Swivel Seat Supplement for the R2900G (XTRA) Load Haul Dump {1000, 7000, 7324} Caterpillar


Swivel Seat Supplement for the R2900G (XTRA) Load Haul Dump {1000, 7000, 7324}

Usage:

R2900G JLK


Load Haul Dump:
R2900G (S/N: JLK1-UP)

Introduction




Illustration 1g01051135

The supplemental product support literature should be used with the appropriate Service Manual and the appropriate Parts Manual that is available for each standard machine. This supplement is used to determine the difference between the custom modifications and a standard machine.

The Service Manual and the Parts Manual that is available for the standard machine should be used if the service information is not in this supplementary product support literature.

Foreword

Literature Information

This supplemental product support literature should be stored in the operators compartment in the literature storage area. Read, study and keep this supplemental product support literature with the machine.

Safety Section

Safety Messages

There are several specific safety signs on this machine. The exact location of the hazards and the description of the hazards are reviewed in this section. Please become familiarized with all safety signs.

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

Replace any safety sign that is damaged, or missing. If a safety sign is attached to a part that is replaced, install a safety sign on the replacement part. Any Caterpillar dealer can provide new safety signs.




Illustration 2g01768873



Illustration 3g02072933

Operator Station Access (1)

This safety label is located on the inside of the operator station door.




Illustration 4g01389329

------ WARNING! ------

No clearance for person in operator's station access area when machine turns. Severe injury or death from crushing could occur.

Engage transmission/primary steering lock before leaving the operator's station.

----------------------

Do Not Operate (2)

This safety label is located in the operator station.




Illustration 5g01370904

------ WARNING! ------

Do not operate or work on this machine unless you have read and understand the instructions and warnings in the Operation and Maintenance Manuals. Failure to follow the instructions or heed the warnings could result in injury or death. Contact your Caterpillar dealer for replacement manuals. Proper care is your responsibility.

----------------------

Seat Swivel (3)

This safety label is located in the operator station.




Illustration 6g01742214

------ WARNING! ------

Reduced clearance for hands and feet when operator seat swivels during operation. Serious injury from crushing may occur. Ensure seat belt is worn at all times. Keep hands on controls and feet on pedals while operating the machine. Read the operators manual for additional procedures on the seat operation.

----------------------

Seat Belt (4)

This safety label is located in the operator station.




Illustration 7g01370908

------ WARNING! ------

A seat belt should be worn at all times during machine operation to prevent serious injury or death in the event of an accident or machine overturn. Failure to wear a seat belt during machine operation may result in serious injury or death.

----------------------

STIC Steering Control (5)

This safety label is located on the inside of the operator station door.




Illustration 8g01389328

------ WARNING! ------

Use grab handle not STIC control when entering or leaving operator's station.

Severe injury or death may be caused by crushing when machine turns

----------------------

Do Not Weld or Drill the ROPS/FOPS (6), (7)

This safety label is located on the right side of the operator station ROPS/FOPS.




Illustration 9g01390454



Illustration 10g02072934

------ WARNING! ------

Structural damage, an overturn, modification, alteration, or improper repair can impair this structure's protection capability thereby voiding this certification. Do not weld on or drill holes in the structure. Consult a Caterpillar dealer to determine this structure's limitations without voiding its certification.

----------------------

Rollover and Falling Object Protective Structure Certification

This machine has been certified to the standards that are listed on the certification film. The maximum mass of the machine, which includes the operator and the attachments without a payload, should not exceed the mass on the certification film.

Sound Level Information

The dynamic operator sound pressure level is 84 dB(A) when "ISO 6396:2008" is used to measure the value for an enclosed cab. The cab was properly installed and maintained. The test was conducted with the cab door closed.

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 in a noisy environment.

Sound Level Information for Machines in European Union Countries and in Countries that Adopt the EU Directives

The information below only applies to machine configurations that have the "CE" mark on the Product Identification Plate.

The dynamic operator sound pressure level is 84 dB(A) when "ISO 6396:2008" is used to measure the value for an enclosed cab. The cab was properly installed and maintained. The test was conducted with the cab door closed.

"The European Union Physical Agents (Vibration) Directive 2002/44/EC"

Vibration Data for Load Haul Dumpers

Information Concerning Hand/Arm Vibration Level

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

Information Concerning Whole Body Vibration Level

This section provides vibration data and a method for estimating the vibration level for Load Haul Dumpers.

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

  • Operator training, behavior, mode and stress

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

  • Machine type, quality of the seat, quality of the suspension system, attachments and condition of the equipment

It is not possible to get precise vibration levels for this machine. The expected vibration levels can be estimated with the information in Table 1 in order to calculate the daily vibration exposure. A simple evaluation of the machine application can be used.

Estimate the vibration levels for the three vibration directions. For typical operating conditions, use the average vibration levels as the estimated level. With an experienced operator and smooth terrain, subtract the scenario factors from the average vibration level in order to obtain the estimated vibration level. For aggressive operations and severe terrain, add the scenario factors to the average vibration level in order to obtain the estimated vibration level.

Note: All vibration levels are in meter per second squared.

Table 1
Equivalent Vibration Levels of Whole Body Vibration Emission for R2900G Load Haul Dumpers Equipped with the 326-6820 Conversion Arrangement - Swivel Seat Cab    
Machine Type     Activity     Vibration Levels     Scenario Factors    
X axis Y axis     Z axis     X axis     Y axis     Z axis    
R2900G Load Haul Dump     Tramming     0.43     0.27     0.48     0.07     0.05     0.07    
Digging/Loading 0.44     0.34     0.48     0.07     0.01     0.07    

Note: The vibration data was measured on R2900G Load Haul Dumpers equipped with the 326-6820 Conversion Arrangement - Swivel Seat Cab, during typical applications. This document provides information about the whole body exposure of operators of earth moving equipment. Refer to Operation and Maintenance Manual Supplement, SEBU8257 for more information about machine vibration levels.

Guidelines for Reducing Vibration Levels on Earth Moving Equipment

Properly adjust machines. Properly maintain machines. Operate machines smoothly. Maintain the conditions of the terrain. The following guidelines can help reduce the whole body vibration level:

  1. Use the right type and size of machine, equipment, and attachments.

  1. Maintain machines according to the manufacturer's recommendations.

    1. Tire pressures.

    1. Brake and steering systems.

    1. Controls, hydraulic system and linkages.

  1. Keep the terrain in good condition.

    1. Remove any large rocks or obstacles.

    1. Fill any ditches and holes.

    1. Provide machines and schedule time in order to maintain the conditions of the terrain.

  1. Keep the seat maintained and adjusted.

    1. Adjust the seat and suspension for the weight and the size of the operator.

    1. Inspect and maintain the seat suspension and adjustment mechanisms.

  1. Perform the following operations smoothly.

    1. Steer.

    1. Brake.

    1. Accelerate.

    1. Shift the gears.

  1. Move the attachments smoothly.

  1. Adjust the machine speed and the route in order to minimize the vibration level.

    1. Drive around obstacles and rough terrain.

    1. Slow down when it is necessary to go over rough terrain.

  1. Minimize vibrations for a long work cycle or a long travel distance.

    1. Use machines that are equipped with suspension systems.

    1. Use the ride control system on wheel loaders.

    1. If no ride control system is available, reduce speed in order to prevent bounce.

    1. Haul the machines between workplaces.

  1. Less operator comfort may be caused by other risk factors. The following guidelines can be effective in order to provide better operator comfort:

    1. Adjust the seat and adjust the controls in order to achieve good posture.

    1. Adjust the mirrors in order to minimize twisted posture.

    1. Provide breaks in order to reduce long periods of sitting.

    1. Avoid jumping from the cab.

    1. Minimize repeated handling of loads and lifting of loads.

    1. Minimize any shocks and impacts during sports and leisure activities.

Sources

The vibration information and calculation procedure is based on "ISO/TR 25398 Mechanical Vibration - Guideline for the assessment of exposure to whole body vibration of ride on operated earth moving machines".

This literature provides information about assessing the whole body vibration exposure of operators of earth moving equipment. The method is based on measured vibration emission under real working conditions for all machines.

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

Refer to Operation and Maintenance Manual, SEBU8257 for more information about vibration.

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

Use the following web site in order to find your local dealer:

Caterpillar, Inc.
www.cat.com

Product Information Section

Model Specifications

Machine operating specifications are listed in the following table.

Table 2
R2900G XTRA Load Haul Dump with Swivel Seat Installed    
Weight (approximate) (1)    
60000 kg (132278 lb)    
Length (maximum)    
11483 mm (452.1 inch)    
Width (maximum)    
3472 mm (136.7 inch)    
Width across Tires    
3228 mm (127.1 inch)    
Height over ROPS/FOPS    
3090 mm (121.7 inch)    
( 1 ) The weight includes a full fuel tank, a 75 kg (165.3 lb) operator, an enclosed swivel seat operator station and a standard bucket. If additional attachments have been installed on your machine, the weight of your machine may vary.

Operation Section

Engine Start Switch




Illustration 11g01746175

Engine start switch (1) - The engine start switch is used to turn the electrical system on and the engine start switch is also used to start the engine.


OFF Position (2) - When you insert the engine start switch key and when you remove the engine start switch key, the engine start switch must be in the OFF position. To disconnect the power to the electrical circuits in the operator station, turn the engine start switch to the OFF position. Also, turn the engine start switch to the OFF position in order to stop the engine.

Note: The front lights, the rear lights, and the dome lamp can be turned on when the engine start switch is in the OFF position.


ON Position (3) - To activate the electrical circuits in the operator station, turn the engine start switch key clockwise to the ON position.


START Position (4) - To start the engine, turn the engine start switch clockwise to the START position. When the engine start switch key is released, the engine start switch will return to the ON position.

Note: If the engine fails to start, return the engine start switch to the OFF position. This must be done before you attempt to start the engine again.

Caterpillar Monitoring System




Illustration 12g01746254



Illustration 13g01772236

The Caterpillar Monitoring System consists of speedometer/tachometer display (1), gauge display (2), an action alarm, monitoring system display (3), and action lamp (5). Individual alert indicators (4) for each machine system are located on monitoring system display (3) .

