operaÃ§Ã£o e manutenÃ§Ã£o - 988h

8/13/2019 Operao e Manuteno - 988H

1/154

SEBU7808-06

May 2007

Operation andMaintenance

Manual988H Wheel Loader

BXY1-Up (Machine)


2/154


3/154

SEBU7808-06 3Table of Contents

Table of Contents

Foreword ................................................................. 4

Safety Section

Safety Messages .................................................... 6

Additional Messages ............................................. 13

General Hazard Information ................................. 14

Crushing Prevention and Cutting Prevention ........ 17

Burn Prevention .................................................... 17

Fire Prevention and Explosion Prevention ............ 18

Fire Extinguisher Location .................................... 20

Tire Information ..................................................... 20

Electrical Storm Injury Prevention ......................... 21

Before Starting Engine .......................................... 21

Engine Starting ..................................................... 21

Before Operation .................................................. 21

Visibility Information .............................................. 21

Operation .............................................................. 22

Engine Stopping ................................................... 22

Parking .................................................................. 23

Equipment Lowering with Engine Stopped ........... 23

Sound Information and Vibration Information ....... 23

Operator Station ................................................... 26

Product Information Section

General Information .............................................. 27

Identification Information ....................................... 30

Operation Section

Before Operation .................................................. 33

Machine Operation ............................................... 35

Engine Starting ..................................................... 62

Parking .................................................................. 63

Transportation Information .................................... 65

Towing Information ................................................ 67

Engine Starting (Alternate Methods) ..................... 70

Maintenance Section

Tire InflationInformation ....................................... 73

Lubricant Viscosities and Refill Capacities ........... 74

Maintenance Support ............................................ 80

Maintenance Interval Schedule ............................ 81

Reference Information Section

Reference Materials ............................................ 147

Index Section

Index ................................................................... 149


4/154

4 SEBU7808-06Foreword

Foreword

Literature Information

This manual should be stored in the operators

compartment in the literature holder or seat backliterature storage area.

This manual contains safety information, operationinstructions, transportation information, lubricationinformation and maintenance information.

Some photographs or illustrations in this publicationshow detailsor attachments that can be differentfrom your machine. Guards and covers might havebeen removed for illustrative purposes.

Continuing improvement and advancement ofproduct design might have caused changes to your

machine which are not included in this publication.Read, study and keep this manual with the machine.

Whenever a question arises regarding your machine,or this publication, please consult your Caterpillardealer for the latest available information.

Safety

The safety section lists basic safety precautions. Inaddition, this section identifies the text and locationsof warningsigns and labels used on the machine.

Read and understand the basic precautions listed

in the safety section before operating or performinglubrication, maintenance and repair on this machine.

Operation

The operation section is a reference for the newoperator and a refresher for the experiencedoperator. This section includes a discussion ofgauges, switches, machine controls, attachmentcontrols, transportation and towing information.

Photographs and illustrations guide the operatorthrough correct procedures of checking, starting,

operating and stopping the machine.

Operating techniques outlined in this publication arebasic. Skill and techniques develop as the operatorgains knowledge of the machine and its capabilities.

Maintenance

The maintenance section is a guide to equipmentcare. The Maintenance Interval Schedule (MIS) liststhe items to be maintained at a specific serviceinterval. Items without specific intervals are listed

under the "When Required" service interval. TheMaintenance Interval Schedule lists the pagenumber for the step-by-step instructions required toaccomplish the scheduled maintenance. Use theMaintenance Interval Schedule as an index or "onesafe source"for all maintenance procedures.

Maintenance Intervals

Use the service hour meter to determine servicingintervals. Calendar intervals shown (daily, weekly,monthly, etc.) can be used instead of service hourmeter intervals if they provide more convenientservicing schedules and approximate the indicatedservice hour meter reading. Recommended serviceshould always be performed at the interval thatoccurs first.

Under extremely severe, dusty or wet operatingconditions, more frequent lubrication than isspecified in the maintenance intervals chart mightbe necessary.

Perform service on items at multiples of the originalrequirement. For example, at every 500 servicehours or 3 months, also service those items listedunder every 250 service hours or monthly and every10 service hours or daily.

California Proposition 65 Warning

Diesel engine exhaust and some of its constituentsare known to the State of California to cause cancer,birth defects, and other reproductive harm.

Battery posts, terminals and related accessoriescontain lead and lead compounds. Wash handsafter handling.

Certified Engine Maintenance

Proper maintenance and repair is essential to keepthe engine and machine systems operating correctly.

As the heavy duty off-road diesel engine owner, youare responsible for the performance of the requiredmaintenance listed in the Owner Manual, Operationand Maintenance Manual, and Service Manual.


5/154

SEBU7808-06 5Foreword

It is prohibited for any person engaged in thebusiness of repairing, servicing, selling, leasing, ortrading engines or machines to remove, alter, orrender inoperative any emission related device orelement of design installed on or in an engine ormachine that is in compliance with the regulations

(40 CFR Part 89). Certain elements of the machineand engine such as the exhaust system, fuel system,electrical system, intake air system and coolingsystem may be emission related and should not bealtered unless approved by Caterpillar.

Machine Capacity

Additionalattachments or modifications may exceedmachine design capacity which can adversely affectperformance characteristics. Included would bestability and system certifications such as brakes,steering, and rollover protective structures (ROPS).

Contact your Caterpillar dealer for further information.

Caterpillar Product IdentificationNumber

EffectiveFirst Quarter 2001 the Caterpillar ProductIdentification Number (PIN) has changed from 8 to 17characters. In an effort to provide uniform equipmentidentification, Caterpillar and other constructionequipment manufacturers are moving to complywith the latest version of the product identificationnumbering standard. Non-road machine PINs aredefined by ISO 10261. The new PIN format will apply

to all Caterpillar machines and generator sets. ThePIN plates and frame marking will display the 17character PIN. The new format will look like thefollowing:

g00751314Illustration 1

Where:

1. Caterpillars World Manufacturing Code(characters 1-3)

2. Machine Descriptor (characters 4-8)

3. Check Character (character 9)

4. Machine Indicator Section (MIS) or ProductSequence Number (characters 10-17). These werepreviously referred to as the Serial Number.

Machines and generator sets produced before FirstQuarter 2001 will maintain their 8 character PINformat.

Components such as engines, transmissions, axles,etc. and work tools will continue to use an 8 characterSerial Number (S/N).


6/154

6 SEBU7808-06Safety SectionSafety Messages

Safety Section

i02762373

Safety Messages

SMCS Code: 7000



7/154

SEBU7808-06 7Safety Section

Safety Messages


There are several specific safety messages on thismachine. The exact location of the hazards andthe description of the hazards are reviewed in thissection. Please become familiarized with all safetymessages.

Make sure that all of the safety messages are legible.Clean the safety messages or replace the safetymessages if you cannot read the words. Replacethe illustrations if the illustrations are not legible.When you clean the safety messages, use a cloth,

water and soap. Do not use solvent, gasoline, orother harsh chemicals to clean the safety messages.Solvents, gasoline, or harsh chemicals could loosenthe adhesive that secures the safety message. Looseadhesive will allow the safety message to fall.

Replace any safety message that is damaged ormissing. If a safety message is attached to a partthat is replaced, install a safety message on thereplacement part. Any Caterpillar dealer can providenew safety messages.


8/154


Do Not Operate (1)


This warning label is located in the cab on the insideof the front door post.

DO NOT OPERATE OR WORK ON THIS MACHINEUNLESS YOU HAVE READ AND UNDERSTANDTHE INSTRUCTIONS AND WARNINGS IN THEOPERATION AND MAINTENANCE MANUALS.FAILURE TO FOLLOW THE INSTRUCTIONS ORHEED THE WARNINGS COULD RESULT IN IN-JURY OR DEATH. CONTACT ANY CATERPILLARDEALER FOR REPLACEMENT MANUALS. PROP-ER CARE IS YOUR RESPONSIBILITY.

Pressurized System (2)


This warning label is located on the back side of theaccess door for the radiatorfi ller cap.

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 relievethe pressure.


9/154


Safety Messages

Crushing Hazard (3)


This warning label is located on both sides of themachine at the articulation joint.

Crushing Hazard. There is no clearance for a per-son in this area when the machine turns. Severeinjury or death from crushing could occur. Con-nect the steering frame lock between front andrear frames before lifting, transporting, or servic-ing the machine in the articulation area.

Disconnect the steering lock and secure beforeresuming operation.

No Clearance (4)


This warning label is located on both sides of themachine at the articulation joint.

Crushing Hazard! Stay back a safe distance. Thereis no clearance for a person in this area when themachine turns. Failure to follow these instructionscould cause serious injury or death.


