Cat 345

SEBU7029-05 (en-us)
June 2020
Operation and
Maintenance
Manual
345B Excavator
4SS 1-UP (345B L)
9GS 1-UP (345B L)
2NW 1-UP (345B L)
Language: Original Instructions
Scan to find and purchase genuine Cat® parts and related

service information.
i07966018
Important Safety Information

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

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on
the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must not
use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that you are authorized to perform this work, and that the
product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair
procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Cat dealers have the most current information available.
NOTICE
When replacement parts are required for this product Caterpillar recommends using original Cater-
pillar® replacement parts.
Other parts may not meet certain original equipment specifications.
When replacement parts are installed, the machine owner/user should ensure that the machine re-
mains in compliance with all applicable requirements.
In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SEBU7029-05 3
Table of Contents
Table of Contents Machine Operation .......................................... 49
Engine Starting................................................ 92
Foreword ........................................................... 4
Operation......................................................... 99
Safety Section
Operating Techniques ................................... 103
Safety Messages............................................... 6
Parking ...........................................................113
General Hazard Information............................ 18
Transportation Information .............................116
Crushing Prevention and Cutting Prevention.. 20
Towing Information ........................................ 131
Burn Prevention............................................... 21
Engine Starting (Alternate Methods)............. 134
Fire Prevention and Explosion Prevention...... 22
Fire Extinguisher Location............................... 25

Maintenance Section
Lubricant Viscosities and Refill Capacities ... 136

Electrical Storm Injury Prevention ................... 25
Maintenance Support .................................... 143
Before Starting Engine .................................... 25
Maintenance Interval Schedule..................... 144
Engine Starting................................................ 25
Before Operation ............................................. 25 Reference Information Section
Work Tools....................................................... 26 Reference Materials ...................................... 214
Operation......................................................... 26 Index Section
Lifting Objects.................................................. 29 Index.............................................................. 216
Parking ............................................................ 30
Equipment Lowering with Engine Stopped ..... 30
Sound Information and Vibration Information . 31
Operator Station .............................................. 33
Guards (Operator Protection) ......................... 33
Product Information Section
General Information ........................................ 35
Identification Information ................................. 45
Operation Section
Before Operation ............................................. 46

4 SEBU7029-05
Foreword
Foreword Whenever a question arises regarding your machine,

or this publication, please consult your Cat dealer for
the latest available information.
California Proposition 65 Warning
Safety
Diesel engine exhaust and some of its
constituents are known to the State of The safety section lists basic safety precautions. In
California to cause cancer, birth defects, addition, this section identifies the text and locations
of warning signs and labels used on the machine.
and other reproductive harm.
Read and understand the basic precautions listed in
WARNING – This product can the safety section before operating or performing
expose you to chemicals lubrication, maintenance, and repair on this machine.
including ethylene glycol, which
is known to the State of California to Operation
cause birth defects or other reproductive
harm. For more information go to: The operation section is a reference for the new
operator and a refresher for the experienced
www.P65Warnings.ca.gov operator. This section includes a discussion of
gauges, switches, machine controls, attachment
Do not ingest this chemical. Wash hands controls, transportation, and towing information.
after handling to avoid incidental Photographs and illustrations guide the operator
ingestion. through correct procedures of checking, starting,
operating, and stopping the machine.
WARNING – This product can
expose you to chemicals Operating techniques outlined in this publication are
basic. Skill and techniques develop as the operator
including lead and lead gains knowledge of the machine and its capabilities.
compounds, which are known to the
State of California to cause cancer, birth Maintenance
defects, or other reproductive harm. For
more information go to: The maintenance section is a guide to equipment
care. The Maintenance Interval Schedule (MIS) lists
www.P65Warnings.ca.gov the items to be maintained at a specific service
interval. Items without specific intervals are listed
Wash hands after handling components under the "When Required" service interval. The
that may contain lead. Maintenance Interval Schedule lists the page number
for the step-by-step instructions required to
accomplish the scheduled maintenance. Use the
Literature Information Maintenance Interval Schedule as an index or "one
safe source" for all maintenance procedures.
This manual should be stored in the operator's
compartment in the literature holder or seat back Maintenance Intervals
literature storage area.
Use the service hour meter to determine servicing
This manual contains safety information, operation
intervals. Calendar intervals shown (daily, weekly,
instructions, transportation information, lubrication
information, and maintenance information. monthly, etc.) can be used instead of service hour
meter intervals if the calendar intervals provide more
Some photographs or illustrations in this publication convenient servicing schedules and approximate the
show details or attachments that can be different indicated service hour meter reading. Perform the
from your machine. Guards and covers might have recommended service at the interval that occurs first.
been removed for illustrative purposes.
Under severe, dusty, or wet operating conditions,
Continuing improvement and advancement of more frequent lubrication than is specified in the
product design might have caused changes to your maintenance intervals chart might be necessary.
machine which are not included in this publication.
Read, study, and keep this manual with the machine.
SEBU7029-05 5
Foreword
Perform service on items at multiples of the original 2. Machine Descriptor (characters 4-8)
requirement. For example, at every 500 service
hours or 3 months, also service those items listed 3. Check Character (character 9)
under every 250 service hours or monthly and every
10 service hours or daily. 4. Machine Indicator Section (MIS) or Product
Sequence Number (characters 10-17). These were
previously referred to as the Serial Number.
Certified Engine Maintenance
Machines and generator sets produced before First
Proper maintenance and repair are essential to keep Quarter 2001 will maintain their 8 character PIN
the engine and machine systems operating correctly. format.
As the heavy-duty off-road diesel engine owner, you
are responsible for the performance of the required Components such as engines, transmissions, axles,
maintenance listed in the Owner Manual, Operation and work tools will continue to use an 8 character
and Maintenance Manual, and Service Manual. Serial Number (S/N).
It is prohibited for any person engaged in the

business of repairing, servicing, selling, leasing, or
trading engines or machines to remove, alter, or to
render inoperative, any emission-related device or
element of design installed on or in an engine or
machine that is in compliance with all applicable
regulations of the intended country to which it has
been shipped. Certain elements of the machine and
engine such as the exhaust system, fuel system,
electrical system, intake air system, and cooling
system may be emission-related and should not be
altered unless approved by Caterpillar.
Machine Capacity
Additional attachments or modifications may exceed
machine design capacity which can adversely affect
performance characteristics. Included would be
stability and system certifications such as brakes,
steering, and rollover protective structures (ROPS).
Contact your Cat dealer for further information.
Product Identification Number

Effective First Quarter 2001 the Product Identification
Number (PIN) has changed from 8 to 17 characters.
To provide uniform equipment identification,
construction equipment manufacturers are moving to
comply with the latest version of the product
identification numbering standard. Non-road machine
PINs are defined by ISO 10261. The new PIN format
will apply to all machines and generator sets. The
PIN plates and frame marking will display the 17
character PIN. The new format will look like the
following:
Illustration 1 g03891925
Where:
1. World Manufacturing Code (characters 1-3)
6 SEBU7029-05
Safety Section
Safety Messages
Safety Section
i08111210
Safety Messages
SMCS Code: 7000; 7405
There are several specific safety messages on this
machine. The exact location of the hazards and the
description of the hazards are reviewed in this
section. Please become familiarized with all safety
messages.
Clean the safety messages or replace the safety
messages if you cannot read the words. Replace the
illustrations if the illustrations are not visible. When
you clean the safety messages, use a cloth, water
and soap. Do not use solvent, gasoline, or other
harsh chemicals to clean the safety messages.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety message. Loose
adhesive will allow the safety message to fall.
Replace any safety message that is damaged, or
missing. If a safety sign is attached to a part that is
replaced, install a safety message on the
replacement part. Any Caterpillar dealer can provide DO NOT OPERATE OR WORK ON THIS MACHINE
new safety messages. UNLESS YOU HAVE READ AND UNDERSTAND
THE INSTRUCTIONS AND WARNINGS IN THE OP-
Do Not Operate ERATION AND MAINTENANCE MANUALS. FAIL-
URE TO FOLLOW THE INSTRUCTIONS OR HEED
THE WARNINGS COULD RESULT IN INJURY OR
DEATH. CONTACT ANY CATERPILLAR DEALER
FOR REPLACEMENT MANUALS. PROPER CARE
IS YOUR RESPONSIBILITY.
Electrical Shock Hazard (If

Equipped)
This safety message is positioned in the cab.
This warning label is located on the engine. This is a

typical example of the location of the warning label.
SEBU7029-05 7
Safety Section
Safety Messages
Illustration 5 g00039226 Illustration 7 g00100702
Electrical shock hazard. The electronic unit injec- Know the maximum height and reach of your ma-
tor system uses 90-120 volts. chine. Serious injury or death by electrocution
can occur if machine, work tools, or attachments
are not kept a safe distance from electrical power
The engine control module (ECM) sends a high lines. Keep distance at least 3 m (10 ft) Plus addi-
voltage signal to the injector solenoid. To help tional 10 mm (.4 inch) for each 1,000 volts over
prevent personal injury, disconnect the electronic unit 50,000 volts.
injector enable circuit connector. Do not come in
contact with the electronic unit injector terminals
while the engine is running.
Improper Connections For Jump
Height And Reach Of Machine Start Cables
This safety message is positioned in the cab. This safety message is positioned on the circuit
breaker panel.
8 SEBU7029-05
Safety Section
Safety Messages
Relieve Hydraulic Tank Pressure
This safety message is located on the top of the

hydraulic tank.
IMPROPER JUMPER CABLE CONNECTIONS

CAN CAUSE EXPLOSION RESULTING IN PER-
SONAL INJURY.
BATTERIES MAY BE LOCATED IN SEPARATE
COMPARTMENTS. WHEN USING JUMPER CA-
BLES, ALWAYS CONNECT POSITIVE (+) CABLE
TO POSITIVE (+) TERMINAL OF BATTERY CON-
NECTED TO STARTER SOLENOID AND NEGA-
TIVE (-) CABLE FROM EXTERNAL SOURCE TO
STARTER NEGATIVE (-) TERMINAL (IF MACHINE
NOT EQUIPPED WITH STARTER NEGATIVE TER-
MINAL, CONNECT TO ENGINE BLOCK.) FOLLOW
PROCEDURE IN THE OPERATION MANUAL.
SEBU7029-05 9
Safety Section
Safety Messages
HYDRAULIC TANK LIFT EYES OR TANK CAN FAIL WHEN LIFTING

TANK CONTAINING FLUIDS RESULTING IN POS-
RELIEVE TANK PRESSURE WITH ENGINE OFF SIBLE PERSONAL INJURY. DRAIN TANK OF ALL
BY REMOVING CAP SLOWLY TO PREVENT FLUIDS BEFORE LIFTING.
BURNS FROM HOT OIL.
High Pressure Gas

Lift Eyes Can Fail
This safety message is positioned on the
This safety message is positioned on the top of the accumulator.
hydraulic tank.
10 SEBU7029-05
Safety Section
Safety Messages
This system contains high pressure gas. Failure

to follow the instructions and warnings could
cause an explosion, resulting in possible injury Illustration 17 g00100742
or death.
HIGH PRESSURE CYLINDER
Do not expose to fire. Do not weld. Do not drill.
Relieve pressure before discharging. Do not remove any parts until all of the pressure has
been relieved. This will avoid possible personal
See Operation and Maintenance Manual for injury. The knob can be rotated to a maximum of one
charging and discharging. See your Caterpillar counterclockwise turn.
Dealer for tools and detailed information.
See the Operation and Maintenance Manual, “Track
Adjustment - Adjust” information for your product.
High Pressure Cylinder
No Ether
This safety message is positioned on the track
adjuster. This safety message is positioned on the air cleaner.
SEBU7029-05 11
Safety Section
Safety Messages
NO ETHER
The following information is not applicable to any
machines that are equipped with an ether starting AUTOMATIC ENGINE SPEED CONTROL (AEC)
aid. WILL INCREASE ENGINE SPEED AUTOMATI-
CALLY WHEN YOU OPERATE THE CONTROL
Do not spray ether into the air intake because this LEVER (S) AND/OR TRAVEL PEDALS WITH AEC
machine is equipped with an air inlet heater. Using SWITCH ON.
ether may result in a serious accident.
WHEN LOADING AND UNLOADING MACHINE
To start engines that are equipped with an ether FROM TRUCK OR WORKING IN CLOSE QUAR-
starting aid, refer to the Operation and Maintenance, TERS ALWAYS TURN OFF AEC SWITCH TO PRE-
“Starting Engine” information for your product. VENT ANY POSSIBILITY OF SUDDEN
MOVEMENT OF MACHINE, WHICH COULD RE-
SULT IN SERIOUS INJURY OR DEATH.
Automatic Engine Speed Control
(AEC)
Travel Speed Control Switch
12 SEBU7029-05
Safety Section
Safety Messages
PUT TRAVEL SPEED CONTROL SWITCH IN LOW PRESSURIZED SYSTEM: HOT COOLANT CAN
POSITION BEFORE DESCENDING A SLOPE OR CAUSE SERIOUS BURN. TO OPEN CAP, STOP
LOADING OR UNLOADING ON TRAILER. IF ENGINE, WAIT UNTIL RADIATOR IS COOL. THEN
TRAVEL SPEED CONTROL SWITCH IS IN HIGH LOOSEN CAP SLOWLY TO RELIEVE THE
POSITION DURING THESE OPERATIONS, SUD- PRESSURE.
DEN CHANGES IN MACHINE SPEED CAN OCCUR
WITH AN ADVERSE EFFECT ON MACHINE CON-
TROL, RESULTING IN PERSONAL INJURY.
Changes To Machine Control
Pattern
Pressurized System
This safety message is positioned on the right side of
This safety message is positioned on the radiator. the cab. This safety message is on machines that are
equipped with a two-way valve.
SEBU7029-05 13
Safety Section
Safety Messages
WHENEVER A CHANGE IS MADE TO THE MA- CHECK MACHINE CONTROL PATTERN FOR
CHINES CONTROL PATTERN ALSO EXCHANGE CONFORMANCE TO PATTERN ON CARD IN CAB.
THE PATTERN CARD IN THE CAB TO MATCH IF NOT, CHANGE CARD TO MATCH PATTERN BE-
THE NEW PATTERN. FOLLOW THE CORRECT FORE OPERATING MACHINE. FAILURE TO DO
PROCEDURE IN THE OPERATOR AND MAINTE- SO COULD RESULT IN INJURY.
NANCE MANUAL.
Engagement of the Quick Coupler

Machine Control Pattern Wedge
This safety message is positioned in the cab if your
machine is equipped with an attachment for the quick
coupler.
14 SEBU7029-05
Safety Section
Safety Messages
INSPECT COUPLER WEDGE ENGAGEMENT BE- DO NOT TILT CAB WHEN OCCUPIED. BEFORE
FORE OPERATING EXCAVATOR. TILTING CAB REMOVE ALL LOOSE ARTICLES
FROM CAB, SECURE ALL WINDOWS AND EXITS,
SERIOUS INJURY OR DEATH MAY RESULT FROM AND THEN CLOSE CAB AND CAB RISER
AN IMPROPERLY ENGAGED COUPLER. DOORS. FAILURE TO DO SO CAN RESULT IN
PERSONAL INJURY OR DAMAGE TO THE
COUPLER WEDGE ENGAGEMENT CAN BE IN- MACHINE.
SPECTED FROM THE CAB BY ROTATING THE
BUCKET OR ATTACHMENT IN. EXTEND THE
BUCKET CYLINDER (BUCKET CLOSE) TO BRING
THE COUPLER ACTUATOR INTO VIEW AND Crush Points
BRING THE STICK IN UNTIL THE WEDGES ARE
VISIBLE.
Tilting the Cab
This safety message can be positioned in the

following locations: inside of the cab riser
compartment access door and next to the cab riser
compartment access door on the left side of the
machine. This safety message is also located on the
This safety message is positioned inside the left front of the machine below the cab riser.
access door on a forest machine. The safety
message is positioned on the outside of the cab riser
compartment access door on a material handler.
SEBU7029-05 15
Safety Section
Safety Messages
STRUCTURAL DAMAGE, AN OVERTURN, MODI-

FICATION, ALTERATION, OR IMPROPER REPAIR
CAN IMPAIR THIS STRUCTURE'S PROTECTION
CAPABILITY THEREBY VOIDING THIS CERTIFI-
CATION. DO NOT WELD ON OR DRILL HOLES IN
Stand away from the cab when the cab is being tilted THE STRUCTURE. CONSULT A CATERPILLAR
for transportation or repair. There is no clearance for DEALER TO DETERMINE THIS STRUCTURE'S
a person in this area. Severe injury or death from LIMITATIONS WITHOUT VOIDING ITS
crushing could occur. CERTIFICATION.
Certification for Falling Object

Electrical Shock Hazard
Guard Structure (If Equipped)
This warning label is located on the generator control
This safety message is located on the left side of the panel. The generator control panel is located inside
falling object guard structure. the cab riser.
16 SEBU7029-05
Safety Section
Safety Messages
Before servicing, turn generator disconnect IMPROPER OPERATION OF THE COUNTER-

switch to the OFF position. Failure to do so could WEIGHT REMOVAL SYSTEM CAN RESULT IN
result in serious injury or death. SERIOUS INJURY OR DEATH. DO NOT OPERATE
THIS SYSTEM UNLESS YOU HAVE READ AND
UNDERSTAND THE INSTRUCTIONS AND WARN-
INGS IN THE OPERATION AND MAINTENANCE
Improper Operation of the System MANUAL.
for the Removal of the
Counterweight Product Link
This safety message is located inside the right rear This safety message is positioned in the cab.
access door.
SEBU7029-05 17
Safety Section
Safety Messages
This machine is equipped with a Cat Product Link

radio communication device which must be deac-
tivated within 6.0 m (20 ft) of a blast zone. Failure
to do so could result in serious injury or death.
Crushing Hazard
If equipped, this safety message is located near the
counterweight mounting bolts.
Crushing Hazard! Personal injury or death can

occur from counterweight falling during removal
or installation. Do not remove any counterweight
mounting bolts unless you have read and under-
stand the instructions and warnings in the Opera-
tion and Maintenance for counterweight removal
and installation.
18 SEBU7029-05
Safety Section
General Hazard Information
Reference: Refer to Operation and Maintenance

Manual, Counterweight Removal and Installation for
further information.
i07746355

SMCS Code: 7000
Wear a hard hat, protective glasses, and other

protective equipment, as required.
Do not wear loose clothing or jewelry that can snag
on controls or on other parts of the equipment.
Make sure that all protective guards and all covers
are secured in place on the equipment.
Illustration 46 g00104545 Keep the equipment free from foreign material.
Typical example Remove debris, oil, tools, and other items from the
deck, from walkways, and from steps.
Attach a “Do Not Operate” warning tag or a similar
warning tag to the start switch or to the controls. Secure all loose items such as lunch boxes, tools,
and other items that are not a part of the equipment.
Attach the warning tag before you service the
equipment or before you repair the equipment. Know the appropriate work site hand signals and the
Warning tag SEHS7332 is available from your Cat personnel that are authorized to give the hand
dealer. 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.
Operating the machine while distracted can result Inhaling the fumes that are released from a flame that
in the loss of machine control. Use extreme cau- contacts air conditioner refrigerant can cause bodily
tion when using any device while operating the harm or death. Inhaling gas from air conditioner
machine. Operating the machine while distracted refrigerant through a lighted cigarette can cause
can result in personal injury or death. bodily harm or death.
Never put maintenance fluids into glass containers.
Know the width of your equipment to maintain proper Drain all liquids into a suitable container.
clearance when you operate the equipment near
fences or near boundary obstacles. Obey all local regulations for the disposal of liquids.
Be aware of high-voltage power lines and power Use all cleaning solutions with care. Report all
cables that are buried. If the machine comes in necessary repairs.
contact with these hazards, serious injury or death
may occur from electrocution. Do not allow unauthorized personnel on the
equipment.
Unless you are instructed otherwise, perform
maintenance with the equipment in the servicing
position. Refer to Operation and Maintenance
Manual for the procedure for placing the equipment
in the servicing position.
SEBU7029-05 19
Safety Section
When you perform maintenance above ground level,

use appropriate devices such as ladders or man lift
machines. If equipped, use the machine anchorage
points and use approved fall arrest harnesses and
lanyards.
Pressurized Air and Water

Pressurized air and/or water can cause debris and/or
hot water to be blown out. The debris and/or hot
water could result in personal injury.
When pressurized air and/or pressurized water is
used for cleaning, wear protective clothing, protective
shoes, and eye protection. Eye protection includes
goggles or a protective face shield.
The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the Always use a board or cardboard when you check for
nozzle is deadheaded and the nozzle is used with an a leak. Leaking fluid that is under pressure can
effective chip deflector and personal protective penetrate body tissue. Fluid penetration can cause
equipment. The maximum water pressure for serious injury and possible death. A pin hole leak can
cleaning purposes must be below 275 kPa (40 psi). cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
Avoid direct spraying of water on electrical from a doctor that is familiar with this type of injury.
connectors, connections, and components. When
using air for cleaning, allow the machine to cool to
reduce the possibility of fine debris igniting when re- Containing Fluid Spillage
deposited on hot surfaces.
Care must be taken in order to ensure that fluids are
contained during performance of inspection,
Trapped Pressure maintenance, testing, adjusting, and repair of the
equipment. Prepare to collect the fluid with suitable
Pressure can be trapped in a hydraulic system. containers before opening any compartment or
Releasing trapped pressure can cause sudden disassembling any component that contains fluids.
machine movement or attachment movement. Use
caution if you disconnect hydraulic lines or fittings. Refer to Special Publication, NENG2500, “Cat dealer
High-pressure oil that is released can cause a hose Service Tool Catalog” for the following items:
to whip. High-pressure oil that is released can cause
oil to spray. Fluid penetration can cause serious • Tools that are suitable for collecting fluids and
injury and possible death. equipment that is suitable for collecting fluids
Fluid Penetration • Tools that are suitable for containing fluids and
equipment that is suitable for containing fluids
Pressure can be trapped in the hydraulic circuit long
after the machine has been stopped. The pressure
can cause hydraulic fluid or items such as pipe plugs
to escape rapidly if the pressure is not relieved
correctly.
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.
20 SEBU7029-05
Safety Section
Crushing Prevention and Cutting Prevention
Obey all local regulations for the disposal of liquids. • Use exhaust ventilation on permanent machining
jobs.
Inhalation • Wear an approved respirator if there is no other
way to control the dust.
• Comply with applicable rules and regulations for
the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”. In Japan,
use the requirements found in the “Ordinance on
Prevention of Health Impairment due to Asbestos”
in addition to the requirements of the Industrial
Safety and Health Act.
• Obey environmental regulations for the disposal of
asbestos.
• Stay away from areas that might have asbestos
Illustration 49 g02159053 particles in the air.
Exhaust Dispose of Waste Properly

Use caution. Exhaust fumes can be hazardous to
your health. If you operate the machine in an
enclosed area, adequate ventilation is necessary.
Asbestos Information
Cat equipment and replacement parts that are
shipped from Caterpillar are asbestos free.
Caterpillar recommends the use of only genuine Cat
replacement parts. Use the following guidelines when
you handle any replacement parts that contain
asbestos or when you handle asbestos debris.
Use caution. Avoid inhaling dust that might be
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain Illustration 50 g00706404
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The Improperly disposing of waste can threaten the
asbestos that is used in these components is bound environment. Potentially harmful fluids should be
in a resin or sealed in some way. Normal handling is disposed of according to local regulations.
not hazardous unless airborne dust that contains
asbestos is generated. Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
If dust that may contain asbestos is present, there drain, or into any source of water.
are several guidelines that should be followed:
• Never use compressed air for cleaning. i01359664
• Avoid brushing materials that contain asbestos. Crushing Prevention and

• Avoid grinding materials that contain asbestos. Cutting Prevention
• Use a wet method in order to clean up asbestos SMCS Code: 7000
materials. Support the equipment properly before you perform
any work or maintenance beneath that equipment.
• A vacuum cleaner that is equipped with a high Do not depend on the hydraulic cylinders to hold up
efficiency particulate air filter (HEPA) can also be the equipment. Equipment can fall if a control is
used. moved, or if a hydraulic line breaks.
SEBU7029-05 21
Safety Section
Burn Prevention
Do not work beneath the cab of the machine unless Check the coolant level only after the engine has
the cab is properly supported. been stopped.
Unless you are instructed otherwise, never attempt Ensure that the filler cap is cool before removing the
adjustments while the machine is moving or while the filler cap. The filler cap must be cool enough to touch
engine is running. with a bare hand. Remove the filler cap slowly to
relieve pressure.
Never jump across the starter solenoid terminals in
order to start the engine. Unexpected machine Cooling system conditioner contains alkali. Alkali can
movement could result. cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.
Whenever there are equipment control linkages the
clearance in the linkage area will change with the
movement of the equipment or the machine. Stay Oils
clear of areas that may have a sudden change in
clearance with machine movement or equipment Hot oil and hot components can cause personal
movement. injury. Do not allow hot oil to contact the skin. Also,
do not allow hot components to contact the skin.
Stay clear of all rotating and moving parts.
Remove the hydraulic tank filler cap only after the
If it is necessary to remove guards in order to perform engine has been stopped. The filler cap must be cool
maintenance, always install the guards after the enough to touch with a bare hand. Follow the
maintenance is performed. standard procedure in this manual to remove the
hydraulic tank filler cap.
Keep objects away from moving fan blades. The fan
blade will throw objects or cut objects.
Batteries
Do not use a kinked wire cable or a frayed wire cable.
Wear gloves when you handle wire cable. The liquid in a battery is an electrolyte. Electrolyte is
an acid that can cause personal injury. Do not allow
When you strike a retainer pin with force, the retainer electrolyte to contact the skin or the eyes.
pin can fly out. The loose retainer pin can injure
personnel. Make sure that the area is clear of people Do not smoke while checking the battery electrolyte
when you strike a retainer pin. To avoid injury to your levels. Batteries give off flammable fumes which can
eyes, wear protective glasses when you strike a explode.
retainer pin.
Chips or other debris can fly off an object when you
strike the object. Make sure that no one can be
injured by flying debris before striking any object.
i07746334
Burn Prevention
SMCS Code: 7000
Do not touch any part of an operating engine. Allow
the engine to cool before any maintenance is
performed on the engine. Relieve all pressure in the
air system, in the oil system, in the lubrication
system, in the fuel system, or in the cooling system
before any lines, fittings, or related items are
disconnected.
Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.
Any contact with hot coolant or with steam can cause
severe burns. Allow cooling system components to
cool before the cooling system is drained.
22 SEBU7029-05
Safety Section
Fire Prevention and Explosion Prevention
Always wear protective glasses when you work with Do not operate the machine near any flame.
batteries. Wash hands after touching batteries. The
use of gloves is recommended. Keep shields in place. Exhaust shields (if equipped)
protect hot exhaust components from oil spray or fuel
i07746336
spray in case of a break in a line, in a hose, or in a
seal. Exhaust shields must be installed correctly.
Fire Prevention and Explosion Do not weld or flame cut on tanks or lines that contain
flammable fluids or flammable material. Empty and
Prevention purge the lines and tanks. Then clean the lines and
SMCS Code: 7000 tanks with a nonflammable solvent prior to welding or
flame cutting. Ensure that the components are
properly grounded in order to avoid unwanted arcs.
Dust that is generated from repairing nonmetallic
hoods or fenders may be flammable and/or
explosive. Repair such components in a well
ventilated area away from open flames or sparks.
Use suitable Personal Protection Equipment (PPE).
Inspect all lines and hoses for wear or deterioration.
Replace damaged lines and hoses. The lines and the
hoses should have adequate support and secure
clamps. Tighten all connections to the recommended
torque. Damage to the protective cover or insulation
may provide fuel for fires.
Store fuels and lubricants in properly marked
containers away from unauthorized personnel. Store
oily rags and flammable materials in protective
containers. Do not smoke in areas that are used for
General storing flammable materials.
All fuels, most lubricants, and some coolant mixtures

are flammable.
To minimize the risk of fire or explosion, Caterpillar
recommends the following actions.
Always perform a Walk-Around Inspection, which
may help you identify a fire hazard. Do not operate a
machine when a fire hazard exists. Contact your Cat
dealer for service.
Understand the use of the primary exit and
alternative exit on the machine. Refer to Operation
and Maintenance Manual, “Alternative Exit”.
Do not operate a machine with a fluid leak. Repair
leaks and clean up fluids before resuming machine
operation. Fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause a
fire. A fire may cause personal injury or death.
Remove flammable material such as leaves, twigs,
papers, trash, and so on. These items may
accumulate in the engine compartment or around Illustration 52 g03839130
other hot areas and hot parts on the machine.
Use caution when you are fueling a machine. Do not
Keep the access doors to major machine smoke while you are fueling a machine. Do not fuel a
compartments closed and access doors in working machine near open flames or sparks. Do not use cell
condition in order to permit the use of fire phones or other electronic devices while you are
suppression equipment, in case a fire should occur. refueling. Always stop the engine before fueling. Fill
the fuel tank outdoors. Properly clean areas of
Clean all accumulations of flammable materials such spillage.
as fuel, oil, and debris from the machine.
SEBU7029-05 23
Safety Section
Avoid static electricity risk when fueling. Ultra low Daily inspect battery cables that are in areas that are
sulfur diesel (ULSD) poses a greater static ignition visible. Inspect cables, clips, straps, and other
hazard than earlier diesel formulations with a higher restraints for damage. Replace any damaged parts.
sulfur content. Avoid death or serious injury from fire Check for signs of the following, which can occur
or explosion. Consult with your fuel or fuel system over time due to use and environmental factors:
supplier to ensure that the delivery system is in
compliance with fueling standards for proper • Fraying
grounding and bonding practices.
• Abrasion
Never store flammable fluids in the operator
compartment of the machine. • Cracking
• Discoloration
Battery and Battery Cables
• Cuts on the insulation of the cable
• Fouling
• Corroded terminals, damaged terminals, and

loose terminals
Replace damaged battery cable(s) and replace any
related parts. Eliminate any fouling, which may have
caused insulation failure or related component
damage or wear. Ensure that all components are
reinstalled correctly.
An exposed wire on the battery cable may cause a
short to ground if the exposed area comes into
contact with a grounded surface. A battery cable
short produces heat from the battery current, which
may be a fire hazard.
An exposed wire on the ground cable between the
battery and the disconnect switch may cause the
disconnect switch to be bypassed if the exposed area
comes into contact with a grounded surface. This
may result in an unsafe condition for servicing the
Illustration 53 g03839133 machine. Repair components or replace components
before servicing the machine.
Caterpillar recommends the following in order to
minimize the risk of fire or an explosion related to the
battery.
Do not operate a machine if battery cables or related Fire on a machine can result in personal injury or
parts show signs of wear or damage. Contact your death. Exposed battery cables that come into
contact with a grounded connection can result in
Cat dealer for service.
fires. Replace cables and related parts that show
Follow safe procedures for engine starting with jump- signs of wear or damage. Contact your Cat
start cables. Improper jumper cable connections can dealer.
cause an explosion that may result in injury. Refer to
Operation and Maintenance Manual, “Engine Starting
with Jump Start Cables” for specific instructions. Wiring
Do not charge a frozen battery. This may cause an
explosion. Check electrical wires daily. If any of the following
conditions exist, replace parts before you operate the
Gases from a battery can explode. Keep any open machine.
flames or sparks away from the top of a battery. Do
not smoke in battery charging areas. Do not use cell • Fraying
phones or other electronic devices in battery
charging areas. • Signs of abrasion or wear
Never check the battery charge by placing a metal • Cracking

object across the terminal posts. Use a voltmeter in
order to check the battery charge. • Discoloration
24 SEBU7029-05
Safety Section
• Cuts on insulation • Outer covers have exposed embedded armoring.

• Other damage • End fittings are displaced.
Make sure that all clamps, guards, clips, and straps Make sure that all clamps, guards, and heat shields
are reinstalled correctly. This will help to prevent are installed correctly. During machine operation, this
vibration, rubbing against other parts, and excessive will help to prevent vibration, rubbing against other
heat during machine operation. parts, excessive heat, and failure of lines, tubes, and
hoses.
Attaching electrical wiring to hoses and tubes that
contain flammable fluids or combustible fluids should Do not operate a machine when a fire hazard exists.
be avoided. Repair any lines that are corroded, loose, or
damaged. Leaks may provide fuel for fires. Consult
Consult your Cat dealer for repair or for replacement your Cat dealer for repair or for replacement parts.
parts. Use genuine Cat parts or the equivalent, for
capabilities of both the pressure limit and
Keep wiring and electrical connections free of debris. temperature limit.
Lines, Tubes, and Hoses Ether

Do not bend high-pressure lines. Do not strike high- Ether (if equipped) is commonly used in cold-weather
pressure lines. Do not install any lines that are bent applications. Ether is flammable and poisonous.
or damaged. Use the appropriate backup wrenches
in order to tighten all connections to the Only use approved Ether canisters for the Ether
recommended torque. dispensing system fitted to your machine, do not
spray Ether manually into an engine, follow the
correct cold engine starting procedures. Refer to the
section in the Operation and Maintenance Manual
with the label “Engine Starting” .
Use ether in ventilated areas. Do not smoke while
you are replacing an ether cylinder.
Do not store ether cylinders in living areas or in the
operator compartment of a machine. Do not store
ether cylinders in direct sunlight or in temperatures
above 49° C (120.2° F). Keep ether cylinders away
from open flames or sparks.
Dispose of used ether cylinders properly. Do not
puncture an ether cylinder. Keep ether cylinders
away from unauthorized personnel.
Check lines, tubes, and hoses carefully. Wear Fire Extinguisher

Personal Protection Equipment (PPE) in order to
check for leaks. Always use a board or cardboard As an additional safety measure, keep a fire
when you check for a leak. Leaking fluid that is under extinguisher on the machine.
pressure can penetrate body tissue. Fluid penetration
can cause serious injury and possible death. A pin Be familiar with the operation of the fire extinguisher.
hole leak can cause severe injury. If fluid is injected Inspect the fire extinguisher and service the fire
into your skin, you must get treatment immediately. extinguisher regularly. Follow the recommendations
Seek treatment from a doctor that is familiar with this on the instruction plate.
type of injury.
Replace the affected parts if any of the following
conditions are present:
• End fittings are damaged or leaking.
• Outer coverings are chafed or cut.

• Wires are exposed.
• Outer coverings are swelling or ballooning.

• Flexible parts of the hoses are kinked.
SEBU7029-05 25
Safety Section
Fire Extinguisher Location
Consider installation of an aftermarket Fire i00771840

Suppression System, if the application and working
conditions warrant the installation. Before Starting Engine
i05474728 SMCS Code: 1000; 7000
Start the engine only from the operator compartment.
Fire Extinguisher Location Never short across the starter terminals or across the
SMCS Code: 7000; 7419 batteries. Shorting could damage the electrical
system by bypassing the engine neutral start system.
Inspect the condition of the seat belt and of the
mounting hardware. Replace any parts that are worn
or damaged. Regardless of appearance, replace the
seat belt after three years of use. Do not use a seat
belt extension on a retractable seat belt.
Adjust the seat so that full pedal travel can be
achieved with the operator's back against the back of
the seat.
Make sure that the machine is equipped with a
lighting system that is adequate for the job
conditions. Make sure that all machine lights are
working properly.
Before you start the engine and before you move the
Illustration 55 g03459623 machine, make sure that no one is underneath the
machine, around the machine, or on the machine.
Typical example Make sure that the area is free of personnel.
Make sure that a fire extinguisher is available. Be
i03562260
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Obey the recommendations Engine Starting
on the instruction plate. The fire extinguisher may be SMCS Code: 1000; 7000
mounted behind the cab. The fire extinguisher should
be mounted so that the fire extinguisher does not If a warning tag is attached to the engine start switch
block the path of the alternate exit. or to the controls, do not start the engine. Also, do not
move any controls.
i01122596
Make sure that you are seated before you start the
Electrical Storm Injury engine.
Prevention Move all hydraulic controls to the HOLD position

before you start the engine. Move the hydraulic
SMCS Code: 7000 lockout control to the LOCKED position. For further
details on this procedure, refer to Operation and
When lightning is striking in the vicinity of the Maintenance Manual, “Operator Controls”.
machine, the operator should never attempt the
following procedures: Diesel engine exhaust contains products of
combustion which can be harmful to your health.
• Mount the machine. Always run the engine in a well ventilated area. If you
are in an enclosed area, vent the exhaust to the
• Dismount the machine. outside.
If you are in the operator's station during an electrical Briefly sound the horn before you start the engine.
storm, stay in the operator's station. If you are on the
ground during an electrical storm, stay away from the
i01340061
vicinity of the machine.
Before Operation
SMCS Code: 7000
Clear all personnel from the machine and from the
area.
26 SEBU7029-05
Safety Section
Work Tools
Clear all obstacles from the machine's path. Beware If your machine is equipped with an extendable stick,
of hazards (wires, ditches, etc). install the transport pin when you are using the
following work tools: hydraulic hammers, augers and
Be sure that all windows are clean. Secure the doors compactors
and the windows in the open position or in the shut
position. Always wear protective glasses. Always wear the
protective equipment that is recommended in the
Adjust the rearview mirrors (if equipped) for the best operation manual for the work tool. Wear any other
visibility close to the machine. Make sure that the protective equipment that is required for the
horn, the travel alarm (if equipped), and all other operating environment.
warning devices are working properly.
To prevent personnel from being struck by flying
Fasten the seat belt securely. objects, ensure that all personnel are out of the work
area.
Warm up the engine and the hydraulic oil before
operating the machine. While you are performing any maintenance, any
testing, or any adjustments to the work tool stay clear
Before moving the machine, check the position of the of the following areas: cutting edges, pinching
undercarriage. The normal travel position is with the surfaces and crushing surfaces.
idler wheels to the front under the cab and the drive
sprockets to the rear. When the undercarriage is in Never use the work tool for a work platform.
the reversed position, the directional controls must be
operated in opposite directions. i07889511
i04159629
Operation
Work Tools SMCS Code: 7000
SMCS Code: 6700
Machine Operating Temperature
Only use work tools that are recommended by Range
Caterpillar for use on Cat machines.
Use of work tools, including buckets, which are The machine must function satisfactorily in the
outside of Caterpillar's recommendations or anticipated ambient temperature limits that are
specifications for weight, dimensions, flows, encountered during operation. The standard machine
pressures, and so on. may result in less-than-optimal configuration is intended for use within an ambient
vehicle performance, including but not limited to temperature range of −18 °C (0 °F) to 43 °C
reductions in production, stability, reliability, and (109 °F). Special configurations for different ambient
component durability. Caterpillar recommends temperatures may be available. Consult your Cat
appropriate work tools for our machines to maximize dealer for additional information on special
the value our customers receive from our products. configurations of your machine.
Caterpillar understands that special circumstances
may lead a customer to use tools outside of our Limiting Conditions and Criteria
specifications. In these cases, customers must be
aware that such choices can reduce vehicle Limiting conditions are immediate issues with this
performance and will affect their ability to claim machine that must be addressed prior to continuing
warranty in the event of what a customer may operation.
perceive as a premature failure.
The Operation and Maintenance Manual, Safety
Work tools and work tool control systems, that are Section describes limiting condition criteria for
compatible with your Cat machine, are required for replacing items such as safety messages, seat belt
safe machine operation and/or reliable machine and mounting hardware, lines, tubes, hoses, battery
operation. If you are in doubt about the compatibility cables and related parts, electrical wires, and
of a particular work tool with your machine, consult repairing any fluid leak.
your Cat dealer.
The Operation and Maintenance Manual,
Make sure that all necessary guarding is in place on Maintenance Interval Schedule describes limiting
the host machine and on the work tool. condition criteria that require repair or replacement
Keep all windows and doors closed on the host for items (if equipped) such as alarms, horns, braking
machine. A polycarbonate shield must be used when system, steering system, and rollover protective
the host machine is not equipped with windows and structures.
when a work tool could throw debris.
Do not exceed the maximum operating weight that is
listed on the ROPS certification.
SEBU7029-05 27
Safety Section
Operation
The Operation and Maintenance Manual, Monitoring