The monitoring system is designed to alert the operator of an immediate or an impending problem in one or more of the machine systems.

Warning Operation

Table 3
Warning Operation    
Warning Category     Warning Indications (1)     Required Action from the Operator     Possible Result (2)    
Alert Indicator Flashes (3) or a Gauge will Show in the Red Range Action Lamp Flashes (4)     The Action Alarm Sounds    
1     X             No immediate action is required. The system needs attention soon.     No harmful effects or damaging effects will occur.    
2     X     X         Change machine operation or perform maintenance to the system.     Damage to machine components will occur.    
2-S     X     X     (5)     Immediately change the machine operation.     Severe damage to components.    
3     X     X     (6)     Immediately perform a safe engine shutdown.     Injury to the operator or severe damage to components will occur.    
( 1 ) The active warning indications are marked with an X.
( 2 ) If the required action is not carried out then the following results will occur.
( 3 ) The alert indicator flashes at a 10 Hz rate.
( 4 ) The action lamp flashes at a 1 Hz rate.
( 5 ) The alarm is on continuously.
( 6 ) The action alarm will sound at a 1 Hz rate.

Warning Categories

The monitoring system provides three warning categories. The first category requires only operator awareness. The second warning category requires the operation of the machine or the maintenance procedure for the machine to be changed. The third warning category requires immediate safe shutdown of the machine.

Warning Category 1

In this category, only the appropriate alert indicators will flash. The alert indicator informs the operator that a machine system needs attention. The condition of the machine system should not endanger the operator. Also, the condition of the machine system should not damage the machine.




Illustration 14g01746273


Parking Brake (1) - Indicates the parking brake is engaged and the transmission is in NEUTRAL. The alert indicator should flash during start-up. It should go out when the parking brake is disengaged.


Electrical System (2) - Indicates a malfunction in the electrical system. If this alert indicator flashes, the system voltage is either too high for normal machine operation or the system voltage is too low for normal machine operation.

If the electrical loads (air conditioning and/or lighting) are high and the engine speed is low, increase the engine speed. This will generate more output from the alternator. If the alert indicator for the electrical system turns off within one minute, the electrical system is operating normally. Overload can occur during periods of low engine speeds.

Revise the operating cycle in order to avoid overloading the electrical system. Overloading the electrical system could result in discharging the batteries.

Low idle must be corrected. Adjust the low idle setting to the high side of low idle when the most common electrical loads are turned on. Reducing loads will also help. Use the medium fan speed instead of the high fan speed.

If this procedure does not cause the alert indicator to turn off, stop the machine and investigate the cause of the fault. The fault may be caused by an alternator belt that is loose or broken. Also, the batteries may be faulty.

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


Maintenance Required (3) - This alert indicator will be on constantly when the machine requires maintenance. The alert indicator can be reset and the maintenance interval can be altered using a laptop computer with Electronic Technician (ET) software.


Fuel Pressure (3) - This alert indicator will flash if the fuel filter is blocked. If this indicator flashes during operation, service the fuel filter that day.


Air Filter Restriction (4) - Indicates the engine air filters are plugged. If this indicator comes on during operation, service the filters that day.



Illustration 15g01772238


Fuel Level Gauge (5) - If the gauge needle enters the red range, this indicates low fuel level (15 percent of the tank capacity). Refuel the tank within the hour in order to avoid running out of fuel.


NOTICE

Running out of fuel can cause engine damage. Do not continue to operate the machine when critically low on fuel.


Warning Category 2

In this category, one of the following conditions will occur:

  • An alert indicator and the action lamp will flash.

  • A gauge will show in the red range and the action lamp will flash.

This warns the operator that a change in machine operation is required in order to reduce excessive temperature in one or more of the systems. Move the machine to a convenient place in order to park the machine and stop the engine. Investigate the cause of the alert indicator or the gauge and report the problem immediately.




Illustration 16g01746313


Engine Coolant Temperature (6) - Indicates excessive engine coolant temperature. If the gauge needle is in the red range, move the machine to a convenient location to park the machine and stop the engine. Investigate the cause of the fault. Do not operate the machine if the gauge needle remains in the red range and the action lamp continues to flash.


Transmission Oil Temperature (7) - Indicates excessive torque converter/transmission oil temperature. If the gauge needle is in the red range, reduce the load on the machine. If the gauge needle is in the red range and the action lamp continues to flash after approximately five minutes, stop the machine and investigate the cause of the fault.


Hydraulic Oil Temperature (8) - Indicates excessive hydraulic oil temperature. If the gauge needle is in the red range, reduce the load on the system. If the gauge needle remains in the red range and the action lamp continues to flash, stop the machine and investigate the cause of the fault.



Illustration 17g01772243


Axle Oil Temperature/Pressure (9) - Indicates excessive front or rear axle oil temperature. It also indicates that the front or rear axle oil pressure is low. If this alert indicator flashes during operation, downshift the transmission to reduce the load on the braking system. If the alert indicator continues to flash, stop the machine. Stop the engine and investigate the cause of the fault.

Warning Category 2-S

The warning category 2-S includes a constant alarm. Warning category 2-S includes all warnings in category 2. The warning category 2-S is a severe condition. The operator should immediately change the operating procedures in order to prevent damage to the machine. When the correct measures have been taken, the alarm will stop. A category 2-S is logged.




Illustration 18g01772244


Parking Brake (10) - Indicates the machine is not in neutral and the parking brake is engaged. The action alarm will continuously sound. If the alert indicator flashes during operation and the alarm continuously sounds, stop the machine immediately. Investigate the cause of the fault.

Warning Category 3

In this category, the alert indicator and the action lamp will flash and the action alarm will sound. This category requires immediate safe shutdown of the machine in order to prevent possible injury to the operator and/or severe damage to the system and the machine.

Do not operate the machine until the cause has been corrected.




Illustration 19g01772245


Engine Oil Pressure (11) - Indicates low engine oil pressure. If this alert indicator flashes, stop the machine immediately and engage the parking brake. Stop the engine and investigate the cause of the fault.


Brake Accumulator Oil Pressure (12) - Indicates low brake accumulator oil pressure. If the brake accumulator oil pressure further decreases, the parking brake will automatically engage. If this alert indicator flashes, stop the machine immediately and engage the parking brake. Stop the engine and investigate the cause of the fault.


Electrical System (13) - Indicates a serious malfunction in the electrical system. If this alert indicator flashes during operation, stop the machine immediately and engage the parking brake. Stop the engine and investigate the cause of the fault.


Engine Coolant Level (14) - Indicates low engine coolant level. If this alert indicator flashes, stop the machine immediately and engage the parking brake. Stop the engine and investigate the cause of the fault.


Transmission Oil Pressure (15) - Indicates that the machine has low transmission oil pressure. If the transmission pressure further decreases the parking brake will automatically engage. If this alert indicator flashes during operation, stop the machine immediately and engage the parking brake. Stop the engine and investigate the cause of the fault.


NOTICE

If the transmission oil pressure indicator comes on, the parking brake may engage. Cease operation, quickly move the machine to a safe area to engage the parking brake and stop the engine. Inspect and repair the cause of the problem before returning the machine to operation.


Gauges




Illustration 20g01772247

Tachometer (1) - The tachometer displays the engine speed during machine operation.


Engine Coolant Temperature (2) - Indicates the temperature of the engine coolant. The normal operating range is the white range. The gauge needle will indicate in the red range if the engine coolant temperature exceeds 106 °C (223 °F).


Transmission Oil Temperature (3) - Indicates the temperature of the torque converter/transmission oil. The normal operating range is the white range. The gauge needle will indicate in the red range if the transmission oil temperature exceeds 129 °C (264 °F).

Speedometer (4) - The speedometer consists of three digits. The speedometer shows the ground speed of the machine in kilometers per hour or miles per hour.

Actual Gear Indicator (5) - The actual gear indicator consists of two digits. The two digits indicate the actual transmission gear that is engaged. The left digit is the actual gear. The right digit shows the direction that was selected.


Hydraulic Oil Temperature (6) - Indicates the temperature of the hydraulic oil. The normal operating range is the white range. The gauge needle will indicate in the red range if the hydraulic oil temperature exceeds 107 °C (225 °F).


Fuel Level (7) - Indicates the amount of fuel remaining in the fuel tank.



Illustration 21g01772248



Illustration 22g00937414

Front brake oil pressure

Front Brake Oil Pressure Gauge (8) (If Equipped) - Shows the hydraulic pressure in the front braking circuit when the service brakes are fully applied. The front brake oil pressure should be 4135 ± 345 kPa (600 ± 50 psi).




Illustration 23g00937415

Rear brake oil pressure

Rear Brake Oil Pressure Gauge (9) (If Equipped) - Shows the hydraulic pressure in the rear braking circuit when the service brakes are fully applied. The rear brake oil pressure should be 4135 ± 345 kPa (600 ± 50 psi).


NOTICE

Loss of brake oil pressure may decrease the brake application force. Also, loss of brake oil pressure may cause the parking brake to engage. If low brake oil pressure is indicated, stop the machine immediately. Inspect the system for the cause of low brake oil pressure. Repair the brake system before returning the machine to operation.





Illustration 24g01772249

Display Window (11) - Indicates various machine system conditions on a six digit display. The display window provides a digital readout that can show total operating hours of the engine (hourmeter), current engine speed (tachometer), total travel distance (odometer), or logged and active diagnostic codes. Also, the gauges in the gauge display may be monitored digitally in the display window.

Press operator mode scroll switch (10) on the right side of the dash panel until the desired information is selected. The proper unit of measurement (°C, kPa, miles, km, rpm, liters, or service code) will be indicated at the top of the display window.

ReferenceFor further information on the operator mode scroll switch and the display windows, refer to the Operation and Maintenance Manual, "Operator Mode Scroll Switch".

Indicators




Illustration 25g01746320


Action Lamp (1) - This indicator flashes to indicate a Warning Category 2 or a Warning Category 3 has been registered by the Caterpillar Monitoring System.


