12 inch) from the lower kickout position, a kickout
Auxiliary Control will occur when the lift control lever is placed in the
float position. If the attachment is less than 305 mm
Left auxiliary hydraulic line Move the thumb (12 inch) from the lower kickout position, then placing
wheel forward in order to pressurize the left supply the lift control lever in the float detent will cause the
line. attachment to float to the ground.
HOLD The thumb wheel will return when the thumb
wheel is released. The left supply line and the right NOTICE
supply line will not be pressurized when the thumb Never use the FLOAT position to lower a loaded buck-
wheel is released. et.

Right auxiliary hydraulic line Move the thumb Machine damage can result from a bucket that falls
wheel backward in order to pressurize the right too fast.
supply line.
Lower (2) Push the lever forward in
Note: Operating instructions for specific attachments order to lower the attachment. The lever
are not provided. The function of the thumb wheel will return to the HOLD position when the
is dependent upon the installation of an Auxiliary lever is released.
Equipment Manufacturers attachment.
60 SEBU7887-03
Operation Section
Machine Operation

The joystick will return to the HOLD position when

HOLD (3) The lever will return to the the joystick is released. The attachment will remain
HOLD position when the lever is released in the FLOAT position until the joystick is moved at
from the RAISE position or from the least 6 from the HOLD position.
LOWER position. The attachment will remain in the
selected position. Note: If the attachment is greater than 305 mm
(12 inch) from the lower kickout position, a lower
Raise (4) Pull the lever backward in kickout will occur when the joystick control is placed
order to raise the attachment. The lever will in the Float position. If the attachment is less than
return to the HOLD position when the lever 305 mm (12 inch) from the lower kickout position,
is released. then placing the lift control lever in the float detent will
cause the attachment to float to the ground.
The control lever is detented in the fully raised
position. When the lever is moved into the soft NOTICE
detent, the operator will feel an increased resistance Never use the FLOAT position to lower a loaded buck-
from the lever. Once in the detent, the lever should et.
be released in order to automatically return to the
HOLD position. The attachment will continue to raise Machine damage can result from a bucket that falls
until the attachment reaches the lift kickout height. In too fast.
order to manually override the detent, the lever must
be moved at least 6 from the HOLD position. The LOWER (2) Push the joystick forward in
detent will not be activated if the lever is held in the order to lower the attachment. The joystick
detent position for more than 1 second. will return to the HOLD position when the
joystick is released.
The control lever is detented in the FLOAT position.
When the lever is moved into the soft detent, the
HOLD (3) The joystick will return to
operator will feel an increased resistance from the
the HOLD position when the joystick is
lever. Once in the detent position, the lever should
released from the RAISE position or from
be released in order to automatically return to the
the LOWER position. The attachment will remain in
HOLD position. The attachment will continue to lower
the selected position.
until the attachment reaches the kickout height. In
order to manually override the detent, the lever must
be moved at least 6 from the HOLD position. The RAISE (4) Pull the joystick backward in
detent will not be activated if the lever is held in the order to raise the attachment. The joystick
detent position for more than 1 second. will return to the HOLD position when the
joystick is released.

The joystick control is detented in the fully raised

position. When the joystick is moved into the soft
detent, the operator will feel an increased resistance
from the joystick. Once in the detent, the joystick
should be released in order to automatically return
to the HOLD position. The attachment will continue
to raise until the attachment reaches the lift kickout
height. In order to manually override the detent, the
joystick must be moved at least 6 from the HOLD
position. The detent will not be activated if the joystick
is held in the detent position for more than 1 second.

g01115228
The joystick control is detented in the FLOAT position.
Illustration 82 When the joystick is moved into the soft detent, the
Machines that are Equipped with a Joystick operator will feel an increased resistance from the
joystick. Once in the detent position, the joystick
FLOAT (1) Push the joystick forward into should be released in order to automatically return to
the soft detent. The attachment will follow the HOLD position. The attachment will continue to
along the contour of the ground. lower until the attachment reaches the kickout height.
In order to manually override the detent, the joystick
must be moved at least 6 from the HOLD position.
The detent will not be activated if the joystick is held
in the detent position for more than 1 second.
SEBU7887-03 61
Operation Section
Machine Operation

Note: If the attachment is greater than 305 mm The control lever is detented in the full DUMP
(12 inch) from the lower kickout position, a lower position. When the control lever is moved into the soft
kickout will occur When the joystick control is placed detent, the operator will feel an increased resistance
in the FLOAT position. If the attachment is less than from the lever. Once in the detent, the lever should
305 mm (12 inch) from the lower kickout position, be released in order to automatically return to the
then placing the lift control lever in the float detent will HOLD position. The attachment will continue to dump
cause the attachment to float to the ground. until the attachment reaches the digging angle that is
preset by the tilt kickout. In order to manually override
the detent, the control lever must be moved at least
Tilt Control (39) 6 from the HOLD position. The detent will not be
activated if the lever is held in the detent position for
more than 1 second.

Note: A machine with ride control may experience

partial lowering of the lift arms when the lever is
held in the DUMP position with the bucket against
the bucket stops and the lift arms are fully raised.
To avoid partial lowering of the lift arms, return the
lever to the HOLD position. An optional feature can
be enabled to help prevent this situation. Enable
Dump Stop Snubbing by using Caterpillar Electronic
Technician.

g01131362
Illustration 83

DUMP (1) Push the lever forward in order

to dump a load from the bucket.

HOLD (2) When you release the lever,

the lever will return the HOLD position. The
bucket will remain in the selected position.

TILT BACK (3) Pull the lever backward

in order to tilt the bucket backward. g01115229
Illustration 84
Machines that are Equipped with a Joystick
The control lever is detented in the full TILT BACK
position. When the lever is moved into the soft Dump (1) Move the joystick to the right
detent, the operator will feel an increased resistance in order to dump a load from the bucket.
from the lever. Once in the detent, the lever should
be released in order to automatically return to the
HOLD position. The attachment will continue to tilt Hold (2) When you release the joystick,
back until the attachment reaches the digging angle the joystick will return the HOLD position.
that is preset by the tilt kickout. In order to manually The bucket will remain in the selected
override the detent, the lever must be moved at least position.
6 from the HOLD position. The detent will not be
activated if the lever is held in the detent position for Tilt Back (3) Move the joystick to the left
more than 1 second. in order to tilt the bucket backward.
62 SEBU7887-03
Operation Section
Machine Operation

The joystick control is detented in the full TILT BACK Autodig Trigger Switch (40) (If
position. When the joystick is moved into the soft
detent, the operator will feel an increased resistance
Equipped)
from the joystick. Once in the detent, the joystick
Reference: Refer to Operation and Maintenance
should be released in order to automatically return
Manual, Aggregate Autodig for more information on
to the HOLD position. The attachment will continue
the autodig system.
to tilt back until the attachment reaches the digging
angle that is preset by the tilt kickout. In order to
manually override the detent, the joystick must be Transmission Downshift Switch
moved at least 6 from the HOLD position. The detent (41)
will not be activated if the joystick is held in the detent
position for more than 1 second. Reference: Refer to Autoshift Control for more
information.
The joystick control is detented in the full DUMP
position. When the joystick is moved into the soft
detent, the operator will feel an increased resistance Directional Turn Signal (42)
from the joystick. Once in the detent, the joystick
should be released in order to automatically return to
the HOLD position. The attachment will continue to
dump until the attachment reaches the digging angle
that is preset by the tilt kickout. In order to manually
override the detent, the joystick must be moved at
least 6 from the HOLD position. The detent will
not be activated if the joystick is held in the detent
position for more than 1 second.

Note: A machine with ride control may experience

partial lowering of the lift arms when the joystick is
held in the DUMP position with the bucket against
the bucket stops and the lift arms are fully raised.
To avoid partial lowering of the lift arms, return the
joystick to the HOLD position.

Additional Features
Full Rack Angle Control (FRAC)

This feature will prevent the bucket from tilting Illustration 85

g01123877
back too far and spilling material over the back of Conventional steering
the bucket. This feature is normally OFF. Use the
Caterpillar Electronic Technician in order to enable
this feature. This feature is not available on machines
that are equipped with the Payload Control System.

Dump Stop Snubbing

This feature prevents the lift cylinders from retracting

during a dump operation. This feature is normally
OFF. Use the Caterpillar Electronic Technician in
order to enable this feature.

Dump Rate Control

This feature provides a constant rate of dumping

throughout the entire range of travel for the bucket. Illustration 86
g01123878
This will provide a steady flow of material from Command control steering
the bucket. This feature is normally OFF. Use the
Caterpillar Electronic Technician in order to enable A turn signal lever may be mounted on the steering
this feature. column.
SEBU7887-03 63
Operation Section
Machine Operation

Security Management
Directional Turn Signal To activate the
left turn signal, push the turn signal lever The MSS has the capability to allow you to program
forward to position (42A). To activate the the system to automatically activate at different time
right turn signal, pull the turn signal lever rearward periods with different keys. The MSS can also be
to position (42B). Move the turn signal lever to the programmed to reject a specific electronic key after a
center position in order to deactivate either turn selected date and time. When you turn the key to the
signal. OFF position and the MSS is active, you have a 30
second interval in order to restart the machine with
An indicator light on the front dash panel will flash an unauthorized key. Also if the machine stalls, there
when the turn signal is activated. is a 30 second interval for restarting the machine.
This 30 second interval is counted from the time of
turning the key to the OFF position.
Machine Security System (If
Equipped) Note: Know your machines settings because the use
of an electronic key is no guarantee that the machine
can be restarted.
NOTICE
This machine is equipped with a Caterpillar Machine An expiration date can be set for each electronic key
Security System (MSS) and may not start under cer- that is contained in the list of keys for the machine.
tain conditions. Read the following information and The key will no longer start the machine when the
know your machines settings. Your Caterpillar Dealer internal clock in the security system passes the
can identify your machine settings. expiration date. Each entry in the list of keys can
have a different expiration date.
Machine Security System (MSS)
Machines that are equipped with a Spare keys are available from your dealer. Before a
Caterpillar Machine Security System (MSS) key can operate the machine, the MSS must be set
can be identified by a decal in the operator station. to accept that particular key. Contact your Caterpillar
MSS is designed to prevent theft of the machine or dealer for information on additional features of the
unauthorized operation. MSS.

Basic Operation i02163986

MSS may be programmed to read a standard

Battery Disconnect Switch
Caterpillar key or an electronic key. The electronic SMCS Code: 1411
key contains an electronic chip within the plastic
housing for the key. Each key emits a unique
signal to the MSS. The keys can be identified by a
gray housing or a yellow housing. MSS can have
programmed settings to require an electronic key or
a standard Caterpillar key for starting during certain
periods of time.

When the key start switch of the machine is turned

to the ON position, the ECM will read the unique ID
that is stored in the electronic key. The ECM will
then compare this ID to the list of authorized keys.
The following table tells the operator the status for
starting the machine. The status light is located near
the key start switch.
g01105336
Illustration 87
Table 9

Green light The machine will start.

Red light The key is not authorized.

Note: MSS will not shut down the machine after the
machine has started.
64 SEBU7887-03
Operation Section
Machine Operation

i02164035

Backup Alarm
SMCS Code: 7406

g01099181
Illustration 88

The battery disconnect switch is located on the left

side of the machine.
g01105102
Disconnect Switch ON (2) To activate Illustration 89
the electrical system, insert the battery
disconnect switch key and turn the key Backup Alarm The alarm will sound
clockwise. The key for the battery disconnect switch when the transmission direction control
must be turned to the ON position before you start switch is in the REVERSE position. The
the engine. backup alarm is used to alert people behind the
machine when the machine is backing up.
Disconnect Switch OFF (1) To
deactivate the electrical system, turn A three-position adjustable switch that is located on
the battery disconnect switch key the rear of the backup alarm regulates the volume of
counterclockwise to the OFF position. the alarm. The alarm is set at the highest sound level
when the machine is shipped from the factory. Unless
a lower volume is required by the job site, the volume
The battery disconnect switch and the engine start should remain on the High setting.
switch perform different functions. To disable the
entire electrical system, turn the battery disconnect
switch to the OFF position. The battery remains i02578209
connected to the electrical system when you turn off
the engine start switch key. Monitoring System
Turn the battery disconnect switch to the OFF SMCS Code: 7451; 7490
position and remove the key when you service the
machine or when the machine will not be used for an Reference: Refer to Service Manual, SENR1394,
extended period of a month or more. This will help to Caterpillar Monitoring System for detailed service
prevent drainage of the battery. information.

NOTICE
Never move the battery disconnect switch to the OFF
position while the engine is operating. Serious dam-
age to the electrical system could result.

g01099810
Illustration 90
SEBU7887-03 65
Operation Section
Machine Operation

Transmission Oil Temperature (6) This

gauge indicates excessive transmission
oil temperature. If the gauge needle is in
the red area, reduce the load on the machine. If the
gauge needle is in the red area and if the action light
continues to flash after approximately five minutes,
stop the machine and investigate the cause of the
fault.

Hydraulic Oil Temperature (7) This

gauge indicates excessive hydraulic oil
temperature. If the gauge needle is in the
red area, reduce the load on the system. If the gauge
needle remains in the red area, stop the machine and
investigate the cause of the fault.

Fuel Level (8) This gauge indicates the

amount of fuel in the fuel tank. If the gauge
needle is in the red zone, the fuel tank is
g00999626 low on fuel. Refuel the machine as soon as possible.
Illustration 91

The Caterpillar Monitoring System is an electronic Speedometer/Tachometer Display

monitoring system that continuously monitors
machine systems. The monitoring system consists
of the following displays: quad gauge module (1),
speedometer/tachometer display (2), indicator
display (3), and main display module (4).

Quad Gauge Module

g00995829
Illustration 93

Tachometer (9) The tachometer displays the

engine rpm during operation.

Speedometer (10) The speedometer displays the

machine ground speed in mph or in km/h.
g00995828
Illustration 92
Gear/Direction Readout (11) The gear readout
Coolant Temperature (5) This gauge displays the selected transmission gear and the
indicates excessive coolant temperature. selected direction.
If the gauge needle is in the red area, stop
the machine and investigate the cause of the fault.
66 SEBU7887-03
Operation Section
Machine Operation

Indicators

g01099583
Illustration 95
g01098001
Illustration 94
Automatic Pile Detection (21) This
Left Turn Signal (12) This indicator indicator illuminates when the autodig
illuminates when the left turn signal is system is in the automatic pile detection
activated. mode. Automatic pile detection mode is the default
mode for the autodig system. Refer to Operation and
Maintenance Manual, Aggregate Autodig for more
Hazard Lights (13) This indicator
detailed information.
illuminates when the hazard lights are
activated.
Operator Triggered Mode (22) This
indicator illuminates when the autodig
Parking Brake (14) This indicator
system is in the operator triggered mode.
illuminates when the parking brake is
Refer to Operation and Maintenance Manual,
engaged. The indicator should flash during
Aggregate Autodig for more detailed information.
start-up.

Record Mode (23) This indicator

Transmission Failure(15) This indicator
illuminates when the autodig system is in
illuminates when a serious problem exists
the record mode. Refer to Operation and
in the electronic system of the transmission.
Maintenance Manual, Aggregate Autodig for more
Immediately stop the machine. Stop the engine.
detailed information.
Investigate the cause.

Transmission Neutralizer (16) This

indicator illuminates when the transmission
neutralizer is deactivated.

Fuel Level (17) This indicator illuminates

when the machine is low on fuel. Refuel the
machine as soon as possible.

Engine Air Filter (18) This indicator

illuminates when the engine air filter is
clogged.

Floodlights (19) This indicator Illustration 96

g01099619
illuminates when the floodlights are on.
Roading Lights (24) This indicator
illuminates when the roading lights are
Fuel Pressure (20) This indicator activated.
illuminates when the fuel pressure is
extremely high or extremely low. If this Action Light (25) This indicator
indicator flashes during operation, stop the machine illuminates when a fault has been detected
immediately and engage the parking brake. Stop the by the monitoring system.
engine and investigate the cause of fault.
SEBU7887-03 67
Operation Section
Machine Operation

Right Turn Signal (26) This indicator Brake Oil Pressure (34) This indicator
illuminates when the right turn signal is indicates low oil pressure to the brakes. If
activated. this alert indicator flashes, stop the machine
immediately and engage the parking brake. Stop the
Engine Lockout(27) This indicator engine and investigate the cause of the fault .
illuminates when the engine lockout has
been activated. The indicator will also be Electrical System (35) This indicator
illuminated when the machine lockout is activated. illuminates when there is a malfunction in
the electrical system. The system voltage is
Ride Control (28) This indicator too high for normal machine operation or the system
illuminates when the ride control is voltage is too low for normal machine operation.
activated.
If the electrical loads (air conditioning and/or lighting)
Air Inlet Heater (29) This indicator are high and the engine speed is low, then increase
illuminates when the air inlet heater is the engine speed. This will generate more output
activated. from the alternator. If the alert indicator for the
electrical system turns off within one minute, the
electrical system is operating normally. Overload can
High Beam Lights (30) This indicator occur during periods of low engine speeds.
illuminates when the high beams are on.
Revise the operating cycle in order to avoid
overloading the electrical system. Overloading the
Transmission Oil Filter (31) This electrical system could result in discharging the
indicator illuminates when the transmission batteries.
oil filter is clogged.
Reducing loads will also help. Use the medium fan
speed instead of the high fan speed.
Main Display Module
If this procedure does not cause the alert indicator to
turn off, stop the machine and investigate the cause
of the fault. The fault may be caused by an alternator
belt that is loose or broken. Also, the batteries may
be faulty.

If the indicator remains on near normal operating

speeds and with light electrical loads, stop the
machine and investigate the cause of the fault. The
fault may be caused by an alternator belt that is
loose or broken. Also, the batteries or the alternator
may be faulty.

Front and Rear Axle Oil Temperature (36)

g01099763
(if equipped) This indicator illuminates
Illustration 97 when the axle oil temperature is high.
If the alert indicator comes on, change operating
Engine Oil Pressure (32) This indicator techniques or park the machine in order to allow the
indicates low oil pressure. If this alert axle to cool down. If the situation continues, consult
indicator flashes, stop the machine your Caterpillar dealer.
immediately and engage the parking brake. Stop the
engine and investigate the cause of the fault.
Hydraulic Oil Filter (37) This indicator
illuminates when the hydraulic oil filter is
Parking Brake (33) This indicator plugged. If this alert indicator flashes during
illuminates when the parking brake is operation, stop the machine immediately and engage
engaged. The indicator should flash during the parking brake. Stop the engine and investigate
start-up. the cause of the fault.
68 SEBU7887-03
Operation Section
Machine Operation

Hydraulic Oil Level (38) This indicator

indicates low hydraulic oil level. If this alert
indicator flashes during operation, stop the
machine immediately and engage the parking brake.
Stop the engine and investigate the cause of the fault.

High Inlet Air Temperature (39) The air

inlet temperature is too high. If the indicator
illuminates, change operating techniques or
park the machine in order to allow the air cooler to
cool down. If the situation continues, consult your
Caterpillar dealer.

Primary Steering (40) This indicator

illuminates when the oil pressure for the
primary steering is low. The indicator
may also indicate a failure of the primary steering.
The secondary steering (if equipped) should be
automatically activated. If this alert indicator flashes
during operation, stop the machine immediately
and engage the parking brake. Stop the engine and
investigate the cause of the fault.

Do not operate the machine until the fault has been

corrected.

Note: Secondary steering only works while the

machine is moving. Directional changes can be
made when the machine operates under secondary
steering.

Secondary Steering (41) (if equipped)

This indicator illuminates when the
secondary steering is functioning. When
you turn the engine start switch to the ON position,
the alert indicator for the secondary steering will
come on for three seconds. Then, the alert indicator
will go off. If the alert indicator for the secondary
steering does not come on, investigate the cause of
the fault. Do not operate the machine until the fault
has been corrected.

Warning Categories
The Caterpillar Monitoring System provides three
warning categories. The first category requires only
operator awareness. The second warning category
requires an operator response. The third warning
category requires immediate shutdown of the
machine.
SEBU7887-03 69
Operation Section
Machine Operation

Table 10
WARNING OPERATION
Warning Indications (1)

Alert Action Action

Indicator Lamp Alarm
Warning Flashes (3) Flashes(4) Sounds
Category Operator Action Required Possible Result (2)
1 X No immediate action is required. No damage will occur to the
The system needs attention soon. machine. Minor reductions in
machine performance may
occur.
2 X X (4) Change machine operation or Severe damage to
perform maintenance to the system. components can occur.
3 X X (4) X (5) Immediately perform a safe engine Injury to the operator
shutdown. or severe damage to
components can occur.
(1) The active warning indications are marked with an X.
(2) This is the possible result, if the operator takes no action.
(3) The alert indicator flashes at a 10 Hz rate.
(4) The action lamp will flash.
(5) The action alarm sounds.

Functional Test The digital speedometer shows 188 mph and

km/h.
The Caterpillar Monitoring System performs an
automatic internal test when the machine is activated. The indicator lamp is on continuously.
Turning the engine start switch from the OFF position
to the ON position will activate the test. The audible alarm sounds once.
The test verifies proper operation of the outputs The display then goes into the Normal Mode of
(displays, indicator lamps, and audible alarms). operation or the display scrolls through the modes if
the service input and the clear input are grounded or
The internal circuits are automatically checked. the operator switch input is grounded.

The operator must observe the outputs in order

i01770815
to determine whether the displays are operating
properly. The length of time for the test is
approximately three seconds.
Payload Control System (PCS)
SMCS Code: 7494
During this test, the alert indicators flash. Also, the
display window shows the following information: The following information is a brief overview of the
basic functions of the system.
All units of measurement (degrees Celsius, kPa,
miles, km, rpm, and liters)

X10 indicator
Symbol for hour meter
8.8.8.X.8.8. on the digital readout
Note: The hydraulic oil level indicator will not
illuminate during the self test.

The tachometer and the gauge needles ramp straight

up. Then, the gauge needles go to the right and to the
left. The gauge needles then go to the final position.

The gear/direction readout shows an asterisk.

70 SEBU7887-03
Operation Section
Machine Operation

General Operations of the Keypad Note: Display (7) will show WEIGH as the system
measures the load. When the measurement is
complete, the top row of the display shows the weight
of the bucket. The bottom row of the display shows
the total weight for the current truck. If display (7)
shows REW, the load was incorrectly measured.
Complete step 2 accurately. Press REW key (2)
and measure the load again.

3. Dump the load into the truck. Repeat the above

steps until the truck is loaded.

4. Push STORE key (3) in order to save the

payload data in the memory. Display (7) will reset
automatically. The payload display is now ready
for a new truck.

Measuring the Load of a Bucket in

the Stationary Position
Measure the load of the bucket in the stationary
g00905299
position. Adjust the final load of the bucket in order
Illustration 98 to attain the correct load of the truck. Perform one of
the following steps:
CLEAR key (1) Use CLEAR key in order to
exit from a function, or use CLEAR key in order to Dump partial loads back into the pile and use
erase an entry. REW key.
STORE key (3) Use STORE key in order to Dump partial loads into the truck and use EXC
store payload data. Use STORE key in order to key.
make a selection from a menu. Use STORE key in
order to enter a number. The system will calculate the new load of the truck
automatically.
SCROLL key (5) Use SCROLL key in order to
move through options of a menu.
REW Key
NEXT FUNCTION key (6) Use NEXT
FUNCTION key in the setup, service, and calibration 1. Remain at the pile as the measurement of the last
modes. load is performed.

2. If display (7) shows that the total load of the truck

Measuring the Load of a Bucket on is too large, then perform the following procedures:
the Go
Dump some material back into the pile.
1. Push the CLEAR key (1) in order to set display
(7) at zero. Adjust the bucket into the fully tilted back
position.
2. Load the first bucket load. Lift the load from the
horizontal to 0.3 m (1.0 ft) from the upper kickout Raise the lift arms slightly.
height:
Press REW key (2).
Keep the bucket in a fully tilted back position.
Keep the machine and lift arms stationary while
Raise the load at a steady rate in the detent the measurement is performed.
position.
If the total load of the truck is too large, then
Keep the engine speed high when a load is repeat step 2.
lifted for greatest accuracy.
3. Dump the load into the truck and press STORE
Operate the lift arms smoothly and avoid key (3).
sudden stops or jerky motion.
SEBU7887-03 71
Operation Section
Machine Operation

EXC Key i02498234

1. Approach the truck as the measurement of the Automatic Lubrication System

last load is performed. (If Equipped)
2. If display (7) shows that the total load of the truck SMCS Code: 7540
is too large, then perform the following procedures:
S/N: A6G1-Up
Dump some material into the truck.
S/N: A7G1-Up
Adjust the bucket into the fully tilted back S/N: A6J1-Up
position.
S/N: A7J1-Up
Raise the lift arms slightly.
Keep the machine and lift arms stationary while The Caterpillar Automatic TWIN
the measurement is performed. Greasing System
Press EXC key (4) in order to measure the Reference: Refer to System Operation, RENR
additional material to the total load of the truck. 6331 for more information on the Automatic TWIN
Greasing System.
Display (7) will update the total load of the truck
automatically. If the total load of the truck is not The lubrication system consists of the following items:
large enough, then repeat step 2.
Grease pump with integrated control unit
3. Press STORE key (3) and dump the excess
material back into the pile. Distribution blocks with metering units

Additional Features Indicator fault light or an optional mode switch with

an integrated lamp
Reference: More complete information is available
from your Caterpillar dealer. Refer to Operation and The lubrication system will automatically lubricate all
Maintenance Manual, SEBU7012, Payload Control of the points that are connected to the system. The
System for additional features. system is on a timed cycle.

Operator Controls
i02095039

Automatic Lubrication System

(If Equipped)
SMCS Code: 7540
S/N: A6D1-Up
S/N: A7D1-Up

The Lincoln Quicklub Lubrication

System
Reference: For information on the operation and g01059732
Illustration 99
maintenance of the Lincoln Quicklub Lubrication
System, refer to Lincoln REHS1396-01 Instruction
Book or consult your Caterpillar dealer. (1) TWIN display operator control
72 SEBU7887-03
Operation Section
Machine Operation

g01059602 g01056074
Illustration 100 Illustration 102

(2) Low Level The grease reservoir needs to be The lubrication system will automatically lubricate the
refilled. following points:

(3) Error The system is out of operation. This is The linkage pin (8) through the linkage pin (16) for
caused by an empty reservoir or a system failure. the loader bucket
The system can be reset with the test button on the
pump, after the grease reservoir is refilled or repairs The articulation hitch (17) and (19)
have been made.
The steering cylinder pins (18) and (20)
(4) Long grease interval Forty Five Minute
Interval The axle oscillating bearings (21)
(5) Normal grease interval Thirty Minute Interval
i02170053
(6) Short grease interval Fifteen Minute Interval
Aggregate Autodig
To select the required grease interval, press the (If Equipped)
mode button (7) repeatedly until the corresponding
LED illuminates. SMCS Code: 5741

Location of Grease Points

g01056045
Illustration 101

g00810525
Illustration 103
SEBU7887-03 73
Operation Section
Machine Operation

Press the top of operating mode switch (2) in order to

turn on the autodig system. One beep will be heard.
This will indicate that the system is in the automatic
pile detection mode. The switch will return to the
center position. Press the top of switch (2) in order to
toggle the autodig system to the operator triggered
mode. Two beeps will be heard. Press the top of
switch (2) again in order to toggle the autodig system
to the record mode. Three beeps will be heard.