System (if equipped) provides information on limiting
condition criteria, including a Warning Category 3
that requires immediate shutdown of the engine.
Critical Failures
The following table provides summary information on
several limiting conditions found in this Operation and
Maintenance Manual. The table provides criteria and
required action for the limiting conditions listed. Each
System or Component in this table, together with the
respective limiting condition, describes a potential
critical failure that must be addressed. Not
addressing limiting conditions with required actions
may, in conjunction with other factors or
circumstances, result in a risk of personal injury or
death. If an accident occurs, notify emergency
personnel and provide location and description of
accident.
Table 1
System or
Limiting Criteria for Required
Component
Condition Action Action
Name
End fittings are damaged or leak- Visible corrosion, loose, or Immediately repair any lines, tubes, or hoses that
ing. Outer coverings are chafed or damaged lines, tubes, or ho- are corroded, loose, or damaged. Immediately re-
cut. Wires are exposed. Outer ses. Visible fluid leaks. pair any leaks as these may provide fuel for fires.
Line, tubes, and coverings are swelling or balloon-
hoses ing. Flexible parts of the hoses
are kinked. Outer covers have ex-
posed embedded armoring. End
fittings are displaced.
Signs of fraying, abrasion, crack- Visible damage to electrical Immediately replace damaged wiring
Electrical Wiring ing, discoloration, cuts on the wiring
insulation
Signs of fraying, abrasion, crack- Visible damage to battery ca- Immediately replace damaged battery cables
ing, discoloration, cuts on the in- ble(s)
Battery cable(s) sulation of the cable, fouling,
corroded terminals, damaged ter-
minals, and loose terminals
Structures that are bent, cracked, Visible damage to structure. Do not operate machine with damaged structure or
Operator Protective or loose. Loose, missing, or dam- Loose, missing, or damaged loose, missing, or damaged bolts. Contact your Cat
Structure aged bolts. bolts. dealer for inspection and repair or replacement
options.
Worn or damaged seat belt or Visible wear or damage Immediately replace parts that are worn or
Seat Belt
mounting hardware damaged.
Age of seat belt Three years after date of Replace seat belt three years after date of
Seat Belt
installation installation
Appearance of safety message Damage to safety messages Replace the illustrations if illegible.
Safety Messages
making them illegible
Audible Warning De- Sound level of audible warning Reduced or no audible warn- Immediately repair or replace audible warning devi-
vice(s) (if equipped) ing present ces not working properly.
Camera(s) (if Dirt or debris on camera lens Dirt or debris obstructing cam- Clean camera before operating machine.
equipped) era view
Dirt, debris, or damaged windows Dirt or debris obstructing oper- Clean windows before operating machine. Repair
Cab Windows (if
ator visibility. Any damaged or replace damaged windows before operating
equipped)
windows. machine.
Dirt, debris, or damaged mirror Dirt or debris obstructing oper- Clean mirrors before operating machine. Repair or
Mirrors (if equipped) ator visibility. Any damaged replace damaged mirrors before operating
mirrors. machine.
(continued)
28 SEBU7029-05
Safety Section
Operation
(Table 1, contd)
System or
Limiting Criteria for Required
Component
Condition Action Action
Name
Inadequate braking performance System does not pass Braking Contact your Cat dealer to inspect and, if neces-
System - Test(s) included in sary, repair the brake system.
Braking System
Maintenance Section or in the
Testing and Adjusting Manual
The coolant temperature is too Monitoring System displays Stop the engine immediately. Check the coolant lev-
high. Warning Category 3 el and check the radiator for debris. Refer to Opera-
tion and Maintenance Manual, Cooling System
Cooling System Coolant Level - Check. Check the fan drive belts for
the water pump. Refer to Operation and Mainte-
nance Manual, Belts - Inspect/Adjust/ Replace.
Make any necessary repairs.
A problem has been detected with Monitoring System displays If the warning stays on during low idle, stop the en-
Engine Oil System the engine oil pressure. Warning Category 3 gine and check the engine oil level. Perform any
necessary repairs as soon as possible.
An engine fault has been detected Monitoring System displays Stop the engine immediately. Contact your Cat
Engine system
by the engine ECM. Warning Category 3 dealer for service.
A problem has been detected with Monitoring System displays Stop the engine. Determine the cause of the fault
Fuel System
the fuel system. Warning Category 3 and perform any necessary repairs.
The hydraulic oil temperature is Monitoring System displays Stop the engine immediately. Check the hydraulic
Hydraulic Oil System too high. Warning Category 3 oil level and check the hydraulic oil cooler for debris.
Perform any necessary repairs as soon as possible.
A problem has been detected with Monitoring System displays Move machine to a safe location and stop the en-
Steering System the steering system. (If equipped Warning Category 3 gine immediately. Contact your Cat dealer to in-
with steering system monitoring.) spect and, if necessary, repair the steering system.
Machine service is required. Monitoring System displays Stop the engine immediately. Contact your Cat
Overall Machine
Warning Category 3 dealer for service.
Machine Operation Be careful to avoid any ground condition which could

cause the machine to tip. Tipping can occur when
Only operate the machine while you are in a seat. you work on hills, on banks, or on slopes. Tipping can
The seat belt must be fastened while you operate the also occur when you cross ditches, ridges, or other
machine. Only operate the controls while the engine unexpected obstructions.
is running.
When possible, operate the machine up slopes and
Check for proper operation of all controls and of all down slopes with the final drive sprockets facing
protective devices while you operate the machine down the slope. Avoid operating the machine across
slowly in an open area. the slope. Place the heaviest end of the machine
uphill when you are working on an incline.
When the machine is moving watch the clearance of
the boom. Uneven ground can cause the boom to Keep the machine under control. Do not overload the
move in all directions. machine beyond capacity.
Make sure that no personnel will be endangered Avoid changing the direction of travel on a slope.
before you move the machine. Do not allow riders on Changing the direction of travel on a slope could
the machine unless the machine has an additional result in tipping or side slipping of the machine.
seat with a seat belt.
Bring the load close to the machine before traveling
Report any machine damage that was noted during any distances.
machine operation. Make any necessary repairs.
Bring the load close to the machine before swinging
Never use the work tool for a work platform. the load.
Hold attachments approximately 40 cm (15 inches) Lifting capacity decreases as the load is moved
above ground level while you drive the machine. Do further from the machine.
not drive the machine close to an overhang, to the
edge of a cliff, or to the edge of an excavation. Make sure that the towing eyes and the towing
devices are adequate for your needs.
If the machine begins to sideslip on a grade,
immediately dump the load and turn the machine Only connect trailing equipment to a drawbar or to a
downhill. hitch.
SEBU7029-05 29
Safety Section
Lifting Objects
Never straddle a wire cable. Never allow other Shut down the machine until damaged or non-
personnel to straddle a wire cable. functioning visibility aid(s) is repaired (if applicable) or
until appropriate job site organization is used to
When you maneuver in order to connect the minimize hazards that are caused by any resulting
equipment, make sure that no personnel are between restricted visibility.
the machine and trailing equipment. Block up the
hitch of the trailing equipment in order to align the
equipment with the drawbar. Machine Operation when the
Check the local regulations, state codes, and/or
Machine is not Completely
directives of the job site for a specific minimum Assembled
distance from obstacles.
Before you operate the machine, check with local
utilities for the locations of underground pipes and for
the locations of buried cables.
Know the maximum dimensions of your machine.
Watch the load at all times.
Do not operate the machine without the
counterweight. The machine can tip when the boom
is over the side.
The clamshell, the grapple, or the magnet can swing
in all directions. Move the joysticks in a continuous
motion. Failure to move the joysticks in a continuous
motion can cause the clamshell, the grapple, or the
magnet to swing into the cab or into a person in the
work area. This will result in personal injury.
Certain machine front linkage combinations (boom,
stick, quick coupler, work tool) can allow the work tool
to contact the machine undercarriage, swing frame,
boom, boom hydraulic cylinder and or the cab. Be
aware of the position of the work tool while you Illustration 56 g02202544
operate the machine.
Attach the tag to the controls of the machine. When
the tag is attached to the controls, operate the
machine as described below.
If the machine needs to be operated without the
boom, stick, and/or counterweight being installed, the
machine should be operated slowly on flat, stable
ground or pavement by qualified operators. Avoid
any machine operations which could affect machine
stability, including the swing function. The ROPS
structural certification depends on the support of the
boom, stick, and counterweight in the event of a
machine tip over or a machine rollover incident.
i07262981
Lifting Objects
SMCS Code: 7000
There may be local regulations and/or government
regulations that govern the use of machines which lift
heavy objects. Obey all local and government
regulations.
30 SEBU7029-05
Safety Section
Parking
If this machine is used to lift objects within an area Turn the engine start switch to the OFF position and
that is controlled by the European Directive “2006/42/ remove the engine start switch key.
EC”, the machine must be equipped with a boom
lowering control valve, a stick lowering control valve, Turn the battery disconnect switch to the OFF
and an overload warning device. position.
Remove the disconnect switch key if you do not
i06781973
operate the machine for an extended period. This will
prevent drainage of the battery. A battery short
Parking circuit, any current draw from certain components,
SMCS Code: 7000 and vandalism can cause drainage of the battery.
The hydraulic system controls remain pressurized if Install barriers or lighting as required to prevent
the accumulator is charged. This condition is true interference in road traffic.
even when the engine is not running. The hydraulic Select places free of danger by flooding and other
control system pressure should decrease in a short water damage.
time (approximately 1 minute). While the hydraulic
controls maintain a charge, the hydraulic work tools
i01329161
and machine controls remain functional.
There can be residual pressure within the hydraulic Equipment Lowering with
system even when the accumulator is empty. Refer
to this Operation and Maintenance Manual, “System Engine Stopped
Pressure Release” before any service is performed to SMCS Code: 7000-II
the hydraulic system.
Before lowering any equipment with the engine
Machine movement that is sudden and unexpected stopped, clear the area around the equipment of all
will occur if any of the controls are moved. Machine personnel. The procedure to use will vary with the
movement that is sudden and unexpected, can cause type of equipment to be lowered. Keep in mind most
personal injury or death. systems use a high pressure fluid or air to raise or
Always move the hydraulic lockout control to the lower equipment. The procedure will cause high
LOCKED position before you shut off the engine or pressure air, hydraulic, or some other media to be
immediately after the engine stops running. released in order to lower the equipment. Wear
appropriate personal protective equipment and follow
Park the machine on a level surface. If you must park the established procedure in the Operation and
on a grade, chock the wheels of the machine. Maintenance Manual, “Equipment Lowering with
Engine Stopped” in the Operation Section of the
manual.
Place the machine in the servicing position.

Note: Make sure that all work tools are in the
recommended servicing position before servicing the
machine.
Move the hydraulic lockout control to the LOCKED
position.
Stop the engine.
SEBU7029-05 31
Safety Section
Sound Information and Vibration Information
i07489719 Estimate the vibration levels for the three vibration

directions. For typical operating conditions, use the
Sound Information and average vibration levels as the estimated level. With
an experienced operator and smooth terrain, subtract
Vibration Information the Scenario Factors from the average vibration level
in order to obtain the estimated vibration level. For
SMCS Code: 7000 aggressive operations and severe terrain, add the
Scenario Factors to the average vibration level in
Sound Level Information order to obtain the estimated vibration level.
Hearing protection may be needed when the Note: All vibration levels are in meter per second
machine is operated with an open operator station for squared.
extended periods or in a noisy environment. Hearing
protection may be needed when the machine is
operated with a cab that is not properly maintained or
when the doors and windows are open for extended
periods or in a noisy environment.
“The European Union Physical

Agents (Vibration) Directive 2002/
44/EC”
Vibration Data for Track Type Excavator
Information Concerning Hand/Arm Vibration
Level
When the machine is operated according to the
intended use, the hand/arm vibration of this machine
is below 2.5 meter per second squared.
Information Concerning Whole Body Vibration
Level
This section provides vibration data and a method for
estimating the vibration level for track type
excavators.
Note: Vibration levels are influenced by many

different parameters. Many items are listed below.
• Operator training, behavior, mode and stress
• Job site organization, preparation, environment,

weather and material
• Machine type, quality of the seat, quality of the

suspension system, attachments and condition of
the equipment
It is not possible to get precise vibration levels for this
machine. The expected vibration levels can be
estimated with the information in Table 2 in order to
calculate the daily vibration exposure. A simple
evaluation of the machine application can be used.
32 SEBU7029-05
Safety Section
Sound Information and Vibration Information
Table 2
“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
excavating 0,44 0,27 0,30 0,24 0,16 0,17
hydraulic breaker application 0,53 0,31 0,55 0,30 0,18 0,28

Track Type
Excavator mining application 0,65 0,42 0,61 0,21 0,15 0,32
transfer 0,48 0,32 0,79 0,19 0,20 0,23
Note: Refer to “ISO/TR 25398 Mechanical Vibration - b. Inspect and maintain the seat suspension and
Guideline for the assessment of exposure to whole adjustment mechanisms.
body vibration of ride on operated earthmoving
machines” for more information about vibration. This 5. Perform the following operations smoothly.
publication uses data that is measured by a. Steer
international institutes, organizations and
manufacturers. This document provides information b. Brake
about the whole body exposure of operators of
earthmoving equipment. Refer to Operation and c. Accelerate.
Maintenance Manual, SEBU8257, “The European d. Shift the gears.
Union Physical Agents (Vibration) Directive 2002/44/
EC” for more information about machine vibration 6. Move the attachments smoothly.
levels.
7. Adjust the machine speed and the route in order to
The Caterpillar suspension seat meets the criteria of minimize the vibration level.
“ISO 7096”. This represents vertical vibration level
under severe operating conditions. a. Drive around obstacles and rough terrain.
Guidelines for Reducing Vibration Levels on b. Slow down when it is necessary to go over
Earthmoving Equipment rough terrain.
8. Minimize vibrations for a long work cycle or a long
Properly adjust machines. Properly maintain
travel distance.
machines. Operate machines smoothly. Maintain the
conditions of the terrain. The following guidelines can a. Use machines that are equipped with
help reduce the whole body vibration level: suspension systems.
1. Use the right type and size of machine, equipment, b. Use the ride control system on track type
and attachments. excavators.
2. Maintain machines according to the c. If no ride control system is available, reduce
manufacturer's recommendations. speed in order to prevent bounce.
a. Tire pressures d. Haul the machines between workplaces.
b. Brake and steering systems 9. Less operator comfort may be caused by other risk
c. Controls, hydraulic system and linkages factors. The following guidelines can be effective
in order to provide better operator comfort:
3. Keep the terrain in good condition.
a. Adjust the seat and adjust the controls in order
a. Remove any large rocks or obstacles. to achieve good posture.
b. Fill any ditches and holes. b. Adjust the mirrors in order to minimize twisted
c. Provide machines and schedule time in order to posture.
maintain the conditions of the terrain. c. Provide breaks in order to reduce long periods
4. Use a seat that meets “ISO 7096”. Keep the seat of sitting.
maintained and adjusted. d. Avoid jumping from the cab.
a. Adjust the seat and suspension for the weight e. Minimize repeated handling of loads and lifting
and the size of the operator. of loads.
SEBU7029-05 33
Safety Section
Operator Station
f. Minimize any shocks and impacts during sports i07746359

and leisure activities.
Guards
Sources (Operator Protection)
The vibration information and calculation procedure SMCS Code: 7000; 7150
is based on “ISO/TR 25398 Mechanical Vibration -
Guideline for the assessment of exposure to whole There are different types of guards that are used to
body vibration of ride on operated earthmoving protect the operator. The machine and the machine
machines”. Harmonized data is measured by application determine the type of guard that should
international institutes, organizations and be used.
manufacturers.
A daily inspection of the guards is required in order to
This literature provides information about assessing check for structures that are bent, cracked, or loose.
the whole body vibration exposure of operators of Never operate a machine with a damaged structure.
earthmoving equipment. The method is based on
measured vibration emission under real working The operator becomes exposed to a hazardous
conditions for all machines. situation if the machine is used improperly or if poor
operating techniques are used. This situation can
You should check the original directive. This occur even though a machine is equipped with an
document summarizes part of the content of the appropriate protective guard. Follow the established
applicable law. This document is not meant to operating procedures that are recommended for your
substitute the original sources. Other parts of these machine.
documents are based on information from the United
Kingdom Health and Safety Executive.
Rollover Protective Structure
Refer to Operation and Maintenance Manual, (ROPS), Falling Object Protective
SEBU8257, “The European Union Physical Agents
(Vibration) Directive 2002/44/EC” for more Structure (FOPS) or Tip Over
information about vibration. Protection Structure (TOPS)
Consult your local Caterpillar dealer for more
information about machine features that minimize The ROPS/FOPS Structure (if equipped) on your
vibration levels. Consult your local Caterpillar dealer machine is specifically designed, tested and certified
about safe machine operation. for that machine. Any alteration or any modification to
the ROPS/FOPS Structure could weaken the
Use the following web site in order to find your local structure. This places the operator into an
dealer: unprotected environment. Modifications or
attachments that cause the machine to exceed the
Caterpillar, Inc. weight that is stamped on the certification plate also
www.cat.com place the operator into an unprotected environment.
Excessive weight may inhibit the brake performance,
i07746362
the steering performance and the ROPS. The
protection that is offered by the ROPS/FOPS
Structure will be impaired if the ROPS/FOPS
Operator Station Structure has structural damage. Damage to the
SMCS Code: 7300; 7301; 7325 structure can be caused by an overturn, a falling
object, a collision, etc.
Any modifications to the inside of the operator station
should not project into the operator space or into the Do not mount items (fire extinguishers, first aid kits,
space for the companion seat (if equipped). The work lights, etc) by welding brackets to the ROPS/
addition of a radio, fire extinguisher, and other FOPS Structure or by drilling holes in the ROPS/
equipment must be installed so that the defined FOPS Structure. Welding brackets or drilling holes in
operator space and the space for the companion seat the ROPS/FOPS Structures can weaken the
(if equipped) is maintained. Any item that is brought structures. Consult your Cat dealer for mounting
into the cab should not project into the defined guidelines.
operator space or the space for the companion seat
(if equipped). A lunch box or other loose items must
be secured. Objects must not pose an impact hazard
in rough terrain or in the event of a rollover.
34 SEBU7029-05
Safety Section
Operator Protection
The Tip Over Protection Structure (TOPS) is another

type of guard that is used on mini hydraulic
excavators. This structure protects the operator in the
event of a tipover. The same guidelines for the
inspection, the maintenance and the modification of
the ROPS/FOPS Structure are required for the Tip
Over Protection Structure.
Other Guards (If Equipped)

Protection from flying objects and/or falling objects is
required for special applications. Logging
applications and demolition applications are two
examples that require special protection.
A front guard needs to be installed when a work tool
that creates flying objects is used. Mesh front guards
that are approved by Caterpillar or polycarbonate
front guards that are approved by Caterpillar are
available for machines with a cab or an open canopy.
On machines that are equipped with cabs, the
windows should also be closed. Safety glasses are
recommended when flying hazards exist for
machines with cabs and machines with open
canopies.
If the work material extends above the cab, top
guards and front guards should be used. Typical
examples of this type of application are listed below:
• Demolition applications
• Rock quarries
• Forestry products
Additional guards may be required for specific
applications or work tools. The Operation and
Maintenance Manual for your machine or your work
tool will provide specific requirements for the guards.
Refer to Operation Maintenance manual,
"Demolition" for additional information. Consult your
Cat dealer for additional information.
SEBU7029-05 35
General Information
Product Information
Section
General Information
i01955327
Specifications
SMCS Code: 7000
S/N: 4SS1–Up
S/N: 9GS1–Up
Table 3 Table 4
345B L Excavator (Fixed Gauge Undercarriage)(1) 345B L Excavator (Fixed Gauge Undercarriage)(1)
Approximate Weight 44950 kg (99000 lb) Approximate Weight 44950 kg (99000 lb)
Shipping Height (A) 4600 mm (15 ft 1 inch) Shipping Height (A) 3760 mm (12 ft 4 inch)
Shipping Length (B) 11570 mm (38 ft) Shipping Length (B) 11790 mm (38 ft 8 inch)
Tail Swing Radius (C) 3650 mm (12 ft) Tail Swing Radius (C) 3650 mm (12 ft)
Length to Center of Rollers (D) 4360 mm (14 ft 4 inch) Length to Center of Rollers (D) 4360 mm (14 ft 4 inch)
Length of Track (E) 5360 mm (17 ft 7 inch) Length of Track (E) 5360 mm (17 ft 7 inch)
Track Gauge (F) 2740 mm (9 ft) Track Gauge (F) 2740 mm (9 ft)
Overall Width(2) (G) 3490 mm (11 ft 5 inch) Overall Width(2) (G) 3640 mm (11 ft 11 inch)
(1) These specifications are for a machine with a 6.9 m (1) These specifications are for a machine with a 6.9 m
(22 ft 8 inch) boom, a 4.8 m (15 ft 9 inch) stick and a 1.7 m3 (22 ft 8 inch) boom, a 3.9 m (12 ft 10 inch) stick and a
(2.25 yd3) bucket. The fuel tank is 10 percent full. 1.7 cubic meter (2.25 yd3) bucket. The fuel tank is 10 percent
(2) Width includes 750 mm (30 inch) track shoes. full.
(2) Width includes 900 mm (36 inch) track shoes.
36 SEBU7029-05
Specifications
Table 5
345B L Excavator (Fixed Gauge Undercarriage)(1) (Table 7, contd)
Approximate Weight 44950 kg (99000 lb) Overall Width(4) (G) 3140 mm (10 ft 4 inch)
Shipping Height (A) 3620 mm (11 ft 11 inch) Overall Width(5) (G) 3640 mm (11 ft 11 inch)
(1) These specifications are for a machine with a 6.9 m
Shipping Length (B) 11760 mm (38 ft 7 inch)
(22 ft 8 inch) boom, a 4.8 m (15 ft 9 inch) stick and a
Tail Swing Radius (C) 3650 mm (12 ft) 1.7 cubic meter (2.25 yd3) bucket. The fuel tank is 10 percent
full.
Length to Center of Rollers (D) 4360 mm (14 ft 4 inch) (2) Retracted
(3) Extended
Length of Track (E) 5360 mm (17 ft 7 inch) (4) Retracted width includes 750 mm (30 inch) track shoes.
(5) Extended width includes 750 mm (30 inch) track shoes.
Track Gauge (F) 2740 mm (9 ft)
Table 8
Overall Width(2) (G) 3640 mm (11 ft 11 inch)
345B L Excavator (Variable Gauge Undercarriage)(1)
(22 ft 8 inch) boom, a 3.35 m (11 ft) stick and a 1.7 cubic meter Approximate Weight 46700 kg (102900 lb)
(2.25 yd3) bucket. The fuel tank is 10 percent full.
(2) Width includes 900 mm (36 inch) track shoes. Shipping Height (A) 3740 mm (12 ft 3 inch)
Table 6 Shipping Length (B) 11710 mm (38 ft 5 inch)
345B L Excavator (Fixed Gauge Undercarriage)(1) Tail Swing Radius (C) 3650 mm (12 ft)
Approximate Weight 44950 kg (99000 lb) Length to Center of Rollers (D) 4360 mm (14 ft 4 inch)
Shipping Height (A) 3730 mm (12 ft 3 inch) Length of Track (E) 5360 mm (17 ft 7 inch)
Shipping Length (B) 11310 mm (37 ft 1 inch) Track Gauge(2) (F) 2390 mm (7 ft 10 inch)
Tail Swing Radius (C) 3650 mm (12 ft) Track Gauge(3)(F) 2890 mm (9 ft 6 inch)
Length to Center of Rollers (D) 4360 mm (14 ft 4 inch) Overall Width(4)(G) 3290 mm (10 ft 10 inch)
Length of Track (E) 5360 mm (17 ft 7 inch) Overall Width(5)(G) 3790 mm (12 ft 5 inch)
Track Gauge (F) 2740 mm (9 ft) (1) These specifications are for a machine with a 6.9 m
Overall Width(2) (G) 3490 mm (11 ft 5 inch) 1.7 cubic meter (2.25 yd3) bucket. The fuel tank is 10 percent
full.
(1) These specifications are for a machine with a 6.55 m (2) Retracted
(21 ft 6 inch) boom, a 3.0 m (9 ft 11 inch) stick and a (3) Extended
1.7 cubic meter (2.25 yd3) bucket. The fuel tank is 10 percent (4) Retracted width includes 900 mm (36 inch) track shoes.
full. (5) Extended width includes 900 mm (36 inch) track shoes.
(2) Width includes 750 mm (30 inch) track shoes.
Table 9
Table 7
Approximate Weight 46700 kg (102900 lb)
Shipping Height (A) 3610 mm (11 ft 10 inch)
Shipping Height (A) 4600 mm (15 ft 1 inch)
Tail Swing Radius (C) 3650 mm (12 ft)
Length to Center of Rollers (D) 4360 mm (14 ft 4 inch)
Length of Track (E) 5360 mm (17 ft 7 inch)
Track Gauge(2) (F) 2390 mm (7 ft 10 inch)
Track Gauge(3)(F) 2890 mm (9 ft 6 inch)

(continued)
(continued)
SEBU7029-05 37
Specifications
(Table 9, contd) (Table 12, contd)

Operating weight with 750 mm (30 inch) track 44356 kg
shoes and counterweight (97775 lb)
1.7 cubic meter (2.25 yd3) bucket. The fuel tank is 10 percent
full. 44718 kg
(2) Retracted Operating weight with 900 mm (36 inch) track
(3) Extended shoes (98573 lb)
(4) Retracted width includes 900 mm (36 inch) track shoes.
Table 10 (1) These specifications are for a machine with a 6.9 m
(22 ft 8 inch) boom, a 3.35 m (11 ft) stick and a 1.82 m3
345B L Excavator (Variable Gauge Undercarriage)(1) (2.38 yd3) bucket.
Consult your Caterpillar dealer for specifications that
Shipping Height (A) 3570 mm (11 ft 9 inch) are not included in this topic.

1.7 cubic meter (2.25 yd3) bucket. The fuel tank is 10 percent
full.
(2) Retracted
(3) Extended
(4) Retracted width includes 750 mm (30 inch) track shoes.
Table 11
345B L Excavator(1)

shoes (97100 lb)


shoes (98749 lb)

(22 ft 8 inch) boom, a 3.9 m (12 ft 10 inch) stick and a 1.82 m3
(2.38 yd3) bucket.
Table 12
345B L Excavator(1)

shoes (96924 lb)
(continued)
38 SEBU7029-05
Specifications
i01955365
Specifications
SMCS Code: 7000
S/N: 2NW1–Up
Table 13 Buckets are grouped into different families by

345B Material Handler(1)
capacity. As a general rule, use a bucket with a
smaller capacity when you are using a longer stick
Approximate Weight(2) 52800 kg (116160 lb) and/or a longer boom. Conversely, use a bucket with
a larger capacity when you are using a shorter stick
Overall Length (A) 13550 mm (44 ft 6 inch) and/or a shorter boom. This rule ensures better
machine stability and protection against structural
Height of Tilted Cab (B) 3350 mm (10 ft 8 inch) machine damage.
Shipping Height (C) 3850 mm (12 ft 8 inch)
Each stick is designed to match a specific family of
Overall Width (D) 3970 mm (12 ft 8 inch) buckets. It is not possible to attach buckets of a
different family to a given stick.
Track Shoe Width (E) 750 mm (2 ft 6 inch)
(1) These specifications can only be obtained by the removal of
Tables 14 through 17 show various compatible
the walkway. boom-stick-bucket combinations. Select an optimum
(2) This specification is for a machine that has a 10 percent full fuel combination according to the working conditions and
tank. according to the type of work that is being done.
i01955306 345B Excavators

Boom/Stick/Bucket
Combinations
SMCS Code: 6000; 6700
This machine can be equipped with a large variety of
boom-stick-bucket combinations in order to meet the
needs of various applications.
SEBU7029-05 39
Boom/Stick/Bucket Combinations
Bucket Specifications
Table 14
345B Excavator(1)
ISO Capacity of Bucket Tip Bucket Weight Number of Bucket

Application Width of Bucket
Bucket Radius (with Tips) Tips
1.1 m3 (1.38 yd3) 925 mm (36.4 inch) 1545 kg (3407 lb)
3
3 3
1.3 m (1.75 yd ) 1098 mm (43.2 inch) 1642 kg (3621 lb)
1.6 m3 (2.13 yd3) 1246 mm (49.1 inch) 1743 kg (3843 lb)

5
3 3
Heavy Duty (HD) 1.9 m (2.5 yd ) 1400 mm (55.1 inch) 1870 mm (73.6 inch) 1882 kg (4150 lb)
2.1 m3 (2.75 yd3) 1540 mm (60.6 inch) 2015 kg (4443 lb)

6
2.4 m3 (3.0 yd3) 1695 mm (66.7 inch) 2143 kg (4725 lb)
2.6 m3 (3.5 yd3) 1820 mm (71.7 inch) 2267 kg (4999 lb) 7
1.3 m3 (1.75 yd3) 925 mm (36.4 inch) 1542 kg (3400 lb) 3

2030 mm (79.9 inch)
3 3
1.6 m (2.13 yd ) 1098 mm (43.2 inch) 1638 kg (3612 lb) 4
3 3
1.8 m (2.38 yd ) 1226 mm (48.3 inch) 1958 mm (77.1 inch) 1540 kg (3396 lb)
General Purpose (GP) 2.0 m3 (2.5 yd3) 1246 mm (49.1 inch) 1758 kg (3876 lb) 5
3 3
2.3 m (3.0 yd ) 1400 mm (55.1 inch) 1793 kg (3954 lb)
2030 mm (79.9 inch)
3 3
2.6 m (3.5 yd ) 1562 mm (61.5 inch) 2025 kg (4465 lb) 6
3.0 m3 (4.0 yd3) 1737 mm (68.4 inch) 2143 kg (4725 lb) 7

3 3
1.3 m (1.75 yd ) 1098 mm (43.2 inch) 1751 kg (3861 lb) 4
3 3
Heavy Duty Rock 1.6 m (2.13 yd ) 1246 mm (49.1 inch) 1870 mm (73.6 inch) 1877 kg (4139 lb)
5
1.9 m3 (2.5 yd3) 1400 mm (55.1 inch) 2019 kg (4452 lb)
Rock Ripping (RR) 0.9 m3 (1.13 yd3) 953 mm (37.5 inch) 1870 mm (73.6 inch) 2024 kg (4163 lb) 5
(1) These specifications are for a machine with a “F” bucket and a reach linkage.
Table 15
345B Excavator(1)
ISO Capacity of Bucket Tip Bucket Weight Number of Bucket

Application Width of Bucket
Bucket Radius (with Tips) Tips
2.6 m3 (3.5 yd3) 1710 mm (67.3 inch) 2509 kg (5520 lb)
Heavy Duty (HD) 1994 mm (78.5 inch) 6
3 3
3.0 m (4.0 yd ) 1900 mm (74.8 inch) 2682 kg (5900 lb)
Heavy Duty Rock

3.0 m3 (4.0 yd3) 1900 mm (74.8 inch) 1994 mm (78.5 inch) 2810 kg (6182 lb) 6
(HDR)
(1) These specifications are for a machine with a “G” bucket and a mass excavation linkage.
40 SEBU7029-05
345B L Excavators
Table 16
345B Excavators with Long Undercarriage
Reach Boom Mass Boom

3.9 m 3.35 m 2.9 m 3.0 m 2.9 m
(12 ft 10 (10 ft 10 (10 ft 10 (9 ft 10 (10 ft 10
SAE Ca- inch) Stick inch) Stick inch) Stick inch) Stick inch) Stick
pacity of Width of Bucket with T with T with T with U with U
Application Bucket Bucket Family Bucket Bucket Bucket Bucket Bucket
1075 mm (1) (1) (1) (2) (2)
1.3 m3 (42.3 inch)
1218 mm (1) (1) (1) (2) (2)

1.6 m3 (48.0 inch)
1225 mm (3) (1) (1) (2) (2)

1.7 m3 (48.2 inch)
Trenching F
3
1410 mm (1) (1) (1) (2) (2)
1.9 m (55.5 inch)
1375 mm (1) (3) (1) (2) (2)

2.0 m3 (54.1 inch)
1525 mm (1) (1) (3) (2) (2)

2.3 m3 (60.1 inch)
1.9 m3 F (1) (1) (1) (2) (2)
1750 mm (2) (2) (2) (1) (1)

2.1 m3 (68.9 inch)
G
3
1980 mm (2) (2) (2) (1) (1)
2.4 m (78.0 inch)
1590 mm (1) (1) (1) (2) (2)

2.0 m3 (62.6 inch)
Excavation
F
1735 mm (1) (1) (1) (2) (2)
2.2 m3 (68.3 inch)
1655 mm (2) (2) (2) (3) (1)

2.2 m3 (65.2 inch)
G
1770 mm (2) (2) (2) (1) (3)
2.4 m3 (69.7 inch)
2135 mm (2) (2) (2) (1) (1)

2.6 m3 (84.1 inch)
Mass Excavation G
3
1895 mm (2) (2) (2) (1) (1)
2.6 m (74.6 inch)
1600 mm (1) (1) (1) (2) (2)

2.0 m3 (63.0 inch)
Extreme Service
F
Excavation 1600 mm
2.1 m3 (1) (1) (1) (2) (2)
(63.0 inch)
1750 mm (2) (2) (2) (1) (1)

2.2 m3 (68.9 inch)
Rock G
3
1880 mm (2) (2) (2) (1) (1)
2.4 m (74.0 inch)
(1) Approved combination
(2) Unavailable
(3) Recommended
SEBU7029-05 41
Note: Never reverse the bucket in order to use the

bucket as a loader.
Note: The “Width of Bucket” indicates the maximum

width.
Consult your Caterpillar dealer for more information.
Table 17
345B Excavators with Long Variable Undercarriage
Reach Boom Mass Boom

3.9 m 3.35 m 2.9 m 3.0 m 2.9 m
(12 ft 10 (10 ft 10 (10 ft 10 (9 ft 10 (10 ft 10
SAE Ca- inch) Stick inch) Stick inch) Stick inch) Stick inch) Stick
pacity of Width of Bucket with T with T with T with U with U
Application Bucket Bucket Family Bucket Bucket Bucket Bucket Bucket
1075 mm (1) (1) (1) (2) (2)
1.3 m3 (42.3 inch)
1218 mm (1) (1) (1) (2) (2)

1.6 m3 (48.0 inch)
1225 mm (1) (1) (1) (2) (2)

1.7 m3 (48.2 inch)
Trenching F
1410 mm (3) (1) (1) (2) (2)
1.9 m3 (55.5 inch)
1375 mm (1) (1) (1) (2) (2)

2.0 m3 (54.1 inch)
1525 mm (1) (1) (1) (2) (2)

2.3 m3 (60.1 inch)
1.9 m3 F (1) (1) (1) (2) (2)
1750 mm (2) (2) (2) (1) (1)

2.1 m3 (68.9 inch)
G
1980 mm (2) (2) (2) (3) (1)
2.4 m3 (78.0 inch)
1590 mm (1) (3) (1) (2) (2)

2.0 m3 (62.6 inch)
Excavation
F
1735 mm (1) (1) (3) (2) (2)
2.2 m3 (68.3 inch)
1655 mm (2) (2) (2) (1) (1)

2.2 m3 (65.2 inch)
G
1770 mm (2) (2) (2) (1) (1)
2.4 m3 (69.7 inch)
2135 mm (2) (2) (2) (1) (3)

2.6 m3 (84.1 inch)
Mass Excavation G
1895 mm (2) (2) (2) (1) (1)
2.6 m3 (74.6 inch)
1600 mm (1) (1) (1) (2) (2)

2.0 m3 (63.0 inch)
Extreme Service
F
Excavation 1600 mm
2.1 m3 (1) (1) (1) (2) (2)
(63.0 inch)
(continued)
42 SEBU7029-05
Lifting Capacities
(Table 17, contd)

1075 mm (1) (1) (1) (2) (2)
Trenching 1.3 m3 F
(42.3 inch)
(1)
1750 mm (2) (2) (2) (1)
2.2 m3 (68.9 inch)
Rock G
1880 mm (2) (2) (2) (1) (1)
2.4 m3 (74.0 inch)
(1) Approved combination
(2) Unavailable
(3) Recommended
Note: Never reverse the bucket in order to use the

bucket as a loader.
Note: The “Width of Bucket” indicates the maximum
width.
Consult your Caterpillar dealer for more information.
i00889197
Lifting Capacities
SMCS Code: 7000
S/N: 2NW1–Up
The pictographs in illustration 60 are in the charts for
lifting capacities. The symbols are explained in the
text that follows illustration 60 .
(A) Load point height
(B) Load radius over the front of the machine
(C) Load radius over the side of the machine
(D) Load at maximum reach
(E) Capacity is limited by hydraulics rather than by a tipping load.
The loads do not exceed 100 percent of hydraulic lifting
capacity. The loads do not exceed 100 percent of tipping
capacity. Weight of all lifting accessories must be subtracted
from the lifting capacities.
SEBU7029-05 43
Lifting Capacities
Metric
English
44 SEBU7029-05
Lifting Capacities
SEBU7029-05 45
Identification Information
Identification Information
i01654027
Plate Locations and Film

Locations
SMCS Code: 1000; 7000
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
and major attachments that are not designed for an
operator to ride are identified by Serial Numbers. Illustration 65 g00110306
For quick reference, record the identification Engine Serial Number

numbers in the spaces that are provided below the
illustration. i08085827
Emissions Certification Film

SMCS Code: 1000; 7000; 7405
Consult your Cat dealer for an Emission Control
Warranty Statement.
The emission certification film is on the engine.
Machine PIN
Service Information Number Plate (SIN)

46 SEBU7029-05
Operation Section
Before Operation
Operation Section • Operation and Maintenance Manual, “Boom, Stick

and Bucket Linkage - Lubricate”
Before Operation Daily Basis

Daily, perform the procedures that are applicable to
i01967054 your machine:
Daily Inspection • Operation and Maintenance Manual, “Cooling

System Level - Check”
SMCS Code: 1000; 6319; 6700; 7000
• Operation and Maintenance Manual, “Engine Oil
Level - Check”
• Operation and Maintenance Manual, “Fuel System
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to Water Separator - Drain”
contact skin. • Operation and Maintenance Manual, “Fuel Tank
At operating temperature, the engine coolant is Water and Sediment - Drain”
hot and under pressure.
• Operation and Maintenance Manual, “Hydraulic
Steam can cause personal injury. System Oil Level - Check”
Check the coolant level only after the engine has • Operation and Maintenance Manual, “Indicators
been stopped and the cooling system pressure and Gauges - Test”
cap is cool enough to touch with your bare hand.
• Operation and Maintenance Manual, “Seat Belt -
Remove the cooling system pressure cap slowly Inspect”
to relieve pressure.
• Operation and Maintenance Manual, “Track
Cooling system conditioner contains alkali. Avoid Adjustment - inspect”
contact with the skin and eyes to prevent person-
al injury. • Operation and Maintenance Manual, “Travel
Alarm - Test”
NOTICE • Operation and Maintenance Manual,
Accumulated grease and oil on a machine is a fire “Undercarriage - Check”
hazard. Remove this debris with steam cleaning or
high pressure water, at least every 1000 hours or Refer to the Maintenance Section for the detailed
each time any significant quantity of oil is spilled on a procedures. Refer to the Maintenance Interval
machine. Schedule for a complete list of scheduled
maintenance.
For maximum service life of the machine, perform a
thorough daily inspection before you mount the Note: Watch closely for leaks. If you observe a leak,
machine and before you start the engine. find the source of the leak and correct the leak. If you
suspect a leak or you observe a leak, check the fluid
First 100 Hours levels more frequently.

your machine:
• Operation and Maintenance Manual, “Boom, Stick
and Bucket Linkage - Lubricate”
Severe Applications
your machine:
SEBU7029-05 47
Operation Section
Mounting and Dismounting
Make sure that all covers and guards are securely

attached. Inspect the covers and the guards for
damage.
Inspect the attachment control linkage, attachment

cylinders, and attachment for damage or excessive Illustration 68 g00101987
wear. Make any necessary repairs.
Inspect the steps, the walkways, and the handholds.
Inspect the lights for broken bulbs and for broken Clean the steps, the walkways, and the handholds.
lenses. Replace any broken bulbs and any broken Make any necessary repairs.
lenses.
Inspect the operator compartment for trash buildup.
Inspect the engine compartment for any trash Check for trash buildup under the floorplate and on
buildup. Remove any trash buildup from the engine the crankcase guard. Keep these areas clean.
compartment.
Adjust the mirrors in order to achieve the best
Inspect the cooling system for any leaks, for faulty visibility.
hoses and for any trash buildup. Correct any leaks.
Remove any trash from the radiator.
i04027420
Inspect all of the belts for the engine attachments.
Replace any belts that are worn, frayed, or broken. Mounting and Dismounting
SMCS Code: 6700; 7000
Inspect the hydraulic system for leaks. Inspect the

tank, cylinder rod seals, hoses, tubes, plugs, Illustration 69 g00037860
connections, and fittings. Correct any leaks in the
hydraulic system. Use steps and handholds whenever you mount the
machine. Use steps and handholds whenever you
Inspect the differential and the final drives for leaks. dismount the machine. Before you mount the
Make any necessary repairs. machine, clean the step and the handholds. Inspect
the step and handholds. Make all necessary repairs.
Inspect the swing drive for leaks.
Face the machine whenever you mount the machine
and whenever you dismount the machine. Maintain a
three-point contact with the step and with handholds.
48 SEBU7029-05
Operation Section
Mounting and Dismounting
Note: Three-point contact can be two feet and one

hand. Three-point contact can also be one foot and
two hands.
Do not mount a moving machine. Do not dismount a
moving machine. Never jump off the machine. Do not
try to mount the machine when you carry tools or
supplies. Do not try to dismount the machine when
you are carrying tools or supplies. Use a hand line to
pull equipment onto the platform. Do not use any
controls as handholds when you enter the operator
compartment or when you exit the operator
compartment.
Machine Access System

Specifications
The machine access system has been designed to
meet the intent of the technical requirements in “ISO
2867 Earth-moving Machinery – Access Systems”.
The access system provides for operator access to
the operator station and to conduct the maintenance
procedures described in Maintenance section.
SEBU7029-05 49
Operation Section
Machine Operation
Machine Operation
i01451689
Alternate Exit
SMCS Code: 7310
Illustration 70 g00101073 The operator can adjust the seat position forward or
backward. The seat position can be adjusted up and
The rear window serves as an alternate exit. down. The operator may also adjust the seat back tilt.
Select the desired position in order to allow full pedal
To remove the rear window, pull the ring and push out travel and full lever travel.
the glass.
The right console and the left console can be
Completely remove the O-ring seal from the seal that adjusted vertically.
supports the glazing support seal. This will provide
enough clearance so that the seal can hinge and the The seat and the consoles can also slide as one unit.
glazing can pass outward.
i01957305
Seat
SMCS Code: 5258-025; 7312-025; 7324; 7327
Put the hydraulic lockout control in the LOCKED
position. For further details on this procedure, refer to
Operation and Maintenance Manual, “Hydraulic
Lockout Control”. Do this procedure before you
adjust the seat and the console. This will prevent any
possibility of unexpected movement of the machine.
Adjust the seat at the beginning of each work period
and adjust the seat when you change operators.
Always use the seat belt when you operate the
machine. For further details on this procedure, refer
to Operation and Maintenance Manual, “Seat Belt”.
The seat should be adjusted so that full pedal travel
is allowed.
50 SEBU7029-05
Operation Section
Seat
Use the two-position adjustment lever (4) in order to

adjust the height of the seat. Pull up lever (4) into the
first position. The angle of the seat can now be
changed. Only the rear of the seat will tilt. Hold the
seat in the desired position. Release the lever. To
adjust the height of the seat, pull up lever (4) through
the first position and into the second position. The
front of the seat and the rear of the seat will raise
simultaneously. The front of the seat and rear of the
seat will lower simultaneously. Hold the seat in the
desired position. Release the lever.
To adjust the seat back tilt to the desired position,
turn knob (5).
To move the seat, the left console, and the right
console forward or backward as one unit, pull up
lever (6) and hold the lever. Hold the seat in the
desired position. Release the lever in order to lock
the seat, the left console, and the right console.
To adjust the seat forward or backward, pull up lever
(7) and hold the lever. Move the seat to the desired
position. To lock the seat in the selected position,
release the lever.
To adjust the seat suspension, turn operator weight
adjustment knob (1) (if equipped) until the dial
indicator shows the approximate weight of the
operator. The adjustment knob has a range of
50 kg to 120 kg (110 lb to 265 lb). Turning the
adjustment knob clockwise increases the reading.
Turning the adjustment knob counterclockwise
decreases the reading.
To adjust the angle of the armrest, operate dial (8). A

dial is on the bottom of each armrest. Place the
armrests in the upright position when you enter the
machine or when you exit the machine.
The operator can adjust the height of headrest (9) (if
equipped) and the angle of the headrest. To adjust
the headrest, hold the headrest with both hands.
Move the headrest forward or backward and move
Turn knob (2) (if equipped) in order to tilt the left the headrest up and down. Release the headrest
console to the desired height. when the desired position is attained. The headrest
will remain in the desired position.
Turn knob (3) (if equipped) in order to tilt the right
console to the desired height. The lumbar support is located in the back of the seat.
Turn knob (10) (if equipped) counterclockwise in
order to increase the force of the lumbar support.
Turn the knob clockwise in order to decrease the
force of the lumbar support.
SEBU7029-05 51
Operation Section
Seat Belt
i04200349
Seat Belt
SMCS Code: 7327
Note: This machine was equipped with a seat belt

when the machine was shipped from Caterpillar. At
the time of installation, the seat belt and the
instructions for installation of the seat belt meet the
SAE J386 and ISO 6683 standards. Consult your Cat
dealer for all replacement parts.
Always check the condition of the seat belt and the
condition of the mounting hardware before you
operate the machine.
Seat Belt Adjustment for Non-

