SEBU9084!11!00 ALLCD Compressed

SEBU9084-11 (en-us)
October 2016
Operation and
Maintenance
Manual
D-Series, D2-Series Compact Track
Loaders (CTL), Multi-Terrain Loaders
(MTL), and Skid Steer Loaders (SSL)
HRD 1-UP (226D) DTB 1-UP (262D) GTC 1-UP (299D)
DPR 1-UP (232D) KTS 1-UP (262D) JST 1-UP (299D XHP)
KXC 1-UP (232D) LST 1-UP (262D) FD2 1-UP (299D2)
BGZ 1-UP (236D) B5W 1-UP (272D) DX2 1-UP (299D2 XHP)
MPW 1-UP (236D) ETL 1-UP (272D XHP) BY4 1-UP (299D2)
SEN 1-UP (236D) BL2 1-UP (272D2) DX9 1-UP (299D2 XHP)
BL9 1-UP (239D) MD2 1-UP (272D2 KHP)
CD4 1-UP (239D) FMT 1-UP (277D)
DZT 1-UP (242D) MLT 1-UP (277D)
A9W 1-UP (242D) NTL 1-UP (277D)
DML 1-UP (242D) GTL 1-UP (279D)
BYF 1-UP (246D) PPT 1-UP (279D)
HMR 1-UP (246D) RCX 1-UP (279D)
JSL 1-UP (246D) HMT 1-UP (287D)
MKT 1-UP (246D) STK 1-UP (287D)
GWR 1-UP (249D) TLK 1-UP (287D)
AH9 1-UP (249D) TAW 1-UP (289D)
EZW 1-UP (257D) WCT 1-UP (289D)
EML 1-UP (257D) A9Z 1-UP (289D)
FMR 1-UP (257D) BE7 1-UP (297D)
FTL 1-UP (259D) HP7 1-UP (297D XHP)
GTK 1-UP (259D) BL7 1-UP (297D2)
FTK 1-UP (259D) HP2 1-UP (297D2 XHP)
Language: Original Instructions
SAFETY.CAT.COM
i06558969
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.
When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts.
Failure to follow this warning may lead to pre-
mature failures, product damage, personal in-
jury or death.
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.
SEBU9084-11 3
Table of Contents
Table of Contents Equipment Lowering with Engine Stopped ..... 48
Sound Information and Vibration Information . 48

Foreword ........................................................... 4
Guards (Operator Protection) ......................... 54
Safety Section
Safety Messages (Only Japanese market) ....... 6

Product Information Section
General Information ........................................ 56

Safety Messages..............................................11
Identification Information ............................... 140
Additional Messages ....................................... 29
General Hazard Information (Only Japanese Operation Section

market)........................................................... 33
Before Operation ........................................... 154
General Hazard Information............................ 34
Machine Operation ........................................ 155
Crushing Prevention and Cutting Prevention.. 37
Engine Starting.............................................. 215
Burn Prevention............................................... 37
Operation....................................................... 218
Fire Prevention and Explosion Prevention...... 38
Parking .......................................................... 234
Fire Safety ....................................................... 42
Transportation Information ............................ 238
Fire Extinguisher Location............................... 42
Towing Information ........................................ 250
Electrical Storm Injury Prevention ................... 43
Engine Starting (Alternate Methods)............. 252
Before Starting Engine .................................... 43
Maintenance Section
Visibility Information ........................................ 43
Maintenance Access ..................................... 255
Engine Starting................................................ 43
Lubricant Viscosities and Refill Capacities ... 263
Before Operation ............................................. 44
Maintenance Support .................................... 273
Operation......................................................... 44
Maintenance Interval Schedule..................... 276
Engine Stopping .............................................. 44
Warranty Section
High Pressure Fuel Lines ................................ 44
Warranty Information..................................... 386
Work Tools....................................................... 47
Reference Information Section
Demolition ....................................................... 47
Reference Materials ...................................... 387
Parking ............................................................ 47
Index Section
Slope Operation .............................................. 48
Index.............................................................. 406
4 SEBU9084-11
Foreword
Foreword Maintenance Intervals

Use the service hour meter to determine servicing
Literature Information intervals. Calendar intervals shown (daily, weekly,
monthly, etc.) can be used instead of service hour
This manual should be stored in the operator's meter intervals if they provide more convenient
compartment in the literature holder or seat back servicing schedules and approximate the indicated
literature storage area. service hour meter reading. Recommended service
should always be performed at the interval that
This manual contains safety information, operation occurs first.
instructions, transportation information, lubrication
information and maintenance information. Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is specified
Some photographs or illustrations in this publication in the maintenance intervals chart might be
show details or attachments that can be different necessary.
from your machine. Guards and covers might have
been removed for illustrative purposes. Perform service on items at multiples of the original
requirement. For example, at every 500 service
Continuing improvement and advancement of hours or 3 months, also service those items listed
product design might have caused changes to your under every 250 service hours or monthly and every
machine which are not included in this publication. 10 service hours or daily.
Read, study and keep this manual with the machine.
Whenever a question arises regarding your machine, California Proposition 65 Warning
or this publication, please consult your Cat dealer for
the latest available information. Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm.
Safety
Battery posts, terminals and related accessories
The safety section lists basic safety precautions. In contain lead and lead compounds. Wash hands
addition, this section identifies the text and locations after handling.
of warning signs and labels used on the machine.
Read and understand the basic precautions listed in Certified Engine Maintenance
the safety section before operating or performing
lubrication, maintenance and repair on this machine. Proper maintenance and repair is essential to keep
the engine and machine systems operating correctly.
As the heavy duty off-road diesel engine owner, you
Operation are responsible for the performance of the required
maintenance listed in the Owner Manual, Operation
The operation section is a reference for the new and Maintenance Manual, and Service Manual.
operator and a refresher for the experienced
operator. This section includes a discussion of
gauges, switches, machine controls, attachment
controls, transportation and towing information.
Photographs and illustrations guide the operator
through correct procedures of checking, starting,
operating and stopping the machine.
Operating techniques outlined in this publication are
basic. Skill and techniques develop as the operator
gains knowledge of the machine and its capabilities.
Maintenance
The maintenance section is a guide to equipment
care. The Maintenance Interval Schedule (MIS) lists
the items to be maintained at a specific service
interval. Items without specific intervals are listed
under the "When Required" service interval. The
Maintenance Interval Schedule lists the page number
for the step-by-step instructions required to
accomplish the scheduled maintenance. Use the
Maintenance Interval Schedule as an index or "one
safe source" for all maintenance procedures.
SEBU9084-11 5
Foreword
It is prohibited for any person engaged in the Machines and generator sets produced before First
business of repairing, servicing, selling, leasing, or Quarter 2001 will maintain their 8 character PIN
trading engines or machines to remove, alter, or format.
render inoperative any emission related device or
element of design installed on or in an engine or Components such as engines, transmissions, axles,
machine that is in compliance with the regulations etc. and work tools will continue to use an 8 character
Serial Number (S/N).
(40 CFR Part 89). 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.
Cat Product Identification Number

Effective First Quarter 2001 the Cat Product
Identification Number (PIN) has changed from 8 to 17
characters. In an effort to provide uniform equipment
identification, Caterpillar and other construction
equipment manufacturers are moving to comply with
the latest version of the product identification
numbering standard. Non-road machine PINs are
defined by ISO 10261. The new PIN format will apply
to all Cat 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 g00751314
Where:
1. Caterpillar's World Manufacturing Code
(characters 1-3)
2. Machine Descriptor (characters 4-8)
3. Check Character (character 9)
4. Machine Indicator Section (MIS) or Product
Sequence Number (characters 10-17). These were
previously referred to as the Serial Number.
6 SEBU9084-11
Safety Section
Safety Messages
Safety Section
i05840662
Safety Messages
(Only Japanese market)
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. Be familiar with all safety messages.
Make sure that all of the safety messages are legible.
Clean the safety messages or replace the safety
messages if you cannot read the words. Replace the
illustrations if the illustrations are not legible. When
you clean the safety messages, use a cloth, water,
and soap. Do not use solvent, gasoline, or other
harsh chemicals to clean the safety 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.
SEBU9084-11 7
Safety Section
Only Japanese market
Crushing Hazard (1)

This safety message is located on both sides of the
lift arm.
8 SEBU9084-11
Safety Section
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
Maintenance Manual. Failure to follow the
instructions and warnings will cause serious
injury or death
Crash Hazard (3)

This safety message is located inside cab.
Stay clear of the work tool during operation. En-

tanglement could result in personal injury or
death.
Electrical Power Lines (2)

This safety message is Located inside cab.
Stay back a safe distance. No clearance for a per-

son in this area when the machine turns. Severe
injury or death from crushing could occur.
Crushing Hazard (4)

This safety message is located inside cab.
SEBU9084-11 9
Safety Section
High Pressure Cylinder. Do not remove any parts

from the cylinder until all of the pressure has
Illustration 6 g03094541 been relieved. This will prevent possible personal
injury or death.
Crush Hazard! A machine may move unexpect-

Explosion Hazard (6)
edly and without warning resulting in personal in-
jury or death. This safety message is located at rear of the
machine.
Before leaving the machine lower the work tool to
the ground, lock operator controls, shut off the
engine and remove the key.
High Pressure Cylinder (5)

This Safety message is positioned on the track
adjusters.
Personal injury can result from improper trouble-

shooting and repair procedures.
The following troubleshooting and repair proce-
dures should only be performed by qualified per-
sonnel familiar with this equipment.
Cutting Hazard (7)

This safety message is located at the rear of the
machine.
10 SEBU9084-11
Safety Section
Cutting Hazard! Keep hands clear of fan while en-

gine is running. May cause serious injury or
death. Illustration 10 g03369790
Rotating Fan (8)

Explosion Hazard! Improper jumper cable con-
This safety message is located at the rear of the nections can cause an explosion resulting in seri-
machine. ous injury or death. Batteries may be located in
separate compartments. Refer to the Operation
and Maintenance Manual for the correct jump
starting procedure.
Jump Start Cables (9)

This warning is located at rear of the machine.
SEBU9084-11 11
Safety Section
Safety Messages
Illustration 11 g03369796 Illustration 12 g03369781
Explosion Hazard! Improper jumper cable con- Do not use this surface as a step or platform. This
nections can cause an explosion resulting in seri- surface may not support additional weight or may
ous injury or death. Batteries may be located in be slippery. Serious injury or death could occur
separate compartments. Refer to the Operation from a fall.
and Maintenance Manual for the correct jump
starting procedure.
i06124054
Falling Hazard (10) Safety Messages

This safety message is located on lift arm. 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. Be familiar with all safety messages.
Make sure that all of the safety messages are legible.
Clean the safety messages or replace the safety
messages if you cannot read the words. Replace the
illustrations if the illustrations are not legible. When
you clean the safety messages, use a cloth, water,
and soap. Do not use solvent, gasoline, or other
harsh chemicals to clean the safety 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.
12 SEBU9084-11
Safety Section
Safety Messages
(1) Do Not Operate. (6) Never Permit Riders. (12) Accumulator

(2) Rollover Protective Structure/Falling (7) Seat Belt (12A) High Pressure Cylinder
Object Protective Structure (8) Pressurized System (13) Aerosol Starting Aid
(3) Jump Starting (9) Work Tool Coupler (14) Armrests
(4) Crushing Hazard (10) Cab Support (15) Product Link
(5) Stay Inside Operator Station (11) Brace for the Loader Lift Arms (16) High Pressure Fuel
Do Not Operate (1)

This warning film is located inside the cab on the left
hand rear ROPS post.
SEBU9084-11 13
Safety Section
Safety Messages
Read and understand the instructions and warn-

ings in the operation and maintenance manuals.
Contact any Caterpillar dealer for replacement
manuals. Proper care is your responsibility.
Be alert! Know work conditions. Note and avoid
all hazards and obstructions. Keep by-standers
Read and understand the instructions and warn- away when operating.
ings in the operation and maintenance manuals.
Contact any Caterpillar dealer for replacement Fasten seat belt and lower armrests.
manuals. Proper care is your responsibility. Make certain all controls are in neutral position
and start engine.
Be alert! Know work conditions. Note and avoid
all hazards and obstructions. Keep by-standers Disengage parking brake.
away when operating.
Machine controls are active.
Fasten seat belt and lower armrests.
Failure to follow the instructions or heed the
Make certain all controls are in neutral position warnings could result injury or death.
and start engine.
Disengage parking brake.
Rollover Protective Structure/
Machine controls are active.
Falling Object Protective Structure
Failure to follow the instructions or heed the (2)
warnings could result injury or death.
The no drill/no weld warning film is located inside the
cab on the left hand rear ROPS post. The ROPS
Do Not Operate (1) (Engine) certification film is located inside the cab on the right
hand rear ROPS post.
This message is also located on the engine.
14 SEBU9084-11
Safety Section
Safety Messages
Structural damage, an overturn, modification, al-

teration, or improper repair can impair this struc-
ture's protection capability thereby voiding this Illustration 17 g01409730
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.
Improper jumper cable connections can cause
explosion resulting in personal injury. Batteries
This machine has been certified to the standards that may be located in separate compartments, al-
are listed on the certification plate. The maximum ways connect positive (+) cable to positive (+) ter-
mass of the machine, which includes the operator
minal of battery connected to starter solenoid
and the attachments without a payload, should not
and negative (−) cable from external source to en-
exceed the mass on the certification film.
gine block or frame.
Jump Start (3)
This warning message is located near the battery on
Crush Hazard (4)
the inside of the engine compartment.
This warning is located on the loader arm linkage of
the machines that are equipped with vertical lift.
SEBU9084-11 15
Safety Section
Safety Messages
Keep your body inside the operator station while

operating the loader.
Never work with your arms, feet or legs beyond
the operator station.
No clearance for person in this area during opera- warnings will result in injury or death.
tion. Severe injury or death from crushing could
occur. Stay away from the work tool while it is in
operation. Never Permit Riders (6)
This warning message is located inside the cab on
Stay Inside Operator Station (5) the upper right-hand switch console.

the upper left-hand switch console.
16 SEBU9084-11
Safety Section
Safety Messages
Never permit riders.

Never use work tool for a work platform. Illustration 21 g01371636

warnings could result in injury or death.
A seat belt should be worn at all times during ma-

Seat Belt (7) chine operation to prevent serious injury or death
in the event of an accident or machine overturn.
This warning message is located inside the cab on Failure to wear a seat belt during machine opera-
the right-hand joystick console. tion may result in serious injury or death.
Refer to Operation and Maintenance Manual, “Seat

Belt” for more information.
Pressurized System (8)

This warning message is located on the radiator by
the radiator cap.
SEBU9084-11 17
Safety Section
Safety Messages
Improper Attachment of the Work Tool could re-

sult in injury or death.
Do not operate the machine without confirmation
that the coupler pins are fully engaged. Follow
the operating procedures in the Operation and
Maintenance Manual.
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 Refer to Operation and Maintenance Manual, “Work
the pressure. Tool Coupler Operation” for the proper procedure for
the work tool coupler.
Work Tool Coupler (9) Cab Support (10)

This warning message is located inside the cab on This warning message is located outside the cab on
the upper left-hand switch console. the right-hand side near the cab support latch.
18 SEBU9084-11
Safety Section
Safety Messages
Refer to Operation and Maintenance Manual,

“Loader Lift Arm Brace Operation” for operating
information.
Accumulator (12)
This warning message is located near the
accumulator behind the cab. If your machine is
equipped with ride control, there will be an additional
accumulator in this location.
Do not go beneath cab unless cab is empty and

support lever is engaged.
Brace for the Loader Lift Arms (11)
This warning message is located on the brace for the
loader lift arms. 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
manual before servicing the accumulator or any
accumulator component.
Failure to follow the instructions and warnings
could result in personal injury or death.
Only use dry nitrogen gas to recharge accumula-
tors. See your Cat dealer for special equipment
and detailed information for accumulator service
and charging.
High Pressure Cylinder (12A)

Loader lift arm brace must be in place when work- This safety message is located on the undercarriage
ing under raised lift arms. by the access panel. (Only on the CTL).

SEBU9084-11 19
Safety Section
Safety Messages
Personal injury can result from grease under high Do not use ether. This machine is equipped with
pressure. glow plugs. Using ether can create explosions or
fires that can cause personal injury or death.
The adjuster cylinder for the track is under high Read and follow the engine starting procedure in
hydraulic pressure. Grease under high pressure the Operation and Maintenance Manual.
can cause injury.
Do not visually inspect the adjuster cylinder to
see if grease is released when the valve is Armrests (14)
opened. Look to see that the track has loosened.
the left-hand joystick console.
Refer to Operation and Maintenance Manual, “Track
- Inspect/Adjust (Detension the Track)” for more
information.
Aerosol Starting Aid (13)

This warning message is located on the side of the
air cleaner housing or inside the engine compartment
on the frame wall near the air cleaner.
20 SEBU9084-11
Safety Section
Safety Messages
This machine is equipped with a Caterpillar Prod-

uct Link communication device. When electric
detonators are used, this communication device
should be deactivated within 12 m (40 ft) of a
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-
Crush/Ejection Hazard! Could cause serious in- plicable legal requirements. Failure to do so
jury or death. could cause interference with blasting operations
and result in serious injury or death.
Always wear seatbelt and lower both armrests
while operating machine. Read the Operation and In cases where the type of Product Link module
Maintenance Manual. cannot be identified, Caterpillar recommends that
the device be disabled no less than 12 m (40 ft)
from the blast perimeter.
Product Link (If equipped) (15)
This safety message is located inside the cab on the High Pressure Fuel (16)
right-hand window.
This safety message is located inside the engine
compartment on the engine on or near the common
rail fuel lines.
SEBU9084-11 21
Safety Section
Safety Messages
Contact with high pressure fuel may cause fluid

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.
Work Tools
22 SEBU9084-11
Safety Section
Safety Messages
SEBU9084-11 23
Safety Section
Safety Messages
Work Tools
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.
Contact your Caterpillar dealer for replacement
manuals. Proper care is your responsibility.
Industrial Grapple Bucket (17)

These warning messages are located on top of the
guards for the grapple cylinders.
No clearance for person in this area during opera-

tion. Severe injury or death from impalement
could occur. Stay away from the work tool while it
is in operation.
Industrial Grapple Fork (19)

These warning messages are located on the guards
for the grapple cylinders.

operation.
Utility Fork (18)

fork carriage.
24 SEBU9084-11
Safety Section
Safety Messages
No clearance for person in this area during opera- No clearance for person in this area during opera-
tion. Severe injury or death from crushing could tion. Severe injury or death from impalement
occur. Stay away from the work tool while it is in could occur. Stay away from the work tool while it
operation. is in operation.
Industrial Grapple Fork (20) Angle Blade (21)

These warning messages are located on top of the These warning messages are located on the back
fork carriage. side of the blade.
SEBU9084-11 25
Safety Section
Safety Messages
tion. Severe injury or death from crushing could tion. Severe injury or death from impalement
occur. Stay away from the work tool while it is in could occur. Stay away from the work tool while it
operation. is in operation.
Utility Grapple Fork (22) Utility Grapple Fork (23)

These warning messages are located on top of the These warning messages are located on top of the
fork carriage. grapple frame.
26 SEBU9084-11
Safety Section
Safety Messages
tion. Severe injury or death from crushing could tion. Severe injury or death from crushing could
occur. Stay away from the work tool while it is in occur. Stay away from the work tool while it is in
operation. operation.
Utility Grapple Bucket (24) Dozer Blade (25)

These warning messages are located on top of the This warning message is located on top of the dozer
grapple frame. blade.
SEBU9084-11 27
Safety Section
Safety Messages
Falling Hazard - Area may be oily and slippery. Do

not step on cylinders. Serious injury or death
could occur from a fall. Illustration 42 g01378775
Dozer Blade (26)

This warning message is located on top of the dozer tion. Severe injury or death from crushing could
blade. occur. Stay away from the work tool while it is in
operation.
Dozer Blade (27)

These warning messages are located on the back
side of the blade.
28 SEBU9084-11
Safety Section
Safety Messages
No clearance for person in this area during opera- DO NOT OPERATE OR WORK ON THIS MACHINE
tion. Severe injury or death from crushing could UNLESS YOU HAVE READ AND UNDERSTAND
occur. Stay away from the work tool while it is in THE INSTRUCTIONS AND WARNINGS IN THE OP-
operation. ERATION AND MAINTENANCE MANUALS. FAIL-
URE TO FOLLOW THE INSTRUCTIONS OR HEED
THE WARNINGS COULD RESULT IN INJURY OR
DEATH. CONTACT ANY CATERPILLAR DEALER
Dozer Blade (28) FOR REPLACEMENT MANUALS. PROPER CARE
IS YOUR RESPONSIBILITY.
This warning is located on right-hand side on the
back of the blade.
Grapple Rake (29)
grapple frame.
SEBU9084-11 29
Safety Section
Additional Messages
The primary alternate exit is the rear window.

However, the front door may also be used if
necessary. Refer to Operation and Maintenance
No clearance for person in this area during opera- Manual, “Alternate Exit” for detailed instructions.
operation. Air Conditioner (If Equipped)
This message is located under the cab, attached to
the air conditioning line near the service port.
i06754269
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 messages are reviewed in this
section. Become familiarized with all messages.
Make sure that all of the messages are legible. Clean
the messages or replace the messages if you cannot
read the words. Replace the illustrations if the
illustrations are not legible. When you clean the
messages, use a cloth, water, and soap. Do not use
solvent, gasoline, or other harsh chemicals to clean
the messages. Solvents, gasoline, or harsh Illustration 47 g00990500
chemicals could loosen the adhesive that secures the
messages. Loose adhesive will allow the messages Read the service manual before you perform any
to fall. maintenance on the air conditioner.
Replace any message that is damaged, or missing. If
a message is attached to a part that is replaced, No Step
install a message on the replacement part. Any Cat
dealer can provide new messages. This message is located in areas that prohibit
standing.
Alternate Exit
This message is located inside the cab on the
window glass.
30 SEBU9084-11
Safety Section
Additional Messages
Do not step in these locations. Do not stand in these Refer to Operation and Maintenance Manual,
locations. “Lubricant Viscosities” for more information about the
hydraulic oil.
Product Link (If Equipped)
DEF Purge
If equipped, this following message is located in the
cab on the left post. DEF purge indicator lamp film is located inside the
engine compartment near the battery disconnect
switch. DEF purge indicator lamp film will only apply
to D2-Series models BL21–Up, DX21–Up, FD21–Up,
MD21–Up, BL71–Up, and HP21–Up.
Machine Hydraulic System

This machine hydraulic system is filled with Cat
HYDO Advanced oil. The following message is
located by the hydraulic tank. NOTICE
Wait until light shuts off to apply the battery discon-
nect. This waiting period will allow the DEF system to
be purged. Purging prevents DEF from freezing in
the lines.
DEF Fill
DEF fill film (will only apply to D2-Series models) and
is located on the right-hand side of the machine near
the DEF fill access door. DEF fill film will only apply to
D2-Series models BL21–Up, DX21–Up, FD21–Up,
MD21–Up, BL71–Up, and HP21–Up.
SEBU9084-11 31
Safety Section
Additional Messages
Japanese Market Only
Emissions (1)
This message is located on the left side of the
machine.
32 SEBU9084-11
Safety Section
Additional Messages
Clean Engine (4)

This message is located at rear side of the machine.
Low Sound Certification (2)

This message is located on the left side of the
machine.
Recycle HFC Refrigerant (5)

Diesel Fuel (3)

SEBU9084-11 33
Safety Section
General Hazard Information
S/N: CD41–Up
S/N: BE71–Up
S/N: BL71–Up
S/N: HP71–Up
S/N: AH91–Up
S/N: BL91–Up
S/N: DX91–Up
S/N: DTB1–Up
S/N: GTC1–Up
Illustration 58 g03351365 S/N: KXC1–Up
S/N: HRD1–Up
OSHA Plate (6)
S/N: BYF1–Up
This message is located at rear side of the machine. S/N: FTK1–Up
S/N: GTK1–Up
S/N: STK1–Up
S/N: TLK1–Up
S/N: DML1–Up
S/N: EML1–Up
S/N: ETL1–Up
S/N: FTL1–Up
S/N: GTL1–Up
S/N: JSL1–Up
S/N: NTL1–Up
S/N: SEN1–Up
S/N: DPR1–Up
S/N: FMR1–Up
S/N: GWR1–Up
i05793252 S/N: HMR1–Up
General Hazard Information S/N: KTS1–Up
(Only Japanese market) S/N: DZT1–Up

SMCS Code: 7000 S/N: FMT1–Up
S/N: BL21–Up S/N: HMT1–Up
S/N: DX21–Up S/N: JST1–Up
S/N: FD21–Up S/N: LST1–Up
S/N: HP21–Up S/N: MLT1–Up
S/N: MD21–Up S/N: PPT1–Up
S/N: BY41–Up S/N: WCT1–Up

34 SEBU9084-11
Safety Section
S/N: A9W1–Up Attach a “Do Not Operate” warning tag or a similar

warning tag to the start switch or to the controls.
S/N: B5W1–Up Attach the warning tag before you service the
S/N: EZW1–Up equipment or before you repair the equipment. These
warning tags (Special Instruction, SEHS7332) are
S/N: MPW1–Up available from your Cat dealer.
S/N: TAW1–Up
S/N: RCX1–Up
Operating the machine while distracted can result
S/N: A9Z1–Up in the loss of machine control. Use extreme cau-
tion when using any device while operating the
S/N: BGZ1–Up machine. Operating the machine while distracted
can result in personal injury or death.
Know the width of your equipment in order 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.
Attach a “Do Not Operate” , or a similar warning tag

to the start switch or to the controls before you
service or repair the equipment. These warning tags
(Special Instruction, RJX88874) are available from
your Cat dealer.
i06534169
General Hazard Information Illustration 62 g00702020
SMCS Code: 7000 Wear a hard hat, protective glasses, and other
protective equipment, as required.
Do not wear loose clothing or jewelry that can snag
on controls or on other parts of the equipment.
Make sure that all protective guards and all covers
are secured in place on the equipment.
Keep the equipment free from foreign material.
Remove debris, oil, tools, and other items from the
deck, from walkways, and from steps.
Secure all loose items such as lunch boxes, tools,
and other items that are not a part of the equipment.
Know the appropriate work site hand signals and the
personnel that are authorized to give the hand
signals. Accept hand signals from one person only.
Typical example
SEBU9084-11 35
Safety Section
Do not smoke when you service an air conditioner. Avoid direct spraying of water on electrical
Also, do not smoke if refrigerant gas may be present. connectors, connections, and components. When
Inhaling the fumes that are released from a flame that using air for cleaning, allow the machine to cool to
contacts air conditioner refrigerant can cause bodily reduce the possibility of fine debris igniting when re-
harm or death. Inhaling gas from air conditioner deposited on hot surfaces.
refrigerant through a lighted cigarette can cause
bodily harm or death. Trapped Pressure
Never put maintenance fluids into glass containers.
Drain all liquids into a suitable container. Pressure can be trapped in a hydraulic system.
Releasing trapped pressure can cause sudden
Obey all local regulations for the disposal of liquids. machine movement or attachment movement. Use
caution if you disconnect hydraulic lines or fittings.
Use all cleaning solutions with care. Report all High-pressure oil that is released can cause a hose
necessary repairs. to whip. High-pressure oil that is released can cause
oil to spray. Fluid penetration can cause serious
Do not allow unauthorized personnel on the injury and possible death.
equipment.
Unless you are instructed otherwise, perform
Fluid Penetration
maintenance with the equipment in the servicing Pressure can be trapped in the hydraulic circuit long
position. Refer to Operation and Maintenance after the machine has been stopped. The pressure
Manual for the procedure for placing the equipment can cause hydraulic fluid or items such as pipe plugs
in the servicing position. to escape rapidly if the pressure is not relieved
When you perform maintenance above ground level, correctly.
use appropriate devices such as ladders or man lift Do not remove any hydraulic components or parts
machines. If equipped, use the machine anchorage until pressure has been relieved or personal injury
points and use approved fall arrest harnesses and may occur. Do not disassemble any hydraulic
lanyards. components or parts until pressure has been relieved
or personal injury may occur. Refer to the Service
Pressurized Air and Water Manual for any procedures that are required to
relieve the hydraulic pressure.
Pressurized air and/or water can cause debris and/or
hot water to be blown out. The debris and/or hot
water could result in personal injury.
When pressurized air and/or pressurized water is
used for cleaning, wear protective clothing, protective
shoes, and eye protection. Eye protection includes
goggles or a protective face shield.
The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the
nozzle is deadheaded and the nozzle is used with an
effective chip deflector and personal protective
equipment. The maximum water pressure for
cleaning purposes must be below 275 kPa (40 psi).
36 SEBU9084-11
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 64 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.
SEBU9084-11 37
Safety Section
Crushing Prevention and Cutting Prevention
• Use exhaust ventilation on permanent machining Do not work beneath the cab of the machine unless
jobs. the cab is properly supported.
• Wear an approved respirator if there is no other Unless you are instructed otherwise, never attempt
way to control the dust. adjustments while the machine is moving or while the
engine is running.
• Comply with applicable rules and regulations for
the work place. In the United States, use Never jump across the starter solenoid terminals in
order to start the engine. Unexpected machine
Occupational Safety and Health Administration movement could result.
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”. In Japan, Whenever there are equipment control linkages the
use the requirements found in the “Ordinance on clearance in the linkage area will change with the
Prevention of Health Impairment due to Asbestos” movement of the equipment or the machine. Stay
in addition to the requirements of the Industrial clear of areas that may have a sudden change in
Safety and Health Act. clearance with machine movement or equipment
movement.
• Obey environmental regulations for the disposal of Stay clear of all rotating and moving parts.
asbestos.
If it is necessary to remove guards in order to perform
• Stay away from areas that might have asbestos maintenance, always install the guards after the
particles in the air. maintenance is performed.
Dispose of Waste Properly Keep objects away from moving fan blades. The fan
blade will throw objects or cut objects.
Do not use a kinked wire cable or a frayed wire cable.
Wear gloves when you handle wire cable.
When you strike a retainer pin with force, the retainer
pin can fly out. The loose retainer pin can injure
personnel. Make sure that the area is clear of people
when you strike a retainer pin. To avoid injury to your
eyes, wear protective glasses when you strike a
retainer pin.
Chips or other debris can fly off an object when you
strike the object. Make sure that no one can be
injured by flying debris before striking any object.
i05160631
Burn Prevention
Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be SMCS Code: 7000
disposed of according to local regulations. Do not touch any part of an operating engine. Allow
machine systems to cool before any maintenance is
Always use leakproof containers when you drain
performed. Relieve all pressure in the air system, in
fluids. Do not pour waste onto the ground, down a
the oil system, in the lubrication system, in the fuel
drain, or into any source of water.
system, or in the cooling system before any lines,
fittings, or related items are disconnected.
i01359664
Crushing Prevention and

Cutting Prevention
SMCS Code: 7000
Support the equipment properly before you perform
any work or maintenance beneath that equipment.
Do not depend on the hydraulic cylinders to hold up
the equipment. Equipment can fall if a control is
moved, or if a hydraulic line breaks.
38 SEBU9084-11
Safety Section
Fire Prevention and Explosion Prevention
Exhaust Gas Recirculation Cooler Remove the hydraulic tank filler cap only after the
engine has been stopped. The filler cap must be cool
The exhaust gas recirculation (EGR) cooler may enough to touch with a bare hand. Follow the
contain a small amount of sulfuric acid. The use of standard procedure in this manual in order to remove
fuel with sulfur levels greater than 15 ppm may the hydraulic tank filler cap.
increase the amount of sulfuric acid that is formed.
The sulfuric acid may spill from the EGR cooler
during service of the engine. The sulfuric acid will Batteries
burn the eyes, skin, and clothing on contact. Always
wear eye shields, rubber gloves, and protective Electrolyte is an acid. Electrolyte can cause personal
clothing when you may come in contact with fluids injury. Do not allow electrolyte to contact the skin or
that may spill from the EGR cooler. If fluid contacts the eyes. Always wear protective glasses for
the eyes, immediately flush with water and seek servicing batteries. Wash hands after touching the
medical help. batteries and connectors. Use of gloves is
recommended.
Coolant i06179517
When the engine is at operating temperature, the

engine coolant is hot. The coolant is also under Fire Prevention and Explosion
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.
Prevention
SMCS Code: 7000
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 in
order to relieve pressure.
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.
Oils
Hot oil and hot components can cause personal
injury. Do not allow hot oil to contact the skin. Also,
do not allow hot components to contact the skin. Regeneration
The exhaust gas temperatures during regeneration
will be elevated. Follow proper fire prevention
instructions and use the disable regeneration
function (if equipped) when appropriate.
General
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”.
SEBU9084-11 39
Safety Section
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.
Keep the access doors to major machine
compartments closed and access doors in working
condition in order to permit the use of fire
suppression equipment, in case a fire should occur.
Clean all accumulations of flammable materials such
as fuel, oil, and debris from the machine.
Do not operate the machine near any flame.
Keep shields in place. Exhaust shields (if equipped)
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. Illustration 67 g03839130
Do not weld or flame cut on tanks or lines that contain Use caution when you are fueling a machine. Do not
flammable fluids or flammable material. Empty and smoke while you are fueling a machine. Do not fuel a
purge the lines and tanks. Then clean the lines and machine near open flames or sparks. Do not use cell
tanks with a nonflammable solvent prior to welding or phones or other electronic devices while you are
flame cutting. Ensure that the components are refueling. Always stop the engine before fueling. Fill
properly grounded in order to avoid unwanted arcs. the fuel tank outdoors. Properly clean areas of
spillage.
Dust that is generated from repairing nonmetallic
hoods or fenders may be flammable and/or Avoid static electricity risk when fueling. Ultra low
explosive. Repair such components in a ventilated sulfur diesel (ULSD) poses a greater static ignition
area away from open flames or sparks. Use suitable hazard than earlier diesel formulations with a higher
Personal Protection Equipment (PPE). sulfur content. Avoid death or serious injury from fire
or explosion. Consult with your fuel or fuel system
Inspect all lines and hoses for wear or deterioration. supplier to ensure that the delivery system is in
Replace damaged lines and hoses. The lines and the compliance with fueling standards for proper
hoses should have adequate support and secure grounding and bonding practices.
clamps. Tighten all connections to the recommended
torque. Damage to the protective cover or insulation
may provide fuel for fires.
Store fuels and lubricants in properly marked
containers away from unauthorized personnel. Store
oily rags and flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials.
40 SEBU9084-11
Safety Section
Never store flammable fluids in the operator • Abrasion

compartment of the machine.
• Cracking
Battery and Battery Cables • Discoloration
• Cuts on the insulation of the cable
• Fouling
• Corroded terminals, damaged terminals, and
loose terminals
Replace damaged battery cable(s) and replace any
related parts. Eliminate any fouling, which may have
caused insulation failure or related component
damage or wear. Ensure that all components are
reinstalled correctly.
An exposed wire on the battery cable may cause a
short to ground if the exposed area comes into
contact with a grounded surface. A battery cable
short produces heat from the battery current, which
may be a fire hazard.
An exposed wire on the ground cable between the
battery and the disconnect switch may cause the
disconnect switch to be bypassed if the exposed area
comes into contact with a grounded surface. This
Illustration 68 g03839133 may result in an unsafe condition for servicing the
machine. Repair components or replace components
Caterpillar recommends the following in order to before servicing the machine.
minimize the risk of fire or an explosion related to the
battery.
Do not operate a machine if battery cables or related
parts show signs of wear or damage. Contact your Fire on a machine can result in personal injury or
Cat dealer for service. death. Exposed battery cables that come into
contact with a grounded connection can result in
Follow safe procedures for engine starting with jump- fires. Replace cables and related parts that show
start cables. Improper jumper cable connections can signs of wear or damage. Contact your Cat
cause an explosion that may result in injury. Refer to dealer.
Operation and Maintenance Manual, “Engine Starting
with Jump Start Cables” for specific instructions.
Do not charge a frozen battery. This may cause an
Wiring
explosion.
Check electrical wires daily. If any of the following
Gases from a battery can explode. Keep any open conditions exist, replace parts before you operate the
flames or sparks away from the top of a battery. Do machine.
not smoke in battery charging areas. Do not use cell
phones or other electronic devices in battery • Fraying
charging areas.
• Signs of abrasion or wear
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter in • Cracking
order to check the battery charge.
• Discoloration
Daily inspect battery cables that are in areas that are
visible. Inspect cables, clips, straps, and other • Cuts on insulation
restraints for damage. Replace any damaged parts.
Check for signs of the following, which can occur • Other damage
over time due to use and environmental factors: Make sure that all clamps, guards, clips, and straps
• Fraying are reinstalled correctly. This will help to prevent
vibration, rubbing against other parts, and excessive
heat during machine operation.
SEBU9084-11 41
Safety Section
Attaching electrical wiring to hoses and tubes that Make sure that all clamps, guards, and heat shields
contain flammable fluids or combustible fluids should are installed correctly. During machine operation, this
be avoided. will help to prevent vibration, rubbing against other
parts, excessive heat, and failure of lines, tubes, and
Consult your Cat dealer for repair or for replacement hoses.
parts.
Do not operate a machine when a fire hazard exists.
Keep wiring and electrical connections free of debris. Repair any lines that are corroded, loose, or
damaged. Leaks may provide fuel for fires. Consult
Lines, Tubes, and Hoses your Cat dealer for repair or for replacement parts.
Use genuine Cat parts or the equivalent, for
Do not bend high-pressure lines. Do not strike high- capabilities of both the pressure limit and
pressure lines. Do not install any lines that are bent temperature limit.
or damaged. Use the appropriate backup wrenches
in order to tighten all connections to the Ether
recommended torque.
Ether (if equipped) is commonly used in cold-weather
applications. Ether is flammable and poisonous.
Only use approved Ether canisters for the Ether
dispensing system fitted to your machine, do not
spray Ether manually into an engine, follow the
correct cold engine starting procedures. Refer to the
section in the Operation and Maintenance Manual
with the label “Engine Starting” .
Manually spraying Ether into an engine with a

Diesel Particulate Filter (DPF) may result in the
accumulation of Ether in the DPF and an explo-
sion. This in conjunction with other factors may
result in an injury or death.
Check lines, tubes, and hoses carefully. Wear
Personal Protection Equipment (PPE) in order to
Use ether in ventilated areas. Do not smoke while
check for leaks. Always use a board or cardboard you are replacing an ether cylinder.
when you check for a leak. Leaking fluid that is under
pressure can penetrate body tissue. Fluid penetration Do not store ether cylinders in living areas or in the
can cause serious injury and possible death. A pin operator compartment of a machine. Do not store
hole leak can cause severe injury. If fluid is injected ether cylinders in direct sunlight or in temperatures
into your skin, you must get treatment immediately. above 49° C (120.2° F). Keep ether cylinders away
Seek treatment from a doctor that is familiar with this from open flames or sparks.
type of injury.
Dispose of used ether cylinders properly. Do not
Replace the affected parts if any of the following puncture an ether cylinder. Keep ether cylinders
conditions are present: away from unauthorized personnel.
• End fittings are damaged or leaking.
Fire Extinguisher
• Outer coverings are chafed or cut.
As an additional safety measure, keep a fire
• Wires are exposed. extinguisher on the machine.
• Outer coverings are swelling or ballooning. Be familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
• Flexible parts of the hoses are kinked. extinguisher regularly. Follow the recommendations
on the instruction plate.
• Outer covers have exposed embedded armoring.
• End fittings are displaced.
42 SEBU9084-11
Safety Section
Fire Safety
Consider installation of an aftermarket Fire Remember, if you are unable to do anything else,
Suppression System, if the application and working shut off the machine before exiting. By shutting off
conditions warrant the installation. the machine, fuels will not continue to be pumped
into the fire.
i04025591
If the fire grows out of control, be aware of the
following risks:
Fire Safety
SMCS Code: 7000 • Tires on wheeled machines pose a risk of
explosion as tires burn. Hot shrapnel and debris
Note: Locate secondary exits and how to use the can be thrown great distances in an explosion.
secondary exits before you operate the machine.
• Tanks, accumulators, hoses, and fittings can
Note: Locate fire extinguishers and how to use a fire rupture in a fire, spraying fuels and shrapnel over
extinguisher before you operate the machine. a large area.
If you find that you are involved in a machine fire, • Remember that nearly all of the fluids on the
your safety and that of others on site is the top machine are flammable, including coolant and oils.
priority. The following actions should only be Additionally, plastics, rubbers, fabrics, and resins
performed if the actions do not present a danger or in fiberglass panels are also flammable.
risk to you and any nearby people. At all times you
should assess the risk of personal injury and move i05149911
away to a safe distance as soon as you feel unsafe.
Move the machine away from nearby combustible Fire Extinguisher Location
material such as fuel/oil stations, structures, trash, SMCS Code: 7000; 7419
mulch and timber.
Lower any implements and turn off the engine as Make sure that a fire extinguisher is on the machine.
soon as possible. If you leave the engine running, the Make sure that you are familiar with the operation of
engine will continue to feed a fire. The fire will be fed the fire extinguisher. Inspect the fire extinguisher and
from any damaged hoses that are attached to the service the fire extinguisher. Obey the
engine or pumps. recommendations on the instruction plate.
If possible, turn the battery disconnect switch to the

OFF position. Disconnecting the battery will remove
the ignition source in the event of an electrical short.
Disconnecting the battery will eliminate a second
ignition source if electrical wiring is damaged by the
fire, resulting in a short circuit.
Notify emergency personnel of the fire and your
location.
If your machine is equipped with a fire suppression
system, follow the manufacturers procedure for
activating the system.
Note: Fire suppression systems need to be regularly

inspected by qualified personnel. You must be
trained to operate the fire suppression system.
Use the on-board fire extinguisher and use the
following procedure:
1. Pull the pin.
2. Aim the extinguisher or nozzle at the base of the
fire. Mount the fire extinguisher on the left side of the cab
3. Squeeze the handle and release the extinguishing behind the seat. Consult your Cat dealer for the
agent. proper procedure for mounting the fire extinguisher.
4. Sweep the extinguisher from side to side across

the base of the fire until the fire is out.
SEBU9084-11 43
Safety Section
Electrical Storm Injury Prevention
i01122596 Your machine may be equipped with visual aids.

Some examples of visual aids are Closed Circuit
Electrical Storm Injury Television (CCTV) and mirrors. Before operating the
machine, ensure that the visual aids are in proper
Prevention working condition and that the visual aids are clean.
Adjust the visual aids using the procedures that are
SMCS Code: 7000 located in this Operation and Maintenance Manual. If
When lightning is striking in the vicinity of the equipped, the Work Area Vision System shall be
machine, the operator should never attempt the adjusted according to Operation and Maintenance
following procedures: Manual, SEBU8157, “Work Area Vision System”. If
equipped, the Cat Detect Object Detection shall be
• Mount the machine. adjusted according to the Operation and
Maintenance Manual, “Cat Detect Object Detection”
• Dismount the machine. for your machine.
If you are in the operator's station during an electrical It may not be possible to provide direct visibility on
storm, stay in the operator's station. If you are on the large machines to all areas around the machine.
ground during an electrical storm, stay away from the Appropriate job site organization is required in order
vicinity of the machine. to minimize hazards that are caused by restricted
visibility. Job site organization is a collection of rules
i00771840
and procedures that coordinates machines and
people that work together in the same area.
Examples of job site organization include the
Before Starting Engine following:
SMCS Code: 1000; 7000
• Safety instructions
Start the engine only from the operator compartment.
Never short across the starter terminals or across the • Controlled patterns of machine movement and
batteries. Shorting could damage the electrical vehicle movement
system by bypassing the engine neutral start system.
• Workers that direct safe movement of traffic
Inspect the condition of the seat belt and of the
mounting hardware. Replace any parts that are worn • Restricted areas
or damaged. Regardless of appearance, replace the
seat belt after three years of use. Do not use a seat • Operator training
belt extension on a retractable seat belt.
• Warning symbols or warning signs on machines or
Adjust the seat so that full pedal travel can be on vehicles
achieved with the operator's back against the back of
the seat. • A system of communication
Make sure that the machine is equipped with a • Communication between workers and operators
lighting system that is adequate for the job prior to approaching the machine
conditions. Make sure that all machine lights are
working properly. Modifications of the machine configuration by the
user that result in a restriction of visibility shall be
Before you start the engine and before you move the evaluated.
machine, make sure that no one is underneath the
machine, around the machine, or on the machine.
Make sure that the area is free of personnel. i02578915
i04862936 Engine Starting

SMCS Code: 1000; 7000
Visibility Information
If a warning tag is attached to the start switch or to
SMCS Code: 7000 the controls, do not start the engine. Also, do not
move any controls.
Before you start the machine, perform a walk-around
inspection in order to ensure that there are no Move all hydraulic controls to the NEUTRAL position
hazards around the machine. before you start the engine.
While the machine is in operation, constantly survey
the area around the machine in order to identify
potential hazards as hazards become visible around
the machine.
44 SEBU9084-11
Safety Section
Before Operation
Diesel engine exhaust contains products of Carry work tools low. Lower the lift arms fully. Tilt
combustion which can be harmful to your health. back the work tool in order to keep the work tool off of
Always start the engine in a well ventilated area. the ground. Do not go close to the edge of a cliff, an
Always operate the engine in a well ventilated area. If excavation, or an overhang.
you are in an enclosed area, vent the exhaust to the
outside. If the machine begins to sideslip downward on a
grade, immediately remove the load and turn the
i02680030
machine downhill.
Avoid any conditions that can lead to tipping the
Before Operation machine. The machine can tip when you work on
hills, on banks and on slopes. Also, the machine can
SMCS Code: 7000 tip when you cross ditches, ridges or other
Video tapes and safety information are available in unexpected obstacles.
English for the machine. A list of some of the material Avoid operating the machine across the slope. When
is available in the Operation and Maintenance possible, operate the machine up the slopes and
Manual, “Reference Material”. Consult your down the slopes.
Caterpillar dealer in order to obtain copies of the
material. The information should be reviewed by Maintain control of the machine. Do not overload the
every person that operates the machine. machine beyond the machine capacity.
Clear all personnel from the machine and from the Never straddle a wire cable. Never allow personnel to
area. straddle a wire cable.
Clear all obstacles from the path of the machine. Know the maximum dimensions of your machine.
Beware of hazards such as wires, ditches, etc.
Always keep the Rollover Protective Structure
Make sure that all windows are clean. Secure all (ROPS) installed during machine operation.
doors in the closed position. Secure the windows in
the open position or in the shut position. This machine is designed to operate in the ambient
Make sure that the machine horn, the backup alarm temperature range of −32 °C (−25 °F) to 43 °C
and all other warning devices are working properly. (109.4 °F).
Fasten the seat belt securely. Lower the armrests. Observe all applicable local government regulations
when you use the Skid Steer Loader, Multi-Terrain
Loader, or Compact Track Loader to lift heavy
i05365872 objects.
Operation i06299648
SMCS Code: 7000
Engine Stopping
Only operate the machine while you are in the seat.
The seat belt must be fastened while you operate the SMCS Code: 1000; 4450; 6461; 6700; 7000; 7451
machine. Only operate the controls while the engine
is running. Do not stop the engine immediately after the machine
has been operated under load. Stopping the engine
Before you move the machine, make certain that no immediately can cause overheating and accelerated
one will be endangered. wear of engine components.
While you operate the machine and the work tool After the machine is parked and the parking brake is
slowly in an open area, check for proper operation of engaged, allow the engine to run at low idle for 5
all controls and all protective devices. minutes before shutdown. Running the engine allows
hot areas of the engine to cool gradually.
Do not allow riders on the machine. Never use the
work tool for a work platform. i05333750
Note any needed repairs during machine operation.

Report any needed repairs. High Pressure Fuel Lines
Use Caterpillar Approved Work Tools on this SMCS Code: 1000; 1252; 1274; 7000
machine. Obey all the lift restrictions. Refer to
Operation and Maintenance Manual, “Caterpillar S/N: BL21–Up
Approved Work Tools” for the approved work tools S/N: DX21–Up
and the lift restriction information.
S/N: FD21–Up
SEBU9084-11 45
Safety Section
High Pressure Fuel Lines
S/N: HP21–Up
S/N: MD21–Up
S/N: BY41–Up
S/N: BE71–Up
S/N: BL71–Up
S/N: HP71–Up
S/N: BL91–Up
S/N: DX91–Up
S/N: DTB1–Up
S/N: GTC1–Up
S/N: HRD1–Up
S/N: BYF1–Up
S/N: ETL1–Up
S/N: FTL1–Up
S/N: GTL1–Up
S/N: DPR1–Up
S/N: GWR1–Up
S/N: DZT1–Up
S/N: FMT1–Up
S/N: HMT1–Up
S/N: JST1–Up
S/N: B5W1–Up
S/N: EZW1–Up
S/N: TAW1–Up
S/N: BGZ1–Up
Contact with high pressure fuel may cause fluid

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.
46 SEBU9084-11
Safety Section
High Pressure Fuel Lines
(1) High-pressure line (2) High-pressure fuel manifold (rail)
The high-pressure fuel lines are the fuel lines that are Visually inspect the high-pressure fuel lines before
between the high-pressure fuel pump and the high- the engine is started. This inspection should be each
pressure fuel manifold. There are also fuel lines day.
between the fuel manifold and cylinder head. These
fuel lines are different from fuel lines on other fuel If you inspect the engine in operation, always use the
systems. proper inspection procedure in order to avoid a fluid
penetration hazard. Refer to Operation and
• The high-pressure fuel lines are constantly Maintenance Manual, “General hazard Information”.
charged with high pressure.
• Inspect the high-pressure fuel lines for damage,
• The internal pressures of the high-pressure fuel deformation, a nick, a cut, a crease, or a dent.
lines are higher than other types of fuel system.
• Do not operate the engine with a fuel leak. If there
• The high-pressure fuel lines are formed to shape is a leak, do not tighten the connection in order to
and then strengthened by a special process. stop the leak. The connection must only be
tightened to the recommended torque. Refer to
Do not step on the high-pressure fuel lines. Do not Disassembly and Assembly, “Fuel injection lines -
deflect the high-pressure fuel lines. Do not bend or Remove and Fuel injection lines - Install”.
strike the high-pressure fuel lines. Deformation or
damage of the high-pressure fuel lines may cause a • If the high-pressure fuel lines are torqued correctly
point of weakness and potential failure. and the high-pressure fuel lines are leaking, the
Do not check the high-pressure fuel lines with the high-pressure fuel lines must be replaced.
engine or the starting motor in operation. After the • Ensure that all clips on the high-pressure fuel lines
engine has stopped, allow 5 minutes to pass in order
to allow the pressure to be purged. Then, any service are in place. Do not operate the engine with clips
or repair may be performed on the engine fuel lines. that are damaged, missing, or loose.
Do not loosen the high-pressure fuel lines in order to • Do not attach any other item to the high-pressure
remove air from the fuel system. This procedure is fuel lines.
not required.
SEBU9084-11 47
Safety Section
Work Tools
i05336713 Demolition machinery is designed for demolishing by

pushing or pulling, or fragmenting. Demolition is done
Work Tools by crushing or shearing, buildings and/or other civil
engineering structures and component parts and/or
SMCS Code: 6700 separating the resultant debris.
Only use work tools that are approved by Caterpillar If this machine is used as a demolition machine,
for use on Caterpillar machines. Refer to the within an area that is controlled by the European
Operation and Maintenance Manual, “Caterpillar Directive 2006/42/EC the machine must be equipped
Approved Work Tools”. with:
If you are in doubt about the compatibility of a • Polycarbonate Front Door
particular work tool with your machine, consult your
Caterpillar dealer. • FOPS Level II
Make sure that all necessary guarding is in place on • Camera, Rear View, and Display
the host machine and on the work tool.
Note: This machine may require additional options to
Note: A Debris Barrier Kit is required for use in operate demolition tools such as a hammer or a
applications which create airborne debris. Consult shear within the EU. Contact your Cat dealer for
your Caterpillar dealer for information about this kit. additional information.
Use of the following equipment or operation in the Demolition applications may generate flying debris.
following applications may create airborne debris: Ensure that there are no personnel in the area
around the machine where flying debris may travel.
• mulching head
Demolition applications may generate airborne dust
• brush cutter that can be hazardous to your health. If you operate
the machine in a dust generating applications, use
• hammers appropriate safeguarding or adequate ventilation to
minimize risk.
• recycling of paper products certain agriculture
applications i05336739
• cold planing
Parking
Keep all windows and doors closed on the host SMCS Code: 7000
machine. Always wear protective glasses. Always
wear the protective equipment that is recommended Park on a level surface. If you must park on a grade,
in the work tool operation manual. Wear any other chock the machine.
protective equipment that is required for the
operating environment. 1. Move the joystick control slowly to the NEUTRAL
position in order to stop the machine.
To prevent personnel from being struck by flying
objects, ensure that all personnel are out of the work 2. Move the engine speed control knob to the LOW
area. IDLE position.
While you are performing any maintenance, any 3. Lower the loader arms and tilt the linkage so that
testing, or any adjustments to the work tool stay clear
the work tool rests firmly on the ground.
of the following areas: cutting edges, pinching
surfaces and crushing surfaces. 4. Move the hydraulic controls to the NEUTRAL
position.
i06158704
5. Turn the engine start switch key to OFF position
Demolition and remove the key.
SMCS Code: 6700 6. Raise the armrests, remove the seat belt, and exit
the machine.
There may be local regulations and/or government
regulations that govern the use of machines which
are designed and used as demolition machinery.
Note: Obey all local and government regulations.
48 SEBU9084-11
Safety Section
Slope Operation
i03745198 Height of the working load of the machine – When

the working loads are in higher positions, the stability
Slope Operation of the machine is reduced.
SMCS Code: 7000 Operated equipment – Be aware of performance
features of the equipment in operation and the effects
Machines that are operating safely in various on machine stability.
applications depend on these criteria: the machine
model, configuration, machine maintenance, Operating techniques – Keep all attachments or
operating speed of the machine, conditions of the pulled loads low to the ground for optimum stability.
terrain, fluid levels and tire inflation pressures. The
Machine systems have limitations on slopes –
most important criteria are the skill and judgment of
Slopes can affect the proper function and operation
the operator.
of the various machine systems. These machine
A well trained operator that follows the instructions in systems are needed for machine control.
the Operation and Maintenance Manual has the
greatest impact on stability. Operator training Note: Safe operation on steep slopes may require
provides a person with the following abilities:
observation of working and environmental conditions, special machine maintenance. Excellent skill of the
feel for the machine, identification of potential operator and proper equipment for specific
hazards and operating the machine safely by making applications are also required. Consult the Operation
appropriate decisions. and Maintenance Manual sections for the proper fluid
level requirements and intended machine use.
When you work on side hills and when you work on
slopes, consider the following important points: i01329161
Speed of travel – At higher speeds, forces of inertia

tend to make the machine less stable. Equipment Lowering with
Roughness of terrain or surface – The machine
Engine Stopped
may be less stable with uneven terrain. SMCS Code: 7000
Direction of travel – Avoid operating the machine Before lowering any equipment with the engine
across the slope. When possible, operate the stopped, clear the area around the equipment of all
machine up the slopes and operate the machine personnel. The procedure to use will vary with the
down the slopes. Place the heaviest end of the type of equipment to be lowered. Keep in mind most
machine uphill when you are working on an incline. systems use a high pressure fluid or air to raise or
Mounted equipment – Balance of the machine may lower equipment. The procedure will cause high
be impeded by the following components: equipment pressure air, hydraulic, or some other media to be
that is mounted on the machine, machine released in order to lower the equipment. Wear
configuration, weights and counterweights. appropriate personal protective equipment and follow
the established procedure in the Operation and
Nature of surface – Ground that has been newly Maintenance Manual, “Equipment Lowering with
filled with earth may collapse from the weight of the Engine Stopped” in the Operation Section of the
machine. manual.
Surface material – Rocks and moisture of the i06849673
surface material may drastically affect the machine's
traction and machine's stability. Rocky surfaces may
promote side slipping of the machine. Sound Information and
Slippage due to excessive loads – This may cause Vibration Information
downhill tracks or downhill tires to dig into the ground, SMCS Code: 7000
which will increase the angle of the machine.
Width of tracks or tires – Narrower tracks or Sound Level Information
narrower tires further increase the digging into the
ground which causes the machine to be less stable. The declared operator Equivalent Sound Pressure
Level (Leq) is shown in Table 1 when "ANSI/SAE
Implements attached to the drawbar – This may J1166 SEP 2014" is used to measure the value for an
decrease the weight on the uphill tracks. This may enclosed cab. This is a work cycle sound exposure
also decrease the weight on the uphill tires. The level. The cab was properly installed and maintained.
decreased weight will cause the machine to be less The test was conducted with the cab doors and the
stable. cab windows closed. The sound level may vary at
different engine cooling fan speeds and during diesel
particulate filter regeneration (if equipped).
SEBU9084-11 49
Safety Section
Sound Information and Vibration Information
Hearing protection may be needed when the

machine is operated with an open operator station for
extended periods or in a noisy environment. Hearing
protection may be needed when the machine is
operated with a cab that is not properly maintained or
when the doors and windows are open for extended
periods or in a noisy environment.
The declared average exterior sound pressure level
is 76 dB(A) when the "SAE J88 JUN2013 - Constant
Speed Moving Test" procedure is used to measure
the value for the standard machine. The
measurement was conducted under the following
conditions: distance of 15 m (49.2 ft) and "the
machine moving forward in an intermediate gear
ratio". The sound level may vary during diesel
particulate filter regeneration.
Sound Level Information for Machines in

European Union Countries and in
Countries that Adopt the "EU Directives"
Note: The information below applies only to
machines that have the CE mark on the PIN plate.
The declared dynamic operator sound pressure level
is shown in Table 1 when "ISO 6396:2008" is used to
measure the value for an enclosed cab. The
measurement was conducted with the cab doors and
the cab windows closed. The cab was properly
installed and maintained. The sound level may vary
at different engine cooling fan speeds and during
diesel particulate filter regeneration (if equipped).
Table 1
Serial Number Prefixes Declared Operator Equivalent Declared Dynamic Operator
Sound Pressure Level (Leq) Sound Pressure Level per
2000/14/EC and ISO 6396
ANSI/SAE J1166 Feb 2014 ISO 6396:2008
226D (HRD), 232D (DPR), 239D (BL9), 249D (GWR) 85 dB(A) 83 dB(A)
236D (BGZ), 242D (DZT), 257D (EZW), 259D (FTL) 85 dB(A) 83 dB(A)
246D (BYF), 262D (DTB), 277D (FMT), 279D (GTL), 287D (HMT),
85 dB(A) 81 dB(A)
289D (TAW)
232D (KXC), 239D (CD4), 249D (AH9) 85 dB(A) 81 dB(A)
236D (MPW & SEN), 242D (A9W & DML), 257D (EML & FMR),259D
85 dB(A) 83 dB(A)
(GTK & FTK)
246D (HMR & JSL), 262D (KTS & LST), 277D (MLT & NTL), 279D (PPT
85 dB(A) 83 dB(A)
& RCX), 287D (STK & TLK), 289D (WCT & A9Z)
272D (B5W), 272D XHP (ETL), 297D (BE7), 297D XHP (HP7),
85 dB(A) 83 dB(A)
299D (GTC), 299D XHP (JST)
272D2 (BL2), 272D2 XHP (MD2), 297D2 (BL7), 297D2 XHP (HP2),
85 dB(A) 83 dB(A)
299D2 (FD2), 299D2 XHP (DX2)
299D2 (BY4), 299D2 XHP (DX9) 85 dB (A) 83 dB(A)

50 SEBU9084-11
Safety Section
The sound power level (LWA) that is labeled on the

machine is shown in Table 2. The measurement of
the sound power level was made according to the
test procedures and conditions that are specified in
the European Union Directive "2000/14/EC" as
amended by "2005/88/EC".
Table 2
Models Sound Power Level (LWA)
226D, 232D, 236D, 242D, 246D, 262D 101 dB (A)
239D, 249D, 259D, 279D, 289D 103 dB (A)
257D, 277D, 287D 103 dB (A)
272D, 272D XHP, 272D2, 272D2 XHP 102 dB (A)
297D, 297 XHP, 297D2, 297D2 XHP 104 dB (A)
299D, 299D XHP, 299D2, 299D2 XHP 104 dB (A)
299D2, 299D2 XHP With Steel Track Undercarriage 107 dB (A)
Sound Level Information for

Machines in Eurasian Economic
Union Countries
The declared dynamic operator sound pressure level
is 85 dB(A) when “ISO 6396:2008” is used to
measure the value for an enclosed cab. The
measurement was conducted at 70 % of the
maximum engine cooling fan speed. The sound level
may vary at different engine cooling fan speeds. The
measurement was conducted with the cab doors and
the cab windows closed.
The declared exterior sound power level LWA, shown
in Table 3 , is when the value is measured according
to the dynamic test procedures and the conditions
that are specified in “ISO 6395:2008”. The
measurement was conducted at 70 % of the
maximum engine cooling fan speed. The sound level
may vary at different engine cooling fan speeds.
Table 3
Models Sound Power Level (LWA)
226D, 232D, 236D, 242D 102 dB (A)
239D, 249D, 257D, 259D 103 dB (A)
246D, 262D, 272D, 272D2, 272D XHP, 272D2 XHP 102 dB (A)
277D, 279D, 287D, 289D, 297D, 297D2, 297D XHP, 297D2 XHP,
105 dB (A)
299D, 299D2, 299D XHP, 299D2 XHP
SEBU9084-11 51
Safety Section
“European Physical Agents

Directive (Vibration) 2002/44/EC”
Vibration Data for the Loaders
Information concerning hand/arm vibration level
When the machine is operated according to the

intended use, the hand/arm vibration of this machine
is below 2.5 m/s2.
Information concerning whole body vibration

level
This section provides vibration data and a method for
estimating the vibration level for skid steer loaders.
Note: Vibration levels are influenced by many
different parameters. Many items are listed below.
• Operator training, behavior, mode and stress
• Job site organization, preparation, environment,

weather and material
• Machine type, quality of the seat, quality of the
suspension system, attachments and condition of
the equipment
It is not possible to get precise vibration levels for this
machine. The expected vibration levels can be
estimated with the information in Table5 in order to
calculate the daily vibration exposure. A simple
evaluation of the machine application can be used.
Estimate the vibration levels for the three vibration
directions. For typical operating conditions, use the
average vibration levels as the estimated level. With
an experienced operator and smooth terrain, subtract
the Scenario Factors from the average vibration level
in order to obtain the estimated vibration level. For
aggressive operations and severe terrain, add the
Scenario Factors to the average vibration level in
order to obtain the estimated vibration level.
Note: All vibration levels are in meter per second

squared.
Table 4
“ISO 5349-1:2001 Hand Transmitted Vibration”
Left Hand/Arm Right Hand/Arm

Machine Operating Cycle
Type (SAEJ1166:2014) Fore/Aft (X Side/Side Vertical (Z Total Fore/Aft (X Side/Side Vertical (Z Total
Axis) (Y Axis) Axis) Vibration Axis) (Y Axis) Axis) Vibration
226D, 232D "Wheel Loader" 0.6 0.7 0.6 1.1 0.5 0.5 0.9 1.1
236D, 242D "Wheel Loader" 0.8 1.4 0.7 1.7 0.6 1.1 0.7 1.4
246D, 262D "Wheel Loader" 0.8 1.0 0.8 1.5 1.1 0.9 1.3 1.9
(continued)
52 SEBU9084-11
Safety Section
(Table 4, contd)
272D, 272D
"Wheel Loader" 0.4 0.5 0.4 0.7 0.4 0.6 0.4 0.8
XHP
272D2,
"Wheel Loader" 0.8 0.9 0.6 1.4 0.6 1 0.6 1.4
272D2 XHP
257D "Crawler Loader" 0.8 1.3 1.0 1.8 0.8 1.5 1.1 2.1
277D, 287D "Crawler Loader" 1.0 1.6 1.3 2.3 1.1 1.6 1.2 2.3
259D "Crawler Loader" 0.9 2.6 1.2 3.0 1.0 2.5 1.7 3.2
297D,
297D XHP
"Crawler Loader" 0.6 1.0 0.7 1.3 0.8 1.5 0.9 1.9
299D, 299D
XHP
297D2,
"Crawler Loader" 0.7 1.2 1.2 1.8 0.6 1.4 0.9 1.7
297D2 XHP
299D2,
"Crawler Loader" 0.7 1.1 0.9 1.6 0.7 1.3 1.1 1.8
299D2 XHP
299D, 299D
XHP
"Crawler Loader" 1.9 1.8 2.2 3.4 1.1 1.7 2.1 2.9
with Steel
Track
299D2,
299D2 XHP
"Crawler Loader" 0.8 1.5 1.6 2.3 0.8 1.5 1.4 2.2
w/ Steel
Track
Table 5
“ISO 2631-1:1997 Whole Body Vibration”
Whole Body
Machine Type Operating Cycle (SAEJ1166:2014) Side/Side Vertical (Z
Fore/Aft (X Axis) Total Vibration
(Y Axis) Axis)
226D, 232D "Wheel Loader" 0.7 0.4 0.5 n/a
272D, 272D
"Wheel Loader" 0.5 0.3 0.3 n/a
XHP
272D2, 272D2
"Wheel Loader" 0.6 0.4 0.4 n/a
XHP
257D "Crawler Loader" 0.7 0.4 0.6 n/a
277D, 287D "Crawler Loader" 0.8 0.3 0.5 n/a
259D "Crawler Loader" 0.5 0.3 0.4 n/a

(continued)
SEBU9084-11 53
Safety Section
(Table 5, contd)
297D
,
297D XHP "Crawler Loader" 0.7 0.4 0.5 n/a
299D, 299D
XHP
297D2, 297D2
"Crawler Loader" 0.5 0.2 0.4 n/a
XHP
299D2, 299D2
"Crawler Loader" 0.4 0.2 0.4 n/a
XHP
299D, 299D
XHP "Crawler Loader" 0.7 0.8 0.6 n/a
with Steel Track
299D2, 299D2
XHP w/ Steel "Crawler Loader" 0.4 0.3 0.6 n/a
Track
Note: Refer to “ISO/TR 25398 Mechanical Vibration - 3. Keep the terrain in good condition.
Guideline for the assessment of exposure to whole
body vibration of ride on operated earthmoving a. Remove any large rocks or obstacles.
machines” for more information about vibration. This
publication uses data that is measured by b. Fill any ditches and holes.
international institutes, organizations, and
manufacturers. This document provides information c. Provide machines and schedule time in order to
about the whole body exposure of operators of maintain the conditions of the terrain.
earthmoving equipment. Refer to Operation and
4. Use a seat that meets “ISO 7096”. Keep the seat
Maintenance Manual, SEBU8257, “The European
Union Physical Agents (Vibration) Directive 2002/44/ maintained and adjusted.
EC” for more information about machine vibration
a. Adjust the seat and suspension for the weight
levels.
and the size of the operator.
The Caterpillar suspension seat meets the criteria of
“ISO 7096”. This represents vertical vibration level b. Inspect and maintain the seat suspension and
under severe operating conditions. This seat is tested adjustment mechanisms.
with the input “spectral class EM9”. The seat has a
transmissibility factor of “SEAT<0.9”. 5. Perform the following operations smoothly.
The whole body vibration level of the machine varies. a. Steer

There is a range of values. The low value is 0.5 m/s2.
The machine meets the short-term level for the b. Brake
design of the seat in “ISO 7096”. The value is 1.59 m/
s2 for this machine. c. Accelerate.
Guidelines for Reducing Vibration Levels on d. Shift the gears.

Earthmoving Equipment 6. Move the attachments smoothly.
Properly adjust machines. Properly maintain 7. Adjust the machine speed and the route in order to
machines. Operate machines smoothly. Maintain the minimize the vibration level.
conditions of the terrain. The following guidelines can
help reduce the whole body vibration level: a. Drive around obstacles and rough terrain.
1. Use the right type and size of machine, equipment, b. Slow down when it is necessary to go over
and attachments. rough terrain.
2. Maintain machines according to the 8. Minimize vibrations for a long work cycle or a long
manufacturer's recommendations. travel distance.
a. Tire pressures a. Use machines that are equipped with
b. Brake and steering systems suspension systems.
c. Controls, hydraulic system, and linkages

54 SEBU9084-11
Safety Section
Guards
b. Use the ride control system on skid steer Caterpillar, Inc.

loaders. www.cat.com
c. If no ride control system is available, reduce i05753797

speed in order to prevent bounce.
d. Haul the machines between workplaces.

Guards
9. Less operator comfort may be caused by other risk
(Operator Protection)
factors. The following guidelines can be effective SMCS Code: 7150-MCH; 7325
in order to provide better operator comfort: There are different types of guards that are used to
protect the operator. The machine and the machine
a. Adjust the seat and adjust the controls in order application, determines the type of guard that should
to achieve good posture. be used.
b. Adjust the mirrors in order to minimize twisted A daily inspection of the guards is required in order to
posture. check for structures that are bent, cracked, or loose.
Never operate a machine with a damaged structure.
c. Provide breaks in order to reduce long periods
The operator becomes exposed to a hazardous
of sitting. situation if the machine is used improperly or if poor
operating techniques are used. This situation can
d. Avoid jumping from the cab. occur even though a machine is equipped with an
appropriate protective guard. Follow the established
e. Minimize repeated handling of loads and lifting operating procedures that are recommended for your
of loads. machine.
f. Minimize any shocks and impacts during sports
and leisure activities.
Roll over Protective Structure
(ROPS), Falling Object Protective
Sources Structure (FOPS) or Tip Over
The vibration information and calculation procedure Protection Structure (TOPS)
is based on “ISO/TR 25398 Mechanical Vibration -
Guideline for the assessment of exposure to whole The ROPS/FOPS Structure (if equipped) on your
body vibration of ride on operated earthmoving machine is specifically designed, tested, and certified
machines”. harmonized data is measured by for that machine. Any alteration or any modification to
international institutes, organizations, and the ROPS/FOPS Structure could weaken the
manufacturers. structure. This action places the operator into an
unprotected environment. Modifications or
This literature provides information about assessing attachments that cause the machine to exceed the
the whole body vibration exposure of operators of weight that is stamped on the certification plate also
earthmoving equipment. The method is based on place the operator into an unprotected environment.
measured vibration emission under real working Excessive weight may inhibit the brake performance,
conditions for all machines. the steering performance, and the ROPS. The
protection that is offered by the ROPS/FOPS
Check the original directive. This document Structure will be impaired if the ROPS/FOPS
summarizes part of the content of the applicable law. Structure has structural damage. Damage to the
This document is not meant to substitute the original structure can be caused by an overturn, a falling
sources. Other parts of these documents are based object, a collision, .
on information from the United Kingdom Health and
Safety Executive. Do not mount items (fire extinguishers, first aid kits,
work lights). By welding brackets to the ROPS/FOPS
Refer to Operation and Maintenance Manual, Structure or by drilling holes in the ROPS/FOPS
SEBU8257, “The European Union Physical Agents Structure. Welding brackets or drilling holes in the
(Vibration) Directive 2002/44/EC” for more ROPS/FOPS Structures can weaken the structures.
information about vibration. Consult your Caterpillar dealer for mounting
guidelines.
Consult your local Caterpillar dealer for more
information about machine features that minimize
vibration levels. Consult your local Caterpillar dealer
about safe machine operation.
Use the web site in order to find your local dealer.
SEBU9084-11 55
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
Caterpillar dealer for additional information.
56 SEBU9084-11
General Information
Product Information
Section
General Information
i06754284
Model View Illustrations

SMCS Code: 1000; 1926; 4450; 4469; 4480; 4490;
4491; 6282; 6700; 7000; 7007; 7451; 7606
Rotating Beacon (1), Front Work Lights(2), Side View
Mirrors(3), Low and High Beam Driving Lights(4) and
Turn Signals (5)
Rear Work Lights (6)
Rear Turn Signals, Position Lights, Stop Lights(7)
and Speed Decal (8)
SEBU9084-11 57
Rated Load
Japanese Market Only
(5) Rear Work Lights
Illustration 75 g06107238 (6) Rear Turn Signals, Position Lights
(7) Reverse Light
(1) Front Work Lights (8) License Plate Holder and Lamp
(2) Side View Mirrors
(3) Low and High Beam Driving Lights
(4) Turn Signals i06674922
Rated Load
SMCS Code: 6001; 6136; 6542; 7000
Bucket Rated Load
Failure to comply to the rated load can cause

possible personal injury or property damage.
This includes the risk of unintended boom lower-
ing. Review the rated load of a particular work
tool before performing any operation. Make ad-
justments to the rated load as necessary for non-
standard configurations.
Note: Rated loads should be used as a guide.