Press the bottom of operating mode switch (2) in

order to turn off the autodig system.

Automatic Pile Detection Mode

g01099863
Illustration 104
The autodig system will be set to the automatic pile
The autodig system is designed to perform the detection mode upon initial activation. This means
operations of a loading cycle of an aggregate mix that the loading cycle will automatically begin when
with minimal effort by the operator. Loading this type the bucket contacts the pile. Indicator (4) will light
of material is generally repetitive and a high level and one beep will be heard when the autodig system
of skill is required to maintain a consistent level of is in the automatic pile detection mode.
productivity during such loading cycles. This feature
will fully load a bucket at consistent loading times. The operator does not need to move the bucket
controls during automatic loading. Lower the bucket
Note: The autodig system is only available on to the ground. Drive the machine into the pile. Do not
machines that are equipped with electrohydraulic move any of the controls. The autodig system will
bucket controls and command control steering. automatically load the bucket. An audible alarm will
briefly sound at the beginning of the loading cycle
Each position of dig mode switch (1) is programmed and at the end of the loading cycle. The machine can
with the appropriate transmission speed for loading now be driven to the hauling unit.
various types of material. The autodig system will only
function up to the third speed. The autodig system Operator Triggered Mode
will downshift the transmission to the proper speed.
Only settings one and two are allowed in second
speed. All nine settings are allowed in first speed.

Note: If the transmission is in first speed and dig

mode switch (1) is programmed for second speed,
the autodig system will not upshift the transmission.

Kickout set switch (3) will record the position of the

lift linkage at the end of a loading cycle. If the kickout
height has been set successfully, one beep will be
heard. If setting the kickout height is unsuccessful,
multiple beeps will be heard.

Operating Modes of the Autodig Illustration 105

g01116225

System
Dig mode switch (1) allows the operator to select
different settings for different types of material for
loading. Rotate the switch counterclockwise in order
to load light material. Rotate the switch clockwise in
order to load heavy material. Intermediate positions
are available. The settings for the first nine positions
are preset. An operators own discretion is advised.
74 SEBU7887-03
Operation Section
Machine Operation

5. Enter the pile and load the bucket manually. While

the bucket is being loaded indicator (6) will flash
slowly. The record mode will capture the lowest
active speed. This speed will be used during the
loading cycle.

6. After loading the bucket, press trigger switch (7) to

complete recording of the loading cycle. Loading
the bucket plus pressing the switch must be done
within 20 seconds. If the trigger switch is not
pressed in this time, the loading cycle will go back
to the previously recorded cycle or the default.

7. If the commands were recorded successfully the

g01132686
autodig system will automatically return to the
Illustration 106 automatic pile detection mode. One long beep
indicates an unsuccessful recording.
The operator may desire to start the autodig system
manually. Playback Steps
1. Rotate dig mode switch (1) in order to select the 1. Toggle operation mode switch (2) until the desired
desired load setting. mode is selected.
2. Toggle the top of operating mode switch (2) in 2. Choose position 10 on dig mode switch (1).
order to place the system in the operator triggered
mode. Two beeps will be heard. Indicator (5) will 3. Keep the same parameters as you approach the
light. pile. Do not touch the bucket levers, the neutralizer
pedal, or the directional controls until the bucket is
3. With the autodig system in the operator triggered fully racked back or the lift arms have reached the
mode, drive into the pile. Press trigger switch (7) autodig systems kickout height.
in order to activate the loading cycle. An audible
alarm will briefly sound at the beginning of the 4. If the operator triggered mode has been selected
loading cycle and at the end of the loading cycle. it will be necessary to press trigger switch (7) as
The machine may be driven to the hauling unit you enter the pile.
when the lift cycle is completed.
5. At any time, the operator may take control by
Record Mode moving the lift lever, the tilt lever, or the joystick.

The operator may record a load cycle that will be Note: The initial settings for the tenth position are
used in place of the preset load cycle. Position 10 is identical to the settings for the ninth position. The
dedicated to the record mode. tenth position can no longer be set back to the default
parameters after the record mode has been utilized.
Record Steps

1. Place dig mode switch (1) into the tenth position

by rotating the switch fully clockwise.

2. Toggle the top of operating mode switch (2) until

three beeps are heard. Indicator (6) will illuminate
on the dash. This indicates that the system is in
the record mode.

3. Position the machine in front of the pile with the

bucket in the dig position.

4. In order to begin recording, press trigger switch

(7). The trigger switch is located near the bucket
controls. A loading cycle must be performed within
20 seconds of pressing the trigger switch.
SEBU7887-03 75
Operation Section
Machine Operation

i02101862 Left Brake Pedal Operation

Service Brake Control The functions of the left brake pedal depend on the
position of the left brake pedal and on the position of
SMCS Code: 4251; 4265; 4269; 4800 the autoshift switch.

g00904188
Illustration 107

Right Service Brake Pedal

The right service brake pedal is used to slow down
the machines ground speed when the operator
does not wish to have the transmission downshift Illustration 108
g00904123
aggressively.
(A) Initial Travel
(B) Downshifting and Service Brake Application
The right service brake pedal is normally used for (C) Additional Travel (application of service brakes)
braking when the autoshift transmission control is (1) Calibrated Initial Brake Pressure Point
downshifting adequately. (2) Set Point for Neutralization
(3) Pedal Position for Stopping the Machine
(4) Maximum Pedal Travel (full application of service brakes)
Left Brake Pedal
Initial travel (A) of the left brake pedal will cause
The left service brake pedal provides three braking the transmission to aggressively downshift. The
functions: transmission will downshift to the lowest available
speed. The lowest available speed depends on
Aggressive Automatic Downshifting of the the position of the autoshift switch. Refer to Table
Transmission 11 for the lowest available speed. Each downshift
of the transmission will reduce the speed of the
Neutralization of the Transmission machine. The transmission will downshift at higher
speeds than the normal automatic downshift speeds.
Conventional Braking The transmission will only downshift if an engine
overspeed will not occur. The transmission will not
The left brake pedal is used to initiate automatic upshift until the left brake pedal is fully released.
downshifting of the transmission at higher ground
speeds than the standard automatic downshifting. The transmission will be engaged again after the left
brake pedal is released 4 degrees from maximum
When the left service brake pedal is depressed pedal position (3). This will only happen if the
beyond a certain point, automatic downshifting and transmission was neutralized. The service brakes will
neutralization of the transmission will occur for all still be applied. This will allow the transmission to be
positions of the autoshift switch. The automatic engaged when the brakes are applied. This will help
downshifting and the neutralizing of the transmission to prevent unwanted movement while you are on a
saves wear on the service brakes, axles, and slope.
components of the power train.
Note: You should wait at least one second after
Use the left brake pedal for most conditions when releasing the left brake pedal to 4 degrees before
adequate traction is available. completely releasing the pedal. This will allow the
transmission to fully engage.
76 SEBU7887-03
Operation Section
Machine Operation

Depressing the left pedal will neutralize the

transmission again.

Note: The left brake pedal requires calibration if

the pedal was replaced. The neutralization of the
transmission can also be adjusted.

Reference: For more information on calibration of

the left brake pedal, refer to Power Train Testing
and Adjusting, Position Sensor (Left Brake Pedal)
Calibrate.

Command Control Steering

g00904125
Illustration 109
Autoshift Switch

Table 11

Modes of Operation for the Transmission Neutralizer

Autoshift Switch Manual Mode (1) 4 3 2 1-4

4th-3rd-2nd-
Shift Pattern 4th-3rd-2nd 4th-3rd-2nd 3rd-2nd None
1st
Neutralizer Gear 2nd 2nd 2nd 2nd 1st

When the left brake pedal is fully released, the

transmission will return to normal operation. The
transmission will remain in the current speed if the
autoshift switch is in MANUAL (1).
SEBU7887-03 77
Operation Section
Machine Operation

Conventional Steering

g00889068
Illustration 110
Autoshift Switch

Table 12

Modes of Operation for the Transmission Neutralizer

Autoshift Switch Manual Mode 2-4 1-4
4th-3rd-2nd-
Shift Pattern 4th-3rd-2nd 4th-3rd-2nd
1st
Neutralizer Gear 2nd 2nd 1st

When the left brake pedal is fully released, the

transmission will return to normal operation. The
transmission will upshift to the selected speed by way
of the transmission control on the steering column.
78 SEBU7887-03
Operation Section
Machine Operation

i02266498 Reference: For additional information about the

functionality of the left service brake pedal, refer to
Autoshift Control the Operation and Maintenance Manual, Service
Brake Control for the machine that is being serviced.
SMCS Code: 4800; 7451-ZS
Manual Shifting
Move the autoshift switch into the MANUAL position
(1). Depressing the left service brake pedal will cause
the transmission to downshift. If the transmission
neutralizer has not been disabled, the transmission
will also neutralize as the machine slows down.

The operator must use the transmission speed

selector in order to change transmission speeds.

Automatic Shifting (Command

Control Steering)
Move the autoshift switch into one of the four
automatic positions (2).

When the autoshift switch is in the 2, 3, or 4 position,

the lowest allowable speed for the transmission is
g00888770
SECOND speed. The transmission will shift into
Illustration 111 SECOND after a change in direction. When the
Command Control Steering autoshift switch is in the 1 through 4 position, the
lowest allowable speed for the transmission is FIRST
speed. The transmission will shift into FIRST after a
change in direction.

Note: The machine can be electronically configured

by a Caterpillar dealer to start in SECOND after a
change in direction when the autoshift switch is in
the 1 through 4position.

Depressing the left service brake pedal will cause

the transmission to downshift. If the transmission
neutralizer has not been disabled, the transmission
will also neutralize. Fully releasing the left service
brake pedal will allow the machine to return to
automatic shifting.

Automatic Shifting (Conventional

Steering)
Move the autoshift switch into one of the two
g00888822 automatic positions (2).
Illustration 112
Conventional Steering When the autoshift switch is in the 2 through
4 position, the lowest allowable speed for the
The autoshift switch determines if the transmission transmission is SECOND speed. The transmission
will be shifted manually or if the transmission will will shift into SECOND after a change in direction.
be shifted automatically. The autoshift switch also When the autoshift switch is in the 1 through
determines the functionality of the left service brake 4 position, the lowest allowable speed for the
pedal. transmission is FIRST speed. The transmission will
shift into FIRST after a change in direction.
SEBU7887-03 79
Operation Section
Machine Operation

Note: The machine can be electronically configured Downshifting (Conventional

by a Caterpillar dealer to start in SECOND after a
change in direction when the autoshift switch is in
Steering)
the 1 through 4 position.

Depressing the left service brake pedal will cause

the transmission to downshift. If the transmission
neutralizer has not been disabled, the transmission
will also neutralize. Fully releasing the left service
brake pedal will allow the machine to return to
automatic shifting.

Downshifting (Command Control

Steering)

g01136837
Illustration 114
Downshift Switch for Machines That are Equipped with a Joystick

g00888840
Illustration 113
Transmission speed selector with command control steering

Manual Shifting
g01132692
Illustration 115
Press the bottom of the transmission speed selector
Downshift Switch for Machines that are Not Equipped With a
that is located on the left side of the steering wheel in Joystick
order to downshift the transmission. The transmission
speed selector can be used to downshift from
SECOND to FIRST in order to load the bucket. The Manual Shifting
transmission will shift into FIRST speed in order to
back away from the pile. The downshift switch can be used to downshift the
machine from SECOND to FIRST in order to load
the bucket. The downshift switch is active when
Automatic Shifting the transmission speed selector lever is set to
SECOND speed. The transmission will remain in the
Press the bottom of the transmission speed selector downshifted speed for three seconds after the switch
that is located on the left side of the steering wheel in is released. The transmission will then shift back into
order to downshift the transmission. The transmission SECOND. The transmission will shift into FIRST if
speed selector can be used to downshift from the direction of the machine is changed within the
SECOND to FIRST in order to load the bucket. The three second interval.
machine will remain in FIRST speed until either the
machine changes direction or the operator manually Note: The transmission will only downshift if an
upshifts the machine. engine overspeed will not occur.
Note: The transmission will only downshift if an
engine overspeed will not occur.
80 SEBU7887-03
Operation Section
Machine Operation

Automatic Shifting 3. Pull up on the toggle switch. Move the toggle

switch to position (3) in order to lower the hood.
The downshift switch can be used to downshift from Hold the switch in this position until the hood is
SECOND to FIRST in order to load the bucket. The fully closed. Release the toggle switch. The toggle
downshift switch is located near the bucket controls. switch will return to the middle position.
The downshift switch is located on the joystick on
machines that are equipped with a joystick. The Note: Do not continue to hold the toggle switch in
downshift switch is active when the autoshift switch the open or in the closed position after movement
is in the automatic modes (2). The transmission will of the hood has stopped. When audible clicks are
remain in the downshifted speed for five seconds heard, release the toggle switch. Failure to release
after the switch is released. Then, automatic shifting the toggle switch will result in damage to the actuator.
will resume.
Manual Operation
i02173758
The hood can be operated manually by using a
Hood Tilt socket head and an air wrench to turn the shaft of the
lift motor. The manual control is located on the right
SMCS Code: 7251-T2; 7275 rear side of the machine.

g01099226 g00882974
Illustration 116 Illustration 118

1. Remove two bolts. Remove the cover.

2. Insert a socket head through the hole and

onto the shaft of the lift motor. Turn the shaft
clockwise in order to raise the hood. Turn the shaft
counterclockwise in order to lower the hood.

g01123573
Illustration 117

The switch that controls the engine hood is located in

a compartment on the left side of the machine.

1. Open the access door.

2. Pull up on the toggle switch. Move the toggle

switch to position (1) in order to raise the hood .
Release the toggle switch. The toggle switch will
return to the middle position (2).
SEBU7887-03 81
Operation Section
Machine Operation

i02173972

Roading Fender Control

Personal injury or death can result from falling ma-
SMCS Code: 7252 terial.

Remove any overhang and watch for sliding ma-

terial.

NOTICE
Do not doze with the bucket in the tilt forward position
to avoid bucket damage.

NOTICE
Striking the stops unnecessarily and repetitively can
result in accelerated wear and high maintenance cost
of the loader linkage.

g01101600
Illustration 119
Downhill Operation
1. Push lever (1) in order to unlock roading fender
(2). Maintain a ground speed that is slow enough for the
conditions. Before you operate down a hill, select the
2. Swing roading fender (2) away from the machine proper gear before you start down the grade. The
in order to access the engine compartment. proper gear should allow the machine to maintain the
appropriate speed on the down grade. The throttle
3. Move roading fender (2) back to the machine and control should be at high idle and the engine should
lock the roading fender in the operating position. not overspeed. In most situations, the proper gear
will be the same gear that is required to drive up the
grade.
i02436951
If the machine builds up excessive speed, the engine
Operation Information can overspeed. This can result in damage to the
engine and/or damage to the power train data link.
SMCS Code: 7000 Use the service brake or the engine brake in order to
slow the machine until a lower gear can be selected.
Follow these basic instructions whenever you are Select the lower gear and proceed with the throttle
operating the machine: control at high idle.
To prevent injury, make sure that no one is working Use the service brakes for stopping the machine.
on the machine or near the machine. Always Using the service brakes in order to control the travel
maintain control of the machine. speed of the machine or using the service brakes for
stopping from high speeds can cause the brake and
Raise the bucket or the work tool enough to axle oil to overheat. This can result in significant wear
negotiate any obstacles. and/or damage to the service brakes.
Before you release the parking brake, depress the Note: The left pedal should not be used for downhill
service brake pedal in order to keep the machine braking.
from moving.

Drive the machine forward for best visibility and Changing Direction and Speed
for best control.
Speed changes at full engine speed and directional
Reduce the engine speed when you maneuver in changes at full engine speed are possible. However,
tight quarters and when you are going over a hill. when you change directions, deceleration will
maximize the comfort of the operator. In order
Note: When the machine is using biodegradable to control the throttle, use the left brake pedal to
hydraulic oil, operation at ambient temperatures decelerate. Deceleration will also maximize the
above 32 C (90 F) should be limited to light duty service life of power train components.
cycles and short periods of time.
82 SEBU7887-03
Operation Section
Machine Operation

i01676264 i01772851

Changing Direction and Speed Secondary Steering

SMCS Code: 1000; 7000 SMCS Code: 7000

Speed changes at full engine speed and directional

changes at full engine speed are possible. However,
when you change directions, deceleration will
maximize the comfort of the operator. In order
to control the throttle, use the left brake pedal to
decelerate. Deceleration will also maximize the
service life of power train components.

i01732114

Parking Brake
SMCS Code: 7000

Personal injury could result from the sudden stop

of the machine. The parking brake is automatically
engaged when brake oil pressure drops below an
adequate operating pressure. g00906417
Illustration 121

Alert indicator (1) indicates a failure of the primary

steering. When alert indicator (2) flashes, the
secondary steering system is active. When the alert
indicators come on and the action alarm sounds,
steer the machine immediately to a convenient
location and stop the machine. Stop the engine and
investigate the cause of the failure. Do not operate
the machine until the cause of the failure has been
corrected.

The Caterpillar Monitoring System will perform a self

test of the secondary steering during engine start-up.
Alert indicator (2) will come on for three seconds in
g00888993
order to verify the pressurization of the secondary
Illustration 120 steering system. The action alarm will sound until the
The alert indicator for the brakes is on the dash panel. end of the self test or until the engine is started.

If the brakes lose oil pressure, an alert indicator for The secondary steering system can be tested
the brakes will flash and an action alarm will sound. manually. Push secondary steering switch (3) in order
to determine whether the secondary steering system
Anticipate a sudden stop. Correct the cause of the and the alert indicator are functional. When the
loss of oil pressure. Do not operate the machine secondary steering switch is pushed, the secondary
without normal brake oil pressure. steering motor will run. Alert indicator (2) will come
on and the action alarm will sound. If alert indicator
The action light will also flash when the lights on the (2) does not come on or the action alarm does not
monitoring system flash. sound, do not operate the machine.

NOTICE
Moving the machine with the parking brake engaged
can cause excessive wear or damage to the brake.

If necessary, have the brake repaired before operating

the machine.
SEBU7887-03 83
Operation Section
Engine Starting

Engine Starting Engine Starting with Ether Starting

Aid (If Equipped)
i02694916
NOTICE
Engine Starting Inject starting aid (ether), only while cranking the en-
gine, or after initial start-up, until the engine is running
SMCS Code: 1000; 7000 smoothly.

1. Make sure that the transmission control is in the Use sparingly, excessive ether without cranking can
NEUTRAL position. cause piston and ring damage.

2. Move the steering column to the desired position. Wait approximately two seconds before injecting
again.
3. Engage the parking brake.
Use ether for cold starting purposes only.
4. Fasten the seat belt.
After every 30 seconds of engine cranking, allow two
5. Make sure that the control levers are in the HOLD minutes for starting motor to cool before cranking
position. again.

6. Before the engine is started, check for the Turbocharger damage can result, if the engine rpm is
presence of bystanders or maintenance not kept low until the engine oil light/gauge verifies the
personnel. Ensure that all personnel are clear oil pressure is sufficient.
of the machine. Briefly sound the forward horn
before you start the engine.
1. Follow Step 1 through Step 7 of the Engine
7. Turn the engine start switch to the START position Starting Procedure.
in order to start the engine.
A premeasured amount of ether will be
Note: Do not depress the accelerator pedal during automatically injected if the ambient conditions
engine starting. call for starting aid.

8. Release the engine start switch key after the 2. Release the engine start switch key after the
engine starts. engine starts.

Note: Machines with conventional steering and For starting below 18C (0F), the use of one of the
electrohydraulic controls refer to Engine Starting following cold weather starting aids is recommended:
for Conventional Steering with Electrohydraulic
Controls. Coolant heater

NOTICE Fuel heater

Do not crank the engine for more than 30 seconds. Al-
low the starter to cool for two minutes before cranking Jacket water heater
again. Turbocharger damage can result if the engine
rpm is not kept low until the oil gauge display verifies Extra battery capacity
that the oil pressure is sufficient.
Reference: At temperatures below 23C (10F),
consult your Caterpillar dealer for additional
information or refer to Special Publication,
SEBU5898, Cold Weather Recommendations.

Engine Starting for Conventional

Steering with Electrohydraulic
Controls
Neutral Start
In order to start the machine, the following items must
be in the NEUTRAL position:
84 SEBU7887-03
Operation Section
Engine Starting

The shift lever that is mounted on the column The hydraulic oil will warm up faster, if the bucket
control is held in the CLOSE position for short periods
The forward/neutral/reverse switch that is mounted of ten seconds or less. This will allow the hydraulic oil
next to the implement controls to reach relief pressure, which causes the hydraulic
oil to warm up more rapidly.
The parking brake
Cycle all controls in order to allow warm hydraulic
Special Operating Modes oil to circulate through all hydraulic cylinders and
through all hydraulic lines.
The shifter must be in the NEUTRAL position in order
to start the machine. The forward/neutral/reverse When you idle the engine in order to warm up the
switch must be in the NEUTRAL position in order to engine, observe the following recommendations:
start the machine. If either device is not in NEUTRAL
position the machine will not start and the neutral Allow the engine to warm up for approximately 15
lamp will be OFF. minutes when the temperature is higher than 0C
(32F).

i01916324 Allow the engine to warm up for approximately 30

minutes or more when the temperature is below
Engine and Machine Warm-Up 0C (32F).
SMCS Code: 1000; 7000
More time may be required if the temperature is
less than 18C (0F). More time may also be
After the engine has been started, allow the required if the hydraulic functions are sluggish.
monitoring system to complete the self test.

g00998329
Illustration 122

NOTICE
Keep engine speed low until the engine oil pressure
alert indicator goes out. If the alert indicator does not
go out within ten seconds, stop the engine and inves-
tigate the cause before starting again. Failure to do so
can cause engine damage.

1. Allow a cold engine to warm up at LOW

IDLE for at least five minutes. To help the
hydraulic components to warm up faster, engage
the attachment controls and disengage the
attachment controls.

2. Look at the indicators and the gauges frequently

during operation.
SEBU7887-03 85
Operation Section
Parking

Parking i02174138

Stopping the Engine if an

i01358133 Electrical Malfunction Occurs
Stopping the Machine SMCS Code: 1000; 7000
SMCS Code: 7000
Turn the engine start switch into the OFF position. If
the engine does not stop, an electrical malfunction
NOTICE exists.
Do not engage the secondary brake while the machine
is moving unless the primary service brake fails.

The use of the secondary brake as a service brake

in regular operation will cause severe damage to the
brake system.

1. Park the machine on a level surface. If it is

necessary to park on a grade, block the wheels.

2. Apply the service brakes in order to stop the

machine.

3. Move the transmission control to the NEUTRAL

position. Illustration 123
g01101611

4. Engage the parking brake. An emergency shutdown switch is located at the left
center of the machine. Move the switch upward in
5. Lower the work tool to the ground and apply slight order to stop the engine.
downward pressure.

i02184463
i00982184

Stopping the Engine Equipment Lowering with

Engine Stopped
SMCS Code: 1000; 7000
SMCS Code: 7000
NOTICE
Stopping the engine immediately after it has been 1. Turn the engine start switch to the ON position.
working under load, can result in overheating and ac-
celerated wear of the engine components. 2. Move the hydraulic lockout control to the
UNLOCKED position.
See the following stopping procedure, to allow the en-
gine to cool, and to prevent excessive temperatures 3. Push the lift control to the LOWER position in
in the turbocharger center housing, which could cause order to lower the bucket or the work tool to the
oil coking problems. ground. The lift control will return to the HOLD
position when the control lever is released.

1. While the machine is stopped, run the engine for 4. Move the hydraulic lockout control to the LOCKED
five minutes at low idle. This allows hot areas of position.
the engine to cool gradually.
5. Turn the engine start switch to the OFF position.
2. Turn the engine start switch to the OFF position
and remove the key. Note: If the work tools will not lower, the pilot supply
on/off solenoid may be inoperable. In this case,
proceed to Step 6.
86 SEBU7887-03
Operation Section
Parking

i02063754

Leaving the Machine

Personal injury or death may occur from failure to
adhere to the following warnings. SMCS Code: 7000
Keep all personnel away from the boom drop area 1. Use the steps and the handholds when you get
when lowering the boom with the engine stopped. off the machine. Face the machine and use both
hands. Make sure that the steps are clear of
Keep all personnel away from the front linkage debris before you dismount.
when lowering the boom.
2. Inspect the engine compartment for debris. Clean
out any debris and paper in order to avoid a fire.

3. Remove all flammable debris in order to reduce a

fire hazard. Dispose of all debris properly.

4. Turn the battery disconnect switch to the OFF

position. If the machine will not be operated for an
extended period of a month or more, remove the
battery disconnect switch key.

5. Install all covers and all vandalism protection

locks.

g01105125
Illustration 124

g01105280
Illustration 125

6. A ball valve is located near the right rear of the

main control valve. This ball valve is used for
manually lowering the work tool. Slowly turn the
square stem in the clockwise direction. The
square stem should be rotated 90 degrees. After
the work tool is resting on the ground, rotate the
square stem counterclockwise.
SEBU7887-03 87
Operation Section
Transportation Information

Transportation Information 8. Lock the door and the access covers. Attach any
vandalism protection.

i01671778 9. Secure the machine, any equipment, and any

tools with adequate tie-downs in order to prevent
Shipping the Machine movement during shipping.
SMCS Code: 7000; 7500 10. Cover the exhaust opening. The turbocharger (if
equipped) should not rotate when the engine is not
Investigate the travel route for overpass clearances. operating. Damage to the turbocharger can result.
Make sure that there will be adequate clearance if
the machine that is transported has a ROPS, a cab,
or a canopy. i01998604

Remove ice, snow, or other slippery material from Roading the Machine
the loading dock and from the transport machine
before you load the machine. This will help to prevent SMCS Code: 7000
slippage of the machine. This will also help to prevent
a shift while the machine is moving in transit. Check with the proper officials in order to obtain
the required licenses and other similar items before
Obey the appropriate laws that govern the parameters roading the machine.
of the load (weight, width, and length).
Complete a thorough daily inspection before you
mount the machine and before you start the engine.

Reference: For more information, refer to Operation

and Maintenance Manual, Daily Inspection.

Carry the work tool as low to the ground as possible.

Disable the controls for the work tool when the
machine is roaded.

Limitations for TON-kilometer per hour (TON-mile per

hour) must be obeyed. Before roading, consult your
tire dealer for recommended tire pressures and for
speed limitations of the tires.

Illustration 126
g00863991 Inflate the tires to the correct pressure. Use a
self-attaching inflation chuck in order to inflate the
Properly chocked trailer wheels
tire. Stand behind the tire tread while you inflate the
tires.
1. Chock the trailer wheels or the rail car wheels
before you load the machine.
Reference: For more information, refer to the
Operation and Maintenance Manual, Tire Inflation
2. After the machine is positioned, connect the
Information.
steering frame lock in order to hold the front frame
and the rear frame in place.
When you road for long distances, schedule stops in
order to allow the tires and the components to cool.
3. Lower the bucket or the work tool to the floor of the
Stop for 30 minutes after every 40 km (25 miles) or
transport vehicle. Move the transmission control
after every hour.
to the NEUTRAL position.