2. To remove the slack in outer loop (1), rotate buckle
Retractable Seat Belts (2). This will free the lock bar. This permits the
Adjust both ends of the seat belt. The seat belt seat belt to move through the buckle.
should be snug but comfortable. 3. Remove the slack from the outer belt loop by
pulling on the buckle.
Lengthening the Seat Belt
4. Loosen the other half of the seat belt in the same
manner. If the seat belt does not fit snugly with the
buckle in the center, readjust the seat belt.
Shortening the Seat Belt
1. Unfasten the seat belt.
1. Fasten the seat belt. Pull out on the outer belt loop
in order to tighten the seat belt.
2. Adjust the other half of the seat belt in the same
manner.
3. If the seat belt does not fit snugly with the buckle in
the center, readjust the seat belt.
52 SEBU7029-05
Operation Section
Seat Belt
Fastening The Seat Belt Releasing The Seat Belt
Fasten the seat belt catch (3) into the buckle (2). Pull up on the release lever. This will release the seat
Make sure that the seat belt is placed low across the belt.
lap of the operator.
Seat Belt Adjustment for
Retractable Seat Belts
Fastening The Seat Belt
Pull seat belt (4) out of the retractor in a continuous

motion.
Fasten seat belt catch (3) into buckle (2). Make sure
that the seat belt is placed low across the lap of the
operator.
The retractor will adjust the belt length and the
retractor will lock in place. The comfort ride sleeve
will allow the operator to have limited movement.
SEBU7029-05 53
Operation Section
Operator Controls
Releasing The Seat Belt
Push the release button on the buckle in order to

release the seat belt. The seat belt will automatically
retract into the retractor.
Extension of the Seat Belt
When using retractable seat belts, do not use

seat belt extensions, or personal injury or death
can result.
The retractor system may or may not lock up de-
pending on the length of the extension and the
size of the person. If the retractor does not lock
up, the seat belt will not retain the person.
Longer, non-retractable seat belts and extensions for
the non-retractable seat belts are available.
Caterpillar requires only non-retractable seat belts to
be used with a seat belt extension.
Consult your Cat dealer for longer seat belts and for
information on extending the seat belts.
i02013271
Operator Controls
SMCS Code: 7300; 7301; 7451
Note: Your machine may not be equipped with all of

the controls that are described in this topic.
54 SEBU7029-05
Operation Section
Operator Controls
(1) Left Console (6) Left Travel Lever (11) Right Console
(2) Hydraulic Lockout Control (7) Right Travel Lever (12) Backup Controls
(3) Left Travel Pedal (8) Service Hour Meter (13) Operator's Seat
(4) Right Travel Pedal (9) Monitor
(5) Left Joystick (10) Right Joystick
SEBU7029-05 55
Operation Section
Battery Disconnect Switch
i05039774 Turn the battery disconnect switch to the OFF

position and remove the disconnect switch key when
Battery Disconnect Switch you service the electrical system or other
components on the machine.
SMCS Code: 1411-B11
Turn the battery disconnect switch to the OFF
position and remove the disconnect switch key if you
do not operate the machine for an extended period of
a month or more. This will prevent drainage of the
battery.
NOTICE
Never move the battery disconnect switch to the OFF
position while the engine is operating. Serious dam-
age to the electrical system could result.
To ensure that no damage to the engine occurs,

verify that the engine is fully operational before
cranking the engine. Do not crank an engine that is
not fully operational.
Illustration 83 g00100862 Perform the following procedure in order to check the

battery disconnect switch for proper operation:
The battery disconnect switch is on the left side of the
machine behind the front access door. 1. With the battery disconnect switch in the ON
position, verify that electrical components in the
operator compartment are functioning. Verify that
the hour meter is displaying information. Verify that
the engine will crank.
2. Turn the battery disconnect switch to the OFF
position.
3. Verify that the following items are not functioning:
electrical components in the operator
compartment, hour meter and engine cranking. If
any of the items continue to function with the
battery disconnect switch in the OFF position,
consult your Cat dealer.
Illustration 84 g00406959 i01966093
ON – To activate the electrical system, Product Link

insert the disconnect switch key and
turn the battery disconnect switch (If Equipped)
clockwise. The battery disconnect switch must SMCS Code: 7490; 7602
be turned to the ON position before you start the
engine. The Product Link System (201) is a satellite
communication device that transmits information
OFF – To deactivate the electrical regarding the machine to Caterpillar and to
system, turn the battery disconnect Caterpillar Dealers and Customers. The device
switch counterclockwise to the OFF contains a Global Positioning System and a satellite
position. transmitter/receiver. All logged events and diagnostic
codes that are available to the Caterpillar Electronic
The battery disconnect switch operates differently Technician (ET) on the CAT data link can be sent to
than the engine start switch. When the battery the satellite. Information can also be sent to the
disconnect switch is in the OFF position, the Product Link 201 from the satellite. The information
electrical system is disabled. When the engine start that is sent by the Product Link 201 goes to the
switch is turned to the OFF position and the battery satellite, and then to the receiving station. The
disconnect switch is turned to the ON position, the receiving station transmits the data to Caterpillar. The
battery remains connected to the entire electrical information can then be sent to Caterpillar dealers
system. and Customers.
56 SEBU7029-05
Operation Section
If Equipped
Note: The Product Link 201 is automatically This warning does not supersede the published
activated when the battery disconnect switch is in the requirements or the regulations that are found in
ON position. “Title 30 of the Code of Federal Regulations (CFR)”.
Every operation of a mine should conduct a hazard
The system consists of three main components: assessment that meets all of the requirements of
“Title 30 of the Code of Federal Regulations (CFR)”.
• Hardware, which includes the following, data This will ensure safe operation in the storage,
module, antenna, wiring and additional mounting transportation, loading, and blasting of explosive
hardware. material. The following specifications are provided in
order to aid in conducting hazard assessments.
• Satellite System and Caterpillar Network These specifications are also provided in order to aid
in ensuring compliance with all local regulations:
• PC Software
• The power of the transmitter for the Product Link is
5 Watts.
• The operating frequency range for the Product

Link is 148 - 150 MHz.
Regulatory Compliance
Typical location
This machine is equipped with a Cat Product Link

radio communication device which must be deac-
tivated within 6.0 m (20 ft) of a blast zone. Failure Illustration 86 g01015248
to do so could result in serious injury or death.
Refer to System Operation, Troubleshooting, and
Testing and Adjusting, RENR5885, “ Product Link
If the machine is required to work within 6.0 m 151/201” for information about this service tool.
(20 ft) of a blast area, then the operator must take
one of the following precautions: Consult your Caterpillar dealer with any questions
that concern the operation of the Product Link in a
• Disconnect the Product Link module from the specific country.
power source by disconnecting the wiring harness
at the Product Link module.
• Temporarily remove the Product Link module from
the machine.
• Install an ON/OFF switch in order to allow the
Product Link module to be turned off from the
inside of the cab.
SEBU7029-05 57
Operation Section
Engine Start Switch
i02169424
Ether Starting Aid Switch

(If Equipped)
SMCS Code: 1456
i01584591
The switch for the ether starting aid is located on the
switch panel on the right side of the cab.
Engine Start Switch
SMCS Code: 1416-ENG Ether Starting Aid – If the engine is
difficult to start in cold weather, ether
can be injected into the air inlet by
activating the ether starting aid.
Ether Starting Aid Activated – Push the
right side of the switch only while you
crank the engine. Release the switch. A
premeasured amount of ether will be injected into
the air inlet.
i00651334
Monitoring System
SMCS Code: 7451; 7490
Illustration 88 g00822102 NOTICE

When the monitor provides a warning, immediately
(1) OFF position. (2) ON position. (3) START position. check the monitor and perform the required action or
maintenance as indicated by the monitor.
For details, see the Operation and Maintenance
Manual, “Engine Starting”. The monitor indicator does not guarantee that the
machine is in a good condition. Do not use the moni-
tor panel as the only method of inspection. Mainte-
nance and inspection of the machine must be
performed on a regular basis. See the Maintenance
Section of this Operation and Maintenance Manual.
58 SEBU7029-05
Operation Section
Monitoring System
The Electronic Monitor Panel consists of indicators The Electronic Monitor Panel consists of an action
(A) and switches (B). The indicators are gauges and alarm, action light (C), and monitor panel (D). The
indicators for various machine systems. The switches monitor panel has individual alert indicators for each
are for selecting the various work modes and the machine system that is listed on the monitor panel.
power modes.
The monitor panel is designed to alert the operator of
an immediate problem or of an impending problem.
The problem could be in more than one of the
machine systems that are listed.
Functional Test
To ensure proper operation, check the system daily.
The functional test can be part of the starting
procedure for the engine. For details on starting
procedures for the engine, see Operation and
Maintenance Manual, “Engine Starting”.
Warning Categories
The electronic monitor panel provides three warning
categories. The first warning category requires only
operator awareness. The second warning category
requires an operator response. The third warning
category requires immediate shutdown of the
machine systems.
SEBU7029-05 59
Operation Section
Monitoring System
Warning Category 1 Restricted Hydraulic Return Filter (3) –

This indicator indicates that one or both
In this category, only the alert indicator comes on. of the two hydraulic return filters
This category alerts the operator that the machine (capsule filters) is restricted. A restricted
system needs attention. Failure of these systems will hydraulic return filter will cause hydraulic
not endanger the operator. Failure of these systems components to malfunction. Immediately replace
will not cause serious damage to the machine the return filter cartridges. Examine the condition
components. of the restricted hydraulic filters. Perform
additional repairs, if necessary.
Electronic Controller (4) – When an

electronic problem occurs, this
indicator light will be activated. The
problem may not exist in the electronic controller.
Stop the engine and restart the engine after a few
minutes. If the indicator light does not come on, this
indicates that a problem does not exist. If the
indicator light comes on again, there is a problem in
the electrical system. Consult your Caterpillar dealer
for any necessary repairs.
Make necessary repairs as soon as possible. If you
cannot make immediate repairs, you can operate the
machine by placing the backup switch in the
MANUAL position. When the backup switch is in the
MANUAL position, the power to the electronic
monitor panel will be switched off. The monitor panel
will not function.
The backup switch is only a temporary procedure.
Perform any necessary repairs as soon as possible.
Monitor Panel (5) – If the indicator light

comes on, a problem may exist in the
monitor panel. The problem might also
exist in the data communication lines. Consult
your Caterpillar dealer for the necessary repairs.
The machine can be operated, but the electronic
Alternator (1) – This alert indicator monitor panel will not function. Perform any
indicates that the electrical charging necessary repairs as soon as possible.
system is malfunctioning. The machine
can be operated while the alternator light is on. Note: If Electronic Controller (4) and Monitor Panel
However, if the electrical accessories are used, (5) come on at the same time, there is a malfunction.
the batteries will discharge rapidly. Perform any This malfunction is in the communication between
necessary repairs. the electronic controller and the monitor panel. In this
case, consult your Caterpillar dealer for any
Restricted Air Filter (2) – This indicator necessary repairs.
indicates that the air filter is restricted. If
the air filter is restricted, then engine Coolant Level (6) – If this indicator is
output will be decreased. Immediately inspect the activated, the coolant level is below the
air filter. Clean the air filter. Inspect the condition specified level. Add coolant.
of the air filter. Replace the air filter, if necessary.
If the engine start switch is placed in the ON position
Perform any necessary repairs. for 2 seconds or longer, the prestart monitoring
function is activated in order to check the coolant
level. This indicator will not go off unless the engine
start switch is turned off. If the engine start switch is
not placed in the ON position for 2 seconds or longer,
the prestart monitoring function will not be activated
and the indicator will go off after flashing for 5
seconds.
60 SEBU7029-05
Operation Section
Monitoring System
Engine Oil Level (7) – If this indicator is

activated, the engine oil level is below
the specified level. Add engine oil.
If the engine start switch is placed in the ON position
for 2 seconds or longer, the prestart monitoring
function is activated in order to check the engine oil
level. This indicator will not go off unless the engine
start switch is turned off. If the engine start switch is
not placed in the ON position for 2 seconds or longer,
the prestart monitoring function will not be activated
seconds.
Hydraulic Oil Level (8) – If this indicator
is activated, the hydraulic oil level is
below the specified level. Add hydraulic Illustration 93 g00115408
oil.
Hydraulic Tank Pressure (14) – If this
If the engine start switch is placed in the ON position indicator is activated, the hydraulic tank
for 2 seconds or longer, the prestart monitoring pressure has not yet reached the
function is activated in order to check the hydraulic oil operating level. While the indicator is activated,
level. This indicator will not go off unless the engine the engine speed is limited to a speed that is less
start switch is turned off. If the engine start switch is than maximum engine speed. The engine speed
not placed in the ON position for 2 seconds or longer, is limited in order to protect the hydraulic pump.
the prestart monitoring function will not be activated The indicator will remain activated until the
seconds. hydraulic tank pressure has reached the
predetermined level and the implement control
Fuel Level (9) – If the fuel in the tank is lever is returned to the HOLD position.
below the specified level, this indicator
will come on. Add fuel. Warning Category 2
Note: This machine is not equipped with an air inlet In this category, the alert indicator and the action light
heater. However, the indicator for the air inlet heater come on. This category requires a change in
(10) will come on when the electronic monitoring machine operation in order to reduce excessive
system is tested. temperature in one of the machine systems or more.
SEBU7029-05 61
Operation Section
Monitoring System
Hydraulic Oil Temperature (11) – This Engine Oil Pressure (13) – This alert
alert indicator indicates excessive indicator indicates low engine oil
hydraulic oil temperature. If this alert pressure. If this alert indicator comes
indicator comes on, reduce the operating speed on, stop the machine immediately. Stop the
of the machine. Keep the engine at low idle until engine and investigate the cause of the problem.
the hydraulic oil temperature decreases to the Do not operate the machine until the cause of the
correct level. If the indicator stays on after problem has been corrected.
restarting machine operation, stop the engine.
Check the hydraulic oil level. Check the oil cooler
for restriction. Perform any necessary repairs as
soon as possible.
Coolant Temperature (12) – This alert

indicator indicates excessive coolant
temperature. If this alert indicator comes
on, reduce the operating speed of the machine.
Keep the engine at low idle until the engine is
cooled down. If the indicator stays on after
running the engine at low idle, stop the engine.
Check the coolant level. Check the fan drive belts
for the water pump and fan blade. Make any
necessary repairs.
Warning Category 3
In this category, the alert indicator and the action light
will come on and the action alarm sounds. This
category requires immediate shutdown of the
machine. The machine must be shutdown in order to
prevent injury to the operator and/or severe damage
to the machine.
62 SEBU7029-05
Operation Section
Gauges
i01496570 in illustration 97 is reached. Each section of the

fuel gauge represents an approximate 8 percent
Gauges change in the fuel level. When the fuel gauge
indicates that the fuel level is in the white range,
SMCS Code: 7450; 7451; 7490 add fuel immediately.
Hydraulic Oil Temperature (2) – This
gauge indicates the temperature of the
hydraulic oil. The normal operating
range is the green range. If the gauge reaches the
red range, reduce the load on the system. If the
gauge stays in the red range, stop the machine
and investigate the cause of the problem.
Engine Coolant Temperature (3) – This

gauge indicates the temperature of the
engine coolant. The green range is the
normal operating temperature. The red range
indicates overheating.
Fuel Level (1) – This gauge indicates

fuel tank levels. By using this gauge, an
operator can determine the amount of
fuel that is in the tank. Use illustration 97 as a
reference in order to determine the amount of
fuel that is in the fuel tank. Each section of the
fuel gauge will illuminate or each section will turn
off when the specified percentage that is shown
SEBU7029-05 63
Operation Section
Magnet Controller and Monitor Panel
i01162607 “ GEN HOT”” (4) – If this indicator comes on, the

generator is overheating. One or more of the
Magnet Controller and Monitor following items could be the reason that the
generator is overheating:
Panel
SMCS Code: 7490 • The magnet is too large.
• There is a short or a ground in the system.
• The duty cycle is too high.

• The voltage is too high.
• There is insufficient airflow through the generator.

• The generator is faulty.
“ + GND FAULT”” (5) – If this indicator comes on, the
resistance to ground in the positive line has dropped
below 50,000 ohms.
“ - GND FAULT”” (6) – If this indicator comes on, the
resistance to ground in the negative line has dropped
below 50,000 ohms.
“ DROP TIME”” (7) – The drop time is controlled by a
control dial and a range switch. The settings of both
controls will vary depending on the size of the
magnet. To achieve the best drop time for a given
magnet, you should use the procedure below.
Use the following procedure to set the “DROP TIME”
.
1. Determine the size of magnet that is installed on
the machine. Locate the settings for the magnet in
Table 18 .
2. Set control dial (7) to the lower value that is given
in Table 18 . Set the range switch to the position
that is shown in Table 18 . The range switch is
located on the lower right exterior of the “PLC”
enclosure.
Table 18
“ MAGNET ON”” (1) – If this indicator comes on, the
magnet is energized. Initial Settings
“ VOLTS FAULT”” (2) – If this indicator comes on, the Magnet Cold Position of
voltage is too high or the voltage is too low in order to Size of Mag- Rating Position of Range
properly operate the magnet. One or more of the net (kW) (amperes) Control Dial Switch
following items could remedy the problem:
0 to 7 0 to 30 1 TO 4 OFF
7 to 10 30 to 45 1 TO 6 OFF
• Check the electrical connections.
11 to 15 45 to 70 1 TO 7 OFF
• Inspect the generator field resistor.
2 TO 8 OFF
16 to 25 70 to 110
• Check that the generator is operating at the 1 TO 6 ON
correct speed (1750 RPM).
26 to 45 110 to 220 3 TO 8 ON
• Check the generator.
“ OVER 75% D.C.”” (Duty Cycle) (3) – If this indicator 3. Lift the load and drop the load at consecutively
comes on, the magnet is being operated more than higher settings until a clean drop is achieved.
75 percent of the time.
64 SEBU7029-05
Operation Section
Clock
4. Record the settings and the size of the magnet that • In order to change the setting for the hour,
is being used. When the same magnet is installed, simultaneously press switch (1) for the boom
set the control dial and the range switch to the priority mode and alarm cancel switch (4). In order
recorded settings. to change the minutes, simultaneously press
power mode switch (2) and alarm cancel switch
Note: The initial settings are only suggestions. The (4). When you push the switches, the unit of time
actual settings may vary depending on the advances by one increment. Hold down the
manufacturer of the magnet. The type of magnet and switches in order to continuously change settings.
the material type and consistency will affect the
setting. The dial setting will usually be higher for • When you hold down alarm cancel switch (4),
larger magnets. The range switch should be in the press AEC switch (3). This sets the clock to “00”
OFF position for magnets that are rated at 110 minutes. If the time that is displayed is 30 minutes
amperes or less. The range switch should only be in or less, the clock will display the preceding hour. If
the ON position when a clean drop cannot be the time that is displayed is more than 30 minutes,
achieved at any dial setting in the OFF position. The the clock will display the succeeding hour.
ON position should only be necessary with magnets
that are rated 111 Amperes and up. i00116845
i01956201 Service Hour Meter

SMCS Code: 7480
Clock
SMCS Code: 7450
Service Hour Meter – This display

indicates the total operating hours of the
engine. Use the display to determine the
service hour maintenance intervals.

The display shows a time of “10:29” .
Turn the disconnect switch to the OFF position or

remove the batteries in order to reset the clock to
“1:00” . The following two methods can be used in
order to adjust the clock.
SEBU7029-05 65
Operation Section
Light Switches
i00130703 i00762969
Light Switches Travel Alarm

SMCS Code: 1429-ZS (If Equipped)
SMCS Code: 7429
The travel alarm is located under the engine. The

travel alarm will sound when the travel lever or the
travel pedal is activated.
Travel Alarm Cancel Switch

(A) Work Light. (B) Work Light. (C) Work Light. (1)
Indicator Light. (2) Indicator Light.
Light Switch – Push the switch in order

to turn on the work lights.
Whenever you push the switch, you change the

pattern of the work lights that are turned on. The
indicator lights that are in the cab indicate the pattern
of the work lights that are turned on. When indicator
light (1) is on, the following work lights are turned on:
work light (A) that is mounted on the chassis, work
light (B) that is mounted on the cab and the lights for
the monitoring panel. Illustration 105 g00100931
(1) Indicator lamp
When indicator light (1) and indicator light (2) are on,
the following work lights are turned on: work light (A)
that is mounted on the chassis, work light (B) that is
mounted on the cab, work light (C) that is mounted
on the boom and the lights for the monitoring panel.
When both of the indicator lights are off, all of the
work lights are off.
66 SEBU7029-05
Operation Section
Storage Box
Travel Alarm Cancel Switch – This

switch is used to stop the travel alarm
from sounding. Press the switch in
order to stop the alarm. Indicator lamp (1) comes
on.
i00659894
Storage Box
SMCS Code: 7268
Interior Storage Box
Note: There is a plugged hole inside the storage box.

Install the plug that is supplied with the machine into
the hole in order to block the air that is coming from
the air conditioner or from the heater.
Exterior Storage Box
The storage box is used to store miscellaneous items

such as a first aid kit or a lunch box.
Pull – Pull the handle in order to open

the storage box. The storage box is
used to store the refueling pump. The
storage box is also used to store miscellaneous
tools.
i01953622
Air Conditioning and Heating

Control
SMCS Code: 7304; 7320; 7337
The automatic temperature control unit adjusts the
temperature inside the cab automatically.
SEBU7029-05 67
Operation Section
Air Conditioning and Heating Control
Temperature Selection Switches – These

switches control the temperature of the
air that is coming from the air outlets in
order to achieve the preset temperature. This
preset temperature appears on display (6). If the
heating and air conditioning system is in the
automatic mode, pushing these switches
changes the preset temperature.
Increase (4) – Push this switch in order
to increase the temperature of the air
that is coming out of the air outlets or
push this switch in order to increase the preset
temperature.
Decrease (5) – Push this switch in order
to decrease the temperature of the air
that is coming out of the air outlets or
push this switch in order to decrease the preset
temperature.
Fan Speed Switches – The fan speed

Illustration 109 g00101001 switch directly controls the fan speed if
Typical example only the fan is being operated. If the
(A) Air outlet heating and air conditioning system is operating
(B) Air outlet in the automatic mode, pushing this switch
(C) Air outlet overrides the automatically selected fan speed.
(D) Control panel
Increase (9) – Push this switch in order
The automatic temperature control unit is located to increase the fan speed.
behind the operator seat.
Redirect the louvers for air outlets (A) and (C) by Decrease (8) – Push this switch in order
hand to the desired direction. The louvers for air to decrease the fan speed.
outlet (B) cannot be redirected.
The heating and air conditioning controls are on Air Inlet Selection Switches – These switches
control panel (D). select the position of the air inlet.
RECIRCULATE (11) – When this position

is selected, the air inlet is closed. The air
will recirculate inside the cab.
FRESH AIR (10) – When this position is
selected, the air inlet is open. Fresh air
will circulate into the cab.
Note: If the heating and air conditioning system is in
the automatic mode at engine start-up and the
temperature inside the cab is too warm or too cool,
the damper for fresh air ventilation may automatically
close for a few minutes. This will help to bring the air
temperature to the preset temperature more quickly.
Air Outlet Selection Switches – This switch selects
On/Off Switch (1) – If the heating and air the position of each air outlet. Each switch controls a
conditioning system is off, pushing this separate air outlet.
switch will turn on the heating and air
conditioning system. If the heating and air Upper Body (15) – Depressing this
conditioning system is on, pushing this switch switch directs the air flow out of air
will turn off the heating and air conditioning outlet (A).
system.
68 SEBU7029-05
Operation Section
Upper Body and Under Seat (14) –

Depressing this switch directs the air
flow out of air outlet (A) and air outlet
(B).
Under Seat (13) – Depressing this switch
directs the air flow out of air outlet (B).
Defrost (12) – Depressing this switch

directs the air flow out of air outlet (A)
and air outlet (C).
Preset Temperature Display (6) – This display
shows the set temperature.

With the display ON, press the temperature selection
switch (increase) (4), the temperature selection This is an example of the display during the fully
switch (decrease) (5) and the On/Off switch (1) automatic mode.
simultaneously. This will toggle the display between
Degrees Celsius and Degrees Fahrenheit.
Air Conditioning Override Switch (3) – If
the heating and air conditioning system
is in the automatic mode, pushing this
switch causes the compressor to run
continuously while the compressor tries to
maintain the preset temperature. If the heating
and air conditioning system is set for operation
of the fan only, this switch has no function. The
compressor may be operated intermittently
during heater operation in order to remove
excess humidity from the cab. To cancel this
override mode, push switch (3) again.
Automatic Temperature Control Switch Illustration 112 g00102108
(2) – Pushing this button causes the
heating and air conditioning system to To fully take advantage of the automatic function of
toggle between the mode for automatic the heating and air conditioning system, always keep
temperature control and the mode for the fan the direct sunlight sensor clean. Do not put objects
only. near the direct sunlight sensor that will affect the
function of the sensor.
Note: If the fan speed is manually selected and/or In cool weather, operate the compressor weekly in
the override for the air conditioner is selected, order to prevent leakage of the refrigerant gas. This
the “ AUT”” switch must be pushed twice in order will also help to maintain the compressor in optimum
to make the fan speed automatic again. working order.
Note: If the heating and air conditioning system is set Consult with your Caterpillar dealer for periodic
for operation of the fan only, pressing the maintenance of the heating and air conditioning
temperature selection switch returns the heating and system.
air conditioning system to the automatic mode and
the preset temperature will change. This will set the
speed of the fan to the mode of fan only.
SEBU7029-05 69
Operation Section
i01962160 Press the “AUT” button. The “AUT” symbol, the

temperature setpoint and the symbol for recirculation
Air Conditioning and Heating appear in display (1). The operator may select either
the open position or the closed position for the fresh
Control air control. The system is in the full automatic mode
only when these three items are shown on the
(If Equipped) display. If there is more than the three symbols
SMCS Code: 7304; 7320; 7337 shown on the display, the system is in the “AUT”
override mode or in the manual control mode. Full
automatic mode controls the output air temperature,
fan speed, and the air outlets. The ambient
temperature determines the air outlets that are used.
If the “AUT” is not showing in display (1), the system
is in the full manual control mode.
Note: If the cab temperature is below the selected

temperature setpoint, the fan speed will not ramp to
full speed until the temperature of the air outlet
reaches a preset temperature.
Control Panel

(A) Vent for upper body
(B) Floor vent
(C) Defroster vent
(D) Control panel
Note: For the most efficient operation of the

system, use the “ AUT”” mode and do not close Illustration 115 g00997486
any of the louvers completely. (1) Display
(2) Air Outlet Selection Switch
(3) Automatic Temperature Control Switch
Automatic Climate Control (4) Fresh Air Control
(5) Temperature Control Knob
(6) Power On/Off and Fan Speed Knob
Power ON/OFF (6) – Push the fan speed

knob to power on the system or push
the fan speed knob to power off the
system.

Full “AUT” Display
70 SEBU7029-05
Operation Section
If Equipped
Note: The automatic climate control system may take

about 3 minutes in order to respond to large
temperature changes. Wait at least 3 minutes
between temperature changes.

Fan Control Knob (6) – The fan speed is
Manual Override of the Automatic Selection of the Air automatically controlled in the
Outlets automatic mode. Rotate the fan control
knob in order to override the automatically
Air Outlet Selection Switch (2) – Press selected fan speed. The symbol for the fan with
the air outlet selection switch in order to the bar graph for speed control will be added to
cycle through the different positions. display (1).
The symbol in the display will show the selected
position. The air outlets are selected
automatically when the graphics for the air Maximum Heating and Cooling
outlets are not shown in display (1). Mode
Automatic Temperature Control Switch
(3) – Press the “ AUT”” button for fully
automatic operation of the climate
control system. Full automatic mode may be
enabled at any time. For more information on the
operation of the automatic temperature control,
refer to “Control Panel”.
Fresh Air Control CLOSED position –
Push fresh air switch (4) in order to Illustration 118 g00788476
change the position of the door of the Display for Maximum Heating
fresh air inlet. The symbol in the display will
show the selected position. When this position is Press “AUT” button (3). Rotate temperature control
selected, the fresh air inlet is closed. The air will knob (5) clockwise until the setting for maximum heat
recirculate inside the cab. is shown on the display as illustration 118 . Rotate
the temperature control knob (5) counterclockwise in
OPEN Position – When this position is order to cancel maximum heating.
selected, the door to the fresh air inlet is
open. Fresh air will be drawn into the
cab.
Note: The door for fresh air may close for a few
minutes when the machine is started and the system
is in automatic mode. This will help to bring the air
temperature to the setpoint more quickly.
Temperature Control Knob (5) –
If the climate control system is Display for Maximum Cooling
in the automatic mode, rotate
the temperature control knob in order to change Press “AUT” button (3). Rotate the temperature
the temperature setpoint. The desired cab control knob (5) counterclockwise until the setting for
temperature appears on display (1). maximum cooling is shown on the display as
illustration 119 . Rotate the temperature control knob
(5) clockwise in order to cancel maximum cooling.
Both maximum functions are automatic modes.
SEBU7029-05 71
Operation Section
Window (Front)
Rotate the temperature control knob (5) to the Push the air outlet selection switch (2) until one of the
desired cab temperature. The climate control system symbols in illustration 121 is shown in display (1).
must be in the full “AUT” mode in order to maintain The air is dehumidified while the compressor is
the temperature. If the display does not match operating. Operating the compressor will also defog
illustration 114 , the air conditioning system may not the windows. The compressor will operate in
activate for cooling. automatic “AUT” mode or in the manual mode when
the symbols for the defrost in illustration 121 are
Manual Operation displayed. The compressor is protected from
operation when the ambient air temperature sensor is
below 4 °C (39 °F).
The operator has full control of the system and can
set the fan speed (6), air outlet (2), and the amount of
heat (5). English Versus Metric Toggle
Turn the system to the ON position. Multiple keys
must be pressed simultaneously. Press and hold the
automatic temperature control switch (3). At the
same time press and hold the temperature control
knob (5). This will toggle the display between
Degrees Celsius and Degrees Fahrenheit.
i01954807
Window (Front)
SMCS Code: 7310-FR
To provide full ventilation inside the cab, the upper
window and the lower window can be fully opened.
Manual Override of Automatic Temperature Control
for Heat
When opening or closing the windows, be extra
Push temperature control knob (5) in order to control careful to prevent any personal injury. Also, the
the temperature manually. The temperature setpoint lever for the hydraulic lockout control must be in
and “AUT” is cleared in display (1). The symbol of the the LOCKED position to prevent any possibility
fan with the bar graph for speed and the air outlet will of sudden movement of machine due to inadver-
be shown on display (1). Rotate the temperature tent contact with the hydraulic control(s).
control knob (5) clockwise in order to increase the
temperature. The temperature range is between one
and fifteen. The air conditioner will not run in this Do not change the position of the window until the
mode except when either of the defrost modes following items have been done:
are selected.
• Park the machine on a level surface.
Defrost or Dehumidify Operation
• Lower the implement to the ground.
• Move the hydraulic lockout control to the LOCKED
position.
• Stop the engine.

Defrost or Dehumidify Operation
72 SEBU7029-05
Operation Section
Mirror
1. Hold both grips (2), and push both latches (1) in

order to release the upper window. Lift the window
upward until the window is securely latched in the
overhead storage position.
2. Release latch (1) in order to lower window (C) from
the overhead storage position.
Lower Window
Perform the following procedure in order to open the
lower window and close the lower window. The upper
window is already open:
1. Squeeze latches (3) in order to release the lower
Illustration 122 g00103209 window.
The hydraulic lockout control is shown in the 2. Raise the lower window out of the window frame.
LOCKED position. For further details on this 3. Store the lower window in brackets (4) that are
procedure, refer to Operation and Maintenance
provided. The brackets are built into the upper
Manual, “Hydraulic Lockout Control”.
window.
4. To close the lower window, reverse the procedure
that is used for opening the lower window.
Note: The lower window will only fit in the brackets
by one way.
Note: The upper window cannot be raised or lowered
with the lower window in the storage brackets.
lower window and close the lower window. The upper
window is closed:
1. Squeeze latches (3) in order to release the lower
window.
2. Raise the lower window out of the window frame.
The lower window will slide directly into the upper
window.
3. To close the lower window, reverse the procedure
that is used for opening the lower window.
Note: The upper window cannot be raised or lowered
with the lower window in the storage brackets.
i00682114
Illustration 123 g00100974 Mirror

This is a typical example of a front window . SMCS Code: 7319
S/N: 4SS1–Up
Upper Window
S/N: 9GS1–Up
upper window and close the upper window.
SEBU7029-05 73
Operation Section
Mirror
i01953612
Window Wiper and Washer

Control
SMCS Code: 7305; 7306
Before operating the machine, adjust the mirrors for

the best visibility for the operator.
i00920425
Mirror Illustration 126 g00436280
SMCS Code: 7319 (A) Windshield Wiper Switch

(B) Switch for the Windshield Washer
(1) Indicator Light
S/N: 2NW1–Up (2) Indicator Light
(3) Indicator Light
Windshield Wiper (A) – Push the switch

in order to activate the windshield wiper.
Whenever the switch is depressed, the
mode of the windshield wiper will change
according to the indicator light that is
illuminated.
When indicator light (1) is on, the windshield wiper
operates intermittently at every five second intervals.
When indicator light (2) is on, the windshield wiper
operates continuously.
NOTICE
If the wiper does not operate with the switch in the
Illustration 125 g00470395 ON position, turn the switch off immediately.
Before operating the machine, adjust mirror (2) so Check the cause. If the switch remains on, motor fail-
that you can view the right side of the machine ure can result.
through mirror (1).
Windshield Washer (B) – Push the
switch in order to activate the
windshield washer. While the switch is
depressed, indicator light (3) will come on and
washer fluid will spray from the nozzle. The
windshield wiper will also operate while the
switch is depressed. After the switch is released
for approximately three seconds, the windshield
wiper will stop.
74 SEBU7029-05
Operation Section
Cab Visor
NOTICE
If the washers are used continuously for more than
20 seconds or used when no washer solution comes
out, motor failure can result.
Lower Windshield Washer – Push down

the right half of the switch and keep the
switch depressed in order to activate
the lower windshield washer. While the switch is
Illustration 127 g00110323 depressed, the windshield washer fluid will spray
from the nozzle. The windshield wiper will also
Lower Windshield Wiper – Push down function. When you release the switch, the
the right half of the switch in order to windshield washer will stop. The windshield
turn on the lower windshield wiper. wiper will continue to function.
Push down the left half of the switch in order to
turn off the lower windshield wiper.
NOTICE
If the washers are used continuously for more than
NOTICE 20 seconds or used when no washer solution comes
If the wiper does not operate with the switch in the out, motor failure can result.
ON position, turn the switch off immediately.
Check the cause. If the switch remains on, motor fail- i01545641
ure can result.
Cab Visor
(If Equipped)
SMCS Code: 7301-ZZ
Extend the cab visor. Hook the cab visor to the

bracket. The cab visor can be used for the front
windshield. The cab visor can also be used for the
overhead window.
SEBU7029-05 75
Operation Section
Cab Door
i00865713
Cab Door
SMCS Code: 7308
Side Window
To disengage the cab door from the catch, move the

cab door release lever away from the operator.
i02171505
Travel Control
SMCS Code: 5462
To open the side window, release latch (1) and latch
(2) and slide the window. Push down latch (2) when
the window is in the desired position.
To close the side window, release latch (2) and slide
the window until latch (1) is engaged.
Cab Door

Position for normal travel
(A) Rear of machine
(B) Final drive
(C) Idler
When you travel, make sure that final drive sprockets

(B) are under the rear of the machine.
Illustration 131 g00101071 Directional changes at full engine speed are possible.
However, decelerating and/or braking is
Push the knob of the cab door latch forward in order recommended for operator comfort. Decelerating
to open the cab door. For additional ventilation, open
and/or braking will also help to achieve the maximum
the cab door all the way and secure the cab door to
service life of the transmission components.
the catch on the wall of the cab.
If the travel alarm (if equipped) does not sound,
consult your Caterpillar dealer.
Stop – Release the travel levers/pedals in order to
stop the machine. When you release the travel
levers/pedals from any position, the travel levers/
76 SEBU7029-05
Operation Section
Travel Control
pedals will return to the CENTER position. This

applies the travel brakes.
Move both of the travel levers or both of the travel

pedals equally in the same direction in order to travel
straight.

Pivot Left Turn (Reverse)

Forward Travel

Counterrotate Turn (Left)

Reverse Travel

Pivot Right Turn (Forward)

Pivot Left Turn (Forward)
SEBU7029-05 77
Operation Section
Engine Speed Control
Engine Speed – Turn the engine speed

dial in order to control the engine speed
(engine rpm). Select the desired position
from the ten available positions. The selected
position of the engine speed dial is indicated on
the electronic monitor panel.
Decrease (1) – Turn the engine speed

dial counterclockwise in order to
decrease the engine speed (engine
rpm).
Increase (2) – Turn the engine speed dial
clockwise in order to increase the
engine speed (engine rpm).
Note: Engine speed is automatically limited to a
Pivot Right Turn (Reverse) value which is less than maximum engine speed until
the hydraulic tank pressure reaches the operating
level.
i01584893
Travel Speed Control

SMCS Code: 7490
Do not change the setting of the travel speed con-

trol switch while you travel. Machine stability may
be adversely affected.
Personal injury can result from sudden changes
Illustration 141 g00731477 in machine stability.
Counterrotate Turn (Right)
i00718877
Engine Speed Control

SMCS Code: 1915

(1) Decrease. (2) Increase.
78 SEBU7029-05
Operation Section
Power Mode Control
Continuous driving at high speed should be limited to

two hours. If you need to continue driving at high
speed for more than two hours, stop the machine for
ten minutes. This will cool down the travel drives
before you resume driving.
i01588941
Power Mode Control

SMCS Code: 7490
Travel Speed Control Switch – Press the

travel speed control switch in order to
select high travel speed or low travel
speed. When the engine start switch is on, the
travel speed control switch is always set at the
LOW SPEED position. Whenever the travel speed
control switch is pressed, the travel speed
changes.
Power Mode Switch – Push this switch

in order to change the power mode to
ON or to OFF. Select a power mode that
is suitable for the working conditions.
When you turn the engine start switch to the OFF
position, the previous switch setting is maintained.
The power mode is preset to the previous setting
when the engine start switch is turned to the ON
position again.
Power Mode ON – When the power mode switch is
pushed to the ON position, indicator lamp (1) comes
Illustration 144 g00824132 on. This power mode is suitable for heavy-duty work
that requires a high operating speed. Changing the
LOW SPEED – Select the LOW SPEED switch to this position provides maximum power to
position if you travel on rough surfaces the machine.
or on soft surfaces or if you require a
great drawbar pull. Also, select the LOW SPEED Power Mode OFF – When the power mode switch is
position if you are loading a machine onto a pushed to the OFF position, indicator lamp (1) turns
trailer or you are unloading a machine from a off. This power mode is suitable for ordinary work.
trailer. This power mode provides sufficient power in most
applications. This power mode will minimize noise
HIGH SPEED – If you travel on a hard, and fuel consumption.
level surface at a fast speed, select the
HIGH SPEED position.
SEBU7029-05 79
Operation Section
Work Mode Control
i00796141 Boom Priority Mode (1) – This work

mode provides oil flow priority to the
Work Mode Control boom circuit. This will raise the boom
quickly in applications such as loading a truck
SMCS Code: 7490 and deep trenching. In these applications, the
raising of the boom is a major portion of the total
cycle time. This work mode is the preferred work
mode in most applications that involve digging.
Swing Priority Mode (2) – This work
mode provides oil flow priority to the
swing circuit. Because the hydraulic
flow from one of the two main pumps is
guaranteed to the swing circuit, swing movement
will be easy and consistent regardless of the
other hydraulic functions that are being used.
This work mode is preferred for applications that
require a smooth trench or a smooth trench wall.
This work mode is also used when the angle of
the swing position is at least 180 degrees.
Fine Control Mode (3) – This work mode

limits the oil flow to the circuit that
moves the stick inward. Normally, the oil
flow to the circuit that moves the stick inward is
available from both pumps. This moves the stick
quickly. When the fine control mode is used, the
oil flow is limited to one pump. This will slow the
stick movement, which allows more control. This
work mode is used most often when you finish a
slope. This work mode is also used for lifting
applications or for fine grading.
User Mode (4) – To select the sub-mode,
Illustration 146 g00101234 press this switch repeatedly until the
(1) Boom priority mode
desired sub-mode is displayed in the
(2) Swing priority mode right two positions of the liquid crystal display.
(3) Fine control mode This work mode has the following three sub-
(4) User mode modes:
There are four work mode switches on the left side of • Tamping mode “U1” is suitable for simple forming
the monitor panel. Each work mode switch is set for of surfaces, for compacting, or for similar
different attachment speeds or for different swing operations that use the bottom of the bucket.
speeds.
When this mode is selected, the boom raises
Only one work mode can be selected at a time. If a smoothly and the boom lowers smoothly in order
new work mode is selected, the previous work mode to avoid bumping of the boom and lifting of the
is deactivated automatically. machine.
When you turn the engine start switch to the ON • Mode “U2” provides optional hydraulic power for
position, the previous switch setting is maintained. special attachments. The “U2” mode is set by your
Select a suitable work mode for the type of work that Caterpillar dealer only for use in special
will be performed. The selected work mode is circumstances.
identified by an indicator lamp to the right of each
work mode switch. • Customer mode “U3” allows the operator to
choose the preferred modes with a single switch.
The operator can set the work mode, the power
mode, the pump flow, and the Automatic Engine
Speed Control (AEC) according to preset settings.
This mode offers the advantage of customizing
these settings in order to meet the operator's
specific needs.
80 SEBU7029-05
Operation Section
User Mode Control
For example, the customer mode is useful during Activating Memory

lifting applications. The fine control mode is the most
appropriate conventional mode for lifting applications,
but the engine speed and the stick cylinder speed
decrease when the machine is not loaded. If the
customer mode is used, the engine speed can be set
at 100 percent and the pump flow can be set at 70
percent. With the presetting in the customer mode,
the machine would achieve the same precise
operation as the fine control mode during lifting
applications, but the stick cylinder speed would be
faster during no-load conditions.
The function of the customer mode cannot be fully
utilized unless the parameters are set. The settings
of the parameters must be memorized. Consult your
Caterpillar dealer if you encounter difficulty in setting
the parameters.
For further details, see Operation and Maintenance
Manual, “User Mode Control”.
i01157837
User Mode Control

SMCS Code: 7490
The user mode cannot be fully utilized unless the
parameters are set. Operational parameters for the
user mode are set by using the six-digit liquid crystal
display (LCD) and the switches on the electronic
monitor panel.
Consult your Caterpillar dealer if you have difficulty in
setting the parameters. Press alarm cancel switch (5) and switch (4) for user
mode simultaneously for more than two seconds.
When display (6) flashes, the customer mode can be
set by using the following switches.
Switch (1) for Boom Priority Mode – The flashing
value in the LCD will increase when this switch is
pressed.
Switch (2) for Swing Priority Mode – The flashing
value in the LCD will decrease when this switch is
pressed.
Switch (3) for Fine Control Mode – The selected
flashing position on the LCD will move by one
position to the right when this switch is pressed.
Switch (4) for User Mode – The selected flashing
position on the LCD will move by one position to the
left when this switch is pressed.
Values can be entered only in the position that is

flashing on the LCD. Use switch (3) and switch (4) to
move the flashing position to the right or to the left.
To return to the normal operating mode, push alarm
cancel switch (5) and switch (4) for mode
simultaneously for more than two seconds. Display
(6) will show the time of day and the position of the
engine speed dial.
SEBU7029-05 81
Operation Section
User Mode Control
If the appropriate sub-mode is not displayed on the

LCD, use switch (3) or switch (4) to move the flashing
character to position (B). Use switch (1) or switch (2)
to change the designation of the sub-mode.
Setting the Customer Mode

To set the user mode, the character in position (B)
must be a “3” .
Position (C) is used to select one of the four
parameters. Positions (D), (E), and (F) are used to
set the function of the parameter.
Refer to the following table in order to determine the
values of the positions that will achieve the desired
function of the hydraulic excavator while you are
operating the machine in the user mode.
Illustration 148 indicates that time of day (A) is 11:30
and the position of the engine speed dial is “10” .
Selecting a Sub-mode
Position (A) and position (B) indicate the sub-mode.
• “U1” indicates the tamping mode. No setting is

required for the tamping mode.
• “U2” indicates mode U2. No setting is required for

mode U2.
• “U3” indicates the customer mode. The settings
for the customer mode can now be set.
82 SEBU7029-05
Operation Section
Automatic Engine Speed Control (AEC)
Table 19
Positions (A)
Position (C) Positions (D), (E), and (F)
and (B)
Setting Function Setting Function

Select work mode. “–1” Select boom priority mode.
“1” “–2” Select swing priority mode.
“–3” Select fine control mode.

