988H M&O manual

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SEBU8480

November 2009

Operation andMaintenance

Manual988H Wheel Loader

BXY4000-Up (988H)

SAFETY.CAT.COM

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i03684547

Important Safety InformationMost accidentsthat involve product operation, maintenance and repair are caused by failure to observebasic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardoussituations before an accident occurs. A person must be alert to potential hazards. This person should alsohave the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous andcould result in injury or death.

Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread and understood the operation, lubrication, maintenance and repair information.

Safety precautions and warnings are provided in this manual and on the product. If these hazard warningsare not heeded, bodily injury or death could occur to you or to other persons.

The hazards are identified by the Safety Alert Symbol and followed by a Signal Word such asDANGER, WARNING or CAUTION. The Safety Alert WARNING label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.

The message that appears under the warning explains the hazard and can be either written or pictoriallypresented.

A non-exhaustive list of operations that may cause product damage are identified by NOTICE labelson the product and in this publication.

Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.The warnings in this publication and on the product are, therefore, not all inclusive. You mustnot use this product in any manner different from that considered by this manual without firstsatisfying yourself that you have considered all safety rules and precautions applicable to theoperation of the product in the location of use, including site-specific rules and precautionsapplicable to the worksite. If a tool, procedure, work method or operating technique that is notspecifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for youand forothers. You should also ensure that the product will not be damaged or become unsafe bythe operation, lubrication, maintenance or repair procedures that you intend to use.

The information, specifications, and illustrations in this publication are on the basis of information thatwas available at the time that the publication was written. The specifications, torques, pressures,measurements, adjustments, illustrations, and other items can change at any time. These changes canaffect the service that is given to the product. Obtain the complete and most current information before youstartany job. Caterpillar dealers have the most current information available.

When replacement parts are required for thisproduct Caterpillar recommends using Caterpil-lar replacement parts or parts with equivalentspecifications including, but not limited to, phys-ical dimensions, type, strength and material.

Failure to heed this warning can lead to prema-ture failures, product damage, personal injury ordeath.

In the United States, the maintenance, replacement, or repair of the emission control devices andsystems may be performed by any repair establishment or individual of the owner's choosing.

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SEBU8480 3Table of Contents

Table of Contents

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

Safety Section

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

Additional Messages ............................................. 12

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

Crushing Prevention and Cutting Prevention ........ 16

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

Fire Prevention and Explosion Prevention ............ 17

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

Tire Information ..................................................... 21

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

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

Visibility Information .............................................. 22

Restricted Visibility ................................................ 22

Engine Starting ..................................................... 23

Before Operation .................................................. 23

Operation .............................................................. 23

Engine Stopping ................................................... 24

Parking .................................................................. 24

Slope Operation .................................................... 24

Equipment Lowering with Engine Stopped ........... 25

Sound Information and Vibration Information ....... 25

Operator Station ................................................... 28

Product Information Section

General Information .............................................. 29

Identification Information ....................................... 33

Operation Section

Before Operation .................................................. 37

Machine Operation ............................................... 39

Engine Starting ..................................................... 74

Parking .................................................................. 75

Transportation Information .................................... 78

Towing Information ................................................ 80

Engine Starting (Alternate Methods) ..................... 83

Maintenance Section

Tire Inflation Information ....................................... 86

Lubricant Viscosities and Refill Capacities ........... 87

Maintenance Support ............................................ 93

Maintenance Interval Schedule ............................ 95

Reference Information Section

Reference Materials ............................................ 162

Index Section

Index ................................................................... 165

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4 SEBU8480Foreword

Foreword

Literature Information

This manual should be stored in the operator's

compartment in the literature holder or seat backliterature storage area.

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

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

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

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

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

Safety

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

Read and understand the basic precautions listed

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

Operation

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

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

operating and stopping the machine.

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

Maintenance

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

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

Maintenance Intervals

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

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

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

California Proposition 65 Warning

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

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

Certified Engine Maintenance

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

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

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SEBU8480 5Foreword

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

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

Machine Capacity

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

Contact your Caterpillar dealer for further information.

Caterpillar Product IdentificationNumber

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

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

g00751314Illustration 1

Where:

1. Caterpillar's World Manufacturing Code (characters1-3)

2. Machine Descriptor (characters 4-8)

3. Check Character (character 9)

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

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

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

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6 SEBU8480Safety SectionSafety Messages

Safety Section

i03308503

Safety Messages

SMCS Code: 7000

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

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

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

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

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SEBU8480 7Safety Section

Safety Messages


(1) Do Not Operate.(2) Pressurized System(3) Falling Hazard

(4) Crushing Hazard(5) No Clearance(6) Parking Brake

(7) Do Not Weld or Drill on the ROPS.

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(3) Falling Hazard(5) No Clearance

(8) Improper Connections of The Jump StartCable

(9) Seat belt(10) Product Link

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Safety Messages

Do Not Operate (1)


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

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

Pressurized System (2)


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

Pressurized system: Hot coolant can cause seri-ous burn. To open cap, stop engine, wait until ra-diator is cool. Then loosen cap slowly to relievethe pressure.