10/154


Parking Brake (5)


This warning is located near the articulation joint onthe cover for the parking brake.

Before you manually release the parking brake, besure to stop the engine and block the wheels inorder to prevent machine movement, which couldresult in personal injury.

Before disassembling the brake, relieve the brakeoil pressure by repeatedly applying the brakes un-til the brake oil pressure gauge indicates zero.

Refer to Operation and Maintenance Manual,

Parking Brake Manual Release for the properprocedure.

Do Not Weld or Drill on the ROPS(6)


This warning label is located on the outside of thecab on the left side below the window.

Structural damage, an overturn, modification, al-teration, or improper repair can impair this struc-tures protection capability thereby voiding thiscertification. Do not weld on or drill holes in thestructure. Consult a Caterpillar dealer to deter-mine this structures limitations without voidingits certification.

Rollover Protective Structure (ROPS) and FallingObject Protective Structure (FOPS) Certification

The structure, when properly installed on a machinewhich is not altered to exceed the certification testmass meets, at the time of installation, criteriaestablished by:SAE J396, SAE J1040 APRIL88, ISO 3471 1986, ISO 3471 1994, SAE J231JANUARY 81, and ISO 3449 1992 LEVEL II.


11/154


Safety Messages

Do Not Operate (7)


This warning label is located on both sides of theengine valve cover.

Do not operate or work on this equipment unlessyou have read and understand the instructionsand warnings in the Operation and MaintenanceManuals. Failure to follow the instructions orheed the warnings could result in serious injuryor death.

Improper Connections Of TheJump Start Cable (8)


This warning label is located in the batterycompartment.

There is limited battery access. Jump starting atthe battery, or improper jumper cable connectionsat thestarter, can cause explosion resulting in per-sonal injury.

Do not jump start the machine at the battery. Usethe remote starting receptacle or jump start to thepositive battery post on the starter.

If remote starting receptacle can not be used,jumper cables may be used at the starter. Alwaysconnect the positive (+) cable to positive (+) termi-nal of the starter and connect negative () cablefrom external source to engine block. Followprocedure from the Operation and MaintenanceManual.


12/154


Seat belt (9)


This warning label is located in the cab near the cupholder.

DO NOT OPERATE OR WORK ON THIS MACHINEUNLESS YOU HAVE READ AND UNDERSTANDTHE INSTRUCTIONS AND WARNINGS IN THEOPERATION AND MAINTENANCE MANUALS.FAILURE TO FOLLOW THE INSTRUCTIONS ORHEED THE WARNINGS COULD RESULT IN IN-JURY OR DEATH. CONTACT ANY CATERPILLARDEALER FOR REPLACEMENT MANUALS. PROP-ER CARE IS YOUR RESPONSIBILITY.

Pressurized System (10)


This warning label is located on the right side of thesight gauge on the hydraulic oil tank.

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 relievethe pressure.


13/154


Additional Messages

Product Link (11)

This warning label is located in the cab.

g01013264

This machine is equipped with a CaterpillarProduct Link radio communication device whichmust be deactivated within 6.0 m (20 ft) of a blastzone. Failure to do so could result in seriousinjury or death.

i02216323

Additional Messages

SMCS Code: 7000

There are several specific messages on thismachine. The exact location of the messages andthe description of the information are reviewed in thissection. Please become familiar with all messages.

Make sure that all of the messages are legible.Clean the messages or replace the messages if youcannot read the words. Replace the illustrations ifthe illustrations are not legible. When you clean themessages, use a cloth, water, and soap. Do notuse solvent, gasoline, or other harsh chemicals toclean the messages. Solvents, gasoline, or harshchemicals could loosen the adhesive that secures the

messages. Loose adhesive will allow the messagesto fall.

Replace any message that is damaged, or missing.If a message is attached to a part that is replaced,install a message on the replacement part. AnyCaterpillar dealer can provide new messages.


14/154

14 SEBU7808-06Safety SectionGeneral Hazard Information


Air Conditioner


This fi lm is located in the cab on the back right post.

i02443908

General Hazard Information

SMCS Code: 7000



15/154


General Hazard Information

Attach a Do NotOperate warning tag or a similarwarning tag to the start switch or to the controlsbefore you service the equipment or before yourepair the equipment. These warning tags (SpecialInstruction, SEHS7332) are available from yourCaterpillar dealer.

Know the width of your equipment in order to maintainproper clearance when you operate the equipmentnear fences or near boundary obstacles.

Be aware of high voltage power lines and powercables that are buried. If the machine comes incontact with these hazards, serious injury or deathmay occur from electrocution.


Wear a hard hat, protective glasses, and otherprotective equipment, as required.

Do not wear loose clothing or jewelry that can snagon controls or on other parts of the equipment.

Make sure that all protective guards and all coversare secured in place on the equipment.

Keep the equipment free from foreign material.Remove debris, oil, tools, and other items from thedeck, 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 andthe personnel that are authorized to give the handsignals. Accept hand signals from one person only.

Do not smoke when you service an air conditioner.Also, do not smoke if refrigerant gas may be present.Inhaling the fumes that are released from a flame thatcontacts air conditioner refrigerant can cause bodilyharm or death. Inhaling gas from air conditionerrefrigerant through a lighted cigarette can causebodily harm or death.

Never put maintenancefluids into glass containers.Drain all liquids into a suitable container.

Obey all local regulations for the disposal of liquids.

Use all cleaning solutions with care. Report allnecessary repairs.

Do not allow unauthorized personnel on the

equipment.

Unless you are instructed otherwise, performmaintenance with the equipment in the servicingposition. Refer to Operation and Maintenance Manualfor the procedure for placing the equipment in theservicing position.

PressurizedAir and Water

Pressurized air and/or water can cause debrisand/or hot water to be blown out. This could result inpersonal injury.

When pressurized air and/or pressurized water isused for cleaning, wear protective clothing, protectiveshoes, and eye protection. Eye protection includesgoggles or aprotective face shield.

The maximum air pressure for cleaning purposesmust be reduced to 205 kPa (30 psi) when thenozzle is deadheaded and the nozzle is used withan effective chip deflector and personal protectiveequipment. The maximum water pressure forcleaning purposes must be below 275 kPa (40 psi).

Trapped Pressure

Pressure can be trapped in a hydraulic system.Releasing trapped pressure can cause suddenmachine movement or attachment movement. Usecaution if you disconnect hydraulic lines orfittings.High pressure oil that is released can cause a hose towhip. High pressure oil that is released can cause oilto spray.Fluid penetration can cause serious injuryand possible death.

Fluid Penetration

Pressure can be trapped in the hydraulic circuit long

after the engine has been stopped. The pressure cancause hydraulic fluid or items such as pipe plugs toescape rapidly if the pressure is not relieved correctly.

Do not remove any hydraulic components or partsuntil pressure has been relieved or personal injurymay occur. Do not disassemble any hydrauliccomponents or parts until pressure has been relievedor personal injury may occur. Refer to the ServiceManual for any procedures that are required torelieve the hydraulic pressure.


16/154

16 SEBU7808-06Safety SectionGeneral Hazard Information


Always use a board or cardboard when you checkfor a leak. Leaking fluid that is under pressure canpenetrate body tissue. Fluid penetration can cause

serious injury and possible death. A pin hole leak cancause severe injury. Iffluid is injected into your skin,you must get treatment immediately. Seek treatmentfrom a doctor that is familiar with this type of injury.

Containing Fluid Spillage

Care must be taken in order to ensure that fluidsare contained during performance of inspection,maintenance, testing, adjusting and repair of theequipment. Prepare to collect the fluid with suitablecontainers before opening any compartment ordisassembling any component that contains fluids.

Refer to Special Publication, NENG2500, CaterpillarDealer Service Tool Catalog for the following items:

Tools that are suitable for collecting fluids andequipment that is suitable for collecting fluids

Tools that are suitable for containing fluids andequipment that is suitable for containing fluids

Obey all local regulations for the disposal of liquids.

Asbestos Information


Caterpillar equipment and replacement parts that areshipped from Caterpillar are asbestos free. Caterpillar

recommends the use of only genuine Caterpillarreplacement parts. Use the following guidelineswhen you handle any replacement parts that containasbestos or when you handle asbestos debris.

Use caution. Avoid inhaling dust that might begenerated when you handle components that containasbestos fibers. Inhaling this dust can be hazardousto your health. The components that may containasbestos fibers are brake pads, brake bands, liningmaterial, clutch plates, and some gaskets. Theasbestosthat is used in these components is usuallybound in a resin or sealed in some way. Normalhandling is not hazardous unless airborne dust that

containsasbestos is generated.

If dust that may contain asbestos is present, thereare 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 asbestosmaterials.