4. Engage the parking brake. i02096860

5. Turn the engine start switch to the OFF position. Implement Restraint (Roading)
Remove the engine start switch key.
SMCS Code: 6001; 6107; 7000
6. Move all of the control levers in order to relieve
any trapped pressure. The United Kingdom requires all machines that have
a height that is greater than 3 m (9.8 ft) or machines
7. Turn the battery disconnect switch to the OFF that have elevating equipment that can exceed 3 m
position. Remove the battery disconnect switch (9.8 ft) in height to be equipped with a locking device
key. that cannot be operated from the cab.
88 SEBU7887-03
Operation Section
Transportation Information

The restraint is provided with the machine in order to Installation of the Implement
restrain the lift arm in the travel position. Install the
restraint between the lift arm and the work tool when
Restraint
you are travelling on public roads. Use the restraint
only in accordance with the following instructions:

The restraint does not replace any existing form of

restraint that is provided with this machine.

The restraint does not supersede any existing form

of restraint that is provided with this machine.

The restraint does not replace any existing feature

that will disable the machine.

All existing restraining devices must continue to

be used in accordance with the Operation and
Maintenance Manual.

Keep the restraint with the machine at all times.

Inspect the restraint regularly for damage. Any
damaged components should be replaced
immediately.

Do not operate the lift arm while the restraint is

installed. Activate the hydraulic lockout control after
the restraint is installed. Activating the hydraulic
lever lock will neutralize the pilot system operation.

Use the restraint only when you are roading the

machine. The restraint must not be used for any Illustration 127
g00587686
other function or operation.
1. Position the lift arm in position for machine
After you reach your destination, remove the roading.
restraint before you operate the lift arm.
2. Attach one end of the restraint (3) to the block (1)
that is located on the work tool.

3. Attach the opposite end of the restraint (3) to the

lifting eye (4) on the left side of the loader frame.

4. Secure the restraint with the ratchet (2). Tighten

the ratchet in order to remove excess slack. Do
not overtighten the restraint.

5. Release the ratchet by pulling the locking plate

toward the handle.
SEBU7887-03 89
Operation Section
Transportation Information

i02696995
Tie Down Point In order to tie down the
Lifting and Tying Down the machine, attach the tie-downs to the tie
Machine down points.

SMCS Code: 7000; 7500 Use properly rated cables and properly rated slings
to lift the machine.

Position the crane or the lifting device in order to lift

Improper lifting and improper tie-downs can allow the machine in a level position.
the load to shift or fail and cause injury or damage.
Use only properly rated cables and slings with lift The width of the spreader bar must be sufficient to
and tie down points provided. prevent the lifting cables or the lifting straps from
contacting the machine.
Follow the instructions in Operation and Main-
tenance Manual, Lifting and Tying Down the 1. Engage the parking brake before you sling the
Machine for the proper technique for securing machine and before you secure the machine with
the machine. Refer to Operation and Maintenance tie-downs.
Manual, Specifications for specific weight in-
formation. 2. Install the frame lock pin prior to lifting the
machine.

3. Attach two lifting cables to the rear of the machine.

There is one lifting eye on each side of the rear of
the machine. The lifting eyes are identified by a
label that shows a hook.

4. Attach two lifting cables to the front of the machine.

There is one eye on each side of the front of the
machine. The lifting eyes are identified by a label
that shows a hook.

5. Connect the four lifting cables to the spreader

bars. The spreader bars must be centered over
the machine.
g00285597
Illustration 128 6. If equipped, secure any attachments.

NOTICE 7. Lift the machine. Move the machine to the desired

Improper lifting or tie-downs can allow the load to shift position.
and cause injury or damage. Install the steering frame
lock link before lifting. 8. When the machine is positioned, place the blocks
behind the tires.
Note: Do not use handles or steps in order to lift or 9. Secure the machine at the tie-down positions. The
tie down the machine. positions are identified on the machine by a label.
Note: The machine shipping weight that is listed is Check all of the laws that govern the load
the weight of the most common configuration of the characteristics (height, weight, width, and length).
machine. If attachments have been installed on your
machine, the weight of your machine and the center Reference: For shipping instructions, refer to
of gravity of your machine may vary. Operation and Maintenance Manual, Shipping the
Machine.
Reference: Refer to Operation and Maintenance
Manual, Specifications for the dimensions and
weight of the machine.

Lifting Point In order to lift the machine,

attach the lifting devices to the lifting points.
90 SEBU7887-03
Operation Section
Towing Information

Towing Information Do not use a chain for pulling. A chain link may break.
This can cause personal injury. Use a wire rope that
has cable loops or end rings. Position an observer at
i01766533 a safe location. The observer should stop the pulling
procedure if the cable starts to break or the cable
Towing the Machine starts to unravel. If the towing machine moves without
the pulled machine, stop the pulling procedure.
SMCS Code: 7000
Keep the tow line angle to a minimum. Do not exceed
a 30 degree angle from the straight ahead position.

Personal injury or death could result when towing Quick machine movement could overload the tow
a disabled machine incorrectly. line or the tow bar. This could cause the tow line
or the tow bar to break. Gradual, smooth machine
Block the machine to prevent movement before movement works better.
releasing the brakes. The machine can roll free if
it is not blocked. Normally, the towing machine should be as large
as the disabled machine. The towing machine must
have enough brake capacity, enough weight, and
enough power for the grade that is involved and for
the distance that is involved.
Personal injury or death can result from brake
malfunction. It may be necessary to connect a larger machine or
additional machines to the disabled machine in order
Make sure all necessary repairs and adjustments to provide sufficient control and sufficient braking.
have been made before a machine that has been This will prevent the disabled machine from rolling
towed to a service area, is put back into operation. away out of control on a downgrade.

The requirements for all different situations cannot

To properly perform the towing procedure, use the be specified. Minimal towing machine capacity is
following recommendations. required on smooth, level surfaces. Maximum towing
machine capacity is required on inclines or on poor
This machine is equipped with spring applied, oil surface conditions.
pressure released parking brakes. If the engine or
the brake oil system is inoperable, the parking brakes Any towed machine with a load must be equipped
are applied and the machine can not be moved. with a braking system that can be operated from the
operator compartment.
Use these towing instructions for moving a disabled
machine over a short distance of 8 kilometers Consult your Caterpillar dealer for more information
(5 miles) or less. Do not move the machine faster than about towing a disabled machine.
3 km/h (2 mph). Move the machine to a convenient
location for repair. Always haul the machine if long
distance moving is required. Towing with a Running Engine
Shielding must be provided on the towing machine in If the engine is running, the machine can be towed for
order to protect the operator in case the tow line or a short distance under certain conditions. The power
the tow bar breaks. train and the steering system must be operable.
Tow the machine for a short distance only. For
Do not allow riders on a machine that is being towed example, pull the machine out of mud or to the side
unless the operator can control the steering and/or of the road.
the braking.
The operator on the towed machine must steer the
Before you tow the machine, inspect the tow line or machine in the direction of the tow line.
the tow bar. Make sure that the tow line or the tow bar
is sturdy enough for towing the disabled machine. Carefully obey all of the instructions that are outlined
The tow line or the tow bar must have a strength that in this topic.
is equal to 1.5 times the gross weight of the machine
that is being towed.
SEBU7887-03 91
Operation Section
Towing Information

Towing with a Stopped Engine Reference: For information about the manual
release of the parking brake, refer to Operation
and Maintenance Manual, Parking Brake Manual
NOTICE
Release.
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
4. Fasten the tow bar or the tow line between the
ing, adjusting and repair of the product. Be prepared to
disabled machine and the towing machine.
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
5. Tow the machine slowly. Do not exceed 3 km/h
nent containing fluids.
(2 mph).
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies i01412935
suitable to collect and contain fluids on Caterpillar
products. Parking Brake Manual Release
Dispose of all fluids according to local regulations and SMCS Code: 4267; 7000
mandates.

g00286064
Illustration 129
(A) Rod end. (B) Head end.

Perform the following steps before you tow the

machine.
g00743860
Illustration 130
1. Reverse the hydraulic steering hose connections
on one cylinder only. This will allow the steering The parking brake actuator is mounted inside the
cylinders to move freely. front loader frame on the right side of the machine.

Note: Make sure that the cylinder hoses are 1. Chock the wheels in order to keep the machine
connected correctly before you operate the machine from rolling when the parking brake is released.
again. The steering system will not function if the
hose connections are reversed. 2. Connect the steering frame lock.

2. If failure of the internal transmission or of the drive 3. Loosen locknut (2) by 18 mm (3/4 inch). Turn
line is suspected, remove the center drive shaft rod (1) until the rod moves out enough to totally
and the rear drive shaft. release the parking brake.

Reference: For the removal procedure for Note: Before you park the machine, the parking
the drive shafts, refer to the Disassembly and brake must be engaged again.
Assembly manual for your machines power train
or consult your Caterpillar dealer.

3. Release the parking brake in order to prevent

excessive wear and damage to the parking brake
system while the machine is being towed.
92 SEBU7887-03
Operation Section
Engine Starting (Alternate Methods)

Engine Starting (Alternate

NOTICE
Methods) When starting from another machine, make sure that
the machines do not touch. This could prevent dam-
age to engine bearings and electrical circuits.
i02187454

Engine Starting with Jump Turn on (close) the battery disconnect switch prior to
the boost connection to prevent damage to electrical
Start Cables components on the stalled machine.

SMCS Code: 1000; 7000 Severely discharged maintenance free batteries do

not fully recharge from the alternator after jump start-
ing. The batteries must be charged to proper voltage
with a battery charger. Many batteries thought to be
unusable are still rechargeable.
Failure to properly service the batteries may cause
personal injury.
This machine has a 24 volt starting system. Use only
the same voltage for jump starting. Use of a higher
Prevent sparks near the batteries. They could
voltage damages the electrical system.
cause vapors to explode. Do not allow the jump
start cable ends to contact each other or the
Refer to Special Instruction, Battery Test Procedure,
machine.
SEHS7633, available from your Caterpillar dealer, for
complete testing and charging information.
Do not smoke when checking battery electrolyte
levels.

Electrolyte is an acid and can cause personal in-

Use of Jump Start Cables
jury if it contacts the skin or eyes.
1. Place the transmission control on the stalled
machine in the NEUTRAL position. Engage the
Always wear eye protection when starting a ma-
parking brake. Lower all attachments to the
chine with jump start cables.
ground. Move all controls to the HOLD position.
Improper jump start procedures can cause an ex-
2. On the stalled machine, turn the engine start switch
plosion resulting in personal injury.
to the OFF position. Turn off the accessories.
When using jumper cables, always connect the
3. On the stalled machine, turn the battery disconnect
positive (+) jumper cable to the positive (+) bat-
switch to the ON position.
tery terminal first. Next, connect the negative (-)
jumper cable to the frame away from the batteries.
4. Move the machine or the auxiliary power source
Follow the procedure in the Operation and Main-
close to the stalled machine so that the cables can
tenance Manual.
reach. DO NOT ALLOW THE MACHINE OR THE
AUXILIARY POWER SOURCE TO CONTACT
Jump start only with an energy source of the same
THE STALLED MACHINE.
voltage as the stalled machine.
5. Stop the engine on the machine that is the
Turn off all lights and accessories on the stalled
electrical source. (If you are using an auxiliary
machine. Otherwise, they will operate when the
power source, turn off the charging system.)
energy source is connected.

Do not attempt to charge a battery that has ice in

any of the cells.

Charging a battery in this condition can cause an

explosion that may result in personal injury or
death.

Always let the ice melt before attempting to

charge.
SEBU7887-03 93
Operation Section
Engine Starting (Alternate Methods)

14. Attempt to start the stalled engine.

Reference: For more information, refer to

Operation and Maintenance Manual, Engine
Starting.

15. Immediately after the stalled engine starts,

disconnect the jump start cables in reverse order.

i02185603

Engine Starting with Auxiliary

Start Receptacle
g01108694
Illustration 131 SMCS Code: 1463
6. The batteries are located on the left side of the
machine. Remove the bolts that secure the access
panel for the batteries. Remove the access panel.

7. Check the battery caps for correct placement

and for correct tightness. Make these checks on
both machines. Make sure that the batteries in
the stalled machine are not frozen. Check the
batteries for low electrolyte.

8. Route the jump start cables around the steps

and away from the mounting and dismounting
paths. Connect the positive jump start cable to the
positive cable terminal of the discharged battery.
g01105336
Illustration 132
Do not allow positive cable clamps to contact any
metal except for battery terminals.

Note: Batteries in series may be in separate

compartments. Use the terminal that is connected to
the starter solenoid. This battery is normally on the
same side of the machine as the starter.

9. Connect the positive jump start cable to the

positive terminal of the electrical source. Use the
procedure from Step 8 in order to determine the
correct terminal.

10. Connect one end of the negative jump start cable

to the negative terminal of the electrical source. g01105344
Illustration 133
11. Make the final connection. Connect the negative
cable to the frame of the stalled machine. Make Some Caterpillar machines may be equipped with
this connection away from the battery, away from auxiliary start receptacles. All other machines can
the fuel, away from the hydraulic lines, and away be equipped with a receptacle from parts service. A
from all moving parts. permanent receptacle is always available for jump
starting.
12. Start the engine of the machine that is the
electrical source. (If you are using an auxiliary There are two cable assemblies that can be used to
power source, energize the charging system on jump start the stalled machine. You can jump start
the auxiliary power source.) the stalled machine from another machine that is
equipped with an auxiliary start receptacle or with
13. Allow the electrical source to charge the batteries an auxiliary power pack. Your Caterpillar dealer can
for two minutes. provide the correct cable lengths for your application.
94 SEBU7887-03
Operation Section
Engine Starting (Alternate Methods)

1. Determine the reason that the engine will not start.

Reference: Refer to Special Instruction,

SEHS7633, Battery Test Procedure for more
information.

2. Move the transmission direction control lever on

the stalled machine to NEUTRAL. Engage the
hydraulic lockout control. Engage the parking
brake. Lower all work tools to the ground. Move all
controls to HOLD.

3. Turn the engine start switch key on the stalled

machine to the OFF position. Turn off all
accessories.

4. Turn the battery disconnect switch on the stalled

machine to ON.

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

source close to the stalled machine. The jump
start cables should reach the batteries on both
machines. DO NOT ALLOW THE MACHINES TO
CONTACT EACH OTHER.

6. Stop the engine on the machine that is being used

as a power source. If you use an auxiliary power
source, turn off the charging system.

7. Connect the appropriate jump start cable to the

auxiliary start receptacle on the stalled machine.

8. Connect the other end of the jump start cable to

the auxiliary start receptacle of the machine that is
being used as a power source.

9. Start the engine on the machine that is being

used as a power source or energize the charging
system on the auxiliary power source.

10. Allow the machine that is being used as a power

source to charge the batteries for two minutes.

11. Attempt to start the stalled engine.

12. Immediately after the stalled engine starts,

disconnect the jump start cable from the power
source.

13. Disconnect the other end of the jump start cable

from the stalled machine.

14. Conclude the failure analysis on the starting

charging system of the stalled machine, as
required. Check the machine while the engine is
running and the charging system is in operation.
SEBU7887-03 95
Maintenance Section
Tire Inflation Information

Maintenance Section Reference: For tire inflation instructions, refer to

Special Instruction, SMHS7867, Nitrogen Tire
Inflation Group.

Tire Inflation Information For nitrogen inflation, use the same tire pressures
that are used for air inflation. Consult your tire dealer
for operating pressures.
i02096880

Tire Inflation with Nitrogen i02284174

SMCS Code: 4203 Tire Inflation Pressure

Caterpillar recommends the use of dry nitrogen gas SMCS Code: 4203; 7500
for tire inflation and for tire pressure adjustments.
This includes all machines with rubber tires. Nitrogen The tire inflation pressure for machines that are
is an inert gas that will not aid combustion inside the shipped from the factory is suitable for shipping only.
tire. Always obtain the proper tire inflation pressures for
your machine from the tire supplier before placing
the machine into operation. The recommended tire
inflation pressures for the front tires and for the rear
tires will vary for each application.
Proper nitrogen inflation equipment, and training
in using the equipment, are necessary to avoid
Proper tire inflation pressure and maintenance of
over inflation. A tire blowout or rim failure can re-
the tire inflation pressure is critical for optimum tire
sult from improper or misused equipment and per-
life. The tire inflation pressure should always be
sonal injury or death can occur.
obtained from the tire supplier due to changes in the
technology of tires, equipment, and job applications.
A tire blowout and/or rim failure can occur if the in-
flation equipment is not used correctly, due to the
Reference: Refer to the latest edition of Special
fact that a fully charged nitrogen cylinders pres-
Publication, Caterpillar Performance Handbook for
sure is approximately 15000 kPa (2200 psi).
general information on tire inflation pressure.

There are other benefits to using nitrogen in addition

i02610518
to reducing the risk of an explosion. The use of
nitrogen for tire inflation lessens the slow oxidation
of the rubber. Use of nitrogen also slows gradual tire
Tire Inflation Pressure
deterioration. This is especially important for tires Adjustment
that are expected to have a long service life of at
least four years. Nitrogen reduces the corrosion of SMCS Code: 4203
rim components. Nitrogen also reduces problems
that result from disassembly. Always obtain the proper tire inflation pressures and
maintenance recommendations for the tires on your
machine from your tire supplier. The tire pressure
in a warm shop area 18 to 21C (65 to 70F) will
significantly change when you move the machine
A tire blowout or a rim failure can cause personal into freezing temperatures. If you inflate the tire to
injury. the correct pressure in a warm shop, the tire will be
underinflated in freezing temperatures. Low pressure
Use a self-attaching inflation chuck and stand be- shortens the life of a tire.
hind the tread when inflating a tire, to prevent per-
sonal injury. Reference: When you operate the machine in
freezing temperatures, refer to Special Publication,
Note: Do not set the tire inflation equipment regulator SEBU5898, Cold Weather Recommendations for All
higher than 140 kPa (20 psi) over the recommended Caterpillar Machines in order to adjust tire inflation
tire pressure. pressures.

Use 6V-4040 Inflation Group or an equivalent

inflation group to inflate tires with a nitrogen gas
cylinder.
96 SEBU7887-03
Maintenance Section
Lubricant Viscosities and Refill Capacities

Lubricant Viscosities and Lubricant Viscosities for Ambient

Refill Capacities Temperatures
NOTICE
i02587466 Do NOT use only the Oil Viscosities column when
determining the recommended oil for a machine com-
Lubricant Viscosities partment. The Oil Type and Classification column
MUST also be used.
SMCS Code: 7581

NOTICE
Selecting the Viscosity The footnotes are a key part of the Lubricant
Ambient temperature is the temperature of the air in Viscosities for Ambient Temperatures tables. Read
ALL footnotes that pertain to the machine compart-
the immediate vicinity of the machine. This may differ
ment in question.
due to the machine application and from the generic
ambient temperature for a geographic region. In order
to select the proper oil viscosity, review the regional Note: Use the oil type and the classification
ambient temperature and the potential ambient that is recommended for the various machine
temperature for a given machine application. Use the compartments.
higher temperature of the two ambient temperatures
in order to select the oil viscosity. Use the highest oil Note: Some machine compartments allow the use of
viscosity that is allowed for the ambient temperature more than one oil type. For the best results, do not
when you start the machine. For arctic applications, mix oil types.
the preferred method is the use of heaters for
machine compartments and a high viscosity oil. Note: Different brands of oils may use different
additive packages. For the best results, do not mix
The proper oil viscosity grade is determined by the oil brands.
minimum outside ambient temperature. This is the
temperature when the machine is started and while Note: Caterpillar oil is the preferred oil. All other listed
the machine is operated. In order to determine the oils are acceptable oils.
proper oil viscosity grade, refer to the Min column
in the table. This information reflects the coldest
ambient temperature condition for starting a cold
machine and for operating a cold machine. Refer to
the Max column in Table 13 in order to select the
oil viscosity grade for operating the machine at the
highest temperature that is anticipated.

Machines that are operated continuously should

use oils that have the higher oil viscosity in the final
drives and in the differentials. The oils that have the
higher oil viscosity will maintain the highest possible
oil film thickness. Consult your dealer if additional
information is needed.

Note: SAE 0W oil and SAE 5W oil are not

recommended for heavily loaded machines or
machines that are operated continuously. These
viscosity grades are not recommended for use in
hydraulic hammers. The oils that have the higher
oil viscosity will maintain the highest possible oil
film thickness. Consult your dealer if additional
information is needed.

Note: Some machine models and/or machine

compartments do not allow the use of all available
viscosity grades.
SEBU7887-03 97
Maintenance Section
Lubricant Viscosities and Refill Capacities

Table 13
Lubricant Viscosities for Ambient Temperatures(1)
C F
Compartment or System Oil Type and Classification Oil Viscosities
Min Max Min Max
SAE 0W20 40 +10 40 +50
SAE 0W30 40 +30 40 +86
SAE 0W40 40 +40 40 +104
Cat DEO Multigrade
Cat DEO SYN SAE 5W30 30 +30 22 +86
Engine Crankcase(2)(3) Cat Arctic DEO SYN(4)
Cat ECF-1(5) SAE 5W40 -30 +50 22 +122
API CG-4 Multigrade(6)
SAE 10W30(7) -18 +40 0 +104
SAE 10W40 -18 +50 0 +122
SAE 15W40 -9.5 +50 +15 +122
SAE 0W20(8) 40 +10 40 +50
SAE 0W30(8) 40 +20 40 +68
SAE 5W30(8) 30 +20 22 +68
Cat TDTO
Power Shift Transmission Cat TDTO-TMS SAE 10W 20 +10 4 +50
commercial TO-4
SAE 30(9) 0 +35 +32 +95
SAE 50(9)(10) +10 +50 +50 +122
TDTO-TMS(9)(11) 10 +43 +14 +110
SAE 0W20 40 +40 40 +104
SAE 0W30 40 +40 40 +104
Cat HYDO SAE 5W30 30 +40 22 +104
Cat DEO
Cat MTO SAE 5W40 30 +40 22 +104
Cat TDTO SAE 10W 20 +40 4 +104
Cat TDTO-TMS
Cat DEO SYN SAE 30 +10 +50 +50 +122
Hydraulic Systems
Cat ECF-1
Cat BIO HYDO (HEES) SAE 10W30 20 +40 4 +104
API CG-4 SAE 15W40 15 +50 +5 +122
API CF
commercial TO-4 Cat MTO 25 +40 13 +104
commercial BF-1(12)
Cat BIO HYDO
40 +43 40 +110
(HEES)(12)
TDTO-TMS(11) 20 +50 -4 +122
SAE 0W20(8) 40 0 40 +32
SAE 0W30(8) 40 +10 40 +50
SAE 5W30(8) 35 +10 31 +50
Cat TDTO
Drive Axles Cat TDTO-TMS SAE 10W 25 +15 13 +59
commercial TO-4
SAE 30 20 +43 4 +110
SAE 50(10) +10 +50 +50 +122
TDTO-TMS(11) 30 +43 22 +110
(continued)
98 SEBU7887-03
Maintenance Section
Lubricant Viscosities and Refill Capacities

(Table 13, contd)

Lubricant Viscosities for Ambient Temperatures(1)
C F
Compartment or System Oil Type and Classification Oil Viscosities
Min Max Min Max
External Lubrication Points Advanced 3Moly NLGI Grade 2 20 40 4 104
Steering Column Multipurpose Grease NLGI Grade 2 30 40 22 104
(1) When you are operating the machine in temperatures below 20C (4F), refer to Special Publication, SEBU5898, Cold Weather
Recommendations. This is available from your Caterpillar dealer.
(2) Supplemental heat is recommended for cold-soaked starts below the minimum ambient temperature. Supplemental heat may be
required for cold-soaked starts that are above the minimum temperature that is stated, depending on the parasitic load and other factors.
Cold-soaked starts occur when the engine has not been operated for a period of time, allowing the oil to become more viscous due to
cooler ambient temperatures.
(3) API CF oils are not recommended for Caterpillar 3500 Series and smaller Direct Injection (DI) diesel engines. API CF-4 oils are not
recommended for Caterpillar machine diesel engines.
(4) Cat Arctic DEO SYN is an SAE 0W-30 viscosity grade oil.
(5) API CI-4 and API CI-4 PLUS oils are acceptable if the requirements of Caterpillars ECF-1 (Engine Crankcase Fluid specification - 1) are
met. API CI-4 and API CI-4 PLUS oils that have not met the requirements of Caterpillars ECF-1 specification may cause reduced engine life.
(6) API CG-4 oils are acceptable for use in all Caterpillar machine diesel engines. When API CG-4 oils are used, the oil change interval
should not exceed 250 hours. API CG-4 oils that also meet API CI-4 API CI-4 PLUS must also meet the requirements of the Caterpillar
ECF-1 specification.
(7) SAE 10W-30 is the preferred viscosity grade for the 3116, 3126, C7, C-9 and the C9 diesel engines when the ambient temperature is
between -18 C (0 F) and 40 C (104 F).
(8) First Choice: Oils of full synthetic base stock without viscosity index improvers that meet the performance requirements of the TO-4
specification for the SAE 30 viscosity grade. Typical viscosity grades are SAE 0W20, SAE 0W30, and SAE 5W30. Second choice: Oils with
a TO-4 type additive package and a lubricant viscosity grade of SAE 0W20, SAE 0W30, or of SAE 5W30.
(9) Except for the gear case for the hydraulic driven winch, use SAE 30 viscosity grade for 0 C (32 F) to 43 C (110 F) or TMS for 10 C
(14 F) to 50 C (122 F).
(10) Do not use SAE 50 viscosity grade oil in ICM controlled transmissions. Do not use SAE 50 viscosity grade for the gear case of the
hydraulic driven winch.
(11) This oil exceeds the requirements of the TO-4/TO-4M specification.
(12) Commercial Biodegradable Hydraulic Oil (HEES) must conform to the Caterpillar BF-1 specification. This ambient temperature range is for
Caterpillar Biodegradable Hydraulic Oil (HEES) only. This range is not for commercial BF-1 oil.
SEBU7887-03 99
Maintenance Section
Lubricant Viscosities and Refill Capacities

i02622967 Table 15

Capacities (Refill) Approximate Refill Capacities 972H

Compartment or US
SMCS Code: 7560 Liters Imp Gal
System Gal

Table 14 Cooling System 39.0 10.3 8.6

Approximate Refill Capacities 966H Fuel Tank 380 109 83.6

Compartment or US Engine Crankcase 35 9.25 7.7

Liters Imp Gal
System Gal
Transmission 44 11.6 9.7
Cooling System 39.0 10.3 8.6
Hydraulic Tank(1) 110 29 24.2
Fuel Tank 380 100 83.6
Two-Valve
198 52.3 43.6
Engine Crankcase 35 9.25 7.7 Hydraulic System(2)

Transmission 44 11.6 9.7 Three-Valve

203 53.6 44.7
Hydraulic System(2)
Hydraulic Tank(1) 110 29 24.2
Front Drive Axle(3) 64 16.9 14.1
Two-Valve
198 52.3 43.6 Rear Drive Axle(3) 64 16.9 14.1
Hydraulic System(2)
Three-Valve Automatic
203 53.6 44.7 Greasing System 4 1 .88
Hydraulic System(2)
Reservoir
Front Drive Axle(3) 64 16.9 14.1
(1) This capacity is only for the hydraulic tank.
Rear Drive Axle(3) 64 16.9 14.1 (2) This capacity includes the hydraulic tank, the hydraulic lines,
and all hydraulic components.
Automatic (3) The amount that is shown includes 1 L (0.3 US gal) of
Greasing System 4 1 .88 1U-9891 Hydraulic Oil Additive.
Reservoir
(1) This capacity is only for the hydraulic tank.
(2) i01822901
This capacity includes the hydraulic tank, the hydraulic lines,
and all hydraulic components.
(3) The amount that is shown includes 1 L (0.3 US gal) of SOS Information
1U-9891 Hydraulic Oil Additive.
SMCS Code: 1348; 1350; 3080; 4070; 4250; 4300;
5050; 7542

SOS Services is a highly recommended process

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

Refer to Special Publication, SEBU6250, Caterpillar

Machine Fluid Recommendations for detailed
information concerning SOS Services.