Automatic Lubrication Indicator (2) (Electric Type) (If Equipped) - This indicator will be on when the automatic lubrication system is in operation.


Automatic Lubrication Indicator (2) (Hydraulic Type) (If Equipped) - This indicator will be on when there is a fault in the automatic lubrication system. Report the fault to service personnel when convenient. This indicator will be on for two seconds after the engine starts in order to alert the operator that the indicator is functioning properly. It is important for the operator to visually inspect this indicator. If the indicator does not come on after start-up, or if the indicator glows dimly after start-up, or if the indicator remains on, stop the engine and find the cause.


Exhaust Back Pressure Indicator (3) (If Equipped) - Indicates high exhaust back pressure. If back pressure is over 6 kPa (25 inches H2O), the light will illuminate and the exhaust purifilter must be cleaned.


Primary/Secondary Steering Indicator (4) (If Equipped) - This indicator will be on if there is a steering system failure in either the primary or secondary steering systems.

Note: The secondary steering system only operates while the machine is moving.


NOTICE

If the primary/secondary steering indicator flashes, cease operation, quickly move the machine to a safe area and shut the machine down. Inspect and rectify the cause of the problem before recommencing operation.



Residual Brake Oil Pressure Indicator (5) (If Equipped) - Indicates that there is oil pressure in the service brake section of the wheel brakes. The lamp will illuminate when the service brakes are applied. The lamp should go out when the brakes are released. If this indicator stays on, the brakes are holding residual brake oil pressure. Stop the machine and investigate the cause.


Ride Control Indicator (6) (If Equipped) - Indicates the ride control system is activated.

Light Switches




Illustration 26g01746321


Front Light Switch (1) - Move the switch to the upper position to turn on the front lights and the tail light (if equipped). Move the switch to the lower position to turn off the lights.


Rear Light Switch (2) - Move the switch to the upper position to turn on the rear lights. Move the switch to the lower position to turn off the rear lights.



Illustration 27g00949389


Dome Lamp Switch (3) - Switch (3) for the interior lamp is located on the interior lamp. Push the left half of switch (3) to turn on the interior lamp. Push the right half of switch (3) to turn off the interior lamp. When the door is opened, an automatic switch turns on the interior lamp.

Window Wiper and Washer Control




Illustration 28g00950042



Illustration 29g01772252


Front Window Wiper and Washer Switch (1) - Turn the knob clockwise to turn on the front window wiper. Push the knob to activate the window washer. Spring force will return the knob when released.


Side Window Wiper and Washer Switch (2) - Turn the knob clockwise to turn on the side window wiper. Push the knob to activate the window washer. Spring force will return the knob when released.


Rear Window Wiper and Washer Switch (3) - Turn the knob clockwise to turn on the rear window wiper. Push the knob to activate the window washer. Spring force will return the knob when released.



Wiper Mode Switch (4) - Turn knob (4) to the LEFT position (5) and press switch (7) to turn on the front, side and rear window wipers. Turn knob (4) to the RIGHT position (6) and press switch (7) to turn on the front side and rear window wipers and washers.

Remote Control Switch (If Equipped)




Illustration 30g01746323


Remote Control Switch (If Equipped) - Move the switch to the upper position to activate the remote control system.

ReferenceFor more information about the remote control operating instructions, refer to the Operation and Maintenance Manual, "Remote Control System".

------ WARNING! ------

Personal injury or machine damage can result if the remote control switch is turned on while manually operating the machine. If the remote control switch is turned on during manual operation, the engine will shut down and the brakes will apply.

----------------------

------ WARNING! ------

This machine can cause severe injury or death if operated by untrained personnel.

If you are not trained in accordance with mine practice in the operation of remote control for this machine, DO NOT OPERATE.

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Lift Arm Positioner Switch




Illustration 31g01746324


Lift Arm Positioner Switch - Move the switch to the upper position to activate the lift arm positioner. The lift arm positioner system returns the lift arm to a preset height when the lift arm is lowered.

Ride Control (If Equipped)

Travel at high speeds over rough terrain causes bucket movement and a swinging motion. The ride control system acts as a shock absorber by dampening forces from the bucket. This helps to stabilize the entire machine.




Illustration 32g01746325


Automatic Ride Control - Move switch (1) to the upper position to turn on the automatic ride control system. The ride control system will automatically turn on if the ground speed exceeds 5 km/h (3 mph). The ride control system will automatically turn off if the ground speed is less than 5 km/h (3 mph). Indicator (2) will come on when the ride control system is automatically activated.

OFF - Move switch (1) to the center position to turn off the ride control system.


Service Mode - Push down and hold switch (1) in the lower position to turn on the ride control system. Switch (1) will return to the OFF position when released. The ride control system will be activated when the switch is held down. Indicator (2) will come on when the ride control system is activated. Hold the switch in SERVICE MODE when testing and/or troubleshooting the ride control system.

ReferenceFor further information on the ride control system, refer to the Hydraulic System, Systems Operation, Testing and Adjusting.

Operator Mode Scroll Switch




Illustration 33g01772256


Operator Mode Scroll Switch (1) - Move switch (1) to the upper position to scroll through the operator modes in display window (2) .

Operator Modes




Illustration 34g00942952

Service Meter - In this mode, the six digit display window will show the total number of machine operating hours. It should be used to determine maintenance intervals. Indicator (3) will show that the display window is operating in the service meter mode.

If there is an active fault, SERV CODE is displayed in the upper right hand corner of the display window. If SERV CODE is displayed during normal operation, an existing problem should be addressed.




Illustration 35g00942956

Odometer - In this mode, the display window will show the total distance that has been travelled by the machine. This measurement can be displayed in "MILES" or "KM" depending on the units of measure selected.




Illustration 36g00942957

Digital Tachometer - In this mode, the engine rpm will be displayed in the display window.




Illustration 37g00942958

Diagnostic Scrolling - In this mode, the display window will show the faults that have been detected by the Caterpillar Monitoring System. Faults cannot be cleared in this mode. Also, faults may not be placed on hold. The service code will only be displayed when the fault is active.

Service Ports




Illustration 38g01746327

ET Service Port (1) - This service port allows for the connection of a laptop computer using Electronic Technician (ET) software. This will allow service personnel to diagnose the Electronic Control Module (ECM) for the engine, the ECM for the transmission, or the ECM for the Payload Control System (PCS).

Service Tool Port (2) - This service port allows for the connection of a Caterpillar 4C-8195 Control Service Tool to provide diagnostic access to the Caterpillar Monitoring System, the Electronic Control Module (ECM) for the engine, the ECM for the transmission, or the ECM for the Payload Control System (PCS). This service tool allows the technician to scroll through display modes on the digital display window and clear recorded faults as required.

ReferenceFor further information on using the Electronic Technician and the Control Service Tool, refer to the Systems Operation, Troubleshooting, Testing and Adjusting, "Caterpillar Monitoring System".

Horn




Illustration 39g01772258


Horn - Push the horn button in order to sound the horn. Use the horn button for alerting personnel or for signalling personnel.

Seat

Adjust the seat in order to allow full travel of the pedals. Make the seat adjustments when the operator is sitting against the back of the seat. In order to reduce fatigue, periodically readjust the seat and the backrest for additional comfort.




Illustration 40g01637107


Seat Recline Lever (1) - In order to move the back of the seat to the desired position, pull up seat recline lever (1). Release the lever in order to lock the back of the seat into position.


Lumbar Support Knob (2) - Turn knob (2) counterclockwise in order to increase the lumbar support. Turn the knob clockwise in order to decrease the lumbar support.



Illustration 41g01866288


Cushion Angle Adjustment (3) - Push and hold lever (3) down, move the seat cushion to the desired angle. Release the lever in order to lock the seat cushion into position. The seat cushion can be adjusted to one of four positions.


Fore and Aft Lever (4) - Pull up fore and aft lever (4). Hold the lever upward and slide the seat forward or backward to the desired position. Release the lever in order to lock the seat into position.


Suspension Damping Knob (5) - Turn suspension damping knob (5) in order to change the stiffness of the suspension. Turn suspension damping knob (5) until the weight setting on the dial is the same as the operator's weight. Do not turn the knob past the maximum weight setting or past the minimum weight setting.

Armrest Raise




    Illustration 42g01775853

  1. In order to move the armrest to the RAISED position, pull up armrest lever (1) .

    Note: If the armrest is raised and the machine ground speed is above 3 km/h (2 mph) the monitoring system activates a category 2-S warning. If the armrest is raised and the machine ground speed is below 3 km/h (2 mph) the parking brake will engage, the transmission will select neutral, the implement and steering functions will neutralize.

Braking

Parking Brake

This machine is equipped with spring applied parking brakes. The spring force engages the brakes on all four wheels. Hydraulic pressure is used to disengage the brakes. If the hydraulic pressure is unavailable, the brakes will remain engaged.

If hydraulic pressure is unavailable and the machine must be towed, use the 212-6102 Portable Hydraulic Pump in order to release the parking brake.

ReferenceFor further information on towing an inoperable machine, consult your Caterpillar dealer or refer to Operation and Maintenance Manual, "Towing Information".

------ WARNING! ------

Personal injury could result from the sudden stop of the machine. The parking brake is automatically engaged when brake oil pressure drops below an adequate operating pressure.

If the brake system oil pressure drops below normal operating pressure, the action alarm will sound. The brake oil pressure indicator and the action lamp will start flashing.

If the pressure drops further, the parking brake will engage automatically, the parking brake indicator on the operator's panel will come on and the transmission will shift to neutral.

Be prepared for a sudden stop. Correct the reason for the loss of brake oil pressure. Do not move the machine without normal brake oil pressure.

----------------------



Illustration 43g01746329

Loss of brake oil pressure will cause the action alarm to sound, action lamp (3) and brake accumulator oil pressure indicator (2) to flash. Further loss of oil pressure will cause parking brake indicator (1) to come on and the parking brake will automatically engage to stop the machine.