A vacuum cleaner that is equipped with a highefficiency particulate airfi lter (HEPA) can also beused.

Use exhaust ventilation on permanent machiningjobs.

Wear an approved respirator if there is no otherway to control the dust.


17/154


Crushing Prevention and Cutting Prevention

Comply with applicable rules and regulationsfor the work place. In the United States, useOccupational Safety and Health Administration(OSHA) requirements. These OSHA requirementscan be found in 29 CFR 1910.1001.

Obey environmental regulations for the disposalof asbestos.

Stay away from areas that might have asbestosparticles in the air.

Dispose of Waste Properly


Improperly disposing of waste can threaten theenvironment. Potentially harmfulfluids should bedisposed of according to local regulations.

Always use leakproof containers when you drainfluids. Do not pour waste onto the ground, down adrain, or into any source of water.

i01359664

Crushing Prevention andCutting 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 holdup the equipment. Equipment can fall if a control ismoved, or if a hydraulic line breaks.

Do not work beneath the cab of the machine unlessthe cab is properly supported.

Unless you are instructed otherwise, never attemptadjustments while the machine is moving or whilethe engine is running.

Never jump across the starter solenoid terminalsin order to start the engine. Unexpected machinemovement could result.

Whenever there are equipment control linkages theclearance in the linkage area will change with the

movement of the equipment or the machine. Stayclear of areas that may have a sudden change inclearance with machine movement or equipmentmovement.

Stay clear of all rotating and moving parts.

If it is necessary to remove guards in order to performmaintenance, always install the guards after themaintenanceis performed.

Keep objects away from moving fan blades. The fanblade will throw objects or cut objects.

Do not use a kinked wire cable or a frayed wire cable.Wear gloveswhen you handle wire cable.

When you strike a retainer pin with force, the retainerpin can fly out. The loose retainer pin can injurepersonnel. Make sure that the area is clear of peoplewhen you strike a retainer pin. To avoid injury toyour eyes,wear protective glasses when you strikea retainer pin.

Chips or other debris can fly off an object when youstrike the object. Make sure that no one can beinjured by flying debris before striking any object.

i01329099

Burn Prevention

SMCS Code: 7000

Do not touch any part of an operating engine.Allow the engine to cool before any maintenance isperformed on the engine. Relieve all pressure in theair system, in the oil system, in the lubrication system,in the fuel system, or in the cooling system beforeany lines, fittings or related items are disconnected.

CoolantWhen the engine is at operating temperature, theengine coolant is hot. The coolant is also underpressure. The radiator and all lines to the heaters orto the engine contain hot coolant.

Any contact with hot coolant or with steam can causesevere burns. Allow cooling system components tocool before the cooling system is drained.

Check the coolant level only after the engine hasbeen stopped.


18/154

18 SEBU7808-06Safety SectionFire Prevention and Explosion Prevention

Ensure that the filler cap is cool before removing thefiller cap. The fi ller cap must be cool enough to touchwith a bare hand. Remove the filler cap slowly inorder to relieve pressure.

Cooling system conditioner contains alkali. Alkali can

cause personal injury. Do not allow alkali to contactthe skin, the eyes, or the mouth.

Oils

Hot oil and hot components can cause personalinjury. Do not allow hot oil to contact the skin. Also,do not allow hot components to contact the skin.

Remove the hydraulic tank filler cap only after theengine has been stopped. The filler cap must becool enough to touch with a bare hand. Follow thestandard procedure in this manual in order to remove

the hydraulic tankfi

ller cap.

Batteries

Electrolyte is an acid. Electrolyte can cause personalinjury. Do not allow electrolyte to contact the skin orthe eyes. Always wear protective glasses for servicingbatteries. Wash hands after touching the batteriesand connectors. Use of gloves is recommended.

i01359795

Fire Prevention and Explosion

PreventionSMCS Code: 7000


All fuels, most lubricants, and some coolant mixturesare flammable.

Flammable fluids that are leaking or spilled onto hotsurfaces or onto electrical components can causea fire. Fire may cause personal injury and propertydamage.

Remove all flammable materials such as fuel, oil, anddebris from the machine. Do not allow any flammablematerials to accumulate on the machine.

Store fuels and lubricants in properly markedcontainers away from unauthorized persons. Store

oily rags andany flammable materials in protectivecontainers. Do not smoke in areas that are used forstoring flammable materials.

Do not operate the machine near any flame.

Exhaust shields (if equipped) protect hot exhaustcomponents from oil spray or fuel spray in case ofa break in a line, in a hose, or in a seal. Exhaustshields mustbe installed correctly.

Do not weld on lines or on tanks that containflammable fluids. Do not flame cut lines or tanksthat contain flammable fluid. Clean any such lines or

tanks thoroughly with a nonflammable solvent priorto weldingorflame cutting.

Check all electrical wires daily. Repair any wiresthat are loose or frayed before you operate themachine. Clean all electrical connections and tightenall electrical connections.

Dust that is generated from repairing nonmetallichoods or nonmetallic fenders can be flammableand/or explosive. Repair such components in a wellventilated area away from open flames or sparks.

Inspect all lines and hoses for wear or for

deterioration. The hoses must be properly routed.The lines and the hoses must have adequate supportand secure clamps. Tighten all connections to therecommended torque. Leaks can cause fires.



19/154


Fire Prevention and Explosion Prevention

Use caution when you are refueling a machine. Donot smoke while you are refueling a machine. Donot refuel a machine near open flames or sparks.

Always stop the engine before refueling. Fill the fueltank outdoors.


Gases from a battery can explode. Keep any openflames or sparks away from the top of a battery. Donot smoke in battery charging areas.

Never check the battery charge by placing a metalobject across the terminal posts. Use a voltmeter ora hydrometer.

Improper jumper cable connections can causean explosion that can result in injury. Refer tothe Operation Section of this manual for specificinstructions.

Do not charge a frozen battery. This may cause anexplosion.

Fire Extinguisher

Make sure that a fire extinguisher is available. Be

familiar with the operation of the fire extinguisher.Inspect the fire extinguisher and service the fireextinguisher regularly. Obey the recommendationson the instruction plate.

Ether

Ether is flammable and poisonous.

Use ether in well ventilated areas. Do not smokewhile you are replacing an ether cylinder or while youare using an ether spray.

Do not store ether cylinders in living areas or in theoperator compartment of a machine. Do not storeether cylinders in direct sunlight or in temperaturesabove 49 C (120 F). Keep ether cylinders awayfrom open flames or sparks.

Dispose of used ether cylinders properly. Do notpuncture an ether cylinder. Keep ether cylindersaway from unauthorized personnel.

Do not spray ether into an engine if the machine isequipped with a thermal starting aid for cold weatherstarting.

Lines, Tubesand Hoses

Do not bend high pressure lines. Do not strike highpressure lines. Do not install any lines that are bentor damaged.

Repair any lines that are loose or damaged. Leakscan cause fires. Consult your Caterpillar dealer forrepair or for replacement parts.

Check lines, tubes and hoses carefully. Do not useyour bare hand to check for leaks. Use a board orcardboardto check for leaks. Tighten all connectionsto the recommended torque.

Replace the parts if any of the following conditionsare present:

End fittings are damaged or leaking.

Outer coverings are chafed or cut.

Wires are exposed.

Outer coverings are ballooning.

Flexible part of the hoses are kinked.

Outer covers have embedded armoring.

End fittings are displaced.

Make sure that all clamps, guards, and heat shields

are installed correctly. During machine operation, thiswill help to prevent vibration, rubbing against otherparts, and excessive heat.


20/154

20 SEBU7808-06Safety SectionFire Extinguisher Location

i00977136

Fire Extinguisher Location

SMCS Code: 7000

Make sure that afi

re extinguisher is on the machine.Make sure that you are familiar with the operation ofthe fire extinguisher. Inspect the fire extinguisher andservice the fire extinguisher on a regular basis. Obeythe recommendations on the instruction plate.

The recommended location for mounting the fireextinguisher is on the platform behind the cab.

If thefire extinguisher is mounted on the ROPS, strapthe mounting plate to a leg of the ROPS. If the weightof the fire extinguisher is more than 4.5 kg (10 lb),mount the fireextinguisher as low as possible on oneleg. Do not mount the fire extinguisher on the upper

one-third area of the leg.

Note: Do not weld the ROPS in order to install thefire extinguisher. Also, do not drill holes in the ROPSin order to mount the fire extinguisher on the ROPS.

i01557411

Tire Information

SMCS Code: 7000

Explosions of air inflated tires have resulted fromheat-induced gas combustion inside the tires.

Explosions can be caused by heat that is generatedby welding, by heating rim components, by externalfire, or by excessive use of brakes.