Attachments, uneven ground conditions, soft ground
conditions, or poor ground conditions have effects on
rated loads. The operator is responsible for being
aware of these effects.
(5) Rear Work Lights
(6) Rear Turn Signals, Position Lights
(7) Reverse Light
(8) License Plate Holder and Lamp
58 SEBU9084-11
Rated Load
Rated loads will vary with different attachments.

Consult your Cat dealer regarding the rated load for
Machine stability is affected by many factors, in- specific attachments.
cluding the type of work tool and the position of a Note: The Steel Track Undercarriage attachment will
work tool.
increase the rated operating loads in the following
Machine stability and machine control can be sig- tables by 191 kg (421 lb) for 299D and 299D XHP
nificantly affected if a work tool is not installed. and by 103 kg (227 lb)for 299D2 and 299D2 XHP
Operating a machine without a work tool can lead machines.
to loss of control or tipping of the machine which
could result in serious injury or death. The rated operating capacity (ROC) is defined by
“SAE J818:2007”, “ISO 14397-1:2007” and “EN 474-
When you operate a machine without a work tool, 3:2006 + A1:2009” as the least amount of weight of
avoid the following conditions: the following conditions:
• excessive speed • 50% of the full static tipping load for wheeled
machines
• sharp turns
• 35% of the full static tipping load for track
• abrupt implement movement machines
• slopes and uneven ground • The lifting capacity to maximum height

The corresponding dump clearance is given for each
Rated loads are based upon a standard machine with bucket at maximum lift height and at a 40 degree
the following conditions: dump angle. The reach is given for each bucket at
maximum lift height and at a 40 degree dump angle.
• lubricants Clearance is measured from the ground to the bucket
edge in order to dump the load. The reach is
• full fuel tank measured from the front tire to the bucket edge.
• Cat bucket
• 75 kg (165 lb) operator

• 10 x 16.5 tires on 226D, 232D
• 12 x 16.5 tires on 236D, 242D, 246D, 262D, 272D,
272D2
• 14 x 17.5 tires on 272D XHP, 272D2 XHP
• Undercarriage with 320 mm wide tracks and dual

flange front/single flange rear idlers on 239D,
249D, and 259D machines.
• Undercarriages with either 400 mm or 450 mm Illustration 78 g02616842

wide tracks and triple flange front/rear idlers on
279D, and 289D machines. Dimension (A) represents the dump clearance.
Dimension (B) represents the reach.
• Undercarriages with 450 mm wide tracks and dual
flange front/single flange rear idlers on 299D, and The following tables provide the rated operating
299D2 machines. loads (ROC) for the standard machine configuration
with a bucket.
• Undercarriages with 400 mm wide tracks and
Note: The dump angle and the clearance angle on all
triple flange front/rear idlers on 299D XHP, and
buckets is 40°.
299D2 XHP machines.
Note: All Caterpillar Premium Conventional tires are
at the suggested operating inflation pressure. Refer
to the Operation and Maintenance Manual, “Tire
Inflation - Check” for the proper tire inflation pressure.
SEBU9084-11 59
Rated Load
Buckets
Table 6
Low Profile Buckets with bolt-on-Edge - Skid Steer Loader
P/N 279-5435 279-5438 279-5441 285-6090 268-4083

Tool Mass
177kg 391lb 204kg 451lb 232kg 511lb 248kg 546lb 264kg 582lb
(kg. lb.)
Bucket
54" 60" 66" 72" 78"
Specs.
Tipping
Load
ROC 50% 686kg 1512lb 669kg 1474lb 655kg 1444lb 646kg 1425lb 639kg 1409lb
Dump
226D Clearance
2102mm 83in 2101mm 83in 2100mm 83in 2099mm 83in 2098mm 83in
@ 40° dump
angle
Reach @
40° dump 628mm 25in 631mm 25in 633mm 25in 634mm 25in 636mm 25in
angle
Tipping
Load
Dump
232D Clearance
@ 40° dump
angle
Reach @
angle
Tipping
Load
Dump
236D Clearance
@ 40° dump
angle
Reach @
angle
Tipping
Load
ROC 5o% 979kg 2158lb 961kg 2119lb 947kg 2089lb 939kg 2071lb 932kg 2054lb
242D
Dump
Clearance
2362mm 93in 2361mm 93in 2359mm 93in 2359mm 93in 2358 93in
@ 40° dump
angle
(continued)
60 SEBU9084-11
Rated Load
(Table 6, contd)
Reach @
angle
Tipping
Load
Dump
246D Clearance
@ 40° dump
angle
Reach @
angle
Tipping
Load
Dump
262D Clearance
2452mm 97in 2451mm 96in 2449mm 96in 2449mm 96in 2448 96in
@ 40° dump
angle
Reach @
angle
Tipping
Load
Dump
272D Clearance
@ 40° dump
angle
Reach @
angle
Tipping
Load
Dump
272D Clearance
XHP @ 40° dump 2544mm 100in 2543mm 100in 2542mm 100in 2541mm 100in 2541mm 100in
angle
Reach @
angle
Tipping
272 Load
D2
(continued)
SEBU9084-11 61
Rated Load
(Table 6, contd)
Dump
Clearance
@ 40° dump
angle
Reach @
angle
Tipping
Load
Dump
272D- Clearance
2 XHP @ 40° dump 2535mm 100in 2534mm 100in 2533mm 100in 2533mm 100in 2532mm 100in
angle
Reach @
angle
Table 7
Low Profile Buckets with bolt-on-Edge Multi-Terrain Loader
P/N 279-5441 285-6090 268-4083

Tool Mass (kg,
232kg 511lb 248kg 546lb 264kg 582lb
lb.)
Bucket Specs. 66" 72" 78"
Tipping Load 2449kg 5401lb 2433kg 5366lb 2419kg 5334lb

257D
ROC 35% 857kg 1890lb 852kg 1878lb 847kg 1867lb
Dump Clearance
@ 40° dump 2340mm 92in 2340mm 92in 2339 92in
angle
Reach @ 40°
861mm 34in 863mm 34in 865mm 30in
dump angle
Dump Clearance
277D @ 40° dump 2456mm 97in 2455mm 97in 2454mm 97in
angle
Reach @ 40°
611mm 24in 613mm 24in 614mm 24in
dump angle
Dump Clearance
angle
Reach @ 40°
939mm 37in 941mm 37in 943mm 37in
dump angle
62 SEBU9084-11
Rated Load
Table 8
Low Profile Buckets with bolt-on-Edge - Multi Terrain Loader
P/N 279-5435 279-5438 279-5441 285-6090 268-4083

Tool Mass
(kg. lb.)
Bucket
54" 60" 66" 72" 78"
Specs.
Tipping
Load
297D
Dump
Clearance
@ 40° dump
angle
Reach @
angle
Tipping
Load
Dump
297D Clearance
XHP @ 40° dump 2450mm 96in 2449mm 96in 2448mm 96in 2447mm 96in 2446 96in
angle
Reach @
angle
Tipping
Load
Dump
297D- Clearance
2 2532mm 100in 2531mm 100in 2531mm 100in 2531mm 100in 2531mm 100in
@ 40° dump
angle
Reach @
angle
Tipping
Load
297D- Dump
2 Clearance
XHP @ 40° dump
angle
Reach @
angle
SEBU9084-11 63
Rated Load
Table 9
Low Profile Buckets with Bolt-On Edge - Compact Track Loader
P/N 279-5438 279-5441 285-6090 268-4083

Tool Mass
204kg 451lb 232kg 511lb 248kg 546lb 264kg 582lb
(kg. lb.)
Bucket
60" 66" 72" 78"
Specs.
Tipping Load 1826kg 4025lb 1799kg 3966lb 1783kg 3931lb 1768kg 3899lb
ROC 35% 639kg 1409lb 630kg 1388lb 624kg 1376lb 619kg 1365lb
Dump Clear-
239D ance @ 40° 2101mm 83in 2101mm 83in 2101mm 83in 2101mm 83in
dump angle
Reach @ 40°
727mm 29in 727mm 29in 727mm 29in 727mm 29in
dump angle
Dump Clear-
dump angle
Reach @ 40°
dump angle
Table 10
P/N 279-5441 285-6090 268-4083
Tool Mass 232 kg 511 lb 248 kg 546 lb 264 kg 582 lb
Bucket
66 in 72 in 78 in
Specs.
Tipping Load 2535kg 5590lb 2519kg 5555lb 2505 kg 5523 lb

259D
ROC 35% 887kg 1956lb 882 1944lb 877kg 1933 lb
Dump Clear-
ance @ 40° 2356mm 93in 2355mm 93in 2354 mm 93 in
dump angle
Reach @ 40°
760mm 30in 762mm 30in 764mm 30in
dump angle
ROC 35% 898kg 1980lb 892kg 1967lb 887kg 1956kg
Dump Clear-
279D ance @ 40° 2449mm 96in 2449mm 96in 2448 mm 96 in
dump angle
Reach @ 40°
549mm 22in 552mm 22in 553mm 22 in
dump angle
Tipping Load 3333kg 7349lb 3317kg 7314lb 3303 kg 7282 lb

289D
ROC 35% 1166kg 2572 1161kg 2560lb 1156 kg 2549 lb
(continued)
64 SEBU9084-11
Rated Load
(Table 10, contd)

Dump Clear-
ance @ 40° 2452mm 97in 2452mm 97in 2451 mm 96 in
dump angle
Reach @ 40°
896mm 35in 897mm 35in 899mm 35in
dump angle
299D Dump Clear-

(Rubber) ance @ 40° 2463mm 97in 2462mm 97in 2461mm 97in
dump angle
Reach @ 40°
935mm 37in 937mm 37in 939mm 37in
dump angle
Tipping Load 4140KG 9128lb 4128kg 9102lb 4115kg 9074lb
ROC 35% 1449kg 3195lb 1445kg 3186lb 1440kg 3176
299D XHP Dump Clear-

dump angle
Reach @ 40°
926mm 36in 928mm 37in 930mm 37in
dump angle
299D Dump Clear-

(Steel) ance @ 40° 2463mm 97in 2462mm 97in 2461mm 97in
dump angle
Reach @ 40°
935mm 37in 937mm 37in 939mm 37in
dump angle

dump angle
Reach @ 40°
926mm 36in 928mm 37in 930mm 37in
dump angle
299D2 Dump Clear-

dump angle
Reach @ 40°
994mm 39in 994mm 39in 994mm 39in
dump angle
299D2 XHP Tipping Load 4209kg 9281lb 4194kg 9247lb 4179kg 9215lb
(Rubber) 1473kg 1468kg 1463kg
ROC 35% 3248lb 3236lb 3225lb
(continued)
SEBU9084-11 65
Rated Load
(Table 10, contd)

Dump Clear-
ance @ 40° 2505mm 99in 2505mm 99in 2505mm 99in
dump angle
Reach @ 40°
994mm 39in 994mm 39in 994mm 39in
dump angle
299D2 Dump Clear-

dump angle
Reach @ 40°
994mm 39in 994mm 39in 994mm 39in
dump angle
299D2 XHP Dump Clear-

dump angle
Reach @ 40°
994mm 39in 994mm 39in 994mm 39in
dump angle
Table 11
Low Profile Buckets
P/N 279-5434 279-5437 279-5440 285-6089 268-4084
Tool Mass
(kg. lb.)
Bucket
54" 60" 66" 72" 78"
Specs.
Tipping
Load
Dump
236D Clearance
@ 40° dump
angle
Reach @
angle
Tipping
Load
Dump
242D Clearance
@ 40° dump
angle
Reach @
angle
66 SEBU9084-11
Rated Load
Table 12
Low Profile Buckets
P/N 279-5440 285-6089 268-4084
Bucket
66 in 72 in 78 in
Specs.
Tipping Load 2528kg 5574lb 2516kg 5548lb 2505kg 5524 lb

257D ROC 35% 885kg 1951lb 881kg 1942lb 877kg 1934 lb
Dump Clear-
ance @ 40° 2396mm 94in 2396mm 94in 2396 mm 94in
dump angle
Reach @
40° dump 796mm 31in 796mm 31in 796mm 31in
angle
Dump Clear-
259D ance @ 40° 2379mm 94 in 2379mm 94in 2379mm 94in
dump angle
Reach @
angle
Table 13
Low Profile Buckets
P/N 279-5434 279-5437 279-5440 285-6089 268-4084
Tool Mass
(kg. lb.)
Bucket
54" 60" 66" 72" 78"
Specs.
Tipping
Load
Dump
246D Clearance
@ 40° dump
angle
Reach @
angle
Tipping
2576kg 5681lb 2554kg 5631kg 2531kg 5581lb 2519kg 5554lb 2508kg 5530lb
Load
Dump
262D Clearance
@ 40° dump
angle
Reach @
angle
SEBU9084-11 67
Rated Load
Table 14
Low Profile Buckets
P/N 279-5440 285-6089 268-4084
Bucket
66 in 72 in 78 in
Specs.

277D ROC 35% 1039kg 2290lb 1035kg 2281lb 1031kg 2273lb
Dump Clear-
dump angle
Reach @
angle
Dump Clear-
279D ance @ 40° 2472mm 97in 2472mm 97in 2472mm 97in
dump angle
Reach @
angle
Dump Clear-
287D ance @ 40° 2477mm 98in 2477kg 98in 2477mm 98in
dump angle
Reach @
angle
Dump Clear-
dump angle
Reach @
40° dump 906m 36in 906mm 36in 906mm 36in
angle
Table 15
Low Profile Buckets
P/N 279-5434 279-5437 279-5440 285-6089 268-4084
Tool Mass
(kg. lb.)
Bucket
54" 60" 66" 72" 78"
Specs.
(continued)
68 SEBU9084-11
Rated Load
(Table 15, contd)

Tipping
Load
Dump
272D- Clearance
2 2529mm 100in 2528mm 100in 2527mm 100in 2527mm 99in 2527mm 99in
@ 40° dump
angle
Reach @
angle
Tipping
Load
272D- Dump
2 Clearance
XHP @ 40° dump
angle
Reach @
angle
Table 16
Low Profile Buckets
P/N 279-5440 285-6089 268-4084
Bucket
66 in 72 in 78 in
Specs.

299D2 STD
(Rubber) ROC 35% 1466kg 3232lb 1462kg 3223lb 1458kg 3215lb
Dump Clear-
dump angle
Reach @
angle
Tipping Load 4300kg 9481lb 4288lb 9456lb 4278kg 9433lb
Dump Clear-
299D2 XHP ance @ 40°
2535mm 100in 2535mm 100in 2535mm 100in
(Rubber) dump angle
Reach @
angle
299D2 STD Tipping Load 4533kg 9996lb 4522kg 9971lb 4511kg 9948lb
(Steel) 1587kg 1583kg 1579kg
ROC 35% 3499lb 3490lb 3482lb
(continued)
SEBU9084-11 69
Rated Load
(Table 16, contd)

Low Profile Buckets
Dump Clear-
dump angle
Reach @
angle
Dump Clear-
299D2 XHP ance @ 40°
2535mm 100in 2535mm 100in 2535mm 100in
(Steel) dump angle
Reach @
angle
Table 17
Low Profile Buckets
P/N 279-5434 279-5437 279-5440 285-6089 268-4084
Tool Mass
(kg. lb.)
Bucket
54" 60" 66" 72" 78"
Specs.
Tipping
Load
Dump
226D Clearance
@ 40° dump
angle
Reach @
angle
Tipping
Load
Dump
232D Clearance
@ 40° dump
angle
Reach @
angle
Table 18
Low Profile Buckets
P/N 279-5437 279-5440 285-6089 268-4084
(continued)
70 SEBU9084-11
Rated Load
(Table 18, contd)

Tool Mass
(kg. lb.)
Bucket
60" 66" 72" 78"
Specs.
Dump Clear-
dump angle
Reach @ 40°
dump angle
Dump Clear-
dump angle
Reach @ 40°
dump angle
Table 19
General Purpose Buckets
P/N 279-5364 279-5368 279-5372 279-5376 292-9270

Tool Mass
(kg, lb)
Bucket
60" 66" 72" 78" 84" High Capacity
Specs.
Tipping
Load
Dump Clear-
226D ance @ 40° 2097mm 83in 2095mm 82in 2094mm 82in 2093mm 82in 2031mm 80in
dump angle
Reach @
angle
Tipping
Load
Dump Clear-
dump angle
Reach @
angle
Tipping
236D 1607kg 35444lb 1573kg 3468lb 1545kg 3407lb 1529kg 3371lb 1513kg 3337lb
Load
(continued)
SEBU9084-11 71
Rated Load
(Table 19, contd)

Dump Clear-
ance @ 40° 2408mm 95in 2407mm 95in 2405mm 95in 2404mm 95in 2404mm 95in
dump angle
Reach @
40° dump 478mm 19in 480kg 19in 481mm 19in 482mm 19in 483mm 19in
angle
Tipping
Load
Dump Clear-
dump angle
Reach @
angle
Tipping
Load
ROC 50% 991kg 2184lb 965kg 2127lb 958kg 2112kg 951kg 2097lb 916kg 2020lb
Dump Clear-
dump angle
Reach @
angle
Tipping
Load
Dump Clear-
dump angle
Reach @
angle
Tipping
Load
Dump Clear-
dump angle
Reach @
angle
Tipping
3282kg 7237lb 3228kg 7117kg 3215kg 7088lb 3199kg 7054lb 3103kg 6843lb
272 D Load
XHP
(continued)
72 SEBU9084-11
Rated Load
(Table 19, contd)

Dump Clear-
dump angle
Reach @
angle
Tipping
Load
272D- Dump Clear-

2 ance @ 40° 2492mm 98in 2491mm 98in 2490mm 98in 2490mm 98in 2427mm 96in
dump angle
Reach @
angle
Tipping
Load
272D- Dump Clear-

2 XHP ance @ 40° 2530mm 100in 2528mm 100in 2528mm 100in 2527mm 100in 2465mm 97in
dump angle
Reach @
angle
Table 20
P/N 279-5368 279-5372 279-5376 292-9270
Tool Mass
221 kg 487 lb 234 kg 516 lb 247 kg 544 lb 279 kg 614 lb
(kg, lb.)
Bucket 66 in 72 in 78 in 84 in High Capacity
257D
Dump Clear-
ance @ 40° 2336mm 92in 2335mm 92in 2334mm 92in 2271mm 89in
dump angle
Reach @ 40°
dump angle
Dump Clear-
277D ance @ max 2420mm 95in 2451mm 97in 2451mm 96in 2388mm 94in
dump angle
Reach @ max
dump angle
(continued)
SEBU9084-11 73
Rated Load
(Table 20, contd)

ROC 35% 1252kg 2760lb 1247kg 2750lb 1242kg 2738lb 1203kg 2653
Dump Clear-
dump angle
Reach @ 40°
dump angle
Table 21
GP Buckets
P/N 279-5364 279-5368 279-5372 279-5376 292-9270
Tool Mass
(kg, lb)
Bucket
60" 66" 72" 78" 84" High Capacity
Specs.
Tipping Load 4054kg 8939lb 4008kg 8837lb 3998kg 8815lb 3982kg 8780lb 3876kg 8547lb
297D
Dump Clear-
dump angle
Reach @ 40°
994mm 39in 998kg 39in 1000mm 39in 1001mm 39in 1074mm 42in
dump angle
297D Dump Clear-

XHP ance @ 40° 2445mm 96in 2442mm 96in 2442mm 96in 2441mm 96in 2378mm 94in
dump angle
Reach @ 40°
dump angle
297D- Dump Clear-

dump angle
Reach @ 40°
dump angle
297D- Dump Clear-
XHP dump angle
Reach @ 40°
dump angle
74 SEBU9084-11
Rated Load
Table 22
GP Buckets
P/N 279-5364 279-5368 279-5372 279-5376 292-9270
Tool Mass
(kg, lb)
Bucket
60" 66" 72" 78" 84" High Capacity
Specs.
Dump Clear-
dump angle
Reach @ 40°
dump angle
Dump Clear-
dump angle
Reach @ 40°
dump angle
Table 23
P/N 279-5368 279-5372 279-5376 292-9270

Tool Mass
(kg, lb.)
Bucket
66" 72" 78" 84" High Capacity
Specs.
259D
ROC 35% 880kg 1940lb 875kg 1930kg 870lb 1919kg 839kg 1851lb
Dump Clear-
dump angle
Reach @ 40°
dump angle
Dump Clear-
dump angle
Reach @ 40°
dump angle
289D Tipping Load 3304kg 7286lb 3291kg 7257lb 3276kg 7223lb 3170kg 6989lb
(continued)
SEBU9084-11 75
Rated Load
(Table 23, contd)

Dump Clear-
dump angle
Reach @ 40°
dump angle
299D Dump Clear-

Rubber ance @ 40° 2457mm 97in 2457mm 97in 2456mm 97in 2393mm 94in
dump angle
Reach @ 40°
dump angle

dump angle
Reach @ 40°
dump angle
299D Dump Clear-

(Steel) ance @ 40° 2457mm 97in 2457mm 97in 2456mm 97in 2393mm 94in
dump angle
Reach @ 40°
dump angle

dump angle
Reach @ 40°
dump angle
299D2 Dump Clear-

dump angle
Reach @ 40°
dump angle
299D2 Tipping Load 4163kg 9179lb 4150kg 9150lb 4133kg 9113lb 4013kg 8848lb
XHP
Rubber ROC 35% 1457kg 3213lb 1452kg 3203lb 1447kg 3190lb 1404kg2 3097lb
(continued)
76 SEBU9084-11
Rated Load
(Table 23, contd)

Dump Clear-
dump angle
Reach @ 40°
dump angle
299D2 Dump Clear-

dump angle
Reach @ 40°
dump angle
299D2 Dump Clear-
XHP ance @ 40° 2499mm 98in 2499mm 98in 2499mm 98in 2438mm 96in
(Steel) dump angle
Reach @ 40°
dump angle
Table 24
Multi-Purpose Buckets
P/N 279-5382 279-5390 279-5398 279-5403 293-0139

Tool Mass
(kg, lb.)
Bucket
60" 66" 72" 78" 84"
Specs.
Dump Clear-
dump angle
Reach @ 40°
dump angle
Dump Clear-
dump angle
Reach @ 40°
dump angle
236D
(continued)
SEBU9084-11 77
Rated Load
(Table 24, contd)

Dump Clear-
dump angle
Reach @ 40°
dump angle
Dump Clear-
dump angle
Reach @ 40°
dump angle
Dump Clear-
dump angle
Reach @ 40°
dump angle
Dump Clear-
dump angle
Reach @ 40°
dump angle
Dump Clear-
dump angle
Reach @ 40°
dump angle
272D Dump @ 40°
XHP 2526mm 99in 2525mm 99in 2524mm 99in 2523mm 99in 2522mm 99in
dump angle
Reach @ 40°
dump angle
272D2
Dump @ 40°
dump angle
(continued)
78 SEBU9084-11
Rated Load
(Table 24, contd)

Reach @ 40°
dump angle
272D2 Dump @ 40°
dump angle
Reach @ 40°
dump angle
Table 25
P/N 279-5390 279-5398 279-5403 293-0139

Tool Mass
(kg, lb.)
Bucket
66" 72" 78" 84"
Specs.
257D
ROC 35% 795kg 1753lb 789kg 1739lb 787lb 1734lb 780kg 1721lb
Dump Clear-
dump angle
Reach @ 40°
dump angle
Dump Clear-
dump angle
Reach @
max dump 652mm 26in 653mm 26in 655mm 26in 656mm 26in
angle
Dump Clear-
287D ance @ 40° 2425mm 95in 2424m 95in 2423mm 95in 2422mm 95in
dump angle
Reach @ 40°
dump angle
Table 26
P/N 279-5382 279-5390 279-5398 279-5403 293-0139

297D Tool Mass
(kg, lb.)
(continued)
SEBU9084-11 79
Rated Load
(Table 26, contd)

Bucket
60" 66" 72" 78" 84"
Specs.
Dump Clear-
dump angle
Reach @ 40°
dump angle
297D Dump Clear-

dump angle
Reach @ 40°
dump angle
Dump Clear-
297D2 ance @ 40° 2519mm 99in 2519mm 99in 2519mm 99in 2519mm 99in 2519mm 99in
dump angle
Reach @ 40°
dump angle
297D2 Dump Clear-

dump angle
Reach @ 40°
dump angle
Table 27
P/N 279-5382 279-5390 279-5398 279-5403 293-0139

Tool Mass
(kg, lb.)
Bucket
60" 66" 72" 78" 84"
Specs.
239D
Dump Clear-
dump angle
(continued)
80 SEBU9084-11
Rated Load
(Table 27, contd)

Reach @ 40°
dump angle
Dump Clear-
dump angle
Reach @ 40°
dump angle
Table 28
P/N 279-5390 279-5398 279-5403 293-0139

Tool Mass
355 kg 782 lb 374 kg 824 lb 393kg 866lb 412kg 908lb
(kg, lb.)
Bucket
66" 72" 78" 84"
Specs.
259D
Dump Clear-
dump angle
Reach @ 40°
dump angle
Tipping Load 2393kg 5277lb 2375kg 5236lb 2365kg 5216kg 2348kg 5177lb
Dump Clear-
dump angle
Reach @ 40°
dump angle
Dump Clear-
289D ance @ 40° 2434mm 96mm 2433mm 96mm 2432mm 96mm 2431mm 96mm
dump angle
Reach @ 40°
dump angle
ROC 35% 1245kg 2744lb 1239kg 2732lb 1239kg 2733lb 1234kg 2722
299D
Rubber Dump Clear-
dump angle
(continued)
SEBU9084-11 81
Rated Load
(Table 28, contd)

Reach @ 40°
dump angle
299 D Dump Clear-
Rubber dump angle
Reach @ 40°
dump angle
299D Dump Clear-

dump angle
Reach @ 40°
dump angle

dump angle
Reach @ 40°
dump angle
299D2 Dump Clear-

dump angle
Reach @ 40°
dump angle
299D2 Dump Clear-
Rubber dump angle
Reach @ 40°
dump angle
299D2 Dump Clear-

dump angle
Reach @ 40°
dump angle
(continued)
82 SEBU9084-11
Rated Load
(Table 28, contd)

299D2 Dump Clear-
(Steel) dump angle
Reach @ 40°
dump angle
Table 29
Multi-Purpose Buckets with Bolt-On Edge and Debris Guard
P/N 325-7040 325-7050 325-7060 325-7070 325-7080

Tool Mass
(kg, lb.)
Bucket
60" 66" 72" 78" 84"
Specs.
Tipping
Load
Dump
226D Clearance
@ 40°
dump angle
Reach @
angle
Tipping
Load
Dump
232D Clearance
@ 40°
dump angle
Reach @
angle
Tipping
Load
Dump
236D Clearance
@ 40°
dump angle
Reach @
angle
Tipping
242D 1686kg 3718lb 1661kg 3664lb 1636kg 3606lb 1620kg 3572lb 1596kg 2778lb
Load
(continued)
SEBU9084-11 83
Rated Load
(Table 29, contd)

Dump
Clearance
@ 40°
dump angle
Reach @
angle
Tipping
Load
Dump
246D Clearance
@ 40°
dump angle
Reach @
angle
Tipping
Load
Dump
262D Clearance
@ 40°
dump angle
Reach @
angle
Tipping
Load
Dump
272D Clearance
@ 40°
dump angle
Reach @
angle
Tipping
Load
272D Dump @
XHP 40° dump 2498mm 98in 2497mm 98in 2496mm 98in 2495mm 98in 2494mm 98in
angle
Reach @
40° dump 951mm 37mm 952mm 37in 953mm 38in 954mm 38in 955mm 38in
angle
(continued)
84 SEBU9084-11
Rated Load
(Table 29, contd)

Tipping
Load
Dump @
272D2 40° dump 2448mm 96in 2447mm 96in 2446mm 96in 2446mm 96in 2445mm 96in
angle
Reach @
angle
Tipping
Load
272D2 Dump @
XHP 40° dump 2486mm 98in 2485mm 98in 2485mm 98in 2484mm 98in 2483mm 98in
angle
Reach @
angle
Table 30
P/N 325-7050 325-7060 325-7070 325-7080

Tool Mass
(kg, lb.)
Bucket
66" 72" 78" 84"
Specs.
257D
Dump Clear-
dump angle
Reach @ 40°
dump angle
Dump Clear-
dump angle
Reach @
angle
Tipping Load 3310kg 7298lb 3283kg 7239lb 3276kg 7223lb 3252lkg 7171lb
Dump Clear-
dump angle
Reach @ 40°
dump angle
SEBU9084-11 85
Rated Load
Table 31
P/N 325-7040 325-7050 325-7060 325-7070 325-7080

Tool Mass
(kg, lb.)
Bucket
60" 66" 72" 78" 84"
Specs.
Tipping
Load
297D
Dump
Clearance
@ 40°
dump angle
Reach @
angle
Tipping
Load
Dump
297D Clearance
@ 40°
dump angle
Reach @
angle
Tipping
Load
Dump
297D2 Clearance
@ 40°
dump angle
Reach @
angle
Tipping
Load
Dump
297D2 Clearance
@ 40°
dump angle
Reach @
angle
86 SEBU9084-11
Rated Load
Table 32
P/N 325-7040 325-7050 325-7060 325-7070 325-7080

Tool Mass
(kg, lb.)
Bucket
60" 66" 72" 78" 84"
Specs.
Tipping
Load
ROC 50% 809kg 1784lb 556kg 1225kg 548kg 1208lb 544kg 1199lb 536kg 1181lb
Dump
239D Clearance
@ 40°
dump angle
Reach @
angle
Tipping
Load
Dump
249D Clearance
@ 40°
dump angle
Reach @
angle
Table 33
P/N 325-7050 325-7060 325-7070 325-7080

Tool Mass
(kg, lb.)
Bucket
66" 72" 78" 84"
Specs.
Tipping Load 2279KG 5025LB 2253KG 4968LB 2240KG 4940LB 2217KG 4888LB
259D
ROC 35% 798KG 1759LB 789kg 1739lb 784kg 1729lb 776kg 1711lb
Dump Clear-
dump angle
Reach @
40° dump 824mm 32in 827mm 33in 830mm 33in 833mm 33in
angle
279D
(continued)
SEBU9084-11 87
Rated Load
(Table 33, contd)

Dump Clear-
dump angle
Reach @
angle
Dump Clear-
dump angle
Reach @
angle
Dump Clear-
Rubber dump angle
Reach @
angle
299D Dump Clear-

XHP ance @ 40° 2420mm 95in 2419mm 95in 2418mm 95in 2416 95in
Rubber dump angle
Reach @
angle
Dump Clear-
(Steel) dump angle
Reach @
angle
299D Dump Clear-

(Steel) dump angle
Reach @
40° dump 989mm 39in 991mm 39in 994mm 39in 996m 39in
angle
(continued)
88 SEBU9084-11
Rated Load
(Table 33, contd)

Dump Clear-
299D2 ance @ 40° 2461mm 97in 2461mm 97in 2461mm 97in 2461mm 97in
Rubber dump angle
Reach @
angle
299D2 Dump Clear-

Rubber dump angle
Reach @
angle
Dump Clear-
(Steel) dump angle
Reach @
angle
299D2 Dump Clear-

(Steel) dump angle
Reach @
angle
Table 34
Utility Buckets
P/N 285-6096 285-6099 285-6102

Tool Mass (kg,
211kg 465lb 226kg 498lb 240kg 529lb
lb.)

226D
Dump Clearance
@ 40° dump 2070mm 81in 2069mm 81in 2069mm 81in
angle
(continued)
SEBU9084-11 89
Rated Load
(Table 34, contd)

Reach @ 40°
693mm 27in 694mm 27in 696mm 27in
dump angle
Dump Clearance
232D @ 40° dump 2251mm 89in 2250mm 2250mm 2250mm 89in
angle
Reach @ 40°
823mm 32in 824mm 824mm 826mm 33in
dump angle
Dump Clearance
angle
Reach @ 40°
543mm 21in 543mm 21in 544mm 21in
dump angle
Dump Clearance
angle
Reach @ 40°
755mm 30in 756mm 30in 757mm 30in
dump angle
Dump Clearance
angle
Reach @ 40°
629mm 25in 630mm 25in 630mm 25in
dump angle
Dump Clearance
angle
Reach @ 40°
974mm 38in 975mm 38in 975mm 38in
dump angle
Dump Clearance
angle
Reach @ 40°
1001mm 39in 1001mm 39in 1002mm 39in
dump angle
(continued)
90 SEBU9084-11
Rated Load
(Table 34, contd)

272D Dump Clearance

XHP @ 40° dump 2513mm 99in 2512mm 99in 2512mm 99in
angle
Reach @ 40°
962mm 38in 962mm 38in 963mm 38in
dump angle
272D2 Dump @ 40°

2466mm 97in 2465mm 97in 2465mm 97in
dump angle
Reach @ 40°
986mm 39in 987mm 39in 988mm 39in
dump angle

272D2 Dump @ 40°
XHP 2503mm 99in 2503mm 99in 2502mm 99in
dump angle
Reach @ 40°
954mm 38in 955mm 38in 955mm 38in
dump angle
Table 35
Utility Buckets
P/N 285-6099 285-6102

Tool Mass (kg, lb.) 224kg 494lb 239kg 526lb
Bucket Specs. 66" 72"
Tipping Load 2433kg 5366lb 2420kg 5337lb

257D
ROC 35% 852kg 1878lb 847kg 1868lb
Dump Clearance @ 40°

2311mm 91in 2310mm 91in
dump angle
Reach @ 40° dump

922mm 36in 923mm 36in
angle
Tipping Load 2870kg 6329lb 2857kg 6300
ROC 35% 1005kg 2215lb 1000kg 2205lb
277D Dump Clearance @ max

2428mm 96in 2427mm 96in
dump angle
Reach @ max dump

673mm 26in 674mm 37in
angle
ROC 35% 1254kg 2766lb 1250kg 2756lb
287D Dump Clearance @ 40°

2416mm 95in 2413mm 95in
dump angle
Reach @ 40° dump

1000mm 39in 1001mm 39in
angle
SEBU9084-11 91
Rated Load
Table 36
Utility Buckets
P/N 285-6096 285-6099 285-6102

Tool Mass (kg,
211kg 465lb 226kg 498lb 240kg 529lb
lb.)
Dump Clearance
angle
Reach @ 40°
789mm 31in 789mm 31in 789mm 31in
dump angle
Dump Clearance
angle
Reach @ 40°
931mm 37in 932mm 37in 932mm 37in
dump angle
Table 37
Utility Buckets
P/N 285-6099 285-6102


259D
ROC 35% 881kg 1943lb 876kg 1933lb

2326mm 92in 2325mm 92in
dump angle
Reach @ 40° dump

820mm 32in 822mm 32in
angle
ROC 35% 891kg 1964lb 886kg 1954lb

2419mm 95in 2419mm 95in
dump angle
Reach @ 40° dump

610mm 24in 611mm 24in
angle
ROC 35% 1155kg 2547lb 1150kg 2537lb

289D
2423mm 95in 2422mm 95in
dump angle
(continued)
92 SEBU9084-11
Rated Load
(Table 37, contd)

Reach @ 40° dump
956mm 38in 958mm 38in
angle
ROC 35% 1299kg 2865lb 1296kg 2857lb

(Rubber) 2432mm 96in 2431mm 96in
dump angle
Reach @ 40° dump

997mm 39in 998mm 39in
angle
ROC 35% 1430kg 3152lb 1426kg 3144lb

299D XHP Dump Clearance @ 40°
dump angle
Reach @ 40° dump

987mm 39in 989mm 39in
angle
ROC 35% 1501kg 3309lb 1497kg 3301lb

(Steel) 2432mm 96in 2431mm 96in
dump angle
Reach @ 40° dump

997mm 39in 998mm 39in
angle
ROC 35% 1630kg 3594lb 1627kg 3587lb

299D XHP Dump Clearance @ 40°
dump angle
Reach @ 40° dump

987mm 39in 989mm 39in
angle
ROC 35% 1421kg 3134lb 1471kg 3124lb

299D2 Dump Clearance @ 40°
dump angle
Reach @ 40° dump

1055mm 42in 1056mm 42in
angle
ROC 35% 1460kg 3219lb 1455kg 3208lb

299D2
XHP Dump Clearance @ 40°
2474mm 97in 2474mm 97in
(Rubber) dump angle
Reach @ 40° dump

1056mm 42in 1056mm 42in
angle
299D2 ROC 35% 1539kg 3394lb 1535kg 3384lb

(Steel)
2474mm 97in 2474mm 97in
dump angle
(continued)
SEBU9084-11 93
Rated Load
(Table 37, contd)

Reach @ 40° dump
1056mm 42in 1056mm 42in
angle
ROC 35% 1568kg 3458lb 1563kg 3447lb

299D2
2474mm 97in 2474mm 97in
(Steel) dump angle
Reach @ 40° dump

1056mm 42in 1056mm 42in
angle
Table 38
Light Material Buckets
P/N 279-5421 279-5424 279-5429, BO Edge 296-7597, BO Edge
Tool Mass
(kg, lb.)
Bucket
72" 78" 84" 96"
Specs.
Dump Clear-
dump angle
Reach @
angle
Dump Clear-
dump angle
Reach @
angle
Dump Clear-
dump angle
Reach @
angle
Tipping Load 1975kg 4354lb 1959kg 4320lb 1944kg 4286 1722kg 3796lb
242D
(continued)
94 SEBU9084-11
Rated Load
(Table 38, contd)

Dump Clear-
dump angle
Reach @
angle
Dump Clear-
dump angle
Reach @
angle
Dump Clear-
dump angle
Reach @
angle
ROC 50% 1451kg 3200lb 1443kg 3182kg 1436lb 3166lb 1286kg 2835lb
Dump Clear-
dump angle
Reach @
angle
Dump @ 40°
272D XHP 2479mm 98in 2479mm 98in 2446mm 96in 2445mm 96in
dump angle
Reach @
angle
Dump @ 40°
272D2 2432mm 96in 2432mm 96in 2399mm 94in 2398mm 94in
dump angle
Reach @
angle
272D2 XHP Tipping Load 3392kg 7478lb 3376kg 7442lb 3269kg 7207lb 2929kg 6457lb
(continued)
SEBU9084-11 95
Rated Load
(Table 38, contd)

Dump @ 40°
dump angle
Reach @
angle
Table 39
P/N 279-5421 279-5424 279-5429, BO Edge 296-7597, BO Edge
Tool Mass
(kg, lb.)
Bucket
72" 78" 84" 96"
Specs.
257D
Dump Clear-
dump angle
Reach @
angle
Dump Clear-
dump angle
Reach @
angle
Dump Clear-
dump angle
Reach @
angle
Table 40
P/N 279-5421 279-5424 279-5429, BO Edge 296-7597, BO Edge

297D Tool Mass
(kg, lb.)
(continued)
96 SEBU9084-11
Rated Load
(Table 40, contd)

Bucket
72" 78" 84" 96"
Specs.
Dump Clear-
dump angle
Reach @
angle
Dump Clear-
XHP dump angle
Reach @
angle
Dump Clear-
dump angle
Reach @
angle
Dump Clear-
297D2 XHP ance @ 40° 2469mm 97in 2469mm 97in 2439mm 96in 2439mm 96in
dump angle
Reach @
angle
Table 41
P/N 279-5421 279-5424 279-5429, BO Edge 296-7597, BO Edge
Tool Mass
(kg, lb.)
Bucket
72" 78" 84" 96"
Specs.
239D
(continued)
SEBU9084-11 97
Rated Load
(Table 41, contd)

Dump Clear-
dump angle
Reach @
angle
Dump Clear-
dump angle
Reach @
angle
Dump Clear-
dump angle
Reach @
angle
Tipping Load 2598kg 5729lb 2583kg 5695lb 2569kg 5664lb 2366kg 5217
Dump Clear-
dump angle
Reach @
angle
Tipping Load 3408kg 7514lb 3392kg 7478lb 3378kg 7448kg 3089lb 6811lb
Dump Clear-
dump angle
Reach @
angle
Dump Clear-
299D Rubber ance @ 40° 2398mm 94in 2398mm 94in 2364mm 93in 2363 93in
dump angle
Reach @
40° dump 1032mm 41in 1034mm 41mm 1051mm 41in 1054mm 42in
angle
(continued)
98 SEBU9084-11
Rated Load
(Table 41, contd)

Dump Clear-
299D XHP ance @ 40° 2403mm 95in 2402mm 95in 2369mm 93in 2368mm 93in
Rubber dump angle
Reach @
angle
Dump Clear-
299D (Steel) ance @ 40° 2398mm 94in 2398mm 94in 2364mm 93in 2363mm 93in
dump angle
Reach @
angle
Dump Clear-
299D XHP ance @ 40° 2403mm 95in 2402mm 95in 2369mm 93in 2368mm 93in
(Steel) dump angle
Reach @
angle
Dump Clear-
Rubber dump angle
Reach @
angle
Dump Clear-
Rubber dump angle
Reach @
angle
299D2 (Steel)
Dump Clear-
dump angle
(continued)
SEBU9084-11 99
Rated Load
(Table 41, contd)

Reach @
angle
Dump Clear-
(Steel) dump angle
Reach @
angle
Table 42
Industrial Grapple Buckets
P/N 157-7223 157-7224 157-7225 217-6229
Tool Mass
(kg,lb)
Bucket
60 in 66 in 72 in 78 in
Specs.
Dump Clear-
dump angle
Reach @ 40°
dump angle
Dump Clear-
dump angle
Reach @ 40°
dump angle
Tipping Load 1451 kg 3200 lb 1436 kg 3166 lb 1421 kg 3133lb 1402 kg 3091 lb
ROC 50% 726kg 1600 lb 718kg 1583 lb 710kg 1566 lb 701kg 1545 lb
Dump Clear-
236D ance @ 40° 2390 mm 94 in 2389 mm 94 in 2388 mm 94 in 2387 mm 94 in
dump angle
Reach @ 40°
526 mm 21 in 527 mm 21 in 528 mm 21 in 529 mm 21 in
dump angle
Tipping Load 1819 kg 4010 lb 1803kg 3976 lb 1789 kg 3943 lb 1770 kg 3902 lb
242D
ROC 50% 909kg 2005 lb 902kg 1988 lb 894kg 1972 lb 885kg 1951lb
(continued)
100 SEBU9084-11
Rated Load
(Table 42, contd)

Dump Clear-
ance @ 40° 2344 mm 92 in 2343 mm 92 in 2343 mm 92 in 2342 mm 92 in
dump angle
Reach @ 40°
736 mm 29 in 737 mm 29 in 738 mm 29 in 739 mm 29in
dump angle
Tipping Load 1857kg 4095lb 1841 kg 4060 lb 1826 kg 4027 lb 1808 kg 3986 lb
ROC 50% 929kg 2047lb 921kg 2030 lb 913kg 2013 lb 904kg 1992lb
Dump Clear-
246D ance @ 40° 2415mm 95in 2414 mm 95 in 2414 mm 95 in 2413 mm 95 in
dump angle
Reach @ 40°
dump angle
Tipping Load 2408kg 5308lb 2392 kg 5274 lb 2377 kg 5241 lb 2359 kg 5200 lb
ROC 50% 1204kg 2654lb 1196 kg 2637 lb 1189 kg 2621 lb 1179 kg 2600 lb
Dump Clear-
262D ance @ 40° 2434mm 96in 2433 mm 96 in 2432 mm 96 in 2431 mm 96 in
dump angle
Reach @ 40°
dump angle
Dump Clear-
dump angle
Reach @ 40°
980mm 39in 980mm 39mm 981mm 39mm 982mm 39in
dump angle
272D Dump @ 40°
XHP 2529mm 100in 2528mm 100in 2527mm 100in 2527mm 99in
dump angle
Reach @ 40°
939mm 37in 939mm 37in 940mm 37in 941m 37in
dump angle
272D2 Dump @ 40°

dump angle
Reach @ 40°
dump angle
272D2 Dump @ 40°
XHP 2522mm 99in 2521mm 99in 2521mm 99in 2520mm 99in
dump angle
Reach @ 40°
dump angle
SEBU9084-11 101
Rated Load
Table 43
P/N 157-7224 157-7225 217-6229

Tool Mass (kg,
425kg 937lb 440kg 970lb 459kg 1012lb
lb.)

257D
Dump Clearance
@ 40° dump 2326mm 92in 2325mm 92in 2324mm 92in
angle
Reach @ 40°
912mm 36in 913mm 36in 915mm 36in
dump angle
ROC 35% 987kg 2176lb 982kg 2165lb 976lb 2151lb
Dump Clearance
277D @ max dump 2440mm 96in 2440mm 96in 2438mm 96in
angle
Reach @ max
657mm 26in 658mm 26in 660mm 26in
dump angle
Dump Clearance
angle
Reach @ 40°
989mm 39in 990mm 39in 992mm 39in
dump angle
Table 44
P/N 157-7223 157-7224 157-7225 217-6229
Tool Mass
(kg,lb)
Bucket
60 in 66 in 72 in 78 in
Specs.
297D
Dump Clear-
dump angle
Reach @ 40°
dump angle
297D
XHP ROC 50% 2241kg 4941lb 2235kg 4928lb 2230kg 4916lb 2223kg 4901lb
(continued)
102 SEBU9084-11
Rated Load
(Table 44, contd)

Dump Clear-
dump angle
Reach @ 40°
dump angle
Dump Clear-
dump angle
Reach @ 40°
dump angle
297D2 Dump Clear-

dump angle
Reach @ 40°
dump angle
Table 45
P/N 157-7223 157-7224 157-7225 217-6229
Tool Mass
(kg,lb)
Bucket
60 in 66 in 72 in 78 in
Specs.
Dump Clear-
dump angle
Reach @ 40°
dump angle
Dump Clear-
dump angle
Reach @ 40°
dump angle
SEBU9084-11 103
Rated Load
Table 46
P/N 157-7224 157-7225 217-6229

Tool Mass
425kg 937lb 440kg 970lb 459kg 1012lb
(kg, lb.)
Bucket
66" 72" 78"
Specs.
Tipping Load 2458kg 5419lb 2443 5388lb 2426kg 5348lb

259D
Dump Clear-
dump angle
Reach @ 40°
813mm 32in 815mm 32in 817mm 32in
dump angle
Dump Clear-
dump angle
Reach @ 40°
601mm 24in 603mm 24in 605mm 24in
dump angle
Dump Clear-
dump angle
Reach @ 40°
946mm 37in 948mm 37mm 950mm 37in
dump angle
Dump Clear-
299D Rubber ance @ 40° 2447mm 96in 2446mm 96in 2445mm 96in
dump angle
Reach @ 40°
987mm 39in 989mm 39in 990 39in
dump angle
Dump Clear-
299D XHP Rubber ance @ 40° 2452mm 97in 2452mm 97in 2451mm 96in
dump angle
Reach @ 40°
977mmm 38in 978mm 39in 980mm 39in
dump angle

299D (Steel)
(continued)
104 SEBU9084-11
Rated Load
(Table 46, contd)

Dump Clear-
dump angle
Reach @ 40°
987mm 39in 989mm 39in 990mm 39in
dump angle
Dump Clear-
299D XHP (Steel) ance @ 40° 2452mm 97in 2452mm 97in 2451mm 96in
dump angle
Reach @ 40°
977mm 38in 978mm 39in 980mm 39in
dump angle
Dump Clear-
299D2 Rubber ance @ 40° 2499mm 98in 2499mm 98in 2499mm 98in
dump angle
Reach @ 40°
1025mm 40in 1025mm 40in 1025mm 40in
dump angle
Dump Clear-
299D2 XHP Rubber ance @ 40° 2499mm 98in 2499mm 98in 2499mm 98in
dump angle
Reach @ 40°
1025mm 40in 1025mm 40in 1025mm 40in
dump angle
Dump Clear-
299D2 (Steel) ance @ 40° 2499mm 98in 2499mm 98in 2499mm 98in
dump angle
Reach @ 40°
1025mm 40in 1025mm 40in 1025mm 40in
dump angle
Dump Clear-
299D2 XHP (Steel) ance @ 40° 2499mm 98in 2499mm 98in 2499mm 98in
dump angle
Reach @ 40°
1025mm 40in 1025mm 40in 1025mm 40in
dump angle
Table 47
Utility Grapple Buckets with Bolt-On Edge
P/N 285-6111 285-6112
(continued)
SEBU9084-11 105
Rated Load
(Table 47, contd)

ROC 50% 583kg 1285lb 575kg 1268lb

2032mm 80in 2031mm 80in
dump angle
Reach @ 40° dump

720mm 28in 721mm 28in
angle
ROC 50% 720kg 1588lb 713kg 1571lb

2211mm 87in 2211mm 87in
dump angle
Reach @ 40° dump

852mm 34in 854mm 34in
angle
ROC 50% 699kg 1540lb 691kg 1523lb

2338mm 92in 2337mm 92in
dump angle
Reach @ 40° dump

565mm 22in 566mm 22in
angle
ROC 50% 871kg 1919lb 863kg 1902lb

2292mm 90in 2291mm 90in
dump angle
Reach @ 40° dump

776mm 31in 776mm 31in
angle
ROC 50% 890kg 1962lb 881kg 1943lb

2362mm 93in 2361mm 93in
dump angle
Reach @ 40° dump

648mm 25in 648mm 26in
angle
ROC 50% 1152kg 2540lb 1144kg 2522lb

2381mm 94in 2380mm 94in
dump angle
Reach @ 40° dump

994mm 39in 995mm 39in
angle

272D
ROC 50% 1306kg 2880lb 1298kg 2862lb
(continued)
106 SEBU9084-11
Rated Load
(Table 47, contd)

2434mm 96in 2433mm 96in
dump angle
Reach @ 40° dump

1019mm 40in 1020mm 40in
angle
ROC 50% 1542kg 3400lb 1534kg 3382lb
272D XHP Dump @ 40° dump

2476mm 97in 2475mm 97in
angle
Reach @ 40° dump

979mm 39in 980mm 39in
angle
ROC 50% 1425kg 3142lb 1417kg 3124lb
272D2 Dump @ 40° dump

2429mm 96in 2429mm 96in
angle
Reach @ 40° dump

1007mm 40in 1008mm 40in
angle
ROC 50% 1531kg 3376lb 1523kg 3358lb
272D2 XHP Dump @ 40° dump

2468mm 97in 2467mm 97in
angle
Reach @ 40° dump

974mm 38in 974mm 38in
angle
Table 48
P/N 285-6111 285-6112


257D
ROC 35% 799kg 1762lb 794kg 1750lb

2273mm 89in 2272mm 89in
dump angle
Reach @ 40° dump

948mm 37in 950mm 37in
angle
ROC 35% 952kg 2099lb 946kg 2087lb
277D Dump Clearance @ max

2388mm 94in 2387mm 94in
dump angle
Reach @ max dump

696mm 27in 697mm 25in
angle
287D Tipping Load 3425kg 7553lb 3409kg 7517lb
(continued)
SEBU9084-11 107
Rated Load
(Table 48, contd)

ROC 35% 1199kg 2643lb 1193kg 2631lb

2376mm 94in 2375mm 91in
dump angle
Reach @ 40° dump

1025mm 40in 1027mm 40in
angle
Table 49
P/N 285-6111 285-6112


297D
ROC 50% 1947kg 4292lb 1940kg 4276lb

2377mm 94in 2376mm 94in
dump angle
Reach @ 40° dump

1056mm 42in 1057mm 42in
angle
ROC 50% 2136kg 4710lb 2129kg 4694lb

XHP 2381mm 94in 2380mm 94in
dump angle
Reach @ 40° dump

1048mm 41in 1050mm 41in
angle
ROC 50% 1988kg 4382lb 1979kg 4363lb

2470mm 97in 2470mm 97in
dump angle
Reach @ 40° dump

967mm 38in 967mm 38in
angle
ROC 50% 2029kg 4473lb 2021kg 4455lb

XHP 2470mm 97in 2470mm 97in
dump angle
Reach @ 40° dump

967mm 38in 967mm 38in
angle
Table 50
P/N 285-6111 285-6112

(continued)
108 SEBU9084-11
Rated Load
(Table 50, contd)

ROC 35% 575kg 1269lb 570kg 1257lb

2040mm 80in 2040mm 80in
dump angle
Reach @ 40° dump

800mm 32in 800mm 32in
angle
ROC 35% 651kg 1434lb 645kg 1422lb

2215mm 87in 2215mm 87in
dump angle
Reach @ 40° dump

943mm 37in 943mm 37in
angle
ROC 35% 828kg 1826lb 823kg 1814lb

2288mm 90in 2287mm 90in
dump angle
Reach @ 40° dump

849mm 33in 850mm 33in
angle
ROC 35% 837kg 1847lb 832kg 1834lb

2383mm 94in 2382mm 94in
dump angle
Reach @ 40° dump

637mm 25in 639mm 23in
angle
ROC 35% 1100kg 2426lb 1094kg 2413lb

2385mm 94in 2384mm 94in
dump angle
Reach @ 40° dump

983mm 39in 984mm 39in
angle
ROC 35% 1256kg 2769lb 1251kg 2758lb

Rubber 2394mm 94in 2394mm 94in
dump angle
Reach @ 40° dump

1023mm 40in 1024mm 40in
angle
ROC 35% 1385kg 3054lb 1380kg 3043lb

299D
2399mm 94in 2399mm 94in
Rubber dump angle
Reach @ 40° dump

1013mm 40in 1014mm 40in
angle
(continued)
SEBU9084-11 109
Rated Load
(Table 50, contd)

ROC 35% 1457kg 3213lb 1452kg 3202lb

dump angle
Reach @ 40° dump

1023mm 40in 1024mm 40in
angle
ROC 35% 1585kg 3496lb 1580kg 3485lb

299D
2399mm 94in 2399mm 94in
(Steel) dump angle
Reach @ 40° dump

1013mm 40in 1014mm 40in
angle
Tipping Load 3899kg 8598kg 3882kg 8561lb
ROC 35% 1365kg 3009lb 1359kg 2996lb

Rubber 2443mm 96in 2443mm 96in
dump angle
Reach @ 40° dump

1067mm 42in 1067mm 42in
angle
ROC 35% 1403kg 3093lb 1397kg 3080lb

299D2
2443mm 96in 2443mm 96in
Rubber dump angle
Reach @ 40° dump

1067mm 42in 1067mm 42in
angle
ROC 35% 1481kg 3266lb 1475kg 3253lb

dump angle
Reach @ 40° dump

1067mm 42in 1067mm 42in
angle
ROC 35% 1510kg 3329lb 1504kg 3315lb

299D2
2443mm 96in 2443mm 96in
(Steel) dump angle
Reach @ 40° dump

1067mm 42in 1067mm 42in
angle
110 SEBU9084-11
Rated Load
Rated Loads for Forks The maximum fork height (ground to top face of fork)
is given for a pallet fork that is horizontal at maximum
lift height. The reach (front tires to front face of fork) is
given for a pallet fork that is horizontal maximum
reach.
Failure to comply to the rated load can cause
possible personal injury or property damage. Rated loads are based upon a standard machine with
This includes the risk of unintended boom lower- the following conditions:
tool before performing any operation. Make ad- • 10 x 16.5 tires on 226D, and 232D
standard configurations. • 12 x 16.5 tires on 236D, 242D, 246D, 262D, 272D,
and 272D2
Note: Rated loads should be used as a guide. • 14 x 17.5 tires on 272D XHP, and 272D2 XHP
conditions, or poor ground conditions have effects on • lubricants
rated loads. The operator is responsible for being
aware of these effects. • full fuel tank
The rated operating capacity (ROC) is defined by • 75 kg (165 lb) operator

“SAE J1197-2011”, “ISO 14397-1:2007” and “EN
474-3:2006+A1:2009” as the least amount of weight • Cat fork, carriage, and tines
of the following conditions:
• Undercarriage with 320 mm wide tracks and dual
• 50% of the full static tipping load for wheeled flange front/single flange rear idlers on 239D,
machines 249D, and 259D machines.
• 35% of the full static tipping load for track • Undercarriages with either 400 mm or 450 mm
machines wide tracks and triple flange front/rear idlers on
279D, and 289D machines.
• The lifting capacity to maximum height
flange front/single flange rear idlers on 299D, and
299D2 machines.
• Undercarriages with 400 mm wide tracks and

299D2 XHP machines.

Note: The Steel Track Undercarriage attachment will

increase the rated operating loads in the following
tables by 111 kg (245 lb) for 299D and 299D XHP
and by 69 kg (152 lb) for 299D2 and 299D2 XHP
machines.
The following tables provide the rated operating
loads for the standard machine configuration with a
fork.
Dimension (A) represents the maximum fork height.
Dimension (B) represents the load center. Dimension
(C) represents the reach. Dimension (D) represents
the fork tine length.
SEBU9084-11 111
Rated Load
Dimension (B) represents the load center.
112 SEBU9084-11
Rated Load
Forks
Table 51
Pallet Fork - Skid Steer Loader
P/N 353-1694 353-1696 353-1697
Tool Mass (kg,
175 kg 386 lb 186 kg 409 lb 195 kg 430 lb
lb.)
Fork Specs. 36 in 42 in 48 in
Load Center 455 mm 18 in 535 mm 21 in 610 mm 24 in


226D Max Fork Height 2705mm 107in 2706mm 107in 2704mm 106in
Max Reach to
747mm 29in 748mm 29in 749mm 29in
Carriage Face

Max Reach to
707mm 28in 707mm 28in 709mm 28in
Carriage Face

Max Reach to
795mm 31in 804mm 32in 802mm 32in
Carriage Face

Max Reach to
691mm 27in 699mm 28in 698mm 27in
Carriage Face
Tipping Load 1552kg 3421 lb 1473 kg 3248 lb 1405 kg 3098 lb
ROC 50% 776 kg 1711 lb 737 kg 1624 lb 703 kg 1549 lb

246D Max Fork Height 3043 mm 120 in 3043 mm 120 in 3043 mm 120 in
Max Reach to
842mm 33in 850mm 33in 849mm 33in
Carriage Face
Tipping Load 1941 kg 4279 lb 1842 kg 4060 lb 1756 kg 3871 lb
ROC 50% 970 kg 2140 lb 921 kg 2030 lb 878 kg 1936 lb

262D Max Fork Height 3066 mm 121 in 3066 mm 121 in 3066 mm 121 in
Max Reach to
730mm 29in 738mm 29in 737mm 29in
Carriage Face
272D Tipping Load 2182kg 4811lb 2072kg 4568lb 1977kg 4359lb
(continued)
SEBU9084-11 113
Rated Load
(Table 51, contd)

Pallet Fork - Skid Steer Loader
Max Fork Height 3118mm 123in 3118mm 123in 3117mm 123in
Max Reach to
737mm 29in 745mm 29in 744mm 29in
Carriage Face

272D XHP Max Fork Height 3158mm 124in 3158mm 124in 3157mm 124in
Max Reach to
699mm 28in 707mm 28in 705mm 28in
Carriage Face

272D2 Max Fork Height 3119mm 123in 3118mm 123in 3117mm 123in
Max Reach to
739mm 29in 739mm 29in 740mm 29in
Carriage Face

272D2 XHP Max Fork Height 3156mm 124in 3156mm 124in 3154mm 124in
Max Reach to
703mm 28in 704mm 28in 705mm 28in
Carriage Face
Table 52
Pallet Fork - Multi-Terrain Loader
P/N 353-1694 353-1696 353-1697
Tool Mass (kg,
175kg 386lb 186kg 409lb 195kg 430lb
lb.)
Fork Specs. 36" 42" 48"
Load Center 455mm 18in 535mm 21in 610mm 24in

257D
ROC 35% 683kg 1505lb 646kg 1425ib 615kg 1356lb

277D

Max Reach to
791mm 31in 799mm 31in 798mm 31in
Carriage Face
114 SEBU9084-11
Rated Load
Table 53
Pallet Fork - Multi-Terrain Loader
P/N 353-1694 353-1696 353-1697
Tool Mass (kg,
175 kg 386 lb 186 kg 409 lb 195 kg 430 lb
lb.)
Fork Specs. 36 in 42 in 48 in
Load Center 455 mm 18 in 535 mm 21 in 610 mm 24 in

297D
Max Reach to
747mm 29in 748mm 29in 750mm 30in
Carriage Face

297D
XHP Max Fork Height 3069mm 121in 3069mm 121in 3067mm 121in
Max Reach to
739mm 29in 740mm 29in 742mm 29in
Carriage Face

297D2 Max Fork Height 3132mm 123in 3132mm 123in 3130mm 123in
Max Reach to
735mm 29in 736mm 29in 738mm 29in
Carriage Face

297D2 XHP Max Fork Height 3132mm 123in 3131mm 123in 3130mm 123in
Max Reach to
735mm 29in 736mm 29in 738mm 29in
Carriage Face
Table 54
Pallet Fork - Compact Track Loader
P/N 353-1694 353-1696 353-1697

Tool Mass (kg,
175kg 386lb 186kg 409lb 195kg 430lb
lb.)
Fork Specs. 36" 42" 48"
Load Center 455mm 18in 535mm 21in 610mm 24in


Max Reach to
815mm 32in 816mm 32in 818mm 32in
Carriage Face
249D Tipping Load 1644kg 3626lb 1556kg 3432lb 1480kg 3264lb
(continued)
SEBU9084-11 115
Rated Load
(Table 54, contd)

Max Reach to
774mm 30in 775mm 31in 777mm 31in
Carriage Face

Max Reach to
750mm 30in 758mm 30in 757mm 30in
Carriage Face
Tipping Load 2198 4848lb 2095kg 4619lb 2005kg 4420

Max Reach to
913mm 36in 921mm 36in 920mm 36in
Carriage Face

Max Reach to
760mm 30in 769mm 30in 768mm 30in
Carriage Face

299D (Rubber) Max Fork Height
3084mm 121in 3084mm 121in 3082mm 121in
Max Reach to
729mm 29in 738mm 29in 737mm 29in
Carriage Face
299D XHP ROC 35% 1179kg 2599lb 1123kg 2476lb 1075kg 2370lb
(Rubber) Max Fork Height 3089mm 122in 3089mm 122in 3067mm 122in

299D (Steel)
299D XHP ROC 35% 1304kg 2876lb 1240kg 2735lb 1186kg 2615lb
(Steel) Max Fork Height 3089mm 122in 3089mm 122in 3087mm 122in

299D2 (Rubber)
(continued)
116 SEBU9084-11
Rated Load
(Table 54, contd)

299D2 XHP ROC 35% 1171kg 2582lb 1113kg 2454lb 1063kg 2343lb
(Rubber) Max Fork Height 3099mm 122in 3099mm 122in 3097mm 122in

299D2 (Steel)
299D2 XHP ROC 35% 1247kg 2750lb 1185kg 2613lb 1132kg 2496lb
(Steel) Max Fork Height 3090mm 122in 3090mm 122in 3089mm 122in
Table 55
Utility Fork
P/N 285-6105 285-6110

Fork Specs. 66" 72"
Load Center 314mm 12in 314mm 12in

226D
ROC 50% 561kg 1238lb 554kg 1220lb

232D
ROC 50% 678kg 1495lb 670kg 1478lb

236D
ROC 50% 661kg 1457lb 653kg 1440lb

242D
ROC 799kg 1762lb 791kg 1745lb

246D
ROC 50% 828kg 1826kg 820kg 1809lb

262D
ROC 1040kg 2293lb 1032kg 2275lb

272D
ROC 50% 1170kg 2580lb 1162kg 2563lb
272D XHP Tipping Load 2726kg 6011kg 2711kg 5976lb
(continued)
SEBU9084-11 117
Rated Load
(Table 55, contd)

ROC 1363kg 3005lb 1355kg 2988lb

272D2
ROC 1271kg 2802lb 1263kg 2784lb

272D2 XHP
ROC 1353kg 2983lb 1345kg 2965lb
Table 56
Utility Fork
P/N 285-6105 285-6110

Fork Specs. 66" 72"

257D
ROC 35% 726kg 1601lb 721kg 1589lb

277D
ROC 35% 761kg 1678lb 755kg 1665lb

287D
ROC 35% 973kg 2145lb 968kg 2133lb
Table 57
Utility Fork
P/N 285-6105 285-6110

Fork Specs. 66" 72"

297D
ROC 50% 1687kg 3720lb 1680kg 3704lb

297D
XHP ROC 3697kg 4076lb 1841kg 4059lb

297D2
ROC 1760kg 3881lb 1753kg 3864lb

297D2 XHP
ROC 1796kg 3959lb 1788kg 3942lb
Table 58
Utility Fork
P/N 285-6105 285-6110

(continued)
118 SEBU9084-11
Rated Load
(Table 58, contd)

Fork Specs. 66" 72"

239D
ROC 35% 545kg 1201lb 539kg 1189lb

249D
ROC 35% 608kg 1341lb 603kg 1329lb

259D
ROC 35% 753kg 1661lb 748kg 1649lb
Tipping Load 2273kg 5012lb 2257kg 4977

279D
ROC 35% 796kg 1754lb 790kg 1742lb

289D
ROC 35% 1008kg 2224lb 1003kg 2211lb

299D (Rubber)
ROC 35% 1121kg 2472lb 1116kg 2460lb

299D XHP (Rubber)
ROC 35% 1234kg 2722lb 1229kg 2710lb

299D (Steel)
ROC 35% 1271kg 2802lb 1266kg 2791lb

299D XHP (Steel)
ROC 35% 1382kg 3047lb 1377kg 3035lb

299D2 (Rubber)
ROC 35% 1212kg 2672lb 1207kg 2660lb

299D2 XHP (Rubber)
ROC 35% 1244kg 2744lb 1239kg 2732lb

299D2 (Steel)
ROC 35% 1306kg 2879lb 1300kg 2867lb

299D2 XHP (Steel)
ROC 35% 1330kg 2932lb 1324kg 2920lb
Table 59
Utility Grapple Fork
P/N 285-6114 285-6115

Fork Specs. 66" 72"
Load Center 314mm 12mm 314mm 12in

226D
ROC 35% 512kg 1128lb 503kg 1108lb
(continued)
SEBU9084-11 119
Rated Load
(Table 59, contd)

232D
ROC 35% 629kg 1386 620kg 1366lb

236D
ROC 35% 611kg 1347lb 602kg 1327lb

242D
ROC 750kg 1653lb 741kg 1634lb

246D
ROC 50% 779kg 1716lb 769kg 1696lb

262D
ROC 991kg 2184lb 982kg 2164lb

272D
ROC 50% 1121kg 2471lb 1112kg 2451lb

272D XHP
ROC 1314kg 2897lb 1305kg 2877lb
Tipping Load 2443 kg 5386lb 2425kg 5346lb

272D2
ROC 1221kg 2993lb 1212kg 2673lb

272D2 XHP
ROC 1304kg 2874lb 1295kg 2854lb
Table 60
P/N 285-6114 285-6115

Fork Specs. 66" 72"

257D
ROC 35% 692kg 1525lb 686kg 1512lb

277D
ROC 35% 725kg 1600lb 719kg 1586lb

287D
ROC 35% 938kg 2068lb 932kg 2055lb
Table 61
P/N 285-6114 285-6115
297D Tool Mass (kg, lb.) 304kg 671lb 326kg 718lb
Fork Specs. 66" 72"
(continued)
120 SEBU9084-11
Rated Load
(Table 61, contd)

Load Center 314mm 12mm 314mm 12in
ROC 35% 1645kg 3627lb 1638kg 3611lb

297D
XHP ROC 1806kg 3982lb 1799kg 3966lb

297D2
ROC 1711kg 3772lb 1702kg 3753lb

297D2 XHP
ROC 1746 3850lb 1738kg 3831lb
Table 62
P/N 285-6114 285-6115

Fork Specs. 66" 72"

239D
ROC 35% 510kg 1124lb 503kg 1110lb

249D
ROC 35% 574kg 1265lb 567kg 1251lb

259D
ROC 35% 719kg 1584lb 712kg 1571lb

279D
ROC 35% 760kg 1676lb 754kg 1662lb

289D
ROC 35% 973kg 2146lb 967kg 2133lb

299D (Rubber)
ROC 35% 1090kg 2404lb 1085kg 2393lb

299D XHP (Rubber)
ROC 35% 1204kg 2654lb 1198kg 2642lb

299D (Steel)
ROC 35% 1241kg 2737lb 1236kg 2726lb

299D XHP (Steel)
ROC 35% 1352kg 2981lb 1347kg 2970lb

299D2 (Rubber)
ROC 35% 1177kg 2596lb 1171kg 2583lb
299D2 XHP (Rubber) Tipping Load 3456kg 7621lb 3439kg 7583lb
(continued)
SEBU9084-11 121
Rated Load
(Table 62, contd)

ROC 35% 1210kg 2668lb 1204kg 2654lb

299D2 (Steel)
ROC 35% 1271kg 2803lb 1265kg 2789lb

299D2 XHP (Steel)
ROC 35% 1295kg 2856lb 1289kg 2842lb
Table 63
Industrial Grapple Fork
P/N 279-5350 279-5360

Fork Specs. 66" 72"

226D
ROC 35% 411kg 905lb 391kg 861lb

232D
ROC 35% 527kg 1162lb 507kg 1118lb

236D
ROC 35% 509kg 1122lb 489kg 1077lb

242D
ROC 646kg 1425lb 626kg 1381lb

246D
ROC 50% 674kg 1485lb 653kg 1440lb

262D
ROC 883kg 1947lb 863kg 1903lb

272D
ROC 50% 1011kg 2230lb 991kg 2186lb

272D XHP
ROC 1201kg 2647lb 1181kg 2603lb

272D2
ROC 1110kg 2448lb 1090kg 2404lb
Tipping Load 2381kg 5249 2341kg 5161lb

272D2 XHP
ROC 1190kg 2625lb 1171kg 2581lb
Table 64
P/N 279-5350 279-5360

257D
(continued)
122 SEBU9084-11
Rated Load
(Table 64, contd)

Fork Specs. 66" 72"

ROC 50% 617kg 1361lb 604kg 1331lb

277D
ROC 50% 653kg 1440lb 639kg 1409lb

287D
ROC 50% 862kg 1901lb 848kg 1870lb
Table 65
P/N 279-5350 279-5360

Fork Specs. 66" 72"