“2” Select power mode. “–1” Power mode is off.
“–2” Power mode is on.
“3” Select the stage of AEC. “–1” Select the first stage of AEC.
“–2” Select the second stage of AEC.
“5” Set the time delay for the AEC. “—” The increment is 0.1 second and the range is 0.1 second to
20 seconds. The initial factory setting for the delay time is 3
“U3” Customer
seconds. The LCD shows “U3:5-30” .
Mode
“6” Set engine speed in the second stage of “—” The increment is 10 rpm and the range is 800 rpm to 2200
AEC. rpm. The initial factory setting is 1300 rpm. If the LCD
shows “US:6-95” , engine speed in the second stage of
AEC is set to 950 rpm.
“7” Limit the maximum engine speed dial. “—” The upper limit of engine speed dial can be set from 1 to
10. The initial factory setting is 10. The LCD shows “US:7-
10” .
“8” Set hydraulic horsepower at position 10 “—” When the engine speed dial is set to position 10 the hy-
on the engine speed dial. draulic horsepower can be set as a percent of the maximum
hydraulic power. The increment is 1 percent and the range
is 0 to 100 percent. The initial factory setting is 70 percent.
The LCD shows “U3:8-70” .
i00117027 Mode I
Automatic Engine Speed • The AEC switch is in the OFF position.
Control (AEC) • The switch for manual low idle is not activated.
SMCS Code: 7490
• The setting of the engine speed dial is between 5
The Automatic Engine Speed Control (AEC) and 10.
automatically reduces engine speed when there is no The electronic controller automatically reduces
hydraulic demand or when the hydraulic demand is engine speed by 100 rpm after there has been no
very small. The AEC system is designed to reduce hydraulic demand for approximately three seconds.
fuel consumption and noise.
The AEC system will be inoperable while the backup Mode II
switch of the electronic controller system is in the
MAN (MANUAL BACKUP) position. If the hydraulic • The AEC switch is in the ON position.
oil is not at a normal operating temperature, the AEC
may respond slowly. • The switch for manual low idle is not activated.
The AEC system operates in the following three • The setting of the engine speed dial is between 5
modes. Operation depends on the position of the and 10.
AEC switch and of the switch for manual low idle.
The engine rpm will recover automatically to the
setting of the engine speed dial when any hydraulic
function is activated.
SEBU7029-05 83
Operation Section
Backup Controls
The AEC system in the electronic controller will

automatically reduce the engine rpm to
approximately 1300 rpm after there has been no
hydraulic demand for approximately three seconds.
Mode III
• The AEC switch is in the ON or OFF position.
• The switch for manual low idle is activated.
• The setting of the engine speed dial is between 3

and 10.
The switch for manual low idle is on the right control
lever. Whenever the switch for manual low idle is
activated, the engine speed is reduced to Illustration 151 g00107439
approximately 950 rpm. Pressing the switch again
will allow the engine speed to return to the setting of Switch for Manual Low Idle – This switch reduces
the engine speed dial. The setting of the engine the engine speed to approximately 950 rpm. This
speed dial is approximately 1300 rpm (Mode II) if the reduction occurs regardless of the setting of the
AEC switch is in the ON position and there is no engine speed dial. This reduction also occurs from a
hydraulic demand. setting of 1300 rpm (Mode II) on the AEC. If the
switch for manual low idle is pressed again, the
engine speed will return to the setting of the engine
speed dial or to the setting of 1300 rpm (Mode II) on
the AEC. Hydraulic demand is a determining factor
for the setting.
i01584900
Backup Controls
SMCS Code: 7000
Automatic Engine Speed Control Switch

(AEC Switch) – The Automatic Engine
Speed Control switch and indicator (1)
are activated when the engine start switch is Illustration 152 g00822272
turned to the ON position. When you press the
AEC switch, the function of the AEC switch The backup switches are located on the back of the
changes from ON to OFF, and vice versa. right console.
Engine Speed Control – By utilizing
these switches, the engine speed can be
controlled manually by the operator or
the engine speed can be controlled automatically
by the electronic controller.
84 SEBU7029-05
Operation Section
Hydraulic Lockout Control
Automatic – When the electronic control Locked – Move the travel levers and
system is functioning properly, backup move the work tool control lever to the
switch (1) should be in the AUTOMATIC center HOLD position. Move the lever
position. for the hydraulic lockout control (1) backward to
the LOCKED position. Crossbar (2) will move
Manual – If a problem occurs in the down. This makes all of the factory installed
electronic control system, move backup hydraulic controls inoperable.
switch (1) to the MANUAL position in
order to disconnect the controller circuit of the Note: Make sure that the lever for the hydraulic
electronic controller system. In this condition, lockout control is in the LOCKED position before
the machine can be operated at a reduced ratio of attempting to start the engine. If the lever is in the
pump output on a temporary basis. At the same UNLOCKED position, the engine start switch will not
time, the power supply to the monitor is cut off function.
and all displays on the monitor panel turn off.
Fast Engine Speed – Move backup
switch (2) to this position in order to
increase the engine speed. This backup
switch will not operate if backup switch (1) is not
in the MANUAL position. When the switch is
released the switch returns to the NEUTRAL
position and the machine will maintain the engine
speed. This switch overrides the function of the
engine speed dial.
Slow Engine Speed – Move backup

switch (2) to this position in order to
decrease the engine speed. This backup
switch will not operate if backup switch (1) is not
in the MANUAL position. When the switch is Illustration 154 g00536457
released the switch returns to the NEUTRAL
position and the machine will maintain the engine Unlocked – Move the lever for the
speed. This switch overrides the function of the hydraulic lockout control (1) forward to
engine speed dial. the UNLOCKED position. Crossbar (2)
will move up. This makes all of the factory
i02287957 installed hydraulic controls operable.
Hydraulic Lockout Control

SMCS Code: 5258-LK
The lever for the hydraulic lockout control is located

on the left console.
SEBU7029-05 85
Operation Section
Joystick Controls
i04036189 The machine control pattern can be varied. Refer to

Operation and Maintenance Manual, “Joystick
Joystick Controls Controls Alternate Patterns” for more information.
SMCS Code: 5705 i02287982
Hammer Control
(If Equipped)
SMCS Code: 5705-WTL
S/N: 4SS1–Up
S/N: 9GS1–Up

(1) STICK OUT
(2) SWING RIGHT
(3) STICK IN
(4) SWING LEFT
(5) BOOM LOWER
(6) BUCKET DUMP
(7) BOOM RAISE
(8) BUCKET CLOSE
(9) HOLD
(9a) HORN (IF EQUIPPED) Illustration 156 g00365096
(9b) AUTOMATIC ENGINE SPEED CONTROL SWITCH (IF
EQUIPPED) The hydraulic hammer control is located on thework
(10) Seat tool control leverthat is located on the right side of the
seat.
Hydraulic Hammer ON – Push down the top left
button on the right hand control lever in order to
The Fine Swing Control delays the engagement activate the hydraulic hammer.
of the swing parking brake.
Hydraulic Hammer OFF – Release the top left
If the machine is operating on a slope with the button on the right hand control lever in order to
Fine Swing Control in the ON position, the swing deactivate the hydraulic hammer.
motion may become uncontrollable which could
result in property damage, personal injury or
death. Note: This machine may also be equipped with a
pedal that controls the hydraulic hammer. Refer to
Turn the Fine Swing Control to the OFF position Operation and Maintenance Manual, “Work Tool
when the machine is operating on a slope. Control Pedal” for more information.
When you release the joysticks from any position, the
joysticks will return to HOLD position (9). Movement
of the upper structure will stop unless the fine swing
control (if equipped) is ON. When the fine swing
control is ON, the swing parking brake will not
activate until 6.5 seconds after the joystick control for
the swing function returns to the HOLD position.
Two functions may be performed at the same time by
moving a joystick diagonally.
The machine control pattern is initially set at the
factory to the SAE system, as shown. The pattern on
the left pertains to the left joystick and the pattern on
the right pertains to the right joystick.
86 SEBU7029-05
Operation Section
Joystick Controls Alternate Patterns
i01521986
Joystick Controls Alternate

Patterns
(If Equipped)
SMCS Code: 5059; 5137
Whenever a change is made to the machine con-

trol pattern, also exchange the pattern card in the
cab to match the new pattern.
Check the machine control pattern for conform- Illustration 158 g00104103
ance to the pattern on the card in the cab. If the (a) Bolt
pattern does not match, change the card to match (b) Lever
the machine control pattern before you operate
the machine. Failure to do so could result in per- 1. Loosen bolt (a) and move lever (b) to the SAE
sonal injury.
position or to the BHL position.
The machine control pattern can easily be changed
to the SAE system or to the standard backhoe loader Note: Illustration 158 shows that the two-way valve is
hydraulic system (BHL) by changing the position of in the SAE position.
the two-way valve (if equipped). Use the following
procedure to change the position of the two-way 2. After you set the machine control pattern, tighten
valve. bolt (a) in order to secure lever (b).
The two-way valve is located at the front left of the

swing drives.

(A) SAE machine control pattern
(B) Machine control pattern for standard backhoe
The patterns on the left side of Illustration 159 show

the possible configurations for the left control lever.
The patterns on the right side of the illustration show
the possible configurations for the right control lever.
STICK OUT (1) – Move the control lever
to this position in order to move the
stick outward.
SEBU7029-05 87
Operation Section
Work Tool Flow Mode Control
SWING RIGHT (2) – Move the control The combined hydraulic attachment circuit is capable
lever to this position in order to swing of providing single action or double action. The
the upper structure to the right. hydraulic attachment electronic controller, the
electronic switch in the operator's compartment, and
STICK IN (3) – Move the control lever to the manual ball valve select the flow mode and the
this position in order to move the stick characteristics of the flow mode. The position of the
inward. ball valve selects the single action hydraulic
attachment circuit or the double action hydraulic
SWING LEFT (4) – Move the control lever attachment circuit. The electronic switch is used to
select the flow modes for each of the hydraulic
to this position in order to swing the
attachment circuits.
upper structure to the left.
The single action hydraulic attachment circuit is used
BOOM LOWER (5) – Move the control with attachments such as hydraulic hammers. The
lever to this position in order to lower double action hydraulic attachment circuit is used
the boom. with attachments such as shears and clamshell
buckets.
BUCKET DUMP (6) – Move the control
lever to this position in order to dump When the machine is equipped with a combined
the bucket. hydraulic attachment circuit, the operator can choose
from four flow modes: two for the single action
BOOM RAISE (7) – Move the control hydraulic attachment circuit and two for the double
lever to this position in order to raise the action hydraulic attachment circuit. The flow modes
boom. limit the maximum engine speed and pump flow. The
ball valve and the electronic switch are used to
change the flow mode. The dealer programs the
BUCKET CLOSE (8) – Move the control
electronic controller for the following reasons:
lever to this position in order to close
the bucket. • Provide the proper flow rates for the attachment.
HOLD (9) – When the control lever is released from
• Provide the proper engine speeds for the
any position, the control lever will return to the HOLD
position. Movement of the upper structure will stop. attachment.
Two functions may be performed at the same time by

moving a control lever diagonally.
If the machine is equipped with a hydraulic hammer,
the functions of positions (6) and (8) are different.
HYDRAULIC HAMMER RAISE (6) – Move the
control lever to this position in order to raise the
hydraulic hammer.
HYDRAULIC HAMMER LOWER (8) – Move the
control lever to this position in order to lower the
hydraulic hammer.
i01546149 Illustration 160 g00101347
Work Tool Flow Mode Control Before you change the flow mode of the hydraulic
attachment circuit, place the machine in the servicing
(If Equipped) position, as shown. Stop the engine.
SMCS Code: 7490
S/N: 4SS1–Up
Make sure that all attachments are in the recom-
S/N: 9GS1–Up mended servicing position and personnel are
clear of the attachment before the manual lever
on the ball valve is moved. Changing the valve
position may cause the attachment to move unex-
pectedly. Serious injury or death may result.
88 SEBU7029-05
Operation Section
Work Tool Flow Control
i01954896
Work Tool Flow Control

(If Equipped)
SMCS Code: 7007-WTL
S/N: 4SS1–Up
S/N: 9GS1–Up
Combined Hydraulic Attachment

Circuit
With a combined hydraulic attachment circuit, the
operator can choose from four flow modes: two for
the single action hydraulic attachment circuit and two
for the double action hydraulic attachment circuit.
The flow modes limit the maximum engine speed and
pump flow. The flow modes are set by selecting a
position for the ball valve and for the electronic
switch. The flow modes are programmed into the
electronic controller for each attachment. Consult
(1) Ball valve your Caterpillar dealer if the flow rate needs to be
(2) Swing drive changed for a different attachment.
(3) Swing drive
(4) Front of the machine

(A) Single action hydraulic attachment
(B) Double action hydraulic attachment
Use the manual lever to turn the ball valve. Make Illustration 163 g00396317
sure that you fully turn the ball valve until the ball
valve stops. The electronic switch is on the right console.
In order to use the single action hydraulic attachment
Hydraulic Flow Rate – To change the
circuit (operation of the hydraulic hammer), position
the manual lever parallel to the hydraulic line. hydraulic flow rate of the hydraulic
circuit, press either side of this switch.
In order to use the double action hydraulic
attachment circuit (operation of the clamshell or of LOW FLOW Position – Press the left
the shear), position the manual lever so that the lever side of the switch for a low hydraulic
is perpendicular to the hydraulic line. flow rate.
Never use the manual lever as a step when the HIGH FLOW Position – Press the right
manual lever is attached to the ball valve. Remove side of the switch for a high hydraulic
the manual lever from the ball valve after adjusting flow rate.
the ball valve.
SEBU7029-05 89
Operation Section
Work Tool Electronic Controller
When you are changing the machine's implement, If a machine or a tool malfunctions, the operator may
the operator must be instructed on the correct need to report the information that is stored in the
positioning of the electronic switch. electronic controller.
Turn the engine start switch to the ON position in
order to activate the electronic controller.

(A) Left Implement Control Lever
(B) Right Implement Control Lever
(1) Counterclockwise rotation of implement Illustration 166 g00101367
(2) Clockwise rotation of implement The illustration shows an electronic controller (typical
(3) Shear blades CLOSE example).
(4) Shear blades OPEN
When you activate the electronic controller, read the
Illustration 164 shows a typical example of the
digital display from left to right. The second digit and
operation of the implement control levers.
the third digit display the version of software. The
fourth digit and the fifth digit indicate the number of
i01546267 programmed changes that have been saved for the
active mode. (The active mode is determined by the
Work Tool Electronic position of the ball valve and of the switch for the
hydraulic attachment.)
Controller
SMCS Code: 6700-EK2 The electronic controller can display the number of
hours that have elapsed in each of the four flow
modes. Likewise, the electronic controller can display
S/N: 4SS1–Up
the settings for the engine speed of the four flow
S/N: 9GS1–Up modes and for the hydraulic oil flow of the four flow
modes.
The Hydraulic Attachment Electronic Controller is
equipped only on certain machines. Push switch (1) in order to scroll through the digital
readouts that pertain to the different flow modes. The
first number that is displayed indicates the amount of
hours that have elapsed in the active flow mode. The
first digit of this number indicates the number that is
assigned to the flow mode. The second digit displays
an “h” . The “h” means hours. The last four digits
indicate the number of hours of machine operation.
Push switch (1) again in order to display the engine
speed setting. The first digit that is displayed
indicates the number that is assigned to the flow
mode. The second digit displays an “E” . The “E”
means engine speed. The third digit and the fourth
digit indicate the engine speed setting. The engine
speed setting determines the speed of the engine.
The engine speed will be equal to one of the ten
Illustration 165 g00101365 positions of the engine speed dial. This occurs when
the hydraulic attachment circuit is activated. If the
The electronic controller is located inside the front setting of the electronic controller for the active mode
access door on the left side of the machine. is at “5” , the engine will run at a speed that is equal
to the setting at the fifth position of the engine speed
dial.
90 SEBU7029-05
Operation Section
Fuel Tank Shutoff and Drain Control
Note: There are two speeds that are set by the i01034388
electronic controller and by the engine speed dial.
During operation of the hydraulic attachment circuit, Fuel Tank Shutoff and Drain
the engine will operate at the lower speed. The
operator should always set the engine speed dial to Control
at least the engine speed setting that is indicated on SMCS Code: 1273
the electronic controller for the active mode.
The fuel shutoff valve and the fuel tank drain valve
The fifth digit shows either an “H” (high flow) or an “L” are located underneath the fuel tank.
(low flow). If the “rabbit” side of the switch for the
hydraulic attachment is depressed, an “H” is
displayed. If the “tortoise” side of the switch for the
hydraulic attachment is depressed, an “L” is
displayed.
The sixth digit shows a “1” (one-way flow) or a “2”
(two-way flow). If the ball valve is positioned parallel
to the hydraulic line, a “1” is displayed. If the ball
valve is positioned perpendicular to the hydraulic line,
a “2” is displayed.
Push switch (1) again in order to display the setting
for the hydraulic oil flow. The first digit of this display
indicates the number that is assigned to the flow
mode. The second digit displays an “F” . The “F”
means flow. The third digit and the fourth digit Illustration 167 g00533127
indicate the setting for the flow.
Fuel Tank Drain Valve (1) – To drain the water and
The fifth digit and the sixth digit display the same sediment from the fuel tank, turn fuel drain valve (1)
reading that is described for the display for the counterclockwise. To close fuel tank drain valve (1),
engine speed. turn the drain valve clockwise.
Continue to push switch (1) in order to scroll through
the remaining flow modes for the following displays: Fuel Shutoff Valve (2) – To shut off the fuel supply,
hours of machine operation, the setting for the engine turn fuel shutoff valve (2) clockwise. To turn on the
speed and the hydraulic oil flow. fuel supply, turn fuel shutoff valve (2)
counterclockwise.
Note: If the machine is equipped with a single action
hydraulic attachment circuit, there are only two
available flow modes that can be programmed into Note: For more detailed information that pertains to
the electronic controller. If the machine is equipped draining the water and sediment from the fuel tank,
with a double action hydraulic attachment circuit, refer to Operation and Maintenance Manual, “Fuel
there is a total of four flow modes that are Tank Water and Sediment - Drain”.
programmed into the electronic controller.
i01289886
Push switch (1) and then push switch (2). The total
number of programmed changes that have been
saved for all flow modes will be displayed.
Hydraulic Tank Shutoff Valve
(If Equipped)
Push switch (1) for the display again in order to
continue scrolling through the settings for the flow SMCS Code: 1329
modes.
S/N: 4SS1–Up
When the necessary information is retrieved from the
electronic controller, close the access door. Turn the S/N: 9GS1–Up
engine start switch to the OFF position.
The hydraulic tank shutoff valve shuts off the
hydraulic oil supply between the hydraulic tank and
the pumps. This allows the pumps to be worked on
without draining the hydraulic tank.
Note: The engine will not start if the hydraulic tank

shutoff valve is closed.
SEBU7029-05 91
Operation Section
If Equipped
To access the hydraulic tank shutoff valves, open the

access door that is located on the right side of the
machine. The hydraulic tank shutoff valves are on the
right side of the compartment near the bottom of the
hydraulic tank.
The machine may be equipped with either 1 or 2
valves. If either of the valves is in the CLOSED
position, the engine will not start. The engine will not
start in order to ensure that the hydraulic pump has a
sufficient supply of hydraulic oil for operation.

Typical valve
(1) Hydraulic tank shutoff valve
(2) OPEN position
(3) CLOSED position
CLOSED (2) – Move shutoff valve (1) downward in

order to shut off the flow of hydraulic oil to the pumps.
OPEN (1) – Move shutoff valve (1) upward in order to

allow hydraulic oil to flow to the pumps. The engine
will be able to be started now.
92 SEBU7029-05
Operation Section
Engine Starting
Engine Starting
i01955647
Engine Starting
(Machines with Generator)
SMCS Code: 1000; 7000
S/N: 2NW1–Up
3. Move the hydraulic lockout control to the LOCKED

position.
This machine is equipped with an engine neutral
start system. The system only allows the engine to
start when the hydraulic lockout control is in the
LOCKED position.
4. Move the joysticks to the HOLD position.
Illustration 170 g00110316 5. Turn the grapple/magnet switch to the GRAPPLE
position.
1. Insert the disconnect switch key into the battery
disconnect switch. Turn the battery disconnect
switch to the ON position.

(1) Engine start switch
(2) Engine speed dial
6. Turn engine start switch (1) to the ON position.
2. Make sure that the reset button for the circuit
breaker remains depressed.
SEBU7029-05 93
Operation Section
Machines with Generator

(1) Engine start switch
(2) Engine speed dial
8. Turn engine speed dial (2) to the LOW IDLE

position.
9. Turn engine start switch (1) to the START position.
NOTICE
Key must be in run position with engine running to
maintain electrical and hydraulic functions and pre-
vent serious machine damage.
Illustration 174 g00101408 If the engine does not start, return the key to OFF be-
(3) Coolant level fore returning it to START.
(4) Engine oil level
(5) Hydraulic oil level Do not crank the engine for more than 30 seconds.
Allow the starter to cool for two minutes before crank-
7. All of the indicators on the monitor panel should be ing again.
activated for approximately 1.5 seconds and the
action alarm should sound for one second. If any 10. Release the engine start switch key after the
of the indicators are not activated or if the action engine starts.
alarm does not sound, check the electrical system.
Make any necessary repairs before you start the The engine of this machine is designed to start
engine. without starting aids at temperatures above 0°C
(32°F). Starting aids are available for
If the starter switch is held in the ON position for 2 temperatures below 0°C (32°F).
seconds or more, the prestart monitoring function
will be activated. If the fluid level of the engine 11. After the engine starts, observe the indicator lamp
coolant, the engine oil, or the hydraulic oil is below for the hydraulic tank pressure.
the specified level, indicator (3), (4), or (5) will
come on.
If the fluid level is too low, add the corresponding
fluid to the specified level. Add the fluid before you
start the engine.
94 SEBU7029-05
Operation Section
Engine Starting
Location of the indicator lamp for the hydraulic tank

pressure on right console 1. Insert the disconnect switch key into the battery
12. When the indicator lamp is no longer illuminated, switch to the ON position.
place the grapple/magnet switch in the MAGNET
position.
Reference: Refer to Operation and Maintenance

Manual, “Grapple and Magnet Control” for further
information on the grapple/magnet switch.
i01961251
Engine Starting
SMCS Code: 1000; 7000
NOTICE
Key must be in run position with engine running to
maintain electrical and hydraulic functions and pre-
vent serious machine damage.
If the engine does not start, return the key to OFF be- 2. Make sure that the reset button for the circuit
fore returning it to START. breaker remains depressed.
Do not crank the engine for more than 30 seconds.
Allow the starter to cool for two minutes before crank-
ing again.

position.
SEBU7029-05 95
Operation Section
Engine Starting with Ether Starting Aid
This machine is equipped with an engine neutral 6. All of the indicators on the monitor panel should be
start system. The system only allows the engine to activated for approximately 1.5 seconds and the
start when the hydraulic lockout control is in the action alarm should sound for one second. If any
LOCKED position. of the indicators are not activated or if the action
4. Move the implement control levers to the HOLD
Make any necessary repairs before you start the
position.
engine.
If the starter switch is held in the ON position for 2
will be activated. If the fluid level of the engine
coolant, the engine oil, or the hydraulic oil is below
come on.
fluid to the specified level. Add the fluid before you
start the engine.

(1) Engine Start Switch. (2) Engine Speed Dial.


position.
9. Release the engine start switch key after the
engine starts.
For temperatures above 0°C (32°F), the engine of
this machine is designed to start without starting
aids. For temperatures below 0°C (32°F), starting
aids are available.
i01956213
Engine Starting with Ether

Starting Aid
SMCS Code: 1456
(3) Coolant Level. (4) Engine Oil Level. (5) Hydraulic If the machine is equipped with an ether starting aid,
Oil Level. the machine can start the engine in areas with
temperatures that can be as low as −32°C (−25.6°F).
96 SEBU7029-05
Operation Section
NOTICE
Inject starting aid (ether), only while cranking the
engine.
Use sparingly, excessive ether without cranking can
cause piston and ring damage.
Wait approximately two seconds before injecting
again.
Use ether for cold starting purposes only.
After every 30 seconds of engine cranking, allow two
minutes for starting motor to cool before cranking
again.

position.
This machine is equipped with an engine neutral
start system. The system only allows the engine to
start when the hydraulic lockout control is in the
LOCKED position.
4. Move the implement control levers to the HOLD
position.
1. Insert the disconnect switch key into the battery


2. Make sure that the reset button for the circuit

breaker remains depressed.
SEBU7029-05 97
Operation Section


position.
9. Release the engine start switch key after the
engine starts.
For temperatures above 0°C (32°F), the engine of
this machine is designed to start without starting
aids. For temperatures below 0°C (32°F), starting
aids are available.
(3) Coolant Level. (4) Engine Oil Level. (5) Hydraulic
Oil Level.
6. All of the indicators on the monitor panel should be

activated for approximately 1.5 seconds and the
action alarm should sound for one second. If any
of the indicators are not activated or if the action
Make any necessary repairs before you start the
engine.
If the starter switch is held in the ON position for 2
will be activated. If the fluid level of the engine
coolant, the engine oil, or the hydraulic oil is below
come on.
(6) Ether Starting Aid Switch.
fluid to the specified level. Add the fluid before you 10. Push the left side of the ether starting aid switch
start the engine. (6) and release the ether starting aid switch.
11. Operate the ether starting aid switch at intervals
of two seconds while you crank the engine.
Continue this procedure until the engine starts and
the engine is running well.
12. Release the engine start switch key when the
engine starts.
98 SEBU7029-05
Operation Section
Engine and Machine Warm-Up
The ether starting aid cylinder (A) is located to the left Note: The lever for the hydraulic lockout control must
of the swing drive. For more information, see be in the UNLOCKED position before the hydraulic
Operation and Maintenance Manual, “Ether Starting controls will function.
Aid Cylinder - Replace”.
1. Allow the engine to warm up at low idle for at least
If you are starting the engine in temperatures below
−18°C (0°F), the use of optional cold weather five minutes. Engage the work tool controls and
starting aids is recommended. A coolant heater, a disengage the work tool controls. This will speed
fuel heater, a jacket water heater, or extra battery up the warm-up of the hydraulic components.
capacity may be required.
When you idle the machine for warm-up, observe
If you are starting the engine in temperatures below the following recommendations:
−23°C (−10°F), consult your Caterpillar dealer. Also
see Operation and Maintenance Manual, SEBU5898, • If the temperature is greater than 0°C (32°F),
“Cold Weather Recommendations”, which is warm up the engine for approximately 15
available from your Caterpillar dealer. minutes.
i02287983 • If the temperature is less than 0°C (32°F),
warm up the engine for approximately 30
Engine and Machine Warm-Up minutes.
SMCS Code: 1000; 7000
• If the temperature is less than − 18°C (0°F) or
S/N: 9GS1–Up if hydraulic functions are sluggish, additional
time may be required.
S/N: 2NW1–Up
2. To warm up the hydraulic oil, turn the engine speed
NOTICE dial to the medium engine speed. Run the engine
Keep the engine speed slow until the indicator light for approximately five minutes and move the
for the engine oil pressure goes out.
joystick intermittently from the BUCKET DUMP
If the light does not go out within ten seconds, stop position to the HOLD position.
the engine and investigate the cause before starting
the engine again. Failure to correct the problem can 3. Turn the engine speed dial to the maximum engine
cause engine damage. speed and repeat Step 2.
This allows the oil to attain relief pressure, which
causes the oil to warm up more rapidly.
4. Cycle all controls in order to circulate warm oil
through all hydraulic cylinders and through all
hydraulic lines.
5. Observe the gauges and the indicators frequently
during the operation.
SEBU7029-05 99
Operation Section
Operation
Operation
i01954582
Operation Information
SMCS Code: 7000
Note: Operating Temperature Range for the

Machine The machine must function satisfactorily in
the anticipated ambient temperature limits that are
encountered during operation. The standard machine
configuration is intended for use within an ambient
temperature range of −18 °C (0 °F) to 43 °C
(109 °F). Special configurations for different ambient
temperatures may be available. Consult your Illustration 192 g00103398
Caterpillar dealer for additional information on special
configurations of your machine. 3. Turn the engine speed dial to the operating range.
Make sure that no personnel are on the machine or 4. Move the hydraulic lockout control to the
near the machine in order to prevent any personal UNLOCKED position.
injury. Keep the machine under control at all times in
order to prevent injury.
Reduce the engine speed when you maneuver the
machine in tight quarters and when you drive over an
incline.
Select the necessary travel speed range before you
drive downgrade. Do not change the travel speed
range while you drive downhill.
Use the same travel speed on a downgrade and on
an upgrade.
When you travel for any distance, keep the stick
inward and carry the boom in a low position.
When you drive up a steep grade, keep the boom as
close to the ground as possible.
When you travel uphill or you travel downhill, keep 5. Raise the boom enough in order to provide
the boom on the uphill side of the machine. sufficient ground clearance.
1. Adjust the operator seat.
2. Fasten the seat belt.
100 SEBU7029-05
Operation Section
Changing Direction and Speed
i00117458
Changing Direction and Speed

SMCS Code: 1000; 7000
Directional changes at full engine speed are possible.
However, decelerating is recommended for operator
comfort. Decelerating will also help to achieve the
maximum service life of the machine components.
If the travel alarm does not sound, consult your
Caterpillar dealer.
6. Select the desired travel speed by operating the

travel speed control switch.
7. Make sure that the position of the upper structure Illustration 195 g00107517
and of the undercarriage is known before you
move the machine. The drive sprockets should be 1. Slowly move both of the travel levers or both of the
at the rear of the machine. travel pedals toward the rear until the STOP
position is reached and the machine stops.
Note: The directional steering controls will operate
normally if the drive sprockets are at the rear of the 2. Then, move both of the travel levers or both of the
machine and the idlers are at the front of the machine travel pedals rearward from the STOP position. If
and under the cab. When the sprockets are under the you move the travel levers or the travel pedals
cab, the travel controls will operate backward. farther toward the rear, the travel speed at the
8. Turn the engine speed dial in order to increase the selected engine speed will be faster.
engine speed (rpm) to the desired speed. 3. Slowly move both of the travel levers or both of the
9. Push both travel levers forward at the same time in travel pedals to the STOP position in order to stop
order to travel forward. If both travel levers are the machine.
pushed farther, the travel speed at the selected
engine speed (rpm) will be faster.
Note: If the machine does not operate or if the
machine does not travel in a straight line, consult
your Caterpillar dealer.
10. See Operation and Maintenance Manual, “Travel

Control” for information about spot turning and
about pivot turns.
11. When you make turns in soft material, travel in a
forward direction occasionally in order to clear the
tracks.
12. Slowly move both of the travel levers or both of
the travel pedals to the CENTER position in order
to stop the machine.
SEBU7029-05 101
Operation Section
Frozen Ground Conditions
i00059294 Machine with a Boom Lowering

Control Valve
Frozen Ground Conditions
SMCS Code: 7000
Boom load may cause cylinder oil pressure to

reach relief pressure of the boom lowering con-
trol device when the boom is supported by one
cylinder. Boom can lower suddenly, causing pos-
sible injury or death.
To avoid possible injury or death, be sure no one
is under or near the work tool before manually
lowering the boom.
Keep all personnel away from the boom drop area
when lowering the boom with the engine
stopped.
If the engine is shut down or the hydraulic system is

disabled, the operator can still lower the boom. Use
Illustration 196 g00101468 the following procedure if the machine is equipped
with a boom lowering control valve.
To free the tracks from frozen ground, swing the
boom to the front of the machine. Use boom down
pressure to free the idler end of the machine.
Swing the boom to the rear of the machine. Use
boom down pressure to free the sprocket end of the
machine.
i03106191
Equipment Lowering with

Engine Stopped
SMCS Code: 7000
In order to lower the boom, place the hydraulic
lockout control in the UNLOCKED position. Move the Illustration 197 g00101574
joystick to the BOOM LOWER position. If the
accumulator is still charged, the boom will lower. The boom lowering control valve is at the back of the
base of the boom. The boom lowering control valve
If the boom does not lower, the accumulator is empty. allows the operator to manually lower the boom if the
Use the following method to lower the boom. engine is stopped. The boom lowering control valve
also ensures that the boom does not fall suddenly if
Note: The boom can be lowered within 60 seconds there is an oil leak in the hydraulic line of the boom.
after turning off the engine if the accumulator is
charged. After 60 seconds, the hydraulic electronic
control module will shut off and the joysticks will be
disabled. The hydraulic lockout control must be in the
UNLOCKED position.
102 SEBU7029-05
Operation Section
Equipment Lowering with Engine Stopped
1. Loosen locknut (1).

2. Slowly turn check valve (2) counterclockwise until
the check valve stops. The boom will lower to the
ground.
3. Make sure that the implement has been
completely lowered onto the ground. Turn check
valve (2) to the CLOSED position.
4. Tighten locknut (1) to a torque of 55 ± 10 N·m
(41 ± 7 lb ft).
5. Before you begin operating the machine, make
any necessary repairs.
For additional information, consult your Caterpillar
dealer.
SEBU7029-05 103
Operation Section
Operating Techniques
Operating Techniques Move the machine whenever the position for

operating the machine is not efficient. The machine
can be moved forward or backward during the
i05125989 operating cycle.
Operating Technique When you operate the machine in close places,

utilize the bucket or the other work tool in order to
Information perform the following functions:
SMCS Code: 7000 • Pushing the machine
• Pulling the machine

• Lifting the tracks
Know the maximum height and the maximum
reach of your machine. Serious injury or death by Use a comfortable travel speed while you operate the
electrocution can occur if the machine or the machine.
work tools are not kept a safe distance from elec-
trical power lines. Keep a distance of at least Operating efficiency can be increased by using more
3000 mm (118 inch) plus an additional 10 mm than one machine control to perform a task.
(0.4 inch) for each 1000 volts over 50000 volts.
Never swing a load over a truck cab or workers.
For safety, one of the following may require a greater
distance: Position the truck so that material can be loaded from
the rear of the truck or from the side of the truck.
• Local codes Load the truck evenly so that the rear axles are not
overloaded.
• State codes
An oversize bucket or a bucket that is equipped with
• Requirements of the job site side cutters should not be used in rocky material.
These types of buckets slow down the cycle.
Damage to the bucket and to other machine
NOTICE components could result.
When swinging into a ditch, do not use the ditch to
stop the swinging motion. Inspect the machine for
damage if the boom is swung into a bank or an Restricted Operation
object.
Repeated stopping by an object can cause structural
damage if the boom is swung into a bank or an
object.
With certain boom-stick-bucket combinations, the
bucket or worktool can hit the cab and/or the front
structure of the machine. Always check for interfer-
ence when first operating a new bucket or a new work
tool. Keep the bucket or work tool away from the cab
and away from the front structure during operation.
Whenever the tracks of the machine raise off the
ground while digging, lower the machine back to the
ground smoothly. DO NOT DROP OR CATCH IT
WITH THE HYDRAULICS. Damage to the machine
can result.
With certain combinations of work tools, the third Do not use the swing force to perform the following
pedal can have different functions. Always check the operations:
function of the third pedal before you use the third
pedal. • Soil compaction
Know the location of any buried cables. Mark the • Ground breaking
locations clearly before you dig.
• Demolition
Consult your Caterpillar dealer for special work tool
tips that are available for use in severe applications. Do not swing the machine while the bucket tips are in
the soil.
104 SEBU7029-05
Operation Section
Operating Technique Information
These operations will damage the boom, the stick,

and the work tool and the operations will reduce the
life of the equipment.
If the stick IN function is operated at full speed with a

Illustration 200 g00529457 fully loaded bucket or heavy work tool attachment to
the end of the cylinder stroke, excessive force will
Do not use the dropping force of the bucket or work occur inside the stick cylinder. This action will reduce
tool as a hammer. This will bring excessive force on the life of the stick cylinder. To avoid this problem,
the rear of the machine. Possible damage to the always operate a stick IN function with moderate
machine could result. speed towards the end of cylinder stroke.
If the cylinder is operated at the end of the stroke While the bucket is in the ground, do not use the
during operations, excessive force will occur on the travel force for any excavation. This operation will
stopper on the inside of the cylinder. This will reduce cause excessive force on the rear of the machine.
the life of the cylinder and structures. To avoid this
problem, always leave a small margin of play when
the cylinder is operated.
SEBU7029-05 105
Operation Section
Travel in Water and Mud
Do not use the dropping force of the rear of the When deep holes are dug, do not lower the boom so
machine for excavation. This operation will damage that the bottom side of the boom touches the ground.
the machine.
When deep holes are dug, do not allow the boom to
interfere with the tracks.
Operating Precaution
i05032265

SMCS Code: 7000-V6
NOTICE
When working in or around any body of water, around
a stream or river, or in conditions of heavy mud, be
careful that the swing bearing, the swing drive gear,
and the swivel joint do not dip into water, mud, sand,
or gravel. If the swing bearing dips into water, mud,
sand, or gravel, immediately grease the swing bear-
ing until the used grease leaks from the outer circle of
the swing bearing. Failure to carry out this procedure
may cause premature wear in the swing bearing.
NOTICE
Do not allow the machine to swing from the force of
traveling when you use the bucket , the stick, or the
boom to assist in travel. If the force from traveling
causes the machine to swing, damage may occur to
the swing motor and to the swing drive.
Do not use the force of the bucket, the stick, or the
boom to assist in turning the machine while the
machine is traveling. This technique is referred to as
“jump steering”. This technique will damage the
swing motor and the swing brake.

Depth of water to the center of the track carrier roller
The following guidelines pertain to travel across

water and travel through mud, sand, or gravel.
106 SEBU7029-05
Operation Section
The machine can travel across a river only under the

following conditions:
• The bed of the river is flat.

• The flow of the river is slow.
• The machine dips into the water only to the center

of the track carrier roller (dimension A).
NOTICE
Do not allow the fan on the engine to contact the
water while the machine travels through the water.
Do not allow the fan on the engine to contact the
water during a swing while the machine is in the
water. Damage to the fan may occur if the fan con-
tacts the water.
1. You may not be able to move the machine by using
While you cross the river, carefully confirm the depth the travel controls only. In this case use both the
of the water with the bucket. Do not move the travel control levers/pedals and the stick to pull the
machine into an area that has a water depth that is
greater than Dimension A. machine out of the water or ground.
The machine may sink gradually on soft ground.

Therefore, you should frequently check the height of
the undercarriage from ground level and the depth of
water on the ground.
Check the swing gear by looking through the port for
inspection that is on the upper frame. If there is water
in the swing gear, contact your Cat dealer for the
required maintenance on the swing gear.
After you travel through water, carefully clean the
machine in order to remove any salt, sand, or other
foreign matter.
Procedure for Removing the

Machine from Water or Mud Illustration 209 g00808151
2. The machine may slip because of a steep slope.

NOTICE
Do not allow the machine to swing from the force of The procedure in Step 1 may not work. In this
traveling when you use the bucket , the stick, or the case, first rotate the upper structure by 180°. Then
boom to assist in travel. If the force from traveling use both the travel control levers/pedals and the
causes the machine to swing, damage may occur to stick to move the machine up the slope.
the swing motor and to the swing drive.
SEBU7029-05 107
Operation Section
Boom, Stick and Bucket Operation
3. It may be impossible to travel because the bottom 2. Position the bucket cutting edge at a 120 degree
of the frame comes into contact with the ground or angle to the ground. Maximum breakout force can
the undercarriage is clogged with mud or gravel. In now be exerted with the bucket.
this case, operate the boom and the stick together.
Raise the track and rotate the track forward and
backward in order to remove the mud and the
gravel.
i05150572
Boom, Stick and Bucket

Operation
SMCS Code: 7000
S/N: 4SS1–Up
S/N: 9GS1–Up
Digging
3. Move the stick toward the cab and keep the bucket
parallel to the ground.
1. Position the stick at a 70 degree angle to the

ground.
108 SEBU7029-05
Operation Section
4. If the stick stops due to the load, raise the boom 9. Engage the swing control when the bucket is clear
and/or perform a curl in order to adjust the depth of the excavation.
of the cut.
5. To apply the greatest force at the cutting edge,
decrease the down pressure as you move the
stick toward the cab.
6. Maintain a bucket attitude that ensures a
continuous flow of material into the bucket.
7. Continue the pass in a horizontal direction so that
material peels into the bucket.
10. To dump a load, move the stick outward and open

the bucket in a smooth motion.
Lifting Objects

To prevent injury, do not exceed the rated load ca-
pacity of the machine. If the machine is not on
level ground, load capacities will vary.
8. Close the bucket and raise the boom when the
pass has been completed.
NOTICE
Damage to bucket cylinder, bucket or linkage could
result if slings are placed incorrectly.
There may be local regulations and/or government

regulations that govern the use of machines which lift
heavy objects. Obey all local and government
regulations.
SEBU7029-05 109
Operation Section
If this machine is used to lift objects within an area

that is controlled by the European Directive “2006/42/
EC”, the machine must be equipped with a boom
lowering control valve, a stick lowering control valve,
and an overload warning device.
Japan regulations require some machines to use a
shovel crane configuration in order to lift ceratin
objects.
Contact your Cat dealer for additional information.
Short slings will prevent excessive load swing.
The most stable lifting position is over a corner of the

machine.
Use the lifting eye that is provided on the linkage to

lift objects.
If the lifting eye is used, the connection must be
made with a sling or with a shackle.
For the best stability, carry a load close to the

machine and to the ground.
An unstable condition can exist if a load exceeds the

machine load rating or if a heavy load is swung over
an end or over a side.
110 SEBU7029-05
Operation Section
Material Handler Operation
Lift capacity decreases as the distance from the An unstable condition can exist if a load exceeds the
swing centerline is increased. machine load rating or if a heavy load is swung over
an end or over a side.
Machines that are Equipped with a
Long Reach Configuration
Machines with a long reach configuration require
larger swing drift than standard machines when
stopping, because inertial force in time of swing is
large. Taking this into account, adjustments are made
in timing for applying the swing brakes and speed of
swinging.
Machines with a long reach configuration could be
damaged and stability of the machine would be
adversely affected if a control was suddenly
operated, because inertial force of work tool is large.
i02541201
The most stable lifting position is over a corner of the

Material Handler Operation machine.
SMCS Code: 7000
S/N: 2NW1–Up
To prevent injury, do not exceed the rated load ca-

pacity of the machine. If the machine is not on
level ground, load capacities will vary.
NOTICE
Damage to the work tool cylinder, work tool, or link-
age could result if the slings are placed incorrectly.
Short slings will prevent excessive load swing. Illustration 225 g00130807
Note: There may be local government regulations For the best stability, carry a load close to the
about the use of excavators for the lifting of heavy machine and to the ground.
objects. Please observe those regulations.
SEBU7029-05 111
Operation Section
Hammer Operation
Before you start hydraulic hammer operation, close

the front window. Caterpillar recommends the
installation of a window guard on the front window for
protection from flying debris.
NOTICE
In order to avoid structural damage to the host ma-
chine or the hydraulic hammer, comply with the
following:
Do not attempt to break rocks or concrete by burying
the hammer tool completely into the rocks or
concrete.
Do not apply a prying force to the hammer tool in or-
der to remove the hammer tool from the material.
The lift capacity decreases as the distance from the Do not allow the hydraulic hammer to continuously
swing centerline increases. Rotate the upper frame operate at one location and for more than 15
by 90 degrees relative to the undercarriage when the seconds. Change the location of the hydraulic
machine is working in a stationary application. This hammer and repeat the procedure. Failure to change
will evenly load the swing bearing. the location of the hydraulic hammer could cause the
hydraulic oil to overheat. Overheated hydraulic oil
could cause damage to the accumulator.
i03548680
Stop the hydraulic hammer immediately if the jumper
Hammer Operation lines are pulsating violently. This indicates that the
accumulator nitrogen charge is lost. Consult your
(If Equipped) Caterpillar dealer for the necessary repair.
SMCS Code: 5705-WTL
NOTICE
Do not use the dropping force of the hydraulic ham-
mer to break rocks or other hard objects. This could
cause structural damage to the machine.
Do not use the sides or back of the hydraulic hammer
to move rocks or other hard objects. Doing this could
cause damage not only to the hammer but to stick or
boom cylinder.
Do not operate the hydraulic hammer with any of the
cylinders fully retracted or extended. Doing this could
cause structural damage to the machine, resulting in
reduced machine life.
Do not use the hydraulic hammer to lift an object.