Also the parking brake will engage when the interlock strategy conditions are not met.

ReferenceFor further information on the interlock strategy conditions, refer to Operation and Maintenance Manual, "Machine Operation Information".

Note: If the machine was started with the parking brake control in the OFF position, reset the control by moving it to the ON position and then to the OFF position before the parking brake will disengage.


NOTICE

The standard parking brake control is a pull-to-engage type. When the knob is pulled OUT, the parking brake will be engaged.

Certain mining regulations require machines to be equipped with a push-to-engage parking brake control. When the knob is pushed IN, the parking brake is engaged.

Before operating the machine, ensure you are familiar with the operation of the parking brake control.


Standard Pull-to-Engage Type Parking Brake Control




Illustration 44g01772262

Use the parking brake control to engage or disengage the parking brake when you park the machine. The parking brake control is a push-pull type switch.



Parking Brake Control - Push parking brake control knob inward to the OFF position in order to disengage the parking brake. Pull the parking brake control knob outward to the ON position in order to engage the parking brake.

Optional Push-to-Engage Type Parking Brake Control




Illustration 45g01746330

Use the parking brake control to engage or disengage the parking brake when you park the machine. The parking brake control is a push-pull type switch.



Parking Brake Control - Pull parking brake control knob outward to the OFF position in order to disengage the parking brake. Push the parking brake control knob inward to the ON position in order to engage the parking brake.

Parking Brake Drive Through

In the case of a hydraulic failure where pressure oil to release the parking brake is not available, a drive through mode is provided. This will allow the machine to be driven through the parking brakes to a safe location.

If a hydraulic or electrical failure occurs, the parking brake may automatically engage. Perform the following procedure to move the machine under these conditions. During this procedure, the monitoring system activates a category 2-S warning.

  1. Make sure the area is clear of personnel and other machines.



    Illustration 46g01744356

  1. Move transmission direction and speed control (1) to the FIRST speed forward or FIRST speed reverse position.

  1. In a rapid motion, move transmission direction control (1) to the NEUTRAL position and then back to FIRST speed forward or FIRST speed reverse position.

  1. Increase the engine speed and the machine will drive through the engaged parking brake.

  1. Steer the machine to a safe location.


NOTICE

Driving the machine through the parking brakes for an extended period can cause severe damage to the braking system.

Inspect the parking brake system and make any necessary repairs before returning the machine to operation.


Service Brake

Note: The function of the service brake pedal is dependant on the position of the transmission neutralizer override switch.




Illustration 47g01634591

Service Brake / Transmission Neutralizer Pedal - With the transmission neutralizer override switch in the ON position, use the brake pedal to disengage the transmission and to slow down the machine's ground speed. This permits higher engine speed for better hydraulic response.


APPLY - Depress the brake pedal when truck loading, positioning or when raising the bucket to increase hydraulic speed and reduce unnecessary torque converter stalling. It can also be used to give additional hydraulic power in difficult or particularly tight digging (mucking) conditions.


RELEASE - Release the pedal to re-engage the transmission and to release the service brake.

Service Brake Pedal - With the transmission neutralizer override switch in the OFF position, the brake pedal slows down the machine ground speed for normal braking.


APPLY - Depress the brake pedal for normal machine braking.


RELEASE - Release the pedal in order to release the brake.

If the service brake pedal does not stop the machine, use the parking brake control to stop the machine. When the machine stops, block the wheels. If necessary, make repairs.

Steering and Transmission Control Lock

------ WARNING! ------

No clearance for person in operator's station access area when machine turns. Severe injury or death from crushing could occur.

Engage transmission/primary steering lock before leaving the operator's station.

----------------------



Illustration 48g01634573

Steering and Transmission Lock Lever - This lock lever is used to lock the transmission shift into neutral and is the primary lockout system used to disable the steering.


Locked - Move the steering and transmission lock lever away from the operator to engage the lock. When the lock lever is moved to the locked position, the steering is disabled and the transmission will shift to neutral.



Illustration 49g01773875


Unlocked - Move the steering and transmission lock lever toward the operator to disengage the lock. When the lock lever is moved to the unlocked position, the transmission will not shift into a speed until the transmission direction control switch is first moved to the NEUTRAL position.

Transmission Control

Direction Selection




Illustration 50g01634568

Machine direction is determined by the position of transmission direction control switch (1) that is located on the steering control lever.


FORWARD (F) - The machine will move in a forward direction.


NEUTRAL (N) - The machine should not move.


REVERSE (R) - The machine will move in a reverse direction.



Illustration 51g00897771

The transmission direction that is currently in use, F (Forward), N (Neutral) or R (Reverse), is displayed on the instrument panel.

Speed Selection




Illustration 52g01634571

Machine gear speed is selected by pushing transmission upshift switch (1) or transmission downshift switch (2). The switches are located on the steering control lever.


Transmission Upshift Switch (1) - Push the transmission upshift switch in order to shift the transmission into the next highest gear speed.


Transmission Downshift Switch (2) - Push the transmission downshift switch in order to shift the transmission into the next lowest gear speed.



Illustration 53g00897762

The transmission has four speeds. The transmission gear speed that is currently in use is displayed on the instrument panel.

1 - First Speed

2 - Second Speed

3 - Third Speed

4 - Fourth Speed (If Equipped)

Note: When the parking brake is engaged, the transmission cannot be shifted into the first gear speed (unless the parking brake drive through feature is activated). For further information on the Parking Brake Drive Through feature, refer to the Operation and Maintenance Manual, "Braking".

Note: The transmission can shift automatically or the transmission can shift manually. Refer to the Operation and Maintenance Manual, "Autoshift Control".

Autoshift Control (STIC Steering)




Illustration 54g01746333



Illustration 55g01744357


Manual Mode (2) - To select the gear speed, turn transmission autoshift switch (1) to manual position (2) .

Pressing transmission upshift switch (3) will cause the transmission to shift into the next highest gear.

Pressing transmission downshift switch (4) will cause the transmission to shift into the next lowest gear.


Automatic Mode - The operator selects the highest desired operating speed from the options on transmission autoshift switch (1). The electronic transmission control selects the proper transmission gear according to the ground speed of the machine.

Downshift switch (4) is active in all gears. Down shift switch (4) can cause transmission downshifts at machine speeds that are higher than normal.

Pressing and releasing downshift switch (4) will cause a downshift of one gear. The downshift will only occur if the machine speed and the engine speed will not result in an engine overspeed condition.

Pressing and holding downshift switch (4) will cause the transmission to continue to downshift as the machine speed decreases.

The transmission will remain in the downshifted gear for three seconds after the downshift switch is released. Then, automatic shifting is resumed.

Turn autoshift switch (1) to a selected gear speed in order to activate the autoshift function. The transmission will shift from first gear through to the selected gear automatically. The highest gear that will be used is determined by the selection on the switch.

As the machine slows, the transmission will automatically downshift.

Throttle Control




Illustration 56g01744359

Throttle Pedal - The throttle pedal is located on the floor of the operator station.


Depressing the Throttle Control - Depress the throttle pedal in order to increase the engine speed.


Releasing the Throttle Control - Release the throttle pedal in order to decrease the engine speed.

Steering Control

Remove the steering frame lock and store in the unlocked position. The steering frame lock must be removed to steer the machine.

ReferenceFor information on removing the steering frame lock, refer to Disassembly and Assembly, "Steering Frame Lock - Remove and Install".

Note: The machines steering control functions will be disabled when the parking brake is engaged and the engine speed is less than 1500 rpm, the armrest is raised or the door is opened.

The directional steering of the machine is controlled by the STIC steering control lever.

When the STIC steering control lever is moved to the right of center, the machine steers to the right. When the STIC steering control lever is moved to the left of center, the machine steers to the left.

Note: When the STIC steering control lever is released, the lever will return to the center position. However, the machine will maintain the direction in which it was moving.

The STIC steering control lever must be moved past center in the opposite direction to which the machine was turning to return to straight ahead travel.




Illustration 57g01634583


Left Turn (1) - Move the STIC steering control lever to the left of center in order to steer the machine to the left. The further the steering control lever is moved, the faster the machine steers to the left.


Right Turn (2) - Move the STIC steering control lever to the right of center in order to steer the machine to the right. The further the steering control lever is moved, the faster the machine steers to the right.

Joystick Control

Note: The machine's joystick control functions will be disabled when the parking brake is engaged and the engine speed is less than 1500 rpm, the armrest is raised or the door is opened.

Note: The joystick control lever is a pull-back-to-raise, push-forward-to-lower type.




Illustration 58g01634585

The joystick control lever performs the functions as listed below.


FLOAT (1) - Push and hold the lever all the way forward for the FLOAT position. The bucket will lower to the ground and move up and down following the ground contour. The lever will return to the HOLD position when released.


NOTICE

Never use the FLOAT position to lower a loaded bucket.

Machine damage can result from a bucket that falls too fast.



LOWER (2) - Push the lever forward to lower the bucket. The lever will return to the HOLD position when released.


RAISE (3) - Pull the lever back to raise the bucket. The lever will return to the HOLD position when released.


DUMP (4) - Push the lever across to the right to dump the bucket. The lever will return to the HOLD position when released.


TILT BACK (5) - Pull the lever across to the left to tilt the bucket back. The lever will return to the HOLD position when released.


HOLD (6) - The lever will return to the HOLD position automatically when released. The bucket will remain in the selected position when in the HOLD position.

Seat Swivel Controls




Illustration 59g02058113


Manual Swivel Switch - Press and release the manual swivel switch to change seat position from forward to reverse or from reverse to forward. Machine speed must be less than 10 km/h (6 mph).



Illustration 60g01624611

Mode Selection Switch (1) - Move mode selection switch (1) to MANUAL position (2), OFF position (3) or AUTO position (4).


MANUAL Position (2) - With mode selection switch (1) in MANUAL position (2), the seat will not respond to operator gear selection. The seat will only respond to the manual swivel switch.