Refer to the Operation and Maintenance Manual,

Maintenance Interval Schedule for a specific
sampling location and a service hour maintenance
interval.

Consult your Caterpillar dealer for complete

information and assistance in establishing an SOS
program for your equipment.
100 SEBU7887-03
Maintenance Section
Lubricant Viscosities and Refill Capacities

i02405775

Diagnostic Lines (Remote

Pressure Taps)
SMCS Code: 7554-PK

Electrohydraulic System

Crushing Hazard. Connect the steering frame lock

between front and rear frames before servicing the
machine in the articulation area. Disconnect the Illustration 135
g01099931
steering frame lock and secure it in the stored po-
(1) Clutch packs
sition before resuming operation. Failure to do so (2) Steering pump pressure
could result in serious injury or death. (3) Brake pressure
(4) Torque converter inlet pressure
(5) Torque converter outlet pressure
(6) Transmission lubrication pressure
(7) Main relief valve pressure for the transmission

g01099999
Illustration 134

Before entering the articulation area, ensure that the

steering frame lock is connected.

The diagnostic lines are located on the right side of

the machine under the platform behind an access
panel.
SEBU7887-03 101
Maintenance Section
Maintenance Support

Maintenance Support
i02000840

Welding on Machines and

Engines with Electronic
Controls
SMCS Code: 1000; 7000

Proper welding procedures are necessary in order to

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

1. Turn off the engine. Place the engine start switch

in the OFF position.

2. If equipped, turn the battery disconnect switch to

the OFF position. If there is no battery disconnect
switch, remove the negative battery cable at the
battery.

NOTICE
Do NOT use electrical components (ECM or ECM sen-
sors) or electronic component grounding points for
grounding the welder.

3. Clamp the ground cable from the welder to the

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

Bearings of the drive train

Hydraulic components
Electrical components
Other components of the machine
4. Protect any wiring harnesses from the debris
which is created from welding. Protect any wiring
harnesses from the splatter which is created from
welding.

5. Use standard welding procedures in order to weld

the materials together.
102 SEBU7887-03
Maintenance Section
Maintenance Interval Schedule

i02438676 Fuel Tank Water and Sediment - Drain ............... 141

Hydraulic System Oil Level - Check ................... 148
Maintenance Interval Schedule Seat Belt - Inspect .............................................. 153
Transmission Oil Level - Check .......................... 159
SMCS Code: 7000 Windows - Clean ................................................. 161
Ensure that all safety information, warnings and Every 50 Service Hours or Weekly
instructions are read and understood before any
operation or any maintenance procedures are Articulation Bearings - Lubricate ......................... 104
performed. Bucket Lower Pivot Bearings - Lubricate ............. 111
Cab Air Filter - Clean/Replace ............................. 113
The user is responsible for the performance of Tire Inflation - Check ........................................... 157
maintenance, including all adjustments, the use of
proper lubricants, fluids, filters, and the replacement Every 100 Service Hours or 2 Weeks
of components due to normal wear and aging. Failure
to adhere to proper maintenance intervals and Axle Oscillation Bearings - Lubricate .................. 105
procedures may result in diminished performance of Bucket Linkage and Loader Cylinder Bearings -
the product and/or accelerated wear of components. Lubricate ............................................................ 111
Bucket Upper Pivot Bearings - Lubricate ............. 113
Use mileage, fuel consumption, service hours, or Logging Fork Clamp - Lubricate ......................... 149
calendar time, WHICH EVER OCCURS FIRST, Steering Cylinder Bearings - Lubricate ............... 155
in order to determine the maintenance intervals.
Products that operate in severe operating conditions Initial 250 Service Hours
may require more frequent maintenance.
Electronic Unit Injector - Inspect/Adjust .............. 124
Note: Before each consecutive interval is performed, Engine Oil Sample - Obtain ................................ 132
all maintenance from the previous interval must be Engine Valve Lash - Check ................................. 136
performed. Engine Valve Rotators - Inspect ......................... 136
Transmission Oil Filter - Replace ........................ 158
When Required
Every 250 Service Hours or Monthly
Automatic Lubrication Grease Tank - Fill ............ 104
Battery - Recycle ................................................ 106 Battery - Clean .................................................... 106
Battery or Battery Cable - Inspect/Replace ........ 107 Belt - Inspect/Adjust/Replace .............................. 107
Bucket Hinge and Lift Arm Clearance Shims - Brake Accumulator - Check ................................ 108
Inspect/Adjust/Replace ...................................... 110 Braking System - Test ......................................... 108
Bucket Wear Plates - Inspect/Replace ................ 113 Cooling System Coolant Sample (Level 1) -
Circuit Breakers - Reset ....................................... 115 Obtain ................................................................ 118
Engine Air Filter Primary Element - Clean/ Differential and Final Drive Oil Level - Check ..... 121
Replace ............................................................. 124 Drive Shaft Spline (Center) - Lubricate ............... 122
Engine Air Filter Secondary Element - Replace .. 126 Engine Crankcase Breather - Clean ................... 127
Engine Air Precleaner - Clean ............................ 127 Engine Oil Sample - Obtain ................................ 132
Ether Starting Aid Cylinder - Replace ................. 137 Quick Coupler - Lubricate ................................... 150
Fuel System - Prime ........................................... 137
Fuses - Replace .................................................. 141 Initial 500 Hours (for New Systems, Refilled
High Intensity Discharge Lamp (HID) - Replace .. 143 Systems, and Converted Systems)
Oil Filter - Inspect ................................................ 150
Quick Coupler - Check ........................................ 150 Cooling System Coolant Sample (Level 2) -
Radiator Core - Clean ......................................... 151 Obtain ................................................................ 119
Ride Control Accumulator - Check ..................... 152
Window Washer Reservoir - Fill .......................... 160 Every 500 Service Hours
Window Wiper - Inspect/Replace ........................ 160
Transmission Oil Filter - Replace ........................ 158
Every 10 Service Hours or Daily Every 500 Service Hours or 3 Months
Backup Alarm - Test ............................................ 105
Differential and Final Drive Oil Sample - Obtain .. 122
Bucket Cutting Edges - Inspect/Replace ............ 109 Engine Oil (High Speed) and Oil Filter - Change .. 128
Bucket Tips - Inspect/Replace ............................. 111
Engine Oil and Filter - Change ........................... 133
Cooling System Coolant Level - Check ............... 118
Fuel System Primary Filter (Water Separator)
Engine Oil Level - Check .................................... 132 Element - Replace ............................................ 139
Fuel System Primary Filter (Water Separator) -
Fuel Tank Cap and Strainer - Clean ................... 140
Drain ................................................................. 138
SEBU7887-03 103
Maintenance Section
Maintenance Interval Schedule

Hydraulic System Biodegradable Oil Filter Element - Every 12 000 Service Hours or 6 Years
Replace ............................................................. 144
Hydraulic System Oil Filter - Replace ................. 147 Cooling System Coolant (ELC) - Change ............ 115
Hydraulic System Oil Sample - Obtain ............... 149
Transmission Oil Sample - Obtain ...................... 160

Every 1000 Service Hours

Drive Shaft Universal Joints - Lubricate .............. 124

Every 1000 Service Hours or 6 Months

Battery Hold-Down - Tighten ............................... 106
Case Drain Screen (Strainer) (Steering Pump,
Hydraulic Fan Pump, Motor) - Clean ................. 114
Fuel System Secondary Filter - Replace ............ 140
Roading Fender Hinges - Lubricate .................... 152
Rollover Protective Structure (ROPS) - Inspect .. 152
Steering Pilot Oil Screen (Command Control
Steering) - Clean/Replace ................................. 156
Transmission Oil - Change ................................. 157

Every 2000 Service Hours or 1 Year

Brake Discs - Check ........................................... 108
Differential and Final Drive Oil - Change ............ 120
Electronic Unit Injector - Inspect/Adjust .............. 124
Engine Valve Lash - Check ................................. 136
Engine Valve Rotators - Inspect ......................... 136
Hood Tilt Actuator - Lubricate ............................. 143
Hydraulic System Oil - Change ........................... 145
Hydraulic Tank Breaker Relief Valve - Clean ...... 149
Service Brake Wear Indicator - Check ................ 153
Steering Column Spline (Command Control Steering)
- Lubricate ......................................................... 154

Every Year
Cooling System Coolant Sample (Level 2) -
Obtain ................................................................ 119
Refrigerant Dryer - Replace ................................ 151

Every 3000 Service Hours

Steering Column Spline (HMU Steering) -
Lubricate ........................................................... 154

Every 3 Years After Date of Installation or

Every 5 Years After Date of Manufacture
Seat Belt - Replace ............................................. 153

Every 5000 Service Hours

Drive Shaft Support Bearing - Lubricate ............. 123

Every 6000 Service Hours or 3 Years

Cooling System Coolant Extender (ELC) - Add ... 117
Cooling System Water Temperature Regulator -
Replace .............................................................. 119
104 SEBU7887-03
Maintenance Section
Articulation Bearings - Lubricate

i02613559 i02094776

Articulation Bearings - Automatic Lubrication Grease

Lubricate Tank - Fill
SMCS Code: 7057-086-BD; 7065-086-BD;
(If Equipped)
7066-086-BD
SMCS Code: 7540-544-TNK
S/N: A6G1-Up

Crushing Hazard. Connect the steering frame lock S/N: A7G1-Up

between front and rear frames before servicing the S/N: A6J1-Up
machine in the articulation area. Disconnect the
steering frame lock and secure it in the stored po- S/N: A7J1-Up
sition before resuming operation. Failure to do so
could result in serious injury or death.
The Groeneveld Automatic TWIN
Refer to Operation and Maintenance Manual,
Greasing System
Steering Frame Lock before entering the articulation Reference: Refer to System Operation, RENR
joint. 6331for more information on the Automatic TWIN
Greasing System.
Wipe all fittings before applying grease.

A pressure hazard is present. Severe personal in-

jury or death can result from removing hoses or
fittings that are under pressure. Relieve the pres-
sure in the system before you remove hoses or
fittings.

g01236829
Illustration 136

g01068678
Apply grease to one fitting on the upper pivot bearing Illustration 137
(1) and one fitting on the lower pivot bearing (2).
Grease reservoir (1) is located near the rear fender
on the right side of the machine.

Filling the Reservoir

1. Remove the dust cap (2) from the grease reservoir
(1).

2. Clean the filler tube assembly (3) and the coupling

on the filler assembly.

3. Install the filler assembly onto the filler tube

assembly (3).
SEBU7887-03 105
Maintenance Section
Axle Oscillation Bearings - Lubricate

4. Fill the grease reservoir (1) with grease to the Wipe all fittings before lubricating.
maximum level which is indicated on the grease
reservoir (1). Grease fitting (1) will lubricate the axle pivot bearing
that is on the front of the rear axle. Grease fitting (2)
Reference: For the correct type of grease, refer will lubricate the axle pivot bearing that is on the rear
to Operation and Maintenance Manual, Lubricant of the rear axle.
Viscosities.
Note: 5P-0960 Molybdenum Grease is preferred.
5. Remove the filler assembly and install the dust 1P-0808 Multipurpose Grease grease may be used.
cap (2).
i02375125

Backup Alarm - Test

i02405789

Axle Oscillation Bearings -

SMCS Code: 7406-081
Lubricate
The backup alarm is on the rear of the machine.
SMCS Code: 3268-086-BD; 3278-086-BD
In order to test the alarm for proper functioning, turn
the engine start switch to the ON position.

Crushing Hazard. Insure that the machine ignition Apply the service brake. Place the transmission into
switch is in the OFF position and that the parking REVERSE.
brake is engaged before entering the articulation
area. Failure to do so could result in serious injury The backup alarm should sound immediately.
or death. The backup alarm will continue to sound until
the transmission is placed intoNEUTRAL or into
FORWARD.

g01103093
Illustration 138
g01043892
Illustration 140
Open the access panel on the right side of the
machine in front of the steps.

g01105565
Illustration 139
106 SEBU7887-03
Maintenance Section
Battery - Clean

i02170472 A battery supplier

Battery - Clean An authorized battery collection facility
SMCS Code: 1401-070 Recycling facility

i02185798

Battery Hold-Down - Tighten

SMCS Code: 7257-527

g01100143
Illustration 141

g00882014
Illustration 143

Open the battery compartment on the left side of the

machine under the platform.

Over time, the vibration of an operating machine can

cause the battery hold-down to loosen. To help to
prevent loose batteries and the possibility of loose
cable connections, tighten the locknut in the center of
g01100147 the hold-down to a torque of 14 3 Nm (10 2 lb ft).
Illustration 142

Open the battery compartment on the left side of

the machine under the platform. Remove the battery
hold-down.

Clean the battery terminals and the surfaces of

the batteries with a clean cloth. Coat the battery
terminals with petroleum jelly. Make sure that the
battery cables are installed securely.

Replace the battery hold-down. Refer to Operation

and Maintenance Manual, Battery Hold-Down -
Tighten for the correct torque. Close the battery
compartment.

i00993589

Battery - Recycle
SMCS Code: 1401-561

Always recycle a battery. Never discard a battery.

Always return used batteries to one of the following

locations:
SEBU7887-03 107
Maintenance Section
Battery or Battery Cable - Inspect/Replace

i02517652 i02168723

Battery or Battery Cable - Belt - Inspect/Adjust/Replace

Inspect/Replace SMCS Code: 1397-025; 1397-040; 1397-510
SMCS Code: 1401-040; 1401-510; 1402-040;
Your machine is equipped with a single serpentine
1402-510 belt. Stop the engine. Open the rear hood. The belt is
located at the rear of the engine.

Personal injury may occur from failure to properly

service the batteries.

Batteries give off flammable fumes that can ex-

plode. Electrolyte is an acid and can cause per-
sonal injury if it contacts the skin or eyes.

Prevent sparks near the batteries. Sparks could

cause vapors to explode. Do not allow jumper ca-
ble ends to contact each other or the engine. Im-
proper jumper cable connections can cause an ex-
plosion.

Always wear protective glasses when working

with batteries.

1. Turn the engine start switch key OFF. Turn all of

the switches OFF.

2. Turn the battery disconnect switch OFF. Remove g01100124

Illustration 144
the key. (1) Alternator
(2) Idler
3. Disconnect the negative battery cable from the (3) Tensioner
disconnect switch. (4) Compressor
(5) Idler
(6) Idler
Note: Do not allow the disconnected battery cable to (7) Serpentine Belt
contact the disconnect switch. (8) Crankshaft Pulley

4. Disconnect the negative battery cable at the Tensioner (3) keeps the correct tension on belt (7).
battery. Insert a ratchet with a square drive into tensioner (3).
Rotate the tensioner counterclockwise in order to
5. Disconnect the positive battery cable at the relieve tension on the belt. Remove the belt.
battery.
Install the new belt. Be sure that the new belt is
6. Inspect the battery terminals for corrosion. Inspect routed correctly, as shown. Rotate the tensioner
the battery cables for wear or damage. counterclockwise in order to install the new belt.
Release the tensioner when the new belt is installed.
7. Make any necessary repairs. If necessary, replace The correct tension will automatically be applied.
the battery cables or the battery.

8. Connect the positive battery cable at the battery.

9. Connect the negative battery cable at the battery.

10. Connect the battery cable at the battery

disconnect switch.

11. Install the key and turn the battery disconnect

switch ON.
108 SEBU7887-03
Maintenance Section
Brake Accumulator - Check

i01714079 i01739721

Brake Accumulator - Check Braking System - Test

SMCS Code: 4263-535 SMCS Code: 4251-081; 4267-081

Fasten the seat belt before you test the brakes.

Park the machine on a dry, level surface.
Check the area around the machine. Make sure
that the machine is clear of personnel and clear of
obstacles.

Make sure that the steering frame lock is in the

unlocked position.

The following tests are used to determine whether

the braking system is functional. These tests are not
g00882020
intended to measure the maximum brake holding
Illustration 145 effort. The required brake holding effort for sustaining
a machine at a specific engine rpm varies from one
1. Turn the engine start switch to the ON position. machine to another machine. The variations include
The alert indicator for brake oil pressure should differences in the engine setting, the power train
come on if the braking system is not at normal efficiency, the brake holding ability, etc.
operating pressure.

2. Start the engine. Run the engine at half speed for Service Brake Holding Ability Test
two minutes in order to increase the accumulator
pressure. The alert indicator for brake oil pressure
should go off.
Personal injury can result if the machine moves
3. Stop the engine. Apply the service brake pedal while testing.
and release the service brake pedal until the alert
indicator for brake oil pressure comes on. This will If the machine begins to move during test, reduce
decrease the accumulator pressure. A minimum the engine speed immediately and engage the
of five applications of the service brake pedal are parking brake.
required.

4. If the alert indicator comes on after less than 1. Start the engine. Raise the implement slightly.
five applications of the brake, measure the Apply the service brake. Release the parking
accumulator precharge pressure. An authorized brake.
Caterpillar dealer can measure the nitrogen gas
pressure in the accumulator. Use only dry nitrogen 2. Move the transmission control to THIRD SPEED
gas for recharging. FORWARD while the service brakes are applied.
Make sure that the autoshift control is in the OFF
position.
i01732078

Brake Discs - Check 3. Gradually increase the engine speed to high idle.
The machine should not move.
SMCS Code: 4255-535
4. Reduce the engine speed to low idle. Move the
Reference: For the correct procedure, refer to the transmission direction control to the NEUTRAL
Testing and Adjusting Service Manual of the braking position. Engage the parking brake. Lower the
system for your machine or consult your Caterpillar implement to the ground. Stop the engine.
dealer.
If the machine moved during the test, consult your
Caterpillar dealer for a brake inspection. Make any
necessary repairs before the machine is returned to
operation.
SEBU7887-03 109
Maintenance Section
Bucket Cutting Edges - Inspect/Replace

Parking Brake Holding Ability Test

Personal injury can result if the machine moves

while testing.

If the machine begins to move, reduce the engine

speed immediately and apply the service brake
pedal.

This test is performed when the parking brake is

engaged. If the machine begins to move, compare
the engine rpm to the engine rpm of a prior test. This g00764365
Illustration 146
will indicate the amount of system deterioration.
Check the cutting edges and the end bits for wear
1. Start the engine. Raise the implement slightly.
and for damage. Use the following procedure to
Engage the parking brake. service the cutting edges and the end bits:
2. Move the transmission control to THIRD SPEED
1. Raise the bucket and place blocking under the
FORWARD. Make sure that the autoshift control bucket.
is in the OFF position.
2. Lower the bucket onto the blocking. Stop the
The parking brake indicator light should come on. engine.
3. Gradually increase the engine speed to high idle.
3. Remove bolts (1), cutting edge (2) and the end
The machine should not move. bits.
4. Reduce the engine speed to low idle. Move the
4. Clean all contact surfaces.
transmission direction control to the NEUTRAL
position. Lower the implement to the ground. Stop
5. If the opposite side of the cutting edge is not worn,
the engine.
use the opposite side of the cutting edge. The end
bits are not reversible.
If the machine moved during the test, consult your
Caterpillar dealer for a brake inspection. Make any
If both sides are worn, install a new cutting edge.
necessary repairs before the machine is returned to
operation.
6. Install bolts (1). Tighten the bolts to the specified
torque.
i02196469
Reference: Refer to Specifications, SENR3130,
Bucket Cutting Edges - Ground Engaging Tool (G.E.T.) Fasteners.
Inspect/Replace 7. Start the engine. Raise the bucket and remove the
blocking. Lower the bucket to the ground.
SMCS Code: 6801-040; 6801-510
8. After a few hours of operation, check the bolts for
proper torque.

Personal injury or death can result from bucket

falling.

Block the bucket before changing bucket cutting

edges.
110 SEBU7887-03
Maintenance Section
Bucket Hinge and Lift Arm Clearance Shims - Inspect/Adjust/Replace

i02677614

Bucket Hinge and Lift

Arm Clearance Shims -
Inspect/Adjust/Replace
SMCS Code: 6001-025-CLR; 6001-040-CLR;
6001-510-Z4; 6119-025-CLR; 6119-040-CLR;
6119-510-Z4

Inspect the Linkage

g01345720
Illustration 148
(4) Install washers on lift arm.

g01345690
Illustration 147
(1) Lift Arm
(2) Bucket
(3) Inspection Points for the Bucket Hinge.

Periodically inspect the bucket linkage. The gap

between the bucket and the linkage should not
exceed the thinnest shim that is available for the
bucket assembly.

1. Lower the lift arm assembly (1) to suitable

blocking. Rest the bucket (2) on the ground. Illustration 149
g01345724

(4) Install washers on tilt arm.

2. Use a gauge to measure the gap at the hinge.
Install washers and pin assembly to the bucket.
3. If the measurement exceeds the required amount, When possible, use washers on both sides of the lift
new shims must be installed. arm in order to reduce the gap between the lift arm
and the hinges on the bucket.
Installing Shims for the Hinge on
Note: Refer to the Disassembly and Assembly
the Bucket Manual, Bucket - Install for the correct procedure
for installing the pins in the linkage.
Note: Refer to the Disassembly and Assembly
Manual, Bucket - Remove for the correct procedure
for removing the pins in the linkage.
SEBU7887-03 111
Maintenance Section
Bucket Linkage and Loader Cylinder Bearings - Lubricate

i02517774 i01924084

Bucket Linkage and Loader Bucket Lower Pivot Bearings

Cylinder Bearings - Lubricate - Lubricate
SMCS Code: 5102-086-BD; 5104-086-BD; SMCS Code: 6101-086-BD; 6107-086-BD
6107-086-BD

Wipe off the fittings before any lubricant is applied.

g01001411
Illustration 152

Wipe off all fittings before any lubricant is applied.

g01001072
Illustration 150
Apply lubricant through one fitting on each side of
the machine.

i02420559

Bucket Tips - Inspect/Replace

SMCS Code: 6805-040; 6805-510

Personal injury or death can result from the bucket

falling.

Block the bucket before changing bucket tips.

g01259751
Illustration 151

To lubricate pins (1) and (3), apply grease through

the remote fittings that are located on the right side of
the machine near the articulation joint.

The pins (2), (4), (5), (6), and (7) do not have remote
grease fittings. These pins have standard grease
fittings.
112 SEBU7887-03
Maintenance Section
Bucket Tips - Inspect/Replace

Bucket Tips

g00590819
Illustration 155
g00101352 (6) Retainer
Illustration 153
(7) Retaining washer
(1) Usable (8) Adapter
(2) Replace
(3) Replace
2. Clean the adapter and the pin.
Check the bucket tips for wear. If the bucket tip has a
hole, replace the bucket tip. 3. Fit retainer (6) into retaining washer (7). Install
this assembly into the groove that is in the side
1. Remove the pin from the bucket tip. The pin can of adapter (8).
be removed by one of the following methods.

Use a hammer and a punch from the retainer

side of the bucket to drive out the pin.

Use a Pin-Master. Follow Step 1.a through Step

1.c for the procedure.

g00101359
Illustration 156

4. Install the new bucket tip onto the adapter.

Note: The bucket tip can be rotated by 180 degrees in

order to allow greater penetration or less penetration.

Illustration 154
g00590670 5. Drive the pin through the bucket tip. The pin can
be installed by using one of the following methods:
(4) Back of Pin-Master
(5) Extractor
From the other side of the retainer, drive the
a. Place the Pin-Master on the bucket tooth. pin through the bucket tip, the adapter, and the
retainer.
b. Align extractor (5) with the pin.
Use a Pin-Master. Follow Step 5.a through Step
c. Strike the Pin-Master at the back of the tool (4) 5.e for the procedure.
and remove the pin.
Note: To correctly install the pin into the retainer, the
pin must be driven in from the right side of the tooth.
Improper installation of the pin can result in the loss
of the bucket tip.
SEBU7887-03 113
Maintenance Section
Bucket Upper Pivot Bearings - Lubricate

Wipe off the fitting before any lubricant is applied.

Apply lubricant through the fitting.

i01709216

Bucket Wear Plates -

Inspect/Replace
SMCS Code: 6120-040; 6120-510

Illustration 157
g00590666 Personal injury or death can result from the bucket
(4) Back of Pin-Master
falling.
(9) Pin setter
(10) Pin holder Block the bucket before changing bucket wear
plates.
a. Insert the pin through the bucket tooth.

b. Place the Pin-Master over the bucket tooth and

locate the pin in the hole of holder (10).

c. Strike the tool with a hammer at the back of the

tool (4) in order to start the pin.

d. Slide pin holder (10) away from the pin and

rotate the tool slightly in order to align pin setter
(9) with the pin.

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

inserted.

6. After you drive the pin, make sure that the retainer Illustration 159
g00879740
fits snugly into the pin groove.
Inspect the wear plates. Replace the wear plates
i01924086
before damage to the bottom of the bucket occurs.
Consult your Caterpillar dealer for replacement of
Bucket Upper Pivot Bearings wear plates.
- Lubricate
i01449996
SMCS Code: 6101-086-BD; 6107-086-BD
Cab Air Filter - Clean/Replace
SMCS Code: 7342-070; 7342-510

Note: Clean the cab air filters more often if the

machine is being operated in dusty conditions.

g01001416
Illustration 158
114 SEBU7887-03
Maintenance Section
Case Drain Screen (Strainer) (Steering Pump, Hydraulic Fan Pump, Motor) - Clean

i02057872

Case Drain Screen (Strainer)

(Steering Pump, Hydraulic Fan
Pump, Motor) - Clean
SMCS Code: 4304-070-Z3; 5057-070-Z3

g00759048
Illustration 160

1. Remove the filter cover behind the seat. Two

threaded knobs (1) are used in order to remove
the cover. Remove the filter element (2).

2. Open the access door (3) on the left side of the

cab. Remove the filter element.
g01056467
Illustration 161
3. Clean the filter elements with pressure air or Top view of the location of the case drain screens (2) and (5).
wash the filter elements in warm water with a
nonsudsing household detergent. Case drain screen (2) and case drain screen (5) are
located in hydraulic line (3) and hydraulic line (4).
4. If water and detergent are used to clean the filter Hydraulic line (3) and hydraulic line (4) are located
elements, rinse the filter elements in clean water behind the hydraulic oil tank (1).
and allow the filter elements to air dry thoroughly.

Note: If either filter element is damaged, install a

new filter element.

5. Install the filter elements. Install the filter cover

and close the access door.

g01056742
Illustration 162
Detail A

1. Disconnect hydraulic line (3) from the hydraulic

tank (1).

2. Remove the case drain screen (2) from the

hydraulic line (2).
SEBU7887-03 115
Maintenance Section
Circuit Breakers - Reset

3. Wash the case drain screen (2) in a clean

nonflammable solvent.

4. Dry the case drain screen (2) by using pressurized

air.