297D
ROC 50% 1547kg 3412lb 1531kg 3375lb

297D
XHP ROC 50% 1706kg 3762lb 1690kg 3725lb

297D2
ROC 50% 1595kg 3517lb 1575kg 3473lb

297D2 XHP
ROC 50% 1630kg 3593lb 1610kg 3550lb
Table 66
P/N 279-5350 279-5360

Fork Specs. 66" 72"

239D
ROC 50% 438kg 967lb 425kg 936lb

249D
ROC 50% 501kg 1106lb 487kg 1075lb

259D
ROC 50% 644kg 1420lb 630kg 1390lb
(continued)
SEBU9084-11 123
Rated Load
(Table 66, contd)

ROC 50% 687kg 1516lb 673kg 1484lb

289D
ROC 50% 897kg 1978lb 883kg 1947lb

299D (Rubber)
ROC 50% 1024kg 2259lb 1012kg 2232lb

299D XHP (Rubber)
ROC 50% 1136kg 2505lb 1124kg 2479lb

299D (Steel)
ROC 50% 1172kg 2585lb 1160kg 2559lb

299D XHP (Steel)
ROC 50% 1281kg 2826lb 1270kg 2800lb

299D2 (Rubber)
ROC 50% 1096kg 2418lb 1083kg 2387lb

299D2 XHP (Rubber)
ROC 50% 1128kg 2488lb 114kg 2457lb

299D2 (Steel)
ROC 50% 1188kg 2620lb 1174kg 2589lb

299D2 XHP (Steel)
ROC 50% 1212kg 2672lb 1198kg 2642lb
Table 67
Industrial Grapple Rakes
P/N 286-9300 286-9301

Fork Specs. 72" 84"

226D
ROC 50% 432kg 952lb 411kg 905lb

232D
ROC 50% 551kg 1215lb 530kg 1169lb

236D
ROC 50% 533kg 1176lb 512kg 1129

242D
ROC 50% 675kg 1489lb 655kg 1443lb

246D
ROC 50% 704kg 1552lb 682kg 1504lb
(continued)
124 SEBU9084-11
Rated Load
(Table 67, contd)

262D
ROC 50% 920kg 2028lb 899kg 1982lb

272D
ROC 50% 1052kg 2319lb 1031kg 2273lb

272D XHP
ROC 50% 1248kg 2752lb 1227kg 2705lb

272D2
ROC 50% 1154kg 2543lb 1133kg 2497lb

272D2 XHP
ROC 50% 1238kg 2729lb 1217kg 2683lb
Table 68
P/N 286-9300 286-9301

Fork Specs. 72" 84"

257D
ROC 50% 640kg 1412lb 626kg 1380lb

277D
ROC 50% 670kg 1476lb 655kg 1444lb

287D
ROC 50% 886kg 1953lb 871kg 1921lb
Table 69
P/N 286-9300 286-9301

Fork Specs. 72" 84"

297D
ROC 50% 1620kg 3571lb 1604kg 3536lb

297D
XHP ROC 50% 1783kg 3931lb 1767kg 3896lb

297D2
ROC 50% 1646kg 3629lb 1625kg 3583lb

297D2 XHP
ROC 50% 1682kg 3707lb 1661kg 3662lb
SEBU9084-11 125
Rated Load
Table 70
P/N 286-9300 286-9301
Fork Specs. 72" 84"
Load Center 469mm 18in 469m 18in

239D
ROC 35% 455kg 1002lb 440kg 971lb

249D
ROC 35% 519kg 1145lb 505kg 1113lb

259D
ROC 35% 667kg 1471lb 653kg 1439lb

279D
ROC 35% 704kg 1553lb 689kg 1520lb

289D
ROC 35% 921kg 2031lb 907kg 1999lb

299D (Rubber)
ROC 35% 1066kg 2350lb 1054kg 2324lb

299D XHP (Rubber)
ROC 35% 1180kg 2601lb 1168kg 2576lb

299D (Steel)
ROC 35% 1223kg 2697lb 1212kg 2672lb

299D XHP (Steel)
ROC 35% 1335kg 2943lb 1324kg 2919lb

299D2 (Rubber)
ROC 35% 1132kg 2496lb 1118kg 2464lb

299D2 XHP (Rubber)
ROC 35% 1165kg 2568lb 1150kg 2536lb

299D2 (Steel)
ROC 35% 1227kg 2706lb 1213kg 2674lb

299D2 XHP (Steel)
ROC 35% 1252kg 2760lb 1237kg 2728lb
126 SEBU9084-11
Rated Load
Agriculture Tools
Table 71
Ag Tool - Bale Spear
*tipping limit is beyond 39" Single Bale 49" Bale Spear 39" Double Bale 49" Double Bale
the tool's strength limit Spear Spear Spear
Tool 907 kg 2000 lbs 907 kg 2000 lbs 1361 kg 3000 lbs 1361 kg 3000 lbs
Limit
Tool 70 kg 155 lbs 72 kg 159 lbs 125 kg 276 lbs 129 kg 285 lbs
Mass
Tipping
1022 kg 2254 lbs 1020 kg 2249 lbs 1066 kg 2349 kg 1061 kg 2339 kg
Load
226D
ROC
511 kg 1127 lbs 510 kg 1125 lbs 533 kg 1175 kg 531 kg 1170 lbs
50%
Tipping
1215 kg 2679 lbs 1213 kg 2674 lbs 1278 kg 2819 lbs 1274 kg 2809 lbs
Load
232D
ROC
50%
Tipping
Load
239D
ROC
35%
Tipping
Load
249D
ROC
35%
Tipping
Load
236D
ROC
50%
Tipping
Load
242D
ROC
50%
Tipping
Load
257D
ROC
35%
Tipping
Load
259D
ROC
35%
Tipping
Load
246D
ROC
740 kg 1632 lbs 739 kg 1629 lbs 774 kg 1707 lbs 772kg 1702 lbs
50%
Tipping
262D 1830 kg 4034 lbs 1828 kg 4029 lbs 1937 kg 4270 lbs 1932 kg 4260 lbs
Load
(continued)
SEBU9084-11 127
Rated Load
(Table 71, contd)

ROC
50%
Tipping
Load
277D
ROC
35%
Tipping
Load
279D
ROC
35%
Tipping
2590 kg 5711 lbs 2588 kg 5706 lbs 2828kg 6234 lbs 2823 kg 6224 lbs
Load
287D
ROC
35%
Tipping
Load
289D
ROC
35%
Tipping
Load
272D2
ROC
50%
Tipping
Load
272D2-XHP
ROC
50%
Tipping
Load
297D2
ROC
35%
Tipping
Load
297D2-XHP
ROC
35%
Tipping
Load
299D2 (Rubber Track)
ROC
35%
Tipping
299D2 -XHP (Rubber Load
Track) ROC
35%
Tipping
Load
299D2 (STL Track)
ROC
35%
Tipping
299D2 -XHP (STL Load
Track) ROC
35%
128 SEBU9084-11
Rated Load
Table 72
Ag Tool - Bale Grapple
*tipping limit is beyond the tool's 71" Single Bale Grapple 84" Bale Grapple
strength limit
Tool Limit 1089 kg 2400 lbs 1089 kg 2400 lbs
Tool Mass 227 kg 501 lbs 250 kg 551 lbs
Tipping Load 811 kg 1787 lbs 715 kg 1576 lbs

226D
ROC 50% 405 kg 893 lbs 357 kg 788 lbs

232D
ROC 50% 493 kg 1087 lbs 437 kg 963 lbs

239D
ROC 35% 397 kg 876 lbs 353 kg 778 lbs

249D
ROC 35% 445 kg 981 lbs 396 kg 873 lbs

236D
ROC 50% 496 kg 1093 lbs 440 kg 970 lbs

242D
ROC 50% 584 kg 1287 lbs 518 kg 1142 lbs

257D
ROC 35% 535 kg 1178 lbs 476 kg 1049 lbs

259D
ROC 35% 554 kg 1222 lbs 494 kg 1088 lbs

246D
ROC 50% 615 kg 1356 lbs 549 kg 1210 lbs

262D
ROC 50% 772 kg 1703 lbs 689 kg 1519 lbs

277D
ROC 35% 578 kg 1274 lbs 521 kg 1148 lbs
Tipping Load 1944 lbs 4285 lbs 1742 kg 3840 lbs

279D
ROC 35% 680 kg 1500 lbs 610 kg 1344 lbs

287D
ROC 35% 784 kg 1729 lbs 700 kg 1544 lbs

289D
ROC 35% 751 kg 1655 lbs 673 kg 1484 lbs

272D2
ROC 50% 950 kg 2094 lbs 849 kg 1871 lbs
272D2-XHP Tipping Load 2016 kg 4446 lbs 1800 kg 3969 lbs
(continued)
SEBU9084-11 129
Rated Load
(Table 72, contd)

ROC 50% 1008 kg 2223 lbs 900 kg 1985 lbs

297D2
ROC 35% 911 kg 2009 lbs 814 kg 1795 lbs

297D2-XHP
ROC 35% 930 kg 2050 lbs 831 kg 1832 lbs
Tipping Load 2581 kg 5691 lbs 2311kg 5095 lbs

299D2 (Rubber Track)
ROC 35% 904 kg 1992 lbs 809 kg 1783 lbs

299D2 -XHP (Rubber Track)
ROC 35% 927 kg 2045 lbs 830 kg 1831 lbs

299D2 (STL Track)
ROC 35% 973 kg 2144 lbs 870 kg 1919 lbs

299D2 -XHP (STL Track)
ROC 35% 997 kg 2197 lbs 892 kg 1966 lbs
Rated Load with a Material Note: The static test coefficient per EU directive
“2006/42/EC” exceeded 1.25 times the working load
Handling Arm limit that is marked on the device. Always select
properly sized lifting accessories. Always inspect the
lifting accessories.
Failure to comply to the rated load can cause The following tables provide the rated operating
possible personal injury or property damage. loads for the standard machine configuration that is
This includes the risk of unintended boom lower- equipped with the following items:
tool before performing any operation. Make ad- • 10 x 16.5 tires on 226D, and 232D
standard configurations. • 12 x 16.5tires on 236D, 242D, 246D, 262D, 272D,
and 272D2
Note: Rated loads should be used as a guide. • 14 x 17.5 tires on 272D XHP, and 272D2 XHP
• lubricants
conditions, or poor ground conditions have effects on
rated loads. The operator is responsible for being • full fuel tank
aware of these effects.
• 75 kg (165 lb) operator
The maximum placement height (ground line to the
chain hook) and maximum reach (front of machine to • Cat Material Handling Arm
the chain hook) are given for the highest position of
the material handling arm. • Undercarriage with 320 mm wide tracks and dual
The rated operating capacity (ROC) is defined by flange front/single flange rear idlers on 239D,
“ISO 14397-1:2007” and “EN 474-3:2006+a1:2009+” 249D, and 259D machines.
as the least amount of weight of the following
conditions: • Undercarriages with either 400 mm or 450 mm
wide tracks and triple flange front/rear idlers on
• 50% of the full static tipping load for wheeled 279D, and 289D machines.
machines
• 35% of the full static tipping load for track flange front/single flange rear idlers on 299D, and
machines 299D2 machines.
• A working load limit ot 907 kg (2000 lb) • Undercarriages with 400 mm wide tracks and
• The lifting capacity to maximum height 299D2 XHP machines.
130 SEBU9084-11
Rated Load

Lifting point 1 (1)
Lifting point 2 (2)
Dimension (A) represents the clearance at the full
down position from Lifting Point 2. Dimension (a)
represents the clearance at the full down position
from Lifting Point 1. Dimension (B) represents the
clearance at maximum height from Lifting Point 2.
Dimension (b) represents the clearance at maximum
height from Lifting Point 1. Dimension (C) represents
the minimum reach from Lifting Point 2. Dimension
(c) represents the minimum reach from Lifting Point
1. Dimension (D) represents the maximum reach
from Lifting Point 2. Dimension (d) represents the
maximum reach from Lifting Point 1.
SEBU9084-11 131
Rated Load
Table 73
Material Handling Arm
P/N 216-8756
Tool Mass (kg, lb.) 131 kg 289 lb
MHA Specs Point 1 Point 2
ROC 417kg 920lb 345kg 760lb
Clearance at Full
-913mm -36in -1407mm -55in
Down
226D
Clearance at Maxi-
4023mm 158in 4468mm 176in
mum Height
Minimum Reach 499mm 20in 379mm 15in

Maximum Reach 1659mm 65in 2102mm 83in
ROC 501kg 1105lb 414kg 914lb
Clearance at Full
-912mm -36in -1406mm -55in
Down
232D
Clearance at Maxi-
4205mm 166in 4651mm 183in
mum Height

Tipping Load 1009 kg 2226lb 838kg 1847 lb
ROC 505 kg 1113 lb 419kg 923lb
Clearance at Full
−994mm −39in −1473mm −58in
Down
236D
Clearance at Maxi-
4337mm 171in 478 mm 188in
mum Height

ROC 588kg 1297lb 485kg 1070lb
Clearance at Full
−946mm −39in −1462m −58in
Down
242D
Clearance at Maxi-
4294mm 169in 4740mm 187in
mum Height

ROC 625kg 1379lb 521kg 1149lb

246D
Clearance at Full
−946mm −37in −1442mm −57in
Down
(continued)
132 SEBU9084-11
Rated Load
(Table 73, contd)

Clearance at Maxi-
4376mm 172 in 4824mm 190in
mum Height

Tipping Load 1629 kg 3591 lb 1349 kg 2974 lb
ROC 814kg 1795lb 674kg 1487lb
Clearance at Full
−938mm −37in −1439mm −57in
Down
262D
Clearance at Maxi-
4398mm 173in 4846mm 191in
mum Height

ROC 50% 866kg 1910lb 718kg 1582lb
Clearance at Full
-940mm -37in -1448 -57in
Down
272D
Clearance at Maxi-
4455mm 175in 4902mm 193in
mum Height

ROC 50% 907kg 2000lb 828kg 1825lb
Clearance at Full
-947mm -37in -1448 -57in
Down
272D XHP
Clearance at Maxi-
4494mm 177in 4941mm 195in
mum Height

ROC 50% 907kg 2000lb 777kg 1713lb
Clearance at Full
-939mm -37in N/A -57in
Down
272D2
Clearance at Maxi-
4456mm 175in 4903mm 193in
mum Height

ROC 50% 907kg 2000lb 820kg 1809lb

272D2 XHP
Clearance at Full
-942mm -37in N/A -57in
Down
(continued)
SEBU9084-11 133
Rated Load
(Table 73, contd)

Clearance at Maxi-
4493mm 177in 4940mm 194in
mum Height

Table 74
P/N 216-8756
Tool Mass (kg, lb.) 131kg 289lb
MHA Specs. POINT 1 Point 2
Least of ROC 35%,

Hyd Lift Cap, or 907kg 535kg 1179lb 44055kg 97142lb
257D tool limit
Clearance at Full
-955mm -38in -1422 -56in
Down
Clearance at Maxi-
4322mm 170in 4768mm 188in
mum Height

Least of ROC 35%,

tool limit
Clearance at Full
277D -1007mm -40in -1496 -59in
Down
Clearance at Maxi-
4354mm 171in 4802mm 189in
mum Height

Least of ROC 35%,

tool limit
Clearance at Full
287D -1017mm -40in -1507mm -59in
Down
Clearance at Maxi-
4347mm 171in 4795mm 189in
mum Height

134 SEBU9084-11
Rated Load
Table 75
P/N 216-8756
Tool Mass (kg, lb.) 131 kg 289 lb
MHA Specs Point 1 Point 2
ROC 50% 907kg 2000lb 907kg 2000lb

297D
Clearance at Full
−40in −60in
Down
Clearance at Maxi-
4411mm 174in 4859 mm 191in
mum Height

ROC 50% 907kg 2000lb 907kg 2000lb
Clearance at Full
−40in −60in
297D Down
XHP Clearance at Maxi-
4411mm 174in 4859mm 191in
mum Height

ROC 50% 907kg 2000lb 907kg 2000lb
Clearance at Full
-967 -38in N/A -58in
Down
297D2
Clearance at Maxi-
4467mm 176in 4915mm 193in
mum Height

ROC 50% 907kg 2000lb 907 2000lb
Clearance at Full
-967mm -38in N/A -58in
Down
297D2 XHP
Clearance at Maxi-
4467mm 176in 4915mm 193in
mum Height

Maximum Reach 1316mm 52in 1761 69in
Table 76
P/N 216-8756
(continued)
SEBU9084-11 135
Rated Load
(Table 76, contd)

Clearance at Full
-934mm -37in N/A -56in
Down
239D Clearance at Maxi-
4027mm 159in 4472mm 176in
mum Height

Clearance at Full
-909mm -36in N/A -55in
Down
349D Clearance at Maxi-
4210mm 166in 4654mm 183in
mum Height

Table 77
P/N 216-8756
Least of ROC 35%,

tool limit
Clearance at Full
259D -978mm -39in -1448 -57in
Down
Clearance at Maxi-
4300mm 169in 4746mm 187in
mum Height

Least of ROC 35%,

tool limit
Clearance at Full
279D -934mm -37in -1429mm -56in
Down
Clearance at Maxi-
4407mm 173in 4855mm 191in
mum Height

(continued)
136 SEBU9084-11
Rated Load
(Table 77, contd)

Least of ROC 35%,
tool limit
Clearance at Full
-951mm -37in -1446mm -57in
Down
Clearance at Maxi-
4411mm 174in 4859mm 191in
mum Height

Least of ROC 35%,

tool limit
Clearance at Full
299D (Rubber) -982mm -39in -1473 -58in
Down
Clearance at Maxi-
4420mm 174in 4869mm 192mm
mum Height

Least of ROC 35%,

tool limit
Clearance at Full
299D XHP (Rubber) -981mm -39in -1473 -58in
Down
Clearance at Maxi-
4421mm 174in 4869mm 192in
mum Height

Least of ROC 35%,

tool limit
Clearance at Full
299D (Steel) -982mm -39in -1479mm -58in
Down
Clearance at Maxi-
4420mm 174in 4868mm 192in
mum Height

Least of ROC 35%,

299D XHP (Steel)
tool limit
Clearance at Full
-981mm -39in -1478mm -58in
Down
(continued)
SEBU9084-11 137
Rated Load
(Table 77, contd)

Clearance at Maxi-
4421mm 174in 4869mm 192in
mum Height

Least of ROC 35%,

tool limit
Clearance at Full
299D2 (Rubber) N/A -39in -1493mm -59in
Down
Clearance at Maxi-
4436mm 175in 4884mm 192in
mum Height

Least of ROC 35%,

tool limit
Clearance at Full
299D2 XHP (Rubber) N/A -39in -1493mm -59in
Down
Clearance at Maxi-
4435mm 175in 4883mm 192in
mum Height

Least of ROC 35%,

tool limit
Clearance at Full
299D2 (Steel) N/A -40in -1505mm -59in
Down
Clearance at Maxi-
4423mm 174in 4871mm 192in
mum Height

Least of ROC 35%,

tool limit
Clearance at Full
299D2 XHP (Steel) N/A -40in -1505mm -59in
Down
Clearance at Maxi-
4423mm 174in 4871mm 192in
mum Height

138 SEBU9084-11
Specifications
i06849679 • Ensure that the operating weight does not exceed

limits set by manufacturer.
Specifications
• Ensure that all frame cracks are identified,
SMCS Code: 7000 inspected, and repaired to prevent further
development.
Intended Use
Machine Data
This machine is classified as a Skid Steer Loader
with wheels or tracks as described in “EN ISO The specifications that are given herein describe the
6165:2012”. This machine normally has a front machine as the machine is manufactured by
mounted bucket or another work tool for the principle Caterpillar Inc. The machine is full of fluids. The
intended functions of digging, loading, lifting, machine is equipped with all options. The weight
carrying, and moving material such as earth, crushed does not include the operator, work tools, or other
rock, or gravel. Additional work tools allow this attachments.
machine to perform other specific tasks.
Table 78
Sales Maximum Length Width Height
Application/Configuration Model Machine
Restrictions Weight
Refer to Operation and Maintenance Manual, 226D 2665kg 2524mm 1497mm 2028mm
“Machine Data” below for information about 5875lb 99in 59in 80in
maximum machine weight.
232D 2989kg 2523mm 1497mm 2029mm
“Caterpillar Approved Work Tools” for information 6589lb 99in 59in 80in
about acceptable work tools. 236D 3544 kg 2792 mm 1676 mm 2120 mm
Lift arm height restrictions will be found in the 7814 lb 110 in 66 in 83 in
Operation and Maintenance Manual for the
appropriate work tool. 239D 3543kg 2522mm 1756mm 2034mm
7811lb 99in 69in 80in

The maximum fore and aft slope for proper
lubrication is 25 degrees continuous and 35 degrees 242D 3616 kg 2792 mm 1676 mm 2120 mm
intermittent. Intermittent time is 2 minutes.
7973 lb 110 in 66 in 83 in
This machine is approved for use in environments
with no explosive gases. 246D 4005 kg 3000 mm 1829 mm 2120 mm
8828 lb 118 in 72 in 83 in
Useful Life 249D 3723kg 2523mm 1756mm 2039mm
The useful life of this machine is dependent upon 8207lb 99in 69in 80in
many factors including the machine owner’s desire to
rebuild the machine back to factory specifications. 257D 3775 kg 2721 mm 1676 mm 2120 mm
Consult your Cat dealer for assistance in calculating 8322 lb 107 in 66 in 83 in
overall owning and operating costs required to
determine the machines useful life. The following 262D 4232 kg 3000 mm 1829 mm 2120 mm
items are required to obtain an economical useful life
of this machine: 9329 lb 118 in 72 in 83 in
259D 4271 kg 2780 mm 1676 mm 2120 mm
• Perform regular preventive maintenance
procedures as described in the Operation and 9416 lb 109 in 66 in 83 in
Maintenance Manual. 272D 4459 kg 2967 mm 1981 mm 2120 mm
• Perform machine inspections as described in the 9830 lb 117 in 78 in 83 in

Operation and Maintenance Manual and correct
272D2 4574kg 3242mm 1829mm 2094mm
any problems discovered.
10084lb 128in 72in 82in
• Perform system testing as described in the
Operation and Maintenance Manual and correct 272D XHP 4646 kg 2967 mm 1981 mm 2120 mm
any problems discovered.
• Ensure that machine application conditions (continued)
comply with Caterpillar’s recommendations.
SEBU9084-11 139
Specifications
(Table 78, contd)

10242 lb 117 in 78in 83 in
272D2 XHP 4327kg 3226mm 1829mm 2133mm
9540lb 127in 72in 84in

277D 4459 kg 2967 mm 1981 mm 2120 mm
9830 lb 117 in 78 in 83 in
279D 4646 kg 2967 mm 1981 mm 2120 mm
10242 lb 117 in 78 in 83 in
287D 4684 kg 2974 mm 1981 mm 2120 mm
10326 lb 117 in 78 in 83 in
289D 4871 kg 2974 mm 1981 mm 2120 mm
10738 lb 117 in 78 in 83 in
297D 4740 kg 3136 mm 1981 mm 2127 mm
10451 lb 123 in 78 in 84 in
297D2 4327kg 3201mm 1981mm 2114mm
9540lb 126in 78in 83in

297D XHP 4743 kg 3136mm 1981 mm 2127 mm
10457 lb 123in 78 in 84 in
297D2 XHP 4327kg 3201mm 1981mm 2114mm
9540lb 126in 78in 83in

299D 4684 kg 2974 mm 1981 mm 2120 mm
10326 lb 117 in 78 in 83 in
299D w/ 5334kg 3136mm 1981mm 2127mm
Steel
11759lb 123in 78in 84in
299D2 5352kg 3189mm 1981mm 2125mm
11800lb 126in 78in 84in

299D2 w/ 5658kg 3189mm 1931mm 2125mm
Steel
12473lb 126in 76in 84in
299D XHP 4871 kg 2974 mm 1981 mm 2120 mm
10738 lb 117 in 78 in 83 in
299D XHP 5337kg 3136mm 1931mm 2127mm
w/Steel
11765lb 123in 76in 84in
299D2 XHP 5352kg 3189mm 1981mm 2125mm
11800lb 126in 78in 84in

299D2 XHP 5658kg 3189mm 1931mm 2125mm
w/Steel
12473lb 126in 76in 84in
140 SEBU9084-11
Identification Information
Identification Information
i06849695
Plate Locations and Film

Locations
SMCS Code: 1000; 7000
Machine PIN Plate

The Product Identification Number (PIN) will be used
to identify a powered machine that is designed for an
operator to ride.
Model Number (A)

Machine PIN (B)
Month (if required) and Year of Manufacturing (C)
CE Plate or EAC Mark (if required) (D)
Country of Origin (E)

Local regulation may require documentation of the
Month and/or Year of manufacture in the Operations
and Maintenance Manual. Enter on line (C) above if
required.
Engine Serial Number Plate

The engine serial number plate is located on the top
Illustration 83 g03395421 of the engine.
The machine PIN plate (1) is located under the lift
arms on the right-hand side of the machine frame. For quick reference, record the identification
numbers in the space that is provided below.
For quick reference, record the identification
numbers in the spaces that are provided below the Engine Serial Number
illustration.
CE Information for European Union

The CE information is on machines that are certified
to the European Union requirements that are listed
on the “Document of Conformity”. If the machine is
equipped with the plate for the European Union, this
information will be incorporated on the Machine PIN
plate in the lower left-hand area.
SEBU9084-11 141
Plate Locations and Film Locations
Month and Year of Manufacture
Manufacturer Information
Manufacturer:
Caterpillar Inc.,
For machines that are compliant to “2006/42/EC”, the 100 N.E. Adams Street
following information is stamped onto the plate. For Peoria, Illinois 61629, USA
quick reference, record this information in the spaces
that are provided below. Entity authorized to communicate on request as
required by Customs Union Technical Regulations of
• Engine Power (kW) the Eurasian Economic Union:
• Typical Machine Operating Weight for European Caterpillar Eurasia LLC
Market (kg) 75, Sadovnicheskaya Emb.
Moscow 115035, Russia
• Year of Manufacture
• Machine Function (Type) Electromagnetic Emissions for
Canada
EAC Mark for Eurasian Economic
Union Note: For machines destined for the Canadian
Market, the following label is located next to the
For machines compliant to the Eurasian Economic Machine PIN Plate.
Union requirements, the EAC Mark and manufacture
date (month and year) is incorporated into the
Machine PIN Plate in the lower left-hand area. The
EAC mark plate is placed on machines certified to the
Eurasian Economic Union requirements effective at
the time of market entry.
For quick reference, record the month and year of
manufacture in spaces that are provided below the
illustration.
142 SEBU9084-11
Emissions Certification Film
Consult your Cat dealer for an Emission Control

Warranty Statement.
This label is located on the engine valve cover.
This label verifies that the product meets the

requirements of ICES-002 Issue 6. Compliance to
ICES-002 Issue 6 is accomplished by meeting
electromagnetic emissions industry standard CISPR-
12.
Sound Certification Film for

European Union
If equipped, 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 film indicates the guaranteed
exterior sound power level Lwa at the time of
manufacture for the conditions that are specified in
"2000/14/EC".
i06624896
Emissions Certification Film

SMCS Code: 1000; 7000; 7405
Certification Label for Emissions

Note: This information is pertinent in the United
States, in Canada, and in Europe.
SEBU9084-11 143
Declaration of Conformity
(A) C2.2 (B) C3.3B (C) C3.8
i06590236
SMCS Code: 1000; 7000
S/N: BY41–Up
S/N: DX91–Up
Table 79
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 S.A.S 40,

Avenue Leon-Blum, B.P. 55, 38041 Grenoble Cedex 9, France
I, the undersigned, _________, hereby certify that the construction equipment specified hereunder
Description: Generic Denomination: Earth moving Equipment
Function: Steel Tracked Loader

Model/Type: ,299D2,299D2 XHP Compact Track Loader
Serial Number:
(continued)
144 SEBU9084-11
(Table 79, contd)

Commercial Name: Caterpillar
Fulfills all the relevant provisions of the following Directives
Directives Notified Body Document No.
2006/42/EC N/A
2000/14/EC amended by 2005/88/EC, Note (1)
2004/108/EC N/A
2014/30/EU N/A
Note (1) Annex -_____ Guaranteed Sound Power Level -____dB (A)
Representative Equipment Type Sound Power Level - ____dB (A)
Engine Power per ____-____ 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 January 2016, but may be subject to change, please refer to the individual declaration of con-
formity issued with the machine for exact details.
i06590991
SMCS Code: 1000; 7000 S/N: DZT1–Up
S/N: BL21–Up S/N: LST1–Up
S/N: MD21–Up S/N: MKT1–Up
S/N: BY41–Up S/N: A9W1–Up
S/N: DX91–Up S/N: B5W1–Up
S/N: DTB1–Up S/N: MPW1–Up
S/N: KXC1–Up
S/N: HRD1–Up
S/N: BYF1–Up
S/N: DML1–Up
S/N: ETL1–Up
S/N: JSL1–Up
S/N: SEN1–Up
S/N: DPR1–Up
S/N: HMR1–Up
S/N: KTS1–Up
SEBU9084-11 145
Table 80

Description: Generic Denomination: Earth-moving Equipment
Function: Wheeled Loader

Model/Type: 226D,232D,236D,242D,246D,262D,272D,272D2, 272D
XHP,272D2 XHP Skid Steer Loader
Serial Number:
2006/42/EC N/A
2000/14/EC amended by 2005/88/EC, Note (1) A V Technology Ltd.
2004/108/EC N/A
2014/30/EU N/A
Note (1) Annex VI____ Guaranteed Sound Power Level -____dB (A)
Done at: Signature
Date: Name/Position
Note: The above information was correct as of January 2016, but may be subject to change, please refer to the individual declaration of con-
i06591000
SMCS Code: 1000; 7000 S/N: FD21–Up
S/N: DX21–Up S/N: CD41–Up

146 SEBU9084-11
S/N: AH91–Up
S/N: BL91–Up
S/N: GTC1–Up
S/N: FTK1–Up
S/N: GTK1–Up
S/N: FTL1–Up
S/N: GTL1–Up
S/N: GWR1–Up
S/N: JST1–Up
S/N: PPT1–Up
S/N: WCT1–Up
S/N: TAW1–Up
S/N: RCX1–Up
S/N: A9Z1–Up
Table 81
Original EC or EU DECLARATION OF CONFORMITY OF MACHINERY

Function: Rubber Tracked Loader

Model/Type: 239D,249D,259D,279D,289D,299D,299D2,299D XHP,299D2 XHP Com-
pact Track Loader
Serial Number:
2006/42/EC N/A
(continued)
SEBU9084-11 147
(Table 81, contd)

2004/108/EC N/A
2014/30/EU N/A
Done at: Signature
Date: Name/Position
Note: The above information was correct as of January 2016, but may be subject to change, please refer to the individual Declaration of Con-
i06591020
SMCS Code: 1000; 7000
S/N: HP21–Up
S/N: BE71–Up
S/N: BL71–Up
S/N: HP71–Up
S/N: STK1–Up
S/N: TLK1–Up
S/N: EML1–Up
S/N: NTL1–Up
S/N: FMR1–Up
S/N: FMT1–Up
S/N: HMT1–Up
S/N: MLT1–Up
S/N: EZW1–Up
Table 82
(continued)
148 SEBU9084-11
(Table 82, contd)

Person authorized to compile the Technical File and to communicate relevant parts of the Technical File to the Authorities of Euro-

Function: Rubber Tracked Loader

Model/Type: 257D,277D,287D,297D,297D2,297D XHP,297D2 XHPMulti-
Terrain Loader
Serial Number:
2006/42/EC N/A
2004/108/EC N/A
2014/30/EU N/A
Done at: Signature
Date: Name/Position
Note: The above information was correct as of January 2016, but may be subject to change, refer to the individual Declaration of Conformity is-
sued with the machine for exact details.
i06591048
SMCS Code: 1000; 7000
Table 83
(continued)
SEBU9084-11 149
(Table 83, contd)

Manufacturer:
Caterpillar Inc., 100 N.E. Adams Street, Peoria, Illinois 61629, USA

Function: Bucket with Top Clamp
Model/Type: Industrial Grapple Bucket, Utility Grapple Bucket
Serial Number:
2006/42/EC N/A
2014/30/EU N/A
Note (1) Technical Documentation accessible through person listed above authorized to compile the Technical File
Done at: Signature
Date: Name/Position
150 SEBU9084-11
i06591080
SMCS Code: 1000; 7000
Table 84
Manufacturer:

Function: Fork with Top Clamp
Model/Type: Industrial Grapple Fork, Utility Grapple Fork
Serial Number:
2006/42/EC N/A
2014/30/EU N/A
Done at: Signature
Date: Name/Position
SEBU9084-11 151
i06591169
SMCS Code: 1000; 7000
Table 85
An EC 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 Declaration of Conformity provided with
the machine. The extract shown below from an EC 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.
EC DECLARATION OF CONFORMITY OF MACHINERY
Manufacturer:

Function: Rake with Top Clamp
Model/Type: Industrial Grapple Rake
Serial Number:
2006/42/EC N/A
2014/30/EU N/A
Done at: Signature
Date: Name/Position
Note: The above information was correct as of May 2013, but may be subject to change, please refer to the individual declaration of conformity
issued with the machine for exact details.
152 SEBU9084-11
i06620800
SMCS Code: 1000; 7000
Table 86
Manufacturer:

Function: Multipurpose Bucket
Model/Type: Multipurpose (MP) Bucket
Serial Number:
2006/42/EC N/A
2014/30/EU N/A
Done at: Signature
Date: Name/Position
Note: The above information was correct as of February 2016, but may be subject to change, please refer to the individual declaration of con-
SEBU9084-11 153
i06620811
SMCS Code: 1000; 7000
Table 87
Manufacturer:

Function: Material Handling Arm
Model/Type: Material Handling Arm (MHA), Truss Boom, Lifting Hook
Serial Number:
2006/42/EC N/A
2014/30/EU N/A
Done at: Signature
Date: Name/Position
154 SEBU9084-11
Operation Section
Before Operation
Operation Section i04744529
Daily Inspection
Before Operation SMCS Code: 1000; 7000
i02601969 NOTICE
Accumulated grease and oil on a machine is a fire
hazard. Remove this debris with steam cleaning or
Mounting and Dismounting high pressure water, at least every 1000 hours or
SMCS Code: 7000 each time any significant quantity of oil is spilled on a
machine.
For maximum service life of the machine, make a

thorough daily inspection before you operate the
machine. Remove any debris from the engine
compartment and the undercarriage. Ensure that all
guards, covers, and caps are secured. Inspect all
hoses and belts for damage. Make the needed
repairs before you operate the machine.
Inspect the area around the machine and under the
machine. Look for loose bolts, trash buildup, oil,
coolant, fuel, or exhaust leakage, broken parts, or
worn parts.
Note: Watch closely for leaks. If you observe a leak,
find the source of the leak and correct the leak. If you
suspect a leak or you observe a leak, check the fluid
levels more frequently.
Typical example
Visually inspect the high-pressure fuel lines before
Mount the machine and dismount the machine only the engine is started. If you inspect the engine in
at locations that have steps and/or handholds. Before operation, always use the proper inspection
you mount the machine, clean the steps and the procedure in order to avoid a fluid penetration
handholds. Inspect the steps and handholds. Make hazard. Refer to Operation and Maintenance Manual,
all necessary repairs. “High Pressure Fuel Lines”, in the Safety Section.
Face the machine whenever you get on the machine Inspect the condition of the equipment and of the
and whenever you get off the machine. hydraulic components.
Maintain a three-point contact with the steps and with Check all of the oil levels, all of the coolant levels,
the handholds. and all of the fuel levels.
Note: Three-point contact can be two feet and one Remove any trash buildup and debris. Inspect the
hand. Three-point contact can also be one foot and area between lift cylinder and lower plate of the lift
two hands. tower for debris and clean as necessary. Inspect the
rear portion of the right side lift cylinder tower for
Do not mount a moving machine. Do not dismount a debris and clean as necessary.
moving machine. Never jump off the machine. Do not
carry tools or supplies when you try to mount the Perform all necessary repairs before you operate the
machine or when you try to dismount the machine. machine.
Use a hand line to pull equipment onto the platform.
Do not use any controls as handholds when you Ensure that all covers and guards are securely
enter the operator compartment or when you exit the attached.
operator compartment. Adjust the mirrors for the correct rear view of the
machine.
Grease all of the fittings that are scheduled on a daily
basis.
Daily, perform the procedures that are applicable to
your machine. Refer to the Operation and
Maintenance Manual, “Maintenance Interval
Schedule” “Every 10 Service Hours or Daily”
category for the list of procedures.
SEBU9084-11 155
Operation Section
Machine Operation
Machine Operation The rear window in the machine serves as the

primary alternate exit. The window will need to be
removed in order to use the primary alternate exit.
i05333475 Pull on the ring at the top of the window in order to
remove the window. This will remove the seal that
Alternate Exit holds the window in place. When the seal is taken
out, carefully remove the window.
SMCS Code: 7000
Secondary Exit
Primary Exit
Illustration 91 g03378582 (2) Release levers for the hinge
(1) Latch pin (3) Door Latch
156 SEBU9084-11
Operation Section
Seat Belt
Seat Belt Adjustment for

Retractable Seat Belts
Fastening The Seat Belt
Pull seat belt out of the retractor in a continuous
If necessary, the cab door may be removed from the motion.
hinges from the inside of the machine. Use the
following procedure: Fasten seat belt catch into buckle. Make sure that the
seat belt is placed low across the lap of the operator.
1. Release the door from the striker (4).
The retractor will adjust the belt length and the
2. Use the two levers (2) in order to release the retractor will lock in place. The comfort ride sleeve
hinge. Move both levers clockwise will allow the operator to have limited movement.
3. Push the door away from the cab.
i03916430
Seat Belt
SMCS Code: 7327
Note: This machine was equipped with a seat belt

when the machine was shipped from Caterpillar. At
the time of installation, the seat belt and the
instructions for installation of the seat belt meet the
SAE J386 and ISO 6683 standards. See your Cat
dealer for all replacement parts.
Consult your Cat dealer for longer seat belts and for
information on extending the seat belts.
Always check the condition of the seat belt and the
condition of the mounting hardware before you
operate the machine.
SEBU9084-11 157
Operation Section
Operator Controls
Releasing The Seat Belt
Push the release button on the buckle in order to

release the seat belt. The seat belt will automatically
retract into the retractor.
i06849739
Operator Controls
SMCS Code: 7300; 7451
Note: Your machine may not be equipped with all

the controls that are discussed in this topic.
The operation section is a reference for the new
operator and a refresher for the experienced
operator. This section includes descriptions of
gauges, switches, machine controls, attachment
controls, transportation, and towing information.
Illustrations guide the operator through correct
procedures of checking, starting, operating, and
stopping the machine. Operating techniques that are
outlined in this publication are basic. Skill and
techniques develop as the operator gains knowledge
of the machine and the capabilities of the machine.
Note: Simple hydromechanical work tools may be
shipped without hydraulic oil. Uneven movement may
occur until all the air has been removed from the
work tool. You may need to add hydraulic oil to the
machine after the machine fills the circuits of the work
tool. Refer to Operation and Maintenance Manual,
“Hydraulic System Oil Level - Check” for the proper
procedure for checking the hydraulic oil level.
Note: If the machine is not equipped with a cab that

is enclosed, Caterpillar recommends the use of a
flying object guard. If the machine is equipped with
an enclosed cab, operate the machine with the cab
door in the CLOSED position.
158 SEBU9084-11
Operation Section
Operator Controls
Left Side Controls
(1) Cab dome light (5) Work tool coupler control switch (9) Parking brake switch
(2) Auxiliary electrical control (6) 12 V power supply (10) Engine key start switch
(3) Multifunction switch for left-hand trigger (7) Heating and air conditioning controls (11) Selectable control pattern switch
(4) Intelligent Leveling System Switch (8) Window wiper and washer control (12) Mirror
SEBU9084-11 159
Operation Section
Operator Controls
Cab Dome Light (1) Note: Keep the work tool close to the ground when
you travel in two-speed mode. This method will
Cab Dome Light – Press either side of maximize the stability of the machine.
the light to turn on the light. Move the
light to the middle position to turn off Note: Do not move the multifunction switch while the
the light. Two Speed function is active. Ensure that the
machine is in one-speed mode before the Auxiliary
Electrical Function “AUX 7” is activated.
Auxiliary Electrical Control “ AUX 8””
(2) Note: The Creep Mode must be turned off to shift the
machine into two-speed. If you activate the Creep
Mode, the machine will return to one-speed mode. If
you set the parking brake, the machine will return to
one-speed mode.
Auxiliary Electrical Function “ AUX 7””

Note: If the switch is not present, the trigger on the
left-hand joystick only provides this auxiliary function.
Auxiliary Electrical Function “ AUX 7”” –
Push the bottom of the switch to
activate the seventh auxiliary electrical
function. Pull the trigger and hold the trigger on
the left-hand joystick to provide electrical power
to pin (A) on the work tool connector on the
Illustration 97 g02931218 loader arm. Release the trigger to deactivate the
Typical electrical connection on the loading arm control.
(A) Left-Hand Trigger Control “AUX 7”
(C) C- Control Cat Intelligent Leveling (ILEV)
(D) C+ Control
(E) C2 Control System Switch (4)
(F) C1 Control
(J) Auxiliary Electrical Control “AUX 8” Press the bottom of the switch to enable
self-level. The alert indicator for ILEV
Auxiliary Electrical Control “ AUX 8”” – will illuminate indicating the system is
The auxiliary electrical control supplies on. Press the top of the switch to turn off the ILEV
continuous electrical power to pin (J) on system.
the connector for the work tool on the loader arm.
Press the bottom of the switch to turn on
electrical power. Press the top of the switch to
turn off electrical power.
Multifunction Switch for the Left-

Hand Trigger (3)
This switch is used to toggle the function of the
trigger on the left-hand joystick between Two Speed
and the Auxiliary Electrical Function “AUX 7” .
Two-Speed
Two-Speed – Push the top of the
multifunction switch to use the trigger
for the two speed control. Press the
trigger and release the trigger on the front of the
left-hand joystick to activate two-speed travel
mode. To return to one-speed travel mode, press
the trigger and release the trigger again.
160 SEBU9084-11
Operation Section
Operator Controls
Self-Level Return to Dig

(1) Cat Control Pattern (1) Cat Control Pattern
(2) H-Control Pattern (2) H-Control Pattern
(3) Hand and Foot Control Pattern (3) Hand and Foot Control Pattern
The ILEV system maintains the approximate starting The ILEV system lowers the lift arms and returns the
angle of the work tool as the loader arms are raised. work tool to a user-selected target angle. Set the
On machines equipped with Dual Direction Self- work tool to the desired angle using the controls. Pull
Level, the system maintains the approximate starting the right-hand joystick trigger and hold for 5 seconds
angle of the work tool as the loader arms are raised to set the target angle. The ILEV alert indicator will
or lowered. flash twice to confirm that the angle was accepted.
After a dump cycle, with the lift arms raised, give a
momentary Lower and Dump or Lower and Tilt Back
command. Momentarily press and release the right-
hand joystick trigger to initiate Return to Dig mode.
The lift arms will lower to the stops and the work tool
will return to the user-selected target angle without
further operator input.
Note: The target angle will reset to a factory default
when the machine is keyed off. The factory default
approximates a level bucket with the lift arms in their
lowest position.
SEBU9084-11 161
Operation Section
Operator Controls
Work Tool Positioner Note: The target angle will reset to a factory default
when the machine is keyed off. The factory default
approximates a level bucket with the lift arms in their
lowest position.
Work Tool Coupler Control (5)
Improper Attachment of the Work Tool could re-

sult in injury or death.
that the coupler pins are fully engaged. Follow
Maintenance Manual.
Work Tool Coupler Control – The work tool coupler

controls the engagement of the coupler pins.
Note: The electric or hydraulic quick coupler only

works while the ENGINE IS RUNNING.
Disengaged – Push the red button

upward and press the bottom of the
switch. Hold the switch in the downward
position until the coupler pins disengage.
Engaged – Press the top of the switch
Illustration 100 g03818497 and hold the top of the switch until the
(1) Cat Control Pattern and H-Control Pattern coupler pins engage.
(2) Hand and Foot Control Pattern
Refer to Operation and Maintenance Manual, “Work
The ILEV system returns the work tool to a user- Tool Coupler Operation” for the proper procedure for
selected target angle. Set the work tool to the desired the work tool coupler.
angle using the controls. Pull the right-hand joystick
trigger and hold for 5 seconds to set the target angle. 12 V Power Supply (6)
The ILEV alert indicator will flash twice to confirm that
the angle was accepted. Start the work tool in the
direction of the target angle by giving a momentary This electrical outlet receptacle is a 12V electrical
Dump or Tilt Back command. Momentarily press and power connection to operate electrical accessories.
release the right-hand joystick trigger to initiate Work
Tool Positioner mode. The work tool will return to the Heating and Air Conditioning
user-selected target angle without further operator
input. Work Tool Positioner mode has no impact on Control Panel (7)
the lift arm position.
Heating and air conditioning control panel (7) houses
the switches for controlling the temperature and
operator comfort level inside the cab.
162 SEBU9084-11
Operation Section
Operator Controls
Note: If the switch for the Joystick Control Pattern is

installed, select a pattern to release the parking
brake.
Note: The parking brake will not release if the

machine security system is enabled and locked. See
"Basic Security Soft Keys" or "Advanced Machine
Security System".
Engine Key Start Switch (10)

OFF – Insert the engine start switch key
only from the OFF position and remove
the engine start switch key only from the
OFF position. Turn the engine start switch key to
Illustration 101 g03212458 the OFF position to stop the engine. In the OFF
position, there is no power to most electrical
Fan Speed Control (7A) – The fan speed circuits on the machine. The cab dome light is
switch controls the three-speed blower operational even when the engine start switch is
fan motor. in the OFF position.
Air Conditioning Switch (7B) – Depress ON – Turn the engine start switch key
A/C switch (7B) to activate the air clockwise to the ON position to activate
conditioning system. Turn fan speed all the cab circuits.
switch (7A) to LOW, MEDIUM, or HIGH speed.
Adjust temperature variable control (7C) for the START – Turn the engine start switch
desired temperature. key clockwise to the START position to
crank the engine. Release the engine
Temperature Variable Control (7C) – start switch key after the engine starts and the
Turn the control knob anywhere engine start switch key returns to the ON
between the blue area (left) and the red position.
area (right). This action will control the amount of
heating and cooling. Note: If the Machine Security System is enabled, the
correct pin code must be entered before the machine
Window Wiper and Window will start. Refer to "Right Side Controls, for further
information.
Washer (8)
Window Wiper and Window Washer –
Move the switch to the middle position
to turn on the wiper. Press the right side
of the switch to operate the washer. Press the left
side of the switch to turn off the wipers.
Parking Brake Control (9)

Parking Brake Control – After starting
the engine, press the right side of the
switch and release the switch to
disengage the parking brake and enable the
hydraulic implement system. Successive
operation of this switch will only cycle the
parking brake on and off and will not impact the
hydraulic implement system.
Note: The parking brake will engage when the
engine is stopped. The parking brake will engage
when the armrests are moved to the RAISED
position. The parking brake will engage when the
operator leaves the operator seat for a time. The
parking brake will engage when the interlock override
is activated.
SEBU9084-11 163
Operation Section
Operator Controls
Note: If the engine fails to start, turn the engine start

switch key to the OFF position to attempt to start the
engine again. Refer to the Operation and
Maintenance Manual, “Engine Starting” for more
details about starting the engine.
Selectable Control Pattern Switch

(11)
If the machine is equipped with the optional
Selectable Control Pattern feature, a rocker switch
will be present at this location with the number (1) on
one side and the number (2) on the other side. After
starting the machine, a control pattern must be
selected before the parking brake can be released.
Press the switch to the (1) position for Cat Control
Pattern or press the switch to the (2) position for H-
Control Pattern. The alert indicators (1) and (2) will
blink until a control pattern is selected. Once a control
pattern has been selected, activating the parking
brake will not affect the selection of the pattern.
Keying the machine off will reset the control pattern
selection. Refer to the section "Joystick Controls" for
detailed information on the possible joystick control
patterns.
Mirror (12)
Adjust the rear view mirror properly to view objects
that are behind the machine.
Right Side Controls
164 SEBU9084-11
Operation Section
Operator Controls

Basic control configuration
(13) Fuel gauge (18) Continuous hydraulic flow (23) Turn Signal
(14) Service hour meter (19) Ride control (24) Engine speed control knob
(15) Hydraulic lockout and interlock override (20) Reversing fan (25) Alert indicator panel
(16) Front working lights (21) Roading lights (26) Anti-Theft security soft keys
(17) Rear working lights (22) Hazard lights (27) Bluetooth microphone
Fuel Level Gauge (13) NOTICE

BEFORE putting the machine into hydraulic interlock
Fuel Level Gauge – The needle in the red override. The work tool hydraulic lines must be con-
range indicates low fuel. nected to the machine couplers. Hooking hydraulic
lines up with pressure, will result in destroyed seals in
the coupler and result in poor hydraulic performance.
Service Hour Meter (14)
Service Hour Meter – The service hour Note: Activate the hydraulic shutoff when you are
meter indicates the total number of roading the machine to prevent unplanned
hours the engine has been running. The movement of the work tool and the loader arms.
service hour meter should be used to determine
service hour maintenance intervals. This window Interlock Override – If equipped, the
will also display the Basic Machine Security interlock override allows the auxiliary
information. See Basic Security Soft Keys. hydraulic circuits to function with the
armrests in the RAISED position. First bring the
machine to a complete stop. Activate the
Hydraulic Lockout and Interlock continuous flow control. Refer to the section
Override (15) “Joystick Controls” for detailed information.
Press the bottom of the interlock override switch
Hydraulic Lockout – Press the top of the and release the switch to activate the interlock
switch to disable the hydraulic override function. To turn off the interlock
functions. Return the switch to the override and continuous flow, press the bottom
middle position to activate the hydraulic of the switch and release the switch again.
functions.
SEBU9084-11 165
Operation Section
Operator Controls
Inadvertent movement of the work tool may occur

if the interlock override function is used with
work tools. This may result in personal injury or
death. Only use interlock override function for
hand-held work tools.
Note: Certain work tools should not be operated with

the hydraulic interlock system overridden. Consult
your work tool's Operation and Maintenance manual
for further information. If the machine will run a work
tool where the presence of this switch represents a
potential safety issue, see your Cat dealer to have
the switch replaced with one having the Hydraulic Illustration 103 g03688299
Lockout feature only. (A) Door jumper installed at this location on an open ROPS
machine
Note: If your machine is equipped with a Hydraulic (B) Door jumper cable-strapped to this location on enclosed ROPS
Lockout switch only and the application requires the machine
ability to override the hydraulic interlock system, see
your Cat dealer to have a dual purpose switch
installed.
Note: The alert indicator for the parking brake will
light when the interlock override is activated. When
the interlock override is deactivated, press the
parking brake switch to disengage the parking brake
and activate the hydraulic functions.
NOTICE
Do not leave the machine unattended while you have
the interlock override function activated.
Switch on the Cab Door

A switch is provided on the cab door that prevents
the work tool from operating when the cab door is
open. If the cab door is not installed or if the cab door
is removed, the cab door jumper plug must be
installed to operate a hydraulic work tool.
Note: The cab door jumper plug is located behind the
seat. The cab door jumper plug is cable-strapped to
the cab harness near the point of use. To enable the
work tool hydraulics with the front door removed, cut
the cable strap securing the jumper plug to the cab
harness, disconnect the front door harness from the
cab harness behind the seat, and connect the front
door jumper plug in its place.
166 SEBU9084-11
Operation Section
Operator Controls
If the cab door jumper plug cannot be found, a plug Note: The ride control will deactivate and the
can be assembled. Refer to M0069152, Assembly of indicator will not be illuminated at the appropriate
Safety Bypass Plug for the Front Door on Compact speed. The ride control will also deactivate if the tilt
Track Loaders, Multi-Terrain Loaders, and Skid steer function for the work tool is operated.
Loaders for instruction on assembling the plug.
Default activation speed is approximately 8 km/h
Front Work Lights (16) (5.0 mph) for wheeled machines and 6 km/h
(3.7 mph) for tracked machines.
Front Work Lights – Press the bottom of
Note: If the Advanced Display is equipped, the Ride
the switch to turn on the lights. Press
Control activation speed may be adjusted to better
the top of the switch to turn off the
suit the application if needed. Refer to Operation and
lights.
Maintenance Manual, “Right Side Controls
(Alternate), Ride Control” for more information.
Rear Work Lights (17)
Rear Work Lights – Press the bottom of
Reversing Fan (20)
the switch to turn on the lights. Press
the top of the switch to turn off the The machine may be equipped with a reversing fan.
Momentarily reversing the cooling fan direction aids
lights. in removing debris from the screened area of the
engine enclosure, thereby improving air flow across
Continuous Flow Switch (18) the engine radiator and hydraulic oil cooler which
may help the machine run cooler.
Continuous Flow – Continuous flow
control (18) supplies continuous flow of Move the switch to the bottom position
hydraulic fluid to the auxiliary hydraulic In order to activate the reversing fan
circuit without continuously holding the auxiliary automatic mode. The frequency and
hydraulic control. Press the bottom of the duration of reversing cycles is controlled by
continuous flow rocker switch. The continuous dealer-only adjustable settings. Press the top of
flow alert indicator will flash continuously the switch momentarily to force a manual reverse
indicating the system is in the “ Continuous Flow cycle as needed.
Ready Mode”” . Press either of the two auxiliary
hydraulic switches (1) or (2) that are located on Note: The reversing cycle parameters for duration
the right-hand joystick. If equipped, you may also and frequency are user adjustable through the
move the thumb wheel on the right-hand joystick advanced display. See "Operator Controls, Right
to the desired flow position and hold either of Side Controls (Alternate), Menu Screen, Operator
these commands for several seconds. The Settings, Reversing Fan" for details. The reversing
continuous flow alert indicator will stop flashing cycle parameters are dealer adjustable regardless of
and remain lit continuously. Releasing the button the monitor equipped.
or thumbwheel at this time will engage • Default reversing cycle frequency is once every 30
Continuous Flow Mode, providing flow to the minutes.
auxiliary hydraulic circuit without further
command input. To disengage continuous flow,
either press the bottom of the continuous flow
switch, press either of the two auxiliary hydraulic
switches or operate the thumb wheel in either
direction.
Ride Control (19)

Ride Control assists in smoothing the ride of the
machine. Travel over rough terrain causes bucket
movement. The ride control system uses the lift
cylinders as shock absorbers. The lift cylinders
dampen the forces from the work tool.
Ride Control – Press the bottom of the
switch to turn on the ride control. Ride
control will activate and the alert
indicator will illuminate at the appropriate speed.
Press the top of the switch to turn off the ride
control.
SEBU9084-11 167
Operation Section
Operator Controls
• Default reversing cycle duration is 8 seconds. When the knob is fully clockwise, the engine speed
control pedal, if equipped, becomes a deceleration
Roading Lights (21) pedal to lower engine RPM. The engine speed
control pedal will temporarily override the engine
speed control set point.
Roading Lights – Move the switch to the
middle position to turn on the control Note: The deceleration function will not lower the
panel lights and position lights. Press RPM to low idle. Do not use this function as a braking
the bottom of the switch to turn on the front low function.
beams. Press the top of the switch to turn off the
lights. Note: There are several features that may impact the
low idle of the machine. Refer to Operation and
Hazard Lights (22) Maintenance Manual, “Engine Starting” for more
detailed information.
Hazard Flasher Control – Press the
When the DPF light is on (if equipped), regeneration
bottom of the switch to activate the is needed. The operator can increase the engine
hazard flashers. Press the top of the speed to the active regeneration threshold. This is
switch to deactivate the hazard flashers. the green shaded area on the engine speed control
knob that has the DPF symbol.
Turn Signals (23)
Refer to this Operation and Maintenance Manual,
Turn Signals – Press the left of the “Diesel Particulate Filter Regeneration”.
switch to turn on the left turn signals.
Press the right of the switch to turn on Alert Indicator Panel (25)
the right turn signals. Move the switch to the
middle position to turn off the turn signals.
Engine Speed Control Knob (24)

Basic electronic display window
Use the knob to set the engine speed. Use the

engine speed control knob when you want to set a
constant engine speed. Move the knob clockwise to
increase engine speed. Move the knob counter
clockwise to decrease engine speed.
168 SEBU9084-11
Operation Section
Operator Controls
Refer to the section Operator and Maintenance Changing the Pin

Manual "Alert Indicators" for a description about the
status indicators. The factory default PIN is "1111" and should be
changed by the machine owner as soon as possible
Anti-Theft Security System Soft after enabling the Anti-Theft Security System. The
PIN can be changed through the Standard Display to
Keys (26) any 4-6 digit code. To change this, the system must
be unlocked first by entering the current secure PIN,
then simultaneously holding down the soft keys
labeled "1/2" and "5/6" for 3 seconds. The system will
prompt for a new "CODE" to be entered twice before
accepting this as the new PIN.
Bluetooth Microphone (27)

This microphone may be set up with your mobile
telephone to provide a hands-free method of
communicating. See the operating manual of your
mobile device for instructions of connecting with the
Bluetooth microphone.

Basic electronic display window
(14) Service hour meter window
(26) Anti-Theft Security System
Entering the Pin

If the Anti-Theft Security System is enabled, service
hour meter window (14) will display “COdE” at
machine start-up. This event occurs when key start
switch (10) is moved to the ON position. Enter the
secure PIN number using soft keys (26). Press the
appropriate key to enter the secure code. For odd
numerals (1, 3, 5, 7, or 9), press the appropriate key
one time. For even numerals (2, 4, 6, 8 or 0), press
the appropriate key twice. After the code is entered,
press the arrow key to submit the code.
If the entered PIN number is correct, the machine
service hours will display in the service hour meter
window (14). Key start switch (10) may be moved to
the START position to start the machine.
If the entered PIN number is incorrect, the window
will flash the word “CODE” for several seconds
before another attempt can be made.
Note: For security purposes, in the event an incorrect
PIN is entered five times consecutively, the system
will lock down for 15 minutes, during which period
even a correct PIN will not allow the engine to crank.
After the 15 minute lockdown period, entry of a
correct PIN will unlock the system as usual.
Right Side Controls (Alternate)

SEBU9084-11 169
Operation Section
Operator Controls
(15) Hydraulic lockout and interlock override (19) Ride control (23) Turn Signal
(16) Front working lights (20) Reversing Fan (24) Engine speed control knob
(17) Rear working lights (21) Roading lights (25) Advanced Display Module
(18) Continuous hydraulic flow (22) Hazard lights (27) Bluetooth microphone
Advanced Display Module (If Equipped) Dedicated Alert Indicators (28)

(27)
There are five dedicated alert indicators located
across the top of the Advanced Display. All other alert
indicators will be located along the sides of the
display window & will activate as needed. See "Alert
Indicators".
Soft Input Keys (29)

There are six soft input keys located across the
bottom of the Advanced Display. These keys are
used to navigate among the various menu screens
and to input operator selections within the menu
screens. The functions will vary depending on the
menu. The current function will be displayed as an
icon on the display window directly above the key

Advanced electronic display window
The optional Advanced Display has a number of

built-in features which are arranged into menu
screens.
170 SEBU9084-11
Operation Section
Operator Controls
Display Window (30)

The Display window will display the welcome screen,
the main monitoring screen, and the various menu
and adjustment screens. The display window will also
become the Backup Camera monitor when that
feature is active. See "Backup Camera Mode".
Monitoring Screen
The monitoring screen is the primary screen that
displays information to the operator during most
operations. Several background color schemes and
gauge layouts are available for selection by the
operator. See "Operator Settings, Gauges" and
"Operator Settings, Background".

Default layout of monitoring screen
Engine Coolant Temperature Gauge (31) Hydraulic Oil Temperature Gauge (32)
The needle in the red zone indicates that the engine The needle in the red zone indicates that the
coolant temperature is too high. If the Gauge Values hydraulic oil temperature is too high. If the Gauge
are enabled, the background will change from black Values are enabled, the background will change from
to red to indicate that the engine coolant is black to red to indicate that the hydraulic oil
approaching an unsafe temperature. The machine temperature is approaching an unsafe temperature.
should be stopped soon and the engine set to low The hydraulics functions should be stopped soon and
idle to allow the engine to cool. See "Operator the engine set to low idle to allow the hydraulic
Settings, Gauge Values". system to cool. See "Operator Settings, Gauge
Values".
SEBU9084-11 171
Operation Section
Operator Controls
Alert Indicators (33) The icon below the DEF gauge is designated the
SCR Warning alert indicator. The status of this lamp
See "Alert Indicators" for a description of the status will vary based on the SCR warning levels. Refer to
indicators. Operation and Maintenance Manual, “Selective
Catalytic Reduction Warning System” for complete
Engine Speed Gauge (34) details.
The needle in the red zone indicates that the engine Menu Screen
RPM is too high. If the Gauge Values are enabled,
the background will change from black to red to The menu screen displays the icons and descriptions
indicate that the engine speed is above the allowable of available sub screens listed below. The icons will
HIGH IDLE limit. The throttle should be turned down scroll horizontally using the Soft Input Keys. The
to the acceptable range. The CAT dealer should be active selection is always in the center of the screen
contacted to determine the cause. See "Operator and appears larger than other inactive selections.
Settings, Gauge Values". The sub screen is selected by pressing the "Enter"
soft input key.
Service Hour Meter (35)
Operator Settings
The service hour meter indicates the number of KEY
ON hours for the machine. The hours should be used The “Operator Settings” screen allows the operator to
to determine which maintenance interval service adjust several machine features. These settings will
items to perform. The hourglass icon blinks slowly be stored under each operator profile. When the
when the engine is running. Advanced Machine Security System is enabled, the
settings take effect each time the proper Operator
Creep Controller (36) Code is entered upon KEY ON. (The operator
settings were set with this Operator Code.) See
This controller will be displayed when “Creep Control” "Advanced Machine Security System".
is engaged. Reference the section, "Operator
Controls, Joystick Controls". This controller allows Hystat Sensitivity
the operator to adjust the creep setting from the main
screen without having to enter the Creep Control sub This parameter is used to change the “Drive Control
screen. See the section, "Menu Screen, Operator Mode” which has three settings.
Settings, Creep Control".
Note: The optional Advanced Display module is
required for Creep Control feature.
Fuel and Diesel Exhaust Fluid (DEF)

Level Gauge and SCR Warning Alert
Indicator (37)
The fuel level gauge indicates the amount of fuel that
remains in the fuel tank. The needle in the red range Standard Mode – one bar
indicates low fuel.
Intermediate Mode – two bars (factory default)
On machines which require diesel exhaust fluid
(DEF), this gauge will contain two independent Maximum Mode – three bars
needles. The top needle will indicate the amount of
fuel that remains in the fuel tank. The bottom needle Note: The Drive Control Mode setting will not return
will indicate the amount of DEF that remains in the
DEF tank. to a default level when the ignition switch is turned
OFF.
Note: DEF will be consumed at a significantly slower
rate than diesel fuel. Note: The machine will start, stop, and steer more
aggressively with each progressive drive control
mode. Test drive the machine in an open area to
become familiar with the new operating
characteristics of the machine.
Implement Sensitivity
This parameter is used to change the “Implement

Control Mode” which has three settings
172 SEBU9084-11
Operation Section
Operator Controls
Reversing Fan
The "Reversing Fan Control Adjustments" allow the

operator to change the duration and frequency of the
reverse cycle.
Reversing Fan Operation Interval Time is adjustable
between 6 minutes and 240 minutes. This is the time
between reverse cycles in the automatic mode. The
Illustration 111 g03216999 lower the setting, the more frequent the reverse cycle
will occur. The factory default is 30 minutes.
Fine Control Mode – one bar
Reversing Fan Operation Time is adjustable between
Standard Mode – two bars (factory default) 5 seconds and 12 seconds. This is the duration of
each reverse cycle in the automatic mode. The fan
Coarse Control Mode – three bars will automatically return to the forward air flow
direction after each reverse cycle. The factory default
Note: The Implement Control Mode setting will not is 8 seconds.
return to a default level when the ignition switch is Speed Limit
turned OFF.
Note: The machine lift arms and work tool coupler Note: If the Anti-Theft Security System is enabled,
will move more aggressively with each progressive Speed Limit is controlled in the Master Profile. A user
implement control mode. Test the implement logged in under an Operator Code will not be allowed
functions in an open area to become familiar with the to adjust this parameter.
new operating characteristics of the machine. The “Speed Limit Adjustment” allows the maximum
travel speed to be limited. The adjustment can be
Creep Control made in 1% increments from 20% to 100% of
maximum travel speed.
The Creep Control allows the operator to set a
maximum machine travel speed at full joystick Automatic Backup Camera
movement. Use Creep control for operations that
require slow, constant speed independent of engine This setting automatically switches the display to the
idle speed. The Creep Control has 20 settings: camera monitor anytime the machine begins to travel
in reverse. This adjustment is either ON or OFF. The
• The slowest Creep Control setting is at 1 bar factory default is "ON". See "Backup Camera Mode."
• The default Creep Control setting is set at five Note: The ability to adjust this parameter is
bars suppressed for certain countries where local
regulations do not allow.
• The fastest Creep Control setting is 20 bars
Units
Note: The machine may not travel at the lower
settings depending on terrain, work tool, load, etc. If The “Units Adjustment” allows the operator to switch
the machine does not travel at a particular setting, between Metric and English units. The factory default
increment the Creep Control to progressively higher is English.
values until travel occurs.
Language
Note: The optional Advanced Display module is
required for Creep Control feature. See "Monitoring The “Language Adjustment” allows the operator to
Screen, Creep Controller " switch the display messages among six languages:
English, Spanish, French, German, Portuguese, and
Ride Control Italian. The factory default is English.
The “Ride Control Adjustment” allows the operator to Gauge Values
change the activation speed at which the system
engages when the Ride Control system is ON. Refer The “Gauge Values Adjustment” allows the operator
to Operation and Maintenance Manual, “Operator to either have the numerical gauge values display
Controls, Joystick Controls”. The adjustment can be turned ON or OFF. The factory default is "ON".
made in 0.1 km/h increments.
Default activation speed is approximately 8 km/h
(5 mph) for wheeled machines and 6 km/h (3.7 mph)
for tracked machines.
SEBU9084-11 173
Operation Section
Operator Controls
Gauge Diagnostics
The “Gauge Adjustment” allows the operator to select Active Diagnostic Codes indicate that a sensor or
the Main Monitor Screen display from several hardware issue has faulted and machine functionality
available layouts. See “Monitoring Screen” . The may be impacted. There are three levels of Active
factory default is Gauge Layout 1. Diagnostics and the pop-up screens will change
depending on which level is active.
Background
Active Events
The "Background Adjustment" allows the operator to
select the background color of the display from Active Event Codes indicate that a sensor is
several available colors. detecting a condition that could result in machine
damage. There are three levels of Active Codes and
Dealer Name the pop-up screens will change depending on which
level is active.
The “Dealer Name” setting allows the owner to enter
a Dealer Name or any other combination of text and Level 1 – A condition is trending in a direction that
numerals. The entry is displayed momentarily on the may indicate that damage could occur if the
Welcome Screen each time the machine is “KEYED operating condition persists. There is no pop-up
ON” . This adjustment requires a Master Code to screen displayed for this level but the Driver Alert
access once a Master Code has been established. Indicator will illuminate continuously. The operator
An Operator Code will not allow access to this should stop the machine at the earliest convenience
adjustment. See "Operator Management, Master and investigate the cause. If no additional alert
Code, and Operator Code." indicators are illuminated, contact your Cat dealer or
refer to the service manual for more information. See
Dealer Number "Alert Indicators".
The “Dealer Number” setting allows the owner to Level 2 – A condition has been detected which could
result in component damage. A yellow pop-up screen
enter a Dealer Phone Number or any other will be displayed providing information on the
combination of numerals. The entry is displayed condition. The Driver Alert will be flashing but no cab
momentarily on the Welcome Screen each time the alarm will be audible. The operator should change
machine is “KEYED ON” . This adjustment requires a operation or perform the indicated maintenance
Master Code to access once a Master Code has being displayed. See"Alert Indicators"
been established. An Operator Code will not allow
access to this adjustment. See "Operator Level 3 – A condition has been detected that is likely
Management, Master Code, and Operator Code". to result in severe component damage and could
result in injury. A red pop-up screen will be displayed
Job Clock Screen providing information on the condition. The Driver
Alert will be flashing and the cab alarm will be
This screen shows the current job clock time. The audible. The operator should stop the machine
screen allows the operator to start, stop, and reset a immediately and perform the indicated maintenance
job clock. The job clock saves over the key cycle and being displayed or contact your Cat dealer. See "Alert
starts up automatically on the next startup or operator Indicators".
login. A separate job clock is stored under each
operator profile.
Service Maintenance Interval Screens
System Information Screen
The service maintenance interval screens are pop-up
This screen will display various system-related reminders to indicate that a scheduled maintenance
information including the following items: interval is approaching. These intervals are based on
machine hours and can be reset by the operator after
• Machine ECM hardware and software part number the maintenance is performed. The screens will
provide the operator several pieces of information
• Engine ECU hardware and software part number including:
• Advanced Display hardware and software part Maintenance Item – The item to be checked or
number changed
Interval Hours – The service interval or machine
Diagnostics and Events Screen hours between repeated services
These screens are popup warnings to provide the Hours Remaining – The number of machine hours
operator information about machine condition remaining before the service item becomes past due
warnings. Activation Hours – The actual value of the machine
hours at which time the service is due
174 SEBU9084-11
Operation Section
Operator Controls
• The total machine hours accrued while the

operator has been logged in.
• Total Fuel used while the operator has been

logged in (electronic engines only).
• The Total Machine Hours and Total Fuel Used
may be reset independently.
• The Display Event and Diagnostic Codes that
have occurred while the operator has been logged
in.
• A log of the Events and Diagnostic Warnings that
have been cleared while the operator is logged in.
Add Operator – Allows the Master Operator to add
an operator profile and set the Operator Name and
Operator Code
Delete Operator – Allows the Master Operator to
delete an operator profile. The Master Operator
cannot be deleted.
Edit Operator – Allows the Master Operator to
Reset – Select this icon to reset the maintenance Change the current Operator Name and Operator
interval after a service has been performed. Code.
Note: Only the Master account can reset the Operator Code
maintenance interval.
If the Operator is currently logged in or if the Anti-
Service Screens Theft Security System is disabled, the options below
are available. In the case that the security system
The service screens allow for viewing the status of has been disabled or not installed, the information
the most important machine parameters such as below applies to a Guest Operator, or an operator
throttle position, engine speed, joystick position, that has never been assigned a login code.
battery voltage, drive motor speed, etc. The View – The Operator can view the following
parameter status information can be used for basic information for the currently logged in operator.
troubleshooting.
Operator Management • The name of the current operator
The operator management screens allow the addition • The total machine hours accrued while the
and deletion of operator profiles as well the viewing operator has been logged in.
of operator-specific information. There are two levels
of codes, the Master Code and the Operator Code. • Total Fuel used while the operator has been
Each level yields specific rights regarding the viewing logged in (electronic engines only).
& editing of information.
• The Display Event and Diagnostic Codes that
Master Code have occurred while the operator has been logged
in
The default Master Code is "1111" and should be
changed by the machine owner as soon as possible Edit Operator – Allows the Operator to Change the
after enabling the Anti-Theft Security System. current Operator Name and Operator Code.
Options available under the Master Code login are
the following items:
View – The master operator can view and edit the
following information for each operator profile.
• An operator profile name up to 15 ASCII

characters
SEBU9084-11 175
Operation Section
Operator Controls
Accugrade Note: The ability to adjust this parameter is

suppressed for certain countries where local
Future functionality regulations do not allow adjustment.
Anti-Theft Security System Other Features in the Cab

This feature if enabled requires an operator to enter a Interlock Control
valid Operator Code before allowing the engine to
crank. There is one Master Code and up to 50 unique
Operator Codes. Entry of a valid code will also
automatically load Operator Settings that have been
previously saved under the current operator profile.
See "Menu Screen, Operator Settings". At key "ON",
if the security system is enabled and locked, the
operator will be prompted to enter their unique 4-digit
to 6-digit Operator Code. Enter the pin code using the
soft keys. Press the appropriate key once for the odd
numeral (1, 3, 5, 7, or 9). Press the key twice quickly
for the even numerals (2, 4, 6, 8 or 0). After the code
is entered, press the "enter" key to submit the code. If
the code is incorrect, the Display Window will show
"Invalid Code" and another attempt can be made. If
the code is correct, the Welcome Operator Screen
will be displayed and the Operator Settings loaded
from the operator profile. The key switch may be
moved to the "START" position to start the machine.
Note: For security purposes, in the event an incorrect

PIN is entered five times consecutively, the system
will lock itself down for 15 minutes, during which
period even a correct PIN will not allow the engine to
crank. After the 15 minute lockdown period, entry of a Illustration 113 g01231722
correct PIN will unlock the system as usual. Armrests
Note: On machines equipped with the latest Interlock Control – Move the armrests to the
Advanced Display software, security may be enabled RAISED position to lock out the hydraulic controls.
by the user under the "User Management" sub menu.
Security may always be enabled by the Cat dealer
regardless of machine configuration. Note: When the armrests are moved to the RAISED
position, the parking brake will engage. Move the
armrests to the LOWERED position and push the
Backup Camera Mode switch for the parking brake to activate the hydraulic
controls.
The Camera Screen shows the input from a
connected camera. The display may be activated at Note: When you start the engine, the parking brake
any time by pressing the soft key which represents must be disengaged in order for the hydraulic
the Camera. The camera screen may be navigated
controls to be activated. If the armrests are raised
away from by pressing the soft key representing the
Home button to return to the Monitoring Screen. If the and lowered during operation, disengage the parking
Automatic Backup Camera mode is "ON", then the brake in order for the hydraulic controls to be
display will automatically switch to the Camera activated.
Screen anytime the machine is commanded to travel
in reverse. Once the reverse travel command is no
longer applied, the screen will automatically revert to
the prior screen. See "Operator Settings, Automatic
Backup Camera".
176 SEBU9084-11
Operation Section
Operator Controls
Engine Speed Control Suspension Seat

(35) Fore/Aft Adjustment
Engine Speed Control – Push down on (37) Adjustment for the suspension
the Engine Speed Control Pedal to
increase engine speed. Release the Fore/Aft lever (35) – Move the lever to adjust the
Engine Speed Control Pedal to decrease engine seat.
speed. The Engine Speed Control Pedal will Height (37) – Turn the knob to adjust the suspension
return to the setting of the engine speed control of the seat. Turn the knob clockwise for a heavier
knob. person. Turn the knob counterclockwise for a lighter
person.
Note: If the Engine Speed Control Knob is fully
clockwise, the Engine Speed Control Pedal will lower
engine RPM. Standard Seat
Note: The deceleration function will not lower the
RPM to low idle. Do not use this function as a braking
function.
Note: There are several features that may impact the
low idle of the machine. Refer to Operation and
Maintenance Manual, “Engine Starting” for more
detailed information.