Falling Hazard (3)


This warning is located on each side of the machine.

Fall Hazard. Severe injury or death could occurfrom falling while servicing components on themachine at elevated positions. Use proper precau-tions and / or external access devices.

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Crushing Hazard (4)


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

Connect the steering frame lock between the frontand the rear frames before lifting, transporting, orservicing the machine in the articulation area. Dis-connect the steering frame lock and secure thesteering frame lock before resuming operation.Severe injury or death could occur.

No Clearance (5)


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

Stay back a safe distance. No clearance for a per-son in this area when the machine turns. Severeinjury or death from crushing could occur.

Parking Brake (6)


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

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

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

Refer to Operation and Maintenance Manual,

Parking Brake Manual Release for the properprocedure.

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Safety Messages

Do Not Weld or Drill on the ROPS(7)


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

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

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

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

Improper Connections of The JumpStart Cable (8)


This warning label is located in the batterycompartment.

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

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

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

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12 SEBU8480Safety Section

Additional Messages

Seat belt (9)


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

A seat belt should be worn at all times during ma-chine operation to prevent serious injury or deathin the event of an accident or machine overturn.Failure to wear a seat belt during machine opera-

tion may result in serious injury or death.

Product Link (10)

This warning label is located in the cab.

g01370917

This machine is equipped with a Caterpillar Prod-uct Link communication device which must be de-activated within 12 m (40 ft) of a blast zone. Failureto do so could result in serious injury or death.

i02880316

Additional Messages

SMCS Code: 7000

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

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

to fall.

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

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Additional Messages


Air Conditioner (1)


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

Data Privacy (2)


This message is located on the window inside thecab.

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14 SEBU8480Safety SectionGeneral Hazard Information

The Product Link System is a satellite communicationdevice that transmits information regarding themachine back to Caterpillar and Caterpillar dealersand customers. All logged events and diagnosticcodes that are available to the Caterpillar ElectronicTechnician (ET) on the CAT data link can be sent

to the satellite. Information can also be sent to theProduct Link System. The information is used toimprove Caterpillar products and Caterpillar services.

Refer to Operation and Maintenance Manual,Product Link for more information.

i03559343

General Hazard Information

SMCS Code: 7000


Attach a Do Not Operate warning tag or a similarwarning tag to the start switch or to the controlsbefore you service the equipment or before yourepair the equipment. These warning tags (SpecialInstruction, SEHS7332) are available from yourCaterpillar dealer.

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

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


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

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

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

Keep the equipment free from foreign material.Remove debris, oil, tools, and other items from thedeck, from walkways, and from steps.

Secure all loose items such as lunch boxes, tools,and other items that are not a part of the equipment.

Know the appropriate work site hand signals and

the personnel that are authorized to give the handsignals. Accept hand signals from one person only.

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

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

Obey all local regulations for the disposal of liquids.

Use all cleaning solutions with care. Report allnecessary repairs.

Do not allow unauthorized personnel on theequipment.

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

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General Hazard Information

When you perform maintenance above ground leveluse appropriate devices such as ladders or man liftmachines. If equipped, use the machine anchoragepoints and useapproved fall arrest harnesses andlanyards.

Pressurized Air and Water

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

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

The maximum air pressure for cleaning purposesmust be reduced to 205 kPa (30 psi) when the

nozzle is deadheaded and the nozzle is used withan effective chip deflector and personal protectiveequipment. The maximum water pressure forcleaning purposes must be below 275 kPa (40 psi).

Trapped Pressure

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

and possible death.

Fluid Penetration

Pressure can be trapped in the hydraulic circuit longafter the engine has been stopped. The pressure cancausehydraulic fluid or items such as pipe plugs toescape rapidly if the pressure is not relieved correctly.

Do not remove any hydraulic components or partsuntil pressure has been relieved or personal injurymay occur. Do not disassemble any hydrauliccomponents or parts until pressure has been relieved

or personal injury may occur. Refer to the ServiceManual for any procedures that are required torelieve the hydraulic pressure.


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

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

Containing Fluid Spillage

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

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

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

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

Obey all local regulations for the disposal of liquids.

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16 SEBU8480Safety SectionCrushing Prevention and Cutting Prevention

Asbestos Information


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

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

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

contains asbestos is generated.

If dust that may contain asbestos is present, thereare several guidelines that should be followed:

Never use compressed air for cleaning.

Avoid brushing materials that contain asbestos.

Avoid grinding materials that contain asbestos.

Use a wet method in order to clean up asbestosmaterials.

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

Use exhaust ventilation on permanent machiningjobs.

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

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

Obey environmental regulations for the disposalof asbestos.

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

Dispose of Waste Properly


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

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

i01359664

Crushing Prevention andCutting Prevention

SMCS Code: 7000

Support the equipment properly before you perform

any work or maintenance beneath that equipment.Do not depend on the hydraulic cylinders to holdupthe equipment. Equipment can fall if a control ismoved, or if a hydraulic line breaks.

Donot work beneath the cab of the machine unlessthe cab is properly supported.

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

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Burn Prevention

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

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

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

Stay clear of all rotating and moving parts.

