MANUAL DE MANTENIMIENTO

1. SAFETY.CAT.COM
QEBU2107-01
May 2010
2005
Operation and
Maintenance
Manual
PM102 Cold Planer
Z2X412-Up (Machine)

2. Important Safety Information
Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards. This person should
also have the necessary training, skills and tools to perform these functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you have
read and understood the operation, lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard
warnings are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the ≈Safety Alert Symbol∆ and followed by a ≈Signal Word∆ such as
≈DANGER∆, ≈WARNING∆ or ≈CAUTION∆. The Safety Alert ≈WARNING∆ label is shown below.
The meaning of this safety alert symbol is as follows:
Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by ≈NOTICE∆ labels on
the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must not
use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that the product will not be damaged or become unsafe by
the operation, lubrication, maintenance or repair procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before
you start any job. Caterpillar dealers have the most current information available.
m WARNING
When replacement parts are required for this
product Caterpillar recommends using
Caterpillar replacement parts or parts with
equivalent specifications including, but not
limited to, physical dimensions, type, strength
and material.
Failure to heed this warning can lead to
premature failures, product damage, personal
injury or death.
m WARNING

3. QEBU2107-01 3
TableofContents
Table of Contents
Foreword................................................................. 4
Safety Section
Safety Messages ................................................... 6
General Hazard Information ................................ 10
Crushing Prevention and Cutting Prevention ....... 13
Burn Prevention ................................................... 13
Fire Prevention and Explosion Prevention ........... 14
Electrical Storm Injury Prevention ........................ 17
Before Starting Engine ......................................... 17
Visibility Information ............................................. 18
Restricted Visibility ............................................... 18
Engine Starting .................................................... 20
Before Operation ................................................. 20
Operation ............................................................. 20
Parking ................................................................. 21
Slope Operation ................................................... 21
Engine Stopping .................................................. 22
Equipment Lowering with Engine Stopped ......... 22
Sound Information and Vibration Information ...... 22
Operator Station ................................................... 24
Guards (Operator Protection) .............................. 24
Track Information ................................................. 24
Product Information Section
General Information ............................................... 25
Identification Information ....................................... 26
Operation Section
Before Operation ................................................... 30
Machine Operation ................................................ 31
Operator Controls .................................................. 37
Operation Information ............................................ 72
Machine Service .................................................... 87
Parking................................................................... 93
Towing Information ................................................ 95
Engine Starting (Alternate Methods)...................... 98
Machine Cleanup ................................................ 100
Transportation Information................................... 102
Maintenance Section
Maintenance Access ........................................... 114
Maintenance Support .......................................... 120
Lubricant Viscosities and Refill Capacities.......... 121
Maintenance Interval Schedule ......................... 123
Reference Information Section
Reference Materials............................................. 191
Index Section
Index.................................................................... 193

4. 4 QEBU2107-01
Foreword
Foreword
Literature Information
This manual should be stored in the operator's
compartment in the literature holder or seat back
literature storage area.
This manual contains safety information, operation
instructions, transportation information, lubrication
information and maintenance information.
Some photographs or illustrations in this publication
show details or attachments that can be different
from your machine. Guards and covers might have
been removed for illustrative purposes.
Continuing improvement and advancement of
product design might have caused changes to your
machine which are not included in this publication.
Read, study and keep this manual with the machine.
Whenever a question arises regarding your
machine, or this publication, please consult your
Caterpillar dealer for the latest available information.
Safety
The safety section lists basic safety precautions. In
addition, this section identifies the text and locations
of warning signs and labels used on the machine.
Read and understand the basic precautions listed in
the safety section before operating or performing
lubrication, maintenance and repair on this machine.
Operation
The operation section is a reference for the new
operator and a refresher for the experienced
operator. This section includes a discussion of
gauges, switches, machine controls, attachment
controls, transportation and towing information.
Photographs and illustrations guide the operator
through correct procedures of checking, starting,
operating and stopping the machine.
Operating techniques outlined in this publication are
basic. Skill and techniques develop as the operator
gains knowledge of the machine and its capabilities.
Maintenance
The maintenance section is a guide to equipment
care. The Maintenance Interval Schedule (MIS) lists
the items to be maintained at a specific service
interval. Items without specific intervals are listed
under the ≈When Required∆ service interval. The
Maintenance Interval Schedule lists the page
number for the step-by-step instructions required to
accomplish the scheduled maintenance. Use the
Maintenance Interval Schedule as an index or ≈one
safe source∆ for all maintenance procedures.
Maintenance Intervals
Use the service hour meter to determine servicing
intervals. Calendar intervals shown (daily, weekly,
monthly, etc.) can be used instead of service hour
meter intervals if they provide more convenient
servicing schedules and approximate the indicated
service hour meter reading. Recommended service
should always be performed at the interval that
occurs first.
Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is
specified in the maintenance intervals chart might
be necessary.
Perform service on items at multiples of the original
requirement. For example, at every 500 service
hours or 3 months, also service those items listed
under every 250 service hours or monthly and every
10 service hours or daily.
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm.
Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands
after handling.
Certified Engine Maintenance
Proper maintenance and repair is essential to keep
the engine and machine systems operating
correctly. As the heavy duty off-road diesel engine
owner, you are responsible for the performance of
the required maintenance listed in the Owner
Manual, Operation and Maintenance Manual, and
Service Manual.

5. QEBU2107-01 5
Foreword
It is prohibited for any person engaged in the
business of repairing, servicing, selling, leasing, or
trading engines or machines to remove, alter, or
render inoperative any emission related device or
element of design installed on or in an engine or
machine that is in compliance with the regulations
(40 CFR Part 89). Certain elements of the machine
and engine such as the exhaust system, fuel system,
electrical system, intake air system and cooling
system may be emission related and should not be
altered unless approved by Caterpillar.
Machine Capacity
Additional attachments or modifications may exceed
machine design capacity which can adversely affect
performance characteristics. Included would be
stability and system certifications such as brakes,
steering, and rollover protective structures (ROPS).
Contact your Caterpillar dealer for further
information.
Caterpillar Product Identification
Number
Effective First Quarter 2001 the Caterpillar Product
Identification Number (PIN) will change from 8 to 17
characters. In an effort to provide uniform equipment
identification, Caterpillar and other construction
equipment manufacturers are moving to comply with
the latest version of the product identification
numbering standard. Non-road machine PINs are
defined by ISO 10261. The new PIN format will apply
to all Caterpillar machines and generator sets. The
PIN plates and frame marking will display the 17
character PIN. The new format will look like the
following:
Illustration 1
Where:
1. Caterpillar's World Manufacturing Code
characters 1-3)
2. Machine Descriptor (characters 4-8)
3. Check Character (character 9)
4. Machine Indicator Section (MIS) or Product
Sequence Number (characters 10-17). These were
previously referred to as the Serial Number.
Machines and generator sets produced before First
Quarter 2001 will maintain their 8 character PIN
format.
Components such as engines, transmissions, axles,
etc. and work tools will continue to use an 8
character Serial Number (S/N).
* *6 S L 1 2 3 4 5
4
G
3
0 7 8 9 B
2
C A T
1
XS0001AA