SEBU9084-11 177
Operation Section
Operator Controls
Push in the knob (36) to increase the stiffness of the

suspension. Pull the knob to decrease the stiffness of
the suspension. The button (37) on the front will turn
on heat. The lever on the left side (38) will Incline and
decline the seat. To adjust the lumbar(39) turn the
knob on left rear of seat.
Note: The engine start switch key must be in the ON

position to increase the stiffness of the seat.
Armbar and Controls - Adjust

The armbar and joystick assemblies may be adjusted
to improve operator comfort.
Cab-Mounted Controls for Mechanical

Suspension Seat
Air Suspension Seat

Mechanical Suspension Seat
1. Remove the three locknuts and washers (A).

2. Raise the controls bracket up to the alternate
mounting slots (B).
Illustration 118 g03385951 3. Adjust for / aft as desired.
(36) Adjustment for the suspension 4. Reinstall the washers and locknuts (A).
(37) Heat
(38) Seat Angle (Incline/Recline) 5. Torque to 15 ± 3 N·m (11 ± 2 lb ft).
(39) Lumbar
Seat Adjustment
178 SEBU9084-11
Operation Section
Operator Controls
Seat-Mounted Controls for Air Ride 3. Hand and Foot Control Pattern – Default control
pattern for machines that are equipped with the
Suspension Seat optional Electrohydraulic (EH) Hand and Foot
Controls.
Refer to the section Operation and Maintenance

Manual, “Auxiliary Hydraulic Controls” following the
three control patterns for instructions about the
Auxiliary Hydraulic System.
Note: Your machine may not be equipped with all the
controls described in this topic.
Cat Control Pattern: Left-Hand Joystick

Air Ride Suspension Seat
1. Remove the three locknuts and washers (A).

2. Raise the controls bracket up to the alternate
mounting slots (B).
3. Adjust fore/aft as desired.
4. Reinstall the washers and locknuts (A).
Joystick Controls
There are three possible joystick control patterns
depending on how the machine is equipped. Each
control pattern will affect movement of the work tool
and movement of the machine. Each pattern will be
discussed in a separate section below.
1. Cat Control Pattern – Default control pattern for Instruction Film for the Left-Hand Joystick
machines that are NOT equipped with either the
optional Selectable Control Pattern feature or the Forward
Dedicated H-Control Pattern feature. Option "1"
control pattern for machines that are equipped with
the Selectable Control Pattern feature. Refer to Forward Travel – Push the joystick
Operation and Maintenance Manual, “Operator forward to travel forward.
Controls, Left Side Controls, Selectable Pattern
Control Switch”.
Backward
2. H-Control Pattern – Default control pattern for
machines that are equipped with the optional Backward Travel – Pull back on the
Dedicated H-Control Pattern feature. Option "2" joystick to travel in reverse.
control pattern for machines that are equipped with
the Selectable Control Pattern feature. Refer to
Operation and Maintenance Manual, “Operator
Controls, Left Side Controls, Selectable Pattern
Control Switch”.
SEBU9084-11 179
Operation Section
Operator Controls
Right Turn Cat Control Pattern: Right-Hand Joystick

Right Turn – Move the joystick to the
right to turn the machine to the right.
Left Turn
Left Turn – Move the joystick to the left

to turn the machine to the left.
Horn
Horn – Press the switch to sound the

horn. Use the horn to alert personnel.
Two Speed Control
Two-Speed – Press the trigger and

release the trigger on the front of the
left-hand joystick to activate rabbit
mode. To activate rabbit mode, the Multifunction
Switch must also be in the Two Speed position.
Refer to “Multifunction Switch for the Left-Hand
Trigger (3)” above for instructions about the
switch.
Note: Keep the work tool close to the ground when

you travel in rabbit mode. This method will maximize
the stability of the machine.
Creep Control Instruction Film for the Right-Hand Joystick
The Creep Control allows the operator to select a Lower
maximum machine travel speed at full joystick
movement. Use creep control for operations that Lower – Push the joystick forward to
require slow, constant speed independent of engine lower the work tool.
idle speed.
Creep Control – To activate the creep Dump
control, stop the machine and return the
joysticks to the NEUTRAL position. Dump – Move the joystick to the right to
Press the bottom left-hand switch on the left- tilt the work tool downward.
hand joystick to turn on the creep control. To
deactivate the creep control, stop the machine
and return the joysticks to the NEUTRAL Raise
position. Press the bottom left-hand switch on
the left-hand joystick to turn off the creep control. Raise – Pull the joystick backward to
raise the work tool.
Refer to "Right Side Controls (Alternate), Creep
Control" for detailed information about the creep
speed control. Tilt Back
Tilt Back – Move the joystick to the left

to tilt the work tool upward.
Float
Float – Float allows the work tool to

follow the contour of the ground.
180 SEBU9084-11
Operation Section
Operator Controls
The following conditions will activate the float function H-Control Pattern: Left-Hand Joystick
on the machine.
Move the joystick to the LOWER position and press
the trigger. Float is activated. You may now release
the trigger.
Once the float function is engaged, the joystick can
be returned to the neutral position without affecting
the float function. Float will remain engaged until the
trigger on the right-hand joystick is pressed again.
The float function will disengage also when the
bucket is raised or when the bucket is lowered by a
command greater than approximately 15% of full
joystick range.
Auxiliary Shake Out Mode
Auxiliary Shake Out mode is an aggressive

movement of the work tool to dislodge wet or sticky
material.
Move the right-hand joystick thumb wheel over the
NEUTRAL position three times within a 2 second
period to activate Auxiliary Shake Out mode.
Auxiliary Shake Out mode will remain engaged while
the thumb wheel is moved back and forth over the
NEUTRAL position. Normal auxiliary control mode
will return when the movement of the thumb wheel is
discontinued.
Bucket Shake Out Mode

Bucket Shake Out mode is an aggressive movement Illustration 123 g03833367
of the work tool to dislodge wet or sticky material. Instruction Film for the Left-Hand Joystick
Move the Right-Hand Joystick over the NEUTRAL
position three times within a 2 second period to Forward Drive
activate Bucket Shake Out mode. Bucket Shake Out
mode will remain engaged while the Right-Hand Forward – Push the left-hand joystick
Joystick is moved left and right over the NEUTRAL forward to move the left side of the
position. Normal bucket control mode will return machine forward.
when the movement of the Right-Hand Joystick is
discontinued. Push both joysticks forward equally to move the
machine in a straight line.
Reverse Drive
Reverse – Pull the left-hand joystick

backward to move the left side of the
machine backward.
Pull both joysticks backward equally to move the
machine backward in a straight line.
Right Turn
Push the left joystick forward to turn the machine to

the right.
Push the left joystick forward and pull the right
joystick backward to turn the machine rapidly to the
right.
SEBU9084-11 181
Operation Section
Operator Controls
Horn H-Control Pattern: Right-Hand Joystick

Two Speed Control

switch.

Lower
Lower – Move the joystick to the right to

lower the work tool.
Raise
Raise – Move the joystick to the left to

raise the work tool.
Creep Control Instruction Film for the Right-Hand Joystick
The Creep Control allows the operator to select a Forward Drive
movement. Use creep control for operations that Forward – Push the right-hand joystick
require slow, constant speed independent of engine
forward to move the right side of the
idle speed.
machine forward.
Creep Control – To activate the creep Push both joysticks forward equally to move the
control, stop the machine and return the machine forward in a straight line.
joysticks to the NEUTRAL position.
Press the bottom left-hand switch on the left- Reverse Drive
hand joystick to turn on the creep control. To
deactivate the creep control, stop the machine Reverse – Pull the right-hand joystick
and return the joysticks to the NEUTRAL backward to move the right side of the
position. Press the bottom left-hand switch on machine backward.
the left-hand joystick to turn off the creep control.
Refer to "Right Side Controls (Alternate), Creep machine backward in a straight line.
speed control. Left Turn
Push the right joystick forward to turn the machine to
the left.
Push the right joystick forward and pull the left
joystick backward to turn the machine rapidly to the
left.
182 SEBU9084-11
Operation Section
Operator Controls
Dump Hand and Foot Control Pattern: Left Side

Controls
Dump – Move the joystick to the right to
tilt the work tool downward.
Tilt Back
Tilt Back – Move the joystick to the left

to tilt the work tool upward.
Float

The following conditions will activate the float function

on the machine.
Move the joystick to the LOWER position and press
the trigger on the right-hand joystick. Float is
activated. You may now release the trigger.
Once the float function is engaged, the joystick can
the float function. Float will remain engaged until the
trigger on the right-hand joystick is pressed again.
The float function will disengage also when the
bucket is raised or when the bucket is lowered by a
command greater than approximately 15% of full
joystick range.
Auxiliary Shake Out Mode Illustration 125 g03819342
Auxiliary Shake Out mode is an aggressive Instruction Film for the Left Side Controls
movement of the work tool to dislodge wet or sticky
material. Note: Film on machine will have black background,
white characters, and symbols.
Move the right-hand joystick thumb wheel over the
NEUTRAL position three times within a 2 second Forward Drive
Auxiliary Shake Out mode will remain engaged while Forward – Push the left-hand joystick
the thumb wheel is moved back and forth over the forward to move the left side of the
NEUTRAL position. Normal auxiliary control mode machine forward.
will return when the movement of the thumb wheel is
discontinued. Push both joysticks forward equally in order to move
the machine in a straight line.
Bucket Shake Out Mode
Reverse Drive
Bucket Shake Out mode is an aggressive movement
of the work tool to dislodge wet or sticky material. Reverse – Pull the left-hand joystick
Move the Right-Hand Joystick over the NEUTRAL backward to move the left side of the
position three times within a 2 second period to machine backwards.
activate Bucket Shake Out mode. Bucket Shake Out Push both joysticks backwards equally to move the
mode will remain engaged while the Right-Hand
Joystick is moved left and right over the NEUTRAL machine backwards in a straight line.
position. Normal bucket control mode will return
when the movement of the Right-Hand Joystick is Right Turn
discontinued.
Push the left joystick forward to turn the machine to
the right.
SEBU9084-11 183
Operation Section
Operator Controls
Push the left joystick forward and pull the right Hand and Foot Control Pattern: Right
joystick backward to turn the machine rapidly to the Side Controls
right.
Horn

Two Speed Control

switch.

Creep Control
The Creep Control allows the operator to select a

movement. Use creep control for operations that
require slow, constant speed independent of engine
idle speed.
Creep Control – To activate the creep Illustration 126 g03819523

control, stop the machine and return the Instruction Film for the Right Side Controls
joysticks to the NEUTRAL position.
Press the bottom left-hand switch on the left- Note: Film on machine will have black background,
hand joystick to turn on the creep control. To white characters, and symbols.
deactivate the creep control, stop the machine
and return the joysticks to the NEUTRAL Forward Drive
position. Press the bottom left-hand switch on
the left-hand joystick to turn off the creep control. Forward – Push the right-hand joystick
forward to move the right side of the
Refer to "Right Side Controls (Alternate), Creep machine forward.
speed control. Push both joysticks forward equally to move the
machine forward in a straight line.
Lower
Reverse Drive
Lower – Press the front portion (Toe) of
the foot pedal to lower the work tool. Reverse – Pull the right-hand joystick
backward to move the right side of the
Raise machine backward.
Press the rear portion (Heel) of the foot machine backward in a straight line.
pedal to raise the work tool.
Left Turn
Push the right joystick forward to turn the machine to

the left.
184 SEBU9084-11
Operation Section
Operator Controls
Push the right joystick forward and pull the left Move the right side pedal over the NEUTRAL
joystick backward to turn the machine rapidly to the position three times within a 2 second period to
left. activate Bucket Shake Out mode. Bucket Shake Out
mode will remain engaged while the right side pedal
Dump is moved forward and backward over the NEUTRAL
position. Normal bucket control mode will return
Dump – Press the front portion (Toe) of when the movement of the right side pedal is
the foot pedal to tilt the work tool discontinued.
downward.
Foot Pedal - Adjust
Tilt Back
The angle of the foot pedal on machines equipped
Tilt Back – Press the rear portion (Heel) with Hand and Foot control pattern may be adjusted
of the foot pedal to tilt the work tool to improve operator comfort.
upward.
Float

The following conditions will activate the float function

on the machine.
Fully press the front portion (Toe) of the left-hand foot
pedal to start the lift arms moving downward and
press the right-hand joystick trigger. Float is
activated. You may now release the trigger.
Once the float function is engaged, the foot pedal can Illustration 127 g06039744
the float function. Float will remain engaged until the Cat Hand and Foot control pattern foot pedal
trigger on the right-hand joystick is pressed again. (1) Foot Control Pedal
The float function will disengage also when the (2) Hex nut
bucket is raised or when the bucket is lowered by a (3) Acorn nut
command greater than approximately 15% of full foot
pedal range. 1. Raise the cab.
Auxiliary Shake Out Mode 2. Remove the acorn nuts (3) and Hex nuts (2) from
beneath the cab floor.
Auxiliary Shake Out mode is an aggressive
movement of the work tool to dislodge wet or sticky 3. Install up to a maximum of four washers 2mm thick
material. washers.
Move the right-hand joystick thumb wheel over the 4. Replace the Hex nuts (2) and torque to
NEUTRAL position three times within a 2 second 12 ± -3 N·m (9± -2 lb ft).
Auxiliary Shake Out mode will remain engaged while 5. Replace the acorn nuts (3) and torque to
the thumb wheel is moved back and forth over the 6 ± -1 N·m (4 ± -1 lb ft).
NEUTRAL position. Normal auxiliary control mode
will return when the movement of the thumb wheel is Auxiliary Hydraulic Controls
discontinued.
Bucket Shake Out Mode If the work tool has a wiring harness, connect the
work tool harness to the electrical plug on the loader
Bucket Shake Out mode is an aggressive movement arm. If your High Flow work tool does not have a
of the work tool to dislodge wet or sticky material. wiring harness, a Jumper Plug should be installed on
the electrical plug for the work tool control. Without
this Jumper Plug, the machine will not provide High
Flow to the work tool. Refer to your Parts Manual for
the current part number for the Jumper Plug.
SEBU9084-11 185
Operation Section
Operator Controls
Note: High flow mode requires an electrical

connection that is located on the loader arm. Refer to
Operation and Maintenance Manual, “Work Tool
Coupler Operation” or Operation and Maintenance
Manual, “Work Tool Operation” for additional details.
Note: If the high flow work tool does not have a
wiring harness, consult the Operation and
Maintenance Manual for the work tool for the proper
instructions for attaching the work tool.

Auxiliary Flow Connections - XHP Models
(EC) Work Tool Electrical Connector
(a2) 3/4 inch Hydraulic Supply
(A2) 1/2 inch Hydraulic Supply
(a1) 3/4 inch Hydraulic Return
(A1) 1/2 inch Hydraulic Return
(L) 3/8 inch Case Drain
(1) A2 Locking Clip
(2) A1 Locking Clip
(3) Magnet
Illustration 128 g03820488 Note: Your machine may not be equipped with all
Auxiliary Flow Connections - non-XHP Models connections shown.
(EC) Work Tool Electrical Connector
(A2) 1/2 inch Hydraulic Supply Note: The Locking Clips (1) and (2) are provided to
(A1) 1/2 inch Hydraulic Return secure the heavier 3/4 inch XHP hydraulic lines to
(L) 3/8 inch Case Drain prevent unintended flow and or pressure loss through
the case drain (L) and to minimize the potential for
Note: Your machine may not be equipped with all line decoupling due to vibration. After making the
connections shown. hydraulic connection, the clips are inserted into the
receiving grooves on the 3/4 inch XHP couplings (a1)
and (a2). The larger clip (a1) cannot be inserted into
the coupling unless a work tool is connected. The
magnet (3) is provided to aid in securing this clip to
the machine structure when not in use to prevent
possible damage.
Auxiliary Hydraulic Control (A1) – This
control provides hydraulic oil flow to the
auxiliary connections on the loader arm.
Engage the control to provide hydraulic oil flow
to the female connector (s) (A1) and (a1).
Auxiliary Hydraulic Control (A2) – This
control provides hydraulic oil flow to the
auxiliary connections on the loader arm.
Engage the control to provide hydraulic oil flow
to the male connector (s) (A2) and (a2).
186 SEBU9084-11
Operation Section
Battery Disconnect Switch
Case drain line (L) – Some hydraulic or Auxiliary Electrical Control 5 (C2) – This
hydromechanical work tools will have a Case drain control provides electrical power to
line coming off the work tool motor. It is a tube that activate additional work tool functions
routes back to the cooler to the low side return and using a three-position diverter valve that is
back to the hydraulic tank. located on some work tools. Press the switch and
hold the switch to send power to the pin (E) this
will activate the required Work Tool function.
Release the switch to deactivate the control.
Auxiliary Electrical Control (C1) – This
control provides electrical power to
activate additional work tool functions
using a three-position diverter valve that is
located on some work tools. Press the switch and
hold the switch to send power to pin (F). This
action will activate the required Work Tool
function. Release the switch to deactivate the
control.
Left Hand Trigger – Pull the trigger and
hold the trigger on the left-hand joystick
Illustration 130 g02931218 to provide electrical power to pin (A).
Work Tool Electrical Connection (EC) Release the trigger to deactivate the control.
(A) Left Hand Trigger Control “AUX 7”
(C) C- Control "Aux 3" Multifunction Switch must be in the Aux 7 position.
(D) C+ Control "Aux 4" Refer to "Multifunction Switch for the Left Hand
(E) C2 Control "Aux 5" Trigger (3) " above for instructions about the switch.
(F) C1 Control "Aux 6"
(J) Auxiliary Electrical Control “AUX 8” Note: These controls are used with the individual
Work Tool Operation and Maintenance Manual to
Auxiliary Electrical Control 3 (C−) – This understand fully the functions of each control.
activate additional work tool functions i06134940
hold the switch to send power to the pin (C) this
action will activate the required Work Tool SMCS Code: 1411-B11; 1411
control. If the auxiliary hydraulic controls (A1/ The battery disconnect switch is located in the engine
A2), and continuous flow is inactive, and a work compartment near the battery. A D2-Series model will
include a DEF Purge Indicator Lamp, which is not
tool featuring auto reverse functionality (such as
used in D-Series models.
cold planers) is connected, pressing the switch
will send power to pin (C) and provide hydraulic
flow to the female connector (s) (A1) and (a1).
Auxiliary Electrical Control 4 (C+) – This
activate additional work tool functions
hold the switch to send power to the pin (D). This
action will activate the required Work Tool
control. Ifthe auxiliary hydraulic controls(A1/A2),
and continuous flow is inactive and a work tool
featuring auto reverse functionality (such as cold
planers) is connected, pressing the switch will
send power to pin (D) and provide hydraulic flow
to the female connector (s) (A1) and (a1).
SEBU9084-11 187
Operation Section
(1) Battery Disconnect Switch (2) Diesel Exhaust Fluid (DEF) Purge
Indicator Lamp
If equipped, the DEF Purge Indicator Lamp (2) will

NOTICE remain ON after the Key Switch is turned OFF. This is
Do not conduct any service procedures on the DEF
system until the DEF purge indicator lamp is not illu- to ensure the DEF injector cool down and DEF
minated. The indicator lamp may remain illuminated system purge processes are complete.
for up to twelve minutes when the key switch is OFF. Disconnecting the battery while the DEF Purge
When the indicator is on, the DEF system is still Indicator Lamp (2) is ON can result in failure of the
powered. DEF injector, DEF Pump, or DEF lines.
Note: The DEF Purge Indicator Lamp is required with

ON – To activate the electrical system, the battery disconnect on D2-Series machines.
insert the disconnect switch key and
turn the battery disconnect switch (1)
clockwise. The battery disconnect switch must
be turned to the ON position before you start the
engine.
OFF – To deactivate the electrical
system, turn the battery disconnect
switch (1) counterclockwise to the OFF
position once the DEF Purge Indicator Lamp (2)
is off.
The battery disconnect switch and the Key Switch
perform different functions. The entire electrical
system is disabled when you turn the Battery
Disconnect Switch to OFF. The battery remains
connected to the electrical system when you turn the
Key Switch to OFF.
188 SEBU9084-11
Operation Section
Diesel Particulate Filter Regeneration
3. Verify that the following items are not functioning:

electrical components in the operator
compartment, hour meter, and engine cranking. If
any of the items continue to function with the
battery disconnect switch in the OFF position,
consult your Cat dealer.
i06153269
Diesel Particulate Filter

Regeneration
SMCS Code: 108F
S/N: BL21–Up
S/N: DX21–Up
S/N: FD21–Up
S/N: HP21–Up
S/N: MD21–Up
S/N: BY41–Up
S/N: BE71–Up
S/N: BL71–Up
Illustration 132 g03821146 S/N: HP71–Up
Turn the battery disconnect switch to the OFF S/N: DX91–Up

position and remove the key when you service the S/N: DTB1–Up
electrical system or any other machine components.
S/N: GTC1–Up
• short circuits
S/N: BYF1–Up
• current draw via some components
S/N: ETL1–Up
• vandalism
S/N: FTL1–Up
NOTICE S/N: GTL1–Up

Never move the battery disconnect switch to the OFF
position while the engine is operating. Serious dam- S/N: DZT1–Up
age to the electrical system could result. S/N: FMT1–Up
S/N: HMT1–Up
To ensure that no damage to the engine occurs,
verify that the engine is fully operational before S/N: JST1–Up
cranking the engine. Do not crank an engine that is
not fully operational. S/N: B5W1–Up
Perform the following procedure in order to check the S/N: EZW1–Up

battery disconnect switch for proper operation: S/N: TAW1–Up
1. With the battery disconnect switch in the ON S/N: BGZ1–Up
position, verify that electrical components in the
operator compartment are functioning. Verify that
the hour meter is displaying information. Verify that
the engine will crank.
2. Turn the battery disconnect switch to the OFF
position.
SEBU9084-11 189
Operation Section
Diesel Particulate Filter Regeneration
General Information When an active regeneration is required with the

parking brake and hydraulic lockout engaged,
Regeneration is the removal of soot from the Diesel automatic adjustments of the engine speed by the
Particulate Filter (DPF). Active and passive ECM may occur to keep the engine RPM above the
regeneration are used to regenerate the DPF. The active regeneration threshold.
DPF traps both soot and ash. The soot is removed
during regeneration. The ash is removed through a When an active regeneration is required and the
cleaning process. Refer to the Operation and machine is being operated below the active
Maintenance Manual, “Diesel Particulate Filter - regeneration threshold, the DPF alert indicator may
Clean/Replace” for more information on the service illuminate. The operator can increase the rpm above
of the DPF. the active regeneration threshold with the Engine
Speed Control Knob. An active regeneration will
Modes of Regeneration occur and the DPF light will turn off.
Passive – Passive Regeneration occurs when the If increasing the RPM is not acceptable, alternatively
exhaust temperature is high enough for regeneration the operator can allow a parked regeneration. In
to occur. Passive regeneration may occur unnoticed order for a parked regeneration to occur. The engine
by the operator. No operator action is required. must be at low idle, the parking brake engaged, and
Operating the machine above mid throttle and under the hydraulic lockout engaged. If those conditions are
load allows for passive regeneration during normal met for approximately 2 minutes, the ECM will slowly
operation. Low idle and low load applications will increase the engine rpm and an active regeneration
have lower exhaust temperatures, where passive will begin. After completing the active regeneration
regeneration is not possible. the engine speed will slowly decrease down to low
idle.
Active – An active regeneration is a late injection of
fuel into the combustion chamber, which sufficiently The following chart describes the alert indicators and
raises the exhaust temperature for an active what actions, if any, the operator needs to perform in
regeneration. The engine ECM uses multiple inputs order to allow an active regeneration.
from the engine to determine when an active
regeneration is needed. All applications, even high Warning Symbols
load, will require active regenerations. However,
active regeneration will not occur as frequently as low 1 - DPF
idle and low load applications.
2 - Alert
3- Engine Condition Indicator

(1) Active regeneration threshold
Note: The green area is the active regeneration

threshold.
There will be a slight change in the exhaust noise
during an active regeneration. Active regenerations
may require the engine rpm to be above the active
regeneration threshold. The active regeneration may
take up to 30 minutes to complete.
190 SEBU9084-11
Operation Section
Selective Catalytic Reduction Warning System
4- Cab Alarm
Engine Emission Alert

Table 88
Warning Symbol Machine Action Operator Action
If the parking brake and hydraulic lockout are en-
None No action required.
gaged, the ECM may increase the engine speed
Increase the engine rpm to the green shaded area on

the Engine Speed Control Knob, and the DPF light will
turn off.
or
If the parking brake is not engaged and the engine
Bring the machine to a stop.
1 Amber speed is below the green shaded area on the Engine
Engage the parking brake and hydraulic lockout.
Speed Control Knob, the DPF light will turn on.
Set the engine speed to low idle.
The ECM will automatically increase the engine rpm to
the regeneration threshold.
The regeneration may take up to 30 minutes.
Bring the machine to a stop.

Engage the parking brake and hydraulic lockout.
1 Amber
The engine will derate until an active regeneration is Set the engine speed to low idle
2 Amber
completed (1) The ECM will automatically increase the engine rpm to
3 Amber
the regeneration threshold.
The regeneration may take up to 30 minutes.
A regeneration can only be done through Cat Elec-

1 Amber tronic Technician (ET), by an authorized Cat dealer.
2 Flash Amber Consult your local Cat dealer.
Engine will remain derated. (2)(3)
3 Red If the engine is run through these warning indicators,
4 Horn the DPF will require servicing and may require replace-
ment. Engine damage can occur.
(1) 3701-15 DPF Status: High - Least Severe
(2) 3701-16 DPF Status: High - Moderate Severity
(3) 3701-0 DPF Status: High - Most Severe
Note: If the machine is equipped with the optional

NOTICE
Advanced Display, the code and description will be Allow the engine to perform a DEF purge of the DEF
displayed in the monitor. The Engine Condition system before you turn the battery disconnect switch
Indicator lamp is not incorporated into the Advanced to OFF. Disconnecting the battery power too soon
Display. may prevent proper cool down of DEF injector and
purging of the DEF system after the engine is shut
i06135026 down. Refer to Operation and Maintenance Manual,
“Battery Disconnect Switch” for more information.
Selective Catalytic Reduction
Warning System
SMCS Code: 1091-WXX; 7400
The selective catalytic reduction (SCR) system is a
system used to reduce NOx emissions from the
engine. Diesel exhaust fluid (DEF) is pumped from
the DEF tank and is sprayed into the exhaust stream.
The DEF reacts with the SCR catalyst to reduce NOx
and leaves a nitrogen and water vapor. Illustration 134 g03821224
The DEF level gauge icon is designated the "SCR

Warning" alert indicator. Refer to "Right Side Controls
(Alternate), Monitoring Screen, Fuel & Diesel
Exhaust Fluid (DEF) Level Gauge " for location.
SEBU9084-11 191
Operation Section
Alert Indicators
Diesel Exhaust Fluid Quality – The sensor in the

DEF tank measures the quality of the DEF. If non-
standard DEF is supplied or is diluted, the lamp will
go to Warning Level 1. After operating for 3 hours
and 15 minutes, the warning will increase to Level 2.
After operating for another 45 minutes, the warning
will increase to a Level 3.
SCR System Fault – If any of the SCR system
Illustration 135 g03821224 sensors are disconnected or any fault codes occur in
the SCR system, the indicator will go to a Warning
• At Level 1 the SCR Warning alert indicator will Level 1. After 3 hours and 15 minutes, the warning
change from white to solid RED. will go to a Level 2. After operating for another 45
minutes, the warning will increase to a Level 3.
i06824481
Alert Indicators
SMCS Code: 7450; 7451
The alert indicators are located on the right-hand
display.
Note: Your machine may not be equipped with all the
• At Level 2 the SCR Warning alert indicator will
indicators that are discussed in this topic.
flash RED, a pop-up warning will appear in the
display with the diagnostic code description, and
the Driver alert indicator will flash AMBER.
Maximum engine speed is reduced to 60% of
rated speed and maximum torque is reduced by
50%.
• At Level 3 the SCR Warning alert indicator will

flash RED, a pop-up warning will appear in the
display with the diagnostic code description. The
Driver alert indicator will flash AMBER, and the
audible alarm will occur. Engine speed is limited
too nearly low idle and no engine torque is
available.
The SCR Warning alert indicator will turn ON when
the DEF tank level is low, a quality issue with the DEF
is detected, or there is a fault in the SCR system. The
following are the parameters for each warning type.
Diesel Exhaust Fluid Level – When the DEF gauge
is near the red range, the indicator will go to a
Warning Level 1. After 45 minutes of operation, the
warning will increase to Level 2. When the DEF tank
level is empty, the warning will increase to a Level 3.
192 SEBU9084-11
Operation Section
Alert Indicators

Left Side
1 – Diesel Particulate Filter • RED Coolant Temperature

TM
2 – Cat Intelligent Leveling (ILEV) System • RED Oil Pressure
3 – Driver Alert • AMBER Air Cleaner Indicator
4 – System Voltage 13 – Anti-Theft Security System
5 – Parking Brake 14 – Two-Speed Indicator
6 – Operator Presence 15 – Creep Control Mode Indicator
7 – Auxiliary Hydraulic High Flow 16 – Ride Control
8 – Continuous Flow 17 – Cat Control Pattern
9 – Work Tool System 18 – H-Control Pattern
• RED Work Tool Lockout 1 - Diesel Particulate FilterThis alert will activate
when the diesel particulate filter needs a
• AMBER Interlock Override regeneration. Refer to this Operation and
Maintenance Manual, “Diesel Particulate Filter
10 – Hydraulics Regeneration” for details.
2 - Cat Intelligent Leveling TM (ILEV) System This
• RED Hydraulic Temperature alert indicator will light when the ILEV System in ON.
This alert indicator will blink twice when the user-
• AMBER Hydraulic Filter Bypass selected work tool target angle is established. Refer
to Operation and Maintenance Manual, “Operator
11 – Cold Starting Aid Controls, Left Side Controls, Cat Intelligent Leveling
TM
12 – Engine Condition Indicator (ILEV) System Switch”.
SEBU9084-11 193
Operation Section
Alert Indicators
3 - Driver Alert This alert indicator will activate when • If the machine is equipped with a Diesel
there is a problem which requires operator attention. Particulate Filter, move the machine to a safe
location and set the parking brake. If the engine
Note: Other alert indicators that light or the gauges RPM begins to rise shortly, allow the machine to
may help investigate the cause of any problems. complete a regeneration cycle. For more
There are three levels of severity for the indicator: information refer to “Operation Maintenance
Manual” Diesel Particulate Filter Regeneration.
Level 1 – If the alert indicator is on continuously, stop
the machine at the earliest convenience. Check the • If the SCR Warning alert indicator is flashing RED,
following before consulting your Cat dealer. check the Diesel Exhaust Fluid Level. See Diesel
Exhaust Fluid - Fill. Refer to Selective Catalytic
Reduction Warning System for an explanation of
• Ensure that the machine has been adequately the various SCR warning levels.
warmed up. Refer to Engine Starting for an
explanation of the engine and ambient conditions • A sensor on the machine may be faulted or has
that may trigger this. come unplugged. For tracked machines, check
that the wiring to the drive motor speed sensor
• If the Engine Condition alert indicator is AMBER, wiring is not damaged. Consult your Cat dealer
water may be present in the fuel. Drain the water for advanced troubleshooting support.
from the fuel/water separator. For more
information refer to “Operation Maintenance Level 3 – If the alert indicator is flashing and there is
Manual” Fuel System Primary Filter (Water an audible alarm, injury to the operator or severe
Separator) - Drain. component damage could occur. Stop the machine
immediately and check the following before
• If the Engine Condition alert indicator is AMBER, consulting your Cat dealer:
the engine air filter may be restricted. For more
information refer to “Operation Maintenance
Manual” Engine Air Filter Primary Element - • Check the engine oil. See lOperation Maintenance
Clean/Replace. manual, Engine Oil level - Check . If the Engine
Condition alert indicator is RED, the engine oil
• If the Hydraulics alert indicator is AMBER, the filter filter may be plugged. See Engine Oil and Filter -
is bypassing. Check that the hydraulic oil filter is Change. See also Oil Filter - Inspect.
not plugged. For more information refer to
“Operation Maintenance Manual” Hydraulic • If the Engine Condition alert indicator is RED, the
System Oil Filter - Replace. See also Oil Filter - engine coolant temperature may be high. Clean
Inspect. the engine radiator, reduce the engine load, and
allow the engine to cool. For more information
• Check for proper battery voltage and ensure that refer to Operation Maintenance Manual, Radiator
the alternator and wiring are good. Core - Clean.
Level 2 – If the alert indicator is flashing and there is • If the Hydraulics alert indicator is RED, the
no audible alarm, severe component damage could hydraulic oil temperature is high. Check the
occur. Stop the machine at the earliest convenience hydraulic oil level. Refer to Operation Maintenance
and check the following before consulting your Cat Manual, Hydraulic System Oil Level - Check.
dealer. Clean the hydraulic oil cooler, reduce the hydraulic
load, and allow the system to cool. See Radiator
Core - Clean.
• If the Engine Condition alert indicator is RED and
the maximum engine speed is reduced, water may • If the SCR Warning alert indicator is flashing RED,
be present in the fuel. Drain the water from the check the Diesel Exhaust Fluid Level. See Diesel
fuel/water separator. For more information refer to Exhaust Fluid - Fill. Refer to Selective Catalytic
“Operation Maintenance Manual” Fuel System Reduction Warning System for an explanation of
Primary Filter (Water Separator) – Drain the various SCR warning levels.
• If the Engine Condition alert indicator is RED and • A sensor on the machine may be faulted or has
the maximum engine speed is reduced, the engine come unplugged. For tracked machines, check
air filter may be restricted. For more information that the wiring to the drive motor speed sensors is
refer to “Operation Maintenance Manual” Engine not damaged. Consult your Cat dealer for
Air Filter Primary Element - Clean/Replace. advance d troubleshooting support.
• Check for proper battery voltage and ensure that
the alternator and wiring are good.
194 SEBU9084-11
Operation Section
Alert Indicators
4 - System Voltage This alert indicator will light if 11 - Cold Starting Aid With the engine start switch in
there is a malfunction in the electrical system. If this the ON position, this alert indicator will light when the
alert indicator comes on, the system voltage is too aid is activated. Refer to Operation and Maintenance
high for normal machine operation or too low for Manual, “Engine Starting” for more information about
normal machine operation. the heater.
If electrical loads are high and the engine speed is 12 - Engine Condition Indicator This alert will
near low idle, increase the engine speed to high idle activate when there is a problem which requires
to get more output from the alternator. If the alert operator attention.
indicator for the electrical system turns off within 1
minute, the electrical system is probably operating in Note: Other alert indicators that light or the gauges
a normal manner. However, the electrical system may help investigate the cause of any problems.
may be overloaded during periods of low engine
speeds. There are three levels of severity for this indicator:
Increase the engine idle speed with the governor • Level 1: If the alert indicator is on continuously,
lever to compensate for a higher electrical load on stop the machine at the earliest convenience. This
the system. alert is for the air cleaner indicator. Stop the
machine and service the air cleaner.
If this procedure does not cause the alert indicator to
turn off, move to a convenient location. Investigate • Level 2: If the alert indicator is flashing and there is
the cause (loose alternator belt, broken alternator no audible alarm, severe component damage
belt, or faulty batteries). could occur. Change your operation or perform the
indicated maintenance.
5 - Parking Brake This alert indicator will light when
the parking brake is engaged. The alert indicator • Level 3: If the alert indicator is flashing and there is
should come on during start-up. The alert indicator an audible alarm, injury to the operator or severe
should go out when the parking brake is disengaged.
component damage could occur. Stop the
6 - Operator Presence This alert indicator will light machine immediately and stop the engine.
when the armrests are in the RAISED position. The
alert indicator will light when the operator gets out of 13 - Anti-Theft Security System This alert indicator
the operator seat. The alert indicator should go out will light when the Anti-Theft Security System is
when the operator is in the operator seat and the activated. Refer to Operation and Maintenance
armrests are in the LOWERED position. Manual, “Anti-Theft Security System” for more details
about the security system.
7 - Auxiliary Hydraulic High Flow This alert
indicator will light when the high flow hydraulic 14 - Two-Speed Indicator This alert indicator will
system is activated. light when two-speed travel mode is engaged.
8 - Continuous Flow This alert indicator will flash 15 - Creep Control Mode Indicator This alert
when the machine is in "Continuous Flow Ready" indicator will light when Creep Control mode is
mode. This alert indicator will light when continuous engaged.
flow is activated.
16 - Ride Control This alert indicator will light when
9 - Work Tool System the Ride Control switch is “ON” and the necessary
ground speed is reached for Ride Control activation.
• This alert indicator will light red when the work tool
lockout control is activated. 17 - Cat Control Pattern If your machine is equipped
with the optional Selectable Control Pattern Switch,
• This alert indicator will light amber when the this alert indicator will flash until a control pattern is
interlock override is activated. selected via the switch. This alert indicator will light
when the Cat Control Pattern is activated.
10 - Hydraulics
Note: Refer to Operation and Maintenance Manual,
• This alert indicator will light red and an audible “Operator Controls - Joystick Controls” for
alert will sound when the temperature of the information about the joystick control patterns.
hydraulic oil is too high. If this indicator comes on,
stop the machine immediately. Stop the engine 18 - H-Control Pattern If your machine is equipped
and investigate the problem. with the optional Selectable Control Pattern Switch,
this alert indicator will flash until a control pattern is
• This indicator will light amber when the hydraulic selected via the switch. This alert indicator will light
oil filter is not functioning properly. Stop the when the H-Control Pattern is activated. This alert
indicator will also be lit when the machine is equipped
machine and replace the oil filter. The indicator will
with the Dedicated H-Control Pattern option.
stay on until the hydraulic oil has warmed up. Do
not operate the machine until the light turns off.
SEBU9084-11 195
Operation Section
Product Link
Note: Refer to Operation and Maintenance Manual, Caterpillar may share some or all of the collected
“Operator Controls - Joystick Controls” for information with Caterpillar affiliated companies,
information about the joystick control patterns. dealers, and authorized representatives. Caterpillar
will not sell or rent collected information to any other
i06702160
third party and will exercise reasonable efforts to
keep the information secure. Caterpillar recognizes
and respects customer privacy. For more information,
Product Link please contact your local Cat dealer.
SMCS Code: 7606
Operation in a Blast Site for
Note: Your machine may be equipped with the Cat ®
Product Link system. Product Link Radios
The Caterpillar Product Link communication device
utilizes cellular and/or satellite technology to
communicate equipment information. This This equipment is equipped with a Cat® Product
information is communicated to Caterpillar, Link communication device. When electric deto-
Catdealers and Caterpillar customers. The Caterpillar nators are being used for blasting operations, ra-
Product Link communication device contain Global dio frequency devices can cause interference
Positioning System (GPS) satellite receivers. with electric detonators for blasting operations
which can result in serious injury or death. The
The capability of two-way communication between Product Link communication device should be
the equipment and a remote user is available with the deactivated within the distance mandated under
Caterpillar Product Link communication device. The all applicable national or local regulatory require-
remote user can be a dealer or a customer. 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
transmitted by Product Link to Caterpillar and/or Cat Note: If using the previous version of Product Link
dealers. The data is used to serve the customer radios (PL121SR, 522, 523, 420, or 421) refer to
better and to improve upon Caterpillar products and blast site requirements as stated in Operation and
services. The information transmitted may include: Maintenance Manual, SEBU8142, “Product Link -
machine serial number, machine location and 121SR/321SR/420/421/522/523”.
operational data, including but not limited to: fault
codes, emissions data, fuel usage, service meter • 12 m (40 ft) for Product Link 121SR and 321SR
hours, software and hardware version numbers and
installed attachments. • 3 m (10 ft) for Product Link 522/523
Caterpillar and/or Cat dealers may use this If required, the following are suggested methods to
information for various purposes. Refer to the disable the Caterpillar Product Link communication
following list for possible uses: device:
• Providing services to the customer and/or the • Turn theProduct Link radio disable switch to the
machine OFF position.
• Checking or maintaining Product Link equipment • Disconnect the Caterpillar Product Link
• Monitoring the health of the machine or communication device from the main power
performance source. This action is performed by disconnecting
the wiring harness at the Product Link radio.
• Helping maintain the machine and/or improve the
efficiency of the machine Note: If no radio disable switch is installed and the
equipment will be operating near a blast zone, a
• Evaluating or improving Caterpillar products and Product Link radio disable switch may be installed on
services the equipment. The switch will allow the Caterpillar
Product Link communication device to be shut off by
• Complying with legal requirements and valid court the operator from the equipment control panel. Refer
orders to Special Instruction, REHS7339, Special
Instruction, REHS2365, Special Instruction,
• Performing market research REHS2368, Special Instruction, REHS5595, Special
Instruction, REHS5596, Special Instruction,
• Offering the customer new products and services REHS8850, and Special Instruction, REHS9111 for
more details and installation instructions.
196 SEBU9084-11
Operation Section
Product Link
Note: For Product Link devices with an internal (Table 89, contd)
battery back-up without a radio disable feature 824 MHz - 849 MHz
including the PL420 system: Do not operate an asset 880 MHZ - 915 MHz
with this type of device within a blast site. Do not 1710 MHz - 1755
operate within mandated or recommended distance MHz 0.5W typical, 2W
PL240
from a blast site perimeter. 1850 MHz - 1910 max
MHz
The following Caterpillar Product Link communication 1920 MHz - 1980
device specifications are provided in order to aid in MHz
conducting any related hazard assessment and to
824 MHz - 849 MHz
ensure compliance with all local regulations:
880 MHZ - 915 MHz
Table 89 1710 MHz - 1755
Radio Transmitter Specifications MHz 0.5W typical, 2W
PL241
1850 MHz - 1910 max
Radio Model Transmitter Fre- Transmitter Power MHz
(Maximum) quency Range 1920 MHz - 1980
MHz
PL121SR 148 MHz -150 MHz 5-10W
824 MHz - 849 MHz Consult your Cat dealer if there are any questions.
880 MHz - 915 MHz
Information for the initial installation of the Caterpillar
PL522/523 1710 MHz - 1785 1W Product Link communication device is available in
MHz Special Instruction, REHS7339, Special Instruction,
REHS8850, Special Instruction, REHS2365, Special
1850 MHz - 1910 Instruction, REHS2368, Special Instruction,
MHz REHS5595, Special Instruction REHS5596, and
850 MHz - 900 MHz 2W for lower
Special Instruction, REHS9111.
PL420/421 frequency,
1800 MHz - 1900 Operation, configuration and troubleshooting
1W for higher
MHz information for the Caterpillar Product Link
824 MHz - 849 MHz
communication device can be found in the Systems
Operation, Troubleshooting, Testing and Adjusting,
880 MHZ - 915 MHz UENR3697, Systems Operation, Troubleshooting,
1710 MHz - 1755
Testing and Adjusting, UENR5823, and Systems
PL640 MHz 0.5W typical, 2W
Operation, Troubleshooting, Testing and Adjusting,
G0100 max UENR5824, Special Instruction, REHS7911, and
1850 MHz - 1910 Special Instruction, REHS8143.
MHz
1920 MHz - 1980 Machine Security
MHz
824 MHz - 849 MHz Machine Lock Icon
880 MHZ - 915 MHz
1710 MHz - 1755
De-rate – Some machines can have the machine
MHz 0.5W typical, 2W engine de-rated remotely by the owner of the
PL641
max machine. The action causes the machine to operate
1850 MHz - 1910
MHz much slower than normal.
1920 MHz - 1980 A warning is given before this action occurs on the
MHz display with the machine lock icon and “Security
1616 MHz - 1626.5
Pending” . When engine de-rate has happened, the
PL631
MHz
5.1W max machine display shows the machine lock icon and
“Security Enabled” . The operator should move the
machine to a safe location, apply the parking brake,
power the machine down, notify the site supervisor,
(continued) and contact your local Cat dealer.
Disable – Some machines can be prevented from
starting remotely by the owner of the machine. When
disabling has happened, the machine display shows
the machine lock icon and “Security Enabled” .
Before the machine is disabled, the machine display
SEBU9084-11 197
Operation Section
Product Link
shows the machine lock icon and “Security Pending”

. The operator should notify the site supervisor.
Tampering – Tampering with the Product Link

system to disable the Product Link can also result in
engine de-rating of the machine. To avoid de-rating,
prevent tampering with the Product Link. If machine
diagnostics occur due to Product Link , notify your
site supervisor immediately to prevent derating. An
example of this situation is an antenna becoming
damaged.
Note: Leaving the blast site switch in the OFF

position for more than 48 machine hours can cause
the machine to derate.
Regulatory Compliance
NOTICE
Transmission of information using Product Link is
subject to legal requirements that may vary from loca-
tion to location, including, but not limited to, radio fre-
quency use authorization. The use of Product Link
must be limited to those locations where all legal re-
quirements for the use of the Product Link communi-
cation network have been satisfied.
If a machine outfitted with Product Link is located in
or relocated to a location where (i) legal requirements
are not satisfied or (ii) transmitting or processing of
such information across multiple locations would not
be legal, Caterpillar disclaims any liability related to
such failure to comply and Caterpillar may discon-
tinue the transmission of information from that
machine.
Consult your Cat dealer with any questions that

concern the operation of the Product Link in a
specific country.
Note: This equipment has been registered with the
Botswana Telecommunications Authority for use in
Botswana. BTA REGISTERED No: BTA/TA/2012/378
198 SEBU9084-11
Operation Section
Product Link

SEBU9084-11 199
Operation Section
Product Link

200 SEBU9084-11
Operation Section
Product Link

SEBU9084-11 201
Operation Section
Product Link

202 SEBU9084-11
Operation Section
Product Link

SEBU9084-11 203
Operation Section
Product Link

204 SEBU9084-11
Operation Section
Product Link
SEBU9084-11 205
Operation Section
Product Link

206 SEBU9084-11
Operation Section
Product Link

SEBU9084-11 207
Operation Section
Product Link
208 SEBU9084-11
Operation Section
Product Link
European Union EC Declaration of

Conformity G0100
Table 90
CATE RPILLAR ®
EC Declaration of Conformity
The undersigned, representing And the authorized representative established within
the Community
CATERPILLAR INC CATERPILLAR INC

100 N.E. Adams Street Alberto JUAREZ-RAMIREZ
Peoria, IL 61629 Fleet Specialist / Technology Distribution Consultant
USA EAME DSD- Equipment Management
Tel: 32(0) 71.25.97.03 / Mob: 32(0) 499.85.97.03
Email: [email protected]
Caterpillar Belgium - Bldg A
1, Avenue des Etats-Unis,
BE 6041, Gosselies , Belgium
hereby declares that the product:
Brand: Product Link

Model: G0100 Part Number: 417-4723
is in conformity with essential requirements of the following EC Directives
1999/5/EC Radio and Telecommunications Terminal Equipment Directive
2006/95/EC Low Voltage Directive
2014/30/EC Electromagnetic Compatibility (ECM) Directive
2011/65/EU Restriction of certain Hazardous Substances Directive

and that the standards referenced below have been applied:
EN 60950-1 (ed.2) EN 301 489-1:V1.8.1: 2008
EN 301 511: v9.0.2 EN 61000-4-2:2008
(continued)
SEBU9084-11 209
Operation Section
Product Link
(Table 90, contd)

EN 300 440-2:V1.4.1:2010 EN 61000-4-3:2006
EN 55022:2006:A1:2007 EN 61000-4-6:2008
EN 62311:2008 CISPR 25 (2nd Edition 2002)
EN 13309:2010 EN 50581:2012

Conformity PL240
Table 91
CATE RPILLAR ®
the Community

Tel: 32(0) 71.25.97.03 / Mob: 32(0) 499.85.97.03
Brand: Product Link

Model: PL240 Part Number: 505-6727
(continued)
210 SEBU9084-11
Operation Section
Product Link
(Table 91, contd)


as is verified by compliance with the following standards:
EN 60950-1:2006+A2:2013 EN 301 489-1:V1.9.2: 2011

EN 301 511: v9.0.2 EN 301 489-3:V1.4.1:2002
EN 300 440-2:V1.4.1:2010 EN 301 489-7:V1.3.1:2005
EN 301 908-1:V5.2.1 and V6.2.1 EN 301 489-24:V1.5.1:2010
EN 301 908-2:V5.2.1 and V6.2.1 EN ISO 14982:2009
EN 62311:2008 EN 13309:2010
ISO 13766:2006 EN 50581:2012

Conformity PL241
Table 92
CATE RPILLAR ®
the Community

(continued)
SEBU9084-11 211
Operation Section
Product Link
(Table 92, contd)

Tel: 32(0) 71.25.97.03 / Mob: 32(0) 499.85.97.03
Brand: Product Link

Model: PL241 Part Number: 444-9619

EN 60950-1:2006+A2:2013 EN 301 489-1:V1.9.2: 2011

EN 301 511: v9.0.2 EN 301 489-3:V1.4.1:2002
EN 300 440-2:V1.4.1:2010 EN 301 489-7:V1.3.1:2005
EN 301 908-1:V5.2.1 and V6.2.1 EN 301 489-24:V1.5.1:2010
EN 301 908-2:V5.2.1 and V6.2.1 EN ISO 14982:2009
EN 62311:2008 EN 13309:2010
ISO 13766:2006 EN 50581:2012
212 SEBU9084-11
Operation Section
Product Link

Conformity PL631
Table 93
CATE RPILLAR ®
the Community

Tel: 32(0) 71.25.97.03 / Mob: 32(0) 499.85.97.03
Brand: Product Link
Model: PL631 Part Number: 442-7199 (external antenna)

(continued)
SEBU9084-11 213
Operation Section
Product Link
(Table 93, contd)
EN 60950-1:2006+A12:2011 EN 300 440-2:V1.4.1

EN 63211:2008 EN 301 441-2:V1.1.1
ISO 13766:2006 EN 301 489-1:V1.9.2
ISO 14982:2009 EN 301 489-20:V1.2.1
ISO 13309:2010 EN 50581:2012

Conformity PL641
Table 94
CATE RPILLAR ®
the Community

Tel: 32(0) 71.25.97.03 / Mob: 32(0) 499.85.97.03
Brand: Product Link
(continued)
214 SEBU9084-11
Operation Section
Product Link
(Table 94, contd)

440-2104 (internal antenna)
Model: PL641
440-2105 (external antenna)

EN 60950-1:2006+A12:2011 EN 301 489-1:V1.9.2: 2011

EN 301 511: v9.0.2 EN 301 489-3:V1.4.1:2002
EN 300 440-2:V1.4.1:2010 EN 301 489-7:V1.3.1:2005
EN 301 908-1:V5.2.1 and V6.2.1 EN 301 489-24:V1.5.1:2010
EN 301 908-2:V5.2.1 and V6.2.1 EN ISO 14982:2009
EN 62311:2008 EN 13309:2010
ISO 13766:2006 EN 50581:2012

SEBU9084-11 215
Operation Section
Engine Starting
Engine Starting 3. Before the engine is started, check for the

presence of bystanders or maintenance
personnel. Ensure that all personnel are clear of
i06592790
the machine. Briefly sound the forward horn before
you start the engine.
Engine Starting
SMCS Code: 1000; 7000 4. Move the engine speed control knob to low idle.
5. Turn the engine start switch key to the ON position.
On machines equipped with the Standard Display,
wait for the cold starting aid alert indicator light to
Do not use aerosol types of starting aids such as go out. On machines equipped with the Advanced
ether. Such use could result in an explosion and Display, wait for the LCD display to load the
personal injury. Welcome screen. On any machine with security
Refer to Operation and Maintenance Manual, Cold- enabled, enter a valid PIN. Refer to Operation
Weather Requirementsto prepare the machine for Maintenance Manual, “Operator Controls, Right
operation in temperatures that are below 0 °C Side Controls” for more information on the Anti-
(32 °F). Follow the appropriate warm-up procedures Theft Security System.
when the machine is operated in temperatures that
are below 0 °C (32 °F). 6. Turn the engine start key to START position in
order to start the engine. Release the key after the
Machine preparation for cold weather includes using engine has started.
the correct hydraulic system oil. The factory fills the
hydraulic system with 10W hydraulic oil which has a Note: If the machine is equipped with the optional
minimum operating temperature of −20 °C (−4 °F). If Selectable Control Pattern feature, a control pattern
the machine will be operated at temperatures below must be selected before the parking brake can be
−20 °C (−4 °F), the 10W oil must be replaced with
0W30 hydraulic oil in order to provide the proper oil disengaged. Refer to Operation and Maintenance
viscosity. Refer to Operation and Maintenance Manual, “Operator Controls, Left Side Controls, and
Manual, “Lubricant Viscosities and Refill Capacities”. Operator Controls, Joystick Controls” for more
Refer to Operation and Maintenance Manual, information on the Selectable Pattern Control switch
SEBU5898, “Cold-Weather Recommendations for and available joystick control patterns.
Caterpillar Machines”. Refer to Operation and
Maintenance Manual, SEBU6250, “Caterpillar 7. Disengage the parking brake.
Machine Fluids Recommendations”.
8. Run the engine for 5 minutes before performing
NOTICE the following procedure. Run the engine at half
Keep the engine speed low until the engine oil pres- throttle. Hold the work tool joystick control in the
sure alert indicator goes out. If the alert indicator TILT BACK position for 30 seconds. Release the
does not go out within ten seconds, stop the engine control for 30 seconds. Hold the work tool joystick
and investigate the cause before starting again. Fail- control in the DUMP position for 30 seconds.
ure to do so can cause engine damage.
Release the control for 30 seconds. Perform the
procedure for 3 minutes.
NOTICE Note: If you are operating the machine below 0 °C
If the engine fails to start after 10 seconds, disengage
the starter. Wait 30 seconds and repeat the proce- (32 °F), perform the procedure for 8 minutes.
dure. Do not allow the starter motor to run continu-
ously for more than 20 seconds. NOTICE
Do not use the hydraulic interlock override function to
warm up the machine.
NOTICE
If you fail to follow the steps described below, dam-
age to the engine or damage to the hydraulic system 9. Keep all personnel away from the machine. Move
may occur. the machine slowly to an open area. Repeat Step
8 as you move the machine back and forth for 3 m
1. Fasten the seat belt. (10 ft).
2. Pull the armrests downward. Note: More warm-up time may be required if the
hydraulic functions are sluggish.
216 SEBU9084-11
Operation Section
Engine Starting
Cold-Weather Requirements
Machine preparation for cold weather includes using
the correct hydraulic system oil. The factory fills the
hydraulic system with 10W hydraulic oil which has a
minimum operating temperature of −20° C (−4° F). If
the machine will be operated at temperatures below
−20° C (−4° F), the 10W oil must be replaced with
0W30 hydraulic oil in order to provide the proper oil
viscosity. Refer to Operation and Maintenance
Manual, "Lubricant Viscosities and Refill Capacities".
Refer to Operation and Maintenance Manual, “Cold-
Weather Recommendations for Caterpillar Machines”
SEBU5898. Refer to Operation and Maintenance
Manual, “Caterpillar Machine Fluids
Recommendations”SEBU6250.
Refer to the following table for requirements and
recommendations for the engine when operating
below −18° C (−0° F)
Table 95
Cold-Weather Engine Requirements and Recommendations
Required Recommended
-18°C to -32° -32°C to -40° -18°C to -40°C (0°F to

Standard Factory Configura- Serial Num-
Models Engine C C (-25°F to -40°F)
tion (1) ber Ranges
(0°F to -25°F) -40°F) (0°F to -40°F)
226D 232D Demand Fan SAE Engine Block Heater

All
239D 249D 10W -30 Engine Oil #1 Diesel or Anti-Gel
SAE 0W -40
C2.2 Additive
CCB Inlet Line Heater (2) HRD , DPR, Engine Oil Insulated CCB Battery Disconnect
BL9, GWR Kit (2) Switch Kit
236D 242D Demand Fan SAE Door Jacket Engine Block Heater
All
246D 257D 10W -30 Engine Oil Kit #1 Diesel or Anti-Gel
259D 262D Additive
277D 279D CCB Inlet Line Leader (2) BGZ, DZT , SAE 0W -40 Battery Disconnect
C3.3B Insulated Breather Lines (2) EZW, FTL, CCB Outlet
287D 289D Engine Oil Switch Kit
Insulated Breather Canister (2) BYF, DTB, Line Heater 1000 CCA Battery
FMT, GTL, Kit
HMT, TAW
272D2 Demand Fan SAE Engine Block Heater

272D2XHP 10W -30 Engine Oil #1 Diesel or Anti-Gel
297D2 CCB Inlet Line Heater (2) SAE 0W -40 Door Jacket Additive
C3.8 All
297D2XH- CCB Outlet Line Heater (2) Engine Oil Kit Battery Disconnect
P299D2 Insulated Breather Lines (2) Switch Kit
299D2XHP Insulated Breather Canister 1000 CCA Battery
(1) The Standard factory configuration is subject to change over time. Verify that your machine is properly equipped for the expected lowest am-
bient conditions prior to operating.
(2) Use of the Closed Circuit Breather (CCB) is governed by local emissions regulations. Your machine may not require this system nor the asso-
ciated ambient protection components listed above. Consult your Cat Dealer for additional information.
SEBU9084-11 217
Operation Section
Engine Starting
Reference: Refer to the Machine Price List for the Cold Engine Elevated Low Idle
appropriate kit part numbers.
(Parked Idle)
Engine Torque Limited During DEF The cold engine elevated low idle feature will slowly
Thawing increase the engine idle speed to a significantly
higher speed when the machine has sat for several
This is only applicable to the models that require minutes with the parking brake is engaged, hydraulic
Diesel Exhaust Fluid (DEF). When the DEF is frozen, lockout is engaged, and interlock override is
there is no DEF circulating to cool the DEF injector. disengaged, and the ambient or engine coolant
To prevent the DEF injector from damage, the engine temperature have fallen below certain temperature
torque is reduced by up to 20%. The message thresholds. This feature is intended to help prevent
"Engine Derate - Protect against cold temperature" certain engine components from damage due to
will appear on the monitoring screen of the Advanced fluids freezing when the machine is left parked in idle.
Display. Once the DEF is thawed, full engine torque This feature will be canceled by the operator when
the parking brake is disengaged, hydraulic lockout is
will return automatically. Refer to the engine's
disengaged, and interlock override is engaged. The
Systems Operation manual, DEF Dosing Control
feature will automatically cancel if the ambient or
System for more information.
engine coolant temperature initiating the response
increase above certain thresholds. This feature
Low System Battery Voltage should not be confused with Diesel Particulate Filter
Regeneration. Refer to "Diesel Particulate Filter
Elevated Low Idle Regeneration" for more information.
The low system battery voltage elevated low idle Note: There may be other machine conditions
feature will immediately raise the low idle engine required to initiate or terminate any of the elevated
speed slightly if the system battery voltage falls low idle modes. Only the primary conditions are listed
below a triggering threshold with the engine speed above.
near low idle. This feature is intended to improve the
reliability of charging system components like the
alternator and battery and help compensate for
increased electrical load resulting from user installed
electrical components. The feature will be canceled
by the operator when the engine speed is raised by
the controls. This feature will automatically cancel if
the system battery voltage rises above a
predetermined threshold.
Cool Engine Elevated Low Idle

(Cold Start)
The cool engine elevated low idle feature will
immediately raise the low idle engine speed slightly if
the machine senses an ambient temperature or
engine coolant temperature below certain thresholds
while the parking brake is engaged, hydraulic lockout
is engaged, and interlock override is disengaged.
This feature is primarily associated with cold startup
and is intended to accelerate the warmup of the
engine and fluids and improve white smoke cleanup.
The feature will be canceled by the operator when
the parking brake is disengaged, hydraulic lockout is
disengaged, and interlock override is engaged, or the
engine speed is raised by the controls. The feature
will automatically cancel if the ambient and engine
coolant temperatures increase above certain
thresholds.
218 SEBU9084-11
Operation Section
Operation
Operation
i06135016
Operation Information
SMCS Code: 7000
Fueling the Machine
Ultra Low Sulfur Diesel (ULSD) poses a greater

static ignition hazard than earlier diesel formula-
tions, with a higher Sulfur content, which may re-
sult in a fire or explosion. Consult with your fuel
or fuel system supplier for details on proper
grounding and bonding practices.
To avoid possible injury or death, do not smoke

while in an area that contains flammable liquids.
All fuels, most lubricants, and some coolants are
flammable.
Keep all fuels and lubricants stored in properly
marked containers and away from unauthorized
persons.
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire.
Store all oily rags or other flammable materials in
a protective container in a safe place.
Remove all flammable materials such as fuel, oil,
and other debris before they accumulate on the Illustration 156 g03821167
machine.
Do not expose the machine to flames, burning Fuel cap may be hot. To avoid injury, use personal
brush, etc., if at all possible. protective equipment. Allow the cap to cool before
fueling the machine.
The fuel fill may either be located inside the engine
compartment on the right hand side or outside the General Information
machine at the left rear corner of the frame. Replace
the fuel cap and lock into place after fueling the To prevent injury, make sure that no people are
machine. working on the machine or near the machine. To
prevent injury, keep the machine under control at all
times.
Reduce engine speed when you maneuver in tight
quarters or when you are going over a hill.
1. Adjust the operator seat.
2. Fasten the seat belt.
3. Lower the armrests.
SEBU9084-11 219
Operation Section
4. Start the engine and allow the machine to warm Note: While you use steel tracks that go over the
up. Refer to Operation and Maintenance Manual, tires, the work tools may not engage the work tool
“Engine Starting”. coupler properly. Work tools may not properly
engage the ground. Steel tracks that go over the
5. Disengage the parking brake. tires should only be used with pneumatic tires.
The loader arms may contact the steel tracks which
6. Raise all lowered work tools and attachments in
may damage to the machine. When you use steel
order to negotiate any obstacles.
tracks that go over the tires, the interval for checking
7. Smoothly move the speed and direction control for the drive chains should be reduced to every 100
the desired direction and speed. Service Hours. Refer to Operation and Maintenance
Manual, “Drive Chain Tension - Check/Adjust” for
To prevent injury, make sure that no people are proper service of the drive chain. The use of rubber
working on the machine or near the machine. To tracks that go over the tires is not recommended.
times.
Operating on a Slope
Do not allow the machine to overspeed when you go
downhill. Move the joystick toward the NEUTRAL When necessary to travel across a slope, never
position in order to reduce the speed of the machine exceed a slope that is greater than 3 to 1 (18.4°).
when you are going downhill. For additional
information, refer to “Operating on a Slope”. When possible, avoid operating the machine across
a slope. When possible, operate the machine up a
Always put the heaviest end of the machine uphill slope and down a slope. Never exceed a slope that is
when you are working on an incline. greater than 25 degrees for continuous fore/aft slope
operation and 35 degrees intermittent fore/aft
Fully lower the loader arms onto the stops when you operation. The engine has an intermittent rating of 2
are digging with the machine. Digging with the loader minutes. Do not turn the machine while you are
arms in the fully lowered position will transfer the operating on a slope.
stress that is placed on the loader arm into the frame.
NOTICE
NOTICE When it is necessary to operate the machine on a
The use of this machine in certain applications can slope, keep bucket loads light in order to decrease
cause premature wear and/or failure of the tracks. the possibility of derailing the tracks.
Applications that may cause premature wear and/or
failure of the tracks include: use in rocky terrain, use
in gravel, use in concrete demolition and use in ter- NOTICE
rain where metal debris is present. If the correct method for turning is not followed, the
tracks may derail.
Damage to the tracks that is caused from using the
machine in these conditions is not covered under
warranty. When necessary to travel across a slope, the
following steps should always be followed:
Avoid any situation that causes the tracks of the
machine to spin on the ground. Avoid spinning the
tracks in order to extend the life of the track.
220 SEBU9084-11
Operation Section
2. Position the machine so that the front of the

machine faces the direction for travel that is
desired.
Operating on a Transition
NOTICE
Avoid operating this machine on transitions. Operat-
ing this machine on transitions may cause the tracks
to derail.
When the machine is operated on a transition, the
tracks may not be supported fully.
1. Stop the machine. Turn the machine slowly while
you are backing down the slope. When the tracks are not supported fully, the wheels
may ride on top of the drive lugs of the tracks. The
Note: Do not back up a hill in order to turn. track will derail if you continue to travel on the
transition.
SEBU9084-11 221
Operation Section
Work Tool Coupler Operation
If you must travel on a transition, travel the machine

at 90° to the transition. Do not perform hard turns or
fast turns when you are operating the machine on the
transition.
Counterrotate turn
For maximum life of the undercarriage, use more
gradual turns while you slowly move forward or
reverse. Gradual turns will help minimize wear on the
track and wear on the wheels. Only use counterrotate
turns, if necessary. Sharp turns will increase the wear
on the components of the undercarriage.
i06849747

SMCS Code: 6129; 7000 2. If the machine is equipped with a manual quick
coupler, ensure that the levers(1) for the coupler
are in the DISENGAGED position. If the machine
is equipped with an electrical or hydraulic quick
Improper Attachment of the Work Tool could re- coupler, refer to Operation and Maintenance
sult in injury or death. Manual, “Operator Controls” for details on the
location and the operation of the coupler control.
that the coupler pins are fully engaged. Follow 3. Enter the machine.
Maintenance Manual. 4. Fasten the seat belt and lower the armrests.
5. Start the engine.
Attaching the Work Tool 6. Disengage the parking brake.