A tire explosion is much more violent than ablowout. The explosion can propel the tire, the rimcomponents, and the axle components as far as500 m (1500 ft) or more from the machine. Both theforce of the explosion and the flying debris can causeproperty damage, personal injury, or death.


(A) At least 15 m (50 ft)(B) At least 500 m (1500 ft)

Do not approach a warm tire. Maintain a minimum

distance, as shown. Stay outside the shaded area inIllustration 24.

Do not use water or calcium as a ballast for the tires.Dry nitrogen gas is recommended for inflation of tires.If the tires were originally inflated with air, nitrogenis still preferred for adjusting the pressure. Nitrogenmixes properly with air.

Nitrogen inflated tires reduce the potential ofa tire explosion because nitrogen does not aidcombustion. Nitrogen helps to prevent oxidation ofthe rubber, deterioration of rubber, and corrosion ofrim components.

To avoid overinflation, proper nitrogen inflationequipment and training in the usage of the equipmentare necessary. A tire blowout or a rim failure canresult from improper equipment or from misusedequipment.

When you inflate a tire, stand behind the tread anduse a self-attaching chuck.

Servicing tires and rims can be dangerous. Onlytrained personnel that use proper tools and properprocedures should perform this maintenance. Ifcorrect procedures are not used for servicing tires

and rims, the assemblies could burst with explosiveforce. This explosive force can cause seriouspersonal injury or death. Carefully obey the specificinstructions from your tire dealer.


21/154


Electrical Storm Injury Prevention

i01122596

Electrical Storm InjuryPrevention

SMCS Code: 7000

When lightning is striking in the vicinity of themachine, the operator should never attempt thefollowing procedures:

Mount the machine.

Dismount the machine.

If you are in the operators station during an electricalstorm, stay in the operators station. If you are on theground during an electrical storm, stay away fromthe vicinityof the machine.

i00934890

Before Starting Engine

SMCS Code: 1000; 7000

The steering frame lock must be in the unlockedposition in order to steer the machine.

Start the engine only from the operator compartment.Never short across the starter terminals or acrossthe batteries. Shorting could bypass the engineneutral start system. Shorting could also damage the

electrical system.

Inspect the condition of the seat belt and the conditionof mounting hardware. Replace any parts that areworn or damaged. Regardless of the appearance,replace the seat belt after three years of use. Do notuse a seat belt extension on a retractable seat belt.

Adjust the seat so that there is full pedal travel whilethe operators back is against the back of the seat.

Make sure that the machine is equipped with alighting system that is adequate for the job conditions.Make sure that all lights are working properly.

Before you start the engine or before you move themachine, make sure that no one is on the machine,underneath the machine, or around the machine.Make sure that there are no personnel in the area.

i01019869

Engine Starting

SMCS Code: 1000; 7000

If a warning tagis attached to the engine start switchor to the controls, do not start the engine and do notmove any controls.

Move all hydraulic controls to the HOLD positionbefore you start the engine.

Move the transmission control to the NEUTRALposition.

Engage the parking brake.

Diesel engine exhaust contains products ofcombustion which can be harmful to your health.

Always operate the engine in a well ventilated area.If you are in an enclosed area, vent the exhaust tothe outside.

i01943255

Before Operation

SMCS Code: 7000

Make sure that there are no personnel on themachine or in the area around the machine.

Clear all obstacles from the path of the machine.

Beware of hazards such as wires, ditches, etc.

Make sure that all windows are clean. Secure thedoors and the windows in the open position or in theshut position.

Adjust the rear view mirrors (if equipped) for the bestvision of the area near the machine.

Ensure that the horn, the backup alarm (if equipped),and all other warning devices are working properly.

Fasten theseat belt securely.

i02725833

Visibility Information

SMCS Code: 7000

Before you start the machine, the operator shallperform a walk-around inspection in order to ensurethat there are no hazards around the machine.


22/154

22 SEBU7808-06Safety SectionOperation

While the machine is in operation, the operator shouldconstantly survey the area around the machine. Theoperator needs to identify potential hazards as ahazard becomes visible around the machine.

Your machine may be equipped with mirrors or other

visual aids.An example of a visual aid is ClosedCircuit Television (CCTV). The operator shouldensure that the visual aids are in proper workingcondition and that the visual aids are clean. Adjustthe visual aids for the best visibility of all areasaround the machine.

It may not be possible to provide direct visibility onlarge machines to all areas around the machine.

Appropriate job site organization is required in orderto minimize hazards that are caused by restrictedvisibility. Job site organization is a collection of rulesand procedures that coordinates machines andpeople that work together in the same area. Examples

of job site organization include the following:

safety instructions

controlled patterns of machine movement

controlled patterns of vehicle movement

restricted areas

operator training

warning symbols or warning signs on machinesor on vehicles

a system of communication

communication between workers and operatorsprior to approaching the machine

Modifications of the machine configuration that resultin a restriction of visibility shall be verified accordingto ISO 5006.

i01353266

Operation

SMCS Code: 7000

Only operate the machine while you are sitting ina seat. The seat belt must be fastened while youoperate the machine. Only operate the controls whilethe engine is running.

While you operate the machine slowly in an openarea, check for proper operation of all controls and allprotective devices.

Before you move the machine, make sure that noone will be endangered.

Do not allow riders on the machine unless themachine has an additional seat with a seat belt.

Note any needed repairs during machine operation.Report any needed repairs.

Carry work tools at approximately 40 cm (15 inches)above ground level.

Do not go closeto the edge of a cliff, an excavation,or an overhang.

Avoid operating the machine across the slope. Whenpossible, operate the machine up the slopes anddown the slopes. If the machine begins to sideslipon a downgrade, immediately remove the load andturn the machine downhill.

Avoid any conditions that can lead to tipping themachine. The machine can tip when you work on

hills, on banks and on slopes. Also, the machinecan tip when you cross ditches, ridges or otherunexpected obstructions.

Maintain control of the machine. Do not overload themachine beyond the machine capacity.

Make sure that the hitches and the towing devicesare adequate. Only connect trailing equipment to adrawbar or to a hitch.

Never straddle a wire cable. Never allow otherpersonnel to straddle a wire cable.

Before you maneuver the machine, make sure thatno personnel are between the machine and thetrailingequipment. Block up the hitch of the trailingequipment in order to align the hitch with the drawbar.Maneuver the machine. Connect the machine to thetrailing equipment.

Know the maximum dimensions of your machine.

i02624835

Engine Stopping

SMCS Code: 1000; 7000

Do not stop the engine immediately after themachine has been operated under load. This cancause overheating and accelerated wear of enginecomponents.

After the machine is parked and the parking brakeis engaged, allow the engine to run for two minutesbefore shutdown. This allows hot areas of the engineto cool gradually.


23/154


Parking

i01353455

Parking

SMCS Code: 7000

Park the machine on a level surface. If you must parkthe machine on a downgrade, block the tires.

Apply the service brake in order to stop the machine.Move the transmission control to the NEUTRALposition.

Engage the parking brake.

Lower all worktools to the ground. Activate anycontrol locks.

Stop the engine.

Turn the engine start switch to the OFF position andremove the key.

Turn the battery disconnect switch to the OFFposition. Ifthe machine will not be operated for anextended period of time, remove the key in order toavoid battery discharge that may be caused by abattery short circuit, by the current draw via certaincomponents, or by vandalism.

i01329161

Equipment Lowering with

Engine StoppedSMCS Code: 7000

Before lowering any equipment with the enginestopped, clear the area around the equipment ofall personnel. The procedure to use will vary withthe type of equipment to be lowered. Keep in mindmost systems use a high pressure fluid or air toraise or lower equipment. The procedure will causehigh pressure air, hydraulic, or some other mediato be released in order to lower the equipment.Wear appropriate personal protective equipment andfollow the established procedure in the Operation

and Maintenance Manual, Equipment Lowering withEngine Stopped in the Operation Section of themanual.

i02662565

Sound Information andVibration Information

SMCS Code: 7000

Sound Level Information

The operator Equivalent Sound Pressure Level(Leq) is 77 dB(A) when ANSI/SAE J1166 OCT 98is used to measure the value for an enclosed cab.This is a work cycle sound exposure level. The cabwas properly installed and maintained. The test wasconducted with the cab doors and the cab windowsclosed.

Hearing protection may be needed when themachine is operated with an open operator station for

extended periods or in a noisy environment. Hearingprotection may be needed when the machine isoperated with a cab that is not properly maintained orwhen the doors and windows are open for extendedperiods orin a noisy environment.

The average exterior sound pressure level is 81dB(A) whenthe SAE J88Apr95 - Constant SpeedMoving Test procedure is used to measure the valuefor the standard machine. The measurement wasconductedunder the following conditions: distance of15 m (49.2 ft) and the machine moving forward in anintermediate gear ratio.