Illustration 227 g01876560 Do not operate the hydraulic hammer while the stick
is vertical to the ground. This could allow the stick
cylinder to vibrate excessively.
NOTICE
Use only a hydraulic hammer that is recommended Operate the attachment control levers carefully in
byCaterpillar. The use of a hydraulic hammer that is order to keep the hydraulic hammer's tool from hitting
not recommended by Caterpillar could damage your the boom.
machine. Consult your Caterpillar dealer for informa-
tion on recommended hydraulic hammers. Do not operate the hydraulic hammer under water
unless the hydraulic hammer is properly equipped.
Only use the hydraulic hammer to break rocks, Operating the hydraulic hammer under water could
concrete, and other hard objects. Before you start cause serious damage to the machine hydraulic
hydraulic hammer operation, place the machine on a system. Consult your Caterpillar dealer for
level, stable surface. information on underwater operation.
112 SEBU7029-05
Operation Section
If Equipped
Do not operate the hydraulic hammer with the upper

structure sideways to the undercarriage. Before you
start hydraulic hammer operation, place the upper
structure in the recommended positions that are
shown in illustration 228 . Any other operating
positions could make the machine unstable. Any
other operating positions could place excessive loads
on the undercarriage.
Refer to the following for any additional questions
about the operation and care of your Caterpillar
hydraulic hammer: Operation and Maintenance
Manual, SEBU7346, “Hydraulic Hammers”,
Operation and Maintenance Manual, HEPU9000,
“Hydraulic Hammers” and Decal, SMEU7397,
“Hammer Operation/Maintenance”.

(1) Incorrect working position
(2) Correct working position
(3) Incorrect working position
(4) Correct working position
SEBU7029-05 113
Operation Section
Parking
Parking
i02014194
Stopping the Machine

SMCS Code: 7000
NOTICE
Park on a level surface. If it is necessary to park on a
grade, chock the tracks securely.
Note: The swing parking brake is automatically

applied when the machine is stopped. The swing
parking brake is released when the engine is running Illustration 231 g00107416
and the joystick controls are activated.

position.
i01871055
Freezing Conditions
SMCS Code: 7000
If freezing temperatures are expected, remove the
mud and the dirt from each track roller frame. Park
the machine on wood planks. Use the following
procedure to clean each track roller frame.
1. Turn the engine speed dial counterclockwise in

order to reduce engine speed.
1. Position the boom over one side of the machine.

2. Use boom down pressure in order to lift the track
on one side off the ground. Operate the track in
the forward direction. Then operate the track in
reverse. Continue this procedure until the
maximum amount of material is thrown off the
Illustration 230 g00107517 track.
2. Release the travel levers and the travel pedals in 3. Lower the track onto the wood planks.
order to stop the machine. 4. Repeat the procedure for the other track.
3. Lower the work tool to the ground. Apply a slight 5. Clean the area around the carrier rollers and
downward pressure. around the track rollers.
114 SEBU7029-05
Operation Section
Engine Stopping
6. Lower the work tool onto a wood plank in order to i00143071

prevent the work tool from touching the ground.
Leaving the Machine
i01957230
SMCS Code: 7000
Engine Stopping
SMCS Code: 1000; 7000
If the engine is turned off immediately and the
machine has been under a load, overheating may
occur. This will cause accelerated wear of the engine
components.
Refer to the following stopping procedure, in order to
allow the engine to cool and prevent excessive
temperatures in the turbocharger center housing.
1. Stop the machine and run the engine at low idle for
five minutes.
NOTICE
Never turn the battery disconnect switch to the OFF Illustration 234 g00103309
position while the engine is running. Serious damage The above illustration shows an operator that is
to the electrical system may result. properly dismounting an excavator.
1. Use the steps and the handholds when you

dismount. When you dismount, face the machine
and use both hands. Be sure that you clean any
debris from the steps.
2. Inspect the engine compartment for debris. Clean
out any debris in order to avoid a fire hazard.
3. Remove all flammable debris from the front bottom
guard through the access doors in order to reduce
a fire hazard. Discard the debris properly.
4. When the machine is left for an extended period of
one month or longer, turn the key for the battery
disconnect switch to the OFF position. Remove
the key. This will help to prevent a battery short
Illustration 233 g00101567 circuit. Removing the key will also help to protect
the battery from vandalism and from the current
2. Turn the engine start switch to the OFF position draw that is made by certain components.
and remove the engine start switch key.
5. Lock all vandalism covers and all compartments.
SEBU7029-05 115
Operation Section
Leaving the Machine
Storing Vandalism Guards
6. Remove the bolt that holds the vandalism guards Illustration 237 g00101581
in place. Remove the vandalism guards from the

storage area. Note: When you are storing the vandalism guards,
make sure that you place the guards in the storage
area in sequential order, as shown. The vandalism
guards will only fit in the storage area in this manner.
7. Install the vandalism guards on the front window

and on the cab door. An identification number is
stamped on each of the vandalism guards. Install
the vandalism guards in the correct sequence.
Use bolts (A) only for vandalism guard (3) and for
vandalism guard (5).
116 SEBU7029-05
Operation Section
Transportation Information
Transportation Information 6. Lower the work tool to the bed or to the floor of the
transport machine.
i08036521 7. To prevent rolling of the machine or sudden
movement of the machine, perform the following
Shipping the Machine items:
SMCS Code: 7000; 7500 • Chock both tracks.
• Install sufficient tie-downs at several locations.
Automatic Engine Speed Control (AEC) will in- • Fasten wire cables.
crease engine speed automatically when you op-
erate the control levers and/or travel pedals with 8. If equipped, remove door hooks, cab bumpers,
AEC switch on. and fuel tank step as necessary. Refer to local
regulations.
When loading and unloading the machine from
the truck or working in close quarters always turn
AEC switch off to prevent any possibility of sud-
den movement of machine, which could result in
serious injury or death.
Set the travel speed control switch to LOW before
loading the machine. Never operate this switch
when loading the machine on a trailer.
Investigate the travel route for overpass clearances.
Make sure that there will be adequate clearance for
the machine.
Remove ice, snow, or other slippery material from the
loading dock and from the truck bed before you load
the machine onto the transport machine. Removing
ice, snow, or other slippery material will help to Illustration 238 g06516462
prevent the machine from slipping in transit.
(1) Cover
(2) Nuts
Note: Obey all laws that govern the characteristics of (3) Door Hook
a load (height, weight, width, and length). Observe all (A) Inside
regulations that govern wide loads. Certain regions (B) Outside
may require the removal of door hooks and cab
bumpers, if equipped. Consult all local and regional a. Remove cover (1) and nuts (2) to remove door
regulations hook (3).
Choose the flattest ground when you load the
machine or when you unload the machine.
1. Before you load the machine, chock the trailer
wheels or the rail car wheels.
2. When you use loading ramps, make sure that the
loading ramps have adequate length, adequate
width, adequate strength, and an adequate slope.
3. Maintain the slope of the loading ramps within 15
degrees of the ground.
4. Position the machine so that the machine can drive
straight up the loading ramps. The final drives
should be toward the rear of the machine. Do not
operate the control levers while the machine is on
the loading ramps.
b. Remove any bumpers on your cab.
5. When you drive over the loading ramp joint areas,
maintain the balance point of the machine.
SEBU7029-05 117
Operation Section
Securing the Machine
NOTICE
Do not allow the chrome surface of the bucket cylin-
der rod to touch any part of the trailer. Damage to the
rod can occur from impact with the trailer during
transport.
Note: Refer to Operation and Maintenance Manual,

“Specifications”.
Shipping a Machine that is not

Completely Assembled
If the machine must be shipped when the boom,
stick, or counterweight is not assembled on the
machine, follow the instructions in Operation and
Maintenance Manual, “Operation”.
position.
2. Turn the engine start switch to the OFF position in
The ROPS structural certification depends on the order to stop the engine. Remove the engine start
support of the boom, stick, and counterweight in switch key.
the event of a machine tip over or a machine roll-
over incident. 3. Turn the battery disconnect switch to OFF and
When the machine needs to be moved without remove the disconnect switch key.
the boom, stick, or counterweight being installed, 4. Remove the ether starting aid cylinder. See
avoid any machine operations which could affect
machine stability as a machine tip over or a ma- Operation and Maintenance Manual, “Ether
chine rollover incident could result in serious in- Starting Aid Cylinder - Replace” for the removal
jury or death. procedure.
The machine should be operated slowly on flat, 5. Lock the door and the access covers. Attach any
stable ground or pavement by qualified vandalism protection.
operators.
6. Cover the exhaust opening.
i01954709 NOTICE
Do not allow the turbocharger to rotate while the en-
gine is not operating. Damage to the turbocharger
Securing the Machine can result.
SMCS Code: 7000
Comply with any laws that govern the characteristics Note: Before you remove the excavator from the
of a load (length, width, height, and weight). transport machine, remove the protective covering
from the exhaust opening.
118 SEBU7029-05
Operation Section
Cab Tilting
Do not tilt the cab when occupied. Before tilting

the cab remove all loose articles from the cab, se-
cure all windows and emergency exits, and then
close the cab and cab riser doors. Failure to do
so can result in personal injury or damage to the
machine.
Lower
7. Chock the tracks and secure the machine with tie-

downs. Make sure that you use the proper rated
wire cable.
Use the front towing eyes on the lower frame, the
rear towing eyes on the lower frame, and the rear
towing eye that is on the upper frame.
Securely fasten all loose parts and all removed
parts to the trailer or to the rail car.
When the engine is stopped, the swing parking
brake is automatically applied. This prevents the
upper structure from swinging. 1. Attach a suitable lifting device to the two lifting
rings.
8. Tilt the cab if the machine is equipped with a tilt
cab. Refer to Operation and Maintenance Manual, Note: The lifting rings are located in the top rear
“Cab Tilting” for the procedure to tilt the cab. corners of the cab. The approximate weight of the
cab, platform, and cab riser is 1700 kg (3750 lb).
Note: The cab must be tilted or the cab must be in
the LOWER position before transporting.
NOTICE
In freezing weather, protect the cooling system with
antifreeze, to the lowest outside expected tempera-
ture on the travel route. Or, drain the cooling system
completely.
i00867921
Cab Tilting
SMCS Code: 7341
S/N: 2NW1–Up Illustration 243 g00274735
The cab and the cab riser must be tilted in order to (1) Cab retention bolts.
lower the overall height of the machine for shipping.
A lifting device such as a crane is needed in order to 2. Remove cab retention bolts (1) from the rear of the
tilt the cab. cab riser compartment and install the cab retention
bolts in the provided weld nuts.
SEBU7029-05 119
Operation Section
Cab Tilting
5. Install cab retention bolts (1).
Raise
Illustration 244 g00274772 1. Attach a suitable lifting device to the two lifting
rings.
3. Raise the cab riser until the cab riser is beyond the
center point. Note: The lifting rings are located in the top rear
corners of the cab. The approximate weight of the
cab, platform, and cab riser is 1700 kg (3750 lb).
2. Remove the brackets. Lay the brackets next to the

generator control panel in the bottom of the
housing.
NOTICE
Improper lifting or tiedowns can allow load to shift
and cause injury or damage.
NOTICE
Do not apply too much pressure with the lifting device
being used. Damage to the riser frame may occur.
4. Slowly lower the cab riser until the brackets can be

installed, as shown.
NOTICE
Do not apply too much pressure with the lifting device
being used. Damage to the riser frame may occur.
120 SEBU7029-05
Operation Section
Mirror Installation
3. Raise the cab riser until the cab riser is beyond the After you transport the machine, reinstall the rearview
center point. mirror or return the rearview mirror to the proper
position. Use the following procedure.
4. Slowly lower the cab riser until the cab riser is in
the original position.
1. Use two bolts (2) and two washers (3) to install

bracket (1) on the right side of the storage box.
(1) Cab retention bolts.
5. Install cab retention bolts (1).

6. Secure the cab retention bolts.
2. Put bar (4) into bracket (1). Align the notches at the
lower part of the bar so that the bar faces outward.
Illustration 249 g00274771 Secure the bar by tightening nut (5) and washer
(6) on the bar.
7. Remove the lifting device from the cab.
i00703722
Mirror Installation
SMCS Code: 7319
S/N: 4SS1–Up
S/N: 9GS1–Up
Note: Before you transport the machine, remove the

rearview mirror or reposition the rearview mirror
inward.
SEBU7029-05 121
Operation Section
Mirror Installation

(1) Mirror
(2) Mirror
3. Install mirror (7) to bar (4). Rotate the mirror by
hand to the desired angle. Before you transport the machine, remove mirror (1)
and mirror (2).
After you transport the machine, reinstall the mirrors
by using the following procedure:
Reposition the rearview mirror inward before you

transport the machine.
i02342040
(2) Mirror
(3) Bolt
Mirror Installation (4) Washer
(5) Bracket
SMCS Code: 7319 (6) Bar
(7) Nut
S/N: 2NW1–Up
1. Use two bolts (3) and two washers (4) to install
bracket (5) to bar (6).
2. Attach mirror (2) to bar (6) by tightening nut (7).
3. Rotate the mirror to the desired angle.
4. Repeat Steps 1 to 3 in order to install mirror (1).
122 SEBU7029-05
Operation Section
Adjustable Gage Undercarriage Frame
i01288120 Retracting
Adjustable Gage Park the machine on a hard, level surface.
Undercarriage Frame Retract the track frames one at a time.
SMCS Code: 4150
S/N: 9GS1–Up
S/N: 2NW1–Up
Before extending or retracting the track frames,

be sure to keep all other people away from the
machine.
Always use two or more people to do this work.
Perform machine movements only after getting
signals from a signal man.
The automatic engine speed control (AEC) switch Illustration 257 g00286822
must be in the OFF position and the travel speed
switch must be in the LOW position. 1. Position the machine with the front at a right angle
Never make a sudden movement of the front to the track frame that is being retracted, as
equipment. When operating the front equipment, shown.
slowly activate the controls with extra care.
2. Stop the engine.
NOTICE
Before starting adjustment of the track frames, clean
the contacting areas of the car body and track
frames, and their mounting bolts. Prior to installing
the bolts, apply 9M-3710 Anti-Seize Compound to
the underside of the head and to the threads of the
bolts.

(2) Bolts
(3) Washers
(4) Cover for travel motor
3. Remove four bolts (2), washers (3), and the cover

for the travel motor (4).
This machine has adjustable track frames that are

held in place with bolts. Completely widen the track
frames when the machine is being operated. Fully
retract the track frames in order to transport the
machine.
SEBU7029-05 123
Operation Section

(5) Carbody (7) Bolts
(6) Track frame (8) Spacers
(7) Bolts
(8) Spacer
(9) Bolt 9. Align the bolt holes of the carbody and track frame.
(10) Washer Install 22 bolts (7) and spacers (8). If necessary,
(11) Plate slowly operate the machine back and forth until
the bolt holes are aligned. Tighten the bolts to a
4. Remove 38 bolts (7) and spacers (8). The bolts torque of 2700 ± 300 N·m (2000 ± 220 lb ft).
hold track frame (6) to carbody (5).
10. Repeat Steps 1 through 9 for the other track
5. Loosen four bolts (9) and washers (10). Remove frame.
two plates (11).
Extending
NOTICE
Damage to the car body guide on the track roller
frame can result if the track is raised more than
60 mm (2.4 inch) off the ground, with the car body
bolts removed.
Park the machine on a hard, level surface.

Extend the track frames one at a time.
6. Start the engine. Apply downward pressure with

the boom in order to raise the track approximately
50 cm (20 inch) above ground level.
7. Slowly run the raised track at a low idle. This will
cause the raised track to slide toward the center of
the machine. The full sliding distance should be
380 mm (1 ft 3 inch).
8. After the raised track frame has been correctly Illustration 262 g00285921
retracted, lower the track frame to the ground. (5) Carbody
(6) Track frame
(7) Bolt
(8) Spacers
124 SEBU7029-05
Operation Section
1. Remove 22 bolts (7) and spacers (8). The bolts

hold track frame (6) to carbody (5).

(5) Carbody
(6) Track frame
Illustration 263 g00286687 (7) Bolts
(8) Spacer
(9) Bolt
2. Position the boom over the opposite track frame
(10) Washer
with the stick at an approximate 80 degree angle (11) Plate
to the ground. Place the bucket teeth into the
ground, as shown. This machine position provides 6. Align the bolt holes of the carbody and track frame.
the best stability for extending the track frames. Install 38 bolts (7) and spacers (8). If necessary,
slowly operate the machine back and forth until
3. Apply a downward pressure with the boom in order
to slightly raise the track. the bolt holes are aligned. Tighten the bolts to a
torque of 2700 ± 300 N·m (2000 ± 220 lb ft).
7. Install two plates (11) with four bolts (9) and
washers (10).
4. Use the STICK IN position to extend the track

frame by moving the carbody away from the track. Illustration 266 g00285695
5. After the track frame has been correctly extended, (2) Bolts
(3) Washers
lower the raised track frame to the ground. (4) Cover for travel motor
8. Install the cover for the travel motor (4), washers

(3), and bolts (2).
SEBU7029-05 125
Operation Section
Counterweight Removal and Installation
9. Repeat Steps 1 through 8 for the other track frame.
i08109798 Crush Hazard. Read and Understand the Opera-

tion and Maintenance Manual before performing
Counterweight Removal and maintenance on equipment. Could cause serious
injury or death.
Installation
SMCS Code: 7056
Unexpected machine damage and personal injury

Unexpected machine movement can cause injury or death can occur from any machine operation
or death. without counterweight bolt tightened properly.
In order to avoid possible machine movement, Make sure to tighten the counterweight mounting
move the hydraulic lockout control to the bolts when the counterweight is installed.
LOCKED position and attach a Special Instruc-
tion, SEHS7332, “Do Not Operate” or similar
warning tag to the hydraulic lockout control. Counterweight Removal and
Installation for Standard Machines
Counterweight Removal
Personal injury or death can occur from a coun-
terweight falling during removal or installation. 1. Position the machine on a surface that is hard and
level. Lower the front implements to the ground.
Do not allow personnel under or around the coun-
terweight during removal or installation. 2. Move the lever for the hydraulic lockout control to
the LOCKED position.
Make sure that the lifting device is in good condi-
tion and is capable of handling the weight of the
counterweight.

terweight falling during removal or installation.
Before you remove the counterweight mounting
bolts, read and understand the instructions and
warnings in the Operation and Maintenance
Manual.
Make certain personnel are clear of cable when (1) Bolt. (2) Washer. (3) Cover. (4) Cover.
there is a load on it. Cable can break and cause
personal injury. 3. Remove six bolts (1) and washers (2). Remove
covers (3) and (4).

terweight falling during removal or installation.
Before you begin the Removal Procedure, make
sure that the support blocks are installed and
tightened properly.
126 SEBU7029-05
Operation Section
Note: Temporarily tighten the six counterweight

mounting bolts. Decrease the tension on the lifting
cable. Make sure that the counterweight is correctly
positioned on the retaining pins. Tighten the bolts to a
torque of 2800 ± 350 N·m (2065 ± 258 lb ft).
Machines Equipped with

Counterweight Removal System
IMPROPER OPERATION OF THE COUNTER-

WEIGHT REMOVAL SYSTEM CAN RESULT IN
SERIOUS INJURY OR DEATH. DO NOT OPERATE
THIS SYSTEM UNLESS YOU HAVE READ AND
UNDERSTAND THE INSTRUCTIONS AND WARN-
INGS IN THE OPERATION AND MAINTENANCE
4. Fasten a proper rated cable with shackles to the MANUAL.
brackets. Use an appropriate lifting device in order
to tension the cable. If the tension in the cable is
too great, removing the bolts will be difficult. Also,
if the tension in the cable is too small, removing
the bolts will be difficult. Before you remove the counterweight, check for
signs of hydraulic oil leaking from the Counter-
weight Removal System. An oil leak may be a
sign of a potential system failure and needs to be
corrected before removing the counterweight
mounting bolts. A hydraulic leak, along with other
factors, can result in personal injury or death.
When the removal cylinder is used to lower the

counterweight, the counterweight can wedge
against the machine frame which stops the down-
ward movement of the counterweight. Since the
removal cylinder continues to retract and the
counterweight stopped, slack in the chain for the
removal cylinder occurs.
The counterweight can suddenly fall due to the
5. Remove six counterweight mounting bolts and six slack in the chain which could result in personal
washers. injury or death.
6. Remove two bolts, two washers and a plate which Monitor the lowering of the counterweight when
is located below the counterweight. the counterweight is being lowered with the re-
moval cylinder. If the removal cylinder is re-
7. Lift the counterweight enough so that there is no tracted and the downward movement of the
load on the retaining pins. counterweight stops, stop the lowering proce-
dure and correct the wedging of the counter-
8. Separate the counterweight from the machine. weight against the machine frame.
Lower the counterweight onto suitable supports.
Counterweight Installation Counterweight Removal

Perform the removal procedure in reverse order. 1. Position the upper structure parallel to the tracks.
2. Start the engine. Adjust the engine speed to one-
third of full throttle engine speed.
SEBU7029-05 127
Operation Section
5. Move switch (1) to the ON position.

6. Move control lever (3) upward in order to relieve
the weight on the counterweight mounting bolts.
There should be a slight tension on the chains.
3. Move the lever for the hydraulic lockout control to

the LOCKED position. Attach a “Do Not Operate”
warning tag or a similar warning tag to the start
switch or to the controls. Illustration 273 g06510567
7. There should be a slight tension on the chains.

Inspect both chains to verify condition and that the
chains are not seized or binding. Monitor chain
tension for 5 minutes to verify no leaks and no
excessive drift is present indicating service is
required before system use. Contact your Cat
dealer if service is required.
4. Open the rear access door on the right side of the

machine.
8. Remove bolts (A) from the counterweight.

9. Reinstall bolts (A) and tighten by hand until the
bolts are fully engaged.
Note: Do not use tools to reinstall bolts (A).
10. Loosen bolts (A) two full revolutions.

Note: Do not remove bolts (A) from the
Illustration 272 g00277670 counterweight.
(1) Stop valves. (2) Switch. (3) Control lever.
11. Remove remaining bolts (B).
128 SEBU7029-05
Operation Section
12. Remove bolts (A) by hand.

Note: Do not use tools to remove bolts (A).
Note: If unable to remove bolts (A) by hand, the

counterweight removal system may not be
appropriately supporting the weight of the
counterweight. Adjustment of the linkage, or
additional support, may be required to safely remove
the final two bolts.
13. Remove two bolts, two washers and a plate that

is located below the counterweight.

(4) Counterweight.
16. Move control lever (3) downward in order to lower

counterweight (4) onto supports on the ground.

(4) Counterweight. (5) Retaining Pin.
14. Move control lever (3) upward in order to raise

the counterweight (4) until access to the retaining
pins (5) can be gained.

(4) Counterweight. (7) Cotter Pin. (8) Nut. (9) Pin. (10)
Chain Bracket.
17. Remove cotter pin (7). Loosen nut (8). Remove

pin (9) in order to disconnect chain bracket (10)
from counterweight (4).

(5) Retaining Pin. (6) Extension.
15. Use a ratchet wrench and an extension (6) in

order to rotate each retaining pin (5). Retaining
pins (5) require ninety degrees of rotation. The
retaining pins (5) are now in the UNLOCKED
position.
SEBU7029-05 129
Operation Section
Lifting and Tying Down the Machine

(10) Chain Bracket. (11) Pin.(12) Plate. (13) Bolt. (14)
Washer. 22. Use an appropriate lifting device in order to put
the counterweight on suitable supports.
18. Pin (11) should be located in one of the storage
boxes. Remove pin (11) from the storage box. Counterweight Installation
19. Install pin (11) into chain bracket (10). Perform the removal procedure in reverse order.
20. Install bolts (13) and washers (14) in order to
Note: Before you install the counterweight mounting
attach pin (11) to plate (12). bolts, make sure that the counterweight is securely
held on the retaining pins. There should be a slight
amount of slack on the chains.
Tighten the counterweight mounting bolts to a torque
of 2800 ± 350 N·m (2065 ± 258 lb ft).
i01953665
Lifting and Tying Down the

Machine
SMCS Code: 7000; 7500
21. Fasten a proper rated cable with shackles to the

lifting eyes on the counterweight.
NOTICE
Improper lifting and improper tie-downs can allow the
load to shift and cause injury or damage.
130 SEBU7029-05
Operation Section
Lifting and Tying Down the Machine
The weight and the instructions that are given herein Bucket
describe the machine as the machine is
manufactured by Caterpillar.
Refer to the Operation and Maintenance,
“Specifications” for specific weight information.
1. Use proper rated cables and slings for lifting. The
crane should be positioned so that the machine is
lifted parallel to the ground.
2. To prevent contact with the machine, lifting cables
should have sufficient length.
3. Use the rear eyes and the front eyes that are
provided on the lower frame to fasten tie-downs.
Use corner protectors for sharp corners.
position.
(1) Pin. (2) Sleeve. (3) Bolts. (4) Nuts.
Lifting the Machine Segments Install pin (1) and install sleeve (2) in the brackets of
the bucket. The previous illustration indicates the
Counterweight method to secure pin (1) with bolts (3) and nuts (4).
Fasten two proper rated wire cables to pin (1).
Refer to the Operation and Maintenance,

“Counterweight Removal and Installation” for specific
information.
SEBU7029-05 131
Operation Section
Towing Information
Towing Information Do not use a chain for pulling a disabled machine. A

chain link can break. This may cause personal injury.
Use a wire rope with ends that have loops or rings.
i03794657 Put an observer in a safe position in order to watch
the pulling procedure. The observer can stop the
Towing the Machine procedure if the wire rope starts to break. Stop pulling
whenever the towing machine moves without moving
SMCS Code: 7000 the towed machine.
During towing, do not allow anyone to step between
the towing and the towed machines.
Personal injury or death could result when towing Do not allow the wire rope to be straddled while the
a disabled machine incorrectly. machine is being towed.
Block the machine to prevent movement before Keep the tow line angle to a minimum. Do not exceed
final drives are disengaged. The machine can roll a 30 degree angle from the straight ahead position.
free if it is not blocked. With final drives disen-
gaged, the machine cannot be stopped or Avoid towing the machine on a slope.
steered.
Quick machine movement could overload the tow line
Follow the recommendations below, to properly or the tow bar. This could cause the tow line or the
perform the towing procedure. tow bar to break. Gradual, steady machine
movement will be more effective.
Relieve the hydraulic tank and line pressure be-
fore any disassembly. Normally, the towing machine should be as large as
the disabled machine. Make sure that the towing
Even after the machine has been turned off, the machine has enough brake capacity, enough weight,
hydraulic oil can still be hot enough to burn. Al- and enough power. The towing machine must be
low the hydraulic oil to cool before draining. able to control both machines for the grade that is
involved and for the distance that is involved.
NOTICE You must provide sufficient control and sufficient

To tow the machine, both final drives must be braking when you are moving a disabled machine
disengaged. downhill. This may require a larger towing machine or
additional machines that are connected to the rear of
Do not operate the travel motors with the final drives the disabled machine. This will prevent the machine
disengaged. Damage could result. from rolling away out of control.
These towing instructions are for moving a disabled All situation requirements cannot be listed. Minimal
machine for a short distance at low speed. Move the towing machine capacity is required on smooth, level
machine at a speed of 2 km/h (1.2 mph) or less to a surfaces. Maximum towing machine capacity is
convenient location for repair. Always haul the required on an incline or on a surface that is in poor
machine if long distance moving is required. condition.
Shields must be provided on both machines. This will Do not tow a loaded machine.
protect the operator if the tow line or the tow bar Consult your Caterpillar dealer for the equipment that
breaks. is necessary for towing a disabled machine.
Do not allow an operator to be on the machine that is
being towed.
Before you tow the machine, make sure that the tow
line or the tow bar is in good condition. Do not use a
wire rope that is kinked, twisted, or damaged. Make
sure that the tow line or the tow bar has enough
strength for the towing procedure that is involved.
The strength of the tow line or of the tow bar should
be at least 150 percent of the gross weight of the
towed machine. This requirement is for a disabled
machine that is stuck in the mud and for being towed
on a grade.
132 SEBU7029-05
Operation Section
Towing the Machine
1. Remove the travel drive covers from the base

frame.
2. Clean the travel motors, travel brake valves, and
nearby areas.
3. Disconnect the hydraulic lines from the brake
valve. Plug the disconnected lines.
5. Remove two plugs (4).

6. Remove two M16 x 16 bolts (5). Install bolts (5) in
two holes (P).
7. Tighten bolts (5). As bolts (5) are tightened, brake
piston (6) will move apart from flange (7). This will
release the travel motor brake.

Brake valve cover (9) is forced by spring (11). It
can fly apart suddenly when the mounting bolts
4. Loosen bolts (1). Remove brake valve (2) from are removed. Take extra care when removing cov-
travel motor (3). er (9).
SEBU7029-05 133
Operation Section
Towing the Machine
14. After the machine has been towed, return the

brake and the brake valve to the original condition.
Verify that the brake and the brake valve activate
correctly.
Table 20
Recommended Torque
Item Number Part N·m lb ft

(1)
Bolt 100 ± 20 74 ± 10
(8)
8. Remove bolts (8) in order to remove cover (9) of

brake valve (2). To remove bolts (8), remove the
two bolts that are separated by 180 degrees.
Install two replacement M12 bolts in the removed
bolt holes. Tighten the bolts.
9. Remove the remaining two bolts (8). Slowly
remove the replacement M12 bolts.
10. Remove bushing (10), spring (11), washer (12)
and spool (13) from the brake valve.
11. Install cover (9) to the valve body. Tighten bolts
(8).
12. Install brake valve (2) to motor (3) with bolts (1).
Reconnect the two lines to brake valve (2).
13. Repeat Steps 1 through 12 for the other travel
motor.
Note: The parking brake has now been released.
The machine is ready for towing.
134 SEBU7029-05
Operation Section
Engine Starting (Alternate Methods)
Engine Starting (Alternate NOTICE

To prevent damage to engine bearings and to electri-
Methods) cal circuits when you jump-start a machine, do not al-
low the stalled machine to touch the machine that is
used as the electrical source.
i05974849
Turn on (close) the battery disconnect switch prior to
Engine Starting with Jump the boost connection to prevent damage to electrical
components on the stalled machine.
Start Cables
Use only equal voltage for starting. Check the battery
(If Equipped) and starter voltage rating of your machine. Use only
SMCS Code: 1000; 7000 the same voltage for jump starting. Use of a welder or
higher voltage will damage the electrical system.
Severely discharged maintenance free batteries do
not fully recharge from the alternator after jump start-
Failure to properly service the batteries may ing. The batteries must be charged to proper voltage
cause peronal injury. with a battery charger. Many batteries thought to be
unusable are still rechargeable.
Prevent sparks near the batteries. They could
cause vapors to explode. Do not allow the jump Refer to Special Instruction, SEHS7633, “Battery Test
start cable ends to contact each other or the Procedure” for complete testing and charging infor-
machine. mation. This publication is available from your Cat
dealer.
Do not smoke when checking battery electrolyte
levels. When the auxiliary start receptacles are not
Electrolyte is an acid and can cause personal in- available, use the following procedure.
jury if it contacts skin or eyes. 1. Lower the equipment to the ground. Move all
Always wear eye protection when starting a ma- controls to the HOLD position. Move the hydraulic
chine with jump start cables. lockout control to the LOCKED position.
Improper jump start procedures can cause an ex- 2. Turn the start switch on the stalled machine to the
plosion resulting in personal injury. OFF position. Turn off all accessories.
Always connect the battery positive (+) to battery 3. Turn the battery disconnect switch on the stalled
positive (+) and the battery negative (−) to battery machine to the ON position.
negative (−).
4. Move the machine that is being used as an
Jump start only with an energy source with the electrical source near the stalled machine so that
same voltage as the stalled machine. the jump-start cables reach the stalled machine.
Do not allow the machines to contact each
Turn off all lights and accessories on the stalled
other.
machine. Otherwise, they will operate when the
energy source is connected. 5. Stop the engine of the machine that is being used
as an electrical source. If you are using an
auxiliary power source, turn off the charging
system.
6. Ensure that battery caps on both machines are
tight and correctly placed. Ensure that batteries in
the stalled machine are not frozen. Make sure that
the batteries have enough electrolyte.
Note: The positive terminal of the 24 V system of the

source and the negative terminal of the 24 V system
of the source must be identified correctly before the
jumper cables are connected. The positive terminal
of the 24 V system of the discharged battery must be
identified correctly before the jumper cables are
connected.
SEBU7029-05 135
Operation Section
If Equipped
7. The positive ends of the jump-start cable are red. 11. Start the engine of the machine that is being used
Connect one positive end of the jump-start cable as an electrical source or energize the charging
to the positive cable terminal of the discharged system on the auxiliary power source.
battery. Some machines have battery sets.
12. Wait at least two minutes before you attempt to
Note: Batteries that are in series may be in separate start the stalled machine. This will allow the
compartments. Use the terminal that is connected to batteries in the stalled machine to partially charge.
the starter solenoid. This battery or battery set is
13. Attempt to start the stalled engine. See Operation
normally on the same side of the machine as the
starter. and Maintenance Manual, “Engine Starting” for the
correct starting procedure.
Do not allow the positive cable clamps to contact
14. Immediately after you start the stalled engine,
any metal except for the battery terminals.
disconnect the jump-start cables in reverse order.

Typical example of the location of the batteries in an
excavator
(1) Red positive post to starter
(2) The black negative post connects to the battery disconnect
switch.
(3) Do not use these two connections for jump starting. The red
positive post is connected in series to the black negative post.
(4) Cover
8. Connect the other positive end of the jump-start

cable to the positive cable terminal of the electrical
source.
9. Connect one negative end of the jump-start cable
to the negative cable terminal of the electrical
source.
10. Finally, connect the other negative end of the
jump-start cable to the frame of the stalled
machine. Do not connect the jump-start cable to
the battery post. Do not allow the jump-start
cables to contact the battery cables, the fuel lines,
the hydraulic lines, or any moving parts.
136 SEBU7029-05
Maintenance Section
Lubricant Viscosities and Refill Capacities
Maintenance Section NOTICE

Not following the recommendations found in this
manual can lead to reduced performance and com-
Lubricant Viscosities and partment failure.
Refill Capacities
Engine Oil
i07279193
Cat oils have been developed and tested in order to
provide the full performance and life that has been
Lubricant Viscosities designed and built into Cat engines.
(Fluids Recommendations) Cat DEO-ULS multigrade and Cat DEO multigrade
SMCS Code: 7581 oils are formulated with the correct amounts of
detergents, dispersants, and alkalinity in order to
provide superior performance in Cat diesel engines
General Information for Lubricants where recommended for use.
When you are operating the machine in temperatures Note: SAE 10W-30 is the preferred viscosity grade
below −20°C (−4°F), refer to Special Publication, for the 3116, 3126, C7, C-9,and C9 diesel engines
SEBU5898, “Cold Weather Recommendations”. This when the ambient temperature is between -18° C (0°
publication is available from your Cat dealer. F) and 40° C (104° F).
Refer to the “Lubricant Information” section in the
latest revision of the Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” for a
list of Cat engine oils and for detailed information.
This manual may be found on the web at Safety.Cat.
com.
The footnotes are a key part of the tables. Read ALL
footnotes that pertain to the machine compartment in
question.
Selecting the Viscosity

To select the proper oil for each machine
compartment, refer to the “Lubricant Viscosity for
Ambient Temperature” table. Use the oil type AND oil
viscosity for the specific compartment at the proper
ambient temperature.
The proper oil viscosity grade is determined by the
minimum ambient temperature (the air in the
immediate vicinity of the machine). Measure the
temperature when the machine is started and while
the machine is operated. To determine the proper oil
viscosity grade, refer to the “Min” column in the table.
This information reflects the coldest ambient
temperature condition for starting a cold machine and
for operating a cold machine. Refer to the “Max”
column in the table for operating the machine at the
highest temperature that is anticipated. Unless
specified otherwise in the “Lubricant Viscosities for
Ambient Temperatures” tables, use the highest oil
viscosity that is allowed for the ambient temperature.
Machines that are operated continuously should use
oils that have the higher oil viscosity. The oils that
have the higher oil viscosity will maintain the highest
possible oil film thickness. Refer to “General
Information for Lubricants” article, “Lubricant
Viscosities” tables, and any associated footnotes.
Consult your Cat dealer if additional information is
needed.
SEBU7029-05 137
Maintenance Section
Fluids Recommendations
Table 21
Lubricant Viscosities for Ambient Temperatures
Oil Type and Performance °C °F

Compartment or System Oil Viscosities
Requirements Min Max Min Max
Cat DEO-ULS Cold Weather SAE 0W-40 −40 40 −40 104
Cat DEO-ULS SYN
SAE 5W-40 −30 50 −22 122
Cat DEO SYN
Engine Crankcase Cat DEO-ULS
SAE 10W-30 −18 40 0 104
Cat DEO
Cat DEO-ULS
SAE 15W-40 −9.5 50 15 122
Cat DEO
Cat DEO-ULS
Pump Coupling (If Equipped) SAE 10W-30 −18 40 0 104
Cat DEO
Note: API engine oil categories are backwards • Cat TDTO

compatible. Cat DEO-ULS (API CK-4) oil can be
used in all engines with some restrictions related to • Cat TDTO Cold Weather
fuel sulfur level. Cat DEO (API CI-4/API CI-4 PLUS)
can be used in engines that are Tier 3 emissions • Cat TDTO-TMS
certified and prior, and in engines that do not use
• Cat DEO-ULS SYN
aftertreatment devices.
• Cat DEO SYN
Hydraulic Systems
• Cat DEO-ULS Cold Weather
Refer to the “Lubricant Information” section in the
latest revision of the Special Publication, SEBU6250, Note: Oil drain intervals of the oils listed above are
“Caterpillar Machine Fluids Recommendations” for less than those of Cat HYDO Advanced oils. The oil
detailed information. This manual may be found on drain interval of these oils is typically 2000 hours and
the web at Safety.Cat.com. up to a maximum of 4000 hours. An exception is Cat
TDTO Cold Weather oil which allows 6000 hours or
The following are the preferred oils for use in most higher oil drain interval. S·O·S Services oil analysis is
Cat machine hydraulic systems: required when the oils listed above are used in Cat
hydraulic system components and hydrostatic
• Cat HYDO Advanced 10 SAE 10W
transmissions.
• Cat HYDO Advanced 30 SAE 30W
• Cat BIO HYDO Advanced
Cat HYDO Advanced oils allow 6000 hours or
higher oil drain intervals for most applications.
S·O·S Services oil analysis is recommended when
the oil drain interval is increased to 6000 hours or
higher. In comparison, non-Cat commercial hydraulic
oils (second choice oils) allow 2000 hours oil drain
interval. Itis recommended to followthe maintenance
interval schedule for oil filter changes and for oil
sampling that is stated in the Operation and
Maintenance Manual for your particular machine.
Consult your Cat dealer for details. When switching
to Cat HYDO Advanced fluids, cross contamination
with the previous oil should be kept to less than 10%.
Second choice oils are listed below.
• Cat MTO
• Cat DEO
• Cat DEO-ULS
138 SEBU7029-05
Maintenance Section
Table 22
Oil Type and Performance °C °F

Compartment or System Oil Viscosities
Requirements Min Max Min Max
Cat HYDO Advanced 10
SAE 10W −20 40 −4 104
Cat TDTO
Cat HYDO Advanced 30
SAE 30 10 50 50 122
Cat TDTO
Cat BIO HYDO Advanced “ISO 46” Multi-Grade −30 50 −22 122
Cat MTO
Cat DEO-ULS SAE10W-30 −20 40 −4 104
Cat DEO
Hydraulic System
Cat DEO-ULS
SAE15W-40 −15 50 5 122
Cat DEO
Cat TDTO-TMS Multi-Grade −15 50 5 122
Cat DEO-ULS SYN
SAE 5W-40 −30 40 −22 104
Cat DEO SYN
Cat DEO-ULS Cold Weather SAE0W-40 −40 40 −40 104
Cat TDTO Cold Weather SAE 0W-20 −40 40 −40 104
Other Fluid Applications

Table 23
Excavators, Front Shovels, Mass Excavators, Demolition Excavators, and Track Material Handlers
Compartment or Oil Type and Perform- °C °F

Oil Viscosity Grade
System ance Requirements Min Max Min Max
SAE 0W-20 -40 0 -40 32
SAE 0W-30 -40 10 -40 50
Cat TDTO
SAE 5W-30 -30 10 -22 50
Cat TDTO-TMS
Final Drives and Swing
Cat TDTO SYN Cold SAE 10W −30 0 -22 32
Drives
Weather
SAE 30 −25 25 −13 77
commercial TO-4
SAE 50 -15 50 5 122
Cat TDTO-TMS −30 25 -22 77
SAE 0W-20 −40 0 −40 32
SAE 0W-30 −40 10 −40 50
Cat TDTO SAE 5W-30 −35 0 −31 32

Track Roller Frame Recoil Cat TDTO-TMS SAE 10W −30 0 −22 32
Spring and Pivot Shaft Cat TDTO SYN Cold
Bearings Weather SAE 30 −20 25 −4 77
commercial TO-4 SAE 40 −10 40 14 104
SAE 50 0 50 32 122
Cat TDTO-TMS −25 25 −13 77
(continued)
SEBU7029-05 139
Maintenance Section
(Table 23, contd)


Oil Viscosity Grade
Cat DEO (single grade) SAE 30 −20 25 −4 77
Cat DEO SYN
Cat DEO-ULS SYN
Track Idlers and Track
Cat ECF-1-a
Rollers SAE 5W-40 −35 40 −31 104
Cat ECF-2
Cat ECF-3
API CF
Table 24

Oil Viscosity Grade
Cat Full Synthetic Multi- SAE 0W40(1) -40 50 -40 122
grade DEO
commercial Full Synthetic
Multigrade Diesel Engine SAE 5W40(1) -40 50 -40 122
Variable Pitch Flexxaire Oil meeting either Cat ECF-
Fan (If Equipped) 1 or API CG-4
Caterpillar Non-Synthetic SAE 30(2) -15 25 -5 77
TO-4
SAE 50(2) −10 50 14 122
(1) This is the first choice. Full synthetic oils are recommended. Synthetic oils may provide longer service life for the fan. Synthetic oils allow for
increased service intervals over non-synthetic oils.
(2) This is the second choice. Caterpillar TDTO is acceptable. Commercial oils that meet the TO-4 specification are also acceptable.TDTO is
non-synthetic. Commercial TO-4 oils are typically non-synthetic.
Special Lubricants
Grease
To use a non-Cat grease, the supplier must certify
that the lubricant is compatible with Cat grease.
Each pin joint should be flushed with the new grease.
Ensure that all old grease is removed. Failure to meet
this requirement may lead to failure of a pin joint.
Table 25
Recommended Grease
°C °F
Compartment or System Grease Type NLGI Grade
Min Max Min Max
Cat Prime Application
NLGI Grade 2 −20 140 −4 284
Grease
External Lubrication Points
Cat Extreme Application NLGI Grade 1 −20 140 −4 284
Grease NLGI Grade 2 −15 140 +5 284
(continued)
140 SEBU7029-05
Maintenance Section
(Table 25, contd)

Recommended Grease
°C °F
Min Max Min Max
Cat Extreme Application
NLGI Grade 0.5 -50 130 -58 266
Grease-Artic
Cat Extreme Application
NLGI Grade 2 −10 140 +14 284
Grease-Desert
Cat Utility Grease NLGI Grade 2 −20 140 −4 284
Cat Ball Bearing Grease NLGI Grade 2 −20 160 −4 320
Grease for the Autolube System (if Equipped)
The grease used with the automatic lubrication

system must not contain any graphite or PTFE.
Note: Pumpability is based on “US Steel Mobility and

