330 GC Operators Manual

M0111427-02 (en-us)
February 2021
Operation and
Maintenance
Manual
330 GC Excavator
FEK 1-UP (330 GC)
SYH 1-UP (330 GC)
Language: Original Instructions
PUBLICATIONS.CAT.COM
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.
M0111427-02 3
Table of Contents
Table of Contents Equipment Lowering with Engine Stopped ..... 45
Sound Information and Vibration Information . 45

Foreword ........................................................... 5
Operator Station .............................................. 48
Safety Section
Guards (Operator Protection) ......................... 48
Safety Messages............................................... 7
Additional Messages ....................................... 20

Product Information Section
General Information ........................................ 50

General Hazard Information............................ 26
Identification Information ................................. 80
Crushing Prevention and Cutting Prevention.. 29
Burn Prevention............................................... 30 Operation Section
Fire Prevention and Explosion Prevention...... 31 Before Operation ............................................. 85
Fire Safety ....................................................... 34 Machine Operation .......................................... 88
Fire Extinguisher Location............................... 35 Engine Starting.............................................. 183
Track Information ............................................ 35 Operation....................................................... 188
High Pressure Fuel Lines ................................ 35 Operating Techniques ................................... 194
Electrical Storm Injury Prevention ................... 36 Parking .......................................................... 224
Before Starting Engine .................................... 36 Transportation Information ............................ 228
Visibility Information ........................................ 36 Towing Information ........................................ 234
Restricted Visibility .......................................... 37 Engine Starting (Alternate Methods)............. 237
Engine Starting................................................ 39 Maintenance Section
Before Operation ............................................. 39 Maintenance Access ..................................... 240
Work Tools....................................................... 39 Lubricant Viscosities and Refill Capacities ... 243
Operation......................................................... 40 Maintenance Support .................................... 250
Engine Stopping .............................................. 43 Maintenance Interval Schedule..................... 257
Lifting Objects.................................................. 43 Warranty Section
Demolition ....................................................... 43 Warranty Information..................................... 329
Parking ............................................................ 44 Reference Information Section
Slope Operation .............................................. 44 Reference Materials ...................................... 330

4 M0111427-02
Table of Contents
Index Section
Index.............................................................. 331
M0111427-02 5
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.
6 M0111427-02
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)
M0111427-02 7
Safety Section
Safety Messages
Safety Section
i07473534
Safety Messages
SMCS Code: 7000; 7405
There are several specific safety messages on this
machine. The exact location of the hazards and the
description of the hazards are reviewed in this
section. Please become familiarized with all safety
messages.
Make sure that all the safety messages are legible.
Clean the safety messages or replace the safety
messages if you cannot read the words. Replace the
illustrations if the illustrations are not visible. When
you clean the safety messages, use a cloth, water,
and soap. Do not use solvent, gasoline, or other
harsh chemicals to clean the safety messages.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety message. Loose
adhesive will allow the safety message to fall.
Replace any safety message that is damaged, or
missing. If a safety message is attached to a part that
is replaced, install a safety message on the
replacement part. Any Cat dealer can provide new
safety messages.
8 M0111427-02
Safety Section
Safety Messages
M0111427-02 9
Safety Section
Safety Messages
10 M0111427-02
Safety Section
Safety Messages
M0111427-02 11
Safety Section
Safety Messages
Lifting Level Warning (1)
Overload Warning Device (2) Overloading the machine could impact the ma-
chine's stability which could result in a tipover
If equipped, this safety message is located in the cab hazard. A tipover hazard could result in serious
on the right side window. injury or death. Always activate the overload
warning device before you handle or lift objects.
Refer to Operation and Maintenance Manual,

“Operator Controls” for further information.
Crushing Injury (3)

If equipped, this safety message is located in the cab
on the right side window.
12 M0111427-02
Safety Section
Safety Messages

“Window (Front)” for further information.
Product Link (5)

Crush injury. Could cause serious injury or death.

Always confirm that the quick coupler is engaged
onto the pins. Read the Operator's Manual.
Refer to Operation and Maintenance Manual, “Quick

Coupler Operation” for further information.
This machine is equipped with a Caterpillar Prod-
Crushing Hazard (4) uct Link communication device. When electric
detonators are used, this communication device
These safety messages are on the left and right side should be deactivated within 12 m (40 ft) of a
cab windows. blast site for satellite-based systems and within
3 m (10 ft) of a blast site for cellular based sys-
tems, or within the distance mandated under ap-
plicable legal requirements. Failure to do so
could cause interference with blasting operations
and result in serious injury or death.
In cases where the type of Product Link module
cannot be identified, Caterpillar recommends that
the device be disabled no less than 12 m (40 ft)
from the blast perimeter.

“Product Link” for further information.
Do Not Operate (6A)

This safety message is located in the cab on the right
side window.
Personal injury can result if the window is not

latched in the overhead position; ensure the auto
lock is engaged.
M0111427-02 13
Safety Section
Safety Messages
Illustration 11 g06188661 Illustration 12 g02282255
Do not operate or work on this machine unless Crush Hazard! A machine may move unexpect-
you have read and understand the instructions edly and without warning resulting in personal in-
and warnings in the Operation and Maintenance jury or death.
Manual. Failure to follow the instructions or heed
the warnings could result in injury or death. Con- Before leaving the machine lower the work tool to
tact any Caterpillar dealer for replacement man- the ground, lock operator controls, shut off the
uals. Proper care is your responsibility. engine and remove the key.
Crushing Hazard (6B) Seat Belt (6C)

If equipped, this safety message is located in the cab This safety message is located in the cab on the right
on the right side window. side window.
14 M0111427-02
Safety Section
Safety Messages
A seat belt should be worn at all times during ma- Crushing Hazard! Certain machine front linkage
chine operation to prevent serious injury or death combinations (boom, stick, quick coupler, work
in the event of an accident or machine overturn. tool) may require keeping the work tool away
Failure to wear a seat belt during machine opera- from the cab during operation. Personal injury or
tion may result in serious injury or death. death may result if the work tool contacts the cab
during operation.
Crushing Hazard (6D)

Crushing Hazard (6E)
This safety message is located in the cab on the right
side window. This safety message is located in the cab on the right
side window.
The impact from objects that strike the front of

the cab or the top of the cab could result in a
crushing hazard with the potential for personal
injury or death.
The front guard and the top guard should be in-
stalled on the cab for applications where the haz-
ard of falling objects exist. Read the Operation
and Maintenance Manual.
M0111427-02 15
Safety Section
Safety Messages

“Guards” for further information.
Joystick Controls Alternate

Patterns (6F)
Electrocution Hazard! Keep the machine and

attachments a safe distance from electrical
power. Stay clear 3 m (10 ft) plus twice the line
insulator length. Read and understand the
instructions and warnings in the Operation and
Illustration 16 g06188665 Maintenance Manual. Failure to follow the
instructions and warnings will cause serious
injury or death
Crush Hazard. Improper joystick setting could Refer to Operation and Maintenance Manual,
cause possible unexpected movement of the “Specifications” for further information.
boom, stick, or worktool which could result in
serious injury or death. Confirm that the joystick
settings are properly configured before you oper- Do Not Lift Over Personnel (7)
ate the machine. Read the Operation and Mainte-
nance Manual. This safety message is located in the cab on the right
side window.

“Joystick Controls Alternate Patterns” for further
information.
Electrical Power Lines (6G)

This safety message is located in the cab.
16 M0111427-02
Safety Section
Safety Messages
This machine has been certified to the standards that

are listed on the certification plate. The maximum
mass of the machine, which includes the operator
and the attachments without a payload, should not
exceed the mass on the certification plate.
“Guards (Operator Protection)” for more information.
Hot Surface (9)

This message is on the outside of the engine hood
and on the inside of the engine hood.
Do not lift
Do Not Weld or Drill on ROPS (8)
Engine hood and engine hood parts can be hot

while engine is running or immediately after en-
gine shutdown. Hot parts or hot components can
cause burns or personal injury. Do not allow
these parts to contact your skin, when engine is
running or immediately after engine shutdown.
Use protective clothing or protective equipment
to protect your skin.
Crushing Hazard (10)

This safety message is on each side of the rear of the

If equipped, this safety message is on the left side machine.
pillar in the cab.
Structural damage, an overturn, modification, al-

teration, or improper repair, can impair this struc-
ture's protective capability thereby voiding this
certification. Do not weld on or drill holes in the
structure. Consult a Caterpillar dealer to deter-
mine this structure's limitations without voiding
its certification.
M0111427-02 17
Safety Section
Safety Messages

“Engine Starting” for the proper starting procedure.
Jump-Start Cables (12)

This safety message is positioned on the circuit
breaker panel.
Machine swings. Stay back. Crushing hazard

could cause serious injury or death.
Aerosol Starting Aid (11)

This safety message is located near the precleaner.
The following information is not applicable to Explosion Hazard! Improper jumper cable con-
machines that are equipped with an ether starting nections can cause an explosion resulting in seri-
aid. ous injury or death. Batteries may be located in
separate compartments. Refer to the Operation
and Maintenance Manual for the correct jump
starting procedure.

“Engine Starting with Jump-Start Cables” for further
information.
High-Pressure Cylinder (13)

This safety message is on the back of both the track
adjuster covers.
Explosion hazard! Do not use ether! This ma-

chine is equipped with an air inlet heater. Using
ether can create explosions or fires that can
cause personal injury or death. Read and follow
the starting procedure in the Operation and Main-
tenance Manual.
18 M0111427-02
Safety Section
Safety Messages
Pressurized System!
Hydraulic accumulators contain gas and oil
under high pressure. DO NOT disconnect lines or
disassemble any component of a pressurized ac-
cumulator. All gas pre-charge must be removed
from the accumulator as instructed by the service
Personal injury or death can result from grease manual before servicing or disposing of the accu-
under pressure. mulator or any accumulator component.
Grease coming out of the relief valve under pres- Failure to follow the instructions and warnings
sure can penetrate the body causing injury or could result in personal injury or death.
death.
Only use dry nitrogen gas to recharge accumula-
Do not watch the relief valve to see if grease is es- tors. See your Cat dealer for special equipment
caping. Watch the track or track adjustment cylin- and detailed information for accumulator service
der to see if the track is being loosened. and charging.
Loosen the relief valve one turn only.

If track does not loosen, close the relief valve and “Equipment Lowering with Engine Stopped” for
contact your Cat dealer. further information.
Crushing Hazard (15)

This safety message is on both sides of the stick.
Recoil system contains high-pressure nitrogen
cylinder. Parts can separate with explosive force
if proper care is not used during disassembly.
This action can cause serious injury or death.
Do not disassemble any part of this cylinder until
you have read and understand the instructions
given in the service manual. Observe the instruc-
tions given in the service manual.
High-Pressure Gas (14)

This safety message is positioned on the
accumulator.
M0111427-02 19
Safety Section
Safety Messages
Explosion hazard! Fuel vapors can accumulate in

the refueling pump compartment and can be ig-
Illustration 26 g01385579 nited by improper operation of the refueling
pump. Failure to follow the operating instructions
for the refueling pump could result in personal in-
jury or death. Read and follow the operating in-
structions for the refueling pump in the Operation
A crushing hazard exists when the stick and and Maintenance Manual.
boom are in motion and when the machine is
being used in object handling applications. Fail-
ure to stay clear of the stick and boom when the Refer to Operation and Maintenance Manual, “Fuel
machine is in operation can result in personal in- Transfer Pump (Refueling)” for further information.
jury or death. Stay clear of the stick and boom
when the machine is in operation. Relieve Hydraulic Tank Pressure
(17)
Vapor Explosion (16) (If Equipped) This safety message is on top of the hydraulic tank.
If equipped, this safety message is inside the rear
storage compartment on the right side, near the fuel
transfer pump.
20 M0111427-02
Safety Section
Additional Messages
Hot Fluid Under Pressure! Structural damage, an overturn, modification, al-

teration, or improper repair can impair this struc-
Do NOT remove pressure cap when hot. Hot oil ture's protection capability thereby voiding this
could cause serious injury or death. certification. Do not weld on or drill holes in the
structure. Consult a Caterpillar dealer to deter-
mine this structure's limitations without voiding
Falling Object Guard Structure (18) its certification.
If equipped, this safety message is on top of the front

falling object guard structure. This safety message is i07856403
also on the left side of the falling object guard
structure on the top of the cab. Additional Messages
SMCS Code: 7000; 7405
There are several specific messages on this
machine. The exact location of the messages and the
description of the information are reviewed in this
section. Become familiar with all messages.
Make sure that all the messages are legible. Clean
the messages or replace the messages if you cannot
read the words. Replace the illustrations if the
illustrations are not legible. When you clean the
messages, use a cloth, water, and soap. Do not use
solvent, gasoline, or other harsh chemicals to clean
the messages. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures the
messages. Loose adhesive will allow the messages
to fall.
Replace any message that is damaged, or missing. If
a message is attached to a part that is replaced,
install a message on the replacement part. Any Cat
dealer can provide new messages.
M0111427-02 21
Safety Section
Additional Messages
22 M0111427-02
Safety Section
Additional Messages
Front Window Usage (1)

M0111427-02 23
Safety Section
Additional Messages
Hammer Operation(2) The Product Link System is a satellite communication

device that transmits information regarding the
This message is on the window on the right side of machine back to Caterpillar and Cat dealers and
the cab. customers. All logged events and diagnostic codes
that are available to the Cat Electronic Technician
(ET) on the Cat data link can be sent to the satellite.
Information can also be sent to the Product Link
System. The information is used to improve Cat
products and Cat services.
“Product Link” for more information.
Joystick Controls Alternate Patterns (4)
If equipped, this message is on the right side window
of the cab.
See Operation and Maintenance Manual, “Hammer

Operation” within Operation and Maintenance
Manual, “Work Tool Control (One-Way Flow)” for
instructions on hammer operation.
Also, see Operation and Maintenance Manual,
“Hydraulic Hammer Control (Foot Switch)” within
Operation and Maintenance Manual, “Work Tool
Control (One-Way Flow)” for instructions on hammer
operation.
Data Privacy (3) Illustration 36 g06214805

“Joystick Controls Alternate Patterns” for further
information.
Hose Burst (5)
24 M0111427-02
Safety Section
Additional Messages
No Step (8)
This message is on various places on the upper
structure and covers. It is also on the engine valve
cover.
Hose Burst (6)
Do not step in this area.

Air Conditioner (9)
These messages are positioned on the left door
behind the cab.
Alternate Exit (7)

If equipped, this message is on the rear window of
the cab in the lower left-hand corner.
(10A) Air conditioning symbol
(10B) R134a (Refrigerant type common name)
(10C) Refrigerant quantity
(10D) PAG (polyalkylene glycol) lubricating oil part number
Pull the ring to pull out the seal. Push the window out
of the cab and exit through the opening.
“Alternate Exit” for further information.
M0111427-02 25
Safety Section
Additional Messages
If equipped, this plate provides the below additional
European Union required greenhouse gas
information.
(10E) (1430) - This is the Global Warming Potential of R134a
(10F) CO2 equivalent
(10G) The system contains 1.430 metric tonne of CO2 equivalent
Tier 3 Engines

“Lubricant Viscosities”.
Diesel Fuel Requirements (11)
This message is located by the fuel tank.
(10H) If equipped, this film provides the required language
translations of the text "Contains fluorinated greenhouse
gases" for the European Union greenhouse gas regulation.
These messages for the air conditioner system have

the appropriate information for the following services:
the air conditioner lubricant, the refrigerant charge,
and the refrigerant capacity.
Engine Oil Requirements (10)
This message is on top of the engine.
26 M0111427-02
Safety Section
General Hazard Information
i08313103

SMCS Code: 7000
Typical example
Attach a “Do Not Operate” warning tag or a similar

warning tag to the start switch or to the controls.
Attach the warning tag before you service the
equipment or before you repair the equipment.
Warning tag SEHS7332 is available from your Cat
Illustration 45 g03218956 dealer.
(A) North America film
(B) Europe, Africa, Middle East film
(C) Japan film
Hydraulic Oil Level Check (12) Operating the machine while distracted can result
in the loss of machine control. Use extreme cau-
This message is located in the right access tion when using any device while operating the
compartment next to the sight gauge for the hydraulic machine. Operating the machine while distracted
oil . can result in personal injury or death.
Know the width of your equipment to maintain proper

clearance when you operate the equipment near
fences or near boundary obstacles.
Be aware of high-voltage power lines and power
cables that are buried. If the machine comes in
contact with these hazards, serious injury or death
may occur from electrocution.
Check hydraulic oil level daily. See Operation and

Maintenance Manual, “Hydraulic System Oil Level -
Check” for details.
M0111427-02 27
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
Wear a hard hat, protective glasses, and other must be reduced to 205 kPa (30 psi) when the
protective equipment, as required. nozzle is deadheaded and the nozzle is used with an
effective chip deflector and personal protective
Do not wear loose clothing or jewelry that can snag equipment. The maximum water pressure for
on controls or on other parts of the equipment. cleaning purposes must be below 275 kPa (40 psi).
Make sure that all protective guards and all covers Avoid direct spraying of water on electrical
are secured in place on the equipment. connectors, connections, and components. When
using air for cleaning, allow the machine to cool to
Keep the equipment free from foreign material. reduce the possibility of fine debris igniting when re-
Remove debris, oil, tools, and other items from the deposited on hot surfaces.
deck, from walkways, and from steps.
Secure all loose items such as lunch boxes, tools, Trapped Pressure
and other items that are not a part of the equipment.
Pressure can be trapped in a hydraulic system.
Know the appropriate work site hand signals and the Releasing trapped pressure can cause sudden
personnel that are authorized to give the hand machine movement or attachment movement. Use
signals. Accept hand signals from one person only. caution if you disconnect hydraulic lines or fittings.
High-pressure oil that is released can cause a hose
Do not smoke when you service an air conditioner. to whip. High-pressure oil that is released can cause
Also, do not smoke if refrigerant gas may be present. oil to spray. Fluid penetration can cause serious
Inhaling the fumes that are released from a flame that injury and possible death.
contacts air conditioner refrigerant can cause bodily
harm or death. Inhaling gas from air conditioner
refrigerant through a lighted cigarette can cause Fluid Penetration
bodily harm or death.
Pressure can be trapped in the hydraulic circuit long
Never put maintenance fluids into glass containers. after the machine has been stopped. The pressure
Drain all liquids into a suitable container. can cause hydraulic fluid or items such as pipe plugs
to escape rapidly if the pressure is not relieved
Obey all local regulations for the disposal of liquids. correctly.
Use all cleaning solutions with care. Report all Do not remove any hydraulic components or parts
necessary repairs. until pressure has been relieved or personal injury
may occur. Do not disassemble any hydraulic
Do not allow unauthorized personnel on the components or parts until pressure has been relieved
equipment. or personal injury may occur. Refer to the Service
Manual for any procedures that are required to
Unless you are instructed otherwise, perform relieve the hydraulic pressure.
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.
28 M0111427-02
Safety Section
Obey all local regulations for the disposal of liquids.
Inhalation
Always use a board or cardboard when you check for

a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak can Illustration 50 g02159053
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment Exhaust
from a doctor that is familiar with this type of injury.
Use caution. Exhaust fumes can be hazardous to
your health. If you operate the machine in an
Containing Fluid Spillage enclosed area, adequate ventilation is necessary.
Care must be taken in order to ensure that fluids are
contained during performance of inspection, Asbestos Information
maintenance, testing, adjusting, and repair of the
equipment. Prepare to collect the fluid with suitable Cat equipment and replacement parts that are
containers before opening any compartment or shipped from Caterpillar are asbestos free.
disassembling any component that contains fluids. Caterpillar recommends the use of only genuine Cat
replacement parts. Use the following guidelines when
Refer to Special Publication, NENG2500, “Cat dealer you handle any replacement parts that contain
Service Tool Catalog” for the following items: asbestos or when you handle asbestos debris.
• Tools that are suitable for collecting fluids and Use caution. Avoid inhaling dust that might be
equipment that is suitable for collecting fluids generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
• Tools that are suitable for containing fluids and to your health. The components that may contain
equipment that is suitable for containing fluids asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is bound
in a resin or sealed in some way. Normal handling is
not hazardous unless airborne dust that contains
asbestos is generated.
If dust that may contain asbestos is present, there
are several guidelines that should be followed:
• Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.
• Avoid grinding materials that contain asbestos.

• Use a wet method in order to clean up asbestos
materials.
• A vacuum cleaner that is equipped with a high
efficiency particulate air filter (HEPA) can also be
used.
M0111427-02 29
Safety Section
Crushing Prevention and Cutting Prevention
• Use exhaust ventilation on permanent machining • Avoid brushing, grinding, or cutting materials
jobs. suspected of containing hexavalent chromium.
• Wear an approved respirator if there is no other • Obey environmental regulations for the disposal of
way to control the dust. all materials that may contain or have come into
contact with hexavalent chromium.
• Comply with applicable rules and regulations for
the work place. In the United States, use • Stay away from areas that might have hexavalent
Occupational Safety and Health Administration chromium particles in the air.
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”. In Japan, Dispose of Waste Properly
use the requirements found in the “Ordinance on
Prevention of Health Impairment due to Asbestos”
in addition to the requirements of the Industrial
Safety and Health Act.
• Obey environmental regulations for the disposal of
asbestos.
• Stay away from areas that might have asbestos
particles in the air.
Hexavalent Chromium Information

Cat equipment and replacement parts comply with
applicable regulations and requirements where
originally sold. Caterpillar recommends the use of
only genuine Cat replacement parts.
Hexavalent chromium has occasionally been
detected on exhaust and heat shield systems on Cat Improperly disposing of waste can threaten the
engines. Although lab testing is the only accurate environment. Potentially harmful fluids should be
way to know if hexavalent chromium is, in fact, disposed of according to local regulations.
present, the presence of a yellow deposit in areas of
high heat (for example, exhaust system components Always use leakproof containers when you drain
or exhaust insulation) may be an indication of the fluids. Do not pour waste onto the ground, down a
presence of hexavalent chromium. drain, or into any source of water.
Use caution if you suspect the presence of i01359664

hexavalent chromium. Avoid skin contact when
handling items that you suspect may contain
hexavalent chromium, and avoid inhalation of any Crushing Prevention and
dust in the suspect area. Inhalation of, or skin contact
with, hexavalent chromium dust may be hazardous to
Cutting Prevention
your health. SMCS Code: 7000
If such yellow deposits are found on the engine, Support the equipment properly before you perform
engine component parts, or associated equipment or any work or maintenance beneath that equipment.
packages, Caterpillar recommends following local Do not depend on the hydraulic cylinders to hold up
health and safety regulations and guidelines, utilizing the equipment. Equipment can fall if a control is
good hygiene, and adhering to safe work practices moved, or if a hydraulic line breaks.
when handling the equipment or parts. Caterpillar
also recommends the following: Do not work beneath the cab of the machine unless
the cab is properly supported.
• Wear appropriate personal protective equipment
(PPE). Unless you are instructed otherwise, never attempt
adjustments while the machine is moving or while the
• Wash your hands and face with soap and water engine is running.
prior to eating, drinking, or smoking, and also Never jump across the starter solenoid terminals in
during rest room breaks, to prevent ingestion of order to start the engine. Unexpected machine
any yellow powder. movement could result.
• Never use compressed air for cleaning areas
suspected of containing hexavalent chromium.
30 M0111427-02
Safety Section
Burn Prevention
Whenever there are equipment control linkages the Cooling system conditioner contains alkali. Alkali can
clearance in the linkage area will change with the cause personal injury. Do not allow alkali to contact
movement of the equipment or the machine. Stay the skin, the eyes, or the mouth.
clear of areas that may have a sudden change in
clearance with machine movement or equipment Oils
movement.
Stay clear of all rotating and moving parts. Hot oil and hot components can cause personal
injury. Do not allow hot oil to contact the skin. Also,
If it is necessary to remove guards in order to perform do not allow hot components to contact the skin.
maintenance, always install the guards after the
maintenance is performed. Remove the hydraulic tank filler cap only after the
engine has been stopped. The filler cap must be cool
Keep objects away from moving fan blades. The fan enough to touch with a bare hand. Follow the
blade will throw objects or cut objects. standard procedure in this manual to remove the
hydraulic tank filler cap.
Do not use a kinked wire cable or a frayed wire cable.
Wear gloves when you handle wire cable. Batteries
When you strike a retainer pin with force, the retainer The liquid in a battery is an electrolyte. Electrolyte is
pin can fly out. The loose retainer pin can injure an acid that can cause personal injury. Do not allow
personnel. Make sure that the area is clear of people electrolyte to contact the skin or the eyes.
when you strike a retainer pin. To avoid injury to your
eyes, wear protective glasses when you strike a Do not smoke while checking the battery electrolyte
retainer pin. levels. Batteries give off flammable fumes which can
explode.
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.
Check the coolant level only after the engine has
been stopped.
Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to touch
with a bare hand. Remove the filler cap slowly to
relieve pressure.
M0111427-02 31
Safety Section
Fire Prevention and Explosion Prevention
Always wear protective glasses when you work with Keep the access doors to major machine
batteries. Wash hands after touching batteries. The compartments closed and access doors in working
use of gloves is recommended. condition in order to permit the use of fire
suppression equipment, in case a fire should occur.
i06179517
Clean all accumulations of flammable materials such
as fuel, oil, and debris from the machine.
Fire Prevention and Explosion
Do not operate the machine near any flame.
Prevention
Keep shields in place. Exhaust shields (if equipped)
SMCS Code: 7000
protect hot exhaust components from oil spray or fuel
spray in a break in a line, in a hose, or in a seal.
Exhaust shields must be installed correctly.
Do not weld or flame cut on tanks or lines that contain
flammable fluids or flammable material. Empty and
purge the lines and tanks. Then clean the lines and
tanks with a nonflammable solvent prior to welding or
flame cutting. Ensure that the components are
properly grounded in order to avoid unwanted arcs.
Dust that is generated from repairing nonmetallic
hoods or fenders may be flammable and/or
explosive. Repair such components in a ventilated
area away from open flames or sparks. Use suitable
Personal Protection Equipment (PPE).
Inspect all lines and hoses for wear or deterioration.
Illustration 52 g00704000 Replace damaged lines and hoses. The lines and the
hoses should have adequate support and secure
clamps. Tighten all connections to the recommended
Regeneration torque. Damage to the protective cover or insulation
may provide fuel for fires.
The exhaust gas temperatures during regeneration
will be elevated. Follow proper fire prevention Store fuels and lubricants in properly marked
instructions and use the disable regeneration containers away from unauthorized personnel. Store
function (if equipped) when appropriate. oily rags and flammable materials in protective
containers. Do not smoke in areas that are used for
General storing flammable materials.
All fuels, most lubricants, and some coolant mixtures

are flammable.
To minimize the risk of fire or explosion, Caterpillar
recommends the following actions.
Always perform a Walk-Around Inspection, which
may help you identify a fire hazard. Do not operate a
machine when a fire hazard exists. Contact your Cat
dealer for service.
Understand the use of the primary exit and
alternative exit on the machine. Refer to Operation
and Maintenance Manual, “Alternative Exit”.
Do not operate a machine with a fluid leak. Repair
leaks and clean up fluids before resuming machine
operation. Fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause a
fire. A fire may cause personal injury or death.
Remove flammable material such as leaves, twigs,
papers, trash, and so on. These items may
accumulate in the engine compartment or around
other hot areas and hot parts on the machine.
32 M0111427-02
Safety Section
Never store flammable fluids in the operator

compartment of the machine.
Battery and Battery Cables
Use caution when you are fueling a machine. Do not

smoke while you are fueling a machine. Do not fuel a
machine near open flames or sparks. Do not use cell
phones or other electronic devices while you are
refueling. Always stop the engine before fueling. Fill Illustration 54 g03839133
the fuel tank outdoors. Properly clean areas of
spillage. Caterpillar recommends the following in order to
minimize the risk of fire or an explosion related to the
Avoid static electricity risk when fueling. Ultra low battery.
sulfur diesel (ULSD) poses a greater static ignition
hazard than earlier diesel formulations with a higher Do not operate a machine if battery cables or related
sulfur content. Avoid death or serious injury from fire parts show signs of wear or damage. Contact your
or explosion. Consult with your fuel or fuel system Cat dealer for service.
supplier to ensure that the delivery system is in Follow safe procedures for engine starting with jump-
compliance with fueling standards for proper start cables. Improper jumper cable connections can
grounding and bonding practices. cause an explosion that may result in injury. Refer to
Operation and Maintenance Manual, “Engine Starting
with Jump Start Cables” for specific instructions.
Do not charge a frozen battery. This may cause an
explosion.
Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. Do
not smoke in battery charging areas. Do not use cell
phones or other electronic devices in battery
charging areas.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter in
order to check the battery charge.
Daily inspect battery cables that are in areas that are
visible. Inspect cables, clips, straps, and other
restraints for damage. Replace any damaged parts.
Check for signs of the following, which can occur
over time due to use and environmental factors:
• Fraying
M0111427-02 33
Safety Section
• Abrasion Attaching electrical wiring to hoses and tubes that

contain flammable fluids or combustible fluids should
• Cracking be avoided.
• Discoloration Consult your Cat dealer for repair or for replacement

parts.
• Cuts on the insulation of the cable
Keep wiring and electrical connections free of debris.
• Fouling
Lines, Tubes, and Hoses
• Corroded terminals, damaged terminals, and
loose terminals Do not bend high-pressure lines. Do not strike high-
pressure lines. Do not install any lines that are bent
Replace damaged battery cable(s) and replace any or damaged. Use the appropriate backup wrenches
related parts. Eliminate any fouling, which may have in order to tighten all connections to the
caused insulation failure or related component recommended torque.
damage or wear. Ensure that all components are
reinstalled correctly.
An exposed wire on the battery cable may cause a
short to ground if the exposed area comes into
contact with a grounded surface. A battery cable
short produces heat from the battery current, which
may be a fire hazard.
An exposed wire on the ground cable between the
battery and the disconnect switch may cause the
disconnect switch to be bypassed if the exposed area
comes into contact with a grounded surface. This
may result in an unsafe condition for servicing the
machine. Repair components or replace components
before servicing the machine.
Check lines, tubes, and hoses carefully. Wear

Fire on a machine can result in personal injury or Personal Protection Equipment (PPE) in order to
death. Exposed battery cables that come into check for leaks. Always use a board or cardboard
contact with a grounded connection can result in when you check for a leak. Leaking fluid that is under
fires. Replace cables and related parts that show pressure can penetrate body tissue. Fluid penetration
signs of wear or damage. Contact your Cat can cause serious injury and possible death. A pin
dealer. hole leak can cause severe injury. If fluid is injected
into your skin, you must get treatment immediately.
Seek treatment from a doctor that is familiar with this
type of injury.
Wiring
Replace the affected parts if any of the following
Check electrical wires daily. If any of the following conditions are present:
conditions exist, replace parts before you operate the
machine. • End fittings are damaged or leaking.
• Fraying • Outer coverings are chafed or cut.
• Signs of abrasion or wear • Wires are exposed.
• Cracking • Outer coverings are swelling or ballooning.
• Discoloration • Flexible parts of the hoses are kinked.
• Cuts on insulation • Outer covers have exposed embedded armoring.
• Other damage • End fittings are displaced.
Make sure that all clamps, guards, clips, and straps
are reinstalled correctly. This will help to prevent
vibration, rubbing against other parts, and excessive
heat during machine operation.
34 M0111427-02
Safety Section
Fire Safety
Make sure that all clamps, guards, and heat shields Consider installation of an aftermarket Fire
are installed correctly. During machine operation, this Suppression System, if the application and working
will help to prevent vibration, rubbing against other conditions warrant the installation.
parts, excessive heat, and failure of lines, tubes, and
hoses. i07041871
Do not operate a machine when a fire hazard exists.

Repair any lines that are corroded, loose, or Fire Safety
damaged. Leaks may provide fuel for fires. Consult SMCS Code: 7000
your Cat dealer for repair or for replacement parts.
Use genuine Cat parts or the equivalent, for Note: Locate secondary exits and how to use the
capabilities of both the pressure limit and secondary exits before you operate the machine.
temperature limit.
Note: Locate fire extinguishers and how to use a fire
Ether extinguisher before you operate the machine.
Ether (if equipped) is commonly used in cold-weather If you find that you are involved in a machine fire,
applications. Ether is flammable and poisonous. your safety and that of others on site are the top
priority. The following actions should only be
Only use approved Ether canisters for the Ether performed if the actions do not present a danger or
dispensing system fitted to your machine, do not risk to you and any nearby people. Assess the risk of
spray Ether manually into an engine, follow the personal injury and move away to a safe distance as
correct cold engine starting procedures. Refer to the soon as you feel unsafe.
section in the Operation and Maintenance Manual
with the label “Engine Starting” . Move the machine away from nearby combustible
material such as fuel/oil stations, structures, trash,
mulch, and timber.
Lower any implements and turn off the engine as
Manually spraying Ether into an engine with a soon as possible. If you leave the engine running, the
Diesel Particulate Filter (DPF) may result in the engine will continue to feed a fire. The fire will be fed
accumulation of Ether in the DPF and an explo- from any damaged hoses that are attached to the
sion. This in conjunction with other factors may engine or pumps.
result in an injury or death.
If possible, turn the battery disconnect switch to the
OFF position. Disconnecting the battery will remove
Use ether in ventilated areas. Do not smoke while the ignition source in the event of an electrical short.
you are replacing an ether cylinder. Disconnecting the battery will eliminate a second
ignition source if electrical wiring is damaged by the
Do not store ether cylinders in living areas or in the fire, resulting in a short circuit.
operator compartment of a machine. Do not store
ether cylinders in direct sunlight or in temperatures Notify emergency personnel of the fire and your
above 49° C (120.2° F). Keep ether cylinders away location.
from open flames or sparks.
If your machine is equipped with a fire suppression
Dispose of used ether cylinders properly. Do not system, follow the manufacturers procedure for
puncture an ether cylinder. Keep ether cylinders activating the system.
away from unauthorized personnel.
Note: Fire suppression systems need to be regularly
Fire Extinguisher inspected by qualified personnel. You must be
trained to operate the fire suppression system.
As an additional safety measure, keep a fire If you are unable to do anything else, shut off the
extinguisher on the machine. machine before exiting. By shutting off the machine,
Be familiar with the operation of the fire extinguisher. fuels will not continue to be pumped into the fire.
Inspect the fire extinguisher and service the fire If the fire grows out of control, be aware of the
extinguisher regularly. Follow the recommendations following risks:
on the instruction plate.
• Tires on wheeled machines pose a risk of
explosion as tires burn. Hot shrapnel and debris
can be thrown great distances in an explosion.
• Tanks, accumulators, hoses, and fittings can

rupture in a fire, spraying fuels and shrapnel over
a large area.
M0111427-02 35
Safety Section
Fire Extinguisher Location
• Remember that nearly all the fluids on the i02546320

machine are flammable, including coolant and oils.
Additionally, plastics, rubbers, fabrics, and resins High Pressure Fuel Lines
in fiberglass panels are also flammable.
SMCS Code: 1000; 1274; 7000
i06952417
Fire Extinguisher Location Contact with high pressure fuel may cause fluid
SMCS Code: 7000; 7419 penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
structions may cause personal injury or death.
The high pressure fuel lines are the fuel lines that are
between the high pressure fuel pump and the high
pressure fuel manifold and the fuel lines that are
between the fuel manifold and cylinder head. These
fuel lines are different from fuel lines on other fuel
systems.
This is because of the following differences:
• The high pressure fuel lines are constantly

charged with high pressure.
• The internal pressures of the high pressure fuel
lines are higher than other types of fuel system.
• The high pressure fuel lines are formed to shape
and then strengthened by a special process.
Do not step on the high pressure fuel lines. Do not
deflect the high pressure fuel lines. Do not bend or
Illustration 56 g06188176 strike the high pressure fuel lines. Deformation or
damage of the high pressure fuel lines may cause a
Installation of a fire extinguisher is recommended. Be point of weakness and potential failure.
familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire Do not check the high pressure fuel lines with the
extinguisher regularly. Obey the recommendations engine or the starting motor in operation. After the
on the instruction plate. engine has stopped allow 10 minutes to pass in order
to allow the pressure to be purged before any service
The recommended location for mounting the fire or repair is performed on the engine fuel lines.
extinguisher is on the upper handrail on the right side
of the machine. Do not loosen the high pressure fuel lines in order to
remove air from the fuel system. This procedure is
not required.
i01329108
Visually inspect the high pressure fuel lines before
Track Information the engine is started. This inspection should be each
day.
SMCS Code: 4170; 7000
If you inspect the engine in operation, always use the
Track adjusting systems use either grease or oil proper inspection procedure in order to avoid a fluid
under high pressure to keep the track under tension. penetration hazard. Refer to Operation and
Grease or oil under high pressure coming out of the Maintenance Manual, “General hazard Information”.
relief valve can penetrate the body causing injury or
• Inspect the high pressure fuel lines for damage,
death. Do not watch the relief valve to see if grease
or oil is escaping. Watch the track or track adjustment deformation, a nick, a cut, a crease, or a dent.
cylinder to see if the track is being loosened.
• Do not operate the engine with a fuel leak. If there
The pins and bushings in a dry track pin joint can is a leak do not tighten the connection in order to
become very hot. It is possible to burn the fingers if stop the leak. The connection must only be
there is more than brief contact with these tightened to the recommended torque. Refer to
components. Disassembly and Assembly for your engine.
36 M0111427-02
Safety Section
Electrical Storm Injury Prevention
• If the high pressure fuel lines are torqued correctly Before you start the engine and before you move the
and the high pressure fuel lines are leaking the machine, make sure that no one is underneath the
high pressure fuel lines must be replaced. machine, around the machine, or on the machine.
Make sure that the area is free of personnel.
• Ensure that all clips on the high pressure fuel lines
are in place. Do not operate the engine with clips i07746368
that are damaged, missing or loose.
Visibility Information
• Do not attach any other item to the high pressure
fuel lines. SMCS Code: 7000
• Loosened high pressure fuel lines must be Before you start the machine, perform a walk-around
replaced. Also removed high pressure fuel lines inspection in order to ensure that there are no
hazards around the machine.
must be replaced. Refer to Disassembly and
Assembly for your engine. While the machine is in operation, constantly survey
the area around the machine in order to identify
i01122596 potential hazards as hazards become visible around
the machine.
Electrical Storm Injury Your machine may be equipped with visual aids.
Prevention Some examples of visual aids are Closed Circuit
Television (CCTV) and mirrors. Before operating the
SMCS Code: 7000 machine, ensure that the visual aids are in proper
working condition and that the visual aids are clean.
When lightning is striking in the vicinity of the Adjust the visual aids using the procedures that are
machine, the operator should never attempt the located in this Operation and Maintenance Manual. If
following procedures: equipped, the Work Area Vision System shall be
adjusted according to Operation and Maintenance
• Mount the machine. Manual, SEBU8157, “Work Area Vision System”. If
equipped, the Cat Detect Object Detection shall be
• Dismount the machine. adjusted according to the Operation and
If you are in the operator's station during an electrical Maintenance Manual, “Cat Detect Object Detection”
storm, stay in the operator's station. If you are on the for your machine.
ground during an electrical storm, stay away from the It may not be possible to provide direct visibility on
vicinity of the machine. large machines to all areas around the machine.
Appropriate job site organization is required in order
i00771840 to minimize hazards that are caused by restricted
visibility. Job site organization is a collection of rules
Before Starting Engine and procedures that coordinates machines and
people that work together in the same area.
SMCS Code: 1000; 7000 Examples of job site organization include the
following:
Start the engine only from the operator compartment.
Never short across the starter terminals or across the • Safety instructions
batteries. Shorting could damage the electrical
system by bypassing the engine neutral start system. • Controlled patterns of machine movement and
Inspect the condition of the seat belt and of the vehicle movement
mounting hardware. Replace any parts that are worn
• Workers that direct safe movement of traffic
or damaged. Regardless of appearance, replace the
seat belt after three years of use. Do not use a seat • Restricted areas
belt extension on a retractable seat belt.
Adjust the seat so that full pedal travel can be • Operator training
achieved with the operator's back against the back of
the seat. • Warning symbols or warning signs on machines or
on vehicles
Make sure that the machine is equipped with a
lighting system that is adequate for the job • A system of communication
conditions. Make sure that all machine lights are
working properly. • Communication between workers and operators
prior to approaching the machine
M0111427-02 37
Safety Section
Restricted Visibility
Modifications of the machine configuration by the

user that result in a restriction of visibility shall be
evaluated.
i07855297
SMCS Code: 7000
The size and the configuration of this machine may
result in areas that cannot be seen when the operator
is seated. For restricted visibility areas, an
appropriate job site organization must be utilized to
minimize hazards of this restricted visibility. For more
information regarding job site organization refer to
Operation and Maintenance Manual, “Visibility
Information”.
Illustrations 57 to 59 provide an approximate visual
indication of the areas at ground level inside a radius
of 12 m (39 ft) from the operator of significant
restricted visibility for various machine configurations.
Refer to the correct illustration for your machine
configuration. All restricted visibility areas less than
300 mm wide may not be shown. These illustrations
do not indicate areas of restricted visibility for
distances outside of the shown radius. The areas of
restricted visibility shown in the illustrations are with
the track and work tool of the machine in the Travel
position. Illustration 60 shows the position of the work Illustration 57 g06366562
tool in the travel position. The Caterpillar authorized
work tool that resulted in the largest visibility Top view of the machine, ground level visibility
restriction was used. without use of optional visual aids
(A) 12 m (39 ft)
Illustration 57 indicates restricted visibility areas at
ground level inside the shown radius from the Note: The shaded areas indicate the approximate
operator without the use of visual aids that may be location of areas with significant restricted visibility.
optional for this product in some markets.
ground level inside the shown radius from the
operator with the use of available rear camera, right
side mirror, and left side mirror installed.
38 M0111427-02
Safety Section

Top view of the machine, ground level visibility with Top view of the machine, ground level visibility with
available camera, left side mirror and right side mirror rear camera, right side camera, left side mirror, and
(A) 12 m (39 ft) left side second mirror.
(A) 12 m (39 ft)
Note: The shaded areas indicate the approximate
location of areas with significant restricted visibility. Note: The shaded areas indicate the approximate
location of areas with significant restricted visibility.
ground level inside the shown radius from the Restricted visibility is measured when the front
operator with the use of available rear camera, right linkage of the machine is in the travel position.
side camera, left side mirrors, and left side second Illustration 60 shows the machine in the travel
mirror. position.
M0111427-02 39
Safety Section
Engine Starting
Be sure that all windows are clean. Secure the doors

and the windows in the open position or in the shut
position.
Adjust the rearview mirrors (if equipped) for the best
visibility close to the machine. Make sure that the
horn, the travel alarm (if equipped), and all other
warning devices are working properly.
Fasten the seat belt securely.
Warm up the engine and the hydraulic oil before
operating the machine.
Before moving the machine, check the position of the
undercarriage. The normal travel position is with the
idler wheels to the front under the cab and the drive
sprockets to the rear. When the undercarriage is in
the reversed position, the directional controls must be
operated in opposite directions.
i04159629
Illustration 60 g06181081 Work Tools

(A) 1 m (3.0 ft) from the front of the machine to the bucket SMCS Code: 6700
(B) 0.5 m (1.6 ft) from ground level
Only use work tools that are recommended by
i03562260 Caterpillar for use on Cat machines.
Engine Starting Use of work tools, including buckets, which are

outside of Caterpillar's recommendations or
SMCS Code: 1000; 7000 specifications for weight, dimensions, flows,
pressures, and so on. may result in less-than-optimal
If a warning tag is attached to the engine start switch vehicle performance, including but not limited to
or to the controls, do not start the engine. Also, do not reductions in production, stability, reliability, and
move any controls. component durability. Caterpillar recommends
appropriate work tools for our machines to maximize
Make sure that you are seated before you start the the value our customers receive from our products.
engine. Caterpillar understands that special circumstances
may lead a customer to use tools outside of our
Move all hydraulic controls to the HOLD position specifications. In these cases, customers must be
before you start the engine. Move the hydraulic aware that such choices can reduce vehicle
lockout control to the LOCKED position. For further performance and will affect their ability to claim
details on this procedure, refer to Operation and warranty in the event of what a customer may
Maintenance Manual, “Operator Controls”. perceive as a premature failure.
Diesel engine exhaust contains products of Work tools and work tool control systems, that are
combustion which can be harmful to your health. compatible with your Cat machine, are required for
Always run the engine in a well ventilated area. If you safe machine operation and/or reliable machine
are in an enclosed area, vent the exhaust to the operation. If you are in doubt about the compatibility
outside. of a particular work tool with your machine, consult
Briefly sound the horn before you start the engine. your Cat dealer.
Make sure that all necessary guarding is in place on
i01340061 the host machine and on the work tool.
Before Operation Keep all windows and doors closed on the host
machine. A polycarbonate shield must be used when
SMCS Code: 7000 the host machine is not equipped with windows and
when a work tool could throw debris.
Clear all personnel from the machine and from the
area. Do not exceed the maximum operating weight that is
listed on the ROPS certification.
Clear all obstacles from the machine's path. Beware
of hazards (wires, ditches, etc).
40 M0111427-02
Safety Section
Operation
If your machine is equipped with an extendable stick, The Operation and Maintenance Manual, Monitoring
install the transport pin when you are using the System (if equipped) provides information on limiting
following work tools: hydraulic hammers, augers and condition criteria, including a Warning Category 3
compactors that requires immediate shutdown of the engine.
Always wear protective glasses. Always wear the
protective equipment that is recommended in the Critical Failures
operation manual for the work tool. Wear any other
protective equipment that is required for the The following table provides summary information on
operating environment. several limiting conditions found in this Operation and
Maintenance Manual. The table provides criteria and
To prevent personnel from being struck by flying required action for the limiting conditions listed. Each
objects, ensure that all personnel are out of the work System or Component in this table, together with the
area. respective limiting condition, describes a potential
critical failure that must be addressed. Not
While you are performing any maintenance, any addressing limiting conditions with required actions
testing, or any adjustments to the work tool stay clear may, in conjunction with other factors or
of the following areas: cutting edges, pinching circumstances, result in a risk of personal injury or
surfaces and crushing surfaces. death. If an accident occurs, notify emergency
personnel and provide location and description of
Never use the work tool for a work platform. accident.
i07889511
Operation
SMCS Code: 7000
Machine Operating Temperature

Range
The machine must function satisfactorily in the
anticipated ambient temperature limits that are
encountered during operation. The standard machine
configuration is intended for use within an ambient
temperature range of −18 °C (0 °F) to 43 °C
(109 °F). Special configurations for different ambient
temperatures may be available. Consult your Cat
dealer for additional information on special
configurations of your machine.
Limiting Conditions and Criteria

Limiting conditions are immediate issues with this
machine that must be addressed prior to continuing
operation.
The Operation and Maintenance Manual, Safety
Section describes limiting condition criteria for
replacing items such as safety messages, seat belt
and mounting hardware, lines, tubes, hoses, battery
cables and related parts, electrical wires, and
repairing any fluid leak.
The Operation and Maintenance Manual,
Maintenance Interval Schedule describes limiting
condition criteria that require repair or replacement
for items (if equipped) such as alarms, horns, braking
system, steering system, and rollover protective
structures.
M0111427-02 41
Safety Section
Operation
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.
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.
(continued)
42 M0111427-02
Safety Section
Operation
(Table 1, contd)
System or
Limiting Criteria for Required
Component
Condition Action Action
Name
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 Bring the load close to the machine before swinging
the load.
Only operate the machine while you are in a seat.
The seat belt must be fastened while you operate the Lifting capacity decreases as the load is moved
machine. Only operate the controls while the engine further from the machine.
is running. Make sure that the towing eyes and the towing
devices are adequate for your needs.
Check for proper operation of all controls and of all
protective devices while you operate the machine Only connect trailing equipment to a drawbar or to a
slowly in an open area. hitch.
When the machine is moving watch the clearance of Never straddle a wire cable. Never allow other
the boom. Uneven ground can cause the boom to personnel to straddle a wire cable.
move in all directions.
When you maneuver in order to connect the
Make sure that no personnel will be endangered equipment, make sure that no personnel are between
before you move the machine. Do not allow riders on the machine and trailing equipment. Block up the
the machine unless the machine has an additional hitch of the trailing equipment in order to align the
seat with a seat belt. equipment with the drawbar.
Report any machine damage that was noted during Check the local regulations, state codes, and/or
machine operation. Make any necessary repairs. directives of the job site for a specific minimum
Never use the work tool for a work platform. distance from obstacles.
Before you operate the machine, check with local
Hold attachments approximately 40 cm (15 inches) utilities for the locations of underground pipes and for
above ground level while you drive the machine. Do the locations of buried cables.
not drive the machine close to an overhang, to the
edge of a cliff, or to the edge of an excavation. Know the maximum dimensions of your machine.
If the machine begins to sideslip on a grade, Watch the load at all times.
immediately dump the load and turn the machine
downhill. Do not operate the machine without the
counterweight. The machine can tip when the boom
Be careful to avoid any ground condition which could is over the side.
cause the machine to tip. Tipping can occur when
you work on hills, on banks, or on slopes. Tipping can The clamshell, the grapple, or the magnet can swing
also occur when you cross ditches, ridges, or other in all directions. Move the joysticks in a continuous
unexpected obstructions. motion. Failure to move the joysticks in a continuous
motion can cause the clamshell, the grapple, or the
When possible, operate the machine up slopes and magnet to swing into the cab or into a person in the
down slopes with the final drive sprockets facing work area. This will result in personal injury.
down the slope. Avoid operating the machine across
the slope. Place the heaviest end of the machine Certain machine front linkage combinations (boom,
uphill when you are working on an incline. stick, quick coupler, work tool) can allow the work tool
to contact the machine undercarriage, swing frame,
Keep the machine under control. Do not overload the boom, boom hydraulic cylinder and or the cab. Be
machine beyond capacity. aware of the position of the work tool while you
operate the machine.
Avoid changing the direction of travel on a slope.
Changing the direction of travel on a slope could
result in tipping or side slipping of the machine.
Bring the load close to the machine before traveling
any distances.
M0111427-02 43
Safety Section
Engine Stopping
Shut down the machine until damaged or non- After the machine is parked and the parking brake is
functioning visibility aid(s) is repaired (if applicable) or engaged, allow the engine to run at low idle for 5
until appropriate job site organization is used to minutes before shutdown. Running the engine allows
minimize hazards that are caused by any resulting hot areas of the engine to cool gradually.
restricted visibility.
i06304391
Machine Operation when the
Machine is not Completely Lifting Objects
Assembled 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.
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.
If this machine is used to lift objects within Japan,
Japanese regulations require the machine to be
equipped with a shovel crane configuration.
Contact your Cat dealer for additional information
i07749631
Demolition
SMCS Code: 6700
There maybe local regulations and/or government
Illustration 61 g02202544 regulations that govern the use of machines which
are designed and used as demolition machinery.
Attach the tag to the controls of the machine. When
the tag is attached to the controls, operate the Note: Obey all local and government regulations.
machine as described below.
Demolition machinery is designed for demolishing by
If the machine needs to be operated without the pushing or pulling, or fragmenting. Demolition is done
boom, stick, and/or counterweight being installed, the by crushing or shearing, buildings and/or other civil
machine should be operated slowly on flat, stable engineering structures and component parts and/or
ground or pavement by qualified operators. Avoid separating the resultant debris.
any machine operations which could affect machine
stability, including the swing function. The ROPS If this machine is used for demolition within an area
structural certification depends on the support of the that is controlled by the European Directive 2006/42/
boom, stick, and counterweight in the event of a EC, the machine must be equipped with:
machine tip over or a machine rollover incident.
• Rollover Protective Structure (ROPS, not required
i06299648 for demolition excavators)
• Boom Lowering Control Valve (BLCV) / Stick
Engine Stopping Lowering Control Valve (SLCV)
SMCS Code: 1000; 7000
• Top Guard / Front Guard
Do not stop the engine immediately after the machine
has been operated under load. Stopping the engine • Bottom / Motor / Swivel Guard
immediately can cause overheating and accelerated
wear of engine components. • EN 356 class P5A front window glass
• If a roof window is used to provide visibility to the
working area, then roof window shall be equipped
with motorized windscreen wipers and washers.
44 M0111427-02
Safety Section
Parking
Demolition applications may generate flying debris. Stop the engine.