6. 6 QEBU2107-01
SafetySection
SafetyMessages
Safety Section
Safety Messages
There are several specific safety messages on this
machine. The exact location of the hazards and the
description of the hazards are reviewed in this
section. Become familiar with all of the safety
messages.
Make sure that all of the safety messages are
legible. Clean the safety messages or replace the
safety messages if you cannot read the words.
Replace the illustrations if the illustrations are not
legible. When you clean the safety messages, use a
cloth, water and soap. Do not use solvent, gasoline,
or other harsh chemicals to clean the safety
messages. Solvents, gasoline, or harsh chemicals
could loosen the adhesive that secures the safety
message. Loose adhesive will allow the safety
message to fall.
Replace any safety message that is damaged, or
missing. If a safety message is attached to a part
that is replaced, install a safety message on the
replacement part. Any Caterpillar dealer can provide
new safety messages.

7. QEBU2107-01 7
SafetySection
SafetyMessages
Illustration 2
5
4
8
7
3
72 6
1
7
3
7
5
4
7
XS0690AB
9
9
9
WARNING
216-8239 1
WARNING
216-8239 1
WARNING
216-8239 1

8. 8 QEBU2107-01
SafetySection
SafetyMessages
Do Not Operate (1)
This safety message is located near the steering
wheel.
m WARNING
Do not operate or work on this machine unless
you have read and understand the instructions
and warnings in the Operation and Maintenance
Manual. Failure to follow the instructions or heed
the warnings could result in injury or death.
Contact any Caterpillar dealer for replacement
manuals. Proper care is your responsibility.
Hot Surface (2)
This safety message is located on the engine cover.
m WARNING
Burn hazard - Touching hot surfaces could cause
serious injury or death. Stay clear.
Rotor (3)
This safety message is located on both sides and on
the rotor door.
m WARNING
Cutting and entanglement hazards. Moving rotor
can cause serious injury or death. Stay clear of
the rotor when the engine is running. Read the
manual and shut off the engine before
performing any service on the rotor or its
housing.
Crush Hazard (4)
This safety message is located on both sides of the
upper conveyor support.
m WARNING
Crush Hazard. Objects may fall from conveyor at
any time causing serious injury or death. Stay
clear.
XS0146AA
XS0147AA
XS0148AA
XS0149AA

9. QEBU2107-01 9
SafetySection
SafetyMessages
No Clearance (5)
This safety message is located at the pivot area of
the secondary conveyor.
m WARNING
Crush Hazard. No room for person in this area.
Conveyor movement could cause serious injury
or death. Stay clear.
Electrocution (6)
This safety message is located on the dashboard.
m DANGER
Electrocution hazard. Allowing any part of the
machine to contact electrical power sources can
cause serious injury or death. Keep machine and
attachments a safe distance from electrical
power.
Runover Hazard (7)
This safety message is located at each track/wheel
assembly.
m WARNING
Entanglement and crushing hazard. Contact with
tracks that both rotate and steer can cause
serious injury or death. Stay back.
Entanglement Hazard (8)
This safety message is located on the doors for the
rotor drive belt.
m WARNING
Entanglement hazard. Contact with moving belts
can cause serious injury or death. Stay clear
while engine is running.
XS0150AA
XS0151AA
XS0152AA
XS0153AA

10. 10 QEBU2107-01
SafetySection
GeneralHazardInformation
Adjustment for the Mirrors (9)
This safety message is located on both sides of the
machine, next to the mirrors.
m WARNING
Do not adjust the mirrors when the machine is
moving. Refer to the Operation and Maintenance
Manual for complete instructions for adjusting
the mirrors. Personal injury or death may result
from adjusting the mirrors when the machine is
moving.
General Hazard Information
Illustration 3
Attach a "Do Not Operate" warning tag or a similar
warning tag to the start switch or to the controls
before you service the equipment or before you
repair the equipment. These warning tags (Special
Instruction, SEHS7332) are available from your
Caterpillar dealer.
Know the width of your equipment in order to
maintain proper clearance when you operate the
equipment near fences or near boundary obstacles.
Illustration 4
Wear a hard hat, protective glasses, and other
protective equipment, as required.
Do not wear loose clothing or jewelry that can snag
on controls or on other parts of the equipment.
Make sure that all protective guards and all covers
are secured in place on the equipment.
Keep the equipment free from foreign material.
Remove debris, oil, tools, and other items from the
deck, from walkways, and from steps.
Secure all loose items such as lunch boxes, tools,
and other items that are not a part of the equipment.
XS1018AB
WARNING
216-8239 1
W
A
R
N
IN
G
operate
sig
ned
by
date
do
not
XS0009AA
XS0010AA

11. QEBU2107-01 11
SafetySection
GeneralHazardInformation
Know the appropriate work site hand signals and the
personnel that are authorized to give the hand
signals. Accept hand signals from one person only.
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 that contacts air conditioner refrigerant can
cause bodily harm or death. Inhaling gas from air
conditioner refrigerant through a lighted cigarette
can cause bodily 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 all
necessary repairs.
Do not allow unauthorized personnel on the
machine.
Dual controls are always active. Several functions
may be controlled at both sides of control panel.
When you perform maintenance procedures that are
not specified, maintenance procedures need to be
performed, as follows:
• Park the machine on level ground.
• Move the rotor control switch to the OFF position.
Reduce engine speed.
• Lower the machine until the rotor is resting on the
ground.
• Apply the parking Brake. Stop the engine.
• Turn the engine start switch key to the OFF
position. Then remove the key.
• Turn the disconnect switch key to the OFF
position. Then remove the key.
When you perform maintenance above ground level
use appropriate devices such as ladders or man lift
machines. If equipped, use the machine anchorage
points and use approved fall arrest harnesses and
lanyards.
Pressure Air and Water
Pressurized air and/or water can cause debris and/
or hot water to be blown out. This could result in
personal injury.
When pressure air and/or pressure water is used for
cleaning, wear protective clothing, protective shoes,
and eye protection. Eye protection includes goggles
or a protective face shield.
The maximum air pressure for cleaning purposes
must be below 205 kPa (30 psi). The maximum
water pressure for cleaning purposes must be below
275 kPa (40 psi).
Trapped Pressure
Pressure can be trapped in a hydraulic system.
Trapped pressure can cause sudden machine
movement or attachment movement. Use caution if
you disconnect hydraulic lines or fittings. High
pressure oil that is released can cause a hose to
whip. High pressure oil that is released can cause oil
to spray. Fluid penetration can cause serious injury
and possible death.
Fluid Penetration
Pressure can be trapped in the hydraulic circuit long
after the engine has been stopped. The pressure
can cause hydraulic fluid or items such as pipe
plugs to escape rapidly if the pressure is not
relieved correctly.
Do not remove any hydraulic components or parts
until pressure has been relieved or personal injury
may occur. Do not disassemble any hydraulic
components or parts until pressure has been
relieved or personal injury may occur. Refer to the
Service Manual for any procedures that are required
to relieve the hydraulic pressure.
Illustration 5
Always use a board or cardboard when you check
for a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak
can cause severe injury. If fluid is injected into your
skin, you must get treatment immediately. Seek
treatment from a doctor that is familiar with this type
of injury.
XS0011AA