OFF Position (3) - With mode selection switch (1) in OFF position (3), the seat remains in the current position until the manual swivel switch is pressed. When the manual swivel switch is pressed and released within 5 seconds of mode selection switch (1) being moved to the OFF position, the seat will swivel to the center position. The seat will no longer swivel regardless of machine operation or pressing the manual swivel switch.


AUTO Position (4) - With the parking brake released and mode selection switch (1) in AUTO position (4), the seat will swivel according to the operator selecting FORWARD or REVERSE. If NEUTRAL is selected the current seat position is held.



Illustration 61g01624610

Speed Selection Switch (1) - Move speed selection switch (1) to SLOW position (2), MEDIUM position (3) or HIGH position (4). Each speed selection has a separate acceleration, deceleration and maximum speed setting.


SLOW Position (2) - Move speed selection switch (1) to SLOW position (2) in order to select the slowest speed the seat will swivel.


MEDIUM Position (3) - Move speed selection switch (1) to MEDIUM position (3) in order to select the next highest speed the seat will swivel.


HIGH Position (4) - Move speed selection switch (1) to HIGH position (4) in order to select the highest speed the seat will swivel.

Transmission Neutralizer Override Control




Illustration 62g01624613

Transmission Neutralizer Override Switch (1) - Move transmission neutralizer override switch (1) down to ON position (2) in order to select the transmission neutralizer function. Move transmission neutralizer override switch (1) up to OFF position (3) in order to deselect the transmission neutralizer function.


ON Position (2) - When transmission neutralizer override switch (1) is moved down to ON position (2), the transmission will neutralize when the brake pedal is pressed and ground speed is less than 5 km/h (3 mph).


OFF Position (3) - When transmission neutralizer override switch (1) is moved up to OFF position (3), the transmission will not neutralize when brake pedal is pressed at any ground speed.

Before Starting Engine

Caterpillar Monitoring System - Self Test




Illustration 63g01772277

Caterpillar Monitoring System

(1) Gauge cluster

(2) Tachometer

(3) Digital speedometer

(4) Actual gear indicator




Illustration 64g01772278

Caterpillar Monitoring System

(5) Action lamp

(6) Alert indicators

(7) Digital display window

In order to check the operation of the Caterpillar Monitoring System, observe the self test when the engine start switch is turned from the OFF position to the ON position.

Note: The battery disconnect switch must be in the ON position in order to supply the operator station with electrical power for the self test.

The Caterpillar Monitoring System will perform an automatic self test at start-up whenever the engine start switch is turned to the ON position. First the Caterpillar Monitoring System calibrates gauge cluster (1) and tachometer (2). Before the beginning of the system test, gauge cluster (1) and tachometer (2) go from the initial value to zero. Then, the Caterpillar Monitoring System performs a test.

Alert indicators (6) flash for approximately three seconds in order to permit the operator to know that the indicators are functioning properly. Certain diagnostics are not possible with the use of LED lamps, so it is important for the operator to visually inspect alert indicators (6) during starting. If an alert indicator does not flash, find the cause immediately. Also, if an alert indicator remains ON after three seconds, find the cause immediately.

Digital display window (7) will show the following readouts for approximately three seconds:

  • All indicators of units (Deg C, kPa, miles, kilometers, rpm and liters).

  • "X 10".

  • Symbol for the service hour meter.

  • "888.8.8.8" in the six digit display area.

The self test will also activate the gauge panel to show the following:

  • The gauges in gauge cluster (1) and tachometer (2) will be calibrated. The gauges will sweep to half scale and the gauges will return to zero. Then, the gauges will sweep to full scale and the gauges will return to operating values.

  • Digital speedometer (3) activates every segment of the display. This will produce the following readout: "188", "MPH", and "km/h".

  • Actual gear indicator (4) for the transmission activates every segment of the readout. You will see a "0" with an "X", and a "+" sign on top of the "0". There should be two of these symbols.

  • Action lamp (5) illuminates.

  • The action alarm will sound once.

If any of the alert indicators, action lamp, or digital readouts do not appear, or if the gauges do not sweep, the electrical system must be inspected. Perform all necessary repairs before the engine is started again.

If all the alert indicators and the action lamp come on, start the engine.

After you start the engine, observe the gauge panel and the monitoring panel. If any alert indicators or the action lamp remain on, or if the action alarm sounds, stop the engine. Inspect the electrical system and any other machine systems which were indicated. Perform all necessary repairs before the engine is started again.

Engine Starting

Starting the Engine

------ WARNING! ------

Diesel engine exhaust contains products of combustion which may cause personal injury.

Always start and operate the engine in a well ventilated area, and, if in an enclosed area, vent the exhaust to the outside.

----------------------

  1. Make sure that no personnel are on the machine, underneath the machine or around the machine. Make sure that there are no personnel in the area.

  1. Close the operator station door.



    Illustration 65g01772279

  1. Move armrest (1) to the LOWERED position.

  1. Adjust the operator's seat.

  1. Fasten the seat belt.

    Note: Before you start the engine, wait for the self test of the Caterpillar Monitoring System. The self test will activate when the engine start switch is turned to the ON position.

    Reference Refer to the Operation and Maintenance Manual, "Caterpillar Monitoring System - Self Test" in this section for further information.




    Illustration 66g02056713

  1. Move transmission direction control switch (2) to the NEUTRAL position. Move steering and transmission lock lever (3) to the LOCKED position.



    Illustration 67g01744360

  1. Move joystick control lever (4) to the HOLD position.



    Illustration 68g01746354

  1. Move parking brake control (5) to the ON position to engage the parking brake.

  1. Sound the horn.

  1. Turn engine start switch key (6) to the START position.

  1. Release the engine start switch key when the engine starts.



    Illustration 69g01777514

  1. Turn mode selection switch (7) to OFF position (8) .

    ------ WARNING! ------

    Reduced clearance for hands and feet when operator seat swivels during operation. Serious injury from crushing may occur. Ensure seat belt is worn at all times. Keep hands on controls and feet on pedals while operating the machine. Read the operators manual for additional procedures on the seat operation.

    ----------------------



    Illustration 70g01777516

  1. Press and release manual swivel switch (9) within 5 seconds of turning mode selection switch (7) to OFF position (8). The seat will move to the center position.


NOTICE

Do not crank the engine continuously for more than 30 seconds. Allow the starting motor to cool for two minutes before cranking the engine again.


Note: For starting below −18 °C (0 °F), use of additional cold weather starting aids is recommended. A coolant heater, a fuel heater or some extra battery capacity may be required. At temperatures below −23 °C (−10 °F), consult your Caterpillar dealer or refer to the Operation and Maintenance Manual, SEBU5898, "Cold Weather Recommendations".

Engine and Machine Warm-Up




Illustration 71g01746358


NOTICE

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


  1. Allow a cold engine to warm up at low idle for at least five minutes. To help the hydraulic components to warm up faster, engage and disengage the hydraulic controls to help speed warm up of the hydraulic oil and components.

    The hydraulic oil will warm up faster if the joystick control is held in the full TILT BACK position for short periods of ten seconds or less. This will allow the hydraulic oil to reach relief pressure, which causes the hydraulic oil to warm more rapidly.

    Cycle all hydraulic controls in order to allow warm hydraulic oil to circulate through all hydraulic cylinders and through all hydraulic lines.

  1. Look at the alert indicators and the gauges frequently during operation.

    When you idle the engine in order to warm up the engine, observe the following recommendations:

    • Allow the engine to warm up for approximately 15 minutes when the temperature is higher than 0 °C (32 °F).

    • Allow the engine to warm up for approximately 30 minutes or more when the temperature is below 0 °C (32 °F).

    • More time may be required if the temperature is less than −18 °C (0 °F). More time may also be required if the hydraulic functions are sluggish.

Preparing to Operate the Machine

  1. Do not attempt to move the machine without normal brake oil pressure.

  1. In order to prevent injury, make sure that no one is working on the machine or near the machine. Keep the machine under control at all times in order to prevent injury.

  1. Know the maximum height of the machine. Know the maximum width of the machine. Maintain proper clearance.

  1. With the engine at low idle and with the oil at normal operating temperature, check the oil level of the transmission.

    ReferenceRefer to the Operation and Maintenance Manual, "Transmission Oil Level - Check" for the machine being serviced.

  1. Before the machine operates at a high speed, check the operation of the braking system and of the steering system. These systems should be checked while the machine maintains a low speed.

Note: Every 10 service hours or daily, test the operation of the braking system. For the correct procedure, refer to the Operation and Maintenance Manual, "Braking System - Test".

Note: Every 10 service hours or daily, test the operation of the steering lockout system. For the correct procedure, refer to the Operation and Maintenance Manual, "Steering Lockout (STIC Steering) - Test".

ReferenceFor further operating information, refer to the Operation and Maintenance Manual, "Operating Technique Information, Loading, Hauling and Dumping, and Bucket Loading Hauling Units".

Machine Operation Information

Follow these basic instructions whenever you are operating the machine:

  • To prevent injury, make sure that no one is working on the machine or near the machine. Always maintain control of the machine.

  • Raise the bucket or the work tool enough to negotiate any obstacles.

  • Before you disengage the parking brake, depress the service brake pedal in order to keep the machine from moving.

  • Reduce the engine speed when you maneuver in tight quarters and when you are going over a hill.

  • When you drive downhill, use the same gear range that is used for driving uphill. Do not change gears while you travel downhill.

  • Do not allow the engine to overspeed while you travel downhill. Apply the service brake in order to reduce the engine speed.




    Illustration 72g01746359

  1. Frequently observe messages, warnings, alert indicators and gauges (1). All gauges should be at normal operating range. The alert indicators, the action lamp and the action alarm should be off.

  1. Adjust the operator's seat.

  1. Fasten the seat belt.

  1. Raise the bucket approximately 400 mm (15 inch) above the ground.



    Illustration 73g01744363

  1. Depress service brake pedal (3) .

  1. Move parking brake control (2) to the OFF position to disengage the parking brake.



    Illustration 74g01751793

  1. Move steering and transmission lock lever (7) to the UNLOCKED position. Move transmission direction control switch (6) to the desired travel direction. Push transmission upshift switch (5) to select the desired speed.