5. Inspect the case drain screen (2) for damage.

Note: If the case drain screen (2) is damaged,

replace the case drain screen (3).

6. Install the case drain screen (3).

7. Connect hydraulic line (3).

g01105741
8. Repeat Step1 through Step 7 for hydraulic line (4) Illustration 164
and case drain screen (5). (1) 105 Amp Circuit Breaker
(2) Spare
(3) Spare
i02622965
(4) 30 Amp Circuit Breaker
(5) 80 Amp Circuit Breaker
Circuit Breakers - Reset (6)
(7)
50 Amp Circuit Breaker
20 Amp Circuit Breaker

SMCS Code: 1420-529 The circuit breakers are located on the left side of the
machine in front of the steps.
Depress the button in order to reset the circuit
breakers. If the circuit is functioning properly, the
button will remain depressed. If the button will not i01921776
remain depressed, check the appropriate electrical
circuit. Cooling System Coolant (ELC)
- Change
SMCS Code: 1350-044-NL

Pressurized system: Hot coolant can cause seri-

ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve
the pressure.

NOTICE
Care must be taken to ensure that fluids are contained
Illustration 163
g01105743 during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, Caterpillar

Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.
116 SEBU7887-03
Maintenance Section
Cooling System Coolant (ELC) - Change

Reference: For information about adding Extender

to your cooling system, refer to Operation and NOTICE
Maintenance Manual, Cooling System Coolant Topping off or mixing Cat ELC with other products that
Extender (ELC) - Add or consult your Caterpillar do not meet Caterpillar EC-1 specifications reduces
dealer. the effectiveness of the coolant and shortens coolant
service life.
If an Extended Life Coolant was previously used,
flush the cooling system with clean water. No other Use only Caterpillar products or commercial products
cleaning agents are required. Use the following that have passed the Caterpillar EC-1 specification for
procedure to change the Extended Life Coolant. pre-mixed or concentrate coolants. Use only Extender
with Cat ELC.

Failure to follow these recommendations can result in

shortened cooling system component life.

5. Add the Extended Life Coolant.

Reference: Refer to Operation and Maintenance

Manual, Capacities (Refill) for the capacity of the
cooling system.

6. Start the engine. Run the engine without the

cooling system pressure cap until the water
temperature regulator opens and the coolant level
stabilizes.

g00807153
Illustration 165

The cooling system pressure cap (1) is located under

the engine hood at the rear of the machine.

1. Slowly loosen the cooling system pressure cap in

order to relieve any system pressure.

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

g01000160
machine in order to access coolant drain valve (2). Illustration 166
Open the drain valve at the bottom of the radiator.
Allow the coolant to drain into a suitable container. 7. Maintain the coolant level in sight gauge (3) on
the upper radiator.
3. Flush the cooling system with clean water until the
draining water is clean. Close drain valve (2). 8. Install the cooling system pressure cap. Stop the
engine.
4. Replace the water temperature regulator.

Reference: Refer to Operation and Maintenance

Manual, Cooling System Water Temperature
Regulator - Replace for the correct procedure.
SEBU7887-03 117
Maintenance Section
Cooling System Coolant Extender (ELC) - Add

i01921794

Cooling System Coolant

Extender (ELC) - Add
SMCS Code: 1352-544-NL

Pressurized system: Hot coolant can cause seri-

ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve
the pressure.

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- g00807153
nent containing fluids. Illustration 167

Refer to Special Publication, NENG2500, Caterpillar Cooling system pressure cap (1) is located under the
Tools and Shop Products Guide for tools and supplies hood at the rear of the machine. Tilt the hood in order
suitable to collect and contain fluids on Caterpillar to access the cooling system pressure cap.
products.
1. Slowly loosen the cooling system pressure cap in
Dispose of all fluids according to local regulations and order to relieve any system pressure. Remove the
mandates. cooling system pressure cap.

2. If necessary, drain enough coolant from the

NOTICE radiator in order to allow the addition of the
Topping off or mixing Cat ELC with other products that Extender to the cooling system. The cooling
do not meet Caterpillar EC-1 specifications reduces system drain valve (2) is located on the lower left
the effectiveness of the coolant and shortens coolant side of the radiator.
service life.
3. Add 1.18 L (40 fl oz) of Extender to the cooling
Use only Caterpillar products or commercial products system.
that have passed the Caterpillar EC-1 specification for
pre-mixed or concentrate coolants. Use only Extender
with Cat ELC.

Failure to follow these recommendations can result in

shortened cooling system component life.

When a Caterpillar Extended Life Coolant (ELC) is

used, an Extender must be added to the cooling
system.

Use a 8T-5296 Coolant Test Kit to check the

concentration of the coolant.

Reference: For additional information about g01000160

Illustration 168
the addition of Extender, refer to Special
Publication, SEBU6250, Caterpillar Machine Fluids
4. Check the coolant level at sight gauge (3).
Recommendations or consult your Caterpillar dealer.
Reference: Refer to Operation and Maintenance
Manual, Cooling System Coolant Level - Check
for the correct procedure.
118 SEBU7887-03
Maintenance Section
Cooling System Coolant Level - Check

5. Install the cooling system pressure cap. Close the Note: Obtain a Coolant Sample (Level 1) if the
engine hood. cooling system is filled with any other coolant
instead of Cat ELC. This includes the following
types of coolants.
i01921821

Cooling System Coolant Level Commercial long life coolants that meet the
Caterpillar Engine Coolant Specification -1
- Check (Caterpillar EC1)

SMCS Code: 1350-535-FLV Cat Diesel Engine Antifreeze/Coolant (DEAC)

Commercial heavy-duty coolant/antifreeze

Pressurized system: Hot coolant can cause seri- NOTICE

ous burn. To open cap, stop engine, wait until ra- Always use a designated pump for oil sampling, and
diator is cool. Then loosen cap slowly to relieve use a separate designated pump for coolant sampling.
the pressure. Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
contaminate may cause a false analysis and an incor-
rect interpretation that could lead to concerns by both
dealers and customers.

Note: Level 1 results may indicate a need for

Level 2 Analysis.

g01000175
Illustration 169

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

Coolant level sight gauge (1) is located on the top
radiator.

Maintain the coolant level within the sight gauge. Add

coolant, if necessary. Illustration 170
g01185306

Left side of machine

Note: If it is necessary to add coolant daily, inspect
the cooling system for leaks. The sampling valve (1) for the cooling system is
located on top of the engine toward the front of the
i02375131
engine on the left side of the machine.

Cooling System Coolant Obtain the sample of the coolant as close as possible
to the recommended sampling interval. In order
Sample (Level 1) - Obtain to receive the full effect of SOS analysis, you
must establish a consistent trend of data. In order
SMCS Code: 1350-008; 1395-008; 7542 to establish a pertinent history of data, perform
consistent samplings that are evenly spaced.
Note: It is not necessary to obtain a Coolant Supplies for collecting samples can be obtained from
Sample (Level 1) if the cooling system is filled your Caterpillar dealer.
with Cat ELC (Extended Life Coolant). Cooling
systems that are filled with Cat ELC should have Use the following guidelines for proper sampling of
a Coolant Sample (Level 2) that is obtained at the coolant:
the recommended interval that is stated in the
Maintenance Interval Schedule.
Complete the information on the label for the
sampling bottle before you begin to take the
samples.
SEBU7887-03 119
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain

Keep the unused sampling bottles stored in plastic The sampling valve (1) for the cooling system is
bags. located on top of the engine toward the front of the
engine on the left side of the machine.
Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples Obtain the sample of the coolant as close as possible
from any other location. to the recommended sampling interval. Supplies
for collecting samples can be obtained from your
Keep the lids on empty sampling bottles until you Caterpillar dealer.
are ready to collect the sample.
Refer to Operation and Maintenance Manual,
Place the sample in the mailing tube immediately Cooling System Coolant Sample (Level 1) - Obtain
after obtaining the sample in order to avoid for the guidelines for proper sampling of the coolant.
contamination.
Submit the sample for Level 2 analysis.
Never collect samples from expansion bottles.
Reference: For additional information about coolant
Never collect samples from the drain for a system. analysis, refer to Special Publication, SEBU6250,
Caterpillar Machine Fluids Recommendations or
Submit the sample for Level 1 analysis. consult your Caterpillar dealer.

For additional information about coolant analysis, see

i02186511
Special Publication, SEBU6250, Caterpillar Machine
Fluids Recommendations or consult your Caterpillar
dealer.
Cooling System Water
Temperature Regulator -
i02375133 Replace
Cooling System Coolant SMCS Code: 1355-510; 1393-010
Sample (Level 2) - Obtain
SMCS Code: 1350-008; 1395-008; 7542
Pressurized system: Hot coolant can cause seri-
NOTICE ous burn. To open cap, stop engine, wait until ra-
Always use a designated pump for oil sampling, and diator is cool. Then loosen cap slowly to relieve
use a separate designated pump for coolant sampling. the pressure.
Using the same pump for both types of samples may
contaminate the samples that are being drawn. This
NOTICE
contaminate may cause a false analysis and an incor-
Failure to replace the engines thermostat on a regu-
rect interpretation that could lead to concerns by both
larly scheduled basis could cause severe engine dam-
dealers and customers.
age.

NOTICE
Caterpillar engines incorporate a shunt design cooling
system and require operating the engine with a ther-
mostat installed.

If the thermostat is installed wrong, it will cause the

engine to overheat. Inspect gaskets before assembly
and replace if worn or damaged.

g01185306
Illustration 171
Left side of the machine
120 SEBU7887-03
Maintenance Section
Differential and Final Drive Oil - Change

i02164355

Differential and Final Drive Oil

- Change
SMCS Code: 3278-044; 4011-044

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, Caterpillar

Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

g01105775 Dispose of all fluids according to local regulations and

Illustration 172
mandates.
Replace the water temperature regulator in order
to reduce the chance of problems with the cooling
system.

Replace the water temperature regulator and the

seals while the cooling system is completely drained
or while the coolant is drained to a level that is below
the water temperature regulator housing.

Note: If you are only replacing the water temperature

regulator, drain the coolant to a level that is below the
water temperature regulator housing.

Reference: Refer to Disassembly and Assembly,

RENR9214, C11 and C13 Engines for Caterpillar
Built Machines for the correct procedure for replacing
the water temperature regulator.

g00287529
Illustration 173
Front axle
SEBU7887-03 121
Maintenance Section
Differential and Final Drive Oil Level - Check

i01102280

Differential and Final Drive Oil

Level - Check
SMCS Code: 3278-535-FLV; 4011-535-FLV

Note: Before you measure the oil level, operate the

machine for a few minutes in order to equalize the
oil level.

1. Park the machine on level ground. Lower the

bucket and apply slight downward pressure.
Engage the parking brake. Stop the engine.

g00287531
Illustration 174
Rear axle

Note: The axle housings are equipped with ecology

drain valves.

1. Remove drain plugs (2). Attach a hose to a

suitable drain adapter. Install the adapter in the
drain valve and allow the oil to drain into a suitable
container.

2. Clean the drain plugs and install the drain plugs.

3. Wipe off dipstick/fill plugs (1) and the surfaces

around dipstick/fill plugs (1). Illustration 175
g00285312

Front Axle
4. Remove the dipstick/fill plugs. Fill each axle with
1.0 L (1.06 qt) of 1U-9891 Hydraulic Oil Additive.
Fill the axles with oil.

Reference: Refer to Operation and Maintenance

Manual, Lubricant Viscosities and Refill
Capacities for the type of lubricant and for the
refill capacity.

5. Clean the dipstick/fill plugs and install the

dipstick/fill plugs.

6. Run the machine on level ground for a few minutes

in order to equalize the oil level in the axle. Check
the oil level in the axle.

Reference: Refer to Operation and Maintenance

Manual, Differential and Final Drive Oil Level -
Check for the correct procedure.

g00287527
Illustration 176
Rear Axle
122 SEBU7887-03
Maintenance Section
Differential and Final Drive Oil Sample - Obtain

2. Remove dipstick/fill plug (1) on the left side of the

axle. Wipe off the level gauge with a clean cloth
and reinsert the plug. This will ensure a more
accurate measurement of the oil level.

Note: Make sure that the plug is installed completely

before you check the oil level. If the plug is not
installed completely, an incorrect oil level reading can
occur.

3. Remove dipstick/fill plug (1) again and check the

oil level. Maintain the oil level between the ADD
mark and the FULL mark. Add oil, if necessary.

Reference: Refer to Operation and Maintenance g00884056

Manual, Lubricant Viscosities and Refill Illustration 177
Capacities for the type of lubricant and for the Rear axle
refill capacity.

4. Clean the plug and install the plug.

i01921974

Differential and Final Drive Oil

Sample - Obtain
SMCS Code: 3278-008; 4011-008; 4070-008; 7542

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- Illustration 178
g00884059
ing, adjusting and repair of the product. Be prepared to
Front axle
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
2. The differential and final drives are not equipped
nent containing fluids.
with sampling valves. Obtaining an oil sample will
require the use of a vacuum pump or equivalent
Refer to Special Publication, NENG2500, Caterpillar
in order to extract the oil from the component.
Tools and Shop Products Guide for tools and supplies
Extract the oil through the filler openings on the
suitable to collect and contain fluids on Caterpillar
differential and final drives.
products.
3. Complete any additional required work. Fill the
Dispose of all fluids according to local regulations and
differential and final drives with oil, as required.
mandates.
Install the dipstick/fill plugs.

1. Operate the machine for a few minutes before Reference: For more information, refer to Special
obtaining the oil sample. This will thoroughly mix Publication, SEBU6250, Caterpillar Machine Fluids
the differential oil for a more accurate sample. Recommendations, SOS Oil Analysis and Special
Publication, PEHP6001, How To Take A Good Oil
Sample.

i02189535

Drive Shaft Spline (Center) -

Lubricate
SMCS Code: 3253-086-SN

Wipe all of the fittings before you apply grease to

the fittings.
SEBU7887-03 123
Maintenance Section
Drive Shaft Support Bearing - Lubricate

In order to lubricate the drive shaft support bearing,

NOTICE you must remove the plug and you must insert
To prevent damage to the seal, articulate the machine a grease zerk. After you lubricate the drive shaft
full right or left, before lubricating the splines. support bearing, remove the grease zerk and install
the plug. Do not grease the drive shaft support
bearing more than the recommended interval.
1. Start the engine. Raise the bucket. Release the
parking brake. Articulate the machine to the right
or to the left in order to gain better access to the NOTICE
splined shaft. Do not over grease the drive shaft support bearing.
The excess grease may get into the brake area. Dam-
2. Lower the bucket to the ground. Engage the age to the brakes or the loss of the brakes may occur.
parking brake. Stop the engine. Take precautions in order to avoid getting grease in
the adjacent brake area.

g01106848
Illustration 179
g00111694
Illustration 180
3. Apply grease to the fitting (1). Apply grease until
the relief (2) overruns.

Note: 5P-0960 Molybdenum Grease is preferred.

1P-0808 Multipurpose Grease may be used.

4. Start the engine. Raise the bucket. Release

the parking brake. Reposition the machine in a
straight direction without articulation.

5. Lower the bucket to the ground. Apply a slight

down pressure. Engage the parking brake. Stop
the engine.

i02571965 g00111696
Illustration 181

Drive Shaft Support Bearing - Wipe off the fitting before any lubricant is applied.
Lubricate
Apply lubricant through the fitting on the drive shaft
SMCS Code: 3267-086-BD support bearing. Refer to Operation and Maintenance
Manual, Lubricant Viscosities for the proper grease.
Note: For better access, articulate the machine to
the right or to the left. Because the steering frame
lock cannot be connected, remove the engine start
switch key and turn the battery disconnect switch to
the OFF position in order to keep the machine from
being articulated.
124 SEBU7887-03
Maintenance Section
Drive Shaft Universal Joints - Lubricate

i02571972 The operation of Caterpillar engines with improper

adjustments of the electronic unit injector can reduce
Drive Shaft Universal Joints - engine efficiency. This reduced efficiency could result
Lubricate in excessive fuel usage and/or shortened engine
component life.
SMCS Code: 3251-086
Adjust the electronic unit injector at the same interval
Note: Do not grease the universal joints more as the valve lash adjustment.
than the recommended interval.
Refer to your machines Service Manual or your
Caterpillar dealer for the complete adjustment
procedure.

i02187095

Engine Air Filter Primary

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

1. The rear hood should be opened in order to

access the air filter. The air filter is located on the
right side of the machine.
g01069141
Illustration 182

1. Wipe off the grease fittings before lubricating.

2. Lubricate all five grease fittings on the universal

joints. Refer to Operation and Maintenance
Manual, Lubricant Viscosities for the proper
grease.

i02061807

Electronic Unit Injector -

Inspect/Adjust
g01105972
SMCS Code: 1251-025; 1251-040; 1290-025; Illustration 183
1290-040
2. Remove the cover on air filter housings (3).

3. Remove primary element (2) from the air filter

housing.
The Electronic Control module produces high
voltage. To prevent personal injury make sure the
4. Clean the inside of air filter housing (1).
Electronic Control Module is not powered and the
unit injector solenoids are disconnected.
5. Inspect the primary element. If the pleats, the
gaskets, or the seals are damaged, discard the
NOTICE element. Replace a damaged primary element
The camshafts must be correctly timed with the crank- with a clean primary element.
shaft before an adjustment of the unit injector lash
is made. The timing pins must be removed from the
camshafts before the crankshaft is turned or damage
to the cylinder block will be the result.
SEBU7887-03 125
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace

Cleaning Primary Air Filter Pressurized Air

Elements Pressurized air can be used to clean primary air filter
elements that have not been cleaned more than two
NOTICE times. Pressurized air will not remove deposits of
Caterpillar recommends certified air filter cleaning ser- carbon and oil. Use filtered, dry air with a maximum
vices available at participating Caterpillar dealers. The pressure of 207 kPa (30 psi).
Caterpillar cleaning process uses proven procedures
to assure consistent quality and sufficient filter life.

Observe the following guidelines if you attempt to

clean the filter element:

Do not tap or strike the filter element in order to re-

move dust.

Do not wash the filter element.

Use low pressure compressed air in order to remove

the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage Illustration 184
g00281692
to the pleats.
Note: When the primary air filter elements are
Do not use air filters with damaged pleats, gaskets, or cleaned, always begin with the clean side (inside)
seals. Dirt entering the engine will cause damage to in order to force dirt particles toward the dirty side
engine components. (outside).

The primary air filter element can be used up to Aim the hose so that the air flows inside the element
six times if the element is properly cleaned and the along the length of the filter in order to help prevent
element is inspected. When the primary air filter damage to the paper pleats. Do not aim the stream of
element is cleaned, check for rips or tears in the filter air directly at the primary air filter element. Dirt could
material. The primary air filter element should be be forced further into the pleats.
replaced at least one time per year. This replacement
should be performed regardless of the number of Vacuum Cleaning
cleanings.
Vacuum cleaning is another method for cleaning
primary air filter elements which require daily cleaning
NOTICE
because of a dry, dusty environment. Cleaning with
Do not clean the air filter elements by bumping or tap-
pressurized air is recommended prior to vacuum
ping. This could damage the seals. Do not use ele-
cleaning. Vacuum cleaning will not remove deposits
ments with damaged pleats, gaskets, or seals. Dam-
of carbon and oil.
aged elements will allow dirt to pass through. Engine
damage could result.

Visually inspect the primary air filter elements before

cleaning. Inspect the air filter elements for damage
to the seal, the gaskets, and the outer cover. Discard
any damaged air filter elements.

There are two common methods that are used to

clean primary air filter elements:

Pressurized air
Vacuum cleaning
126 SEBU7887-03
Maintenance Section
Engine Air Filter Secondary Element - Replace

Inspecting the Primary Air Filter Do not use paint, a waterproof cover, or plastic as a
protective covering for storage. An airflow restriction
Elements may result. To protect against dirt and damage, wrap
the primary air filter elements in Volatile Corrosion
Inhibited (VCI) paper.

Place the primary air filter element into a box for

storage. For identification, mark the outside of the
box and mark the primary air filter element. Include
the following information:

Date of cleaning
Number of cleanings
Store the box in a dry location.

g00281693
Illustration 185
i01693619

Inspect the clean, dry primary air filter element. Use Engine Air Filter Secondary
a 60 watt blue light in a dark room or in a similar
facility. Place the blue light in the primary air filter Element - Replace
element. Rotate the primary air filter element. Inspect
the primary air filter element for tears and/or holes. SMCS Code: 1054-510-SE
Inspect the primary air filter element for light that may
show through the filter material. If it is necessary in NOTICE
order to confirm the result, compare the primary air Service the air filter only with the engine stopped. En-
filter element to a new primary air filter element that gine damage could result.
has the same part number.

Do not use a primary air filter element that has any NOTICE
tears and/or holes in the filter material. Do not use Always replace the secondary element. Do not at-
a primary air filter element with damaged pleats, tempt to reuse it by cleaning. Engine damage could
gaskets or seals. Discard damaged primary air filter result.
elements.
Note: Replace the secondary element when you
Storing Primary Air Filter Elements service the primary element for the third time. If
a clean primary element has been installed and
If a primary air filter element that passes inspection a warning for the air filter still occurs, replace the
will not be used, the primary air filter element can secondary element. Also if the exhaust smoke
be stored for future use. remains black and a clean primary element has been
installed, replace the secondary element.

1. Remove the primary element.

Reference: Refer to Operation and Maintenance

Manual, Engine Air Filter Primary Element -
Clean/Replace for the correct procedure.

g00281694
Illustration 186
SEBU7887-03 127
Maintenance Section
Engine Air Precleaner - Clean

1. Empty the precleaner bowl whenever the dirt

reaches the FULL mark.

g00864077
Illustration 187

2. Remove the secondary element. g00101875

Illustration 189

2. Loosen the wing nut on the cover and remove

the cover.

3. Empty the precleaner bowl. Wash the precleaner

bowl and wash the cover.

4. Install the precleaner bowl and install the cover.

Tighten the wing nut until the wing nut is only finger
tight. Do not use a tool to tighten the wing nut.

i02197033

Engine Crankcase Breather -

Illustration 188
g00864079
Clean
3. Cover the air inlet opening. Clean the inside of SMCS Code: 1317-070
the air cleaner housing.

4. Inspect the gasket between the air inlet pipe and

the air cleaner housing. Replace the gasket if the
gasket is damaged.

5. Uncover the air inlet opening. Install a new

secondary element.

6. Install a clean primary element and the cover for

the air cleaner housing.

7. Close the access door.

8. Repeat the procedure for the other air cleaner.

i00103643

Engine Air Precleaner - Clean

SMCS Code: 1055-070
g01109682
Illustration 190
Use the ladder and the platform in order to access
the precleaner bowl. The ladder and the platform are Open the hood on the rear of machine in order to
located on the right side of the machine. access the engine compartment. The crankcase
breather is located on the right side of the engine.
128 SEBU7887-03
Maintenance Section
Engine Oil (High Speed) and Oil Filter - Change

1. Remove the four bolts (1) that hold the breather

(2) onto the cover. Remove the breather.

2. Check the condition of the cover seal (3). Replace

the seal if the seal is damaged.

3. Wash the breather (2) and the filter element in a

clean nonflammable solvent. The filter element is
located inside the breather.

4. Shake the breather or use pressure air in order

to dry the breather.

5. Inspect the breather hose for damage. Replace

the breather hose if it is necessary. g01126916
Illustration 191
6. Install the breather assembly. Install the hose and
install the hose clamp. Abnormally harsh operating cycles or harsh
environments can shorten the service life of
7. Close the access door. the engine oil. Arctic temperatures, corrosive
environments, or extremely dusty conditions may
require a reduction in engine oil change intervals
i02280844 from the recommendations in Table 16 and Table 17.
Also refer to Special Publication, SEBU5898, Cold
Engine Oil (High Speed) and Weather Recommendations. Poor maintenance of
Oil Filter - Change air filters or of fuel filters requires reduced oil change
intervals. See your Caterpillar dealer for more
SMCS Code: 1318-510-HZ information if this product will experience abnormally
harsh operating cycles or harsh environments.
Selection of the Oil Change Interval
NOTICE
A 500 hour engine oil change interval is available, pro-
vided that the operating conditions and recommend-
ed multigrade oil types are met. When these require-
ments are not met, shorten the oil change interval to
250 hours, or use an SOS oil sampling and analysis
program to determine an acceptable oil change inter-
val.

If you select an interval for oil and filter change that is

too long, you may damage the engine.

Caterpillar oil filters are recommended.

Recommended multigrade oil types are listed in Table

16 and in Table 17. Do not use single grade oils.
SEBU7887-03 129
Maintenance Section
Engine Oil (High Speed) and Oil Filter - Change

Table 16 Table 17
966H Wheel Loader 972H Wheel Loader
Engine Oil Change Interval(1) Engine Oil Change Interval(1)
Operating Conditions Operating Conditions
Severe Severe
Normal(2) High Fuel Altitude Normal(2) High Fuel Altitude
Load Sulfur above Load Sulfur above
Multigrade Factor(3) from 1830 m Multigrade Factor(3) from 1830 m
Oil Type above 0.3% to (6000 ft) Oil Type above 0.3% to (6000 ft)
27 L 0.5% 30 L 0.5%
(7.1 US (4) (7.9 US (4)
gal) per gal) per
hr of hr of
fuel fuel
Cat DEO Cat DEO
500 hr 500 hr 500 hr 250 hr(6) 500 hr 500 hr 500 hr 250 hr(6)
Preferred Preferred
ECF-1 ECF-1
11.0 11.0
minimum 500 hr 500 hr 500 hr 250 hr(6) minimum 500 hr 500 hr 500 hr 250 hr(6)
TBN(4) TBN(4)
Preferred Preferred
ECF-1 ECF-1
TBN(4) 500 hr 500 hr 250 hr(5) 250 hr(6) TBN(4) 500 hr 500 hr 250 hr(5) 250 hr(6)
below 11.0 below 11.0
API CG-4 500 hr 250 hr(5) 250 hr(5) 250 hr(6) API CG-4 500 hr 250 hr(5) 250 hr(5) 250 hr(6)
(1) The traditional oil change interval for engines is 250 hours. (1) The traditional oil change interval for engines is 250 hours.
The standard oil change interval in this machine is 500 hours, if The standard oil change interval in this machine is 500 hours, if
the operating conditions and recommended oil types that are the operating conditions and recommended oil types that are
listed in this table are met. Improvements in the engine allow listed in this table are met. Improvements in the engine allow
this engine oil change interval. This new standard interval is not this engine oil change interval. This new standard interval is not
permitted for other machines. Refer to the applicable Operation permitted for other machines. Refer to the applicable Operation
and Maintenance Manuals for the other machines. and Maintenance Manuals for the other machines.
(2) Normal conditions include these factors: Fuel sulfur below (2) Normal conditions include these factors: Fuel sulfur below
0.3%, altitude below 1830 m (6000 ft), and good air filter and 0.3%, altitude below 1830 m (6000 ft), and good air filter and
fuel filter maintenance. Normal conditions do not include high fuel filter maintenance. Normal conditions do not include high
load factor, harsh operating cycles, or harsh environments. load factor, harsh operating cycles, or harsh environments.
(3) High load factors can shorten the service life of your engine (3) High load factors can shorten the service life of your engine
oil. Continuous heavy load cycles and very little idle time oil. Continuous heavy load cycles and very little idle time
result in increased fuel consumption and oil contamination. result in increased fuel consumption and oil contamination.
These factors deplete the oil additives more rapidly. If the These factors deplete the oil additives more rapidly. If the
average fuel consumption of your 966H Wheel Loader exceeds average fuel consumption of your 972H Wheel Loader exceeds
27 L (7.1 US gal) per hour, follow the High Load Factor 30 L (7.9 US gal) per hour, follow the High Load Factor
recommendations in Table 16. To determine average fuel recommendations in Table 17. To determine average fuel
consumption, measure average fuel consumption for a period consumption, measure average fuel consumption for a period
of 50 to 100 hours. If the application of the machine is changed, of 50 to 100 hours. If the application of the machine is changed,
the average fuel consumption may change. the average fuel consumption may change.
(4) For sulfur content above 0.5%, refer to Operation and (4) For sulfur content above 0.5%, refer to Operation and
Maintenance Manual, SEBU6250, Total Base Number (TBN) Maintenance Manual, SEBU6250, Total Base Number (TBN)
and Fuel Sulfur Levels for Direct Injection (DI) Diesel Engines. and Fuel Sulfur Levels for Direct Injection (DI) Diesel Engines.
(5) In order to verify an oil change interval of 500 hours, refer to (5) In order to verify an oil change interval of 500 hours, refer to
Program A below. Program A below.
(6) Use Program B below to determine an appropriate interval. (6) Use Program B below to determine an appropriate interval.