12. 12 QEBU2107-01
SafetySection
GeneralHazardInformation
Containing Fluid Spillage
Care must be taken in order to ensure that fluids are
contained during performance of inspection,
maintenance, testing, adjusting and repair of the
equipment. Prepare to collect the fluid with suitable
containers before opening any compartment or
disassembling any component containing fluids.
Reference: Refer to Special Publication,
NENG2500 ≈Tools and Shop Products Guide∆ for the
following items:
• Tools that are suitable for collecting fluids and
equipment that is suitable for collecting fluids.
• Tools that are suitable for containing fluids and
equipment that is suitable for containing fluids.
Obey all local regulations for the disposal of liquids.
Asbestos Information
Illustration 6
Caterpillar equipment and replacement parts that
are shipped from Caterpillar are asbestos free.
Caterpillar recommends the use of only genuine
Caterpillar replacement parts. Use the following
guidelines when you handle any replacement parts
that contain asbestos or when you handle asbestos
debris.
Use caution. Avoid inhaling dust that might be
generated when you handle components that
contain asbestos fibers. Inhaling this dust can be
hazardous to your health. The components that may
contain asbestos fibers are brake pads, brake
bands, lining material, clutch plates, and some
gaskets. The asbestos that is used in these
components is usually bound in a resin or sealed in
some way. Normal handling is not hazardous unless
airborne dust that contains asbestos is generated.
If dust that may contain asbestos is present, there
are several guidelines that should be followed:
• Never use compressed air for cleaning.
• Avoid brushing materials that contain asbestos.
• Avoid grinding materials that contain asbestos.
• Use a wet method in order to clean up asbestos
materials.
• A vacuum cleaner that is equipped with a high
efficiency particulate air filter (HEPA) can also be
used.
• Use exhaust ventilation on permanent machining
jobs.
• Wear an approved respirator if there is no other
way to control the dust.
• Comply with applicable rules and regulations for
the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements
can be found in "29 CFR 1910. 1001".
• Obey environmental regulations for the disposal of
asbestos.
• Stay away from areas that might have asbestos
particles in the air.
Dispose of Waste Properly
Illustration 7
Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
disposed of according to local regulations.
Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
XS0012AA
XS0013AA

13. QEBU2107-01 13
SafetySection
CrushingPreventionandCuttingPrevention
Crushing Prevention and
Cutting Prevention
Support the equipment properly before you perform
any work or maintenance beneath that equipment.
Do not depend on the hydraulic cylinders to hold up
the equipment. Equipment can fall if a control is
moved, or if a hydraulic line breaks.
Do not work beneath the cab of the machine unless
the cab is properly supported.
Unless you are instructed otherwise, never attempt
adjustments while the machine is moving or while
the engine is running.
Never jump across the starter solenoid terminals in
order to start the engine. Unexpected machine
movement could result.
Whenever there are equipment control linkages the
clearance in the linkage area will change with the
movement of the equipment or the machine. Stay
clear of areas that may have a sudden change in
clearance with machine movement or equipment
movement.
Stay clear of all rotating and moving parts.
If it is necessary to remove guards in order to
perform maintenance, always install the guards after
the maintenance is performed.
Keep objects away from moving fan blades. The fan
blade will throw objects or cut objects.
Do not use a kinked wire cable or a frayed wire
cable. Wear gloves when you handle wire cable.
When you strike a retainer pin with force, the retainer
pin can fly out. The loose retainer pin can injure
personnel. Make sure that the area is clear of people
when you strike a retainer pin. To avoid injury to your
eyes, wear protective glasses when you strike a
retainer pin.
Chips or other debris can fly off an object when you
strike the object. Make sure that no one can be
injured by flying debris before striking any object.
Burn Prevention
Do not touch any part of an operating engine. Allow
the engine to cool before any maintenance is
performed on the engine. Relieve all pressure in the
air system, in the oil system, in the lubrication
system, in the fuel system, or in the cooling system
before any lines, fittings or related items are
disconnected.
Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.
Any contact with hot coolant or with steam can
cause severe burns. Allow cooling system
components to cool before the cooling system is
drained.
Check the coolant level only after the engine has
been stopped.
Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to
touch with a bare hand. Remove the filler cap slowly
in order to relieve pressure.
Cooling system conditioner contains alkali. Alkali
can cause personal injury. Do not allow alkali to
contact the skin, the eyes, or the mouth.
Oils
Hot oil and hot components can cause personal
injury. Do not allow hot oil to contact the skin. Also,
do not allow hot components to contact the skin.
Remove the hydraulic tank filler cap only after the
engine has been stopped. The filler cap must be
cool enough to touch with a bare hand. Follow the
standard procedure in this manual in order to
remove the hydraulic tank filler cap.
Batteries
Electrolyte is an acid. Electrolyte can cause
personal injury. Do not allow electrolyte to contact
the skin or the eyes. Always wear protective glasses
for servicing batteries. Wash hands after touching
the batteries and connectors. Use of gloves is
recommended.

14. 14 QEBU2107-01
SafetySection
FirePreventionandExplosionPrevention
Fire Prevention and Explosion
Prevention
Illustration 8
General
All fuels, most lubricants, and some coolant mixtures
are flammable.
To minimize the risk of fire or explosion, Caterpillar
recommends the following actions.
Always perform a Walk-Around Inspection, which
may help you identify a fire hazard. Do not operate a
machine when a fire hazard exists. Contact your
Caterpillar dealer for service..
Understand the use of the primary exit and
alternative exit on the machine. Refer to Operation
and Maintenance Manual, ≈Alternative Exit∆.
Do not operate a machine with a fluid leak. Repair
leaks and clean up fluids before resuming machine
operation. Fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause a
fire. A fire may cause personal injury or death.
Remove flammable material such as leaves, twigs,
papers, trash, etc. These items may accumulate in
the engine compartment or around other hot areas
and hot parts on the machine.
Keep the access doors to major machine
compartments closed and access doors in working
condition in order to permit the use of fire
suppression equipment, in case a fire should occur..
Clean all accumulations of flammable materials such
as fuel, oil and debris from the machine.
Do not operate the machine near any flame.
Keep shields in place. Exhaust shields (if equipped)
protect hot exhaust components from oil spray or
fuel spray in case of a break in a line, in a hose, or in
a seal. Exhaust shields must be installed correctly.
Do not weld or flame cut on tanks or lines that
contain flammable fluids or flammable material.
Empty and purge the lines and tanks. Then clean the
lines and tanks with a nonflammable solvent prior to
welding or flame cutting. Ensure that the
components are properly grounded in order to avoid
unwanted arcs.
Dust that is generated from repairing nonmetallic
hoods or fenders may be flammable and/or
explosive. Repair such components in a well
ventilated area away from open flames or sparks.
Use suitable Personal Protection Equipment (PPE).
Inspect all lines and hoses for wear or deterioration.
Replace damaged lines and hoses. The lines and
the hoses should have adequate support and
secure clamps. Tighten all connections to the
recommended torque. Damage to the protective
cover or insulation may provide fuel for fires.
Store fuels and lubricants in properly marked
containers away from unauthorized personnel. Store
oily rags and flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials.
Illustration 9
Use caution when you are fueling a machine. Do not
smoke while you are fueling a machine. Do not fuel a
machine near open flames or sparks. Always stop
the engine before fueling. Fill the fuel tank outdoors.
Properly clean areas of spillage.
XS0014AA
XS0015AA