  1. Release service brake pedal (3) .

  1. Depress throttle pedal (4) to the desired engine and machine speed.

Interlock Strategy

When operating the machine with the parking brake released you must perform one of the following actions within three seconds or the parking brake will engage, the transmission will select neutral, the implement and steering functions will neutralize and the engine will stop.

  • Apply the service brake

  • Maintain engine speed above 850 rpm

  • Maintain ground speed above 5 km/h (3.1 mph)

When the machine is stopped you must perform one of the following actions within three seconds or the parking brake will engage, the transmission will select neutral, the implement and steering functions will neutralize and the engine will stop.

  • Apply the service brake

  • Maintain engine speed above 850 rpm

  • Engage the parking brake

Note: The interlock function engine stop can be configured using Caterpillar Electronic Technician (ET) service tool. The engine will stop when ENABLED. The engine will not stop when DISABLED.

Also, to operate the steering and implement functions with the parking brake engaged you must perform the following action.

  • Maintain engine speed above 1500 rpm.

Downhill Operation

Maintain a ground speed that is slow enough for the conditions. Before you operate the machine down a hill, select the proper gear before you start down the grade. The proper gear should allow the machine to maintain the appropriate speed on the down grade. The throttle control should be at high idle and the engine should not overspeed. In most situations, the proper gear will be the same gear that is required to drive up the grade.

If the machine builds up excessive speed, the engine can overspeed. This can result in damage to the engine. Use the service brake in order to slow the machine until a lower gear can be selected. Select the lower gear and proceed with the throttle control at high idle.

Use the service brakes for stopping the machine. Using the service brakes in order to control the travel speed of the machine or using the service brakes for stopping from high speeds can cause the axle oil to overheat. This will result in significant wear and/or damage to the service brakes and the axle components.

Parking Brake

------ WARNING! ------

Personal injury could result from the sudden stop of the machine. The parking brake is automatically engaged when brake oil pressure drops below an adequate operating pressure.

----------------------



Illustration 75g01746361

If the braking system loses oil pressure, the alert indicator for the brakes and the action lamp will flash, and the action alarm will sound. The alert indicator for the brakes is on the dash panel. Loss of oil pressure will cause the parking brake to automatically engage. This will stop the machine.

Anticipate a sudden stop. Correct the cause of the loss of oil pressure. Do not operate the machine without normal brake oil pressure.


NOTICE

Moving the machine with the parking brake engaged or the service brake pedal locked can cause excessive wear or damage to the brake. If necessary, have the brake repaired before operating the machine.


Secondary Steering (If Equipped)




Illustration 76g01746362

The activation of the primary/secondary steering indicator indicates a failure of the primary or secondary steering system. If this indicator comes on during operation, steer the machine to a convenient location and immediately stop the machine. Stop the engine and investigate the cause of the problem.

Note: The secondary steering system only works while the machine is in motion.

Complete any necessary repairs before you return the machine to operation.

Loading, Hauling and Dumping




    Illustration 77g01740154

    Typical example

  1. Position the bucket parallel to the ground. The bucket should barely skim the ground. Drive the bucket straight into the pile.



    Illustration 78g02060153

  1. Move the joystick control lever to the RAISE position as forward movement slows. Return to the HOLD position for additional tilt back power.



    Illustration 79g01740179

    Typical example

  1. To fill the bucket, work the joystick control lever back and forth from the TILT BACK to the HOLD position while continuing to use RAISE as required to reduce wheel slip.



    Illustration 80g02060273

  1. When the bucket is loaded, move the joystick control lever to the TILT BACK position.



    Illustration 81g01740134

    Typical example

  1. Raise the bucket high enough to clear the material being loaded. Tilt the bucket back until the bucket contacts the stops. Always carry the load with the bucket in the fully tilted back position to avoid material spillage and minimize loader linkage wear.

  1. Move the transmission direction and speed control to the REVERSE position. Carry the loaded bucket approximately 400 mm (15 inch) above the ground level.



    Illustration 82g02060274

  1. When reaching the dump area, move the joystick control lever to the RAISE position.



    Illustration 83g02060293

  1. When at the correct height, move the joystick control lever to the DUMP position.

  1. To control dumping, move the joystick control lever to the DUMP position. Then, return the lever to the HOLD position. Repeat this procedure until the bucket is empty.



    Illustration 84g01740193

    Typical example

  1. To achieve the maximum angle for dumping, use the stops for the bucket.


NOTICE

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


Bucket Loading Hauling Units

  1. To reduce the loader turning and the travel distance, position the hauling unit at an angle to the material that is being loaded (if possible).

  1. The optimum travel distance should be long enough so that the bucket can reach the lift height without slowing the movement of the loader. This may vary due to specific underground loading areas.



    Illustration 85g01741874

    Typical example

  1. Position the loader in order to dump the load in the center of the hauling unit body. If the hauling unit body is two bucket widths or more in length, load the material into the hauling unit body from the front to the rear.



    Illustration 86g02060293

  1. Move the joystick control lever to the DUMP position in order to dump the load from the bucket.



    Illustration 87g01741915

    Typical example

  1. Shake the bucket in order to loosen sticky material. Move the joystick control lever quickly from the TILT BACK to the DUMP position, allowing the lift arm to strike the stops.


    NOTICE

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





    Illustration 88g02060273

  1. Move the joystick control lever to the TILT BACK position.

  1. Before lowering the bucket, make sure that the hauling unit is out from under the bucket.

  1. Lower the bucket while positioning the loader for the next load.

Stopping the Machine

------ WARNING! ------

Personal injury or death can result from not engaging the parking brake.

If the parking brake is not engaged, the machine may roll while personnel are on or near the machine.

Always engage the parking brake before leaving the machine.

----------------------

------ WARNING! ------

No clearance for person in operator's station access area when machine turns. Severe injury or death from crushing could occur.

Engage transmission/primary steering lock before leaving the operator's station.

----------------------

------ WARNING! ------

Reduced clearance for hands and feet when operator seat swivels during operation. Serious injury from crushing may occur. Ensure seat belt is worn at all times. Keep hands on controls and feet on pedals while operating the machine. Read the operators manual for additional procedures on the seat operation.

----------------------


NOTICE

Do not engage the parking brake while the machine is moving unless the service brakes fail. The use of the parking brake as a service brake in regular operation will cause severe damage to the parking brake.


  1. Park the machine on a level surface. If it is necessary to park on a grade, block the wheels.



    Illustration 89g02060314

  1. Release throttle pedal (2). Depress service brake pedal (1) in order to stop the machine.



    Illustration 90g01749622

  1. Move transmission direction control switch (3) to the FORWARD position in order to move the seat counterclockwise to the FORWARD position. When the seat is in the FORWARD position move transmission direction control switch (3) to the NEUTRAL position. Move steering and transmission lock lever (4) to the LOCKED position.



    Illustration 91g01746367

  1. Move parking brake control (5) to the ON position in order to engage the parking brake.

  1. Lower the bucket to the ground and apply a slight downward pressure.



    Illustration 92g01775833

  1. Move armrest (6) to the RAISED position.

Stopping the Engine

  1. Park the machine on level ground. For the recommended procedure, refer to the Operation and Maintenance Manual, "Stopping the Machine".


    NOTICE

    Stopping the engine immediately after it has been working under load can result in overheating and accelerated wear of the engine components.

    If the engine has been operating at high rpm and/or high loads, run at low idle for at least three minutes to reduce and stabilize internal engine temperature before stopping the engine.

    Avoiding hot engine shutdowns will maximize turbocharger shaft and bearing life.


  1. In order to allow the engine to gradually cool, operate the engine at low idle for three minutes.



    Illustration 93g01746368

  1. Turn engine start switch key (1) to the OFF position in order to stop the engine.


    NOTICE

    Never turn the battery disconnect switch key to OFF with the engine running. Electrical system damage could result.


  1. If the machine is parked, block the wheels.

Before Operation (Remote Control)

------ WARNING! ------

A safe operating distance in accordance with mine practice must be maintained between the machine and the operator and transmitter.

Operating the machine within an unsafe distance can be dangerous and could result in severe injury or death.

----------------------

Before using the machine on remote control do a walk around inspection. Check levels of oil and water and check for leaks and damage.

Operate the machine manually to ensure that all controls operate normally and the brakes operate effectively.

Always ensure no personnel are near the machine or in the area where the machine will be operating while it is on remote control.

Under no circumstances should any service work or testing and adjusting be carried out on the machine while the machine is operating on remote control.

  1. Park the machine in a convenient and safe location to start remote control operation.

  1. Shift the transmission direction and speed control to the NEUTRAL position. Move the steering and transmission lock control to the locked position.


    NOTICE

    The transmission direction and speed control must be in the NEUTRAL position.

    Failure to put the transmission direction and speed control in the Neutral position may result in the start function being disabled.


  1. Engage the parking brake.

  1. Lower the bucket and move the hydraulic controls to the HOLD position.

  1. Stop the engine.



    Illustration 94g01746369

  1. Turn the engine start switch to the ON position.



    Illustration 95g01746370



    Illustration 96g00946499

  1. Move remote control switch (3) to the upper position to turn on the remote control system. Green light (4) (if equipped) on the operator station will light up and stay on while the remote control system is activated. Amber light (5) will light up and stay on until the brakes are released by the remote control system.

  1. Move front light switch (1) and rear light switch (2) to the lower position to turn the front and rear lights off. Ensure the machine does not move. Leave the machine.



    Illustration 97g00901748

  1. Position the remote control transmitter in a safe location, away from where the machine will be operating on remote control.

  1. Connect a 12 volt battery or other 12V DC power source to the transmitter. Push parking brake switch (8) up to the ON position (parking brake engaged).

  1. Turn clockwise and pull up on remote shutdown switch (6) to turn on the transmitter. LED indicator (7) will light up when the transmitter is turned on. The machine is now ready for remote control operation.

Parking (Remote Control)




Illustration 98g00901851

  1. Release motion control lever (1) or move motion control lever (1) to the center position. When the motion control lever is in the center position, the brakes will apply. The amber light on the operator station should illuminate.