Ensure that there are no personnel in the area
around the machine where flying debris may travel. Turn the engine start switch to the OFF position.
Demolition applications may generate airborne dust Turn the battery disconnect switch to the OFF
that can be hazardous to your health. If you operate position, if you do not intend on operating the
the machine in a dust generating applications, use machine for an extended period. This will prevent
appropriate safeguarding or adequate ventilation to drainage of the battery. A battery short circuit, any
minimize risk. current draw from certain components, and
vandalism can cause drainage of the battery.
i07857348
Parking
SMCS Code: 7000
The hydraulic system controls remain pressurized if
the accumulator is charged. This condition is true
even when the engine is not running. The hydraulic
control system pressure should decrease in a short
time (approximately 1 minute). While the hydraulic
controls maintain a charge, the hydraulic work tools
and machine controls remain functional.
There can be residual pressure within the hydraulic
system even when the accumulator is empty. Refer
to this Operation and Maintenance Manual, “System Illustration 63 g06217247
Pressure Release” before any service is performed to
the hydraulic system. Note: Do not turn off the battery disconnect switch
Machine movement that is sudden and unexpected until 5 seconds have elapsed after turning the engine
will occur if any of the controls are moved. Machine start switch to the OFF position. Do not turn off the
movement that is sudden and unexpected, can cause battery disconnect switch while the “Lock Security?”
personal injury or death. screen is displayed on the monitor.
Always move the hydraulic lockout control to the Install barriers or lighting as required to prevent
LOCKED position before you shut off the engine or interference in road traffic.
immediately after the engine stops running.
Select places free of danger by flooding and other
Park the machine on a hard, level surface. If you water damage.
must park the machine on a grade, chock the tracks
of the machine. i07746366
Slope Operation
SMCS Code: 7000
Machines that are operating safely in various
applications depend on these criteria: the machine
model, configuration, machine maintenance,
operating speed of the machine, conditions of the
terrain, fluid levels, and tire inflation pressures. The
most important criteria are the skill and judgment of
the operator.
A well trained operator that follows the instructions in
the Operation and Maintenance Manual has the
greatest impact on stability. Operator training
provides a person with the following abilities:
observation of working and environmental conditions,
Place the machine in the servicing position. feel for the machine, identification of potential
hazards and operating the machine safely by making
Note: Make sure that all work tools are in the appropriate decisions.
recommended servicing position before servicing the When you work on side hills and when you work on
machine. slopes, consider the following important points:
M0111427-02 45
Safety Section
Equipment Lowering with Engine Stopped
Speed of travel – At higher speeds, forces of inertia i08229294

tend to make the machine less stable.
Roughness of terrain or surface – The machine
Equipment Lowering with
may be less stable with uneven terrain. Engine Stopped
Direction of travel – Avoid operating the machine SMCS Code: 7000-II
across the slope. When possible, operate the
machine up the slopes and operate the machine Before lowering any equipment with the engine
down the slopes. Place the heaviest end of the stopped, clear the area around the equipment of all
machine uphill when you are working on an incline. personnel. The procedure to use will vary with the
type of equipment to be lowered. Keep in mind most
Mounted equipment – Balance of the machine may systems use a high pressure fluid or air to raise or
be impeded by the following components: equipment lower equipment. The procedure will cause high
that is mounted on the machine, machine pressure air, hydraulic, or some other media to be
configuration, weights, and counterweights. released in order to lower the equipment. Wear
Nature of surface – Ground that has been newly appropriate personal protective equipment and follow
filled with earth may collapse from the weight of the the established procedure in the Operation and
machine. Maintenance Manual, “Equipment Lowering with
Engine Stopped” in the Operation Section of the
Surface material – Rocks and moisture of the manual.
surface material may drastically affect the machine's
traction and machine's stability. Rocky surfaces may i07452241
promote side slipping of the machine.
Slippage due to excessive loads – This may cause Sound Information and
downhill tracks or downhill tires to dig into the ground,
which will increase the angle of the machine.
Vibration Information
SMCS Code: 7000
Width of tracks or tires – Narrower tracks or
narrower tires further increase the digging into the
ground which causes the machine to be less stable. Sound Level Information
Implements attached to the drawbar – This may The declared dynamic operator sound pressure level
decrease the weight on the uphill tracks. This may is 71 dB(A) when “ISO 6396: 2008” is used to
also decrease the weight on the uphill tires. The measure the value for an enclosed cab. The
decreased weight will cause the machine to be less measurement was conducted at 70% of the
stable. maximum engine cooling fan speed. The sound level
may vary at different engine cooling fan speeds. The
Height of the working load of the machine – When measurement was conducted with the cab doors and
the working loads are in higher positions, the stability the cab windows closed. The cab was properly
of the machine is reduced. installed and maintained.
Operated equipment – Be aware of performance The declared sound levels listed above include both
features of the equipment in operation and the effects measurement uncertainty and uncertainty due to
on machine stability. production variation.
Operating techniques – Keep all attachments or
pulled loads low to the ground for optimum stability.
Machine systems have limitations on slopes –
Slopes can affect the proper function and operation
of the various machine systems. These machine
systems are needed for machine control.
Note: Operators with lots of experience and proper

equipment for specific applications are also required.
Safe operation on steep slopes may also require
special machine maintenance. Refer to Lubricant
Viscosities and Refill Capacities in this manual for the
proper fluid level requirements and intended machine
use. Fluids must be at the correct levels to ensure
that systems will operate properly on a slope.
46 M0111427-02
Safety Section
Sound Information and Vibration Information
Hearing protection may be needed when the The declared sound levels listed above include both
machine is operated with an open operator station for measurement uncertainty and uncertainty due to
extended periods or in a noisy environment. Hearing production variation.
protection may be needed when the machine is
operated with a cab that is not properly maintained, “The European Union Physical
or when the doors and windows are open for
extended periods or in a noisy environment. Agents (Vibration) Directive 2002/
44/EC”
Sound Level Information for
Machines in European Union Vibration Data for Track Type Excavator
Countries and in Countries that Information Concerning Hand/Arm Vibration
Adopt the “EU Directives” Level
The declared exterior sound power level (LWA) is 103 When the machine is operated according to the
dB(A) when the value is measured according to the intended use, the hand/arm vibration of this machine
dynamic test procedures and conditions that are is below 2.5 meter per second squared.
specified in “ISO 6395:2008”. The measurement was
conducted at 70% of the maximum engine cooling Information Concerning Whole Body Vibration
fan speed. The sound level may vary at different Level
engine cooling fan speeds.
This section provides vibration data and a method for
The declared dynamic operator sound pressure level estimating the vibration level for track type
is 71 dB(A) when “ISO 6396: 2008” is used to excavators.
measure the value for an enclosed cab. The
measurement was conducted at 70% of the Note: Vibration levels are influenced by many
maximum engine cooling fan speed. The sound level different parameters. Many items are listed below.
may vary at different engine cooling fan speeds. The
measurement was conducted with the cab doors and • Operator training, behavior, mode, and stress
the cab windows closed. The cab was properly
installed and maintained. • Job site organization, preparation, environment,
weather, and material
The declared sound levels listed above include both
measurement uncertainty and uncertainty due to • Machine type, quality of the seat, quality of the
production variation. suspension system, attachments, and condition of
the equipment
Sound Level Information for
It is not possible to get precise vibration levels for this
Machines in Eurasian Economic machine. The expected vibration levels can be
Union Countries estimated with the information in Table 2 to calculate
the daily vibration exposure. A simple evaluation of
The declared dynamic operator sound pressure level the machine application can be used.
is 71 dB(A) when “ISO 6396: 2008” is used to
measure the value for an enclosed cab. The Estimate the vibration levels for the three vibration
measurement was conducted at 70% of the directions. For typical operating conditions, use the
maximum engine cooling fan speed. The sound level average vibration levels as the estimated level. With
may vary at different engine cooling fan speeds. The an experienced operator and smooth terrain, subtract
measurement was conducted with the cab doors and the Scenario Factors from the average vibration level
the cab windows closed. The cab was properly to obtain the estimated vibration level. For aggressive
installed and maintained. operations and severe terrain, add the Scenario
Factors to the average vibration level to obtain the
The declared exterior sound power level (LWA) is 103 estimated vibration level.
dB(A) when the value is measured according to the
dynamic test procedures and conditions that are Note: All vibration levels are in meter per second
specified in “ISO 6395:2008”. The measurement was squared.
conducted at 70% of the maximum engine cooling
fan speed. The sound level may vary at different
engine cooling fan speeds.
M0111427-02 47
Safety Section
Sound Information and Vibration Information
Table 2
“ISO Reference Table A - Equivalent vibration levels of whole body vibration emission for earthmoving equipment.”
Typical Operating Vibration Levels Scenario Factors

Machine Type
Activity X axis Y axis Z axis X axis Y axis Z axis
excavating 0,44 0,27 0,30 0,24 0,16 0,17
hydraulic breaker application 0,53 0,31 0,55 0,30 0,18 0,28

Track Type
Excavators mining application 0,65 0,42 0,61 0,21 0,15 0,32
transfer 0,48 0,32 0,79 0,19 0,20 0,23
Note: Refer to “ISO/TR 25398 Mechanical Vibration - b. Inspect and maintain the seat suspension and
Guideline for the assessment of exposure to whole adjustment mechanisms.
body vibration of ride on operated earthmoving
machines” for more information about vibration. This 5. Perform the following operations smoothly.
publication uses data that is measured by a. Steer
international institutes, organizations, and
manufacturers. This document provides information b. Brake
about the whole body exposure of operators of
earthmoving equipment. Refer to Operation and c. Accelerate.
Maintenance Manual, SEBU8257, “The European d. Shift the gears.
Union Physical Agents (Vibration) Directive 2002/44/
EC” for more information about machine vibration 6. Move the attachments smoothly.
levels.
7. Adjust the machine speed and the route 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 manufacturer c. If no ride control system is available, reduce
recommendations. speed 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
to provide better operator comfort:
3. Keep the terrain in good condition.
a. Adjust the seat and adjust the controls to
a. Remove any large rocks or obstacles. achieve good posture.
b. Fill any ditches and holes. b. Adjust the mirrors to minimize twisted posture.
c. Provide machines and schedule time to c. Provide breaks to reduce long periods of sitting.
maintain the conditions of the terrain.
d. Avoid jumping from the cab.
4. Use a seat that meets “ISO 7096”. Keep the seat
maintained and adjusted. e. Minimize repeated handling of loads and lifting
of loads.
a. Adjust the seat and suspension for the weight
and the size of the operator.
48 M0111427-02
Safety Section
Operator Station
f. Minimize any shocks and impacts during sports i07746359

and leisure activities.
Guards
Sources (Operator Protection)
The vibration information and the calculation SMCS Code: 7000; 7150
procedure is based on “ISO/TR 25398 Mechanical
Vibration - Guideline for the assessment of exposure There are different types of guards that are used to
to whole body vibration of ride on operated protect the operator. The machine and the machine
earthmoving machines”. Harmonized data is application determine the type of guard that should
measured by international institutes, organizations, be used.
and 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 to find your local dealer: structure. This places the operator into an
unprotected environment. Modifications or
Caterpillar, Inc. attachments that cause the machine to exceed the
www.cat.com weight that is stamped on the certification plate also
place the operator into an unprotected environment.
i07746362
Excessive weight may inhibit the brake performance,
the steering performance and the ROPS. The
protection that is offered by the ROPS/FOPS
Operator Station Structure will be impaired if the ROPS/FOPS
SMCS Code: 7300; 7301; 7325 Structure has structural damage. Damage to the
structure can be caused by an overturn, a falling
Any modifications to the inside of the operator station object, a collision, etc.
should not project into the operator space or into the
space for the companion seat (if equipped). The Do not mount items (fire extinguishers, first aid kits,
addition of a radio, fire extinguisher, and other work lights, etc) by welding brackets to the ROPS/
equipment must be installed so that the defined FOPS Structure or by drilling holes in the ROPS/
operator space and the space for the companion seat FOPS Structure. Welding brackets or drilling holes in
(if equipped) is maintained. Any item that is brought the ROPS/FOPS Structures can weaken the
into the cab should not project into the defined structures. Consult your Cat dealer for mounting
operator space or the space for the companion seat guidelines.
(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.
M0111427-02 49
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.
50 M0111427-02
General Information
Product Information • Ensure that machine application conditions

comply with Caterpillar’s recommendations.
Section • Ensure that the operating weight does not exceed
limits set by manufacturer.
General Information • Ensure that all frame cracks are identified,
inspected, and repaired to prevent further
i07896205 development.
Specifications Application/Configuration
SMCS Code: 7000 Restrictions
The maximum travel operating slope for machine
Intended Use lubrication is 35 degrees
The intended use of this machine is for excavating
with a bucket or working with approved work tools.
The machine should be operated with the
undercarriage in a stationary position since the upper
structure is normally capable of 360 degree swing
with mounted equipment. This machine can be used
in object handling applications that are within the lift
capacity of the machine. When this machine is used
in object handling applications, ensure that the
machine is properly configured and operated
properly. Obey any local governmental regulations
and regional governmental regulations. Only lift
objects from approved lifting points and with
approved lifting devices.
Expected Life
The expected life, defined as total machine hours, of
this machine is dependent upon many factors
including the machine owner’s desire to rebuild the
machine back to factory specifications. The expected
life interval of this machine is 10,000 service hours.
The expected life interval corresponds to the service
hours to engine overhaul. Service hours to engine
overhaul may vary based on overall machine duty
cycle. At the expected life interval, remove the
machine from operation and consult your Cat dealer
for inspect, repair, rebuild, install remanufactured,
install new components, or disposal options and to
establish a new expected life interval. If a decision is
made to remove this machine from service, refer to
Operation and Maintenance Manual,
“Decommissioning and Disposal”.
The following items are required to obtain an
economical expected life of this machine:
• Perform regular preventive maintenance
procedures as described in the Operation and
Maintenance Manual.
• Perform machine inspections as described in the
Operation and Maintenance Manual and correct
any problems discovered.
• Perform system testing as described in the
Operation and Maintenance Manual and correct
any problems discovered.
M0111427-02 51
Specifications
The operator station is ROPS certified up to a mass

of 36100 kg (79587 lb) per ISO 12117-2:2008.
Specification Data
Table 3
330 GC Specifications
Boom Reach Boom Mass Boom

3.2 m 2.65 m 2.5 m
Stick (10 ft 6 inch) (8 ft 8 inch) (8 ft 2 inch)
1.54 m3 1.54 m3 2.12 m3

Bucket (2.01 yd3) (2.01 yd3) (2.80 yd3)
27219 kg(1) 27119 kg(1) 27988 kg(1)
Weight
(60890 lb) (60669 lb) (62585 lb)
10390 mm 10400 mm 9830 mm

Overall Length (A)
(34 ft 1 inch) (34 ft 1 inch) (32 ft 3 inch)
3090 mm
Swing Radius (B)
(10 ft 2 inch)
3370 mm 3450 mm 3520 mm

Overall Height(2) (C)
600 mm 2990 mm
(24 inch) (9 ft 10 inch)
700 mm 3090 mm
Overall Width (D)
800 mm 3190 mm
(continued)
52 M0111427-02
Specifications
(Table 3, contd)
330 GC Specifications

3.2 m 2.65 m 2.5 m
1.54 m3 1.54 m3 2.12 m3

Bucket (2.01 yd3) (2.01 yd3) (2.80 yd3)
3490 mm
Length to Centers of Rollers (E)
(11 ft 5 inch)
4350 mm
Length of Track (F)
(14 ft 3 inch)
(1) Approximate weight for machines equipped with 700 mm (30 inch) triple grouser track shoes, a 5800 kg (12787 lb) counterweight, and with-
out a quick coupler.
(2) Including track shoe lug height
M0111427-02 53
Specifications
Working Ranges
Table 4
330 GC
3.2 m 2.65 m 2.5 m
1.54 m3 1.54 m3 2.12 m3

Bucket (2.01 yd3) (2.01 yd3) (2.80 yd3)
Maximum Digging Depth (A) 7250 mm 6700 mm 6100 mm
Maximum Reach at Ground Level (B) 10680 mm 10200 mm 9430 mm

Maximum Cutting Height (C) 10010 mm 9900 mm 9130 mm

(continued)
54 M0111427-02
Boom/Stick/Bucket Combinations
(Table 4, contd)
330 GC
3.2 m 2.65 m 2.5 m
1.54 m3 1.54 m3 2.12 m3

Bucket (2.01 yd3) (2.01 yd3) (2.80 yd3)
Maximum Loading Height (D) 6950 mm 6800 mm 6000 mm
Minimum Loading Height (E) 2290 mm 2840 mm 2470 mm

Maximum Cut Depth (F)(1) 7090 mm 6520 mm 5910 mm

Maximum Digging Depth (Vertical Wall) (G) 5980 mm 5680 mm 4250 mm

(1) 2440 mm (8 ft) level bottom
i07896366
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.
Buckets are grouped into families according to the
capacity of the bucket. Generally, use a bucket with a
smaller capacity when you are using a longer stick
and/or a longer boom. Conversely, use a bucket with
a larger capacity when you are using a shorter stick
and/or a shorter boom. This rule ensures better
machine stability and protection against structural
machine damage.
A stick is designed to match only one specific family
of buckets.
Note: The selection of a compatible boom-stick-

bucket combination is a guide. Work tools, uneven
ground conditions, soft ground conditions, or poor
ground conditions have effects on machine
performance. The operator is responsible for being
aware of these effects.
Contact your Cat dealer for information on selecting
the correct boom-stick-bucket combination.
The following tables show various compatible boom-
stick-bucket combinations. Select an optimum
combination according to the working conditions and
according to the type of work that is being done.
M0111427-02 55
330 GC
Table 5
330 GC Excavator without a quick coupler
Reach Boom
5800 kg (12785 lb)
Width of SAE Capacity Weight of Counterweight
Bucket Type Linkage Fill (%)
Bucket of Bucket Bucket
2.65 m 3.2 m
(8 ft 10 inch) (10 ft 6 inch)
Stick Stick
600 mm 0.52 m3 659 kg (1) (1)
(24 inch) (0.68 yd3) (1454 lb)
750 mm 0.71 m3 731 kg (1) (1)

(30 inch) (0.93 yd3) (1611 lb)
1000 mm 1.03 m3 835 kg (1) (1)

(40 inch) (1.35 yd3) (1841 lb)
1050 mm 1.12 m3 865 kg (1) (1)

(42 inch) (1.46 yd3) (1906 lb)
General Duty 1200 mm 1.33 m3 928 kg (1) (1)

CB 100
(GD) (48 inch) (1.74 yd3) (2047 lb)
1350 mm 1.54 m3 1011 kg (2) (3)

(54 inch) (2.02 yd3) (2228 lb)
1400 mm 1.54 m3 1125 kg (2) (3)

(55 inch) (2.02 yd3) (2480 lb)
1500 mm 1.76 m3 1075 kg (3) (3)

(60 inch) (2.30 yd3) (2370 lb)
1600 mm 1.86 m3 1099 kg (3) (4)

(63 inch) (2.43 yd3) (2423 lb)
600 mm 0.63 m3 724 kg (1) (1)

(24 inch) (0.83 yd3) (1597 lb)
750 mm 0.86 m3 811 kg (1) (1)

(30 inch) (1.13 yd3) (1788 lb)
900 mm 1.09 m3 908 kg (1) (1)

General Duty (36 inch) (1.43 yd3) (2002 lb)
CB 100
Capacity (GDC) 1050 mm 1.34 m3 980 kg (1) (2)
(42 inch) (1.75 yd3) (2161 lb)
1200 mm 1.58 m3 1072 kg (2) (3)

(48 inch) (2.07 yd3) (2363 lb)
1350 mm 1.83 m3 1166 kg (3) (4)

(54 inch) (2.40 yd3) (2570 lb)
600 mm 0.52 m3 733 kg (1) (1)

(24 inch) (0.68 yd3) (1616 lb)
Heavy Duty 750 mm 0.71 m3 851 kg (1) (1)

CB 100
(HD) (30 inch) (0.93 yd3) (1876 lb)
900 mm 0.91 m3 945 kg (1) (1)

(36 inch) (1.19 yd3) (2084 lb)
(continued)
56 M0111427-02
(Table 5, contd)
Reach Boom
5800 kg (12785 lb)
2.65 m 3.2 m
Stick Stick
1050 mm 1.12 m3 1041 kg (1) (1)
(42 inch) (1.46 yd3) (2295 lb)
1200 mm 1.33 m3 1159 kg (1) (2)

(48 inch) (1.74 yd3) (2556 lb)
1250 mm 1.33 m3 1158 kg (1) (2)

(49 inch) (1.74 yd3) (2554 lb)
1300 mm 1.36 m3 1173 kg (1) (2)

(51 inch) (1.78 yd3) (2587 lb)
1350 mm 1.45 m3 1194 kg (2) (3)

(53 inch) (1.90 yd3) (2633 lb)
1350 mm 1.54 m3 1212 kg (2) (3)

(54 inch) (2.02 yd3) (2672 lb)
1400 mm 1.54 m3 1263 kg (2) (3)

(55 inch) (2.02 yd3) (2784 lb)
1450 mm 1.57 m3 1308 kg (3) (3)

(57 inch) (2.16 yd3) (2884 lb)
1500 mm 1.65 m3 1306 kg (3) (4)

(60 inch) (2.30 yd3) (2879 lb)
1500 mm 1.76 m3 1306 kg (3) (4)

(60 inch) (2.30 yd3) (2879 lb)
1650 mm 1.97 m3 1383 kg (4) (5)

(66 inch) (2.58 yd3) (3048 lb)
1050 mm 1.12 m3 1070 kg (1) (1)

(42 inch) (1.47 yd3) (2360 lb)
Heavy Duty 1200 mm 1.33 m3 1148 kg (1) (2)

CB 100
Power (HDP) (48 inch) (1.73 yd3) (2532 lb)
1350 mm 1.53 m3 1253 kg (2) (3)

(54 inch) (2.01 yd3) (2762 lb)
1300 mm 1.10 m3 1110 kg (1) (1)

Heavy Duty Ex- (51 inch) (1.44 yd3) (2447 lb)
CB 100
cavation (HDX) 1450 mm 1.30 m3 1213 kg (1) (2)
(57 inch) (1.70 yd3) (2674 lb)
600 mm 0.52 m3 755 kg (1) (1)

(24 inch) (0.68 yd3) (1665 lb)
Severe Duty 600 mm 0.51 m3 832 kg (1) (1)

CB 90
(SD) (24 inch) (0.66 yd3) (1835 lb)
750 mm 0.71 m3 915 kg (1) (1)

(30 inch) (0.93 yd3) (2017 lb)
(continued)
M0111427-02 57
(Table 5, contd)
Reach Boom
5800 kg (12785 lb)
2.65 m 3.2 m
Stick Stick
900 mm 0.91 m3 1000 kg (1) (1)
(36 inch) (1.19 yd3) (2204 lb)
900 mm 0.88 m3 1062 kg (1) (1)

(36 inch) (1.16 yd3) (2341 lb)
1050 mm 1.12 m3 1099 kg (1) (1)

(42 inch) (1.46 yd3) (2424 lb)
1050 mm 1.08 m3 1170 kg (1) (1)

(42 inch) (1.42 yd3) (2580 lb)
1200 mm 1.33 m3 1177 kg (1) (1)

(48 inch) (1.74 yd3) (2596 lb)
1200 mm 1.28 m3 1257 kg (1) (1)

(48 inch) (1.68 yd3) (2772 lb)
1300 mm 1.36 m3 1321 kg (1) (2)

(51 inch) (1.78 yd3) (2911 lb)
1350 mm 1.56 m3 1239 kg (2) (3)

(54 inch) (2.04 yd3) (2731 lb)
1350 mm 1.45 m3 1346 kg (2) (2)

(54 inch) (1.90 yd3) (2967 lb)
1400 mm 1.54 m3 1421 kg (2) (3)

(56 inch) (2.02 yd3) (3133 lb)
3945 kg 3585 kg
Maximum load pin-on (payload + bucket)
(8697 lb) (7904 lb)
(1) 2100 kg/m3 (3500 lb/yd3) is the maximum density of material.
Table 6
330 GC Excavator with Pin Grabber Coupler
Reach Boom
5800 kg (12785 lb)
2.65 m 3.2 m
Stick Stick
600 mm 0.52 m3 659 kg (1) (1)
CB 100
(GD) 750 mm 0.71 m3 731 kg (1) (1)
(30 inch) (0.93 yd3) (1611 lb)
(continued)
58 M0111427-02
(Table 6, contd)
Reach Boom
5800 kg (12785 lb)
2.65 m 3.2 m
Stick Stick
1000 mm 1.03 m3 835 kg (1) (1)
(40 inch) (1.35 yd3) (1841 lb)
1050 mm 1.12 m3 865 kg (1) (2)

(42 inch) (1.46 yd3) (1906 lb)
1200 mm 1.33 m3 928 kg (2) (3)

(48 inch) (1.74 yd3) (2047 lb)
1350 mm 1.54 m3 1011 kg (3) (4)

(54 inch) (2.02 yd3) (2228 lb)
1400 mm 1.54 m3 1125 kg (3) (4)

(55 inch) (2.02 yd3) (2480 lb)
1500 mm 1.76 m3 1075 kg (4) (5)

(60 inch) (2.30 yd3) (2370 lb)
1600 mm 1.86 m3 1099 kg (4) (5)

(63 inch) (2.43 yd3) (2423 lb)
600 mm 0.63 m3 724 kg (1) (1)

(24 inch) (0.83 yd3) (1597 lb)
750 mm 0.86 m3 811 kg (1) (1)

(30 inch) (1.13 yd3) (1788 lb)
900 mm 1.09 m3 908 kg (1) (2)

CB 100
Capacity (GDC) 1050 mm 1.34 m3 980 kg (2) (3)
(42 inch) (1.75 yd3) (2161 lb)
1200 mm 1.58 m3 1072 kg (3) (4)

(48 inch) (2.07 yd3) (2363 lb)
1350 mm 1.83 m3 1166 kg (4) (5)

(54 inch) (2.40 yd3) (2570 lb)
600 mm 0.52 m3 733 kg (1) (1)

(24 inch) (0.68 yd3) (1616 lb)
750 mm 0.71 m3 851 kg (1) (1)

(30 inch) (0.93 yd3) (1876 lb)
900 mm 0.91 m3 945 kg (1) (1)

Heavy Duty (36 inch) (1.19 yd3) (2084 lb)
CB 100
(HD) 1050 mm 1.12 m3 1041 kg (1) (2)
(42 inch) (1.46 yd3) (2295 lb)
1200 mm 1.33 m3 1159 kg (3) (3)

(48 inch) (1.74 yd3) (2556 lb)
1250 mm 1.33 m3 1158 kg (3) (3)

(49 inch) (1.74 yd3) (2554 lb)
(continued)
M0111427-02 59
(Table 6, contd)
Reach Boom
5800 kg (12785 lb)
2.65 m 3.2 m
Stick Stick
1300 mm 1.36 m3 1173 kg (3) (4)
(51 inch) (1.78 yd3) (2587 lb)
1350 mm 1.45 m3 1194 kg (3) (4)

(53 inch) (1.90 yd3) (2633 lb)
1350 mm 1.54 m3 1212 kg (3) (4)

(54 inch) (2.02 yd3) (2672 lb)
1400 mm 1.54 m3 1263 kg (4) (4)

(55 inch) (2.02 yd3) (2784 lb)
1450 mm 1.57 m3 1308 kg (4) (5)

(57 inch) (2.16 yd3) (2884 lb)
1500 mm 1.65 m3 1306 kg (4) (5)

(60 inch) (2.30 yd3) (2879 lb)
1500 mm 1.76 m3 1306 kg (4) (5)

(60 inch) (2.30 yd3) (2879 lb)
1650 mm 1.97 m3 1383 kg (5) (6)

(66 inch) (2.58 yd3) (3048 lb)
1050 mm 1.12 m3 1070 kg (1) (2)

(42 inch) (1.47 yd3) (2360 lb)
Heavy Duty 1200 mm 1.33 m3 1148 kg (2) (3)

CB 100
Power (HDP) (48 inch) (1.73 yd3) (2532 lb)
1350 mm 1.53 m3 1253 kg (4) (4)

(54 inch) (2.01 yd3) (2762 lb)
1300 mm 1.10 m3 1110 kg (1) (2)

Heavy Duty Ex- (51 inch) (1.44 yd3) (2447 lb)
CB 100
cavation (HDX) 1450 mm 1.30 m3 1213 kg (3) (4)
(57 inch) (1.70 yd3) (2674 lb)
600 mm 0.52 m3 755 kg (1) (1)

(24 inch) (0.68 yd3) (1665 lb)
600 mm 0.51 m3 832 kg (1) (1)

(24 inch) (0.66 yd3) (1835 lb)
750 mm 0.71 m3 915 kg (1) (1)

Severe Duty (30 inch) (0.93 yd3) (2017 lb)
CB 90
(SD) 900 mm 0.91 m3 1000 kg (1) (1)
(36 inch) (1.19 yd3) (2204 lb)
900 mm 0.88 m3 1062 kg (1) (1)

(36 inch) (1.16 yd3) (2341 lb)
1050 mm 1.12 m3 1099 kg (1) (2)

(42 inch) (1.46 yd3) (2424 lb)
(continued)
60 M0111427-02
(Table 6, contd)
Reach Boom
5800 kg (12785 lb)
2.65 m 3.2 m
Stick Stick
1050 mm 1.08 m3 1170 kg (1) (2)
(42 inch) (1.42 yd3) (2580 lb)
1200 mm 1.33 m3 1177 kg (2) (3)

(48 inch) (1.74 yd3) (2596 lb)
1200 mm 1.28 m3 1257 kg (2) (3)

(48 inch) (1.68 yd3) (2772 lb)
1300 mm 1.36 m3 1321 kg (2) (4)

(51 inch) (1.78 yd3) (2911 lb)
1350 mm 1.56 m3 1239 kg (3) (4)

(54 inch) (2.04 yd3) (2731 lb)
1350 mm 1.45 m3 1346 kg (3) (4)

(54 inch) (1.90 yd3) (2967 lb)
1400 mm 1.54 m3 1421 kg (3) (4)

(56 inch) (2.02 yd3) (3133 lb)
3419 kg 3059 kg
(7537 lb) (6743 lb)
(6) Not Recommended
Table 7
330 GC Excavator with CW-40 Coupler
Reach Boom
5800 kg (12785 lb)
2.65 m 3.2 m
Stick Stick
750 mm 0.71 m3 634 kg (1) (1)
(30 inch) (0.93 yd3) (1399 lb)
900 mm 0.91 m3 730 kg (1) (1)

CB 100
(GD) 1050 mm 1.12 m3 806 kg (1) (1)
(42 inch) (1.46 yd3) (1777 lb)
1200 mm 1.33 m3 870 kg (1) (2)

(48 inch) (1.74 yd3) (1918 lb)
(continued)
M0111427-02 61
(Table 7, contd)
Reach Boom
5800 kg (12785 lb)
2.65 m 3.2 m
Stick Stick
1200 mm 1.29 m3 894 kg (1) (2)
(48 inch) (1.69 yd3) (1971 lb)
1300 mm 1.44 m3 960 kg (2) (3)

(51 inch) (1.88 yd3) (2117 lb)
1350 mm 1.54 m3 951 kg (2) (3)

(54 inch) (2.02 yd3) (2097 lb)
1400 mm 1.57 m3 1003 kg (3) (3)

(55 inch) (2.05 yd3) (2211 lb)
1500 mm 1.76 m3 1017 kg (3) (4)

(60 inch) (2.30 yd3) (2242 lb)
1500 mm 1.71 m3 1047 kg (3) (4)

(59 inch) (2.24 yd3) (2308 lb)
1600 mm 1.86 m3 1113 kg (4) (4)

(63 inch) (2.43 yd3) (2453 lb)
1650 mm 1.97 m3 1099 kg (4) (5)

(66 inch) (2.58 yd3) (2422 lb)
1050 mm 1.12 m3 945 kg (1) (1)

(42 inch) (1.46 yd3) (2083 lb)
Heavy Duty 1350 mm 1.54 m3 1088 kg (3) (3)

CB 100
(HD) (54 inch) (2.02 yd3) (2398 lb)
1650 mm 1.97 m3 1258 kg (4) (5)

(66 inch) (2.58 yd3) (2774 lb)
1050 mm 1.13 m3 1013 kg (1) (1)

Severe Duty (42 inch) (1.48 yd3) (2233 lb)
CB 100
(SD) 1350 mm 1.56 m3 1201 kg (3) (4)
(54 inch) (2.04 yd3) (2647 lb)
3652 kg 3292 kg
(8051 lb) (7258 lb)
62 M0111427-02
Table 8
Reach Boom
5800 kg (12785 lb)
2.65 m 3.2 m
Stick Stick
1500 mm 1.76 m3 1075 kg (1) (1)
CB 100
(GD) 1650 mm 1.97 m3 1159 kg (1) (2)
(66 inch) (2.58 yd3) (2555 lb)
1350 mm 1.54 m3 1148 kg (3) (1)

(54 inch) (2.02 yd3) (2530 lb)
Heavy Duty 1500 mm 1.76 m3 1245 kg (1) (2)

CB 100
(HD) (60 inch) (2.30 yd3) (2746 lb)
1650 mm 1.97 m3 1318 kg (2) (2)

(66 inch) (2.58 yd3) (2906 lb)
3510 kg 3150 kg
(7738 lb) (6945 lb)
Table 9
330 GC Excavator with CW-45S Coupler
Reach Boom
5800 kg (12785 lb)
2.65 m 3.2 m
Stick Stick
750 mm 0.71 m3 693 kg (1) (1)
(30 inch) (0.93 yd3) (1529 lb)
1050 mm 1.12 m3 948 kg (1) (2)

(42 inch) (1.46 yd3) (2090 lb)
General Duty 1350 mm 1.54 m3 1144 kg (3) (4)

CB 100
(GD) (54 inch) (2.02 yd3) (2521 lb)
1500 mm 1.76 m3 1243 kg (4) (5)

(60 inch) (2.30 yd3) (2741 lb)
1650 mm 1.97 m3 1316 kg (5) (5)

(66 inch) (2.58 yd3) (2902 lb)
3540 kg 3180 kg
(7804 lb) (7011 lb)
M0111427-02 63
Table 10
330 Excavator without a quick coupler
Long
Undercarriage
Mass Boom
SAE Capacity Weight of 5800 kg
Bucket Type Linkage Width of Bucket Fill (%) (12785 lb)
of Bucket Bucket
Counterweight
2.5 m
(8 ft 2 inch)
Stick
1350 mm 1.64 m3 1186 kg (1)
(53 inch) (2.14 yd3) (2614 lb)
General Duty 1650 mm 2.12 m3 1366 kg (2)

DB 100
(GD) (65 inch) (2.77 yd3) (3012 lb)
1800 mm 2.36 m3 1445 kg (3)

(71 inch) (3.08 yd3) (3186 lb)
1350 mm 1.64 m3 1461 kg (1)

(54 inch) (2.14 yd3) (3220 lb)
1400 mm 1.64 m3 1523 kg (1)

(55 inch) (2.14 yd3) (3358 lb)
1500 mm 1.88 m3 1646 kg (2)

(60 inch) (2.46 yd3) (3629 lb)
1500 mm 1.88 m3 1633 kg (2)

(61 inch) (2.46 yd3) (3601 lb)
Heavy Duty (HD) DB 100
1550 mm 1.88 m3 1621 kg (2)
(61 inch) (2.46 yd3) (3574 lb)
1650 mm 2.12 m3 1690 kg (3)

(66 inch) (2.77 yd3) (3726 lb)
1650 mm 2.12 m3 1731 kg (3)

(67 inch) (2.77 yd3) (3817 lb)
1700 mm 2.12 m3 1719 kg (3)

(67 inch) (2.77 yd3) (3790 lb)
1500 mm 1.91 m3 1677 kg (2)

(60 inch) (2.50 yd3) (3696 lb)
Severe Duty (SD) DB 90
1650 mm 2.15 m3 1815 kg (3)
(66 inch) (2.81 yd3) (4002 lb)
Extreme Duty 1400 mm 1.64 m3 1892 kg (1)

DB 90
(XD) (56 inch) (2.14 yd3) (4171 lb)
5000 kg
(11023 lb)
64 M0111427-02
Table 11
330 Excavator with Pin Grabber Coupler
Long
Undercarriage
Mass Boom
of Bucket Bucket
Counterweight
2.5 m
(8 ft 2 inch)
Stick
1350 mm 1.64 m3 1186 kg (1)
(53 inch) (2.14 yd3) (2614 lb)

DB 100
(GD) (65 inch) (2.77 yd3) (3012 lb)
1800 mm 2.36 m3 1445 kg (3)

(71 inch) (3.08 yd3) (3186 lb)
1350 mm 1.64 m3 1461 kg (4)

(54 inch) (2.14 yd3) (3220 lb)
1400 mm 1.64 m3 1523 kg (2)

(55 inch) (2.14 yd3) (3358 lb)
1500 mm 1.88 m3 1646 kg (2)

(60 inch) (2.46 yd3) (3629 lb)
1500 mm 1.88 m3 1633 kg (2)

(61 inch) (2.46 yd3) (3601 lb)
1550 mm 1.88 m3 1621 kg (3)
(61 inch) (2.46 yd3) (3574 lb)
1650 mm 2.12 m3 1690 kg (3)

(66 inch) (2.77 yd3) (3726 lb)
1650 mm 2.12 m3 1731 kg (3)

(67 inch) (2.77 yd3) (3817 lb)
1700 mm 2.12 m3 1719 kg (2)

(67 inch) (2.77 yd3) (3790 lb)
1500 mm 1.91 m3 1677 kg (2)

(60 inch) (2.50 yd3) (3696 lb)
1650 mm 2.15 m3 1815 kg (2)
(66 inch) (2.81 yd3) (4002 lb)
Extreme Duty 1400 mm 1.64 m3 1892 kg (4)

DB 90
(XD) (56 inch) (2.14 yd3) (4171 lb)
4474 kg
(9863 lb)
M0111427-02 65
Lifting Capacities
Table 12
330 Excavator with CW-45S Coupler
Long
Undercarriage
Mass Boom
of Bucket Bucket
Counterweight
2.5 m
(8 ft 2 inch)
Stick
1200 mm 1.40 m3 1077 kg (1)
(47 inch) (1.84 yd3) (2374 lb)

DB 100
(GD) (59 inch) (2.46 yd3) (2781 lb)
1650 mm 2.12 m3 1340 kg (3)

(65 inch) (2.77 yd3) (2955 lb)
1350 mm 1.64 m3 1430 kg (2)

(54 inch) (2.14 yd3) (3152 lb)
1500 mm 1.88 m3 1527 kg (3)

(60 inch) (2.46 yd3) (3366 lb)
1650 mm 2.12 m3 1663 kg (4)
(66 inch) (2.77 yd3) (3667 lb)
1800 mm 2.36 m3 1763 kg (4)

(72 inch) (3.08 yd3) (3887 lb)
1500 mm 1.91 m3 1648 kg (3)

(60 inch) (2.50 yd3) (3632 lb)
1650 mm 2.15 m3 1788 kg (4)
(66 inch) (2.81 yd3) (3942 lb)
4595 kg
(10130 lb)
i08368764 There may be local regulations and/or government

regulations that govern the use of excavators which
Lifting Capacities lift heavy objects. Obey all local and government
regulations.
(330 GC)
Lifting capacities should be used as a guide. Work
SMCS Code: 7000 tools, uneven ground conditions, soft ground
conditions, or poor ground conditions have effects on
lifting capacities. The operator is responsible for
being aware of these effects.
Failure to comply to the rated load can cause
possible personal injury or property damage. The lifting capacities are defined by “ISO 10567
This includes the risk of unintended boom lower- 2007”. The lifting capacities are defined as the lower
ing. Review the rated load of a particular work value of 75% of the static tipping capacity or 87% of
tool before performing any operation. Make ad- the hydraulic lift capacity. Lifting capacities should be
justments to the rated load as necessary for non- within 5% of the below values for machines with
standard configurations. different shoes.
66 M0111427-02
330 GC
Note: Lifting capacities are based on a standard Table 13

machine with the following conditions: Configuration Identification
• Lift point: Stick nose without bucket Component Configuration Abbreviation
• Lubricants full Reach Boom R
• Fuel tank full Mass Boom M

Variable Angle
• Steel track VA
Boom
• Complete cab with a 75 kg (165 lb) operator Super Long Reach

SLR
Boom
Lifting capacities will vary with different work tools Standard STD
and attachments. The weight of a work tool
attachment must be subtracted from the lift capacity. Front Short Reach Stick SR
Consult your Cat ® dealer regarding the lifting
Severe Duty
capacities for specific work tools and attachments. SD
Bucket
This machine may be equipped with various sticks. Heavy Duty HD
Lifting capacities may vary between the different
sticks. Measure the distance on the stick between the Semi-Heavy Duty S-HD
boom hinge pin and the work tool hinge pin. This
distance will inform you of the size of the stick that is Extreme Special ES
equipped on the machine. Thumb Ready
TR
Stick
Use the lifting eye that is provided on the stick nose
to lift objects. When the lifting eye is used, the Short Undercar-
STD
connection must be made with a sling or shackle. riage (Crawler)
Note: Japan regulations require a shovel crane Long Undercar-

LC
configuration to lift certain objects. A shovel crane Undercarriage riage (Crawler)
has a rated load capacity, therefore, the lift capacities Long Narrow
discussed below do not apply to a shovel crane Undercarriage LN
configuration. Consult your Cat dealer for additional (Crawler)
information.
Standard -
Cylinder
Note: In European countries, regulations require a Heavy Lift HL
load sensing indicator and a boom and stick lowering
control device if more than 1000 kg (2200 lb) is lifted Counterweight Metric Ton (tonne) t(1)
during object handling applications. Regulations also (1) Counterweight stamp indicates metric ton. (example 1.0t =
require a load sensing indicator and a boom lowering 1000 kg)
control device if a force that is greater than
40000 N·m (29500 lb ft) is created during object
handling applications. Even if the hydraulic lift Symbols Found in the Lifting
capacity is capable, do not exceed a load of 1000 kg Capacity Charts
(2200 lb). Do not exceed a force of 40000 N·m
(29500 lb ft) in European object handling Below are symbols that are commonly found on lifting
applications. capacity charts for track excavators.
Note: Depending on the machine configuration,

Configuration Identification some symbols may not be used.
Note: Each component has a stamp to identify the Measurements are provided in
configuration affecting lifting capacity. millimeters and inches
The owner will need to check the machine
configuration to identify the correct lifting capacity.
Lift Capacities are provided in kilograms
The configuration identifier will be located with the and pounds
part number stamped on the component. Refer to the
following table for the abbreviation of the Load is limited by hydraulic lifting
configuration. capacity rather than by a tipping load
M0111427-02 67
330 GC
Lift point radius
Lift point height
Lifting capacity over the front of the

machine
Lifting capacity over the side of the

machine
Heavy Lift ON
Reach Boom with a 3.2 m

(10 ft 6 inch) Reach Stick
Lift Chart Above : 330 GC, 5800 kg (12790 lb) counterweight, 6.15 m (20 ft 2 inch) reach boom, 3.2 m
(10 ft 6 inch) reach stick, 600 mm (24 inch) triple grouser track shoes, and heavy lift OFF
68 M0111427-02
330 GC
M0111427-02 69
330 GC

70 M0111427-02
330 GC
Mass Boom with a 2.5 m (8 ft 2 inch)

Mass Stick
Lift Chart Above : 330 GC, 5800 kg (12790 lb) counterweight, 5.5 m (18 ft 2 inch) mass boom, 2.5 m (8 ft 2 inch)
mass stick, 600 mm (24 inch) triple grouser track shoes, and heavy lift OFF
M0111427-02 71
330 GC
72 M0111427-02
330 GC

Lift Chart Above : 330 GC Long Undercarriage, 6700 kg (14770 lb) counterweight, 6.15 m (20 ft 2 inch) reach
boom, 3.2 m (10 ft 6 inch) reach stick, 600 mm (24 inch) triple grouser track shoes, and heavy lift OFF
M0111427-02 73
330 GC
74 M0111427-02
330 GC
M0111427-02 75
330 GC

76 M0111427-02
330 GC
M0111427-02 77
330 GC
78 M0111427-02
330 GC
Mass Boom with a 2.5 m (8 ft 2 inch)

Mass Stick
M0111427-02 79
330 GC
80 M0111427-02
Identification Information
Identification Information
i08288047
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.
For quick reference, record the identification
numbers in the spaces that are provided below the
illustration.
Product Identification Number Illustration 91 g06184421

(PIN) and CE Plate
Model number (A)
Build (B)
Machine PIN (C)
Country of Origin Info Plate (If Required) (D)
Month and Year of Manufacture (If Required)
(E)
Regional Certification Plate (If Required) (F)
Service Information Plate (G)
Local regulation may require documentation of the
month and/or year of manufacture in the Operation
and Maintenance Manual. Enter on line (E) above if
required.
The PIN plate is positioned on the front of the

machine, close to the operator compartment.
M0111427-02 81
Plate Locations and Film Locations
European Union
Illustration 92 g06201193 This plate is positioned on the bottom left side of the
plate for the PIN.
This plate is positioned on the bottom left side of the
plate for the PIN. Note: The CE plate is on machines that are certified
to the European Union requirements that were
Note: The CE plate is on machines that are certified effective at that time.
to the European Union requirements that were
For machines compliant to 98/37/EC and 89/392/
effective at that time.
EEC, the following information is stamped onto the
For machines compliant to 2006/42/EC, the following CE plate. For quick reference, record this information
information is stamped onto the CE plate. For quick in the spaces that are provided below.
reference, record this information in the spaces that
are provided below. • Engine Power Primary Engine (kW)
• Engine Power Primary Engine (kW) • Typical Machine Operating Weight for European
Market (kg)
• Engine Power for Additional Engine (kW) (If
Equipped) • Year
For manufacturer name and address and the country
• Typical Machine Operating Weight for European
of origin, see the PIN plate.
Market (kg)
• Year of Construction Eurasian Economic Union

• Machine Type For machines compliant to the Eurasian Economic
Union requirements, the EAC plate is positioned on
or near the Product Identification Number (PIN) plate
(see Product Information Section of the machine
Operation and Maintenance Manual). The EAC plate
is placed on machines certified to the Eurasian
Economic Union requirements effective at the time of
market entry.
Note: One of the below plates may be installed on

the machine.
82 M0111427-02
Plate Locations and Film Locations
Caterpillar Inc.,
100 N.E. Adams Street
Peoria, Illinois 61629, USA
Entity authorized by the manufacturer at the territory
of Eurasian Economic Union:
Caterpillar Eurasia LLC

75, Sadovnicheskaya Emb.
Moscow 115035, Russia
China Pin Plate

Will be located next to the pin plate or on the pin
plate.
If equipped, the Month and Year of Manufacture are

on the PIN plate.
Engine Serial Number

This label is located on the engine.
Engine Serial Number
Sound Certification Film

If equipped, this label is located on the cab door.
If equipped, the following information is stamped onto

the EAC plate. For quick reference, record this
information in the spaces provided below.
• Primary Engine Power (kW)
• Additional Engine Power (kW)
• Typical Machine Operating Weight for Eurasian

Economic Union (kg)
• Month and Year of Manufacture

• Machine Type
Manufacturer Information
Manufacturer:
M0111427-02 83
Emissions Certification Film
i08085827

SMCS Code: 1000; 7000; 7405
Consult your Cat dealer for an Emission Control
Warranty Statement.
The emission certification film is on the engine.
If equipped, this label will be located on the cab door.

The certification label is used to verify the
environmental sound certification of the machine to
the requirements of the European Union. The value
that is listed on the label indicates the guaranteed
exterior sound power level LWA at the time of
manufacture for the conditions that are specified in
“2000/14/EC”.
i05757951

SMCS Code: 1000; 7000; 7405
Note: This information is pertinent in Japan.
2014 certification label example
A certification label is located on the cab door.

The certification label verifies that the machine
conforms to the 2014 Japan Nonroad Special Motor
Vehicle Exhaust Regulation.
84 M0111427-02
Declaration of Conformity
Declaration of Conformity
SMCS Code: 1000; 7000
Table 14
An EC or EU Declaration of Conformity document was provided with the machine if it was manufactured to comply with specific requirements
for the European Union. In order to determine the details of the applicable Directives, review the complete EC or EU Declaration of Conformity
provided with the machine. The extract shown below from an EC or EU Declaration of Conformity for machines that are declared compliant to
“2006/42/EC” applies only to those machines originally “CE” marked by the manufacturer listed and which have not since been modified.
ORIGINAL EC or EU DECLARATION OF CONFORMITY
Manufacturer: Caterpillar Inc., 100 N.E. Adams Street, Peoria, Illinois 61629, USA
Person authorized to compile the Technical File and to communicate relevant part (s) of the Technical File to the Authorities of Euro-
pean Union Member States on request:
Standards & Regulations Manager,Caterpillar France SAS

40 Avenue Leon-Blum 38000 Grenoble, France
I, the undersigned, _________, hereby certify that the construction equipment specified hereunder
Description: Generic Denomination: Earth - moving Equipment
Function: Hydraulic Excavator
Model/Type: 330 GC
Serial Number:
Commercial Name: Caterpillar
Fulfills all the relevant provisions of the following Directives
Directives Notified Body Document No.
2000/14/EC amended by 2005/88/EC, Note (1)
2006/42/EC N/A
2014/30/EU N/A
Note (1) Guaranteed Sound Power Level -_____dB (A) Annex VI
Representative Equipment Type Sound Power Level - _____dB (A)
[Engine Power per ISO 14396 -____ kW, Rated engine speed - _____ rpm
Technical Documentation accessible through person listed above authorized to compile the Technical File
Done at: Signature
Date: Name/Position
Note: The above information was correct as of August 2017, but may be subject to change, please refer to the individual declaration of con-
formity issued with the machine for exact details.
M0111427-02 85
Operation Section
Before Operation
Operation Section Machine Access System

Specifications
Before Operation The machine access system has been designed to
meet the intent of the technical requirements in “ISO
2867 Earth-moving Machinery – Access Systems”.
i07103304 The access system provides for operator access to
the operator station and to conduct the maintenance
Mounting and Dismounting procedures described in Maintenance section.
SMCS Code: 6700; 7000
Alternate Exit
Machines that are equipped with cabs have alternate
exits. For additional information, see Operation and
Maintenance Manual, “Alternate Exit”.
i08019624
Daily Inspection
SMCS Code: 1000; 6319; 6700; 7000
Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact skin.
At operating temperature, the engine coolant is
hot and under pressure.
Steam can cause personal injury.
Check the coolant level only after the engine has
Illustration 99 g06224270 been stopped and the cooling system pressure
cap is cool enough to touch with your bare hand.
Typical example
Remove the cooling system pressure cap slowly
Mount the machine and dismount the machine only to relieve pressure.
at locations that have steps and/or handholds. Before
you mount the machine, clean the steps and the Cooling system conditioner contains alkali. Avoid
handholds. Inspect the steps and handholds. Make contact with the skin and eyes to prevent person-
all necessary repairs. al injury.
Face the machine whenever you get on the machine
and whenever you get off the machine.
NOTICE
Maintain a three-point contact with the steps and with Accumulated grease and oil on a machine is a fire
the handholds. hazard. Remove this debris with steam cleaning or
high pressure water, at least every 1000 hours or
Note: Three-point contact can be two feet and one each time any significant quantity of oil is spilled on a
hand. Three-point contact can also be one foot and machine.
two hands. For maximum service life of the machine, perform a
Do not mount a moving machine. Do not dismount a thorough walk-around inspection before you mount
moving machine. Never jump off the machine. Do not the machine and before you start the engine.
carry tools or supplies when you try to mount the
machine or when you try to dismount the machine. First 100 Hours
Use a hand line to pull equipment onto the platform.
Do not use any controls as handholds when you Daily, perform the procedures that are applicable to
enter the operator compartment or when you exit the your machine:
operator compartment.
• Operation and Maintenance Manual, “Boom and
Stick Linkage - Lubricate”
86 M0111427-02
Operation Section
Daily Inspection
• Operation and Maintenance Manual, “Bucket

Linkage - Lubricate”
Daily Basis
Daily, perform the procedures that are applicable to
your machine:
• Operation and Maintenance Manual, “Cooling

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

Level - Check”
• Operation and Maintenance Manual, “Fuel System
Water Separator - Drain” Illustration 100 g06181597
• Operation and Maintenance Manual, “Fuel Tank Inspect the attachment control linkage, attachment
Water and Sediment - Drain” cylinders, and attachment for damage or excessive
wear. Make any necessary repairs.
• Operation and Maintenance Manual, “Hydraulic
System Oil Level - Check” Inspect the lights for broken bulbs and for broken
lenses. Replace any broken bulbs and any broken
• Operation and Maintenance Manual, “Indicators lenses.
and Gauges - Test”
Inspect the engine compartment for any trash
• Operation and Maintenance Manual, “Seat Belt - buildup. Remove any trash buildup from the engine
Inspect” compartment.
• Operation and Maintenance Manual, “Track Inspect the cooling system for any leaks, for faulty
Adjustment - Inspect” hoses and for any trash buildup. Correct any leaks.
Remove any trash from the radiator.
• Operation and Maintenance Manual, “Travel
Inspect all the belts for the engine attachments.
Alarm - Test” Replace any belts that are worn, frayed, or broken.
“Maintenance Interval Schedule” for all maintenance
recommendations.
Note: Watch closely for leaks. If you observe a leak,

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

tank, cylinder rod seals, hoses, tubes, plugs,
connections, and fittings. Correct any leaks in the
hydraulic system.
Inspect the tubes and hoses along the boom and
stick for wear and leaks. Replace any hoses or tubes
that are worn or leak.
Inspect the differential and the final drives for leaks.
M0111427-02 87
Operation Section
Daily Inspection
Inspect the swing drive for leaks.