15. QEBU2107-01 15
SafetySection
FirePreventionandExplosionPrevention
Follow practices for safe fueling that are described
in the ≈Operation∆ section of the Operation and
Maintenance Manual section and follow local
regulations. Never store flammable fluids in the
operator compartment of the machine.
Battery and Battery Cables
Illustration 10
Caterpillar recommends the following in order to
minimize the risk of fire or an explosion related to the
battery.
Do not operate a machine if battery cables or related
parts show signs of wear or damage. Contact your
Caterpillar dealer for service.
Follow safe procedures for engine starting with jump
start cables. Improper jumper cable connections
can cause an explosion that may result in injury.
Refer to Operation and Maintenance Manual,
≈Engine Starting with Jump Start Cables∆ for specific
instructions.
Do not charge a frozen battery. This may cause an
explosion.
Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. Do
not smoke in battery charging areas.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter or
a hydrometer.
Daily inspect battery cables that are in visible areas.
Identify cables, clips, straps, and other restraints for
damage. Replace these items if necessary. Look for
signs of the following, which can occur over time
due to use and environmental factors:
• Fraying
• Abrasion
• Cracking
• Discoloration
• Cuts on the insulation of the cable
• Fouling
• Corroded terminals, damaged terminals, and
loose terminals
Replace damaged battery cable(s) and replace any
related parts. Eliminate any fouling, which may have
caused insulation failure or related component
damage or wear. Ensure that all components are
reinstalled correctly.
An exposed wire on the battery cable may cause a
short to ground if the exposed area comes into
contact with a grounded surface. A battery cable
short produces heat from the battery current, which
may be a fire hazard.
An exposed wire on the ground cable between the
battery and the disconnect switch may cause the
disconnect switch to be bypassed if the exposed
area comes into contact with a grounded surface.
This may result in an unsafe condition for servicing
the machine. Repair components or replace
components before servicing the machine.
m WARNING
Fire on a machine can result in personal injury or
death. Exposed battery cables that come into
contact with a grounded connection can result in
fires. Replace cables and related parts that show
signs of wear or damage. Contact your
Caterpillar dealer.
XS0017AA

16. 16 QEBU2107-01
SafetySection
FirePreventionandExplosionPrevention
Wiring
Check electrical wires daily. If any of the following
conditions exist, replace parts before you operate
the machine.
• Fraying
• Signs of abrasion or wear
• Cracking
• Discoloration
• Cuts on insulation
• Other damage
Make sure that all clamps, guards, clips, and straps
are reinstalled correctly. This will help to prevent
vibration, rubbing against other parts, and excessive
heat during machine operation.
Attaching electrical wiring to hoses and tubes that
contain flammable fluids or combustible fluids
should be avoided.
Consult your Caterpillar dealer for repair or for
replacement parts.
Keep wiring and electrical connections free of
debris
Lines, Tubes and Hoses
Do not bend high pressure lines. Do not strike high
pressure lines. Do not install any lines that are bent
or damaged. Use the appropriate backup wrenches
in order to tighten all connections to the
recommended torque.
Illustration 11
Check lines, tubes and hoses carefully. Wear
Personal Protection Equipment (PPE) in order to
check for leaks. Always use a board or cardboard
when you check for a leak. Leaking fluid that is
under pressure can penetrate body tissue. Fluid
penetration can cause serious injury and possible
death. A pin hole leak can cause severe injury. If
fluid is injected into your skin, you must get
treatment immediately. Seek treatment from a doctor
that is familiar with this type of injury.
Replace the affected parts if any of the following
conditions 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 shields
are installed correctly. During machine operation,
this will help to prevent vibration, rubbing against
other parts, excessive heat, and failure of lines,
tubes and hoses.
Do not operate a machine when a fire hazard exists.
Repair any lines that are corroded, loose or
damaged. Leaks may provide fuel for fires. Consult
your Caterpillar dealer for repair or for replacement
parts. Use genuine Caterpillar parts or the
equivalent, for capabilities of both the pressure limit
and temperature limit.
Ether
Ether (if equipped) is commonly used in cold
weather applications. Ether is flammable and
poisonous.
Follow the correct cold engine starting procedures.
Refer to the section in the Operation and
Maintenance Manual with the label ≈Engine
Starting∆.
Do not spray ether into an engine if the machine is
equipped with a thermal starting aid for cold weather
starting.
Use ether in well ventilated areas. Do not smoke
while you are replacing an ether cylinder or while
you are using an ether spray.
XS0011AA

17. QEBU2107-01 17
SafetySection
ElectricalStormInjuryPrevention
Do not store ether cylinders in living areas or in the
operator compartment of a machine. Do not store
ether cylinders in direct sunlight or in temperatures
above 49° C (120.2° F). Keep ether cylinders away
from open flames or sparks.
Dispose of used ether cylinders properly. Do not
puncture an ether cylinder. Keep ether cylinders
away from unauthorized personnel.
Fire Extinguisher
As an additional safety measure, keep a fire
extinguisher on the machine.
Be familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Follow the recommendations
on the instruction plate.
Consider installation of an aftermarket Fire
Suppression System, if the application and working
conditions warrant the installation.
Fire Extinguisher Location
Make sure that the fire extinguisher is on the
machine. Make sure that you are familiar with the
operation of the fire extinguisher. Inspect the fire
extinguisher and service the fire extinguisher. Obey
the recommendations that are on the instruction
plate.
Illustration 12
Mount the fire extinguisher on the support next to the
operator's seat.
Electrical Storm Injury
Prevention
When lightning is striking in the vicinity of the
machine, the operator should never attempt the
following procedures:
• Mount the machine.
• Dismount the machine.
If you are in the operator's station during an
electrical storm, stay in the operator's station. If you
are on the ground during an electrical storm, stay
away from the vicinity of the machine.
Before Starting Engine
Never short across the starter terminals or across
the batteries. Shorting could damage the electrical
system by bypassing the engine neutral start
system.
Make sure that the machine is equipped with a
lighting system that is adequate for the job
conditions. Make sure that all machine lights are
working properly.
Before you start the engine and before you move the
machine, make sure that no one is underneath the
machine, around the machine, or on the machine.
Make sure that the area is free of personnel.
Adjust the mirrors before you start the engine and
before you move the machine.
XS0633AB