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

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

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

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

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

i01329099

Burn Prevention

SMCS Code: 7000

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

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

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

Check the coolant level only after the engine hasbeen stopped.

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

Cooling system conditioner contains alkali. Alkali can

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

Oils

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

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

the hydraulic tankfi

ller cap.

Batteries

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

i03659986

Fire Prevention and Explosion

PreventionSMCS Code: 7000


General

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

To minimize the risk offire or explosion, Caterpillarrecommends the following actions.

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18 SEBU8480Safety SectionFire Prevention and Explosion Prevention

Always performa Walk-Around Inspection, whichmay help you identify a fire hazard. Do not operatea machine when a fire hazard exists. Contact yourCaterpillar dealer for service.

Understand the use of the primary exit and alternative

exit on the machine. Refer to Operation andMaintenance Manual, Alternative Exit.

Do not operate a machine with a fluid leak. Repairleaks and clean up fluids before resuming machineoperation. Fluids that are leaking or spilled onto hotsurfaces oronto electrical components can cause afire. A fire may cause personal injury or death.

Remove flammable material such as leaves, twigs,papers, trash, etc. These items may accumulate inthe engine compartment or around other hot areasand hot parts on the machine.

Keep the access doors to major machinecompartments closed and access doors in workingcondition in order to permit the use offire suppressionequipment, in case a fire should occur.

Clean all accumulations offlammable materials suchas fuel, oil and debris from the machine.

Do not operate the machine near any flame.

Keep shields in place. Exhaust shields (if equipped)protect hot exhaust components from oil spray or fuelspray in case of a break in a line, in a hose, or in aseal. Exhaust shields must be installed correctly.

Do not weld orflame cut on tanks or lines that containflammable fluids orflammable material. Empty andpurge the lines and tanks. Then clean the lines andtanks with a nonflammable solvent prior to weldingorflame cutting. Ensure that the components areproperly grounded in order to avoid unwanted arcs.

Dustthat is generated from repairing nonmetallichoods or fenders may be flammable and/or explosive.Repair such components in a well ventilated areaawayfrom open flames or sparks. Use suitablePersonal Protection Equipment (PPE).

Inspect all lines and hoses for wear or deterioration.Replace damaged lines and hoses. The lines andthe hoses should have adequate support and secureclamps. Tighten all connections to the recommendedtorque. Damage to the protective cover or insulationmay provide fuel forfires.

Store fuels and lubricants in properly markedcontainers away from unauthorized personnel. Storeoily rags and flammable materials in protectivecontainers. Do not smoke in areas that are used forstoring flammable materials.


Use caution when you are fueling a machine. Do notsmoke while you are fueling a machine. Do not fuela machine near open flames or sparks. Always stopthe engine before fueling. Fill the fuel tank outdoors.Properly clean areas of spillage.

Follow practices for safe fueling that are describedin the Operation section of the Operation andMaintenance Manual section and follow localregulations. Never store flammable fluids in theoperator compartment of the machine.

Battery and Battery Cables


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Fire Prevention and Explosion Prevention

Caterpillar recommends the following in order tominimize the risk offire or an explosion related tothe battery.

Do not operate a machine if battery cables or relatedparts show signs of wear or damage. Contact your

Caterpillardealer for service.

Follow safe procedures for engine starting with jumpstart cables. Improper jumper cable connections cancause an explosion that may result in injury. Refer toOperation and Maintenance Manual, Engine Startingwith Jump Start Cables for specific instructions.

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

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

Never check the battery charge by placing a metalobject across the terminal posts. Use a voltmeter inorder to check the battery charge.

Daily inspect battery cables that are in areas thatare visible. Inspect cables, clips, straps, and otherrestraints for damage. Replace any damaged parts.Check for signs of the following, which can occurover time due to use and environmental factors:

Fraying

Abrasion

Cracking

Discoloration

Cuts on the insulation of the cable

Fouling

Corroded terminals, damaged terminals, and looseterminals

Replace damaged battery cable(s) and replaceany related parts. Eliminate any fouling, which may

have caused insulation failure or related componentdamage or wear. Ensure that all components arereinstalled correctly.

An exposed wire on the battery cable may causea short to ground if the exposed area comes intocontact with a grounded surface. A battery cableshort produces heat from the battery current, whichmay be a fire hazard.

An exposed wireon the ground cable between thebattery and the disconnect switch may cause thedisconnect switch to be bypassed if the exposed areacomes into contact with a grounded surface. Thismay result in an unsafe condition for servicing themachine. Repair components or replace components

before servicing the machine.

Fire on a machine can result in personal injuryor death. Exposed battery cables that come intocontact with a grounded connection can result infires. Replace cables and related parts that showsigns of wear or damage. Contact your Caterpillardealer.

Wiring

Check electrical wires daily. If any of the followingconditions exist, replace parts before you operatethe machine.

Fraying

Signs of abrasion or wear

Cracking

Discoloration

Cuts on insulation

Other damage

Make sure that all clamps, guards, clips, and strapsare reinstalled correctly. This will help to preventvibration, rubbing against other parts, and excessiveheatduring machine operation.