Make sure that all covers and guards are securely
attached. Inspect the covers and the guards for
damage.
Inspect the steps, the walkways, and the handholds.

Clean the steps, the walkways, and the handholds.
Inspect the operator compartment for trash buildup.
Check for trash buildup under the floorplate and on
the crankcase guard. Keep these areas clean.
Adjust the mirrors to achieve the best visibility.
88 M0111427-02
Operation Section
Machine Operation
Machine Operation To remove the rear window, pull ring (3) and
completely remove the window seal, then push out
the glass. Climb through the rear window opening to
i06952448 exit the cab.
Alternate Exit Rear Window with Lever (If

SMCS Code: 7310 Equipped)
Rear Window with Ring Seal (If
Equipped)
Alternate Exit – The rear window serves

as an alternate exit. Illustration 104 g06213470
Inside lever in latched position
Alternate Exit – The rear window serves

as an alternate exit.
To remove the rear window, rotate handle from its

latched position, then push out the glass. Climb
through the rear window opening to exit the cab.
M0111427-02 89
Operation Section
Seat
i07868899
Seat
SMCS Code: 5258-025; 7312-025; 7324; 7327
Comfort Seat
The window is also equipped with an outside handle.

If the operator is unable, outside personnel can rotate
the outside handle and pull the window out.

(1) Headrest
(2) Backrest adjuster
(3) Seat and console fore and aft adjuster
(4) Indicator
(5) Seat height adjustment lever
(6) Seat fore and aft lever
The operator can adjust the height of headrest (1). To

adjust the headrest, hold the headrest with both
hands. Move the headrest up and down. Release the
headrest when the desired position is attained. The
headrest will remain in the desired position.
90 M0111427-02
Operation Section
Seat Belt
Pull up on backrest adjuster (2) to release the lock. Seat Belt Adjustment for
Move the backrest to the desired position and then
release the adjuster. Retractable Seat Belts
Lift up on fore and aft adjuster (3) to release the seat Fastening The Seat Belt
from the locked position. Adjust the seat and console
forward or rearward to the desired position and then
release the lever to lock the seat.
Use seat height adjustment lever (5) to adjust the
seat for the operator's height and weight. Move the
adjuster switch to the “+” symbol to raise the height.
Ratchet the seat upward without sitting in the seat.
Then sit in the seat to check the color of indicator (4).
When the indicator is showing green, the seat is in
the right range for the operator. Further adjustment
can be made as long as the indicator stays green.
To lower the seat, move the adjust switch to the “-”
symbol. Ratchet the adjuster downward without
sitting in the seat. Then sit in the seat to check the
color of indicator (4). When the indicator is showing
green, the seat is in the right range for the operator.
Further adjustment can be made as long as the
indicator stays green.
Pull upward on seat fore and aft lever (6) to release
the cushion lock. Adjust the seat cushion forward or
backward to the desired position and then release
the lock to lock the cushion in place.
i07092308
Pull seat belt (2) out of retractor (1) in a continuous
motion.
Seat Belt
Fasten seat belt catch (3) into buckle (4). Make sure
SMCS Code: 7327 that the seat belt is placed low across the lap of the
operator.
Note: This machine was equipped with a seat belt
when the machine was shipped from Caterpillar. At The retractor will adjust the belt length and the
the time of installation, the seat belt and the retractor will lock in place. The comfort ride sleeve
instructions for installation of the seat belt meet the will allow the operator to have limited movement.
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.
M0111427-02 91
Operation Section
Operator Controls
Releasing The Seat Belt
Push the release button on the buckle to release the

seat belt. The seat belt will automatically retract into
the retractor.
Extension of the Seat Belt (1) Hydraulic lockout control

(2) Left side switch panel
(3) Joystick controls
(4) Travel controls
(5) Monitor
(6) Right side switch panel
When using retractable seat belts, do not use (7) Engine start switch
seat belt extensions, or personal injury or death (8) Operator seat
can result.
The retractor system may or may not lock up de- Hydraulic Lockout Control (1)
pending on the length of the extension and the
size of the person. If the retractor does not lock The lever for the hydraulic lockout control is at the left
up, the seat belt will not retain the person. side of the left console.
Longer, non-retractable seat belts and extensions for Locked – Move the travel levers/pedals
the non-retractable seat belts are available. and move the joysticks to the HOLD
Caterpillar requires only non-retractable seat belts to (center) position. Move the lever for the
be used with a seat belt extension. hydraulic lockout control backward to the
LOCKED position. All the factory installed
Consult your Cat dealer for longer seat belts and for hydraulic controls will become inoperable.
information on extending the seat belts.
Note: Make sure that the lever for the hydraulic
i07952210 lockout control is in the LOCKED position before
attempting to start the engine. If the lever is in the
Operator Controls UNLOCKED position, the engine start switch will not
function.
SMCS Code: 7300; 7301; 7451
Unlocked – Move the lever for the
Note: Your machine may not be equipped with all the hydraulic lockout control forward to the
controls that are described in this topic. UNLOCKED position. All the factory
installed hydraulic controls will become
operable.
92 M0111427-02
Operation Section
Operator Controls
Tilt – For machines equipped with the For further details, see Operation and Maintenance
tilt-up console, pull the lever to the Manual, “Quick Coupler Operation”.
rearmost position to release the console
lock and tilt the console upward for easier exit Joystick Controls (3)
and entry.
The joystick control is used to control the functions of
Left Side Switch Panel (2) the machine implements. For more information on
the individual functions of the joysticks, refer to
Operation and Maintenance Manual, “Joystick
Controls”.
Travel Control (4)

Position for normal travel
(A) Rear of machine
(B) Final drive
Beacon Light Switch (2A) (If equipped) (C) Idler
Beacon Light Switch – Push the top of When you travel, make sure that final drive sprockets
the switch to turn on the beacon light. (B) are under the rear of the machine.
Push the bottom of the switch to turn off
the beacon light. Stop – Release the travel levers/pedals to stop the
machine. When you release the travel levers/pedals
from any position, the travel levers/pedals will return
Quick Coupler Control (2B) (If equipped) to the CENTER position. The travel brakes will be
applied.
Move both of the travel levers or both of the travel

pedals equally in the same direction to travel straight.
If equipped, the switch for the quick coupler control is
on the left console. The switch is equipped with a
spring loaded lock button. To operate the switch, the
lock button must be pushed forward to release the
switch. With the lock held forward, press the rear of
the switch downward to uncouple the bucket or work
tool. Press the button again to attach the bucket or
work tool.
Note: An alarm will sound whenever the switch has
been activated to lock or unlock a work tool.
M0111427-02 93
Operation Section
Operator Controls

FORWARD travel Pivot left turn (FORWARD)

REVERSE travel Pivot Left Turn (REVERSE)
94 M0111427-02
Operation Section
Operator Controls

Counterrotate turn (LEFT) Pivot right turn (REVERSE)

Pivot right turn (FORWARD)
M0111427-02 95
Operation Section
Operator Controls

(A) Off
(B) On
(1) Engine start ring
(2) Start button
OFF – Turn the engine start ring (1) to

Illustration 119 g06178313 the OFF position (A) to stop the engine.
Counterrotate turn (RIGHT)
ON – To activate the electrical circuits in
Monitor (5) the cab and enable engine starting, turn
the engine start ring (1) clockwise to the
The monitor is used to display various operating ON position (B).
information of the machine. For more information on
the operation of the monitor, refer to Operation and START – To start the engine, enter the
Maintenance Manual, “Monitoring System”. code on the monitor. Press start button
(2). After the engine starts, release the
Engine Start Switch (7) button.
Note: Pressing the start button with the engine on will
NOTICE also turn off the engine.
The engine start switch must be in the ON position
and the engine must be running in order to maintain
electrical functions and hydraulic functions. This pro- Engine Idle Shutdown
cedure must be followed in order to prevent serious
machine damage. If the operator has not operated the machine for a
period of time, this function shuts down the engine.
Engine Idle Shutdown does not shut down other
systems, such as the AC, which can run down the
battery after idle shutdown. This function comes
disabled from the factory but can be enabled and
adjusted in the monitoring system. Refer to Operation
and Maintenance Manual, “Monitoring System”
Note: Engine Idle Shutdown may be required for
local regulations.
The Engine Idle Shutdown (EIS) shuts down the
engine if the following conditions are met:
• The control levers are in neutral.
• The engine coolant temperature is greater than

70° C (158° F).
• The battery voltage is greater than 24.5V
• The engine speed is less than 2000 rpm.

96 M0111427-02
Operation Section
Operator Controls
• The ambient temperature range is between 0° C

(32° F) and 30° C (86° F).
• The Back Pressure Valve (BPV) is not working.

Note: If any service tests or calibrations are running,
the machine will not enter into engine idle shutdown.
Engine Idle Shut down – The action

lamp will illuminate and the monitor will
display a message 20 seconds before
the engine shuts down. An operator can cancel
the shutdown by pressing a button on the
monitor or move one of the controls.
Operator's Seat (8)

There are different options for operators seats. Each
operator seat and console have various adjustments
to meet a wide range of operators. For more
information, refer to Operation and Maintenance
Manual, “Seat”.
Right Side Switch Panel (6)

Right side switch panel
(10) Engine speed / power mode control (15) Heating and air conditioning (20) Radio mute switch
(11) Light switch (16) Next menu (21) Window wiper
(12) Window washer (17) Travel alarm mute (If Equipped) (22) Travel speed control
(13) Operator Information (18) Home
(14) Jog dial (19) Radio control
Note: In addition to the intended functions, the

buttons on the switch panel are numbered from 0-9.
The numbered buttons can be used to enter numbers
into the monitor for screens such as the passcode
screen.
M0111427-02 97
Operation Section
Operator Controls
Engine Speed / Power Mode Control (10) Pattern 2 – When you press the light switch twice,
the first indicator light and the second indicator light
Engine Speed Control – Turn the dial to control turn on. When the first indicator light and the second
the engine speed (engine rpm). Select the desired indicator lights are on, the following work lights are
position from the seven available positions. Turn turned on: work light (D), which is mounted on the
the dial counterclockwise to decrease the engine chassis, work lights (F), which are mounted on the
speed (engine rpm). Turn the dial clockwise to cab, and work lights (E), which are mounted on the
increase the engine speed (engine rpm). boom.
Power Mode Control – Push in the dial to OFF – When both of the indicator lights are off, all the
change the power mode settings. The work lights are off.
Power Mode Control allows the operator
to choose what power mode to operate the
engine. The modes that can be selected are: Note: Your machine may be equipped with a
“ SMART”” and “ POWER”” . premium surrounding lighting package with left side,
right side and rear lights. Refer to Monitoring System,
Note: The default power mode setting can be set Work Light Control for more information.
within the monitor. For more information, refer to
Operation and Maintenance Manual, “Monitoring Note: Your machine may be equipped with a lighting
System”. system that has a time delay. When this system is
installed, the exterior lights will not turn off for a
Light Switch (11) predetermined amount of time after the engine start
switch has been turned to the OFF position. Refer to
Monitoring System, Lighting Shutdown Timer for
more information.
Window Washer (12)

Window Washer (12) – Push the switch
to activate the window washer. While the
switch is depressed, the indicator light
will come on and washer fluid will spray from the
nozzle. The window wiper will also operate while
the switch is depressed. After the switch is
released for approximately 3 seconds, the
window wiper will stop.
NOTICE
If the wiper does not operate with the switch in the
ON position, turn the switch off immediately. Check
the cause. If the switch remains on, motor failure can
result.
NOTICE
Illustration 122 g06178337 If the washer is used continuously for more than 20
seconds or used when no washer solution comes
Light Switch – Push the switch to turn out, motor failure can result.
on the work lights.
Whenever you push the switch, you change the Operator Information (13)
pattern of the work lights that are turned on. The
indicator lights in the cab indicate the pattern of the Help Button (13) – Press and hold this
work lights. button to view the operator information
screen. The indicator light will illuminate
Pattern 1 – When you press the light switch once, when the button is pressed.
the first indicator light turns on. When the first
indicator light is on, the following work lights are
turned on: work light (D), which is mounted on the
chassis, and work lights (F), which are mounted on
the cab.
98 M0111427-02
Operation Section
Operator Controls
Jog Dial (14) Radio Mute (20)

The jog dial can be used to select items displayed on Radio Mute (20) – Press radio mute
the monitor screen. The dial can be rotated 360 switch (20) to mute the radio. The
degrees. The dial can also be moved left, right, up, indicator light will illuminate when mute
and down. The dial can be pushed in to make a is activated. Press the button again to unmute the
selection. radio.
Air Conditioning and Heating (15) Window Wiper (21)
Air Conditioning and Heating (15) – Window Wiper (21) – Push the switch to
Press this button to bring up the air activate the window wiper. Whenever
conditioning and heating menu. The the switch is depressed, the mode of the
indicator light will illuminate when the heating window wiper will change according to the
and cooling system is active. The jog dial (13) can indicator light that is illuminated.
be used to make selections. If equipped with a
touch screen, the selections can be made by 6 Second Delay – When the window wiper switch is
touching the monitor. depressed one time, the first indicator light will turn
on. The window wiper will operate intermittently at six
Refer to Air Conditioning and Heating Control for second intervals.
more information.
3 Second Delay – When the window wiper switch is
Next Menu (16) depressed two times, the second indicator light will
turn on. The window wiper will operate intermittently
Next Menu (16) – Press the next menu at three second intervals.
button to access the next higher menu. Continuous Operation – When the window wiper
If there is not a menu above the current switch is depressed three times, the first indicator
screen being viewed, the button will not do light and the second indicator light will turn on. The
anything. window wiper will operate continuously.
Refer to Monitoring System for more information. OFF – When the window wiper switch is depressed
four times, the indicator lights will turn off. The
Travel Alarm Mute Switch (17) (If window wiper stops.
Equipped)
Travel Speed Control (22)
Travel Alarm Mute Switch (17) – Press
travel alarm mute switch (17) to mute the
travel alarm.
Note: The travel alarm will sound when the travel Do not change the setting of the travel speed con-
levers or the travel pedals are activated. trol switch while you travel. Machine stability may
be adversely affected.
Home (18)
Personal injury can result from sudden changes
in machine stability.
Home Key (18) – Press the home key to
return to the default display at any time.
Travel Speed Control Switch (22) –
Refer to Monitoring System for more information. Press the travel speed control switch to
select automatic travel speed or low
Radio Control (19) travel speed. When the engine start switch is on,
the travel speed control switch is always set at
Radio Control (19) – Press this button to the LOW SPEED position. Whenever the travel
display the radio controls on the speed control switch is pressed, the travel speed
monitor. The indicator light on the changes. The indicator lights illuminate to show
button will illuminate when the radio is turned on. which speed selection is active.
Use jog dial (14) to make selections. If equipped
with a touch screen display, touch the icons on
the screens to make a selection.
Refer to Radio for more information.
M0111427-02 99
Operation Section
Operator Controls
LOW SPEED – Select the LOW SPEED AUX – The AUX port is used to play music from a
position if you travel on rough surfaces portable device. AUX must be selected on the
or on soft surfaces or if you require a radio screen on the monitor.
great drawbar pull. Also, select the LOW SPEED
position if you are loading a machine onto a 12V Power Receptacle (24) & (25)
trailer or you are unloading a machine from a
trailer.
AUTOMATIC – If you travel on a hard,
level surface at a fast speed, select the
AUTO position.
Continuous driving at high speed should be limited to
2 hours. If you need to continue driving at high speed
for more than 2 hours, stop the machine for 10
minutes. This process will cool down the travel drives
before you resume driving.
USB/Aux Ports (23) (If Equipped)

Electronic Technician service port
12V Power Receptacle – The power

receptacles can be used to power
automotive electrical equipment or
accessories. The power receptacle only operates
when the engine start switch is in the ON
position.
Service Port (26)

An Electronic Technician (ET) service port is located
Illustration 123 g06204950 inside the cab behind the seat. This service port
(23) USB/AUX/MIC port allows service personnel to connect a laptop
(24) 12V power receptacle computer that is equipped with Electronic Technician.
Service personnel can use electronic technician to
USB – The USB port is used to play diagnose machine and engine systems.
music from a portable device. The USB
symbol on the radio screen on the
monitor must be selected.
100 M0111427-02
Operation Section
Battery Disconnect Switch
Contact your Cat dealer for additional information. When the right side of the light is pressed, the lamp
will be illuminated until the lamp is switched to
Dome Light (27) another position.
i07857842
Battery Disconnect Switch

SMCS Code: 1411-B11

The battery disconnect switch is on the left side of the
The dome light has three different positions. When machine behind the rear access door.
the dome light is in the center position (horizontal),
the light will come on when the door is open and shut
off when the door is closed.
When the left side of the light is pressed, the lamp will
be inoperable.

(1) Battery disconnect switch
Battery Disconnect Switch – The battery

disconnect switch can be used to
disconnect the battery from the
machines electrical system. The key must be
inserted into the battery disconnect switch
before the battery disconnect switch can be
turned.
ON – To activate the electrical system,

insert the disconnect switch key and
turn the battery disconnect switch
clockwise. The battery disconnect switch must
be turned to the ON to enable battery power to
start the engine.
M0111427-02 101
Operation Section
Product Link
OFF – To deactivate the electrical Caterpillar and/or Cat dealers may use this
system, turn the battery disconnect information for various purposes. Refer to the
switch counterclockwise to the OFF following list for possible uses:
position.
• Providing services to the customer and/or the
The battery disconnect switch and the engine start machine
switch perform different functions. The entire
electrical system is disabled when you turn the • Checking or maintaining Cat Product Link
battery disconnect switch to the OFF position. The equipment
battery remains connected to the electrical system
when you turn the engine start switch to the OFF • Monitoring the health of the machine or
position. performance
Turn the battery disconnect switch to the OFF • Helping maintain the machine and/or improve the
position and remove the key when you service the efficiency of the machine
electrical system or any other machine components.
If installed with a cover lock, close the cover and • Evaluating or improving Cat products and
install a padlock. services
It is also good practice to use the disconnect switch • Complying with legal requirements and valid court
after you operate the machine. This will prevent the orders
battery from being discharged. The following
problems can cause battery discharge: • Performing market research
• short circuits • Offering the customer new products and services
• current draw via some components Caterpillar may share some or all the collected
information with Caterpillar affiliated companies,
• vandalism dealers, and authorized representatives. Caterpillar
will not sell or rent collected information to any other
i08001446 third party and will exercise reasonable efforts to
keep the information secure. Caterpillar recognizes
Product Link and respects customer privacy. For more information,
please contact your local Cat dealer.
SMCS Code: 7490; 7606
Note: Your machine may be equipped with the Cat ® Operation in a Blast Site for
Product Link™ system. Product Link Radios
The Cat Product Link communication device utilizes
cellular and/or satellite technology to communicate
equipment information. This information is
communicated to Caterpillar, Cat dealers, and This equipment is equipped with a Cat® Product
Caterpillar customers. The Cat Product Link Link communication device. When electric deto-
communication device uses Global Positioning nators are being used for blasting operations, ra-
System (GPS) satellite receivers. dio frequency devices can cause interference
with electric detonators for blasting operations
The capability of two-way communication between which can result in serious injury or death. The
the equipment and a remote user is available with the Product Link communication device should be
Cat Product Link communication device. The remote deactivated within the distance mandated under
user can be a dealer or a customer. all applicable national or local regulatory require-
ments. In the absence of any regulatory require-
ments Caterpillar recommends the end user
Data Broadcasts perform their own risk assessment to determine
safe operating distance.
Data concerning this machine, the condition of the
machine, and the operation of the machine is being Refer to your products Operation and Maintenance
transmitted by Cat Product Link to Caterpillar and/or Manual Supplement, “Regulatory Compliance
Cat dealers. The data is used to serve the customer Information” for more information.
better and to improve upon Cat products and
services. The information transmitted may include: For information regarding the methods to disable the
machine serial number, machine location, and Cat Product Link communication device, please refer
operational data, including but not limited to: fault to your specific Cat Product Link manual listed below:
codes, emissions data, fuel usage, service meter
hours, software, and hardware version numbers and • Operation and Maintenance Manual, SEBU8142, “
installed attachments.
Product Link - PL121, PL321, PL522, and PL523”
102 M0111427-02
Operation Section
Machine Security System
• Operation and Maintenance Manual, SEBU8832, “

Product Link PLE702, PLE602, PLE601, PL641,
PL631, PL542, PL240, PL241, PL243, PL141,
PL131, PL161, PL083 and PL042 Systems”
Note: If no radio disable switch is installed and the
equipment will be operating near a blast zone, a
Product Link radio disable switch may be installed on
the equipment. The switch will allow the Cat Product
Link communication device to be shut off by the
operator from the equipment control panel. For more Machines that are equipped with Cat MSS can be
details and installation procedures, refer to the identified by a decal in the operator station Read the
following: following information and know your machines
settings. Your Cat dealer can identify your machine
• Special Instruction, REHS7339, “Installation settings.
Procedure for Product Link PLE640 Systems”
The Cat Machine Security System (MSS)
• Special Instruction, REHS8850, “Installation discourages unwanted operation of a machine. When
Procedure for the Elite Product Link PLE601, armed, the MSS requires operator login to start the
PLE641, and PLE631 Systems” engine. The following methods of operator login to
disarm the security system are available:
• Special Instruction, SEHS0377, “Installation
Procedure for the Product Link PL131, PL141, • Cat Bluetooth® key fob
and PL161 Systems”
• Cat App: Fleet Management
• Special Instruction, REHS9111, “Installation
Procedure for the Pro Product Link PL641 and • Passcode
PL631 Systems”
• Special Instruction, M0098124, “Installation

Procedure for Pro Product Link PL243 Systems”
• Special Instruction, M0109130, “Installation
Procedure for Product Link PL683 and PL783
Systems”
i07785958

SMCS Code: 7631
General Information
NOTICE
This machine may be equipped with a Cat ® Machine
Security System (MSS) and may not start under cer-
tain conditions.

Bluetooth Connections
(1) Cat Bluetooth key fob (CATBTFOB)
(2) Cat App: Fleet Management mobile application
(3) Cat Bluetooth transceiver (CATBTNT)
M0111427-02 103
Operation Section
The Cat Bluetooth key fob (1) contains an electronic When the engine start switch is turned to the ON
chip. The electronic chip has a unique identification position, the display boots up. If Bluetooth detection
number (ID). A Bluetooth transceiver is mounted in is enabled, the transceiver will receive a signal from
the cab to read the ID of the key. The Bluetooth any Bluetooth key that is present or from the mobile
transceiver module translates the information application. The ECM will then compare this ID to the
received from the key fob into a J1939 message. This list of authorized keys.
message is sent to the Electronic Control Module
(ECM) that is connected to the MSS. The ECM is Note: If multiple devices are present, the first valid
typically the Machine ECM. The ECM is set up with device detected by the transceiver will be read.
the ID of the keys of the intended users.
If the ID of the key matches an authorized key, the
When the MSS is armed, the ECM validates the ID of status indicator on the engine start switch will turn a
the key fob. If the key ID is on the list of authorized green color and the MSS will disarm. This disarming
keys in the ECM and the key is valid, the machine will will allow the operator access to critical functions of
operate normally. If the key ID is not on the list of the machine.
authorized keys in the ECM or is not valid, the MSS
will keep the critical machine functions disabled. If the ID of the key that is read does not match the list
in the ECM, the status indicator will remain a red
Note: A Bluetooth enabled phone can disarm MSS if color. The MSS remains in the “armed” state and the
the phone is on the list. Operator Management machine will remain disabled.
System (OMS) is necessary to be able to add phones If the MSS is disabled and the ID of the key matches
to the vehicle ID list. After the phone is added, OMS an authorized key, the operator will be identified and
is no longer needed for the Cat App: Fleet allowed access to the critical machine functions. The
management mobile application to function as a valid operator will be able to save configurations and start
key. the machine.
If the MSS is not installed, the operator can skip the If the MSS is disabled and the ID of the key that is
login and the machine will operate normally. read does not match an authorized key, the operator
must log in as a guest. The operator will not be able
to save custom configurations but will have access to
Components starting the engine.
The Machine Security System (MSS) consists of the
following components: Activating Bluetooth Functionality
• Electronic Control Module (ECM) For shipping purposes, Bluetooth functionality is
deactivated. Ensure that Bluetooth functionality is
• Cat Bluetooth key fob (CATBTFOB) active on your machine using the following
procedure:
• Machine display
1. Ensure that the function is active from the radio
• Bluetooth transceiver module (CATBTNT) screen:
• Engine start switch
System Overview
The Machine Security System (MSS) is designed to
restrict operation of a machine. A list of the
authorized electronic keys and passcodes for a
machine is contained in the ECM for the MSS. A valid
Bluetooth key fob, mobile application, or passcode
can disarm the MSS. If the MSS is disabled or not
installed, any operator may access critical machine
functions.
The Cat ® Electronic Technician (Cat ET) Service Tool
can be used to program the ECM with the authorized
keys and passcodes. Bluetooth devices and Illustration 130 g06319669
passcodes can be registered using the in-cab display
if the operator is logged in to the system using a
master access account. a. From the home screen, press the navigation
button in the lower left corner, then select
“Audio” .
104 M0111427-02
Operation Section
2. Press the radio function list menu button in the

lower right corner, then select “Bluetooth” .
b. Press the radio function list menu button in the

lower right corner, then select “Bluetooth” .
Ensure that “Bluetooth” is set to “ON” .
Pairing Your Device to the Machine

Use to following procedure to pair your device to the
machine:
3. Select “Pairing” , then “Device Name” .
1. From the home screen, press the navigation

button in the lower left corner, then select “Audio” .
M0111427-02 105
Operation Section
There are two states of operation within the “armed”

mode:
Engine Start Switch Ring Position OFF – When no
power is applied to the MSS, the MSS will default to
“armed” state. When power is applied to the MSS
and the grace period has expired, the MSS will return
to the “MSS Armed” .
Engine Start Ring Switch Position ON – When the

engine start switch ring is first moved to the ON
position, the display boots up and the system
attempts to detect a Bluetooth key ID or mobile
application ID. The ECM will continue reading until a
valid key ID is read or a passcode is entered. If a
valid key ID or passcode is not read, the MSS status
indicator will remain red and the MSS remains
armed.
Disarmed
When the MSS is disarmed, normal machine
Illustration 135 g06319681 operation is allowed. A message is sent to the other
Machine name on monitoring system and operator machine ECMs over the Cat data link. or J1939 data
device link. The machine will be able to start. The green LED
on the status indicator will illuminate.
4. Find your device on the list and pair the devices. There are multiple ways to disarm the machine:
Ensure that the devices are paired on your phone
as well. • Use a valid passcode
Note: The device name on your phone should be “## • Use a valid Bluetooth key fob
CAT RADIO” , with the number being from “00” to
“99” . • Use the Cat App: Fleet management mobile
application
Reading the ID of a Key • Use the Cat ® Electronic Technician (Cat ET)
Service Tool to configure the MSS bypass
The Machine Security System (MSS) must identify a schedule to allow machine operations during
valid passcode, Bluetooth key fob ID, or Cat App: scheduled periods of time during the week.
Fleet management mobile application ID.
When the engine start switch ring is turned to the ON Grace Period
position, the MSS will check the ID of any key fob or
mobile application. If the ID matches a key ID stored After a machine has been started successfully, the
in the machine ECM, the critical ECM functions are operator will have a grace period after the machine is
enabled. An enable message is also sent via the Cat turned off before the MSS is automatically armed.
®
data link or J1939 data link to the other ECMs on The operator is not required to arm the system
the machine. The machine will operate normally. manually.
Note: If the machine ECM has failed or has been During the grace period an operator can start the
removed, the critical machine operations controlled machine without a key ID or passcode. When the
by the other electronic control modules will not grace period expires, the MSS will rearm
operate. automatically.
If the MSS is unable to read a key ID, the system will
Armed remain armed. When the MSS identifies a key with
an invalid key ID, the system will remain armed.
When the MSS is armed, critical machine functions
are disabled. The MSS disables the power that is
supplied to each component that is powered by the
output drivers. The machine will not be able to
operate normally.
106 M0111427-02
Operation Section
The grace period for a machine can be configured configurations and operator management. If the
with Cat ET if a factory password or master level Machine Security System (MSS) is enabled, guest
account is available. operators cannot start the machine.
Standard – A standard operator is a registered user
Navigating the User Interface of the machine. Operators with this access level can
Touchscreen Display start the engine whether or not the MSS is installed.
This user may save a control configuration for future
application.
Master – Master accounts can perform operator
management in addition to all standard level
functions.
Any “Standard” or “Master” account may be created

or removed by a “Master” level operator.
Table 15
Selections and Access for the Touchscreen Display
Access Level Operator Setting

“Operator Input Configuration”
Guest “Response”
“Change Operator”
Startup sequence screens “Operator Input Configuration”
“Response”
Standard
The display will start up automatically after turning “Controls Setup”
“Change Operator”
the battery disconnect switch to the ON position. The
screen will prompt the operator to turn the engine “Operator Input Configuration”
start ring to the ON position. When the engine start “Response”
ring is turned to the ON position, the display will Master “Controls Setup”
navigate to the passcode entry screen. “Change Operator”
“Manage Operator”
If the operator has not turned the engine start ring to
the ON position, the display will time out after 1
minute.
Operation of Status Indicator
If the battery disconnect switch is already on and the
display is off, the display will startup automatically
after the engine start ring is powered on. The Cat
screen will appear for a short time and then login
keypad will appear.
Note: Avoid touching the screen with sharp objects.

The access level assigned to the operator can limit or
expand the amount of freedom the user has to
manage the system. The following paragraphs
explain access levels.
There are three levels of operator access recognized
by the touchscreen display. The following levels are
available:
• Guest
• Standard
• Master
Guest – If an operator does not have an
authenticated key or passcode, the user is able to
bypass log in as a guest. Some menu features will
not be available such as the options for saving Engine start switch with integrated MSS indicator
M0111427-02 107
Operation Section
The Machine Security System (MSS) uses a status For machines with a standard key switch, a separate
indicator that is integrated into the engine start switch status indicator will be available.
in the cab. This indicator provides a visible alert for
the security system. Operator Login
The operator can use the status indicator to
determine the status of the system or for Any user may start the engine if the Machine Security
troubleshooting. System (MSS) is disabled.
If the MSS is active, only a “Standard” or “Master”
account can start the machine engine. Before starting
the machine engine, the security system must
identify a registered operator. An operator can
access the machine display using one of the
following methods:
• Passcode
• Cat Bluetooth key
• Cat App: Fleet management mobile application
Passcode Entry
Illustration 138 g06226442 To log in using a passcode, refer to the following

steps:
Status indicator when the MSS is armed
When the MSS is armed, the status indicator will be

red. The red light warns the operator that the
machine is armed with the security system and that
an operator login is required. The red LED will remain
ON until a valid key is read while the key switch or
engine start switch ring is in the ON position.

(A) Off
(B) On
(1) Engine start switch ring
(2) Engine start button
Illustration 139 g06226444 1. Turn engine start switch (1) to the ON position (B).
Status indicator when the MSS is disarmed or
uninstalled
When the MSS is disarmed, the status indicator will

be green. The green light notifies the operator that an
operator is logged on the machine and the security
system has been disarmed. The status indicator will
be green if the MSS is not installed on the machine.
Also, the green LED will remain ON after power down
for the duration of the grace period. After the grace
period, the MSS automatically returns to the “armed”
mode.
108 M0111427-02
Operation Section
2. Enter a registered passcode using the monitor 3. Select “Enter” to confirm the passcode. If a
keypad and then press “Enter” . registered passcode is recognized, the operator
information screen will appear on the display. If the
Note: The jog dial or the numbered buttons on the MSS is not installed, the passcode screen will be
right-side switch panel can also be used to enter the
bypassed automatically after 10 seconds. The
code.
operator will be logged in to the system as a guest.
Refer to Illustration 142 .
4. Select “OK” to continue to the display homescreen.
M0111427-02 109
Operation Section
The operator has five tries to enter a valid passcode

successfully. After a fifth unsuccessful attempt, a
lockout screen will appear and remain on the display
for a duration of 5 minutes.
Note: If the Machine Security System (MSS) is not
active, the user can select the “Skip Login” button to
avoid the lockout period. Refer to the “Bypass login”
section for further information.
Bypass login
Operator login can be bypassed if the user selects

the “Skip Login” button on the display. The operator
will be logged in to the machine with “Guest” level
access.
If the MSS is inactive, the operator will be able to
start the engine as normal and view all display
screens.
If the MSS is active on the machine, the operator is
able to view all display screens but will not have
access to starting the engine.
Bluetooth Entry
5. After an operator logs in to the system
successfully, an “Engine Start Allowed” message Alternatively, a Bluetooth Operator ID can be used to
will appear across the top of the monitor. Refer to log in to the machine. For a Bluetooth key to be
Operation and Maintenance Manual, Engine detected by the system, ensure that the following
Starting for instructions on starting the engine. qualifications are met:
Invalid Passcode • The key must be registered with the machine

• The key must be within the cab
• Bluetooth setting must be enabled on the display

Refer to the following steps when logging in to a
machine using the Bluetooth key:

(A) Off
Invalid passcode screen (B) On
If a passcode is not recognized, the display will notify (2) Engine start button
the user with an “Invalid code” message. Refer to
Illustration 144 . 1. Turn engine start switch (1) to the ON position (B).
110 M0111427-02
Operation Section
2. Wait several seconds for the system to detect the

key when the passcode dialog appears. Once the
key is detected, the “Operator Information” screen
will display.

successfully, an “Engine Start Allowed” message
will appear across the top of the monitor. Refer to
Operation and Maintenance Manual, Engine
Bluetooth operator information screen Starting for instructions on starting the engine.
3. Select the “OK” button if the proper operator has NOTICE
been displayed. The access level will change to a “Guest” account au-
tomatically if the key is removed from the cab at any
time. If the MSS is enabled and the engine is on
when the key is removed from the cab, the operator
will not be able to start the engine if turned off. To turn
on the engine again without the Bluetooth key, the
operator will need to log in a registered account using
either the smart phone application or passcode.
Note: If multiple Bluetooth devices are within the cab,

the system will select the first device detected by the
Bluetooth transceiver as the active operator.
Cat ®Fleet Management Mobile

Application
Operators can also log in to a machine using the Cat
App: Fleet management mobile application. For the
application to be detected by the system, ensure that
the following qualifications are met:
• The Mobile Device ID (MDID) of the mobile
application must be assigned to the machine in the
Operator Management System (OMS)
Note: It is not possible to assign mobile devices
through the MSS interface.
• The mobile device must be within the cab

M0111427-02 111
Operation Section
• “Operator Management Bluetooth Device

Enabled Status” is enabled (Cat ET
Configuration)
Note: For adding an operator, adding MDID to the

machine key list, and pushing the machine key list
from the OMS to the machine refer to the OMS
documentation at:
https://myoperators.cat.com/
Mobile Device / Operating Software Compatibility
Table 16
Mobile Device / Operating Software Compatibility
Operating
Make Model
Software
Android 8.x Oreo
Android Varies and up (Preferably
Android 9.x Pie )
iPhone 6/ iPhone 6 iOS 11.0 and up

Apple Illustration 149 g06400799
Plus and up (Preferably 12)
2. Open the Cat App: Fleet management mobile

Note: Android mobile hardware support for Bluetooth application on the mobile device.
can vary, so it is possible that a mobile device
running Android 8.x software or higher could have
hardware that does not support Bluetooth 4.1.
Mobile Application Entry (Android Devices)
To log in using the Cat App: Fleet management

mobile application, refer to the following steps:

(A) Off 3. Click “I Agree” to agree with the End-User License
(B) On
Agreement and sign in with Cat eCustomer
(2) Engine start button account credentials.
1. Turn engine start switch (1) to the ON position (B). Note: If you do not have a Cat eCustomer account,
click “Get Started” to create one.
4. Select “Login” .
112 M0111427-02
Operation Section

CWS login screen (1) Menu Icon
(2) Map Icon
(3) Add Equipment Icon
5. Enter Cat eCustomer account credentials.
7. Upon login, the Cat App: Fleet management
mobile application will open onto the equipment
tab.
Note: The “Equipment” tab will be empty on the first

login.
The Menu Icon (1) includes “Preferences” ,

“Notifications and Alerts” , along with various
documents covering the end-user license
agreement, and privacy notice.
By tapping the Map Icon (2), the operator will be
able to see the location of each vehicle on their
“Equipment” tab on a map.
If a vehicle is not equipped with a telematics
device, or the vehicle is a non-caterpillar machine
6. Click “Allow” to enable the Cat App: Fleet
it may be necessary to add it manually using the
management mobile application to work as
Add Equipment Icon (3).
designed.
Note: Cat App: Fleet management requires access
to the mobile device location to use Bluetooth radio
to connect to Cat machines.
M0111427-02 113
Operation Section
8. Go to the keys tab. 10. Ensure that the machine is ON to connect to a

machine.
Keys are necessary to connect to vehicles. If no
keys are given, the screen in Illustration 154 will The machine display should prompt the operator
be displayed. The MDID is necessary to assign for a password. In the “Keys” tab in the Cat App:
keys to the user account. The MDID of Android Fleet management mobile application and tap the
devices is linked to the app. key that matches the machine. If a vehicle is OFF,
currently occupied, or too far away the key will be
Note: Uninstalling the Cat App: Fleet management grayed out and say “Out of range” .
mobile application will result in the MDID and keys
being deleted. The Sim card of the phone contains Note: If the machine has a user signed in that is not
the MDID information, damage to the Sim card may in the cab and it has become necessary for a
result in keys being lost, if the phone is replaced different user to operate the machine, change the
transfer the Sim card to avoid key loss. operator in operator setting.
9. Pull the “Equipment Keys” down to refresh the list
once the Fleet/Key configuration process has
finished. Wait up to 30 seconds until the keys
populate. If the keys do not populate, check that
the MDID is correct and that the list was pushed
properly through OMS.
114 M0111427-02
Operation Section
11. Access the “Equipment” tab by tapping it. The 13. After an operator logs in to the system
machines associated with the keys should have successfully, an “Engine Start Allowed” message
populated. To learn more about a machine, tap it. will appear across the top of the monitor. Refer to
Starting for instructions on starting the engine.
Mobile Application Entry (iOS Devices)
To log in using the Cat App: Fleet management

mobile application, refer to the following steps:

(A) Off
12. Press the “Disconnect” button if the user wishes (B) On
to disconnect. If the user wants to switch (1) Engine start switch ring
machines, tap the arrow in the upper left then tap (2) Engine start button
the machine the operator wants to be switched to.
1. Turn engine start switch (1) to the ON position (B).
Note: Disconnect from vehicles if the user is not
2. Ensure that Bluetooth detection is enabled on the
going to be using a vehicle again within a short time.
in-cab display.
M0111427-02 115
Operation Section

Cat App: Fleet management mobile application icon
6. Enter eCustomer account credentials to log in.
3. Open the Cat App: Fleet management mobile
application on the mobile device.

(1) Menu Icon
Illustration 161 g06433528 (2) Map Icon
(3) Add Equipment Icon
4. Click “I Agree” to agree with the End-User License

7. Upon login the Cat App: Fleet management mobile
Agreement and sign in with Cat eCustomer
application will open onto the equipment tab.
account credentials.
Note: The equipment tab will be empty on the first
Note: If you do not have a Cat eCustomer account,
login.
click “Get Started” to create one.
5. Select “Login” .
116 M0111427-02
Operation Section
The Menu Icon (1) includes “Preferences” ,

“Notifications and Alerts” , along with various
documents covering the end-user license
agreement, and privacy notice.
By tapping the Map (2), the operator will be able to
see the location of each vehicle on the equipment
tab on a map.
When using this for the first time, the Cat App:
Fleet management mobile application will ask if it
can use the location feature. Allow the location
feature to use the map.
If a vehicle is not equipped with a telematics
device, or the vehicle is a non-caterpillar machine
it may be necessary to add it manually using the
add equipment button (3).
10. To connect to a machine, ensure that the

machine is ON. The machine display should
prompt the operator for a password. At this point
on the Cat App: Fleet management mobile
application go to the “Keys” tab and tap the key
that matches the machine. If a vehicle is OFF,
currently occupied, or too far away the key will be
grayed out and say “Out of range” .
8. Access the “Keys” tab. Keys are necessary to

connect to vehicles. If no keys are given, the
screen in Illustration 164 will be displayed. The
MDID is necessary to assign keys to the user
account. The MDID of IOS devices is linked to the
user account.
9. Once the Fleet/Key configuration process has
finished, tap the refresh button in the Cat App:
Fleet management mobile application top right.
Wait up to 30 seconds until the keys populate. If
the keys do not populate, check that the MDID is
correct and that the list was pushed properly in Illustration 166 g06433540
OMS.
11. Press the disconnect button if the user wishes to
disconnect. If the user wants to switch machines
tap the arrow in the upper left, then tap the key of
the machine to switch to.
M0111427-02 117
Operation Section
Note: Disconnect from vehicle if the user will not be

using the vehicle again within a short time.

successfully, an “Engine Start Allowed” message
will appear across the top of the monitor. Refer to
Starting for instructions on starting the engine.
Engine Start Switch Troubleshooting

Table 17
Switch Status Possible Cause Resolution
Engine start accessory power not on Turn engine start switch ring to ON position
Engine startswitch is not illuminated
Cycle engine start switch ring and try to
Power management triggered
restart
Engine start switch is green Starting component failure Contact your Cat dealer
Machine interlock conditions not met Hydraulic lock in LOCKED position
Engine shut down without cycling start switch

Cycle engine start switch ring and try restart
ring
Add operator to machine authorized user list

Operator not authenticated (Passcode login) Switch operator from guest mode using
Engine start switch is red
display
Replace key fob battery

Operator not authenticated (Bluetooth key)
Ensure more than 4.5 m (15 ft) from other
Bluetooth equipped machine
(continued)
118 M0111427-02
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Monitoring System
(Table 17, contd)

Switch Status Possible Cause Resolution
Alternately login with display passcode or
contact local Cat dealer
Ensure more than 4.5 m (15 ft) from other

Bluetooth equipped machine
Enable phone Bluetooth and connect Cat

Operator not authenticated (Cat Fleet man-
Fleet management app
agement app)
Change Bluetooth system
enable status to enabled (Cat dealer)
Contact local Cat dealer if unable to see ma-

chine Bluetooth device
i08257831
Monitoring System
SMCS Code: 7451; 7490
NOTICE
When the monitor provides a warning, immediately
check the monitor and perform the required action or
maintenance as indicated by the monitor.
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.
General Information
Note: Your machine may not be equipped with all the
functions described in this topic.
The monitoring system is an input and an output of
the Machine Control System. The monitor has a
multi-touch 8 inch display. The Machine Control
System communicates back and forth on the data
link. The monitoring system consists of the following
components: Illustration 168 g06469575
(1) Action Lamps
• Display (with numerous screens and menus) (2) Status Information Area
(3) Event Indicator Area
• Indicators (4) Camera View Area
(5) Gauge Area
• Gauges (6) Navigation Area
(7) Function List
• Soft Switch Panel (8) Shortcuts
• Jog Dial
M0111427-02 119
Operation Section
Monitoring System
The monitoring system displays various warnings Time To Regen (2A) – Shows the
and information about the condition of the machine, estimated time left for regeneration.
and the machines surrounding with various camera
views. There are gauges and several alert indicators
included on monitoring system display. Each gauge Fuel Consumption Rate (2A) – Displays
is dedicated to a parameter within a machine system. fuel consumption per hour. Fuel
The monitoring system will allow the user to do the consumption can be measured in liters
following: or gallons.
• View Surroundings Fuel Remain Time (2A) – Shows the

estimated time until fuel is empty.
• Interpret status information
• Interpret parameters Tool name(2A) – Shows the tool name

selected.
• View OMM
• View service intervals Note: When the cursor is on this area, the
information can be changed by touching the area or
• Perform calibrations by rotating the jog dial.
• Troubleshoot machine systems Seatbelt Switch Status (If equipped) / Power
Mode (2B)
Action Lamps (1)
Not Fastened (2B) – Displays when the
The action lamps illuminate to show that a problem seatbelt is not fastened.
has occurred with the machine.
Status Information Area (2) Smart Mode (2B) – This indicator shows
that the machine is set to operate in the
SMART mode.
Power Mode (2B) – This indicator shows

that the machine is set to operate in the
Power mode.
Disabled (2B)
Work Tool (2C)
Work Tool – Displays the current work tool.
Off (inactive, Not Installed)

(2A) Multi Status Information
(2B) Seatbelt Switch Status(if equipped) / Power Mode Other
(2C) Work tool
(2D) Heavy Lift / Cat Dig Boost (if equipped)
(2E) Lever Pattern / Fuel Level
(2F) Clock Hammer
Multi Status Information (2A)
Service Hour Meter (2A) – Shows the Grapple

total operating hours of the engine. Use
the display to determine the service-
hour maintenance intervals. Bucket
Soot Load (2A) – The amount of soot
built up in the Diesel Particulate Filter
(DPF) at the time of regeneration.
120 M0111427-02
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Monitoring System
Shear Clock (2F)
Clock (2F) – The clock function displays the current

time.
Thumb
Event Indicator Area (3)

Magnet
Compactor
Clamshell
Rotary Cutter
Tilt Bucket
(3A) Event Description
Tilt Rotor (3B) Event Symbol
(3C) e-OMM Key
(3D) Close Key
(3E) Event ID
(3F) Order Number / Total Number
Quick Coupler (3G) Arrow Key
Event Description (3A) – This area will display the

Heavy Lift / Cat Dig Boost (If Equipped) (2D) description of pop-up message of the impending
problem.
On (Active) (2D) – The Heavy Lift / Cat
Dig Boost is in active status. • Line 1 : System
Off (inactive, Not Installed)(2D) • Line 2 : Condition

• Line 3 : Action to be taken
Event Symbol (3B) – This area will display the
Lever Pattern/Fuel Level (2E) symbol of the problem
Lever Pattern – The lever pattern will be displayed if
the hydraulic lock switch is locked. The lever patterns e-OMM Key (3C) – This area will indicate that the e-
that can be displayed are: ISO/JIS, KOBE, MHL, OMM is available for this event. If e-OMM is not
SCM, and BHL. available for this event, area will be blank.
Fuel Level – The fuel level will be displayed when Close Key (3D) – Select this key to hide the pop-up
the hydraulic lock switch is unlocked and the fuel message and display the event icon list.
gauge is not displayed in Gauge Area (5). The fuel
level will indicate the amount of fuel left in the fuel Event ID (3E) – The identification number for the
tank. 100% is displayed when the fuel tank is full. The
displayed fuel level will decrease by 10% as fuel is event will be shown here.
consumed. "E" in red will be displayed when the fuel
tank is empty. Priority Number / Total Number (3F) – The priority
number of the pop-up message is displayed next to
the total number of messages. The messages are
Note: If the hydraulic lock switch is unlocked and the ordered from the highest to the lowest priority.
fuel gauge is displayed in Gauge Area (5), then this
area will be blank.
M0111427-02 121
Operation Section
Monitoring System
Arrow Keys (3G) – The arrow keys are shown when Navigation Bar (6)
there is a next or previous message. Select the arrow
key to display the next or previous message. Apps Key – Allows you to display
different information in the gauge area
related to operation. Also contains air
Camera View (4) conditioner and radio controls. This key includes
the settings screen allowing change of a
This area on the monitor displays the view of the multitude of parameters, some password
cameras. A rear view camera mounted on top of the protected.
counterweight and an optional side view camera
mounted in the side panel next to the hydraulic tank. Function List Key – Allows you to turn
on and off various functions related to
If both rear view camera and side view camera are
equipped, the monitor screen can be toggled to the active screen. This icon only
show: appears in certain screens where additional
settings are necessary.
• Rear only
Shortcuts – Allows you to set certain shortcuts on
• Side only the navigation bar.
• Split vertically
Machine Warnings
• Split horizontally
The camera view can be toggled when the cursor is
on the camera view area and the area is touched or
the jog dial is turned.
Gauge Area (5)

Fuel Level – This gauge indicates the
amount of fuel that is remaining in the
fuel tank. When the fuel gauge is in the
red range, add fuel immediately.
Hydraulic Oil Temperature – This gauge
indicates the temperature of the
hydraulic oil. The normal operating
range is the green range. If the gauge is in the
white range, the engine and machine warm-up is
required. Refer to Operation and Maintenance
Manual, “Engine and Machine Warm-up”. 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. Illustration 171 g06223766
Engine Coolant Temperature – This Event Indicator Area

gauge indicates the temperature of the (1) Event Icon List
engine coolant. The normal operating (2) Pop-up Event Message
range is the green range. If the gauge is in the
white range, the engine and machine warm-up is The Monitor will display warnings, and log events for
machine conditions that are not within normal
required. Refer to Operation and Maintenance operating parameters.
Manual, “Engine and Machine Warm-up”. If the
gauge reaches the red range, stop the machine The event warnings are classified into three warning
and investigate the cause of the problem. levels. Warning Level 1 represents the least severe
problem and Warning Level 3 represents the most
Diesel Exhaust Fluid (DEF) Gauge – This severe problem. The warning levels, monitor
gauge indicates the level of DEF fluid in response, and the required operator actions are
the DEF tank. When the DEF gauge is in given below.
the red range, add DEF immediately.
Warning Level 1 (Gray) – Requires operator
awareness. The icon and pop-up message will both
appear gray.
122 M0111427-02
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Monitoring System
E237–1 Overload Warning Sensor

Warning Level 2 (Amber) – Requires a change in Malfunction - Check Sensor
the operation of the machine or a change in the
maintenance of the machine to correct the condition.
The icon and pop-up message will both appear E237–2 Overload Warning Overload -
amber and the action lamp will blink. Reduce Load
Warning Level 3 (Red) – Requires immediate
shutdown of the machine to prevent damage to the E241–2 e-fan Failure - Service Required
machine or personnel. The icon and pop-up message
will both appear red, the action lamp will blink, and
the buzzer will sound.
E363–1 Fuel Temp High
When multiple warnings are present in the system,

the highest warning is shown first. Press the right or
left key to view all the logged warnings. If no keys are E363–2 Fuel Temp High / Power Derate
pressed within a few seconds, the display will return
to the highest warning.
E534–2 Swing Parking Brake
Event Icon List Malfunction - Service Required
E534–3 Hyd Lock Active - Cycle The

Lock Lever
E862–2 Att Hyd Oil Filter Plugged -

Replace Filter
E875–2 Battery Voltage Low - Service

Required
E876–2 Battery Voltage High - Service

Required
Illustration 172 g06223816 E878–2 Hyd Oil Temp High - Stop

Operating
The Event Icon List display all active events. The list
orders the higher-level warnings first, with the red
furthest left, and gray furthest right. The currently E1046–2 Tool Control Hyd Oil Temp High
selected icon will be highlighted with a yellow box - Stop Operating
surrounding the icon. Turn the jog dial left and right to
change the highlighted icon and press down on the
jog dial to navigate to the highlighted icon pop-up E1132–1 Machine Software
message. Configuration Inconsistent - Check
Software Version
Arrows will appear at either side of the icon list if
there are too many icons to display on a single bar. E1377–1 Security System Disable/Derate
The arrow will navigate to the next set of icons Pending
instantly rather than the next icon from the bold one.
Refer to “List of Warning Messages” for more E1377–2 Security System Disable/Derate
information on possible causes and responses to
Pending
Machine System Event Codes.
E119–2 Fuel Level Low - Refill Fuel E1378–2 Machine Fault - Service
Required
E236–2 Hyd Oil Filter Plugged - Replace E1379–2 Machine Fault - Service
Filter Required
M0111427-02 123
Operation Section
Monitoring System
E1634–2 Refueling Pump Strainer

Plugged - Check Strainer
E1635–2 Refueling Pump Runs Dry -

Stop Refueling
E2138–1 Payload Memory Full
List of Warning Messages

Note: Not all the warnings that are listed may be
applicable to all machine models.
Table 18
Machine System Event Codes
Event Code Description Possible Cause / Recommended Response

Possible Cause: Low fuel level in the tank, fuel line leakage, or the
fuel filter is plugged.
E119-2 Fuel Level Low - Refill Fuel
Recommended Response: Check the fuel level in the tank.
Possible Cause: This event is active only when the machine is travel-
ing and the oil temperature is greater than 50° C (122° F) for 10 sec-
onds or more.
E236–2 Hyd Oil Filter Plugged - Replace Filter Recommended Response: Replace the filter as soon as possible. If
filter replacement is not convenient, stop machine travel until oil tem-
perature is less than 50° C (122° F) for 180 seconds or more.
If a code is present after the filter is replaced, inspect the hydraulic
lines for signs of severe bending or internal collapse.
Possible Cause: The Boom Cylinder Head Pressure Sensor has ex-
Overload Warning Sensor Malfunction - Check perienced a failure.
E237–1
Sensor
Recommended Response: Contact your Cat dealer for service.
Immediate Safe Shutdown of Machine is required

Possible Cause: The machine overload pressure threshold has been
exceeded.
E237–2 Overload Warning Overload - Reduce Load
Recommended Response: Reduce the load on the machine before
shutting down machine. Inspect machine stress points.
Possible Cause:This event is active when fan embedded control de-

tects locked rotor, high electric current, or internal error.
E241–2 e-fan Failure - Service Required
Recommended Response:Investigate if fan is obstructed. Test the
fan with the override e-fan speed command in the monitor.
Possible Cause: This event is active only when the fuel temperature
reaches the trip level.
E363–1 Fuel Temp High
Recommended Response: Reduce Engine Load.
Possible Cause: This event is active only when the fuel temperature
reaches the trip level.
E363–2 Fuel Temp High / Power Derate
Recommended Response: Reduce Engine Load.
(continued)
124 M0111427-02
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Monitoring System
(Table 18, contd)


Possible Cause: Swing movement detected with no command given.
Swing Parking Brake Malfunction - Service
E534–2
Required
Possible Cause: Swing movement detected with no command given.