18. 18 QEBU2107-01
SafetySection
VisibilityInformation
Visibility Information
Before you start the machine, perform a walk-around
inspection in order to ensure that there are no
hazards around the machine.
While the machine is in operation, constantly survey
the area around the machine in order to identify
potential hazards as hazards become visible around
the machine. Your machine may be equipped with
visual aids.
Some examples of visual aids are Closed Circuit
Television (CCTV) and mirrors. Before operating the
machine, ensure that the visual aids are in proper
working condition and that the visual aids are clean.
Adjust the visual aids using the procedures that are
located in this Operation and Maintenance Manual.
If equipped, the Work Area Vision System shall be
adjusted according to Operation and Maintenance
Manual, SEBU8157, ≈Work Area Vision System∆.
It may not be possible to provide direct visibility on
large machines to all areas around the machine.
Appropriate job site organization is required in order
to minimize hazards that are caused by restricted
visibility. Job site organization is a collection of rules
and procedures that coordinates machines and
people that work together in the same area.
Examples of job site organization include the
following:
• Safety instructions
• Controlled patterns of machine movement and
vehicle movement
• Workers that direct traffic to move when it is safe
• Restricted areas
• Operator training
• Warning symbols or warning signs on machines or
on vehicles
• A system of communication
• communication between workers and operators
prior to approaching the machine
Modifications of the machine configuration that
result in a restriction of visibility shall be evaluated.
Restricted Visibility
The size and the configuration of this machine may
result in areas that can not be seen when the
operator is seated.
The illustrations indicates areas of restricted visibility
near the machine in two locations.
One location is on a rectangular line 1.00 m (3.00 ft)
from the outside of the machine profile at a height of
1.5 m (5.00 ft).
The second location is on the ground level at a
radius of 12.00 m (40.00 ft) from the operator.
This machine may be equipped with optional
visibility aids that may provide visibility to some of
the restricted visibility areas. Refer to this Operation
and Maintenance Manual, ≈Mirror∆ for more
information on additional visibility.
If your machine is equipped with cameras, refer to
this Operation and Maintenance Manual, ≈Camera∆
for more information on additional visibility. For areas
that are not covered by the optional visual aids, a
appropriate job site organization must be utilized to
minimize hazards of this restricted visibility. For
more information regarding job site organization
refer to Operation and Maintenance Manual,
≈Visibility Information∆.

19. QEBU2107-01 19
SafetySection
RestrictedVisibility
Illustration 13
NOTE: The shaded areas indicate the approximate
location of areas with significant restricted visibility if
the machine is equipped with camera.
Illustration 14
NOTE: The shaded areas indicate the approximate
location of areas with significant restricted visibility if
the machine is not equipped with camera.
XS0101AC
XS0100AC

20. 20 QEBU2107-01
SafetySection
EngineStarting
Engine Starting
Illustration 15
Do not start the engine or move any controls if there
is a ≈Do Not Operate∆ or similar warning tag
attached to the start switch or controls.
Move the parking brake switch to the "ON" position.
Start the engine and operate the engine in a well
ventilated area. In an enclosed area, vent the
exhaust to the outside.
Before Operation
NOTE: The monitoring system will perform a self
test when the engine is started. Always allow the
monitoring system to complete the self test before
you start the engine.
Clear all personnel from the machine and from the
area.
Clear all obstacles that are in the path of the
machine. Beware of hazards such as wires, ditches,
etc.
Make sure that the machine horn, the backup alarm
and all other warning devices are working properly.
Fasten the seat belt securely.
Warm up the engine and hydraulic oil before
operating the machine.
Operation
Machine operating temperature
range
The standard machine configuration is intended for
use within an ambient temperature range of -40 °C (-
40 °F) to 50 °C (122 °F). Special configuration for
different ambient temperature may be available.
Consult your Caterpillar dealer for additional
information on special configurations of your
machine.
Machine operation
Only operate the controls when the engine is
running. You may operate the controls that have a
DC power supply when the engine is off.
The seat belt (if equipped) must be fastened while
you operate the machine.
While you operate the machine slowly in an open
area, check for proper operation of all controls and
all protective devices.
Before you move the machine be sure that no one is
in danger.
When the machine is moving in reverse and the rotor
is running, raise the rotor in order to clear all the
obstacles.
When you start a cut, lower the milling rotor drum
slowly. This will help prevent the machine from riding
up on the milling rotor drum and lunging backward.
Never allow work to be performed in the area of the
rotor while the rotor is running.
When the machine is operating do not allow anyone
to stand or walk behind the machine. The machine
may lunge backward if the rotor hits an obstruction.
Never allow a truck to hit the conveyor. The
conveyor structure or the support members could
fail immediately, if a truck contacts the upper
conveyor with enough force. Minor contact by a
truck can cause enough stress to start a hairline
crack in the conveyor structure, support members,
and welds that will lead to a later failure.
Do not allow riders on the machine.
Never use the work tool as a work platform.
Note any needed repairs during machine operation.
Report any needed repairs.
W
A
R
N
IN
G
operate
sig
ned
by
date
do
not
XS0009AA

21. QEBU2107-01 21
SafetySection
Parking
Do not go close to the edge of a cliff, an excavation,
or an overhang.
Turn the machine downhill, if the machine begins to
sideslip downward on a grade.
Avoid any conditions that can lead to tipping the
machine. The machine can tip when you work on
hills, on banks and on slopes. Also, the machine can
tip when you cross ditches, ridges or other
unexpected obstructions.
Avoid operating the machine across the slope.
When possible, operate the machine up the slopes
and down the slopes.
Maintain control of the machine. Do not overload the
machine beyond the machine capacity.
Be sure that the hitches and the towing devices are
adequate.
Never straddle a wire cable. Never allow other
personnel to straddle a wire cable.
Know the maximum dimensions of your machine.
Parking
Park the machine on a level surface. If you must park
the machine on a grade, you must block the
machine.
Move the propel lever to NEUTRAL position in order
to stop the machine. Then move the throttle switch to
LOW IDLE position.
Apply the parking brake.
Lower the mainframe until the rotor rests on the
ground, or until the mainframe rests on the support
legs.
Stop the engine.
Turn the main power switch to the OFF position and
remove the key.
Turn the key for the battery disconnect switch to the
OFF position. Remove the key when you exit the
machine for an extended period of time.
Turning the battery disconnect switch to the OFF
position will provide the following benefits:
• Prevent battery discharge that is caused by a
battery short circuit.
• Prevent battery discharge that is caused by some
of the components.
• Prevent battery discharge that is caused by
vandalism.
Slope Operation
Machines that are operating safely in various
applications depend on these criteria: the machine
model, configuration, machine maintenance,
operating speed of the machine, conditions of the
terrain, fluid levels, conveyor position and height of
machine off the ground. The most important criteria
are the skill and judgment of the operator.
A well trained operator that follows the instructions in
the Operation and Maintenance Manual has the
greatest impact on stability. Operator training
provides a person with the following abilities:
observation of working and environmental
conditions, feel for the machine, identification of
potential hazards, and operating the machine safely
by making appropriate decisions.
The machine is equipped with an inclinometer.
Illustration 16
Theillustrationshowstheinclinometer.
Refer to the inclinometer when operating the
machine in a slope condition. There are three zones
on the inclinometer which have the following
meanings:
Green √ Operate the machine with a normal level of
caution and concern for the factors influencing slope
operation.
Yellow √ Operate the machine with enhanced
caution and concern for the factors influencing slope
operation.
XS0108AC