Sound Level Information forMachines in European UnionCountries and in Countries thatAdopt the EU Directives

The dynamic operator sound pressure level is 73dB(A) when ISO 6396:1992 is used to measure thevalue for an enclosed cab. The cab was properlyinstalled and maintained. The test was conductedwith the cab doors and the cab windows closed.

The European Union PhysicalAgents (Vibration) Directive2002/44/EC

Vibration Data for Wheel Loaders

Information Concerning Hand/Arm VibrationLevel

When the machine is operated according to theintended use, the hand/arm vibration of this machineis below 2.5 meter per second squared.


24/154

24 SEBU7808-06Safety SectionSound Information and Vibration Information

Information Concerning Whole Body VibrationLevel

This section provides vibration data and a method forestimating the vibration level for wheel loaders.

Note: Vibration levels are influenced by manydifferent parameters. Many items are listed below.

Operator training, behavior, mode, and stress

Job site organization, preparation, environment,weather, andmaterial

Machine type, quality of the seat, quality of thesuspension system, attachments, and condition ofthe equipment

It is not possible to get precise vibration levels forthis machine. The expected vibration levels can be

estimated with the information in Table 1 in orderto calculate the daily vibration exposure. A simpleevaluation of the machine application can be used.

Estimate the vibration levels for the three vibrationdirections. For typical operating conditions, use theaverage vibration levels as the estimated level. Withan experienced operator and smooth terrain, subtractthe Scenario Factors from the average vibration levelin order to obtain the estimated vibration level. Foraggressive operations and severe terrain, add theScenario Factors to the average vibration level inorder to obtain the estimated vibration level.

Note: All vibration levels are in meter per secondsquared.

Table 1

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

Vibration Levels Scenario FactorsMachineType

Typical OperatingActivity X axis Y axis Z axis X axis Y axis Z axis

load and carry motion 0,84 0,81 0,52 0,23 0,20 0,14

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

transfer(2) 0,76 0,91 0,49 0,33 0,35 0,17

WheelLoader

V-shape motion(3)

0,99 0,84 0,54 0,29 0,32 0,14(1) Loading at the face(2) Travel at high speed on the job site or on public roads(3) Loading a truck in short cycles


25/154


Sound Information and Vibration Information

Note:Refer to ISO/TR 25398 Mechanical Vibration -Guideline for the assessment of exposure to wholebody vibration of ride on operated earthmovingmachines formore information about vibration.This publication uses data that is measuredby international institutes, organizations and

manufacturers. This document provides informationabout the whole body exposure of operators ofearthmoving equipment. Refer to Operation andMaintenance Manual, SEBU8257, The EuropeanUnion Physical Agents (Vibration) Directive2002/44/EC for more information about machinevibration levels.

The Caterpillar suspension seat meets the criteria ofISO 7096.This represents vertical vibration levelunder severe operating conditions. This seat is testedwith the input spectral class EM3. The seat has atransmissibility factor of SEAT


26/154

26 SEBU7808-06Safety SectionOperator Station

Sources

The vibration information and calculation procedureis based on ISO/TR 25398 Mechanical Vibration- Guideline for the assessment of exposureto whole body vibration of ride on operated

earthmoving machines. Harmonized data ismeasured by international institutes, organizationsand manufacturers.

This literature provides information about assessingthe whole body vibration exposure of operators ofearthmoving equipment. The method is based onmeasured vibration emission under real workingconditions for all machines.

You should check the original directive. Thisdocument summarizes part of the content of theapplicable law. This document is not meant tosubstitute the original sources. Other parts of these

documents are based on information from the UnitedKingdom Health and Safety Executive.

Refer to Operation and Maintenance Manual,SEBU8257, The European Union Physical

Agents (Vibration) Directive 2002/44/EC for moreinformation about vibration.

Consult your local Caterpillar dealer for moreinformation about machine features that minimizevibration levels. Consult your local Caterpillar dealerabout safe machine operation.

Use the following web site in order to find your local

dealer:

Caterpillar, Inc.www.cat.com

i01649970

Operator Station

SMCS Code: 7000

Any modifications to the inside of the operatorstation should not project into the operator space.

The addition of a radio,fi

re extinguisher, and otherequipment must be installed so that the definedoperator space is maintained. Any item that is broughtinto the cab should not project into the definedoperator space. A lunch box or other loose itemsmust be secured. Objects must not pose an impacthazard in rough terrain or in the event of a rollover.


27/154


28/154

28 SEBU7808-06Product Information SectionGeneral Information

Table 3

Rated Load3.88 m

Ground Engaging Tools Rated Volume Rated Operating Load Dump ClearanceA

ReachB

Spade Rock with Teeth andSegments (Standard Bucket)

6.4m3 (8.33 yd3) 11340 kg (25000 lb) 3742 mm

(147 inch) 1494 mm (59 inch)

Wide Spade Rock with Teethand Segments

6.9 m3 (9 yd3) 11340 kg (25000 lb) 3682 mm

(145 inch) 1554 mm (61 inch)

General Purpose with Bolt-OnCutting Edges

7 m3 (9.2 yd3) 11340 kg (25000 lb) 3790 mm

(149 inch) 1720 mm (68 inch)

Straight Rock with Teeth andSegments

6.3 m3 (8.2 yd3) 11340 kg (25000 lb) 4011 mm

(158 inch) 1526 mm (60 inch)

Rock Quarry (Heavy Duty) withTeeth and Segments

6.4m3 (8.33 yd3) 11340 kg (25000 lb) 3728 mm

(147 inch) 1543 mm (61 inch)

Mining (Heavy Duty) with Teethand Segments

6.4m3 (8.33 yd3) 11340 kg (25000 lb) 3811 mm

(150 inch) 1577 mm (62 inch)

Spade Rock with Bolt-OnCutting Edges

6.9 m3 (9 yd3) 11340 kg (25000 lb) 3638 mm

(143 inch) 1881 mm (74 inch)

Spade Rock with Teeth andSegments

6.6m3 (8.75 yd3) 11340 kg (25000 lb) 3742 mm(147 inch)

1494 mm (59 inch)


29/154

SEBU7808-06 29Product Information Section

General Information

Table 4

Rated Load4.25 m

Ground Engaging Tools Rated Volume Rated Operating Load Dump ClearanceA

ReachB

Spade Rock with Teeth andSegments (Standard Bucket)

6.4m3 (8.33 yd3) 11340 kg (25000 lb) 4155 mm

(164 inch) 1591 mm (63 inch)

Wide Spade Rock with Teethand Segments

6.9 m3 (9 yd3) 11340 kg (25000 lb) 4095 mm

(161 inch) 1652 mm (65 inch)

General Purpose with Bolt-OnCutting Edges

7 m3 (9.2 yd3) 11340 kg (25000 lb) 4203 mm

(165 inch) 1818 mm (72 inch)

Straight Rock with Teeth andSegments

6.3 m3 (8.2 yd3) 11340 kg (25000 lb) 4424 mm

(174 inch) 1623 mm (64 inch)

Rock Quarry (Heavy Duty) withTeeth and Segments

6.4m3 (8.33 yd3) 11340 kg (25000 lb) 4141 mm

(163 inch) 1641 mm (65 inch)

Mining (Heavy Duty) with Teethand Segments

6.4m3 (8.33 yd3) 11340 kg (25000 lb) 4225 mm

(166 inch) 1674 mm (66 inch)

Spade Rock with Bolt-OnCutting Edges

6.9 m3 (9 yd3) 11340 kg (25000 lb) 4051 mm

(159 inch) 1699 mm (67 inch)

Spade Rock with Teeth andSegments

6.6m3 (8.75 yd3) 11340 kg (25000 lb) 3742 mm(147 inch)

1494 mm (59 inch)


30/154

30 SEBU7808-06Product Information SectionIdentification Information

Identification Information

i01914225

Plate Locations and Film

LocationsSMCS Code: 1000; 7000

The Product Identification Number (PIN) is used toidentify a powered machine that is designed for anoperator to ride.

For quick reference, record the identification numbersin the spaces that are provided below the illustration.

Product Identification Number(PIN) and CE Plate


Left side of front frame

Machine PIN ________________________________________________


If the machine is equipped with the plate for theEuropean Union, this plate will be attached to thePIN plate. Several pieces of information are stampedonto the CE plate. For quick reference, record thisinformation in the spaces that are provided below.

Engine Power(kW)______________________________________

Machine Weight (kg)____________________________________

Year of Manufacture_____________________________________

Serial Number

Caterpillarproducts such as engines, transmissions,and major attachments that are not designed for anoperator to ride are identified by Serial Numbers. Forquick reference, record the identification numbers inthe spaces that are provided below the illustration.