E534–3 Hyd Lock Active - Cycle The Lock Lever
Possible Cause: Occurs when hydraulic oil temperature exceeds

50° C (122° F) for more than 5 seconds.
E862–2 Att Hyd Oil Filter Plugged - Replace Filter

Recommended Response: Replace filter as soon as possible. If
code is present after the filter is replaced, inspect the hydraulic lines
for damage.
Possible Cause: Event is active when the system voltage is less than
18 VDC for more than 60 seconds.
E875–2 Battery Voltage Low - Service Required
Recommended Response: The machine returns to normal operation
when the voltage exceeds 18 VDC for more than 2 seconds.
Possible Cause: Event is active when the system voltage exceeds

E876–2 Battery Voltage High - Service Required
when the voltage is less than 31.5 VDC for more than 2 seconds.
Possible Cause: The event is active when the temperature of the hy-
draulic oil exceeds 126° C (259° F) for more than 2 seconds.
E878–2 Hyd Oil Temp High - Stop Operating
Recommended Response:
Change the operation of the machine to allow the hydraulic oil to cool.
Possible Cause: The event is active when the temperature of the hy-
draulic oil exceeds 126° C (259° F) for more than 2 seconds.
E1046–2 Tool Control Hyd Oil Temp High - Stop Operating
Recommended Response: Change the operation of the machine to
allow the hydraulic oil to cool.
Possible Cause: An attachment valve has not been configured

correctly.
Machine Software Configuration Inconsistent -
E1132–1
Check Software Version
Recommended Response: Reconfiguration of one or more of the at-
tachment valves is required.
Possible Cause: This code is used to inform the operator that the
machine is remotely disabled.
E1377–1 Security System Disable/Derate Pending
Possible Cause: This code is used to inform the operator that the
machine is remotely disabled.
E1377–2 Security System Disable/Derate Pending
Possible Cause: Event is active when the system voltage exceeds

E1378–2 Machine Fault - Service Required
when the voltage is less than 31.5 VDC for more than 2 seconds.
(continued)
M0111427-02 125
Operation Section
Monitoring System
(Table 18, contd)


Possible Cause: Event is active when the system voltage is less than
E1379–2 Machine Fault - Service Required
when the voltage exceeds 18 VDC for more than 2 seconds.
Possible Cause: Debris in foot valve screen.

E1634–2 Refueling Pump Strainer Plugged - Check Strainer
Recommended Response: Clean or replace the foot valve screen.
Possible Cause: Kink in fuel hose or source fuel low.

E1635–2 Refueling Pump Runs Dry - Stop Refueling
Recommended Response: Check source fuel and check for kink in
hose.
Possible Cause:When data transfer between machine ECM and net-
work manager (product link elite) is failed.
E2138–1 Payload Memory Full
Recommended Response: Reconfigure the machine and clear the
payload memory.
Logging In
There are different ways to access the monitor which

include:
• Guest access
• Passcode access
• Bluetooth access
• Cat ® Fleet Management app
126 M0111427-02
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Monitoring System
For more information on logging in, refer to Operation

and Maintenance Manual, Machine Security System Air conditioner button (3) – Press the button to
- Operator Login. access the air conditioner controls.
Next menu button (4) – This button is equivalent to
Navigation the function list key on the monitor. This button can
only be used on screens where the function list key is
shown.
Home button (5) – Press this button to return to the
main screen.
Radio button (6) – Press this button to access the
radio controls.
Mute button (7) – Press this button to mute the
radio. Press the button again to unmute the radio.
Each of the buttons is also assigned a number which

is imprinted in the top corner of the button. These
buttons can be used to enter the numerical
passcodes used to log in to the monitor.
Operator Screen

Right side switch panel
(1) Operator information button
(2) Jog dial
(3) Air conditioner button Illustration 175 g06241547
(4) Next menu button
(5) Home button After logging in, the operator information screen will
(6) Audio button appear. The screen provides the following
(7) Mute button
information for the logged in operator:
The monitor can be navigated by touch screen or the
• Operator ID
switch panel. Switch panel components can be used
to interface with the monitor in the following ways: • Joystick pattern
Operator information button (1) – Press and hold
• Active tool
this button to access the operator information screen.
This screen shows information such as operator • Spool response speed
settings.
Jog dial (2) – Rotate the jog dial to highlight menu • Joystick button assignments
items in the monitor. Push the jog dial down to select
the highlighted item.
M0111427-02 127
Operation Section
Monitoring System
Application Menu
The operator information screen can be accessed at

any time by pressing the operator information button
on the right side switch panel.
Press the application menu button to access the

Application menu.
128 M0111427-02
Operation Section
Monitoring System
Setting Menu
From the main screen, press the application menu

button. In the Application menu, select “Setting” .
The Application menu or “Apps” menu contains the

following menu items:
• Setting
• Air Conditioner
• Audio
• Phone
• Bucket/Work Tool Setting

• Electronic OMM
A warning will appear notifying the operator that the

camera is not visible in the Setting menu. After you
have read the warning and understand the content,
press the “OK” button.
M0111427-02 129
Operation Section
Monitoring System
The Setting menu contains the following menu items: The Display Setting menu contains the following
menu items:
• Display Setting
• Clock Adjust
• Information
• Time Zone
• Machine Setting
• Brightness Adjust
• Operator Setting
• Display Unit
• Service
• Default Camera View
Note: A dealer password is necessary to access the
Service menu. • Language
Display Setting Clock Adjust
Note: Master level access is required to adjust clock

settings.
The clock adjust feature allows the operator to set the
clock and set the date.

Next, select “Display Setting” .
130 M0111427-02
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Monitoring System
To access the Clock Adjust screen, press the To access the Time Zone screen, press the
application menu button. Select Setting, Display application menu button. Select Setting, Display
Setting, then Clock Adjust. Setting, then Time Zone.
Adjust the date and time as necessary. Select the Select the correct time zone setting from the list.
Home button to return to the main screen. Select the Home button to return to the main screen.
Time Zone Brightness Adjust
The time zone feature allows the operator to set the The brightness adjust function allows the operator to
time zone for the region the machine is operating in. adjust the brightness of the display for day and night
mode.
M0111427-02 131
Operation Section
Monitoring System
To access the Brightness Adjust screen, press the Adjust the brightness level then select “Home” to
application menu button. Select Setting, Display return to the main screen.
Setting, then Brightness Adjust.
Display Unit
Display unit allows the operator to choose between

Metric or English units being displayed.
Select Day or Night to adjust the brightness level.

Next, select “Display Setting” and then “Display Unit”
.
132 M0111427-02
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Monitoring System
Select either Metric or English then select “Home” to Select between “Vertical Split” or “Horizontal Split”
return to the main screen. then select “Home” to return to the main screen.
Default Camera View Language
Default camera view allows the operator to choose Language allows the operator to choose the
the default camera view. The two choices are split language for the monitor.
screen horizontal or split screen vertical.

From the main screen, press the application menu button. In the Application menu, select “Setting” .
button. In the Application menu, select “Setting” . Next, select “Display Setting” and then “Language” .
Next, select “Display Setting” and then “Default
Camera View” .
M0111427-02 133
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Monitoring System
Select the desired language, then select “Home” to From the main screen, press the application menu
return to the main screen. button. In the Application menu, select “Setting” .
Next, select “Shortcut” .
Shortcut
Illustration 197 g06389546 Select the desired shortcuts to be displayed on the

home screen.
Shortcut allows the operator to choose up to 4
shortcuts to be displayed on home screen of the
monitor.
134 M0111427-02
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Monitoring System
Information • Diagnostics
Performance
The Performance screen allows the operator to view

performance information such as pump outlet
pressure and battery voltage.

Next, select “Information” .

Next, select “Information” and then “Performance” .
The Information menu contains the following menu

items:
• Performance Illustration 203 g06217555
• Current Totals Scroll through the list of values to view machine

performance. Press the “Home” button to return to
• License Information the main screen.
• ECM Summary
M0111427-02 135
Operation Section
Monitoring System
Current Totals License Information

The Current Totals screen allows the operator to view The License Information screen allows the operator
operating hours for machine components such as the or maintenance personnel to view the software
hydraulic pump and swing motor. license agreement.
From the main screen, press the application menu From the main screen, press the application menu
button. In the Application menu, select “Setting” . button. In the Application menu, select “Setting” .
Next, select “Information” and then “Current Totals” . Next, select “Information” and then “License
Information” .

Scroll through the list of values to view component
operating hours. Press the “Home” button to return to Press the “Home” button to return to the main screen.
the main screen.
136 M0111427-02
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Monitoring System
ECM Summary
The ECM Summary screen allows the operator to

choose any electronic control module (ECM) on the
machine and view the following for that ECM:
• Hardware part number
• Hardware serial number
• Software description
• Software part number
• Software release date
Select one of the components to view hardware and

software information. Press the “Home” button to
return to the main screen.
Diagnostics
The Diagnosis screen allows the operator to view the

following diagnostic items:
• Active diagnostic codes

• Logged diagnostic codes
• Active event codes

• Logged event codes
Next, select “Information” and then “ECM Summary” .
M0111427-02 137
Operation Section
Monitoring System
Machine Setting

Next, select “Machine Setting” .

Next, select “Information” and then “Diagnostics” .
Select from the groups of diagnostic codes to view Illustration 213 g06469610
active and logged codes. Press the “Home” button to
return to the main screen. The Machine Settings menu contains the following
menu items:
• Engine Shutdown Setting
• Power Mode Setting

• Reverse Fan
• Audio
138 M0111427-02
Operation Section
Monitoring System
• Lighting Shutdown Timer

• Auto Warm Up
• Sleep Time
• Security
Engine Shutdown Setting
Note: Master level access is required to adjust

engine shutdown settings.
The Engine Shutdown Setting screen allows the
operator to enable, disable, and adjust the engine
shutdown timer. This feature operates the engine at
idle speed for a set amount of time to cool the engine
before shutting down automatically.
Select “Idle Shutdown Enable” to enable or disable

the idle shutdown feature. If enabled, select “Idle
Shutdown Delay Timer” to change the delay time.
Power Mode Setting
Note: Master level access is required to adjust power

mode settings.
The Power Mode Setting screen allows the operator
to choose what power mode to operate the engine.

Next, select “Machine Setting” , and then “Engine
Shutdown Setting” .

Next, select “Machine Setting” , and then “Power
Mode Setting” .
M0111427-02 139
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Monitoring System
Select the desired power mode to operate in and From the main screen, press the application menu
switch to “ON” . The operator can also select the button. In the Application menu, select “Setting” .
default power mode when the engine is first started. Next, select “Machine Setting” , and then “Reverse
Once finished, press the “Home” button to return to Fan” .
the main screen.
Note: Economy Mode is not available on GC models.
Reverse Fan (If Equipped)

reverse fan settings.
The reversing fan feature allows the operator or
maintenance personnel to reverse the fan to clean
debris from the cooling group. The Reverse Fan
screen allows the activation of the reverse fan
feature.
Note: The HVAC system in the cab will reduce air
flow in the cab and disengage the compressor so it
doesn’t over pressurize during a reverse fan
operation.
Follow the instructions and prompts on the monitor to

reverse the fan.
140 M0111427-02
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Monitoring System
Reverse Fan - Auto Mode
The reversing fan feature allows the operator or

maintenance personnel to reverse the fan to clean
debris from the cooling group. The Reverse Fan
screen allows the activation of the reverse fan
feature.
Select “Auto Reversal Fan Enable” to enable or

disable the idle Auto Reverse fan feature. If enabled,
select “Auto Reverse Fan Interval” to set the interval
time for auto reverse fan feature. Once finished,
press the “Home” button to return to the main screen.
Audio
From the main screen, press the application menu The Audio screen allows the user to choose the radio
button. In the Application menu, select “Setting” . region, enable Bluetooth, pair devices, and scan for
Next, select “Machine Setting” , and then “Reverse Digital Audio Broadcast (DAB) channels.
Fan” .
M0111427-02 141
Operation Section
Monitoring System
• DAB Channel Scan - Start a scan to find DAB

channels in the area with good reception.
• Volume Gain - Allows the user to individually

adjust the gain on various outputs such as the AM
radio, FM radio, and the phone.
Lighting Shutdown Timer
Note: Master level access is required to lighting

shutdown settings.
The Lighting Shutdown Timer screen allows the user
to enter a delay time for the exterior lights to shut off.
The Lighting Shutdown Timer provides light for a set
amount of time to allow the operator to safely
dismount the machine.

Next, select “Machine Setting” , and then “Audio” .

Next, select “Machine Setting” , and then “Lighting
Shutdown Timer” .
The Audio screen contains the following menu items:
• Radio Region Setting - Choose the radio region

from the list of locations around the world.
• Bluetooth - Allows the operator to enable
Bluetooth and pair a phone. This menu is also
available through the main Audio screen. Refer to
Operation and Maintenance Manual, Monitoring
System - Bluetooth for information on the
Bluetooth screen.
142 M0111427-02
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Monitoring System
Use the keypad to enter the number of minutes for To enable or disable auto warm-up, press the “Auto
the light delay. Select “Apply” when done. Warm Up Enable Status” window, then select
“Enabled” or “Disabled” .
Auto Warm Up
The Auto Warm Up screen allows the user to enable

and set the auto warm-up feature. This feature
automatically starts a warm-up period when the
engine is started and the hydraulic oil is below the set
temperature.
To set the auto warm-up temperature, press the

“Auto Warm Up Target Temp” window, then enter the
temperature. If the hydraulic oil is below the set
temperature, the auto warm-up feature will activate
after the engine is started.

Next, select “Machine Setting” , and then “Auto Warm
Up” .
M0111427-02 143
Operation Section
Monitoring System
Sleep Time Security

security settings.
The Security screen allows the user to set the
operator lockout time. The lockout time is the amount
of time after engine shutdown that an operator can
start the engine without logging back in to the
monitor.
The Sleep time Setting feature allows the user to set

a sleep timer for the engine start switch. If the start
switch is left in the ON position, power will
automatically shut off once the chosen timer interval
has elapsed.

Next, select “Machine Setting” , and then “Security” .

Next, select “Machine Setting” , and then “Sleep
Time” .
144 M0111427-02
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Monitoring System
Operator Setting

Next, select “Operator Setting” .
Select “Operator ID Timeout” to select the amount of

time before the operators passcode times out after
engine shutdown. To block out periods of time
throughout the week to bypass security, select
“Security Bypass Time” .
The Operator Setting menu contains the following

menu items:
• Operator Inputs Configuration
Illustration 235 g06242071 • Response
Enter the times and the days to bypass the security • Change Operator
system.
• Manage Operator
Operator Inputs Configuration
The operator inputs configuration screen allows the

operator to configure the joystick buttons for personal
preference. The settings will be stored in the
preferences for that login ID.
M0111427-02 145
Operation Section
Monitoring System
From the main screen, press the application menu Select the button to configure.
Next, select “Operator Setting” , then “Operator
Inputs Configuration” .
Select the category of button functions to choose

Illustration 239 g06222026 from.
Choose the joystick to configure.

146 M0111427-02
Operation Section
Monitoring System
Select the desired function from the list. Repeat for

the remaining buttons and press the “Home” button
to return to the main screen.
Lever Pattern
From the Operator Inputs Configuration screen,

select “Lever Pattern” .
M0111427-02 147
Operation Section
Monitoring System
(8) 4-way menu items (9) 2-way menu items (10) Clamshell menu items (if equipped)
Select the desired lever pattern from the menu items.

Press the “Home” button to return to the main screen.
Restore to Factory Setting
Select the item from the list to be restored.
From the Operator Inputs Configuration screen,

select “Restore to Factory Setting” .
148 M0111427-02
Operation Section
Monitoring System
A warning will appear asking if you want to proceed.

Press “Restore” to restore the settings or press
“Cancel” to abort. After pressing “Restore” , the
operator information screen will appear to show the
new button assignments. Press the “OK” button to
return to the main screen. Illustration 248 g06261337
Response From the main screen, press the application menu

The response screen allows the operator to adjust Next, select “Operator Setting” , then “Response” .
the spool settings which will affect how quick the Once in the Response screen, select “Spool
machine responds when using the joysticks. The Response Selection” .
settings can be set to slow, medium, or fast.
Select the desired response speed, then select the

“Home” button to return to the main screen.
M0111427-02 149
Operation Section
Monitoring System
Change Operator
The change operator screen allows a new operator to

log in. After successfully logging in, the previous
operators preferences will be overridden with the new
operators preferences.
If the login was successful, the operator screen will

appear showing the preferences for the new
operator. Press the “OK” button to return to the main
screen.
Manage Operator
button. In the Application menu, select “Setting” . Note: Master level access is required to manage
Next, select “Operator Setting” , then “Change operator settings.
Operator” .
The Manage Operator screen allows users to add
and remove operators to the machine.
Enter the passcode or press the “Guest” button to log

in as a guest.
150 M0111427-02
Operation Section
Monitoring System
From the main screen, press the application menu Enter the key type, access level, operator name, and
button. In the Application menu, select “Setting” . the key code for the new operator. Select the “Home”
Next, select “Operator Setting” , then “Manage button to return to the main screen.
Operator” .
Edit/Delete Operator
Add Operator

To edit or delete an operator, scroll through the
In the Manage Operator screen, select “Add operator list in the Manage Operator screen and find
Operator” . the operator to be changed.
M0111427-02 151
Operation Section
Monitoring System
Phone

button. In the Application menu, select “Phone” .
To change the access level, select the window and

change to either Master or Standard.
To edit the operator name, select the window and use
the keyboard to change the name.
To delete the operator, select “Delete The Operator” .
Air Conditioner
Refer to Operation and Maintenance Manual, Air
Conditioning and Heating Control for coverage of the
air conditioner screen in the monitor.
Audio
Refer to Operation and Maintenance Manual, Radio
for coverage of the audio screen in the monitor.
To make a call, select “Call” , then use the keypad to

dial the number.
Note: There must be a paired phone in the cab and

Bluetooth enabled to make a call.
To check for recent calls, select “Recent Calls” from
the menu. The Recent Calls screen will appear listing
the most recent calls.
To access the Audio menu, press button (7).
152 M0111427-02
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Monitoring System
The Audio menu contains the following:

2. Ensure that the Bluetooth power is on in the
• Bluetooth - Allows the operator to enable monitor. If not, select “Power” and switch to On.
Bluetooth and pair a phone. This menu is also
3. Ensure that the Bluetooth setting on the phone is
available through the main Audio screen. Refer to
Operation and Maintenance Manual, Monitoring on, then select “Pairing” from the monitor menu.
System - Bluetooth for information on the
Bluetooth screen.
Bluetooth
Pairing A Phone
1. While in the phone application, select “Bluetooth

Setting” from the Function List menu.
4. If the phone does not automatically search for

devices, activate the search feature on the phone
and follow any phone prompts.
M0111427-02 153
Operation Section
Monitoring System
Once paired, the phone will be added to the “Paired

Devices” screen. On the screen the connected phone
will have a Bluetooth symbol next to the listing. To
change the name assigned to the phone, go to
“Device Name Change” screen and edit the name.
Bucket/Work Tool Setting

The Bucket/Work Tool Setting screen allows the
operator to choose the tool being used for work.
The Tool screen contains the following:

• Tool Name - Enter this screen to edit the name of
From the main screen, press the application menu the tool.
button. In the Application menu, select “Bucket/Work • Tool Type
Tool Setting” .
• Tool Program - This screen requires a dealer
password and is used to set parameters for the
tool.
Electronic OMM
The Electronic OMM screen allows the operator to
view the Operation and Maintenance Manual (OMM)
for the machine.
Select the desired tool.


Next, select “Information” and then “Electronic OMM”
.
154 M0111427-02
Operation Section
Monitoring System
Note: Contact your Cat Dealer for information to

update the electronic OMM.
Function List Screen
Navigate through the OMM to find the topic of choice.

Press the “Home” button to return to the main screen.
Press the Function List icon to access the Function

List screen.
M0111427-02 155
Operation Section
Monitoring System
The Function List screen allows the user to turn on or

off the available functions on the machine. Tap or
select with the jog dial the item to turn on or off.
Auto Warm Up
The auto warm-up feature is a convenient way to
make sure that the machine component
temperatures are optimum for machine operation.
More settings are located in Settings, Machine
Settings, Auto Warm Up screen.
AEC
When enabled, the Automatic Engine Speed Control
(AEC) automatically reduces engine speed when the
machine is inactive. The AEC system is designed to
reduce fuel consumption and noise. Lower engine
speeds can also increase engine life.
The engine rpm will recover automatically to the
setting of the engine speed dial when any hydraulic
function is activated.
Table 19
Position of Manual Low Description of Mode
AEC State
Idle Switch
The electronic controller will automatically reduce the engine rpm after there
has been no hydraulic demand for a set amount of time. The default time setting
Enabled OFF is 5 seconds.
Approximate engine rpm: 320 GC - 950 rpm, All models except 320 GC - 1000
rpm.
The engine speed is reduced.

Enabled or Disabled ON Approximate engine rpm: 320 GC - 950 rpm, All models except 320 GC - 1000
rpm..
Note: The position of the engine speed dial has no

relevance on the actions described in Table 19 .
156 M0111427-02
Operation Section
Fuel Transfer Pump (Refueling)
Fine Swing Work Light Control
The Fine Swing Control delays the engagement

of the swing parking brake.
If the machine is operating on a slope with the
Fine Swing Control in the ON position, the swing
motion may become uncontrollable which could
result in property damage, personal injury or
death.
Turn the Fine Swing Control to the OFF position
when the machine is operating on a slope.
When the fine swing control is enabled, the swing

parking brake is released. Swing control improves
during deceleration of a swing because the swing is
allowed to drift instead of stopping abruptly.
Operate the machine with the fine swing control
disabled when the machine is on a slope. Operate
the machine with the fine swing control disabled
when great swing forces are required. For example,
digging on a sidewall requires great swing force. Illustration 270 g06493153
Operate the machine with the fine swing control
disabled to control the motion with the swing brake. If equipped with premium surrounding lighting
package, the lights are selected by this menu. The
operator can activate or deactivate the lights and the
lights can be selected based upon operator
preference.
i06951931
Fuel Transfer Pump

(Refueling)
(If Equipped)
SMCS Code: 1256
Use the following procedure to pump fuel and store
the hose.
M0111427-02 157
Operation Section
If Equipped

(1) Suction valve Suction valve (1) is at the end of hose (2).
(2) Suction hose
(3) Electric refueling pump Turn the end of the suction valve clockwise to open
(4) ON/OFF switch the valve
ON/OFF Switch – Push the ON/OFF 5. Uncoil the hose and turn the end of the suction
switch to activate or deactivate the fuel valve clockwise to open the suction valve.
transfer pump. A red indicator on the
switch will illuminate when the fuel transfer pump 6. Properly insert the end of the suction valve into a
is activated. container of fuel.
If one of the following conditions occur, the fuel 7. Push switch (4) to activate the fuel transfer pump
transfer pump will not activate and/or stop operating: and supply the fuel to the tank. A red indicator on
the switch will illuminate when the fuel transfer
• Battery disconnect switch is in the OFF position pump is activated.
• Engine is operating When the fuel tank is full, the fuel transfer pump
will automatically stop.
• Engine start switch is moved to the START
position. When the fuel container is empty, push the switch
again to stop refueling. If additional fuel is needed,
• Engine start switch is in the OFF position
wait 30 seconds and return to step 6.
• Hydraulic lockout control is not in the LOCKED
Note: The red indicator on the switch will no longer
position
illuminate when the fuel transfer pump has stopped
• Fuel tank level is full refueling.
• Fuel is not detected at the suction valve. Note: The fuel transfer pump will not activate for 30
seconds following a detection of no fuel at the suction
• 30 seconds following a detection of no fuel at the valve.
suction valve.
8. Push the switch at any time to deactivate the fuel
Use the following procedure to pump fuel and store transfer pump.
the hose.
Note: The red indicator on the switch will no longer
1. Park the machine on a level surface. Move the
illuminate when the fuel transfer pump has stopped
hydraulic lockout control to the LOCKED position. refueling.
Stop the engine
2. Turn the engine start switch to the ON position 9. Drain excess fuel from the hose and turn the end
without starting the engine. of the suction valve counter-clockwise to close the
suction valve.
3. Remove the fuel tank cap from the fuel tank.
10. Wind the hose and store in the hose container.
4. Open the access that is on the right side of the
machine.
158 M0111427-02
Operation Section
Radio
NOTICE
To prevent hose damage, do not coil the hose in a
tight radius.
11. Close the access door.

12. Install the fuel tank cap onto the fuel tank.
13. Turn the engine start switch to the OFF position.
i07092848
Radio
SMCS Code: 7338
The radio is integrated into the monitoring system. All
the radio controls are adjusted using the monitor. The
actual radio is mounted in the right rear console
behind the operator seat.
Press radio button (3) to go directly to the radio

screen. To navigate to the radio screen from the main
screen, press application menu button (4).

(1) Jog dial
(2) Home button
(3) Radio button
The audio menu can be directly accessed by

pressing radio button (3) on the right side switch
panel. Input selections can be made using jog dial (1) Illustration 275 g06213198
or using the monitor touch screen. Home button (2)
can be used to return to the main screen. Use jog dial (1) to highlight “Audio” and then press
the jog dial downward to select the entry. You may
also access the screen by simply touching the
“Audio” box on the touch screen.
M0111427-02 159
Operation Section
Radio
Radio function list menu button (11) – Pressing

this button leads to the radio function list menu.
AM button (12) – Press this button to access AM
radio. The indicator light will illuminate when this
mode is active.
FM button (13) – Press this button to access FM
radio. The indicator light will illuminate when this
mode is active.
Radio Function List

To access the radio function list, press the function
list button (11) in the lower right corner of the radio
screen.

Radio screen
(4) Application menu button
(5) Volume control
(6) Tuner
(7) Preset stations
(8) Auxiliary button
(9) USB button
(10) Power button
(11) Radio Function List menu
(12) AM button
(13) FM button
Application menu button (4) – Use this button to

return to the application menu.
Volume control (5) – The volume control is used to
raise or lower the audio volume.
Tuner (6) – The tuner is used to tune the radio to the
desired station. The function list menu consists of the following items:
Preset stations (7) – The preset stations store Treble – Allows the user to adjust the treble.
favorite radio stations for the operator. To set a
station, tune to the desired station. Press and hold Bass – Allows the user to adjust the bass.
the preset number you want to assign to that station.
Once a beep is heard, release the button. The Balance – Allows the user to adjust the balance
indicator light for the active preset station will between speakers.
illuminate. Auto Loudness – When on, this feature
automatically adjust treble and bass levels when
Auxiliary button (8) – When a device is plugged into
the auxiliary port, press the auxiliary button to reducing the volume setting. This effect allows the
connect the device to the radio. The indicator light will user to hear more clearly at a lower volume.
illuminate when this mode is active. Bluetooth – Allows the user to pair a phone, view
paired devices, and edit device names.
USB button (9) – When a device is plugged into the
USB port, press the USB button to connect the
device to the radio. The indicator light will illuminate
when this mode is active.
Power button (10) – Pressing this button turns the
radio on and off. The indicator light on the monitor
and on button (3) will illuminate when the power is
on.
160 M0111427-02
Operation Section
Radio
Refer to Operation and Maintenance Manual, 5. When the machine is in operation turn down the
Monitoring System - Bluetooth for information on the volume of the radio.
Bluetooth screen.
USB/AUX Operation
Selection Method
All settings can be made using the touch screen or by
using the jog dial. The method depends on the
preference of the operator. When using the touch
screen, simply touch the icon you want to select.
When using the jog dial, rotate the dial to switch to
different selections within the screen. Press the jog
dial downward to choose a selection.
1. To play music from a device such as an MP3

player or a phone, connect the device using an
auxiliary cable or a USB cable. Depending on the
cable being used, plug the cable into the
appropriate port on the console.
2. Select either USB or AUX depending on which
When using the jog dial to set the volume or tuner, type of cable was used. Play the music from the
rotate the dial clockwise to increase and counter-
clockwise to decrease. Press downward on the dial device. The music should be playing over the
to enter the desired setting. radio speakers if properly connected. Adjust the
volume as necessary.
Radio Operation
1. To operate the system, press power button (10).
2. Select between the AM button for AM stations or
select the FM button for FM stations.
3. Use tuner (6) to adjust to the desired station. If
presets stations (7) are set, press the desired
preset station.
4. Use volume control (5) to adjust the volume.
M0111427-02 161
Operation Section
Air Conditioning and Heating Control

(1) Jog dial
Note: If USB is selected, extra controls appear on the (2) Heating and air conditioning button
screen for playing music. They include the following: (3) Home button
14 – Skip to the beginning of the track Air conditioning and heating functions are controlled
through the monitor. The heating and cooling menu
15 – Rewind the track can be directly accessed by pressing button (2) on
the right side switch panel. Input selections can be
16 – Pause/Play the track made using jog dial (1) or using the monitor touch
17 – Fast forward the track screen. Home button (3) can be used to return to the
main screen.
18 – Skip to the end of the track
i08031142
Air Conditioning and Heating

Control
SMCS Code: 7304; 7320; 7337
Consult with your Cat dealer for periodic
maintenance of the heating and air conditioning
system.
Press the Air Conditioning and Heating button (2) to

go directly to the air conditioner screen. To navigate
to the air conditioner screen from the main screen,
press application menu button (4).
162 M0111427-02
Operation Section

(14) Front vents
(15) Front and rear vents
(16) Front, foot, and rear vents
(17) Foot vents
(18) Defrost and foot mode
Application menu button (4) – Use this button to

return to the application menu.
Temperature control (5) – The temperature control
is used to raise or lower the desired temperature.
Fan blower speed control (6) – The blower control
is used to increase or decrease the desired blower
Illustration 283 g06213088 speed.
Use jog dial (1) to highlight “Air Conditioner” and then Air outlet settings (7) – The desired air outlet setting
press the jog dial downward to select the entry. You can be chosen from this panel. The indicator light will
may also access the screen by simply touching the illuminate to show the active setting.
“Air Conditioner” box on the touch screen.
Defroster (8) – Pressing this button activates and
deactivates the defroster. Use the defroster to
remove steam and frost from the windows. The
indicator light will illuminate when this mode is active.
Compressor ON/OFF (9) – Pressing this button
activates and deactivates the air conditioner. The
indicator light will illuminate when this mode is active.
Power (10) – Pressing this button turns the heating
and cooling system on and off. Push and hold the
power button for 3 seconds to turn OFF the HVAC
system. The indicator light on the monitor and on
button (2) will turn green when power is on.
Home button (11) – Use this button to return to the
main screen.
Auto (12) – Select this option to hold the system at
the desired temperature. The system will modulate to
keep the cab at the temperature that the system is
set to. The indicator light will illuminate when this
mode is active.
Recirculation (13) – This option recirculates air from
Illustration 284 g06213092 the cab instead of pulling air from the outside. This
Air conditioner screen mode is more efficient because the system is
recycling conditioned air from the cab. However, no
(4) Application menu button fresh air is coming into the cab when in this mode.
(5) Temperature control
(6) Fan blower speed control The indicator light will illuminate when this mode is
(7) Air outlet settings active.
(8) Defroster
(9) Compressor ON/OFF Front vents (14) – In this mode, air will only circulate
(10) Power from the front vents.
(11) Home button
(12) Auto Front and rear vents (15) – In this mode, air will
(13) Recirculation circulate from the front vents and rear vents.
M0111427-02 163
Operation Section
Front, foot, and rear vents (16) – In this mode, air Note: In cold ambient temperature condition, fan
will circulate from the front vents, rear vents, and foot speed is stopped or restricted depend on coolant
vents. temperature.
Foot vents (17) – In this mode, air will only circulate
from the foot vents.
Defrost and foot mode (18) – In defrost mode, air
will circulate from the defrost vents and foot vents.
Selection Method
All settings can be made using the touch screen or by
using the jog dial. The method depends on the
preference of the operator. When using the touch
screen, simply touch the icon you want to select.
When using the jog dial, rotate the dial to switch to
different selections within the screen. Press the jog
dial downward to choose a selection.

(A) Defrost vent (front window)
(B) Foot air vents
(C) Rear air vents
When using the jog dial to set the temperature or

blower speed, rotate the dial clockwise to increase
and counter-clockwise to decrease. Press downward
on the dial to enter the desired setting.
Operation
1. To operate the system, press power button (10).
2. Use temperature control (5) to adjust to the desired
temperature.
3. Select the desired mode and outlet vents. (A) Front vent
(B) Defrost vent (RH window)
4. Use fan blower speed control (6) to adjust the
blower. If the system is in “Auto” mode, the blower
fan speed and air outlet setting will automatically
be adjusted. But recirculation air intake is not
changed automatically.
164 M0111427-02
Operation Section
Mirror
5. Redirect the louvers for air outlets (A) and (C) by

hand to the desired direction. The louvers for air
outlet (B) cannot be redirected.
i07088628
Mirror
SMCS Code: 7319
Adjust all mirrors as specified in the Operation

and Maintenance Manual. Failure to heed this
warning can lead to personal injury or death.
Note: Your machine may not be equipped with all the

mirrors that are described in this topic.

(3) Tank mirror
Mirrors provide additional visibility around your

machine. Make sure that the mirrors are in proper
working condition and that the mirrors are clean.
Adjust all mirrors at the beginning of each work
period and adjust the mirrors when you change
operators.
Modified machines or machines that have additional
equipment or attachments may influence your
visibility.
Mirror Adjustment
• Park the machine on a level surface.
• Lower the work tool to the ground.
• Move the hydraulic lockout control to the LOCKED
position. For further details on this procedure,
(1) Right Side View Mirror on the Cab refer to Operation and Maintenance Manual,
(2) Left Side View Mirror on the Cab “Operator Controls”.
• Stop the engine.

• Adjust rear view mirrors to provide visibility behind
the machine at a maximum distance of 30 m
(98 ft) from the rear corners of the machine.
M0111427-02 165
Operation Section
Mirror
Right Side View Mirror on the Cab (3)

Tightening sequence
After adjustment of the mirror angle, make sure that
the CAT logo is at the top. If equipped, adjust the right side view mirror on the
cab (1) so the front of the right track can be seen
It may be necessary to periodically tighten the mirror from the operator seat. A view of at least 1 m (3.3 ft)
mounting bolts. If the bolts are loose, tighten the bolts from the right front of the machine should be seen
in the sequence shown in Illustration 291 . Tighten from the operator seat.
bolts (1) and (2) to 11 ± 2 N·m (8.1 ± 1.5 lb ft).
Tighten the bolts (3) through (6) to 2 ± 0.4 N·m
(1.5 ± 0.3 lb ft).
166 M0111427-02
Operation Section
Mirror
Left Side View Mirror on the Cab (4) Tank Mirror (3)
If equipped, adjust the left side view mirror on the cab If equipped, adjust the tank mirror so the fuel tank
(4) so the left side of the cab, access door, and rear and the hydraulic tank can be seen from the operator
of left track can be seen from the operator seat. A seat. A view of at least 1 m (3.3 ft) from the side of
view of at least 1 m (3.3 ft) from the side of the the machine should be seen from the operator seat.
machine should be seen from the operator seat.
Additionally, provide as much visibility to the rear as
possible.
M0111427-02 167
Operation Section
Camera
i07854649 For more information refer to Operation and

Maintenance Manual, “Monitoring System”.
Camera
SMCS Code: 7347; 7348 Side View Camera (If Equipped)
Rear View Camera
The side view camera system consists of a camera

Illustration 295 g06184579 mounted on the panel next to the pump
compartment.
The rear view camera system consists of a camera
that is located in the middle of the top of the Note: The side view camera system has been set up
counterweight. by the factory or by a Cat dealer to provide views
which comply with specified machine side views.
Note: The rear view camera system has been set up Consult your Cat dealer before any adjustments are
by the factory or by a Cat dealer to provide views made to the system.
which comply with specified guidelines. Consult your
Cat dealer before any adjustments are made to the For more information refer to Operation and
system. Maintenance Manual, “Monitoring System”.
i07427990
Window (Front)
SMCS Code: 7310-FR
To provide full ventilation inside the cab, the upper
window and the lower window can be fully opened.
When opening or closing the windows, be extra

careful to prevent any personal injury. The hy-
draulic lockout control must be in the LOCKED
position in order to prevent any possibility of
sudden movement of the machine due to inadver-
tent contact with the hydraulic control(s).
Do not change the position of the window until the

following items have been done:
168 M0111427-02
Operation Section
Window (Front)
• Park the machine on a level surface. Note: If equipped, the Cat Grade Control monitor
may interfere with the window when closing. Ensure
• Lower the work tool to the ground. that the monitor is adjusted out of the way before
closing the window.
position. 4. Release the auto-lock latches by pressing release
• Stop the engine. levers (1) on the window handles.
5. Reverse Steps 1 through 3 to close the upper
Perform Step 1 through Step 3 to open the upper
window. window.
Perform Steps 6 through 8 to open the lower
Note: If equipped, the Cat Grade Control monitor
window and close the lower window.
may interfere with the window when opening. Ensure
that the monitor is adjusted out of the way before 6. Raise the lower window out of the window frame.
opening the window.

(2) Catch
(3) Brackets
7. Store the lower window in the holder that is located

in the rear of the left side cab frame. To store the
lower window, locate one end of the lower window
into brackets (3). Secure the opposite end of the
(1) Release lever
lower window with catch (2).
8. To close the lower window, reverse the procedure
1. Release the auto-lock latches by pressing release that is used for opening the lower window.
levers (1) on the window handles.
Note: The lower window is curved. The lower window
2. Holding both handles on the window frame, pull can only be positioned one way in the holders.
the window upward.
3. Hold both grips that are provided on the window
frame and move the window into the storage
position until the auto-lock latches near the ceiling
are engaged.
Perform Steps 4 through 5 to close the upper
window.
M0111427-02 169
Operation Section
Sun Screen
i07538754
Sun Screen
SMCS Code: 7165-ZZ

NOTICE
Do not change the position of the sun screen without
performing the following actions:

position.
Pull sun screen (1) down from the ceiling. Hook the
sun screen to the brackets (2) at both sides of the
front window. The sun screen may be positioned at
two different heights.
i07538807
Roof Hatch
SMCS Code: 7303

170 M0111427-02
Operation Section
Cab Door
i06949447
NOTICE
Do not change the position of the roof hatch without
performing the following actions: Cab Door
SMCS Code: 7308

position.
Illustration 300 g06179871 To open the cab door from the outside of the cab, pull
(1) Grip outward on the door handle.
(2) Lock
To open the roof hatch, release lock (2). Hold grip (1)
and push the roof hatch upward.
To close the roof hatch, hold grip (1) and pull the roof
hatch downward. Engage lock (2) securely.
NOTICE
Do not stand or walk on the hatch or the roof of the
cab. Serious damage may occur.
To open the cab door while inside the cab, push

forward on the lever for the cab door latch.
For additional ventilation, open the cab door all the
way to engage the catch on the exterior wall of the
cab.
M0111427-02 171
Operation Section
Travel Control
i06946782
Travel Control
(Straight Travel Pedal (If
Equipped))
SMCS Code: 5462
With certain attachment combinations, the third

pedal can have different functions. Always check
for third pedal function before using the third
pedal. Improper operation of the third pedal could
Illustration 303 g06180267 result in serious injury or death.
To release the cab door from the catch, pull

downward on the cab door release lever.

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.
To open a window, release the window latch, and

then slide the window to the desired position.
172 M0111427-02
Operation Section
Straight Travel Pedal (If Equipped)

(1) Forward Travel
(2) Reverse Travel
The third pedal is to the right of the right travel pedal.

The third pedal controls the forward and backward
movement of the machine.
Note: If the third pedal is depressed and a travel (3) Lock pin
pedal or a travel lever is operated, the machine will (4) Pin
turn accordingly. (5) Notch
(A) LOCKED position
(B) UNLOCKED position
When the machine is not operated with the third

pedal, install lock pin (3) at the LOCKED position to
prevent accidental operation.
Note: To prevent lock pin (3) from being pulled out,

insert pin (4) through notch (5) and turn lock pin (3)
counterclockwise by 1/4 turn.
M0111427-02 173
Operation Section
Joystick Controls
i08015281 Two functions may be performed at the same time by

moving a joystick diagonally.
Joystick Controls The machine control pattern is initially set at the
SMCS Code: 5705 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.
The machine control pattern can be varied. Refer to
Operation and Maintenance Manual, “Joystick
Controls Alternate Patterns” for more information.
Manual Low Idle – Activate the manual low idle to
reduce the engine speed to approximately 1000 rpm.
Pressing the switch again will allow the engine speed
to return to the original setting of the engine speed
dial.
The manual low idle allows the operator to reduce the

rpm without touching the engine speed dial. Manual
low idle is useful when the operator wants to reduce
the engine speed to talk to someone or while the
Illustration 308 g06180324 operator is waiting for a truck.
(1) STICK OUT
(2) SWING RIGHT
(3) STICK IN
3 Button Joystick Controls
(4) SWING LEFT
(5) BOOM LOWER
(6) BUCKET DUMP
(7) BOOM RAISE
(8) BUCKET CLOSE
(9) HOLD
The joystick and controls on the joystick can be

configured with different functions. Always make
sure to check the joystick configuration on the
monitor before using the machine to avoid unex-
pected machine movement. These unexpected
machine movements could cause a hazard result-
ing in serious injury or death.
The Fine Swing Control delays the engagement

of the swing parking brake.
If the machine is operating on a slope with the Illustration 309 g06223512
Fine Swing Control in the ON position, the swing
motion may become uncontrollable which could 3 Button Joystick Controls
result in property damage, personal injury or (1) Left joystick switch 1
death. (2) Left joystick switch 2
(3) Left joystick switch 3
Turn the Fine Swing Control to the OFF position (4) Right joystick switch 2
when the machine is operating on a slope. (5) Right joystick switch 3
(6) Right joystick switch 1
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.
174 M0111427-02
Operation Section
Joystick Controls
Table 20
Joystick Configurations
Switch Location 3 Button Joystick

1 Horn
2 Configurable
3 Configurable
4 Configurable
5 Configurable
6 Configurable
Vertical Slider Joystick Controls (If

Equipped)
Note: The following functions can be assigned to the
configurable buttons: radio mute, one-touch low idle,
work tool select, and HVAC.

Vertical Slider Joystick Controls
(7) Left joystick switch 3 (11) Left joystick thumbwheel (15) Right joystick switch 4
(8) Left joystick switch 4 (12) Right joystick thumbwheel (16) Right joystick switch 3
(9) Left joystick switch 1 (13) Right joystick switch 2
(10) Left joystick switch 2 (14) Right joystick switch 1
M0111427-02 175
Operation Section
Work Tool Control (One-Way Flow)
Table 21
Joystick Configurations (4) AEC SWITCH – Press the AEC switch
on the right joystick to activate low
Joystick With Tool Con-
Switch Location trol Sliders engine speed. Press the switch again to
activate high engine speed.
7(1) Hammer
8 Configurable i08222281
9 Horn Work Tool Control (One-Way

10 Configurable
Flow)
11(1) Work Tool Rotation
(If Equipped)
12(1) Work Tool Open / Close
SMCS Code: 6700
13 Configurable
The following information pertains to work tools that
14 Configurable require hydraulic oil flow in one direction. Hydraulic
hammers are an example of work tools that require
15 Configurable hydraulic oil flow in one direction.
16 Configurable
Note: For information that pertains to work tools that
(1) Button is configurable on machines without tool control. require hydraulic oil flow in two directions, refer to
Operation and Maintenance Manual, “Work Tool
Medium Pressure (If Equipped) Control (Two-Way Flow)”.
Rotating Tool Control

(A) Left joystick
(B) Right joystick
(1) Thumb wheel (Clockwise)
(2) Thumb wheel (Counterclockwise)
(3) Horn switch
(4) AEC switch
(1) ROTATE CLOCKWISE – Move the

thumb wheel upward to rotate the work
tool clockwise.
(2) ROTATE COUNTERCLOCKWISE –

Move the thumb wheel downward to
rotate the work tool counterclockwise.
(3) HORN – Press the horn switch on the

left joystick to activate the horn.
176 M0111427-02
Operation Section
If Equipped
Joystick (2-2) On/Off (Toggled) – Press the switch

once to activate the work tool. Press the
switch again to turn off the work tool.
Work Tool Pedal
With certain attachment combinations, the work

tool pedal can have different functions. Always
check for work tool pedal function before using
the work tool pedal. Improper operation of the
work tool pedal could result in serious injury or
death.
The work tool pedal can be installed on either side of
the travel pedals. The work tool pedal allows the
Illustration 312 g06588792 operator to modulate the speed of the work tool.

(A) Left joystick
(B) Right joystick
(1) Variable Speed – Move the thumb

wheel downward to activate the work Illustration 314 g06180447
tool. Move the thumb wheel further to
increase the speed of the work tool. Variable Speed – Push down on the front
(2-1) On/Off (Momentary) – While of the pedal to activate the work tool.
pressing this switch, the work tool will Move the pedal further to increase the
remain activate at a constant rate. speed of the work tool. Release the pedal to turn
Release the switch to turn off the work tool. off the work tool.
M0111427-02 177
Operation Section
Work Tool Control (Two-Way Flow)
Note: To prevent lock pin (1) from being accidentally

pulled out, insert pin (2) through notch (3) and turn
lock pin (1) counterclockwise by 1/4 turn.
i07243676
Work Tool Control (Two-Way

Flow)
(If Equipped)
SMCS Code: 6700
The joystick and controls on the joystick can be

configured with different functions. Always make
sure to check the joystick configuration on the
monitor before using the machine to avoid unex-
pected machine movement. These unexpected
machine movements could cause a hazard result-
ing in serious injury or death.
The following information pertains to work tools that
require hydraulic oil flow in two directions. These
work tools can also be equipped with a rotate circuit.
Hydraulic shears, pulverizers, crushers, and grapples
are examples of work tools that require hydraulic oil
flow in two directions.
(1) Lock pin Note: For information that pertains to hydraulic
(2) Pin hammers, refer to Operation and Maintenance
(3) Notch Manual, “Work Tool Control (One-Way)”.
(A) UNLOCKED position
(B) LOCKED position
Joystick
When you are not using the work tool, put the lock pin
(1) in LOCKED position (B). This will lock the work
tool pedal to prevent any unexpected operation of the
work tool.

(A) Left joystick
(B) Right joystick
(1) ROTATE CLOCKWISE – Move the

thumb wheel upward to rotate the work
tool clockwise.
(2) ROTATE COUNTERCLOCKWISE –
Move the thumb wheel downward to
rotate the work tool counterclockwise.
178 M0111427-02
Operation Section
If Equipped
(3) CLOSE – Move the thumb wheel

upward to close the work tool.
(4) OPEN – Move the thumb wheel

downward to open the work tool.
Work Tool Pedal
With certain attachment combinations, the work

tool pedal can have different functions. Always
check for work tool pedal function before using
the work tool pedal. Improper operation of the
work tool pedal could result in serious injury or
death.
The work tool pedal can be installed on either side of
the travel pedals. The work tool pedal allows the
operator to vary the speed of the work tool.