  1. Engage the parking brake by pushing park brake switch (4) up to the ON position.

  1. If the bucket is empty, lower the bucket to the ground.

  1. If the bucket is loaded, fully tilt the bucket back and lower it to the carry position, approximately 400 mm (15 inch) above the ground.


    NOTICE

    Stopping the engine immediately after it has been working under load can result in overheating and accelerated wear of the engine components.

    If the engine has been operating at high rpm and/or high loads, run at low idle for at least three minutes to reduce and stabilize internal engine temperature before stopping the engine.

    Avoiding hot engine shutdowns will maximize turbocharger shaft and bearing life.


  1. Push up engine stop switch (3) until the engine shuts down.

  1. Push down remote shutdown switch (2) to turn off the transmitter. The machine can now be mounted.



    Illustration 99g01746372

  1. Push down remote control switch (5) to turn off the remote control system. The machine can now be operated manually.


NOTICE

If the machine is not going to be operated by remote control for an extended period of time, remove the receiver from the machine and store it in a dry, secure place. This will prevent accidental damage to the receiver.


Parking Brake Manual Release

------ WARNING! ------

Personal injury or death can result from a brake malfunction. Do not operate the machine if the brake was applied due to a malfunction of the oil system or the brake.

Correct any problem before attempting to operate the machine.

----------------------


NOTICE

Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.

Refer to Special Publication, NENG2500, "Caterpillar Dealer Service Tool Catalog" for tools and supplies suitable to collect and contain fluids on Caterpillar products.

Dispose of all fluids according to local regulations and mandates.





    Illustration 100g00943687

    212-6102 Portable Hydraulic Pump

  1. Connect plug (1) of the 212-6102 Portable Hydraulic Pump to the machine's 24 volt DC power supply.

    Note: The machine batteries must be fully charged for the operation of the portable hydraulic pump. If battery charge is low, connect to an external 24 volt DC power supply.

  1. Turn the battery disconnect switch to the ON position.

  1. Turn the engine start switch to the ON position.

  1. Depress the service brake pedal at least 80 times to release the oil pressure from the brake hydraulic system.

  1. Move the joystick control lever several times through the full range of travel to release any pressure in the implement pilot circuits.

  1. Move the STIC steering control several times in both directions to release any pressure in the steering hydraulic system.

  1. Press and hold the breaker relief valve to release any pressure in the hydraulic tank.



    Illustration 101g00943686



    Illustration 102g00943685

  1. Remove the caps from quick connect couplers (2) and (3). Connect the hydraulic hoses from the portable hydraulic pump to quick connect couplers (2) and (3) .

  1. Connect a 4C-8195 Control Service Tool and a 257-8717 Cable Adapter to the service tool port.

    ReferenceFor information on using the 4C-8195 Control Service Tool , refer to the Service Manual, "Caterpillar Monitoring System".




    Illustration 103g01749376

  1. Use the control service tool to access Mode 6.0 (Transmission Pressure Override) on the Caterpillar Monitoring System display window (7). The default display window reading is "PO-OFF".

  1. Operate the clear switch on the control service tool to change the display window reading to "PO-ON".

    Note: Leave the Caterpillar Monitoring System in Mode 6.0 until the procedure has been completed. Changing to another mode will cause the Caterpillar Monitoring System to revert to the default setting and the parking brake will not disengage.




    Illustration 104g00943691

  1. Position switch (8) (from the portable hydraulic pump) inside the operator station.

  1. Press and hold switch (8) in the ON position to activate the portable hydraulic pump. Brake accumulator oil pressure indicator (5) will go out when the braking system has full oil pressure.

    Note: Operation of the switch should only take place from inside the operator station. Observe brake indicators and gauges (if equipped) while operating the portable hydraulic pump.

  1. When the braking system has full oil pressure, move parking brake control (6) to the OFF position to disengage the parking brake. Hold switch (8) in the ON position until parking brake indicator (4) on the Caterpillar Monitoring System panel goes out. The parking brake is now disengaged.

    Note: The service brakes can be used to stop the machine when the machine has brake oil pressure. Use the service brakes to control the machine when the machine is being towed.

    Note: Using the service brakes will cause the braking system oil pressure to decrease. If brake accumulator oil pressure indicator (5) comes on, operate the portable hydraulic pump to increase the braking system pressure. Ensure that the braking system pressure is maintained for the duration of the towing.


    NOTICE

    Operating the portable hydraulic pump for extended periods of time may cause overheating and possible damage of the electric motor. If overheating is observed, stop operating the portable hydraulic pump and allow it time to cool before towing is continued.


    Note: For the removal of the portable hydraulic pump from the machine, refer to Step 15 through Step 17.

    Note: Turning the engine start switch to the OFF position will change the Caterpillar Monitoring System Mode 6.0 to the default setting.

  1. Repeat Step 3 through Step 7.

  1. Disconnect and remove the portable hydraulic pump from the machine.

  1. Install the caps on the quick connect couplers.

Machine Recovery if an Electrical Malfunction Occurs (Mode 8.0)

In the event an electrical malfunction occurs with either the door proximity switch or the armrest switch the machine will be disabled. In order to move the machine, perform the following procedure:




    Illustration 105g02036033

  1. Use key start switch (1) to start the engine.

  1. Connect a 4C-8195 Control Service Tool and a 257-8717 Service Tool Adapter to the service tool port.

    ReferenceFor information on using the 4C-8195 Control Service Tool , refer to the Service Manual, "Caterpillar Monitoring System" .

  1. Use the control service tool to access Mode 8.0 (Switch Override) on the Caterpillar Monitoring System display window (3). The default display window reading is "SO-OFF".

  1. Operate the clear switch on the control service tool to change the display window reading to "SO-ON".

    Note: Leave the Caterpillar Monitoring System in Mode 8.0 until the procedure has been completed. Changing to another mode will cause the Caterpillar Monitoring System to revert to the default setting and the parking brake will not disengage.

  1. Move parking brake control (2) to the OFF position to disengage the parking brake.

  1. Move the machine to a safe location and carry out any necessary repairs.

    Note: The machine will be restricted to first gear.

  1. Stop the engine.

  1. Lower the work tool to the ground.

  1. To change the Caterpillar Monitoring System Mode 8.0 to the default setting, disconnect the 4C-8195 Control Service Tool from the service tool port.

Lift Arm Positioner

------ WARNING! ------

Use caution to avoid possible personal injury when adjusting the lift arm positioner.

Install the bucket control group safety pins and stop the engine prior to making any adjustments.

Engage the parking brake and block the wheels to prevent sudden movement of the machine.

Keep unauthorized personnel off the machine.

----------------------



Illustration 106g01749401

  1. Move lift arm positioner switch (1) to the ON position.

  1. With the engine running, move joystick control lever (2) to the TILT BACK position until the bucket is fully tilted back.

  1. Raise the lift arm to the full height. Move the joystick control lever to the FLOAT position to lower the lift arm. The lift arm positioner should bring the lift arm to a controlled stop at the correct height for digging.



    Illustration 107g00902134

    Typical example

  1. Illustration 107 shows the correct setup height. Dimension (A) should be 300 ± 25 mm (11.8 ± 1 inch).



    Illustration 108g00945404

  1. If Dimension (A) is greater than 325 mm (12.8 inch), adjust magnetic switch (3) downwards. If Dimension (A) is less than 275 mm (10.8 inch), adjust magnetic switch (3) upwards.

  1. To adjust magnetic switch (3), loosen two bolts (4) that fasten the switch to the frame and move the switch to the desired position. Tighten bolts (4) .

  1. Repeat Steps 3 through 6 until Dimension (A) is correct.



    Illustration 109g00945866

    Typical example

  1. To check the final setup height, repeat Step 3. Tilt the bucket forward until the cutting edge of the bucket touches the ground. The bucket should be in the digging position, as shown in Illustration 109. A final adjustment may be necessary to obtain the correct digging position.

  1. Finally, tighten bolt (4) to a torque of 47 ± 9 N·m (35 ± 7 lb ft).

Maintenance Section

Maintenance Interval Schedule

Ensure that all safety information, warnings and instructions are read and understood before any operation or any maintenance procedures are performed.

The user is responsible for the performance of maintenance, including all adjustments, the use of proper lubricants, fluids, filters, and the replacement of components due to normal wear and aging. Failure to adhere to proper maintenance intervals and procedures may result in diminished performance of the product and/or accelerated wear of components.

Use mileage, fuel consumption, service hours, or calendar time, WHICH EVER OCCURS FIRST, in order to determine the maintenance intervals. Products that operate in severe operating conditions may require more frequent maintenance.

Note: Before each consecutive interval is performed, all maintenance from the previous interval must be performed.

Every 250 Service Hours or Monthly

Swivel Seat Bearing - Lubricate

Swivel Gear - Lubricate

Swivel Seat Hosing - Inspect

Every 500 Service Hours or 3 Months

Seat Brake - Inspect

Swivel Seat Bearing - Lubricate




Illustration 110g01637108

  1. Install the steering frame lock. Refer to Disassembly and Assembly, RENR8556, "Steering Frame Lock - Remove and Install".

  1. Wipe off the fitting before any lubricant is applied.

  1. The fitting for the swivel bearing is located behind the seat.

  1. Apply lubricant through fitting (1) for the swivel bearing.

Swivel Gear - Lubricate




    Illustration 111g01775854

  1. Install the steering frame lock. Refer to Disassembly and Assembly, RENR8556, "Steering Frame Lock - Remove and Install".

  1. Remove cover (1) .



    Illustration 112g01871375

    View from below the operator station

  1. With the swivel seat in the centre position, apply lubricant to the ring gear. Refer to Illustration 112.

Swivel Seat Hosing - Inspect




    Illustration 113g01775854



    Illustration 114g01777523

  1. Install the steering frame lock. Refer to Disassembly and Assembly, RENR8556, "Steering Frame Lock - Remove and Install".