Rear view of the torque converter housing

Torque Converter Serial Number_______________________


Engine valve cover

Engine Serial Number____________________________________


31/154

SEBU7808-06 31Product Information Section

Identification Information


Right side of planetary case

Transmission Serial Number_____________________________

Certification

Sound


Typical example

If equipped, the film is used to verify the environmentalsound certification of the machine. The value thatis listed on the fi lm indicates the guaranteed soundlevel. The guaranteed sound level is measured atthe time of manufacture. Refer to Operation andMaintenance Manual, Sound Information and

Vibration Information for the guaranteed sound levelfor your machine.

ROPS/FOPS Film


This warning film is located on the outside of thecab on the left side below the window. This machine

has been certified to the standards that are listedon the certification label. The maximum mass ofthe machine, which includes the operator and theattachments without a payload, should not exceedthe mass on the certification label.

i01547936

Emissions Certification Film

SMCS Code: 1000; 7000; 7405

Certification Label for Emissions

The certification label (if equipped) is used to verify anengines conformance to the emissions requirementsof the EPA.

This label is located on the engine.


32/154

32 SEBU7808-06Product Information SectionIdentification Information


Typical Example (English)


Typical Example (French)


33/154

SEBU7808-06 33Operation SectionBefore Operation

Operation Section

Before Operation

i02189821

Mounting and Dismounting

SMCS Code: 7000


Typical example

Mount the machine and dismount the machine onlyat locations that have steps and/or handholds. Beforeyou mount the machine, clean the steps and thehandholds. Inspect the steps and handholds. Make

all necessary repairs.

Face the machine whenever you get on the machineand whenever you get off the machine.

Maintain a three-point contact with the steps and withthe handholds.

Note: Three-point contact can be two feet and onehand. Three-point contact can also be one foot andtwo hands.

Do not mount a moving machine. Do not dismount amoving machine. Never jump off the machine. Do

not carry tools or supplies when you try to mount themachine or when you try to dismount the machine.Use a hand line to pull equipment onto the platform.Do not use any controls as handholds when youenter the operator compartment or when you exit theoperator compartment.

Alternate Exit

Machines that are equipped with cabs have alternateexits.For additional information, see Operation andMaintenance Manual, Alternate Exit.

i01922360

Daily Inspection

SMCS Code: 1000; 7000

Hot oil and hot components can cause personalinjury. Do not allow hot oil or hot components tocontact skin.

At operating temperature, the engine coolant ishot and under pressure.

Steam can cause personal injury.

Check the coolant level only after the engine hasbeen stopped and the cooling system pressurecap is cool enough to touch with your bare hand.

Remove the cooling system pressure cap slowlyto relieve pressure.

Cooling system conditioner contains alkali. Avoidcontact with the skin and eyes to prevent personalinjury.

NOTICEAccumulated grease and oil on a machine is a fire haz-ard. Remove this debris with steam cleaning or highpressure water, at least every 1000 hours or each timeany significant quantity of oil is spilled on a machine.

Note: For maximum service life of the machine,make a thorough daily inspection before you operatethe machine. Inspect the machine for leaks. Removeany debris from the engine compartment and theundercarriage. Ensure that all guards, covers, andcaps are secured. Inspect all hoses and belts fordamage. Inspect all lights and mirrors for damage.Make the needed repairs before you operate themachine.

Perform the following procedures on a daily basis.

Operation and Maintenance Manual, BucketCutting Edges - Inspect/Replace

Operation and Maintenance Manual, Bucket Stops- Inspect/Replace

Operation and Maintenance Manual, Bucket Tips- Inspect/Replace

Operation and Maintenance Manual, Bucket WearPlates - Inspect/Replace

Operation and Maintenance Manual, BackupAlarm - Test


34/154

34 SEBU7808-06Operation SectionBefore Operation

Operation and Maintenance Manual, CoolingSystem Coolant Level - Check

Operation andMaintenance Manual, Engine OilLevel - Check

Operation andMaintenance Manual, Engine AirFilter Service Indicator - Inspect

Operation and Maintenance Manual, HydraulicSystem Oil Level - Check

Operation and Maintenance Manual, LoaderBoom Pin and Lift Cylinder Pin - Inspect

Operation and Maintenance Manual, Loader Pinsand Bearings - Lubricate

Operation and Maintenance Manual, Seat Belt -Inspect

Operation and Maintenance Manual, TransmissionOil Level - Check

Operation and Maintenance Manual, Windows -Clean

Refer to theMaintenance Section for the detailedprocedures. Refer to the Maintenance IntervalSchedule for a complete list of scheduledmaintenance.

i01922365

Steering Frame Lock

SMCS Code: 7506

No clearance for person in this area when machineturns. Severe injury or death from crushing couldoccur.


The steering frame lock is located at the articulationjoint on the left side of the machine.


Connect steering frame lock (1) when the machine

is being lifted and when the machine is beingtransported. Also connect the steering frame lock ifyou are performing service work near the articulation

joint. Install pin (2) and secure the pin with lockingpin (3).


Separate steering frame lock (1) before the machineis operated.

Move the steering frame lock to the front frame andinstall pin (2). Secure the pin with locking pin (3).


35/154

SEBU7808-06 35Operation Section

Machine Operation

Machine Operation

i01612239

Alternate Exit

SMCS Code: 7310


The right side cab window can be used as analternateexit. The window can only be opened fromthe inside of the cab.

Pull latch(2) backward and push the latch outwardin order to open the window to the partial openposition. Remove pin (1) from the window and pushthe windowto the fully open position.

i02203596

Seat

SMCS Code: 7312

Note: The operators seat that is provided with thismachine is in compliance with the appropriate classof ISO 7096.

Adjust the seat in order to allow full travel of thepedals. Make the seat adjustments when the operatoris sitting against the back of the seat.


Mechanical Suspension

Backrest (1) Pull up on the backrest inorder to remove extension.

Lumbar Support (2) Push the leverbackward in order to increase support tothe lowerback. Pull the lever forward in

order to decrease support to the lower back. Releasethe lever in order to lock the seat into position.

Rotate knob (3) in order to adjust the angle of thearmrest in the operating position.

Cushion Angle Adjustment (4) Pull thelever upward. Hold the lever upward and

move the seat cushion to the desired angle.Releasethe lever in order to lock the seat cushioninto position. The seat cushion can be adjusted toone of three positions.

Fore andAft Position (5) Pull the leverupward. Hold the lever upward and slidethe seat forward or backward to the desired

position. Release the lever in order to lock the seatinto position.


36/154

36 SEBU7808-06Operation SectionMachine Operation

Seat Backrest Angle Adjustment (6) Pull the lever upward. Hold the leverupward and adjust the backrest to the

desired angle. Release the lever in order to lock thebackrest into position.

Seat Height (7) Pull the lever upward.Hold the lever upward and move the seatto the desired height. Release the lever in

order to lockthe seat into position.

Air Suspension (If Equipped)

Seat Height (Air suspension) (7) Pushin on the air valve knob (7) in order to raisethe height ofthe seat. Pull out on the air

valve knob (7) in order to lower the height of the seat.

i02707449

Seat Belt

SMCS Code: 7327

Note: This machine was equipped with a seat beltwhen the machine was shipped from Caterpillar.

At the time of installation, the seat belt and theinstructions for installation of the seat belt meet theSAE J386 standards. See your Caterpillar dealer forall replacement parts.

Always check the condition of the seat belt andthe condition of the mounting hardware before youoperate the machine.

Seat Belt Adjustment forNon-Retractable Seat Belts

Adjust both ends of the seat belt. The seat belt shouldbe snug but comfortable.

Lengthening the Seat Belt


1. Unfasten the seat belt.


2. To remove the slack in outer loop (1), rotate buckle(2). This will free the lock bar. This permits theseat belt to move through the buckle.

3. Remove the slack from the outer belt loop bypulling on the buckle.

4. Loosen the other half of the seat belt in the samemanner. If the seat belt does not fit snugly with thebuckle in the center, readjust the seat belt.


37/154


38/154


Releasing The Seat Belt


Push the release button on the buckle in order torelease the seat belt. The seat belt will automatically

retract into the retractor.

Extension of the Seat Belt

When using retractable seat belts, do not use seatbelt extensions, or personal injury or death canresult.

The retractor system may or may not lock up de-pending on the length of the extension and thesize of the person. If the retractor does not lock

up, the seat belt will not retain the person.

Longer, non-retractable seat belts and extensions forthe non-retractable seat belts are available.

Caterpillar requires only non-retractable seat belts tobe used with a seat belt extension.

Consult your Caterpillar dealer for longer seat beltsand for information on extending the seat belts.

i02754670

Operator Controls(Overhead Switch Panels)

SMCS Code:7300; 7301; 7451

Note: Your machine may not be equipped with all ofthe controls that are discussed in this topic.