Attaching electrical wiring to hoses and tubes thatcontain flammable fluids or combustiblefluids shouldbe avoided.

Consult your Caterpillar dealer for repair or forreplacement parts.

Keep wiring and electrical connections free of debris.

Lines, Tubes and Hoses

Do not bend high pressure lines. Do not strike highpressure lines. Do not install any lines that are bent ordamaged. Use the appropriate backup wrenches inorder to tighten all connections to the recommendedtorque.

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20 SEBU8480Safety SectionFire Extinguisher Location


Check lines, tubes and hoses carefully. WearPersonal Protection Equipment (PPE) in order tocheck for leaks. Always use a board or cardboard

when you check for a leak. Leaking fluid that is underpressure can penetrate body tissue. Fluid penetrationcan cause serious injury and possible death. A pinhole leak can cause severe injury. Iffluid is injectedinto your skin, you must get treatment immediately.Seek treatment from a doctor that is familiar with thistype of injury.

Replace the affected parts if any of the followingconditions are present:

End fittings are damaged or leaking.

Outer coverings are chafed or cut.

Wires are exposed.

Outer coverings are swelling or ballooning.

Flexible parts of the hoses are kinked.

Outer covers have exposed embedded armoring.

End fittings are displaced.

Make sure that all clamps, guards, and heat shieldsare installed correctly. During machine operation, thiswill help to prevent vibration, rubbing against other

parts, excessive heat, and failure of lines, tubes andhoses.

Do not operate a machine when a fire hazardexists. Repair any lines that are corroded, looseor damaged. Leaks may provide fuel for fires.Consult your Caterpillar dealer for repair or forreplacement parts. Use genuine Caterpillar parts orthe equivalent, for capabilities of both the pressurelimit and temperature limit.

Ether

Ether (if equipped) is commonly used in cold weatherapplications. Ether is flammable and poisonous.

Follow the correct cold engine starting procedures.

Refer to the section in the Operation and MaintenanceManual with the label Engine Starting.

Do not spray ether manually into an engine if themachine is equipped with a thermal starting aid forcold weather starting.

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

Do not store ether cylinders in living areas or in theoperator compartment of a machine. Do not storeether cylinders in direct sunlight or in temperatures

above 49C (120.2 F). Keep ether cylinders awayfrom open flames or sparks.

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

Fire Extinguisher

As an additional safety measure, keep a fireextinguisher on the machine.

Be familiar with the operation of the fire extinguisher.

Inspect thefi

re extinguisher and service the fi

reextinguisher regularly. Follow the recommendationson the instruction plate.

Consider installation of an aftermarket FireSuppression System, if the application and workingconditions warrant the installation.

i00977136

Fire Extinguisher Location

SMCS Code: 7000

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

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

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Tire Information

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

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

i01557411

Tire Information

SMCS Code: 7000

Explosions of air inflated tires have resulted fromheat-induced gas combustion inside the tires.Explosions can be caused by heat that is generatedby welding, by heating rim components, by externalfire, or by excessive use of brakes.

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


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

Do not approach a warm tire. Maintain a minimumdistance, as shown. Stay outside the shaded area inIllustration 25.

Donot use water or calcium as a ballast for the tires.Dry nitrogen gas is recommended for inflation of tires.If the tires were originally inflated with air, nitrogenis still preferred for adjusting the pressure. Nitrogenmixes properly with air.

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

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

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

Servicingtires and rims can be dangerous. Onlytrained personnel that use proper tools and properprocedures should perform this maintenance. Ifcorrect procedures are not used for servicing tiresand rims, the assemblies could burst with explosive

force. This explosive force can cause seriouspersonalinjury or death. Carefully obey the specificinstructions from your tire dealer.

i01122596

Electrical Storm InjuryPrevention

SMCS Code: 7000

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

following procedures:

Mount the machine.

Dismount the machine.

If you are in the operator's station during an electricalstorm, stay in the operator's station. If you are on theground during an electrical storm, stay away fromthe vicinity of the machine.

i00934890

Before Starting EngineSMCS Code: 1000; 7000

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

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

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22 SEBU8480Safety SectionVisibility Information

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

Adjust the seat so that there is full pedal travel whilethe operator's back is against the back of the seat.

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

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

i03162317

Visibility InformationSMCS Code: 7000

Before you start the machine, perform a walk-aroundinspection in order to ensure that there are nohazardsaround the machine.

While the machine is in operation, constantly surveythe area around the machine in order to identifypotential hazards as hazards become visible aroundthe machine.

Your machine may be equipped with visual aids.Some examples of visual aids are Closed CircuitTelevision (CCTV) and mirrors. Before operating themachine, ensure that the visual aids are in properworking condition and that the visual aids are clean.

Adjust the visual aids using the procedures that arelocated in this Operation and Maintenance Manual.If equipped, the Work Area Vision System shall beadjusted according to Operation and MaintenanceManual, SEBU8157, Work Area Vision System.