Lincoln Ventmeter Tests”. Performance may vary
depending on lubrication equipment and the length of
the lines.
Reference: Refer to Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” for
additional information about grease. This manual
may be found on the web at Safety.Cat.com.
Table 26
Recommended Grease for the Autolube System
°C °F
Min Max Min Max
Cat Autolube System Cat Extreme Application NLGI Grade 1 −35 40 -31 104
Grease NLGI Grade 2 −30 50 -22 122
Diesel Fuel Recommendations • Increase the wear
Diesel fuel must meet “Caterpillar Specification for • Increase the corrosion
Distillate Fuel” and the latest versions of “ASTM
D975” or “EN 590” to ensure optimum engine • Increase the deposits
performance. Refer to Special Publication,
SEBU6250, “Caterpillar Machine Fluids • Lower fuel economy
Recommendations” for the latest fuel information and
for Cat fuel specification. This manual may be found • Shorten the time period between oil drain intervals
on the web at Safety.Cat.com. (more frequent oil drain intervals)
The preferred fuels are distillate fuels. These fuels • Increase overall operating costs
are commonly called diesel fuel, furnace oil, gas oil,
or kerosene. These fuels must meet the “Caterpillar • Negatively impact engine emissions
Specification for Distillate Diesel Fuel for Off-
Highway Diesel Engines”. Diesel Fuels that meet the Failures that result from the use of improper fuels are
Caterpillar specification will help provide maximum not Caterpillar factory defects. Therefore the cost of
engine service life and performance. repairs would not be covered by a Caterpillar
warranty.
Misfueling with fuels of high sulfur level can have
the following negative effects:
• Reduce engine efficiency and durability

SEBU7029-05 141
Maintenance Section
Capacities (Refill)
Caterpillar does not require the use of ULSD in off All the guidelines and requirements are provided in
road and machine applications that are not Tier 4/ the latest revision of Special Publication, SEBU6250,
Stage IIIB certified engines. ULSD is not required in “Caterpillar Machine Fluids Recommendations”. This
engines that are not equipped with after treatment manual may be found on the web at Safety.Cat.com.
devices.
Follow operating instructions and fuel tank inlet Coolant Information
labels, if available, to ensure that the correct fuels are
used. The information provided in this “Coolant
Recommendation” section should be used with the
Refer to Special Publication, SEBU6250, “Caterpillar “Lubricants Information” provided in the latest
Machine Fluids Recommendations” for more details revision of Special Publication, SEBU6250,
about fuels and lubricants. This manual may be “Caterpillar Machine Fluids Recommendations”. This
found on the web at Safety.Cat.com. manual may be found on the web at Safety.Cat.com.
The following two types of coolants may be used in
Fuel Additives Cat diesel engines:
Cat Diesel Fuel Conditioner and Cat Fuel System Preferred – Cat ELC (Extended Life Coolant)
Cleaner are available for use when needed. These
products are applicable to diesel and biodiesel fuels. Acceptable – Cat DEAC (Diesel Engine Antifreeze/
Consult your Cat dealer for availability. Coolant)
Biodiesel
NOTICE
Biodiesel is a fuel that can be made from various Never use water alone as a coolant. Water alone is
renewable resources that include vegetable oils, corrosive at engine operating temperatures. In addi-
animal fat, and waste cooking oil. Soybean oil and tion, water alone does not provide adequate protec-
rapeseed oil are the primary vegetable oil sources. tion against boiling or freezing.
To use any of these oils or fats as fuel, the oils or fats
are chemically processed (esterified). The water and
contaminants are removed. i01984063
U.S. distillate diesel fuel specification “ASTM D975-

09a” includes up to B5 (5 percent) biodiesel.
Currently, any diesel fuel in the U.S. may contain up
to B5 biodiesel fuel.
European distillate diesel fuel specification “EN 590”
includes up to B5 (5 percent) and in some regions up
to B7 (7 percent) biodiesel. Any diesel fuel in Europe
may contain up to B5 or in some regions up to B7
biodiesel fuel.
When biodiesel fuel is used, certain guidelines must
be followed. Biodiesel fuel can influence the engine
oil, aftertreatment devices, non-metallic, fuel system
components, and others. Biodiesel fuel has limited
storage life and has limited oxidation stability. Follow
the guidelines and requirements for engines that are
seasonally operated and for standby power
generation engines.
To reduce the risks associated with the use of
biodiesel, the final biodiesel blend and the biodiesel
fuel used must meet specific blending requirements.
Capacities (Refill)
SMCS Code: 1000; 7000
142 SEBU7029-05
Maintenance Section
S·O·S Information
Table 27
Approximate Refill Capacities
Component or System Liters US gal Imp gal Recommended Type

Cooling System 73 19 16 Caterpillar Extended Life Coolant (ELC)
Coolant Reservoir 4.5 1.2 1.0 Caterpillar Extended life Coolant (ELC)
Fuel Tank 600 156 132 No. 1 Diesel Fuel or No. 2 Diesel Fuel
API CG-4 Diesel Engine Oil (DEO) or API CF-4 Diesel
Engine Crankcase with Filter 30 7.8 6.6
Engine Oil (DEO)
Hydraulic System(1) 370 96 81 Caterpillar HYDO or Caterpillar HEES
Each Swing Drive 11 2.9 2.4 Caterpillar TDTO
Each Final Drive 15 3.9 3.3 Caterpillar TDTO
Swing Gear 41.6 11 9 Multipurpose Lithium Grease NLGI Grade 2

(1) The amount of hydraulic fluid that is needed to refill the hydraulic system after performing Operation and Maintenance Manual, “Hydraulic
System Oil - Change”
i07445339
S·O·S Information
SMCS Code: 1000; 1348; 3080; 4050; 5050; 7000;
7542-008
S·O·S Services is a highly recommended process for
Cat customers to use in order to minimize owning
and operating cost. Customers provide oil samples,
coolant samples, and other machine information. The
dealer uses the data in order to provide the customer
with recommendations for management of the
equipment. In addition, S·O·S Services can help
determine the cause of an existing product problem.
Refer to Special Publication, SEBU6250, “Caterpillar
Machine Fluid Recommendations” for detailed
information concerning S·O·S Services.
The effectiveness of S·O·S Services is dependent on
timely submission of the sample to the laboratory at
recommended intervals.
Refer to the Operation and Maintenance Manual,
“Maintenance Interval Schedule” for a specific
sampling location and a service hour maintenance
interval.
Consult your Cat dealer for complete information and
assistance in establishing an S·O·S program for your
equipment.
SEBU7029-05 143
Maintenance Section
Maintenance Support
Maintenance Support
i07746333
Welding on Machines and

Engines with Electronic
Controls
SMCS Code: 1000; 7000
Do not weld on any protective structure. If it is
necessary to repair a protective structure, contact
your Cat dealer.
Proper welding procedures are necessary to avoid
damage to the electronic controls and to the
bearings. When possible, remove the component
that must be welded from the machine or the engine
and then weld the component. If you must weld near
an electronic control on the machine or the engine,
temporarily remove the electronic control to prevent
heat related damage. The following steps should be
followed to weld on a machine or an engine with
electronic controls.
1. Turn off the engine. Place the engine start switch
in the OFF position.
2. If equipped, turn the battery disconnect switch to
the OFF position. If there is no battery disconnect
switch, remove the negative battery cable at the
battery.
NOTICE
Do NOT use electrical components (ECM or sensors)
or electronic component grounding points for ground-
ing the welder.
3. Clamp the ground cable from the welder to the

component that will be welded. Place the clamp as
close as possible to the weld. Make sure that the
electrical path from the ground cable to the
component does not go through any bearing. Use
this procedure to reduce the possibility of damage
to the following components:
• Bearings of the drive train
• Hydraulic components
• Electrical components
• Other components of the machine
4. Protect any wiring harnesses and components

from the debris and the spatter which is created
from welding.
5. Use standard welding procedures to weld the
materials together.
144 SEBU7029-05
Maintenance Section
Maintenance Interval Schedule
i08110823 “ Track Adjustment - Adjust“ . . . . . . . . . . . . . . . . . 209
Maintenance Interval Schedule “ Window Washer Reservoir - Fill“ . . . . . . . . . . . . 212
SMCS Code: 7000 “ Window Wiper - Inspect/Replace“ . . . . . . . . . . . 212
Ensure that all safety information, warnings and “ Windows - Clean“. . . . . . . . . . . . . . . . . . . . . . . . . 212
instructions are read and understood before any
operation or any maintenance procedures are Every 10 Service Hours or Daily for
performed.
First 100 Hours
The user is responsible for the performance of
maintenance, including all adjustments, the use of “ Boom, Stick and Bucket Linkage - Lubricate“ . . 151
proper lubricants, fluids, filters, and the replacement
of components due to normal wear and aging. Failure Every 10 Service Hours or Daily
to adhere to proper maintenance intervals and
procedures may result in diminished performance of “ Boom and Stick Linkage - Lubricate“ . . . . . . . . . 150
the product and/or accelerated wear of components.
“ Cooling System Coolant Level - Check“. . . . . . . 163
Use mileage, fuel consumption, service hours, or
calendar time, WHICH EVER OCCURS FIRST, in “ Engine Oil Level - Check“ . . . . . . . . . . . . . . . . . . 171
order to determine the maintenance intervals.
Products that operate in severe operating conditions “ Fuel System Water Separator - Drain“ . . . . . . . . 183
may require more frequent maintenance.
“ Fuel System Water Separator - Drain“ . . . . . . . . 182
Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be “ Fuel Tank Water and Sediment - Drain“ . . . . . . . 185
performed.
“ Hydraulic System Oil Level - Check“ . . . . . . . . . 199
When Required “ Indicators and Gauges - Test“ . . . . . . . . . . . . . . . 200
“ Adjustable Gage Undercarriage Frame - “ Radiator Core - Clean“ . . . . . . . . . . . . . . . . . . . . 202
Lubricate“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
“ Radiator Core - Clean“ . . . . . . . . . . . . . . . . . . . . 201
“ Air Conditioner/Cab Heater Filter (Recirculation) -
Inspect/Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . . 147 “ Seat Belt - Inspect“ . . . . . . . . . . . . . . . . . . . . . . . 204
“ Battery - Recycle“ . . . . . . . . . . . . . . . . . . . . . . . . 147 “ Track Adjustment - Inspect“ . . . . . . . . . . . . . . . . 210
“ Battery or Battery Cable - Inspect/Replace“. . . . 148 “ Travel Alarm - Test“ . . . . . . . . . . . . . . . . . . . . . . . 211
“ Boom Base Pins - Lubricate“ . . . . . . . . . . . . . . . 149 “ Undercarriage - Check“ . . . . . . . . . . . . . . . . . . . . 211
“ Bucket Linkage - Inspect/Adjust“ . . . . . . . . . . . . 153 Every 10 Service Hours or Daily for

“ Bucket Tips - Inspect/Replace“ . . . . . . . . . . . . . . 154 Machines Used in Severe
“ Cab Air Filter (Fresh Air) - Clean/Replace“ . . . . 158 Applications
“ Circuit Breakers - Reset“ . . . . . . . . . . . . . . . . . . . 158 “ Boom, Stick and Bucket Linkage - Lubricate“ . . 151
“ Counterweight Removal Chain - Clean“. . . . . . . 166
Every 50 Service Hours or Weekly
“ Engine Air Filter Primary Element - Clean/
Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 “ Boom, Stick and Bucket Linkage - Lubricate“ . . 151
“ Engine Air Filter Secondary Element - Every 100 Service Hours of

Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Continuous Hammer Use
“ Engine Air Precleaner - Clean“ . . . . . . . . . . . . . . 170
“ Hydraulic System Oil Filter - Replace“ . . . . . . . . 195
“ Ether Starting Aid Cylinder - Replace“ . . . . . . . . 175
“ Fuses - Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . 185 Initial 250 Service Hours
“ Oil Filter - Inspect“ . . . . . . . . . . . . . . . . . . . . . . . . 201 “ Engine Valve Lash and Fuel Injector Timing -
Check“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
SEBU7029-05 145
Maintenance Section
“ Final Drive Oil - Change“ . . . . . . . . . . . . . . . . . . . 176 “ Swing Drive Oil Level - Check“ . . . . . . . . . . . . . . 206
Every 250 Service Hours of Partial
“ Swing Drive Oil - Change“. . . . . . . . . . . . . . . . . . 205 Hammer Use (50% of Service
Every 250 Service Hours Hours)
“ Cooling System Coolant Sample (Level 1) -
Obtain“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Initial 500 Hours (for New Systems,
“ Counterweight Removal Chain - Inspect“ . . . . . 165
Refilled Systems, and Converted
“ Engine Oil Sample - Obtain“ . . . . . . . . . . . . . . . . 174 Systems)
“ Final Drive Oil Sample - Obtain“ . . . . . . . . . . . . . 178
Obtain“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Every 250 Service Hours or
Monthly Every 500 Service Hours
“ Adjustable Gage Undercarriage Frame - “ Hydraulic System Oil Sample - Obtain“ . . . . . . . 200
Lubricate“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
“ Swing Drive Oil Sample - Obtain“ . . . . . . . . . . . . 207
“ Belts - Inspect/Adjust/Replace“. . . . . . . . . . . . . . 148
“ Condenser (Refrigerant) - Clean“ . . . . . . . . . . . . 158 Every 500 Service Hours or 3
Months
“ Cooling System Hoses - Inspect“ . . . . . . . . . . . . 164
“ Engine Crankcase Breather - Clean“ . . . . . . . . . 171
“ Engine Oil and Filter - Change“. . . . . . . . . . . . . . 172
“ Fuel System - Prime“ . . . . . . . . . . . . . . . . . . . . . . 177
“ Final Drive Oil Level - Check“ . . . . . . . . . . . . . . . 177
“ Fuel Tank Cap and Strainer - Clean“ . . . . . . . . . 184
“ Fuel System Primary Filter (Water Separator)
Element - Replace“ . . . . . . . . . . . . . . . . . . . . . . . . 178 “ Hydraulic System Oil Filter - Replace“ . . . . . . . . 195
“ Fuel System Primary Filter/Water Separator -
Clean/Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 Every 600 Service Hours of
“ Fuel System Primary Filter/Water Separator - Continuous Hammer Use
Clean/Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
“ Hydraulic System Oil - Change“ . . . . . . . . . . . . . 186
“ Fuel System Secondary Filter - Replace“. . . . . . 181
Every 1000 Service Hours or 6
“ (INACTIVE) Fuel System Water Separator Element
- Replace (INACTIVE)“ . . . . . . . . . . . . . . . . . . . . . 183 Months
“ Swing Bearing - Lubricate“ . . . . . . . . . . . . . . . . . 205 “ Battery - Clean“ . . . . . . . . . . . . . . . . . . . . . . . . . . 147
“ Battery Hold-Down - Tighten“ . . . . . . . . . . . . . . . 148
“ Counterweight Removal Chain - Lubricate“ . . . . 166
“ Hydraulic System Oil Filter (Return) -
Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
146 SEBU7029-05
Maintenance Section
“ Swing Drive Oil - Change“. . . . . . . . . . . . . . . . . . 205
Every 1000 Service Hours of Partial

Hammer Use (50% of Service
Hours)
Every 2000 Service Hours or 1 Year

“ Engine Valve Lash and Fuel Injector Timing -
Check“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
“ Engine Valve Rotators - Inspect“ . . . . . . . . . . . . 175
“ Final Drive Oil - Change“ . . . . . . . . . . . . . . . . . . . 176
“ Receiver Dryer (Refrigerant) - Replace“. . . . . . . 203
“ Swing Gear - Lubricate“. . . . . . . . . . . . . . . . . . . . 208
Every Year
Obtain“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Every 3 Years After Date of

Installation or Every 5 Years After
Date of Manufacture
“ Seat Belt - Replace“. . . . . . . . . . . . . . . . . . . . . . . 204

Years

Years
“ Cooling System Coolant Extender (ELC) -
Add“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
“ Cooling System Coolant Extender (ELC) -
Add“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Every 12 000 Service Hours or 6

Years
“ Cooling System Coolant (ELC) - Change“ . . . . . 160
SEBU7029-05 147
Maintenance Section
Adjustable Gage Undercarriage Frame - Lubricate
i00910226
Adjustable Gage
Undercarriage Frame -
Lubricate
(If Equipped)
SMCS Code: 4150-086-AE
The air conditioner filter is located on the lower left

side of the cab behind the seat.
1. Slide the operator seat forward.
2. Loosen the bolts and remove the cover.
3. Slide the filter element outward.
4. Clean the filter element with a maximum of
200 kPa (30 psi) pressure air.
5. After you clean the filter element, inspect the filter
element. If the filter element is damaged or badly
contaminated, use a new filter element. Make sure
that the filter element is dry.
Illustration 291 g00464474 6. Install the filter element and the cover.
(A) Fittings
(B) Carbody i00934864
(C) Left track
(D) Right track
Battery - Clean
The top and the bottom of carbody (B) has sixteen SMCS Code: 1401-070
lubrication grease points.
Clean the battery surface with a clean cloth. Keep the
1. Apply lubricant through fittings (A) on the top and terminals clean and keep the terminals coated with
the bottom of the carbody. petroleum jelly. Install the post cover after you coat
the terminal post with petroleum jelly.
i01546851
i07746330
Air Conditioner/Cab Heater
Filter (Recirculation) - Inspect/ Battery - Recycle
SMCS Code: 1401-561
Replace
SMCS Code: 1054-510-A/C; 1054-040-A/C Always recycle a battery. Never discard a battery.
Always return used batteries to one of the following
NOTICE locations:
An air recirculation filter element plugged with dust
will result in decreased performance and service life • A battery supplier
to the air conditioner or cab heater.
• An authorized battery collection facility
To prevent decreased performance, clean the filter el-
ement, as required. • Recycling facility
148 SEBU7029-05
Maintenance Section
Battery Hold-Down - Tighten
i00934872 i01955418
Battery Hold-Down - Tighten Belts - Inspect/Adjust/Replace

SMCS Code: 7257 SMCS Code: 1356; 1357; 1357-040; 1357-510;
1357-025; 1358-025; 1358-510; 1359-510; 1359-
Tighten the hold-downs for the battery in order to 040; 1359-025; 1359-510-BE; 1359-025-BE; 1359-
prevent the batteries from moving during machine 040-BE; 1361-025; 1361-025-BE; 1361-040-BE;
operation. 1361-510; 1361-040; 1361-510-BE; 1397-025; 1397-
040; 1397-510; 1405-040; 1405-025-BE; 1405-036;
i04064489 1405-510-BE; 1405-510; 1405-025; 1405-040-BE;
1802-025; 1802-510
Battery or Battery Cable -
Your engine can be equipped with the following belts:
Inspect/Replace
SMCS Code: 1401-040; 1401; 1401-510; 1401-561; • Alternator belt
1402-040; 1402-510 • Air conditioner belt
For maximum engine performance and maximum
utilization of your engine, inspect the belts for wear
Personal injury can result from battery fumes or and for cracking. Check the belt tension. Adjust the
explosion. belt tension in order to minimize belt slippage. Belt
slippage will decrease the belt life. Belt slippage will
Batteries give off flammable fumes that can ex- also cause poor performance of the alternator and of
plode. Electrolyte is an acid and can cause per- any driven equipment.
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
explosion.
Always wear protective glasses when working
with batteries.
1. Turn all of the switches to the OFF position. Turn

the engine start switch key to the OFF position.
2. Turn the battery disconnect switch to the OFF
position. Remove the key. Illustration 293 g00464178
3. Disconnect the negative battery cable at the (1) Air conditioner compressor
(2) Alternator
battery.
4. Disconnect the positive battery cable at the To check the belt tension, apply 110 N (25 lb)of force
midway between the pulleys. Correctly adjusted belts
battery. will deflect 14 to 20 mm (9/16 to 13/16 inch).
5. Disconnect the battery cables at the battery
If new belts are installed, recheck the belt adjustment
disconnect switch. The battery disconnect switch after 30 minutes of operation. If two belts or more are
is connected to the machine frame. required for an application, replace the belts in belt
sets. If only one belt of a matched set is replaced, the
6. Make necessary repairs or replace the battery. new belt will carry more load. This is due to the fact
7. Connect the battery cable at the battery disconnect that the older belts are stretched. The additional load
on the new belt could cause the new belt to break.
switch.
8. Connect the positive battery cable of the battery.
9. Connect the negative battery cable of the battery.
10. Install the key and turn the battery disconnect
SEBU7029-05 149
Maintenance Section
Boom Base Pins - Lubricate
Alternator Belt and Air Conditioner

Belt
The 345B and 345B L Excavators are equipped with

a belt tightener that automatically adjusts the belt to
Illustration 294 g00278210 the correct position.
Unlatch the engine hood and raise the engine hood. The following belts must be replaced:
• Worn belts
• Damaged belts
• Belts that cannot be adjusted to the correct

tension
Close the engine hood and latch the engine hood.
i03865131
Boom Base Pins - Lubricate

SMCS Code: 6501-086
Illustration 295 g00354002 Note: Caterpillar recommends the use of 5%

molybdenum grease for lubricating the boom linkage.
Note: For maximum engine performance and Refer to Special Publication, SEBU6250, “Caterpillar
maximum utilization of your engine, inspect the belts Machine Fluids Recommendations” for more
for wear and for cracking. Check the belt tension. If information on molybdenum grease.
the belt tension is too loose, the battery may not
charge correctly. Insufficient belt tension may cause When the boom pin is replaced, lubricate the new
wear. If the belt tension is too tight, bearing damage boom pin.
or belt damage may occur.
Note: To check the belt tension, apply 110 N (25 lb)

of force midway between the pulleys. Correctly
adjusted belts will deflect 13 to 19 mm
(1/2 to 3/4 inch).
150 SEBU7029-05
Maintenance Section
Boom and Stick Linkage - Lubricate
Note: For some applications of the machine, the

repeated duty cycle of the front linkage may only
require small angular movements of the boom or
stick. There might not be enough angular motion in
order to distribute the grease between the pin and
the bearing. The operator should operate the boom,
the stick and the work tool in order to distribute the
grease within the joint assemblies.
Note: Caterpillar recommends the use of 5%
molybdenum grease for lubricating the boom and
stick linkage. Refer to Special Publication,
SEBU6250, “Caterpillar Machine Fluids
Recommendations” for more information on
molybdenum grease.
1. Park the machine on a level surface and lower the

bucket to the ground.
Wipe all fittings before you apply lubricant.

Typical example
(1) Vent plug
(2) Fitting
Note: Vent plug (1) and fitting (2) are on the base of
the boom.
2. Remove vent plug (1).

3. Apply lubricant through fitting (2) until lubricant
comes out of the plug hole.
4. Install vent plug (1).
i02288188 Illustration 300 g00470094
Boom and Stick Linkage - 1. Apply lubricant through the fitting at the base of
each boom cylinder.
Lubricate
SMCS Code: 6501-086; 6502-086
S/N: 2NW1–Up
SEBU7029-05 151
Maintenance Section
Boom, Stick and Bucket Linkage - Lubricate
2. The fittings are at the base of the boom. To 4. This fitting is located at the end of the stick. Apply
lubricate the lower boom bearings, apply lubricant lubricant through fitting (6) in order to lubricate the
through fittings (1). To lubricate the boom cylinder connection point between the stick and the work
rod, apply lubricant through fittings (2). To lubricate tool.
the stick cylinder head, apply lubricant through
fittings (3). i03865613
Note: To ensure proper lubrication of the lower boom Boom, Stick and Bucket
bearings and of the boom cylinder rod end bearings,
lubricant should be applied through fittings (1) and Linkage - Lubricate
(2). Apply lubricant first when the boom is raised and SMCS Code: 6501-086; 6502-086; 6513-086
any work tool is suspended. Then apply lubricant
when the boom is lowered and the work tool is rested S/N: 4SS1–Up
on the ground with a slight downward pressure.
S/N: 9GS1–Up
Note: Caterpillar recommends the use of 5%

molybdenum grease for lubricating the boom, stick,
and bucket linkage. Refer to Special Publication,
SEBU6250, “Caterpillar Machine Fluids
molybdenum grease.
3. The fittings are located at the end of the stick.

Apply lubricant through fittings (5) in order to
lubricate the connection point of the boom and the
stick. Apply lubricant through fittings (4) in order to
lubricate the rod end of the stick cylinder.
Wipe all fittings before you apply lubricant.

152 SEBU7029-05
Maintenance Section
Boom, Stick and Bucket Linkage - Lubricate
1. Apply lubricant through the fitting at the base of 3. Apply lubricant through fittings (6) and (7). These
each boom cylinder. fittings are on the bucket.
4. Apply lubricant through fittings (8) and (9). These
fittings are on the stick.
5. Apply lubricant through fittings (10), (11), and (12).
These fittings are on the link.
2. The fittings are at the base of the boom. The

fittings can be serviced from the platform on the
storage box. To lubricate the lower boom bearings,
apply lubricant through fittings (1) and (2). To Illustration 308 g01122102
lubricate the boom cylinder rod, apply lubricant
through fittings (3) and (4). To lubricate the stick 6. Apply lubricant through fitting (13). Fitting (13) is at
cylinder head, apply lubricant through fitting (5). the connection point of the boom and of the stick.
Note: To ensure proper lubrication of the lower boom

bearings and of the boom cylinder rod end bearings,
lubricant should be applied through fittings (1), (2),
(3), and (4). Apply lubricant first when the boom is
raised and any work tool is suspended. Then apply
lubricant when the boom is lowered and the work tool
is rested on the ground with a slight downward
pressure.
SEBU7029-05 153
Maintenance Section
Bucket Linkage - Inspect/Adjust
Unexpected machine movement can cause injury

or death.
To avoid possible machine movement, move the
hydraulic lockout control to the LOCKED position
and attach a Special Instruction, SEHS7332, “Do
Not Operate” or similar warning tag to the hy-
draulic lockout control.
NOTICE
Improperly adjusted bucket clearance could cause
galling on the contact surfaces of the bucket and
stick, resulting in excessive noise and/or damaged O-
Illustration 309 g01122103 ring seals.
7. Apply lubricant through fitting (14) on the stick

cylinder rod. Apply lubricant through fitting (15).
Fitting (15) is at the connection point of the boom
and of the stick. Apply lubricant through fitting (16)
on the bucket cylinder head end.
Grease Block on the Stick

(1) No gap. (2) Stick boss. (3) Bucket clearance. (4)
Shims. (5) Pin. (6) Plate. (7) Bolts. (8) Washers. (9)
Location. (10) Flange. (11) Bucket boss.
The clearance of the bucket control linkage on this

machine can be adjusted by shimming. If the gap
between the bucket and the stick becomes
Illustration 310 g01396894 excessive, adjust bucket clearance (3) to 0.5 to 1 mm
(0.02 to 0.04 inch).
(13) Left side connection point of boom and stick
(14) Stick cylinder rod
(15) Right side connection point of boom and stick
Two shims of different thickness are used at location
(16) Bucket cylinder head end
(9). The thicknesses of the shims are 0.5 mm
(0.02 inch) and 1.0 mm (0.04 inch).
Some machines may be equipped with a grease
block that is located on the stick. Apply lubricant
through the fittings.
i03902571
Bucket Linkage - Inspect/

Adjust
SMCS Code: 6513-025; 6513-040
S/N: 4SS1–Up
S/N: 9GS1–Up
154 SEBU7029-05
Maintenance Section
Bucket Tips - Inspect/Replace
S/N: 9GS1–Up
Block the bucket before changing the bucket

teeth.
To prevent possible injury to the eyes, wear a pro-
tective face shield when striking the pin.
The pin, when struck, can fly out and cause injury
to nearby personnel.
Bucket Tips
Area for linkage adjustment
1. Position the machine on a level surface and lower

the bucket to the ground.
2. Slowly operate the swing control lever until stick
boss (2) and the bucket boss (11) are in full face
contact at no gap (1). This will help to determine
the total clearance of the connection point of the
stick and of the bucket.
position. Stop the engine.
4. Measure bucket clearance (3), which is the
existing total clearance. Illustration 313 g01577934
(1) Usable tip
5. Determine the number of shims that need to be (2) Replaceable bucket tip
removed from shims (4) by using the following (3) Overworn tip
calculation:
Check the bucket tips for wear. If the bucket tip has a
Subtract 0.5 mm (0.02 inch) or 1.0 mm hole, replace the bucket tip.
(0.04 inch) from bucket clearance (3).
1. Remove the pin from the bucket tip. The pin can be
6. Remove the appropriate number of shims at removed by one of the following methods.
location (9) in order to meet the above thickness.
Make sure that you use a minimum of three • Use a hammer and a punch from the retainer
0.5 mm (0.02 inch) shims. To remove the shims, side of the bucket to drive out the pin.
remove bolts (7), washers (8), and plate (6).
• Use a Pin-Master. Follow Step 1a through Step
7. After the correct number of shims has been 1c for the procedure.
removed and pin (5) is aligned with the pin hole,
install plate (6), washers (8), and bolts (7). Tighten
bolts (7) to a torque of 240 ± 40 N·m
(175 ± 30 lb ft).
8. After installation, make sure that bucket clearance
(3) is still correct.
i03574842

SMCS Code: 6805-510; 6805-040
S/N: 4SS1–Up
SEBU7029-05 155
Maintenance Section
4. Install the new bucket tip onto the adapter.

Note: The bucket tips can be rotated by 180 degrees
in order to allow the tip to wear evenly. You may also
Illustration 314 g01577993 move the tips from the outside teeth to the inside
(4) Back of Pin-Master teeth. Check the tips often. If wear is present on the
(5) Extractor tips, rotate the tips. The outside teeth generate the
most wear.
a. Place the Pin-Master on the bucket tip.
5. Drive the pin through the bucket tip. The pin can be
b. Align extractor (5) with the pin.
installed by using one of the following methods:
c. Strike the Pin-Master at the back of the tool (4)
and remove the pin. • From the same side of the retainer, drive the
pin through the bucket tip, the retainer
Note: Discard the old pin and the retainer assembly, and the adapter.
assembly. When you change tips, use a new pin
and a new retainer assembly. Refer to the • Use a Pin-Master. Follow Step 5a through Step
appropriate parts manual for your machine. 5e for the procedure.

(8) Pin
(6) Retainer assembly
(7) Adapter
a. Insert pin (8) through the bucket tip.
2. Clean the adapter and the pin.
3. Fit retainer assembly (6) into the counterbore that
is in the side of adapter (7). Make sure that the
face of the retainer assembly with the marking
“OUTSIDE” is visible.
156 SEBU7029-05
Maintenance Section
e. Strike the end of the tool until the pin is fully

inserted.
Side Cutters
b. Place the Pin-Master over the bucket tips so

that the pin will fit into the counterbore of the pin
holder (9).
c. Strike the Pin-Master with a hammer at the Illustration 320 g01579693
back of the tool (4) in order to insert the pin. Bucket With Side Cutters
d. Slide pin holder (9) away from the pin and 1. Remove the mounting bolts and the side cutters
rotate the tool slightly in order to align pin setter (11).
(10) with the pin.
2. Clean the mounting surface of the side plate on the
bucket and of the side cutter. Remove any burrs or
protrusions on the mating surfaces.

Final assembly of pin into bucket tip
SEBU7029-05 157
Maintenance Section

(12) Shear ledge on a side cutter
(13) Side plate on a bucket
(B) 0.0 mm (0.0 inch)
Note: Some side cutters may be rotated for

additional wear.
3. Install the side cutter.
Note: Certain bolts may require thread compound.

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

158 SEBU7029-05
Maintenance Section
Cab Air Filter (Fresh Air) - Clean/Replace
4. Align two pin holes of the new protector and the i00143074
side plate. Hit the pin from the retainer side of the
bucket. Circuit Breakers - Reset
Note: If the pin and/or the retainer are worn, replace SMCS Code: 1420-529
the pin and/or the retainer.
i01546947
Cab Air Filter (Fresh Air) -

Clean/Replace
SMCS Code: 7342-070; 7342-510

The circuit breakers are inside the access door on
the front left of the machine.
Alternator Circuit (1) – This circuit

breaker is designed to protect the
alternator. If the batteries are installed
with reversed polarity, the circuit breaker would
prevent the alternator from damaging the
Illustration 324 g00102781 rectifier.
The cab air filter is behind the cab. Main Circuit (2) – This circuit breaker is
1. Loosen two bolts (1) and remove filter cover (2) designed to protect the wires between
the batteries and the fuses. If the wires
and air filter (3).
are shorted to the machine's body, this circuit
2. Clean the air filter with a maximum of 200 kPa breaker would minimize the damage to the wires.
(30 psi) pressure air.
Both circuit breakers have a capacity of 80 Amp.
3. After you clean the air filter, inspect the air filter. If
the air filter is damaged or badly contaminated, Circuit Breaker Reset – Push in the button in order
to reset the circuit breaker. If the electrical system is
use a new air filter. working properly, the button will remain depressed. If
4. Install the air filter and the filter cover. the button does not remain depressed, check the
appropriate electrical circuit. Repair the electrical
Note: Make sure that the arrow on top of the air filter circuit, if necessary.
is facing forward.
i01041005
Condenser (Refrigerant) -
Clean
SMCS Code: 1805-070
NOTICE
If excessively dirty, clean condenser with a brush. To
prevent damage or bending of the fins, do not use a
stiff brush.
Repair the fins if found defective.
SEBU7029-05 159
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
Note: Obtain a Coolant Sample (Level 1) if the

cooling system is filled with any other coolant
instead of Cat ELC. This includes the following
types of coolants.
• Commercial long life coolants that meet the
Caterpillar Engine Coolant Specification -1
(Caterpillar EC-1)
• Cat Diesel Engine Antifreeze/Coolant (DEAC)
• Commercial heavy-duty antifreeze/coolant

solution
NOTICE
Illustration 326 g00102191 Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sam-
1. Open the access door on the left side of the pling. Using the same pump for both types of sam-
ples may contaminate the samples that are being
machine. drawn. This contaminate may cause a false analysis
and an incorrect interpretation that could lead to con-
cerns by both dealers and customers.
Note: Level 1 results may indicate a need for

Level 2 Analysis.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Illustration 327 g00537515 Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
Typical example products.
2. Inspect the condenser for debris. Clean the Dispose of all fluids according to local regulations
condenser, if necessary. and mandates.
3. Use clean water to wash off all dust and dirt from Obtain the sample of the coolant as close as possible
the condenser. to the recommended sampling interval. The
recommended sampling interval for Level 1 Coolant
4. Close the access door. Analysis is every 250 service hours. In order to
receive the full effect of S·O·S analysis, you must
i02425978 establish a consistent trend of data. In order to
establish a pertinent history of data, perform
Cooling System Coolant consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from
Sample (Level 1) - Obtain your Caterpillar dealer.
SMCS Code: 1395-554; 1395-008; 7542 Use the following guidelines for proper sampling of
the coolant:
Note: It is not necessary to obtain a Coolant
Sample (Level 1) if the cooling system is filled • Complete the information on the label for the
with Cat ELC (Extended Life Coolant). Cooling sampling bottle before you begin to take the
systems that are filled with Cat ELC should have a samples.
Coolant Sample (Level 2) that is obtained at the
recommended interval that is stated in the • Keep the unused sampling bottles stored in plastic
Maintenance Interval Schedule. bags.
160 SEBU7029-05
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
• Keep the lids on empty sampling bottles until you i07349178

are ready to collect the sample.
Cooling System Coolant
• Place the sample in the mailing tube immediately
after obtaining the sample in order to avoid Sample (Level 2) - Obtain
contamination. SMCS Code: 1395-008; 1395-554; 7542
• Never collect samples from expansion bottles. Reference: Refer to Operation and Maintenance
• Never collect samples from the drain for a Manual, “Cooling System Coolant Sample (Level 1) -
system. Obtain” for the guidelines for proper sampling of the
coolant.
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. Supplies for
collecting samples can be obtained from your Cat
dealer.
Submit the sample for Level 2 analysis.
Reference: For additional information about coolant

analysis, refer to Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” or
consult your Cat dealer.
i02014186
Cooling System Coolant (ELC)

- Change
SMCS Code: 1350-044
Pressurized System: Hot coolant can cause seri- NOTICE

ous burns. To open the cooling system filler cap, Do not change the coolant until you read and under-
stop the engine and wait until the cooling system stand the cooling system information in Special Publi-
components are cool. Loosen the cooling system cation, SEBU6250, “Caterpillar Machine Fluids
pressure cap slowly in order to relieve the Recommendations”.
pressure.
Failure to do so could result in damage to the cooling
system components.
1. The machine needs to be operated in order to
circulate the coolant. Collect the sample after a
normal workday. Collect the samples from one to NOTICE
two hours after the engine has been shut off. Mixing ELC with other products will reduce the effec-
tiveness of the coolant.
2. Start the engine momentarily in order to circulate
the coolant again. This could result in damage to cooling system
components.
3. Shut off the engine.
If Caterpillar products are not available and commer-
4. Carefully remove the radiator cap. cial products must be used, make sure they have
passed the Caterpillar EC-1 specification for pre-
5. Use a vacuum pump and draw the sample. Do not mixed or concentrate coolants and Caterpillar
allow dirt or other contaminants to enter the Extender.
sampling bottle. Fill the sampling bottle three-
fourths from the top. Do not fill the bottle
completely. Note: This machine was filled at the factory with
Caterpillar Extended Life Coolant.
6. Place the sampling bottle with the completed label
into the mailing tube. If the coolant in the machine is changed to Extended
Life Coolant from another type of coolant, see
7. Install the radiator cap. Special Publication, SEBU6250, “Caterpillar Machine
Fluids Recommendations”.
SEBU7029-05 161
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
4. Open the drain valve and allow the coolant to drain

into a suitable container. The drain valve is under
the radiator.
Note: Dispose of drained fluids according to local
regulations.
5. Flush the cooling system with clean water until the

draining water is clean.
6. Close the drain valve.
7. Add the Extended Life Coolant. See Operation and
Maintenance Manual, “Capacities (Refill)”.
8. Start the engine. Operate the engine without the
Illustration 329 g00694095 radiator cap until the thermostat opens and the
coolant level stabilizes.
1. Open the radiator cap access cover.
2. Loosen the radiator cap slowly in order to release
pressure. Remove the radiator cap.

(1) “FULL”
(2) “LOW”
Illustration 330 g00101813 9. Check the coolant reservoir. Maintain the coolant
level between the “FULL” mark and the “LOW”
3. Open the radiator access door. mark.
10. Install the radiator cap.
11. Stop the engine.
12. Close the radiator access door.
i02014215

Extender (ELC) - Add
SMCS Code: 1352; 1353; 1395
Use Caterpillar Extended Life Coolant (ELC) when
you add coolant to the cooling system. See Special
Publication, SEBU6250, “Caterpillar Machine Fluids
Recommendations” for all cooling system
requirements.
“General Hazard Information” for information that Use a Coolant Conditioner Test Kit in order to check
pertains to containing fluid spillage. the concentration of the coolant.
162 SEBU7029-05
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
4. It may be necessary to drain some coolant from

NOTICE
Mixing ELC with other products will reduce the effec- the radiator so that Extender can be added to the
tiveness of the coolant. cooling system.
This could result in damage to cooling system Note: Dispose of drained fluids according to local
components. regulations.
If Caterpillar products are not available and commer- 5. Add 1.7 L (24 oz) of Extender to the cooling
cial products must be used, make sure they have
system.
passed the Caterpillar EC-1 specification for pre-
mixed or concentrate coolants and Caterpillar 6. Replace the radiator cap if the cap gasket is
Extender. damaged. Install the radiator cap.
Note: This machine was filled at the factory with i08129124

Caterpillar Extended Life Coolant.
Extender (ELC) - Add
SMCS Code: 1352; 1353; 1395
Personal injury can result from hot coolant,

steam and alkali.
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines to
heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove cooling system pressure cap slowly to
relieve pressure only when engine is stopped and
Illustration 333 g00101813 cooling system pressure cap is cool enough to
touch with your bare hand.
1. Open the radiator access door.
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
When a Caterpillar Extended Life Coolant (ELC) is

used, an Extender must be added to the cooling
system. See the Special Publication, SEBU6250,
“Coolant Recommendations” for all cooling system
requirements.
Use a coolant conditioner test kit to check the
concentration of the coolant.

3. Loosen the radiator cap slowly in order to relieve
pressure. Remove the radiator cap.
“General Hazard Information” for information on
containing fluid spillage.
SEBU7029-05 163
Maintenance Section
Cooling System Coolant Level - Check
i02586603
NOTICE
Use only Caterpillar products or commercial products
that have passed Caterpillar EC-1 specification for Cooling System Coolant Level
pre-mixed or concentrated coolants. - Check
Use only Caterpillar Extender with Extended Life SMCS Code: 1350-535-FLV; 1350-040; 1395-535-
Coolant. FLV
Mixing Extended Life Coolant with other products re-
duces the Extended Life Coolant service life. Failure
to follow the recommendations can reduce cooling
system components life unless appropriate corrective Personal injury can result from hot coolant,
action is performed. steam and alkali.
At operating temperature, engine coolant is hot
Note: Refer to Special Publication, SEBU6250, and under pressure. The radiator and all lines to
“Extended Life Coolant (ELC)” for instructions heaters or the engine contain hot coolant or
regarding contamination of the ELC Cooling System. steam. Any contact can cause severe burns.
1. Open the rear access door on the left side of the Remove cooling system pressure cap slowly to
relieve pressure only when engine is stopped and
machine. cooling system pressure cap is cool enough to
touch with your bare hand.
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
1. Open the access doors on the left side of the

machine.