(3) Lock pin
(4) Pin
(5) Notch
(A) LOCKED position
(B) UNLOCKED position
When you are not using the work tool, put the lock pin
(3) in LOCKED position (A). This will lock the work
tool pedal to prevent any unexpected operation of the
work tool.
(1) CLOSE – Push down on the front of

the pedal to close the work tool.
(2) OPEN – Push down on the rear of the

pedal to open the work tool.
M0111427-02 179
Operation Section
Joystick Controls Alternate Patterns
Note: To prevent lock pin (3) from being accidentally

pulled out, insert pin (4) through notch (5) and turn
lock pin (3) by 1/4 turn.
i08209549
Joystick Controls Alternate

Patterns
SMCS Code: 5059; 5137
Changing Machine Control Pattern

(If Equipped)
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-
ance to the pattern on the card in the cab. If the
pattern does not match, change the card to match
the machine control pattern before you operate
the machine. Failure to do so could result in per-
sonal injury.
The machine control pattern can be changed to the
ISO/JIS pattern, BHL pattern, MHI pattern, KOBE
pattern, or the former SCM pattern. To change the
joystick controls between the patterns, refer to
Operation and Maintenance Manual, Monitoring
System for more information.

(A) ISO/JIS machine control pattern
(B) BHL machine control pattern
(C) MHI machine control pattern
(D) KOBE machine control pattern
(E) Former SCM machine control pattern
The patterns on the left side of the Illustration 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 to move the stick
outward.
SWING RIGHT (2) – Move the control
lever to this position to swing the upper
structure to the right.
180 M0111427-02
Operation Section
Work Tool Flow Control
STICK IN (3) – Move the control lever to

this position to move the stick inward.
i07362012
SWING LEFT (4) – Move the control lever
to this position to swing the upper Work Tool Flow Control
structure to the left.
SMCS Code: 7007-WTL
BOOM LOWER (5) – Move the control Many hydraulic attachment circuits are adaptable on
lever to this position to lower the boom. this machine. Various types of work tools can be
installed. Select a suitable arrangement of the
BUCKET DUMP (6) – Move the control hydraulic circuit in order to provide the requirements
lever to this position to dump the for flow and the requirements for action for the work
bucket. tool that is used.
BOOM RAISE (7) – Move the control One-way flow is available for work tools such as
lever to this position to raise the boom. hydraulic hammers.
Two-way flow is available for work tools such as
BUCKET CLOSE (8) – Move the control hydraulic shears.
lever to this position to close the bucket.
A manually controlled ball valve is provided in the
return line.
HOLD (9) – When the control lever is released from
any position, the control lever will return to the HOLD Before attachment hydraulic circuits are serviced,
position. Movement of the upper structure will stop. place the machine in the servicing position. Stop the
engine.
Two functions may be performed at the same time by Place the ball valve in the correct position. To
moving a control lever diagonally. determine the correct position, refer to the
If the machine is equipped with a hydraulic hammer, requirements for the work tool on Illustrations 320 ,
the function of position (6) and of position (8) is 321 , and 322 .
different. Use the manual lever to turn the ball valve. Make
sure that you fully turn the ball valve until the ball
HYDRAULIC HAMMER RAISE (6) – Move the valve stops.
control lever to this position to raise the hydraulic
hammer. Never use the manual lever as a step when the
manual lever is attached to the ball valve. Remove
HYDRAULIC HAMMER LOWER (8) – Move the the manual lever from the valve after the valve is
control lever to this position to lower the hydraulic adjusted.
hammer.
If the machine is equipped with a grapple, the

function of position (6) and of position (8) is different.
GRAPPLE OPEN (6) – Move the control lever to this
position to open the grapple arms.
GRAPPLE CLOSE (8) – Move the control lever to
this position to close the grapple arms.
If the machine is equipped with a clamshell, the

function of position (6) and of position (8) is different
when in “Clamshell” mode.
Note: When in “Clamshell” mode, the work tool can
only be operated if Work Tool Select also has
clamshell selected.
CLAMSHELL OPEN (6) – Move the control lever to
this position to open the clamshell.
CLAMSHELL CLOSE (8) – Move the control lever to
this position to close the clamshell.
M0111427-02 181
Operation Section
Fuel Tank Shutoff and Drain Control

Ball valve (two-way flow position)
(B) Ball valve closed
i06951805
Illustration 320 g06295566 Fuel Tank Shutoff and Drain

Ball valve location Control
(1) Ball valve
SMCS Code: 1273

Ball valve (one-way flow position)
Fuel tank drain valve and shutoff
(A) Ball valve open
Fuel Tank Drain Valve (1) – The drain valve for the
fuel tank is located behind the right side access door.
To drain the water and sediment from the fuel tank,
turn the fuel drain valve counterclockwise. To close
the fuel tank drain valve, turn the drain valve
clockwise.
Fuel Shutoff Valve (2) – The fuel shutoff valve is

located behind right side access door. To shut off the
fuel supply, turn the fuel shutoff valve clockwise. To
turn on the fuel supply, turn the fuel shutoff valve
counterclockwise.
182 M0111427-02
Operation Section
Fuel Tank Shutoff and Drain Control
Note: For more detailed information that pertains to

draining the water and sediment from the fuel tank,
refer to Operation and Maintenance Manual, “Fuel
Tank Water and Sediment - Drain”.
M0111427-02 183
Operation Section
Engine Starting
Engine Starting
i08185791
Engine Starting
SMCS Code: 1000; 1090; 1456; 7000
NOTICE
This machine is equipped with a Cat ® Machine Se-
curity System (MSS) and may not start under certain
conditions.
NOTICE
The engine start switch must be in the ON position
and the engine must be running in order to maintain
electrical functions and hydraulic functions. This pro-
cedure must be followed in order to prevent serious
machine damage.

Note: The engine can start in areas that have
temperatures as low as −18°C (0°F). For areas that
are colder, a starting kit for cold weather is available. 3. The operator passcode, Bluetooth key or Cat App:
Fleet management app must be authenticated
1. Move the hydraulic lockout control to the LOCKED before starting the engine. Once authenticated, an
position. “Engine Start Allowed” message will appear
across the top of the monitor and the start switch
This machine is equipped with an engine neutral
LED will turn green.
start system. The system only allows the engine to
start when the lever for the hydraulic lockout
control is in the LOCKED position.
2. Ensure that the joysticks and travel controls are in
the HOLD position.
184 M0111427-02
Operation Section
Engine and Machine Warm-Up

(A) Off
(B) On
(1) Engine start ring
(2) Engine start button
6. Turn the engine start ring(1) to the ON position,

then press and hold start button (2) to start the
engine. Release the button after the engine has
started.
If the engine is having trouble starting, do not
crank the engine for more than 30 seconds.
Cranking the engine for more than 30 seconds can
damage starting system components.
i07552385
4. Bluetooth devices and passcodes can be SMCS Code: 1000; 7000
registered using the in-cab display if the operator
is logged in to the system using a master access
account. Contact your Cat dealer for additional NOTICE
Keep engine speed low and do not operate until the
information. message 'Warm-Up Mode Power Derate" on the
monitor goes out. If it does not go out within thirty
Reference: Refer to Operation and Maintenance seconds, stop the engine and investigate the cause
Manual, Machine Security System, Operator Login before starting again. Failure to do so, can cause en-
for instructions. gine damage.
5. Before you start the engine, check for the
presence of bystanders or maintenance
NOTICE
personnel. Ensure that all personnel are clear of Always run the engine at low idle for at least ten mi-
the machine. Briefly sound the horn before you nutes before performing any other operations in cold
start the engine. conditions or each time the engine oil and oil filter are
changed in order to protect your engine and hydraulic
components.
M0111427-02 185
Operation Section
NOTICE
Depending on the ambient temperature, in order to
prevent the machine operation with high speed with-
out sufficient lubrication at the turbo bearing, the en-
gine speed may be set to low speed and the
hydraulic power minimized for a pre-determined time
after the engine starts. Refer to turbo protection
feature.
The engine may automatically change speeds when
the machine is stationary and idling in cold ambient
temperature for an extended time. This is to:
• Maintain desired coolant temperature.

• Maintain desired operation of engine systems.
During extended idling in cold ambient conditions,
engine speed may operate between 900 rpm and
1000 rpm. Operation at 1000 rpm is minimal and will
only last for up to 20 minutes.
Hydraulic System Illustration 328 g06219830
Automatic Warm-Up Manual Warm-Up

This machine comes with an automatic warm-up
feature that can be enabled or disabled. If the feature
is enabled, and the hydraulic oil temperature is below
the threshold that has been set, a prompt will appear When you cycle the machine controls, the ma-
on the monitor after starting the machine. Follow the chine can move suddenly. Contact between the
prompts on the monitor. If this feature is disabled or machine and external objects or ground person-
you would like to change the temperature setting, nel can result in serious injury or death. Before
refer to Operation and Maintenance Manual, you cycle the machine controls, the machine
Monitoring System. should be located in an unobstructed, hazard-
free work area that is away from external objects
and ground personnel.
1. Make sure that the area is clear of personnel and

equipment.
Note: The hydraulic lockout control must be in the

UNLOCKED position before the hydraulic controls
will function.
2. Allow the engine to warm up at low idle for at least

5 minutes. Engage the work tool controls and
disengage the work tool controls. This will speed
up the warm-up of the hydraulic components.
When you idle the machine for warm-up, observe
the following recommendations:
• If the temperature is greater than 0°C (32°F),

warm up the engine for approximately 15
minutes.
• If the temperature is less than 0°C (32°F),

warm up the engine for approximately 30
minutes.
186 M0111427-02
Operation Section
• If the temperature is less than − 18°C (0°F) or Install the covers if overcooling is observed while the
if hydraulic functions are sluggish, additional machine is idling in ambient temperatures below
time may be required. −15° C (5° F).
Stop the machine, and remove the covers under the
NOTICE following conditions:
The hydraulic oil temperature should be higher than
25 ° C (77 ° F) before performing work with the ma- • The ambient temperature is above −15° C (5° F).
chine. Make sure that the warm-up procedure is
performed. • The engine temperature gauge indicates
overheating.
If the hydraulic oil temperature is less than 25 ° C
(77 °F) and the machine is operated abruptly, serious • The hydraulic oil temperature gauge indicates
damage to the hydraulic components may occur. overheating.
Note: The recommended operating temperature of

Recommendation for Crankcase
the hydraulic fluid for this machine is 55 °C (131 °F). Breather Protection (Machines with C4.4
and C7.1)
3. To warm up the hydraulic oil, turn the engine speed
dial to the medium engine speed. Run the engine Crankcase ventilation gases contain a large quantity
for approximately 5 minutes and move the joystick of water vapor. This water vapor can freeze in cold
intermittently from the BUCKET DUMP position to ambient conditions and can plug or damage the
the HOLD position. Do not hold the joystick in the crankcase ventilation system. If the engine is
operated in temperatures below −25° C (−13° F),
BUCKET DUMP position with the bucket cylinder measures must be taken to prevent freezing and
fully extended for more than 10 seconds. plugging of the breather system. Insulated hoses and
a heated canister assembly should be installed.
This allows the oil to attain relief pressure, which
causes the oil to warm up more rapidly. Consult with your Cat dealer for the recommended
breather components for operation from
4. Turn the engine speed dial to the maximum engine −25° to −40° C (−13° to −40°F).
speed and repeat Step 3.
5. Cycle all controls to circulate warm oil through all Installation
hydraulic cylinders and all hydraulic lines, and
through the swing motor and travel motors.
6. Observe the gauges and the indicators frequently
during the operation.
Turbo Protection Power Derate – After

an engine start, the engine speed will be
set to low speed and the hydraulic
power limited for a time period . During this
period, the monitor displays the message "Warm
-Up Mode Power Derate". (Maximum is around 30
seconds). After the turbo bearing lubrication is
sufficient, the engine speed goes to the setting
dial speed and the monitor stops to display the
message.
Improve Cold-Weather
Performance
Covers installed over the vents in the radiator
compartment door will help to control overcooling in
ambient temperatures below −15° C (5° F).
The materials used for the covers and the method Vent locations on the radiator compartment door.
used to install the covers is at the installers
discretion. 1. Clean the surface of the radiator compartment
door.
M0111427-02 187
Operation Section
2. Install the covers in the locations shown in

Illustration 329 . The covers should fully cover the
door vents.
188 M0111427-02
Operation Section
Operation
Operation
i07348768
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 Cat Illustration 330 g06181515
dealer for additional information on special
configurations of your machine. 3. Turn the engine speed dial to the desired operating
range.
Make sure that no personnel are on the machine or
near the machine to prevent any personal injury. 4. Move the hydraulic lockout control to the
Keep the machine under control at all times to UNLOCKED position.
prevent injury.
Sound the horn and allow adequate time for
bystanders to clear the area before moving the
machine into a restricted visibility area. Follow local
practices for your machine application. For more
information refer to Operation and Maintenance
Manual, “Restricted Visibility”.
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. Illustration 331 g06181525
When you travel for any distance, keep the stick 5. Raise the boom enough to provide sufficient
inward and carry the boom in a low position. ground clearance.
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
the boom on the uphill side of the machine.
1. Adjust the operator seat.
2. Fasten the seat belt.
M0111427-02 189
Operation Section
Frozen Ground Conditions
11. When you make turns in soft material, travel in a

forward direction occasionally to clear the tracks.
12. Slowly move both of the travel levers or both of
the travel pedals to the CENTER position to stop
the machine.
Lifting Objects
If the machine is equipped with the CE plate per
requirements for the European Union, used to lift
objects, then the machine must be equipped with a
boom lowering control valve, a stick lowering control
valve, and an overload warning device.
A fit for purpose test was completed to confirm that a
properly equipped machine meets the requirements
of the European Union Machinery Directive “2006/42/
EC” for lifting objects.
The overload warning device (if equipped) must be
adjusted for the bucket linkage and bucket size that is
installed on the machine. Adjust the overload warning
device for proper operation.
The setting for the overload warning device (if
equipped) should be checked by an authorized
dealer.
i06981624
6. Select the desired travel speed by operating the

Frozen Ground Conditions
travel speed control switch. The indicator will light SMCS Code: 7000
to display the active mode.
7. Make sure that the position of the upper structure
and of the undercarriage is known before you
move the machine. The drive sprockets should be
at the rear of the machine.
Note: The directional steering controls will operate

normally if the drive sprockets are at the rear of the
machine and the idlers are at the front of the machine
and under the cab. When the sprockets are under the
cab, the travel controls will operate backward.
8. Turn the engine speed dial to increase the engine

speed (rpm) to the desired speed.
9. Push both travel levers forward at the same time to Illustration 333 g06185895
travel forward. If both travel levers are pushed
farther, the travel speed at the selected engine To free the tracks from frozen ground, swing the
speed (rpm) will be faster. boom to the front of the machine. Use boom down
pressure to free the idler end of the machine.
Note: If the machine does not operate or if the
machine does not travel in a straight line, consult Swing the boom to the rear of the machine. Use
your Cat dealer. boom down pressure to free the sprocket end of the
machine.
10. See Operation and Maintenance Manual,
“Operator Controls” for information about spot
turning and about pivot turns.
190 M0111427-02
Operation Section
i07474576 If the engine or the hydraulic system is disabled and

the boom is up, the boom can be lowered manually.
Equipment Lowering with Boom lowering control valves allow the boom to be
manually lowered. The boom lowering control valves
Engine Stopped are located at the head end port on the boom
cylinders.
SMCS Code: 7000
To lower the boom, place the hydraulic lockout
control in the UNLOCKED position. Move the joystick
to the BOOM LOWER position. If the accumulator is
still charged, the boom will lower.
If the boom does not lower, the accumulator is empty.
Use one of the following procedures to lower the
boom.
Machines Equipped with Boom

Lowering Control Valves
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 Illustration 334 g06263683
is under or near the work tool before manually (1) Boom lowering control valve
lowering the boom. (2) Line relief
Keep all personnel away from the boom drop area

when lowering the boom with the engine
stopped.
Be sure no one is under or near the work tools be-

fore manually lowering the boom. Keep all per-
sonnel away from the boom drop area when
lowering the boom with the engine stopped in or-
der to avoid possible personal injury.

Personal injury can result from hydraulic oil pres-
sure and hot oil. (1) Boom lowering control valve
(2) Line relief
Hydraulic oil pressure can remain in the hydraulic (3) Locknut
system after the engine has been stopped. Seri- (4) Set screw
ous injury can be caused if this pressure is not
released before any service is done on the hy- 1. Loosen the locknut (3) at each of the boom
draulic system. lowering control valves.
Make sure all of the work tools have been lowered 2. Slowly, turn set screw (4) counterclockwise until
to the ground, and the oil is cool before removing the boom begins to lower onto the ground.
any components or lines. Remove the oil filler
cap only when the engine is stopped, and the fill- Note: Once the boom begins to lower, stop turning
er cap is cool enough to touch with your bare set screw (4).
hand.
M0111427-02 191
Operation Section
3. After the boom has lowered completely onto the

ground, turn set screw (4) back to the original
position.
4. Tighten locknut (3) to 40 ± 4 N·m (29.5 ± 3 b ft).
5. Before operating the machine, make any
necessary repairs.
For additional information, consult your Cat dealer.
Machines without a Boom

Lowering Control Valve
Be sure no one is under or near the work tools be-

fore manually lowering the boom. Keep all per-
sonnel away from the boom drop area when
lowering the boom with the engine stopped in or-
der to avoid possible personal injury.
Use the following procedure to manually lower the
boom due to an engine malfunction. Filler cap
(A) LOCK position
(B) PRESSURE RELEASE - START position
(C) PRESSURE RELEASE - END position
(D) OPEN position
1. Release the pressure that may be present in the

return hydraulic circuit with the following
procedure. Refer to Illustration 337 for filler cap
positions.
a. Turn the filler cap counterclockwise and move
the arrow from position (A) to position (B).
b. Release the pressure for a minimum of 45
seconds by moving the arrow from position (B)
to position (C).
c. Move the arrow from position (C) to position
(D).
d. After the tank pressure is relieved, remove the
filler cap.

Hydraulic tank filler cap location
Pressurized system!
The hydraulic tank contains hot oil under pres-
sure. To prevent burns from the sudden release
of hot oil, relieve the tank pressure with the en-
gine off. Relieve pressure by slowly turning the
cap until the cap reaches the secondary stop.
192 M0111427-02
Operation Section

Main control valve
2. Open the engine hood. (5) Screw
4. Connect one end of the radiator hose to screw (5).

Put the other end of the hose into the hydraulic
tank opening. The screw is located at the front,
right side of the main control valve.
5. Slowly loosen screw (5) by a maximum of 1/2 turn.
This allows the hydraulic oil in the boom circuit to
drain into the hydraulic tank. The boom will now
start to lower.
6. Make sure that the work tool has lowered all the
way to the ground. Tighten screw (5) to 13 ± 2 N·m
(9 ± 1 lb ft).
7. Disconnect the hose from the screw. Do not allow
Illustration 339 g06184089 the oil that is contained in the hose to spill. Drain
(3) Hose the oil into a suitable container.
(4) Clamp
8. Connect the hose to the original position on the
3. Loosen clamp (4) and disconnect hose (3) from the radiator and install the hydraulic tank filler cap.
reservoir. Remove the clamps and the cable
9. Close the engine hood.
straps that secure the hose to the machine.
M0111427-02 193
Operation Section
After completion of the manual boom lowering, make

necessary repairs before you operate the machine
again.
Pressure Release of Auxiliary

Lines
Personal injury can result from hot oil spray and

raised work tools.
Make sure all the work tools have been lowered,
the oil is cool and the pressure has been released
from the hydraulic system before removing any
components or lines.
Do not allow hot oil or components to contact
skin.
Note: Refer to Operation and Maintenance, “General

Hazard Information” for information on containing
fluid spillage.
Refer to the procedure below before any of the
following conditions.
• The work tool is changed.
• The position of the ball valve is changed.
1. Turn the engine start switch to the OFF position.

2. Place the hydraulic lockout lever in the
UNLOCKED position.
3. Release the pressure in the auxiliary lines by
pressing the auxiliary control buttons or the
auxiliary control pedal three times.
4. Place the hydraulic lockout lever in the LOCKED
position.
5. Change the work tool.
Note: There should be movement in the auxiliary

hydraulic lines as the pressure is released. If there is
no movement in the auxiliary hydraulic lines, start the
engine and run the engine for 20 seconds. Repeat
steps 1 to 5.
For additional information, consult your Cat dealer.
194 M0111427-02
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
i07887891 operating cycle.
Operating Technique When you operate the machine in close places,

utilize the bucket or the other work tool to perform the
Information following functions:
SMCS Code: 7000 • Pushing the machine
• Pulling the machine
Know the maximum height and the maximum • Lifting the tracks
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
work tools are not kept a safe distance from elec- machine.
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 Coaching Tips
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

pedal can have different functions. Always check the
function of the third pedal before you use the third
pedal.
Know the location of any buried cables. Mark the Illustration 341 g06223763
locations clearly before you dig.
Digging with a stable machine increases productivity.
Consult your Cat dealer for special work tool tips that Create a stable work platform.
are available for use in severe applications.
M0111427-02 195
Operation Section
Operating Technique Information

(A) Most stable dig
(B) Dump
For improved stability: Do not dig over the drives or

perpendicular to the tracks.
Minimize unneeded movement. During backfilling,

start with the material closest to the trench.

(C) Weak crowd force
(D) Ideal crowd force
Dig from the top down in layers. Try to have a full

bucket by the time the stick is vertical, but do not Illustration 345 g06210343
reach too far with the stick. The most crowd force is
generated with the stick +/- 30 degrees from vertical. Watch your surroundings. Swing left to dump
material for better visibility.
Minimize unneeded movement. Only curl/dump the
bucket as much as required to hold/dump material. Watch the bucket. The bucket can contact the tracks
or the cab.
Concentrate on being smooth, speed will come with
practice.
196 M0111427-02
Operation Section
These operations will damage the boom, the stick,

and the work tool and the operations will reduce the
life of the equipment.
Truck placement will affect efficiency: 45 degree truck

loading is more efficient than 90 degree. Spotting the Illustration 348 g06212594
truck too far from the excavator causes excessive
motion. Do not use the dropping force of the bucket or work
tool as a hammer. Using the bucket or work tool as a
Load from a bench when possible. Bench loading is
more efficient. hammer will bring excessive force on the rear of the
machine. Possible damage to the machine could
result.
Restricted Operation
Illustration 347 g06222487 If the cylinder is operated at the end of the stroke
during operations, excessive force will occur on the
Do not use the swing force to perform the following stopper on the inside of the cylinder. This will reduce
operations: the life of the cylinder and structures. To avoid this
problem, always leave a small margin of play when
• Soil compaction the cylinder is operated.
• Ground breaking
• Demolition
Do not swing the machine while the bucket tips are in
the soil.
M0111427-02 197
Operation Section
If the stick IN function is operated at full speed with a Do not use the dropping force of the rear of the
fully loaded bucket or heavy work tool attachment to machine for excavation. This operation will damage
the end of the cylinder stroke, excessive force will the machine.
occur inside the stick cylinder. This action will reduce
the life of the stick cylinder. To avoid this problem, Operating Precaution
always operate a stick IN function with moderate
speed towards the end of cylinder stroke.

While the bucket is in the ground, do not use the NOTICE

travel force for any excavation. This operation will Do not allow the machine to swing from the force of
cause excessive force on the rear of the machine. 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.
198 M0111427-02
Operation Section
Travel in Water and Mud
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.
When deep holes are dug, do not lower the boom so
that the bottom side of the boom touches the ground. While you cross the river, carefully confirm the depth
of the water with the bucket. Do not move the
When deep holes are dug, do not allow the boom to machine into an area that has a water depth that is
interfere with the tracks. greater than Dimension A.
i07058371 The machine may sink gradually on soft ground.

Therefore, you should frequently check the height of
Travel in Water and Mud the undercarriage from ground level and the depth of
water on the ground.
SMCS Code: 7000-V6
Check the swing gear by looking through the port for
inspection that is on the upper frame. If there is water
NOTICE in the swing gear, contact your Cat dealer for the
When working in or around any body of water, around required maintenance on the swing gear.
a stream or river, or in conditions of heavy mud, be
careful that the swing bearing, the swing drive gear, After you travel through water, carefully clean the
and the swivel joint do not dip into water, mud, sand, machine to remove any salt, sand, or other foreign
or gravel. If the swing bearing dips into water, mud, matter.
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 Procedure for Removing the
may cause premature wear in the swing bearing. Machine from Water or Mud
NOTICE
Do not allow the machine to swing from the force of
traveling when you use the bucket , the stick, or the
boom to assist in travel. If the force from traveling
causes the machine to swing, damage may occur to
the swing motor and to the swing drive.

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.
M0111427-02 199
Operation Section
Boom, Stick and Bucket Operation
1. You may not be able to move the machine by using 3. It may be impossible to travel because the bottom
the travel controls only. In this case use both the of the frame comes into contact with the ground or
travel control levers/pedals and the stick to pull the the undercarriage is clogged with mud or gravel. In
machine out of the water or ground. this case, operate the boom and the stick together.
Raise the track and rotate the track forward and
backward to remove the mud and the gravel.
i07107419
Boom, Stick and Bucket

Operation
SMCS Code: 7000
Digging
2. The machine may slip because of a steep slope.

The procedure in Step 1 may not work. In this
case, first rotate the upper structure by 180°. Then
use both the travel control levers/pedals and the
stick to move the machine up the slope.
1. Position the stick at a 70 degree angle to the

ground.
200 M0111427-02
Operation Section
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.
2. Position the bucket cutting edge at a 120 degree

angle to the ground. Maximum breakout force can
now be exerted with the bucket.
8. Close the bucket and raise the boom when the

pass has been completed.
3. Move the stick toward the cab and keep the bucket
parallel to the ground.
9. Engage the swing control when the bucket is clear

of the excavation.
4. If the stick stops due to the load, raise the boom

and/or perform a curl to adjust the depth of the cut.
M0111427-02 201
Operation Section
10. To dump a load, move the stick outward and open

the bucket in a smooth motion.
Lifting Objects
Use the lifting eye that is provided on the linkage to

lift objects.
To prevent injury, do not exceed the rated load ca-
pacity of the machine. If the machine is not on If the lifting eye is used, the connection must be
level ground, load capacities will vary. made with a sling or with a shackle.
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.
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 a shovel crane
configuration to lift certain objects.
Contact your Cat dealer for additional information.
Short slings will prevent excessive load swing.
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.
202 M0111427-02
Operation Section
The most stable lifting position is over a corner of the Lift capacity decreases as the distance from the
machine. swing centerline is increased.
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.
For the best stability, carry a load close to the

machine and to the ground.
M0111427-02 203
Operation Section
Bucket - Remove and Install
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.
i06978374

SMCS Code: 6001; 6001-012; 6001-011; 6101;
6102; 6523
Removal Procedure

Failure to follow the instruction below for the in-
stallation of a work tool may result in personal in- 2. Slide O-ring seals (1) off the pin joints and onto the
jury or death. Special care must be taken if more flanges of the bucket.
than one person is installing the work tool.
• Confirm the verbal communication and the

hand signals that will be used during the
installation. When the pin assembly is removed, the linkage
assembly may swing out of the bucket. To pre-
• Be alert for sudden movement of the front link- vent possible personal injury, do not stand in
age and the work tool. front of the linkage assembly when the pin as-
sembly is being removed.
• Do not insert fingers into the bores of the sup-
port pins when the support pins and the bores
are being aligned. Note: Removing the support pin may be difficult due
to excessive pressure on the support pin. Remove
the pressure on the support pin by adjusting the front
linkage.
NOTICE
To facilitate removal of the bucket pins without caus-
ing damage to the pins, the bearings, and/or the O-
ring seals put the bucket on the floor and the stick in
a vertical position, as shown.

1. Start the engine. Park the machine on a hard, level
surface. Position the bucket, the stick, and the 3. Remove nuts and retaining bolt (7) from support
bucket control linkage, as shown. Shut off the pin (2). Remove the support pin .
engine.
204 M0111427-02
Operation Section
4. Remove bolts (3) and adapter plate (4). Remove

the shims.
5. Remove nuts and retaining bolt (6) from support
pin (5). Remove the support pin.
6. Start the engine and raise the stick out of the
bucket.
7. Remove the O-ring seals (1) from the flanges on
the bucket.
Note: After the support pins have been removed,

make sure that the support pins do not become
contaminated with sand or dirt. Make sure that the
seals on the end of the stick and the seals on the end
of the link do not become damaged.
Installation Procedure
1. Clean each pin and each pin bore. Lubricate each
pin bore with molybdenum grease.
4. Install support pin (5). Align the retaining bolt hole

in the support pin with the retaining bolt hole in the
bucket.
5. Install the retaining bolt and nuts (6). Install
adapter plate (4) without the shims, and without
bolts (3) that hold the adapter plate.
6. Refer to Operation and Maintenance Manual,
“Bucket Linkage - Inspect/Adjust” to adjust the
bucket clearance.
7. Slide O-ring seals (1) in position over the pin joints
between the bucket and the stick.
8. Start the engine and position the bucket linkage
2. Position the O-ring seals (1) onto the flanges of the into the bucket until the pin bores are in alignment
bucket. with each other. Stop the engine.
3. Start the engine and lower the stick into the bucket 9. Install support pin (2). Align the retaining bolt hole
until the pin bores are in alignment with each in the bucket pin with the retaining bolt hole in the
other. Stop the engine. bucket.
10. Install retaining bolt and nuts (7).
11. Slide the O-ring seals (1) over the pin joints
between the bucket and the link assembly.
M0111427-02 205
Operation Section
Quick Coupler Operation
The work tools are held onto the quick coupler by

hydraulic pressure. If pressure is lost, a locking bar
keeps the work tool locked with the force of built-in
springs. Ensure that the hydraulic system and the
blocking bar are working properly before using the
quick coupler.
A lifting eye is included on the quick coupler. Release
the work tool from the quick coupler to use the lifting
eye to pick up loads. To lift a load with the lifting eye,
extend the bucket cylinder until the quick coupler is in
a VERTICAL position. Do not exceed the rated load
for the machine.
12. Tighten retaining nuts (6) and (7). Position the

outside nut even with the end of the retaining bolt
or 0.5 mm (0.02 inch) beyond the end of the
retaining bolt. Tighten the inside nut against the
outside nut.
13. Lubricate the bucket pins. Refer to Operation and
Maintenance Manual, “Bucket Linkage -
Lubricate”.
i07757775

(Circuit for CW Coupler (If
Equipped))
SMCS Code: 6129; 6522; 7000
NOTICE
The Cat Quick Coupler (CW Coupler) is not designed
to be used in applications where there is long expo-
sure to excessive vibration. The vibration caused by
extensive use of a hydraulic hammer as well as the
added weight of certain demolition tools such as
shears, crushers, and pulverizers may cause prema-
ture wear and decreased service life of the coupler.
Be sure to carefully inspect the coupler daily for
cracks, bent components, wear, distressed welds,
etc. when operating with any of the above work tools.
General Operation
The quick coupler is used to change work tools while
the operator remains in the cab. The quick coupler
can be used with a broad range of buckets and work
tools. Each work tool must have a set of pins in order
for the quick coupler to work properly.
206 M0111427-02
Operation Section
Circuit for CW Coupler (If Equipped)
NOTICE
Coupling the Work Tool
Once the work tool has been properly attached to the
coupler, no loosening of the work tool should occur.
Refer to the “Quick Coupler Installation and Removal”
section of the quick coupler Operation and Mainte- Inspect the coupler wedge engagement before
nance Manual for additional information. If at any you operate the excavator.
point after the proper attachment and back drag test-
ing of the work tool, should the work tool then be- Serious injury or death may result from an im-
come loose or if the rear pin of the work tool detaches properly engaged coupler.
from the movable hook, stop work immediately and
safely ground and detach the work tool. Consult your Inspect coupler wedge engagement from the cab
Cat dealer to inspect the coupler prior to putting the by rotating the bucket or the work tool inward.
coupler back into service. This situation could indi- Extend the bucket cylinder to bring the coupler
cate potential coupler damage that may not be read- actuator into view and bring the stick in until the
ily visible to the customer or operator of the machine wedges are visible.
and coupler.
Electric Switch Operation
1. Position the work tool on a level surface.

2. Retract the bucket cylinder. Position the quick
Quick coupler switch (1) is located inside the cab on coupler in alignment between the hinges of the
the switch panel to the left of the operator's seat. The work tool.
electric switch has only one position for coupling the
work tool and uncoupling the work tool. The switch is
equipped with a safety lock (2). The locking tab must
be pushed forward before the switch can be pressed.
M0111427-02 207
Operation Section

(1) Hinges (3) Center bosses
(2) Lower bosses (4) Locking area
3. Move the stick forward and raise the stick until the 5. Extend the bucket cylinder to rotate the quick
lower bosses (2) engage the hinges (1) of the work coupler toward the work tool.
tool.
Center bosses (3) must engage with the cutout of
4. There are two possible settings for locking the the hinge.
quick coupler in Cat ET, "Alarm" and "Hold to
6. Release the quick coupler switch to lock the work
Run". For the "Hold to Run" setting, push the
tool.
locking tab on the switch forward and then
depress and hold the rear of the switch until the The springs in the quick coupler will move the
quick coupler engages the work tool. The wedge into the locking area (4).
message “Quick Coupler Locking” will display on
The monitor will display the message “Verify Tool
the monitor. For the "Alarm" setting, push the
Locking” .
locking tab on the switch forward and then
depress, but do not hold, the rear of the switch
until the quick coupler engages the work tool. The
message “Quick Coupler Locking” will display on
the monitor.
208 M0111427-02
Operation Section
7. Raise the boom or raise the stick. Retract the 1. Level the bucket or level the work tool on the
bucket cylinder to confirm that the wedge is fully ground.
engaged. If the wedge is fully engaged, the work 2. Push the locking tab on the switch forward and
tool is locked in place. The work tool is ready to then depress the rear of the switch until the quick
use. coupler releases the work tool. The message
“Quick Coupler Unlock” will display on the monitor.
Uncoupling the Work Tool For the "Alarm" setting, push the locking tab on the
switch forward and then depress, but do not hold,
the rear of the switch until the quick coupler
engages the work tool. The message “Quick
Place the work tool or bucket in a safe position Coupler Locking” will display on the monitor.
before disengaging the coupler. Disengaging the
coupler will release the work tool or bucket from
control of the operator.
Serious injury or death may result from disengag-
ing the work tool or bucket when it is in an unsta-
ble position or carrying a load.
M0111427-02 209
Operation Section
3. Retract the bucket cylinder to move the quick 5. Lower the stick and move the stick toward the
coupler toward the machine. machine to disengage the quick coupler.
4. Release the quick coupler switch to retract the
i07852525
wedge.
(Hydraulic Pin Grabber Quick
Coupler (If Equipped))
SMCS Code: 6129; 6522; 7000
NOTICE
The Cat Quick Coupler (Hydraulic Pin Grabber) is not
designed to be used in applications where there is
long exposure to excessive vibration. The vibration
caused by extensive use of a hydraulic hammer as
well as the added weight of certain demolition tools
such as shears, crushers, and pulverizers may cause
premature wear and decreased service life of the
coupler.
Be sure to carefully inspect the coupler daily for
cracks, bent components, wear, distressed welds,
etc. when operating with any of the above work tools.
General Operation
The quick coupler is used to change work tools while
the operator remains in the cab. The quick coupler
can be used with a broad range of buckets and work
tools. Each work tool must have a set of pins in order
for the quick coupler to work properly.
210 M0111427-02
Operation Section
Hydraulic Pin Grabber Quick Coupler (If Equipped)
The work tools are held onto the quick coupler by

hydraulic pressure. If pressure is lost, a check valve NOTICE
Once the work tool has been properly attached to the
in the hydraulic cylinder traps oil in the cylinder. coupler, no loosening of the work tool should occur.
Ensure that the hydraulic system is working properly Refer to the “Quick Coupler Installation and Removal”
before using the quick coupler. section of the quick coupler Operation and Mainte-
A lifting eye is included on the quick coupler. Release nance Manual for additional information. If at any
the work tool from the quick coupler to use the lifting point after the proper attachment and back drag test-
eye to pick up loads. To lift a load with the lifting eye, ing of the work tool, should the work tool then be-
extend the bucket cylinder until the quick coupler is in come loose or if the rear pin of the work tool detaches
a VERTICAL position. Do not exceed the rated load from the movable hook, stop work immediately and
for the machine. safely ground and detach the work tool. Consult your
Cat dealer to inspect the coupler prior to putting the
coupler back into service. This situation could indi-
cate potential coupler damage that may not be read-
ily visible to the customer or operator of the machine
and coupler.

Electric Switch Operation
Quick coupler switch (1) is located inside the cab on

the switch panel to the left of the operator's seat. The
electric switch has only one position for coupling the
work tool and uncoupling the work tool. The switch is
equipped with safety lock (2). The locking tab must
be pushed forward before the switch can be pressed.
M0111427-02 211
Operation Section
Coupling the Work Tool
Place the work tool or bucket in a safe position

before engaging the quick coupler. Ensure that
the work tool or bucket is not carrying a load.
Serious injury or death may result from engaging
the work tool or bucket when it is in an unstable
position or carrying a load.
Inspect the quick coupler engagement before op- Illustration 386 g06187057
erating the machine.
3. Extend the stick cylinder and fully extend the
Serious injury or death may result from improp-
erly engaged coupler. bucket cylinder until the quick coupler is curled
past a vertical position. This action must be
performed before pressing the switch.
Crush injury. Could cause serious injury or death.

Always confirm that the quick coupler is engaged
onto the pins. Read the Operator's Manual.
4. Push the lock mechanism on the switch forward

and then depress the rear of the switch. The alarm
The alarm will go off when the coupler is locked will sound continuously and the message “Quick
and the monitor will display a message. These as- Coupler Unlock” will display on the monitor.
surances do not confirm that the coupler pins are
engaged. A physical test is required by dragging 5. Hold the control lever for the bucket cylinder in the
the attachment on the ground to confirm the cou- EXTEND position for 5 seconds to unlock the
pler pins are engaged.
hook.
NOTICE
With certain work tool combinations, including quick
couplers, the work tool can hit the cab or the front of
the machine. Always check for interference when first
operating a new work tool.
1. Position the bucket or the work tool on a level

surface.
2. Make sure that the pins are in the bucket or the
work tool. Make sure that the pin keepers are
installed correctly.
6. Align the quick coupler with the work tool.

212 M0111427-02
Operation Section

and then depress the rear of the switch. The alarm
will sound continuously and the message “Quick
Coupler Locking” will display on the monitor.
11. Hold the control lever for the bucket cylinder in
the EXTEND position for 5 seconds to lock the
hook. The monitor will display the message “Verify
Illustration 389 g06187068 Tool Locking” and the alarm will stop.
7. Rotate the quick coupler to grab the top pin.
8. Rotate the quick coupler downward to grab the Inspect the quick coupler engagement before op-
bottom pin. erating the machine.
Verify that the quick coupler is engaged per the
procedure in the Operation and Maintenance
Manual. Verify prior to operating the machine,
after every engine start, and after an extended
time of inactivity.
Serious injury or death may result from improp-
erly engaged coupler.
12. Verify that the quick coupler and the work tool are
locked together.
a. Retract the bucket cylinder and place the work
tool on the ground.
b. Apply pressure to the work tool against the
Illustration 391 g06187108 ground.
9. Extend the stick cylinder and extend the bucket

cylinder until the work tool is curled past a vertical
position.
M0111427-02 213
Operation Section
NOTICE NOTICE
Back drag the work tool on the ground to ensure the Auxiliary hoses for work tools must be disconnected
quick coupler is properly locked. before the Hydraulic Quick Coupler is disengaged.
Do Not strike the work tool on the ground to ensure Pulling the work tool with the auxiliary hoses could re-
the quick coupler is properly locked. Striking the work sult in damage to the host machine or the work tool.
tool on the ground will result in damage to the coupler
cylinder.
c. Drag the work tool backward.
1. Extend the stick cylinder and fully extend the

bucket cylinder until the work tool is curled past a
vertical position. This action must be performed
before pressing the switch.
and then depress the rear of the switch to unlock
the work tool. The alarm will sound continuously
Illustration 394 g06458083 and the message “Quick Coupler Unlock” will
display on the monitor.
13. Raise the boom or raise the stick. Retract the
bucket cylinder to confirm that the coupler is fully
engaged. If the coupler is fully engaged, the work
tool is locked in place. The work tool is ready to
use.
Uncoupling the Work Tool
Place the work tool or bucket in a safe position

before disengaging the coupler. Disengaging the 3. Hold the control lever for the bucket cylinder in the
coupler will release the work tool or bucket from EXTEND position for 5 seconds to unlock the
control of the operator. hook.
Serious injury or death may result from disengag-

ing the work tool or bucket when it is in an unsta-
ble position or carrying a load.
214 M0111427-02
Operation Section
4. Move the boom and the stick until the tool or the 6. Continue to rotate the quick coupler upward to
bucket is in the storage position. Keep the tool release the top pin and completely release the
close to the ground. work tool from the quick coupler.
7. Move the stick to a position that is clear of the work
tool.
Note: To lift objects with the lifting eye of the quick
coupler, refer to “Coupler Lifting Eye Operation
without Bucket” later in this chapter.
Coupling a Bucket that is Reversed
5. Rotate the quick coupler upward to release the

bottom pin.
1. When you use a hydraulic pin grabber quick

coupler, you can connect to a bucket that is in a
reversed position. Refer to Illustration 400 for an
example of connecting to a bucket that is in a
reversed position.
M0111427-02 215
Operation Section

(1) Quick coupler
(2) Bucket
2. Extend the stick cylinder and fully extend the (3) Boss
bucket cylinder until the quick coupler is curled (4) Hook
past a vertical position. This action must be
performed before pressing the switch. Coupler Lifting Eye Operation without
3. Follow the same steps for coupling the work tool to Bucket
couple the host machine to a bucket that is
reversed. Refer to “Coupling the Work Tool” for the 1. Remove the work tool. Refer to “Uncoupling the
proper procedure. Work Tool” for the proper procedure.
NOTICE
When some Caterpillar buckets are used in the re-
verse position, it can be more difficult to couple the
bucket and uncouple the bucket than in the normal
position.
Care must be taken to ensure that the position of the
boom, stick, and bucket are aligned to ensure smooth
coupling. The coupler must be in position between
the bucket bosses.
If the bucket is not fully engaged in the jaw of the cou-
pler, the quick coupler can become snagged on the
bucket bosses. The full weight of the bucket is then
carried by the quick coupler sideplates, which can
cause damage to the quick coupler.
2. The quick coupler must be curled past a vertical

position before depressing the switch. Extend the
stick cylinder and fully extend the bucket cylinder
until the quick coupler is curled past a vertical
position.
216 M0111427-02
Operation Section

and then depress the rear of the switch to lock the
quick coupler. The alarm will sound continuously
and the message “Quick Coupler Locking” will
display on the monitor.

4. Hold the control lever for the bucket cylinder in the 6. Use the lifting eye of the quick coupler, as needed.
EXTEND position for 5 seconds to lock the hook.
The monitor will display the message “Verify Tool
Locking” and the alarm will stop.
5. Rotate the quick coupler downward and move the

stick to a position that is clear of the work tool.
M0111427-02 217
Operation Section
Work Tool Operation
7. To reinstall the bucket or the work tool, refer to Do not allow the hydraulic hammer to operate at one
“Coupling the Work Tool” for the proper procedure. location and for more than 15 seconds. Change the
location of the hydraulic hammer and repeat the
procedure. Failure to change the location of the
i07349163
hydraulic hammer could cause the hydraulic oil to
overheat. Overheated hydraulic oil could damage the
Work Tool Operation accumulator.
(If Equipped) Stop the hydraulic hammer immediately if the jumper
SMCS Code: 6700; 7000 lines are pulsating violently. This indicates that the
accumulator nitrogen charge is lost. Consult your Cat
dealer for the necessary repair.
Hammer Operation (If Equipped)
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.

Do not operate the hydraulic hammer while the stick
is vertical to the ground. This could allow the stick
NOTICE cylinder to vibrate excessively.
Use only a hydraulic hammer that is recommended
by Caterpillar. Operate the attachment control levers carefully to
keep the hydraulic hammer tool from hitting the
The use of a hydraulic hammer that is not recom- boom.
mended by Caterpillar could result in structural dam-
age to the host machine. Do not operate the hydraulic hammer under water
unless the hydraulic hammer is properly equipped.
Consult your Cat dealer for information on recom- Operating the hydraulic hammer under water could
mended hydraulic hammers. damage the machine hydraulic system. Consult your
Cat dealer for information on underwater operation.
Only use the hydraulic hammer to break rocks,
concrete, and other hard objects. Before you start Do not operate the hydraulic hammer with the upper
hydraulic hammer operation, place the machine on a structure sideways to the undercarriage. Before you
level, stable surface. start hydraulic hammer operation, place the upper
structure in the recommended positions that are
Before you start hydraulic hammer operation, close shown in illustration 409 . Any other operating
the front window. Caterpillar recommends the positions could make the machine unstable. Any
installation of a window guard on the front window for other operating positions could place excessive loads
protection from flying debris. on the undercarriage.
NOTICE Refer to the following for any additional questions

In order to avoid structural damage to the host ma- about the operation and care of your Cat hydraulic
chine or the hydraulic hammer, comply with the hammer:
following:
• Operation and Maintenance Manual, SEBU7346,
Do not attempt to break rocks or concrete by burying “Hydraulic Hammers”
the hammer tool completely into the rocks or
concrete. • The Operation and Maintenance Manual specific
to your machine
Do not apply a prying force to the hammer tool in or-
der to remove the hammer tool from the material.
218 M0111427-02
Operation Section
If Equipped
An operation and maintenance decal, SMEU7397, is

available for all hydraulic hammers. The decal
provides procedures for operation and maintenance
of the hydraulic hammers. The decal can be placed
on the machine or the hammer. The decal can be
obtained through the normal literature ordering
channels.

(1) Incorrect working position
(2) Correct working position
(3) Incorrect working position
(4) Correct working position
M0111427-02 219
Operation Section
If Equipped
Shear Operation (If Equipped)

Serious injury or death could occur from the dem-
olition of pipes, vessels, tanks or other contain-
ers that may contain gas, flammable materials or
hazardous chemicals.
Do not perform any demolition work on these
items until all of their contents have been
removed.
Follow all regulations for the removal and dis-
posal of these materials.
NOTICE
Using the demolition tool to level the work site or
push over standing structures may damage the ma-
chine or the demolition tool. Use appropriate equip-
ment to do site preparation or maintenance
operations.
NOTICE
To avoid structural damage to the machine, do not
break road surfaces by placing the cutting edge of
the hydraulic shear on the ground and moving the
machine.
Be sure that no one is near the work tool to prevent

injury. Keep the work tool under control at all times to
prevent injury. When a demolition tool is used, all
Illustration 410 g06222798 personnel must maintain a minimum distance of 10 m
(33 ft).
Do not operate or work on this work tool unless

you have read and understand the instructions
and warnings in the Operation And Maintenance
Manual for both the work tool and the host
machine.
Failure to follow the instructions or heed the
warnings could result in injury or death.
Contact your Caterpillar dealer for replacement
manuals. Proper care is your responsibility.
NOTICE
Selection of a hydraulic shear must be done with ex-
tra care.
Use of a hydraulic shear not recommended by Cater-
pillar could result in structural damage to the host
machine.
Consult your Cat dealer for hydraulic shear
information.
220 M0111427-02
Operation Section
If Equipped
Close all windows. Make sure that all required guards

are in place. Wear all required protective equipment.
Follow the instructions in the Operation and
Maintenance Manual for the work tool.
Crusher Operation (If Equipped)
Improper operation and maintenance of the

crusher could cause personal injury or death. Ob-
serve the following procedures for safe operation
of the crusher.
Consult your Cat dealer for more information on
the operation and maintenance of the crusher.
Do not operate the host machine with the work
tool unless you have read and understood the in-
structions and warnings in the Operation and
Maintenance Manual. Failure to follow the in-
structions or heed the warnings could result in
machine or work tool damage, and/or serious in- Illustration 411 g06222800
jury or death. Contact your Cat dealer for a re-
placement manual, if needed. Demolition work on the roof of a building could lead
to serious personal injury if the building were to
When the crusher is installed on the host ma- collapse and the excavator turned over or fell off the
chine, always make sure that the protective roof. The demolition work must be started ONLY
guarding is in place. AFTER surveying the building for its structural
integrity.
Using the crusher in an incorrect manner can
damage the machine and/or cause personal in-
jury or death.
Always ensure that the work area is clear of
ground personnel, due to the potential crush haz-
ards with falling debris and machine movement.
Resting or placing your foot on the work tool ped-
al could result in unexpected movement of the
machine / work tool which could result in person-
al injury or death. Always lock the crusher when
not in use.
NOTICE
Selection of a hydraulic crusher must be done with
extra care.
Use of a hydraulic crusher not recommended by Cat-
erpillar could result in structural damage to the host
machine.
Consult your Cat dealer for hydraulic crusher
information. Illustration 412 g06222803
Close all windows. Make sure that all required guards Crushing work above your head must be avoided
are in place. Wear all required protective equipment. because objects can fall and damage the machine.
Follow the instructions in the Operation and
Maintenance Manual for the work tool.
M0111427-02 221
Operation Section
If Equipped
Crushing work using impact, swing, or dropping

forces of the excavator could cause damages to the
machine and also could lead to personal injury. As
such, NEVER perform such an operation.
Do not perform demolition work at the base of the

machine, because the ground could be unstable and
cause the machine to fall.

Do not suddenly lower or stop the work tool,
otherwise the excavator could turn over. Crushing work with hydraulic cylinder at stroke end
position could damage the excavator, resulting in
shortening of lifespan. Also, as it could lead to
unexpected personal injury due to breakage of the
machine, do not perform any work at stroke end.
222 M0111427-02
Operation Section
If Equipped
When performing work at elevated positions, always Crushers could interfere with the boom and the cab
use care for the surroundings as well as for falling depending on the type and method of usage. Know
objects to avoid personal injury. Use guide personnel the working range of the crusher being used.
and signs as required.

If the tooth of the crusher engages an object at a
When working sideways, the track can lift. Avoid slant, excessive forces could be applied to the front
abrupt operation and operate slowly. regions. As such move the crusher to the front.
M0111427-02 223
Operation Section
If Equipped
Never extend the boom cylinder suddenly. Sudden

extension of the boom could cause tip backwards.
Sudden extension of the bucket cylinder, or sudden

extension of the stick cylinder could cause damages
at the stroke end position, resulting in personal injury.
Operations that cause sudden extension of the
cylinders is PROHIBITED!
224 M0111427-02
Operation Section
Parking
Parking 3. Lower the work tool to the ground. Apply a slight

downward pressure.
i07868085 4. Move the hydraulic lockout control to the LOCKED
position.
Stopping the Machine
i07088536
SMCS Code: 7000
Freezing Conditions
SMCS Code: 7000
Leaving the machine unattended when the engine
is running may result in personal injury or death. If freezing temperatures are expected, remove the
Before leaving the machine operator station, neu- mud and the dirt from each track roller frame. Park
tralize the travel controls, lower the work tools to the machine on wood planks. Use the following
the ground and deactivate all work tools, and procedure to clean each track roller frame.
place the lever for the hydraulic lockout control
in the LOCKED position.
Note: There may be regulations that define the

requirements for the operator and/or support
personnel to be present when the engine is running.
Park on a level surface. If the machine must be
parked on a grade, chock the tracks securely.
Note: The swing parking brake is automatically

applied when the machine is stopped. The swing
parking brake is released when the engine is running
and the joystick is activated.
1. Turn the engine speed dial counterclockwise to Illustration 424 g06188791
reduce engine speed.