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

Appropriate job site organization is required in order

to minimize hazards that are caused by restrictedvisibility. Job site organization is a collection of rulesand procedures that coordinates machines andpeople that work together in the same area. Examplesof job site organization include the following:

Safety instructions

Controlled patterns of machine movement andvehicle movement

Workers that direct traffic to move when it is safe

Restricted areas

Operator training

Warning symbols or warning signs on machinesor on vehicles

A system of communication

Communication between workers and operatorsprior to approaching the machine

Modifications of the machine configuration by theuser that result in a restriction of visibility shall beevaluated.

i03297985

Restricted Visibility

SMCS Code: 7000

The size and the configuration of this machine mayresult in areas that can not be seen when the operatoris seated. Illustration 26 provides an approximatevisual indication of areas of significant restrictedvisibility. Illustration 26 indicates restricted visibilityareas atground level inside a radius of 12 m (40 ft)from the operator on a machine without the use ofoptional visual aids. This illustration does not provideareas ofrestricted visibility for distances outside aradius of 12 m (40 ft).

This machine may be equipped with optional visualaids that may provide visibility to some of the

restricted visibility areas. Refer to this Operation andMaintenance Manual, Mirror for more information onadditional visibility. If your machine is equipped withcameras, refer to this Operation and MaintenanceManual, Camera for more information on additionalvisibility. For areas that are not covered by theoptional visual aids, the job site organization mustbe utilized to minimize hazards of this restrictedvisibility. For more information regarding job siteorganization refer to Operation and MaintenanceManual, Visibility Information.

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Engine Starting


Top viewof the machine

Note: The shaded areas indicate the approximatelocation of areas with significant restricted visibility.

i03690423

Engine Starting

SMCS Code: 1000; 7000

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

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

Move the transmission control to the NEUTRALposition.

Engage the parking brake.

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

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

Briefly sound the horn before you start the engine.

Check for the presence of personnel. Ensure that allpersonnel are clear of the machine.

i01943255

Before Operation

SMCS Code: 7000

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

Clear all obstacles from the path of the machine.Beware of hazards such as wires, ditches, etc.

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

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

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

Fasten the seat belt securely.

i03690422

Operation

SMCS Code: 7000

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

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

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

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

Never use the work tool for a work platform.

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

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

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

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24 SEBU8480Safety SectionEngine Stopping

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

Avoid any conditions that can lead to tipping themachine. The machine can tip when you work onhills, on banks and on slopes. Also, the machinecan tip whenyou cross ditches, ridges or otherunexpected obstructions.

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

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

Know the maximum dimensions of your machine.

Always keep the Rollover Protective Structure(ROPS) installed during machine operation.

i02624835

Engine Stopping

SMCS Code: 1000; 7000

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

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

i01353455

Parking

SMCS Code: 7000

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

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

Engage the parking brake.

Lower all work tools to the ground. Activate anycontrol locks.

Stop the engine.

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

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

i03745198

Slope Operation

SMCS Code: 7000

Machines that are operating safely in variousapplications depend on these criteria: the machinemodel, configuration, machine maintenance,operating speed of the machine, conditions of theterrain, fluid levels, and tire inflation pressures. Themost important criteria are the skill and judgment ofthe operator.

A well trained operator that follows the instructionsin the Operation and Maintenance Manual hasthe greatest impact on stability. Operator trainingprovides a person with the following abilities:observation of working and environmental conditions,feel for the machine, identification of potentialhazards, and operating the machine safely by makingappropriate decisions.

When you work on side hills and when you work onslopes, consider the following important points:

Speed of travel At higher speeds, forces of inertiatend to make the machine less stable.

Roughness of terrain or surface The machinemay be less stable with uneven terrain.

Direction of travel Avoid operating the machineacross the slope. When possible, operate themachine up the slopes and operate the machinedown the slopes. Place the heaviest end of themachine uphill when you are working on an incline.

Mounted equipment Balance of the machinemay be impeded by the following components:

equipment that is mounted on the machine, machineconfiguration, weights, and counterweights.

Nature of surface Ground that has been newlyfilled with earth may collapse from the weight of themachine.

Surface material Rocks and moisture of thesurface material may drastically affect the machine'straction and machine's stability. Rocky surfaces maypromote side slipping of the machine.

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Equipment Lowering with Engine Stopped

Slippage due toexcessive loads This may causedownhill tracks or downhill tires to dig into the ground,which will increase the angle of the machine.

Width of tracks or tires Narrower tracks ornarrower tires further increase the digging into the

ground whichcauses the machine to be less stable.

Implements attached to the drawbar This maydecrease the weight on the uphill tracks. This mayalso decrease the weight on the uphill tires. Thedecreased weight will cause the machine to be lessstable.

Height of the working load of the machine When the working loads are in higher positions, thestability of the machine is reduced.

Operated equipment Be aware of performancefeatures of the equipment in operation and the effects

on machine stability.

Operating techniques Keep all attachments orpulled loads low to the ground for optimum stability.

Machine systems have limitations on slopes Slopes can affect the proper function and operationof the various machine systems. These machinesystems are needed for machine control.