3. Loosen the radiator cap slowly to relieve pressure.
Remove the radiator cap.
“General Hazard Information” for information that
pertains to containing fluid spillage.
4. It may be necessary to drain some coolant from

the radiator so that Extender can be added to the
cooling system.
2. Maintain the coolant level between the marks on
Note: Dispose of drained fluids according to local the coolant reservoir.
regulations.
5. Add 0.7 L (24 oz) of Extender to the cooling “General Hazard Information” for information that
system. pertains to containing fluid spillage.
6. Replace the radiator cap if the cap gasket is 3. If additional coolant is necessary, remove the
damaged. Install the radiator cap. coolant filler cap and add the appropriate coolant
mixture. Install the filler cap.
7. Close the access door.
164 SEBU7029-05
Maintenance Section
Cooling System Hoses - Inspect
i00560630
Cooling System Hoses -

Inspect
SMCS Code: 1380-040
4. If the coolant reservoir is empty, open the radiator

cap access cover.
5. Slowly loosen the cooling system pressure cap.
Add coolant to the radiator.
(1) Bolts. (2) Washers.
1. Remove six bolts (1) and washers (2). Remove the

engine hood.
6. Inspect the condition of the cap gasket. Replace

the cap gasket, if necessary.
7. Install the cooling system pressure cap.
8. Inspect the radiator core for debris and clean the
radiator core, if necessary. Refer to Operation and 2. Inspect all hoses for leaks due to cracking, for
Maintenance, “Radiator Core - Clean” for more softness next to the clamps, and for loose clamps.
information on cleaning the radiator core.
3. Replace hoses that are cracked or soft and tighten
any loose clamps.
SEBU7029-05 165
Maintenance Section
Counterweight Removal Chain - Inspect
Replace the Hoses 4. Add coolant until the level is between the marks on
the coolant reservoir.
i03481843
Counterweight Removal Chain

- Inspect
(If Equipped)
SMCS Code: 7056-040-CX
Proper operation of the Counterweight Removal

System depends on a properly lubricated coun-
terweight chain. If the chain is not lubricated
Illustration 341 g00115407 properly, the chain may rust and seize during the
removal operation. A seized chain can fracture
1. Loosen the radiator cap slowly in order to relieve and result in complete failure of the chain. The
any pressure. Remove the radiator cap. counterweight can then suddenly fall which can
result in personal injury or death.
“General Hazard Information” for information that Use an approved ladder or platform when lubri-
cating the upper portion of the chain.
If seizure of the chain occurs during counter-
2. Drain the coolant from the cooling system to a weight removal, stop the operation of the coun-
level that is below the hose that is being replaced. terweight removal system and contact your
nearest dealer for chain replacement.
regulations. The counterweight removal chain must be clean and
free from rust. A chain with dirt or rust cannot be
3. Loosen the hose clamps and disconnect the wound correctly.
damaged hose. Replace the damaged hose with a
1. Inspect the chain.
new hose.
2. Make sure that the chain is properly lubricated.
3. Make sure that the chain is free of defects, rust, or
foreign contaminants.
166 SEBU7029-05
Maintenance Section
Counterweight Removal Chain - Clean
i03591653 i03591620
Counterweight Removal Chain Counterweight Removal Chain

- Clean - Lubricate
(If Equipped) (If Equipped)
SMCS Code: 7056-070-CX SMCS Code: 7056-086-CX
Proper operation of the Counterweight Removal Proper operation of the Counterweight Removal
System depends on a properly lubricated coun- System depends on a properly lubricated coun-
terweight chain. If the chain is not lubricated terweight chain. If the chain is not lubricated
properly, the chain may rust and seize during the properly, the chain may rust and seize during the
removal operation. A seized chain can fracture removal operation. A seized chain can fracture
and result in complete failure of the chain. The and result in complete failure of the chain. The
counterweight can then suddenly fall which can counterweight can then suddenly fall which can
result in personal injury or death. result in personal injury or death.
Use an approved ladder or platform when lubri- Use an approved ladder or platform when lubri-
cating the upper portion of the chain. cating the upper portion of the chain.
If seizure of the chain occurs during counter- If seizure of the chain occurs during counter-
weight removal, stop the operation of the coun- weight removal, stop the operation of the coun-
terweight removal system and contact your terweight removal system and contact your
nearest dealer for chain replacement. nearest dealer for chain replacement.
The counterweight removal chain must be clean and The counterweight removal chain must be clean and
free from rust. A chain with dirt or rust cannot be free from rust. A chain with dirt or rust cannot be
wound correctly. wound correctly.
1. If necessary, remove the entire chain assembly in 1. Inspect the chain.
order to properly clean the chain assembly of rust
2. Remove any foreign material and rust from the
and foreign contaminants.
chain.
2. Clean the chain assembly with a clean,
nonflammable solvent and a wire brush.
3. Allow the chain assembly to dry. Lubricate the
counterweight removal chain. Refer to Operation
and Maintenance Manual, “Counterweight
Removal Chain - Lubricate” for the proper
procedure.
4. If the chain assembly was removed, install the
chain assembly.
Note: Always clean the chain of rust and foreign
contaminants.

(1) Link plate edge. (2) Roller.
3. Lubricate the surfaces between each link plate

edge (1) and roller (2) with SAE 30 engine oil.
Note: Always lubricate the chain during removal of

the counterweight, after the counterweight is lowered
to the blocks on the ground.
SEBU7029-05 167
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
i02354405
Engine Air Filter Primary

Element - Clean/Replace
SMCS Code: 1054-510; 1054-070
1. Open the access door on the front left side of the

machine.
4. Remove the primary filter element from the air

cleaner housing.
5. Clean the air cleaner cover and the inside of the air
cleaner housing.
6. Inspect the O-ring seal on the air cleaner cover.
Replace the O-ring seal if the O-ring seal is worn
Illustration 343 g00537958 or damaged.
7. Inspect the primary filter. If the primary filter
2. Squeeze the outlet tube slightly into a container in
element is not damaged, you can clean the
order to purge the dirt from the outlet tube.
primary element.
Refer to “Cleaning Primary Air Filter Elements”.
3. Loosen the 6 cover latches and remove the air Illustration 346 g00102884
cleaner cover.
8. Direct air along the pleats inside the primary filter
element and outside the primary filter element.
9. Inspect the primary filter element after cleaning.
Do not use a primary filter element with damaged
pleats, damaged gaskets or damaged seals.
10. Encase the clean primary filter element and store
the clean primary filter element in a clean, dry
place.
11. Install the clean primary filter.
168 SEBU7029-05
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
12. Install the air cleaner cover and close the latches Visually inspect the primary air filter elements before
securely. cleaning. Inspect the air filter elements for damage to
the seal, the gaskets, and the outer cover. Discard
13. Change the filter if any of the following conditions any damaged air filter elements.
occurs:
There are two common methods that are used to
• Restricted Air Filter indicator on the monitor clean primary air filter elements:
panel still comes on. • Pressurized air
• Exhaust smoke is still black after the • Vacuum cleaning
installation of a primary filter.
Note: The primary filter can be cleaned up to six
Pressurized Air
times. Replace the primary filter if the primary filter Pressurized air can be used to clean primary air filter
has been used for one year. elements that have not been cleaned more than two
times. Pressurized air will not remove deposits of
Cleaning Primary Air Filter carbon and oil. Use filtered, dry air with a maximum
pressure of 207 kPa (30 psi).
Elements
NOTICE
Caterpillar recommends certified air filter cleaning
services available at participating Caterpillar dealers.
The Caterpillar cleaning process uses proven proce-
dures 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 Note: When the primary air filter elements are
pleats and down the pleats from the inside of the filter cleaned, always begin with the clean side (inside) in
element. Take extreme care in order to avoid damage order to force dirt particles toward the dirty side
to the pleats. (outside).
Do not use air filters with damaged pleats, gaskets, Aim the hose so that the air flows inside the element
or seals. Dirt entering the engine will cause damage along the length of the filter in order to help prevent
to engine components. damage to the paper pleats. Do not aim the stream of
air directly at the primary air filter element. Dirt could
The primary air filter element can be used up to six be forced further into the pleats.
times if the element is properly cleaned and if the
element is properly inspected. When the primary air
filter element is cleaned, check for rips or tears in the
filter material. The primary air filter element should be
replaced at least one time per year. This replacement
should be performed regardless of the number of
cleanings.
NOTICE
Do not clean the air filter elements by bumping or tap-
ping. This could damage the seals. Do not use ele-
ments with damaged pleats, gaskets, or seals.
Damaged elements will allow dirt to pass through.
Engine damage could result.
SEBU7029-05 169
Maintenance Section
Engine Air Filter Secondary Element - Replace
Vacuum Cleaning
Vacuum cleaning is another method for cleaning
primary air filter elements which require daily
cleaning because of a dry, dusty environment.
Cleaning with pressurized air is recommended prior
to vacuum cleaning. Vacuum cleaning will not
remove deposits of carbon and oil.
Inspecting the Primary Air Filter

Elements
Do not use paint, a waterproof cover, or plastic as a

protective covering for storage. An airflow restriction
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
Inspect the clean, dry primary air filter element. Use a
60 watt blue light in a dark room or in a similar facility. Store the box in a dry location.
Place the blue light in the primary air filter element.
Rotate the primary air filter element. Inspect the
i00702568
primary air filter element for tears and/or holes.
Inspect the primary air filter element for light that may
show through the filter material. If it is necessary in Engine Air Filter Secondary
order to confirm the result, compare the primary air
filter element to a new primary air filter element that
Element - Replace
has the same part number. SMCS Code: 1054-510
Do not use a primary air filter element that has any
tears and/or holes in the filter material. Do not use a NOTICE
primary air filter element with damaged pleats, Always replace the secondary filter element. Never
gaskets or seals. Discard damaged primary air filter attempt to reuse the secondary filter element by
elements. cleaning the element.
Storing Primary Air Filter Elements When the primary filter element is replaced, the sec-
ondary filter element should be replaced.
If a primary air filter element that passes inspection The secondary filter element should also be replaced
will not be used, the primary air filter element can be if the restricted Air Filter indicator comes on after the
stored for future use. installation of a clean primary filter element or if the
exhaust smoke is still black.
170 SEBU7029-05
Maintenance Section
Engine Air Precleaner - Clean
i02174202
Engine Air Precleaner - Clean

SMCS Code: 1055-070-DJ
1. Open the access door on the front left side of the

machine.
2. See Operation and Maintenance Manual, “Engine
Air Filter Primary Element - Clean/Replace”.
Remove the air cleaner cover from the air cleaner Check the precleaner for accumulation of trash and
housing. Remove the primary filter element from dirt.
the air cleaner housing.
1. Empty the precleaner bowl whenever the dirt
reaches the “FULL” mark.
2. Loosen the wing nut on the cover and remove the
cover.
3. Empty the precleaner bowl. Wash the precleaner
bowl and 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.
3. Remove the secondary filter element.

4. Cover the air inlet opening. Clean the inside of the
air cleaner housing.
5. Remove the cover from the air inlet opening.
6. Install the new secondary filter element.
7. Install the primary filter element.
8. Install the air cleaner cover and close the latches
securely.
SEBU7029-05 171
Maintenance Section
Engine Crankcase Breather - Clean
i00561879 6. Install the O-ring seal and clean breather (3).

Tighten four bolts (4) to 14 ± 3 N·m (10 ± 2 lb ft).
Engine Crankcase Breather - 7. Slide hose on breather (3). Tighten hose clamp (1).
Clean 8. Close the engine hood. Latch the engine hood.
SMCS Code: 1317-070-DJ
i01310252
Engine Oil Level - Check

SMCS Code: 1000-535
NOTICE
Do not overfill the crankcase. Engine damage can
result.
Note: This machine is equipped with a function for

checking fluid levels. However, if the machine is on
an incline or the engine has been stopped only for a
short time, the engine oil does not return to the
crankcase. The fluid level cannot be properly
Illustration 353 g00278210 checked. Park the machine on level ground and
check the oil level after the engine has been stopped
1. Unlatch the engine hood. Raise the engine hood. for at least 15 minutes.
The oil level can be checked while the engine is
running or while the engine is stopped. The
recommended procedure is checking the oil while the
engine is stopped.

(1) Hose clamp. (2) Outlet hose. (3) Breather. (4)
Bolts.
2. Loosen hose clamp (1). Disconnect outlet hose (2) Illustration 355 g00278210
from breather (3).
1. Unlatch the engine hood and raise the engine
3. Loosen four bolts (4). Remove breather (3) and the
hood.
seal.
4. Wash breather (3) in a clean, nonflammable

solvent.
5. Inspect the seal. If the seal is damaged, install a
new seal.
172 SEBU7029-05
Maintenance Section
Engine Oil and Filter - Change
4. Remove the oil filler plug in order to add oil.

Note: Oil that is badly contaminated or deteriorated
should be replaced early regardless of the change
interval.
5. Clean the filler plug and install the filler plug.

6. Close the engine hood and latch the engine hood.
i02014235

SMCS Code: 1318-510
Illustration 356 g00694259 Park the machine on a level surface and engage the
parking brake. Stop the engine.
2. Remove the dipstick. Wipe the oil off the dipstick Note: Drain the crankcase while the oil is warm. This
and reinsert the dipstick. allows waste particles that are suspended in the oil to
drain. As the oil cools, the waste particles will settle
to the bottom of the crankcase. The particles will not
be removed by draining the oil and the particles will
recirculate in the engine lubrication system with the
new oil.
3. Maintain the oil level between the marks on the

“ENGINE STOPPED” side of the dipstick. Add oil,
if necessary.
The crankcase drain valve is located under the rear
of the upper structure.
1. Remove the bolts and the washers. Open the

crankcase drain valve access cover.

SEBU7029-05 173
Maintenance Section
Note: Refer to Operation and Maintenance Manual, 7. Apply a thin coat of engine oil to the gasket of the
“General Hazard Information” for information that new filter.
8. Install the new filter by hand. When the gasket
2. Open the crankcase drain valve. Allow the oil to contacts the filter base, turn the filter by 270
drain into a suitable container. degrees more. This will tighten the filter
sufficiently.
regulations. Every new oil filter has rotation index marks that
are spaced at 90 degree increments. Use the
3. Close the drain valve. rotation index marks as a guide for tightening the
oil filter.
9. Close the access door on the left side of the
machine.
10. Close the crankcase drain valve access cover.
11. Install the bolts and the washers.
4. Open the access door on the left side of the

machine.
5. Remove the oil filter with a strap type wrench. See
Operation and Maintenance Manual, “Oil Filter -
Inspect”. Illustration 363 g00278210
Note: Dispose of the used oil filter according to local

regulations.
hood.
6. Clean the filter housing base. Make sure that all of
the old filter gasket is removed.
174 SEBU7029-05
Maintenance Section
Engine Oil Sample - Obtain
i02098807
Engine Oil Sample - Obtain

SMCS Code: 1000; 1000-008; 1348-008; 1348-554-
SM; 7542-554-SM; 7542-008; 7542-554-OC
13. Remove oil filler plug (2). Fill the crankcase with
new oil. See Operation and Maintenance Manual,
“Capacities (Refill)”. Clean the oil filler plug and
install the oil filler plug.
NOTICE
Do not under fill or overfill engine crankcase with oil. Open the access door on the right side of the
Either condition can cause engine damage. machine in order to access the sampling valve.
14. Start the engine and allow the oil to warm. Check
the engine for leaks. Stop the engine.
The sampling valve for the engine oil is located on

the top of the engine oil filter.
Illustration 365 g00115428 Refer to Special Publication, SEBU6250, “Caterpillar

Machine Fluids Recommendations” “S·O·S Oil
15. Wait for fifteen minutes so that the oil can drain Analysis” for information that pertains to obtaining a
sample of the engine oil. Refer to Special Publication,
back into the crankcase, before you check the oil. PEHP6001, “How To Take A Good Oil Sample” for
16. Check the dipstick. Maintain the oil between the more information about obtaining a sample of the
engine oil.
marks on the “ENGINE STOPPED” side of the
dipstick.
17. Close the engine hood and latch the engine
hood.
SEBU7029-05 175
Maintenance Section
Engine Valve Lash and Fuel Injector Timing - Check
i00707053
Engine Valve Lash and Fuel

Injector Timing - Check
SMCS Code: 1105-025; 1209-535; 1290-531-FT
Refer to the Service Manual for the complete
procedure for checking the engine valve lash. This
procedure lists the steps for the engine valve lash
adjustment and the steps in order to check the
engine valve lash.
Note: Make sure that a qualified mechanic works on
the injector fuel timing. Special tools and training are
required.
Refer to the Service Manual for the complete
procedure for checking the injector fuel timing or for 2. Watch the top surface on each valve rotator. Each
adjusting the injector fuel timing. valve rotator should turn slightly whenever the
cylinder valve closes.
Note: The correct fuel timing specification is given on
the Engine Information Plate. Fuel timing If a cylinder valve fails to rotate, consult your
specifications may differ for distinct engine Caterpillar dealer.
applications and/or power ratings.
i01313174
i00059702
Ether Starting Aid Cylinder -

Engine Valve Rotators -
Replace
Inspect
SMCS Code: 1456-510-CD
SMCS Code: 1109-040
When inspecting the valve rotators, protective

glasses or face shield and protective clothing
must be worn to prevent being burned by hot oil
spray.
1. Start the engine and run the engine at low idle.

The ether cylinder is located inside the front access
door on the front left side of the machine.
Refer to Operation and Maintenance, “Fire
Prevention and Explosion Prevention” before you
replace the ether cylinders.
1. Open the front access door on the left side of the
machine.
176 SEBU7029-05
Maintenance Section
Final Drive Oil - Change

(1) Oil level plug
(2) Oil drain plug
2. Loosen the cylinder retaining clamp. Unscrew the
empty ether cylinder and remove the empty ether
1. Position one final drive so that oil drain plug (2) is
cylinder.
at the bottom.

Containing Fluid Spillage.
2. Remove drain plug (2) and level plug (1). Allow the
oil to drain into a suitable container.
3. Clean the plugs and inspect the O-ring seals. If
wear or damage is evident, replace the drain plug,
the level plug, and/or the O-ring seals.
4. Install drain plug (2).
5. Fill the final drive to the bottom of the opening on
level plug (1). See Operation and Maintenance
Illustration 371 g00695155 Manual, “Lubricant Viscosities” and Operation and
Maintenance Manual, “Capacities (Refill)”.
3. Remove the used gasket. Install the new gasket. A
new gasket is provided with each new ether Note: If the oil fills slowly, the fill hole may be blocked
starting aid cylinder. by the planetary gear. Rotate the final drive to move
the planetary gear away from the fill hole.
4. Install the new ether starting aid cylinder. Tighten
the ether starting aid cylinder hand tight. Tighten Note: Overfilling the final drive will cause the seals
the cylinder retaining clamp securely. on the travel motor to allow hydraulic oil or water to
enter the final drive. The final drive may become
5. Close the access door. contaminated.
i06882903 6. Install level plug (1).

7. Perform Step 1 to Step 6 on the other final drive.
Final Drive Oil - Change Use a different container for the oil so that the oil
SMCS Code: 4050-044-FLV samples from the final drives will be separate.
8. Completely remove the oil that has spilled onto
surfaces.
Hot oil and hot components can cause personal 9. Start the machine and allow the final drives to run
injury. Do not allow hot oil or hot components to through several cycles.
contact skin.
10. Stop the machine. Check the oil level.
SEBU7029-05 177
Maintenance Section
Final Drive Oil Level - Check
11. Check the drained oil for metal chips or for 5. Clean oil level plug (1). Inspect the O-ring seal.
particles. If there are any chips or particles, Replace the O-ring seal if the O-ring seal is worn
consult your Cat dealer. or damaged.
12. Properly dispose of the drained material. Obey 6. Install oil level plug (1).
local regulations for the disposal of the material.
7. Repeat the procedure for the other final drive.
i03914051
i02024665
Final Drive Oil Level - Check Fuel System - Prime

SMCS Code: 4050-535-FLV
SMCS Code: 1250-548
Hot oil and hot components can cause personal

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

hood.

(1) Oil level plug
(2) Oil drain plug
1. Position one final drive so that oil drain plug (2) is

at the bottom.

Containing Fluid Spillage.
2. Remove oil level plug (1).

3. Check the oil level. The oil should be near the
bottom of the level plug opening.
4. Add oil through the level plug opening, if
(1) Vent plug
necessary. See Operation and Maintenance, (2) Priming pump plunger
“Lubricant Viscosities”.
2. Loosen vent plug (1) on the filter.
Note: If the oil fills slowly, the fill hole may be blocked
by the planetary gear. Rotate the final drive in order 3. Turn priming pump plunger (2) counterclockwise in
to move the planetary gear away from the fill hole. order to unlock priming pump plunger (2). Operate
priming pump plunger (2).
Note: Overfilling the final drive will cause the seals
on the travel motor to allow hydraulic oil or water to 4. Tighten vent plug (1) when the fuel flows without
enter the final drive. The final drive may become air bubbles.
contaminated.
178 SEBU7029-05
Maintenance Section
Final Drive Oil Sample - Obtain
5. Push in priming pump plunger (2) and tighten i02076875

priming pump plunger (2) by hand.
6. Crank the engine. If the engine does not start or if
Fuel System Primary Filter
the engine misfires, additional priming is required. (Water Separator) Element -
Also if the engine emits smoke, additional priming Replace
is required.
SMCS Code: 1263-510-FQ
7. If the engine starts but the engine runs rough,
continue to run the engine at low idle. Run the S/N: 4SS552–Up
engine at low idle until the engine runs properly.
S/N: 9GS192–Up
8. Check the fuel system for leaks. Stop the engine.
S/N: 2NW1–Up
9. Close the engine hood and latch the engine hood.
i01958150
Personal injury or death may result from failure
Final Drive Oil Sample - Obtain to adhere to the following procedures.
SMCS Code: 4011-008; 4050-008; 4050-SM; 7542- Fuel leaked or spilled onto hot surfaces or electri-
008 cal components can cause a fire.
Clean up all leaked or spilled fuel. Do not smoke
while working on the fuel system.
Turn the disconnect switch OFF or disconnect
the battery when changing fuel filters.
NOTICE
Do not fill the fuel filters with fuel before installing the
fuel filters. The fuel will not be filtered and could be
contaminated. Contaminated fuel will cause acceler-
ated wear to fuel system parts.

(1) Oil drain plug
(2) Oil level plug
1. Position the final drive so that oil drain plug (1) is at

the bottom.
2. Remove oil level plug (2).
3. Obtain a sample of the final drive oil through the
hole for the oil level plug.
4. Install oil level plug (2).
Refer to Special Publication, SEBU6250, “S·O·S Oil
Analysis” for more information on obtaining a sample The primary filter/water separator is located behind
of the final drive oil. For additional information about the left front access door.
obtaining an oil sample, refer to Special Publication,
PEHP6001, “How To Take A Good Oil Sample”. 1. Open both access doors on the left side of the
machine.
SEBU7029-05 179
Maintenance Section
Fuel System Primary Filter/Water Separator - Clean/Replace
i01955470
Fuel System Primary Filter/

Water Separator - Clean/
Replace
SMCS Code: 1260-510; 1261; 1263-070
S/N: 4SS1–551
S/N: 9GS1–191
Personal injury or death can result from a fire.

(1) Filter Fuel leaked or spilled onto hot surfaces or electri-
(2) Bowl cal components can cause a fire.
(3) Drain valve
Clean up all leaked or spilled fuel. Do not smoke
2. Turn drain valve (3) counterclockwise in order to while working on the fuel system.
open. The drain valve is located on the bottom of Turn the disconnect switch OFF or disconnect
the water separator. the battery when changing fuel filters.
“General Hazard Information” that pertains to NOTICE
containing fluid spillage. Do not fill fuel filters with fuel before installing them.
Contaminated fuel will cause accelerated wear to fuel
3. Drain the water and sediment into a suitable system parts.
container.
Note: Dispose of drained fluids and used filters

according to local regulations.
4. Close drain valve (3).

5. Hold the bottom of the filter (1) while you loosen
bowl (2).
6. Remove bowl (2).
7. Remove filter (1). Discard filter(1).
Note: The primary filter is a cartridge type filter. The
filter cannot be reused.
8. Clean the inside surface of the filter head and of

bowl (2). Illustration 379 g00290716
9. Inspect the O-ring on bowl (2). Also inspect the

seal on the filter head. Replace these seals if the 1. The fuel shutoff valve is located under the fuel
seals are worn or damaged. tank. Turn the fuel supply valve clockwise in order
to shut off the fuel supply.
10. Lubricate the seal of the new element with clean
diesel fuel.
11. Install the new filter. Tighten the filter by hand
until the seal contacts the filter base. Additionally
tighten the filter by 1/3 to 1/2 turn onto filter base.
12. Install bowl (2).
13. Close the access doors.
180 SEBU7029-05
Maintenance Section
Fuel System Primary Filter/Water Separator - Clean/Replace
Note: The water separator element is a cartridge

type filter. The filter cannot be reused.

bowl (3).
seal on the filter head. Replace these seals if the
seals are worn or damaged.
10. Install a new water separator element. Tighten
water separator element (2) onto base (1).
11. Install bowl (3).
Note: Do not start the engine until all service to the
Illustration 380 g00101429 fuel system is complete. Refer to Operation and
Maintenance Manual, “Fuel System Priming Pump -
2. Open the access door on the left side of the Operation” for instructions on priming the fuel
machine. system.

13. Turn the fuel shutoff valve counterclockwise in
order to open the fuel supply.
i01955480
Fuel System Primary Filter/

Water Separator - Clean/
Replace
SMCS Code: 1260-510; 1261; 1263-070
S/N: 4SS552–Up
Illustration 381 g00290717 S/N: 9GS192–Up
(1) Base. (2) Water separator element. (3) Bowl. (4)
S/N: 2NW1–Up
Drain valve.
The water separator is located behind the left side
access door.
3. Turn drain valve 4 counterclockwise in order to Personal injury or death can result from a fire.
open. Fuel leaked or spilled onto hot surfaces or electri-
4. Drain the water and sediment into a suitable cal components can cause a fire.
container. Clean up all leaked or spilled fuel. Do not smoke
while working on the fuel system.
according to local regulations. Turn the disconnect switch OFF or disconnect
the battery when changing fuel filters.
6. Hold water separator element (2) while you
NOTICE
remove bowl (3). Do not fill fuel filters with fuel before installing them.
7. Remove water separator element (2) from base Contaminated fuel will cause accelerated wear to fuel
system parts.
(1). Discard water separator element (2).

SEBU7029-05 181
Maintenance Section
Fuel System Secondary Filter - Replace
7. Remove filter (1). Discard filter(1).

Note: The primary filter is a cartridge type filter. The
filter cannot be reused.

bowl (2).
seal on the filter head. Replace these seals if the
10. Lubricate the seal of the new element with clean
diesel fuel.
11. Install the new filter. Tighten the filter by hand
Illustration 382 g00101721 until the seal contacts the filter base. Additionally
tighten the filter by 1/3 to 1/2 turn onto filter base.
The primary filter/water separator is located behind
the left front access door. 12. Install bowl (2).
1. Open both access doors on the left side of the 13. Close the access doors.
machine.
i02077031
Fuel System Secondary Filter -

Replace
SMCS Code: 1261-510
NOTICE
Turn the disconnect switch OFF or disconnect the
battery when changing fuel filters.
Do not fill fuel filters with fuel before installing them.
Contaminated fuel will cause accelerated wear to fuel
system parts.

(1) Filter
(2) Bowl
(3) Drain valve
2. Turn drain valve (3) counterclockwise in order to

open. The drain valve is located on the bottom of
the water separator.

“General Hazard Information” that pertains to
3. Drain the water and sediment into a suitable

container.
according to local regulations. 1. Unlatch the engine hood and raise the engine
hood.
5. Hold the bottom of the filter (1) while you loosen
bowl (2).
6. Remove bowl (2).
182 SEBU7029-05
Maintenance Section
Fuel System Water Separator - Drain
i00779879
Fuel System Water Separator -

Drain
SMCS Code: 1263
S/N: 4SS552–Up
S/N: 9GS192–Up
S/N: 2NW1–Up
2. Remove the fuel filter.

3. Inspect the fuel filter for debris by cutting the fuel
filter open.
Note: The fuel filter is a cartridge type filter. The filter
cannot be reused.
Note: Dispose of used filters and used fluids
4. Clean the filter mounting base. Make sure that all
The water separator is located inside the front access
of the old seal is removed.
door on the front left side of the machine.

5. Lubricate the seal of the new filter with clean diesel If the bowl is full, the water and sediment should be
fuel. drained.
6. Install the new filter by hand. Additionally tighten 1. Turn the drain valve counterclockwise in order to
the filter by 3/4 of a turn, after the gasket contacts open.
the filter base.
The filter has rotation index marks that are spaced “General Hazard Information” for information that
at 90 degree intervals. Use these rotation index pertains to containing fluid spillage.
marks as a guide for proper tightening.
2. Drain the water and drain the sediment into a
7. Prime the fuel system. Refer to Operation and suitable container.
Maintenance, “Fuel System - Prime”.
SEBU7029-05 183
Maintenance Section
Fuel System Water Separator - Drain
Note: Dispose of drained fluids according to local Note: Refer to Operation and Maintenance Manual,
regulations. “General Hazard Information” for information that
2. Drain the water and drain the sediment into a
suitable container.
i00877408 Note: Dispose of drained fluids according to local
regulations.
Fuel System Water Separator -
Drain
SMCS Code: 1263
S/N: 4SS1–551 i00571622
S/N: 9GS1–191 Fuel System Water Separator

Element - Replace
SMCS Code: 1263-510-FQ
S/N: 4SS1–Up
S/N: 9GS1–Up

The water separator is located inside the rear access
door on the left side of the machine.

The water separator is located behind the left side
access door.
1. Open the access door on the left side of the

machine.
If the bowl is full, the water and sediment should be

drained.
1. Turn the drain valve counterclockwise in order to
open.
184 SEBU7029-05
Maintenance Section
Fuel Tank Cap and Strainer - Clean
Note: Do not start the engine until all service to the

fuel system is complete. For instructions about
priming the fuel system, refer to Operation and
Maintenance Manual, “Fuel System Priming Pump -
Operate”.
i01313516
Fuel Tank Cap and Strainer -

Clean
SMCS Code: 1273-070-STR

(1) Collar. (2) Water separator element. (3) Collar. (4)
Drain valve . (5) Bowl.
2. Turn drain valve (4) counterclockwise in order to

open. The drain valve is located on the bottom of
the water separator.
3. Drain the water and the sediment into a suitable
container.


5. Hold the bottom of water separator element (2)
while you loosen collar (3). 1. Remove the fuel tank cap.
6. Remove bowl (5).
7. Loosen collar (1).
8. Remove water separator element (2). Discard
water separator element (2).
9. Clean the inside surfaces of the filter head and of

bowl (5).
seal on the filter head. Replace these seals if the Illustration 394 g00695360
2. Remove the fuel fill screen.
11. Install a new water separator element. Tighten
collar (1) in order to secure the water separator 3. Wash the fuel fill screen and the fuel tank cap in a
element. clean, nonflammable solvent.
12. Install bowl (5). Tighten collar (3). 4. Inspect the gasket of the cap for damage. Replace
the cap if the gasket is damaged.
5. Install the fuel fill screen.
6. Install the fuel tank cap.
SEBU7029-05 185
Maintenance Section
Fuel Tank Water and Sediment - Drain
Note: Refer to Operation and Maintenance Manual, Make sure that you lock the fuel tank cap after the
“General Hazard Information” for information on refueling is complete.
i00919685
i01502765
Fuses - Replace
Fuel Tank Water and Sediment SMCS Code: 1417-510
- Drain
SMCS Code: 1273-543
The fuel tank drain valve is located underneath the
fuel tank.
The fuse panel is located on the left console. Open

the access cover for fuse access.
Fuses – Fuses protect the electrical
system from damage that is caused by
overloaded circuits. Change a fuse if the
element separates. If the element of a new fuse
separates, check the circuit and/or repair the
circuit.
1. Open the drain valve by turning the valve
counterclockwise. Allow the water and the NOTICE
sediment to drain into a suitable container. Always replace fuses with the same type and ca-
pacity fuse that was removed. Otherwise, electrical
Note: Dispose of drained fluids according to local damage could result.
regulations.
2. Close the drain valve by turning the valve NOTICE

clockwise. If it is necessary to replace fuses frequently, an elec-
trical problem may exist.
Fill the Fuel Tank Contact your Caterpillar dealer.
You can now add fuel to the fuel tank, if necessary.

Remove the fuel tank cap and pump fuel through the To replace a fuse, use a puller that is stored in the
opening. fuse panel. The following fuses are contained in the
fuse panel as spare fuses:
• Two 10 Amp fuses
• One 15 Amp fuse

The following list identifies the circuits that are
protected by each fuse. The amperage for each fuse
is included with each circuit.
186 SEBU7029-05
Maintenance Section
Hydraulic System Oil - Change
Auxiliary Circuit (Attachment) (13) – 10 Amp

Attachment Fine Swing Control (14) – 10 Amp
Boom Lamp (15) – 10 Amp
Attachment Lubricator (16) – 10 Amp
Hydraulic Oil Filter Switch and Switch Panel (17)
– 10 Amp
Cigar Lighter (18) – 10 Amp
Heater and Air Conditioner (19) – 15 Amp
Windshield Washer and Windshield Wiper (20) –
10 Amp
Lower Windshield Washer and Lower Windshield
Wiper (21) – 10 Amp
Converter (22) – 10 Amp
Cab and Chassis Lamp (23) – 15

Auxiliary Hydraulics (Attachment) (24) – 15 Amp
Spare (25) – 10 Amp
i01965930

SMCS Code: 5056-044
4000 Hour Oil Change Interval
Engine Control Module (ECM) (1) – 15 Amp
Auxiliary Circuit (Attachment) (2) – 10 Amp A 4000 hour maintenance interval for hydraulic oil
(change) is available. The extended interval requires
Attachment Fan (3) – 10 Amp S·O·S monitoring of the hydraulic oil. The interval for
S·O·S monitoring is every 500 hours. The
Backup Switches for Engine and Pump Controller maintenance interval for the hydraulic oil filter is not
(4) – 10 Amp changed. If S·O·S monitoring is not performed, the
2000 hour maintenance interval must be used.
Attachment Lamps (5) – 15 Amp
Machines with hammers are not included in the 4000
Auxiliary Circuit (6) – 10 Amp hour maintenance interval. Machines with hammers
must use the intervals that are listed in the
Hydraulic Lock Solenoid and Hydraulic Lock Maintenance Interval Schedule. Machines that are
Limit Switch (7) – 10 Amp used in severe conditions are not included in the
4000 hour maintenance interval. Machines that are
Engine and Pump Controller (8) – 15 Amp used in severe conditions must use the interval in the
Maintenance Interval Schedule.
Horn (9) – 10 Amp
Cab Dome Light (10) – 10 Amp
Auxiliary Circuit (11) – 10 Amp
Engine Start Switch (12) – 10 Amp
SEBU7029-05 187
Maintenance Section
Lubricants Note: Industrial hydraulic oils are not recommended

for the hydraulic systems of Caterpillar machines.
Approved hydraulic oil must be used to obtain the Industrial hydraulic oils are more likely to allow
4000 hour hydraulic oil change. Refer to the list that corrosion and Industrial hydraulic oils are more likely
follows for approved oils. to allow excessive wear.
Caterpillar Hydraulic Oils
Procedure to Change the Hydraulic
• Cat HYDO Oil
• TDTO
• TDTO (TMS)
• DEO
• Biodegradable Hydraulic Oil (HEES)
• MTO
Commercial Oils
Diesel engine oils (Heavy Duty) with a minimum zinc
content of 900 ppm can be used. Acceptable
commercial oils are identified by the American
Petroleum Institute trademark (API) . Refer to the list
that follows for acceptable types of hydraulic oils.
• CF
1. Park the machine on level ground. Lower the
• CF-4 bucket to the ground so that the stick is vertical.
• CG-4
• CH-4

(1) Bolts
(2) Washers
(3) Cover
2. Remove bolts (1), washers (2) and cover (3) from

the top of the hydraulic tank.
188 SEBU7029-05
Maintenance Section
3. Clean the area thoroughly in order to keep dirt out Note: Refer to Operation and Maintenance Manual,
of the screen cover. Clean the area thoroughly in “General Hazard Information” for information that
order to keep dirt out of the fill/vent plug. pertains to containing fluid spillage.
4. Relieve the internal pressure from the hydraulic 6. Remove the oil drain valve plug.
tank by loosening the fill/vent plug. After the
pressure is relieved, remove the fill/vent plug.
Illustration 402 g00101446 7. Install a Swivel Hose with clear plastic tubing in
The oil drain valve is located under the hydraulic order to open the drain valve. Drain the oil into a
tank. suitable container.
8. Remove the Swivel Hose in order to close the
5. Remove the hydraulic tank access cover that is
drain valve.
located under the upper structure. This will allow
access to the drain valve. 9. Inspect the O-ring. Replace the O-ring if wear or
damage is evident.
10. Clean the drain plug. Install the drain plug.
SEBU7029-05 189
Maintenance Section
11. Open the access door that is located on the right

side of the machine.
12. Clean the pump, the hydraulic lines, and the
hydraulic tank.

(4) Bolts
(5) Washers
(6) Cover
(7) Spring
(8) Screen
16. Remove bolts (4), washers (5) and cover (6).

Illustration 406 g00833606 according to local regulations.
Note: Do not allow spring (7) to fall back into the

13. Remove the plug from the tube. Allow the oil to
tank.
drain into a container.
17. Remove spring (7) and screen (8).
according to local regulations. Note: Refer to Operation and Maintenance, “General
Hazard Information” for information on containing
14. Inspect the O-ring. Replace the O-ring if wear or
fluid spillage.
damage is evident.
15. Clean the plug. Install the plug and the O-ring into 18. Wash the screen in a clean nonflammable
the drain port. solvent. Allow the screen to dry. Inspect the
screen. Replace the screen, if the screen is
damaged.
190 SEBU7029-05
Maintenance Section
a. While the engine is stopped, remove the vent

plug on the top of the pump. Leave the vent
plug unattached for several minutes until the
pump is filled with hydraulic oil. After the pump
is filled with hydraulic oil, tighten the vent plug.
Start the engine. When the engine is at low idle,
fully raise the boom. Hold the boom in this
position.
b. Stop the engine. Slowly lower the boom until
the bucket is on the ground. This pressurizes
the hydraulic tank.
c. Slowly loosen the vent plug for several turns
until the hydraulic oil flows out of the opening
Illustration 408 g00278486 for the vent plug. This indicates that the air has
(9) O-ring seal been released from the pump. Tighten the vent
(10) O-ring seal plug again.
19. Inspect O-ring seals (9) and (10). Replace the O- 24. Close the access door.
ring seals if wear or damage is evident. 25. Start the engine. Operate the engine at idling
20. Install screen (8) and spring (7). Then install speed for five minutes.
cover (6), washers (5), and bolts (4).
Note: Make sure that the O-ring seals and the spring
are properly positioned during installation.
21. Fill the hydraulic system oil tank. Refer to

Operation and Maintenance Manual, “Refill
Capacities”.
22. Inspect the O-ring seal on the filler plug for
damage. Replace the O-ring, if necessary. Clean
the filler plug. Install the filler plug.
26. Operate the control levers in order to circulate the

hydraulic oil. Lower the bucket to the ground so
that the stick is vertical to the ground. Stop the
engine.
27. Open the access door that is located on the right
side of the machine.
Note: Make no attempt to start the engine until the

pump has been filled with hydraulic oil. Serious
damage to the hydraulic components can result.
23. When the hydraulic oil has been replaced, the air
must be removed from the hydraulic oil system.
Use the following procedure to remove the air from
the hydraulic oil system.
SEBU7029-05 191
Maintenance Section
Hydraulic System Oil Filter (Return) - Replace
(A) High temperature range

(B) Low temperature range 1. Loosen the filler plug in order to relieve the
hydraulic tank pressure. Tighten the filler plug after
28. Maintain the oil level between the marks on the the hydraulic tank pressure is relieved.
sight gauge in the appropriate temperature range.
i01961629
Hydraulic System Oil Filter

(Return) - Replace
SMCS Code: 5068-510-RJ
The return filter is a cartridge type filter. The return
filter reduces the amount of foreign material that
enters the hydraulic system when the filter element is
replaced.
Note: The return filters are located behind the filler

plug.
2. Remove the filter cartridge. Perform Step 2a

through Step 2f in order to remove the filter
cartridge.
Note: If the indicator for a Restricted Hydraulic

Return Filter comes on, push the reset switch at the
filter case. Run the machine on level ground for
approximately 10 minutes. If the indicator still comes
on, inspect the filter and replace the filter, if
necessary.
192 SEBU7029-05
Maintenance Section

(1) Bolts
(2) Washers d. Turn the filter cartridge counterclockwise by
(3) Cover 180 degrees in order to align the projection of
(4) Plug
(5) Filter cartridge the filter cartridge with the notch of the filter
case. Pull out the filter cartridge.
a. Remove bolts (1), washers (2), and cover (3).
Note: Refer to Operation and Maintenance

Manual, “General Hazard Information” for
information on containing fluid spillage.
b. Remove plug (4) in order to release the

pressure in filter cartridge (5).

(7) O-ring
e. Inspect the cover and O-ring (7). If either part is

damaged, replace the part.
f. Inspect the filter cartridge for debris and for
damage. If necessary, replace the filter
Illustration 416 g00102212 cartridge.
(5) Filter cartridge
(6) Filter case 3. Remove the filter element. Perform Steps 3a
(A) Guide through 3f in order to remove the other filter
element.
c. Pull up the handle at the top of filter cartridge
(5) until the filter cartridge contacts guide (A) on
filter case (6).
SEBU7029-05 193
Maintenance Section

(4) Plug (8) Plate
(8) Plate (10) Shell
(18) O-ring (11) O-ring
(12) Filter element
a. Make sure that plug (4) is removed. Make sure
that all of O-ring (18) is removed from plate (8). c. Hold the filter cartridge with one hand. Grasp
the grip of plate (8) with your other hand. Lift
plate (8) in order to separate plate (8) from the
filter cartridge.
d. Remove O-ring (11) from plate (8).
e. Lift filter element (12) from shell (10).
f. Pour the remaining oil into a suitable container.
Note: Dispose of used oil according to local
regulations.
g. Repeat Step 3a through Step 3f for the other

filter.
4. Clean the shell of the filter cartridge. Perform Step
Illustration 420 g00918893 4a through Step 4d in order to clean the shell of
(8) Plate the filter cartridge.
(9) Spiral retaining ring
b. Remove spiral retaining ring (9).

(13) Slide plate
(14) Pads
(15) Screws
(19) Port
a. Turn shell (10) upside-down.

194 SEBU7029-05
Maintenance Section
b. Remove screws (15). j. Apply grease to new O-ring (18). Install O-ring
(18) on plug (4).
c. Remove pads (14) from slide plate (13).
k. Install plug (4) into plate (8).
d. Wash the following parts in a clean
nonflammable solvent: plug (4), plate (8), spiral l. Repeat Steps 5a through 5k for the other filter.
retaining ring (9), shell (10) and pads (14). Dry
6. Install the filter cartridge. Perform Step 6a through
the parts.
Step 6e in order to install the filter cartridge.
e. Repeat Steps 4a through 4d for the other filter.
5. Install the filter elements. Perform Step 5a through
Step 5k in order to install the filter elements.
Note: Consult a Caterpillar dealer for the Service Kit
that is needed to install the filter element and the filter
cartridge.
a. Apply spray type oil to the inside of shell (10) in

order to prevent rust.
b. Apply grease to a new O-ring (11).
c. Plate (8) will contact the inside of shell (10).
Apply grease to this point.
d. Apply grease to O-rings inside ports (19) at the
bottom of shell (10). (B) Port
(C) Slide plate
e. Install new pads (14). Tighten screws to a
torque of 4 N·m (35 lb in). a. Check that ports (B) at the bottom of the filter
case are closed.
f. Apply spray type oil into the clearance between
shell (10) and slide plate (13). Note: If the ports are open, rotate slide plate (C)
counterclockwise to the stopper in order to fully
close the ports. When the ports are fully closed,
any remaining oil in the filter case should be
completely removed.

(8) Plate
(10) Shell
(16) Boss
(17) Notch
g. Turn over shell (10). Apply grease to the two O- (E) Slide plate
(D) Port
rings on new element (12). Install element (12)
into shell (10).
b. Check that ports (D) of the filter cartridge are
h. Move boss (16) in alignment with notch (17). fully closed.
Install plate (8) into shell (10).
i. Install spiral retaining ring (9) into the groove in
shell (10).
SEBU7029-05 195
Maintenance Section
Hydraulic System Oil Filter - Replace
Note: The filter cartridge cannot be installed unless

the ports are fully closed. If the ports are open,
rotate slide plate (E) counterclockwise to the
stopper in order to fully close the ports.
7. To turn off the indicator for a Restricted Hydraulic

Return Filter, push the reset switches on the filter
Illustration 426 g00102222 case while the engine start switch is in the ON
(F) O-rings position.
8. Repeat Steps 6a through 6e for the other filter.
c. Check that O-rings (F) have been installed and
that oil has been applied to O-rings (F).
i00872233
Hydraulic System Oil Filter -

Replace
SMCS Code: 5068-510
Replace the Pilot Filter

(1) Bolts
d. Install the filter cartridge into the filter case.

Turn the filter cartridge clockwise by 180
degrees and push down the filter cartridge
when the filter cartridge contacts guide (A).
e. Install plug (4), cover (3), washers (2), and bolts
(1). Tighten bolts (1) to a torque of 29 ± 5 N·m
(22 ± 4 lb ft).
1. Open the access door on the right side of the
machine.
196 SEBU7029-05
Maintenance Section
Replace the Case Drain Filter
2. Clean the area in order to keep dirt out of the filter

base.
3. Remove the used pilot filter element from the filter
base. The case drain filter is located on the side of the fuel
tank.
Note: This element is a cartridge type filter. The
element cannot be reused.
Note: Dispose of used filters according to local

regulations.
4. Clean the filter base.

base.
2. Remove the used case drain filter from the filter
base.
5. Coat the seal of a new pilot filter with clean element cannot be reused.
hydraulic oil. Install the new pilot filter in the filter
base. Tighten the pilot filter hand tight. Note: Dispose of used filters according to local
regulations.
3. Clean the filter base.