1. Position the boom over one side of the machine.
2. Use boom down pressure to lift the track on one
side off the ground. Operate the track in the
forward direction. Then operate the track in
reverse. Continue this procedure until the
maximum amount of material is thrown off the
track.
3. Lower the track onto the wood planks.
4. Repeat the procedure for the other track.
5. Clean the area around the carrier rollers and
around the track rollers.
6. Lower the work tool onto a wood plank to prevent
the work tool from touching the ground.
2. Release the travel levers/pedals to stop the

machine.
M0111427-02 225
Operation Section
Stopping the Engine
i07889731
Stopping the Engine

SMCS Code: 1000; 7000
NOTICE
Stopping the engine immediately after it has been
working under load can result in overheating and ac-
celerated wear of engine components.
Refer to the following procedure to allow the engine
to cool and to prevent excessive temperatures in the
turbocharger housing, which could cause oil coking
problems.
NOTICE
Never turn the battery disconnect switch to the OFF
position while the engine is running. Serious damage
to the electrical system may result.
1. Park the machine on level ground. Refer to Illustration 425 g06181487

Operation and Maintenance Manual, “Stopping the
Machine” for the recommended procedure. 1. The engine shutdown switch is located below the
left side of the operator seat.
2. While the machine is stopped, run the engine for 5
minutes at low idle. Idling the engine allows hot 2. Lift cover (1).
areas of the engine to cool gradually. 3. Push switch (2) upward. Pushing the switch
3. Turn the engine start switch to the OFF position. upward should stop the engine and prevent the
engine from being started again.
Note: If the “Regen Active” indicator is illuminated,
do not shut off the engine. Refer to Operation and 4. Return the switch to the original position. The
Maintenance Manual, “Monitoring System” for more engine will be enabled to start.
information on indicators.
Note: Do not operate the machine again until the
malfunction has been corrected.
Engine Shutdown Switch
5. Use the method that follows if the previous steps
NOTICE do not stop the engine.
Perform a walk around inspection after actuation of a
shutdown device. Stop the Engine if an Electrical
Take necessary corrective action to resolve the cause Malfunction Occurs
of the shutdown.
Turn the engine start switch to the OFF position. If
Ensure that no additional damage has been done or the engine does not stop, perform the following
could occur before returning to operation. procedure.
Turn the engine start switch to the OFF position. If
the engine does not stop, perform the following
procedure.
Note: Always use the engine start switch to stop the

engine. Use the engine shutdown switch as an
alternate method to stop the engine if the start switch
fails.
226 M0111427-02
Operation Section
Leaving the Machine
Repair the engine before you restart the engine. The

fuel system may need to be primed. See Operation
and Maintenance Manual, “Fuel System - Prime” for
instructions.
i07103299
Leaving the Machine

SMCS Code: 7000

The fuel shutoff valve is located behind the right
access door.
Shut off the fuel supply by turning the fuel shutoff

valve clockwise. The engine will stop after consuming
the fuel in the fuel line. The engine may continue to
run for a few minutes.
1. Use the steps and the hand holds when you

dismount. When you dismount, face the machine
and use both hands.
2. Inspect the engine compartment for debris. Clean
out any debris to avoid a fire hazard.
3. Remove all flammable debris from the front bottom
guard through the access doors to reduce a fire
hazard. Discard the debris properly.
4. Always turn the battery disconnect switch to the
OFF position before leaving the machine.
5. If the machine will not be operated for a month or
more, remove the battery disconnect switch key.
6. Lock all compartments and all vandalism covers (if
equipped).
M0111427-02 227
Operation Section
Machine Storage and Specified Storage Period
i07735116
Machine Storage and

Specified Storage Period
SMCS Code: 7000
Machine Storage
The Safety Section of this Operation and
Maintenance Manual contains storage information for
fuels, lubricants, and ether (if equipped).
The Operation Section of this Operation and
Maintenance Manual contains information for short-
term storage of this machine, including engine
shutdown, parking, and instructions for leaving the
machine.
For detailed steps on long-term storage refer to
Special Instruction, SEHS9031, “Storage Procedure
for Caterpillar Products”.
Specified Storage Period

The specified storage period of this machine is 1
year.
After the specified storage period has expired,
consult your Cat dealer for inspect, repair, rebuild,
install remanufactured, or install new components,
and disposal options, and to establish a new
specified storage period.
If a decision is made to remove the machine from
service, refer to Decommissioning and Disposal for
further information.
228 M0111427-02
Operation Section
Transportation Information
Transportation Information 6. Lower the work tool to the bed or to the floor of the
transport machine.
i08163556 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 428 g06516462
prevent the machine from slipping in transit.
Typical example of door hook
Note: Obey all laws that govern the characteristics of (A) Inside
a load (height, weight, width, and length). Observe all (B) Outside
(1) Cover
regulations that govern wide loads. Certain regions (2) Nuts
may require the removal of door hooks and cab (3) Door Hook
bumpers, if equipped. Consult all local and regional
regulations a. Remove cover (1) and nuts (2) to remove door
Choose the flattest ground when you load the hook (3).
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.
Typical example of cab bumper
5. When you drive over the loading ramp joint areas,
maintain the balance point of the machine. b. Remove any bumpers on your cab.
M0111427-02 229
Operation Section
Securing the Machine
3. Turn the battery disconnect switch to OFF and

NOTICE
Do not allow the chrome surface of the bucket cylin- remove the disconnect switch key.
der rod to touch any part of the trailer. Damage to the 4. Remove the ether starting aid cylinder. See
rod can occur from impact with the trailer during
transport. Operation and Maintenance Manual, “Ether
Starting Aid Cylinder - Replace” for the removal
procedure.
Note: Refer to Operation and Maintenance Manual,
“Specifications”. 5. Lock the door and the access covers. Attach any
vandalism protection.
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”.
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 roll-
over incident.
When the machine needs to be moved without
the boom, stick, or counterweight being installed,
avoid any machine operations which could affect
machine stability as a machine tip over or a ma-
chine rollover incident could result in serious in-
jury or death.
The machine should be operated slowly on flat,
stable ground or pavement by qualified
operators.
Note: Caterpillar strongly recommends removing the
Cat Grade Control monitor (if equipped) before
i07539618
transporting the machine to protect the monitor from
damage or theft.
Securing the Machine 6. Disconnect the wiring harness from the Cat Grade
SMCS Code: 7000 Control monitor. Remove the three screws that
secure the monitor to the mounting bracket and
remove the monitor. Remove the monitor from the
cab and store in the monitor carrying case.
Do not transport the machine if there is a mal-
function of the swing parking brake system. 7. Cover the exhaust opening.
The machine may swing during transportation if NOTICE

the swing parking brake system is not function- Do not allow the turbocharger to rotate while the en-
ing properly which could result in injury or death. gine is not operating. Damage to the turbocharger
can result.
Contact your Cat dealer for service.
Comply with any laws that govern the characteristics Note: Before you unload the excavator from the
of a load (length, width, height, and weight). transport machine, remove the protective covering
from the exhaust opening.
1. Move the hydraulic lockout control to the LOCKED
position.
2. Turn the engine start ring to the OFF position or
press button to stop engine.
230 M0111427-02
Operation Section
Lifting and Tying Down the Machine
i07785977
Lifting and Tying Down the

Machine
SMCS Code: 7000; 7500
Improper lifting and tie-down techniques can al-

low the load to shift or fail resulting in personal
injury or property damage. Use only properly
rated cables and slings with lift and tie down
points provided on the machine. Keep the deck of
the transport vehicle clean and use anti-slip mats
Illustration 431 g06289667 on steel decks.
Follow the instructions in Operation and Mainte-
8. Chock the tracks and secure the machine with tie-
nance Manual, “Lifting and Tying Down the Ma-
downs. Make sure that you use the proper rated chine” for the proper technique for securing the
wire cable. machine. Refer to Operation and Maintenance
Manual, “Specifications” for specific weight
Use the front towing eyes on the lower frame, the information.
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. The swing brake
prevents the upper structure from rotating.
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.
The lift and tie-down film is located near the base of

the boom.
M0111427-02 231
Operation Section
Lifting the machine

The machine center of gravity is located at the center of the swing gear.
Lifting Point – To lift the machine, attach 6. If the full length roller guard is equipped, remove
the lifting devices to the lifting points. the guard.
The weight and the instructions that are given herein 7. Apply the proper protector to prevent machine/wire
describe the machine as the machine is damage and slippage. Make sure that the rollers
manufactured by Caterpillar. are not affected by the load.
Refer to the Operation and Maintenance,
“Specifications” for specific weight information. Tying Down the Machine
Note: Only lift objects from approved lifting points There are two methods that can be used to tie down
and with approved lifting devices a machine. Local and/or regional regulations will
determine which method to use.
1. Use proper rated cables and slings for lifting. The
Note: Obey all local and regional governmental
crane should be positioned so that the machine is regulations.
lifted parallel to the ground.
2. To prevent contact with the machine, lifting cables Frictional and Direct Lashing
should have sufficient length.
When allowed, a combination of frictional lashing and
3. Move the hydraulic lockout control to the LOCKED direct lashing is the preferred method to tie down a
position. machine.
4. Thread the cable between the first and second

rollers at each end of the track.
5. Do not use the foot step as a lifting point.
232 M0111427-02
Operation Section
(A) Front of the machine (B) Rear of the machine
Diagonal Lashing
In areas where frictional lashing is not allowed,
diagonal lashing can be used as shown below.
(A) Front of the machine (B) Rear of the machine
Tying Down the Machine The weight and the instructions that are given herein
describe the machine as the machine is
Tie Down Point – To tie down the manufactured by Caterpillar.
machine, attach the tie-downs to the tie-
Refer to the Operation and Maintenance,
down points. “Specifications” for specific weight information.
M0111427-02 233
Operation Section
1. Use proper rated cables and shackles for tying

down the machine.
2. 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.
4. If there is a requirement of diagonal lashing for
tying down, use the proper tie-down point on the
lower frame. Set the lashing angle which is on the
longitudinal axis of the machine and the cable, at
30 to 50 degrees.
5. Keep the transport vehicle surface clean (for
example, trailer deck).
6. For steel deck transport vehicles use skid-
inhibiting or anti-slip mats (for example, rubber
mats) with a friction coefficient of at least 0.3.
Lifting the Machine Segments

Bucket

(1) Pin.(2) Sleeve.(3) Bolts.(4) Nuts.
Install pin (1) and install sleeve (2) in the brackets of

the bucket. The previous illustration indicates the
method to secure pin (1) with bolts (3) and nuts (4).
Fasten two proper rated wire cables to pin (1).
234 M0111427-02
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.
i07348733 Put an observer in a safe position to watch the pulling
procedure. The observer can stop the procedure if
Towing the Machine the wire rope starts to break. Stop pulling whenever
the towing machine moves without moving the towed
SMCS Code: 7000 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. Prior to releasing the brake of the final drive, firmly
lock both tracks to prevent the machine from moving
Even after the machine has been turned off, the suddenly. When the machine is ready to be towed,
hydraulic oil can still be hot enough to burn. Al- release the brake of the final drive. Refer to
low the hydraulic oil to cool before draining. Operation and Maintenance Manual, “Final Drive Sun
Gear Removal”.
Normally, the towing machine should be as large as
NOTICE
To tow the machine, both final drives must be the disabled machine. Make sure that the towing
disengaged. machine has enough brake capacity, enough weight,
and enough power. The towing machine must be
Do not operate the travel motors with the final drives able to control both machines for the grade that is
disengaged. Damage could result. involved and for the distance that is involved.
These towing instructions are for moving a disabled You must provide sufficient control and sufficient
machine for a short distance at low speed. Move the braking when you are moving a disabled machine
machine at a speed of 2 km/h (1.2 mph) or less to a downhill. This may require a larger towing machine or
convenient location for repair. Always haul the additional machines that are connected to the rear of
machine if long distance moving is required. the disabled machine. This will prevent the machine
from rolling away out of control.
Shields must be provided on both machines. This will
protect the operator if the tow line or the tow bar All situation requirements cannot be listed. Minimal
breaks. towing machine capacity is required on smooth, level
surfaces. Maximum towing machine capacity is
Do not allow an operator to be on the machine that is required on an incline or on a surface that is in poor
being towed. condition.
Before you tow the machine, make sure that the tow Do not tow a loaded machine.
line or the tow bar is in good condition. Do not use a Consult your Cat dealer for the equipment that is
wire rope that is kinked, twisted, or damaged. Make necessary for towing a disabled machine.
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.
M0111427-02 235
Operation Section
Final Drive Sun Gear Removal
Retrieval and Towing of Machine Shackles must be used for towing the machine. The
wire rope should be horizontal and straight to the
track frame.
Install a properly rated wire rope to the lower frame of
the towing machine and the lower frame of the towed
machine. Operate the machine at a low speed.
i06954175

SMCS Code: 4050
Note: Shackles must be used for towing the

machine. The wire rope should be horizontal and
straight to the track frame.
Install a properly rated wire rope to the lower frame of
the towing machine and the lower frame of the towed
machine. The permissible force for the lower frame is
100 percent of the gross weight of the towed
machine.
Note: To prevent damage to the wire rope or the
lower frame of the machines, use protective sleeves
on the corners of the lower frame.
Retrieve the disabled machine carefully. The applied
load for each wire rope should be equal. The angle
(A) between each wire rope should be 60 degree
maximum. Operate the machine at a low speed. Illustration 439 g06188195
(1) Bolt
Lightweight Towing (2) Ring gear
(3) Ring gear
(4) Sun gear
(5) Final drive cover
Without the sun gear in place, the brakes are inef-

fective. Personal injury or death could result. Pro-
vide other means to hold or stop the machine.
1. Thoroughly clean the area around the final drive.

Make sure that you also clean the track shoes that
are positioned above the final drive.

“General Hazard Information” for information on
Illustration 438 g06186106 containing fluid spillage.
The maximum load for lightweight towing is 2. Drain the final drive oil into a suitable container.
102900 N (75895 lb). See Operation and Maintenance Manual, “Final
Drive Oil - Change” for the procedure.
236 M0111427-02
Operation Section
3. Remove 14 of 16 cover bolts (1) from final drive

cover (5). Do not leave a bolt in the top hole of the
cover.
4. Insert an alignment dowel through the top hole of
the cover and into the threads in the final drive
housing. This is necessary to support ring gear (2)
and ring gear (3) while you are removing the final
drive cover.
5. Remove one track shoe to allow access to the face
between final drive cover (5) and ring gear (2).
6. Loosen remaining two cover bolts (1).
7. Use a hammer and a wedge to separate final drive
cover (5) and ring gear (2). Make sure that ring
gear (2) and ring gear (3) stay in place.
8. Remove remaining two cover bolts (1) and final
drive cover (5).
9. Remove sun gear (4) from final drive.
10. Install final drive cover (5) and 16 cover bolts (1).
11. Fill the final drive with new oil. See Operation and
Maintenance Manual, “Final Drive Oil - Change”
for the procedure.
12. Repeat Steps 1 through 11 for the other final
drive.
13. Refer to the Service Manual for information on
the installation of the final drive sun gear.
M0111427-02 237
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.
i06953771
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 personal 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.
238 M0111427-02
Operation Section
If Equipped
7. The positive ends of the jump-start cable are red.

Connect one positive end of the jump-start cable
to the positive cable terminal of the discharged
battery. Some machines have battery sets.
Note: Batteries that are in series may be in separate

compartments. Use the terminal that is connected to
the starter solenoid. This battery or battery set is
normally on the same side of the machine as the
starter.
Do not allow the positive cable clamps to contact

any metal except for the battery terminals.
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.
11. Start the engine of the machine that is being used
as an electrical source or energize the charging
system on the auxiliary power source.
12. Wait at least two minutes before you attempt to
start the stalled machine. This will allow the
batteries in the stalled machine to partially charge.
13. Attempt to start the stalled engine. See Operation
and Maintenance Manual, “Engine Starting” for the
correct starting procedure.
(1) Red positive post to starter 14. Immediately after you start the stalled engine,
(2) The black negative post connects to the battery disconnect disconnect the jump-start cables in reverse order.
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
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.
M0111427-02 239
Operation Section
Engine Starting with Auxiliary Start Receptacle
i07349165 There are two cable assemblies that can be used to

jump-start the stalled machine. You can jump-start
Engine Starting with Auxiliary the stalled machine from another machine that is
equipped with an auxiliary start receptacle or with an
Start Receptacle auxiliary power pack. Your Cat dealer can provide the
correct cable lengths for your application.
(If Equipped)
1. Determine the reason that the engine will not start.
SMCS Code: 1000; 7000
Reference: Refer to Special Instruction, SEHS7633,
“Battery Test Procedure” for more information.
2. Ensure that the travel control levers on the stalled
machine are in the CENTER position. Engage the
hydraulic lockout control. Engage the parking
brake. Lower all work tools to the ground. Move all
controls to HOLD.
3. Turn the engine start switch key on the stalled
machine to the OFF position. Turn off all
accessories.
4. Turn the battery disconnect switch on the stalled
machine to ON.
5. Move the machine that is being used as a power
source close to the stalled machine. The jump-
start cables should reach the batteries on both
machines. DO NOT ALLOW THE MACHINES TO
CONTACT EACH OTHER.
6. Stop the engine on the machine that is being used
as a power source. If you use an auxiliary power
source, turn off the charging system.
7. Connect the appropriate jump-start cable to the
auxiliary start receptacle on the stalled machine.
8. Connect the other end of the jump-start cable to
the auxiliary start receptacle of the machine that is
being used as a power source.
9. Start the engine on the machine that is being used
as a power source or energize the charging
system on the auxiliary power source.
10. Wait for a minimum of 2 minutes while the
batteries in the stalled machine partially charge.
11. Attempt to start the stalled engine.
12. Immediately after the stalled engine starts,
(1) Cover disconnect the jump-start cable from the power
(2) Receptacle
source.
Some Cat products may be equipped with an 13. Disconnect the other end of the jump-start cable
auxiliary start receptacle as a standard part. If your
machine is not equipped with an auxiliary start from the stalled machine.
receptacle, the machine can be equipped with an 14. Conclude the failure analysis on the starting
auxiliary start receptacle from parts service. This will
ensure that a permanent receptacle is always charging system of the stalled machine, as
available to jump-start the machine. required. Check the machine while the engine is
running and the charging system is in operation.
240 M0111427-02
Maintenance Section
Maintenance Access
Maintenance Section
Maintenance Access
i07945107
Access Door and Cover

Locations
SMCS Code: 726A-CH
Engine Hood
1. Open the engine hood.

2. Gas spring (1) will lock in place to hold the engine
hood open.
Operation of the Push Button Release for the En-

gine Hood
When closing the engine hood, only operate the
push-button release by hand.
Failure to remove hands from the push-button re-
Illustration 444 g06225770 lease before closing the engine hood could result
Allows access to engine and coolant tank. in personal injury.
Be sure to remove hands from the push-button
release before completely closing the engine
hood.
NOTICE
Do not add pressure to the engine hood when open.
When closing the engine hood, Do Not operate

the push-button release by foot.
Operation of the push-button release by foot
could result in damage to the gas spring of the
closing mechanism and/or personal injury.
Only operate the push-button release for closing
the engine hood by hand.
M0111427-02 241
Maintenance Section
Access Door and Cover Locations
3. To close the engine hood, support the engine hood Left Front Access Door
with the door handle. Press the push-button
release (2) to unlock the gas spring. Release the
push button and slowly close the engine hood.
Engine Service Door

Allows access to engine air filter, batteries, and
window washer reservoir.
Right Side Access Door

Allows access to the engine oil filler cap and the
upper dipstick.
Left Rear Access Door

Allows access to the engine oil filter, engine oil
sampling port, and ground level dipstick. Additionally,
the compartment houses the hydraulic pump, fuel
filters, refueling pump, fuel tank drain valve, and
hydraulic tank sight gauge.
Allows access to the coolant sample port, coolant
drain, cooling cores, power fuses, battery disconnect
switch, and coolant reservoir.
242 M0111427-02
Maintenance Section
Access Door and Cover Locations
Storage Box

Allows access to the storage box.
Note: The storage box has a maximum allowable

weight of 15 kg (33 lbs).
M0111427-02 243
Maintenance Section
Lubricant Viscosities and Refill Capacities
Lubricant Viscosities and NOTICE

Not following the recommendations found in this
Refill Capacities manual can lead to reduced performance and com-
partment failure.
i07279902
Lubricant Viscosities Engine Oil

(Fluids Recommendations) Cat oils have been developed and tested in order to
SMCS Code: 7581 provide the full performance and life that has been
designed and built into Cat engines.
General Information for Lubricants Cat DEO-ULS multigrade and Cat DEO multigrade
oils are formulated with the correct amounts of
When you are operating the machine in temperatures detergents, dispersants, and alkalinity in order to
below −20°C (−4°F), refer to Special Publication, provide superior performance in Cat diesel engines
SEBU5898, “Cold Weather Recommendations”. This where recommended for use.
publication is available from your Cat dealer.
Note: SAE 10W-30 is the preferred viscosity grade
Refer to the “Lubricant Information” section in the for the 3116, 3126, C7, C-9,and C9 diesel engines
latest revision of the Special Publication, SEBU6250, when the ambient temperature is between -18° C (0°
“Caterpillar Machine Fluids Recommendations” for a F) and 40° C (104° F).
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.
244 M0111427-02
Maintenance Section
Fluids Recommendations
Table 22
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
M0111427-02 245
Maintenance Section
Table 23
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 24
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)
246 M0111427-02
Maintenance Section
(Table 24, 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 25

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 26
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)
M0111427-02 247
Maintenance Section
(Table 26, 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 27
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 corrosion
Diesel fuel must meet “Caterpillar Specification for • Increase the deposits
Distillate Fuel” and the latest versions of “ASTM
D975” or “EN 590” to ensure optimum engine • Lower fuel economy
performance. Refer to Special Publication,
SEBU6250, “Caterpillar Machine Fluids • Shorten the time period between oil drain intervals
Recommendations” for the latest fuel information and (more frequent oil drain intervals)
for Cat fuel specification. This manual may be found
on the web at Safety.Cat.com. • Increase overall operating costs
The preferred fuels are distillate fuels. These fuels • Negatively impact engine emissions
are commonly called diesel fuel, furnace oil, gas oil,
or kerosene. These fuels must meet the “Caterpillar Failures that result from the use of improper fuels are
Specification for Distillate Diesel Fuel for Off- not Caterpillar factory defects. Therefore the cost of
Highway Diesel Engines”. Diesel Fuels that meet the repairs would not be covered by a Caterpillar
Caterpillar specification will help provide maximum warranty.
engine service life and performance.
Caterpillar does not require the use of ULSD in off
Misfueling with fuels of high sulfur level can have road and machine applications that are not Tier 4/
the following negative effects: Stage IIIB certified engines. ULSD is not required in
engines that are not equipped with after treatment
• Reduce engine efficiency and durability devices.
• Increase the wear
248 M0111427-02
Maintenance Section
Follow operating instructions and fuel tank inlet Preferred – Cat ELC (Extended Life Coolant)
labels, if available, to ensure that the correct fuels are
used. Acceptable – Cat DEAC (Diesel Engine Antifreeze/
Coolant)
Refer to Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” for more details
about fuels and lubricants. This manual may be
found on the web at Safety.Cat.com.
Fuel Additives
Cat Diesel Fuel Conditioner and Cat Fuel System
Cleaner are available for use when needed. These
products are applicable to diesel and biodiesel fuels.
Consult your Cat dealer for availability.
Biodiesel
Biodiesel is a fuel that can be made from various
renewable resources that include vegetable oils,
animal fat, and waste cooking oil. Soybean oil and
rapeseed oil are the primary vegetable oil sources.
To use any of these oils or fats as fuel, the oils or fats
are chemically processed (esterified). The water and
contaminants are removed.
U.S. distillate diesel fuel specification “ASTM 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.
All the guidelines and requirements are provided in
the latest revision of Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations”. This
manual may be found on the web at Safety.Cat.com.
Coolant Information
The information provided in this “Coolant
Recommendation” section should be used with the
“Lubricants Information” provided in the latest
revision of Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations”. This
manual may be found on the web at Safety.Cat.com.
The following two types of coolants may be used in
Cat diesel engines:
M0111427-02 249
Maintenance Section
Capacities (Refill)
NOTICE
Never use water alone as a coolant. Water alone is
corrosive at engine operating temperatures. In addi-
tion, water alone does not provide adequate protec-
tion against boiling or freezing.
i07896240
Capacities (Refill)
SMCS Code: 1000; 7000
Table 28
Approximate Capacities (Refill)
Component or System Liters US gal Recommended Type
Cooling System 25 6.6
Fuel Tank 474 125

Engine Crankcase with Filter 25 6.6 Refer to Operation and Maintenance Manual, “Lubricant
Hydraulic System(1) 147 38.8 Viscosities”.
Swing Drive 10 2.6
Each Final Drive 5.5 1.45

kg lbs
Refer to Operation and Maintenance Manual, “Lubricant

Swing Gear 14.9 32.8
Viscosities”.
Refrigerant(2) 0.9 2.0 R-134a
mL oz
Refrigerant Oil (2) 240 8 Polyalkylene Glycol (PAG) Oil

(1) The amount of hydraulic fluid that is needed to refill the hydraulic system after performing Operation and Maintenance Manual, “Hydraulic
System Oil - Change”
(2) Refer to Service Manual, “Air Conditioning and Heating R-134a for All Caterpillar Machines” for additional information
i07445339 Refer to the Operation and Maintenance Manual,

“Maintenance Interval Schedule” for a specific
S·O·S Information sampling location and a service hour maintenance
interval.
SMCS Code: 1000; 1348; 3080; 4050; 5050; 7000;
7542-008 Consult your Cat dealer for complete information and
assistance in establishing an S·O·S program for your
S·O·S Services is a highly recommended process for equipment.
Cat customers to use in order to minimize owning
and operating cost. Customers provide oil samples,
coolant samples, and other machine information. The
dealer uses the data in order to provide the customer
with recommendations for management of the
equipment. In addition, S·O·S Services can help
determine the cause of an existing product problem.
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.
250 M0111427-02
Maintenance Section
Maintenance Support
Maintenance Support 5. Release the pressure in the hydraulic system.

“System Pressure Release” for more information.
i07477696
Perform a visual inspection first. If the visual checks
Prepare the Machine for are completed but the problem has not been
identified, perform operational checks. If the problem
Maintenance has not been identified, perform instrument tests.
SMCS Code: 1000; 7000 This procedure will help to identify system problems.
Refer to the following procedure before you perform i07214904

any maintenance to the machine.
Service Interval Chart
SMCS Code: 7000
Personal injury can result from hydraulic oil pres- The service interval chart is inside the battery
sure and hot oil. compartment door on the left side of the machine.
Hydraulic oil pressure can remain in the hydraulic Refer to the Operation and Maintenance Manual,
system after the engine has been stopped. Seri- “Maintenance Interval Schedule” for the correct
ous injury can be caused if this pressure is not maintenance intervals and procedures that are
released before any service is done on the hy- specific to your machine.
draulic system.
Make sure all of the attachments have been low-
ered, oil is cool before removing any components
or lines. Remove the oil filler cap only when the
engine is stopped, and the filler cap is cool
enough to touch with your bare hand.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, PERJ1017, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat ® products.
Dispose of all fluids according to local regulations
and mandates.
Note: Permit only one operator on the machine.

Keep all other personnel away from the machine or in
view of the operator.
1. Park the machine on a dry, level, solid surface that

is free of any debris.
Note: The surface must be solid enough to support

the weight of the machine and any tooling that is
used to support the machine.
2. Engage the parking brake. Place wheel blocks in

front and behind the wheels or tracks.
3. Lower all work tools to the ground.
4. Stop the engine.
M0111427-02 251
Maintenance Section
Service Interval Chart
Operation and Maintenance Manual – Engine oil filter – Change the engine oil
Refer to the OMM for maintenance filter.
instructions and guidelines.
Service hour interval – Hourly interval in Final drive oil level – Check the final
which a maintenance procedure should drive oil level.
be performed.
Final drive oil – Change the final drive
Cooling system coolant – Change the oil.
ELC (Extended Life Coolant) .
Fuel cap filter – Replace the fuel cap
Engine air filter primary element – Clean filter.
or replace the primary air filter element.
Fuel level – Check the fuel level.

Engine air filter secondary element –
Replace the secondary air filter element.
Fuel system filter – Replace the fuel

Engine oil level – Check the engine oil
system filters.
level.
Fuel system water separator – Drain the

Engine oil – Change the engine oil. water separator.
252 M0111427-02
Maintenance Section
System Pressure Release
Fuel system water separator element – To relieve the pressure from the coolant system, turn
Replace the fuel system water separator off the machine. Allow the cooling system pressure
element. cap to cool. Remove the cooling system pressure
cap slowly to relieve pressure.
Fumes Disposal Filter Element –
Replace the fumes disposal filter Hydraulic System
element.
The release of hydraulic pressure in a hydraulic
Grease zerk – Lubricate the designated circuit is required before service is performed to that
locations. hydraulic circuit. Release the pressure in the
following hydraulic circuits before any hydraulic lines
Hydraulic oil level – Check the hydraulic are disconnected or removed from that hydraulic
oil level. circuit.
• Boom hydraulic circuit
Hydraulic oil – Change the hydraulic oil.
• Stick hydraulic circuit
Hydraulic oil filter – Change the • Bucket hydraulic circuit

hydraulic oil filter.
• Swing hydraulic circuit
Swing drive oil level – Check the swing • Travel hydraulic circuit
drive oil level.
• Attachment hydraulic circuits (if equipped)
Swing drive oil – Change the swing drive • Pilot hydraulic circuit
oil.
• Return hydraulic circuit
i07107723
Note: Refer to the Disassembly and Assembly
Manual for additional information concerning service
of the components of specific hydraulic circuits.
SMCS Code: 1250-553-PX; 1300-553-PX; 1350- Release of Hydraulic Pressure from the
553-PX; 5050-553-PX; 6700-553-PX; 7540-553-PX Main Hydraulic System
Personal injury or death can result from sudden

machine movement. Personal injury can result from hydraulic oil pres-
sure and hot oil.
Sudden movement of the machine can cause in-
jury to persons on or near the machine. Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Seri-
To prevent injury or death, make sure that the ous injury can be caused if this pressure is not
area around the machine is clear of personnel released before any service is done on the hy-
and obstructions before operating the machine. draulic system.
Make sure all of the work tools have been lowered
to the ground, and the oil is cool before removing
Coolant System any components or lines. Remove the oil filler
cap only when the engine is stopped, and the fill-
er cap is cool enough to touch with your bare
hand.
Pressurized system: Hot coolant can cause seri-
ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve
the pressure.
M0111427-02 253
Maintenance Section
c. Place the hydraulic activation control lever in

NOTICE
Care must be taken to ensure that fluids are con- the UNLOCKED position.
and mandates.
Perform the following steps to release the hydraulic
system pressure from the main hydraulic system.
Note: For additional safety, wrap hydraulic joint with
material that could absorb/reduce any residual
pressure of oil when released. Loosen the joint
slowly, pause, and carefully check hydraulic joint for
tensions indicating presence of pressure or spring
force in lines or components.
1. Position the machine on level ground. Illustration 453 g06184822
d. Move both joysticks in a circular motion to the

FULL STROKE positions multiple times until the
pilot accumulator has been exhausted.
Note: Pilot pressure is required to relieve hydraulic

system pressure.
e. Place the hydraulic activation control lever in

the LOCKED position.
f. Start the engine to recharge the pilot
accumulator.
Note: Do not activate any controls when

recharging the pilot accumulator.
g. Shut off the engine.
2. Fully retract the stick cylinder rod. Adjust the h. Repeat Step 3b through Step 3g until the high-
position of the bucket so that the bucket is parallel pressure lines have been released.
to the ground. Lower the boom until the work tool
is flat on the ground. Refer to Illustration 452 . Note: Each time the accumulator is recharged,
start the joysticks at different positions or rotate in
3. Release the system pressure from the implement the reverse direction. Doing so will ensure that the
and swing hydraulic circuits. same circuit is not being relieved each time.
Note: Perform Step 3b through Step 3d immediately Note: You can also move only the joysticks or
after the engine is shut off to insure adequate pilot pedals of the hydraulic circuit that requires service
system pressure is available to release the pressure to the full stroke positions after moving joysticks in
in the hydraulic circuits. a circular motion multiple times. This action will
release the high pressure only in that single
a. Shut off the engine. hydraulic circuit. This action will also release any
pressure that might be present in the pilot hydraulic
b. Turn the engine start switch to the ON position
circuit.
without starting the engine.
254 M0111427-02
Maintenance Section
4. Release hydraulic system pressure in the

attachment circuits.
a. Start the engine to charge pilot accumulator.
b. Shut off the engine.
Note: Perform Step 4c through Step 4e

immediately after the engine is shut off to insure
adequate pilot system pressure is available to
release the pressure in the hydraulic circuits.
c. Turn the engine start switch to the ON position

without starting the engine.
d. Place the hydraulic activation control lever in
the UNLOCKED position.
e. Activate the switch or pedal for the attachment
circuit.
f. Place the hydraulic activation control lever in
the LOCKED position.
g. Start the engine to recharge pilot accumulator. Illustration 454 g06184990
Hydraulic oil tank filler cap
Note: Do not activate any controls when (A) LOCK position
recharging pilot accumulator. (B) PRESSURE RELEASE - START position
h. Shut off the engine. (D) OPEN position
i. Repeat Step 4c through Step 4f for each 7. Release the pressure that may be present in the
attachment circuit. return hydraulic circuit with the following
5. After releasing the hydraulic pressure in each of procedure. Refer to Illustration 454 for filler cap
the desired hydraulic circuits, place the hydraulic positions.
activation control lever in the LOCKED position. a. Turn the filler cap counterclockwise and move
6. Turn the engine start switch to the OFF position. the arrow from position (A) to position (B).
to position (C).
c. Push down the filler cap and move the arrow
from position (C) to position (D).
Note: The travel hydraulic circuit is open to the
hydraulic tank. Pressure from the travel circuit is
released by releasing pressure from the return
circuit.

boom circuit to remove the risk of residual
pressure in the line. Make sure that the engine
start switch is in the OFF position and the pressure
in the hydraulic tank has been released.
a. Remove the hydraulic oil tank filler cap.
b. Remove any covers to access the main control
valve.
M0111427-02 255
Maintenance Section
Welding on Machines and Engines with Electronic Controls
9. The pressure in the multiple hydraulic circuits that

require service is now released and lines and
components can be disconnected or removed
from those hydraulic circuits.
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
Main control valve an electronic control on the machine or the engine,
(5) Screw temporarily remove the electronic control to prevent
heat related damage. The following steps should be
c. Use a clean hose of adequate length and size followed to weld on a machine or an engine with
and connect to screw (5). Put the other end of electronic controls.
the hose in the filler cap opening. 1. Turn off the engine. Place the engine start switch
d. Slowly loosen screw (5) by a maximum of 1/2 in the OFF position.
turn. Loosening the screw allows the hydraulic 2. If equipped, turn the battery disconnect switch to
oil in the boom circuit to drain into the hydraulic the OFF position. If there is no battery disconnect
tank. switch, remove the negative battery cable at the
e. Tighten screw (5) to 13 ± 2 N·m (9 ± 1 lb ft). battery.
Note: Refer to the Operation and Maintenance NOTICE

Manual, Equipment Lowering with Engine Stopped Do NOT use electrical components (ECM or sensors)
for information on lowering the work tool with the or electronic component grounding points for ground-
ing the welder.
engine off.
f. Disconnect the hose from screw (5). Do not 3. Clamp the ground cable from the welder to the
allow the oil that is contained in the hose to spill. component that will be welded. Place the clamp as
Drain the oil into a suitable container. 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.
256 M0111427-02
Maintenance Section
Welding on Machines and Engines with Electronic Controls
5. Use standard welding procedures to weld the

materials together.
M0111427-02 257
Maintenance Section
Maintenance Interval Schedule
i08368294 “ Ether Starting Aid Cylinder - Replace“ . . . . . . . . 289
Maintenance Interval Schedule “ Film (Product Identification) - Clean“ . . . . . . . . . 290
SMCS Code: 7000 “ Fuel System - Prime“ . . . . . . . . . . . . . . . . . . . . . . 292
Ensure that all safety information, warnings, and “ Fuel Tank Strainer - Clean“ . . . . . . . . . . . . . . . . . 297
instructions are read and understood before any
operation or any maintenance procedures are “ Fuses - Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . 298
performed.
“ High Intensity Discharge Lamp (HID) -
The user is responsible for the performance of Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
maintenance. All adjustments, the use of proper
lubricants, fluids, filters, and the replacement of “ Oil Filter - Inspect“ . . . . . . . . . . . . . . . . . . . . . . . . 315
components due to normal wear and aging are “ Radiator, Aftercooler and Oil Cooler Cores -
included. Failure to adhere to proper maintenance Clean“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 316
intervals and procedures may result in diminished
performance of the product and/or accelerated wear “ Rollover Protective Structure (ROPS) -
of components. Inspect“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317
Use mileage, fuel consumption, service hours, or “ Track Adjustment - Adjust“ . . . . . . . . . . . . . . . . . 323
calendar time, WHICH EVER OCCURS FIRST, to
determine the maintenance intervals. Products that “ Undercarriage - Check“ . . . . . . . . . . . . . . . . . . . . 326
operate in severe operating conditions may require
more frequent maintenance. Refer to the “ Window Washer Reservoir - Fill“ . . . . . . . . . . . . 326
maintenance procedure for any other exceptions that
may change the maintenance intervals. “ Window Wiper - Inspect/Replace“ . . . . . . . . . . . 327
Note: Before each consecutive interval is performed, “ Windows - Clean“. . . . . . . . . . . . . . . . . . . . . . . . . 327

all maintenance from the previous interval must be
performed. Every 10 Service Hours or Daily for
The following guidelines should be followed if the First 50 Hours
service hours are not met:
“ Boom and Stick Linkage - Lubricate“ . . . . . . . . . 261
Items listed between 10 and 100 service hours
should be performed at least every 3 months. “ Bucket Linkage - Lubricate“ . . . . . . . . . . . . . . . . 263
Items listed between 250 and 500 service hours Every 10 Service Hours or Daily
should be performed at least every 6 months.
Items listed between 1000 service hours and 2500 “ Cooling System Coolant Level - Check“. . . . . . . 276
service hours should be performed at least every
year. “ Engine Oil Level - Check“ . . . . . . . . . . . . . . . . . . 282
“ Fuel System Water Separator - Drain“ . . . . . . . . 296
When Required
“ Fuel Tank Water and Sediment - Drain“ . . . . . . . 297
“ Air Conditioner/Cab Heater Filter (Recirculation) -
Inspect/Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . . 259 “ Hydraulic System Oil Level - Check“ . . . . . . . . . 311
“ Battery Electrolyte Level - Check“ . . . . . . . . . . . 259 “ Indicators and Gauges - Test“ . . . . . . . . . . . . . . . 313
“ Battery or Battery Cable - Inspect/Replace“. . . . 260 “ Track Adjustment - Inspect“ . . . . . . . . . . . . . . . . 325
“ Bucket Linkage - Inspect/Adjust“ . . . . . . . . . . . . 262 “ Travel Alarm - Test“ . . . . . . . . . . . . . . . . . . . . . . . 325
“ Bucket Tips - Inspect/Replace“ . . . . . . . . . . . . . . 264 “ Seat Belt - Inspect“ . . . . . . . . . . . . . . . . . . . . . . . 318
“ Cab Air Filter (Fresh Air) - Clean/Replace“ . . . . 270 Every 100 Service Hours
“ Camera - Clean“ . . . . . . . . . . . . . . . . . . . . . . . . . 271
“ Bucket Linkage - Lubricate“ . . . . . . . . . . . . . . . . 263
“ Condenser (Refrigerant) - Clean“ . . . . . . . . . . . . 272
“ Engine Air Filter Primary and/or Secondary Element
- Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
258 M0111427-02
Maintenance Section
Maintenance Interval Schedule
“ Oil Filter (Hydraulic Hammer) - Replace“ . . . . . . 313 “ Swing Gear - Lubricate“. . . . . . . . . . . . . . . . . . . . 321
Every 250 Service Hours Every Year

“ Cooling System Coolant Sample - Obtain“ . . . . 277 “ Cooling System Coolant Sample - Obtain“ . . . . 277
“ Engine Oil Sample - Obtain“ . . . . . . . . . . . . . . . . 284
Every 3000 Service Hours
Initial 500 Service Hours “ Hydraulic System Oil Filter (Return) -
Replace“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
“ Engine Oil and Filter - Change“. . . . . . . . . . . . . . 284
“ Final Drive Oil - Change“ . . . . . . . . . . . . . . . . . . . 290 Every 3 Years
“ Swing Drive Oil - Change“. . . . . . . . . . . . . . . . . . 319 “ Seat Belt - Replace“. . . . . . . . . . . . . . . . . . . . . . . 318
Initial 500 Hours (for New Systems, Every 5000 Service Hours
Refilled Systems, and Converted
“ Receiver Dryer (Refrigerant) - Replace“. . . . . . . 317
Systems)
“ Cooling System Coolant Sample - Obtain“ . . . . 277
Every 6000 Service Hours or 3
Years
Every 500 Service Hours “ Cooling System Coolant Extender (ELC) -
Add“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
“ Boom and Stick Linkage - Lubricate“ . . . . . . . . . 261
“ Hydraulic System Oil - Change“ . . . . . . . . . . . . . 302
“ Final Drive Oil Level - Check“ . . . . . . . . . . . . . . . 291
“ Final Drive Oil Sample - Obtain“ . . . . . . . . . . . . . 292 Every 12 000 Service Hours or 6
“ Hydraulic System Oil Sample - Obtain“ . . . . . . . 313 Years
“ Swing Bearing - Lubricate“ . . . . . . . . . . . . . . . . . 318 “ Cooling System Coolant (ELC) - Change“ . . . . . 272
“ Swing Drive Oil Level - Check“ . . . . . . . . . . . . . . 320

“ Swing Drive Oil Sample - Obtain“ . . . . . . . . . . . . 321

“ Battery - Clean“ . . . . . . . . . . . . . . . . . . . . . . . . . . 259
“ Battery Hold-Down - Tighten“ . . . . . . . . . . . . . . . 260
“ Belt - Inspect/Adjust/Replace“. . . . . . . . . . . . . . . 260
“ Engine Oil and Filter - Change“. . . . . . . . . . . . . . 284
“ Engine Valve Lash - Check“ . . . . . . . . . . . . . . . . 288
“ Fuel System Primary Filter (Water Separator)
Element - Replace“ . . . . . . . . . . . . . . . . . . . . . . . . 293
“ Fuel System Secondary Filter - Replace“. . . . . . 295
“ Swing Drive Oil - Change“. . . . . . . . . . . . . . . . . . 319

“ Final Drive Oil - Change“ . . . . . . . . . . . . . . . . . . . 290
“ Fuel Cap Filter - Replace“ . . . . . . . . . . . . . . . . . . 292
M0111427-02 259
Maintenance Section
Air Conditioner/Cab Heater Filter (Recirculation) - Inspect/Replace
i06954215 5. After you clean the filter element, inspect the filter
element. If the filter element is damaged or badly
Air Conditioner/Cab Heater contaminated, use a new filter element. Make sure
Filter (Recirculation) - Inspect/ that the filter element is dry.
Replace 6. Install the filter element.

SMCS Code: 1054-040-A/C; 1054-510-A/C 7. Install the cover.
NOTICE
NOTICE Failure to reinstall the filter element for the air condi-
An air recirculation filter element plugged with dust tioning system will contaminate and damage the sys-
will result in decreased performance and service life tem components.
to the air conditioner or cab heater.
To prevent decreased performance, clean the filter el-
ement, as required. i00934864
The air conditioner filter is on the lower left side of the

cab behind the seat.
Battery - Clean
SMCS Code: 1401-070
1. Slide the operator seat forward.
Clean the battery surface with a clean cloth. Keep the
terminals clean and keep the terminals coated with
petroleum jelly. Install the post cover after you coat
the terminal post with petroleum jelly.
i06019968
Battery Electrolyte Level -

Check
SMCS Code: 1401; 1401-535; 1401-535-FLV
All lead-acid batteries contain sulfuric acid which

can burn the skin and clothing. Always wear a
face shield and protective clothing when working
on or near batteries.
2. Release the cover latch.
Note: If the machine is operated in extreme

temperatures, check the electrolyte level Every 500
Service Hours or 3 months.
When the engine is not run for long periods of time or
when the engine is run for short periods, the batteries
may not fully recharge. Ensure a full charge in order
to help prevent the battery from freezing.
1. Clean the battery surface with a clean cloth. Clean
the terminals and the cable clamps. Coat the
clamps and the terminals with silicone lubricant or
petroleum jelly. Install the post cover.
2. Inspect the electrolyte level in each battery cell.
Maintain the electrolyte level to the bottom of the
filler openings. Use distilled water. If distilled water
is not available, use clean drinking water.
3. Slide the filter element upward.
4. Tap the air filter to remove the dirt. Do not use
compressed air to clean the filter.
260 M0111427-02
Maintenance Section
Battery Hold-Down - Tighten
i00934872 9. Make any necessary repairs. If necessary, replace

the battery cables and/or the battery.
Battery Hold-Down - Tighten 10. Connect the positive battery cable at the battery.
SMCS Code: 7257
11. Connect the negative battery cable at the battery.
Tighten the hold-downs for the battery in order to
prevent the batteries from moving during machine 12. Coat the battery terminals with petroleum jelly to
operation. prevent corrosion and install the terminal covers.
13. Reinstall the battery hold-down. Tighten the hold-
i07592714
downs for the battery to prevent the batteries from
moving during machine operation.
Battery or Battery Cable -
14. Connect the battery cable at the battery
Inspect/Replace disconnect switch.
SMCS Code: 1401-510; 1401-040; 1401-561; 1401;
1402-510; 1402-040 15. Install the key and turn the battery disconnect
switch ON.
Recycle the Battery

Personal injury can result from battery fumes or
explosion. Always recycle a battery. Never discard a battery.
Batteries give off flammable fumes that can ex- Always return used batteries to one of the following
plode. Electrolyte is an acid and can cause per- locations:
sonal injury if it contacts the skin or eyes.
• A battery supplier
Prevent sparks near the batteries. Sparks could
cause vapors to explode. Do not allow jumper ca- • An authorized battery collection facility
ble ends to contact each other or the engine. Im-
proper jumper cable connections can cause an • Recycling facility
explosion.
i07041934
Always wear protective glasses when working
with batteries. Belt - Inspect/Adjust/Replace
SMCS Code: 1357-510; 1357-025; 1357-040; 1397-
1. Turn all the switches to the OFF position. Turn the 510; 1397-025; 1397-040
engine start switch key to the OFF position.
Note: This engine is equipped with a belt tightener
2. Turn the battery disconnect switch to the OFF
that automatically adjusts the belt to the correct
position. Remove the key. tension.
3. Remove the battery hold-down.
1. Unlatch the engine hood and raise the engine
Note: The machine may contain more than one set of hood.
batteries.
4. Disconnect the negative battery cable at the

battery.
5. Disconnect the positive battery cable at the
battery.
6. Disconnect the battery cable at the battery
disconnect switch.
7. Inspect the battery terminals for corrosion. Clean
the battery terminals and the surfaces of the
batteries with a clean cloth.
8. Inspect the battery cables for wear or damage.
M0111427-02 261
Maintenance Section
Boom and Stick Linkage - Lubricate
i07531958
Boom and Stick Linkage -

Lubricate
SMCS Code: 6501-086; 6502-086
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.
Apply lubricant through all fittings after operation
under water.
(A) New belt Wipe all fittings before you apply lubricant.
(B) Worn belt
2. Inspect the condition of the serpentine belt. Over

time the belt ribs will lose material (C). The space
between the ribs will increase (D). The loss of
material will cause the pulley sheave to contact
the belt valley. This will lead to belt slippage and
accelerated wear (E). Replace the belt if the belt is
worn or frayed.
3. If the belt requires replacement, perform Step 3a
through Step 3f.
a. Remove the upper fan guard.
1. Apply lubricant through the fitting at the base of

each boom cylinder.
b. Rotate the belt tensioner clockwise to remove

the belt.
c. Remove the belt.
d. Install a new belt. Illustration 461 g06183534
e. Rotate the belt tensioner clockwise to install the

belt. Note: Your machine may have the fittings mounted in
a vertical position as shown in the illustration above,
f. Install the upper fan guard. or your machine may have the fittings mounted in a
horizontal position.
g. Lower the engine hood and latch the engine
hood.
262 M0111427-02
Maintenance Section
Bucket Linkage - Inspect/Adjust
2. The fittings are at the base of the boom. The

fittings can be serviced from the platform on the
fuel tank. To lubricate the lower boom bearings,
apply lubricant through fittings (1) and (2).
3. Apply lubricant through fittings (3) and (4) for the
boom cylinder rod.
4. Apply lubricant through fitting (5) for the stick
cylinder head.
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 attachment is suspended. Then apply
lubricant when the boom is lowered and the
attachment is rested on the ground with a slight
downward pressure. 6. Apply lubricant through fitting (7) on the stick
cylinder rod. Apply lubricant through fitting (8) at
the connection point of the boom and of the stick.
Apply lubricant through fitting (9) at the bucket
cylinder head end.
i06980273
Bucket Linkage - Inspect/

Adjust
SMCS Code: 6513-025; 6513-040
Unexpected machine movement can cause injury

or death.
To avoid possible machine movement, move the
5. Apply lubricant through fitting (6). Fitting (6) is at hydraulic lockout control to the LOCKED position
the connection point of the boom and of the stick. 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-
ring seals.
M0111427-02 263
Maintenance Section
Bucket Linkage - Lubricate
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 (4) and the bucket boss (6) are in full face
contact at no gap (5). 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 (7), which is the
existing total clearance.
5. Determine the number of shims that need to be
removed from shims (2) by using the following
Area for linkage adjustment calculation:
Subtract 0.5 mm (0.02 inch) or 1.0 mm
(0.04 inch) from bucket clearance (7).
6. Remove the appropriate number of shims at
location (8) to meet the above thickness. Make
sure that you use a minimum of three 0.5 mm
(0.02 inch) shims. To remove the shims, remove
bolts (9), washers (10), and plate (11).
7. After the correct number of shims has been
removed and pin (1) is aligned with the pin hole,
install plate (11), bolts (9), and washers (10).
Tighten the bolts to 240 ± 40 N·m (175 ± 30 lb ft).
8. After installation, make sure that bucket clearance
(7) is still correct.
i06970647
Bucket Linkage - Lubricate

SMCS Code: 6513-086
(1) Pin Note: Caterpillar recommends the use of 5%
(2) Shims molybdenum grease for lubricating the bucket
(3) Flange linkage. Refer to Special Publication, SEBU6250,
(4) Stick boss “Caterpillar Machine Fluids Recommendations” for
(5) No gap
(6) Bucket boss
more information on grease.
(7) Bucket clearance
(8) Location Wipe all fittings before you apply lubricant.
(9) Bolts
(10) Washers
(11) Plate
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
excessive, adjust bucket clearance (7) to 0.5 to 1 mm
(0.02 to 0.04 inch).
Two shims of different thickness are used at location
(8). The thicknesses of the shims are 0.5 mm
(0.02 inch) and 1.0 mm (0.04 inch).
264 M0111427-02
Maintenance Section
Bucket Tips - Inspect/Replace

Acceptable wear
Note: Completely fill all cavities of the bucket control

linkage with grease when you initially install a bucket.
1. Apply lubricant through fittings for the linkages (1),

(2), (3), and (4).
2. Apply lubricant through fittings for the bucket (5),
(6), and (7).
Note: Service the above fittings after you operate the
bucket under water. Illustration 468 g01055196
Replace this bucket tip.
i08059817
Check the bucket tips for wear. If the bucket tip has a
Bucket Tips - Inspect/Replace hole, replace the bucket tip.
SMCS Code: 6805-510; 6805-040 Removal Procedure
Personal injury or death can result from bucket Retainer pin, when struck with force, can fly out
falling. and cause injury to nearby people.
Block the bucket before changing bucket tips or Make sure the area is clear of people when driv-
side cutters. ing retainer pins.
To avoid injury to your eyes, wear protective
K Series GET Drive-through glasses when striking a retainer pin.
System Bucket Tips
Note: To maximize the life of the bucket tip and the
penetration of the bucket tip, the bucket tip can be
rotated.
M0111427-02 265
Maintenance Section

(1) Bucket tip Proper location for installing the retainer
(2) Retainer
(3) Adapter
3. The retainer can be installed from the top of the
Note: Retainers are often damaged during the bucket tip or from the bottom of the bucket tip. Use
removal process. Caterpillar recommends the a hammer and a 1 inch X 1 inch X 8 inch steel bar
installation of a new retainer when bucket tips are stock to drive retainer (2) into adapter (3).
rotated or replaced.