Adjustment of the Oil Change Interval

Note: Your Caterpillar dealer has additional
information on these programs.

Program A

Verification for an Oil Change Interval of 500 Hours

130 SEBU7887-03
Maintenance Section
Engine Oil (High Speed) and Oil Filter - Change

This program consists of three oil change intervals of Procedure for Changing the Engine
500 hours. Oil sampling and analysis is done at 250
hours and 500 hours for each of the three intervals
Oil and Filter
for a total of six oil samples. The analysis includes
oil viscosity and infrared (IR) analysis of the oil. If NOTICE
all of the results are satisfactory, the 500 hour oil Care must be taken to ensure that fluids are contained
change interval is acceptable for the machine in that during performance of inspection, maintenance, test-
application. Repeat Program A if you change the ing, adjusting and repair of the product. Be prepared to
application of the machine. collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
If a sample does not pass the oil analysis, take one nent containing fluids.
of these actions:
Refer to Special Publication, NENG2500, Caterpillar
Shorten the oil change interval to 250 hours. Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
Proceed to Program B. products.

Change to a preferred oil type in Table 16 or Table Dispose of all fluids according to local regulations and
17. mandates.

Program B Your machine may be equipped with a high speed

arrangement for changing the engine oil. The high
Optimizing Oil Change Intervals speed arrangement allows service personnel to
change the oil from the engine access door on
Begin with a 250 hour oil change interval. The oil the right side of the machine. The high speed
change intervals are adjusted by increments. Each arrangement allows the oil to be changed faster than
interval is adjusted an additional 50 hours. Periodic oil conventional methods.
sampling and analysis is done during each interval.
The analysis includes oil viscosity and infrared (IR)
analysis of the oil. Repeat Program B if you change
the application of the machine.

If an oil sample does not pass the analysis, shorten

the oil change interval, or change to a preferred
multigrade oil type in the listing above.

References

Reference: Form, PEDP7035, Optimizing Oil

Change Intervals

Reference: Form, PEDP7036, SOS Fluid Analysis

Reference: Form, PEHP7076, Understanding SOS

Services Test

g00812715
Illustration 192

1. Open the service door that is located on the right

side of the machine.

2. Remove the cap that protects the male coupler.

Connect an oil pump to the fitting. The fitting on
the machine is a male coupler.

3. Turn on the oil pump and withdraw the engine oil

from the engine oil pan.

4. Open the engine hood.

SEBU7887-03 131
Maintenance Section
Engine Oil (High Speed) and Oil Filter - Change

8. Tighten the filter according to the instructions

that are printed on the filter. Use the index marks
as a guide. For non-Caterpillar filters, use the
instructions that are provided with the filter.

Note: You may need to use a Caterpillar strap

wrench, or another suitable tool, in order to turn
the filter to the amount that is required for final
installation. Make sure that the installation tool does
not damage the filter.

9. Connect an oil pump to the male coupler for the

high speed arrangement. Fill the crankcase with
new oil.

Reference: Refer to Operation and Maintenance

Manual, Lubricant Viscosities and Refill
Capacities for the correct type of oil and for the
correct amount of oil.

10. Clean the end of the male coupler. Clean the cap
Illustration 193
g01109909 that covers the male coupler and install the cap.

5. Use a strap type wrench to remove the filter 11. Start the engine and allow the oil to warm. Check
element. Inspect the filter. the machine for oil leaks.

6. Clean the filter mounting base with a clean cloth. 12. Check the engine oil level.
Make sure that the used filter gasket has been
completely removed. Reference: Refer to Operation and Maintenance
Manual, Engine Oil Level - Check for the correct
procedure.

13. Stop the engine. Close the engine access door

and the engine hood.

g00101318
Illustration 194

7. Apply a thin film of clean engine oil to the seal

on the new filter element. Install a new engine oil
filter hand tight until the seal of the engine oil filter
contacts the base. Note the position of the index
marks on the filter in relation to a fixed point on
the filter base.

Note: There are rotation index marks on the engine

oil filter that are spaced 90 degrees or 1/4 or a turn
away from each other. When you tighten the engine
oil filter, use the rotation index marks as a guide.
132 SEBU7887-03
Maintenance Section
Engine Oil Level - Check

i02188149 i02188187

Engine Oil Level - Check Engine Oil Sample - Obtain

SMCS Code: 1000-535-FLV SMCS Code: 1348-008; 7542

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, Caterpillar

Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

1. Operate the machine for a few minutes before

obtaining the oil sample. This will thoroughly mix
the engine oil for a more accurate sample.
g01106343
Illustration 195
2. Open the engine hood.
Open the service door that is located on the right
side of the machine. The oil level dipstick is located
in the service door.

g01106355
Illustration 197

3. Use the sampling valve in order to obtain a

Illustration 196
g00746755 sample of engine oil.

Maintain the oil level between the FULL mark and 4. Close the engine hood.
ADD mark on the dipstick. Check the level of the
engine oil while the engine is shut off. Add oil, if Reference: For more information, refer to Special
necessary. Publication, SEBU6250, Caterpillar Machine Fluids
Recommendations, SOS Oil Analysis and Special
Publication, PEHP6001, How To Take A Good Oil
Sample.
SEBU7887-03 133
Maintenance Section
Engine Oil and Filter - Change

i02280850 Table 18

Engine Oil and Filter - Change 966H Wheel Loader

Engine Oil Change Interval(1)
SMCS Code: 1318-510 Operating Conditions
Severe
Selection of the Oil Change Interval
Normal(2) High Fuel Altitude
Load Sulfur above
NOTICE Multigrade Factor(3) from 1830 m
A 500 hour engine oil change interval is available, pro- Oil Type above 0.3% to (6000
vided that the operating conditions and recommend- 27 L 0.5% ft)
ed multigrade oil types are met. When these require- (7.1 US (4)
ments are not met, shorten the oil change interval to gal) per
hr of
250 hours, or use an SOS oil sampling and analysis fuel
program to determine an acceptable oil change inter-
val. Cat DEO
500 hr 500 hr 500 hr 250 hr(6)
Preferred
If you select an interval for oil and filter change that is ECF-1
too long, you may damage the engine. 11.0
minimum 500 hr 500 hr 500 hr 250 hr(6)
TBN(4)
Caterpillar oil filters are recommended. Preferred
Recommended multigrade oil types are listed in Table ECF-1
18 and in Table 19. Do not use single grade oils. TBN(4) 500 hr 500 hr 250 hr(5) 250 hr(6)
below 11.0
API CG-4 500 hr 250 hr(5) 250 hr(5) 250 hr(6)
(1) The traditional oil change interval for engines is 250 hours.
The standard oil change interval in this machine is 500 hours, if
the operating conditions and recommended oil types that are
listed in this table are met. Improvements in the engine allow
this engine oil change interval. This new standard interval is not
permitted for other machines. Refer to the applicable Operation
and Maintenance Manuals for the other machines.
(2) Normal conditions include these factors: Fuel sulfur below
0.3%, altitude below 1830 m (6000 ft), and good air filter and
fuel filter maintenance. Normal conditions do not include high
load factor, harsh operating cycles, or harsh environments.
(3) High load factors can shorten the service life of your engine
oil. Continuous heavy load cycles and very little idle time
result in increased fuel consumption and oil contamination.
g01126916
These factors deplete the oil additives more rapidly. If the
Illustration 198 average fuel consumption of your 966H Wheel Loader exceeds
API Trademark 27 L (7.1 US gal) per hour, follow the High Load Factor
recommendations in Table 18. To determine average fuel
Commercial oils that are licensed by the American Petroleum consumption, measure average fuel consumption for a period
Institute (API) bear this trademark. Commercial oils that do of 50 to 100 hours. If the application of the machine is changed,
not bear this trademark are not licensed and these oils are not the average fuel consumption may change.
recommended. Oils that are not listed in Table 18 and in Table 19 (4) For sulfur content above 0.5%, refer to Operation and
are not recommended. Maintenance Manual, SEBU6250, Total Base Number (TBN)
and Fuel Sulfur Levels for Direct Injection (DI) Diesel Engines.
Abnormally harsh operating cycles or harsh (5) In order to verify an oil change interval of 500 hours, refer to

environments can shorten the service life of Program A below.

(6) Use Program B below to determine an appropriate interval.
the engine oil. Arctic temperatures, corrosive
environments, or extremely dusty conditions may
require a reduction in engine oil change intervals
from the recommendations in Table 18 and Table 19.
Also refer to Special Publication, SEBU5898, Cold
Weather Recommendations. Poor maintenance of
air filters or of fuel filters requires reduced oil change
intervals. See your Caterpillar dealer for more
information if this product will experience abnormally
harsh operating cycles or harsh environments.
134 SEBU7887-03
Maintenance Section
Engine Oil and Filter - Change

Table 19 This program consists of three oil change intervals of

972H Wheel Loader
500 hours. Oil sampling and analysis is done at 250
Engine Oil Change Interval(1) hours and 500 hours for each of the three intervals
for a total of six oil samples. The analysis includes
Operating Conditions oil viscosity and infrared (IR) analysis of the oil. If
Severe all of the results are satisfactory, the 500 hour oil
change interval is acceptable for the machine in that
Normal(2) High Fuel Altitude application. Repeat Program A if you change the
Load Sulfur above application of the machine.
Multigrade Factor(3) from 1830 m
Oil Type above 0.3% to (6000
If a sample does not pass the oil analysis, take one
30 L 0.5% ft)
(7.9 US of these actions:
(4)
gal) per
hr of Shorten the oil change interval to 250 hours.
fuel
Cat DEO
Proceed to Program B.
500 hr 500 hr 500 hr 250 hr(6)
Preferred
Change to a preferred oil type in Table 18 or Table
ECF-1 19.
11.0
minimum 500 hr 500 hr 500 hr 250 hr(6) Program B
TBN(4)
Preferred Optimizing Oil Change Intervals
ECF-1
TBN(4) 500 hr 500 hr 250 hr(5) 250 hr(6) Begin with a 250 hour oil change interval. The oil
below 11.0 change intervals are adjusted by increments. Each
interval is adjusted an additional 50 hours. Periodic oil
API CG-4 500 hr 250 hr(5) 250 hr(5) 250 hr(6)
sampling and analysis is done during each interval.
(1) The traditional oil change interval for engines is 250 hours. The analysis includes oil viscosity and infrared (IR)
The standard oil change interval in this machine is 500 hours, if analysis of the oil. Repeat Program B if you change
the operating conditions and recommended oil types that are
listed in this table are met. Improvements in the engine allow the application of the machine.
this engine oil change interval. This new standard interval is not
permitted for other machines. Refer to the applicable Operation If an oil sample does not pass the analysis, shorten
and Maintenance Manuals for the other machines. the oil change interval, or change to a preferred
(2) Normal conditions include these factors: Fuel sulfur below
multigrade oil type in the listing above.
0.3%, altitude below 1830 m (6000 ft), and good air filter and
fuel filter maintenance. Normal conditions do not include high
load factor, harsh operating cycles, or harsh environments. References
(3) High load factors can shorten the service life of your engine
oil. Continuous heavy load cycles and very little idle time Reference: Form, PEDP7035, Optimizing Oil
result in increased fuel consumption and oil contamination. Change Intervals
These factors deplete the oil additives more rapidly. If the
average fuel consumption of your 972H Wheel Loader exceeds
30 L (7.9 US gal) per hour, follow the High Load Factor Reference: Form, PEDP7036, SOS Fluid Analysis
recommendations in Table 19. To determine average fuel
consumption, measure average fuel consumption for a period Reference: Form, PEHP7076, Understanding SOS
of 50 to 100 hours. If the application of the machine is changed,
the average fuel consumption may change.
Services Test
(4) For sulfur content above 0.5%, refer to Operation and
Maintenance Manual, SEBU6250, Total Base Number (TBN)
and Fuel Sulfur Levels for Direct Injection (DI) Diesel Engines.
(5) In order to verify an oil change interval of 500 hours, refer to
Program A below.
(6) Use Program B below to determine an appropriate interval.

Adjustment of the Oil Change Interval

Note: Your Caterpillar dealer has additional
information on these programs.

Program A

Verification for an Oil Change Interval of 500 Hours

SEBU7887-03 135
Maintenance Section
Engine Oil and Filter - Change

Procedure for Changing the Oil

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, Caterpillar

Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
g00101318
Illustration 200
Dispose of all fluids according to local regulations and
mandates. 5. Apply a thin coat of oil to the seal on the new
engine oil filter. Install a new engine oil filter hand
1. Open the engine hood. tight until the seal of the engine oil filter contacts
the base. Note the position of the index marks on
2. The drain plug is located on the left side of the the filter in relation to a fixed point on the filter
engine oil pan toward the rear of the machine. base.
Open the oil drain valve and allow the oil to drain
into a suitable container. Close the drain valve. Note: There are rotation index marks on the engine
oil filter that are spaced 90 degrees or 1/4 or a turn
away from each other. When you tighten the engine
oil filter, use the rotation index marks as a guide.

6. Tighten the filter according to the instructions

that are printed on the filter. Use the index marks
as a guide. For non-Caterpillar filters, use the
instructions that are provided with the filter.

Note: You may need to use a Caterpillar strap

wrench, or another suitable tool, in order to turn
the filter to the amount that is required for final
installation. Make sure that the installation tool does
not damage the filter.

g01109909
Illustration 199

3. Use a strap type wrench to remove the engine oil

filter from the right side of the engine. Inspect the
oil filter.

4. Clean the filter mounting base. Make sure that all

of the used gasket has been completely removed.

g00806758
Illustration 201
136 SEBU7887-03
Maintenance Section
Engine Valve Lash - Check

7. Remove oil filler cap (1) on the right side of the

engine. Fill the crankcase with new oil.

Reference: Refer to Operation and Maintenance

Manual, Lubricant Viscosities and Refill
Capacities for the correct type of oil and for the
correct amount of oil.

8. Clean the oil filler cap and install the oil filler cap.

9. Start the engine and allow the oil to warm. Check

for any oil leaks.

10. Check the oil level on dipstick (2).

g00941949
Reference: Refer to Operation and Maintenance Illustration 202
Manual, Engine Oil Level - Check for the correct
procedure. 1. Start the engine. Run the engine at low idle.

11. Close the engine hood and stop the engine.

i01181536

Engine Valve Lash - Check

SMCS Code: 1105-535

For the correct procedure, refer to the appropriate

Service Manual module for your machines engine or
consult your Caterpillar dealer.

Note: A qualified mechanic should adjust the engine

valve lash because special tools and training are Illustration 203
g00038585
required.
2. Watch the top surface of each valve rotator.
i01959344
Whenever an inlet valve closes or an exhaust
valve closes, each valve rotator should turn.
Engine Valve Rotators - Inspect
3. If a valve rotator fails to rotate, consult your
SMCS Code: 1109-040 Caterpillar dealer for service.

Note: Caterpillar recommends replacing valve

rotators that are operating improperly. An improperly
operating valve rotator will shorten valve life because
When inspecting the valve rotators, protective of accelerated wear on the valves.
glasses or face shield and protective clothing
must be worn, to prevent being burned by hot oil Note: If a damaged valve rotator is not replaced,
or spray. some valve face guttering could result. Metal particles
from the valve could fall into the cylinder. This could
cause damage to the piston head and to the cylinder
head.
Electrical shock hazard. The electronic unit injec-
tor system uses 90-120 volts.
SEBU7887-03 137
Maintenance Section
Ether Starting Aid Cylinder - Replace

i02188275 3. Remove the gasket. Install the new gasket that is

provided with each new ether starting aid cylinder.
Ether Starting Aid Cylinder -
Replace 4. Install new ether starting aid cylinder (2) hand
tight. Tighten retaining clamp (1) securely.
(If Equipped)
5. Close the engine hood.
SMCS Code: 1456-510-CD

i01715517

Fuel System - Prime

Ether is poisonous and flammable.
SMCS Code: 1250-548
Breathing ether vapors or repeated contact of
ether with skin can cause personal injury. NOTICE
Care must be taken to ensure that fluids are contained
Use ether only in well ventilated areas. during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
Do not smoke while changing ether cylinders. collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
Use ether with care to avoid fires. nent containing fluids.
Do not store replacement ether cylinders in living Refer to Special Publication, NENG2500, Caterpillar
areas or in the operators compartment. Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
Do not store ether cylinders in direct sunlight or products.
at temperatures above 49 C (120 F).
Dispose of all fluids according to local regulations and
Discard cylinders in a safe place. Do not puncture mandates.
or burn cylinders.

Keep ether cylinders out of the reach of unautho- Note: The volume of the air in the water separator
rized personnel. is small. Usually, it is not necessary to prime the
fuel system if only the water separator element was
To avoid possible injury, be sure the brakes are ap- changed.
plied and all controls are in Hold or Neutral when
starting the engine.

g01106393
Illustration 204

1. Open the access door. The ether starting aid

cylinder is mounted on the left side of the machine
next to the air cleaner.

2. Loosen retaining clamp (1) and unscrew ether

starting aid cylinder (2).
138 SEBU7887-03
Maintenance Section
Fuel System Primary Filter (Water Separator) - Drain

i01715535

Fuel System Primary Filter

(Water Separator) - Drain
SMCS Code: 1263-543

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, Caterpillar

Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

g00882774
Illustration 205

1. Stop the engine and open the engine hood. The

fuel priming pump is located above the primary
fuel filter on the right side of the machine. This
machine is equipped with an electric fuel priming
pump. The toggle switch for the pump is located
on the filter base. Operate the fuel pump for
approximately 60 seconds.

2. Start the engine.

Note: Additional priming may be needed if you are

priming because of the following circumstances:

The engine will not start.

The engine starts but the engine continues to
misfire.

The engine starts but the engine continues to emit

smoke.
g00882783
The engine has run out of fuel. Illustration 206

The fuel injectors have been removed from the 1. Open the engine hood. The water separator is
engine. located on the bottom of the primary fuel filter on
the right side of the machine.
Operate an electric fuel pump for approximately 30
seconds for this additional priming. 2. Open the drain valve on the bottom of the water
separator bowl. Allow the water and the fuel to
drain into a suitable container.

3. Close the drain valve.

SEBU7887-03 139
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace

Note: The water separator is under suction during

normal engine operation. Tighten the drain valve
securely in order to prevent air leakage into the fuel
system.

4. Close the engine hood.

i02250381

Fuel System Primary Filter

(Water Separator) Element -
Replace
SMCS Code: 1260-510; 1263-510-FQ

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- Illustration 207
g00806773
ing any compartment or disassembling any compo-
nent containing fluids. 2. Open drain valve (3) on the bottom of water
separator bowl (2). Allow the water and the fuel to
Refer to Special Publication, NENG2500, Caterpillar drain into a suitable container.
Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar 3. Use a strap type wrench in order to remove the
products. primary fuel filter (1). Unscrew the sediment bowl
from the fuel filter.
Dispose of all fluids according to local regulations and
mandates. 4. Clean the water separator bowl and the O-ring
groove.
NOTICE
Do not fill fuel filters with fuel before installing them. Note: The water separator bowl is reusable. Do not
The fuel will not be filtered and could be contaminated. discard the water separator bowl.
Contaminated fuel will cause accelerated wear to fuel
system parts. The fuel system should be primed prior 5. Inspect the O-ring seal on the water separator
to starting the engine. bowl. Replace the O-ring seal, if necessary.

6. Lubricate the O-ring seal with clean diesel fuel or

1. Open the engine hood. The primary fuel filter is with engine oil. Place the O-ring seal in the water
located on the right side of the machine. separator bowl.

7. Install the water separator bowl onto the new filter

element until the filter element is snug.

8. Apply a thin coat of clean diesel fuel to the seal on

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

Note: There are rotation index marks on the fuel filter

that are spaced 90 degrees or 1/4 of a turn away
from each other. When you tighten the fuel filter, use
the rotation index marks as a guide.
140 SEBU7887-03
Maintenance Section
Fuel System Secondary Filter - Replace

9. Tighten the filter according to the instructions 4. Lubricate the seal of a new fuel filter with clean
that are printed on the filter. Use the index marks diesel fuel. Install the new fuel filter hand tight
as a guide. For non-Caterpillar filters, use the until the seal of the fuel filter contacts the base.
instructions that are provided with the filter. Note the position of the index marks on the filter in
relation to a fixed point on the filter base.
Note: You may need to use a Caterpillar strap
wrench, or another suitable tool, in order to turn Note: There are rotation index marks on the fuel filter
the filter to the amount that is required for final that are spaced 90 degrees or 1/4 of a turn away
installation. Make sure that the installation tool does from each other. When you tighten the fuel filter, use
not damage the filter. the rotation index marks as a guide.

10. Close drain valve (1). 5. Tighten the filter according to the instructions
that are printed on the filter. Use the index marks
Note: The water separator element is under suction as a guide. For non-Caterpillar filters, use the
during normal engine operation. Tighten the drain instructions that are provided with the filter.
valve securely in order to prevent air leakage into
the fuel system. Note: You may need to use a Caterpillar strap
wrench, or another suitable tool, in order to turn
11. Prime the fuel system in order to fill the water the filter to the amount that is required for final
separator element with fuel. installation. Make sure that the installation tool does
not damage the filter.
Reference: Refer to Operation and Maintenance
Manual, Fuel System - Prime for the correct NOTICE
procedure. Do not fill fuel filters with fuel before installing them.
Contaminated fuel will cause accelerated wear to fuel
12. Close the engine hood. system parts.

i02187930
6. Prime the fuel system.
Fuel System Secondary Filter - Reference: Refer to Operation and Maintenance
Replace Manual, Fuel System - Prime for the correct
procedure.
SMCS Code: 1261-510-SE
7. Close the engine hood.

i02619810

Fuel Tank Cap and Strainer -

Clean
SMCS Code: 1273-070-Z2; 1273-070-STR

g01106196
Illustration 208

1. Open the hood. Secondary fuel filter (1) is located

on the right side of the machine.

2. Open drain valve (2) in order to allow fuel to flow

from the filter. The fuel will flow out of hose (3).
Catch the fuel in a suitable container and dispose
of the fuel properly. Close the drain valve. Remove
the fuel filter. Dispose of the used filter properly. Illustration 209
g00882838

3. Clean the filter mounting base. Make sure that all Open the rear grill in order to access the fuel tank
of the used gasket is removed. cap.
SEBU7887-03 141
Maintenance Section
Fuel Tank Water and Sediment - Drain

1. Lift lever (2) and turn the lever counterclockwise i01922977

until the lever stops. Remove the fuel tank cap.
Fuel Tank Water and Sediment
2. Inspect seal (4) for damage. Replace the seal, if
necessary.
- Drain
SMCS Code: 1273-543-M&S
3. Remove screws (1), filter assembly (3), valve (5)
and the gaskets.
NOTICE
Care must be taken to ensure that fluids are contained
4. Remove the strainer from the filler tube.
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
5. Wash the fuel tank cap and the strainer in a clean,
collect the fluid with suitable containers before open-
nonflammable solvent.
ing any compartment or disassembling any compo-
nent containing fluids.
6. Install a new cap filter kit. Install the other
components in reverse order.
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies
7. Install the strainer.
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

g01000726
Illustration 211
g01312901
Illustration 210
The drain valve is under the fuel tank at the rear of
(1) Cap the machine.
(2) Fuel Cap Boot
(3) Fuel Tank
1. Open drain valve (1). Allow the water and the
sediment to drain into a suitable container.
8. Inspect the fuel cap boot(if equipped). If the fuel
cap boot is damaged, replace the fuel cap boot.
2. Close the drain valve.
If your machine does not have a fuel cap boot,
contact your Caterpillar dealer for information
about the fuel cap boot. i02200478

9. Wash the fuel cap boot in a clean, nonflammable Fuses - Replace

solvent.
SMCS Code: 1417-510
10. Install the fuel cap boot and the fuel tank cap.
NOTICE
Replace fuses with the same type and size only. Oth-
erwise, electrical damage can result.

If it is necessary to replace fuses frequently, an electri-

cal problem may exist. Contact your Caterpillar dealer.
142 SEBU7887-03
Maintenance Section
Fuses - Replace

(8) ECM Switched Power ...................... 10 Amperes

Fuses The fuses protect the electrical
system from a circuit that has been (9) Front Cab Floodlights ...................... 15 Amperes
overloaded. Change a fuse if the element
separates. If the element of a new fuse separates, (10) Beacon and Heated Mirrors ........... 10 Amperes
check the circuit. Repair the circuit, if necessary.
(11) Turn Signal Flasher, Front Flood Relays, and
Rear Flood Relays ........................... 10 Amperes

(12) Machine Security System and Product

Link .................................................. 10 Amperes

(13) LH Indicator Display and RH Indicator

Display ............................................. 10 Amperes

(14) Tilt Position Sensor and Lift Position

Sensor ............................................. 10 Amperes

(15) Lever Sensors and LH Brake Pedal

Sensor ............................................. 10 Amperes

(16) Air Seat and Heated Seat .............. 10 Amperes

(17) EMS, Quad Gauge, Tachometer, and

Backlights ........................................ 10 Amperes

(18) Wiper and Washer for the Front and the Rear
g01000750 Windows .......................................... 10 Amperes
Illustration 212
(19) Payload Control System (PCS) ..... 10 Amperes

(20) Voltage Converter for Radio .......... 10 Amperes

(21) Voltage Converter Memory

(Attachment) .................................... 10 Amperes

(22) Engine ECM .................................. 15 Amperes

(23) Transmission ECM ........................ 15 Amperes

(24) Implement ECM ............................. 15 Amperes

(25) ECAP and Center Dash Indicator

Illustration 213
g01078009 Display ............................................. 10 Amperes

The fuses are located in the cab on the right side of (26) LH Tail and Clearance Lights ......... 10 Amperes
the operator seat.
(27) Hood Actuator ................................ 10 Amperes
(1) Axle Oil Cooler Clutch ..................... 20 Amperes
(28) Stop Lamps ................................... 10 Amperes
(2) HMU Shift Handle ............................ 10 Amperes
(29) Horn ............................................... 10 Amperes
(3) HVAC Blower ................................... 20 Amperes
(30) Voltage Converter Memory
(4) Quick Coupler .................................. 10 Amperes (Standard) ........................................ 10 Amperes

(5) Rear Cab Floodlights ....................... 15 Amperes (31) Key Start Switch and Product Link .. 10 Amperes

(6) Spare ............................................... 10 Amperes (32) Dome Lamps ................................. 10 Amperes

(7) Secondary Steering ......................... 10 Amperes

SEBU7887-03 143
Maintenance Section
High Intensity Discharge Lamp (HID) - Replace

i02245859 6. Reattach the electrical power to the HID lamp.