22. 22 QEBU2107-01
SafetySection
EngineStopping
Red √ If operation in this zone is required, an
experienced crew following site- specific rules and
precautions should operate with extreme caution
and follow the important points below.
When you work on slopes or uneven terrain,
consider the following important points:
Speed of travel √ At higher speeds, forces of inertia
tend to make the machine less stable.
Roughness of terrain or surface √ The machine
may be less stable with uneven terrain. Use the
elevation controls to keep the machine level when
entering or exiting a previously milled area.
Nature of surface √ Ground that has been newly
filled with earth may collapse from the weight of the
machine. Milling of the surface may expose soft
material that may not support the weight of the
machine.
Height of the working load of the machine √ When
the machine and conveyor are in higher positions,
the stability of the machine is reduced.
Water Tank Fill Level √ Cold Planers have large
water tanks. The level of water in the tank can affect
the machine stability.
Operated equipment √ Be aware of performance
features of the equipment in operation and the
effects on machine stability.
Operating techniques √ Keep the machine and
conveyor low to the ground for optimum stability.
Always position the conveyor to discharge from the
uphill side of the machine when operating on slopes.
Machine systems have limitations on slopes √
Slopes can affect the proper function and operation
of the various machine systems. These machine
systems are needed for machine control on slopes.
NOTE: Safe operation on steep slopes may require
special machine maintenance. Excellent skill of the
operator and proper equipment for specific
applications are also required. Consult the
Operation and Maintenance Manual sections for the
proper fluid level requirements and intended
machine use.
Engine Stopping
Do not stop the engine immediately after the
machine has been operated under load. This can
cause overheating and accelerated wear of engine
components.
After the machine is parked and the parking brake is
engaged, allow the engine to run for five minutes
before shutdown. This allows hot areas of the engine
to cool gradually.
Equipment Lowering with
Engine Stopped
The machine cannot be raised or lowered with a
stopped engine.
Sound Information and
Vibration Information
Sound Level Information
Hearing protection may be needed when the
machine is operated with an open operator station
for extended periods or in a noisy environment.
Sound Level Information for
Machines in European Union
Countries and in Countries that
Adopt the “EU Directives”
The operator sound pressure level that is measured
according to the static test procedures and
conditions that are specified in ≈EN500-2006∆ is 85
dB (A) for a machine that is equipped with a canopy.
The exterior sound power level is 108 dB (A). The
exterior sound power level was measured according
to the static test procedures and conditions that are
specified in ≈2000/14/EC∆.
“The European Union Physical
Agents (Vibration) Directive 2002/
44/EC”
Vibration Data for Cold Planer
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.

23. QEBU2107-01 23
SafetySection
SoundInformationandVibrationInformation
“The European Union Physical
Agents (Vibration) Directive 2002/
44/EC”
Vibration Data for Cold Planer
Information Concerning Whole Body Vibration Level
This section provides vibration data and a method
for estimating the vibration level for cold planers.
NOTE: Vibration levels are influenced by many
different parameters. Many items are listed below.
• Operator training, behavior, mode, and stress
• Machine type, quality of the seat, quality of the
suspension system 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.
Table1
NOTE: Refer to ≈ISO/TR 25398 Mechanical
Vibration - Guideline for the assessment of exposure
to whole body vibration of ride on operated
earthmoving machines∆ for more information about
vibration. This publication uses data that is
measured by international institutes, organizations
and manufacturers. This document provides
information about the whole body exposure of
operators of earthmoving equipment. Refer to
Operation and Maintenance Manual Supplement,
SEBU8257 for more information about machine
vibration levels.
The Caterpillar suspension seat meets the criteria of
≈ISO 7096∆. This represents vertical vibration level
under severe operating conditions.
Guidelines for Reducing Vibration Levels
Properly adjust machines. Properly maintain machines.
Operate machines smoothly. The following guidelines
can help reduce the whole body vibration level:
1. Maintain machines according to the
manufacturer»s recommendations.
a. Brake and steering systems
b. Controls, hydraulic system and linkages
2. Use a seat that meets ≈ISO 7096∆. Keep the seat
maintained and adjusted.
a. Adjust the seat and suspension for the weight
and the size of the operator.
b. Inspect and maintain the seat suspension and
adjustment mechanisms.
3. Perform the following operations smoothly.
a. Steer
b. Brake
c. Accelerate
d. Shift the gears
4. Minimize vibrations for a long work cycle or a
long travel distance.
a. If no ride control system is available, reduce
speed in order to prevent bounce.
b. Haul the machines between workplaces.
5. Less operator comfort may be caused by other risk
factors. The following guidelines can be effective in
order to provide better operator comfort:
a. Adjust the seat and adjust the controls in
order to achieve good posture.
b. Adjust the mirrors in order to minimize twisted
posture.
“ISO Reference Table A - Equivalent vibration levels of whole body vibration emission for earthmoving equipment.”
Machine
Type
Typical Operating
Activity
Vibration Levels Scenario Factors
X axis Y axis Z axis X axis Y axis Z axis
ColdPlaner/Mill workcycle 0,15 0,14 0,17 0,05 0,08 0,03

24. 24 QEBU2107-01
SafetySection
OperatorStation
c. Provide breaks in order to reduce long
periods of sitting.
d. Avoid jumping from the operator platform
e. 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 earthmoving
machines∆. Harmonized data is measured by
international institutes, organizations and
manufacturers.
This literature provides information about assessing
the whole body vibration exposure of operators of
earthmoving 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
Supplement, 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
Operator Station
Any modifications to the inside of the operator
station should not project into the operator space.
The addition of a radio, fire extinguisher, and other
equipment must be installed so that the defined
operator space is maintained. Any item that is
brought into the cab should not project into the
defined operator space. A lunch box or other loose
items must be secured. Objects must not pose an
impact hazard in rough terrain or in the event of a
rollover.
Guards (Operator Protection)
There are different types of guards that are used to
protect the operator. The machine and the machine
application determines the type of guard that should
be used. A daily inspection of the guards is required
in order to check for structures that are bent,
cracked or loose. Never operate a machine with a
damaged structure. The operator becomes exposed
to a hazardous situation if the machine is used
improperly or if poor operating techniques are used.
This situation can occur even though a machine is
equipped with an appropriate protective guard.
Follow the established operating procedures that
are recommended for your machine.
Track Information
Track adjusting systems use grease under high
pressure to keep the track under tension.
Grease under high pressure coming out of the relief
valve can penetrate the body causing injury or
death. Do not watch the relief valve to see if grease
is escaping. Watch the track or track adjustment
cylinder to see if the track is being loosened.
The pins and bushings in a dry track pin joint can
become very hot. It is possible to burn the fingers if
there is more than brief contact with these
components.