Illustration 470 g01054386 Internal View
Internal view The latch of the retainer is properly seated in the
recess of the bucket tip.
1. Use a hammer and a punch to drive out the
retainer. The retainer can be removed from the top
of the bucket tip or from the bottom of the bucket
tip.
2. Remove the bucket tip from the adapter with a
slight counterclockwise rotation.
Installation Procedure
1. Clean the adapter, if necessary.
2. Install the new bucket tip or the rotated bucket tip
onto the adapter with a slight clockwise rotation.
266 M0111427-02
Maintenance Section
1. Remove the pin from the bucket tip. The pin can be
removed by one of the following methods.
• Use a hammer and a punch from the retainer

side of the bucket to drive out the pin.
• Use a Pin-Master. Follow Step 1a through Step

1c for the procedure.

A properly installed retainer does not extend beyond
the ear of the bucket tip.
4. The retainer is properly seated if the retainer can

be moved slightly by the technicians hand. If the
retainer cannot be moved, adjust the retainer, as
needed. The ends of the retainer should not
extend beyond the ear of the bucket tip. Illustration 475 g06214793
(4) Back of Pin-Master
(5) Extractor
J Series GET Bucket Tips
a. Place the Pin-Master on the bucket tip.
b. Align extractor (5) with the pin.
Block the bucket before changing the bucket c. Strike the Pin-Master at the back of the tool (4)
teeth.
and remove the pin.
To prevent possible injury to the eyes, wear a pro-
tective face shield when striking the pin. Note: Discard the old pin and the retainer
assembly. When you change tips, use a new pin
The pin, when struck, can fly out and cause injury and a new retainer assembly. Refer to the
to nearby personnel. appropriate parts manual for your machine.

(1) Usable tip
(2) Replaceable bucket tip
(3) Overworn tip
hole, replace the bucket tip.
M0111427-02 267
Maintenance Section
• From the same side of the retainer, drive the

pin through the bucket tip, the retainer
assembly, and the adapter.
• Use a Pin-Master. Follow Step 5a through Step

5e for the procedure.

(6) Retainer assembly (8) Pin
(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.
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
back of the tool (4) to insert the pin.
4. Install the new bucket tip onto the adapter. d. Slide pin holder (9) away from the pin and
rotate the tool slightly to align pin setter (10)
Note: The bucket tips can be rotated by 180 degrees
to allow the tip to wear evenly. You may also move with the pin.
the tips from the outside teeth to the inside teeth.
Check the tips often. If wear is present on the tips,
rotate the tips. The outside teeth generate the most
wear.
5. Drive the pin through the bucket tip. The pin can be
installed by using one of the following methods:
268 M0111427-02
Maintenance Section
Removal

Final assembly of pin into bucket tip
e. Strike the end of the tool until the pin is fully (1) Bucket Tip
inserted. (2) Retainer
(3) Adapter
(4) Compression Sleeve
Bucket Tips (Cat® Advansys ) - If
Equipped 1. Use a 1/2" ratchet and rotate the retainer (2) 180
degrees to the unlocked position.
2. Remove the bucket tip (1) from adapter (3).
3. Clean adapter (3).
Installation
1. Clean the adapter and the area around the latch, if
necessary.
2. Install the new bucket tip (1) onto the adapter (3).

(1) Usable tip
(2) Replaceable bucket tip
(3) Overworn tip
hole, replace the bucket tip.
M0111427-02 269
Maintenance Section
3. Use a 1/2" ratchet to rotate the retainer (2) 180

degrees to the locked position.
Side Cutters
(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.

5. Make sure that there is not a gap between the side
plate on the bucket and the shear ledge on the
side cutter.
Bucket With Side Cutters 6. Torque the mounting bolts to the correct
specification.
1. Remove the mounting bolts and the side cutters
(11). Side Protectors (If Equipped)
2. Clean the mounting surface of the side plate on the Inspect the wear of the side protector. When too
bucket and of the side cutter. Remove any burrs or much wear is present, replace the protector.
protrusions on the mating surfaces.
270 M0111427-02
Maintenance Section
Cab Air Filter (Fresh Air) - Clean/Replace
1. Hit pin (17) from the side of the bucket without the
retainer to remove side protector (16) from side
plate (14).
2. Clean side protector (16), pin (17), retainer(15),
and side plate (14) before installation.
Note: Lateral clearance between the side plate and
the side protector should not exceed 1 mm
(0.04 inch). Shims (18) may be required to decrease
the lateral clearance which will decrease movement.
Install the shims between the side plate and the side
protector on the opposite side of the retainer.
3. Put retainer (15) in side plate (14).

4. Align two pin holes of the new protector and the
side plate. Hit the pin from the retainer side of the
bucket.
Note: If the pin and/or the retainer are worn, replace
the pin and/or the retainer.
i07092323
Cab Air Filter (Fresh Air) -

Clean/Replace
SMCS Code: 7342-070; 7342-510
The cab air filter is on the left side of the cab.
1. Use the ignition key to open the access panel.
2. Remove air filter (1).

3. Tap the air filter to remove the dirt. Do not use
compressed air to clean the filter.
(14) Side plate
(15) Retainer 4. After you clean the air filter, inspect the air filter. If
(16) Side protector
(17) Pin
the air filter is damaged or badly contaminated,
(18) Shim use a new air filter.
5. Install the air filter.
6. Close and lock the access panel.
M0111427-02 271
Maintenance Section
Camera - Clean
i07243995 If necessary, use a damp cloth to clean the glass of

the camera. The camera is sealed. The camera is not
Camera - Clean affected by a wash with high-pressure spray.
SMCS Code: 7348-070 Note: Alternatively, cameras may be cleaned from

ground level by using a wash with a high-pressure
spray or a damp rag on a wand.
Failure to use an appropriate external ladder or

an appropriate platform for direct access to the
rear view camera could result in slipping and fall-
ing which could result in personal injury or death.
Be sure to use an appropriate external ladder or
an appropriate platform for direct access to the
rear view camera.
The machine's counterweight and the engine
hood are not approved as a maintenance
platforms.
Unexpected machine movement can cause injury

or death.
In order to avoid possible machine movement,
move the hydraulic lockout control to the
LOCKED position and attach a Special Instruc-
tion, SEHS7332, “Do Not Operate” or similar
warning tag to the hydraulic lockout control.
If equipped, clean the right side view camera.

Note: When you access the camera for cleaning, be
sure to observe safe procedures for access. Maintain
a three-point contact and/or use a body harness.
If equipped, clean the left side view camera.

The rear view camera is on top of the counterweight.

272 M0111427-02
Maintenance Section
Condenser (Refrigerant) - Clean
2. Inspect the condenser for debris. Clean the

condenser, if necessary.
3. Use clean water to wash off all dust and dirt from
the condenser.
If equipped, clean the front view camera.
i06971000
i06969907
Condenser (Refrigerant) - Cooling System Coolant (ELC)

Clean - Change
SMCS Code: 1350-044
SMCS Code: 1805-070
NOTICE
If excessively dirty, clean condenser with a brush. To Engine hood and engine hood parts can be hot
prevent damage or bending of the fins, do not use a while engine is running or immediately after en-
stiff brush. gine shutdown. Hot parts or hot components can
Repair the fins if found defective. cause burns or personal injury. Do not allow
1. Open the access door on the left side of the

machine. The condenser is located in front of the
radiator.
M0111427-02 273
Maintenance Section
Cooling System Coolant (ELC) - Change
Personal injury can result from hot coolant,

steam and alkali.
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines to
heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove cooling system pressure cap slowly to
relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
touch with your bare hand.
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
NOTICE Illustration 495 g06225770

Do not change the coolant until you read and under-
stand the cooling system information in Special Publi-
cation, SEBU6250, “Caterpillar Machine Fluids 1. Unlatch the engine hood and raise the engine
Recommendations”. hood.
Failure to do so could result in damage to the cooling

system components.
NOTICE
Mixing ELC with other products will reduce the effec-
tiveness of the coolant.
This could result in damage to cooling system
components.
If Caterpillar products are not available and commer-
cial products must be used, make sure they have
passed the Caterpillar EC-1 specification for pre-
mixed or concentrate coolants and Caterpillar
Extender.
Note: This machine was filled at the factory with Cat

Extended Life Coolant.
If the coolant in the machine is changed to Extended
Life Coolant from another type of coolant, see
Special Publication, SEBU6250, “Caterpillar Machine Illustration 496 g06183808
Fluids Recommendations”.
2. Slowly loosen the pressure cap that is on the
coolant reservoir to release pressure from the
cooling system.
3. Remove the pressure cap.
4. Inspect the gasket on the pressure cap. If the
gasket is damaged, replace the pressure cap.
274 M0111427-02
Maintenance Section
Cooling System Coolant (ELC) - Change
g. Open the drain valve that is on the bottom of

the radiator and allow the coolant to drain into a
suitable container.
h. Flush the radiator with clean water until the
draining water is transparent.
8. Close the drain valve.
9. Add the Extended Life Coolant. Refer to the
following topics:
• Special Publication, SEBU6250, “Caterpillar

Machine Fluids Recommendations”
• Operation and Maintenance Manual,

Illustration 497 g06179792 “Capacities (Refill)”
5. Open the rear access door on the left side of the 10. After the cooling system has been filled, perform
machine. the following procedures during initial start-up:
a. Start the engine without the filler cap.
b. Run the engine at low idle for 10 minutes.
c. Then, increase the engine speed to a high idle
until the water temperature regulator is open
and the coolant level is stabilized.
d. Maintain the coolant at the proper level as the
water temperature regulator opens and air is
purged from the system. Refer to Operation and
Maintenance Manual, “Cooling System Coolant
Level - Check”.
11. Install the cooling system pressure cap.
12. Stop the engine.
6. Open the drain valve and allow the coolant to drain

into a suitable container. The drain valve is on the
bottom of the radiator.

“General Hazard Information” for information that
pertains to containing fluid spillage.
7. Flush the cooling system. Follow Step 7a through

Step 7h to flush the cooling system.
a. Close the drain valve.
b. Fill the cooling system with clean water.
c. Install the pressure cap.
d. Start the engine and run the engine until the
engine reaches operating temperature.
e. Stop the engine and allow the engine to cool.
f. Loosen the pressure cap slowly to relieve any
pressure in the cooling system.
M0111427-02 275
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
Personal injury can result from hot coolant,

steam and alkali.
At operating temperature, engine coolant is hot
heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
relieve pressure only when engine is stopped and
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.
Use Cat Extended Life Coolant (ELC) when you add
coolant to the cooling system. See Special
Publication, SEBU6250, “Caterpillar Machine Fluids
Recommendations” for all cooling system
13. Check the coolant reservoir. Maintain the coolant requirements.
level so that coolant is between the “ADD” and
“FULL” lines. If more coolant is needed, see Use a Coolant Conditioner Test Kit to check the
concentration of the coolant.
Operation and Maintenance Manual, “Cooling
system Coolant Extender (ELC) - Add”.
NOTICE
14. If more coolant is necessary, remove the Mixing ELC with other products will reduce the effec-
tiveness of the coolant.
pressure cap and add the appropriate coolant
solution. This could result in damage to cooling system
components.
15. Install the pressure cap.
If Caterpillar products are not available and commer-
16. Close and latch the engine hood. Close the left cial products must be used, make sure they have
access door. passed the Caterpillar EC-1 specification for pre-
mixed or concentrate coolants and Caterpillar
i06972485 Extender.
Cooling System Coolant

Note: This machine was filled at the factory with Cat
Extender (ELC) - Add Extended Life Coolant.
SMCS Code: 1352; 1353; 1395
1. Park the machine on level ground.
2. Stop the engine.

276 M0111427-02
Maintenance Section
Cooling System Coolant Level - Check
5. You may need to drain some coolant from the

radiator so that Cat Extender can be added to the
cooling system.
Note: Always discard drained fluids according to
local regulations.
6. Add Cat Extended Life Coolant (ELC) to the

cooling system. Refer to the following topics for
the proper amount of Cat Extender:
• Special Publication, SEBU6250, “Caterpillar

Machine Fluids Recommendations”
• Operation and Maintenance Manual,

“Capacities (Refill)”
7. Inspect the o-ring of the cooling system pressure

cap. If the o-ring is damaged, replace the pressure
cap.
8. Install the cooling system pressure cap.
9. Close and latch the engine hood.
3. Unlatch the engine hood and raise the hood.
i07038988
Cooling System Coolant Level

- Check
SMCS Code: 1350-535-FLV; 1350-040; 1395-535-
FLV

4. Make sure that the cooling system has cooled

down. Loosen the cooling system pressure cap
slowly to relieve system pressure. Remove the
pressure cap.

containing fluid spillage.
M0111427-02 277
Maintenance Section
Cooling System Coolant Sample - Obtain
i07836536
Personal injury can result from hot coolant, Cooling System Coolant
steam and alkali. Sample - Obtain
At operating temperature, engine coolant is hot SMCS Code: 1395-554; 1395-008
heaters or the engine contain hot coolant or The cooling system coolant should be sampled and
steam. Any contact can cause severe burns. monitored with regular frequency. The samples
should be analyzed per the following guidelines:
relieve pressure only when engine is stopped and • Level 1 analysis: Every 250 hours
touch with your bare hand. • Level 2 analysis: Every Year
Do not attempt to tighten hose connections when Note: It is not necessary to obtain a Coolant
the coolant is hot, the hose can come off causing Sample (Level 1) if the cooling system is filled
burns. with Cat ELC (Extended Life Coolant). Cooling
Cooling System Coolant Additive contains alkali. systems that are filled with Cat ELC only require
Avoid contact with skin and eyes. Level 2 analysis.
Note: Obtain a Coolant Sample (Level 1) if the
1. Park the machine on level ground. cooling system is filled with any other coolant
instead of Cat ELC. This includes the following
2. Stop the engine. types of coolants.
3. Open the rear access door on the left side of the
• Commercial long life coolants that meet the
machine.
Caterpillar Engine Coolant Specification -1
(Caterpillar EC-1)
• Cat Diesel Engine Antifreeze/Coolant (DEAC)

• Commercial heavy-duty coolant/antifreeze
Note: A level 1 analysis may indicate the need for

a Level 2 analysis.
Note: A Level 2 analysis is required after 500
hours of operation for the following reasons:
• The cooling system is new
• The cooling system has been refilled

• The cooling system has been converted to a new
coolant
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sam-
pling. Using the same pump for both types of sam-
Illustration 502 g06205196 ples may contaminate the samples that are being
drawn. This contaminate may cause a false analysis
4. Maintain the coolant level so that coolant is and an incorrect interpretation that could lead to con-
cerns by both dealers and customers.
between the “ADD” and “FULL” marks. If more
coolant is needed, see Operation and
Maintenance Manual, “Cooling system Coolant
Extender (ELC) - Add”.
278 M0111427-02
Maintenance Section
Engine Air Filter Primary and/or Secondary Element - Replace
• Complete the information on the label for the

NOTICE
Care must be taken to ensure that fluids are con- sampling bottle before you begin to take the
tained during performance of inspection, mainte- samples.
Be prepared to collect the fluid with suitable contain- • Keep the unused sampling bottles stored in plastic
ers before opening any compartment or disassem- bags.
• Obtain coolant samples directly from the coolant
Refer to Special Publication, PERJ1017, “Dealer sample port. You should not obtain the samples
Service Tool Catalog” for tools and supplies suitable from any other location.
• Keep the lids on empty sampling bottles until you
Dispose of all fluids according to local regulations are ready to collect the sample.
and mandates.
• Place the sample in the mailing tube immediately
after obtaining the sample to avoid contamination.
• Never collect samples from expansion bottles.
• Never collect samples from the drain for a system.

Submit the sample for the appropriate analysis.
For additional information about coolant analysis, see
Special Publication, SEBU6250, “Caterpillar Machine
Fluids Recommendations” or consult your Cat dealer.
i08165097
Engine Air Filter Primary and/

or Secondary Element -
Replace
SMCS Code: 1054-510-PY; 1054-510-SE
Primary Air Filter Element -

Replace
NOTICE
Service the air cleaner only with the engine stopped.
Engine damage could result.
NOTICE
Service the engine air filter elements only when a
message or a warning is displayed on the monitor
display. Do not open the filter compartment unless
service is indicated. Opening the filter compartment
The coolant sampling port is on the radiator. when not necessary to do so increases the chance of
dirt contamination in engine air intake system
Obtain the sample of the coolant as close as possible components.
to the recommended sampling interval. To receive
the full effect of S·O·S analysis, a consistent trend of
data must be established. To establish a pertinent NOTICE
history of data, perform consistent samplings that are Short air filter life can result if the pre-cleaner system
evenly spaced. Supplies for collecting samples can malfunctions. If air filter life is drastically reduced from
be obtained from your Cat dealer. typical for the operating conditions, consult your Cat
dealer.
Use the following guidelines for proper sampling of
the coolant:
M0111427-02 279
Maintenance Section
NOTICE
Do not use the air filter elements longer than 1 year.
The engine air cleaner assembly is located behind

the front access door on the left side of the machine.
1. Park the machine on a level surface. Stop the
engine.
4. Release latches (2) that secure pre-cleaner (3) to

engine air filter housing (6).
5. Remove pre-cleaner (3).
6. Clean inside the air filter housing where the pre-
cleaner was removed.
NOTICE
2. Open the front access door on the left side of the Caterpillar does not recommend cleaning the primary
machine. air filter element. Caterpillar only recommends to re-
place the primary air filter element. Caterpillar does
not cover costs for damage to engine components
caused by cleaning the primary air filter element.
Observe the following guidelines if you attempt to
clean the primary 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 500 kPa (73 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage
to the pleats.
Do not clean the air filter element more than three
3. Squeeze outlet tube (1) to purge the dirt from the times. The air filter element must be replaced if the fil-
ter has been in use for one year, regardless of the
outlet tube. number of times the filter has been cleaned.
Note: Purge the dirt from the outlet tube every 10 Do not use air filters with damaged pleats, gaskets,
service hours or daily in a dirty environment. or seals. Dirt entering the engine will cause damage
to engine components.
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.
280 M0111427-02
Maintenance Section
7. Remove primary air filter element (4). Replace the 2. Refer to the section “Primary Air Filter Element -
filter element as necessary. Replace”. Remove the pre-cleaner from the
engine air filter housing. Remove the primary air
Note: Replace the primary filter if the filter has been filter element from the air filter housing.
in use for 1 year.
8. Clean inside the air filter assembly housing.
Note: Do not allow any dirt or debris to contact the

secondary air filter element (5).
9. Inspect the seal area ensure that no foreign debris

has fallen into the seal area. Clean the air cleaner
interior to remove remaining dust or debris
10. Without removing secondary air filter element (5),
inspect the filter element for damage. Replace if
necessary or dirty. Refer to Secondary Air Filter
Element - Replace.
11. Install the secondary air filter element.
12. Install the primary filter.
3. Secondary air filter element (5) is pressed into the
Note: Filters must be fully installed before the pre-
rear portion of engine air filter housing (6). Pull
cleaner can be attached. If the pre-cleaner cannot be
fully latched, verify that the filter elements are forward on the secondary air filter element to
properly seated. remove the element from the engine air filter
housing.
13. Install the pre-cleaner and secure the latches that
4. Cover the air inlet opening. Clean inside the air
hold the pre-cleaner to the air filter housing.
cleaner housing.
5. Clean all surfaces of the pre-cleaner cover and
body.
Secondary Air Filter Element -
6. Uncover the air inlet opening.
Replace
7. Carefully press the secondary air filter element into
NOTICE the rear portion of the engine air filter housing.
Always replace the secondary element. Do not at-
tempt to reuse it by cleaning. Engine damage could Note: Be certain that the new secondary air filter
result. element is properly seated in the filter housing. Also,
check to see that no damage to the filter element has
occurred during installation.
NOTICE
Do not use the air filter elements longer than 1 year. 8. Install the primary air filter element and the pre-
cleaner.
NOTICE
Replace the secondary filter element when you serv-
ice the primary element for the third time. If a clean Engine Air Pre-Cleaner - Clean
primary element has been installed and the filter ele-
ment indicator is still flashing, replace the secondary Note: Do not attempt to clean the pre-cleaner by
filter element. Also if the exhaust smoke remains hitting the filter against another object. Damage to
black and a clean primary filter element has been in- the filter is likely to occur.
stalled, replace the secondary filter element.
1. Open the front access door on the left side of the

machine.
M0111427-02 281
Maintenance Section
2. Lift the locking tabs on one end of the cover away

from the retainers. Move the locking tabs only far
enough to clear the retention posts.
Illustration 509 g06183310 Note: Do not bend the locking tabs farther than
necessary to release the tabs. Damage to the air
After removing the pre-cleaner from the air filter cleaner can result. Do not use tools to force the snap
housing, inspect the interior of the pre-cleaner features off the retainers.
through the ejection ports around the perimeter.
3. Pull one end of the top cover away from the bottom
In general, dust and debris will clear automatically half.
through normal pre-cleaner operation and no further
service will be required. 4. Hold one end of the cover sections apart and
separate one of the locking tabs on the other end
If the ejection ports are blocked, or dust is packed
between the pre-cleaner tubes, first try to clear any of the pre-cleaner.
accumulation by vigorously shaking the pre-cleaner.
If the pre-cleaner is still blocked with dirt, the pre-
cleaner may be separated by releasing the snap
features holding the front cover to the pre-cleaner
body.
5. Pull the top cover up and away from the bottom.

6. Clear any blockage by shaking the pre-cleaner
components and/or brushing away accumulated
Illustration 510 g06069263 debris.
1. Place the pre-cleaner assembly on a suitable work Note: Do not use picks or other stiff implements to
surface. The interior of the pre-cleaner may have clear debris, you may damage the pre-cleaner
accumulated debris. Protect your work surface to components
collect excess debris and to avoid scattering
debris.
282 M0111427-02
Maintenance Section
Engine Oil Level - Check
Note: Do not attempt to remove the pre-cleaner 11. Before installing the pre-cleaner to the air filter
tubes from the top cover or you will damage the air housing, inspect the pre-cleaner gasket for
cleaner. damage. Replace if damaged.
7. If the blockage is still not cleared, you may attempt
i06970869
to clear the debris by use of an air nozzle limited to
500 kPa (73 psi). Engine Oil Level - Check
Alternately, each part of the pre-cleaner may be SMCS Code: 1000-535
submerged in water to loosen mud or other debris
that may have dried on the interior surface of the
air cleaner.
Note: Never attempt to use a pressure washer or injury. Do not allow hot oil or hot components to
other high-pressure water sources to clean the pre- contact skin.
cleaner. Use of high-pressure water may damage the
pre-cleaner tubes and reduce the pre-cleaner
effectiveness. NOTICE
Do not overfill the crankcase. Engine damage can
8. After cleaning, reassemble the pre-cleaner by result.
lining up the tubes on the pre-cleaner top with the
tubes in the pre-cleaner bottom. This machine is equipped with both an automated
function for checking fluid levels and dipsticks. Refer
9. Allow the pre-cleaner top to rest on the pre-cleaner to Operation and Maintenance Manual, “Monitoring
bottom and ensure that the four snap features are System” regarding the automated system. If the
aligned. machine is on an incline or the engine has been
stopped only for a short time, all engine oil may not
be in the crankcase. The fluid level cannot be
properly checked by either method during these
instances. Park the machine on level ground. The
engine oil level can be checked after the engine has
been stopped for at least 30 minutes. Do not check
the oil level while the engine is running.
The machine is equipped with a ground level dipstick
and a dipstick on top of the engine.
10. If all the tabs are aligned, gently push the pre-
cleaner top down into place. Ensure that all the
snap features have engaged.
1. Open the access door on top of the machine.

M0111427-02 283
Maintenance Section
Engine Oil Level - Check
Ground Level Dipstick
2. Remove dipstick (1). Wipe the oil off the dipstick Illustration 517 g06182545
and reinsert the dipstick.

To access the ground level dipstick, open the right
access door.
3. Remove the dipstick and check the dipstick. The

oil level should be between the “L” mark and the
“H” mark.
NOTICE
Operating your engine when the oil level is above the
“H” mark could cause the crankshaft to dip into the
oil. This could lead to excessively high oil tempera-
tures which can reduce the lubricating characteristics
of the oil, lead to bearing damage, and could result in
loss of engine power.

Containing Fluid Spillage.
4. Remove oil filler plug (2) to add oil, if necessary.

See Operation and Maintenance Manual,
Note: If the oil is deteriorated or badly contaminated,
change the oil regardless of the maintenance
interval.
5. Clean the oil filler plug. Install the oil filler plug.
284 M0111427-02
Maintenance Section
Engine Oil Sample - Obtain
i08290580
Engine Oil and Filter - Change

SMCS Code: 1318-510
NOTICE
The engine oil and filter change interval for standard
service application is every 1000 hours when the fol-
lowing requirements are met:
• Utilize Cat Recommended Fluids

• Utilize Cat Filters
• Utilize S·O·S Services at recommended interval

When these requirements are not met, the oil and fil-
The ground level dipstick is located near the engine ter change interval should be every 500 hours, or use
oil filter and main hydraulic pump. S·O·S Services oil sampling and analysis program to
determine an acceptable oil change interval.
i07088417
If you select an interval for oil and filter change that is
too long, you may damage the engine.
Engine Oil Sample - Obtain
SMCS Code: 1000-008; 1000; 1348-008; 1348-554-
SM; 7542-554-SM; 7542-008; 7542-554-OC NOTICE
When operating in any of the conditions or environ-
ments outlined in this Operation and Maintenance
Manual, Severe Service Application, use S·O·S Serv-
ices oil analysis to determine the best oil and filter
change interval.
When S·O·S Services are not used in severe service
applications, the oil and filter change interval should
be every 250 hours..
If you select an interval for oil and filter change that is
too long, you may damage the engine.
Reference: Operation and Maintenance Manual,

“Lubricant Viscosities”
“Maintenance Interval Schedule”
“Severe Service Application”

“S·O·S Information”
Use the table below to determine the appropriate
Obtain a sample of the engine oil from the engine oil oil and filter change interval.
sampling valve that is located on the engine oil filter
housing. Refer to Special Publication, SEBU6250,
“S·O·S Oil Analysis” for information that pertains to
obtaining a sample of the engine oil. Refer to Special
Publication, PEGJ0047, “How To Take A Good Oil
Sample” for more information about obtaining a
sample of the engine oil.
M0111427-02 285
Maintenance Section
Table 29
Selection of Oil and Filter Change Interval
Conditions
Cat Recommended Interval
Cat Filters S·O·S Services
Fluids
YES YES YES 1000 hours
YES YES NO 500 hours
Standard Service
YES NO YES 500 hours
Application
NO YES YES 500 hours
NO NO NO 250 hours
NO NO NO 250 hours
YES YES NO 250 hours
Severe Service
YES YES YES Use S·O·S(1)
Application
YES NO YES Use S·O·S(1)
NO YES YES Use S·O·S(1)

(1) If operating in any of the conditions or environments outlined in the Severe Service Application, use S·O·S Services oil analysis to determine
the best oil change interval.
Note: Initial oil and filter change is required at initial

500 hours.
Procedure for Changing Engine Oil

and Filter

contact skin.
Note: If the sulfur content in the fuel is greater than

1.5 percent by weight, use an oil that has a TBN of 30 Illustration 520 g06183508
and reduce the oil change interval by one-half.
Note: Drain the crankcase while the oil is warm. This 2. Open the crankcase drain valve. Allow the oil to
allows waste particles that are suspended in the oil to drain into a suitable container.
drain. As the oil cools, the waste particles will settle
to the bottom of the crankcase. The particles will not Note: Discard any drained fluids according to local
be removed by draining the oil and the particles will regulations.
recirculate in the engine lubrication system with the
3. Close the drain valve.
new oil.
1. Prepare the machine for maintenance. Refer to

“Prepare the Machine for Maintenance“.
Note: Refer to “General Hazard Information“ for

information on Containing Fluid Spillage.
286 M0111427-02
Maintenance Section
4. Open the access door at the right side of the

machine.
7. Remove the filter from the housing.

8. Clean the filter housing and the base thread.
9. Install the new filter element into the housing.
10. After installing the new element, hand tighten the
drain valve at the bottom of the housing.
5. Loosen drain valve and allow the oil to drain out of

the housing. The drain valve is on the bottom of
the engine oil filter housing.
Note: If equipped with a fast fill system, the oil can be

drained and filled using the fast fill coupler. Refer to
“Fast Fill (If Equipped)” in this chapter.
6. Remove the oil filter housing. Refer to Operation

and Maintenance Manual, “Oil Filter - Inspect”.
Dispose of the used filter according to local
regulations.
M0111427-02 287
Maintenance Section
15. Open the access door on top of the machine.

Refer to “Access Door and Cover Locations“.
11. Apply a thin coat of engine oil to the gasket of the

filter. Refer to Illustration 524 for lubrication points
on the gasket.
12. Install the filter housing with element to the filter
base utilizing a socket wrench. Illustration 526 g06614930
(1) Oil level gauge
Note: Apply a tightening torque of 90 N·m (66 lb ft) (2) Oil filler cap
and tighten until metal to metal contact is achieved.
16. Remove oil filler cap (2). Fill the crankcase with
13. Re-tighten the drain valve to a torque of 2.5 N·m new oil. Refer to Operation and Maintenance
(22.1 lb in). Manual, “Capacities (Refill)”. Clean the oil filler cap
14. Close the access door. and install the oil filler cap.
NOTICE
Do not under fill or overfill engine crankcase with oil.
Either condition can cause engine damage.
17. Start the engine and allow the oil to warm. Refer
to Operation and Maintenance Manual, “Engine
Starting”. Check the engine for leaks. Stop the
engine.
288 M0111427-02
Maintenance Section
Engine Valve Lash - Check
18. Wait for 30 minutes to allow the oil to drain back

into the crankcase. Check the oil level with oil level
gauge (1). Maintain the oil between the “L” and “H”
marks on the oil level gauge. If necessary, add oil.
2. Remove the dust cover.
Fast Fill (If Equipped)
3. Attach a hose that is equipped with a nozzle.
If your machine is equipped with a deluxe service
center, you may drain and add the engine oil through Note: Make sure that the nozzle and the receiver are
the fast fill port. free from debris before attaching.
4. Drain the oil or add the oil, as needed.

5. Install the dust cover.
1. Open the access door on the right side of the

machine. Illustration 530 g06211545
6. Verify that the correct amount of oil was added and

add or remove oil as necessary. A ground level oil
level gauge is located in the same compartment
as the fast fill port.
i01747875
Engine Valve Lash - Check

SMCS Code: 1102; 1102-535; 1102-082; 1105-535;
1105-025; 1121-535; 1209-082; 1209; 1209-535;
7527
Refer to Engine Systems Operation/Testing and
Adjusting in order to perform the complete procedure
for the valve lash adjustment.
M0111427-02 289
Maintenance Section
Ether Starting Aid Cylinder - Replace
i07051358
Ether Starting Aid Cylinder -

Replace
(If Equipped)
SMCS Code: 1456-510-CD
Breathing ether vapors or repeated contact of

ether with skin can cause personal injury. Per-
sonal injury may occur from failure to adhere to
the following procedures.
Use ether only in well ventilated areas.
Do not smoke while changing ether cylinders.
Use ether with care to avoid fires.
Do not store replacement ether cylinders in living
areas or in the operator's compartment. Illustration 532 g06211094
Do not store ether cylinders in direct sunlight or 2. Loosen the cylinder retaining clamp.
at temperatures above 49 °C (120 °F).
3. Unscrew the empty ether starting aid cylinder and
Discard cylinders in a safe place. Do not puncture remove the empty ether starting aid cylinder.
or burn cylinders.
Keep ether cylinders out of the reach of unauthor-
ized personnel.
The ether cylinder is located inside the rear access

door on the left side of the machine.
Refer to Operation and Maintenance, “Fire
Prevention and Explosion Prevention” before you
replace the ether cylinder.
4. Remove the used gasket.

5. Install a new gasket.
1. Open the rear access door at the left side of the
Note: A new gasket and O-ring is provided with each
machine. new ether starting aid cylinder.
6. Install the new ether starting aid cylinder.

7. Tighten the ether starting aid cylinder hand tight.
290 M0111427-02
Maintenance Section
Film (Product Identification) - Clean
8. Tighten the cylinder retaining clamp securely. Excessive pressure during power washing can
damage the product identification films by forcing
9. Close the access door. water underneath the product identification films.
Water lessens the adhesion of the product
i07786001 identification film to the product, allowing the product
identification film to lift or curl. These problems are
Film (Product Identification) - magnified by wind. These problems are critical for the
perforated film on windows.
Clean
To avoid lifting of the edge or other damage to the
SMCS Code: 7405-070; 7557-070 product identification films, follow these important
steps:
• Use a spray nozzle with a wide spray pattern.

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

• Hold the nozzle perpendicular to the product
identification film at a minimum distance of
305 mm (12 inch).
• Do not direct a stream of water at a sharp angle to
the edge of the product identification film.
i06969803

Final Drive Oil - Change
Cleaning of the Films SMCS Code: 4050-044-FLV
Make sure that all the product identification films are

legible. Make sure that the recommended
procedures are used to clean the product Hot oil and hot components can cause personal
identification films. Ensure that all the product injury. Do not allow hot oil or hot components to
identification films are not damaged or missing. contact skin.
Clean the product identification films or replace the
films.
Hand Washing
Use a wet solution with no abrasive material that
contains no solvents and no alcohol. Use a wet
solution with a “pH” value between 3 and 11. Use a
soft brush, a rag, or a sponge to clean the product
identification films. Avoid wearing down the surface
of the product identification films with unnecessary
scrubbing. Ensure that the surface of the product
identification films is flushed with clean water and
allow the product identification films to air dry.
Power Washing
Power washing or washing with pressure may be
used to clean product identification films. However,
aggressive washing can damage the product
identification films.

(1) Oil level plug
(2) Oil drain plug
M0111427-02 291
Maintenance Section
Final Drive Oil Level - Check
1. Position one final drive so that oil drain plug (2) is

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
Manual, “Lubricant Viscosities” and Operation and
Maintenance Manual, “Capacities (Refill)”.
Note: If the oil fills slowly, the fill hole may be blocked
by the planetary gear. Rotate the final drive to move Illustration 536 g06182944
the planetary gear away from the fill hole.
(1) Oil level plug
(2) Oil drain plug
Note: Overfilling the final drive will cause the seals
on the travel motor to allow hydraulic oil or water to
enter the final drive. The final drive may become 1. Position one final drive so that oil drain plug (2) is
contaminated. at the bottom.
6. Install level plug (1). Note: Refer to Operation and Maintenance Manual,
7. Perform Step 1 to Step 6 on the other final drive. Containing Fluid Spillage.
Use a different container for the oil so that the oil
samples from the final drives will be separate. 2. Remove oil level plug (1).
8. Completely remove the oil that has spilled onto 3. Check the oil level. The oil should be near the
surfaces. bottom of the level plug opening.
9. Start the machine and allow the final drives to run 4. Add oil through the level plug opening, if
through several cycles. necessary. See Operation and Maintenance,
10. Stop the machine. Check the oil level.
Note: If the oil fills slowly, the fill hole may be blocked
11. Check the drained oil for metal chips or for by the planetary gear. Rotate the final drive to move
particles. If there are any chips or particles, the planetary gear away from the fill hole.
consult your Cat dealer.
Note: Overfilling the final drive will cause the seals
12. Properly dispose of the drained material. Obey on the travel motor to allow hydraulic oil or water to
local regulations for the disposal of the material. enter the final drive. The final drive may become
contaminated.
i06969810
5. Clean oil level plug (1). Inspect the O-ring seal.
Final Drive Oil Level - Check Replace the O-ring seal if the O-ring seal is worn
or damaged.
SMCS Code: 4050-535-FLV
6. Install oil level plug (1).
7. Repeat the procedure for the other final drive.
contact skin.
292 M0111427-02
Maintenance Section
Final Drive Oil Sample - Obtain
i06969816 i07088575
Final Drive Oil Sample - Obtain Fuel Cap Filter - Replace

SMCS Code: 4011-008; 4050-008; 4050-SM; 7542- SMCS Code: 1261-510
008

contact skin.
1. Remove the fuel cap.

2. Remove filter element screws (2) from the
underside of the fuel cap and remove filter
element (1).
3. Install a clean fuel cap filter element.
4. Install the screws to secure the filter element to the
fuel cap.
5. Install the fuel tank cap.

i06674757
(1) Oil level plug
(2) Oil drain plug
Fuel System - Prime
1. Position the final drive so that oil drain plug (2) is at SMCS Code: 1250-548
the bottom.

“General Hazard Information” for information on Fuel leaked or spilled onto hot surfaces or electri-
Containing Fluid Spillage. cal components can cause a fire. To help prevent
possible injury, turn the start switch off when
2. Remove oil level plug (1). changing fuel filters or water separator elements.
Clean up fuel spills immediately.
3. Obtain a sample of the final drive oil through the
hole for the oil level plug.
4. Install oil level plug (1).
Machine Fluids Recommendations” “S·O·S Oil
Analysis” for more information on obtaining a sample
of the final drive oil. For additional information about
taking an oil sample, refer to Special Publication,
PEGJ0047, “How To Take A Good Oil Sample”.
M0111427-02 293
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
i07511456
NOTICE
tained during performance of inspection, mainte- Fuel System Primary Filter
Be prepared to collect the fluid with suitable contain- (Water Separator) Element -
ers before opening any compartment or disassem- Replace
SMCS Code: 1263-510-FQ
Dispose of all fluids according to local regulations Personal injury or death may result from failure
and mandates. to adhere to the following procedures.
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire.
NOTICE
Do not loosen the fuel lines at the fuel manifold. The Clean up all leaked or spilled fuel. Do not smoke
fittings may be damaged and/or a loss of priming while working on the fuel system.
pressure may occur when the fuel lines are loosened.
Turn the disconnect switch OFF or disconnect
the battery when changing fuel filters.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that NOTICE
will be disconnected. Fit a suitable cover over any Do not fill the fuel filters with fuel before installing the
disconnected fuel system components. fuel filters. The fuel will not be filtered and could be
contaminated. Contaminated fuel will cause acceler-
Prime the fuel system in order to fill the fuel filter, and ated wear to fuel system parts.
prime the fuel system in order to purge trapped air.
The fuel system should be primed under the following The primary filter/water separator is located behind
conditions: the access door on the right side of the machine.
• The fuel tank is running low.
• The machine has been stored.

• The fuel filter is being replaced.
1. Turn the engine start switch to the ON position.

Leave the engine start switch in the ON position
for 2 minutes.
2. Verify that the water separator is full of fuel.
3. If the water separator is not full of fuel, turn the
engine start switch OFF and then turn the engine
start switch ON. Turning the engine start switch off
and on will cycle the fuel priming pump again.
4. When the water separator is full of fuel, attempt to
start the engine. If the engine starts and the
engine runs rough or the engine misfires, operate
at low idle until the engine is running smoothly. If
the engine cannot be started, or if the engine
continues to misfire or smoke, repeat Step 1.
294 M0111427-02
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace

Typical example of primary filter water separator
(1) Filter base
(2) Filter
(3) Filter housing
(4) Drain valve
(5) Sensor
2. Turn drain valve (4) counterclockwise to open. The

drain valve is on the bottom of the water separator.
Illustration 540 g06342852 Note: Refer to Operation and Maintenance Manual,

Typical Example “General Hazard Information” for information that
1. Open the rear access door on the right side of the
3. Drain the water and the sediment into a suitable
machine.
container.
Note: Dispose of used fluids according to local
regulations.
4. Close the drain valve (4).

5. Disconnect the water sensor (5) from the harness.
Note: Do not attempt to remove the sediment bowl
from the housing. The sediment bowl is permanently
attached to the housing. Attempting to remove the
sediment bowl may damage the bowl.
6. Unscrew filter housing (3) and remove primary

filter (2). A filter wrench may be used to loosen the
filter housing. Properly discard the used filter.
7. Clean the mounting base (1).
8. Lubricate the seal of the new filter (2) with clean
diesel fuel.
9. Install the new filter (2) into the housing.
M0111427-02 295
Maintenance Section
Fuel System Secondary Filter - Replace
10. Tighten the filter housing approximately 1/6 of a

turn. Do not use tools to tighten the filter housing
to the filter base.
11. Ensure that sensor (5) is in the correct position
and connect to the wiring harness. If the sensor
was removed from the bowl, install the sensor and
tighten to 2.5 ± 0.5 N·m (22 ± 4 lb in).
12. Open the fuel shutoff valve.
i07506478
Fuel System Secondary Filter - Illustration 542 g06182545

Replace
SMCS Code: 1261-510 1. Open access door on the right side of the machine.
2. Shut off the fuel supply. Refer to Fuel Tank Shutoff
and Drain Control for additional information.
Personal injury or death can result from a fire.

Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire.
Clean up all leaked or spilled fuel. Do not smoke
while working on the fuel system.
Turn the disconnect switch OFF or disconnect
the battery when changing fuel filters.
NOTICE
Do not fill fuel filters with fuel before installing them.
Contaminated fuel will cause accelerated wear to fuel
system parts.
Typical Example
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that 3. Loosen drain valve (2) and allow the fuel to drain
will be disconnected. Fit a suitable cover over any out of the housing into a suitable container.
disconnected fuel system components.
4. After all the fuel has been removed, tighten the

drain.
5. Remove the secondary fuel filter housing (1) from
the base.
6. Remove the filter element from the housing.
7. Clean the filter housing and the base.
8. Install the new filter element into the housing.
9. Apply a thin coat of clean diesel fuel to the sealing
surface of the new fuel filter.
296 M0111427-02
Maintenance Section
Fuel System Water Separator - Drain
10. Install the new filter and tighten to 50 +/- 5 N·m

(36.9 +/- 4 ft lb).
11. Turn on the fuel supply.
i06969852
Fuel System Water Separator -

Drain
SMCS Code: 1263
NOTICE
2. Open drain valve (1) on the bottom of the fuel/
Dispose of all fluids according to local regulations water separator element. Drain the water into a
and mandates. suitable container.
3. Close the drain valve when all the water has been
drained.
Note: When water is not drained from the primary
filter sufficiently, water will collect in the secondary
fuel filter. Trapped water will eventually overflow.
Draining water from the secondary fuel filter will
prevent water damaging the fuel system. The
procedure for the secondary filter is the same as the
primary filter.

machine.
M0111427-02 297
Maintenance Section
Fuel Tank Strainer - Clean
i06969894
Fuel Tank Strainer - Clean

SMCS Code: 1273-070-STR
1. Open the right compartment door.

1. Remove fuel tank cap (1).

2. Remove strainer (2) from the filler opening.
3. Wash the strainer in a clean, nonflammable
solvent.
4. Install the strainer into the filler opening.
5. Install the fuel tank cap.
i06954978
2. Open the drain valve by turning the valve
Fuel Tank Water and Sediment counterclockwise. Allow the water and the
- Drain sediment to drain into a suitable container.
SMCS Code: 1273-543 Note: Dispose of drained fluids according to local
regulations.
The drain valve for the fuel tank is located in the right
compartment. 3. Close the drain valve by turning the valve
clockwise.
4. Close the compartment door.
298 M0111427-02
Maintenance Section
Fuses - Replace
i07397104
Fuses - Replace
SMCS Code: 1417-510
The fuse panel is on the left side of the interior

storage box. Remove the cover to access the fuses.
Fuses – Fuses protect the electrical

system from damage that is caused by
overloaded circuits. Change a fuse if the
element separates. If the element of a new fuse
separates, check the circuit and/or repair the
circuit.
NOTICE
Always replace fuses with the same type and ca-
pacity fuse that was removed. Otherwise, electrical
damage could result.
NOTICE
If it is necessary to replace fuses frequently, an elec-
trical problem may exist.
Contact your Cat dealer.
To replace a fuse, use the puller that is stored in the

fuse panel.
The following list identifies the circuits that are
protected by each fuse. The amperage for each fuse
is included with each circuit.
M0111427-02 299
Maintenance Section
Fuses - Replace
(1) Heater and Air Conditioner Control and

Monitor – 5 Amp (7)12V Converter – 10 Amp
(2) Electronic Switch Control Panel – 5 Amp (8) Window Wiper and Window Washer – 15 Amp
(3) Grip, Seat Heater, and Air Suspension Seat – (9) Radio – 10 Amp
15 Amp
(10) Cat Grade Control – 15 Amp
(4) Beacon – 10 Amp
(11) Spare – 5 Amp
(5) Spare – 5 Amp
(6) Electric Refueling Pump – 25 Amp
300 M0111427-02
Maintenance Section
Fuses - Replace
(13) Spare – 15 Amp Relays

(14) Hydraulic Lock – 5 Amp
(17) 24V Auxiliary Circuit – 10 Amp
(18) 24V Auxiliary Circuit – 30 Amp
(22) Display and ET Connector – 10 Amp
(23) Body Control Module – 15 Amp
(24) Engine Electronic Control Module – 30 Amp
(25) Dome Light – 15 Amp
(26) Primary Electronic Control Module – 15 Amp
(27) Secondary Electronic Control Module – 15
Amp
(28) Boom Lamp – 10 Amp
(30) Product Link Module – 5 Amp
(31) Air Conditioner and Heater Blower – 20 Amp Illustration 551 g06223517
(32) Horn – 10 Amp (41) Horn – Relay

(33) Spare – 15 Amp (42) DEF Pump – Relay
(34) Spare – 15 Amp (43) Priming Pump – Relay
(35) 12V Converter – 10 Amp (44) Lifting Pump – Relay
(36) Cat Grade Control – 15 Amp (45) Boom Light – Relay
(37) Fuel Lifting Pump – 5 Amp (46) Chassis Light and Cab Light – Relay
(38) Spare – 25 Amp (47) Lower Washer – Relay
(39) Auxiliary Circuit – 10 Amp (48) Lower Wiper – Relay
(40) Spare – 15 Amp (49) Caution – Relay
(50) Spare – Relay
M0111427-02 301
Maintenance Section
Fuses - Replace
Main Circuit 100 Amp (54) – This fuse is

designed to protect the wires between
Power Fuse Module the batteries and the fuses. If the wires
are shorted to the machine body, this fuse would
minimize the damage to the wires.
Alternator Circuit 150 Amp (55) – This
fuse is designed to protect the
alternator. If the batteries are installed
with reversed polarity, the fuse would prevent the
alternator from damaging the rectifier.
Secondary Power Fuse Module -

Tier 4 Only
330 machines equipped with Tier 4 engines are
equipped with a secondary power fuse module.
The power fuse module is located behind the rear

access door on the left side of the machine. Remove
the cover to access the fuses.
The secondary power fuse module is located behind

the front access door on the left side of the machine.
Remove the cover to access the fuses.

Typical Example
Spare (51) – The fuse module includes

spare fuses which can be used if one of
the installed fuses opens. One spare
fuse is provided for each fuse in use.
Electric Cooling Fans 100 Amp (52)/(53)
– This fuse is designed to protect the
cooling fans.

Typical Example
302 M0111427-02
Maintenance Section
High Intensity Discharge Lamp (HID) - Replace
Spare (51) – The fuse module includes Note: On some HID lamps, the bulb is a part of the
spare fuses which can be used if one of lens assembly. The bulb is not removed separately
the installed fuses opens. One spare from the lens assembly. Replace the entire lens
fuse is provided for each fuse in use. assembly on these HID lamps.
Alternator Circuit 150 Amp (56) – This 4. Remove the bulb from the HID lamp.
fuse is designed to protect the
alternator. If the batteries are installed 5. Install the replacement bulb in the HID lamp.
with reversed polarity, the fuse would prevent the If the bulb is a part of the lens assembly, install the
alternator from damaging the rectifier.
replacement lens assembly in the HID lamp.
Glow Plug Circuit 70 Amp (57) – This
Note: To avoid failure to the bulb that is premature,
fuse is designed to protect the glow
avoid touching the bulb's surface with your bare
plugs.
hands. Clean any fingerprints from the bulb with
Diesel Exhaust Fluid (DEF) Pump Circuit alcohol prior to operation.
40 Amp (58) – This fuse is designed to
6. Reassemble the housing for the HID lamp. Ensure
protect the DEF pump circuit.
that any printing on the lens is oriented correctly
for the HID lamp's mounting position on the
i08067436
machine.
High Intensity Discharge Lamp 7. Reattach the electrical power to the HID lamp.
(HID) - Replace 8. Check the HID lamp for proper operation.
(If Equipped) Note: Consult your Cat dealer for additional
SMCS Code: 1434-510 information on HID lamps.
i07833138
HID lamps operate at very high voltages. To avoid Hydraulic System Oil - Change
electrical shock and personal injury, disconnect
power before servicing HID lamps. SMCS Code: 5056-044
Cat HYDO Advanced 10 Oil

Change Interval
HID bulbs become very hot during operation. Be- The standard Cat HYDO Advanced 10 oil change
fore servicing, remove power from lamp for at interval is every 6000 service hours or 3 years. But a
least five minutes to ensure lamp is cool. 6000 service hour or 3-year maintenance interval for
hydraulic oil (change) is strongly recommended with
S·O·S monitoring of the hydraulic oil after 3000
NOTICE service hours. The interval for S·O·S monitoring is
Although HID bulb materials may change over time, every 500 hours. The hydraulic oil change is strongly
HID bulbs produced at the time of the printing of this recommended when the oil deterioration or
manual contain mercury. When disposing of this com- contamination is detected. The maintenance interval
ponent, or any waste that contains mercury, please for the hydraulic oil filter is not changed.
use caution and comply with any applicable laws.
Hydraulic Hammer Use
1. Prepare the machine for maintenance. Refer to The use of hydraulic hammers shortens the life of
Operation and Maintenance Manual, “Prepare the hydraulic oil. If a hydraulic hammer is used, the
Machine for Maintenance”. maintenance interval is shortened, refer to Table 30
for the intervals.
2. Remove the electrical power from the high
intensity discharge lamp (HID). The electrical
power must be removed from the HID lamp for at
least 5 minutes, to ensure that the bulb is cool.
3. Disassemble the housing for the HID lamp to have
access to the bulb.
M0111427-02 303
Maintenance Section
Hydraulic System Oil - Change
Table 30
Percentage of Hammer Hydraulic System Oil -

Use Change
50% Every 1000 service hours
Procedure to Change the Hydraulic

Oil

contact skin.
NOTICE
2. Remove five bolts (1) and washers (2). Remove
Refer to Special Publication, PERJ1017, “Dealer cover (3) from the top of the hydraulic tank.
and mandates.
1. Park the machine on level ground. Lower the

bucket to the ground so that the stick is vertical.
3. Clean the area thoroughly to keep dirt out of the

screen cover and filler cap (4).
304 M0111427-02
Maintenance Section

Hydraulic tank filler cap location Filler cap
(A) LOCK position
(D) OPEN position
Pressurized system!
The hydraulic tank contains hot oil under pres-
sure. To prevent burns from the sudden release return hydraulic circuit with the following
of hot oil, relieve the tank pressure with the en- procedure. Refer to Illustration 559 for filler cap
gine off. Relieve pressure by slowly turning the positions.
to position (C).
c. Move the arrow from position (C) to position
(D).
d. After the tank pressure is relieved, tighten the
filler cap.
M0111427-02 305
Maintenance Section
5. Remove the hydraulic tank access cover that is 8. Use a bar to push the plunger up to allow the oil to
located under the upper structure. Removing the drain.
cover will allow access to the drain valve.
9. Drain the oil into a suitable container.
Note: Dispose of used fluids according to local
regulations.
10. After the oil has been drained, clean drain plug
(5) and install. Tighten the plug to 68 ± 7 N·m
(50 ± 5 lb ft).
machine.
12. Clean the pump, the hydraulic lines, and the
hydraulic tank.