Note: Safe operation on steep slopes may requirespecial machine maintenance. Excellent skill ofthe operator and proper equipment for specificapplications are also required. Consult the Operation

and Maintenance Manual sections for the properfluidlevel requirements and intended machine use.

i01329161

Equipment Lowering withEngine Stopped

SMCS Code: 7000

Before lowering any equipment with the enginestopped, clear the area around the equipment ofall personnel. The procedure to use will vary with

thetype of equipment to be lowered. Keep in mindmost systems use a high pressure fluid or air toraise or lower equipment. The procedure will causehigh pressure air, hydraulic, or some other mediato be released in order to lower the equipment.Wear appropriate personal protective equipment andfollow the established procedure in the Operationand Maintenance Manual, Equipment Lowering withEngine Stopped in the Operation Section of themanual.

i03699940

Sound Information andVibration Information

SMCS Code: 7000

Sound Level Information

The operator Equivalent Sound Pressure Level (Leq)is 75 dB(A) when ANSI/SAE J1166 FEB 2008 isused to measure the value for an enclosed cab.This is a work cycle sound exposure level. The cabwas properly installed and maintained. The test wasconductedwith the cab doors and the cab windowsclosed.

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

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

The average exterior sound pressure level is 81dB(A) when the SAE J88FEB 2006 - Constant SpeedMoving Test procedure is used to measure the valuefor the standard machine. The measurement wasconducted under the following conditions: distance of15 m (49.2 ft) and the machine moving forward in anintermediate gear ratio.

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

The dynamic operator sound pressure level is 72dB(A) when ISO 6396:2008 is used to measure thevalue for an enclosed cab. The cab was properlyinstalled and maintained. The test was conductedwith the cab doors and the cab windows closed.

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

Vibration Data for Wheel Loaders

Information Concerning Hand/Arm VibrationLevel

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

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26 SEBU8480Safety SectionSound Information and Vibration Information

Information Concerning Whole Body VibrationLevel

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

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

Operator training, behavior, mode, and stress

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

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

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

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

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

Note: All vibration levels are in meter per secondsquared.

Table1

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

Vibration Levels Scenario FactorsMachineType

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

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

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

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

WheelLoader

V-shape motion(3)

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

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Sound Information and Vibration Information

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

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

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

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28 SEBU8480Safety SectionOperator Station

Sources

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

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

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

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

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

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

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

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

Use the following web site in order to find your local

dealer:

Caterpillar, Inc.www.cat.com

i03634321

Operator Station

SMCS Code: 7000

Any modifications to the inside of the operator stationshould not project into the operator space or into

the space for the companion seat (if equipped).The addition of a radio, fire extinguisher, and otherequipment must be installed so that the definedoperator space and the space for the companion seat(if equipped) is maintained. Any item that is broughtinto the cab should not project into the definedoperator space or the space for the companion seat(if equipped). A lunch box or other loose items mustbe secured. Objects must not pose an impact hazardin rough terrain or in the event of a rollover.

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30 SEBU8480Product Information SectionGeneral Information


Dimension (A) represents the dump clearance. Dimension (B)represents the reach.

The following table provides the rated operating loads

for the standard machine configuration.

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SEBU8480 31Product Information Section

General Information

Table 3

Rated Load3.88 m

Ground Engaging Tools Rated Volume Rated Operating Load Dump ClearanceA

ReachB

Spade Rock with Teeth andSegments (Standard Bucket)

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

(147 inch) 1494 mm (59 inch)

Wide Spade Rock with Teethand Segments

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

(145 inch) 1554 mm (61 inch)

General Purpose with Bolt-OnCutting Edges

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

(149 inch) 1720 mm (68 inch)

Straight Rock with Teeth andSegments

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

(158 inch) 1526 mm (60 inch)

Rock Quarry (Heavy Duty) withTeeth and Segments

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

(147 inch) 1543 mm (61 inch)

Mining (Heavy Duty) with Teethand Segments

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

(150 inch) 1577 mm (62 inch)

Spade Rock with Bolt-OnCutting Edges

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

(143 inch) 1881 mm (74 inch)

Spade Rock with Teeth andSegments

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

1494 mm (59 inch)

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32 SEBU8480Product Information SectionGeneral Information

Table 4

Rated Load4.25 m

Ground Engaging Tools Rated Volume Rated Operating Load Dump ClearanceA

ReachB

Spade Rock with Teeth andSegments (Standard Bucket)

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

(164 inch) 1591 mm (63 inch)

Wide Spade Rock with Teethand Segments

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

(161 inch) 1652 mm (65 inch)

General Purpose with Bolt-OnCutting Edges

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

(165 inch) 1818 mm (72 inch)

Straight Rock with Teeth andSegments

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

(174 inch) 1623 mm (64 inch)

Rock Quarry (Heavy Duty) withTeeth and Segments

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

(163 inch) 1641 mm (65 inch)

Mining (Heavy Duty) with Teethand Segments

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

(166 inch) 1674 mm (66 inch)

Spade Rock with Bolt-OnCutting Edges

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

(159 inch) 1699 mm (67 inch)

Spade Rock with Teeth andSegments

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

1494 mm (59 inch)

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SEBU8480 33Product Information Section

Identification Information

Identification Information

i03770369

Plate Locations and Film

LocationsSMCS Code: 1000; 7000

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

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

Product Identification Number (PIN)


Left side of front frame

Machine PIN ________________________________________________

European Union

Note: The CE plate is on machines that are certifiedto the valid European Union requirements at thattime.