7. Tilt the quick coupler assembly forward.
Note: Before you install the work tool, inspect the
coupler and the work tool mounting bracket for any
wear or for any damage. Ensure that the work tool
mounting bracket and the face of the coupler are
clean. Ensure that the coupler has no accumulation
of material. Refer to Operation and Maintenance
Manual, “Quick Coupler - Clean/Inspect” and
Operation and Maintenance Manual, “Work Tool
Mounting Bracket - Inspect” for inspection
procedures.
1. Position the work tool on a level surface. Move the

hydraulic lines (if equipped) for the work tool and
electrical lines (if equipped) away from the work
tool mounting bracket.
222 SEBU9084-11
Operation Section
12. Engage the coupler pins(3). If the machine is

equipped with a manual quick coupler, ensure that
the levers(1) for the coupler are in the ENGAGED
position. If the machine is equipped with an
Illustration 160 g01278223 electrical or hydraulic quick coupler, refer to
Operation and Maintenance Manual, “Operator
8. Align the quick coupler assembly (6) between the Controls” for details on engaging the coupler pins.
outer plates (5) of the mounting bracket. Move the
13. If the work tool requires hydraulics, refer to the
quick coupler assembly under the angled plate (4)
following procedure to connect the hydraulic
of the mounting bracket and rack back the work
hoses.
tool.
9. Fully lower the loader arms.
Improper attachment of the work tool could result

in injury or death. If the work tool touches the
ground, the work tool may move away from the
coupler. Do not allow the work tool to touch the
ground until the coupler pins are fully engaged.
10. Turn the engine start switch key to the OFF

position to stop the engine.
11. Exit the machine.
Note: If you are installing a material handling arm
that is not equipped with the optional center step, do
not exit the machine. A second person needs to
perform steps 12 through step 14.
a. Route the hydraulic hoses through the hose

guide on the machine to prevent damage to the
hoses. Not all work tools require the hydraulic
hoses to be routed through the hose guide. The
work tool Operation and Maintenance Manual
will inform you if the hydraulic hoses need to be
routed through the hose guide. Cat work tools
SEBU9084-11 223
Operation Section
require the hoses to be routed through the hose

guide.
b. Ensure that the quick connect couplers are

clean. Visually inspect the couplers for
corroding, cracking, damage, or excessive wear.
Replace the couplers if necessary.
c. Release the system pressure that may be

stored in the machine's hydraulic lines. If the
machine is equipped with connect-under-
pressure style couplings, push the face of the
coupling inwards (towards machine) and hold
for 5 seconds. This may also be accomplished
by pushing the couplers of the machine and
work tool together to displace the machine's
coupling face. Alternatively, the machine system
pressure may be released by operating the
auxiliary hydraulic controls in each direction
several times when the following conditions are
met: operator is in the seat with the armrests
down, the engine key start switch is in the ON
position, and the parking brake has been
released.
d. Connect the auxiliary hydraulic hoses for the
work tool to the machine. Refer to section in this
Operation and Maintenance Manual, Operator
Controls, Joystick Controls, Auxiliary Hydraulic
Controls for a complete explanation on the
machine's hydraulic and electrical outputs. Full
connection is made when the sleeve of the
female coupler slides forward.
e. If the work tool is equipped with electrical lines, (3) Coupler Pins
then route the electrical lines with the hydraulic (4) Manual Work Tool Coupler
(5) Electric or Hydraulic Work Tool Coupler
hoses. Connect the wire harness to the (6) Lever for the Coupler Pin
electrical connector (EC) on the host machine.
Check the connections in order to ensure that 14. Visually ensure that both coupler pins (3) are
the connections are properly secured. Check extending out of the holes in the work tool
the connections on the work tool to ensure that mounting bracket.
the connections are in the correct receptacle.
15. Use the following procedure to verify engagement
Note: If your High Flow work tool does not have a of the coupler pins.
wiring harness, a Jumper Plug should be installed
on the electrical plug for the work tool control. a. Enter the machine.
Without this Jumper Plug, the machine will not
provide high flow to the work tool. Consult your Cat b. Fasten the seat belt and lower the armrests.
dealer for the current part number for the Jumper
Plug. c. Start the engine.
d. Disengage the parking brake.

f. If the work tool is equipped with a water line,
then connect the water line from the work tool to e. Raise the work tool off the ground.
the connector on the machine. Move the water
line to a position that is away from the work tool f. Visually inspect the coupler pins (3) to ensure
mounting bracket. that the pins are fully extended through the work
tool.
224 SEBU9084-11
Operation Section
g. Visually inspect the lever (6) that holds the 6. Release the system pressure that may be stored in
coupler pins to ensure that the lever is in the the machine's hydraulic lines. If the machine is
proper position. equipped with connect-under-pressure style
couplings, push the face of the coupling inwards
h. Activate the tilt control to tilt the work tool (towards machine) and hold for 5 seconds. This
downward. may also be accomplished by pushing the
i. Apply down pressure on the work tool. couplers of the machine and work tool together to
displace the machine's coupling face.
Note: The work tool Operation and Maintenance Alternatively, the machine system pressure may
Manual will inform you if forward pressure should be released by operating the auxiliary hydraulic
not be applied on a work tool. controls in each direction several times when the
following conditions are met: operator is in the
j. Move the machine backward. Ensure that the seat with the armrests down, the engine key start
coupler pins do not disengage from the work switch is in the ON position, and the parking brake
tool. has been released.
16. Test the work tool for leaks and for proper 7. Retract the coupler sleeve to disconnect the
operation. coupler. Disconnect the auxiliary hydraulic hoses
from the machine.
Removing the Work Tool
Note: If protective caps are available, install
protective caps over the quick connect couplers.
8. If hoses are routed through the hose guide,

Disengaging the coupler pins will release the remove the hoses from the hose guide. Move the
work tool from control of the operator. hoses to a position that is away from the work tool
Serious injury or death may result from disengag- mounting bracket.
ing the work tool when it is in an unstable posi-
tion or carrying a load. Note: Connect the hoses for the work tool together.
Connecting the hoses together will reduce the
Place the work tool in a safe position before dis- probability of contaminating the hydraulic system.
engaging the coupler pins. Connecting the hoses together will reduce the
buildup of pressure in the hoses. Connecting the
hoses together will ease the connection of the hoses
NOTICE to the machine.
Auxiliary hoses for work tools must be disconnected
before the Hydraulic Quick Coupler is disengaged. 9. If the work tool is equipped with an electrical line,
then disconnect the wire harness from the
Pulling the work tool with the auxiliary hoses could re-
connector on the machine. If protective caps are
sult in damage to the host machine or the work tool.
available, install protective caps over the electrical
connectors.
1. Position the machine on level ground.
10. If the auxiliary electrical line is routed through the
2. Lower the work tool to the ground. hose guide, remove the line from the hose guide.
3. Rack back the work tool until the work tool is Move the auxiliary electrical line to a position that
slightly off the ground. is away from the work tool mounting bracket.
4. Turn the engine start switch key to the OFF 11. If the work tool is equipped with a water line, then
position to stop the engine. disconnect the water line from the connector on
the machine. Move the water line to a position that
5. If the work tool requires hydraulics, the hydraulic is away from the work tool mounting bracket.
system pressure must be released.
12. Exit the machine.
Note: If you are removing a material handling arm
that is not equipped with an optional center step, do
not exit the machine. A second person needs to
perform step 13.
SEBU9084-11 225
Operation Section
13. Disengage the coupler pins. If the machine is If the electric quick coupler fails to function due to
equipped with a manual quick coupler, ensure that loss of machine electrical power, physically dismantle
the levers for the coupler are in the DISENGAGED the actuator or cut through the exposed rod. Insert a
pair of 3/8" square drivers into the square openings
position. If the machine is equipped with an
of the linkage flags and rotate each towards the
electrical or hydraulic quick coupler, refer to centerline of the machine to disengage the work tool
Operation and Maintenance Manual, “Operator retention pins from the work tool.
Controls” for details on disengaging the coupler
pins with the coupler control. If the hydraulic quick coupler fails to function due to
loss of machine electrical or hydraulic power, slightly
14. Enter the machine. open the hydraulic lines at the service connectors
under the lift arm cross member. Provide a means to
15. Fasten the seat belt and lower the armrests. capture any hydraulic fluid in a suitable catch
container. Insert a pair of 3/8" square drivers into the
16. Start the engine. square openings of the linkage flags and rotate each
17. Disengage the parking brake. towards the centerline of the machine to disengage
the work tool retention pins from the work tool. Some
18. As you slowly back away from the mounting later hydraulic quick couplers may be fitted with
bracket, tilt the quick coupler assembly forward backup manual hand levers instead of the square
until the top of the quick coupler assembly clears driver openings. Simply lift these manual levers to
disengage the work tool retention pins.
the angled plate.
19. Back away from the work tool.
Removing the Work Tool if an

Electrical or Hydraulic Quick
Coupler Malfunctions
Disengaging the coupler pins will release the

work tool from control of the operator.
Serious injury or death may result from disengag-
ing the work tool when it is in an unstable posi-
tion or carrying a load.
Place the work tool in a safe position before dis-
engaging the coupler pins.
NOTICE
Auxiliary hoses for work tools must be disconnected
before the Hydraulic Quick Coupler is disengaged.
Pulling the work tool with the auxiliary hoses could re-
sult in damage to the host machine or the work tool.
Note: The electrical or hydraulic quick coupler only

work while the ENGINE IS RUNNING. The hydraulic
quick coupler only works when the hydraulic
interlocks are made and the machine has hydraulic
power.
Using suitable blocking material, block the machine
to ensure it does not move unexpectedly.
226 SEBU9084-11
Operation Section
Material Handling Arm Operation
i01964204

Operation
SMCS Code: 6542; 6700; 7000

(1) Location of Optional Center Step
(2) Tie-Down Point
(3) Lifting Point 2
(4) Shackle
(5) Hook Clasp
(6) Hook
(7) Lifting Point 1
(8) Stored location of Position Lock Pin
Inspect the material handling arm and the

Illustration 165 g03653014 attachments for wear and damage. Ensure that the
with 3/8" square driver rotate towards centerline load is properly attached to the material handling arm
before you operate the machine.
Note: The physical size and the weight of the load

determines the lifting point that is appropriate.
Whenever it is possible, use the lifting point 1. This
will improve the stability and this will reduce the
movement of the load. Refer to the Operation and
Maintenance Manual, “Material Handling Arm Rated
Load” for the limitations on the weight.
Note: Use only Caterpillar 9V-2714 Hook and
Caterpillar 9V-2715 Shackle to attach a load to the
material handling arm. Never use an open hook. Use
a line that is rated for 2.5 times the weight of the load.
Do not allow anyone to be near a suspended load

unless the position lock pin is installed. If the lift
arms must be raised to handle a tall load, do not
allow anyone to be near the suspended load un-
less the lift arms are blocked. Failure to follow the
instructions or heed the warnings could result in
injury or death.
SEBU9084-11 227
Operation Section
Two Person Operation

Attaching A Load
1. Verify that the load does not exceed the weight
limit. Refer to the Operation and Maintenance
Manual, “Material Handling Arm Rated Load” for
the rated load capacities.
2. Keep all personnel out of the work area at all
times, except when you are attaching or removing
a load.
3. Enter the machine. Start the engine.
4. Disengage the parking brake.
14. Wait as the second person installs the position

lock pin through the hole in the material handling
arm and the hole in the loader arm of the machine.
Note: This will prevent the material handling arm

from tilting forward.
15. Wait as the second person secures the load to

Illustration 167 g01020534 the tie-down points with a suitable line in order to
minimize load swing.
5. Keep the loader arms in the fully lowered position.
Slowly position the material handling arm until Note: Do not move the load when you are securing
either lifting point 1 or the lifting point 2 is directly the load. Do not pull the load toward the material
above the load. handling arm when you are securing the load to the
tie-down points.
6. Tilt the material handling arm forward until the
hook is slightly higher than the load in order to 16. Wait as the second person removes the position
minimize swinging of the load. lock pin. Wait as the second person places the pin
in the STORED position on the material handling
7. Stop the engine.
arm.
8. Wait as the second person attaches the load
securely to the hook. The second person needs to Removing a Load
ensure that the hook clasp is in the locked
position. 1. Slowly tilt back the material handling arm until the
material handling arm is fully tilted back. Lower the
9. Ensure that ALL personnel have left the work area. loader arms fully.
10. Start the engine. 2. Stop the engine.
11. Disengage the parking brake. 3. Wait as the second person installs the position lock
12. Slowly tilt back the material handling arm until the pin through the hole in the material handling arm
material handling arm is fully tilted back. and the hole in the loader arm of the machine.
13. Stop the engine. 4. Wait as the second person removes the line that
secures the load to the tie-down points.
228 SEBU9084-11
Operation Section
5. Wait as the second person removes the position

lock pin. Wait as the second person places the pin
in the STORED position on the material handling
arm.
6. Remove all personnel from the work area.
9. Lower the load to the ground.
10. Stop the engine.
11. Wait as the second person removes the load from
the hook.
12. Remove all personnel from the work area.
13. Start the engine. 5. Keep the loader arms in the fully lowered position.
Slowly position the material handling arm until
14. Disengage the parking brake. either lifting point 1 or lifting point 2 is directly
15. Slowly tilt back the material handling arm until the above the load.
material handling arm is fully tilted back. 6. Tilt the material handling arm forward until the
16. Back away from the load. hook is slightly higher than the load in order to
minimize swinging of the load.
One Person Operation 7. Stop the engine. Exit the machine.
Note: The material handling arm must be equipped 8. Attach the load securely to the hook. Ensure that
with a center step in order to do the one person the hook clasp is in the LOCKED position.
operation.
9. Keep all personnel out of the work area.
Attaching the Load 10. Enter the machine. Start the engine.
1. Verify that the load does not exceed the weight 11. Disengage the parking brake.
limit. Refer to the Operation and Maintenance 12. Slowly tilt back the material handling arm until the
Manual, “Material Handling Arm Rated Load” for material handling arm is fully tilted back.
the rated load capacities.
13. Stop the engine. Exit the machine.
2. Keep all personnel out of the work area at all
times, except when you are attaching or removing
a load.
SEBU9084-11 229
Operation Section
Pallet Forks Operation
9. Lower the load to the ground.

Note: Make sure that the load is stable.
11. Remove the load from the hook.

15. Slowly tilt back the material handling arm until the
material handling arm is fully tilted back.
16. Back away from the load.
Traveling with a Load

1. Ensure that all personnel have left the work area.
14. Install the position lock pin through the hole in the 4. Raise the load so that the load is slightly off of the
material handling arm and the hole in the loader ground.
arm of the machine.
5. Slowly travel to the destination. Keep the load as
15. Secure the load to the tie-down points with a close to the ground as possible. Travel up slopes
suitable line in order to minimize load swing. with the load uphill. Travel down slopes with the
load uphill. Do not travel across slopes.
Note: Do not move the load when you are securing
the load. Do not pull the load toward the material i01878348
handling arm when you are securing the load to the
tie-down points.
Pallet Forks Operation
16. Remove the position lock pin and place the pin in SMCS Code: 6700; 7000
the STORED position on the material handling
arm.
Removing a Load
1. Fully tilt back the material handling arm. Fully
lower the loader arms.
3. Install the position lock pin through the hole in the
loader arm of the machine.
4. Remove the line that secures the load to the tie-
down points .
5. Remove the position lock pin and place the pin in
the STORED position on the material handling Illustration 171 g00955937
arm. The “type 1” pin that is in the UNLOCKED position (2)
and the LOCKED position (1).
230 SEBU9084-11
Operation Section
Angle Blade Operation
i02955359
Angle Blade Operation

SMCS Code: 6060; 7000

The “type 2” pin that is in the UNLOCKED position (1)
and the LOCKED position (2).
1. Put the fork tines in the UNLOCKED position.

Space the fork tines as far as possible from each
other.
2. Put the fork tines in the LOCKED position.
3. Slowly, move the machine into position and
engage the load. The machine should be square
with the load. Space the forks evenly between the
pallet stringers.
4. Move the machine forward until the load contacts
the carriage.
5. Lift the load carefully.
6. Slowly, move the machine in reverse until the load
is clear enough to lower.
7. Carefully lower the load while you tilt the forks
back to the travel position.
Travel with the load as low as possible while you still
maintain ground clearance.
Travel with the load uphill on upgrades and on
downgrades.

(1) Springs
(2) Blade
(3) Pivot pin for the blade
(4) Locking pin
(5) Vertical pivot pin
(6) Bolts for adjusting height
(7) Shims
Height Adjustment
In order to properly adjust the height of the blade, use
the following procedure:
SEBU9084-11 231
Operation Section
Work Tool Operation
2. Position the blade so that the vertical pivot pin (5) Note: All of the work tool functions that are described
is in the VERTICAL position. below are viewed as the operator seated in the
machine.
3. Move the angle of the blade fully from one side to
the other side. The blade cutting edge should Operate the machine and the work tool slowly in an
remain parallel to the ground. open area. Check for proper operation of all controls
and all protective devices on the machine and the
4. If the blade cutting edge does not remain parallel work tool.
to the ground, the height of the blade needs to be
Note: During initial operation, unexpected motion
adjusted. Use the following steps in order to adjust
may occur due to air in the hydraulic system. Cycle
the height: the hydraulic system approximately five times in
order to purge air out of the circuit. You may need to
a. Lower the blade and the frame onto adjustable
add hydraulic oil to the machine after the machine
stands. fills the hydraulic circuits of the work tool. Refer to
b. Stop the engine and remove the ignition key. Operation and Maintenance Manual, “Hydraulic
System Oil Level - Check” for the proper procedure
c. Remove the bolts (6) for adjusting the height. for checking the hydraulic oil level.
d. Move the frame to the desired height.
e. Ensure that the shims are installed. Install the

bolts for adjusting the height. Tighten the bolts
to a torque of 270 ± 40 N·m (199 ± 30 lb ft).
f. In order to test the adjustment, start the engine.
g. Repeat steps 2 and 3.
Tilt Lock
The angle blade has two modes of operation:
• Locked
• Spring load trip
In order to lock the blade, install the locking pin (4). In
the LOCKED position, the blade can be used for
heavy operations. The blade will not tilt with the
locking pin in the LOCKED position.
There may be lighter operations that allow the blade
to tilt. Remove the locking pin and store the locking
pin in the cab. This will help prevent damage to the
blade or to the frame. If the plowing overcomes
306 kg (675 lb) of spring force, the top of the blade
will tilt forward.
i06134334
For all High Flow work tools, refer to Operation and
Work Tool Operation Maintenance Manual, “Joystick and Auxiliary
Hydraulic Controls”. Connect the wiring harness to
SMCS Code: 6700; 7000 the electrical plug (E).
The following table describes the functionality of Note: If your High Flow work tool does not have a
approved Cat work tools. wiring harness, a Jumper Plug should be installed on
the electrical plug (E) for the work tool control.
Refer to Operation and Maintenance Manual, Without this Jumper Plug, the machine will not
“Operator Controls, Joystick Controls, and Operator provide High Flow to the work tool. Consult your Cat
Controls, Auxiliary Hydraulic Controls” for the
location and operation of the joystick controls that are for the correct part number for your machine.
referenced below.
232 SEBU9084-11
Operation Section
Work Tool Operation
Simple Hydromechanical Work

Tools
Work tools in the following table are approved by Cat.
“Operator Controls, Joystick Controls, and Operator
Controls, Auxiliary Hydraulic Controls” for the
location and operation of the joystick controls that are
referenced in the table.
Read the manual and understand the instructions
and warnings in the Operation and Maintenance
Manual for these work tools. Consult your Cat dealer
for replacement manuals. Proper care is your
responsibility.
Table 96
Operation of Cat Simple Hydromechanical Work Tools
Work Tool Actions

Aux5 C2 Aux6 C1 Aux1 A1 Aux2 A2 Aux3 C- Aux4 C+ Aux 7
Multipurpose Bucket X The bucket clam closes.
X The bucket clam opens.
All Grapple tools X The grapple closes.
X The grapple opens.
Angle Blade X The blade angles to the

left.
X The blade angles to the
right.
Dozer Blade X The blade angles to the

left.
X The blade angles to the
right.
X X The blade tilts down to

the left.
the right.

the left and the blade an-
gles to the left.

the right and the blade
angles to the right.
Proper operation of the work tool is your • Remove the work tool from the machine before
responsibility. Do not use the work tool improperly. you lift the host machine. Refer to Operation and
Maintenance Manual, “Lifting and Tying Down the
Please follow the instructions that are listed below in Machine” for details.
order to use the grapple tools safely.
• Do not pry with one rake tine. Use multiple rake
tines in order to loosen material.
SEBU9084-11 233
Operation Section
Work Tool Operation
• Do not place the weight of the host machine on the

grapples in the open position.
Complex Hydromechanical Work

Tools
Note: For the functionality of Cat Complex Work
Tools, please read the Operation and
Maintenance Manual for the work tool.
Consult your Cat dealer for replacement manuals.
Please read all the safety messages and understand
all the safety messages for each work tool.
234 SEBU9084-11
Operation Section
Parking
Parking i05757869
i05757850
Stopping the Engine if an
Electrical Malfunction Occurs
Stopping the Engine SMCS Code: 1000; 7000
SMCS Code: 1000; 7000
Inside Cab
NOTICE
Stopping the engine immediately after it has been
working under load, can result in overheating and ac-
celerated wear of the engine components.
Refer to the following procedure, to allow the engine
to cool, and to prevent excessive temperatures in the
turbocharger housing (if equipped), which could
cause oil coking problems.
1. Operate the engine for 5 minutes at low idle with

no load.
Note: This operation allows hot areas in the engine
to cool gradually. This operation will extend the
engine life.
2. Move the joysticks to the NEUTRAL position.

position.
The fuse panel is located behind the seat on the right

side.
Remove the cover in order to access the fuse panel.

SEBU9084-11 235
Operation Section
Equipment Lowering with Engine Stopped
Note: Do not operate the machine until the

malfunction has been corrected.
i06135052
Equipment Lowering with

Engine Stopped
SMCS Code: 6700; 7000
Personal injury or death can result from a work

tool falling.
Keep personnel away from the front of the ma-
chine when lowering the work tool.
Before lowering any equipment with the engine

stopped, clear the area around the equipment of all
personnel. The procedure will vary with the type of
equipment that is lowered. Keep in mind that most
systems use a high-pressure fluid or air in order to
raise or lower the equipment. The procedure will
cause high-pressure air, hydraulic fluid, or some
other media to be released in order to lower the
equipment. Wear appropriate personal protective
equipment and follow the established procedure in
the Operation and Maintenance Manual, “Equipment
Lowering with Engine Stopped” in the Operation
Section of the manual.
Lowering the Equipment with the

Accumulator Charged
If electrical power is available and the accumulator is
charged, the loader arms can be lowered from the
operator station with the work tool control.
1. Fasten the seat belt. Lower the armrests.
2. Move the engine start switch to the ON position.
Illustration 177 g03654885 Press the parking brake switch and release the
Engine ECM fuse parking brake switch.
Remove the Engine ECM fuse in order to stop the Note: The parking brake indicator will remain
engine. illuminated since the engine is not running. When the
indicator for the work tool is no longer illuminated, the
pressure can be released.
3. Slowly move the work tool control to the LOWER

position in order to slowly lower the loader arms.
If the loader arms do not lower, the accumulator is
not charged. It is possible to recharge the
accumulator by cranking the engine for 15 seconds.
Repeat step 2 and 3.
236 SEBU9084-11
Operation Section
Equipment Lowering with Engine Stopped
If there is no electrical power the loader arms must

be lowered by using the procedure that is explained
next.
Alternate Lowering the Equipment
Personal injury can result from oil under high

pressure.
DO NOT allow high pressure oil to contact skin.
Wear appropriate protective equipment while
working with high pressure oil systems.
The loader arms must be lowered manually if the

accumulator is not charged or if there is no electrical
power.
Do not go under the raised lift arm without the brace
for the loader lift arm in the LOCKED position.
Note: Make sure that there are no people near the
front or sides of the machine. Type 2 Roof-mounted Finger Latch
The bypass valve (Dead Engine Lower) may be

located either on the left side next to the seat in the
cab (Type 1) or overhead on the underside of the cab
roof (Type 2).

Film located next to the red handle (Type 1) or icon
molded into the finger latch (Type 2).
Type 1 Pull Handle near Seat. Type 1 Actuation
1. Slide the seat forward. Slide the left-hand armrest
forward.
2. Pull up on the red handle. Push the handle in order
to stop the loader arms, if necessary.
3. Allow the loader arms to lower until the work tool is
on the ground.
4. Push the red handle to the original position.
SEBU9084-11 237
Operation Section
Leaving the Machine
5. Make the necessary repairs before you operate If the engine will not be started for several weeks, the
the machine. lubricating oil will drain from the cylinder walls and
from the piston rings. Rust can form on the cylinder
Type 2 Actuation liner surface. Rust on the cylinder liner surface will
cause increased engine wear and a reduction in
engine service life.
1. Pull down on the finger latch. Release the finger
latch in order to stop the loader arms, if necessary. To help prevent excessive engine wear, use the
following guidelines:
on the ground. • Complete all of the lubrication recommendations
that are listed in this Operation and Maintenance
3. Release the finger latch.
Manual, “Maintenance Interval Schedule”
4. Make the necessary repair before you operate the (Maintenance Section).
machine.
• If freezing temperatures are expected, check the
cooling system for adequate protection against
i05339858
freezing. See this Operation and Maintenance
Manual, “Refill Capacities and Recommendations”
Leaving the Machine (Maintenance Section).
SMCS Code: 7000
If an engine is out of operation and if use of the
Refer to Operation and Maintenance Manual, engine is not planned, special precautions should be
“Parking” for details about stopping the engine and made. If the engine will be stored for more than 1
lowering the equipment. month, a complete protection procedure is
recommended.
The use of a wheel chock & warning triangles may be
required when you leave the machine at the side of For more detailed information on engine storage, see
the road in Germany. Special Instruction, SEHS9031, “Storage Procedure
For Caterpillar Products”.
i05354436 Your Cat dealer can assist in preparing the engine for
extended storage periods.
Machine Storage Procedure
SMCS Code: 7000
NOTICE
If long-term storage for time exceeding 1 year is nec-
essary, contact your local Caterpillar dealer for the
preferred procedure to use in your specific case.
This machine may be stored for 1 year or less in a
temperature range of −32 °C (−25.6 °F) to 43 °C
(109.4 °F).
To store machines in ambient temperatures between
−20 °C (−4.0 °F) to 43 °C (109.4 °F), refer to Special
Instructions, SEHS9031, “Storage Procedure for
Caterpillar Products”.
To store machines in ambient temperatures between
−32 °C (−26 °F) and −21 °C (−6 °F), refer to the
following publications and topics:
• Special Instructions, SEHS9031, “Storage

Procedure For Caterpillar Products”
• Operation and Maintenance Manual, SEBU5898,

“Cold Weather Recommendations for Caterpillar
Machines”
238 SEBU9084-11
Operation Section
Transportation Information
Transportation Information 2. When you use loading ramps, make sure that the
loading ramps have adequate length, adequate
width, and adequate strength. In addition, make
i02520157
sure that the surface of the loading ramps are
clean. This will help prevent the machine from
Shipping the Machine sliding in all types of weather conditions. This will
SMCS Code: 7000 allow the machine to move on the ramps smoothly.
Investigate the travel route for overpass clearances. 3. Maintain the slope of the loading ramps within 15
Make sure that there will be adequate clearance. degrees of the ground.
Before you load the machine and before you unload 4. Minimize any step between the base of the loading
the machine remove ice, snow, or other slippery ramps and the ground.
material from the loading dock and from the trailering
surface. Removal of ice, snow, or other slippery 5. Clean the tracks on the machine in order to
material will help prevent the slipping of the machine prevent any slippage.
as you load the machine. Removing ice, snow, or
other slippery material will help prevent the machine
from moving in transit. Loading the Machine
NOTICE 1. Position the machine so that the heaviest end of
Obey all state and local laws governing the weight, the machine is going up the ramps first.
width and length of a load.
2. Use caution when you travel over the areas around
Make sure the cooling system has proper antifreeze the loading ramp joints. Maintain the balance point
if moving machine to a colder climate. of the machine. Keep the work tool low.
Observe all regulations governing wide loads. 3. After you load the machine onto the trailer be sure
that the machine is properly positioned on the
trailer bed.
Do not use a fork lift to lift the machine. Using a fork
lift to move your machine can result in property 4. Lower the work tool to the floor of the transport
damage. vehicle.
Choose the flattest ground when you load the 5. Turn the engine start switch key to the OFF
machine or when you unload the machine. position in order to stop the engine.
6. Turn the engine start switch key to the ON position.
Push the parking brake switch.
7. Move all joystick controls while you are pressing
several times on each side of the auxiliary
hydraulic control (if equipped) in order to relieve
hydraulic pressure.
8. Move all hydraulic controls to the NEUTRAL
position.
position. Remove the engine start switch key.
10. Move the armrests to the RAISED position.
Unfasten the seat belt.
11. Attach any vandalism protection.
1. Before you load the machine chock the trailer
12. Refer to the Operation and Maintenance Manual,
wheels or the rail car wheels. Before you unload
“Lifting and Tying Down the Machine” for
the machine chock the trailer wheels or the rail car
information on tying down the machine.
wheels.
SEBU9084-11 239
Operation Section
Before Roading the Machine
13. Cover the exhaust opening when the machine

has cooled down.
Unloading the Machine

1. Position the machine so that the machine can drive
straight down the loading ramps. Position the
machine so that the heaviest end of the machine
goes down the ramps last.
2. Use caution when you travel over the areas around
the loading ramp joints in order to maintain the
balance point of the machine. Keep the work tool
low.
i06134872

SMCS Code: 7000
Ensure that your machine has a work tool that is
approved for roading. Refer to Operation and
Maintenance Manual, “Caterpillar Approved Work Type 1: All except 226D, 232D, 239D, and 249D
Tools and Work Tool Attachments” for the approved
work tools for roading.
Complete all of the following operations that are
applicable to your machine before you road the
machine.
Rear Lights
1. Verify that all lights are in proper working order.
2. Turn on the roading lights when you are roading
the machine.
Headlights
“Headlights - Adjust” for the proper procedure to
adjust the headlights.
Hydraulic Shutoff
Disable the work tool control, the auxiliary hydraulic
control (if equipped), and the high flow control (if Illustration 183 g03821779
equipped) when you are roading the machine. Refer Type 2: 226D, 232D, 239D, and 249D
to Operation and Maintenance Manual, “Hydraulic
Lockout and Interlock Override” for the procedure. 3. Raise off the lift arms of the lower stop
approximately 30 mm (1.2 inch) for Type 1 models
Lift Arm and 180 mm (7.1 inch) for Type 2 models.
Where required by local regulations, place the lift arm 4. Stop the engine.
and the work tool in the roading position and activate
ride control if equipped.
1. Enter the machine. Fasten the seat belt. Lower the
armrests. Start the engine.
240 SEBU9084-11
Operation Section
9. Raise the armrests. Unfasten the seat belt. Exit the

machine.

Type 1: All except 226D, 232D, 239D, and 249D
10. Insert the locking pin (1) for the coupler through
the tab on the coupler and through the hole (2) in
the lift arm.
11. Secure the locking pin (3) for the coupler with a
cotter pin.
NOTICE
Do not tilt the coupler forward while the locking pin for
the coupler is installed. Damage to the coupler may
result.

Type 2: 226D, 232D, 239D, and 249D
5. Insert the block for the lift arms between the frame
and the lift arm. For Type 1 models, place the lip of
the block over the left hand lower stop. For Type 2
models, thread the guide plate of the right hand
lower stop through the slot in the block.
6. Start the engine. Disengage the parking brake.
7. Slowly lower the lift arm onto the block.
8. Fully tilt back the coupler. Stop the engine.
SEBU9084-11 241
Operation Section
12. Disable the hydraulics for the linkage while the

locking pin for the coupler is installed. Disable the
hydraulics for the linkage with the hydraulic shutoff
control. Refer to Operation and Maintenance
Manual, “Hydraulic Lockout and Interlock
Override” for the procedure.
Mirrors
If necessary, adjust the mirrors.
Portable Warning Light

Where required by local regulations, install the
portable warning light on top of the cab.
Rotating Beacon Light

Where required by local regulations, install the
rotating beacon light on top of the cab. Insert the plug
into the receptacle which is located on the right rear
of the cab.
(1) Rotating Beacon Light
(2) Receptacle
Slow Moving Vehicle Sign

Where required by local regulations, install the slow
moving vehicle sign on the rear of the machine.
Tires
Ensure that your machine has tires that are approved
for roading. Ensure that the tires have the proper
pressure. Refer to Operation and Maintenance
Manual, “"Tire Inflation - Check"”.
Traffic Regulations
Learn and obey all of the traffic regulations when you
are roading the machine.
Work Lights
Turn off all work lights.
242 SEBU9084-11
Operation Section
Prepare the Work Tool

Angle Blade
1. Make sure that the two front roading decals (5) are
properly attached to the guard (1) for the bucket.
Illustration 188 g00718258 Make sure that the side roading decals (4) are
properly attached to the guard for the bucket.
1. Ensure that all roading decals (5) are properly There are a total of four decals on the guard for
attached to the front and side of each of the the bucket.
guards (1) for the Angle Blade. There are a total of
2. Loosen the wing nuts (3) and move the guard for
four decals for the Angle Blade.
the bucket so that the guard fits over the outside
2. Place the guard (1) on the lower corner of the edge of the bucket. Tighten the wing nuts.
blade so that the hole in the blade is aligned with
3. Install the bolts, three washers, plates, and wing
the hole in the guard.
nuts (2) on both side plates of the bucket.
3. Install the bolt, two washers and the wing nut (6).
4. Repeat steps 2 and step 3 on the other end of the
Angle Blade.
5. Install the articulation lock (2) for the angle blade.
Install cotter pin (3) in the end of the articulation
lock.
Buckets
The guard for the buckets is used on both simple
buckets and hydromechanical buckets.
SEBU9084-11 243
Operation Section
Cold Planer Landscape Rake
1. Ensure that all roading decals (5) are properly

attached to both of the guards (1) for the Cold
Planer. There are a total of two decals for the Cold
Planer.
2. Place the guards (1) on the front skid pads so that
the holes in the guards align with the holes in the Ensure that the two front decals (1) are attached to
Cold Planer. Install the bolts, washers, and nuts the Landscape Rake. Ensure that the two side decals
(2). (2) are attached to the Landscape Rake.
3. Install the side shift lock (3) for the Cold Planer. Pickup Broom
4. Install the pivot lock (4) for the Cold Planer.
1. Ensure that all roading decals (3) are properly

attached to the work tool. There are a total of four
decals for the Pickup Broom.
244 SEBU9084-11
Operation Section
After Roading the Machine
2. Place the guards (1) on the front corners of the e. Reverse the installation steps to remove the
broom so that the holes in the guard align with the block for the lift arms. Refer to "Before Roading
holes in the broom. Install the bolts and locknuts the Machine".
(2).
f. Start the engine. Disengage the parking brake.
Note: The guards for the broom can be permanently
installed. The broom can be operated with the guards g. Lower the lift arms all the way.
on the broom. 2. Turn off the roading lights.
Vibratory Compactor 3. Turn off the engine. Remove the locking pin for the
coupler.
Note: In order to remove the locking pin for the
coupler, the coupler may need to be tilted back.
4. Remove all guards and locks for the work tools.

5. Remove beacon light
i05285518
Roading the Machine

SMCS Code: 7000
Limitations for TON-kilometers per hour (TON-miles
per hour) must be obeyed. Consult your tire dealer
Illustration 193 g00716894 for the speed limit of the tires that are used.
Ensure that the two front decals (1) are attached to Ensure that you have the required licenses and other
the Vibratory Compactor. Make sure that the two side similar items with you while you road the machine.
decals (2) are attached to the Vibratory Compactor.
Ensure that your machine is equipped to comply with
roading regulations.
i06598952
Learn and obey all traffic regulations when you are
After Roading the Machine roading the machine. Travel at a moderate speed.
Observe all speed limitations when you road the
SMCS Code: 7000 machine. Ensure that all work tools remain securely
attached to the work tool coupler. Ensure that
When you are finished roading, perform the following appropriate locking pins remain in position.
procedure in order to prepare the machine for work
operation. Note: In Italy, limit machines that are equipped with 2
speed to low speed while roading.
NOTICE
Do not tilt the coupler forward while the locking pin for
the coupler is installed. Damage to the coupler may i06849768
result.
Lifting and Tying Down the
1. Use the following steps to remove the block for the Machine
lift arms: SMCS Code: 7000
a. Enter the machine. Fasten the seat belt. Lower
the armrest. Start the engine. NOTICE
Improper lifting or tiedowns can allow load to shift
b. Disengage the parking brake. and can cause injury and damage.
c. Raise the lift arms slightly.

Lifting the Machine
d. Stop the engine.
There are two lifting attachments for the machine:
• The single point lifting assembly.
SEBU9084-11 245
Operation Section
Lifting and Tying Down the Machine
• The four-point lifting group.

Use one of the lifting attachments in order to lift the
machine. Do not attach both lifting devices to the
machine at the same time.
For lifting the machine, use properly rated cables and
properly rated slings. Position the crane for a level
machine lift. Do not drag the machine with a crane.
All work tools must be removed from the machine
before the machine is lifted.
Note: Do not exceed the weight limit . This film is

located on the outside of the right-hand side of the
cab.
The lifting devices will be mounted on the top of the

cab. If any accessory is mounted to the cab roof, the
attachment must be removed before lifting the
machine.
246 SEBU9084-11
Operation Section
When the four-point lifting group is used, the chain for

each leg should be a minimum of 1 m (3.3 ft) in
length. Keep the machine level during the lift.
SEBU9084-11 247
Operation Section
Refer to the Cat Parts Manual for the current part 5. Use properly rated cables and slings for lifting. The
numbers for the lifting devices for your machine. The crane should be in a position that the machine is
parts manuals are listed in the Operation and lifted without swinging.
Maintenance Manual, “Reference Information
Section”.
Lifting the Grapple Rake
Lifting Point – Lifting points are
designated by this symbol.
The weight and the instructions that are given

describe the machine as manufactured by Caterpillar.
Refer to the Operation and Maintenance Manual,
“Specifications” for weight information about your
machine.
Do not allow any personnel in the area around the
machine.
1. Remove the work tool. If necessary, cover any
hydraulic lines and quick disconnect coupler on
the machine.
2. Lower the lift arms completely.
3. Turn off the machine.
4. Attach the single point lifting device or the four
point lifting device to the machine.
Use properly rated cables and properly rated slings

for lifting work tools. Position the crane for a level lift.
Do not drag the work tool with a crane.
Note: The approximate weight of the 1829 mm

(72 inch) Grapple Rake is 458 kg (1010 lb). The
approximate weight of the 2134 mm (84 inch)
Grapple Rake is 506 kg (1116 lb).
248 SEBU9084-11
Operation Section
Use two hooks in the lifting eyes on the frame. Use a

sling around the front torque tube at the center rake
tine.
Tying Down the Machine

There may be more than one way to tie down the
machine. Local regulations should be used to
determine the best method. Obey all local and
regional governmental regulations.

Two eyes are located on the front of the machine frame and two eyes are located on the rear of the machine frame.
Use the tie-downs shown in illustration 198 . Note: Where possible, avoid routing cables over tires
or tracks. Avoid contact with the work tool to prevent
Note: Use only the specified locations for tying down false tension.
the machine. Do not use any other locations in order
to tie down the machine.
Install tie-downs at all four locations. Place chocks in
front of the machine and behind the machine.
Tie-Down Point – Tie-down points are

designated by this symbol.
The weight and the instructions that are given

describe the machine as manufactured by Caterpillar.
“Specifications” for weight information about your
machine.
1. Turn off the machine.
2. Use the properly rated cables and shackles for
tying down the machine.
3. Use the front eyes and the rear eyes that are
provided on the lower frame of your machine. Use
corner protection when necessary.
SEBU9084-11 249
Operation Section
Alternate Method
If the alternate method is used, the cable angle

should be between 30 degrees and 50 degrees.
Note: If the front two tie down locations on front of

machine are not applicable or desired. Use the
alternate tie down location on each side of the lift
arm.
Note: Use only the specified locations for tying down
the machine. Do not use any other locations in order
to tie down the machine.
Install tie-downs at four out of the six locations. Place
chocks in front of the machine and behind the
machine.
Consult your Cat dealer for shipping instructions for
your machine.

250 SEBU9084-11
Operation Section
Towing Information
Towing Information
i05289397
Machine Retrieval
SMCS Code: 7000
If the machine is disabled, the machine should be
lifted onto a trailer in order to be transported. Refer to
Operation and Maintenance Manual, “Lifting and
Tying Down the Machine” for the lifting procedure.
If the machine cannot be lifted, use the following
guidelines in order to retrieve the machine.

Two towing eyes (2) are located on the rear of the
machine.
• The strength of the line should be at least 1.5

times the gross weight of the machine.
• Provide shielding in order to protect the operator if
the line breaks.
• If a single line is used to pull the machine, then the

line must be a minimum of 3 m (10 ft). If two lines
are used to pull the machine, then each line must
be a minimum of 1.5 m (5.0 ft).
Illustration 201 g03359096 • Do not exceed a maximum pull angle of 20

Two towing eyes (1) are located on the front of the degrees in any direction.
machine.
• Attach the line to the towing eyes. Two towing
eyes (1) are located on the front of the machine
and two towing eyes (2) are located on the rear of
the machine. Do not attach the line to any other
point on the machine.
NOTICE
Do not attach the line to only one towing eye
when you are retrieving the machine. Use both
towing eyes. Damage to the machine may occur.
SEBU9084-11 251
Operation Section
Machine Retrieval

Each of the lines (3) must be a minimum of 1.5 m
(5.0 ft).
NOTICE
Do not drag the machine for long distances. Damage
to the tracks or the tires may occur.
252 SEBU9084-11
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.
i06134153
Severely discharged maintenance free batteries do
Engine Starting with Jump not fully recharge from the alternator after jump start-
ing. The batteries must be charged to proper voltage
Start Cables with a battery charger. Many batteries thought to be
SMCS Code: 1000; 1401; 7000 unusable are still rechargeable.
Use only equal voltage for starting. Check the battery
and starter voltage rating of your machine. Use only
the same voltage for jump starting. Use of a welder or
Batteries give off flammable fumes that can ex- higher voltage damages the electrical system. This
plode resulting in personal injury. machine has a 12 volt starting system. Use only the
same voltage for jump starting.
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” available from your Caterpillar dealer, for
machine. complete testing and charging information.
Do not smoke when checking battery electrolyte
levels. 1. Engage the parking brake. Lower the work tools to
Electrolyte is an acid and can cause personal in- the ground.
jury if it contacts skin or eyes. Reference: Refer to Operation and Maintenance
Always wear eye protection when starting a ma- Manual, “Equipment Lowering with Engine Stopped”.
chine with jump start cables. 2. Move all hydraulic controls to the NEUTRAL
Improper jump start procedures can cause an ex- position.
plosion resulting in personal injury. 3. Turn the engine start switch key to the OFF
Always connect the positive (+) to positive (+) position and turn all accessory switches to the
and the negative (−) to negative (−). OFF position.
Jump start only with an energy source with the 4. Move the machine that is being used as an
same voltage as the stalled machine. electrical source near the stalled machine so that
the jump-start cables reach the stalled machine.
Turn off all lights and accessories on the stalled Do not allow the machines to contact each
machine. Otherwise, they will operate when the
energy source is connected. other.
5. Stop the engine of the machine that is being used
as an electrical source. If you are using an
auxiliary power source, turn off the charging
system.
6. Ensure that the battery in the stalled machine is
not frozen.
SEBU9084-11 253
Operation Section
Engine Starting with Jump Start Cables

C3.8 Battery Location
7. Connect the positive jump-start cable to the

positive terminal on the battery of the stalled
machine.
Do not allow the positive cable clamps to contact
C2.2 Battery Location any metal except for the 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.

C3.3B Battery Location
254 SEBU9084-11
Operation Section
Engine Starting with Jump Start Cables
10. Connect the other negative end of the jump-start

cable to the lifting eye on the engine 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 2 minutes before you attempt to start
the stalled machine. The battery in the stalled
machine will partially charge.
13. Attempt to start the stalled engine.
Reference: For the correct starting procedure, refer
to Operation and Maintenance Manual, “Engine
Starting”.
14. After the stalled engine starts, disconnect the
negative jump-start cable from the stalled
machine.
15. Disconnect the negative jump-start cable from the
negative terminal of the electrical source.
16. Disconnect the positive jump-start cable from the
positive terminal of the electrical source.
17. Disconnect the positive jump-start cable from the
positive terminal of the stalled machine.
18. Conclude the failure analysis on the starting
system of the stalled machine and/or on the
charging system of the stalled machine. Check the
machine while the engine is running and the
charging system is in operation.
SEBU9084-11 255
Maintenance Section
Maintenance Access
Maintenance Section
Maintenance Access
i04429328
Access Doors and Covers

SMCS Code: 7273-573; 7273-572
Engine Access Door

Note: A pinch point exists between the top of the
engine access door and the radiator guard. Keep Illustration 209 g01019162
hands away from this area when you close the
engine access door. 2. Move the retaining pin from the stored position (3)
The engine access door is located on the back of the and put the retaining pin in the LOCKED position
machine. (4). The engine access door is locked in the open
position.
3. In order to close the engine access door, put the
retaining pin in the STORED position.
4. Close the engine access door. Ensure that the
latch is engaged.
i06141206
Cab Tilting
SMCS Code: 7301-506; 7301-509
Do not go beneath cab unless cab is empty and

support lever is engaged.

(1) Engine Access Door
(2) Release Lever Access
Do not tilt the cab using an open door. The door
must be closed and latched when lifting the cab.
1. Pull the release lever in order to open the engine The door may become dislodged from its hinges
access door. and may cause serious personal injury or death.
Tilting the Cab Upward

1. Park the machine on level ground.
Note: Empty the water tank (if equipped) before you
tilt the cab.
256 SEBU9084-11
Maintenance Section
Cab Tilting
2. Lower the loader arms fully. If you tilt the cab

upward with the loader lift arms in the RAISED
position, engage the brace for the loader lift arms.
See Operation and Maintenance Manual, “Loader
Lift Arm Brace Operation” for the process for
engaging the brace for the loader lift arms.
position.
4. Remove the two front bolts for the ROPS. There is
one bolt on each side of the cab under the lift arm.
5. Close the cab door and ensure that the door is
latched.
6. Tilt the cab upward. Stand on the ground when you
tilt the cab.
Note: More than one person may be needed to tilt
the cab.
7. The cab support lever is on the right side of the

machine. As the cab raises, the locking lever will
slide into the LOCKED position. Ensure that the
cab support lever is in the LOCKED position.
Tilting the Cab Downward

Note: More than one person may be needed to tilt
the cab.
1. Remove the cover from the ventilation ducts.

2. Ensure that no person is under the cab. Remove
all of the tools and unsecured items that are
underneath the cab.
3. Tilt the cab upward. Move the cab support lever to
the UNLOCKED position.

4. Tilt the cab downward.
Cab support lever. For clarity the lift arm is not 5. Install the bolts for the ROPS. Torque the bolts to
shown. 125 ± 10 N·m (92 ± 7 lb ft).
(1) Unlocked
(2) Locked
SEBU9084-11 257
Maintenance Section
Loader Lift Arm Brace Operation

Type 2 Cab Mount
(1) Bolt
(2) Washer
(3) Rubber Mount - Top Half
(4) ROPS Structure
(5) Rubber Mount - Bottom Half
Illustration 212 g01271548 (6) Washer
(7) Frame
Type 1 Cab Mount (8) Spacer
(1) Bolt (9) Locknut
(2) Washer
(3) Rubber mount - top half
i05802037
(4) Washer
(5) ROPS structure
(6) Spacer Loader Lift Arm Brace
(7) Rubber mount - bottom half
(8) Washer Operation
(9) Frame
(10) Spacer SMCS Code: 6119-012-AB; 6119-011-AB
(11) Locknut
Loader lift arm brace must be in place when work-

ing under raised lift arms.
258 SEBU9084-11
Maintenance Section
Manual Lift Arm Brace (If

Equipped)
Engage the Lift Arm Brace
1. Empty the work tool. Remove the work tool. Park
the machine on level ground. Lower lift arms to the
ground.
2. Remain in the seat with the seat belt fastened until
the brace is installed.

(5) Lift arm brace in the locked position
Disengage the Lift Arm Brace

armrests and remain in the seat until the brace is
in the stored position.
3. Slowly raise the lift arms until the brace is free. A
(1) Lift arm
(2) Lift arm brace
second person must remove the retaining pin.
(3) Retaining pin
(4) Lift cylinder
4. Slowly lower the lift arms.
5. A second person must return the brace to the
3. A second person must remove the brace(2) from storage position. Secure the brace with the
the storage position. Remove the retaining pin(3) retaining pin.
and allow the lift arm brace to lower.
6. Slowly lower the lift arms to the ground.
4. Raise the lift arms to the maximum height.
5. The second person should then swing the lift arm Self-Raising Lift Arm Brace (If
brace into the locked position on the lift cylinder. Equipped)
Secure the brace with the retaining pin.
6. Lower the lift arms against the brace. Engage the Lift Arm Brace
1. Empty the work tool. Remove the work tool. Park
the machine on level ground. Lower lift arms to the
ground.
SEBU9084-11 259
Maintenance Section

(1) Lift arm (5) Lift arm brace in the locked position
(2) Lift arm brace
(3) Retaining pin
(4) Lift cylinder
8. Secure the brace with the retaining pin.
2. Stop the engine and exit the machine. Disengage the Lift Arm Brace
3. Remove arm brace retaining pin and lower brace 1. Remove the retaining pin.
down to lift cylinder.
2. Rotate the brace lift pin onto the cylinder.
4. Enter the machine, fasten the seat belt, and lower
the armrests. Start the engine.
armrests.
5. Release parking brake. Raise the lift arms slowly
until the lift arm brace just drops down to the lift 4. Start the engine.
cylinder rod.
6. Lower the lift arms against the brace.
7. Stop the engine and exit the machine.
260 SEBU9084-11
Maintenance Section
Radiator Tilting

(1) Latch
(2) Radiator guard
2. The release latch for the guard is located on the

rear of the radiator. Pull the rubber T-handle down
Illustration 218 g03676231 to release the guard. Tilt the guard upward.
5. Slowly raise the lift arms until the brace lift pin
drops into position on the cylinder rod.
6. Slowly lower the lift arms. Ensure that the lift pin
lifts the arm brace over the cylinder.
7. Slowly lower the lift arms to the ground.
8. Stop the engine and exit the machine.
9. Secure the brace in the storage position with the
retaining pin.
i06137399
Radiator Tilting
SMCS Code: 1353-509; 1353-506
1. Open the engine access door. Refer to Operation

and Maintenance Manual, “Access Doors and
Covers”.
3. To raise the radiator, remove the two bolts.

SEBU9084-11 261
Maintenance Section
Radiator Tilting

(1) Release Latch (Both Sides)
4. Raise the radiator. As the radiator raises, the latch (2) Radiator Guard
will move (1).
2. Release latches for the guard are located on either
5. Raise the radiator until the latch moves over the side of the radiator near the rear of the radiator.
catch pin (2). Press both release latches upwards
6. In order to lower the radiator downward, push up simultaneously and tilt the guard upwards.
on the radiator. Move the latch to unlatch the lock.
Lower the radiator.
7. Install the two bolts to secure the radiator.
8. In order to lower the radiator guard, move the
support rod to the storage position and lower the
guard.
9. Fasten the rubber T-handle latch.
10. Close the engine access door.
Alternate Release Latch Location

Only for HRD 1-Up, DPR 1-Up, KXC 1-Up, BL9 1-Up,
CD4 1-Up, GWR 1-Up, and AH9 1-Up machines.
Covers”.
262 SEBU9084-11
Maintenance Section
Radiator Tilting
7. Tilt the guard downward until both the release

latches lock onto the catch pins.
3. To raise the radiator, remove the two nuts (3) from

the radiator mount on each side.
4. The strut lock is located on the right side of the

engine compartment. Make sure that the strut lock
is in the LOCKED position with the radiator tilted
up.
5. In order to lower the radiator downward, lift slightly
on the radiator and push the strut lock to the left
and lower the radiator carefully.
6. Install the two nuts to the radiator mount on each
side.
SEBU9084-11 263
Maintenance Section
Lubricant Viscosities and Refill Capacities
Lubricant Viscosities and Machines that are operated continuously should use
oils that have the higher oil viscosity in the final drives
Refill Capacities and in the differentials. The oils that have the higher
oil viscosity will maintain the highest possible oil film
thickness. Refer to “General Information for
i06134131 Lubricants” article, “Lubricant Viscosities” tables, and
any associated footnotes. Consult your Cat dealer if
Lubricant Viscosities additional information is needed.
(Fluids Recommendations) NOTICE

Not following the recommendations found in this
SMCS Code: 7581 manual can lead to reduced performance and com-
partment failure.
General Information for Lubricants
When you are operating the machine in temperatures Engine Oil
below −20°C (−4°F), refer to Special Publication,
SEBU5898, “Cold Weather Recommendations”. This
publication is available from your Cat dealer. Cat oils have been developed and tested in order to
provide the full performance and life that has been
For cold-weather applications where transmission oil designed and built into Cat engines.
SAE 0W-20 is recommended, Cat Cold Weather
TDTO is recommended. Cat DEO-ULS or oils that meet the Cat ECF-3
specification and the API CJ-4 are required for use in
Refer to the “Lubricant Information” section in the the applications listed below. Cat DEO-ULS and oils
latest revision of the Special Publication, SEBU6250, meeting Cat ECF-3 specification and the API CJ-4
“Caterpillar Machine Fluids Recommendations” for a and ACEA E9 oil categories have been developed
list of Cat engine oils and for detailed information. with limited sulfated ash, phosphorus, and sulfur.
This manual may be found on the Web at Safety.Cat. These chemical limits are designed to maintain the
com. expected aftertreatment devices life, performance,
and service interval. If oils meeting the Cat ECF-3
The footnotes are a key part of the tables. Read ALL specification and the API CJ-4 specifications are not
footnotes that pertain to the machine compartment in available, oils meeting ACEA E9 may be used. ACEA
question. E9 oils meet the chemical limits designed to maintain
aftertreatment device life. ACEA E9 oils are validated
Selecting the Viscosity using some but not all ECF-3 and API CJ-4 standard
engine performance tests. Consult your oil supplier
In order to select the proper oil for each machine when considering use of an oil that is not Cat ECF-3
compartment, refer to the “Lubricant Viscosity for or API CJ-4 qualified.
Ambient Temperature” table. Use the oil type AND oil
viscosity for the specific compartment at the proper Failure to meet the listed requirements will damage
ambient temperature. aftertreatment-equipped engines and can negatively
impact the performance of the aftertreatment
The proper oil viscosity grade is determined by the devices. The Diesel Particulate Filter (DPF) will plug
minimum ambient temperature (the air in the sooner and require more frequent DPF ash service
immediate vicinity of the machine). Measure the intervals.
temperature when the machine is started and while
the machine is operated. In order to determine the Typical aftertreatment systems include the following:
proper oil viscosity grade, refer to the “Min” column in • Diesel Particulate Filters (DPF)
the table. This information reflects the coldest
ambient temperature condition for starting a cold
machine and for operating a cold machine. Refer to • Diesel Oxidation Catalysts (DOC)
the “Max” column in the table for operating the Other systems may apply.
machine at the highest temperature that is
anticipated. Unless specified otherwise in the Note: For territories where high sulfur diesel fuel is
“Lubricant Viscosities for Ambient Temperatures” available and allowed by law, these engines will not
tables, use the highest oil viscosity that is allowed for have aftertreatment. For the areas that have diesel
the ambient temperature.
fuel sulfur levels greater than .2% (2,000 ppm), refer
to Special Publications, SEBU6250, “Caterpillar
Machine Fluids Recommendations” “Total Base
Number (TBN) and Fuel Sulfur Levels for Direct
Injection (DI) Diesel Engines” for recommendations.
264 SEBU9084-11
Maintenance Section
Fluids Recommendations
Table 97
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
Engine Crankcase SAE 10W-30 −18 40 0 104
Cat DEO-ULS
SAE 15W-40 −9.5 50 15 122
Note: For engines with NO aftertreatment, Cat DEO

can also be used. Refer to Special Publications,
SEBU6250, “Caterpillar Machine Fluids
Recommendations” “Cat Diesel Engine Oils
Recommendations”.
Hydraulic Systems
Refer to the “Lubricant Information” section in the
latest revision of the Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” for
detailed information. This manual may be found on
the Web at Safety.Cat.com.
The following are the preferred oils for use in most
Cat machine hydraulic systems:
• Cat HYDO Advanced 10 SAE 10W
• Cat HYDO Advanced 30 SAE 30W

• Cat BIO HYDO Advanced
Cat HYDO Advanced fluids have a 50% increase
in the standard oil drain interval for machine
hydraulic systems (3000 hours versus 2000 hours)
over second and third choice oils when you follow the
maintenance interval schedule for oil filter changes
and for oil sampling that is stated in the Operation
and Maintenance Manual for your particular machine.
6000 hour oil drain intervals are possible when using
S·O·S Services oil analysis. 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
• Cat TDTO
• Cat TDTO Cold Weather

• Cat TDTO-TMS
• Cat DEO-ULS Cold Weather
SEBU9084-11 265
Maintenance Section
Table 98
Lubricant Viscosities for Ambient Temperatures
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 0 50 32 122
Cat TDTO
Cat BIO HYDO Advanced “ISO 46” Multi-Grade −30 45 −22 113
Cat MTO
Hydraulic System Cat DEO-ULS SAE10W-30 −20 40 −4 104
Cat DEO
Cat DEO-ULS
SAE15W-40 −15 50 5 122
Cat DEO
Cat TDTO-TMS Multi-Grade −15 50 5 122
Cat DEO-ULS Cold Weather SAE0W-40 −40 40 −40 104
Cat TDTO Cold Weather SAE 0W-20 −40 40 −40 104
Drive Train Components

Refer to the “Lubricant Information” section in the
latest revision of the Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” for
detailed information. This manual may be found on
the Web at Safety.Cat.com.
When you are operating the machine in temperatures
below −20°C (−4°F), refer to Special Publication,
SEBU5898, “Cold Weather Recommendations”. This
publication is available from your Cat dealer.
Table 99
Oil Type and Per- °C °F

Compartment or
formance Oil Viscosities
System Min Max Min Max
Requirements
Cat DEO-ULS Cold
SAE 0W-40 −40 40 −40 104
MTL/CTL Track Idlers and Weather
MTL/CTL Track Rollers
Cat DEO-ULS SAE 10W-30 −18 40 0 104
SSL Drive Chain Case
Cat DEO SAE 15W-40 −9.5 50 15 122
Caterpillar Synthetic
Final Drive SAE 75W-140 -30 45 -22 113
GO(1)(2)
Caterpillar Deo SAE 30 -20 25 -4 77

EMA LRG-1
SAE 40 -10 40 14 104
Steel Track Idlers and Steel API CH-4
Track Rollers API CG-4
API CF-4 SAE 5W40 -35 40 -31 104
API CF
Caterpillar GO SAE 75W90 -30 40 -22 104

Track Pins
API GL-5 SAE 80W90 -20 40 -4 104
(continued)
266 SEBU9084-11
Maintenance Section
(Table 99, contd)

Oil Type and Per- °C °F

Compartment or
formance Oil Viscosities
System Min Max Min Max
Requirements
SAE 85W140 -10 50 14 122
SAE 90 0 40 32 104
(1) Cat Synthetic GO is the preferred oil for the final drive. If Cat Synthetic GO is not available, Cat GO, or API GL-5 grade oil may be
substituted.
(2) Cat GO (Gear Oil) is available in SAE 80W-90 and SAE 85W-140 viscosity grades.
Special Lubricants
Grease
In order 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 100
Recommended Grease
°C °F
Compartment or System GreaseType NLGI Grade
Min Max Min Max
Cat Prime Application NLGI Grade 2 −20 40 −4 104
NLGI Grade 2 −30 50 −22 122

Cat Extreme Application NLGI Grade 1 −35 40 −31 104
External Lubrication Points NLGI Grade 0 −40 35 −40 95

Cat Extreme Application-
NLGI Grade 0 −50 20 −58 68
Arctic
Cat Extreme Application-
NLGI Grade 2 −20 60 −4 140
Desert
Steering Column(1)
Drive Shaft Universal Joints(2) Cat Utility NLGI Grade 2 −30 40 −22 104
Drive Shaft Support Bearing
(1) HMU Steering
(2) 980 Drive Shaft is maintenance free.
Diesel Fuel Recommendations

SEBU9084-11 267
Maintenance Section
• Shorten the time interval between

aftertreatment device service intervals (cause
the need for more frequent service intervals)
• Adversely impact the performance and life of

aftertreatment devices (cause loss of
performance)
• Reduce regeneration intervals of

aftertreatment devices
• Reduce engine efficiency and durability.

• Increase the wear.
• Increase the corrosion.

United States and Canada • Increase the deposits.
• Lower fuel economy

• Shorten the time period between oil drain intervals
(more frequent oil drain intervals).
• Increase overall operating costs.

Failures that result from the use of improper fuels
are not Cat factory defects. Therefore the cost of
repairs would not be covered by a Cat warranty.
For Tier 4/Stage IIIB/Stage IV certified engines
always follow operating instructions. Fuel tank inlet
labels are installed in order to ensure that the correct
fuels are used.
Refer to Special Publication, SEBU6250, “Caterpillar
Illustration 226 g02052934 Machine Fluids Recommendations” for more details
Rest of World Film about fuels, lubricants, and Tier 4 requirements.
Diesel fuel must meet “Cat Specification for Distillate Note: The maximum allowable fuel sulfur level is
Fuel” and the latest versions of “ASTM D975” or “EN controlled by various emissions laws, regulations and
590” in order to ensure optimum engine performance. mandates consult federal, state and local authorities
Refer to Special Publication, SEBU6250, “Caterpillar for guidance on fuel requirements for your area.
Machine Fluids Recommendations” for the latest fuel
information and for Cat fuel specification. This Diesel fuel containing greater than .0015% (15 ppm)
manual may be found on the Web at Safety.Cat.com. sulfur is acceptable for areas of the world where
allowed by law. The engines in these territories are
NOTICE not equipped with aftertreatment. For these lesser
Ultra Low Sulfur Diesel (ULSD) fuel 0.0015 percent regulated countries, refer to the following for
(≤15 ppm (mg/kg)) sulfur is required by regulation for allowable diesel fuel sulfur content.
use in engines certified to nonroad Tier 4 standards
(U.S. EPA Tier 4 certified) and that are equipped with For engines that do not use aftertreatment but do use
exhaust aftertreatment systems. Exhaust Gas Recirculation (EGR), diesel fuel
containing more than 0.05% (500 ppm) sulfur is not
European ULSD 0.0010 percent (≤10ppm (mg/kg)) approved.
sulfur fuel is required by regulation for use in engines
certified to European nonroad Stage IIIB and newer
standards and are equipped with exhaust aftertreat-
ment systems.
Misfueling with fuels of higher sulfur level may

void the warranty or affect warranty claims
coverage and have the following negative effects:
268 SEBU9084-11
Maintenance Section
For engines that DO NOT use aftertreatment nor use

Exhaust Gas Recirculation (EGR), use of diesel fuel NOTICE
Do not use agriculture grade urea solutions. Do
containing more than 1.0% (10,000 ppm) sulfur is not not use any fluids that do not meet “ISO 22241-1” Re-
approved. Diesel fuel containing less than 0.1% quirements in SCR emissions reduction systems.
(1,000 ppm) sulfur is highly recommended. Fuel Use of these fluids can result in numerous problems
sulfur levels between 0.5% (5,000 ppm) and up to including damage to SCR equipment and a reduction
1.0% (10,000 ppm) may significantly shorten the oil in NOx conversion efficiency.
change interval. Cat S.O.S. Service oil analysis is
very strongly recommended. Refer to Special
Publication, SEBU6250, “Caterpillar Machine Fluids DEF is a solution of solid urea that is dissolved in
Recommendations” “Total Base Number (TBN) and demineralized water to produce a final concentration
Fuel Sulfur Levels for Direct Injection (DI) Diesel of 32.5% urea. DEF concentration of 32.5% is
Engines” for more information. optimal for use in SCR systems. DEF solution of
32.5% urea has the lowest attainable freeze point of
Diesel Exhaust Fluid −11.5° C (11.3° F). DEF concentrations that are
higher or lower than 32.5% have higher freeze
points. DEF dosing systems and “ISO 22241-1”
General Information specifications are designed for a solution that is
approximately 32.5%.
Diesel Exhaust Fluid (DEF) is a liquid that is injected
into the exhaust system of engines equipped with Caterpillar offers a refractometer, Cat part number
Selective Catalytic Reduction (SCR) systems. SCR 360-0774, that can be used to measure DEF
reduces emissions of nitrogen oxides (NOx) in diesel concentration. Follow the instructions provided with
engine exhaust. the instrument. Appropriate commercial portable
refractometers can be used to determine urea
Diesel Exhaust Fluid (DEF) is also known under concentration. Follow the instructions from the
other names including Aqueous Urea Solution (AUS) manufacturer.
32, AdBlue, or generically referred to as urea.
DEF Guidelines
In engines equipped with SCR emissions reduction
system, DEF is injected in controlled amounts into DEF solution is typically colorless and clear. Changes
the engine exhaust stream. At the elevated exhaust to color or clarity are indicators of quality issues.
temperature, urea in DEF is converted to ammonia. Quality of DEF can degrade when stored and
The ammonia chemically reacts with NOx in diesel handled inappropriately or if DEF is not protected
exhaust in the presence of the SCR catalyst. The from contamination. Details are provided below.
reaction converts NOx into harmless nitrogen (N2)
and water (H2O). If quality issues are suspected, testing of DEF should
focus on urea percentage, alkalinity as NH3 and
DEF Recommendations biuret content. DEF that does not pass all these tests
or that is no longer clear should not be used.
For use in Cat engines, DEF must meet all the
requirements defined by “ISO 22241-1” Materials compatibility
Requirements.
DEF is corrosive. Due to the corrosion caused, DEF
Caterpillar recommends the use of DEF available must be stored in tanks constructed of approved
through the Cat parts ordering system for use in Cat materials. Recommended storage materials:
engines equipped with SCR systems.
Stainless Steels:
In North America, commercial DEF that is API
approved and meets all the requirements defined in • 304 (S30400)
“ISO 22241-1” may be used in Cat engines that are
equipped with SCR systems. • 304L (S30403)
Outside of North America, commercial DEF that • 316 (S31600)

meets all requirements defined in “ISO 22241-1” may
be used in Cat engines that are equipped with SCR • 316L (S31603)
systems.
Alloys and metals:
The supplier should provide documentation to prove
the DEF is compliant with the requirements of “ISO • Chromium Nickel (CrNi)
22241-1”.
• Chromium Nickel Molybdenum (CrNiMo)
NOTICE
Cat does not warrant the quality or performance of • Titanium
non-Cat fluids. Non-metallic materials:
SEBU9084-11 269
Maintenance Section
• Polyethylene Cleanliness
• Polypropylene Contaminants can degrade the quality and life of
DEF. Filtering DEF is recommended when dispensed
• Polyisobutylene into the DEF tank. Filters should be compatible with
DEF and should be used exclusively with DEF.
• Teflon (PFA) Check with the filter supplier to confirm compatibility
with DEF before using. Mesh-type filters using
• Polyfluoroethylene (PFE) compatible metals, such as stainless steel, are
recommended. Paper (cellulose) media and some
• Polyvinylidene fluoride (PVDF) synthetic filter media are not recommended because
of degradation during use.
• Polytetrafluoroethylene (PTFE)
Care should be taken when dispensing DEF. Spills
Materials NOT compatible with DEF solutions include should be cleaned immediately. Machine or engine
Aluminum, Magnesium, Zinc, Nickel coatings, Silver surfaces should be wiped clean and rinsed with
and Carbon steel and Solders containing any of the water. Caution should be used when dispensing DEF
above. Unexpected reactions may occur if DEF near an engine that has recently been running.
solutions come in contact with any non-compatible Spilling DEF onto hot components will cause harmful
material or unknown materials. vapors.
Bulk storage Stability
Follow all local regulations covering bulk storage DEF fluid is stable when stored and handled properly.
tanks. Follow proper tank construction guidelines. The quality of DEF rapidly degrades when stored at
Tank volume typically should be 110% of planned high temperatures. The ideal storage temperature for
capacity. Appropriately vent indoor tanks. Plan for DEF is between −9° C (15.8° F) and 25° C (77° F).
control of overflow of the tank. Heat tanks that DEF that is stored above 35° C (95° F) for longer
dispense DEF in cold climates. than 1 month must be tested before use. Testing
should evaluate Urea Percentage, Alkalinity as NH3
Bulk tank breathers should be fitted with filtration to and Biuret content.
keep airborne debris from entering the tank.
Desiccant breathers should not be used because The length of storage of DEF is listed in the following
water will be absorbed, which potentially can alter table:
DEF concentration.
Table 101
Handling Storage Temperature Expected DEF Life
Follow all local regulations covering transport and Below 25° C (77° F) 18 months
handling. DEF transport temperature is
25° C (77° F) to 30° C (86° F) 12 months
recommended to be −5° C (23° F) to 25° C (77° F).
All transfer equipment and intermediate containers 30° C (86° F) to 35° C (95° F) 6 months
should be used exclusively for DEF. Containers
should not be reused for any other fluids. Ensure that Above 35° C (95° F) test quality before use
transfer equipment is made from DEF-compatible
materials. Recommended material for hoses and Refer to “ISO 22241” document series for more
other non-metallic transfer equipment include: information about DEF quality control.
• Nitrile Rubber (NBR)
• Fluoroelastomer (FKM)
• Ethylene Propylene Diene Monomer (EPDM)

The condition of hoses and other nonmetallics that
are used with DEF should be monitored for signs of
degradation. DEF leaks are easily recognizable by
white urea crystals that accumulate at the site of the
leak. Solid urea can be corrosive to galvanized or
unalloyed steel, aluminum, copper, and brass. Leaks
should be repaired immediately to avoid damage to
surrounding hardware.
270 SEBU9084-11
Maintenance Section
Capacities (Refill)
Note: Dispose of all fluids according to applicable All the guidelines and requirements are provided in
regulations and mandates. the latest revision of Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations”. This
manual may be found on the Web at Safety.Cat.com.
Fuel Additives
Cat Diesel Fuel Conditioner and Cat Diesel Fuel Coolant Information
System Cleaner are available for use when needed.
These products are applicable to diesel and biodiesel The information provided in this “Coolant
fuels. Caterpillar recommends the addition of Cat Recommendation” section should be used with the
Diesel Fuel System Cleaner every 3000 hours of “Lubricants Information” provided in the latest
engine operation on particular models. Refer to revision of Special Publication, SEBU6250,
"Diesel Fuel System Cleaner - Add" for model “Caterpillar Machine Fluids Recommendations”. This
information. Contact your Cat dealer for availability. manual may be found on the Web at Safety.Cat.com.
The following two types of coolants may be used in
Biodiesel Cat diesel engines:
Biodiesel is a fuel that can be made from various Preferred – Cat ELC (Extended Life Coolant)
renewable resources that include vegetable oils,
animal fat, and waste cooking oil. Soybean oil and Acceptable – Cat DEAC (Diesel Engine Antifreeze/
rapeseed oil are the primary vegetable oil sources. In Coolant)
order to use any of these oils or fats as fuel, the oils
or fats are chemically processed (esterified). The
water and contaminants are removed. NOTICE
Never use water alone as a coolant. Water alone is
U.S. distillate diesel fuel specification “ASTM D975- corrosive at engine operating temperatures. In addi-
09a” includes up to B5 (5 percent) biodiesel. tion, water alone does not provide adequate protec-
Currently, any diesel fuel in the U.S. may contain up tion against boiling or freezing.
to B5 biodiesel fuel.
European distillate diesel fuel specification “EN 590”
includes up to B5 (5 percent) and in some regions up i06134090
to B7 (7 percent) biodiesel. Any diesel fuel in Europe
may contain up to B5 or in some regions up to B7 Capacities (Refill)
biodiesel fuel.
SMCS Code: 7560
Note: The diesel portion used in the biodiesel blend
must be Ultra Low Sulfur Diesel (15 ppm sulfur or Note: All values are approximate refill capacities.
less, per “ASTM D975”). In Europe the diesel fuel Table 102
portion used in the biodiesel blend must be sulfur free
diesel (10 ppm sulfur or less, per “EN 590”). The final 272D, 272D XHP, 297D, 297D XHP, 299D, and 299D XHP
blend must have 15 ppm sulfur or less. Compartment or Imperial
Liters US Gallons
System Gallons
Note: Up to B7 biodiesel blend level is acceptable for
use in SSL, MTL, and CTL engines. Engine Crankcase 13.2 (1) 3.5 (2) 2.9 (3)
When biodiesel fuel is used, certain guidelines must Hydraulic Tank 39 10.3 8.6
be followed. Biodiesel fuel can influence the engine Cooling System 15.5 4.1 3.4
oil, aftertreatment devices, non-metallic, fuel system
components, and others. Biodiesel fuel has limited Fuel Tank 122 32.2 26.8
storage life and has limited oxidation stability. Follow
the guidelines and requirements for engines that are Window Washer Fluid 2 0.53 0.44
seasonally operated and for standby power (1) The amount includes 1L in the filter.
generation engines. (2) The amount includes 0.26G in the filter.
(3) The amount includes 0.22G in the filter.
In order to reduce the risks associated with the use of
biodiesel, the final biodiesel blend and the biodiesel Table 103
fuel used must meet specific blending requirements.
272D2, 272D2 XHP, 297D2, 297D2 XHP, 299D2, and 299D2
XHP
Compartment or Imperial
Liters US Gallons
System Gallons
(continued)
SEBU9084-11 271
Maintenance Section
Capacities (Refill)
(Table 103, contd) Table 106