25. QEBU2107-01 25
ProductInformationSection
GeneralInformation
Product Information
Section
General Information
Specifications
The standard machine shipping specifications are
listed in the table below.
Table2
Weights shown are approximate and include:
* coolant, lubricants, 50% fuel tank, 50% water tank
and a 75 kg operator.
** coolant, lubricants, 50% fuel level and empty
water tank.
Intended Use
A PM102 Cold Planer is classified as a road-milling
machine, a mobile road construction machine used
to mill material from paved surfaces. The machine
includes milling equipment, a power-driven
cylindrical body or rotor, on which the milling tools
are installed. The rotor rotates during the milling
operation.
Cold planing or road-milling is done on asphalt road
surfaces or cement slabs on flat ground or slight
inclines.
Application/Configuration
Restrictions
• Use only in non-explosive gas environments.
• Use machine only with approved tools and guards
in place.
• Not for use in underground applications.
• Not for use in near external sources of electricity.
• Towing trailers is prohibited.
PM102 Cold Planer
Operating Weights*
Trackundercarriage 17600kg(38,800lb)
Wheelundercarriage 17100kg(37,700lb)
Shipping Weights**
Trackundercarriage 17100kg(37,700lb)
Wheelundercarriage 16400kg(36,155lb)
Lengthwithloading
conveyor
10.755mm(35.28ft)
Lengthwithloading
conveyorfolded
8505mm(27.9ft)
Lengthwithoutconveyor 5330mm(17.5ft)
Widthwithrearright-hand
wheelextended
2400mm(7.87ft)
Widthwithrearright-hand
wheelretracted
1980mm(6.5ft)
Widthwithrearright-hand
trackextended
2535mm(8.32ft)
Widthwithrearright-hand
trackretracted
2000mm(6.56ft)
Heightwithcanopyfolded 3100mm(10.17ft)
Heightwithcanopy 3400mm(11.2ft)

26. 26 QEBU2107-01
ProductInformationSection
IdentificationInformation
Identification Information
Plate Locations and Film
Locations
The Product Identification Number (PIN) is used to
identify a powered machine that is designed for an
operator to ride.
Caterpillar products such as engines, transmissions
and major attachments that are not designed for an
operator to ride are identified by Serial Numbers.
The Certification Plate (CE) is used to verify that the
product conforms to all of the requirements that
were established by a country or a group of
countries. The product is tested by a certified testing
group in order to verify conformance.
The emission certification film (if equipped) is used
to verify that the engine meets the EPA emissions
requirements.
For quick reference, record the identification
numbers in the spaces that are provided below the
illustration.
Product Identification Number
(PIN)
Illustration 17
Machine PIN
Engine Serial Number
Illustration 18
Engine Serial Number
Certification
European Union
This plate is positioned on the bottom left side of the
plate for the PIN.
Illustration 19
NOTE: The CE plate is on machines that are
certified to the European Union requirements that
were effective at that time.
XS0354AA
XS0634AB
225-4148 11
XS1261AB

27. QEBU2107-01 27
ProductInformationSection
IdentificationInformation
For machines compliant to 2006/42/EC, the following
information is stamped onto the CE plate. For quick
reference, record this information in the spaces that
are provided below.
• Engine Power Primary Engine (kW)
• Engine Power for Additional Engine
(If Equipped)
• Typical Machine Operating Weight for European
Market (kg)
• Year of Construction
• Machine Type
Sound Certification
Illustration 20
A typical example of this film is shown. Your
machine may have a different value.
If equipped, the certification film is used to verify the
environmental sound certification of the machine.
The value that is listed on the film indicates the
guaranteed sound power level. The guaranteed
sound power level is measured at the time of
manufacture. The guaranteed sound power level is
measured according to the conditions that are
specified in ≈ISO 6394:1998∆.
Product Link
If equipped, this message is used to verify the
certification of the Product Link as a RF transmitter.
The following specifications are provided to aid in
ensuring compliance with all local regulations:
Table3
This message is located on the control group for the
Product Link. The control group is located on the left
operator console storage compartment.
Illustration 21
m WARNING
This machine is equipped with a Caterpillar
Product Link radio communication device which
must be deactivated within 6.0 m (20 ft) of a blast
zone. Failure to do so could result in serious
injury or death.
If the machine is required to work within 6 m (20 ft) of
a blast area, power to the Product Link module must
be disconnected.
Consult your Caterpillar dealer with any questions
that concern the operation of the Product Link in a
specific country.
XS1229AB
Operatingfrequencyrange 48to150MHz
Transmitterpower 5Watts
ORBCOMM TYPE
APPROVAL: 801QWI
IC: 4650A-Q121415
XS1135AB

28. 28 QEBU2107-01
ProductInformationSection
IdentificationInformation
Emissions Certification Film
NOTE: This information is pertinent in the United
States, in Canada and in Europe.
Contact your Caterpillar dealer for an Emission
Control Warranty Statement.
.
A typical example is shown.
Illustration 22
XS0350AA

29. QEBU2107-01 29
ProductInformationSection
IdentificationInformation
Declaration of Conformity
NOTE: The extract from the EC Declaration of Conformity shown below applies only to those machines originally
≈CE∆ marked by the manufacturer listed and have not since been modified. This declaration is applicable for
machines with serial number Z2X412-Up.
EC DECLARATION OF CONFORMITY OF MACHINERY
Manufacturer:
Person authorized to compile the Technical File and to communicate relevant part (s) of the Technical File
to the Authorities of European Union Member States on request:
CaterpillarPavingProductsInc.
BrooklynPark,MN55445
USA
I, the undersigned, , hereby certify that the construction equipment specified hereunder
Description: GenericDenomination:
Function:
Model/Type:
SerialNumber:
CommercialName:
FulfilsalltherelevantprovisionsofthefollowingDirectives
Note(1)Annex- GuaranteedSoundPowerLevel- dB(A)
RepresentativeEquipmentTypeSoundPowerLevel- dB(A)
EnginePowerper - kWRatedenginespeed- rpm
TechnicalDocumentationaccessiblethroughpersonlistedaboveauthorizedtocompiletheTechnicalFile
Done at: Signature
Date: Name/Position
NOTE: Theaboveinformationwascorrectasof(dateofpublish),butmaybesubjecttochange,pleaserefertothe
individualdeclarationofconformityissuedwiththemachineforexactdetails.
Directives NotifiedBody DocumentNo.
2006/42/EC
2000/14/ECamendedby2005/88/EC,
Note(1)
2004/108/EC