If the machine is equipped with the plate for theEuropean Union, this plate will be attached to the PINplate. The CE plate is positioned on the bottom leftside of the plate for the PIN.

For machines compliant to 2006/42/EC, thefollowing information is stamped onto the CE plate.For quick reference, record this information in thespaces provided below.


Engine Power primary engine (kW)__________________

Engine Power for additional engine if equipped

(kW)________________________________________________________

Typical machine operating weight for Europeanmarket (kg)________________________________________________

Year of construction_____________________________________

Machine Type____________________________________________

For the name, the address and the country of originfor the manufacturer, see the PIN plate.

For machines compliant to 1998/37/EC, thefollowing information is stamped onto the CE plate.

For quick reference, record this information in thespaces provided below.


Engine Power primary engine (kW)__________________

Typical machine operating weight for Europeanmarket (kg)________________________________________________

Year________________________________________________________

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34 SEBU8480Product Information SectionIdentification Information

Serial Number

Caterpillar products such as engines, transmissions,and major attachments that are not designed for anoperator to ride are identified by Serial Numbers. Forquick reference, record the identification numbers in

the spaces that are provided below the illustration.


Rear view of the torque converter housing

Torque Converter Serial Number_______________________


Engine valve cover

Engine Serial Number ____________________________________


Right side of planetary case

Transmission Serial Number_____________________________

Certification

Sound


Typical example

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

Vibration Information for the guaranteed sound levelfor your machine.

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36 SEBU8480Product Information SectionIdentification Information

i03765310

Declaration of Conformity

SMCS Code: 1000; 7000

Table 5

An EC Declaration of Conformity document was provided with the machine if it was manufactured to comply with specificrequirements for the European Union. In order to determine the details of the applicable Directives, review the completeEC Declaration of Conformity provided with the machine. The extract shown below from an EC Declaration of Conformityfor machines that are declared compliant to 2006/42/EC applies only to those machines originally CE marked by themanufacturer listed and which have not since been modified.

EC DECLARATION OF CONFORMITY OF MACHINERY

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

Person authorized to compile the Technical File and to communicate relevant part (s) of the Technical File to theAuthorities of European Union Member States on request:

Standards & Regulations Manager,Caterpillar France S.A.S 40,Avenue Leon-Blum, B.P. 55, 38041 Grenoble Cedex 9, France

I, the undersigned,_________,hereby certify that the construction equipment specified hereunder

Description: Generic Denomination: Earth moving Equipment

Function: Wheeled loader

Model/Type: 988H Wheel Loader

Serial Number:

Commercial Name: Caterpillar

Fulfils all the relevant provisions of the following Directives

Directives Notified Body Document No.

2006/42/EC N/A

2000/14/EC amended by 2005/88/EC,Note (1)

2004/108/EC N/A

Note (1) Annex -_____ Guaranteed Sound Power Level -_____dB (A)Representative Equipment Type Sound Power Level - _____dB (A)Engine Power per ____-____ kW Rated engine speed - _____ rpmTechnical Documentation accessible through person listed above authorized to compile the Technical File

Done at: Signature

Date: Name/Position

Note:The above information was correct as of September 2009, but may be subject to change, please refer to the individualdeclaration of conformity issued with the machine for exact details.

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SEBU8480 37Operation SectionBefore Operation

Operation Section

Before Operation

i02189821

Mounting and Dismounting

SMCS Code: 7000


Typical example

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

all necessary repairs.

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

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

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

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

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

Alternate Exit

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

i01922360

Daily Inspection

SMCS Code: 1000; 7000

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

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

Steam can cause personal injury.

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

Remove the cooling system pressure cap slowlyto relieve pressure.

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

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

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

Perform the following procedures on a daily basis.

Operation and Maintenance Manual, BucketCutting Edges - Inspect/Replace

Operation and Maintenance Manual, Bucket Stops- Inspect/Replace

Operation and Maintenance Manual, Bucket Tips- Inspect/Replace

Operation and Maintenance Manual, Bucket WearPlates - Inspect/Replace

Operation and Maintenance Manual, BackupAlarm - Test

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38 SEBU8480Operation SectionBefore Operation

Operation and Maintenance Manual, CoolingSystem Coolant Level - Check

Operation andMaintenance Manual, Engine OilLevel - Check

Operation and Maintenance Manual, Engine AirFilter Service Indicator - Inspect

Operation and Maintenance Manual, HydraulicSystem Oil Level - Check

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

Operationand Maintenance Manual, Loader Pinsand Bearings - Lubricate

Operationand Maintenance Manual, Seat Belt -Inspect

Operation and Maintenance Manual, TransmissionOil Level - Check

Operation and Maintenance Manual, Windows -Clean

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

i01922365

Steering Frame Lock

SMCS Code: 7506

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


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


Connect steering frame lock (1) when the machine

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

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


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

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

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SEBU8480 39Operation Section

Machine Operation

Machine Operation

i03654709

Alternate Exit

SMCS Code: 7310


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

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

i02203596

Seat

SMCS Code: 7312

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

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


Mechanical Suspension

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

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

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

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

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

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

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

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

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40 SEBU8480Operation SectionMachine Operation

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

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

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

order to lock the seat into position.