Engine Crankcase 13.2 (1) 3.5 (2) 2.9 (3) Wheeled Machines (SSL)
Hydraulic Tank 39 10.3 8.6 Compartment or Imperial

Liters US Gallons
System Gallons
Cooling System 15.5 4.1 3.4
Each Drive Chain
Fuel Tank 122 32.2 26.8 7.0 1.8 1.5
Case (226D, 232D)
Diesel Engine Flu-
18.9 5.0 4.2 Each Drive Chain
id (DEF) Tank 8.8 2.3 1.9
Case (236D, 242D)
Window Washer
2 0.53 0.44 Each Drive Chain
Fluid 12.7 3.3 2.8
Case (246D, 262D)
(1) The amount includes 1L in the filter.
(2) The amount includes 0.26G in the filter. Each Drive Chain
(3) The amount includes 0.22G in the filter. Case (272D, 272D
10.2 2.7 2.2
XHP, 272D2, 272D2
Table 104 XHP)
226D, 232D, 239D, and 249D
Table 107
Compartment or Imperial
Liters US Gallons Tracked Machines (MTL & CTL)
System Gallons
Engine Crankcase 8.2 (1) 2.2 (2) 1.8 (3) Compartment or Imperial
Liters US Gallons
System Gallons
Hydraulic Tank 35 9.2 7.7
Final Drive 1.0 0.26 0.22
Cooling System 14.0 3.7 3.1
Fuel Tank 57 15.1 12.5 Table 108
Window Washer Multi Terrain Loaders (MTL)

2 0.53 0.44
Fluid Compartment or System Milliliters Grams
(2) The amount includes 0.26G in the filter. Roller and Idler Axle Spindle - 257D
33 ± 3 ml N/A
(3) The amount includes 0.22G in the filter. (CAT DEO 10W-30)
Table 105 Roller and Idler Axle Spindle - 277D, 287D,

297D 60 ± 5 ml N/A
236D, 242D, 246D, 257D, 259D, 262D,277D, 279D, 287D and (Cat DEO 10W-30)
289D
Roller and Idler External Bearing - All
Compartment or Imperial Models 30 ± 5 g
Liters US Gallons N/A
System Gallons (Cat Arctic Platinum, NLGI Grade 00)
Engine Roller and Idler Axle Tube - All Models
11.2 (1) 3.0 (2) 2.5 (3)
Crankcase N/A 30 ± 5 g
(Cat Advanced 3Moly, NLGI Grade 02)
Hydraulic Tank 39 10.3 8.6
Table 109
Cooling System 14 3.7 3.1
Compact Track Loaders (CTL)
Fuel Tank (236D,
242D, 257D, 105 27.7 23.1 Compartment or System Milliliters
259D)
Track Roller (239D, 249D) 165 ± 12 ml
Fuel Tank (246D,
262D, 277D, Idler - Single Flange (239D, 249D) 230 ± 15 ml
94 24.8 20.7
279D, 287D,
Idler - Dual Flange (239D, 249D) 200 ± 15 ml
289D)
Idler - Triple Flange (239D, 249D) 230 ± 15 ml
Window Washer
2 0.53 0.44
Fluid Track Roller (All Other Models) 240 ± 12 ml
(2) The amount includes 0.28G in the filter. Idler - Single Flange (All Other Models) 349 ± 12 ml
(3) The amount includes 0.22G in the filter.
Idler - Dual Flange (All Other Models) 354 ± 15 ml
Idler - Triple Flange (All Other Models) 354 ± 15 ml

272 SEBU9084-11
Maintenance Section
S·O·S Information
Table 110
Steel Track Loaders
Compartment or System Milliliters
Steel Track Idler 250 ± 12 ml
Steel Track Roller 100 ± 5 ml
Steel Track Carry Roller 90 ± 5 ml
Steel Track Pin 11 ± 0.5 ml
Table 111
HVAC R-134a Refrigerant (If Equipped) PAG 46
Models kg lbs cc
226D, 232D, 236D, 239D, 242D,

0.81 1.8 150
249D, 257D, 259D
246D, 262D, 277D,

1.00 2.2 150
279D, 287D, 289D
272D, 272D XHP, 272D2, 272D2

XHP, 297D, 297D XHP, 297D2,
0.81 1.8 150
297D2 XHP, 299D, 299D XHP,
299D2, 299D2 XHP
i04311449
S·O·S Information
SMCS Code: 1000; 7000; 7542-008
S·O·S Services is a highly recommended process for
Cat customers to use in order to minimize owning
and operating cost. Customers provide oil samples,
coolant samples, and other machine information. The
dealer uses the data in order to provide the customer
with recommendations for management of the
equipment. In addition, S·O·S Services can help
determine the cause of an existing product problem.
Refer to Special Publication, SEBU6250, “Caterpillar
Machine Fluid Recommendations” for detailed
information concerning S·O·S Services.
“Maintenance Interval Schedule” for a specific
sampling location and a service hour maintenance
interval.
Consult your Cat dealer for complete information and
assistance in establishing an S·O·S program for your
equipment.
SEBU9084-11 273
Maintenance Section
Maintenance Support
Maintenance Support
i06824039
Service Interval Chart

SMCS Code: 7000
Refer to the following service interval charts and
service intervals for additional maintenance
information.
Example Service Interval Chart
Service Intervals Closed Circuit Breather

Element – Change the breather
Use the example service interval chart and the element after every 1500
following information as a guide only. The specific service hours.
service interval chart film for your machine is located
on the back side of the engine access door. Coolant additive – Add the extender to
the extended life coolant after every
Reference: Always refer to the Operation and 6000 service hours or every 3 years.
Maintenance Manual, “Maintenance Interval
Schedule” for details about each maintenance item.
274 SEBU9084-11
Maintenance Section
Welding on Machines and Engines with Electronic Controls
Coolant level (radiator) – Check the Fuel Pump Filter – Replace the filter
coolant level in the radiator at the sight after every 500 service hours or every 6
gauge after every 10 service hours or at months.
the end of each day.
Fuel System Filter/Water Separator
Coolant level (reservoir) – Check the Element – Replace the filter after every
coolant level in the coolant reservoir 500 service hours or every 6 months.
after every 10 service hours or at the
end of each day. Diesel Fuel System Cleaner (C2.2 Only)
– Add Cat Diesel Fuel System Cleaner
Cooling system coolant – Change the to a full tank of diesel every 3000 hours.
ELC (Extended Life Coolant) after every
12,000 hours or every 6 years. Grease zerk – Lubricate the designated
locations after every 10 service hours or
Diesel Exhaust Fluid Filter – The DEF at the end of each day.
filter must be replaced every 3000
hours. Hydraulic oil filter – Change the filter
after every 1000 hrs or every year.
Diesel Particulate Filter Clean – The DPF
must be cleaned or replaced by your Cat Hydraulic oil level check – Check the
dealer every 3000 hours. hydraulic oil level at the sight gauge
Drive Chain Case Oil (Wheeled after every 10 service hours or at the
Machines Only) – Check the oil level end of each day.
every 500 service hours or every 3 Hydraulic oil – Change the hydraulic oil
months. Change the Drive Chain Case oil after after every 2000 service hours or every 2
every 1000 service hours or every 6 months years.
Final Drive Oil (Tracked Machines Only)
– Change the final drive oil after the i03636245
initial 250hrs. Check the final drive oil
level after every 250 hrs. Change the final drive Welding on Machines and
oil after every 500 hrs. Engines with Electronic
Engine air filter primary element – Clean Controls
the primary air filter element or replace
the primary air filter element. The alert SMCS Code: 1000; 7000
indicator for the air filter indicates when servicing Do not weld on any protective structure. If it is
is necessary. necessary to repair a protective structure, contact
your Caterpillar dealer.
Engine air filter secondary element –
Replace the secondary air filter element Proper welding procedures are necessary in order to
with every third change of the primary avoid damage to the electronic controls and to the
air filter element or replace the secondary air bearings. When possible, remove the component
filter element when necessary. that must be welded from the machine or the engine
and then weld the component. If you must weld near
Engine oil level check – Check the an electronic control on the machine or the engine,
engine oil level after every 10 service temporarily remove the electronic control in order to
hours or at the end of each day. prevent heat related damage. The following steps
should be followed in order to weld on a machine or
Engine oil – Change the engine an engine with electronic controls.
oil after every 500 service
1. Turn off the engine. Place the engine start switch
hours or every year.
in the OFF position.
Engine oil filter – Change the filter after 2. If equipped, turn the battery disconnect switch to
every 500 service hours or every year.
the OFF position. If there is no battery disconnect
switch, remove the negative battery cable at the
Fuel system water separator – Drain the battery.
water separator after every 10 service
hours or at the end of each day.
SEBU9084-11 275
Maintenance Section
Welding on Machines and Engines with Electronic Controls
NOTICE
Do NOT use electrical components (ECM or sensors)
or electronic component grounding points for ground-
ing the welder.
3. Clamp the ground cable from the welder to the

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

from the debris and the spatter which is created
from welding.
5. Use standard welding procedures in order to weld
the materials together.
276 SEBU9084-11
Maintenance Section
Maintenance Interval Schedule
i06849916 “ Engine Air Filter Secondary Element -

Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 315
Maintenance Interval Schedule “ Fuel System Priming Pump - Operate”. . . . . . . . 331
SMCS Code: 7000
“ Fuel Tank Cap - Clean” . . . . . . . . . . . . . . . . . . . . 332
Ensure that all safety information, warnings, and
instructions are read and understood before any “ Fuel Tank Water and Sediment - Drain” . . . . . . . 332
operation or any maintenance procedures are
performed. “ Fuses - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 333
The user is responsible for the performance of “ Headlights - Adjust” . . . . . . . . . . . . . . . . . . . . . . . 336

maintenance. All adjustments, the use of proper
“Lower Machine Frame - Clean” . . . . . . . . . . . . . . 354
lubricants, fluids, filters, and the replacement of
components due to normal wear and aging are “ Oil Filter - Inspect” . . . . . . . . . . . . . . . . . . . . . . . . 355
included. Failure to adhere to proper maintenance
intervals and procedures may result in diminished “ Radiator Core - Clean” . . . . . . . . . . . . . . . . . . . . 356
performance of the product and/or accelerated wear
of components. “ Sprocket - Inspect”. . . . . . . . . . . . . . . . . . . . . . . . 359
Use mileage, fuel consumption, service hours, or “ Sprocket - Inspect”. . . . . . . . . . . . . . . . . . . . . . . . 360

calendar time, WHICH EVER OCCURS FIRST, in
order to determine the maintenance intervals. “ Track (Rubber) - Remove/Replace” . . . . . . . . . . 370
Products that operate in severe operating conditions
may require more frequent maintenance. Refer to the “ Track - Remove/Replace” . . . . . . . . . . . . . . . . . . 375
maintenance procedure for any other exceptions that
may change the maintenance intervals. “ Track - Remove/Replace” . . . . . . . . . . . . . . . . . . 376
Note: The aftertreatment system can be expected to “ Window Washer Reservoir - Fill” . . . . . . . . . . . . 381
function properly for the useful life of the engine “ Window Wiper - Inspect/Replace” . . . . . . . . . . . 381
(emissions durability period), as defined by
regulation. All prescribed maintenance requirements “ Windows - Clean”. . . . . . . . . . . . . . . . . . . . . . . . . 381
must be followed.
“ Work Tool Guard and Reflector - Inspect/
Note: Before each consecutive interval is performed, Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
all maintenance from the previous interval must be
performed. Every 10 Service Hours or Daily
Note: If Cat HYDO Advanced hydraulic oils are used, “ Air Cleaner Dust Valve - Clean/Inspect” . . . . . . . 279
the hydraulic oil change interval is extended
substantially. S·O·S services may extend the oil “ Axle Bearings - Lubricate” . . . . . . . . . . . . . . . . . . 281
change even longer. Consult your Cat dealer for
details. “ Axle Bearings - Lubricate” . . . . . . . . . . . . . . . . . . 279
“ Backup Alarm - Test” . . . . . . . . . . . . . . . . . . . . . . 282
When Required
“ Bogie and Idler - Inspect/Replace” . . . . . . . . . . . 288
“ Air Conditioner Condenser - Clean” . . . . . . . . . . 279
“ Bogie and Idler - Inspect/Replace” . . . . . . . . . . . 290
“ Battery or Battery Cable - Inspect/Replace”. . . . 282
“ Cooling System Level - Check”. . . . . . . . . . . . . . 303
“ Blade Frame - Adjust” . . . . . . . . . . . . . . . . . . . . . 287
“ Engine Compartment - Inspect/Clean” . . . . . . . . 316
“ Bucket Cutting Edges - Inspect/Replace” . . . . . 294
“ Engine Oil Level - Check” . . . . . . . . . . . . . . . . . . 318
“ Bucket Tips - Inspect/Replace” . . . . . . . . . . . . . . 295
“ Equipment Lowering Control Valve - Check” . . . 324
“ Cab Air Filter - Clean/Replace” . . . . . . . . . . . . . . 295
“ Fuel System Primary Filter (Water Separator) -
“ Cab Interior - Clean” . . . . . . . . . . . . . . . . . . . . . . 296 Drain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
“ Diesel Exhaust Fluid - Fill”. . . . . . . . . . . . . . . . . . 306 “ Hydraulic System Oil Level - Check ” . . . . . . . . . 351
“Drive Line Wear Sleeve - Inspect/Replace” . . . . 312 “ Lift Arm and Cylinder Linkage - Lubricate” . . . . . 353
“ Engine Air Filter Primary Element - Clean/ “ Quick Coupler - Clean/Inspect”. . . . . . . . . . . . . . 356
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313
SEBU9084-11 277
Maintenance Section
“ Seat Belt - Inspect” . . . . . . . . . . . . . . . . . . . . . . . 358 “ Hydraulic System Oil Sample - Obtain” . . . . . . . 352
“ Sprocket Retaining Nuts - Check” . . . . . . . . . . . 365
Every 500 Service Hours or 3
“ Tilt Cylinder Bearings and Bucket Linkage Bearings Months
- Lubricate” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
“ Drive Chain Case Oil - Check” . . . . . . . . . . . . . . 309
“ Tire Inflation - Check” . . . . . . . . . . . . . . . . . . . . . 367
“ Drive Chain Tension - Check/Adjust” . . . . . . . . . 310
“ Track (Rubber) - Inspect/Adjust”. . . . . . . . . . . . . 369
“ Equipment Lowering Control Valve - Check” . . . 324
“ Track - Inspect/Adjust”. . . . . . . . . . . . . . . . . . . . . 373
“ Track Roller and Idler - Inspect/Replace”. . . . . . 380 Every 500 Service Hours or 6
“ Wheel Nuts - Tighten” . . . . . . . . . . . . . . . . . . . . . 380 Months
“ Work Tool - Lubricate” . . . . . . . . . . . . . . . . . . . . . 382 “ Fuel System Filter (In-Line) - Replace”. . . . . . . . 328
“ Work Tool Mounting Bracket - Inspect”. . . . . . . . 385 “ Fuel System Primary Filter (Water Separator)
Element - Replace” . . . . . . . . . . . . . . . . . . . . . . . . 330
Initial 50 Service Hours
Every 500 Service Hours or 1 Year
“ Track (Steel) - Inspect/Adjust”. . . . . . . . . . . . . . . 371
“ Engine Oil and Filter - Change”. . . . . . . . . . . . . . 320
Every 50 Service Hours or Weekly “ Hydraulic Tank Breather - Replace” . . . . . . . . . . 352
“ Track Pins - Inspect” . . . . . . . . . . . . . . . . . . . . . . 379
Every 1000 Service Hours
Initial 100 Service Hours “ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . 323
“ Track (Steel) - Inspect/Adjust”. . . . . . . . . . . . . . . 371 “ Drive Chain Case Oil - Change” . . . . . . . . . . . . . 308
“ Rollover Protective Structure (ROPS) and Falling
Initial 250 Service Hours Object Protective Structure (FOPS) - Inspect” . . . 358
Every 1000 Service Hours or 1 Year
“ Final Drive Oil - Change” . . . . . . . . . . . . . . . . . . . 326
“ Hydraulic System Oil Filter - Replace” . . . . . . . . 350
Every 250 Service Hours “ Sprocket Sleeve - Inspect” . . . . . . . . . . . . . . . . . 366
“ Belts - Inspect/Adjust/Replace”. . . . . . . . . . . . . . 283
“Cooling System Coolant Sample (Level 1) -
Obtain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 301 “ Engine Crankcase Breather - Replace” . . . . . . . 316
“ Engine Oil Sample - Obtain” . . . . . . . . . . . . . . . . 320 Every 2000 Service Hours

“ Final Drive Oil Level - Check” . . . . . . . . . . . . . . . 327
“Refrigerant Dryer - Replace” . . . . . . . . . . . . . . . . 357
Initial 500 Hours (for New Systems, Years
Refilled Systems, and Converted
“ Hydraulic System Oil - Change” . . . . . . . . . . . . . 348
Systems)
“ Hydraulic System Oil - Change” . . . . . . . . . . . . . 347
“Cooling System Coolant Sample (Level 2) -
Obtain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
Every Year
Every 500 Service Hours “Cooling System Coolant Sample (Level 2) -
Obtain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
“ Final Drive Oil - Change” . . . . . . . . . . . . . . . . . . . 326
278 SEBU9084-11
Maintenance Section
“ Hoses and Clamps - Inspect/Replace”. . . . . . . . 337
Every 2 Years
“ Hoses and Clamps - Replace” . . . . . . . . . . . . . . 346

“ Diesel Exhaust Fluid Filter - Replace” . . . . . . . . 307
“ Diesel Fuel System Cleaner - Add” . . . . . . . . . . 307
“ Diesel Particulate Filter - Clean/Replace” . . . . . 308
“ Exhaust Gas Recirculation Valve - Clean ” . . . . 325

Years
“ Cooling System Water Temperature Regulator -
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 304
Every 3 Years
“ Seat Belt - Replace”. . . . . . . . . . . . . . . . . . . . . . . 359
Every 3 Years After Date of

Installation or Every 5 Years After
Date of Manufacture
“ Seat Belt - Replace”. . . . . . . . . . . . . . . . . . . . . . . 359

Years
“ Cooling System Coolant Extender (ELC) -
Add” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 299
Every 12 000 Service Hours or 6

Years
“ Cooling System Coolant (ELC) - Change” . . . . . 297
SEBU9084-11 279
Maintenance Section
Air Cleaner Dust Valve - Clean/Inspect
i04727032 i05289983
Air Cleaner Dust Valve - Clean/ Air Conditioner Condenser -

Inspect Clean
SMCS Code: 1051-571-VL (If Equipped)
Service the air filter elements when the alert indicator SMCS Code: 1805-070
for air filter restriction lights. Refer to Operation and
Maintenance Manual, “Alert Indicators” for
information about the indicator.
1. Open the engine access door. Personal injury can result from air pressure.
2. The air filter housing is located on the right side of Personal injury can result without following prop-
the engine compartment. er procedure. When using pressure air, wear a
protective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
The air conditioner condenser is attached to the

engine access door.
Note: Blow compressed air through the core in the
opposite direction of air flow to clean condenser.
i02418750
3. Check the dust valve after every 10 service hours

or at the end of each day. Actuate the valve by
squeezing the lips of the valve in order to remove
any accumulated debris.
Axle Bearings - Lubricate
SMCS Code: 3282-086-BD S/N: FMR1–Up
S/N: HP21–Up S/N: FMT1–Up
S/N: BE71–Up S/N: HMT1–Up
S/N: BL71–Up S/N: MLT1–Up
S/N: HP71–Up S/N: EZW1–Up
S/N: STK1–Up
S/N: TLK1–Up
S/N: EML1–Up
S/N: NTL1–Up
280 SEBU9084-11
Maintenance Section

Single Level Suspension (SLS) undercarriage
(1) Front pivot (2) Rear pivot
(3) Front grease zerks (4) Rear grease zerks

SEBU9084-11 281
Maintenance Section

Dual Level Suspension (DLS) undercarriage
(5) Front pivot (6) Rear pivot
(7) Front grease zerks (8) Rear grease zerks
Apply lubricant to all grease fittings. i05342096
Repeat the process for the opposite side of the

machine.
SMCS Code: 3282-086-BD
S/N: DX21–Up
S/N: FD21–Up
S/N: BY41–Up
282 SEBU9084-11
Maintenance Section
Backup Alarm - Test
S/N: CD41–Up
S/N: AH91–Up
S/N: BL91–Up
S/N: DX91–Up
S/N: GTC1–Up
S/N: FTK1–Up
S/N: GTK1–Up
S/N: FTL1–Up
S/N: GTL1–Up
S/N: GWR1–Up Illustration 234 g03384140
S/N: JST1–Up (1) Front Pivot

(2) Rear Pivot
S/N: PPT1–Up
i02580453
S/N: WCT1–Up
S/N: TAW1–Up Backup Alarm - Test
S/N: RCX1–Up SMCS Code: 7406-081
S/N: A9Z1–Up To prevent injury, make sure that no people are

working on the machine or near the machine. To
times.
1. Get into the operator's seat. Fasten the seat belt
and pull the armrests downward.
4. Move the joystick control to the REVERSE
position.
The backup alarm should sound immediately. The
backup alarm should continue to sound until the
joystick control is returned to the NEUTRAL
position or to the FORWARD position.
i06607826
Apply lubricant to all grease fittings.
(1) Front pivot Battery or Battery Cable -
(2) Rear pivot Inspect/Replace
SMCS Code: 1401-510; 1401-561; 1401-040; 1402-
machine. 510; 1402-040
Battery Life and Recommended

Practices
Battery life is very difficult to predict and can vary
greatly based on a number of factors including:
• Battery age
• Machine configuration
SEBU9084-11 283
Maintenance Section
Belts - Inspect/Adjust/Replace
• Engine starting frequency 5. Disconnect the positive battery cable at the

battery.
• Ambient conditions
6. Perform the necessary repairs. Replace the cables
• Storage practices or the battery, as needed.
There are a number of components that draw small 7. Connect the positive battery cable at the battery.
amounts of electrical current even when the key
switch is OFF. Some of these include: 8. Connect the negative battery cable to the frame of
the machine.
• Electronic control modules for the machine,
engine, emissions system, etc 9. Connect the negative battery cable at the battery.
• Radios or displays with memory features
• Product Link or other GPS-based systems Recycle the Battery
It is recommended to start and operate your machine Always recycle a battery. Never discard a battery.
normally for at least 15 minutes every few weeks to
prevent battery discharge which may damage the Always return used batteries to one of the following
battery beyond simple recharge. This time should be locations:
extended during the winter as the load on the battery
increase with extended heater usage, heated seat • A battery supplier
usage, and typically increased usage of the work
lights. • An authorized battery collection facility
The use of a battery disconnect switch or • Recycling facility
disconnection of the battery cables is recommended
if the machine will sit longer than a few weeks under i06134052
normal conditions. The use of a battery disconnect
switch may be advisable at the end of each working
day in extreme ambient conditions. Belts - Inspect/Adjust/Replace
SMCS Code: 1357-510; 1357-040; 1357-025
Additional references:
If a new belt is installed, check the belt adjustment
• “Operation and Maintenance Manual” Machine after 30 minutes of operation. A belt is considered
Storage Procedure used after 30 minutes of operation.
• “Operation and Maintenance Manual” DEF
Guidelines Belts
• “Operation and Maintenance Manual” Battery 1. Stop the engine in order to inspect the belt.
Disconnect Switch
• “Operation and Maintenance Manual” Engine and Maintenance Manual, “Access Doors and
Starting Covers”.
Inspect / Replace
1. Turn the engine start switch to the OFF position.
Turn all switches to the OFF position.
2. The battery is located in the engine compartment
and may either be on the left-hand side or right-
hand side. Open the engine access door.
3. Disconnect the negative battery cable at the
battery.
Note: Do not allow the disconnected battery cable to

contact the negative battery post.
4. Disconnect the negative battery cable from the

frame in order to inspect the cable.
284 SEBU9084-11
Maintenance Section

Typical Example
3. Loosen the quarter-turn fasteners (1) on the front

of the guard.
4. Remove the guard for the V-belt.
C2.2
(3) V-belt
(4) Alternator mounting bolt
(5) Adjusting bolt

C3.3B
(3) V-belt
(4) Alternator mounting bolt
(5) Adjusting bolt
SEBU9084-11 285
Maintenance Section
Table 112
Belt Tension Belt Tension
Initial Used
534 ± 22 N (120 ± 5 lb) 400 ± 44 N (90 ± 10 lb)
6. Loosen the mounting bolt (4). Loosen the adjusting

bolt (5).
7. Move the alternator until the correct tension is
reached.
8. Tighten the adjusting bolt. Tighten the mounting
bolt.
9. Recheck the belt deflection. If the amount of
deflection is incorrect, repeat step 5 to step 8.
Air Conditioner (if equipped)

Note: If your machine is equipped with an air
conditioner, use the same procedure and the same
Illustration 238 g02625628 measurements for the belt tension.
C3.8
(3) V-belt 1. Inspect the condition of the belt and the
(4) Alternator mounting bolt adjustment of the belt. The belt should deflect
(5) Adjusting bolt 10 mm (0.39 inch) to 12 mm (0.47 inch) under a
straight pull of 10 kg (22 lb). This measurement
should be taken between the air conditioner
compressor pulley and the crankshaft pulley.

(1) C3.3B
(2) C2.2 and C3.8
5. Inspect the condition of the belt and the

adjustment of the belt. The belt should deflect
10 mm (0.39 inch) to 12 mm (0.47 inch) under a
straight pull of 10 kg (22 lb). This measurement
should be taken between the alternator pulley and
the crankshaft pulley.
Note: A 144-0235 Borroughs Belt Tension Gauge

may be used to measure belt tension. This
measurement should be taken between the
alternator pulley and the crankshaft pulley. Refer to
the following table for belt tension.
286 SEBU9084-11
Maintenance Section

C3.8
(6) Mounting bolt
(7) Adjusting bolt
2. Loosen the mounting bolt (6) for the air conditioner

Illustration 240 g03820548 compressor. Loosen the adjusting bolt (7) for the
C2.2 air conditioner compressor.
(6) Mounting bolt 3. Move the air conditioner compressor until the
(7) Adjusting bolt
correct tension is reached.
4. Tighten the adjusting locknut. Tighten the
mounting bolt.
5. Recheck the belt deflection. If the amount of
deflection is incorrect, repeat step 2 to step 4.
Finish
1. Install the guard for the V-belt.

C3.3B
(6) Mounting bolt
(7) Adjusting bolt
SEBU9084-11 287
Maintenance Section
Blade Frame - Adjust
i02549571
Blade Frame - Adjust

SMCS Code: 6060-025-BG
Height Adjustment
2. Tighten the quarter-turn fasteners (1)

(1) Height Adjustment for the Frame
(2) Adjusting Bolts
(3) Frame
The height of the frame may be adjusted in order to

compensate for the wear on the cutting edge. The
front portion of the frame needs to be lowered as the
cutting edge wears. Remove the bolts (2) and lower
the frame (3). Install the bolts. This will keep the
blade level with the ground and this will prevent the
blade from digging into the ground.
288 SEBU9084-11
Maintenance Section
Bogie and Idler - Inspect/Replace
Note: In order to properly adjust the blade, the work Note: Some noise is typical and the noise does not
tool coupler needs to be vertical. The position of the indicate a problem.
pivot point of the blade is perpendicular to the
ground. Follow this procedure in order to ensure that i03318544
the cutting edge will remain flat on the ground during
operation. Bogie and Idler - Inspect/
Trunnion Joint Replace
SMCS Code: 4159-510; 4159-040; 4192-040; 4192-
Note: The trunnion is a dry joint. Adding grease to 510
the trunnion simply attracts abrasive particles. The
tightness of the joint should be monitored. Shims S/N: EML1–Up
should be removed when the joint becomes too
loose. This may be indicated by excessive movement S/N: FMR1–Up
in the blade. S/N: EZW1–Up
Inspect
Clean the undercarriage before inspecting the bogies
and the idlers.
Inspect the bogies and idlers for damage and wear.
Note: Minor damage to the rubber on the bogies and

idlers is acceptable. Minor damage includes nicks,
cuts, small pieces that are missing, and small
grooves. This minor damage is normal and
acceptable. Minor damage will not adversely affect
machine performance.
The bogies and the idlers should be replaced when
the damage to the rubber wheels adversely affects
machine performance. Replace the bogies and the
idlers when the rubber is worn beyond the minimum
specifications that are listed below.

(A) Trunnion Joint
(B) Bolts
(C) Shims
• Remove the four retaining bolts (B) and the cap.
• Remove the necessary shims.

• Replace the cap and bolts.
• The tightening sequence is shown in illustration

245 .
• Torque the bolts to 530 ± 70 N·m (391 ± 52 lb ft).
SEBU9084-11 289
Maintenance Section
Table 113
Bogie Wheels and Idler Wheels
Wear Limits
Minimum Width Minimum Thickness
254 mm (10 inch) 48 mm (1.9 inch) 3 mm (0.12 inch)
Loosen the Track Note: The track may be removed in the illustrations
for clarity.
Idler wheels
Use an appropriate floor jack in order to lift the

machine off the ground. Use appropriate jack stands
(1) in order to block up the machine. Raise the
machine until tracks are approximately 50 mm (2) Outer idler wheel
(2.0 inches) (A) off the ground. (3) Bolts and washers for the wheels
Loosen the track in order to work on the bogies and 1. Remove the bolts (3) and the washers for the outer
idlers. Refer to Operation and Maintenance Manual, idler wheel (2).
“Track - Inspect/Adjust” for the procedure.
2. Remove the outer idler wheel.
3. If necessary, remove the bolts and the washers for
the inner idler wheel and remove the wheel.
290 SEBU9084-11
Maintenance Section
4. Install the wheels. Tighten the bolts to a torque of Inspect

50 ± 5 N·m (37 ± 3.7 lb ft). Turn the bolts an
additional 45 degrees ±5 degrees in the same star Clean the undercarriage before inspecting the bogies
pattern. and the idlers.
Inspect the bogies and idlers for damage and wear.
Bogie wheels
Note: Minor damage to the rubber on the bogies and
idlers is acceptable. Minor damage includes nicks,
cuts, small pieces that are missing, and small
grooves. This minor damage is normal and
acceptable. Minor damage will not adversely affect
machine performance.
The bogies and the idlers should be replaced when
the damage to the rubber wheels adversely affects
machine performance. Replace the bogies and the
idlers when the rubber is worn beyond the minimum
specifications that are listed below.
Note: The hubs for the bogies and the hubs for the
idlers contain oil. Periodically, inspect the hubs for
leaks or for excessive end play. Contact your
Caterpillar dealer if either leaks or excessive end play
Illustration 248 g01393304 is found.
(4) Bogie Wheel
(5) Bolts and washers for the wheels
1. Remove the bolts (5) and the washers for the outer
bogie wheel (4).
2. Remove the outer bogie wheel.
the inner bogie wheel and remove the wheel.
4. Install the wheels. Tighten the bolts to a torque of
150 ± 20 N·m (110 ± 15 lb ft).
i05366267
Bogie and Idler - Inspect/

Replace
SMCS Code: 4159-510; 4159-040; 4192-040; 4192-
510
S/N: HP21–Up
S/N: BE71–Up
S/N: BL71–Up
S/N: HP71–Up
S/N: STK1–Up
S/N: TLK1–Up
S/N: NTL1–Up
S/N: FMT1–Up
S/N: HMT1–Up
S/N: MLT1–Up
SEBU9084-11 291
Maintenance Section
Table 114
Bogie Wheels and Idler Wheels
Wear Limits
Minimum Width Minimum Thickness
Loosen the Track
Use an appropriate floor jack in order to lift the

machine off the ground. Use appropriate jack stands
(1) in order to block up the machine. Raise the
machine until tracks are approximately 50 mm
(2.0 inch) (A) off the ground.
Loosen the track in order to work on the bogies and
idlers. Refer to Operation and Maintenance Manual,
“Track (Rubber) - Inspect/Adjust” for the procedure.
292 SEBU9084-11
Maintenance Section
Note: The track may be removed in the illustrations

for clarity.
Dual Level Suspension
(1) Idler wheels (2) Bogie wheels

SEBU9084-11 293
Maintenance Section
Idler wheels

(5) Outer idler wheel
(6) Bolts and washers for the wheels
(7) Inner idler wheel
1. Remove the bolts (6) and the washers for the outer
idler wheel.
2. Remove the outer idler wheel.

(3) Front scraper plate
(4) Rear scraper plate
3. If the inner idler wheel needs to be removed, you

will need to remove the scraper plate. Remove the
bolts that hold each scraper plate.
the inner idler wheel and remove the wheel.
5. Install the wheels in reverse order. Tighten the
bolts in a star pattern to a torque of 50 ± 5 N·m
(37 ± 3.7 lb ft). Tighten the bolts an additional 45
degrees ± 5 degrees in the same star pattern.
6. If necessary, install the scraper plates and torque
the bolts to standard torque value for the fastener
size.
294 SEBU9084-11
Maintenance Section
Bucket Cutting Edges - Inspect/Replace
Bogie wheels 4. Install the suspension group halves (5) together

and loosely install the bolts (4) and associated
washers and nuts.
5. Slide the suspension group pair onto the frame.
6. Lubricate the rubber inserts and slide the rubber
inserts into the suspension group.
7. Tighten the bolts (4) to a torque of 120 ± -20 N·m
(87 ± -15 lb ft)
8. Install the cover plate (2) & tighten the bolts (3) to a
torque of 50 ± -10 N·m (37 ± -7 lb ft)
9. Fill the axle with 60 mL (2.3 oz)of 10w-30 oil
through the access plug.
10. Slide the suspension group onto the frame.
11. Tighten the track to the proper tension. Refer to
Operation and Maintenance Manual, “"Track
(Rubber) - Inspect/Adjust”for the procedure.
i01743875
Bucket Cutting Edges -

Inspect/Replace
SMCS Code: 6801-040; 6801-510
Personal injury or death can result from bucket

falling.
Block the bucket before changing bucket cutting
edges.
1. Remove the bolts (3) and plate( 2). Remove bolts
(4) and suspension group halves (5).
1. Lower the lift arms fully. Tilt back the bucket so that
Note: There are four rubber inserts between the two the bucket cutting edge is accessible.
suspension group halves. Retain these inserts for
installation later. 2. Place blocks under the raised edge of the bucket.
2. Remove bolt (6) and bogie wheel ((7)) from 3. Remove the bolts. Remove the cutting edge and
suspension group (5). the end bits.
4. Clean the contact surfaces.
Note: Repeat for opposite side
5. Use the opposite side of the cutting edge, if this
Note: Use caution not to damage the duo-cone seal side is not worn.
and rubber seals under wheel. Retain these seals for
the installation later. 6. Install a new cutting edge, if both edges are worn.
Note: The duo cone sealing faces must be kept clean 7. Install the bolts.
3. Install the new bogie wheel (7) to suspension 8. Remove the blocks that are under the bucket.
group (5) and tighten bolt (6) to a torque of 9. After a few hours of operation, check the bolts for
240± 40N·m (177 ± 30lb ft). proper torque.
Note: Note: Repeat for opposite side
SEBU9084-11 295
Maintenance Section
Bucket Tips - Inspect/Replace
i01764331
Bucket Tips - Inspect/Replace

SMCS Code: 6805-040; 6805-510
Personal injury or death can result from bucket

falling.
Block the bucket before changing bucket cutting
edges.
1. Lower the lift arms fully. Tilt back the bucket so that
the bucket tips are accessible.
2. Place blocks under the raised edge of the bucket.
3. Remove the mounting bolts. Remove the bucket
tips.
4. Clean the mounting surface. Illustration 255 g01287414
5. Replace the bucket tips.

1. Rotate the latch to free the cover from the
6. Install the bolts. ductwork. Do NOT use excessive force. Lift up on
7. Remove the blocks that are under the bucket. the cover and remove the cover.
8. After a few hours of operation, check the bolts for 2. Remove the air filter element from the duct and
proper torque. clean the filter element with low-pressure air
(maximum 207 kPa (30 psi)). Direct the air flow up
i05290094 the pleats and down the pleats from the side of the
filter opposite of the air flow. Replace the element
Cab Air Filter - Clean/Replace if the element is damaged or if the element seal is
damaged. Replace the element if the air
(If Equipped) conditioner performance is low.
SMCS Code: 7342-510; 7342-070
Note: Do not use water for cleaning the filter.
Fresh Air Filter
Note: The cover for the cab air filter is located on the
left-hand side of the machine behind the cab.
296 SEBU9084-11
Maintenance Section
Cab Interior - Clean
3. Install the element. Replace the cover and tighten

the thumb screw.
Recirculation Filter

Floor mat in the cab
1. Turn the thumb screws until the thumb screws are

free from the duct. Remove the cover.
2. Remove the air filter element from the duct and
clean the filter element with low-pressure air
(maximum 207 kPa (30 psi)). Direct the air flow up
the pleats and down the pleats from the side of the
filter opposite of the air flow. Replace the element
if the element is damaged or if the element seal is
damaged. Replace the element if the air
conditioner performance is low.
Note: Do not use water for cleaning the filter.
3. Install the element. Replace the cover and tighten

the thumb screws.
i05290820 Illustration 258 g03359669

The drain on the rear and two drains on the front of
Cab Interior - Clean the cab.
SMCS Code: 7301-070 You can wash the floor of the cab with water. There
are drains in front and one in the back of the floor of
The floor mat is removable. The floor mat has sides the cab
in order to help retain the material.
SEBU9084-11 297
Maintenance Section
Cooling System Coolant (ELC) - Change
i06134931
Cooling System Coolant (ELC)

- Change
SMCS Code: 1395-044-NL

diator is cool. Then loosen cap slowly to relieve
the pressure.
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: The machine was shipped from the factory Illustration 259 g03821056
with Extended Life Coolant (ELC) in the cooling
C2.2
system.
For information about the addition of Extender to your
cooling system, see the Operation and Maintenance
Manual, “Cooling System Coolant (ELC) Extender -
Add” or consult your Cat dealer.
Drain the coolant whenever the coolant is dirty or
whenever the coolant is foaming.
The radiator cap is located under the radiator guard
on the top of the engine compartment.
Allow the machine to cool before you change the
coolant.
1. Open the engine access door and raise the
radiator guard. Refer to Operation and
Maintenance Manual, “Access Doors and Covers”.
Note: The radiator cap may be located either on the

left side of the radiator (C3.3B and C3.8 engines) or
the right side of the radiator (C2.2 engine).

C3.3B and C3.8
2. Slowly loosen the radiator cap in order to relieve

system pressure. Remove the radiator cap.
298 SEBU9084-11
Maintenance Section
Cooling System Coolant (ELC) - Change

Coolant drain (C3.8)
3. Locate the drain for the coolant system on the left

side of the C3.8engine by the oil filter. Locate the
drain for the coolant on the right side for the C3.3B
Illustration 261 g03822259 engine. Use the attached drain hose on the valve.
Coolant Drain (C2.2)

4. Remove the access panel under the rear of the
Coolant drain (C3.3B) machine. Pull the drain hose through the access
hole.
5. Open the drain and allow the coolant to drain into a
suitable container.
6. Close the drain.
SEBU9084-11 299
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
7. Push the hose back into the engine compartment. When a Cat Extended Life Coolant is used, an
Replace the access panel. extender must be added to the cooling system
periodically.
8. Replace the thermostat. See Operation and
Maintenance Manual, “Cooling System Water 1. Open the engine access door and raise the
Temperature Regulator - Replace” for the process radiator guard. Refer to Operation and
for replacing the thermostat. Maintenance Manual, “Access Doors and Covers”.
9. Add the coolant solution directly to the radiator. Do Note: The radiator cap may be located either on the
not use the coolant overflow reservoir as a filler for left side of the radiator (C3.3B and C3.8 engines) or
the coolant. Refer to Operation and Maintenance the right side of the radiator (C2.2 engine).
Manual, “Capacities - (Refill)”. Refer to Special
Publication, SEBU6250, “Caterpillar Machine
Fluids Recommendations”.
Note: Premix the coolant solution before filling

the cooling system. The coolant solution should
contain 50 percent coolant and 50 percent
distilled water.
Note: Add the coolant solution at a maximum rate
of 5 liters per minute. The chance of trapping air
inside the engine block will be reduced. A large
amount of trapped air can cause localized heating to
occur upon start-up. Localized heating may result in
engine damage, which may lead to failure of the
engine.
10. Start the engine. Run the engine without the

radiator cap until the thermostat opens and the
coolant level stabilizes. If necessary, add coolant.
Note: The sight gauge for the coolant level is located
near the radiator cap.
11. Check the coolant level in the sight gauge on the

radiator. Maintain the coolant level to the top of the
sight gauge with the radiator in the LOWERED
position.
12. Stop the engine. Inspect the radiator cap and the Illustration 265 g03821056
gasket. Replace the cap if the cap or the gasket is C2.2
damaged. Install the radiator cap.
13. Pull the radiator guard downward.
i06134984
Cooling System Coolant

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

the pressure.
300 SEBU9084-11
Maintenance Section
Cooling System Coolant Extender (ELC) - Add

C3.3B and C3.8 Coolant drain (C3.3B)
2. Slowly loosen the radiator cap in order to relieve

system pressure. Remove the radiator cap.

Coolant drain (C3.8)
3. If necessary, drain enough coolant from the

radiator in order to allow the addition of the coolant
additive.
4. Add 0.17 L (0.18 qt) of cooling system additive.
5. Inspect the radiator cap and the gasket. If the cap
or the gasket is damaged, replace the cap. Install
Coolant Drain (C2.2) the radiator cap.
SEBU9084-11 301
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain
6. Check the coolant level in the sight gauge on the

radiator. Maintain the coolant level to the top of the
sight gauge with the radiator in the LOWERED
position.
7. Add the extender directly to the radiator. Do not
use the coolant overflow reservoir as a filler for the
extender.
8. Tilt the radiator guard downward.
For additional information on the addition of extender,
see Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations”.
i06134962
Cooling System Coolant

Sample (Level 1) - Obtain
SMCS Code: 1350-008; 1395-008; 7542
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-
ples may contaminate the samples that are being
drawn. This contaminate may cause a false analysis Illustration 270 g03821056
and an incorrect interpretation that could lead to con- C2.2
cerns by both dealers and customers.
Note: Level 1 results may indicate a need for

Level 2 Analysis.

C3.3B and C3.8

“Access Doors and Covers” for the location of the
service points.
302 SEBU9084-11
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
i06134979
Pressurized system: Hot coolant can cause seri- Cooling System Coolant
Sample (Level 2) - Obtain
the pressure. SMCS Code: 1350-008; 1395-008; 7542
Obtain the sample of the coolant from the radiator. NOTICE

When the system is cool, slowly remove the radiator Always use a designated pump for oil sampling, and
cap (2). use a separate designated pump for coolant sam-
pling. Using the same pump for both types of sam-
Note: Do not take the sample from the Coolant ples may contaminate the samples that are being
Overflow Reservoir. drawn. This contaminate may cause a false analysis
and an incorrect interpretation that could lead to con-
Obtain the sample of the coolant as close as possible cerns by both dealers and customers.
to the recommended sampling interval. In order to
receive the full effect of S·O·S analysis, establish a
consistent trend of data. In order to establish a
pertinent history of data, perform consistent
samplings that are evenly spaced. Supplies for
collecting samples can be obtained from your Cat
dealer.
Use the following guidelines for proper sampling of
the coolant:
• Keep the unused sampling bottles stored in plastic
bags.
• Keep the lids on empty sampling bottles until you
are ready to collect the sample.
• Complete the information on the label for the

sampling bottle before you begin to take the
samples.
• Use a designated pump to collect the sample in

order to avoid contamination.
• Obtain coolant samples directly from the coolant

tank. You should not obtain the samples from any
other location.
• Place the sample in the mailing tube immediately

after obtaining the sample in order to avoid
contamination.
• Never collect samples from the drain for a system. Illustration 272 g03821056
C2.2
Submit the sample for Level 1 analysis.
For additional information about coolant analysis, see
Special Publication, SEBU6250, “Caterpillar Machine
Fluids Recommendations” or consult your Cat dealer.
SEBU9084-11 303
Maintenance Section
Cooling System Level - Check
i06134839
Cooling System Level - Check

SMCS Code: 1350-535-FLV; 1350-040-HX; 1382-
070; 1382-510

the pressure.
1. Open the engine access door and raise the

radiator guard. Refer to Operation and
Maintenance Manual, “Access Doors and Covers”.

C3.3B and C3.8

“Access Doors and Covers” for the location of the
service points.

the pressure.
Obtain the sample of the coolant from the radiator.

When the system is cool, slowly remove the radiator
cap (2).
Note: Do not take the sample from the Coolant Illustration 274 g03821017
Overflow Reservoir.
(1) Sight Gauge
Obtain the sample of the coolant as close as possible (2) Radiator Cap
to the recommended sampling interval. Supplies for
collecting samples can be obtained from your Cat 2. Check the coolant level in the sight gauge (1) on
dealer. the radiator. Maintain the coolant level to the top of
the sight gauge with the radiator in the LOWERED
“Cooling System Coolant Sample (Level 1) - Obtain” position. If you need to add coolant, add the
for the guidelines for proper sampling of the coolant. coolant directly to the radiator. Remove the
radiator cap (2) slowly in order to relieve system
Submit the sample for Level 2 analysis. pressure.
For additional information about coolant analysis, see Note: The radiator cap may be located either on the
Special Publication, SEBU6250, “Caterpillar Machine left side of the radiator (C3.3B and C3.8 engines) or
Fluids Recommendations” or consult your Cat dealer. the right side of the radiator (C2.2 engine).
3. Inspect the radiator cap and the gasket. Replace

the cap if the cap or the gasket is damaged. Install
the radiator cap.
4. Tilt the radiator guard downward.
304 SEBU9084-11
Maintenance Section
Cooling System Water Temperature Regulator - Replace
5. The coolant reservoir is located on the left-hand

side of the engine bay or on the back of the engine
compartment door. Maintain the coolant level in
the coolant overflow reservoir between the "MIN"
and "MAX" lines. “MIN” and “MAX” lines.
i06133974
Cooling System Water

Temperature Regulator - Water Temperature Regulator (C2.2)
Replace
SMCS Code: 1355-510; 1393-010
Replace the thermostat on a regular basis in order to
reduce the chance of unscheduled downtime and of
problems with the cooling system. Failure to replace
the engine thermostat on a regularly scheduled basis
could cause severe engine damage.
The thermostat should be replaced after the cooling
system has been cleaned. Replace the thermostat
while the cooling system is drained. Ensure that the
cooling system coolant is drained to a level that is
below the thermostat housing.
Cat engines incorporate a shunt design cooling
system. Always operate the engine with a thermostat.
Covers”.
2. Drain the coolant from the machine. See Operation
and Maintenance Manual, “Cooling System
Coolant (ELC) - Change” for the procedure to Illustration 277 g01327027
drain the cooling system. (1) Bolts
(2) Cover
(3) Gasket
(4) Temperature Regulator
(5) Housing
SEBU9084-11 305
Maintenance Section
Cooling System Water Temperature Regulator - Replace

Water Temperature Regulator (C3.3B) Water Temperature Regulator (C3.8)

(1) Cover (1) Cover
(2) Gasket (2) Gasket
(3) Temperature Regulator (3) Temperature Regulator
(4) Housing (4) Housing
3. Loosen the hose clamp and remove the hose from

the cover (1).
4. Remove the two bolts from the housing assembly.
Remove the cover (1).
5. Install the temperature regulator in the housing (4).
6. Install a new gasket (2).
306 SEBU9084-11
Maintenance Section
Diesel Exhaust Fluid - Fill
Note: For machines with the C3.8 apply liquid

sealant to the housing side. Do not apply sealant to
the cover.
7. Install the cover.

8. Install the hose. Tighten the hose clamp.
9. Refill the cooling system. Refer to Operation and
Maintenance Manual, “Capacities - (Refill)”. Refer
to Operation and Maintenance Manual, “Cooling
System Coolant (ELC) - Change” for information
about refilling the cooling system. Refer to Special
Publication, SEBU6250, “Caterpillar Machine Fluid
Recommendations” for coolant information.
10. Close the engine access door. Illustration 282 g03821455
DEF Filler Cap Location
i06136000
Diesel Exhaust Fluid - Fill

SMCS Code: 108K-544
S/N: BL21–Up
S/N: DX21–Up
S/N: FD21–Up
S/N: HP21–Up
S/N: MD21–Up
S/N: BY41–Up
S/N: BL71–Up
S/N: DX91–Up (1) DEF Tank Filler Cap
NOTICE 1. Clean blue DEF tank filler cap (1) and the
Care must be taken to ensure that fluids are con- surrounding area.
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the machine. 2. Remove the blue DEF tank filler cap (1).
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem- 3. Fill the tank with diesel exhaust fluid (DEF).
bling any component containing fluids.
Note: Do not fill the DEF tank from a contaminated
Dispose of all fluids according to local regulations container or funnel.
and mandates.
Note: Do not over fill the tank. DEF can freeze and
needs room for expansion.
Reference: See Operation and Maintenance
Manual, “Capacities (Refill)” for the capacity of the 4. Install the blue DEF tank filler cap (1).
DEF tank for your machine. Refer to Operation and Maintenance Manual,
“Lubricant Viscosities” for more information on diesel
exhaust fluid (DEF) guidelines.
SEBU9084-11 307
Maintenance Section
Diesel Exhaust Fluid Filter - Replace
i06136002
Diesel Exhaust Fluid Filter -

Replace
SMCS Code: 108K-510-FI; 108K-544
S/N: BL21–Up
S/N: DX21–Up
S/N: FD21–Up
S/N: HP21–Up
S/N: MD21–Up
S/N: BY41–Up
S/N: BL71–Up
S/N: DX91–Up
NOTICE
Ensure that the engine is stopped before any servic- Illustration 284 g03821620
ing or repair is performed.
2. Remove the black plastic cover and then diesel
exhaust fluid (DEF) filter assembly, which is
NOTICE shown.
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- 3. Install new DEF filter. Replace DEF filter cap.
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain- 4. Tilt the cab downward. Refer to Maintenance
ers before opening any compartment or disassem- Section, “Cab Tilting” for the procedure.
Refer to Special Publication, NENG2500, “Cat Dealer i06155020
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog” Diesel Fuel System Cleaner -
for tools and supplies suitable to collect and contain
fluids on Cat products. Add
SMCS Code: 1250-538-ADD; 1280-538-ADD
Dispose of all fluids according to local regulations
and mandates. S/N: CD41–Up
S/N: AH91–Up
1. The DEF filter is located on the left side of the
machine under the cab. Tilt the cab upward. Refer S/N: BL91–Up
to the Maintenance Section, “Cab Tilting” for the
S/N: KXC1–Up
procedure.
S/N: HRD1–Up
S/N: DPR1–Up
S/N: GWR1–Up
Add Cat Diesel Fuel System Cleaner every 3000
hours of engine operation. This operation is to
remove built up deposits and maintain engine power
output. Pour 0.95L (32 oz.) of the cleaner into a full
tank of diesel fuel and operate the machine normally.
308 SEBU9084-11
Maintenance Section
Diesel Particulate Filter - Clean/Replace
Due to regional fuel variations and different usage • The DPF from your machine can be replaced with
cycles, deposits may build up in shorter periods. a new DPF
Caterpillar recommends using the cleaner as
required, if a power reduction is observed. Contact • The DPF from your machine can be replaced with
your Cat dealer for availability. a remanufactured DPF
i05761300 • The DPF from your machine can be cleaned by

your local authorized Cat dealer, or a Caterpillar
Diesel Particulate Filter - approved DPF cleaning machine, and reinstalled
Clean/Replace Note: In order to maintain emissions documentation,

the DPF that is removed from the machine when the
SMCS Code: 108F-510; 108F-070; 1091-070; 1091- DPF is cleaned must be reinstalled on the same
510 machine.
S/N: BL21–Up
i02417847
S/N: DX21–Up
S/N: FD21–Up
Drive Chain Case Oil - Change
SMCS Code: 3261-543-OC; 3261-544-OC
S/N: HP21–Up
S/N: BL21–Up
S/N: MD21–Up
S/N: MD21–Up
S/N: BY41–Up
S/N: DTB1–Up
S/N: BE71–Up
S/N: KXC1–Up
S/N: BL71–Up
S/N: HRD1–Up
S/N: HP71–Up
S/N: BYF1–Up
S/N: DX91–Up
S/N: DML1–Up
S/N: DTB1–Up
S/N: ETL1–Up
S/N: GTC1–Up
S/N: JSL1–Up
S/N: BYF1–Up
S/N: SEN1–Up
S/N: ETL1–Up
S/N: DPR1–Up
S/N: FTL1–Up
S/N: HMR1–Up
S/N: GTL1–Up
S/N: KTS1–Up
S/N: DZT1–Up
S/N: DZT1–Up
S/N: FMT1–Up
S/N: LST1–Up
S/N: HMT1–Up
S/N: MKT1–Up
S/N: JST1–Up
S/N: A9W1–Up
S/N: B5W1–Up
S/N: B5W1–Up
S/N: EZW1–Up
S/N: MPW1–Up
S/N: TAW1–Up
S/N: BGZ1–Up
S/N: BGZ1–Up
Note: Only applies to engines with aftertreatment.
Consult your Cat dealer when the DPF needs to be
cleaned.
The approved Caterpillar DPF maintenance
procedure requires that one of the following actions
be taken when the DPF needs to be cleaned:
SEBU9084-11 309
Maintenance Section
Drive Chain Case Oil - Check

The plugs for the drive chain cases as the plugs are
viewed from the underside of the machine. 3. Remove the filler plug for the right side drive chain
case. Fill the drive chain case with oil to the
1. Remove the drain plug for the left drive chain case bottom of the threads on the fill port. Refer to
and the right drive chain case. Allow the oil to Operation and Maintenance Manual, “Lubricant
drain into a suitable container. Viscosities” and Operation and Maintenance
2. Apply 169-5464 Quick Cure Primer and Manual, “Refill Capacities”.
5P-3413 Pipe Sealant to the threads on the drain 4. Apply 169-5464 Quick Cure Primer and
plugs. Install the drain plugs. 5P-3413 Pipe Sealant to the threads on the filler
plug. Install the filler plug.
5. Repeat the process for the left side drive chain
case.
i02422873
Drive Chain Case Oil - Check

SMCS Code: 3261-535
S/N: BL21–Up
S/N: MD21–Up
S/N: DTB1–Up
S/N: KXC1–Up
S/N: HRD1–Up
S/N: BYF1–Up
S/N: DML1–Up
S/N: ETL1–Up
S/N: JSL1–Up
S/N: SEN1–Up
S/N: DPR1–Up
310 SEBU9084-11
Maintenance Section
Drive Chain Tension - Check/Adjust
S/N: HMR1–Up S/N: MD21–Up

S/N: KTS1–Up S/N: DTB1–Up
S/N: DZT1–Up S/N: KXC1–Up
S/N: LST1–Up S/N: HRD1–Up
S/N: MKT1–Up S/N: BYF1–Up
S/N: A9W1–Up S/N: DML1–Up
S/N: B5W1–Up S/N: ETL1–Up
S/N: MPW1–Up S/N: JSL1–Up
S/N: BGZ1–Up S/N: SEN1–Up
S/N: DPR1–Up
S/N: HMR1–Up
S/N: KTS1–Up
S/N: DZT1–Up
S/N: LST1–Up
S/N: MKT1–Up
S/N: A9W1–Up
S/N: B5W1–Up
S/N: MPW1–Up
S/N: BGZ1–Up
Note: Steel tracks that go over the tires should

only be used with pneumatic tires. When you use
steel tracks that go over tires or any drive train device
except tires, the interval for checking the drive chains
should be reduced to every 100 Service Hours. The
Illustration 287 g01210036 use of rubber tracks that go over the tires is not
recommended.
1. Remove the filler plug for the right side drive chain
Note: There are four drive chains on the skid steer
case. The oil level should be at the bottom of the loader that must be checked and adjusted.
threads on the fill port. If necessary, refer to
Operation and Maintenance Manual, “Drive Chain 1. Park the machine on level ground and stable
Case Oil - Change” for the proper procedure to ground.
add oil.
2. Use appropriate floor jacks in order to lift the
2. Apply 169-5464 Quick Cure Primer and machine off the ground.
5P-3413 Pipe Sealant to the threads on the filler
plug. Install the filler plug.
3. Repeat the process for the left side drive chain
case.
i02710828
Drive Chain Tension - Check/

Adjust
SMCS Code: 3261-025; 3261-535
S/N: BL21–Up
SEBU9084-11 311
Maintenance Section
Drive Chain Tension - Check/Adjust
3. Rotate the front wheel forward and backward. 6. Loosen the eight bolts (5) for the axle housing.
Measure the total free play (A). Repeat the Place the chain tension adjuster (7) between the
process for the rear wheel. axle housings (6).
Note: If the total free play (A) does not exceed
15 mm (0.6 inch) the chain tension does not need
further inspection. If the total free play exceeds
15 mm (0.6 inch), you should continue with the
inspection.
7. Rotate the axle in order to ensure that the chain (8)

is taut below the sprockets. Place a straight edge
across the top of the sprockets. Measure the total
amount of movement in the chain (B). Set the
chain tension so that there is a total of 15 mm
(0.6 inch) movement in the chain. This is equal to
4. Remove the wheel nuts (3). Use an appropriate
7.5 mm (0.3 inch) of movement above the straight
nylon lifting strap and a hoist in order to remove
edge and 7.5 mm (0.3 inch) of movement below
the tire and rim (1). The weight of the standard tire
the straight edge.
and rim is 51 kg (113 lb).
5. Remove bolts and the cover (2) for the drive chain
case.
Note: Remove the sealant from the cover and from
the machine.
312 SEBU9084-11
Maintenance Section
Drive Line Wear Sleeve - Inspect/Replace
i06601450
Drive Line Wear Sleeve -

Inspect/Replace
SMCS Code: 3154-040; 3154-510
8. Torque the nuts for the axle housing in the order

that is shown above to 160 ± 15 N·m
(118 ± 11 lb ft) and turn an additional 60° ±5° in the
same order.
9. Remove the chain tension adjuster.
10. Install the bolts and the cover for the drive chain
case.
Note: Use 8T-9022 Silicone Gasket in order to seal
the cover to the machine.
11. Use an appropriate nylon lifting strap and a hoist

in order to position the tire and rim to the axle. The
weight of the tire and rim is 51 kg (113 lb). Refer
to Operation and Maintenance Manual, “Wheel
Nuts - Tighten” for the procedure to tighten the
wheel nuts. Illustration 293 g06040640
12. Repeat the procedure on the opposite side of the (1) Wear Sleeve
(2) Friction Tape
machine if it is necessary. (3) Tie Strap
13. Lower the machine to the ground.
1. Cut both tie straps and remove the worn wear
sleeve.
2. Install a new wear sleeve onto the hose in the
same location. Use the grip tape on the hose as a
guide. Replace the grip tape as needed. The
sleeve should fall where the hose assembly
makes contact with metal frame members or other
hoses.
3. Secure the wear sleeve using two tie straps.
SEBU9084-11 313
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
i05366418 1. Open the engine access door.

2. The air filter housing is located on the right side of
Engine Air Filter Primary the engine compartment.
Element - Clean/Replace
SMCS Code: 1054-070-PY; 1054-510-PY
Personal injury can result from air pressure.

Personal injury can result without following prop-
er procedure. When using pressure air, wear a
protective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
NOTICE
Never service the air cleaner when the engine is run- Illustration 294 g00101864
ning, to avoid engine damage.
3. Unlatch the air cleaner housing cover (1). Rotate
the cover counterclockwise and remove the cover.
NOTICE
Caterpillar recommends certified air filter cleaning 4. Remove the primary filter element (2).
services that are available at Cat dealers. The Cat 5. If appropriate, clean the primary filter element. Use
cleaning process uses proven procedures to assure
consistent quality and sufficient filter life. air pressure to clean the primary filter elements.
Pressurized air will not remove deposits of carbon
Observe the following guidelines if you attempt to and oil. Use filtered, dry air with a maximum
clean the filter element: pressure of 207 kPa (30 psi).
Do not tap or strike the filter element in order to re-
move dust. Note: When the primary filter elements are cleaned,
always begin with the inside in order to force dirt
Do not wash the filter element. particles toward the outside. Aim the hose so that the
air flows inside the element along the length of the
Use low pressure compressed air in order to remove filter in order to help prevent damage to the paper
the dust from the filter element. Air pressure must not pleats. Do not aim the stream of air directly at the
exceed 207 kPa (30 psi). Direct the air flow up the primary filter element.
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage
6. Inspect the cleaned, dry primary air filter element.
to the pleats.
Use a 60 watt blue light in a dark room or in a
Do not use air filters with damaged pleats, gaskets, similar facility. Place the blue light in the primary
or seals. Dirt entering the engine will cause damage air filter element. Rotate the primary air filter
to engine components. element. Inspect the primary air filter element for
Service the air filter elements when the alert indicator tears and/or holes. Inspect the primary air filter
for air filter restriction lights. Refer to Operation and element for light that may show through the filter
Maintenance Manual, “Alert Indicators” for material. If necessary in order to confirm the result,
information about the indicator. compare the primary air filter element to a new
primary air filter element that has the same part
Clean number.
The primary filter element can be used up to three Note: Do not use a primary air filter element that has
times if the element is properly cleaned and if the any tears and/or holes in the filter material. Do not
element is properly inspected. When the primary use a primary air filter element with damaged pleats,
filter element is cleaned, check for rips or tears in the gaskets, or seals. Discard damaged primary air filter
filter material. The primary filter element should be elements.
replaced at least one time per year. This replacement
should be performed regardless of the number of
cleanings.
314 SEBU9084-11
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
7. Clean the inside of the air cleaner housing with a

damp cloth. Do not use compressed air to clean
the housing.
8. Install the primary filter element into the filter
housing.
9. Install the cover for the filter housing.

4. Remove the primary filter element (2).
5. Clean the inside of the air cleaner housing with a
damp cloth. Do not use compressed air to clean
the housing.
6. Install a new primary filter element into the filter
housing.
10. Rotate the cover clockwise and latch the cover.
Note: Make sure that the cover is properly

positioned.

12. Start the engine. The alert indicator for air filter
restriction should turn off. If the alert indicator
continues to light, replace the secondary air filter.
“Engine Air Filter Secondary Element - Replace”.
Replace
The primary filter element should be replaced at least
one time per year. You can clean the primary filter
up to three times.
1. Open the engine access door.
the engine compartment. 8. Rotate the cover clockwise and latch the cover.
Note: Make sure that the cover is properly
positioned.

SEBU9084-11 315
Maintenance Section
Engine Air Filter Secondary Element - Replace
10. Start the engine. The alert indicator for air filter
restriction should turn off. If the alert indicator
continues to light, replace the secondary air filter.
“Engine Air Filter Secondary Element - Replace”.
i05355849
Engine Air Filter Secondary

Element - Replace
SMCS Code: 1054-510-SE
NOTICE
Always replace the secondary filter element. Illustration 299 g00038606
Never attempt to reuse the secondary filter ele-
ment by cleaning the element. 5. Clean the inside of the air cleaner housing with a
When the primary filter element is cleaned for the damp cloth. Do not use compressed air to clean
third time, the secondary filter element should be the housing.
replaced.
6. Remove the secondary filter element.
The secondary filter element should also be replaced 7. Cover the air inlet opening.
if the restricted Air Filter indicator comes on after the
installation of a clean primary filter element or if the 8. Clean the inside of the air cleaner housing with a
exhaust smoke is still black. damp cloth, if necessary. Do not use compressed
air to clean the housing.
NOTICE 9. Uncover the air inlet opening.
The filter should be kept in service for no longer than
one year 10. Install a new secondary element.
11. Install the primary element.
1. Open the engine access door.
the engine compartment.

4. Remove the primary filter element (2). Illustration 300 g02828636
13. Rotate the cover clockwise and latch the cover.

316 SEBU9084-11
Maintenance Section
Engine Compartment - Inspect/Clean
Note: Ensure that the cover is properly positioned. Use low-pressure water in order to clean the
condenser.
i06133897
i04434042
Engine Crankcase Breather -
Engine Compartment - Replace
Inspect/Clean (and PCV Valve Check)
SMCS Code: 1000-040-CPA; 1000-070-CPA
SMCS Code: 1317-510
Inspect the engine compartment for dirt buildup or
debris. Remove any dirt or debris from the engine S/N: BL21–Up
compartment.
S/N: DX21–Up
S/N: FD21–Up
Covers”. S/N: HP21–Up
S/N: MD21–Up
S/N: BY41–Up
S/N: BE71–Up
S/N: BL71–Up
S/N: HP71–Up
S/N: BL91–Up
S/N: DX91–Up
S/N: DTB1–Up
S/N: GTC1–Up
S/N: HRD1–Up
S/N: BYF1–Up
S/N: ETL1–Up
S/N: FTL1–Up
S/N: GTL1–Up
S/N: DPR1–Up
2. Remove any debris or dirt from the engine
compartment. If necessary, remove the access S/N: GWR1–Up
panel in order to clean out the engine S/N: DZT1–Up
compartment.
S/N: FMT1–Up
Note: Use care when you clean the engine
S/N: HMT1–Up
compartment. Damage to the machine may occur.
S/N: JST1–Up
S/N: B5W1–Up
Air Conditioning Condenser S/N: EZW1–Up
The air conditioning condenser is located on the S/N: TAW1–Up
access door of the engine compartment. Cleaning
the air conditioning condenser will maintain optimum S/N: BGZ1–Up
performance of the air conditioning system.
Note: Only applies to engines with aftertreatment.
SEBU9084-11 317
Maintenance Section
and PCV Valve Check

Covers”.
2. Tilt the radiator upward. Refer to Operation and
Maintenance Manual, “Radiator Tilting”.

C2.2 and C3.3B

C2.2

C3.8

C3.3B
318 SEBU9084-11
Maintenance Section
Engine Oil Level - Check

C3.8
3. The breather is located in the engine compartment

on the right-hand side of engine. There is cap on
the breather and a replaceable element inside.
Note: This service may be performed without
C3.8
removing the housing from the engine.
(1) Cover
(2) O-ring
4. Remove the breather cap and remove the filter (3) Filter Element
element. (4) Housing
Note: The C2.2 and C3.3B are equipped with cap on 6. For the C3.8 only, press the PCV valve to ensure
bottom portion of the canister. Use a wrench to
that the valve moves smoothly. If the valve does
remove the breather cap. The C3.8 is equipped with
cap on top of canister, remove cap by applying not move smoothly, replace the housing.
downward pressure on the cap while turning.
a. Install the new filter element in the breather.
5. Clean the housing and the cap for the breather. Install the breather cap.
b. Tilt the radiator downward.

c. Close the engine access door.
i06133893

SMCS Code: 1348-535-FLV
NOTICE
Do not overfill the crankcase. Engine damage can
result.
1. Stop the engine and allow 10 to 20 minute for the

oil to drain back into the oil pan.
SEBU9084-11 319
Maintenance Section

C3.3B Engine

C2.2 Engine
320 SEBU9084-11
Maintenance Section
Engine Oil Sample - Obtain
5. Clean the oil filler cap and install the oil filler cap.
i05354546
Engine Oil Sample - Obtain

SMCS Code: 1348-554-SM; 7542-008
Obtain the oil sample of the engine oil through the

opening for the dipstick.
Reference: For more information, refer to Special
C3.8 engine
Publication, SEBU6250, “Caterpillar Machine Fluids
(1) Oil Filler Cap Recommendations” “S·O·S Oil Analysis” and Special
(2) Dipstick
(3) Oil Filter Publication, PEHP6001, “How To Take A Good Oil
Sample”.
i06133499
Covers”.
Engine Oil and Filter - Change
SMCS Code: 1308-510; 1348-044
NOTICE
ers before opening any compartment or disassem-
Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat ® products.
and mandates.
(1) Oil level add mark The normal oil change interval for the machine is
(2) Full mark Every 500 Service Hours or every year when the
following conditions are met:
3. Maintain the oil level between the “ADD” (1) mark
and the “FULL” (2) mark on the dipstick. • Use an engine oil in the Operation and
Maintenance Manual, “Lubricant Viscosities”.
4. Remove the oil filler cap (1) and add oil.
SEBU9084-11 321
Maintenance Section
• Cat filters are used.

• The altitude does not exceed 2300 m (7545 ft).
An oil change interval of Every 250 Service Hours or
every 6 months is required when the following
conditions occur:
• Not using a recommended engine oil in the
Operation and Maintenance Manual, “Lubricant
Viscosities”.
• Cat filters are not used.
• The altitude exceeds 2300 m (7545 ft).

Refer to the results of the S·O·S oil analysis in order
to determine if the oil change interval should be
decreased. Consult your Cat Dealer for detailed
information regarding the optimum oil change
interval.
Note: Diesel Fuel Specification Type and Sulfur

Content % (ppm), must be compliant with all Illustration 313 g02625826
applicable emission regulations for the are in which
the engine is operated.
2. Remove the access panel that is located below the
Note: For engines that do not have aftertreatment drain plug. Remove the drain plug and allow the oil
and do not have EGR, use of ULSD is not required. If to drain into a suitable container. Install the drain
the diesel fuel contains sulfur greater than 0.5% plug and install the access panel.
(5,000ppm), reduce the oil change interval by one-
half. Diesel fuel containing more than 1.0% (10,000
ppm) sulfur is not approved for the engine.

Covers”.
Note: The crankcase drain is located on the right

side of the oil pan.
322 SEBU9084-11
Maintenance Section

C3.3B Engine

C2.2 Engine
SEBU9084-11 323
Maintenance Section
Engine Valve Lash - Check
7. Remove the oil filler cap (1). Fill the crankcase with
new oil. Refer to Operation and Maintenance
Manual, “Lubricant Viscosities” and Operation and
Maintenance Manual, “Refill Capacities” for
information about the oil. Clean the oil filler plug
and install the oil filler plug.
8. Start the engine and allow the oil to warm. Check
for leaks.