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

SMCS Code: 1434-510

i02375128

Hood Tilt Actuator - Lubricate

HID lamps operate at very high voltages. To avoid SMCS Code: 7275-086
electrical shock and personal injury, disconnect
power before servicing HID lamps. Wipe all fittings before lubricating.

HID bulbs become very hot during operation.

Before servicing, remove power from lamp for at
least five minutes to ensure lamp is cool.

NOTICE
Although HID bulb materials may change over time,
HID bulbs produced at the time of the printing of this
manual contain mercury. When disposing of this com-
ponent, or any waste that contains mercury, please
use caution and comply with any applicable laws.
g01185302
Illustration 214
1. Remove the electrical power from the high
intensity discharge lamp (HID). The electrical 1. Raise the engine hood. The hood tilt actuator is
power must be removed from the HID lamp for located on the left side of the machine.
at least five minutes, in order to ensure that the
bulb is cool. 2. Fully extend the cylinder and wipe off the inner
post with a clean cloth. Then, lubricate the entire
2. Disassemble the housing for the HID lamp in order length of the inner post.
to have access to the bulb.
3. Wipe off both fittings on the cylinder. Then, apply
Note: On some HID lamps, the bulb is an integral lubricant through the two fittings until the lubricant
part of the lens assembly. The bulb is not removed escapes back through each fitting.
separately from the lens assembly. Replace the
entire lens assembly on these HID lamps. 4. Close the engine hood.

3. Remove the bulb from the HID lamp.

4. Install the replacement bulb in the HID lamp.

If the bulb is an integral part of the lens assembly,

install the replacement lens assembly in the HID
lamp.

Note: In order to avoid failure to the bulb that is

premature, avoid touching the bulbs surface with
your bare hands. Clean any fingerprints from the bulb
with alcohol prior to operation.

5. Reassemble the housing for the HID lamp. Ensure

that any printing on the lens is oriented correctly
with respect to the HID lamps mounting position
on the machine.
144 SEBU7887-03
Maintenance Section
Hydraulic System Biodegradable Oil Filter Element - Replace

i02375417

Hydraulic System
Biodegradable Oil Filter
Element - Replace
SMCS Code: 5068-510

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo- g00101318
Illustration 216
nent containing fluids.

Refer to Special Publication, NENG2500, Caterpillar 3. Apply a thin coat of hydraulic oil to the seals on
Dealer Service Tool Catalog for tools and supplies the new filters. Install each new hydraulic oil filter
suitable to collect and contain fluids on Caterpillar hand tight until the seals of the hydraulic oil filters
products. contact each filter base. Note the position of the
index marks on each filter in relation to a fixed
Dispose of all fluids according to local regulations and point on each filter base.
mandates.
Note: There are rotation index marks on each
hydraulic oil filter that are spaced 90 degrees or 1/4
of a turn away from each other. When you tighten
the hydraulic oil filters, use the rotation index marks
as a guide.

4. Tighten each filter according to the instructions

that are printed on each filter. Use the index marks
as a guide. For non-Caterpillar filters, use the
instructions that are provided with the filter.

Note: You may need to use a Caterpillar strap

wrench, or another suitable tool, in order to turn
the filter to the amount that is required for final
installation. Make sure that the installation tool does
g01108153 not damage the filter.
Illustration 215

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

The hydraulic filters are located on the right side
Inspect the hydraulic system for leaks.
of the machine under the platform. There are two
hydraulic oil filters. Each filter must be replaced
during this procedure.

1. Use a strap type wrench to remove each filter

element. Dispose of the used filter elements
properly.

2. Clean the filter mounting bases. Make sure that all

of the used seals are completely removed.

g01185406
Illustration 217

6. Maintain the oil level above the ADD COLD mark

on the sight gauge. Add hydraulic oil, if necessary.
SEBU7887-03 145
Maintenance Section
Hydraulic System Oil - Change

i02375399 If an oil sampling program is not available, the

standard 2000 oil change interval should be used.
Hydraulic System Oil - Change
SMCS Code: 5056-044 Measured Data
The following information should be monitored
Selection of the Oil Change Interval through sampling of the oil:

Your machine may be able to use a 4000 hour Significant changes in wear metals should be
interval for the hydraulic oil. The hydraulic oil is in monitored. These metals include iron, copper,
the system that is not integral to the service brakes, chromium, lead, aluminum, and tin.
the clutches, the final drives, or the differentials.
The standard change interval is 2000 hours. The oil Significant changes in the following additives
should be monitored during intervals of 500 hours. should be monitored: zinc, calcium, magnesium,
The extended 4000 hour interval can be used if the and phosphorus.
following criteria are met.
Contaminants should not be present. These
Oil Filters contaminants include fuel and antifreeze. Water
content should be .5 percent or less.
Caterpillar oil filters are recommended. The interval
for changing the oil filter should be 500 hours. The silicon level should not exceed 15 parts per
million for new oil. The particle counts should be
monitored.
Oil
The 4000 hour interval for changing the oil is for the The recommended level of cleanliness for
Caterpillar machines that are operated in the field
following oil types.
is ISO 18/15 or cleaner. The cleanliness should be
monitored by particle count analysis. The levels
Caterpillar Hydraulic Oil (HYDO) of contamination should not exceed the normal
by more than two ISO codes. Action should be
Caterpillar Transmission and Drive Train Oil taken in order to determine the cause of the
(TDTO)
contamination. The system should be returned to
the original levels of contamination.
Caterpillar TDTO-TMS
Caterpillar Diesel Engine Oil There should not be significant changes in sodium,
silicon, copper, and potassium.
Caterpillar Biodegradable Hydraulic Oils (HEES)
The allowable level of oxidation is 40 percent (0.12
Abs units).
Caterpillar Multipurpose Tractor Oil (MTO)
Heavy-duty diesel engine oils with a minimum zinc The kinematic viscosity of 100 C (212 F) oil
should not exceed a change of more than 2 cSt
content of 900 ppm
from new oil.
If Caterpillar oils cannot be used, use heavy-duty oils
with the following classification: Caterpillar ECF-1,
API CG-4, API CF, and TO-4. These oils must have
a minimum zinc additive of 0.09 percent (900 ppm).

Note: Industrial hydraulic oils are not recommended

in Caterpillar hydraulic systems.

Monitoring the Condition of the Oil

The oil should be monitored during intervals of 500
hours. Caterpillars standard SOS Fluids Analysis or
an equivalent oil sampling program should be used.

The current guidelines for cleanliness of the oil

should be observed. Refer to Measured Data.
146 SEBU7887-03
Maintenance Section
Hydraulic System Oil - Change

Procedure for Changing the 3. The hydraulic tank is behind the cab of the
machine. Press the button on breaker relief valve
Hydraulic Oil (1) in order to relieve any tank pressure.

NOTICE 4. Remove hydraulic tank filler cap (2) and the filler
Care must be taken to ensure that fluids are contained strainer. The filler strainer is located right beneath
during performance of inspection, maintenance, test- the hydraulic tank filler cap. Wash the filler cap
ing, adjusting and repair of the product. Be prepared to and the strainer in a clean, nonflammable solvent.
collect the fluid with suitable containers before open- Install the strainer.
ing any compartment or disassembling any compo-
nent containing fluids. 5. Inspect the gasket on the hydraulic tank filler cap
for damage. Replace the gasket, if necessary.
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

1. Operate the machine in order to warm the

hydraulic oil.

2. Park the machine on level ground. Lower the

attachment to the ground and apply slight
downward pressure. Engage the parking brake
and stop the engine.

g01108775
Illustration 220

6. The hydraulic tank has a remote drain plug which

is located on the right side of the machine under
the platform. Remove drain plug (4). Wash the
drain plug in a clean, nonflammable solvent.

7. The hydraulic tank is equipped with an ecology

g01185530
drain valve. Attach a hose to a suitable drain
Illustration 218 adapter. Install the adapter in the drain valve and
allow the oil to drain into a suitable container.

8. After you have drained the oil, remove the adapter

from the drain opening.

NOTICE
Never start the engine while the hydraulic oil tank is
being drained or while the hydraulic oil tank is empty.
Excessive wear and damage to the hydraulic compo-
nents can occur.

9. Close the drain valve. Install the drain plug.

g01185539 10. Change the hydraulic oil filter.

Illustration 219
SEBU7887-03 147
Maintenance Section
Hydraulic System Oil Filter - Replace

Reference: Refer to Operation and Maintenance i02375329

Manual, Hydraulic System Oil Filter - Replace for
the correct procedure. Hydraulic System Oil Filter -
11. Fill the hydraulic tank with clean oil. Make sure
Replace
that the oil level is at the FULL mark on sight SMCS Code: 5068-510
gauge (3). Install the filler cap.
NOTICE
Reference: Refer to Operation and Maintenance
Care must be taken to ensure that fluids are contained
Manual, Lubricant Viscosities and Refill
during performance of inspection, maintenance, test-
Capacities for the correct type of oil and for the
ing, adjusting and repair of the product. Be prepared to
correct amount of oil.
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
12. Start the engine and run the engine for at least ten
nent containing fluids.
seconds. Then, stop the engine and add hydraulic
oil to the tank until the oil level is at the FULL
Refer to Special Publication, NENG2500, Caterpillar
mark on the sight gauge. Install the filler cap.
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
13. Start the engine and run the engine at low idle.
products.
Cycle the implements so that all hydraulic systems
are filled with oil.
Dispose of all fluids according to local regulations and
mandates.
Note: If the alert indicator for a low oil level comes
on, stop the engine and immediately add oil to the
hydraulic tank. The oil level should not be below the
suction ports in the hydraulic tank while the engine
is running.

14. Add hydraulic oil to the tank until the oil level is at
the FULL mark on the sight gauge.

15. Stop the engine. Top off the hydraulic tank so

that the oil level is at the FULL mark on the sight
gauge. Install the filler cap.

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

bubbles are present in the hydraulic oil, air is entering
the hydraulic system. Inspect the hydraulic suction g01108153
line and the hose clamps. Illustration 221

16. If necessary, tighten any loose clamps or any The hydraulic filters are located on the right side
loose connections. Replace any damaged hoses. of the machine under the platform. There are two
hydraulic oil filters. Each filter must be replaced
during this procedure.

1. Use a strap type wrench to remove each filter

element. Dispose of the used filter elements
properly.

2. Clean the filter mounting bases. Make sure that all

of the used seals are completely removed.
148 SEBU7887-03
Maintenance Section
Hydraulic System Oil Level - Check

6. The oil gauge and the hydraulic oil filler are on

the left side of the machine above the platform.
Maintain the oil level above the ADD COLD mark
on the sight gauge. Add hydraulic oil, if necessary.

i02375341

Hydraulic System Oil Level -

Check
SMCS Code: 5056-535-FLV

g00101318
Illustration 222

3. Apply a thin coat of hydraulic oil to the seals on

the new filters. Install each new hydraulic oil filter
hand tight until the seals of the hydraulic oil filters
contact each filter base. Note the position of the
index marks on each filter in relation to a fixed
point on each filter base.

Note: There are rotation index marks on each

hydraulic oil filter that are spaced 90 degrees or 1/4
of a turn away from each other. When you tighten
g01185406
the hydraulic oil filters, use the rotation index marks Illustration 224
as a guide.

4. Tighten each filter according to the instructions

that are printed on each filter. Use the index marks
as a guide. For non-Caterpillar filters, use the
instructions that are provided with the filters.

Note: You may need to use a Caterpillar strap

wrench, or another suitable tool, in order to turn
the filter to the amount that is required for final
installation. Make sure that the installation tool does
not damage the filter.

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

Inspect the hydraulic system for leaks. g01185435
Illustration 225

The hydraulic tank is located on the left side of the

machine behind the cab.

The lift arms must be lowered with the bucket flat in

order to check the hydraulic oil. Check the hydraulic
oil level while the engine is stopped. Maintain the oil
level above the ADD COLD mark on sight gauge
(2). If necessary, remove filler cap (1) slowly and add
oil.

g01185406
Illustration 223
SEBU7887-03 149
Maintenance Section
Hydraulic System Oil Sample - Obtain

i02375351 5. Close the access door to the service center on the

right side of the machine.
Hydraulic System Oil Sample
- Obtain Reference: For more information, refer to Special
Publication, SEBU6250, Caterpillar Machine Fluids
SMCS Code: 5050-008; 5056-008; 7542 Recommendations, SOS Oil Analysis and Special
Publication, PEHP6001, How To Take A Good Oil
Sample.
NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test- i02375419
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open- Hydraulic Tank Breaker Relief
ing any compartment or disassembling any compo-
nent containing fluids.
Valve - Clean
SMCS Code: 5118-070
Refer to Special Publication, NENG2500, Caterpillar
Dealer Service Tool Catalog for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

1. Operate the machine for a few minutes before

obtaining the oil sample. Operate the hydraulic
controls. This will thoroughly mix the hydraulic oil
for a more accurate sample.

g01185542
Illustration 227

The hydraulic tank breaker relief valve is located on

the top of the hydraulic tank behind the cab of the
machine.

1. Press the button on the top of the hydraulic

breaker in order to relieve the pressure in the
hydraulic tank. Remove the hydraulic tank breaker
relief valve.

2. Clean the hydraulic tank breaker relief valve in a

Illustration 226
g01185445 clean, nonflammable solvent. Shake the breaker
relief valve dry or use pressure air to dry the
2. If the machine is equipped with conventional oil, breaker relief valve.
open the access door to the service center on
the right side of the machine. The hydraulic oil 3. Install the hydraulic tank breaker relief valve.
filter is above the shelf. The sampling valve for the
hydraulic oil is located on the hydraulic oil filter i02189793
base.
Logging Fork Clamp -
3. If the machine is equipped with biodegradable
hydraulic oil, open the access door to the service Lubricate
center on the right side of the machine. The
hydraulic oil filter is above the shelf. The sampling SMCS Code: 6113-086-BD; 6410-086-BD
valve for the hydraulic oil is located on the
hydraulic oil filter base. Wipe off all fittings before any lubricant is applied.

4. Use the in-line sampling valve in order to obtain a

sample of hydraulic oil.
150 SEBU7887-03
Maintenance Section
Oil Filter - Inspect

Nonferrous metals can indicate wear on the

aluminum parts of the engine such as main bearings,
rod bearings, or turbocharger bearings.

Small amounts of debris may be found in the filter

element. This could be caused by friction and by
normal wear. Consult your Caterpillar dealer in order
to arrange for further analysis if an excessive amount
of debris is found.

Using an oil filter element that is not recommended

by Caterpillar can result in severe engine damage
to engine bearings, to the crankshaft, and to other
parts. This can result in larger particles in unfiltered
g01107035
oil. The particles could enter the lubricating system
Illustration 228 and the particles could cause damage.
Apply lubricant through three fittings on each side
of the logging fork. i01794005

There is a total of six fittings. Quick Coupler - Check

SMCS Code: 6129-535
i02106227
When you install a work tool on the quick coupler,
Oil Filter - Inspect inspect the engagement of the coupler pins. If there is
play between the coupler pins and the corresponding
SMCS Code: 1308-507; 3004-507; 3067-507; bores, inspect the coupler pins and the bores for
5068-507 damage or wear.

Inspect a Used Filter for Debris If there is play between the quick coupler and the
hooks of the work tool, inspect the quick coupler and
the hooks for wear or for damage.

Make any necessary repairs before you operate the

work tool.

i02062586

Quick Coupler - Lubricate

SMCS Code: 6129-086

Note: Refer to Operation and Maintenance Manual,

Lubricant Viscosities for more information on
g00100013
the types of grease to use. Refer to Special
Illustration 229 Publication, SEBU6250, Caterpillar Machine Fluids
The element is shown with debris. Recommendations for more information on grease.

Use a filter cutter to cut the filter element open. Wipe off all lubricant fittings before you apply
Spread apart the pleats and inspect the element for lubricant through the lubricant fittings.
metal and for other debris. An excessive amount of
debris in the filter element can indicate a possible Do not lubricate the wedge and the wear plates.
failure. Friction is needed in order to hold the wedge in place
during backfilling.
If metals are found in the filter element, a magnet can
be used to differentiate between ferrous metals and
nonferrous metals.

Ferrous metals can indicate wear on steel parts and

on cast iron parts.
SEBU7887-03 151
Maintenance Section
Radiator Core - Clean

i02191167 i02192350

Radiator Core - Clean Refrigerant Dryer - Replace

SMCS Code: 1353-070-KO SMCS Code: 7322-510

1. Open the radiator grill at the rear of the machine.

Personal injury can result from contact with refrig-

erant.

Contact with refrigerant can cause frost bite. Keep

face and hands away to help prevent injury.

Protective goggles must always be worn when re-

frigerant lines are opened, even if the gauges in-
dicate the system is empty of refrigerant.

Always use precaution when a fitting is removed.

Slowly loosen the fitting. If the system is still un-
der pressure, release it slowly in a well ventilated
area.

Personal injury or death can result from inhaling

refrigerant through a lit cigarette.

Inhaling air conditioner refrigerant gas through a

lit cigarette or other smoking method or inhaling
Illustration 230
g01107157 fumes released from a flame contacting air con-
ditioner refrigerant gas, can cause bodily harm or
2. Use the control knob (1) in order to release the death.
hydraulic oil cooler. Swing hydraulic oil cooler (2)
and condenser (3) away from the radiator. Do not smoke when servicing air conditioners or
wherever refrigerant gas may be present.

Use a certified recovery and recycling cart to prop-

erly remove the refrigerant from the air condition-
ing system.

g00101939
Illustration 231

3. You can use compressed air, high pressure water,

or steam to remove dust and other debris from
the radiator fins. However, the use of compressed
air is preferred. Illustration 232
g01107270

(1) Refrigerant accumulator

4. Swing the hydraulic oil cooler and the air (2) Refrigerant dryer
conditioner condenser (if equipped) back into the
operating position. Access refrigerant accumulator (1) from the left side
of the machine. Access in-line refrigerant dryer (2)
5. Close the radiator grill. from the right side of the machine.
152 SEBU7887-03
Maintenance Section
Ride Control Accumulator - Check

Refer to Service Manual, SENR5664, Refrigerant

Accumulator - Remove and Install for the
replacement procedure of accumulator (1).

Refer to Service Manual, SENR5664, In-Line

Refrigerant Dryer - Remove and Install for the
replacement procedure of refrigerant dryer (2).

Note: When you operate the machine in a climate

with high humidity, replace the in-line refrigerant dryer
after every 1000 service hours or 6 months.

i02194127

Ride Control Accumulator -

Check
SMCS Code: 5077-535-R6

Note: When the ride control accumulator is properly

charged, the fore and aft motion of the machine is Illustration 233
g01309725
reduced by the ride control accumulator.
Open the roading fender. Apply lubricant through one
Special tools and equipment are required in order fitting on the hinge. There is one hinge on each side
to test the accumulator. of the machine.
Reference: For more information, refer to Testing
and Adjusting, RENR8858, 966H Wheel Loader and i01457460
972H Wheel Loader Electrohydraulic System, Ride
Control Accumulator - Test and Charge or consult Rollover Protective Structure
your Caterpillar dealer. (ROPS) - Inspect
i02616510
SMCS Code: 7323-040; 7325-040

Roading Fender Hinges -

Lubricate
SMCS Code: 7252-086-RNG

Wipe off the fitting before any lubricant is applied.

g00762107
Illustration 234
SEBU7887-03 153
Maintenance Section
Seat Belt - Inspect

Inspect the ROPS for bolts that are loose or damaged. Note: Within three years of the date of installation or
Use original equipment parts only to replace bolts within five years of the date of manufacture, replace
that are damaged or missing. Tighten the four the seat belt. Replace the seat belt at the date which
cab mounting bolts to a torque of 850 100 Nm occurs first. A date label for determining the age of
(629 74 lb ft). the seat belt is attached to the seat belt, the seat belt
buckle, and the seat belt retractor.
Note: Apply oil to all bolt threads before installation.
Failure to apply oil can result in improper bolt torque. If your machine is equipped with a seat belt
extension, also perform this inspection procedure for
Do not repair the ROPS by welding reinforcement the seat belt extension.
plates to the ROPS. Consult your Caterpillar dealer
for repair of cracks in any welds, in any castings, or
i02429594
in any metal section of the ROPS.
Seat Belt - Replace
i02429589
SMCS Code: 7327-510
Seat Belt - Inspect
Within three years of the date of installation or within
SMCS Code: 7327-040 five years of the date of manufacture, replace the
seat belt . Replace the seat belt at the date which
Always check the condition of the seat belt and the occurs first. A date label for determining the age of
condition of the seat belt mounting hardware before the seat belt is attached to the seat belt, the seat belt
you operate the machine. Replace any parts that are buckle, and the seat belt retractor.
damaged or worn before you operate the machine.

g01152685
Illustration 236
(1) Date of installation (retractor)
g00932801 (2) Date of installation (buckle)
Illustration 235 (3) Date of manufacture (tag) (fully extended web)
Typical example (4) Date of manufacture (underside) (buckle)

Check the seat belt mounting hardware (1) for wear Consult your Caterpillar dealer for the replacement of
or for damage. Replace any mounting hardware that the seat belt and the mounting hardware.
is worn or damaged. Make sure that the mounting
bolts are tight. If your machine is equipped with a seat belt
extension, also perform this replacement procedure
Check buckle (2) for wear or for damage. If the buckle for the seat belt extension.
is worn or damaged, replace the seat belt.
i02197967
Inspect the seat belt (3) for webbing that is worn or
frayed. Replace the seat belt if the seat belt is worn Service Brake Wear Indicator -
or frayed.
Check
Consult your Caterpillar dealer for the replacement of
the seat belt and the mounting hardware. SMCS Code: 4255-535-IND

Reference: For information about checking the

service brake wear indicator, refer to Testing and
Adjusting, Braking System for the machine that is
being serviced or consult your Caterpillar dealer.
154 SEBU7887-03
Maintenance Section
Steering Column Spline (Command Control Steering) - Lubricate

i02585698 i02502006

Steering Column Spline Steering Column Spline (HMU

(Command Control Steering) - Steering) - Lubricate
Lubricate SMCS Code: 4310-086-SN; 4338-086-SN
SMCS Code: 4310-086-SN; 4338-086-SN

g01240200
Illustration 238

The metering pump is located under the cab.

Crushing Hazard. Connect the steering frame lock

g00812993 between front and rear frames before servicing the
Illustration 237
machine in the articulation area. Disconnect the
steering frame lock and secure it in the stored po-
1. Remove the steering shaft from the machine.
sition before resuming operation. Failure to do so
could result in serious injury or death.
Reference: Refer to Disassembly and Assembly
Manual for the removal procedure and for the
installation procedure. Refer to Operation and Maintenance Manual,
Steering Frame Lock before entering the articulation
2. Wipe off all of the fittings before any lubricant is joint.
applied.
Note: Do not disconnect any hydraulic lines from the
3. Refer to Operation and Maintenance Manual, metering pump.
Lubricant Viscositiesfor the proper grease to
use. Apply the grease through fittings (1), (2), (3), Use the following steps to lubricate the splines on
(4), (5), (6), (7), and (8). the steering column:

4. Install the steering shaft on the machine.

SEBU7887-03 155
Maintenance Section
Steering Cylinder Bearings - Lubricate

g01294342 g01294357
Illustration 239 Illustration 242
(1) Panel
(2) Bolts 4. Lower the pump in order to expose the splines (6).

1. Remove five bolts (2) and panel (1) from each 5. Clean the male splines on the steering column.
side of the machine. Clean the female splines in the pump.

6. Apply proper grease to the splines. Refer to

Operation and Maintenance Manual, Lubricant
Viscosities for selecting the proper grease.

7. Push the pump into position.

8. Tighten the four bolts that hold the pump.

9. Test the steering system.

i02405791

Steering Cylinder Bearings -

Illustration 240
g01294346
Lubricate
SMCS Code: 4303-086-BD

Crushing Hazard. Insure that the machine ignition

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

g01294352
Illustration 241

2. Support the metering pump (3). Do not loosen the

hose couplings (5).

3. Loosen the four bolts (4) that hold the pump.

156 SEBU7887-03
Maintenance Section
Steering Pilot Oil Screen (Command Control Steering) - Clean/Replace

i01923541

Steering Pilot Oil Screen

(Command Control Steering) -
Clean/Replace
SMCS Code: 4304-070-Z3; 4304-510-Z3

Personal injury can result from working with

cleaning solvent.

Illustration 243
g01105600 Because of the volatile nature of many cleaning
solvents, extreme caution must be exercised
(1) Location of the grease fittings for the rod ends
when using them. If unsure about a particular
(2) Remote location of the grease fittings for the head ends cleaning fluid, refer to the manufacturers instruc-
tions and directions.

Always wear protective clothing and eye protec-

tion when working with cleaning solvents.

g01105611
Illustration 244
Location of the grease fittings for the rod ends (both sides)

g01000991
Illustration 246

The screen group (3) is located behind the cab.

1. Disconnect hoses (1) and (2) that are connected

to the screen group (3).

2. Remove the two connectors that are attached to

the block.

3. Use an allen wrench in order to remove the two

screens from screen group (3).
g01105595
Illustration 245
4. Wash the screens in a clean, nonflammable
Remote location of the grease fittings for the rod ends
solvent.
Wipe off the fittings before any lubricant is applied.
5. Dry each screen with pressure air. Inspect each
The rod end of the steering cylinders are lubricated screen for damage. Replace the screen if the
by using standard grease fittings (3). screen is damaged.
The head ends of the steering cylinders are lubricated 6. Install the screens. Install the connectors and
by using remote grease fittings (4) that are located on connect the hoses.
the right side of the machine in front of the steps.
SEBU7887-03 157
Maintenance Section
Tire Inflation - Check

i02305841

Tire Inflation - Check

SMCS Code: 4203-535-AI

g01002772
Illustration 248

3. Remove drain plug (1) on the bottom of the

transfer case.
g01160201
Illustration 247 4. Change the transmission oil filter.

Always obtain proper tire inflation pressures and Reference: Refer to Operation and Maintenance
maintenance recommendations for the tires on your Manual, Transmission Oil Filter - Replace for the
machine from your tire supplier. Measure the tire correct procedure.
pressure on each tire.

Inflate the tires with nitrogen , if necessary.