SEBU7029-05 197
Maintenance Section

(A) High temperature range
4. Coat the seal of a new case drain filter with clean (B) Low temperature range
hydraulic oil. Install the new case drain filter in the
filter base. Tighten the case drain filter hand tight. 9. Maintain the oil level in the low temperature range
for a cold machine. Maintain the oil level in the
5. Drive the machine slowly for 10 to 15 minutes. high temperature range for a machine that is at a
Move each cylinder evenly through several cycles. normal operating temperature.

6. Return the machine to the servicing position, as 10. Slowly loosen the filler plug in order to relieve any
shown. Check the machine for oil leaks. pressure. Remove the filler plug in order to add oil,
7. Stop the engine. if necessary.
8. Open the access door on the right side of the 11. Clean the filler plug. Install the filler plug.
machine in order to access the sight gauge. 12. Close the access door.
Replace the Case Drain Filter for

the Generator (If Equipped)
1. Open the cab riser compartment access door on
the left side of the machine.
198 SEBU7029-05
Maintenance Section

base.
3. Remove the used case drain filter from the filter
base.
element cannot be reused. 8. Return the machine to the servicing position, as
shown. Check the machine for oil leaks.
Note: Dispose of used filters according to local
regulations. 9. Stop the engine.
4. Clean the filter base. 10. Open the access door on the right side of the
machine in order to access the sight gauge.

5. Coat the seal of a new case drain filter with clean (A) High temperature range
(B) Low temperature range
hydraulic oil. Install the new case drain filter in the
filter base. Tighten the case drain filter hand tight.
11. Maintain the oil level in the low temperature range
6. Close the cab riser compartment access door. for a cold machine. Maintain the oil level in the
high temperature range for a machine that is at a
7. Drive the machine slowly for 10 to 15 minutes.
normal operating temperature.
Move each cylinder evenly through several cycles.
SEBU7029-05 199
Maintenance Section
Hydraulic System Oil Level - Check
12. Slowly loosen the filler plug in order to relieve any 2. Open the access door on the right side of the
pressure. Remove the filler plug in order to add oil, machine.
if necessary.
13. Clean the filler plug. Install the filler plug.
i00670130
Hydraulic System Oil Level -

Check
SMCS Code: 5050-535
NOTICE
Never remove the fill/vent plug from the hydraulic
tank if the oil is hot.
Air can enter the system and cause pump damage.
(A) High Temperature Range. (B) Low Temperature
Range.
3. For a cold machine, maintain the hydraulic oil level

in the low temperature range. For a machine that
is at normal operating temperature, maintain the
hydraulic oil level in the high temperature range.

The hydraulic oil tank is on the right side of the
machine.
1. Park the machine on level ground. Lower the

bucket to the ground with the stick in a vertical
position, as shown.
200 SEBU7029-05
Maintenance Section
Hydraulic System Oil Sample - Obtain
The hydraulic oil sampling valve is located between

the engine oil filter and the main pump.
containing fluid spillage. Refer to Special Publication, SEBU6250, “S·O·S Oil
Analysis” for information that pertains to a sample of
5. Slowly loosen the filler plug in order to relieve any the hydraulic oil. For additional information about
pressure. Add oil, if necessary. taking an oil sample, refer to Special Publication,
PEHP6001, “How To Take A Good Oil Sample”.
6. Check the O-ring seal of the filler plug. Replace the
O-ring seal if the O-ring seal is damaged.
i00073295
7. Clean the filler plug and install the filler plug.
Indicators and Gauges - Test
SMCS Code: 7450-081; 7490-081
i01958140
Hydraulic System Oil Sample -

Obtain
SMCS Code: 5050-008-OC; 5095-SM; 5095-008;
7542-008; 7542
1. Look for broken lenses on the gauges, broken

indicator lights, broken switches, and other broken
components in the cab.
2. Start the engine.
Illustration 447 g00101628 3. Look for inoperative gauges.
Open the access door on the right side of the 4. Turn on all machine lights. Check for proper
machine in order to access the sampling valve. operation.
5. Move the machine forward. Release the travel
levers and the travel pedals. The machine should
stop.
SEBU7029-05 201
Maintenance Section
Oil Filter - Inspect
6. Stop the engine. Using an oil filter element that is not recommended
by Caterpillar can result in severe engine damage to
7. Make any repairs that are required before engine bearings, to the crankshaft, and to other
operating the machine. parts. This can result in larger particles in unfiltered
oil. The particles could enter the lubricating system
i02106227 and the particles could cause damage.
Oil Filter - Inspect i00872584
SMCS Code: 1308-507; 5068-507 Radiator Core - Clean

Inspect a Used Filter for Debris SMCS Code: 1353-070
S/N: 4SS1–Up
S/N: 9GS1–Up

The element is shown with debris.
Use a filter cutter to cut the filter element open. Illustration 451 g00102191
Spread apart the pleats and inspect the element for
metal and for other debris. An excessive amount of 1. Open the rear access door on the left side of the
debris in the filter element can indicate a possible
failure. machine.
If metals are found in the filter element, a magnet can

be used to differentiate between ferrous metals and
nonferrous metals.
Ferrous metals can indicate wear on steel parts and
on cast iron parts.
Nonferrous metals can indicate wear on the
aluminum parts of the engine such as main bearings,
rod bearings, or turbocharger bearings.
Small amounts of debris may be found in the filter
element. This could be caused by friction and by
normal wear. Consult your Caterpillar dealer in order
to arrange for further analysis if an excessive amount
of debris is found.
2. Check the radiator fins for debris.

3. Remove dust and debris from the radiator fins.
Refer to Operation and Maintenance, “General
Hazard Information” for the proper safety
precautions that should be followed before
compressed air is used.
202 SEBU7029-05
Maintenance Section
Radiator Core - Clean
Compressed air is preferred, but high pressure

water or steam can be used to remove dust and
general debris from a radiator. Clean the radiator
according to the condition of the radiator.
Refer to Special Publication, SEBD0518, “Know
Your Cooling System” for more detailed
information about cleaning radiator fins.
i00872615
Radiator Core - Clean

SMCS Code: 1353-070
S/N: 2NW1–Up
4. Remove four bolts from the hydraulic oil cooler.

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

machine. 5. Slide the hydraulic oil cooler and the aftercooler
away from the machine in order to gain access to
the radiator fins.
2. Remove two bolts from the hood that is over the Illustration 457 g00442484
radiator.
6. Check the radiator fins for debris.
3. Lift the hood and lock the hood in place.
7. Remove dust and debris from the radiator fins and
from the screen of the radiator.
SEBU7029-05 203
Maintenance Section
Receiver Dryer (Refrigerant) - Replace
Refer to Operation and Maintenance, “General

Hazard Information” for the proper safety
precautions that should be followed before
compressed air is used.
Compressed air is preferred, but high pressure
water or steam can be used to remove dust and
general debris from a radiator. Clean the radiator
according to the condition of the radiator.
Refer to Special Publication, SEBD0518, “Know
Your Cooling System” for more detailed
information about cleaning radiator fins.
11. Install the two bolts back into the hood.

i05805860
Receiver Dryer (Refrigerant) -

Replace
SMCS Code: 7322-510; 7322-710
8. Slide the hydraulic oil cooler and the aftercooler Personal injury can result from contact with
refrigerant.
toward the machine.
Contact with refrigerant can cause frost bite.
Keep face and hands away to help prevent injury.
Protective goggles must always be worn when re-
frigerant lines are opened, even if the gauges in-
dicate the system is empty of refrigerant.
Always use precaution when a fitting is removed.
Slowly loosen the fitting. If the system is still
under pressure, release it slowly in a well venti-
lated area.
Personal injury or death can result from inhaling
refrigerant through a lit cigarette.
Inhaling air conditioner refrigerant gas through a
lit cigarette or other smoking method or inhaling
Illustration 459 g00442483 fumes released from a flame contacting air condi-
tioner refrigerant gas, can cause bodily harm or
9. Install the four bolts back into the hydraulic oil death.
cooler. Do not smoke when servicing air conditioners or
wherever refrigerant gas may be present.
10. Close the hood that is over the radiator.
Use a certified recovery and recycling cart to
properly remove the refrigerant from the air con-
ditioning system.
204 SEBU7029-05
Maintenance Section
Seat Belt - Inspect
i06891605
NOTICE
If the refrigerant system has been open to the outside
air (without being plugged) for more than 30 minutes, Seat Belt - Replace
the receiver-dryer must be replaced. Moisture will en- SMCS Code: 7327-510
ter an open refrigerant system and cause corrosion
which will lead to component failure. The seat belt should be replaced within 3 years of the
date of installation. A date of installation label is
Refer to Service Manual, “Air Conditioning and attached to the seat belt retractor and buckle. If the
Heating R-134a for All Caterpillar Machines” for the date of installation label is missing, replace belt within
proper procedure to change the receiver-dryer 3 years from the year of manufacture as indicated on
assembly and for the procedure to reclaim the belt webbing label, buckle housing, or installation
refrigerant gas. tags (non-retractable belts).
i00112638
Seat Belt - Inspect

SMCS Code: 7327-040

Typical Example
(1) Date of installation (retractor)
(2) Date of installation (buckle)
(3) Year of manufacture (tag) (fully extended web)
(4) Year of manufacture (underside) (buckle)
Consult your Cat dealer for the replacement of the

seat belt and the mounting hardware.
Determine age of new seat belt before installing on
When this machine was shipped from Caterpillar, seat. A manufacture label is on belt webbing and
Inc., this machine was equipped with a seat belt and imprinted on belt buckle. Do not exceed install by
with a seat belt installation. At the time of installation, date on label.
the seat belt and the seat belt installation met “SAE
J386 JUN85” for an industrial machine and “SAE Complete seat belt system should be installed with
J386 JUN93”. Consult your Caterpillar dealer for all new mounting hardware.
replacement parts.
Date of installation labels should be marked and
Regardless of appearance, replace the seat belt after affixed to the seat belt retractor and buckle.
every three years of use. A date label for determining
the age of the seat belt is attached to each seat belt. Note: Date of installation labels should be
permanently marked by punch (retractable belt) or
Always check the condition of the seat belt and the stamp (non-retractable belt).
condition of the seat belt mounting hardware before
you operate the machine. If damage or wear is found, If your machine is equipped with a seat belt
replace either the seat belt or the seat belt mounting extension, also perform this replacement procedure
hardware before operating the machine. for the seat belt extension.
SEBU7029-05 205
Maintenance Section
Swing Bearing - Lubricate
i03867596 i02077056
Swing Bearing - Lubricate Swing Drive Oil - Change

SMCS Code: 7063-086 SMCS Code: 5459-044
Note: Caterpillar recommends the use of

multipurpose lithium grease NLGI Grade 2 for
lubricating the swing bearing. Refer to Special
Publication, SEBU6250, “Caterpillar Machine Fluids
multipurpose lithium grease.
Note: Do not overgrease the swing bearings. Do not

grease more than the recommended maintenance
interval. Refer to Operation and Maintenance
Manual, “Maintenance Interval Schedule” for more
information.
Wipe the fittings before you lubricate the swing
bearings.
The oil drain hose is under the center of the upper

structure.
The swing bearings are under the base of the boom.

(1) Holder
(2) Drain hose
(3) Hole

1. Remove drain hose (2) from holder (1) on the

upper frame. Face the end of the hose toward the
container.
Illustration 464 g01106319 2. Use a universal joint with a socket extension to

loosen the drain valve in hole (3). Drain the oil into
Apply lubricant through the fittings until the lubricant a suitable container.
overflows the bearing seals.
regulations.
206 SEBU7029-05
Maintenance Section
Swing Drive Oil Level - Check
Note: There are two swing drives that are located

between the swivel joint and the main control valve.
Perform the same procedure for both swing drives.
6. Make sure that the oil level is maintained between

the tip of the dipstick and the “FULL” mark on the
dipstick.
(1) Holder
(2) Drain hose 7. Check the oil that has been drained for metal chips
or metal particles. Consult your Caterpillar dealer if
3. Tighten the drain valve. Hook the drain hose (2) to any metal chips or metal particles are found.
the holder (1). Make sure that the end of the hose
is facing upward. Note: Dispose of drained materials according to local
regulations.
i03867532
Swing Drive Oil Level - Check

SMCS Code: 5459-535-FLV
4. Remove the dipstick.

5. Add the specified quantity of oil through the
dipstick tube. See Operation and Maintenance,
“Capacities (Refill)”.
The dipstick for the swing drive oil is on the swing

drive at the rear base of the boom.

SEBU7029-05 207
Maintenance Section
Swing Drive Oil Sample - Obtain
i04787571
Swing Drive Oil Sample -

Obtain
SMCS Code: 5459-008-OC; 5459-008; 5459-OC;
5459-554-OC; 7542-008
1. Remove the dipstick.
The dipstick for the swing drive oil is on the swing

drive at the rear base of the boom.

2. Check the dipstick. Maintain the oil level between

the tip of the dipstick and the “FULL” mark on the
dipstick. Add oil through the dipstick tube, if
necessary. When the oil level becomes close to
the “ADD” mark, add approximately 500 cc of oil.
See Operation and Maintenance, “Lubricant
Viscosities”. Illustration 474 g01106264
3. Insert the dipstick. Obtain an oil sample of the swing drive oil through
the opening for the dipstick. Refer to Special
4. Check the dipstick again. Publication, SEBU6250, “S·O·S Oil Analysis” for
5. Reinsert the dipstick. information that pertains to obtaining an oil sample
from the swing drive housing. Refer to Special
Publication, PEGJ0047, “How To Take A Good Oil
Sample” for more information about obtaining an oil
sample from the swing drive housing.
208 SEBU7029-05
Maintenance Section
Swing Gear - Lubricate
i03804517
Swing Gear - Lubricate

SMCS Code: 7063-086
NOTICE
Improper lubrication can cause damage to machine
components.
To avoid damage, make sure that the proper amount
of grease is applied to the swing drive.
When the amount of grease in the compartment be-
comes too large, the agitation loss becomes large,
thereby accelerating grease deterioration.
Grease deterioration can cause damage to the pinion
gear of the swing drive and swing internal gear. 2. Inspect gasket (4). Replace the gasket if damage
Not enough grease will result in poor gear lubrication. is evident.
3. Check the level of the grease. The grease should
be evenly distributed on the floor of the pan.
Refer to Operation and Maintenance Manual,
“Capacities (Refill)” for the capacity of the swing
gear.
Add grease, as needed. Remove grease, as
needed. Too much grease will result in the
deterioration of the grease that is caused by
excessive movement of the grease. Too little
grease will result in poor lubrication of the swing
gear.
Remove the inspection cover that is located near the

boom base. Inspect the grease.
4. Check for contamination and for discolored

grease.
5. If the grease is contaminated or discolored with
Illustration 476 g00688056 water, change the grease. Remove plug (5) in
order to allow the water to drain. When you
1. Remove bolts (1) and washers (2). Remove cover reinstall plug (5), inspect O-ring seal (6). Replace
(3) and gasket (4). the O-ring seal if damage is evident.
SEBU7029-05 209
Maintenance Section
Track Adjustment - Adjust
6. Raise the boom and turn the upper structure by 90 2. Stop with one track pin directly over the front
degrees. Lower the bucket to the ground. carrier roller. Park the machine and turn off the
engine.
7. Repeat Step 6 at every 90 degrees in 4 places.
Add grease, as needed.
i05647259
Track Adjustment - Adjust

SMCS Code: 4170-025
Personal injury or death can result from grease

under pressure.
Grease coming out of the relief valve under pres-
sure can penetrate the body causing injury or
death.
Do not watch the relief valve to see if grease is es-
caping. Watch the track or track adjustment cylin- 3. Place a straight edge on top of the track grousers
der to see if the track is being loosened. between the front carrier roller and the idler. The
straight edge should be long enough to reach from
Loosen the relief valve one turn only.
the front carrier roller to the idler.
If track does not loosen, close the relief valve and
contact your Caterpillar dealer. Note: If your machine is equipped with three carrier
rollers, place a straight edge on the tracks between
the carrier rollers. The straight edge should be long
NOTICE enough to reach from one carrier roller to another
Keeping the track properly adjusted will increase the carrier roller.
service life of the track and drive components.
4. Measure the maximum amount of sag in the track.
The sag is measured from the highest point of the
Note: The track tension must be adjusted according track grouser to the bottom of the straight edge. A
to the current operating conditions. Keep the track as track that is properly adjusted will have a sag of
slack as possible if the soil is heavy. 40.0 to 55.0 mm (1.57 to 2.17 inch).
Measuring Track Tension

1. Operate the machine in the direction of the idlers.
210 SEBU7029-05
Maintenance Section
Track Adjustment - Inspect
5. If the track is too tight, or if the track is too loose, Loosening the Track
adjust the track tension according to the
appropriate procedure below.
Adjusting Track Tension

(1) Grease fitting
(2) Relief valve
Illustration 482 g00270405 1. Loosen relief valve (2) carefully until the track
Typical example begins to loosen. One turn should be the
maximum.
The track adjuster is located on the track frame.
2. Tighten relief valve (2) to 34 ± 5 N·m (25 ± 4 lb ft)
Tightening the Track when the desired track tension is reached.
3. Operate the machine back and forth in order to
equalize the pressure.
4. Check the amount of sag. Adjust the track, as
needed.
i00370385
Track Adjustment - Inspect

SMCS Code: 4170-040

(1) Grease fitting
(2) Relief valve
Wipe the fitting before you add grease.

1. Add grease through grease fitting (1) until the
correct track tension is reached.
2. Operate the machine back and forth in order to
equalize the pressure.
3. Check the amount of sag. Adjust the track, as Illustration 485 g00270359
needed.
Check the track adjustment. Check the track for wear
and for excessive dirt buildup.
SEBU7029-05 211
Maintenance Section
Travel Alarm - Test
If the track appears to be too tight or too loose, see

Operation and Maintenance Manual, “Track
Adjustment - Adjust”.
i01981714
Travel Alarm - Test

(If Equipped)
SMCS Code: 7429-081
You must move the machine in order to test the travel
alarm.
1. Start the engine. Move the hydraulic lockout
control to the UNLOCKED position.
2. Raise the implements in order to avoid any
obstacles. Make sure that there is adequate 6. Push the alarm cancel switch. The travel alarm
overhead clearance. should shut off.
7. Stop the machine. Lower the implements. Move
the hydraulic lockout control to the LOCKED
position. Stop the engine.
i03934011
Undercarriage - Check
SMCS Code: 4150-535
3. Use the travel levers or the travel pedals to move

the machine forward. The travel alarm should
sound.
4. Release the travel levers and the travel pedals in
order to stop the machine.
5. Use the travel levers and the travel pedals to move
the machine backward. The travel alarm should Illustration 488 g02154815
sound.
1. Check the carrier rollers, the track rollers, and the
idler wheels for possible leakage.
2. Check the surface of the track, the carrier rollers,
the track rollers, the idler wheels, the track shoes,
and the drive sprockets. Look for signs of wear
and loose mounting bolts.
3. Listen for any abnormal noises while you are
moving slowly in an open area.
4. If abnormal wear exists or abnormal noises or
leaks are found, consult your Caterpillar dealer.
212 SEBU7029-05
Maintenance Section
Window Washer Reservoir - Fill
i01955707 6. The window washer nozzles can be adjusted so

that the washer fluid will be sprayed in the desired
Window Washer Reservoir - direction.
Fill i01258249
SMCS Code: 7306-544-KE
Window Wiper - Inspect/
NOTICE
When operating in freezing temperatures, use Cater-
Replace
pillar or any commercially available nonfreezing win- SMCS Code: 7305-040; 7305-510
dow washer solvent.
Inspect the condition of the wiper blades. Replace
the wiper blades if the wiper blades are worn or
damaged or if streaking occurs.
i03912371
Windows - Clean
SMCS Code: 7310-070; 7340-070
Clean the outside of the windows from the ground,
unless handholds are available.
The bottle for the windshield washer fluid is located

behind the cab.
1. Open both access doors on the left side of the
machine. The rear access door must be opened
first.

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

Use a clean sponge or a soft cloth. Wash the
2. Remove the filler cap. windows with a mild soap or with a mild detergent.
Also use plenty of lukewarm water. Rinse the
3. Fill the bottle with washer fluid through the filler windows thoroughly. Dry the windows with a moist
opening. chamois or with a moist cellulose sponge.
4. Install the filler cap.
5. Close the access doors.
SEBU7029-05 213
Maintenance Section
Windows - Clean
Stubborn Dirt and Grease

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

equipped)
Wash polycarbonate windows with a mild soap or
detergent. Never use a cleaning solvent on
polycarbonate windows.
Wash polycarbonate windows with warm water and a
soft sponge, or damp cloth. Never use a dry cloth or
paper towels on polycarbonate windows.
Rinse the windows with a sufficient amount of clean
water.
214 SEBU7029-05
Reference Information Section
Reference Materials
Reference Information Special Publication, PECP9067, “One Safe Source”
Section Special Publication, PEHP6047, “Product Data Sheet

for Caterpillar Biodegradable Hydraulic Oil (HEES)”
Special Publication, PEHP7041, “Product Data Sheet
Reference Materials for Caterpillar Diesel Engine Oils (DEO)” CG-4
Engine Oils (International Markets)
i01958158 Special Publication, PEHP8038, “Product Data Sheet
for Caterpillar Diesel Engine Oils (DEO)” CH-4
Reference Material Engine Oils, (North America, Australia)
SMCS Code: 1000; 7000 Special Publication, PEHP4036, “Product Data Sheet
for Caterpillar ELC”
Caterpillar Reference Material Special Publication, PEHP7508, “Product Data Sheet
Special Publication, SENR5664, “Air Conditioning for Caterpillar Gear Oil (GO)”
and Heater R-134a for All Caterpillar Machines” Special Publication, PEHP0005, “Product Data Sheet
Special Publication, SEBU6250, “Caterpillar Machine for Caterpillar Hydraulic Oil (HYDO)”
Fluids Recommendations” Special Publication, PEHP0003, “Product Data Sheet
Special Publication, LEDQ7315, “CG-4 Oil The for Multipurpose Lithium Complex Grease (MPG)”
Preferred Oil for Caterpillar Engines”
Special Publication, NEDG6022, “Product Data
Special Publication, SEBU5898, “Cold Weather Sheet for Multipurpose Lithium Complex Grease with
Recommendations” Molybdenum (MPGM)”
Special Publication, SEBD0970, “Coolant and Your Special Publication, PEHP3050, “Product Data Sheet
Engine” for Caterpillar Multipurpose Tractor Oil (MTO)”
Special Publication, SEBD400-03, “Dictionary of Special Publication, PEHP8035, “Product Data Sheet
Pictograph Symbols” for TDTO Transmission Multi-Season (TMS)”
Special Publication, SEBD0717, “Diesel Fuels and Special Publication, PEHP0017, “Product Data Sheet
Your Engine” for Special Purpose Grease (SPG) Bearing
Lubricant”
Special Publication, NEHP5621, “How to Select the
Right Grease for Any Job”. This publication lists the Special Publication, PEHP7057, “S·O·S Coolant
typical characteristics for eleven of Caterpillar's Analysis”
greases.
Special Publication, SENR3130, “Torque
Special Publication, PEHP6001, “How to Take a Specifications”
Good Oil Sample”
Special Publication, PEHP7076, “Understanding
Special Publication, SEBD0518, “Know Your Cooling S·O·S Services Test”
System”
Special Publication, PEEP5027, “Label - ELC
Additional Reference Material
Radiator Label” SAE J183, “Classification” This can normally be
Special Publication, SEBD0640, “Oil and Your found in the SAE handbook.
Engine” SAE J313, “Diesel Fuels” This publication can be
found in the SAE handbook. This publication can also
Special Publication, SMBU6981, “Emissions Control be obtained from your local technological society,
Warranty Information for US, Canada, and California” from your local library, or from your local college.
Service Magazine, SEBD1587, “What ROPS/FOPS Engine Manufacturers Association, “Engine Fluids
Certification Means” Data Book”
Service Magazine, SEBD6929, “Inspection,
Maintenance and Repair of ROPS and Attachment
Installation Guidelines”
System Operation, Troubleshooting and Testing
Adjusting, RENR5885, “Product Link 151/201”
SEBU7029-05 215
Reference Information Section
Decommissioning and Disposal
Engine Manufacturers Association

Two North LaSalle Street, Suite 2200
Chicago, Illinois, USA 60602
E-mail: [email protected]
(312) 827-8700
Facsimile: (312) 827-8737
SAE J754, “Nomenclature” This can normally be
found in the SAE handbook.
ASTM D2896, “TBN Measurements” This can
normally be obtained from your local technological
society, from your local library, or from your local
college.
i07743978
Decommissioning and
Disposal
SMCS Code: 1000; 7000
When the product is removed from service, local
regulations for the product decommissioning will
vary. Disposal of the product will vary with local
regulations.
Improperly disposing of waste can threaten the
environment. Obey all local regulations for the
decommissioning and disposal of materials.
Utilize appropriate personal protective equipment
when decommissioning and disposing product.
Consult the nearest Cat dealer for additional
information. Including information for component
remanufacturing and recycling options.
216 SEBU7029-05
Index Section
Index
A Bucket Linkage - Inspect/Adjust.................... 153
Bucket Tips - Inspect/Replace ...................... 154
Adjustable Gage Undercarriage Frame ........ 122
Bucket Tips ................................................ 154
Extending................................................... 123
Side Cutters ............................................... 156
Retracting .................................................. 122
Side Protectors (If Equipped) .................... 157
Adjustable Gage Undercarriage Frame -
Burn Prevention............................................... 21
Lubricate (If Equipped) ................................ 147
Batteries....................................................... 21
Air Conditioner/Cab Heater Filter
Coolant ........................................................ 21
(Recirculation) - Inspect/Replace ................ 147
Oils............................................................... 21
Air Conditioning and Heating Control.............. 66
Air Conditioning and Heating Control (If
Equipped) ...................................................... 69 C
Automatic Climate Control........................... 69 Cab Air Filter (Fresh Air) - Clean/Replace .... 158
Control Panel ............................................... 69 Cab Door ......................................................... 75
Defrost or Dehumidify Operation................. 71 Cab Door...................................................... 75
English Versus Metric Toggle ...................... 71 Side Window................................................ 75
Manual Operation ........................................ 71 Cab Tilting ......................................................118
Maximum Heating and Cooling Mode ......... 70 Lower ..........................................................118
Alternate Exit ................................................... 49 Raise...........................................................119
Automatic Engine Speed Control (AEC) ......... 82 Cab Visor (If Equipped) ................................... 74
Mode I .......................................................... 82 Capacities (Refill) .......................................... 141
Mode II ......................................................... 82 Changing Direction and Speed ..................... 100
Mode III ........................................................ 83 Circuit Breakers - Reset ................................ 158
Clock................................................................ 64
B Condenser (Refrigerant) - Clean................... 158
Cooling System Coolant (ELC) - Change ..... 160
Backup Controls .............................................. 83
Cooling System Coolant Extender (ELC) -
Battery - Clean............................................... 147
Add ...................................................... 161–162
Battery - Recycle ........................................... 147
Cooling System Coolant Level - Check......... 163
Battery Disconnect Switch .............................. 55
Cooling System Coolant Sample (Level 1) -
Battery Hold-Down - Tighten ......................... 148
Obtain .......................................................... 159
Battery or Battery Cable - Inspect/Replace... 148
Cooling System Coolant Sample (Level 2) -
Before Operation ....................................... 25, 46
Obtain .......................................................... 160
Before Starting Engine .................................... 25
Cooling System Hoses - Inspect ................... 164
Belts - Inspect/Adjust/Replace ...................... 148
Replace the Hoses .................................... 165
Alternator Belt and Air Conditioner Belt..... 149
Counterweight Removal and Installation ...... 125
Boom and Stick Linkage - Lubricate ............. 150
Counterweight Removal and Installation for
Boom Base Pins - Lubricate.......................... 149
Standard Machines.................................. 125
Boom, Stick and Bucket Linkage -
Machines Equipped with Counterweight
Lubricate...................................................... 151
Removal System...................................... 126
Grease Block on the Stick ......................... 153
Counterweight Removal Chain - Clean (If
Boom, Stick and Bucket Operation ............... 107
Equipped) .................................................... 166
Digging....................................................... 107
Counterweight Removal Chain - Inspect (If
Lifting Objects ............................................ 108
Equipped) .................................................... 165
Machines that are Equipped with a Long
Counterweight Removal Chain - Lubricate
Reach Configuration .................................110
(If Equipped) ................................................ 166
Boom/Stick/Bucket Combinations................... 38
Crushing Prevention and Cutting Prevention.. 20
345B Excavators ......................................... 38
345B L Excavators....................................... 40
SEBU7029-05 217
Index Section
D Ether ............................................................ 24
Fire Extinguisher.......................................... 24
Daily Inspection ............................................... 46
General ........................................................ 22
Daily Basis ................................................... 46
Lines, Tubes, and Hoses ............................. 24
First 100 Hours ............................................ 46
Wiring........................................................... 23
Severe Applications..................................... 46
Foreword ........................................................... 4
Decommissioning and Disposal.................... 215
California Proposition 65 Warning ................. 4
Certified Engine Maintenance ....................... 5
E Literature Information .................................... 4
Electrical Storm Injury Prevention ................... 25 Machine Capacity .......................................... 5
Emissions Certification Film ............................ 45 Maintenance .................................................. 4
Engine Air Filter Primary Element - Clean/ Operation ....................................................... 4
Replace ....................................................... 167 Product Identification Number ....................... 5
Cleaning Primary Air Filter Elements ........ 168 Safety............................................................. 4
Inspecting the Primary Air Filter Freezing Conditions .......................................113
Elements .................................................. 169 Frozen Ground Conditions ............................ 101
Engine Air Filter Secondary Element - Fuel System - Prime...................................... 177
Replace ....................................................... 169 Fuel System Primary Filter (Water
Engine Air Precleaner - Clean....................... 170 Separator) Element - Replace..................... 178
Engine and Machine Warm-Up ....................... 98 Fuel System Primary Filter/Water
Engine Crankcase Breather - Clean ............. 171 Separator - Clean/Replace.................. 179–180
Engine Oil and Filter - Change ...................... 172 Fuel System Secondary Filter - Replace ...... 181
Engine Oil Level - Check............................... 171 Fuel System Water Separator - Drain ... 182–183
Engine Oil Sample - Obtain........................... 174 Fuel System Water Separator Element -
Engine Speed Control ..................................... 77 Replace ....................................................... 183
Engine Start Switch ......................................... 57 Fuel Tank Cap and Strainer - Clean .............. 184
Engine Starting.................................... 25, 92, 94 Fuel Tank Shutoff and Drain Control ............... 90
Engine Starting (Alternate Methods)............. 134 Fuel Tank Water and Sediment - Drain ......... 185
Engine Starting (Machines with Generator) .... 92 Fill the Fuel Tank........................................ 185
Engine Starting with Ether Starting Aid ........... 95 Fuses - Replace ............................................ 185
Engine Starting with Jump Start Cables (If
Equipped) .................................................... 134 G
Engine Stopping .............................................114
Gauges ............................................................ 62
Engine Valve Lash and Fuel Injector Timing
General Hazard Information............................ 18
- Check ........................................................ 175
Containing Fluid Spillage............................. 19
Engine Valve Rotators - Inspect .................... 175
Dispose of Waste Properly .......................... 20
Equipment Lowering with Engine Stopped .... 30,
Fluid Penetration ......................................... 19
101
Inhalation ..................................................... 20
Machine with a Boom Lowering Control
Pressurized Air and Water........................... 19
Valve ........................................................ 101
Trapped Pressure ........................................ 19
Ether Starting Aid Cylinder - Replace ........... 175
General Information ........................................ 35
Ether Starting Aid Switch (If Equipped)........... 57
Guards............................................................. 33
Guards (Operator Protection)
F Other Guards (If Equipped) ......................... 34
Final Drive Oil - Change ................................ 176 Rollover Protective Structure (ROPS), Falling
Final Drive Oil Level - Check......................... 177 Object Protective Structure (FOPS) or Tip
Final Drive Oil Sample - Obtain..................... 178 Over Protection Structure (TOPS)............. 33
Fire Extinguisher Location............................... 25
Fire Prevention and Explosion Prevention...... 22 H
Battery and Battery Cables.......................... 23
Hammer Control (If Equipped) ........................ 85
218 SEBU7029-05
Index Section
Hammer Operation (If Equipped) ................... 111 M

Hydraulic Lockout Control ............................... 84
Machine Operation .......................................... 49
Hydraulic System Oil - Change ..................... 186
Magnet Controller and Monitor Panel ............. 63
4000 Hour Oil Change Interval .................. 186
Maintenance Interval Schedule..................... 144
Procedure to Change the Hydraulic Oil..... 187
Every 10 Service Hours or Daily................ 144
Hydraulic System Oil Filter - Replace ........... 195
Every 10 Service Hours or Daily for First 100
Replace the Case Drain Filter ................... 196
Hours ....................................................... 144
Replace the Case Drain Filter for the
Every 10 Service Hours or Daily for Machines
Generator (If Equipped) ........................... 197
Used in Severe Applications.................... 144
Replace the Pilot Filter............................... 195
Every 100 Service Hours of Continuous
Hydraulic System Oil Filter (Return) -
Hammer Use............................................ 144
Replace ....................................................... 191
Every 1000 Service Hours of Partial Hammer
Hydraulic System Oil Level - Check.............. 199
Use (50% of Service Hours) .................... 146
Hydraulic System Oil Sample - Obtain.......... 200
Every 1000 Service Hours or 6 Months..... 145
Hydraulic Tank Shutoff Valve (If Equipped)..... 90
Every 12 000 Service Hours or 6 Years..... 146
Every 2000 Service Hours or 1 Year ......... 146
I Every 250 Service Hours ........................... 145
Identification Information ................................. 45 Every 250 Service Hours of Partial Hammer
Important Safety Information............................. 2 Use (50% of Service Hours) .................... 145
Indicators and Gauges - Test ........................ 200 Every 250 Service Hours or Monthly ......... 145
Every 3 Years After Date of Installation or
Every 5 Years After Date of
J
Manufacture ............................................. 146
Joystick Controls ............................................. 85 Every 4000 Service Hours or 2 Years ....... 146
Joystick Controls Alternate Patterns (If Every 50 Service Hours or Weekly............ 144
Equipped) ...................................................... 86 Every 500 Service Hours ........................... 145
Every 500 Service Hours or 3 Months....... 145
L Every 600 Service Hours of Continuous
Hammer Use............................................ 145
Leaving the Machine ......................................114 Every 6000 Service Hours or 3 Years ....... 146
Storing Vandalism Guards..........................115 Every Year ................................................. 146
Lifting and Tying Down the Machine ............. 129 Initial 250 Service Hours............................ 144
Lifting the Machine Segments ................... 130 Initial 500 Hours (for New Systems, Refilled
Lifting Capacities ............................................. 42 Systems, and Converted Systems) ......... 145
English ......................................................... 43 When Required.......................................... 144
Metric ........................................................... 43 Maintenance Section..................................... 136
Lifting Objects.................................................. 29 Maintenance Support .................................... 143
Light Switches ................................................. 65 Material Handler Operation ............................110
Lubricant Viscosities (Fluids Mirror ......................................................... 72–73
Recommendations) ..................................... 136 Mirror Installation................................... 120–121
Biodiesel .................................................... 141 Monitoring System........................................... 57
Coolant Information ................................... 141 Functional Test............................................. 58
Diesel Fuel Recommendations ................. 140 Warning Categories ..................................... 58
Engine Oil .................................................. 136 Mounting and Dismounting ............................. 47
Fuel Additives ............................................ 141 Machine Access System Specifications...... 48
General Information for Lubricants............ 136
Hydraulic Systems..................................... 137
O
Other Fluid Applications ............................ 138
Selecting the Viscosity............................... 136 Oil Filter - Inspect .......................................... 201
Special Lubricants ..................................... 139 Inspect a Used Filter for Debris ................. 201
Lubricant Viscosities and Refill Capacities ... 136 Operating Technique Information.................. 103
SEBU7029-05 219
Index Section
Operating Precaution................................. 105 Improper Connections For Jump Start

Restricted Operation.................................. 103 Cables .......................................................... 7
Operating Techniques ................................... 103 Improper Operation of the System for the
Operation................................................... 26, 99 Removal of the Counterweight .................. 16
Critical Failures ............................................ 27 Lift Eyes Can Fail........................................... 9
Limiting Conditions and Criteria .................. 26 Machine Control Pattern.............................. 13
Machine Operating Temperature Range ..... 26 No Ether....................................................... 10
Machine Operation ...................................... 28 Pressurized System..................................... 12
Machine Operation when the Machine is not Product Link................................................. 16
Completely Assembled .............................. 29 Relieve Hydraulic Tank Pressure .................. 8
Operation Information ..................................... 99 Tilting the Cab.............................................. 14
Operation Section............................................ 46 Travel Speed Control Switch ........................11
Operator Controls............................................ 53 Safety Section ................................................... 6
Operator Station .............................................. 33 Seat ................................................................. 49
Seat Belt .......................................................... 51
P Extension of the Seat Belt ........................... 53
Seat Belt Adjustment for Non-Retractable
Parking .....................................................30, 113 Seat Belts................................................... 51
Plate Locations and Film Locations ................ 45 Seat Belt Adjustment for Retractable Seat
Power Mode Control........................................ 78 Belts ........................................................... 52
Product Information Section............................ 35 Seat Belt - Inspect ......................................... 204
Product Link (If Equipped)............................... 55 Seat Belt - Replace ....................................... 204
Regulatory Compliance ............................... 56 Securing the Machine.....................................117
Service Hour Meter ......................................... 64
R Shipping the Machine.....................................116
Shipping a Machine that is not Completely
Radiator Core - Clean ........................... 201–202
Assembled ................................................117
Receiver Dryer (Refrigerant) - Replace ........ 203
Sound Information and Vibration
Reference Information Section ..................... 214
Information..................................................... 31
Reference Material ........................................ 214
Sound Level Information.............................. 31
Additional Reference Material ................... 214
Sources........................................................ 33
Caterpillar Reference Material................... 214
“The European Union Physical Agents
Reference Materials ...................................... 214
(Vibration) Directive 2002/44/EC”.............. 31
Specifications ............................................ 35, 38
S Stopping the Machine.....................................113
S·O·S Information ......................................... 142 Storage Box..................................................... 66
Safety Messages............................................... 6 Exterior Storage Box ................................... 66
Automatic Engine Speed Control (AEC) ......11 Interior Storage Box..................................... 66
Certification for Falling Object Guard Swing Bearing - Lubricate ............................. 205
Structure (If Equipped)............................... 15 Swing Drive Oil - Change .............................. 205
Changes To Machine Control Pattern ......... 12 Swing Drive Oil Level - Check....................... 206
Crush Points ................................................ 14 Swing Drive Oil Sample - Obtain................... 207
Crushing Hazard.......................................... 17 Swing Gear - Lubricate.................................. 208
Do Not Operate.............................................. 6
Electrical Shock Hazard .............................. 15 T
Electrical Shock Hazard (If Equipped)........... 6
Table of Contents .............................................. 3
Engagement of the Quick Coupler Wedge.. 13
Towing Information ........................................ 131
Height And Reach Of Machine ...................... 7
Towing the Machine....................................... 131
High Pressure Cylinder................................ 10
Track Adjustment - Adjust ............................. 209
High Pressure Gas ........................................ 9
Adjusting Track Tension ............................ 210
220 SEBU7029-05
Index Section
Measuring Track Tension .......................... 209

Track Adjustment - Inspect............................ 210
Transportation Information .............................116
Travel Alarm - Test (If Equipped)....................211
Travel Alarm (If Equipped) .............................. 65
Travel Alarm Cancel Switch ........................ 65
Travel Control .................................................. 75
Travel in Water and Mud ............................... 105
Procedure for Removing the Machine from
Water or Mud ........................................... 106
Travel Speed Control ...................................... 77
U
Undercarriage - Check ...................................211
User Mode Control .......................................... 80
Activating Memory ....................................... 80
Selecting a Sub-mode ................................. 81
Setting the Customer Mode......................... 81
W
Welding on Machines and Engines with
Electronic Controls ...................................... 143
Window (Front)................................................ 71
Lower Window ............................................. 72
Upper Window ............................................. 72
Window Washer Reservoir - Fill .................... 212
Window Wiper - Inspect/Replace .................. 212
Window Wiper and Washer Control ................ 73
Windows - Clean ........................................... 212
Cleaning Methods...................................... 212
Polycarbonate Windows (If equipped) ...... 213
Work Mode Control ......................................... 79
Work Tool Electronic Controller....................... 89
Work Tool Flow Control (If Equipped) ............. 88
Combined Hydraulic Attachment Circuit ..... 88
Work Tool Flow Mode Control (If Equipped) ... 87
Work Tools....................................................... 26
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:
SEBU7029 CAT, CATERPILLAR, LET’S DO THE WORK, their respective
©2020 Caterpillar logos, “Caterpillar Corporate Yellow”, the “Power Edge” and Cat
All Rights Reserved “Modern Hex” trade dress as well as corporate and product identity
used herein, are trademarks of Caterpillar and may not be used
without permission.
222 June 2020

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Important Safety Information

The meaning of this safety alert symbol is as follows:

Table of Contents Machine Operation .......................................... 49

Fire Extinguisher Location............................... 25

Lubricant Viscosities and Refill Capacities ... 136

Before Operation ............................................. 25 Reference Information Section

Work Tools....................................................... 26 Reference Materials ...................................... 214

Operation......................................................... 26 Index Section

Lifting Objects.................................................. 29 Index.............................................................. 216

Equipment Lowering with Engine Stopped ..... 30

Sound Information and Vibration Information . 31

Operator Station .............................................. 33

Guards (Operator Protection) ......................... 33

Product Information Section

General Information ........................................ 35

Identification Information ................................. 45

Before Operation ............................................. 46

Foreword Whenever a question arises regarding your machine,

It is prohibited for any person engaged in the

Product Identification Number

Electrical Shock Hazard (If

This safety message is positioned in the cab.

This warning label is located on the engine. This is a

Illustration 5 g00039226 Illustration 7 g00100702

Illustration 6 g00274805 Illustration 8 g00100710

Relieve Hydraulic Tank Pressure

This safety message is located on the top of the

IMPROPER JUMPER CABLE CONNECTIONS

Illustration 11 g00100722 Illustration 13 g00100728

HYDRAULIC TANK LIFT EYES OR TANK CAN FAIL WHEN LIFTING

High Pressure Gas

This system contains high pressure gas. Failure

Illustration 19 g00100745 Illustration 21 g00100749

Illustration 23 g00100755 Illustration 25 g00100763

Illustration 27 g00100767 Illustration 29 g00100776

Engagement of the Quick Coupler

Illustration 31 g00100783 Illustration 33 g00102389

Tilting the Cab

This safety message can be positioned in the

STRUCTURAL DAMAGE, AN OVERTURN, MODI-

Certification for Falling Object

Illustration 39 g00709188 Illustration 41 g00115455

Before servicing, turn generator disconnect IMPROPER OPERATION OF THE COUNTER-

Illustration 40 g00278621 Illustration 42 g01021158

Illustration 43 g01013264 Illustration 44 g06548865

This machine is equipped with a Cat Product Link

Crushing Hazard! Personal injury or death can

Reference: Refer to Operation and Maintenance

General Hazard Information

Wear a hard hat, protective glasses, and other

When you perform maintenance above ground level,

Pressurized Air and Water

Exhaust Dispose of Waste Properly

• Never use compressed air for cleaning. i01359664

• Avoid brushing materials that contain asbestos. Crushing Prevention and

All fuels, most lubricants, and some coolant mixtures