(1) Oil level add mark
(2) Full mark
C3.8 Engine 9. Stop the engine and allow the oil to drain back into
the oil pan. Fill the crankcase to the “FULL” mark
(1) Oil Filler Cap
(2) Dipstick (2) on the dipstick. Do not exceed the “ FULL””
(3) Oil Filter mark on the dipstick. Add oil or drain oil if
necessary.
3. Remove the filter element with a 187-2718 Filter
Wrench. Refer to Operation and Maintenance 10. Close the engine access door.
Manual, “Oil Filter - Inspect” in order to inspect the
i06849849
used filter for debris.
4. Apply a thin film of clean engine oil to the sealing Engine Valve Lash - Check
surface of the new filter element.
SMCS Code: 1105-025
5. Install a new engine oil filter hand tighten one turn
Refer to the Service Manual for the complete
after the seal first contacts the base. Note the adjustment procedure for the engine valve lash.
position of the index marks on the filter in relation
to a fixed point on the filter base. A qualified mechanic should adjust the engine valve
lash and the fuel injector timing because special tools
Note: There are rotation index marks on the engine and training are required.
oil filter that are spaced 90 degrees or 1/4 of a turn
away from each other. When you tighten the engine See your Cat dealer for this service.
oil filter, use the rotation index marks as a guide.
6. Tighten the filter according to the instructions that

are printed on the filter. Use the index marks as a
guide. For non-Cat filters, use the instructions that
are provided with the filter.
Note: Use a Cat strap wrench, or another suitable
tool, in order to turn the filter to the amount that is
required for final installation. Ensure that the
installation tool does not damage the filter.
324 SEBU9084-11
Maintenance Section
Equipment Lowering Control Valve - Check
i06137313
Equipment Lowering Control

Valve - Check
(Type 1)
SMCS Code: 5147-MA

tool falling.
Keep personnel away from the front of the ma-
chine when lowering the work tool. Illustration 319 g01332374
Film located next to the red handle.
The loader arms must be lowered manually if the
accumulator is not charged or if there is no electrical
power. Type 1 Actuation
Do not go under the raised lift arm without the brace
for the loader lift arm in the LOCKED position. 1. Slide the seat forward. Slide the left-hand armrest
forward.
Note: Make sure that there are no people near the
2. Pull up on the red handle. Push the handle in order
front or sides of the machine.
to stop the loader arms, if necessary.
on the ground.
4. Push the red handle to the original position.
5. Make the necessary repairs before you operate
the machine.
i06158746
Equipment Lowering Control

Valve - Check
(Type 2)
SMCS Code: 5147-MA

tool falling.
Illustration 318 g01400888 Keep personnel away from the front of the ma-
Type 1 Pull Handle near Seat. chine when lowering the work tool.
The bypass valve (Dead Engine Lower) is located on

the left side next to the seat in the cab.
SEBU9084-11 325
Maintenance Section
Exhaust Gas Recirculation Valve - Clean
4. Make the necessary repair before you operate the

machine.
i06624703
Exhaust Gas Recirculation

Valve - Clean
SMCS Code: 5137-070
S/N: BL91–Up
S/N: HRD1–Up
S/N: DPR1–Up
S/N: GWR1–Up
At 3000 hours, the warning lamp will operate and a
diagnostic code 5838-31 will be active, perform the
exhaust gas recirculation valve Clean. If the service
is not performed within approximately 100 hours, the
engine will be derated.
The exhaust gas recirculation valve connecting pipe
Type 2 Roof-mounted Finger Latch
and cooler will need to be removed and cleaned in
order for the engine to function correctly.
The bypass valve (Dead Engine Lower) is located
overhead on the underside of the cab roof.

Icon located on molded into the finger latch.
Type 2 Actuation
1. Pull down on the finger latch. Release the finger (1) Exhaust gas recirculation valve
latch in order to stop the loader arms, if necessary. (2) Connecting pipe
(3) Cooler
on the ground. With the exhaust gas recirculation valve, connecting
pipe and the cooler removed use a neutral cleaner in
3. Release the finger latch. order to clean the components. All components must
be dried before installation.
Refer to the Disassembly and Assembly manual for
information on removing and installing the
components.
326 SEBU9084-11
Maintenance Section
Final Drive Oil - Change
The electronic service tool will need to be connected S/N: RCX1–Up

in order to reset the timer after the exhaust gas
recirculation valve has been cleaned. and installed. S/N: A9Z1–Up
i06600880
Final Drive Oil - Change

SMCS Code: 4011-044-OC; 4050; 4050-044-OC;
4050-535-FLV; 4050-044; 4050-044-FLV; 4070-044;
7527
S/N: DX21–Up
S/N: FD21–Up
S/N: HP21–Up
S/N: BY41–Up
S/N: CD41–Up
S/N: BE71–Up
S/N: BL71–Up
S/N: HP71–Up
S/N: AH91–Up Illustration 323 g01291697
S/N: BL91–Up Multi-Terrain Loader

S/N: DX91–Up
S/N: GTC1–Up
S/N: FTK1–Up
S/N: GTK1–Up
S/N: STK1–Up
S/N: TLK1–Up
S/N: EML1–Up
S/N: FTL1–Up
S/N: GTL1–Up
S/N: NTL1–Up
S/N: FMR1–Up
S/N: GWR1–Up
S/N: FMT1–Up
S/N: HMT1–Up
S/N: JST1–Up Compact Track Loader
(1) Oil fill/drain plug
S/N: MLT1–Up (2) Oil check plug
S/N: PPT1–Up
1. Position one final drive so that the oil fill/drain plug
S/N: WCT1–Up (1) is at the bottom.
S/N: EZW1–Up
Note: Refer to Operation and Maintenance Manual,
S/N: TAW1–Up “General Hazard Information” for information on
containing fluid spillage.
SEBU9084-11 327
Maintenance Section
Final Drive Oil Level - Check
2. Use an 8 mm (5/16 inch) allen wrench. Remove S/N: AH91–Up

the oil plugs (1) and (2). Allow the oil to drain into a
S/N: BL91–Up
suitable container.
S/N: DX91–Up
3. Check the drained oil for large metal chips or a
significant number of metal particles. S/N: GTC1–Up
Note: Some small amount of break-in debris is S/N: FTK1–Up
normal and should not cause alarm.
S/N: GTK1–Up
Note: Dispose of drained fluids according to local S/N: STK1–Up
regulations.
S/N: TLK1–Up
4. Clean the plugs and inspect the plugs. Replace a
S/N: EML1–Up
worn plug or a damaged plug.
5. Position the final drive so that the oil fill/drain plug S/N: FTL1–Up
(1) is at the top. S/N: GTL1–Up
6. Add oil through the opening of the oil fill/drain plug S/N: NTL1–Up
(1) that is now at the top.
S/N: FMR1–Up
7. Fill the final drive to the bottom of the opening for
S/N: GWR1–Up
the oil check plug (2). Refer to Operation and
Maintenance Manual, “Lubricant Viscosities” and S/N: FMT1–Up
Operation and Maintenance Manual, “Capacities
(Refill)”. S/N: HMT1–Up
S/N: JST1–Up
8. Install the two oil plugs. Tighten the oil plugs to a
torque of 27 ± 1 N·m (20 ± 0.7 lb ft). S/N: MLT1–Up
9. Perform Step 1 to Step 8 on the other final drive. S/N: PPT1–Up
10. Completely remove any oil that has spilled. S/N: WCT1–Up
11. Start the engine and allow the final drives to S/N: EZW1–Up
operate through several cycles.
S/N: TAW1–Up
12. Stop the engine.
S/N: RCX1–Up
13. Check the oil level.
S/N: A9Z1–Up
14. Maintain the oil level to the bottom of the opening
for the fill/drain plug (2).
i06600865
Final Drive Oil Level - Check

SMCS Code: 4011-535-FLV; 4050-535-FLV; 4050;
4070-535-FLV; 7524; 7527
S/N: DX21–Up
S/N: FD21–Up
S/N: HP21–Up
S/N: BY41–Up
S/N: CD41–Up
S/N: BE71–Up
S/N: BL71–Up
S/N: HP71–Up
328 SEBU9084-11
Maintenance Section
Fuel System Filter (In-Line) - Replace
2. Use an 8 mm (5/16 inch) allen wrench. Remove

the oil check plug (2).
3. Check the oil level. The oil should be near the
bottom of the opening for the oil check plug (2).
4. Add oil through the opening for the oil fill/drain plug
(1), if necessary.
Note: Overfilling the final drive will cause the seals
on the travel motor to allow hydraulic oil or water to
enter the final drive and contaminate the oil.
5. Clean the oil plugs.
Note: Some small amount of break-in debris is

normal and should not cause alarm.
6. Install the oil plugs. Tighten the oil plugs to a

torque of 27 ± 1 N·m (20 ± 0.7 lb ft).
7. Repeat the procedure for the other final drive.
i06133218
MTL model
(1) Oil fill/drain plug
(2) Oil check plug
Fuel System Filter (In-Line) -
Replace
SMCS Code: 1261-510
NOTICE
and mandates.
Note: Do not fill fuel filters before installation in any

circumstance.
Note: Do not open any high-pressure lines in order to

Illustration 326 g01457009 purge air from the fuel system.
CTL model Note: Replace the fuel filter before the scheduled
(1) Oil fill/drain plug interval if any of the following occur:
(2) Oil check plug
• Engine performance is poor.
1. Position one final drive so that the oil fill/drain plug
(1) is at the top. • Hard Starting
Note: Refer to Operation and Maintenance Manual, • Engine dies under load.
“General Hazard Information” for information on
Containing Fluid Spillage.
SEBU9084-11 329
Maintenance Section
Fuel System Primary Filter (Water Separator) - Drain
1. Open the engine access door. Refer to Operation 4. Replace the fuel filter. Ensure that the arrow on the
and Maintenance Manual, “Access Doors and filter points upwards or towards the fuel system
Covers”. The filter is located on the left side of the priming pump.
engine compartment. Most machines have the in-
5. For Type 1 only, tighten to a torque of 10 ± 3 N·m
line filter attached to the bottom of the fuel system
(7.5 ± 2 lb ft).
priming pump (Type 1). Some machines are
equipped with an in-line filter that is not connected Note: For Type 1 only, use a wrench on the hex shaft
to the pump (Type 2). of the pump to hold the pump securely to avoid pump
damage.
6. Tighten the hose clamps.

8. Check for leaks.
Note: For Type 1, the clear plastic in-line filter
attached to the bottom of the lift pump will have air
present when it is new. As the filter accumulates with
debris, the air will purge from the filter.
i06133412
Fuel System Primary Filter

(Water Separator) - Drain
SMCS Code: 1263-543
NOTICE
Illustration 327 g02841456 Care must be taken to ensure that fluids are con-
Type 1 tained during performance of inspection, mainte-
(1) Filter
(2) Pump Hex Shaft
and mandates.
The fuel system water separator is located in the left

side of the engine compartment.

Type 2
2. Loosen the hose clamps.

3. Remove the fuel filter and discard the fuel filter.
Note: For Type 1 only, use a wrench on the hex shaft
of the pump to hold the pump securely to avoid pump
damage.
330 SEBU9084-11
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace
i06133433
Fuel System Primary Filter

(Water Separator) Element -
Replace
SMCS Code: 1260-510-FQ; 1263-510-FQ
NOTICE
(1) Filter Housing Refer to Special Publication, NENG2500, “Dealer
(2) Drain Valve Service Tool Catalog” for tools and supplies suitable
(3) Drain Hose to collect and contain fluids on Cat ® products.
(4) Water-In-Fuel Sensor Plug
1. Open the engine access door. Refer to Operation and mandates.
Covers”.
Note: This unit has a dual purpose. The element
2. If equipped, disconnect the water-in-fuel sensor serves as a water separator and a fuel filter.
plug (4).
3. Insert the drain hose (3) into a suitable container.
Loosen the drain valve (2) on the bottom of the
housing.
Note: One half turn to one full turn will fully open the
valve.
4. Tighten the drain valve (2) by hand. Do not tighten

the drain valve (2) with a tool. Damage to the valve
or to the seals may occur.
5. If equipped, reconnect the water-in-fuel sensor
plug (4).
7. Dispose of the water and sediment according to (1) Filter Housing
local regulations. (2) Drain Valve
(3) Drain Hose
(4) Water-In-Fuel Sensor Plug

Covers”.
2. If equipped, disconnect the water-in-fuel sensor
plug (4).
3. Open the drain on the fuel filter. Allow the water
and fuel to drain into a suitable container.
Note: One half to one full turn will fully open the valve
(2).
SEBU9084-11 331
Maintenance Section
Fuel System Priming Pump - Operate
4. Close the drain valve (2) by hand. Do not tighten 2. The Primary Fuel Filter is located in the left side of
the drain valve (2) with a tool. Damage to the valve the engine compartment.
or to the seals may occur.
3. Examine the clear bowl. The bowl must contain
5. Rotate the fuel filter housing (1) counterclockwise only fuel. If the bowl is not full of fuel, repeat Steps
to remove. 1 and 2.
6. Clean the mounting base for the fuel filter. 4. Attempt to start the engine. If the engine starts and
the engine runs rough or the engine misfires,
7. Clean the housing for the fuel filter.
operate the engine at low idle until the engine runs
8. Lubricate the seal with clean fuel. Install the new smoothly.
fuel filter and housing onto the mounting base.
Rotate clockwise in order to fasten the fuel filter to Note: If the engine fails to start or if the engine
continues to misfire or smoke, stop the engine and
the mounting base. Hand tighten until the lip of the
repeat the procedure. If the problem persists after
housing is in contact with the mounting base.
repeating the procedure, consult your Cat dealer.
Note: Do not prefill the filter with fuel. Contamination Note: Do not open any high-pressure lines in order to
of the fuel system will occur and damage to the
purge air from the fuel system.
injectors may occur.
9. If equipped, reconnect the water-in-fuel sensor Manual Fuel Transfer

plug (4).
10. Prime the fuel system in order to fill the fuel filter
with fuel. Refer to Operation and Maintenance
Manual, “Fuel System Priming Pump - Operate”.
i06137435
Fuel System Priming Pump -

Operate
SMCS Code: 1258-548
Most machines are equipped with a fuel transfer
pump that is electric. See the following story if your
machine is instead equipped with a manual-style
transfer pump.
Two examples that may cause the fuel system to lose
prime are listed here:
• The machine runs out of fuel. Illustration 331 g03822107
• The Fuel System Filter/Water Separator Element

is replaced. 1. Open the engine access door. Refer to Operation
Follow the steps below in order to prime the fuel Covers”.
system.
2. Push down on the top of the fuel priming pump
Electric Fuel Transfer plunger and release the fuel priming pump plunger
in order to operate the fuel priming pump. Operate
1. Ensure that the engine start switch is in the OFF the fuel priming pump plunger in order to fill the
position. Turn the engine start switch to the ON new filter element with fuel. Continue to pump until
position. increased resistance is felt. This resistance will
indicate that the filter element is full of fuel.
Note: Do not start the engine. This operation only
starts the fuel pump. The pump will run
approximately 30 seconds.
332 SEBU9084-11
Maintenance Section
Fuel Tank Cap - Clean
3. Attempt to start the engine. If the engine starts and i06132814

the engine runs rough or the engine misfires,
operate the engine at low idle until the engine runs Fuel Tank Water and Sediment
smoothly. If the engine fails to start or if the engine
continues to misfire or smoke repeat the priming
- Drain
procedure. SMCS Code: 1273-543-M&S

NOTICE
i01819309 tained during performance of inspection, mainte-
Fuel Tank Cap - Clean Be prepared to collect the fluid with suitable contain-
SMCS Code: 1273-070-Z2 bling any component containing fluids.
1. Remove the fuel cap. Refer to Special Publication, NENG2500, “Dealer

and mandates.
Note: Drain the water and the sediment from the fuel
tank when the tank is almost empty.
1. Slowly remove the fuel tank cap in order to allow

the tank to vent while you drain the tank.
2. Inspect the cap. Replace the cap if the cap is

damaged.
3. Wash the fuel cap in a clean, nonflammable
solvent and dry the fuel cap.
4. Put a light coating of fuel on the cap gasket.
5. Install the fuel cap.

Type 1
SEBU9084-11 333
Maintenance Section
Fuses - Replace
NOTICE
Replace the fuses with the same type and size only.
Otherwise, electrical damage can result.
If it is necessary to replace fuses frequently, an elec-
trical problem may exist. Contact your Caterpillar
dealer

Type 2
2. If the machine is equipped with a plastic fuel tank

inside the engine compartment (Type 1), remove
the access plate on the bottom of the engine
compartment.
3. Remove the fuel tank drain plug. Allow the water Illustration 335 g01287527
and the sediment to drain into a suitable container.
The fuse panel is located behind the seat on the right
4. Install the fuel tank drain plug. side.
Note: For Type 1 only, apply 5P-3413 Pipe Sealant
to the threads on the drain plug and torque to
11 ± 1 N·m (8 ± 1 lb ft).
Note: For Type 2 only, no sealant is required. Torque
the drain plug to 420 ± 63 N·m (310 ± 46 lb ft).
5. Install the fuel tank cap.
i06128250
Fuses - Replace
SMCS Code: 1417; 1417-510; 7528
Fuses Inside the Cab

Fuses – Protect the electrical system from damage
that is caused by overloaded circuits. Replace the
fuse if the element separates. If the element of a new
fuse separates, check the circuit. Repair the circuit, if
necessary. Illustration 336 g01210555
Remove the cover in order to access the fuse panel.

334 SEBU9084-11
Maintenance Section
Fuses - Replace
12V Power Socket (5) – 10 Amp
Radio (6) – 10 Amp
Air Ride/Heated Seat (7) – 15 Amp
Air Conditioner (8) – 20 Amp
Note: 226D, 232D, 239D & 249D use a 15 Amp

Condenser Fan breaker instead. D2-Series models
have a 10A Spare instead.
Right Joystick (9) – 10 Amp
Engine ECM Key Switch Input/LRC

Throttle Actuator (10) – 15 Amp
Note: Secondary Engine Shut-Off. Refer to Stopping

the Engine if an Electrical Malfunction Occurs.
Front Working Lights (11) – 15 Amp
Backup Alarm/Brake Lights (12)

– 10 Amp
HVAC Blower/Compressor (13) – 20 Amp
Rear Camera (14) – 10 Amp

Roading Lights (15) – 15 Amp
The following is a list of the fuses in the panel:
Spare (1) – 15 Amp

Work Tool Switch - "Aux 8" (16) – 15
Amp
Wiper/Washer (2) – 15 Amp

Fuel Pump (17) – 15 Amp
Rear Work Lights/Beacon (3) – 15 Amp

ILEV/Ride Control (18) – 15
Amp
Left Joystick (4) – 10 Amp

Work Tool Relays/High Flow Relay (19) –
15 Amp
SEBU9084-11 335
Maintenance Section
Fuses - Replace
Spare (20) – 20 Amp
Relays
21 – Auxiliary electrical control “AUX6
(C1)”

(C2)”
23 – Solenoid for secondary auxiliary

electrical control “AUX4 (C+)”
24 – Solenoid for secondary auxiliary

electrical control “AUX3 (C−)”

(Trigger)”
(A) First pair
26 – Stop lamp (B) Second pair
(C) Third pair
This panel may have as many as eight fuses

27 – Backup alarm depending on how the machine is equipped. In order
to change these fuses, push up on the locking tab on
the fuse cover. Pull the cover away from the back of
the cab.
28 – Fuel Pump
29 – ILEV/Ride Control
30 – High Flow/Auxiliary Hydraulic

Cooler Enable
Fuses Behind the Cab

If an optional Auxiliary Hydraulic Cooler is installed, a
60A fuse will be located in an in-line fuse holder near
the power relay modules.
Machine ECM (31) – 30 Amp
Engine Control Module Power Relay (32)

– 30 Amp
Note: 236D, 242D, 257D, 259D, 272D, 272D2 XHP,

277D, 279D, 287D, 289D, 297D, 297D XHP, 299D,
299D XHP use a 20 Amp fuse
Horn (33) – 20 Amp

336 SEBU9084-11
Maintenance Section
Headlights - Adjust
Main power relay 1 (34) – 60 Amp Quick Coupler Fuse

If equipped with the optional work tool electric quick
Miscellaneous cab accessories (35) – 20 coupler, a 35A fuse will be located along the right-
hand wall of the engine compartment.
Amp
i05297485
Main power relay 2 (36) – 60 Amp
Headlights - Adjust
SMCS Code: 1429-025
NOx Sensors (37) – 10A
Note: D2-Series only.
Ignition Switch (38) – 15A
Note: Located above the fuse panel as an in-line

fuse.
Fuses Inside Engine Compartment

Main Fuse
The main fuse is a 100 Amp buss bar style fuse. The
fuse is mounted to the engine bay wall and is located
near the battery. Disconnect the negative battery
cable at the battery connection before you replace
this fuse.

(1) Rotating Beacon
(2) Work Lights
(3) Rear View Mirror
(4) Headlights
(5) Turn Signals
Perform the following procedure in order to align the

headlights:
1. Verify that the tires are inflated properly.
2. Position the machine in the following manner when
you adjust the headlights:
a. Park the machine in a dark area.

b. Park the machine on level ground.
c. Face the machine toward a wall with 10 m

(32.8 ft) between the wall and the face of the
headlights.
3. Place a second person or 75 kg (165 lb) in the
operator seat.
4. Turn on the headlights.
5. Cover one headlight.
6. Loosen the other headlight clamp.
SEBU9084-11 337
Maintenance Section
Hoses and Clamps - Inspect/Replace
7. Move the headlight so that the headlight is pointing S/N: EZW1–Up

straight ahead. Measure the height from the
S/N: TAW1–Up
ground to the center of the headlight.
S/N: BGZ1–Up
8. Twist the headlight so that the upper edge of the
light that is shown on the wall is two-thirds of the Note: Only applies to engines with aftertreatment.
height from the ground to the center of the
headlight. Ensure that the line of the light that is For each hose use the following procedure:
shown on the wall is horizontal. 1. Inspect all hoses due to cracking, for softness next
9. Tighten the headlight clamp. to the clamps, and for loose clamps.
10. Repeat the process for the other headlight. 2. Tighten any loose clamps.
3. Replace hoses that are cracked or soft. Use new
i06128512 clamps, when replacing hoses.
Hoses and Clamps - Inspect/ The following is a summary of all the hoses that
require replacement.
Replace
SMCS Code: 1000; 7554-510; 7554-040
S/N: BL21–Up
S/N: DX21–Up
S/N: FD21–Up
S/N: HP21–Up
S/N: MD21–Up
S/N: BY41–Up
S/N: BE71–Up
S/N: BL71–Up
S/N: HP71–Up
S/N: BL91–Up
S/N: DX91–Up
S/N: DTB1–Up
S/N: GTC1–Up
S/N: HRD1–Up
S/N: BYF1–Up
S/N: ETL1–Up
S/N: FTL1–Up
S/N: GTL1–Up
S/N: DPR1–Up
S/N: GWR1–Up
S/N: DZT1–Up
S/N: FMT1–Up
S/N: HMT1–Up
S/N: JST1–Up
S/N: B5W1–Up
338 SEBU9084-11
Maintenance Section
Table 115
C3.8 Hose Replacement
Location Hose Quantity
A Turbo Oil Return 1
B Closed Crankcase Breather (CCB) 6
C Boost Pressure 1
D Air Intake (non-XHP models) 1
E Oil Cooler 2
F NOx Reduction System (NRS) Cooler 3
G NOx Reduction System (NRS) Valve 3
H Cooler Bypass 1

C3.8 Left Side
SEBU9084-11 339
Maintenance Section

C3.8 Top View
340 SEBU9084-11
Maintenance Section

C3.8 Right Side
Table 116
C3.3B Hose Replacement
C Boost Pressure 1
D Air Intake 1
E Oil Cooler 2
G NOx Reduction System (NRS) Valve 3

SEBU9084-11 341
Maintenance Section

C3.3B Left Side
342 SEBU9084-11
Maintenance Section

C3.3B Top View
SEBU9084-11 343
Maintenance Section

C3.3B Right Side
Table 117
C2.2 Hose Replacement
A Turbo Oil Return 1
E Oil Cooler 2
F NOx Reduction System (NRS) Cooler 2
H Cooler Bypass 1
344 SEBU9084-11
Maintenance Section

C2.2 Right Side
SEBU9084-11 345
Maintenance Section

C2.2 Top View
346 SEBU9084-11
Maintenance Section
Hoses and Clamps - Replace

C2.2 Left Side
i06823469 S/N: HP21–Up

S/N: MD21–Up
Hoses and Clamps - Replace
SMCS Code: 1380-510 S/N: BY41–Up
S/N: BE71–Up
S/N: BL21–Up
S/N: BL71–Up
S/N: DX21–Up
S/N: HP71–Up
S/N: FD21–Up
SEBU9084-11 347
Maintenance Section
Hydraulic System Oil - Change
S/N: DX91–Up
S/N: DTB1–Up
S/N: GTC1–Up
S/N: BYF1–Up
S/N: ETL1–Up
S/N: FTL1–Up
S/N: GTL1–Up
S/N: DZT1–Up
S/N: FMT1–Up
S/N: HMT1–Up
S/N: JST1–Up
S/N: B5W1–Up
S/N: EZW1–Up
S/N: TAW1–Up Illustration 351 g03650231
S/N: BGZ1–Up (A) C3.8 DPF Differential Pressure Hoses
Note: Only applies to engines with aftertreatment. i06128477
Replace hose (A) Hydraulic System Oil - Change

(1) Loosen the clamps. SMCS Code: 5095-044
(2) Replace the hose and clamps. S/N: CD41–Up
(3) Tighten the clamps. S/N: AH91–Up
The following is a summary of all the hoses that S/N: BL91–Up
require replacement.
S/N: KXC1–Up
S/N: HRD1–Up
S/N: DPR1–Up
S/N: GWR1–Up

(A) C3.3B DPF Differential Pressure Hoses
348 SEBU9084-11
Maintenance Section
i06849868

SMCS Code: 5095-044
Selection of the Oil Change Interval

Your machine may be able to use an extended
interval for the hydraulic oil. The standard change
interval is listed in the Operation and Maintenance
Manual, “Maintenance Interval Schedule”. The oil
should be monitored during intervals of 500 hours.
The extended interval can be used if the following
criteria are met.
HYDO Advanced 10
Cat HYDO Advanced 10 is the preferred oil for use in
most Cat machine hydraulic and hydrostatic
transmission systems when ambient temperature is
between −20 °C (−4 °F) and 40 °C (104 °F). Cat
Illustration 352 g03818604 HYDO Advanced 10 has an SAE viscosity grade of
10W. Cat HYDO Advanced 10 has a 50% increase
(1) Hydraulic Fill Cap in the standard oil drain interval (up to 3000 hours)
(2) Hydraulic Tank Drain Plug
for machine hydraulic systems over second and third
choice oils when you follow the maintenance interval
1. Remove the hydraulic oil tank cap (1). schedule for oil filter changes and for oil sampling
2. Remove the hydraulic oil tank drain plug (2). that is stated in the Operation and Maintenance
Manual. 6000 hour oil drain intervals are possible
3. Drain the oil into a suitable container. when using S·O·S Services oil analysis. When you
switch to Cat HYDO Advanced 10, cross
4. Install the drain plug into the tank. Tighten to contamination with the previous oil should be kept to
420 ± 63 N·m (310 ± 46 lb ft) less than 10%. Consult your Cat dealer for details
about the benefits from the improved performance
5. Change the hydraulic system filter. Refer to designed into Cat HYDO Advanced 10.
Operation and Maintenance Manual, “Hydraulic
System Oil Filter - Change”. Non HYDO Advanced 10
6. Fill the hydraulic system oil tank. Refer to When using other oils, the hydraulic oil change
Operation and Maintenance Manual, “Lubricant interval is limited to every 2000 Service Hours. By
Viscosities” and Operation and Maintenance performing S·O·S oil analysis, the hydraulic oil
Manual, “Capacities (Refill)” for the type of oil and change interval may be extended to 4000 Service
Hours. S·O·S oil analysis must be performed every
the proper amount of oil. 500 Service Hours in order to extend the hydraulic oil
7. Refer to Operation and Maintenance Manual, change interval. The results from the S·O·S oil
“Hydraulic System Oil Level - Check”. Maintain the analysis will determine if the hydraulic oil change
interval may be extended. Refer to “Operations and
hydraulic oil level approximately in the middle of Maintenance Manual”S·O·S Information.
the gauge (2).
Check the oil level with the loader arms in the fully
lowered position.
Note: The oil must be free of bubbles. If bubbles are

present in the oil, air is entering the hydraulic system.
Inspect the suction hoses and hose clamps.
8. Install the hydraulic tank filler cap.

SEBU9084-11 349
Maintenance Section
Note: If HYDO Advanced 10 is used but The machine should be on level ground. Lower the
contaminated by 10% or more with other oils, follow bucket to the ground and apply slight downward
the maintenance interval requirements for Non pressure. Engage the parking brake and stop the
HYDO Advanced 10. engine. Keep the armrests lowered. Turn the engine
start switch key to the ON position. Push the parking
brake switch. Move all of the hydraulic controls in
Procedure for Changing the order to relieve hydraulic pressure. Move the engine
Hydraulic Oil start switch key to the OFF position.
NOTICE
and mandates.
Note: This film is located near the hydraulic filler

cap on machines that are filled with arctic oil.
Operate the machine for a few minutes in order to (1) Hydraulic oil tank cap
warm the hydraulic system oil. (2) Sight Gauge
Note: Most machines are equipped with a molded

hydraulic tank represented here. See the following
Personal injury or death can result without re- story if your machine is instead equipped steel tanks
leasing all of the hydraulic pressure. as part of the structural frame (226D, 232D, 239D
and 249D).
Release all the pressure from the hydraulic sys-
tem before any lines are disconnected. 1. Remove the hydraulic oil tank cap (1).
350 SEBU9084-11
Maintenance Section
Hydraulic System Oil Filter - Replace
8. Install the hydraulic tank filler cap.
i06677184
Hydraulic System Oil Filter -

Replace
SMCS Code: 5068-510
NOTICE
Illustration 355 g01333250 and mandates.
Access panel
2. Remove the access panel in the belly guard

underneath the machine. Refer to "Lower Machine
Frame - Clean".
3. The hose is located on the right side. Pull the drain
hose through the access hole in the belly guard.
Remove the plug from the end of the drain hose.
Drain the oil into a suitable container.
4. Install the drain plug into the drain hose. Tighten to
22 ± 3 N·m (16 ± 2 lb ft). Pull the drain hose back
into the machine.
5. Change the hydraulic system filter. Refer to
Operation and Maintenance Manual, “Hydraulic Illustration 356 g03819062
System Oil Filter - Change”.
Location of Hydraulic Oil Filter
6. Fill the hydraulic system oil tank. Refer to
Operation and Maintenance Manual, “Lubricant
Viscosities” and Operation and Maintenance
Manual, “Capacities (Refill)” for the type of oil and
the proper amount of oil.
7. Refer to Operation and Maintenance Manual,
“Hydraulic System Oil Level - Check”. Maintain the
hydraulic oil level approximately in the middle of
the gauge (2).
Check the oil level with the loader arms in the fully
lowered position.
Note: The oil must be free of bubbles. If bubbles are
present in the oil, air is entering the hydraulic system.
Inspect the suction hoses and hose clamps. Illustration 357 g03819066
(1) Type 1 Filter
(2) Type 2 Filter
SEBU9084-11 351
Maintenance Section
Hydraulic System Oil Level - Check
1. Open the engine access door. Refer to "Access i06128383

Doors and Covers".
2. Remove the Hydraulic tank filler cap. Refer to
Hydraulic System Oil Level -
"Hydraulic System Oil Level - Check". Check
3. Remove drain plug from bottom of filter housing SMCS Code: 5095-535-FLV
(canister) to drain oil from the housing. Drain into a
suitable container.
Note: Use sockets or box end wrenches when
servicing the hydraulic oil filter. Do not use an air
wrench, open-end wrenches, or an adjustable
wrench.
4. Unscrew canister from filter mounting base. Filter

element will come out with housing. Discard the
filter element.
Note: For Type 2 Filter (2) squeeze the two tabs on

filter element to unlatch it from the canister.
5. Inspect the O-ring or O-rings on the canister or

mounting base for damage and replace them if
needed.
6. Clean the inside of the filter mounting base and
clean the inside of the canister.
7. Apply a thin coat of oil to the O-ring on the new
filter element and the O-ring or O-rings on the
canister or mounting base.
8. Insert the new filter element in the canister.
Note: For Type 2 Filter (2), ensure that the two tabs
are latched onto the side of the canister.
9. Install the canister onto the mounting base.

Element will center on its own as the canister is
turned in. Torque to 40 ± 5 N·m (30 ± 4 lb ft)
10. Install the drain plug. Torque to 30 ± 5 N·m
(22 ± 4 lb ft)
11. Maintain the hydraulic oil level to the proper level. Type 1 Hydraulic Oil Level Gauge and Fill
Refer to "Hydraulic System Oil Level - Check". Do (1) Hydraulic Oil Fill
not overfill the hydraulic tank. (2) Hydraulic Oil Level Needle Gauge
12. Inspect the gasket on the hydraulic tank filler cap

for damage. Replace the hydraulic tank filler cap, if
necessary. Install the hydraulic tank filler cap.
352 SEBU9084-11
Maintenance Section
Hydraulic System Oil Sample - Obtain
The location of the sampling port for the hydraulic oil

is on the cooling fan.
i06127563
Illustration 359
Type 2 Hydraulic Oil Level Gauge and Fill
g03818578
Hydraulic Tank Breather -
(1) Hydraulic Oil Fill Replace
(2) Hydraulic Oil Sight Gauge
SMCS Code: 5050-510-BRE; 5056-510-BRE
1. Park the machine on level ground.
2. Lower the work tool to the ground. Turn off the
engine.
3. Wait for about 5 minutes before checking the level
of the hydraulic oil.
4. Use the hydraulic oil filler (1) in order to top off the
hydraulic oil.
5. Maintain the oil level to the green area of the
gauge (Type 1) or midway between the upper and
lower gauge lines (Type 2). If hydraulic work tools
are used often, you may fill closer to the upper
gauge limit to account for potential work tool
leakage, but do not overfill the hydraulic tank. Do
not overfill the hydraulic tank.
i06755609
Hydraulic System Oil Sample -

Obtain Illustration 361 g02626172
SMCS Code: 5050-008; 7542-008 The breather for the hydraulic tank is located
remotely behind the cab on the right side.
Open the rear access door. Refer to Operation and
Maintenance Manual, “Access Doors and Covers” for 1. Tilt the cab upward. Refer to the Operation and
information about the rear door. Maintenance Manual, “Cab Tilting” for more
information.
2. Remove the breather.
3. Install the new breather and tighten to 11 ± 1 N·m
(8.1 ± 0.7 lb ft).
SEBU9084-11 353
Maintenance Section
Lift Arm and Cylinder Linkage - Lubricate
i05864372
Lift Arm and Cylinder Linkage

- Lubricate
SMCS Code: 5102-086-BD; 6107-086-BD

Vertical Lift
(1) Lift Arm Pivot
(2) Lift Cylinder Rod End
(3a) Head End Fitting
(3b) Alternate Location Remote Head End Fitting
(4) Link Arm

Radial Lift
(1) Lift Arm Pivot
(2) Lift Cylinder Rod End
(3a) Head End Fitting
(3b) Alternate Location Remote Head End Fitting
354 SEBU9084-11
Maintenance Section
Lower Machine Frame - Clean
2. The access panel (1) is located in the frame

underneath the machine.
3. Remove the four retaining bolts (2).
Illustration 364 g02626192 4. Slide the panel forward or slide the panel rearward.
The Link Arm is located behind the loader arm. Some models allow the panel to drop down from
(5) Mounting for Link Pin the machine. Use caution while lowering the
(6) Rear of Link Arm panel, as accumulated debris may make the panel
substantially heavier.
Apply lubricant to all the grease fittings on both sides.
5. Remove any debris or dirt from inside the frame.
machine. 6. Reinstall the access panel.
i06836610
Note: Some models may have secondary clean out
Lower Machine Frame - Clean plates (3) for localized debris removal.
SMCS Code: 7050-070
1. Tilt the cab upward. Refer to Operation and

Maintenance Manual, “Cab Tilting”.
SEBU9084-11 355
Maintenance Section
Oil Filter - Inspect
i02106227
Oil Filter - Inspect

SMCS Code: 1308-507; 3067-507; 5068-507
Inspect a Used Filter for Debris

The element is shown with debris.
Use a filter cutter to cut the filter element open.

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
failure.
If metals are found in the filter element, a magnet can
be used to differentiate between ferrous metals and
nonferrous metals.
Ferrous metals can indicate wear on steel parts and
on cast iron parts.
Nonferrous metals can indicate wear on the
aluminum parts of the engine such as main bearings,
rod bearings, or turbocharger bearings.
Small amounts of debris may be found in the filter
element. This could be caused by friction and by
normal wear. Consult your Caterpillar dealer in order
to arrange for further analysis if an excessive amount
of debris is found.
356 SEBU9084-11
Maintenance Section
Quick Coupler - Clean/Inspect
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.
i04436199
Quick Coupler - Clean/Inspect

SMCS Code: 6129-040; 6129-070
Personal injury or death can result from improp- Illustration 370 g02626326
erly checking for a leak.
Back side of the electric quick coupler. The lift arm
Always use a board or cardboard when checking and the tilt cylinder are removed for clarity.
for a leak. Escaping air or fluid under pressure,
even a pin-hole size leak, can penetrate body tis- 2. Tilt the quick coupler all the way forward in order to
sue causing serious injury, and possible death. clean the debris away from the pins.
If fluid is injected into your skin, it must be 3. Move the quick coupler levers. Ensure that the
treated immediately by a doctor familiar with this levers are not bent or broken.
type of injury.
4. Make sure that the coupler pins extend through the
bottom of the quick coupler assembly. Check the
Note: Do not weld on the quick coupler without pins for wear and check the pins for damage.
consulting your Cat dealer.
5. Check the top edges of the quick coupler assembly
1. Clean the quick coupler prior to inspection in order for wear or for damage. Check the face of the
to inspect the quick coupler properly. quick coupler assembly for wear or for damage.
6. Inspect the components inside the quick coupler
for the following problems:loose bolts, oil leaks,
broken parts, missing parts and cracked
components
7. Inspect the electric harness for damage or
abrasion. Check for loose connections or broken
wires. Repair any worn components or replace
any worn components. Repair any leaking
components.
8. Inspect the steel material of the quick coupler for
cracks.
Note: Perform all repairs before placing the quick

coupler back into operation.
Back side of the manual quick coupler. The lift arm
and the tilt cylinder are removed for clarity. i04456539
Radiator Core - Clean

SMCS Code: 1353-070-KO
The radiator is located at the rear of the machine
above the engine compartment.
SEBU9084-11 357
Maintenance Section
Refrigerant Dryer - Replace
Note: Adjust the frequency of cleaning according to 5. Inspect the fins and tubes of the radiator core for
the effects of the operating environment. If equipped, damage. Some fins and tubes may be worn from
clean the aftercooler core when you clean the abrasive material that has passed through the
radiator core. radiator core . Bent fins may be opened with a
“comb”.
1. Stop the engine. Open the engine access door.
Refer to Operation and Maintenance Manual, NOTICE
“Access Doors and Covers”. Do not clean a rotating fan with high pressure water.
Fan blade failure can result.
2. Tilt the radiator guard upward. Refer to Operation
and Maintenance Manual, “Radiator Tilting”.
6. Remove any dirt or debris from the fan, the fan
hub, the oil cooler, the radiator guard, and the fan
guard.
Personal injury can result from air pressure.
Note: Dirt or debris on the cooling fan can cause an
Personal injury can result without following prop- imbalance.
er procedure. When using pressure air, wear a
protective face shield and protective clothing. 7. Tilt the radiator guard downward.
Maximum air pressure at the nozzle must be less 8. Close the engine access door.
i06849898
NOTICE
When you are using compressed air or high pressure
Refrigerant Dryer - Replace
water to clean the radiator fins, ensure that the air or (If Equipped)
water is directed parallel to the fins. If the com-
pressed air or high pressure water is not directed par- SMCS Code: 7322-510
allel to the radiator fins, the radiator fins could be
bent or damaged.
Personal injury can result from contact with

Note: Pressurized air is the preferred method for refrigerant.
removing loose debris. Hold the nozzle
approximately 6 mm (0.25 inch) away from the fins. Contact with refrigerant can cause frost bite.
Slowly move the air nozzle in a direction that is Keep face and hands away to help prevent injury.
parallel with the tubes. The air nozzle should point in
the opposite direction of the flow of the fan to remove Protective goggles must always be worn when re-
debris between the tubes. Pressurized water may frigerant lines are opened, even if the gauges in-
also be used for cleaning. The maximum water dicate the system is empty of refrigerant.
pressure for cleaning purposes must be less than
Always use precaution when a fitting is removed.
275 kPa (40 psi). Use pressurized water in order to
Slowly loosen the fitting. If the system is still
soften mud. Use a degreaser and steam for removal under pressure, release it slowly in a well venti-
of oil and grease. Wash the core with detergent and lated area.
hot water. Thoroughly rinse the core with clean water.
Personal injury or death can result from inhaling
3. Clean the radiator core from the top toward the refrigerant through a lit cigarette.
fan.
Inhaling air conditioner refrigerant gas through a
Note: If parts of the cooling system appear to be lit cigarette or other smoking method or inhaling
damaged or if parts of the cooling system are fumes released from a flame contacting air condi-
repaired, a leak test is highly recommended. Consult tioner refrigerant gas, can cause bodily harm or
your Caterpillar dealer for the most current death.
information about the cooling system. Do not smoke when servicing air conditioners or
wherever refrigerant gas may be present.
4. After cleaning, start the engine and accelerate the
engine to high idle rpm. The fan will help in the Use a certified recovery and recycling cart to
removal of debris and drying of the core. Stop the properly remove the refrigerant from the air con-
engine. Use a light bulb behind the core in order to ditioning system.
inspect the core for cleanliness. Repeat the
cleaning, if necessary.
358 SEBU9084-11
Maintenance Section
Rollover Protective Structure (ROPS) and Falling Object Protective Structure (FOPS) - Inspect
2. Operate the machine on a rough surface. Replace

NOTICE
If the refrigerant system has been open to the outside the ROPS mounting supports if the ROPS emits a
air (without being plugged) for more than 30 minutes, noise. Replace the ROPS mounting supports if the
the receiver-dryer must be replaced. Moisture will en- ROPS rattles. Refer to Operation and
ter an open refrigerant system and cause corrosion Maintenance Manual, “Cab Tilting” for a
which will lead to component failure. description of the mounting support.
Consult your Caterpillar dealer for inspection of any
Refer to Service Manual, UENR4125, “Air potential damage or repair of any damage to any
Conditioning and Heating R-134a For All Caterpillar
Machines” for the proper procedure to change the Operator Protective structure, including ROPS,
receiver-dryer assembly and for the procedure to FOPS, TOPS, OPS, and OPG. Refer to Special
reclaim the refrigerant gas. Instruction SEHS6929 Inspection, “Maintenance, and
Repair of Operator Protective Structures (OPS) and
A qualified mechanic should perform this service Attachment Installation Guidelines for All
because special refrigerant handling tools and Earthmoving Machinery”, for more information.
training are required.
i04423622
See your Cat dealer for this service.
Seat Belt - Inspect
i06127550
SMCS Code: 7327-040
Rollover Protective Structure Always inspect the condition of the seat belt and the
condition of the seat belt mounting hardware before
(ROPS) and Falling Object you operate the machine. Replace any parts that are
Protective Structure (FOPS) - damaged or worn before you operate the machine.
Inspect
SMCS Code: 7323-040; 7325-040

Typical example
Inspect buckle (1) for wear or for damage. If the

buckle is worn or damaged, replace the seat belt.
Inspect seat belt (2) for webbing that is worn or
frayed. Replace the seat belt if the webbing is worn
or frayed.
Inspect all seat belt mounting hardware for wear or
for damage. Replace any mounting hardware that is
worn or damaged. Make sure that the mounting bolts
are tight.
1. Inspect the ROPS for loose bolts. Tighten the bolts
(1) to the following torque 125 ± 10 N·m If your machine is equipped with a seat belt
(92 ± 7.5 lb ft). Check the hinge on the cab (2). extension, also perform this inspection procedure for
Check the ROPS and the FOPS for damaged the seat belt extension.
bolts or missing bolts. Replace any damaged bolts Contact your Cat dealer for the replacement of the
or missing bolts with original equipment parts only. seat belt and the mounting hardware.
SEBU9084-11 359
Maintenance Section
Seat Belt - Replace
Note: The seat belt should be replaced within 3 years i05750770

of the date of installation. A date of installation label
is attached to the seat belt retractor and buckle. If the Sprocket - Inspect
date of installation label is missing, replace belt within
3 years from the year of manufacture as indicated on SMCS Code: 4164-040
belt webbing label, buckle housing, or installation
S/N: DX21–Up
tags (non-retractable belts).
S/N: FD21–Up
i06806238
S/N: BY41–Up
Seat Belt - Replace S/N: CD41–Up
SMCS Code: 7327-510 S/N: AH91–Up
The seat belt should be replaced within 3 years of the S/N: BL91–Up
date of installation. A date of installation label is
attached to the seat belt retractor and buckle. If the S/N: DX91–Up
date of installation label is missing, replace belt within
3 years from the year of manufacture as indicated on S/N: GTC1–Up
belt webbing label, buckle housing, or installation
tags (non-retractable belts). S/N: FTK1–Up
S/N: GTK1–Up
S/N: FTL1–Up
S/N: GTL1–Up
S/N: GWR1–Up
S/N: JST1–Up
S/N: PPT1–Up
S/N: WCT1–Up
S/N: TAW1–Up
Illustration 373 g01152685 S/N: RCX1–Up
Typical Example S/N: A9Z1–Up
(1) Date of installation (retractor)
(2) Date of installation (buckle) Note: Operating the machine in conditions that are
(3) Year of manufacture (tag) (fully extended Web)
(4) Year of manufacture (underside) (buckle)
muddy or sandy will cause accelerated wear on the
sprocket and other undercarriage components. Clean
Consult your Cat dealer for the replacement of the the undercarriage of the machine daily in order to
seat belt and the mounting hardware. maximize component life.
Determine age of new seat belt before installing on

seat. A manufacture label is on belt webbing and
imprinted on belt buckle. Do not exceed install by
date on label.
Complete seat belt system should be installed with
new mounting hardware.
Date of installation labels should be marked and
affixed to the seat belt retractor and buckle.
Note: Date of installation labels should be

permanently marked by punch (retractable belt) or
stamp (non-retractable belt).
If your machine is equipped with a seat belt
extension, also perform this replacement procedure
for the seat belt extension.
360 SEBU9084-11
Maintenance Section
Sprocket - Inspect
Inspect 3. If the average of the 3 measurements is less than

the 50% wear limit listed below, relocate the
sprocket to the opposite side of the machine.
Follow the steps in the "Relocate" section. If the
average of the 3 measurements is less than the
75% wear limit listed below, replace the sprocket.
Follow the steps in the "Replace" section.
Table 118
CTL Rubber CTL Steel
Action Track Track
50% Wear 178mm 144mm
Relocate Limit
(7.0 inch) (5.7 inch)
75% Wear 165mm 140mm

Replace Limit
(6.5 inch) (5.51 inch)
Relocate
1. Remove the track on both sides of the machine.
2. Remove the sprocket on the left side of the
machine. Move the sprocket to the right side.
CTL steel track sprocket
3. Remove the sprocket on the right side of the
machine. Move the sprocket to the left side.
4. Install the sprockets. Tighten the bolts to the
proper torque.
5. Install the track on both sides of the machine.
Replace
1. Remove the track on both sides of the machine.
2. Remove the sprocket on the left side of the
machine. Install the new sprocket.
3. Tighten the bolts to the proper torque.
4. Remove the sprocket on the right side of the
machine. Install the new sprocket.
5. Tighten the bolts to the proper torque.
6. Install the track on both sides of the machine.
i06600763
CTL rubber track sprocket Sprocket - Inspect
1. Measure the sprocket teeth in three places as SMCS Code: 4164-040
shown in illustration 375 .
S/N: HP21–Up
2. Calculate the average of the 3 measurements.
S/N: BE71–Up
S/N: BL71–Up
S/N: HP71–Up
SEBU9084-11 361
Maintenance Section
Sprocket - Inspect
S/N: STK1–Up
S/N: TLK1–Up
S/N: EML1–Up
S/N: NTL1–Up
S/N: FMR1–Up
S/N: FMT1–Up
S/N: HMT1–Up
S/N: MLT1–Up
S/N: EZW1–Up
Note: Operating the machine in conditions that are

the undercarriage of the machine daily in order to
maximize component life.
Sprocket Inspection for Models

with Single Lug Drive System
Note: Sleeves that do not meet the minimum
thickness or sleeves that do not turn freely may
cause unnecessary wear on the drive lugs on the
rubber track.
362 SEBU9084-11
Maintenance Section
Sprocket - Inspect
Remove the Sprocket
(1) Drive motor (2) Bolts and washers (3) Sprocket assembly
Note: In order to service the sprocket, the tracks Sleeves and Rings
must be loosened. Refer to Operation and
Maintenance Manual, “Track (Rubber) - Inspect/
Adjust” for the procedure.
1. Remove the 12 bolts and the 12 washers that hold

the sprocket assembly to the drive motor.
2. Slide the sprocket assembly off the drive motor.

(4) Sprocket mounting ring
(5) Washers and Locknuts
(6) Outer sleeve
(7) Inner sleeve
The sprocket is equipped with two types of sleeves.
• Inner Sleeves (6)

SEBU9084-11 363
Maintenance Section
Sprocket - Inspect
• Outer sleeves (5) Track

The outer sleeves are free to rotate on the inner Tighten the track to the proper tension. Refer to
sleeves . The sleeves are held in position by the Operation and Maintenance Manual, “Track (Rubber)
sprocket mounting ring. - Inspect/Adjust” for the procedure.
Note: There are many parts in the sprocket
assembly. Remove the sprocket completely from the Sprocket Inspection for Models
machine in order to work on the sprocket. Use a with Triple Lug Drive System
clean, flat surface in order to disassemble the
sprocket and assemble the sprocket. Note: Operating the machine in conditions that are
1. Remove the 12 locknuts and washers that hold the sprocket and other undercarriage components. Clean
sprocket mounting ring in place. the undercarriage of the machine daily in order to
maximize component life. Sleeves that do not meet
2. Remove the ring.
the minimum thickness or sleeves that do not turn
3. Remove the outer sleeves and the inner sleeves. freely may cause unnecessary wear on the drive lugs
on the rubber track.
4. Measure thickness (A) for the outer sleeves. If the
thickness of the outer sleeves measures less than
3 mm (0.12 inch), replace the sleeves. Sleeves
that do not meet the minimum thickness or
sleeves that do not turn freely may cause
unnecessary wear on the drive lugs on the rubber
track.
5. When you replace the outer sleeves, rotate the
inner sleeves for 180°. If the inner sleeves have
already been rotated, replace the inner sleeves.
6. Repeat steps 2 through 5 for each set of sleeves.
7. The sprocket mounting rings of the drive sprocket
will wear from the rotation of the outer sleeves.
Measure the thickness of the inner rings and outer
rings. If the thickness of the inner ring or outer ring
measures less than 4.75 mm (0.19 inch), replace
the ring.
8. Install the sleeves and the rings.
9. Install the new locknuts. Do not reuse the
locknuts. Tighten the locknuts to a torque of
70 ± 5 N·m (51.6 ± 3.7 lb ft) in a star pattern. Turn
the nuts an additional 120 degrees and plusmn; 5
degrees in the same star pattern.
10. Install the sprocket on the drive motor. Tighten
the bolts to a torque of 270 ± 40 N·m
(199 ± 30 lb ft).
364 SEBU9084-11
Maintenance Section
Sprocket - Inspect
Remove the Sprocket
(1) Drive motor (2) Bolts and washers (3) Sprocket assembly
Note: In order to service the sprocket, the tracks Sleeves and Rings
must be loosened. Refer to Operation and
Adjust” for the procedure.
1. Remove the 12 bolts (2) and the 12 washers that

hold the sprocket assembly (3) to the drive motor
(1).
2. Slide the sprocket assembly off the drive motor.

(4) Outer ring
(5) Washers and Locknuts
(6) Outer sleeve
(7) Inner sleeve
(8) Sprocket mounting ring
(9) Middle ring
(10) Inner ring
The sprocket is equipped with two types of sleeves.

SEBU9084-11 365
Maintenance Section
Sprocket Retaining Nuts - Check
• Inner Sleeves (7) Track

• Outer sleeves (6) Tighten the track to the proper tension. Refer to
Operation and Maintenance Manual, “Track (Rubber)
The outer sleeves (6) are free to rotate on the inner - Inspect/Adjust” for the procedure.
sleeves (7). The sleeves are held in position by the
outer ring (4), the sprocket mounting ring (8), the i02418761
middle ring (9), and inner ring (10).
Note: There are many parts in the sprocket Sprocket Retaining Nuts -
assembly. Remove the sprocket completely from the
machine in order to work on the sprocket. Use a
Check
clean, flat surface in order to disassemble the SMCS Code: 4164-535-NT
sprocket and assemble the sprocket.
S/N: HP21–Up
1. Remove the 12 locknuts and washers that hold the
S/N: BE71–Up
outer ring (4) in place.
S/N: BL71–Up
2. Remove the ring.
S/N: HP71–Up
3. Remove the outer sleeves and the inner sleeves.
S/N: STK1–Up
4. Measure thickness (A) for the outer sleeves. If the
thickness of the outer sleeves measures less than S/N: TLK1–Up
3 mm (0.12 inch), replace the sleeves. Sleeves
S/N: EML1–Up
that do not meet the minimum thickness or
sleeves that do not turn freely may cause S/N: NTL1–Up
unnecessary wear on the drive lugs on the rubber
S/N: FMR1–Up
track.
S/N: FMT1–Up
5. When you replace the outer sleeves, rotate the
inner sleeves for 180°. If the inner sleeves have S/N: HMT1–Up
already been rotated, replace the inner sleeves.
S/N: MLT1–Up
6. Repeat steps 2 through 5 for each set of sleeves.
S/N: EZW1–Up
7. Install the sleeves and the rings.
8. Install the new locknuts. Do not reuse the
locknuts. Tighten the locknuts to a torque of
55 ± 5 N·m (40.6 ± 3.7 lb ft) in a star pattern. Turn
the locknuts an additional 180° ± 5° in the star
pattern.
9. Install the sprocket on the drive motor. Tighten the
bolts to a torque of 270 ± 40 N·m (199 ± 30 lb ft).
Rings
The inner ring (10), the middle ring (9), the outer ring
(4), and the sprocket mounting ring (8) will wear from
the rotation of the outer sleeves. Measure the
thickness of the inner ring, the middle ring, and outer
ring. If the thickness of the rings measures less than
4.75 mm (0.19 inch), replace the ring. If the
thickness of the sprocket mounting ring measures
less than 8 mm (0.32 inch), replace the sprocket
mounting ring.

(1) Sprocket retaining nut
366 SEBU9084-11
Maintenance Section
Sprocket Sleeve - Inspect
Check the torque on the nuts for new sprockets or for

sprockets that have been reinstalled after every ten
service hours until the specified torque is maintained.
Check the nuts on both sprockets. Use a star pattern
when you tighten the nuts.
Tighten the nuts to a torque of 270 ± 40 N·m
(199 ± 30 lb ft).
i06600421
Sprocket Sleeve - Inspect

SMCS Code: 4164-040-ZV
S/N: HP21–Up
S/N: BE71–Up
S/N: BL71–Up
S/N: HP71–Up
S/N: STK1–Up Illustration 381 g01394383
Models with Single Lug Drive System
S/N: TLK1–Up
S/N: EML1–Up
S/N: NTL1–Up
S/N: FMR1–Up
S/N: FMT1–Up
S/N: HMT1–Up
S/N: MLT1–Up
S/N: EZW1–Up
Note: Operating the machine in conditions that are
the undercarriage of the machine daily in order to
maximize component life. Sleeves that do not meet
the minimum thickness or that do not turn freely may
cause unnecessary wear on the drive lugs on the
rubber track.

Models with Triple Lug Drive System
Check the outer sleeves in order to ensure that the

sleeves rotate freely. If the sleeves do not rotate
freely, refer to Operation and Maintenance Manual,
“Sprocket - Inspect” for information about the
inspection of the sprocket assembly.
SEBU9084-11 367
Maintenance Section
Tilt Cylinder Bearings and Bucket Linkage Bearings - Lubricate
i01878236
Tilt Cylinder Bearings and

Bucket Linkage Bearings -
Lubricate
SMCS Code: 5104-086-BD; 6107-086-BD
Wipe all of the grease fittings before you apply
lubricant.
Note: Lubricate the fittings with the loader lift arms in

the fully lowered position.
Apply lubricant to the grease fittings (1) for the upper
bearings for the tilt cylinders.
Apply lubricant to the grease fittings (2) for the lower
bearings for the tilt cylinders.
Apply lubricant to the grease fittings (3) for the
coupler engagement pins.
Apply lubricant to the grease fitting (4) for the pivot
pin of the quick coupler assembly.
There are a total of 8 grease fittings.
i04439604
Tire Inflation - Check

SMCS Code: 4203-535-AI S/N: HRD1–Up
S/N: BL21–Up S/N: BYF1–Up
S/N: MD21–Up S/N: DML1–Up
S/N: DTB1–Up S/N: ETL1–Up
S/N: KXC1–Up S/N: JSL1–Up

368 SEBU9084-11
Maintenance Section
Tire Inflation - Check
S/N: SEN1–Up
S/N: DPR1–Up
S/N: HMR1–Up
S/N: KTS1–Up
S/N: DZT1–Up
S/N: LST1–Up
S/N: MKT1–Up
S/N: A9W1–Up
S/N: B5W1–Up
S/N: MPW1–Up
S/N: BGZ1–Up
Table 119
Tire size and recommended inflation pressure (cold) for Cat Skid Steer Loader D-Series Models
Size Ply Rating Pressure
12x16.5 10 310 kPa 45 psi 3.10 bar

Cat Premium Conventional
14x17.5 14 414 kPa 60 psi 4.14 bar
Cat Low Side Wall 305-546 10 310 kPa 45 psi 3.10 bar
12x16.5 14 345 kPa 50 psi 3.45 bar

Cat Extreme Duty
14x17.5 14 414 kPa 60 psi 4.14 bar
Cat Premium Conventional

33x15.5x16.5 12 240 kPa 35 psi 2.41 bar
Floatation
Galaxy Beefy Baby 12x16.5 10 310 kPa 45 psi 3.10 bar
The above recommended tire inflation pressure is Tire Inflation with Air
based on a standard machine with the following
conditions:
• 75 kg operator
Use a self-attaching inflation chuck and stand be-
• Typical operating conditions hind the tread when inflating a tire.
• Full fluid levels Proper inflation equipment, and training in using

the equipment, are necessary to avoid overinfla-
• The machine weight and the weight of the work tion. A tire blowout or rim failure can result from
tool must not exceed the weight limit on the improper or misused equipment.
“ROPS” certification. Before inflating tire, install on the machine or put
tire in restraining device.
Note: Consult your Cat dealer if your machine is
experiencing excessive tire slippage. Slippage may
be the result of tire wear.
Inflate the tires, if necessary.
SEBU9084-11 369
Maintenance Section
Track (Rubber) - Inspect/Adjust
NOTICE NOTICE
Set the tire inflation equipment regulator at no more Do not overtighten the tracks. Tracks that are too tight
than 140 kPa (20 psi) over the recommended tire can cause premature failure of the tracks. Tracks that
pressure. are too tight can cause power loss and bearing
failures.
i02418763
Tracks that are too loose increase the possibility of
the track derailing or the drive lugs mis-feeding on
the drive sprocket. In aggressive operating condi-
Track (Rubber) - Inspect/ tions, occasional mis-feeding is normal. If consistent
Adjust mis-feeding is observed, ensure that the track tension
is set to the recommended specification. If the track
SMCS Code: 4197; 4198-025; 4198-040 tension is set to the recommended specification and
mis-feeding is still observed, then your application
S/N: HP21–Up may require a tighter track tension. Increase the track
tension until consistent mis-feeding is no longer
S/N: BE71–Up observed.
S/N: BL71–Up The intervals for track tension vary depending on the
S/N: HP71–Up following conditions: the machine application, the op-
erator, the soil conditions, the climate and the condi-
S/N: STK1–Up tion of the undercarriage components. Operators are
responsible for basic visual inspections of the track
S/N: TLK1–Up tension on a daily basis.
S/N: EML1–Up
S/N: NTL1–Up Inspect
S/N: FMR1–Up
S/N: FMT1–Up
S/N: HMT1–Up
S/N: MLT1–Up
S/N: EZW1–Up
Periodic adjustment of the track tension is necessary
in order to avoid damage to the tracks. Maintaining
the tracks at the proper tension will maximize the
service life of the undercarriage components. The
undercarriage components include the sleeves of the
drive sprocket, the rings of the drive sprocket, the
wheels, and the track.
(1) Weight
(2) Straight edge
(3) Adjuster
(4) Jam nut
Place approximately 45 kg (100 lb) (1) between the

drive sprocket and the front idler wheel. Place a
straight edge (2) across the drive sprocket and idlers.
Measure the track sag between the bottom of the
straight edge and the top of the track. The track sag
should be set at 12 mm (0.5 inch). If the track
needs adjustment proceed with the following steps.
Track Adjustment
1. Loosen the jam nut (4). A 48 mm (1.875 inch)
wrench is recommended.
370 SEBU9084-11
Maintenance Section
Track (Rubber) - Remove/Replace
2. Turn the adjuster (3) in order to raise or lower the 4. Lower the drive sprocket completely in order to
drive sprocket. A 44 mm (1.75 inch) wrench is provide the necessary clearance for maintenance
recommended. or for removal of the track.
3. Tighten the jam nut to the following torque
i06127510
270 ± 40 N·m (199 ± 30 lb ft).
4. Recheck the track tension. Track (Rubber) - Remove/
Replace
Detension the track
(MTL)
SMCS Code: 4197; 4198-510; 4198-011
S/N: HP21–Up
S/N: BE71–Up
S/N: BL71–Up
S/N: HP71–Up
S/N: STK1–Up
S/N: TLK1–Up
S/N: EML1–Up
S/N: NTL1–Up
S/N: FMR1–Up
S/N: FMT1–Up
S/N: HMT1–Up
S/N: MLT1–Up
Illustration 385 g01286098 S/N: EZW1–Up
Clean the area under the sprocket.
Note: Many operations for maintenance of the

Removing the Track
undercarriage require the track to be loosened. Note: The track may weigh as much as
approximately 136 kg (300 lb) clean depending on
1. Remove any debris from the area under the
model and track style.
sprocket before you loosen the track. Trapped
material in this area may prevent the drive 1. Position the machine on firm, level ground.
sprocket from lowering fully.
2. Remove any work tool that is attached to the quick
2. Loosen the jam nut (4). A 48 mm (1.875 inch) coupler.
wrench is recommended.
3. Raise the loader arms and install the brace for the
3. Turn the adjuster (3) in order to lower the drive loader lift arm. Refer to Operation and
sprocket. A 44 mm (1.75 inch) wrench is Maintenance Manual, “Loader Lift Arm Brace
recommended. Operation”.
SEBU9084-11 371
Maintenance Section
Track (Steel) - Inspect/Adjust
8. Grasp the track on top of the front idler. Pull the

track forward and pull the track away from the
frame. Slide the drive lugs past the inside front
idler wheels.
9. Lift the track off the drive sprocket and pull the
track away from the rear idler wheels.
Installing the Track

Note: The track may weigh as much as
1. Slide the track onto the drive sprocket.

2. Position the rear of the track so that the drive lugs
are aligned between the rear idler wheels.
3. Pull all of the slack forward and make sure that the
drive lugs are properly meshed with the drive
sprocket. This will provide the maximum amount of
Illustration 386 g01393193 slack to aid with installation across the front idler.
4. Use an appropriate floor jack in order to lift the 4. Lubricate the idler wheels and the inside of the
machine off the ground. Use appropriate jack track in order to ease the installation of the track.
stands (1) in order to block up the machine. Raise 5. Pull the track over the front idler wheel.
the machine until tracks are approximately 50 mm
(2.0 inch) (A) off the ground. 6. Install the front idler wheel. Refer to Operation and
Maintenance Manual, “Bogie and Idler - Inspect/
5. Detension the track. Refer to Operation and Replace” for the procedure to install the idler
Maintenance Manual, “Track (Rubber) - Inspect/ wheel.
Adjust”.
7. Tension the track. Refer to Operation and
Adjust”.
i05754276

SMCS Code: 4170-025; 4170-040; 4197
S/N: DX21–Up
S/N: FD21–Up
S/N: BY41–Up
S/N: DX91–Up
S/N: GTC1–Up
6. Remove the front idler wheel. Refer to Operation S/N: JST1–Up
and Maintenance Manual, “Bogie and Idler -
Inspect/Replace” for the procedure to remove the
idler wheels.
7. If necessary, lubricate the remaining front idler
wheel and the inside of the track in order to ease
the removal of the track.
372 SEBU9084-11
Maintenance Section
Track Inspect New tracks should meet this condition and should
periodically be checked. Check after the first 50
Inspect the track visually for damage or missing hours and then again at 100 hours. Check every 250
fasteners. Replace any grousers that are damaged hours after the first two checks.
and replace any fasteners that are missing.
Track Adjustment
Track Measurement

(A) First point of measure
(B) Second point of measure
(C) Reference string
(D) Track Profile
With a long string (C) and two weights, lay the string Illustration 389 g03023837
over the track making sure that the string extends (E) Greaser Valve - Recoil Gp
past the rear idler and front idler and does NOT touch (F) Right-Hand undercarriage assembly
the ground. Attach a weight to both ends of the string (G) Cover Plate for Recoil Gp Greaser Valve
so the weights pull the string taut. Measure from the
two lowest points(A & B) in the track to the string. To adjust the tension, there is a greaser valve on the
Average these two measurements. The distance recoil group. To relax the tension on the track, loosen
between the string and the track should be between the greaser with an appropriate wrench or socket. To
6.35 mm (0.25 inch) and 12.7 mm (0.50 inch). tighten the tension on the track, make sure that the
greaser is tight. Apply grease to the greaser until the
proper tension is achieved.
Note: Turn the greaser a maximum of one full turn
when releasing track tension.
Track Bolts - Check

Check the torque for the track grouser bolts and the
master link bolts. Torque to the required value per the
table in "Torque Specifications for Ground Engaging
Bolts.
SEBU9084-11 373
Maintenance Section
Track - Inspect/Adjust
Periodic adjustment of the track tension is necessary

in order to avoid damage to the tracks. Maintaining
the tracks at the proper tension will maximize the
service life of the undercarriage components. The
undercarriage components include the final drive
sprocket, idlers, rollers, and the track.
NOTICE
Do not overtighten the tracks. Tracks that are too tight
can cause premature failure of the tracks. Tracks that
are too tight can cause power loss and bearing
failures.
Tracks that are too loose increase the possibility of
the track derailing or the drive lugs mis-feeding on
the drive sprocket. In aggressive operating condi-
tions, occasional mis-feeding is normal. If consistent
mis-feeding is observed, ensure that the track tension
is set to the recommended specification. If the track
tension is set to the recommended specification and
mis-feeding is still observed, then your application
may require a tighter track tension. Increase the track
tension until consistent mis-feeding is no longer
Illustration 390 g03653135 observed.
(A) Track Grouser bolts
(B) Master Link bolts
The intervals for track tension vary depending on the
following conditions: the machine application, the op-
erator, the soil conditions, the climate and the condi-
i06127490 tion of the undercarriage components. Operators are
responsible for basic visual inspections of the track
Track - Inspect/Adjust tension on a daily basis.
SMCS Code: 4170-040; 4170-025
S/N: DX21–Up Inspect

S/N: FD21–Up
S/N: CD41–Up
S/N: AH91–Up
S/N: BL91–Up
S/N: GTC1–Up
S/N: FTK1–Up
S/N: GTK1–Up
S/N: FTL1–Up
S/N: GTL1–Up
S/N: GWR1–Up
S/N: JST1–Up
Support the machine so that the track is a minimum
S/N: PPT1–Up of 51 mm (2 inch) above the ground.
S/N: WCT1–Up
S/N: TAW1–Up
S/N: RCX1–Up
S/N: A9Z1–Up
374 SEBU9084-11
Maintenance Section
Track - Inspect/Adjust
Table 120
Track Sag Specifications
299D/D2
239D and 279D and
259D and 299D/
249D 289D
D2 XHP
Minimum 15 mm 15 mm 25 mm 25 mm
Sag (0.59 inch) (0.59 inch) (0.98 inch) (0.98 inch)
Maximum 25 mm 25 mm 35 mm 35 mm
Sag (0.98 inch) (0.98 inch) (1.378 inch) (1.378 inch)
Track Adjustment
Measure the track sag at the middle track roller.

Measure the distance from the bottom surface of the
flange on the roller to the inside top surface of the
track. Refer to the table for the proper specifications
for your model.
1. In order to adjust the track, remove the access

panel on the side of the undercarriage.
SEBU9084-11 375
Maintenance Section
Track - Remove/Replace
Note: Catch the grease in a suitable container.

Dispose of the grease in accordance with all
applicable regulations.
Note: One turn should be sufficient. If grease does

not flow as expected, the lock plate can be
temporarily removed. The relief valve can be turned
further to allow for increased flow. Do not turn the
relief valve more than eight turns.
3. Tighten the grease fitting to a torque of

74 ± 14 N·m (55 ± 10 lb ft) when the desired track
tension is reached.
4. Replace the access panel.
i06127473
SMCS Code: 4170-011; 4170-510; 4170

S/N: DX21–Up
S/N: FD21–Up
2. Pressurized grease in a cylinder is used in order to
provide tension on the track. Use a grease gun in S/N: CD41–Up
order to apply grease to the grease fitting on the S/N: AH91–Up
cylinder. The track will be tightened.
S/N: BL91–Up
3. Recheck the track tension.
S/N: GTC1–Up
4. Replace the access panel when the desired sag is
achieved. S/N: FTK1–Up
S/N: GTK1–Up
Detension the track
S/N: FTL1–Up
S/N: GTL1–Up
Personal injury or death can result from grease S/N: GWR1–Up

under pressure. S/N: JST1–Up
Grease coming out of the relief valve under pres- S/N: PPT1–Up
sure can penetrate the body causing injury or
death. S/N: WCT1–Up
Do not stand directly in front of the relief valve to S/N: TAW1–Up
see if grease is escaping. Watch the track or track
adjustment cylinder to see if the track is being S/N: RCX1–Up
loosened. S/N: A9Z1–Up
If track does not loosen, close the relief valve and
consult your Cat dealer. Removing the Track
1. Position the machine on firm, level ground.
Note: Many operations for maintenance of the
undercarriage require the track to be loosened. 2. Remove any work tool that is attached to the quick
coupler.
1. In order to detension the track, remove the access
panel on the side of the undercarriage. 3. Raise the loader arms and install the brace for the
loader lift arm. Refer to Operation and
2. Loosen the grease fitting with a suitable device. Maintenance Manual, “Loader Lift Arm Brace
Loosen the grease fitting carefully until the track Operation”.
begins to loosen.
376 SEBU9084-11
Maintenance Section
8. Lift the track over the sprocket with a suitable lifting

device. The inner guides need to clear the
sprocket teeth.
9. Lift the track over the rear idler. The inner track
guides need to clear the rear idler.