39/154


Machine Operation



(1) Front Window Wiper and Washer(2) Ride Control(3) Torque Converter Lockup Control(4) Beacon Switch(5) Autoshift Control(6) Rear Window Wiper/Washer Switch(7) Fan Speed Switch

(8) Heating and Air Conditioning Switch(9) Temperature Control(10) HID Light Switch(11) Stairway Access Light(12) Main Lighting Switch(13) Reduced Rimpull Switch(14) Loose Material Control

(15) Kickout and Positioner Control(16) Override Switch for the Automatic

Lubrication System (If equipped)(17) Reversing Fan Switch(18) Hazard Light Switch

Front Window Wiper and Washer(1)

Front Window Wiper and Washer Turnthe knob clockwise in order to turn on thewindow wiper. Push the knob in order to

activate the window washer. Spring force will returnthe knob after use.

Note: For machines that have intermittent frontwipers, there are several positions that will affectthe wipers.

Turn the knob in a clockwise direction. The followingsettings may be selected: OFF position, LONGDELAY position, INTERMITTENT DELAY position,SHORT DELAY position, LOW position, and HIGHposition.


40/154


Ride Control (2)

Ride Control Switch (If Equipped) Travel at high speeds over rough terraincauses bucket movement and a swinging

motion. The ride control system acts as a shock

absorber by dampening forces from the bucket. Thishelps to stabilize the entire machine.

ON Push the bottom of the ride control switch inorder to turn on the ride control system. When the ridecontrol switch is in the ON position, the ride controlsystem will be operational at all times. This function isused primarily during servicing the accumulator. Fornormal operation, the ride control switch should beplaced in either the automatic position or in the OFFposition during the loading cycle. Failure to movethe ride control switch to the recommended positioncould result in damage to the machine.

OFF Push the ride control switch to the middleposition in order to turn off the ride control system.

AUTOMATIC Push the top of the ridecontrol switch in order to turn on theautomatic ride control.

When the switch for the ride control system is in theAUTOMATIC position, an indicator light on the frontdash panel comes on. A light on the switch comeson also.

The automatic ride control turns on when the ground

speed exceeds 9.6 km/h (6 mph). The automatic ridecontrol turns off when the ground speed is less than9.6 km/h (6 mph).

Torque Converter Lockup Control(3)

Torque Converter Lockup Switch Pressing the top of the switch enables thelockup clutch for all gears except for the first

gear forward. When the engine speed is in the correctspeed range, the torque converter will lock up. Theindicator light on the instrument panel will illuminate

when the torque converter lockup switch is activated.

This feature provides more efficient operation for highspeeds and for carrying loads.

Note: The torque converter lockup switch must beactivated in order to use the engine brake control (ifequipped).

Beacon Switch (4)

Rotating Beacon Press the top of switchin order to turn on the rotating beacon.Press the bottom of the switch in order to

turn off the rotating beacon.

Autoshift Control (5)

Manual Mode The gear speed isselected by rotating the switch to themanual position.

Automatic Mode The operator selectsthe highest desired operating speed fromthe options on the switch. The control

selects the proper transmission gear according to theground speed of the machine.

Note: Do not use the autoshift mode when the fuelmanagement switch (if equipped) is enabled.

Pressing the upshift gear speed switch on the STICcontrol will cause the machine to shift into the nexthighest gear.

Pressing the downshift gear speed switch on theSTIC control will cause the machine to shift into thenext lowest gear.

The indicator light that is located on the instrumentpanel will illuminate when the autoshift control is

activated.

The downshift gear speed switch on the STIC controlis active in all gears. The downshift gear speedswitch on the STIC control can cause transmissiondownshifts at machine speeds that are higher thannormal.

Pressing the downshift gear speed switch on theSTIC control will cause a downshift of one gear.The downshift will only occur if the machine speedand the engine speed will not result in an engineoverspeed condition.

Holding down the downshift gear speed switch on theSTIC control will cause the transmission to continueto downshift as the machine speed decreases.

The transmission will remain in the downshiftedgear for three seconds after the downshift switch isreleased. Then, automatic shifting is resumed.

Turn switch (5) to a selected gear speed in order toactivate the autoshift function. The transmission willshift from first gear through fourth gear automatically.The highest gear that will be used is determined bythe selection on the switch.


41/154


Machine Operation

As the machine slows, the transmission willautomatically downshift. The transmission will notshift lower than second gear.

Note: The 988H does not have a separate Quick-Shiftfunction as the former 988F model. In the automatic

mode of autoshift, the transmission will automaticallyshift from the first gear to the second gear. Thishappens when the operator shifts the directionfrom forwardto reverse. When one then shifts fromreverse to forward, the transmission will remain insecond gear. This feature only functions when themachine is in first gear. A transmission quick-shiftcan only occur when the operator shifts the directionfrom forward to reverse. This feature does not affectany directional shift in any of the other gears.

Rear WindowWiper/Washer Switch(6)

Rear Window Wiper and Washer Turnthe knob clockwise in order to turn on thewindow wiper. Push the knob in order to

activate the window washer. Spring force will returnthe knob after use.

Note: For machines that have intermittent frontwipers, there are several positions that will affectthe wipers.

Turn the knob in a clockwise direction. The followingsettings may be selected: OFF position, LONGDELAY position, INTERMITTENT DELAY position,SHORT DELAY position, LOW position, and HIGHposition.

Fan Speed Switch (7)

The heating or the air conditioning must be activatedin order for the fan to operate.

Fan Speed Switch The switch controlsthe speed of the blower fan motor for theheatingand air conditioning system.

Low Press the top of the switch.

Medium Move the switch to the middle position.

High Press the bottom of the switch.

Heating and Air ConditioningSwitch (8)

Air Conditioner Press the top of the switch.

Off Move the switch to the center position in orderto deactivate the heating and air conditioning system.This will also deactivate the blower fan motor.

Heater Press the bottom of the switch.

Temperature Control (9)

Temperature Variable Control Turn theknob clockwise for warmer air. Turn theknob counterclockwise for cooler air.

HID Light Switch (10)

Press the top of the switch in order to turn on thelights. Press the bottom of the switch in order to turnoff the lights.

Stairway Access Light (11)Stairway Access Light Press the topof switch in order to turn on the stairwayaccess light. Press the bottom of the switch

in order to turn off the stairway access light.

g00841327

Illustration 50

Note: The stairway access light can also becontrolled by the switch next to the engine shutdowncontrol. The engine shutdown control is located onthe left rear bumper.

Main Lighting Switch (12)

Off Rotate the knob counterclockwise inorder to shut off all of the lights.


42/154


Parking Lights and Cab Interior Lights Rotate the knob clockwise to the firstposition in order to turn on both the parking

lights and the interior cab lights.

Roading Lights Rotate the knobclockwise to the second position in order toturn on the roading lights.

Rear Floodlights Rotate the knobclockwise to the third position in order toturn on the rearfloodlights.

Front Floodlights Rotate the knobclockwise to the fourth position in order toturn on front floodlights.

Reduced Rimpull Switch (13)The reduced rimpull switch reduces the potentialfor wheel slippage without reducing the hydraulicefficiency. The reduced rimpull switch is afour-position switch. Each setting corresponds to amaximum allowable percentage of maximum rimpull.

There are two types of settings for the maximumallowable percentage of maximum rimpull.

Type 1


Machines that are equipped with the rimpull switch, located on theright side of the control console

Type 2


Machines that are equipped with the fuel management switch,located on the right side of the control console

Note: The rimpull settings may be adjusted in orderto meet operating conditions.

Reference: To change the maximum allowablepercentages for each setting of the rimpull switch,refer to Testing and Adjusting, RENR3095, PowerTrain.

Operating with Reduced Rimpull

To select a reduced rimpull setting, move the reducedrimpull switch to the desired setting and move thereduced or maximum rimpull switch that is locatedon the right side control console to the REDUCEDposition.

If the machine is in first speed, the reduced rimpullswitch will provide an impeller clutch pressure whichlimits the rimpull to the desired level when the leftbrake pedal is fully released.

Depressing the left brake pedal will further reducerimpull from the selected percentage. The rimpull thatis commanded by the fully released pedal will equalthe reduced rimpull that is selected on the reducedrimpull switch.

When a lower rimpull is selected, pedal travel willresult in a more gradual decrease in rimpull.

If the machine is not in first speed, the impeller clutchpressure will remain at the maximum level until thetransmission is placed into first speed.

The reduced rimpull switch will continue to limitrimpull until the transmission is shifted out offirstspeed or until the reduced or maximum rimpull switchis placed in the MAXIMUM position.