  1. Remove cover (1) and cover (2) .

  1. Remove cover (1) and cover (2) .



    Illustration 115g01775855

    View from below the operator station




    Illustration 116g01777377

    View from below the operator station




    Illustration 117g01777524

    View from inside operator station




    Illustration 118g01777526

    View from behind the operators seat

  1. Inspect each hose indicated in Illustrations 115, 116, 117, 118 for the following conditions: leaks, wear and damage.

  1. Correct any leaks. Replace any worn or damaged hoses.

Seat Brake - Inspect

Table 4
Required Tools    
Tool     Part Number     Part Description     Qty    
A     338-6750     Harness     1    

------ WARNING! ------

Personal injury or death can result if two persons are not used in the following procedure.

----------------------

------ WARNING! ------

Reduced clearance for hands and feet when operator seat swivels during operation. Serious injury from crushing may occur. Ensure seat belt is worn at all times. Keep hands on controls and feet on pedals while operating the machine. Read the operators manual for additional procedures on the seat operation.

----------------------

  1. Install the steering frame lock. Refer to Disassembly and Assembly, RENR8556, "Steering Frame Lock - Remove and Install".



    Illustration 119g01775754

    The seat brake is located behind the operators seat.

  1. Measure the thickness of the brake pads. If the thickness of either of the two brake pads is less than 4.00 mm (0.16 inch), replace the brake pads.

    ReferenceFor the procedure to replace the brake pads. Refer to Disassembly and Assembly, "Seat Brake - Remove" and Disassembly and Assembly, "Seat Brake - Install".




    Illustration 120g02060393

  1. Move seat mode switch (1) to the manual position.



    Illustration 121g02061973

  1. Lower armrest (2) .

  1. While seated in the operator seat, close the operator station door and start the engine.



    Illustration 122g02060394

  1. Move parking brake switch (3) to the OFF position, move parking brake switch (3) to the ON position.

  1. Press manual swivel switch (4) to move the swivel seat counterclockwise to the FORWARD position.

  1. Stop the engine.



    Illustration 123g02060413

  1. Remove the four bolts and front light mount assembly (5). Disconnect the front light harness.



    Illustration 124g02063295

  1. Disconnect connectors (6), (7) and (8) .



    Illustration 125g02063313

    View of Tooling (A)

    (9) Connect to flow control solenoid

    (10) Connect to directional solenoid (outer)

    (11) Connect to front light harness




    Illustration 126g02063353



    Illustration 127g02063358

    View of Tooling (A) installed

    (9) Connect to flow control solenoid

    (10) Connect to directional solenoid (outer)

    (11) Connect to front light harness

  1. Install Tooling (A). Refer to Illustration 125, Illustration 126 and Illustration 127.

    Note: Tooling (A) is used in order to release the seat brake using the front light switch.




    Illustration 128g02063361

  1. While seated in the operators seat, close the operator station door and start the engine.

  1. Move front light switch (12) to the ON position.

    Note: This step provides power to the swivel seat solenoids to hold the swivel seat in the FORWARD position and disengage the seat brake.




    Illustration 129g02063363

  1. Have an assistant measure the clearance between brake pads (13) and brake disc (14) if the clearance is greater than 2.7 mm (0.10630 inch) adjust the seat brake.

    ReferenceFor the procedure to adjust the seat brake. Refer to Testing and Adjusting, "Seat Brake - Adjust".

  1. Stop the engine.



    Illustration 130g02063353

  1. Remove Tooling (A).



    Illustration 131g02063295

  1. Connect connector (6), (7) and connector (8) .



    Illustration 132g02060413

  1. Connect the front light harness. Install front light mount assembly (5) and the four bolts.

  1. Remove the steering frame lock. Refer to Disassemble and Assemble, "Steering Frame Lock - Remove and Install".

Braking System - Test

------ WARNING! ------

Personal injury can result if the machine moves while testing.

If the machine begins to move during test, reduce the engine speed immediately and engage the parking brake.

----------------------

Be sure the area around the machine is clear of personnel and obstructions. Be sure the steering frame lock is in the stored position.

Test the brakes on a dry, level surface. Fasten the seat belt before testing the brakes.

The following tests are to determine if the parking brake and the service brakes are functional. These tests are not intended to measure maximum holding effort. Brake holding effort required to hold a machine at a specific engine rpm will vary from machine to machine due to differences in engine setting, power train efficiency, etc., as well as differences in brake holding ability.

Engine rpm at beginning of machine movement, with the brake applied, should be compared against the engine rpm your specific machine was able to hold on a prior test, as an indication of system deterioration.

To carry out the brake test, first start the engine and let the brake oil pressure build up to the operating range. The parking brake will stay engaged until operating oil pressure has been reached and the parking brake control is moved to the OFF position (parking brake disengaged). Once operating oil pressure has been reached a test of the braking system can be commenced.

Service Brake Holding Ability Test

  1. Move the transmission direction and speed control to the NEUTRAL position. Start the engine. Raise the bucket slightly.

  1. Move transmission neutralizer override switch to the OFF position.



    Illustration 133g01744374

  1. Depress the service brake pedal.



    Illustration 134g01746330

  1. Disengage the parking brake by moving the parking brake control to the OFF position.

  1. Move the transmission direction and speed control to the SECOND SPEED FORWARD position.

  1. Gradually increase engine speed to high idle. The machine should not move.

  1. Reduce the engine speed to low idle. Move the transmission direction and speed control to the NEUTRAL position. Engage the parking brake and lower the bucket to the ground. Stop the engine.


NOTICE

If the machine moved while testing the brakes, contact your Caterpillar dealer.

Have the dealer inspect and, if necessary, repair the service brake before returning the machine to operation.


Parking Brake Holding Ability Test


NOTICE

The standard parking brake control is a pull-to-engage type. When the knob is pulled OUT, the parking brake will be engaged.

Certain mining regulations require machines to be equipped with a push-to-engage parking brake control. When the knob is pushed IN, the parking brake is engaged.

Before operating the machine, ensure you are familiar with the operation of the parking brake control.


Standard Pull-to-Engage Type

------ WARNING! ------

Personal injury can result if the machine moves while testing the parking brake.

If the machine begins to move during the test, reduce the engine speed immediately and apply the service brakes.

----------------------

  1. Move the transmission direction and speed control to the NEUTRAL position. Start the engine. Raise the bucket slightly.



    Illustration 135g01746330

  1. Engage the parking brake by pulling the parking brake control knob out to the ON position.

  1. Move the transmission direction and speed control to the SECOND SPEED FORWARD position.

    Note: The parking brake indicator and the action lamp should illuminate. The action alarm should sound.

  1. In a rapid motion, move the transmission direction and speed control to the NEUTRAL position and then back to SECOND SPEED FORWARD position.

  1. Gradually increase engine speed to high idle. The machine should not move.

  1. Reduce the engine speed to low idle. Move the transmission direction and speed control to the NEUTRAL position. Lower the bucket to the ground. Stop the engine.


NOTICE

If the machine moved while testing the brakes, contact your Caterpillar dealer.

Have the dealer inspect and, if necessary, repair the parking brakes before returning the machine to operation.


Optional Push-to-Engage Type

------ WARNING! ------

Personal injury can result if the machine moves while testing the parking brake.

If the machine begins to move during the test, reduce the engine speed immediately and apply the service brakes.

----------------------

  1. Move the transmission direction and speed control to the NEUTRAL position. Start the engine. Raise the bucket slightly.



    Illustration 136g01746330

  1. Engage the parking brake by pushing the parking brake control in to the ON position.

  1. Move the transmission direction and speed control to the SECOND SPEED FORWARD position.

    Note: The parking brake indicator and the action lamp should illuminate. The action alarm should sound.

  1. In a rapid motion, move the transmission direction and speed control to the NEUTRAL position and then back to SECOND SPEED FORWARD position.

  1. Gradually increase engine speed to high idle. The machine should not move.

  1. Reduce the engine speed to low idle. Move the transmission direction and speed control to the NEUTRAL position. Lower the bucket to the ground. Stop the engine.


NOTICE

If the machine moved while testing the brakes, contact your Caterpillar dealer.

Have the dealer inspect and, if necessary, repair the parking brakes before returning the machine to operation.


Circuit Breakers - Reset


NOTICE

Replace circuit breakers with the same type and size only. Otherwise, electrical damage can result.

If it is necessary to reset circuit breakers frequently, an electrical problem may exist. Contact your Caterpillar dealer.



Circuit Breakers - Push in the button to reset the circuit breaker. If the electrical system is working properly, the button will remain depressed. If the button does not remain depressed, check the appropriate electrical circuit. Repair the electrical circuit, if necessary.



Illustration 137g01767113

The circuit breaker panel is located at the rear of the operator station.




Illustration 138g00945903


(1) Caterpillar Monitoring System - 15 Amp


(1) Instrument Illumination


(1) Monitor, Telemetry Port, Electronic Access Module (EAM)


(2) Remote Control System (If Equipped) - 15 Amp


(3) Spare (24V) (Door Proximity Switch (If Equipped)) - 15 Amp


(4) Payload Control System (If Equipped) - 15 Amp


(5) Remote Control System (If Equipped) - 15 Amp


(5) Service Port


(6) Air Conditioner (If Equipped) - 15 Amp


(7) Automatic Lubrication System (If Equipped) - 15 Amp


(7) Exhaust Gas Pressure (If Equipped)


(7) Horn


(8) 24V to 12V Converter - 15 Amp


(8) Instrument Illumination


(8) Radio (Accessories) (If Equipped)


(9) Power Train Electronic Control Module (ECM) - 15 Amp


(10) Front Window Washer and Wiper - 15 Amp


(10) Side Window Washer and Wiper


(10) Rear Window Washer and Wiper


(11) Key switch - 15 Amp


(11) Service Port


(11) Remote Control System (If Equipped)


(11) Engine Electronic Control Module (ECM)


(11) Monitor, Telemetry Port, Electronic Access Module (EAM)


(12) 24V to 12V Converter - 15 Amp


(12) Dome Lamp (If Equipped)


(12) Power Train Electronic Control Module (ECM)