Reference: Refer to the Tire Inflation Information

section of the Operation and Maintenance Manual
for more information.

i02189470

Transmission Oil - Change

SMCS Code: 3030-044

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.
g00884724
Illustration 249
Refer to Special Publication, NENG2500, Caterpillar
Tools and Shop Products Guide for tools and supplies 5. The magnetic strainer is on the right rear side
suitable to collect and contain fluids on Caterpillar of the transfer case. Remove the four bolts, the
products. cover and the seal that holds the magnets and
the screen in place.
Dispose of all fluids according to local regulations and
mandates. 6. Remove the screen and the magnets from the
transfer case housing.
1. Operate the engine in order to warm the
transmission oil. Park the machine on level 7. Wash the screen in a clean, nonflammable
ground. Lower the bucket and apply slight solvent. Use a bristle brush or pressure air to
downward pressure. clean the screen. Clean the magnets. Replace
any damaged magnets.
2. Engage the parking brake. Stop the engine.
158 SEBU7887-03
Maintenance Section
Transmission Oil Filter - Replace

8. Clean the cover. Inspect the cover seal. Replace 13. Start and run the engine at low idle. Inspect the
the cover seal if the seal is damaged. machine for leaks. Slowly operate the transmission
controls in order to circulate the transmission oil.
9. Insert the magnets and the screen into the transfer
case housing. Install the seal, the cover and the 14. Check the transmission oil level.
four bolts.
Reference: Refer to Operation and Maintenance
10. Clean the transmission oil drain plug and install Manual, Transmission Oil Level - Check for the
the transmission oil drain plug. correct procedure.

i02194865

Transmission Oil Filter -

Replace
SMCS Code: 3004-510; 3067-510

NOTICE
Care must be taken to ensure that fluids are contained
during performance of inspection, maintenance, test-
ing, adjusting and repair of the product. Be prepared to
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, Caterpillar

Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
g01106816
Illustration 250
Dispose of all fluids according to local regulations and
11. Remove the oil filler cap on the left side of the mandates.
machine and fill the transmission with oil.

Reference: Refer to Operation and Maintenance

Manual, Lubricant Viscosities and Refill
Capacities for the type of lubricant and for the
refill capacity.

g01002778
Illustration 251 g01108389
Illustration 252

12. Remove the breather from the top of the transfer

case. Wash the breather in a clean, nonflammable The transmission oil filter is located on the right side
solvent. Install the breather. of the machine under the platform.
SEBU7887-03 159
Maintenance Section
Transmission Oil Level - Check

1. Operate the machine in order to warm the oil. Park i01468938

the machine on level ground. Lower the bucket to
the ground and apply slight downward pressure. Transmission Oil Level - Check
2. Engage the parking brake and stop the engine. SMCS Code: 3030-535-FLV

3. Open the access panel.

4. Remove the filter housing drain plug and allow the

oil in the filter to drain into a suitable container.

5. Use a strap type wrench to remove the filter

housing.

6. Remove the used filter element. Dispose of the

used filter element properly.

7. Clean the filter housing and the filter housing base

with a clean, nonflammable solvent.

8. Inspect the filter housing seal. Replace the seal

if the seal is damaged.

9. Install the new filter element into the transmission

filter housing. Clean the filter housing drain plug
and install the drain plug.
g00766406
Illustration 253
10. Start the engine. Slowly operate the transmission
controls in order to circulate the transmission oil. The sight gauge for the transmission oil level is
Check the machine for oil leaks. located on the left side of the machine near the
articulation joint.
11. Check the transmission oil level.
1. Operate the machine for a few minutes in order to
Reference: Refer to Operation and Maintenance warm the transmission oil.
Manual, Transmission Oil Level - Check for the
correct procedure. 2. Park the machine on a hard, level surface. Put the
transmission control into the NEUTRAL position.
Lower the bucket to the ground with a slight
downward pressure. Engage the parking brake.

Note: Before the machine is started, the transmission

oil level should be above MIN START mark (1) on
the upper end of the sight gauge.

3. Check the oil level while the engine is running at

low idle.

While the engine is running at low idle, the

transmission oil level should be between the MIN
mark (3) and the MAX mark (2).

4. If necessary, remove the filler cap and add oil.

160 SEBU7887-03
Maintenance Section
Transmission Oil Sample - Obtain

i02195036 i02189520

Transmission Oil Sample - Window Washer Reservoir -

Obtain Fill
SMCS Code: 3080-008; 7542 SMCS Code: 7306-544

NOTICE NOTICE
Care must be taken to ensure that fluids are contained When operating in freezing temperatures, use
during performance of inspection, maintenance, test- Caterpillar nonfreezing window washer solvent or
ing, adjusting and repair of the product. Be prepared to equivalent. System damage can result from freezing.
collect the fluid with suitable containers before open-
ing any compartment or disassembling any compo-
nent containing fluids.

Refer to Special Publication, NENG2500, Caterpillar

Tools and Shop Products Guide for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.

Dispose of all fluids according to local regulations and

mandates.

1. Operate the machine for a few minutes before

obtaining the oil sample. This will thoroughly mix
the transmission oil for a more accurate sample. g01106828
Illustration 255

Window Washer Reservoir The window

washer reservoir is located under an access
door on the platform on the right side of the
machine. Fill the window washer reservoir through
the filler opening.

i01552025

Window Wiper -
Inspect/Replace
SMCS Code: 7305-040; 7305-510
g01108497
Illustration 254

2. The sampling valve for the transmission oil is

located on the transmission oil filter base on the
right side of the machine under the platform. Use
the in-line sampling valve in order to obtain a
sample of transmission oil.

Reference: For more information, refer to Special

Publication, SEBU6250, Caterpillar Machine Fluids
Recommendations, SOS Oil Analysis and Special
Publication, PEHP6001, How To Take A Good Oil
Sample.

g00807031
Illustration 256

Inspect the condition of the wiper blades. Replace

the wiper blades if the wiper blades are worn or
damaged or if the streaking occurs.
SEBU7887-03 161
Maintenance Section
Windows - Clean

i00037755

Windows - Clean
SMCS Code: 7310-070

g00038949
Illustration 257

Use commercially available window cleaning

solutions in order to clean the windows. Clean the
outside windows from the ground unless handholds
are available.
162 SEBU7887-03
Reference Information Section
Reference Materials

Reference Information Special Publication, PEHJ0009, Product Data Sheet

for Caterpillar Hydraulic Oil (HYDO) (SAE 10W)
Section
Special Publication, PEHP6047, Product Data Sheet
for Caterpillar Biodegradable Hydraulic Oil (HEES)

Reference Materials Miscellaneous Publications

i02702378 Power Train Disassembly and Assembly, RENR6422,
Tire and Rim - Remove and Install
Reference Material
Special Publication, PECP9067, One Safe Source
SMCS Code: 1000; 7000
Special Publication, PEDP9131, Fluid Contamination
Cooling System - The Silent Thief

Special Publication, PMEP5027, Label - ELC Special Publication, PEWJ0074, Cat Filter & Fluid
Radiator Label Application Guide

Special Publication, PEHJ0067, Product Data Sheet Special Publication, SEBD0400 , Dictionary of
for Caterpillar ELC Pictographic Symbols

Special Publication, PEHP9554, Product Data Special Publication, SEBD0717, Diesel Fuels and
Sheet for Caterpillar DEAC (Diesel Engine Your Engine
Antifreeze/Coolant)
Special Publication, SEBF1015, Improving
Special Publication, SEBD0518, Know Your Cooling Component Durability - Final Drives and Differentials
System
Special Publication, SEBU6250, Caterpillar Machine
Special Publication, SEBD0970, Coolant and Your Fluid Recommendations
Engine
Special Publication, SEBU5898, Cold Weather
Recommendations
Grease
Special Publication, SENR5664, Air Conditioning
Data Sheet, NEHP6010, Cat Ultra 5Moly Grease and Heater R-134a for All Caterpillar Machines
(NLGI grade 1 and grade 2)
Special Publication, SENR9620, Improving Fuel
Data Sheet, NEHP6011, Cat Arctic Platinum Grease System Durability
(NLGI grade 0)
Special Publication, SMBU6981, Emissions Control
Data Sheet, NEHP6012, Cat Desert Gold Grease Warranty Information
(NLGI grade 2)
Special Instruction, SMHS7867, Nitrogen Tire
Data Sheet, NEHP6015, Cat High Speed Ball Inflation Group
Bearing Grease (NLGI grade 2)

Special Publication, PEGJ0035, Grease Selection Oil

Guide
Special Publication, PEHP3050, Product Data Sheet
Data Sheet, PEHJ0088, Cat Multipurpose Grease for Caterpillar Multipurpose Tractor Oil (MTO)
(NLGI grade 2)
Special Publication, PEHP6001, How to Take a
Data Sheet, PEHP0002, Cat Advanced 3Moly Good Oil Sample
Grease (NLGI grade 2)
Special Publication, PEHJ0007, Product Data Sheet
for Caterpillar Arctic TDTO (SAE 0W-20) (synthetic
Hydraulic Oil blend)
Special Publication, PEGP6028, Caterpillar Special Publication, PEHJ0008, Product Data Sheet
Hydraulic Systems Management Guide for Caterpillar Arctic DEO (SAE 0W-30)
SEBU7887-03 163
Reference Information Section
Reference Materials

Special Publication, PEHJ0030, Product Data Sheet Safety Manuals

for Caterpillar Synthetic Gear Oil (SAE 75W-140)
Safety Manual, SEBU5407, Safety Manual
Special Publication, PEHJ0059, Product Data Sheet
for Caterpillar DEO (SAE 10W-30) Operation and Maintenance Manual, SEBU8257,
The European Union Physical Agents (Vibration)
Special Publication, PEHP7506, Product Data Sheet Directive 2002/44/EC
for Caterpillar TDTO (SAE 10W, SAE 30, SAE 50)

Special Publication, PEHP7508, Product Data Sheet

SOS Information
for Caterpillar Gear Oil (GO) (SAE 80W-90 and SAE
Special Publication, PEDP7036, SOS Services
85W-140)
Special Publication, PEHP7052, Making the Most
Special Publication, PEHP7062, Product Data Sheet
of SOS Services
for Caterpillar DEO Synthetic (SAE 5W-40)
Special Publication, PEHP7057, SOS Coolant
Special Publication, PEHP9530, Product Data Sheet
Analysis
for Caterpillar FDAO (SAE 60)
Special Publication, PEHP7076, Understanding
Special Publication, PEHP9570, Product Data Sheet
SOS Services Tests
for Caterpillar FDAO Synthetic (Multigrade)

Special Publication, PELJ0179, Caterpillar Engine Specifications Manuals

Crankcase Fluid-1 Specifications (Cat ECF-1)
Specifications Manual, SENR3130, Torque
Special Publication, PEHP8035, Product Data Sheet Specifications
for TDTO Transmission Multi-Season (TMS)

Special Publication, SEBD0640, Oil and Your

Tools
Engine Special Publication, NENG2500, Caterpillar Dealer
Service Tool Catalog
Parts Manuals
Parts Manual, SEBP3743, 966H Wheel Loader(S/N:
Additional Reference Material
A6D) SAE J183, Classification This can normally be
found in the SAE handbook.
Parts Manual, SEBP3744, 972H Wheel Loader(S/N:
A7D) SAE J313, Diesel Fuels This can be found in the
SAE handbook. Also, this publication can be obtained
Parts Manual, SEBP3847, 966H Wheel Loader(S/N: from your local technological society, from your local
A6G) library, or from your local college.
Parts Manual, SEBP3848, 972H Wheel Loader(S/N: SAE J754, Nomenclature This can normally be
A7G) found in the SAE handbook.
Parts Manual, XEBP8558, 966H Wheel Loader(S/N: Engine Manufacturers Association, Engine Fluids
A6J) Data Book
Parts Manual, XEBP8559, 972H Wheel Loader(S/N: Engine Manufacturers Association
A7J) Two North LaSalle Street, Suite 2200
Chicago, Illinois USA 60602
ROPS/FOPS Structure E-mail: [email protected]
(312) 827-8700
Special Publication, SEBD1587, What ROPS/FOPS Facsimile: (312) 827-8737
Certification Means

Special Publication, SEHS6929, Inspection,

Maintenance and Repair of ROPS and Attachment
Installation Guidelines
164 SEBU7887-03
Reference Information Section
Reference Materials

i00852444

Decommissioning and
Disposal
SMCS Code: 1000; 7000

Decommissioning and disposal will vary with local

regulations. Consult the nearest Caterpillar dealer
for additional information.
SEBU7887-03 165
Index Section

Index
A C

Additional Messages .............................................. 11 Cab Air Filter - Clean/Replace.............................. 113

Aggregate Autodig (If Equipped) ........................... 72 Capacities (Refill) .................................................. 99
Operating Modes of the Autodig System ........... 73 Case Drain Screen (Strainer) (Steering Pump,
Alternate Exit ......................................................... 38 Hydraulic Fan Pump, Motor) - Clean .................. 114
Articulation Bearings - Lubricate.......................... 104 Changing Direction and Speed.............................. 82
Automatic Lubrication Grease Tank - Fill (If Circuit Breakers - Reset ....................................... 115
Equipped) .......................................................... 104 Cooling System Coolant (ELC) - Change............. 115
The Groeneveld Automatic TWIN Greasing Cooling System Coolant Extender (ELC) - Add.... 117
System ........................................................... 104 Cooling System Coolant Level - Check ................ 118
Automatic Lubrication System (If Equipped) ......... 71 Cooling System Coolant Sample (Level 1) -
The Caterpillar Automatic TWIN Greasing Obtain ................................................................. 118
System ............................................................. 71 Cooling System Coolant Sample (Level 2) -
The Lincoln Quicklub Lubrication System.......... 71 Obtain ................................................................. 119
Autoshift Control .................................................... 78 Cooling System Water Temperature Regulator -
Automatic Shifting (Command Control Replace............................................................... 119
Steering)........................................................... 78 Crushing Prevention and Cutting Prevention ........ 16
Automatic Shifting (Conventional Steering) ....... 78
Downshifting (Command Control Steering) ....... 79
Downshifting (Conventional Steering)................ 79 D
Manual Shifting .................................................. 78
Axle Oscillation Bearings - Lubricate................... 105 Daily Inspection ..................................................... 36
Decommissioning and Disposal .......................... 164
Diagnostic Lines (Remote Pressure Taps) .......... 100
B Electrohydraulic System .................................. 100
Differential and Final Drive Oil - Change ............. 120
Backup Alarm ........................................................ 64 Differential and Final Drive Oil Level - Check...... 121
Backup Alarm - Test ............................................ 105 Differential and Final Drive Oil Sample - Obtain.. 122
Battery - Clean..................................................... 106 Drive Shaft Spline (Center) - Lubricate................ 122
Battery - Recycle ................................................. 106 Drive Shaft Support Bearing - Lubricate.............. 123
Battery Disconnect Switch..................................... 63 Drive Shaft Universal Joints - Lubricate .............. 124
Battery Hold-Down - Tighten ............................... 106
Battery or Battery Cable - Inspect/Replace ......... 107
Before Operation ............................................. 20, 36 E
Before Starting Engine .......................................... 20
Belt - Inspect/Adjust/Replace .............................. 107 Electrical Storm Injury Prevention ......................... 20
Brake Accumulator - Check................................. 108 Electronic Unit Injector - Inspect/Adjust............... 124
Brake Discs - Check ............................................ 108 Emissions Certification Film .................................. 34
Braking System - Test.......................................... 108 Engine Air Filter Primary Element - Clean/
Parking Brake Holding Ability Test ................... 109 Replace.............................................................. 124
Service Brake Holding Ability Test ................... 108 Cleaning Primary Air Filter Elements ............... 125
Bucket Cutting Edges - Inspect/Replace ............. 109 Inspecting the Primary Air Filter Elements....... 126
Bucket Hinge and Lift Arm Clearance Shims - Engine Air Filter Secondary Element - Replace .. 126
Inspect/Adjust/Replace ....................................... 110 Engine Air Precleaner - Clean ............................. 127
Inspect the Linkage........................................... 110 Engine and Machine Warm-Up ............................. 84
Installing Shims for the Hinge on the Bucket .... 110 Engine Crankcase Breather - Clean.................... 127
Bucket Linkage and Loader Cylinder Bearings - Engine Oil (High Speed) and Oil Filter - Change.. 128
Lubricate ............................................................. 111 Procedure for Changing the Engine Oil and
Bucket Lower Pivot Bearings - Lubricate.............. 111 Filter ............................................................... 130
Bucket Tips - Inspect/Replace.............................. 111 Selection of the Oil Change Interval ................ 128
Bucket Tips ....................................................... 112 Engine Oil and Filter - Change ............................ 133
Bucket Upper Pivot Bearings - Lubricate.............. 113 Procedure for Changing the Oil ....................... 135
Bucket Wear Plates - Inspect/Replace ................. 113 Selection of the Oil Change Interval ................ 133
Burn Prevention..................................................... 17 Engine Oil Level - Check ..................................... 132
Batteries............................................................. 17 Engine Oil Sample - Obtain ................................. 132
Coolant............................................................... 17
Oils..................................................................... 17
166 SEBU7887-03
Index Section

Engine Starting ................................................ 20, 83 Hood Tilt ................................................................ 80

Engine Starting for Conventional Steering with Manual Operation .............................................. 80
Electrohydraulic Controls ................................. 83 Hood Tilt Actuator - Lubricate .............................. 143
Engine Starting with Ether Starting Aid (If Hydraulic System Biodegradable Oil Filter Element -
Equipped)......................................................... 83 Replace.............................................................. 144
Engine Starting (Alternate Methods) ..................... 92 Hydraulic System Oil - Change ........................... 145
Engine Starting with Auxiliary Start Receptacle .... 93 Procedure for Changing the Hydraulic Oil ....... 146
Engine Starting with Jump Start Cables ................ 92 Selection of the Oil Change Interval ................ 145
Use of Jump Start Cables .................................. 92 Hydraulic System Oil Filter - Replace.................. 147
Engine Stopping .................................................... 21 Hydraulic System Oil Level - Check .................... 148
Engine Valve Lash - Check ................................. 136 Hydraulic System Oil Sample - Obtain ................ 149
Engine Valve Rotators - Inspect .......................... 136 Hydraulic Tank Breaker Relief Valve - Clean....... 149
Equipment Lowering with Engine Stopped...... 22, 85
Ether Starting Aid Cylinder - Replace (If
Equipped) .......................................................... 137 I

Identification Information ....................................... 32

F Implement Restraint (Roading).............................. 87
Installation of the Implement Restraint............... 88
Fire Extinguisher Location ..................................... 19 Important Safety Information ................................... 2
Fire Prevention and Explosion Prevention ............ 17
Ether .................................................................. 18
Fire Extinguisher ................................................ 18 L
Lines, Tubes and Hoses .................................... 19
Foreword ................................................................. 5 Leaving the Machine ............................................. 86
California Proposition 65 Warning ....................... 4 Lifting and Tying Down the Machine...................... 89
Caterpillar Product Identification Number ............ 5 Logging Fork Clamp - Lubricate .......................... 149
Certified Engine Maintenance.............................. 4 Lubricant Viscosities.............................................. 96
Literature Information........................................... 4 Lubricant Viscosities for Ambient
Machine Capacity ................................................ 5 Temperatures ................................................... 96
Maintenance ........................................................ 4 Selecting the Viscosity ....................................... 96
Operation ............................................................. 4 Lubricant Viscosities and Refill Capacities ............ 96
Safety................................................................... 4
Fuel System - Prime ............................................ 137
Fuel System Primary Filter (Water Separator) - M
Drain .................................................................. 138
Fuel System Primary Filter (Water Separator) Machine Configuration........................................... 26
Element - Replace ............................................. 139 Configurations for the Hydraulic Controls .......... 26
Fuel System Secondary Filter - Replace ............. 140 Steering Configurations ..................................... 26
Fuel Tank Cap and Strainer - Clean .................... 140 Machine Operation ................................................ 38
Fuel Tank Water and Sediment - Drain ............... 141 Maintenance Interval Schedule ........................... 102
Fuses - Replace .................................................. 141 Maintenance Section ............................................. 95
Maintenance Support .......................................... 101
Monitoring System................................................. 64
G Functional Test................................................... 69
Indicators ........................................................... 66
General Hazard Information .................................. 14 Main Display Module.......................................... 67
Asbestos Information ......................................... 15 Quad Gauge Module.......................................... 65
Containing Fluid Spillage ................................... 15 Speedometer/Tachometer Display..................... 65
Dispose of Waste Properly ................................ 16 Warning Categories ........................................... 68
Fluid Penetration................................................ 15 Mounting and Dismounting.................................... 36
Pressurized Air and Water ................................. 15 Alternate Exit...................................................... 36
Trapped Pressure .............................................. 15
General Information............................................... 26
O

H Oil Filter - Inspect ................................................ 150

Inspect a Used Filter for Debris ....................... 150
High Intensity Discharge Lamp (HID) - Replace (If Operation............................................................... 21
Equipped) .......................................................... 143
SEBU7887-03 167
Index Section

Operation Information............................................ 81 Payload Control System (PCS) ............................. 69

Changing Direction and Speed .......................... 81 Additional Features ............................................ 71
Downhill Operation............................................. 81 EXC Key .......................................................... 71
Operation Section.................................................. 36 General Operations of the Keypad .................... 70
Operator Controls .................................................. 42 Measuring the Load of a Bucket in the Stationary
12 Volt Power Receptacle (18) .......................... 54 Position ............................................................ 70
Autodig Control (20) (If Equipped) ..................... 54 Measuring the Load of a Bucket on the Go ....... 70
Autodig Trigger Switch (40) (If Equipped) .......... 62 REW Key ......................................................... 70
Autoshift Control (26) ......................................... 56 Plate Locations and Film Locations....................... 32
Auxiliary Control (37) (If Equipped).................... 58 Certification ........................................................ 32
Auxiliary Control with Joystick (37) (If Product Information Section .................................. 26
Equipped)......................................................... 58
Beacon Switch (15) (If Equipped) ...................... 53
Bucket Kickout Set Switch (22).......................... 55 Q
Continuous Flow Control (13) (If Equipped)....... 53
Directional Turn Signal (42) ............................... 62 Quick Coupler - Check ........................................ 150
Engine Start Switch (17) .................................... 54 Quick Coupler - Lubricate.................................... 150
Fan Reversing (30) (If Equipped)....................... 57
Fine Modulation (34) (If Equipped) .................... 57
Front Windshield Wiper/Washer Switch (23) ..... 55 R
Governor Control (7) .......................................... 51
Hazard Switch (16) ............................................ 53 Radiator Core - Clean.......................................... 151
Heated Mirror (31) (If Equipped) ........................ 57 Rated Load ............................................................ 27
Heating and Air Conditioning Controls (25) ....... 55 Rated Load for the Bucket ................................. 27
HID Lights (12)................................................... 52 Rated Load for the Logging Fork ....................... 31
Horn (2).............................................................. 47 Reference Information Section ............................ 162
Hydraulic Control Support (9) ............................ 52 Reference Material .............................................. 162
Hydraulic Lockout (35) ....................................... 58 Additional Reference Material.......................... 163
Implement Function (36) (If Equipped) .............. 58 Cooling System................................................ 162
Lift Control (38) .................................................. 59 Grease ............................................................. 162
Light Switch (11) ................................................ 52 Hydraulic Oil..................................................... 162
Lighter (10)......................................................... 52 Miscellaneous Publications.............................. 162
Machine Security System (If Equipped)............. 63 Oil..................................................................... 162
Parking Brake Control (14) ................................ 53 Parts Manuals .................................................. 163
Payload Control System (33) (If Equipped) ....... 57 ROPS/FOPS Structure .................................... 163
Quick Coupler (21) (If Equipped) ....................... 55 SOS Information ............................................ 163
Rear Windshield Wiper/Washer Switch (24) ...... 55 Safety Manuals ................................................ 163
Ride Control (27) (If Equipped) .......................... 56 Specifications Manuals .................................... 163
Seat (3) .............................................................. 47 Tools................................................................. 163
Secondary Steering (29) (If Equipped) .............. 57 Reference Materials ............................................ 162
Service Brake Control (Pedals) (6) .................... 49 Refrigerant Dryer - Replace................................. 151
Steering Control (1)............................................ 47 Ride Control Accumulator - Check ...................... 152
Switch for the Display Module (32) .................... 57 Roading Fender Control ........................................ 81
Telescopic Control for the Steering (8)............... 52 Roading Fender Hinges - Lubricate..................... 152
Tilt Control (39) .................................................. 61 Roading the Machine............................................. 87
Tilt Control for the Steering Wheel (5) ............... 49 Rollover Protective Structure (ROPS) - Inspect .. 152
Transmission Control (4).................................... 48
Transmission Downshift Switch (41) .................. 62
Transmission Neutralizer Override Switch (28).. 57 S
Variable Shift Control (19) (If Equipped) ............ 54
Operator Station .................................................... 25 SOS Information .................................................. 99
Safety Messages ..................................................... 6
Safety Section ......................................................... 6
P Seat ................................................................. 3839
Air Suspension (If Equipped) ............................. 39
Parking ............................................................ 21, 85 Mechanical Suspension ..................................... 38
Parking Brake ........................................................ 82
Parking Brake Manual Release ............................. 91
168 SEBU7887-03
Index Section

Seat Belt ................................................................ 39 W

Extension of the Seat Belt ................................. 41
Seat Belt Adjustment for Non-Retractable Seat Welding on Machines and Engines with Electronic
Belts ................................................................. 39 Controls ............................................................. 101
Seat Belt Adjustment for Retractable Seat Window Washer Reservoir - Fill .......................... 160
Belts ................................................................. 40 Window Wiper - Inspect/Replace ........................ 160
Seat Belt - Inspect ............................................... 153 Windows - Clean ................................................. 161
Seat Belt - Replace.............................................. 153 Work Tools............................................................. 22
Secondary Steering ............................................... 82
Service Brake Control............................................ 75
Command Control Steering ............................... 76
Conventional Steering........................................ 77
Left Brake Pedal ................................................ 75
Right Service Brake Pedal ................................. 75
Service Brake Wear Indicator - Check ................ 153
Shipping the Machine ............................................ 87
Sound Information and Vibration Information ........ 22
Sound Level Information .................................... 22
Sound Level Information for Machines in European
Union Countries and in Countries that Adopt the
EU Directives ................................................. 23
Sources.............................................................. 25
The European Union Physical Agents (Vibration)
Directive 2002/44/EC ...................................... 23
Specifications ........................................................ 26
Application/Configuration Restrictions ............... 26
Intended Use...................................................... 26
Machine Data..................................................... 27
Steering Column Spline (Command Control Steering)
- Lubricate.......................................................... 154
Steering Column Spline (HMU Steering) -
Lubricate ............................................................ 154
Steering Cylinder Bearings - Lubricate................ 155
Steering Frame Lock ............................................. 37
Steering Pilot Oil Screen (Command Control
Steering) - Clean/Replace ................................. 156
Stopping the Engine .............................................. 85
Stopping the Engine if an Electrical Malfunction
Occurs ................................................................. 85
Stopping the Machine............................................ 85

Table of Contents..................................................... 3
Tire Inflation - Check ........................................... 157
Tire Inflation Information........................................ 95
Tire Inflation Pressure ........................................... 95
Tire Inflation Pressure Adjustment ........................ 95
Tire Inflation with Nitrogen..................................... 95
Tire Information ..................................................... 19
Towing Information ................................................ 90
Towing the Machine............................................... 90
Towing with a Running Engine........................... 90
Towing with a Stopped Engine........................... 91
Transmission Oil - Change .................................. 157
Transmission Oil Filter - Replace ........................ 158
Transmission Oil Level - Check ........................... 159
Transmission Oil Sample - Obtain....................... 160
Transportation Information .................................... 87
Product and Dealer Information
Note: For product identification plate locations, see the section Product Identification Information in the Operation
and Maintenance Manual.

Delivery Date:

Product Information
Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information
Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:
2007 Caterpillar
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