43/154


Machine Operation

Loose Material Control (14)

Loose Material Mode When you areloading loose material, press the top ofthe switch in order to activate the loose

material mode. The loose material mode provides

maximum hydraulic pump flow for faster loading inloose materials.

Note: Do not use the loose material mode in diggingconditions that are tough. In the normal mode fortougher digging, hydraulic pumpflow is reduced forbetter performance.

The indicator light that is located on the instrumentpanel will illuminate when the switch is activated.

Kickout and Positioner Control (15)

Lift Kickout Position and Lower KickoutPosition To set the lift kickout, raise thebucket to the desired position above the

midway point. Then depress the bottom of the kickoutset switch. The boom will return to the programmedposition when the raise detent is activated and theboom is below the kickout position.

To set the lower kickout, lower the bucket to thedesired position below the midway point. Thendepress the bottom of the kickout set switch. Theboom will return to the programmed position whenthe float detent is activated and the boom is at leasta foot above the kickout position.

Note: If the boom is a foot or less above the lowerkickout position, placing the lift control lever in thefloat detent will cause the bucket to float and thebucket will hit the ground.

Bucket Kickout Position To set thebucket kickout position, tilt the bucket to thedesired digging angle and depress the top

of the kickout set switch. The bucket will return tothe programmed position when the tilt control leveris placed in the tilt back detent and the bucket isdumped beyond the kickout.

Override Switch for the AutomaticLubrication System (16)

Press the top of the switch and release the switch.This will override the automatic lubrication system.This will dispense grease to the lubrication points.

After lubrication is complete, the automatic lubricationsystem will return to normal operation.

Reversing Fan Switch (17)

The reversing fan will reverse the direction of thecooling fan in order to purge debris that is trappedin the radiator grill.

The auto reversing fan automatically reverses thecooling fan for 25 seconds after every 30 minuteinterval. Then, the cooling fan returns to the normaldirection.

Switch (17) provides a manual override controlthat will immediately initiate the purge cycle whenthe engine is on. Press the top of the switch andrelease the switch in order to manually activate thereversing fan. Then, the cycle will reset the timer forthe automatic purge cycle.

Note: Your machine may be equipped with a featurethat will not allow the cooling fan to automatically

reverse when the parking brake is applied. Pressingthe reversing fan switch (17) will override this feature.

Hazard Light Switch (18)

Hazard Lights Press the top of theswitch in order to turn on the hazard lights.Press the bottom of the switch in order to

turn off the hazard lights.


44/154


i02754385

Operator Controls(Steering Control Console)

SMCS Code:7300; 7301; 7451


(1) STIC Control (2) Armrest

STIC Control (1)

The STIC Control controls the following machine

functions: Steering, Direction Control, and SpeedControl.

Speed Control

Push upshift switch (1A) in order to shift the machineinto the next highest speed.

Push downshift switch (1B) in order to shift themachine into the next lowest speed.

1 indicates First Speed.

2 indicates Second Speed.

3 indicates Third Speed.

Note: When the parking brake is engaged, the

machine can only be shifted into second speed orinto third speed.

Direction Control

REVERSE Move the top of the trigger switch (1C)to R. This will enable the machine to move in thereverse direction.

NEUTRAL Move the trigger switch (1C) to N.This will disengage the transmission.


45/154


Machine Operation

FORWARD Move the bottom of the trigger switch(1C) to F. This will enable the machine to move inthe forward direction.

The active transmission direction will be shown onthe speedometer.

Steering Control

Note: The steering frame lock must be in theunlocked position in order to steer the machine.

Move the STICcontrol to the right of the centerposition in order to steer the machine to the right.

Move the STICcontrol to the left of the center positionin order to steer the machine to the left.

Note: When you release the STIC control, the STICcontrol will return to the center position. However, themachine will maintain the current travel direction.

STIC Control Lock

Move the lock lever (1D) all the way to the left inorder to mechanically lock the STIC control. Thetransmission controls will be electronically locked.

Move the lock lever (1D) all the way to the front inorder to unlock the STIC control. The transmissioncontrols will unlock.

Armrest (2)

Push down the knob (2A) in order to move the controlconsole forward or backward. Release the knob inorder to lock the console into position.

Turn the knobs (2B) counterclockwise in order toadjust the height and the angle of the armrest. Turnthe knobs clockwise in order to secure the armrest inthe position that is desired.

i02741395

Operator Controls

(Electrohydraulic ControlConsole)

SMCS Code:7300; 7301; 7451

Note: Your machine may not be equipped with all ofthe controls that are discussed in this topic.


46/154



Standard control console

(1) Armrest(1A),(1B),(1C) Adjustment knobs for the

console and armrest(2) Third function hydraulic control(3) Lift control(4) Horn

(5) Tilt control(6) Hydraulic lockout control(7) Lighter(8) Ashtray(9A) Rimpull select switch (If equipped)(9B) Fuel management switch (If equipped)

(10) Store button(11) Set/Decel switch(12) Resume/Accel switch(13) Auxiliary hydraulic lockout control


47/154


Machine Operation


(3) Lift control(4) Horn(5) Tilt control

(6) Hydraulic lockout control(9A) Rimpull select switch (If equipped)(9B) Fuel management switch (If equipped)

(10) Store button(11) Set/Decel switch(12) Resume/Accel switch

Armrest (1)

Push down on the knob (1B) in order to move thecontrol console forward or backward. Release theknob in order to lock the console into position.

Turn the knobs (1A) counterclockwise in order toadjust the height and the angle of the armrest. Turnthe knobs clockwise in order to secure the armrest inthe position that is desired.

Turn the knob (1C) counterclockwise in order toadjust the height of the implement control. Turn theknob clockwise in order to secure the implementcontrol in the position that is desired.

Third Function Hydraulic Control(2)

Note: Do not use any lubricants on any part of theimplement controls.

Pull back the lever in order to pressurize the leftauxiliary hydraulic line. Push the lever forward inorder to pressurize the right auxiliary hydraulic line.

Lift Control (3)


FLOAT Push the bucket lift lever forwardthrough the detent. The bucket will lowerto the ground. The bucket will float with the

contour of the ground.

The bucket lift lever will remain in the FLOAT positionuntil the lever is moved out of the detent. The bucketlift lever will return to the HOLD position when thelever isreleased.

NOTICENEVER use FLOAT position to lower a loaded bucket.

Machine damage can result from bucket falling toofast.

LOWER Push the bucket lift lever forwardin orderto lower the bucket. The bucket liftlever will return to the HOLD position when

the lever is released.


48/154


HOLD The bucket lift lever will returnto the HOLD position when the bucket liftlever is released from the RAISE position

or from the LOWER position. The bucket will remainin the selected position.

RAISE Pull the bucket lift lever backwardin order to raise the bucket. Release thebucket lift lever in order to stop lifting the

bucket. The bucket lift lever will return to the HOLDposition when the lever is released.

The bucket lift lever is detented in the fully raisedposition. The bucket lift lever will stay in the detentand the bucket will continue to rise until the bucketreaches the lift kickout height. Then, the bucket liftlever will return to the HOLD position.

Horn (4)

Horn Press the button in order to soundthe horn. Use the horn in order to alertpersonnel.

Tilt Control (5)


DUMP Push the bucket tilt lever forwardin order to dump a load from the bucket.

HOLD The bucket tilt lever will returnto the HOLD position when the lever isreleased from the DUMP position or from

the TILT BACK position. The bucket will remain inthe selected position.

TILT BACK Pull the bucket tilt leverbackward in order to tilt back the bucket.

The bucket tilt lever is detented in the full TILT BACK

position. The bucket tilt lever will stay detented andthe bucket will continue to tilt back until the bucketreaches the preset digging angle. The operator setsthe preset digging angle with the tilt kickout. Then,the bucket tilt lever returns to the HOLD position.

Hydraulic Lockout Control (6)

LOCKED Press the top of the switch inorder to electronically lock the implementcontrols.

UNLOCKED Press the bottom of theswitch in order to electronically unlock theimplement controls.

Lighter (7)Lighter Push the lighter inward andrelease the lighter. The lighter will moveoutward slightly when the lighter is ready

for use.

Ashtray (8)

Pull out on the ashtray in order to open the ashtray.

Rimpull Select Switch (9A) (If

Equipped)Maximum Rimpull To providemaximum rimpull, press the top of theswitch. Maximum rimpull will be provided

regardlessof the setting of the rimpull select switch.

Reduced Rimpull To provide reducedrimpull, press the bottom of the switch. Themachine will return to the selected setting

of the rimpull select switch. This is only true if thetransmission is in first speed. If the transmissionis not in first speed, the ma

operaÃ§Ã£o e manutenÃ§Ã£o - 988h

Documents