(5) Plug

6. Remove plug (5).
7. Inspect the O-ring. Replace the O-ring if wear or 13. Remove plug (6) from the tube. Allow the oil to
damage is evident. drain into a container.
14. Inspect the O-ring. Replace the O-ring if wear or
damage is evident.
15. Clean the plug. Install the plug and the O-ring into
the drain port.
306 M0111427-02
Maintenance Section
Hydraulic Tank Screen - Clean

(12) O-ring seal
(7) Bolts 3. Remove O-ring seal (12) from the screen.
(8) Washers
(9) Cover
1. Remove bolts (7), washers (8), and cover (9).

(13) O-ring seal
4. Remove O-ring seal (13) from the tank.

5. Inspect O-ring seals (12) and (13). Replace the O-
ring seals if wear or damage is evident.
6. Wash the screen in a clean nonflammable solvent.
Allow the screen to dry. Inspect the screen.
Replace the screen, if the screen is damaged.
(10) Spring 7. Install O-ring seal (12) on screen (11).
(11) Screen
8. Install screen (11) and spring (10). Then install
2. Remove spring (10) and screen (11). cover (9), washers (8), and bolts (7).
Note: Do not allow spring (10) to fall back into the Note: Make sure that the O-ring seals and the spring
tank. are properly positioned during installation.
M0111427-02 307
Maintenance Section
Case Drain Filter - Clean 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.
Main Pump and Hydraulic System Air

Purge
1. Access the hydraulic pump. The hydraulic pump is
located behind the right access door.

(1) Hose Illustration 569 g06205207
(2) Hose
(3) Case drain filter (14) Hose
(4) Tee (15) Connector
(16) Elbow
1. Remove hose (1) and hose (2) from tee (4).
Remove tee (4). 2. While the engine is stopped, remove hose (14),
elbow (15), and connector (16) from the top of the
2. Remove case drain filter (3) from the hydraulic pump. Add hydraulic oil through the opening.
tank.
3. Check the condition of the seals. If a seal is
3. Wash the screen of the case drain filter in a clean damaged, replace the seal.
nonflammable solvent. Allow the filter to dry.
Inspect the filter. Replace the filter if the filter is 4. After the pump has been filled with oil, install drain
damaged. hose (14), connector (15), and seal (16) to the
original locations.
4. Inspect the O-ring seal on the filter. Replace the O-
ring seal if wear or damage is evident. 5. Start the engine. When the engine is at low idle,
raise the boom. Hold the boom in this position.
5. Install the filter in the hydraulic tank. Tighten the
filter to 175 ± 26 N·m (129 ± 19 lb ft). 6. Stop the engine. Slowly lower the boom until the
work tool is on the ground. The hydraulic tank will
6. Install the tee onto the filter. Tighten the tee to pressurize.
65 ± 10 N·m (48 ± 7 lb ft).
7. Slowly loosen hose (14) until hydraulic oil flows
7. Install the two hoses onto the tee. from the connection. Oil flowing from the
connection indicates that the air has been
Hydraulic System Oil - Fill released from the pump.
1. Fill the hydraulic system oil tank. Refer to 8. Tighten hose (14).
Operation and Maintenance Manual, “Capacities 9. Start the engine. Operate the engine at idling
(Refill)”. speed for 5 minutes.
2. Inspect the O-ring seal on the filler cap for
damage. Replace the O-ring, if necessary. Clean
the filler cap. Install the filler cap.
308 M0111427-02
Maintenance Section
Hydraulic System Oil Filter (Return) - Replace
10. Operate the joysticks to circulate the hydraulic oil.

Lower the bucket to the ground so that the stick is
vertical to the ground. Stop the engine.
11. Check the hydraulic oil level.
Reference: For the correct procedure, refer to
Operation and Maintenance Manual, “Hydraulic
System Oil Level - Check”.
13. Close the engine hood and latch the engine
hood.
Fast Fill Illustration 572 g06182544
If your machine is equipped with a deluxe service

center, you may drain the hydraulic oil through the 1. Remove the dust cover.
fast fill port. You may also add the hydraulic oil 2. Attach the hose to the male coupling.
through a fast fill port.
3. Drain the oil or add the oil, as needed.
i07833122
Hydraulic System Oil Filter

(Return) - Replace
SMCS Code: 5068-510-RJ

contact skin.
The return filter is a cartridge type filter. The amount

of foreign material that enters the hydraulic system is
reduced when the filter element is replaced.
Two different filters are available for the return filter.
One filter is used for standard applications such as
digging and normal use of a hammer. The second
filter is used for an application such as demolishing a
ceiling in a tunnel with a hammer.
M0111427-02 309
Maintenance Section
Note: If the message display shows that the

hydraulic return filter is plugged, turn off the machine.
After you make sure that the warning has Pressurized system!
disappeared, start the machine and run the machine
on level ground for approximately 10 minutes. If the The hydraulic tank contains hot oil under pres-
warning still appears in the message display, inspect sure. To prevent burns from the sudden release
the filter and replace the filter, if necessary. of hot oil, relieve the tank pressure with the en-
Hydraulic Hammer Use
The use of hydraulic hammers shortens the life of
hydraulic oil. If a hydraulic hammer is used, the
maintenance interval is shortened, refer to Table31
for the intervals.
Table 31
Percentage of Hydraulic System Oil Filter (Re-

Hammer Use turn) - Replace
Return Filter Replacement

Procedure

Filler cap
(A) LOCK position
(D) OPEN position

positions.
to position (C).
1. Remove five bolts (1) and washers (2). Remove c. Move the arrow from position (C) to position
cover (3) from the top of the hydraulic tank. (D).
2. Clean the area thoroughly to keep dirt out of the d. After the tank pressure is relieved, tighten the
return filter and filler cap. filler cap on the hydraulic tank to position (A).
4. Check the hydraulic system oil level.

310 M0111427-02
Maintenance Section
5. Remove four bolts (4), disconnect the harness 7. Place cover assembly (5) into position in the tank.
connector from the filter bypass switch, and Install four bolts (4) and tighten to 30 ± 7 N·m
remove cover assembly (5) from the tank. Inspect (22 ± 5 lb ft). Install the harness connector on the
the O-ring on the cover for damage and replace as filter bypass switch.
necessary.
6. Remove filter element (6) and discard. Install a

new element into the filter case.
M0111427-02 311
Maintenance Section
Hydraulic System Oil Level - Check
1. Park the machine on level ground. Lower the

bucket to the ground with the stick in a vertical
position, as shown.
8. Position cover (3) in place on the top of the

hydraulic tank. Install five bolts (1) and washers
(2).
i07174987
Hydraulic System Oil Level -

Check
SMCS Code: 5050-535

injury. Do not allow hot oil or hot components to 2. Open the access door on the right side of the
contact skin. machine.
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
(C) Mid temperature range
312 M0111427-02
Maintenance Section
Hydraulic System Oil Level - Check
3. If the hydraulic oil temperature is between 10° to

30° C (50° to 86° F), maintain the oil level in low
temperature range (B). If the hydraulic oil
temperature is between 50° to 80° C (122° to 187°
F), maintain the oil level in high temperature range
(A). If the hydraulic oil temperature is between 31°
to 49° C (87° to 121° F), maintain the oil level in
mid temperature range (C).
Note: Perform Step 5 through Step 8 if the oil level is

low.
pertains to Containing Fluid Spillage.
Pressurized system!
The hydraulic tank contains hot oil under pres- Illustration 582 g06182653
sure. To prevent burns from the sudden release
of hot oil, relieve the tank pressure with the en-

Filler cap
(A) LOCK position
(D) OPEN position

positions.
M0111427-02 313
Maintenance Section
Hydraulic System Oil Sample - Obtain
b. Release the pressure for a minimum of 45 i03753191

to position (C). Indicators and Gauges - Test
c. Move the arrow from position (C) to position SMCS Code: 7450-081; 7490-081
(D).
1. Look for broken lenses on the gauges, broken
d. After the tank pressure is relieved, remove the indicator lights, broken switches, and other broken
filler cap. components in the cab.
6. Add oil if necessary. See Operation and 2. Start the engine.
Maintenance, “Lubricant Viscosities”
3. Look for inoperative gauges.
7. Check the O-ring seal on the filler cap. Replace the
O-ring seal if the seal is damaged. 4. Turn on all machine lights. Check for proper
operation.
8. Clean the filler cap and install on the tank. Tighten
the filler cap on the hydraulic tank to position (A). 5. Move the machine forward. Release the travel
levers and the travel pedals. The machine should
i07590874
stop.
6. Stop the engine.
Hydraulic System Oil Sample -
7. Make any repairs that are required before
Obtain operating the machine.
SMCS Code: 5050-008-OC; 5095-SM; 5095-008;
7542; 7542-008 i07833447
Note: If Cat HYDO Advanced hydraulic oils are used, Oil Filter (Hydraulic Hammer) -
the hydraulic oil change interval is extended to 6000
hours. S·O·S services after 3,000 hour is Replace
recommended. Consult your Cat dealer for details. (If Equipped)
SMCS Code: 5068-510

contact skin.
The use of hydraulic hammers shortens the life of

hydraulic oil. If a hydraulic hammer is used, the
maintenance interval is shortened, refer to Table 32
for the intervals.
Table 32
Percentage of Hammer Oil Filter (Hydraulic Hammer)

Use - Replace
The hydraulic oil sampling valve (1) is connected to
the pilot line of the main hydraulic pump regulator.
Obtain a sample of the hydraulic oil from the
hydraulic oil sampling valve. Refer to Special
Publication, SEBU6250, “S·O·S Oil Analysis” for
information that pertains to obtaining a sample of the
hydraulic oil. Refer to Special Publication,
PEGJ0047, “How To Take A Good Oil Sample” for
more information about obtaining a sample of the
hydraulic oil.
314 M0111427-02
Maintenance Section
If Equipped
1. Park the machine on level ground in the service

position as shown.
2. Move the hydraulic lockout control to the
UNLOCKED position.
3. Turn the engine start switch to the ON position. Filler cap
4. Move the joysticks and the travel levers/pedals to (A) LOCK position
the full stroke positions to relieve the pressure in (C) PRESSURE RELEASE - END position
the hydraulic lines. (D) OPEN position
5. Turn the engine start switch to the OFF position

and return the lever for the hydraulic lockout
control to the LOCKED position.
positions.
Pressurized system! the arrow from position (A) to position (B).
The hydraulic tank contains hot oil under pres- b. Release the pressure for a minimum of 45
sure. To prevent burns from the sudden release seconds by moving the arrow from position (B)
of hot oil, relieve the tank pressure with the en- to position (C).
cap until the cap reaches the secondary stop. c. Move the arrow from position (C) to position
(D).
d. After the tank pressure is relieved, remove the
filler cap.
7. The oil filter for the hammer is located near the
base of the boom.
Note: Some configurations may invert the hammer

filter installation.
M0111427-02 315
Maintenance Section
Oil Filter - Inspect
Note: Used filter elements should always be

disposed of according to local regulations.
11. Install the new filter element.

12. Clean the filter housing and install on the filter
base. Tighten the nut on the filter case to
98 ± 10 N·m (72 ± 7 lb ft).
13. Start the engine and operate the machine slowly
for 10 to 15 minutes. Move each cylinder evenly
through several cycles and operate the hammer.
14. Return the machine to the service position.
Check the machine for oil leaks.
15. Stop the engine.
16. Check the hydraulic oil level.

i07349186
8. Position a suitable container to contain the oil.
Oil Filter - Inspect
“General Hazard Information” for information on SMCS Code: 1308-507; 5068-507
Inspect a Used Filter for Debris
9. Loosen the filter housing and remove. Inspect the
plug on the top of the housing. If there are signs of
leakage, replace the O-ring on the plug. Tighten
the plug to59 ± 5 N·m (44 ± 4 lb ft).

The element is shown with debris.
Use a filter cutter to cut the filter element open.
Illustration 588 g06211156 Spread apart the pleats and inspect the element for
metal and for other debris. An excessive amount of
debris in the filter element can indicate a possible
10. Remove the filter element and discard. The
failure.
element cannot be reused.
316 M0111427-02
Maintenance Section
Radiator, Aftercooler and Oil Cooler Cores - Clean
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 from steel parts
and on cast iron parts.
Nonferrous metals can indicate wear from 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 debris could be caused by friction and
by normal wear. Consult your Cat dealer to arrange
for further analysis if an excessive amount of debris
is found.
Using an oil filter element that is not recommended
by Caterpillar can result in severe engine damage to
engine bearings, to the crankshaft, and to other
parts. This can result in larger particles in unfiltered
oil. The particles could enter the lubricating system
and the particles could cause damage.
i06972489
Radiator, Aftercooler and Oil

Cooler Cores - Clean
SMCS Code: 1063-070-KO; 1353-070-KO; 1374-
070-KO Illustration 591 g06183814
2. Remove dust and debris from all the core fins.
Personal injury can result from air pressure. Compressed air is preferred, but high-pressure
water or steam can be used to remove dust and
Personal injury can result without following prop- general debris from a core.
er procedure. When using pressure air, wear a
protective face shield and protective clothing. See Special Publication, SEBD0518, “Know Your
Cooling System” for more detailed information
Maximum air pressure at the nozzle must be less about cleaning core fins.
than 205 kPa (30 psi) for cleaning purposes.
3. Close the access door on the left side of the
machine.

machine.
M0111427-02 317
Maintenance Section
Receiver Dryer (Refrigerant) - Replace
i08192239 i07349192
Receiver Dryer (Refrigerant) - Rollover Protective Structure

Replace (ROPS) - Inspect
SMCS Code: 7322-510; 7322-710 SMCS Code: 7323-040; 7325-040
Personal injury can result from contact with

refrigerant.
Contact with refrigerant can cause frost bite.
Keep face and hands away to help prevent injury.
Protective goggles must always be worn when re-
frigerant lines are opened, even if the gauges in-
dicate the system is empty of refrigerant.
Always use precaution when a fitting is removed.
Slowly loosen the fitting. If the system is still
under pressure, release it slowly in a well venti-
lated area.
Personal injury or death can result from inhaling
refrigerant through a lit cigarette.
Inhaling air conditioner refrigerant gas through a
lit cigarette or other smoking method or inhaling
fumes released from a flame contacting air condi-
tioner refrigerant gas, can cause bodily harm or
death.
Do not smoke when servicing air conditioners or
wherever refrigerant gas may be present.
Use a certified recovery and recycling cart to
properly remove the refrigerant from the air con- Illustration 592 g06184357
ditioning system.
Consult your Cat dealer for repair of any cracks in the
ROPS.
NOTICE
If the refrigerant system has been open to the outside Inspect the ROPS for loose bolts or for damaged
air (without being plugged) for more than 30 minutes, bolts. Replace any damaged bolts or missing bolts
the receiver-dryer must be replaced. Moisture will en- with original equipment parts only. Tighten the M24
ter an open refrigerant system and cause corrosion bolt (1) to 425 ± 50 N·m (315 ± 40 lb ft).
which will lead to component failure.
Note: Apply oil to all ROPS bolt threads before you
Prepare the machine for maintenance. Refer to install the bolts. Failure to apply oil to the bolt threads
Operation and Maintenance Manual, “Prepare the can result in improper bolt torque.
Machine for Maintenance”.
Do not straighten the ROPS. Do not repair the ROPS
Refer to Service Manual, “Air Conditioning and by welding reinforcement plates to the ROPS.
Heating R-134a for All Caterpillar Machines” for the
proper procedure to change the receiver-dryer Consult your Cat dealer for inspection of any
assembly and for the procedure to reclaim the potential damage or repair of any damage to any
refrigerant gas. operator protective structure. (Including ROPS,
FOPS, TOPS, OPS, and OPG) Refer to Special
Instruction, SEHS6929, “Inspection, Maintenance,
and Repair of Operator Protective Structures (OPS)
and Attachment Installation Guidelines for All
Earthmoving Machinery”
318 M0111427-02
Maintenance Section
Seat Belt - Inspect
i07103309 i06970675
Seat Belt - Inspect Seat Belt - Replace

SMCS Code: 7327-040 SMCS Code: 7327-510
Always inspect the condition of the seat belt and the The seat belt should be replaced within 3 years of the
condition of the seat belt mounting hardware before date of installation. A date of installation label is
you operate the machine. Replace any parts that are attached to the seat belt retractor and buckle. If the
damaged or worn before you operate the machine. date of installation label is missing, replace the belt
within 3 years from the year of manufacture as
indicated on the belt webbing label, buckle housing,
or installation tags (non-retractable belts).

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

seat belt and the mounting hardware.
Determine the age of a new seat belt before installing
on seat. A manufacture label is on the belt webbing
and imprinted on the belt buckle. Do not exceed the
install by date on the label.
Typical example
A complete seat belt system should be installed with
Inspect buckle (2) for wear or for damage. If the new mounting hardware.
buckle is worn or damaged, replace the seat belt.
Date of installation labels should be marked and
Inspect seat belt (1) for webbing that is worn or affixed to the seat belt retractor and buckle.
frayed. Replace the seat belt if the webbing is worn
or frayed. Note: Date of installation labels should be
permanently marked by punch (retractable belt) or
Inspect all seat belt mounting hardware for wear or stamp (non-retractable belt).
for damage. Replace any mounting hardware that is
worn or damaged. Make sure that the mounting bolts If your machine is equipped with a seat belt
are tight. extension, also perform this replacement procedure
for the seat belt extension.
If your machine is equipped with a seat belt
extension, also perform this inspection procedure for i06987212
the seat belt extension.
Contact your Cat dealer for the replacement of the Swing Bearing - Lubricate
seat belt and the mounting hardware. SMCS Code: 7063-086
Note: The seat belt should be replaced within 3 years Note: Refer to Special Publication, SEBU6250,
of the date of installation. A date of installation label
“Caterpillar Machine Fluids Recommendations” for
is attached to the seat belt retractor and buckle. If the more information on grease.
date of installation label is missing, replace belt within
3 years from the year of manufacture as indicated on Note: Do not overgrease the swing bearings. Do not
belt webbing label, buckle housing, or installation grease more than the recommended maintenance
tags (non-retractable belts). interval. Refer to Operation and Maintenance
Manual, “Maintenance Interval Schedule” for more
information.
M0111427-02 319
Maintenance Section
Swing Drive Oil - Change
Wipe the fittings before you lubricate the swing

bearing.
Illustration 595 g06210366 1. Remove the access cover that is located below the
swing drives.
The swing bearing grease zerks are located at the
front of the swing drive housing near the boom
cylinders.
Illustration 596 g06188212 Note: Refer to Operation and Maintenance Manual,

Apply lubricant through the fittings until the lubricant
pertains to Containing Fluid Spillage.
overflows the bearing seals.
2. Remove drain hose (3) from holder (1) on the
i07349198
upper frame. Face the end of the hose toward the
container.
Swing Drive Oil - Change
3. Loosen drain valve (2). Drain the oil into a suitable
SMCS Code: 5459-044
container.
Note: Drained fluids should always be disposed of
according to local regulations.
contact skin.
320 M0111427-02
Maintenance Section
Swing Drive Oil Level - Check
4. Tighten the drain valve. Return the drain hose to 7. Maintain the oil level between the “ADD” and
holder (1). Make sure that the end of the hose is “FULL” marks on the dipstick.
facing upward.
8. Check the oil that has been drained for metal chips
or metal particles. Consult your Cat dealer if any
metal chips or metal particles are found.
9. Drained materials should always be disposed of
according to local regulations.
i06988089
Swing Drive Oil Level - Check

SMCS Code: 5459-535-FLV

contact skin.
5. Remove dipstick (4).
6. 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.
M0111427-02 321
Maintenance Section
Swing Drive Oil Sample - Obtain
i06988143
Swing Drive Oil Sample -

Obtain
SMCS Code: 5459-OC; 5459-554-OC; 5459-008-
OC; 5459-008; 7542-008

contact skin.
1. Remove the dipstick.
Obtain an oil sample of the swing drive oil through

the opening for the dipstick. Refer to Special
Publication, SEBU6250, “S·O·S Oil Analysis” for
Illustration 604 g06188660 information that pertains to obtaining an oil sample
from the swing drive housing. Refer to Special
Note: Refer to Operation and Maintenance Manual, Publication, PEGJ0047, “How To Take A Good Oil
“General Hazard Information” for information that Sample” for more information about obtaining an oil
pertains to Containing Fluid Spillage. sample from the swing drive housing.
2. Check the dipstick. Maintain the oil level between i06988169

the “ADD” and “FULL” marks on the dipstick. Add
oil through the dipstick tube, if necessary. Refer to Swing Gear - Lubricate
Operation and Maintenance Manual, “Lubricant SMCS Code: 7063-086
Viscosities” when you select an oil. If the oil level is
above the “FULL” line, then remove oil from the Note: Refer to Special Publication, SEBU6250,
system. Restore the oil to the correct level “Caterpillar Machine Fluids Recommendations” for
position. more information on grease.
3. Insert the dipstick.
322 M0111427-02
Maintenance Section
Swing Gear - Lubricate
NOTICE
Improper lubrication can cause damage to machine
components.
To avoid damage, make sure that the proper amount
of grease is applied to the swing drive.
When the amount of grease in the compartment be-
comes too large, the agitation loss becomes large,
thereby accelerating grease deterioration.
Grease deterioration can cause damage to the pinion
gear of the swing drive and swing internal gear.
Not enough grease will result in poor gear lubrication.
Remove the inspection cover that is located near the Illustration 607 g06188736
boom base. Inspect the grease.
3. Check the level of grease. The level of grease is
correct when:
• Waves of grease are present from the rotating

swing drive pinion.
• The grease is evenly distributed on the floor of

the pan.
Note: Smeared or waveless areas are evidence for a

lack of grease.
Note: Add grease, as needed. Remove grease, as
needed. Too much grease will result in the
deterioration of the grease because of excessive
Illustration 606 g06188728 movement of the grease. Too little grease will result
(1) Bolts in poor lubrication of the swing gear.
(2) Washers
(3) Cover Refer to Operation and Maintenance Manual,
(4) Gasket
“Capacities (Refill)” for the size of the pan.
1. Remove bolts (1) and washers (2). Remove cover 4. Check for contamination and for discolored
(3) and gasket (4). grease.
2. Inspect gasket (4). Replace the gasket if damage
is evident.

(5) Bolts
(6) Washers
(7) Cover
(8) Gasket
M0111427-02 323
Maintenance Section
Track Adjustment - Adjust
5. If the grease is contaminated or discolored with

NOTICE
water, change the grease. Remove the covers Keeping the track properly adjusted will increase the
from below the swing drive underneath the service life of the track and drive components.
undercarriage frame.
6. Remove bolts (5), washers (6), cover (7), and Note: The track tension must be adjusted according
gasket (8) to allow the water to drain. When you to the current operating conditions. Keep the track as
reinstall cover (7), inspect gasket (8). Replace the slack as possible if the soil is heavy.
gasket if damage is evident.
Measuring Track Tension
1. Operate the machine in the direction of the idlers.
7. Raise the boom and turn the upper structure by 1/4

turn. Lower the bucket to the ground. Illustration 610 g06188816
8. Repeat Step 7 at every 1/4 turn in four places. Add

2. Stop with one track pin directly over the front
grease, as needed.
carrier roller. Park the machine and turn off the
9. Install gasket (4), cover (3), washers (2), and bolts engine.
(1).
i06988628

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-
der to see if the track is being loosened.
Loosen the relief valve one turn only.
If track does not loosen, close the relief valve and
contact your Caterpillar dealer.
324 M0111427-02
Maintenance Section
5. If the track is too tight, or if the track is too loose,

adjust the track tension according to the
appropriate procedure below.
Adjusting Track Tension

Typical example
3. Place a straight edge on top of the track grousers
between the front carrier roller and the idler. The The track adjuster is located on the track frame.
straight edge should be long enough to reach from
the front carrier roller to the idler. Tightening the Track
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
enough to reach from one carrier roller to another
carrier roller.
4. Measure the maximum amount of sag in the track.

The sag is measured from the highest point of the
track grouser to the bottom of the straight edge. A
track that is properly adjusted will have a sag of
40.0 to 55.0 mm (1.57 to 2.17 inch).

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

1. Add grease through grease valve (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
needed.
M0111427-02 325
Maintenance Section
Track Adjustment - Inspect
Loosening the Track i06954313
Travel Alarm - Test

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

(1) Grease valve
1. Loosen grease valve (1) carefully until the track

begins to loosen. One turn should be the
maximum.
2. Tighten grease valve (1) to 34 ± 5 N·m
(25 ± 4 lb ft) 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.
i06969791
Track Adjustment - Inspect Illustration 616 g06181402
SMCS Code: 4170-040 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 to
stop the machine.
5. Use the travel levers and the travel pedals to move
the machine backward. The travel alarm should
sound.
Check the track adjustment. Check the track for wear

and for excessive dirt buildup.
If the track appears to be too tight or too loose, refer
to Operation and Maintenance Manual, “Track
Adjustment - Adjust”.
326 M0111427-02
Maintenance Section
Undercarriage - Check
i08233399
Undercarriage - Check
SMCS Code: 4150-535
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
Illustration 617 g06181631 and loose mounting bolts.
6. Press the alarm mute button. The travel alarm 3. Listen for any abnormal noises while you are
should shut off. moving slowly in an open area.
7. Stop the machine. Lower the work tool to the 4. If required, clean the undercarriage to keep excess
ground. Move the hydraulic lockout control to the material from building up and solidifying.
LOCKED position. Stop the engine. 5. If abnormal wear exists or abnormal noises or
leaks are found, consult your Cat ® dealer.
i06954326
Window Washer Reservoir -

Fill
SMCS Code: 7306-544-KE
NOTICE
When operating in freezing temperatures, use Cater-
pillar or any commercially available nonfreezing win-
dow washer solvent.
M0111427-02 327
Maintenance Section
Window Wiper - Inspect/Replace
i07103291
Windows - Clean
SMCS Code: 7310-070; 7340-070
Clean the outside of the windows from the ground,
unless handholds are available.

machine.

Typical example
2. Remove the filler cap.
3. Fill the window washer reservoir with washer fluid Cleaning Methods
through the filler opening.
4. Install the filler cap. Aircraft Window Cleaner
5. Close the access door. Apply the cleaner with a soft cloth. Rub the window
with moderate pressure until all the dirt is removed.
i01258249 Allow the cleaner to dry. Wipe off the cleaner with a
clean soft cloth.
Window Wiper - Inspect/ Soap and Water
Replace
Use a clean sponge or a soft cloth. Wash the
SMCS Code: 7305-040; 7305-510
windows with a mild soap or with a mild detergent.
Inspect the condition of the wiper blades. Replace Also use plenty of lukewarm water. Rinse the
the wiper blades if the wiper blades are worn or windows thoroughly. Dry the windows with a moist
damaged or if streaking occurs. chamois or with a moist cellulose sponge.
328 M0111427-02
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)
Special care is needed to clean polycarbonate
windows.
Wash polycarbonate windows with mild soap and
warm water that does not exceed 50° C (122° F).
Use a soft sponge, or damp cloth. Never use a dry
cloth or paper towels on polycarbonate windows.
Rinse the windows with a sufficient amount of clean
cold water.
Note: Naphtha or kerosene can be used to remove
labels, films, paint, or marking pen from
polycarbonate windows.
Note: Do not use abrasive, or highly alkaline
cleaners. Do not use sharp instruments, such as
squeegees or razor blades on polycarbonate
windows. Do not clean polycarbonate windows in the
hot sun or at elevated temperatures.
M0111427-02 329
Warranty Section
Warranty Information
Warranty Section 3. New non-road diesel engines installed in

construction machines conforming to the South
Korean regulations for construction machines
Warranty Information manufactured after January 1, 2015, and operated
and serviced in South Korea, including all parts of
their emission control systems (“emission related
i06044323 components”), are:
Emissions Warranty a. Designed, built, and equipped so as to conform,
at the time of sale, with applicable emission
Information standards prescribed in the Enforcement Rule
SMCS Code: 1000 of the Clean Air Conservation Act promulgated
by South Korea MOE.
The certifying engine manufacturer warrants to the
ultimate purchaser and each subsequent purchaser b. Free from defects in materials and
that: workmanship in emission-related components
1. New non-road diesel engines and stationary diesel that can cause the engine to fail to conform to
engines less than 10 liters per cylinder (including applicable emission standards for the warranty
Tier 1 and Tier 2 marine engines < 37 kW, but period.
excluding locomotive and other marine engines) The aftertreatment system can be expected to
operated and serviced in the United States and function properly for the lifetime of the engine
Canada, including all parts of their emission (emissions durability period) subject to prescribed
control systems (“emission related components”), maintenance requirements being followed.
are:
A detailed explanation of the Emission Control
a. Designed, built, and equipped so as to conform, Warranty that is applicable to new non-road and
at the time of sale, with applicable emission stationary diesel engines, including the components
standards prescribed by the United States covered and the warranty period, is found in a
supplemental Special Publication. Consult your
Environmental Protection Agency (EPA) by way authorized Cat dealer to determine if your engine is
of regulation. subject to an Emission Control Warranty and to
obtain a copy of the applicable Special Publication.
b. Free from defects in materials and
workmanship in emission-related components
that can cause the engine to fail to conform to
applicable emission standards for the warranty
period.
2. New non-road diesel engines (including Tier 1 and
Tier 2 marine propulsion engines < 37 kW and Tier
1 through Tier 4 marine auxiliary engines < 37 kW,
but excluding locomotive and other marine
engines) operated and serviced in the state of
California, including all parts of their emission
control systems (“emission related components”),
are:
a. Designed, built, and equipped so as to conform,
at the time of sale, to all applicable regulations
adopted by the California Air Resources Board
(ARB).
b. Free from defects in materials and
workmanship which cause the failure of an
emission-related component to be identical in
all material respects to the component as
described in the engine manufacturer's
application for certification for the warranty
period.
330 M0111427-02
Reference Information Section
Reference Materials
Reference Information
Section
Reference Materials
i08292374
Reference Material
SMCS Code: 1000; 7000
Additional literature regarding your product may be
purchased from your local Cat dealer or by visiting
publications.cat.com. Use the product name, sales
model, and serial number to obtain the correct
information for your product.
publications.cat.com
i08292382
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.
M0111427-02 331
Index Section
Index
A K Series GET Drive-through System Bucket
Tips .......................................................... 264
Access Door and Cover Locations................ 240
Side Cutters ............................................... 269
Engine Hood .............................................. 240
Side Protectors (If Equipped) .................... 269
Engine Service Door.................................. 241
Burn Prevention............................................... 30
Left Front Access Door .............................. 241
Batteries....................................................... 30
Left Rear Access Door............................... 241
Coolant ........................................................ 30
Right Side Access Door............................. 241
Oils............................................................... 30
Storage Box ............................................... 242
Additional Messages ....................................... 20
Air Conditioner/Cab Heater Filter C
(Recirculation) - Inspect/Replace ................ 259 Cab Air Filter (Fresh Air) - Clean/Replace .... 270
Air Conditioning and Heating Control............ 161 Cab Door ....................................................... 170
Operation ................................................... 163 Camera.......................................................... 167
Selection Method ....................................... 163 Rear View Camera .................................... 167
Alternate Exit ................................................... 88 Side View Camera (If Equipped) ............... 167
Rear Window with Lever (If Equipped) ........ 88 Camera - Clean ............................................. 271
Rear Window with Ring Seal (If Capacities (Refill) .......................................... 249
Equipped)................................................... 88 Condenser (Refrigerant) - Clean................... 272
Cooling System Coolant (ELC) - Change ..... 272
B Cooling System Coolant Extender (ELC) -
Add .............................................................. 275
Battery - Clean............................................... 259
Cooling System Coolant Level - Check......... 276
Battery Disconnect Switch ............................ 100
Cooling System Coolant Sample - Obtain .... 277
Battery Electrolyte Level - Check .................. 259
Crushing Prevention and Cutting Prevention.. 29
Battery Hold-Down - Tighten ......................... 260
Battery or Battery Cable - Inspect/Replace... 260
Recycle the Battery.................................... 260 D
Before Operation ....................................... 39, 85 Daily Inspection ............................................... 85
Before Starting Engine .................................... 36 Daily Basis ................................................... 86
Belt - Inspect/Adjust/Replace ........................ 260 First 100 Hours ............................................ 85
Boom and Stick Linkage - Lubricate ............. 261 Declaration of Conformity................................ 84
Boom, Stick and Bucket Operation ............... 199 Decommissioning and Disposal.................... 330
Digging....................................................... 199 Demolition ....................................................... 43
Lifting Objects ............................................ 201
Machines that are Equipped with a Long
E
Reach Configuration ................................ 202
Boom/Stick/Bucket Combinations................... 54 Electrical Storm Injury Prevention ................... 36
330 GC......................................................... 55 Emissions Certification Film ............................ 83
Bucket - Remove and Install ......................... 203 Emissions Warranty Information ................... 329
Installation Procedure................................ 204 Engine Air Filter Primary and/or Secondary
Removal Procedure................................... 203 Element - Replace ....................................... 278
Bucket Linkage - Inspect/Adjust.................... 262 Engine Air Pre-Cleaner - Clean ................. 280
Bucket Linkage - Lubricate............................ 263 Primary Air Filter Element - Replace ......... 278
Bucket Tips - Inspect/Replace ...................... 264 Secondary Air Filter Element - Replace .... 280
Bucket Tips (Cat® Advansys ) - If Engine and Machine Warm-Up ..................... 184
Equipped.................................................. 268 Hydraulic System....................................... 185
J Series GET Bucket Tips.......................... 266 Improve Cold-Weather Performance ........ 186
Engine Oil and Filter - Change ...................... 284
332 M0111427-02
Index Section
Fast Fill (If Equipped)................................. 288 Freezing Conditions ...................................... 224

Procedure for Changing Engine Oil and Frozen Ground Conditions ............................ 189
Filter ......................................................... 285 Fuel Cap Filter - Replace .............................. 292
Engine Oil Level - Check............................... 282 Fuel System - Prime...................................... 292
Ground Level Dipstick ............................... 283 Fuel System Primary Filter (Water
Engine Oil Sample - Obtain........................... 284 Separator) Element - Replace..................... 293
Engine Starting........................................ 39, 183 Fuel System Secondary Filter - Replace ...... 295
Engine Starting (Alternate Methods)............. 237 Fuel System Water Separator - Drain ........... 296
Engine Starting with Auxiliary Start Fuel Tank Shutoff and Drain Control ............. 181
Receptacle (If Equipped)............................. 239 Fuel Tank Strainer - Clean............................. 297
Engine Starting with Jump Start Cables (If Fuel Tank Water and Sediment - Drain ......... 297
Equipped) .................................................... 237 Fuel Transfer Pump (Refueling) (If
Engine Stopping .............................................. 43 Equipped) .................................................... 156
Engine Valve Lash - Check ........................... 288 Fuses - Replace ............................................ 298
Equipment Lowering with Engine Stopped .... 45, Power Fuse Module................................... 301
190 Relays ........................................................ 300
Machines Equipped with Boom Lowering Secondary Power Fuse Module - Tier 4
Control Valves.......................................... 190 Only.......................................................... 301
Machines without a Boom Lowering Control
Valve ........................................................ 191 G
Pressure Release of Auxiliary Lines.......... 193
Ether Starting Aid Cylinder - Replace (If General Hazard Information............................ 26
Equipped) .................................................... 289 Containing Fluid Spillage............................. 28
Dispose of Waste Properly .......................... 29
Fluid Penetration ......................................... 27
F
Inhalation ..................................................... 28
Film (Product Identification) - Clean.............. 290 Pressurized Air and Water........................... 27
Cleaning of the Films ................................. 290 Trapped Pressure ........................................ 27
Final Drive Oil - Change ................................ 290 General Information ........................................ 50
Final Drive Oil Level - Check......................... 291 Guards............................................................. 48
Final Drive Oil Sample - Obtain..................... 292 Guards (Operator Protection)
Final Drive Sun Gear Removal ..................... 235 Other Guards (If Equipped) ......................... 49
Fire Extinguisher Location............................... 35 Rollover Protective Structure (ROPS), Falling
Fire Prevention and Explosion Prevention...... 31 Object Protective Structure (FOPS) or Tip
Battery and Battery Cables.......................... 32 Over Protection Structure (TOPS)............. 48
Ether ............................................................ 34
Fire Extinguisher.......................................... 34 H
General ........................................................ 31
Lines, Tubes, and Hoses ............................. 33 High Intensity Discharge Lamp (HID) -
Regeneration ............................................... 31 Replace (If Equipped).................................. 302
Wiring........................................................... 33 High Pressure Fuel Lines ................................ 35
Fire Safety ....................................................... 34 Hydraulic System Oil - Change ..................... 302
Foreword ........................................................... 5 Cat HYDO Advanced 10 Oil Change
California Proposition 65 Warning ................. 5 Interval ..................................................... 302
Certified Engine Maintenance ....................... 6 Fast Fill ...................................................... 308
Literature Information .................................... 5 Procedure to Change the Hydraulic Oil..... 303
Machine Capacity .......................................... 6 Hydraulic System Oil Filter (Return) -
Maintenance .................................................. 5 Replace ....................................................... 308
Operation ....................................................... 5 Hydraulic Hammer Use ............................. 309
Product Identification Number ....................... 6 Return Filter Replacement Procedure....... 309
Safety............................................................. 5 Hydraulic System Oil Level - Check...............311
Hydraulic System Oil Sample - Obtain.......... 313
M0111427-02 333
Index Section
I Activating Bluetooth Functionality ............. 103

Armed ........................................................ 105
Identification Information ................................. 80
Components .............................................. 103
Important Safety Information............................. 2
Disarmed ................................................... 105
Indicators and Gauges - Test ........................ 313
Engine Start Switch Troubleshooting .........117
General Information................................... 102
J Grace Period.............................................. 105
Joystick Controls ........................................... 173 Navigating the User Interface Touchscreen
3 Button Joystick Controls ......................... 173 Display ..................................................... 106
Medium Pressure (If Equipped)................. 175 Operation of Status Indicator..................... 106
Vertical Slider Joystick Controls (If Operator Login........................................... 107
Equipped)................................................. 174 Pairing Your Device to the Machine .......... 104
Joystick Controls Alternate Patterns ............. 179 Reading the ID of a Key............................. 105
Changing Machine Control Pattern(If System Overview....................................... 103
Equipped)................................................. 179 Machine Storage and Specified Storage
Period .......................................................... 227
Machine Storage ....................................... 227
L
Specified Storage Period........................... 227
Leaving the Machine ..................................... 226 Maintenance Access ..................................... 240
Lifting and Tying Down the Machine ............. 230 Maintenance Interval Schedule..................... 257
Lifting the machine..................................... 231 Every 10 Service Hours or Daily................ 257
Lifting the Machine Segments ................... 233 Every 10 Service Hours or Daily for First 50
Tying Down the Machine ........................... 231 Hours ....................................................... 257
Lifting Capacities (330 GC) ............................. 65 Every 100 Service Hours ........................... 257
Configuration Identification.......................... 66 Every 1000 Service Hours......................... 258
Mass Boom with a 2.5 m (8 ft 2 inch) Mass Every 12 000 Service Hours or 6 Years..... 258
Stick ..................................................... 70, 78 Every 2000 Service Hours......................... 258
Reach Boom with a 2.65 m (8 ft 8 inch) Every 250 Service Hours ........................... 258
Reach Stick.......................................... 69, 75 Every 3 Years............................................. 258
Reach Boom with a 3.2 m (10 ft 6 inch) Every 3000 Service Hours......................... 258
Reach Stick.......................................... 67, 72 Every 500 Service Hours ........................... 258
Symbols Found in the Lifting Capacity Every 5000 Service Hours......................... 258
Charts ........................................................ 66 Every 6000 Service Hours or 3 Years ....... 258
Lifting Objects.................................................. 43 Every Year ................................................. 258
Lubricant Viscosities (Fluids Initial 500 Hours (for New Systems, Refilled
Recommendations) ..................................... 243 Systems, and Converted Systems) ......... 258
Biodiesel .................................................... 248 Initial 500 Service Hours............................ 258
Coolant Information ................................... 248 When Required.......................................... 257
Diesel Fuel Recommendations ................. 247 Maintenance Section..................................... 240
Engine Oil .................................................. 243 Maintenance Support .................................... 250
Fuel Additives ............................................ 248 Mirror ............................................................. 164
General Information for Lubricants............ 243 Mirror Adjustment ...................................... 164
Hydraulic Systems..................................... 244 Monitoring System..........................................118
Other Fluid Applications ............................ 245 Application Menu ....................................... 127
Selecting the Viscosity............................... 243 Electronic OMM ......................................... 153
Special Lubricants ..................................... 246 Function List Screen .................................. 154
Lubricant Viscosities and Refill Capacities ... 243 General Information....................................118
Logging In .................................................. 125
M Machine Warnings ..................................... 121
Navigation.................................................. 126
Machine Operation .......................................... 88 Operator Screen ........................................ 126
Machine Security System.............................. 102
334 M0111427-02
Index Section
Mounting and Dismounting ............................. 85 Data Broadcasts ........................................ 101

Alternate Exit ............................................... 85 Operation in a Blast Site for Product Link
Machine Access System Specifications...... 85 Radios ...................................................... 101
O Q
Oil Filter - Inspect .......................................... 315 Quick Coupler Operation (Circuit for CW
Inspect a Used Filter for Debris ................. 315 Coupler (If Equipped)) ................................. 205
Oil Filter (Hydraulic Hammer) - Replace (If Coupling the Work Tool.............................. 206
Equipped) .................................................... 313 Electric Switch Operation .......................... 206
Operating Technique Information.................. 194 General Operation ..................................... 205
Coaching Tips ............................................ 194 Uncoupling the Work Tool.......................... 208
Operating Precaution................................. 197 Quick Coupler Operation (Hydraulic Pin
Restricted Operation.................................. 196 Grabber Quick Coupler (If Equipped)) ........ 209
Operating Techniques ................................... 194 General Operation ..................................... 209
Operation................................................. 40, 188 Quick Coupler Operation ........................... 210
Critical Failures ............................................ 40
Limiting Conditions and Criteria .................. 40 R
Machine Operating Temperature Range ..... 40
Machine Operation ...................................... 42 Radiator, Aftercooler and Oil Cooler Cores
Machine Operation when the Machine is not - Clean ......................................................... 316
Completely Assembled .............................. 43 Radio ............................................................. 158
Operation Information ................................... 188 Radio Function List .................................... 159
Lifting Objects ............................................ 189 Radio Operation......................................... 160
Operation Section............................................ 85 Selection Method....................................... 160
Operator Controls............................................ 91 USB/AUX Operation .................................. 160
12V Power Receptacle (24) & (25).............. 99 Receiver Dryer (Refrigerant) - Replace ........ 317
Dome Light (27) ......................................... 100 Reference Information Section ..................... 330
Engine Idle Shutdown.................................. 95 Reference Material ........................................ 330
Engine Start Switch (7) ................................ 95 Reference Materials ...................................... 330
Hydraulic Lockout Control (1) ...................... 91 Restricted Visibility .......................................... 37
Joystick Controls (3) .................................... 92 Rollover Protective Structure (ROPS) -
Left Side Switch Panel (2) ........................... 92 Inspect ......................................................... 317
Monitor (5) ................................................... 95 Roof Hatch..................................................... 169
Operator's Seat (8) ...................................... 96
Right Side Switch Panel (6) ......................... 96 S
Service Port (26).......................................... 99
S·O·S Information ......................................... 249
Travel Control (4) ......................................... 92
Safety Messages............................................... 7
USB/Aux Ports (23) (If Equipped)................ 99
Aerosol Starting Aid (11).............................. 17
Operator Station .............................................. 48
Crushing Hazard (10) .................................. 16
Crushing Hazard (15) .................................. 18
P Crushing Hazard (4) .................................... 12
Parking .................................................... 44, 224 Crushing Hazard (6B).................................. 13
Plate Locations and Film Locations ................ 80 Crushing Hazard (6D).................................. 14
Engine Serial Number ................................. 82 Crushing Hazard (6E).................................. 14
Product Identification Number (PIN) and CE Crushing Injury (3) ........................................11
Plate ........................................................... 80 Do Not Lift Over Personnel (7) .................... 15
Sound Certification Film .............................. 82 Do Not Operate (6A).................................... 12
Prepare the Machine for Maintenance.......... 250 Do Not Weld or Drill on ROPS (8) ............... 16
Product Information Section............................ 50 Electrical Power Lines (6G) ......................... 15
Product Link .................................................. 101 Falling Object Guard Structure (18) ............ 20
M0111427-02 335
Index Section
High-Pressure Cylinder (13)........................ 17 Swing Drive Oil Level - Check....................... 320

High-Pressure Gas (14)............................... 18 Swing Drive Oil Sample - Obtain................... 321
Hot Surface (9) ............................................ 16 Swing Gear - Lubricate.................................. 321
Joystick Controls Alternate Patterns (6F).... 15 System Pressure Release............................. 252
Jump-Start Cables (12) ............................... 17 Coolant System ......................................... 252
Lifting Level Warning (1)...............................11 Hydraulic System....................................... 252
Overload Warning Device (2) .......................11
Product Link (5) ........................................... 12 T
Relieve Hydraulic Tank Pressure (17) ......... 19
Seat Belt (6C) .............................................. 13 Table of Contents .............................................. 3
Vapor Explosion (16) (If Equipped).............. 19 Towing Information ........................................ 234
Safety Section ................................................... 7 Towing the Machine....................................... 234
Seat ................................................................. 89 Lightweight Towing .................................... 235
Comfort Seat................................................ 89 Retrieval and Towing of Machine .............. 235
Seat Belt .......................................................... 90 Track Adjustment - Adjust ............................. 323
Extension of the Seat Belt ........................... 91 Adjusting Track Tension ............................ 324
Seat Belt Adjustment for Retractable Seat Measuring Track Tension .......................... 323
Belts ........................................................... 90 Track Adjustment - Inspect............................ 325
Seat Belt - Inspect ......................................... 318 Track Information ............................................ 35
Seat Belt - Replace ....................................... 318 Transportation Information ............................ 228
Securing the Machine.................................... 229 Travel Alarm - Test (If Equipped)................... 325
Service Interval Chart.................................... 250 Travel Control (Straight Travel Pedal (If
Shipping the Machine.................................... 228 Equipped)) ................................................... 171
Shipping a Machine that is not Completely Travel in Water and Mud ............................... 198
Assembled ............................................... 229 Procedure for Removing the Machine from
Slope Operation .............................................. 44 Water or Mud ........................................... 198
Sound Information and Vibration
Information..................................................... 45 U
Sound Level Information.............................. 45
Undercarriage - Check .................................. 326
Sound Level Information for Machines in
Eurasian Economic Union Countries......... 46
Sound Level Information for Machines in V
European Union Countries and in Countries Visibility Information ........................................ 36
that Adopt the “EU Directives” ................... 46
Sources........................................................ 48
W
“The European Union Physical Agents
(Vibration) Directive 2002/44/EC”.............. 46 Warranty Information..................................... 329
Specifications .................................................. 50 Warranty Section ........................................... 329
Application/Configuration Restrictions ........ 50 Welding on Machines and Engines with
Expected Life ............................................... 50 Electronic Controls ...................................... 255
Intended Use ............................................... 50 Window (Front).............................................. 167
Specification Data........................................ 51 Window Washer Reservoir - Fill .................... 326
Working Ranges .......................................... 53 Window Wiper - Inspect/Replace .................. 327
Stopping the Engine ...................................... 225 Windows - Clean ........................................... 327
Engine Shutdown Switch........................... 225 Cleaning Methods...................................... 327
Stop the Engine if an Electrical Malfunction Polycarbonate Windows (If equipped) ...... 328
Occurs...................................................... 225 Work Tool Control (One-Way Flow) (If
Stopping the Machine.................................... 224 Equipped) .................................................... 175
Sun Screen.................................................... 169 Joystick ...................................................... 176
Swing Bearing - Lubricate ............................. 318 Work Tool Pedal......................................... 176
Swing Drive Oil - Change .............................. 319
336 M0111427-02
Index Section
Work Tool Control (Two-Way Flow) (If

Equipped) .................................................... 177
Joystick ...................................................... 177
Work Tool Pedal......................................... 178
Work Tool Flow Control ................................. 180
Work Tool Operation (If Equipped)................ 217
Crusher Operation (If Equipped) ............... 220
Hammer Operation (If Equipped) .............. 217
Shear Operation (If Equipped) .................. 219
Work Tools....................................................... 39
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:
M0111427 CAT, CATERPILLAR, LET’S DO THE WORK, their respective logos, “Caterpillar Corporate
©2021 Caterpillar Yellow”, the “Power Edge” and Cat “Modern Hex” trade dress as well as corporate and product
All Rights Reserved identity used herein, are trademarks of Caterpillar and may not be used without permission.
338 February 2021

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M0111427-02 (en-us)

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Important Safety Information

The meaning of this safety alert symbol is as follows:

Table of Contents Equipment Lowering with Engine Stopped ..... 45

Sound Information and Vibration Information . 45

Additional Messages ....................................... 20

General Information ........................................ 50

Burn Prevention............................................... 30 Operation Section

Fire Prevention and Explosion Prevention...... 31 Before Operation ............................................. 85

Fire Safety ....................................................... 34 Machine Operation .......................................... 88

Fire Extinguisher Location............................... 35 Engine Starting.............................................. 183

Track Information ............................................ 35 Operation....................................................... 188

High Pressure Fuel Lines ................................ 35 Operating Techniques ................................... 194

Electrical Storm Injury Prevention ................... 36 Parking .......................................................... 224

Before Starting Engine .................................... 36 Transportation Information ............................ 228

Visibility Information ........................................ 36 Towing Information ........................................ 234

Restricted Visibility .......................................... 37 Engine Starting (Alternate Methods)............. 237

Engine Starting................................................ 39 Maintenance Section

Before Operation ............................................. 39 Maintenance Access ..................................... 240

Work Tools....................................................... 39 Lubricant Viscosities and Refill Capacities ... 243

Operation......................................................... 40 Maintenance Support .................................... 250

Engine Stopping .............................................. 43 Maintenance Interval Schedule..................... 257

Lifting Objects.................................................. 43 Warranty Section

Demolition ....................................................... 43 Warranty Information..................................... 329

Parking ............................................................ 44 Reference Information Section

Slope Operation .............................................. 44 Reference Materials ...................................... 330

Foreword Whenever a question arises regarding your machine,

It is prohibited for any person engaged in the

Product Identification Number

Lifting Level Warning (1)

Refer to Operation and Maintenance Manual,

Crushing Injury (3)

Refer to Operation and Maintenance Manual,

Product Link (5)

Crush injury. Could cause serious injury or death.

Refer to Operation and Maintenance Manual, “Quick

Refer to Operation and Maintenance Manual,

Do Not Operate (6A)

Personal injury can result if the window is not

Illustration 11 g06188661 Illustration 12 g02282255

Crushing Hazard (6B) Seat Belt (6C)

Illustration 13 g06188642 Illustration 14 g06188644

Crushing Hazard (6D)

The impact from objects that strike the front of

Refer to Operation and Maintenance Manual,

Joystick Controls Alternate

Electrocution Hazard! Keep the machine and

Refer to Operation and Maintenance Manual,

Electrical Power Lines (6G)

This machine has been certified to the standards that

Hot Surface (9)

Do Not Weld or Drill on ROPS (8)

Engine hood and engine hood parts can be hot

Crushing Hazard (10)

This safety message is on each side of the rear of the

Structural damage, an overturn, modification, al-

Refer to Operation and Maintenance Manual,

Jump-Start Cables (12)