1. Use a suitable lifting device. Slide the track onto

the rear idler so that the inner track guides
Illustration 395 g01451611 straddle the rear idler. If your machine is equipped
with an idler with dual flanges, the inner track
4. Use an appropriate floor jack in order to lift the guides must seat between the flanges.
machine off the ground. Use appropriate jack
stands in order to block up the machine. Raise the 2. Pull the track forward in order to ensure that the
machine until tracks are approximately 50 mm track guides are fully seated on the rear idler.
(2.0 inch) (A) off the ground. 3. Lift the track over the final drive sprocket so that
5. Detension the track. Refer to Operation and the inner track guides straddle the sprocket teeth.
Maintenance Manual, “Track - Inspect/Adjust”. The sprocket teeth should seat in the openings in
the middle of the track.
4. Pull all of the slack forward. This will provide the
maximum amount of slack to aid with installation
across the front idlers.
Note: It is helpful to support the bottom of the track in
order to maximize the slack. This will help with
installation.
5. Position the track so that the inner track guides

seat between the flanges on the front idler.
6. Tension the track. Refer to Operation and
Maintenance Manual, “Track - Inspect/Adjust” for
the procedure.
i06625263
(1) Final Drive Sprocket
(2) Front idler wheel
(Steel)
model and track style. SMCS Code: 4170-011; 4170-510; 4170
6. Use a suitable lifting device. Lift the track at S/N: DX21–Up

MIDDLE position between the front idler and the
S/N: FD21–Up
final drive sprocket until the front idler collapses
fully. S/N: BY41–Up
Note: It is helpful to support the bottom of the track in S/N: DX91–Up

order to maximize the slack between the front idler S/N: GTC1–Up
and the drive sprocket.
S/N: JST1–Up
7. Keep the track supported with a hoist. Lift the track
over the flange of the front idler so that the inner
track guides clear flanges.
SEBU9084-11 377
Maintenance Section
Steel
Removing the Track

1. Position the machine on firm, level ground.
2. Remove any work tool that is attached to the quick
coupler.
3. Raise the loader arms and install the brace for the
loader lift arm. Refer to Operation and
Maintenance Manual, “Loader Lift Arm Brace
Operation”.

(1) Final Drive Sprocket
(2) Front idler wheel
Note: The approximate weight of the track is 400 kg

(882 lb).
6. Use a suitable method to flag the track shoe over

the master link so that the track location can be
seen from the operator station.
4. Use an appropriate floor jack in order to lift the

machine off the ground. Use appropriate jack
stands in order to block up the machine. Raise the
machine until tracks are approximately 50 mm
(2.0 inch) (A) off the ground.
5. Detension the track. Refer to Operation and
Maintenance Manual, “Track (Steel) - Inspect/
Adjust”.
378 SEBU9084-11
Maintenance Section
Steel
9. Use suitable blocking material in front of the front

idler to catch the forward portion of the track
10. Remove the four master link bolts of the flagged

track shoe over the master link and remove the
track shoe.
(2) Front Idler Wheel
(3) Flagged Track over Master Link
(4) Lifting Device Location
7. Operate the machine drive control to position the

flagged track shoe at the top of the front idler &
shut the machine off.
8. Use a suitable lifting device. Strap the track just
behind the flagged track shoe by routing a lifting
sling through the debris openings of the track shoe
next to the flagged track shoe per
11. Lift up the strapped rear portion of the track and

over the sprocket and lay this portion on the
ground behind the machine.
12. Repeat steps 6 through 11 for the other side.

Note: The approximate weight of the track is 400 kg
(882 lb).
Route strap through debris openings.
SEBU9084-11 379
Maintenance Section
Track Pins - Inspect
1. Unroll out the track assembly on a flat, level

surface. Ensure that the two master links are free
of any paint and primer. Orient the track assembly
so the leading edge of the track shoes face
forward when on the top of the undercarriage.

(5) Carrier Roller Alignment bolt
(6) Center of Link Assembly
(7) Roller Assembly
8. Remove blocking and strapping.

i06134832
2. Use suitable lifting or moving equipment to lay out
the track under the undercarriage. Ensure that Track Pins - Inspect
placement of the track allows enough length
behind the machine to wrap over the sprocket.
(Steel)
SMCS Code: 4175-040; 4175; 4175-040-PN; 7521
3. Use an appropriate lifting device. Strap the track
by routing a lifting sling through the debris S/N: DX21–Up
openings of the rear most track shoe
S/N: FD21–Up
4. Lift the rear portion of the track over the sprocket,
engaging enough teeth to retain the weight of the S/N: BY41–Up
track. S/N: DX91–Up
5. Lift the front portion of the track over the carrier S/N: GTC1–Up
roller. Use suitable blocking material at the front
idler to prevent the track from slipping off the S/N: JST1–Up
undercarriage.
6. Connect the two master links insuring all of the
teeth align. Secure the two links together with four Fingers can be burned from hot pins and
master link bolts. Torque the master link bolts to bushings.
280 ± 15 N·m (206.5 ± 11.1 lb ft).
The pins and bushings in a dry joint can become
7. Check and adjust the alignment of the carrier roller very hot. It is possible to burn the fingers if there
with respect to the center of the link assembly. is more than brief contact with these
components.
Loosen the carrier roller alignment bolt and shift
the roller assembly as needed. Torque the carrier Use the recommendations in order to extend the life
alignment bolt to 186 ± 10 N·m (137.2 ± 7.4 lb ft). of the undercarriage. Use the recommendations in
order to avoid excessive downtime.
380 SEBU9084-11
Maintenance Section
Track Roller and Idler - Inspect/Replace
1. During the machine operation, listen for unusual Inspect the idlers and the rollers for damage and
squeaking and for unusual squealing. This noise wear.
can indicate a dry joint. The idlers and the rollers should be replaced when
2. Check the machine for dry joints weekly. Check for the damage to the wheels adversely affects machine
performance.
dry joints immediately after machine operation.
After machine operation, lightly touch the end of Note: The idlers and the rollers contain oil. The idlers
each track pin or bushing. Touch the track pin or and the rollers are sealed for life. Periodically, inspect
the track bushing with the back of your hand. the idlers and the rollers for leaks or for excessive
Make a mark on any dry track pin joint that is hot to end play. Contact your Caterpillar dealer if either
the touch. leaks or excessive end play is found.
Consult the Custom Track Service expert at any Cat i02558956

dealer if you detect dry joints or leaks. The Custom
Track Service expert at the Cat dealer can perform
track inspection. Wheel Nuts - Tighten
SMCS Code: 4210-527
i03880910
S/N: BL21–Up
Track Roller and Idler - S/N: MD21–Up
Inspect/Replace S/N: DTB1–Up
SMCS Code: 4159-510; 4159-040; 4180-510; 4180-
040 S/N: KXC1–Up
S/N: HRD1–Up
S/N: DX21–Up
S/N: BYF1–Up
S/N: FD21–Up
S/N: DML1–Up
S/N: BY41–Up
S/N: ETL1–Up
S/N: CD41–Up
S/N: JSL1–Up
S/N: AH91–Up
S/N: SEN1–Up
S/N: BL91–Up
S/N: DPR1–Up
S/N: DX91–Up
S/N: HMR1–Up
S/N: GTC1–Up
S/N: KTS1–Up
S/N: FTK1–Up
S/N: DZT1–Up
S/N: GTK1–Up
S/N: LST1–Up
S/N: FTL1–Up
S/N: MKT1–Up
S/N: GTL1–Up
S/N: A9W1–Up
S/N: GWR1–Up
S/N: B5W1–Up
S/N: JST1–Up
S/N: MPW1–Up
S/N: PPT1–Up
S/N: BGZ1–Up
S/N: WCT1–Up
When wheels are installed, check the torque after
S/N: TAW1–Up every one service hour until the specified torque is
maintained. After the specified torque is maintained,
S/N: RCX1–Up
check the torque on the nuts after every ten service
S/N: A9Z1–Up hours or every day.
Check the nuts on all four wheels. Use a star pattern
Inspect when you are tightening the nuts.
Clean the undercarriage before inspecting the idlers The torque specifications are given in the following
and the rollers. table.
SEBU9084-11 381
Maintenance Section
Window Washer Reservoir - Fill
Table 121
Tightening Torque for Wheels i02810705
Solid Tires 163 ± 7 N·m (120 ± 5 lb ft)

Window Wiper - Inspect/
Pneumatic Tires 149 ± 7 N·m (110 ± 5 lb ft)
Replace
i02418610
(If Equipped)
SMCS Code: 7305-040; 7305-510
Window Washer Reservoir -
Inspect the condition of the front window wiper blade.
Fill Replace the window wiper blade if the window wiper
blade is worn or damaged. If the window wiper blade
(If Equipped) streaks the window, replace the window wiper blade.
SMCS Code: 7306-544-KE
i06137269
NOTICE
When operating in freezing temperatures, use Cater- Windows - Clean
pillar nonfreezing window washer solvent or equiva-
lent. System damage can result from freezing. SMCS Code: 7310-070
Rear Window and Glass Front Door

Use commercially available window cleaning
solutions in order to clean the windows.
Apply the cleaning solution liberally. Wipe the
surface.
Dry the surface in order to prevent spots.
Side Windows
Use commercially available window cleaning
solutions in order to clean the windows.
The upper sliding side windows of the cab can be
removed for cleaning. Refer to the following
procedure in order to remove the side windows.
The reservoir for the window washer solvent is

located inside the cab by the left footrest.
Fill the reservoir with window washer solvent.
Window washer solvent with isopropyl alcohol is
recommended.
382 SEBU9084-11
Maintenance Section
Work Tool - Lubricate
Apply the cleaning solution liberally. Wipe the

surface.
i02729220

SMCS Code: 6700-086
Multipurpose Bucket
1. Release the latch. Slide the front window rearward

between the circular marks (1) in the top of the
window frame. Push the window upward in the Illustration 407 g01280216
track. Pull outward on the bottom of the window in
order to remove the window. Apply lubricant to the grease fitting (1) for the pivot
pin of the apron.
2. Release the latch. Slide the rear window forward
between the circular marks (1) in the top of the Apply lubricant to the grease fitting (2) for the rod end
of the multipurpose bucket cylinder.
window frame. Push the window upward in the
track. Pull outward on the bottom of the window in Apply lubricant to the grease fitting (3) for the head
order to remove the window. end of the multipurpose bucket cylinder.
3. Reverse the process in order to install the Repeat for the other side of the bucket.
windows. Install the rear window in the outer track.
Install the front window in the inner track next.
Polycarbonate Front Door and

Polycarbonate Top Window
Note: Do not wipe the window dry. Do not use
paper towels. This may scratch the finish of the
polycarbonate windows over time.
For cleaning your polycarbonate top window or
polycarbonate front door, use a soft cloth, a sponge,
or a chamois. Use any of the following cleaners:
• soap and water

• isopropyl alcohol
• kerosene
• denatured alcohol
• commercially available window cleaning solutions

SEBU9084-11 383
Maintenance Section
There are six grease fittings. There are six grease fittings.
Utility Grapple Bucket and Utility Industrial Grapple Bucket and

Grapple Fork Industrial Grapple Fork
Apply lubricant to the four grease fittings for the Apply lubricant to the four grease fittings for the fork
grapples. cylinders.
Apply lubricant to the two fittings for the grapple Apply lubricant to the four grease fittings for the two
cylinder. forks.
384 SEBU9084-11
Maintenance Section
There are eight grease fittings.
Grapple Rake
Apply lubricant to the grease fitting on the horizontal

pivot point of the blade.
Apply lubricant to the four grease fittings for the

grapple cylinders.
Apply lubricant to the four grease fittings for the two
grapples.
There are eight grease fittings.
Angle Blade Apply lubricant to the grease fitting on the vertical

pivot point of the blade. Repeat for opposite side of
the blade.

Apply lubricant to the grease fitting on the rod end of This is a bottom view of the angle blade.
the angle cylinder.
Apply lubricant to the grease fitting on the pivot point
of the cylinder.
SEBU9084-11 385
Maintenance Section
Work Tool Guard and Reflector - Inspect/Replace
There are five grease fittings. i01809997
Dozer Blade Work Tool Mounting Bracket -

Inspect
SMCS Code: 6700-040-BK
Inspect upper angled plate (1) and ensure that the

plate is not bent or otherwise damaged. Inspect holes
Illustration 417 g01073259 (2) for wear and for damage. Inspect lower angled
plate (3) and ensure that the plate is not bent or
Apply lubricant to the grease fitting on both ends of otherwise damaged. If any wear is suspected or any
the right hand angle cylinder (1). Repeat for opposite damage is suspected, consult your Caterpillar dealer
side of the blade. before you use the work tool.
Apply lubricant to the grease fitting on the pivot points
on each end of the tilt cylinder (2).
There are six grease fittings.
i03881935
Work Tool Guard and Reflector

- Inspect/Replace
SMCS Code: 6700
Ensure that all safety reflectors are clean. Ensure
that all safety reflectors are not damaged. When you
clean the safety reflectors, use a cloth, water and
soap. Do not use solvent, gasoline, or other harsh
chemicals to clean the safety reflectors. Solvents,
gasoline, or harsh chemicals could loosen the
adhesive that secures the safety reflectors. Loose
adhesive will allow the safety reflectors to fall.
Replace any safety reflector or replace any guards
that are damaged, or missing. If a safety reflector is
attached to a part that is replaced, install a safety
reflector on the replacement part. Any Caterpillar
dealer can provide new safety reflectors.
386 SEBU9084-11
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
i06112217 components”), are:
Emissions Warranty a. Designed, built, and equipped so as to conform,
Information at the time of sale, with applicable emission
standards prescribed in the Enforcement Rule
SMCS Code: 1000 of the Clean Air Conservation Act promulgated
The certifying engine manufacturer warrants to the by South Korea MOE.
ultimate purchaser and each subsequent purchaser
that: b. Free from defects in materials and workmanship
in emission-related components that can cause
1. New non-road diesel engines and stationary diesel the engine to fail to conform to applicable
engines less than 10 liters per cylinder (including emission standards for the warranty period.
Tier 1 and Tier 2 marine engines < 37 kW, but
excluding locomotive and other marine engines) A detailed explanation of the Emission Control
operated and serviced in the United States and Warranty that is applicable to new non-road and
stationary diesel engines, including the components
Canada, including all parts of their emission
covered and the warranty period, is found in a
control systems (“emission related components”), supplemental Special Publication. Consult your
are: authorized Cat dealer to determine if your engine is
subject to an Emission Control Warranty and to
a. Designed, built, and equipped so as to conform, obtain a copy of the applicable Special Publication.
at the time of sale, with applicable emission
standards prescribed by the United States
Environmental Protection Agency (EPA) by way
of regulation.
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.
SEBU9084-11 387
Reference Materials
Reference Information Trailer Transportation

Section In principle, this machine should be transported by a
trailer. Select the appropriate trailer regarding the
machine weight and measurements shown in the
major specifications in the specification part of this
Reference Materials manual. Be aware machine weight and transportation
measurements differ depending on the various types
i06746033 of attachments.
• In the event heavy items are to be transported,
Reference Material observe the related laws such as Road Traffic
SMCS Code: 1000; 7000 Law, Road Laws, Road Transportation Vehicle
Laws, and Vehicle Restriction Laws.
Additional literature regarding your product maybe
purchased from your local Cat dealer or by visiting • Conduct prior investigation of the road width,
www.cat.com. Use the product name, sales model, ground clearance of road/railway bridges, weight
and serial number to obtain the correct information restrictions and so on, of the planned
for your product. transportation route, to confirm the viability of the
transportation execution.
Regulatory Information (Japan)
Load
Vehicle Inspection
Vehicle inspection certification is required to operate
a machine on public roads. This includes driving on
as well as crossing public roads. For details, consult
your Cat dealer.
Qualifications for Machine Operation

The following qualifications are required for the
operation of this machine:
Excavation and Loading
Completion of the construction machines (for land
leveling, hauling, loading, and excavation) operation
skill training course. (Qualification by the Industrial
Safety and Health Act)
Demolition
Completion of the construction machines (for
demolition) operation skill training course.
(Qualification by the Industrial Safety and Health Act) Illustration 419 g02698738
Mining Jobs • Not more than 3.8 m (12 ft 6 inch)

Certification by the Director General or Deputy • Not more than 2.5 m (8 ft 2 inch)(Safety Standard)
Director General of Bureau of Mine Safety after
completion of the safety training course. • Not more than 2.5 m (8 ft 2 inch) (Vehicle
(Qualification by the Mine Safety Act) Restriction Laws)
Crane Slinging for the Bucket with a Hook • Items that protrude out are not allowed.
(Government ordinance for Road Traffic Laws)
Completion of the special slinging training for the
crane for loads weighing less than 1 ton. Transportation weight and measurements are
(Qualification by the Industrial Safety and Health Act) restricted by the Vehicle Restriction Laws. If the
actual weight/measurements exceed the limitation
figures, you must submit the restriction relaxation
request to the pertinent governmental agencies. For
details, consult your Cat dealer.
388 SEBU9084-11
Reference Material
Table 122
Total Length Not more than 12 m Acquisition of the Qualifications
(39 ft 4 inch)
Total Width (A) Not more than 2.5 m The company offers training courses for construction
(8 ft 2 inch) machine operation, in addition to other skills. For
details, contact the company's dealer in your area.
Total Height (B) Not more than 3.8 m
(12 ft 6 inch) when loaded on Regarding machine operation qualifications, also
the trailer. refer to the laws related to the construction machines
shown at the end of this manual.
Total Weight 20 to 25 ton (depending on
road, axle, and vehicle length)
Operation of Construction Equipment
and the Governing Laws and Regulations
Note: If the size or weight exceeds what is listed, an
accommodation application is required. Contact your
Cat dealer for more information. NOTICE
Information of operating skill course for vehicle-
Qualification of Operators type construction equipment (for ground leveling,
transporting, loading, excavating)
Operation of construction equipment is limited to Industrial Safety and Health Act requires opera-
operators who have any of the following licenses by tors of construction equipment weight 3 tons and
law. over to acquire a certificate of completion of an
operating skill course. Registered with and au-
Note: Employers will face imprisonment up to a thorized by the respective directors general of
maximum of 6 months or a fine of up to a the regional labor bureaus, we offer operating
maximum of five hundred thousand yen if they let skill courses for vehicle-type construction equip-
unqualified personnel operate equipment. ment and special trainings.
Unqualified operators will also be fined up to a
maximum of five hundred thousand yen.
• One who completed an operating skill course for
Caterpillar Operating Training Center
vehicle-type construction equipment at a
Head Office:
registered training institution.
Address: 3700 Tana, Sagamihara-City,
• One who passed the construction equipment and
Kanagawa
technologies license examination (Type 1-3)
Tel: (042) 763-7130
defined by the Construction Industry Law.
Fax: (042) 761-5540
• One who completed an operating training course Website: http://cot.catjs.com
for construction equipment defined by the e-mail: [email protected]
Vocational Training Law. Training centers registered with the respective
directors general of the regional labor bureaus and
• One who took a special training (rules and skills)
special training sites:
at a registered training institution to operate
equipment weighing less than 3 tons. Locations
• With an auto-drivers license which is conformed to
• Shizuoka Operating Training Center (Fujieda-City)
each model, an operator does not need to
(Registered with Director General of Shizuoka
complete an operating skill course for construction
Regional Labor Bureau) Tel: (054) 641-7010
equipment to operate equipment on the roads that
apply to the rules of the Road Traffic Act. • Tokai Operating Training Center (Toyohashi-City)
However, the operator needs to complete the (Registered with Director General of Aichi
course to engage in snow clearing or excavating Regional Labor Bureau) Tel: (053) 265-5151
on the roads.
• Chugoku Operating Training Center Okayama
• Operator needs to be qualified under the Mine Operating Training Center (Okayama-City)
Safety Act to operate construction equipment in a (Registered with Director General of Okayama
mine. Regional Labor Bureau) Tel: (086) 272-0001
SEBU9084-11 389
Reference Material
• Chugoku Operating Training Center Hiroshima • Sagami Operating Training Center (Sagamihara-
Operating Training Center (Hiroshimma-City) City) (Registered with Director General of
(Registered with Director General of Hiroshima Kanagawa Regional Labor Bureau) Tel: (042) 763-
Regional Labor Bureau) Tel: (082) 893-3011 7103
• Caterpillar Kyushu Ltd. (Registered with the • Kinki Operating Training Center Ibaraki Operating
Director General of the Regional Labor Bureau) Training Center (Ibaraki-City) (Registered with
Fukuoka Operating Training Center Tel: (092) 924- Director General of Osaka Regional Labor
1455 Nagasaki Operating Training Center Tel: Bureau) Tel: (072) 641-1121
(095) 725-3735 Kumamoto Operating Training
Center Tel: (096) 359-0052 Miyazaki Operating • Kinki Operating Training Center Nara Operating
Training Center Tel: (098) 530-2075 Oita Training Center (Yamato-Koriyama-City)
Operating Training Center Tel: (097) 573-5955 (Registered with Director General of Nara
• Hyogo Operating Training Center (Ono-City)
(Registered with the Director General of Hyogo Request for Periodical Self-Inspection
Self-inspection of Equipment
• Kinki Operating Training Center Osaka-Minami
Operating Training Center (Izumi-City) Laws require that users should regularly inspect
(Registered with Director General of Osaka equipment to operate it under good conditions at all
Regional Labor Bureau) Tel: (072) 556-6373 times.
• Kinki Operating Training Center Wakayama Inspections are classified into three types:
Operating Training Center (Wakayama-City)
(Registered with Director General of Wakayama • before-work inspection
• monthly inspection
• Hokuriku Operating Training Center (Kanazawa-
• annual inspection
City) (Registered with Director General of
Ishikawa Regional Labor Bureau) Tel: (076) 258- The respective inspection items are specified by law.
2302 It is also required to retain the inspection record.
Customers are recommended to conduct regular
• Hokuriku Operating Training Center Niigata self-inspections as they are keys to increase the life
Operating Training Center (Niigata-City) Tel: (025) of equipment and to use it efficiently.
266-6161
Rules of Periodical Self-Inspection
• Hokkaido Operating Training Center (Sapporo-
City) (Registered with Director General of The employer shall, as provided for by the Ordinance
Hokkaido Regional Labor Bureau) Tel: (011) 795- of the Ministry of Health, Labor and Welfare, conduct
7022 self-inspection periodically and keep the records of
the results in respect to construction equipment such
• Caterpillar Tohoku Ltd. Miyagi Operating Training as tractor shovels and power shovels, etc., specified
Center (Iwanuma-City) (Registered with Director by Cabinet Order. (from Article 45, Industrial Safe
General of Migyagi Regional Labor Bureau) Tel: and Health Act)
(022) 329-3911
Ordinance on Industrial Safety and Hygiene
• Saitama Operating Training Center Fukaya
Operating Training Center (Fukaya-City) Periodical self-inspections Article 167
(Registered with Director General of Saitama
Regional Labor Bureau) Tel: (048) 572-1177 (1) The employer shall, as regards a vehicle type
construction machine, carry out self-inspections for
• Saitama Operating Training Center Chichibu the following matters periodically once every period
Operating Training Center (Chichibu-City) within a year. However, this shall not apply to the
(Registered with Director General of Saitama non-use period of a vehicle type construction
machine, which is not used for a period exceeding 1
Regional Labor Bureau) Tel: (049) 424-7319 year.
• Higashi-Kanto Operating Training Center (2) The employer shall, as regards a vehicle type
(Kashiwa-City) (Registered with Director General construction machine set forth in the proviso of the
of Chiba Labor Bureau) Tel: (047) 133-2126 proceeding paragraph, carry out self-inspection for
abnormalities in each part of a construction machine
before resuming the operation.
390 SEBU9084-11
Reference Material
Periodical self-inspections Article 168 Other Rules

(1) The employer shall, as regards a vehicle type Besides qualification for operating equipment and
construction machine, carry out self-inspections for self inspections, the following obligations are set forth
the following matters periodically once every period in the Industrial Safety and Health Act:
within a month. However, this shall not apply to the
non-use period of a vehicle type construction • To conduct health and safety training for new
machine, which is not used for a period exceeding recruits and shop foremen.
one month:
• To appoint the operation leader or supervisor, and
• (i) Abnormalities in a brake, a clutch, a controlling establish health and safety management system.
device, and working devices.
• To inform employees of a chain of command at the
• (ii) Damage in a wire, rope, and a chain worksite, communication and signal rules,
traveling route of equipment, speed limits, signs of
• (iii) Damage in a bucket, a zipper, etc. restricted areas, etc. for securing safety in the
(2) The employer shall, as regards to the vehicle type workplace.
construction machine set forth in the proviso of the Industrial Safety and Health Act further also sets
preceding paragraph, carry out self-inspection for the obligations related to mechanical structures and
matters listed in each item of the same paragraph rental activities of equipment.
before resuming the operation.
Safety comes before anything else. Please
Record of Periodical Self-Inspections Article 169 establish a workplace where no injuries occur by
observing the governing laws and by referring to
The employer shall, when having carried out the self-
this manual, specifically the descriptions on
inspections set forth in the preceding two Articles,
safety.
record the results and retain the records for 3 years.
Specified Self-Inspection Article 169-2 Information of Japan Construction
Equipment Manufacturers Association
The specified self-inspection pertaining to the vehicle
type construction machine shall be the self- Dear Customers
inspection (prescribed by Article 167) and carried out
by qualified personnel. The employer shall, when Japan Construction Equipment Manufacturers
having carried out the specified self-inspection Association
pertaining to a vehicle type construction machine,
affix an inspection sticker stating the month and year Standard Certificate of Transfer
when the said specified self-inspection was carried
out at a readily visible location of the said machine. Issued by the Japan Construction Equipment
Manufacturers Association
• Caterpillar Japan has a supporting program for Standard Certificate of Transfer issued by the
self-inspection as a registered inspection agency. Japan Construction Equipment Manufacturers
Qualified personnel and inspection equipment are Association proves the ownership of your
available to help customers who do not conduct equipment. Please request us to issue the
internal inspections or do not have time to conduct certificate as a proof of transfer of ownership.
the specified self-inspections. Please contact a
Cat dealer near you for details. Commercial transactions of construction equipment
are generally made on a long-term installment plan
• Maintenance and inspection record book for a basis with a special provision of reservation of
record-saving purpose can be purchased at ownership that the seller retains the ownership of the
Caterpillar Japan. sold equipment until the buyer completely pays off
the installments.
• Penalty: Employer who fails to carry out self-
inspections and to record the results will face a Ownership of some construction equipment can be
proved with a vehicle inspection certificate, but the
fine of up to five hundred thousand yen. certificate is not issued for most of the equipment.
Checkup before Commencing the Work Article 170 Therefore, the buyer will need to present a third party
with a proof of ownership of the sold equipment.
The employer shall, when carrying out the work using
a vehicle type construction machine, check functions
of a brake and a clutch before commencing the work
for the day.
SEBU9084-11 391
Caterpillar Approved Work Tools
Japan Construction Equipment Manufacturers a. Discretionary page/s to the certificate will be

Association launched a system of standard certificate valid with a tally seal of the issuer at the joint of
of transfer in 1971 to normalize trading in two pages.
construction equipment and establishes a business
practice relating to transfer of ownership. Customers Please contact CEMA-member companies or
are kindly requested to understand the intent of the distributors for more details of the system.
system and request your seller to issue a certificate
of transfer.
Maintenance Interval Schedule for
1. About the standard certificate of transfer significant parts (Japan)
a. Japan Construction Equipment Manufacturers
Association (hereinafter referred to as CEMA) Caterpillar is asking periodic maintenance to secure
safety and performance. To make safety better,
sets the rules and form of standard certificate of Caterpillar recommend periodic replacement of
transfer (hereinafter referred to as certificate of significant parts especially.
transfer), and members of the CEMA issue the
certificate of transfer. A certificate of transfer The parts below are easy to wearing, changing of
proves the ownership of equipment. material properties, and deterioration. Furthermore,
degree of damage is hard to be measured by visual
2. Purpose of issuance inspection.
a. A certificate of transfer will be issued for Please contact Cat dealer to ask inspection when
clarifying the ownership of equipment and each interval comes.
Table 123
preventing misconduct such as trades of stolen
equipment or fraud. Significant Parts Required Interval
3. Issuer Fuel system hoses Every 2 years
Brake system hoses Every 4 years

a. A certificate of transfer will be issued by a
distributor (Primary transferor) who sells new Brake system components Every 2 years
construction equipment and is authorized by the
Steering system hoses Every 2 years
CEMA.
Work Tool (Bucket i.e.) hoses Every 2 years
4. Eligibility
a. A certificate of transfer will be issued for the i06737192

equipment, which is sold by CEMA-member
distributors and defined as construction Caterpillar Approved Work
equipment by the CEMA
Tools
5. Issuance
SMCS Code: 6700
a. A certificate of transfer will be issued and
Only use Cat approved work tools on this machine.
directly given to a buyer upon the buyer's
request when he/she buys eligible equipment Note: Do not use a Cat work tool on a machine that
from an issuer. is not approved by Cat.
b. A certificate of transfer may not be issued for Note: A Debris Barrier Kit is required for use in
the equipment, which was sold as new applications which create airborne debris. Consult
merchandise more than 10 years ago. your Cat dealer for information about this kit.
c. A certificate of transfer is not permitted to Use of the following equipment or operation in the
substitute a vehicle inspection certificate. following applications may create airborne debris:
6. Prohibition of reissuance • mulching head
a. Certificate of transfer should be safely stored as • brush cutter

it will not be reissued under any circumstances.
• hammers
7. In case a certificate description runs out of space
• recycling of paper products certain agriculture
applications
• cold planing
392 SEBU9084-11
Note: See your Cat dealer for work tools and for work
tool attachments that are approved for roading.
Note: The combination of Water Tank, Backhoe

Loader, and Hydraulic Hammer exceeds the
recommended load rating.
Table 124
Work Tool 226D 232D 239D 249D 236D 242D 257D 259D
General Purpose
Bucket 1524 mm (60 C C C C C C C C
inch)
General Purpose
inch)
General Purpose
inch)
General Purpose
inch)
General Purpose
inch)
Multipurpose Bucket
C C C C C C C C
1524 mm (60 inch)
Multipurpose Bucket
C C C C C C C C
1676 mm (66 inch)
Multipurpose Bucket
C C C C C C C C
1829 mm (72 inch)
Multipurpose Bucket
C C C C C C C C
1981 mm (78 inch)
Multipurpose Bucket
C C C C C C C C
2133 mm (84 inch)
Low Profile Bucket

C C C C C C C C
1372 mm (54 inch)
Low Profile Bucket

C C C C C C C C
1524 mm (60 inch)
Low Profile Bucket

C C C C C C C C
1676 mm (66 inch)
Low Profile Bucket

C C C C C C C C
1829 mm (72 inch)
Low Profile Bucket

C C C C C C C C
1981 mm (78 inch)
Light Material Bucket

C C C C C C C C
1829 mm (72 inch)

C C C C C C C C
1981 mm (78 inch)
(continued)
SEBU9084-11 393
(Table 124, contd)

C C C C C C C C
2134 mm (84 inch)

C C C C C C C C
2438 mm (96 inch)
Utility Bucket 1524

C C C C C C C C
mm (60 inch)
Utility Bucket 1676

C C C C C C C C
mm (66 inch)
Utility Bucket 1829

C C C C C C C C
mm (72 inch)
Mixing Bucket MB200 C C C C C C C C
Mixing Bucket MB250 C^ C C
A14B Auger C C C C C C C C
BH27 Backhoe C C C C C C C C
BH30 w Backhoe
BH160 Backhoe
Angle Blade 1829 mm
C C C C C C C C
(72 inch)
Angle Blade 2134 mm

C C C C C C C C
(84 inch)
Dozer Blade 2007 mm

C C C C C C C C
(79 inch)
Dozer Blade 2337 mm

C C C C C C C C
(92 inch)
BA18 Angle Broom C C C C C C C C
BU115 Utility Broom C C C C* C C C C
BU118 Utility Broom C* C* C* C* C* C*
BP15B Pickup Broom C C C C* C C C C
BP18B Pickup Broom C C* C* C* C*
BA118C Angle Broom C C C C C C C C
BP115C Pickup
C* C* C C C* C C C
Broom
BP118C Pickup
C* C* C* C C C
Broom
PC203 Cold Planer C C C C C C C C
(continued)
394 SEBU9084-11
(Table 124, contd)

PC210 Cold Planer
PC104B Cold Planer C C C C C C C C
PC306B XD Cold
Planer
PC310B Cold Planer
PC310B XD Cold
Planer
PC408B Cold Planer
PC412B Cold Planer
Carriage and Fork
C C C C C C C C
Tines
Utility Fork 1676 mm
C C C C C C C C
(66 inch)
Utility Fork 1829 mm

C C C C C C C C
(72 inch)
Industrial Grapple
inch)
Industrial Grapple
inch)
Industrial Grapple
inch)
Industrial Grapple
inch)
Industrial Grapple
Fork 1676 mm (66 C C C C C C C C
inch)
Industrial Grapple
Fork 1829 mm (72 C C C C C C C C
inch)
Industrial Grapple
Rake 1829 mm (72 C C C C C C C C
inch)
Industrial Grapple
Rake 2134 mm (84 C C C C C C C C
inch)
Utility Grapple Bucket

C C C C C C C C
1676 mm (66 inch)
(continued)
SEBU9084-11 395
(Table 124, contd)

Utility Grapple Bucket
C C C C C C C C
1829 mm (72 inch)

C C C C C C C C
1676 mm (66 inch)

C C C C C C C C
1829 mm (72 inch)
Material Handling Arm C C C C C C C C
SR117 Snowblower C C C C
SR318 Snowblower C C C C C C C C
SR321 Snowblower C C C C C C C C
Sectional Snow Push
C C C C C C C C
2440 mm (8 ft)
Sectional Snow Push

C C C C C C
3050 mm (10 ft)
Sectional Snow Push

3660 mm (12 ft)
Sectional Snow Push

4270 mm (15 ft)
LR15B Landscape
C* C* C* C* C* C* C* C*
Rake
LR18B Landscape
C* C* C* C*
Rake
PR172 Power Rake C C C C C C C C
LT13B Landscape
C C C C C C C C
Tiller
LT18B Landscape
C C C
Tiller
SG16B Stump Grinder C C C C C C C C
SG18b Stump Grinder C C C C C C C C
T6B Trencher C C C C C C C C
CV16B Vibratory
C* C* C* C* C C C* C*
Compactor
CV18B Vibratory
Compactor
SW45 Wheel Saw 3

C* C* C* C*
inch
(continued)
396 SEBU9084-11
(Table 124, contd)

SW45 Wheel Saw 6
C* C* C* C*
inch
SW45 Wheel Saw 8
C* C* C* C*
inch
SW60 Wheel Saw 6
inch
SW60 Wheel Saw 8
inch
SW80 Wheel Saw
SW345B Wheel Saw 3
C^ C* C* C
inch
SW345B Wheel Saw 5
C* C* C* C*
inch
SW360B Wheel Saw 3
inch
SW360B Wheel Saw 4
inch
SW360B Wheel Saw 5
inch
SW360B Wheel Saw 6
inch
SW360B Wheel Saw 8
inch
SW460B Wheel Saw 3
inch
SW460B Wheel Saw 6
inch
SW460B Wheel Saw 8
inch
SW380B Wheel Saw
SW480B Wheel Saw
H55Es Hammer CD CD CD CD CD CD CD CD
H65Es Hammer CD CD CD CD CD CD CD CD
BR160 Brush Cutter C C C C
BR378 Brush Cutter
BR318 XC
BR418 XC
S305 Shear CD CD CD CD CD CD
HM112C C C C C
HM115C C C C C
(continued)
SEBU9084-11 397
(Table 124, contd)

HM215C C C C C C C C C
HM315C
HM415C
HM418C
HM312 Mulcher
HM315 Mulcher
HM315B Mulcher
HM415B Mulcher
Single Bale Spear 39" C C C C C C C C
Double Bale Spear 39" C C C C C C C C
Single Bale Spear 49" C C C C C C C C
Double Bale Spear 49" C C C C C C C C
Bale Grapple C C C C C C C C
84" Material Handling

C C C C C C C C
Bucket
C C C C C C C C
Bucket
C C C C C C C C
Bucket
8' Snow Pusher C C C C C C C C
8' Snow Pusher (Rub-
C C C C C C C C
ber Edge)
10' Snow Pusher

C C C C C C C C
(Rubber Edge)
12' Snow Pusher

C C C C C C C C
(Rubber Edge)
6' Snow Blade C C C C C C C C

DFS118
C C C C C C C C
Silage Defacer
DFS121
C C C C C C C C
Silage Defacer
DFS124
C C C C C C C C
Silage Defacer
398 SEBU9084-11
Table 125
272D/ 297D/ 299D/
272D/ 297D/ 299D/
Work Tool 246D 262D D2 277D 287D 279D 289D D2 D2
D2 D2 D2
XHP XHP XHP
General Purpose
Bucket 1524 mm C C C C C C C C C C C C
(60 inch)
General Purpose
(66 inch)
General Purpose
(72 inch)
General Purpose
(78 inch)
General Purpose
(84 inch)
Multipurpose Buck-
et 1524 mm (60 C C C C C C C C C C C C
inch)
Multipurpose Buck-
inch)
Multipurpose Buck-
inch)
Multipurpose Buck-
inch)
Multipurpose Buck-
inch)
Low Profile Bucket

C C C C C C C C C C C C
1372 mm (54 inch)
Low Profile Bucket

1524 mm (60 inch)
Low Profile Bucket

1676 mm (66 inch)
Low Profile Bucket

1829 mm (72 inch)
Low Profile Bucket

1981 mm (78 inch)
Light Material
(72 inch)
Light Material
(78 inch)
(continued)
SEBU9084-11 399
(Table 125, contd)

272D/ 297D/ 299D/
272D/ 297D/ 299D/
D2 D2 D2
XHP XHP XHP
Light Material
(84 inch)
Light Material
(96 inch)
Utility Bucket 1524

mm (60 inch)
Utility Bucket 1676

mm (66 inch)
Utility Bucket 1829

mm (72 inch)
Mixing Bucket
MB200
Mixing Bucket
MB250
A14B Auger C C C C C C C C C C C C
BH27 Backhoe
BH30 Backhoe
BH30 w Backhoe C C C C C C C C C C C C
BH150 Backhoe C C C C C C C C C C C C
BH160 Backhoe C C C C C C C C C C C CR
Angle Blade 1829
mm (72 inch)
Angle Blade 2134

mm (84 inch)
Dozer Blade 2007

mm (79 inch)
Dozer Blade 2337

mm (92 inch)
BA18 Angle Broom C C C C C C C C C C C C
BU115 Utility
Broom
BU118 Utility
Broom
BP15B Pickup
Broom
BP18B Pickup
Broom
(continued)
400 SEBU9084-11
(Table 125, contd)

272D/ 297D/ 299D/
272D/ 297D/ 299D/
D2 D2 D2
XHP XHP XHP
BA118C Angle
Broom
BP115C Pickup
Broom
BP118C Pickup
Broom
PC203 Cold Planer C C C C C C C C C C C C
PC210 Cold Planer C* C C C C C C C C C C C
PC104B Cold
Planer
PC205B Cold
Planer
PC306B Cold
Planer
PC306B XD Cold
C* C* C* C C C C C C CR
Planer
PC310B Cold
C* C C C C C C C C C C C
Planer
PC310B XD Cold
C* C*R C* C* C*R C*R
Planer
PC408B Cold
C C C
Planer
PC412B Cold
C C C
Planer
Carriage and Fork
Tines
Utility Fork 1676
mm (66 inch)
Utility Fork 1829

mm (72 inch)
Industrial Grapple
(60 inch)
Industrial Grapple
(66 inch)
Industrial Grapple
(72 inch)
(continued)
SEBU9084-11 401
(Table 125, contd)

272D/ 297D/ 299D/
272D/ 297D/ 299D/
D2 D2 D2
XHP XHP XHP
Industrial Grapple
(78 inch)
Industrial Grapple
Fork 1676 mm (66 C C C C C C C C C C C C
inch)
Industrial Grapple
Fork 1829 mm (72 C C C C C C C C C C C C
inch)
Industrial Grapple
Rake 1829 mm (72 C C C C C C C C C C C C
inch)
Industrial Grapple
Rake 2134 mm (84 C C C C C C C C C C C C
inch)
Utility Grapple
(66 inch)
Utility Grapple
(72 inch)

1676 mm (66 inch)

1829 mm (72 inch)
Material Handling
Arm
SR117 Snowblower
SR118 Snowblower C C C C C C C C C C C C
Sectional Snow
Push 2440 mm (8 C C C C C C C C C C C C
ft)
Sectional Snow
Push 3050 mm (10 C C C C C C C C C C C C
ft)
Sectional Snow
Push 3660 mm (12 C C C C C C C C C C C
ft)
Sectional Snow
Push 4270 mm (15 C C C C C C
ft)
(continued)
402 SEBU9084-11
(Table 125, contd)

272D/ 297D/ 299D/
272D/ 297D/ 299D/
D2 D2 D2
XHP XHP XHP
LR15B Landscape
Rake
LR18B Landscape
Rake
PR172 Power Rake C C C C C C C C C C C C
LT13B Landscape
Tiller
LT18B Landscape
Tiller
SG16B Stump
Grinder
SG18b Stump
Grinder
T6B Trencher C C C C C C C C C C C C
CV16B Vibratory
Compactor
CV18B Vibratory
Compactor
SW45 Wheel Saw 3

C^ C^ C C C C C C C C C C
inch
SW45 Wheel Saw 6
inch
SW45 Wheel Saw 8
inch
SW60 Wheel Saw 6
C^ C^ C^ C C C^ C C C C C
inch
SW60 Wheel Saw 8
C^ C^ C^ C C C^ C C C C C
inch
SW80 Wheel Saw C* C* C* C* C* C C C C C
SW345B Wheel
Saw 3 inch
SW345B Wheel
Saw 5 inch
SW360B Wheel
C^ C^ C^ C^ C^ C^ C C C CR
Saw 3 inch
SW360B Wheel
C^ C^ C^ C^ C^ C^ C^ C C C CR
Saw 4 inch
SW360B Wheel
Saw 5 inch
(continued)
SEBU9084-11 403
(Table 125, contd)

272D/ 297D/ 299D/
272D/ 297D/ 299D/
D2 D2 D2
XHP XHP XHP
SW360B Wheel
Saw 6 inch
SW360B Wheel
Saw 8 inch
SW460B Wheel
C^ C CR
Saw 3 inch
SW460B Wheel
C^ C CR
Saw 6 inch
SW460B Wheel
C^ C CR
Saw 8 inch
SW380B Wheel
C^ C^ C^ C^ C^ C^ C C C CR
Saw
SW480B Wheel
C^ C CR
Saw
H55Es Hammer CD CD CD CD CD CD CD CD CD CD CD CD
H65Es Hammer CD CD CD CD CD CD CD CD CD CD CD CD
BR160 Brush
Cutter
BR166 Brush
Cutter
BR172 Brush
Cutter
BR272 Brush
Cutter
BR378 Brush
Cutter
BR318 XC C C C C C C C C C C C C
BR418 XC C C C
S305 Shear CD CD CD CD CD CD CD CD CD CD CD CD
HM112C
HM115C C C C C C C C C C C C C
HM215C
HM315C C C C C C C C C C C C C
HM415C C C C
HM418C C C C
HM312 Mulcher C C C C C C C C C C C C
HM315 Mulcher C C C C C C C C C C C C
HM315B Mulcher C C C C C C C C C C C C
HM415B Mulcher C C C
Single Bale Spear
39"
(continued)
404 SEBU9084-11
(Table 125, contd)

272D/ 297D/ 299D/
272D/ 297D/ 299D/
D2 D2 D2
XHP XHP XHP
Double Bale Spear
39"
Single Bale Spear
49"
Double Bale Spear
49"
Bale Grapple C C C C C C C C C C C C
84" Material Han-

dling Bucket
96" Material Han-

dling Bucket
102" Material Han-

dling Bucket
8' Snow Pusher C C C C C C C C C C C C

8' Snow Pusher
(Rubber Edge)
10' Snow Pusher

(Rubber Edge)
12' Snow Pusher

(Rubber Edge)
6' Snow Blade C C C C C C C C C C C C

DFS118
Silage Defacer
DFS121
Silage Defacer
DFS124
Silage Defacer
Legend R - Machine must have limited options installed to

avoid exceeding the maximum total machine rated
C - Compatible capacity. Refer to the Operation and Maintenance
Manual for the specific Work Tool for details.
C* - Compatible But Lift Restriction Apply
Many of the work tools in the table have an Operation
C^ - Compatible But Lift Restrictions Apply and Max and Maintenance Manual. Refer to the Operation and
Machine Counterweights Required Maintenance Manual that is provided with the work
tool for the proper use of the work tool.
D - European Union Restrictions Apply; Refer to
Operation Maintenance Manual, “Safety Section:
Worktools: Demolition”
SEBU9084-11 405
Decommissioning and Disposal
Consult your Cat dealer concerning specific work • Demolition

tools that are approved by Cat for this machine. This
list was complete at the time of publication. There • Industrial
may be additional work tools that have been
approved since that time. Consult your Cat dealer for • Construction
an updated list of approved work tools.
Do not use the work tool improperly.
INTENDED USE STATEMENT for • Do not pry with one rake tine. Use multiple rake
the Material Handling Arm tines in order to loosen material.
• Remove the work tool from the machine before
This Work Tool has the intended functions of lifting
you lift the host machine. Refer to Operation and
and transporting suspended loads. Always select
sufficiently sized lifting accessories. Always inspect Maintenance Manual, “Lifting and Tying Down the
the lifting accessories before use. Machine” for details.
Do not use the work tool improperly. • Do not place the weight of the host machine on the
grapples in the open position.
Remove the work tool from the machine before you
lift the host machine. Refer to Operation and INTENDED USE STATEMENT for
Machine” for details. the Grapple Forks
INTENDED USE STATEMENT for This Work Tool has the intended functions of loading,
carrying, and moving bulky materials.
the Multipurpose Bucket
This Work Tool has the intended functions of dozing,
digging, loading, lifting, carrying, and moving material Remove the work tool from the machine before you
such as earth, crushed rock, or gravel. lift the host machine. Refer to Operation and
Do not use the work tool improperly. Machine” for details.
Remove the work tool from the machine before you i03989612
lift the host machine. Refer to Operation and
Machine” for details.
Decommissioning and
Disposal
INTENDED USE STATEMENT for SMCS Code: 1000; 7000
the Grapple Bucket When the product is removed from service, local
regulations for the product decommissioning will
This Work Tool has the intended functions of digging, vary. Disposal of the product will vary with local
loading, lifting, carrying, and moving material such as regulations. Consult the nearest Cat dealer for
earth, crushed rock, gravel, or debris. additional information.
Remove the work tool from the machine before you
lift the host machine. Refer to Operation and
Machine” for details.
INTENDED USE STATEMENT for

the Grapple Rake
This Work Tool has the intended functions of raking,
loading, carrying, and moving bulky material. The
material may be encountered in the following
applications:
• Landscape cleanup
• Storm debris cleanup
406 SEBU9084-11
Index Section
Index
A Rotating Beacon Light ............................... 241
Slow Moving Vehicle Sign ......................... 241
Access Doors and Covers............................. 255
Tires ........................................................... 241
Engine Access Door .................................. 255
Traffic Regulations..................................... 241
Additional Messages ....................................... 29
Work Lights ................................................ 241
Air Conditioner (If Equipped) ....................... 29
Before Starting Engine .................................... 43
Alternate Exit ............................................... 29
Belts - Inspect/Adjust/Replace ...................... 283
Clean Engine (4).......................................... 32
Air Conditioner (if equipped)...................... 285
DEF Fill ........................................................ 30
Belts ........................................................... 283
DEF Purge ................................................... 30
Finish ......................................................... 286
Diesel Fuel (3) ............................................. 32
Blade Frame - Adjust..................................... 287
Emissions (1) ............................................... 31
Height Adjustment ..................................... 287
Japanese Market Only................................. 31
Trunnion Joint ............................................ 288
Low Sound Certification (2) ......................... 32
Bogie and Idler - Inspect/Replace ......... 288, 290
Machine Hydraulic System .......................... 30
Bogie wheels ............................................. 290
No Step ........................................................ 29
Dual Level Suspension.............................. 292
OSHA Plate (6) ............................................ 33
Idler wheels................................................ 289
Product Link (If Equipped) ........................... 30
Inspect ............................................... 288, 290
Recycle HFC Refrigerant (5) ....................... 32
Loosen the Track ............................... 289, 291
After Roading the Machine............................ 244
Bucket Cutting Edges - Inspect/Replace ...... 294
Air Cleaner Dust Valve - Clean/Inspect......... 279
Bucket Tips - Inspect/Replace ...................... 295
Air Conditioner Condenser - Clean (If
Burn Prevention............................................... 37
Equipped) .................................................... 279
Batteries....................................................... 38
Alert Indicators .............................................. 191
Coolant ........................................................ 38
Alternate Exit ................................................. 155
Exhaust Gas Recirculation Cooler .............. 38
Primary Exit ............................................... 155
Oils............................................................... 38
Secondary Exit........................................... 155
Angle Blade Operation .................................. 230
Height Adjustment ..................................... 230 C
Tilt Lock...................................................... 231 Cab Air Filter - Clean/Replace (If Equipped
Axle Bearings - Lubricate ...................... 279, 281 ).................................................................... 295
Fresh Air Filter ........................................... 295
B Recirculation Filter..................................... 296
Cab Interior - Clean ....................................... 296
Backup Alarm - Test ...................................... 282 Cab Tilting ..................................................... 255
Battery Disconnect Switch ............................ 186 Tilting the Cab Downward.......................... 256
Battery or Battery Cable - Inspect/Replace... 282 Tilting the Cab Upward .............................. 255
Battery Life and Recommended Capacities (Refill) .......................................... 270
Practices .................................................. 282 Caterpillar Approved Work Tools................... 391
Recycle the Battery.................................... 283 INTENDED USE STATEMENT for the
Before Operation ..................................... 44, 154 Grapple Bucket ........................................ 405
Before Roading the Machine......................... 239 INTENDED USE STATEMENT for the
Headlights.................................................. 239 Grapple Forks .......................................... 405
Hydraulic Shutoff ....................................... 239 INTENDED USE STATEMENT for the
Lift Arm....................................................... 239 Grapple Rake........................................... 405
Mirrors........................................................ 241 INTENDED USE STATEMENT for the
Portable Warning Light .............................. 241 Material Handling Arm ............................. 405
Prepare the Work Tool ............................... 242 INTENDED USE STATEMENT for the
Rear Lights ................................................ 239 Multipurpose Bucket ................................ 405
SEBU9084-11 407
Index Section
Cooling System Coolant (ELC) - Change ..... 297 Cold Engine Elevated Low Idle (Parked
Cooling System Coolant Extender (ELC) - Idle) .......................................................... 217
Add .............................................................. 299 Cold-Weather Requirements..................... 216
Cooling System Coolant Sample (Level 1) - Cool Engine Elevated Low Idle (Cold
Obtain .......................................................... 301 Start) ........................................................ 217
Cooling System Coolant Sample (Level 2) - Engine Torque Limited During DEF
Obtain .......................................................... 302 Thawing ................................................... 217
Cooling System Level - Check ...................... 303 Low System Battery Voltage Elevated Low
Cooling System Water Temperature Idle ........................................................... 217
Regulator - Replace..................................... 304 Engine Starting (Alternate Methods)............. 252
Crushing Prevention and Cutting Prevention.. 37 Engine Starting with Jump Start Cables ....... 252
Engine Stopping .............................................. 44
D Engine Valve Lash - Check ........................... 323
Equipment Lowering Control Valve - Check
Daily Inspection ............................................. 154 (Type 1)........................................................ 324
Declaration of Conformity..... 143–145, 147–148, Type 1 Actuation ........................................ 324
150–153 Equipment Lowering Control Valve - Check
Decommissioning and Disposal.................... 405 (Type 2)........................................................ 324
Demolition ....................................................... 47 Type 2 Actuation ........................................ 325
Diesel Exhaust Fluid - Fill.............................. 306 Equipment Lowering with Engine Stopped .... 48,
Diesel Exhaust Fluid Filter - Replace ............ 307 235
Diesel Fuel System Cleaner - Add ................ 307 Alternate Lowering the Equipment ............ 236
Diesel Particulate Filter - Clean/Replace ...... 308 Lowering the Equipment with the Accumulator
Diesel Particulate Filter Regeneration .......... 188 Charged ................................................... 235
Engine Emission Alert ............................... 190 Exhaust Gas Recirculation Valve - Clean ..... 325
General Information................................... 189
Warning Symbols....................................... 189
F
Drive Chain Case Oil - Change ..................... 308
Drive Chain Case Oil - Check ....................... 309 Final Drive Oil - Change ................................ 326
Drive Chain Tension - Check/Adjust ............. 310 Final Drive Oil Level - Check......................... 327
Drive Line Wear Sleeve - Inspect/Replace ... 312 Fire Extinguisher Location............................... 42
Fire Prevention and Explosion Prevention...... 38
E Battery and Battery Cables.......................... 40
Ether ............................................................ 41
Electrical Storm Injury Prevention ................... 43 Fire Extinguisher.......................................... 41
Emissions Certification Film .......................... 142 General ........................................................ 38
Certification Label for Emissions ............... 142 Lines, Tubes, and Hoses ............................. 41
Emissions Warranty Information ................... 386 Regeneration ............................................... 38
Engine Air Filter Primary Element - Clean/ Wiring........................................................... 40
Replace ....................................................... 313 Fire Safety ....................................................... 42
Clean.......................................................... 313 Foreword ........................................................... 4
Replace...................................................... 314 California Proposition 65 Warning ................. 4
Engine Air Filter Secondary Element - Cat Product Identification Number ................ 5
Replace ....................................................... 315 Certified Engine Maintenance ....................... 4
Engine Compartment - Inspect/Clean........... 316 Literature Information .................................... 4
Air Conditioning Condenser ...................... 316 Machine Capacity .......................................... 5
Engine Crankcase Breather - Replace (and Maintenance .................................................. 4
PCV Valve Check) ....................................... 316 Operation ....................................................... 4
Engine Oil and Filter - Change ...................... 320 Safety............................................................. 4
Engine Oil Level - Check............................... 318 Fuel System Filter (In-Line) - Replace .......... 328
Engine Oil Sample - Obtain........................... 320
Engine Starting........................................ 43, 215
408 SEBU9084-11
Index Section
Fuel System Primary Filter (Water L

Separator) - Drain........................................ 329
Leaving the Machine ..................................... 237
Fuel System Primary Filter (Water
Lift Arm and Cylinder Linkage - Lubricate ..... 353
Separator) Element - Replace..................... 330
Lifting and Tying Down the Machine ............. 244
Fuel System Priming Pump - Operate .......... 331
Lifting the Grapple Rake............................ 247
Electric Fuel Transfer................................. 331
Lifting the Machine..................................... 244
Manual Fuel Transfer................................. 331
Tying Down the Machine ........................... 248
Fuel Tank Cap - Clean................................... 332
Loader Lift Arm Brace Operation .................. 257
Fuel Tank Water and Sediment - Drain ......... 332
Manual Lift Arm Brace (If Equipped) ......... 258
Fuses - Replace ............................................ 333
Self-Raising Lift Arm Brace (If Equipped).. 258
Fuses Behind the Cab ............................... 335
Lower Machine Frame - Clean ...................... 354
Fuses Inside Engine Compartment ........... 336
Lubricant Viscosities (Fluids
Fuses Inside the Cab................................. 333
Recommendations) ..................................... 263
Biodiesel .................................................... 270
G Coolant Information ................................... 270
General Hazard Information...................... 33–34 Diesel Exhaust Fluid .................................. 268
Containing Fluid Spillage............................. 36 Diesel Fuel Recommendations ................. 266
Dispose of Waste Properly .......................... 37 Drive Train Components............................ 265
Fluid Penetration ......................................... 35 Engine Oil .................................................. 263
Inhalation ..................................................... 36 Fuel Additives ............................................ 270
Pressurized Air and Water........................... 35 General Information for Lubricants............ 263
Trapped Pressure ........................................ 35 Hydraulic Systems..................................... 264
General Information ........................................ 56 Selecting the Viscosity............................... 263
Guards............................................................. 54 Special Lubricants ..................................... 266
Guards (Operator Protection) Lubricant Viscosities and Refill Capacities ... 263
Other Guards (If Equipped) ......................... 55
Roll over Protective Structure (ROPS), Falling M
Object Protective Structure (FOPS) or Tip
Machine Operation ........................................ 155
Over Protection Structure (TOPS)............. 54
Machine Retrieval.......................................... 250
Machine Storage Procedure ......................... 237
H Maintenance Access ..................................... 255
Headlights - Adjust ........................................ 336 Maintenance Interval Schedule............. 276–277
High Pressure Fuel Lines ................................ 44 Every 10 Service Hours or Daily................ 276
Hoses and Clamps - Inspect/Replace........... 337 Every 1000 Service Hours......................... 277
Hoses and Clamps - Replace ....................... 346 Every 1000 Service Hours or 1 Year ......... 277
Hydraulic System Oil - Change ............. 347–348 Every 12 000 Service Hours or 6 Years..... 278
Procedure for Changing the Hydraulic Every 1500 Service Hours......................... 277
Oil............................................................. 349 Every 2 Years............................................. 278
Selection of the Oil Change Interval .......... 348 Every 2000 Service Hours......................... 277
Hydraulic System Oil Filter - Replace ........... 350 Every 2000 Service Hours or 2 Years ....... 277
Hydraulic System Oil Level - Check.............. 351 Every 250 Service Hours ........................... 277
Hydraulic System Oil Sample - Obtain.......... 352 Every 3 Years............................................. 278
Hydraulic Tank Breather - Replace ............... 352 Every 3 Years After Date of Installation or
Every 5 Years After Date of
Manufacture ............................................. 278
I
Every 3000 Service Hours......................... 278
Identification Information ............................... 140 Every 3000 Service Hours or 2 Years ....... 278
Important Safety Information............................. 2 Every 50 Service Hours or Weekly............ 277
Every 500 Service Hours ........................... 277
Every 500 Service Hours or 1 Year ........... 277
SEBU9084-11 409
Index Section
Every 500 Service Hours or 3 Months....... 277 Heating and Air Conditioning Control Panel
Every 500 Service Hours or 6 Months....... 277 (7)............................................................. 161
Every 6000 Service Hours or 3 Years ....... 278 Hydraulic Lockout and Interlock Override
Every Year ................................................. 277 (15)........................................................... 164
Initial 100 Service Hours............................ 277 Joystick Controls ....................................... 178
Initial 250 Service Hours............................ 277 Left Side Controls ...................................... 158
Initial 50 Service Hours.............................. 277 Menu Screen ............................................. 171
Initial 500 Hours (for New Systems, Refilled Mirror (12) .................................................. 163
Systems, and Converted Systems) ......... 277 Monitoring Screen ..................................... 170
When Required.......................................... 276 Multifunction Switch for the Left-Hand Trigger
Maintenance Section..................................... 255 (3)............................................................. 159
Maintenance Support .................................... 273 Other Features in the Cab ......................... 175
Material Handling Arm Operation.................. 226 Parking Brake Control (9) .......................... 162
One Person Operation............................... 228 Rear Work Lights (17)................................ 166
Two Person Operation............................... 227 Reversing Fan (20) .................................... 166
Model View Illustrations .................................. 56 Ride Control (19) ....................................... 166
Japanese Market Only................................. 57 Right Side Controls.................................... 163
Mounting and Dismounting ........................... 154 Right Side Controls (Alternate).................. 168
Roading Lights (21) ................................... 167
O Selectable Control Pattern Switch (11)...... 163
Service Hour Meter (14) ............................ 164
Oil Filter - Inspect .......................................... 355 Turn Signals (23) ....................................... 167
Inspect a Used Filter for Debris ................. 355 Window Wiper and Window Washer (8).... 162
Operation................................................. 44, 218 Work Tool Coupler Control (5) ................... 161
Operation Information ................................... 218
Counterrotate turn ..................................... 221
P
Fueling the Machine .................................. 218
General Information................................... 218 Pallet Forks Operation .................................. 229
Operating on a Slope................................. 219 Parking .................................................... 47, 234
Operating on a Transition .......................... 220 Plate Locations and Film Locations .............. 140
Operation Section.......................................... 154 CE Information for European Union .......... 140
Operator Controls.......................................... 157 EAC Mark for Eurasian Economic Union .. 141
12 V Power Supply (6)............................... 161 Electromagnetic Emissions for Canada .... 141
Alert Indicator Panel (25)........................... 167 Engine Serial Number Plate ...................... 140
Anti-Theft Security System ........................ 175 Machine PIN Plate ..................................... 140
Anti-Theft Security System Soft Keys Manufacturer Information .......................... 141
(26)........................................................... 168 Sound Certification Film for European
Armbar and Controls - Adjust .................... 177 Union........................................................ 142
Auxiliary Electrical Control “AUX 8” (2) ..... 159 Product Information Section............................ 56
Auxiliary Hydraulic Controls ...................... 184 Product Link .................................................. 195
Backup Camera Mode............................... 175 Data Broadcasts ........................................ 195
Bluetooth Microphone (27) ....................... 168 European Union EC Declaration of Conformity
Cab Dome Light (1) ................................... 159 G0100 ...................................................... 208
Cat Intelligent Leveling (ILEV) System Switch European Union EC Declaration of Conformity
(4)............................................................. 159 PL240....................................................... 209
Continuous Flow Switch (18)..................... 166 European Union EC Declaration of Conformity
Engine Key Start Switch (10)..................... 162 PL241....................................................... 210
Engine Speed Control Knob (24)............... 167 European Union EC Declaration of Conformity
Front Work Lights (16) ............................... 166 PL631....................................................... 212
Fuel Level Gauge (13) ............................... 164 European Union EC Declaration of Conformity
Hazard Lights (22) ..................................... 167 PL641....................................................... 213
410 SEBU9084-11
Index Section
Machine Security ....................................... 196 Industrial Grapple Fork (19)......................... 23

Operation in a Blast Site for Product Link Industrial Grapple Fork (20)......................... 24
Radios ...................................................... 195 Jump Start (3) .............................................. 14
Regulatory Compliance ............................. 197 Never Permit Riders (6) ............................... 15
Pressurized System (8) ............................... 16
Q Product Link (If equipped) (15) .................... 20
Rollover Protective Structure/Falling Object
Quick Coupler - Clean/Inspect ...................... 356 Protective Structure (2).............................. 13
Seat Belt (7) ................................................. 16
R Stay Inside Operator Station (5) .................. 15
Utility Fork (18) ............................................ 23
Radiator Core - Clean ................................... 356
Utility Grapple Bucket (24)........................... 26
Radiator Tilting .............................................. 260
Utility Grapple Fork (22) .............................. 25
Alternate Release Latch Location ............. 261
Utility Grapple Fork (23) .............................. 25
Rated Load ...................................................... 57
Work Tool Coupler (9).................................. 17
Bucket Rated Load ...................................... 57
Work Tools ................................................... 21
Rated Load with a Material Handling
Safety Messages (Only Japanese market)
Arm........................................................... 129
Crash Hazard (3) ........................................... 8
Rated Loads for Forks ................................110
Crushing Hazard (1) ...................................... 7
Reference Information Section ..................... 387
Crushing Hazard (4) ...................................... 8
Reference Material ........................................ 387
Cutting Hazard (7) ......................................... 9
Maintenance Interval Schedule for significant
Electrical Power Lines (2).............................. 8
parts (Japan)............................................ 391
Explosion Hazard (6) ..................................... 9
Regulatory Information (Japan)................. 387
Falling Hazard (10) .......................................11
Reference Materials ...................................... 387
High Pressure Cylinder (5) ............................ 9
Refrigerant Dryer - Replace (If Equipped) .... 357
Jump Start Cables (9).................................. 10
Roading the Machine .................................... 244
Rotating Fan (8)........................................... 10
Rollover Protective Structure (ROPS) and
Safety Section ................................................... 6
Falling Object Protective Structure
Seat Belt ........................................................ 156
(FOPS) - Inspect.......................................... 358
Seat Belt Adjustment for Retractable Seat
Belts ......................................................... 156
S Seat Belt - Inspect ......................................... 358
S·O·S Information ......................................... 272 Seat Belt - Replace ....................................... 359
Safety Messages..........................................6, 11 Selective Catalytic Reduction Warning
Accumulator (12) ......................................... 18 System......................................................... 190
Aerosol Starting Aid (13) ............................. 19 Service Interval Chart.................................... 273
Angle Blade (21) .......................................... 24 Example Service Interval Chart ................. 273
Armrests (14) ............................................... 19 Service Intervals ........................................ 273
Brace for the Loader Lift Arms (11).............. 18 Shipping the Machine.................................... 238
Cab Support (10) ......................................... 17 Loading the Machine ................................. 238
Crush Hazard (4) ......................................... 14 Unloading the Machine.............................. 239
Do Not Operate (1) ...................................... 12 Slope Operation .............................................. 48
Do Not Operate (1) (Engine) ....................... 13 Sound Information and Vibration
Dozer Blade (25).......................................... 26 Information..................................................... 48
Dozer Blade (26).......................................... 27 “European Physical Agents Directive
Dozer Blade (27).......................................... 27 (Vibration) 2002/44/EC” ............................. 51
Dozer Blade (28).......................................... 28 Sound Level Information.............................. 48
Grapple Rake (29) ....................................... 28 Sound Level Information for Machines in
High Pressure Cylinder (12A)...................... 18 Eurasian Economic Union Countries......... 50
High Pressure Fuel (16) .............................. 20 Sources........................................................ 54
Industrial Grapple Bucket (17)..................... 23 Specifications ................................................ 138
SEBU9084-11 411
Index Section
Application/Configuration Restrictions ...... 138 Transportation Information ............................ 238

Intended Use ............................................. 138
Machine Data............................................. 138 V
Useful Life .................................................. 138
Sprocket - Inspect ................................. 359–360 Visibility Information ........................................ 43
Inspect ....................................................... 360
Relocate..................................................... 360 W
Replace...................................................... 360
Warranty Information..................................... 386
Sprocket Inspection for Models with Single
Warranty Section ........................................... 386
Lug Drive System..................................... 361
Welding on Machines and Engines with
Sprocket Inspection for Models with Triple Lug
Electronic Controls ...................................... 274
Drive System............................................ 363
Wheel Nuts - Tighten..................................... 380
Sprocket Retaining Nuts - Check .................. 365
Window Washer Reservoir - Fill (If
Sprocket Sleeve - Inspect ............................. 366
Equipped) .................................................... 381
Stopping the Engine ...................................... 234
Window Wiper - Inspect/Replace (If
Stopping the Engine if an Electrical
Equipped) .................................................... 381
Malfunction Occurs...................................... 234
Windows - Clean ........................................... 381
Inside Cab.................................................. 234
Polycarbonate Front Door and Polycarbonate
Top Window ............................................. 382
T Rear Window and Glass Front Door.......... 381
Table of Contents .............................................. 3 Side Windows ............................................ 381
Tilt Cylinder Bearings and Bucket Linkage Work Tool - Lubricate .................................... 382
Bearings - Lubricate .................................... 367 Angle Blade ............................................... 384
Tire Inflation - Check ..................................... 367 Dozer Blade ............................................... 385
Tire Inflation with Air .................................. 368 Grapple Rake............................................. 384
Towing Information ........................................ 250 Industrial Grapple Bucket and Industrial
Track - Inspect/Adjust.................................... 373 Grapple Fork ............................................ 383
Detension the track.................................... 375 Multipurpose Bucket .................................. 382
Inspect ....................................................... 373 Utility Grapple Bucket and Utility Grapple
Track Adjustment....................................... 374 Fork .......................................................... 383
Track - Remove/Replace............................... 375 Work Tool Coupler Operation........................ 221
Installing the Track..................................... 376 Attaching the Work Tool............................. 221
Removing the Track................................... 375 Removing the Work Tool ........................... 224
Track - Remove/Replace (Steel)................... 376 Removing the Work Tool if an Electrical or
Installing the Track..................................... 378 Hydraulic Quick Coupler Malfunctions .... 225
Removing the Track................................... 377 Work Tool Guard and Reflector - Inspect/
Track (Rubber) - Inspect/Adjust .................... 369 Replace ....................................................... 385
Detension the track.................................... 370 Work Tool Mounting Bracket - Inspect .......... 385
Inspect ....................................................... 369 Work Tool Operation...................................... 231
Track Adjustment....................................... 369 Complex Hydromechanical Work Tools .... 233
Track (Rubber) - Remove/Replace (MTL) .... 370 Simple Hydromechanical Work Tools........ 232
Installing the Track..................................... 371 Work Tools....................................................... 47
Removing the Track................................... 370
Track (Steel) - Inspect/Adjust ........................ 371
Track Adjustment....................................... 372
Track Bolts - Check.................................... 372
Track Inspect ............................................. 372
Track Measurement................................... 372
Track Pins - Inspect (Steel) ........................... 379
Track Roller and Idler - Inspect/Replace....... 380
Inspect ....................................................... 380
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:
SEBU9084 CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade
©2016 Caterpillar dress as well as corporate and product identity used herein, are trademarks of Caterpillar and
All Rights Reserved may not be used without permission.
414 October 2016

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SEBU9084-11 (en-us)

Language: Original Instructions

Important Safety Information

The meaning of this safety alert symbol is as follows:

When replacement parts are required for this

Table of Contents Equipment Lowering with Engine Stopped ..... 48

Sound Information and Vibration Information . 48

Safety Messages (Only Japanese market) ....... 6

General Information ........................................ 56

General Hazard Information (Only Japanese Operation Section

Foreword Maintenance Intervals

Cat Product Identification Number

Crushing Hazard (1)

Electrocution Hazard! Keep the machine and

Crash Hazard (3)

Stay clear of the work tool during operation. En-

Electrical Power Lines (2)

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

Crushing Hazard (4)

High Pressure Cylinder. Do not remove any parts

Crush Hazard! A machine may move unexpect-

High Pressure Cylinder (5)

Personal injury can result from improper trouble-

Cutting Hazard (7)

Cutting Hazard! Keep hands clear of fan while en-

Rotating Fan (8)

Jump Start Cables (9)

Illustration 11 g03369796 Illustration 12 g03369781

Falling Hazard (10) Safety Messages

(1) Do Not Operate. (6) Never Permit Riders. (12) Accumulator

Do Not Operate (1)

Read and understand the instructions and warn-

Structural damage, an overturn, modification, al-

Keep your body inside the operator station while

This warning message is located inside the cab on

Never permit riders.

Failure to follow the instructions or heed the

A seat belt should be worn at all times during ma-

Refer to Operation and Maintenance Manual, “Seat

Pressurized System (8)

Improper Attachment of the Work Tool could re-

Work Tool Coupler (9) Cab Support (10)

Refer to Operation and Maintenance Manual,

Do not go beneath cab unless cab is empty and

High Pressure Cylinder (12A)

Failure to follow the instructions or heed the

Illustration 27 g01372252 Illustration 28 g01372254

Aerosol Starting Aid (13)

This machine is equipped with a Caterpillar Prod-

Contact with high pressure fuel may cause fluid

Do not operate or work on this work tool unless

Industrial Grapple Bucket (17)

No clearance for person in this area during opera-

Industrial Grapple Fork (19)

No clearance for person in this area during opera-

Utility Fork (18)

Illustration 35 g01378775 Illustration 36 g01389170

Industrial Grapple Fork (20) Angle Blade (21)

Illustration 37 g01377717 Illustration 38 g01389170

Utility Grapple Fork (22) Utility Grapple Fork (23)