Air Suspension (If Equipped)

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

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

i03415082

Seat Belt

SMCS Code: 7327

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

At the time of installation, the seat belt and theinstructions for installation of the seat belt meetthe SAE J386 and ISO 6683 standards. See yourCaterpillar dealer for all replacement parts.

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

Seat Belt Adjustment forNon-Retractable Seat Belts

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

Lengthening the Seat Belt


1. Unfasten the seat belt.


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

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

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

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Machine Operation

Shortening theSeat Belt


1. Fasten the seat belt. Pull out on the outer belt loopin order to tighten the seat belt.

2. Adjust the other half of the seat belt in the samemanner.

3. If the seat belt does not fit snugly with the bucklein the center, readjust the seat belt.

Fastening The Seat Belt


Fasten the seat belt catch (3) into the buckle (2).Make sure that the seat belt is placed low across thelapof the operator.

Releasing The Seat Belt


Pull up on the release lever. This will release the seatbelt.

Seat Belt Adjustment forRetractable Seat Belts

Fastening The Seat Belt


Pull seat belt (4) out of the retractor in a continuousmotion.

Fasten seat belt catch (3) into buckle (2). Make surethat the seat belt is placed low across the lap of theoperator.

The retractor will adjust the belt length and theretractor will lock in place. The comfort ride sleevewill allow the operator to have limited movement.

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Releasing The Seat Belt


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

retract into the retractor.

Extension of the Seat Belt

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

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

up, the seat belt will not retain the person.

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

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

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

i03290932

Mirror(If Equipped)

SMCS Code: 7319

Adjust all mirrors as specified in the Operationand Maintenance Manual. Failure to heed thiswarning can lead to personal injury or death.

Slips and falls can result in personal injury. Usethe machines access systems when adjusting themirrors. If the mirrors cannot be reached using themachine access systems follow the instructionsfound within the Operation and Maintenance Man-ual, Mirror in order to access the mirrors.

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


(1) Left Outside Mirror(2) Right Outside Mirror


(3) Left Inside Mirror(4) Right Inside Mirror

Mirrors provide additional visibility around yourmachine. Make sure that the mirrors are in properworking condition and that the mirrors are clean.

Adjust all mirrors at the beginning of each work periodand adjust the mirrors when you change operators.

The appropriate organization of the job site is alsorecommended in order to minimize hazards due tovisibility. For more information refer to this Operationand Maintenance Manual, Visibility Information.

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Machine Operation

Modified Machines or machines that have additionalequipment or attachments may influence yourvisibility.

Mirror Adjustment

Park the machine on a level surface.

Lower the work tool to the ground.

Move the hydraulic lockout control to the LOCKEDposition. For further details on this procedure, referto Operation and Maintenance Manual, OperatorControls

Stop the engine.

Adjust rear view mirrors in order to provide visibilitybehind the machine at a maximum distance of

30 m (98 ft) from the rear corners of the machine.

Note: You may need to use hand tools in order toadjust certain types of mirrors.

Left Outside Mirror (1)


If equipped, adjust the left outside mirror (1) so thatan area of at least 1 m (3.3 ft) from the rear of themachine can be seen from the operator seat.

Right Outside Mirror (2)


If equipped, adjust the right outside mirror (2) sothat an area of at least 1 m (3.3 ft) from the side of

the machine can be seen from the operator seat.Additionally, provide as much visibility to the rear aspossible.

Left Inside Mirror (3)


If equipped, adjust the left inside mirror (3) so thatan area of at least 1 m (3.3 ft) from the side ofthemachine can be seen from the operator seat.

Additionally, provide as much visibility to the rear aspossible.

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Right Inside Mirror (4)


If equipped, adjust the right inside mirror (4) sothat an area of at least 1 m (3.3 ft) from the side of

the machine can be seen from the operator seat.Additionally, provide as much visibility to the rear aspossible.

i03747127

Operator Controls

SMCS Code:7300; 7301; 7451

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

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

Illustrations guide the operator through correctprocedures of checking, starting, operating, andstopping the machine. Operating techniques thatareoutlined in this publication are basic. Skill andtechniques develop as the operator gains knowledgeof the machine and the capabilities of the machine.

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Machine Operation

Overhead Switch Panels



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

(7) Fan Speed Switch(8) Heating and Air Conditioning Switch(9) Temperature Control(10) HID Light Switch(11) Stairway Access Light(12) Main Lighting Switch

(13) Reduced Rimpull Switch(14) Kickout and Positioner Control(15) Override Switch for the Automatic

Lubrication System (If equipped)(16) Reversing Fan Switch(17) Hazard Light Switch

Front Window Wiper and Washer (1)

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

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

Note:

988H M&O manual

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