30. 30 QEBU2107-01
OperationSection
BeforeOperation
Operation Section
Before Operation
Mounting and Dismounting
Illustration 23
Use steps and handholds whenever you mount the
machine. Use steps and handholds whenever you
dismount the machine. Before you mount the
machine, clean the step and the handholds. Inspect
the step and handholds. Make all necessary repairs.
Face the machine whenever you mount the machine
and whenever you dismount the machine. Maintain a
three-point contact with the step and with
handholds.
NOTE: Three-point contact can be two feet and one
hand. Three-point contact can also be one foot and
two hands.
Do not mount a moving machine. Do not dismount a
moving machine. Never jump off the machine. Do
not try to mount the machine when you carry tools or
supplies. Do not try to dismount the machine when
you are carrying tools or supplies. Use a hand line to
pull equipment onto the platform. Do not use any
controls as handholds when you enter the operator
compartment or when you exit the operator
compartment.
Daily Inspection
m 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.
To secure the machine:
• Lower the machine until the rotor is on the ground.
NOTE: This will prevent movement of the machine
while the machine is being serviced.
For maximum service life of the machine, always
make a walk-around inspection of the machine. The
walk around inspection must be done before you
mount the machine in order to start the engine.
Look around the machine and under the machine for
items such as loose bolts, trash, oil leaks, coolant
leaks, broken parts or worn parts.
Inspect the condition of the attachments. Inspect the
condition of the tracks and the condition of the
hydraulic components.
NOTICE
Accumulatedgreaseandoilonamachineisafirehazard.
Removethisdebriswithsteamcleaningorhighpressure
water,atleastevery1000hoursoreachtimeany
significantquantityofoilisspilledonthemachine.
Perform the following procedures on a daily basis.
• Backup Alarm - Test
• Conveyor Support Cables - Check
• Cooling System Coolant Level - Check
• Engine Air Precleaner - Clean
• Engine Oil Level - Check
• Fuel System Primary Filter (Water Separator) -
Drain
• Hydraulic System Oil Level - Check
• Indicators and Gauges - Test
• Moldboard Cutting Edge -Inspect/Adjust/Replace
• Rotor Cutter Bits - Inspect/Replace
• Rotor Drive (Planetary) Oil Level - Check
Refer to the Maintenance Section for the detailed
procedures. Refer to the Maintenance Interval
Schedule for a complete list of scheduled
maintenance.
XS0022AA

31. QEBU2107-01 31
OperationSection
MachineOperation
Machine Operation
Seat
Adjust the seat at the beginning of each work period
and adjust the seat when you change operators.
The seat and the operator side console move as one
unit.
NOTE: Do not contact any of the machine controls.
Unexpected movement of the machine may result.
Always use the seat belt (if equipped) when you
operate the machine. For further details on this
procedure, refer to Operation and Maintenance
Manual, ≈Seat Belt∆.
The seat must be adjusted so all of the controls are
easily reached.
Lock the seat into position before you operate the
machine. This will prevent unexpected movement of
the seat.
Illustration 24
The operator can adjust the seat position forward or
backward. The operator can slide the seat to the left
or to the right. The operator can adjust the height of
the seat.
Illustration 25
To adjust the seat forward or backward, move lever
(1) to the left. Move the seat to the desired position.
To lock the seat in the selected position, release the
lever.
Use the seat height control (2) in order to adjust the
height of the seat. Place the handle in the operating
position. Turning the handle clockwise increases the
height of the seat. Turning the handle
counterclockwise decreases the height of the seat.
The indicator (3) shows the operator weight in
kilograms and pounds.
Move lever (4) to the left to slide the seat assembly
to the right, to the left or center position. Release the
lever to lock the seat in the desired position.
XS0631AB
(1) Seat position lever
(2) Seat height control
(3) Seat height indicator
(4) Seat sliding lever
1
2
3
XS0632AB
4

32. 32 QEBU2107-01
OperationSection
MachineOperation
Windscreen (If Equipped)
Illustration 26
The canopy provided with this machine is equipped
with a front movable windscreen.
To lower the front windscreen to the down position
lift the windscreen (1), unlock the locking bar (2),
rotate the windscreen (1) to the opened position and
secure it using the straps (3).
To raise the front windscreen to the closed position,
fully raise the windscreen (1) and lock it using the
locking bar (2).
NOTE: The machine may be operated with the
windscreen in either the up or down position.
Product Link (If Equipped)
The Product Link PL321SR is a satellite
communication device that transmits information
regarding the machine to Caterpillar, Caterpillar
dealers, and Caterpillar customers. The unit
contains a Global Positioning System receiver (GPS
receiver) and a satellite transceiver.
The Product Link PL321SR is capable of two-way
communication between the machine and a remote
user. The remote user can be a dealer or a
customer. At any time, a user can request updated
information from a machine such as hours of use or
the location of the machine. Also, the system
parameters for Product Link PL321SR can be
changed. Data is transmitted from the machine to a
satellite. Next, the data is transmitted to a ground
station. The receiving station transmits the data to
Caterpillar Inc. The data can then be sent to a
Caterpillar dealer and to the customer.
Data Broadcasts
Machine data about the machine's condition and
operation is being transmitted by Product Link to
Caterpillar and/or Caterpillar dealers in order to
better serve the customer and to improve Caterpillar
products and services. The information that is
transmitted may include the following data: machine
serial number, location of the machine, fault codes,
emissions data, fuel usage, service meter hours,
version numbers for software and hardware, and
installed attachments.
Caterpillar and/or Caterpillar dealers may use this
information for various purposes: providing services
to the customer and/or the machine, checking or
maintaining Product Link equipment, monitoring the
machine's health or performance, helping to
maintain the machine, improving the machine's
efficiency, evaluating or improving Caterpillar
products and services, complying with legal
requirements and valid court orders, performing
market research, and offering the customer new
products and services.
Caterpillar may share some or all of the collected
information with Caterpillar affiliated companies,
dealers, and authorized representatives. Caterpillar
will not sell or rent collected information to any other
third party and will exercise reasonable efforts to
keep the information secure. Caterpillar recognizes
and respects customer privacy. For more
information, please contact your local Caterpillar
dealer.
XS0355AA

33. QEBU2107-01 33
OperationSection
MachineOperation
Operation in a Blast Zone
If the machine is required to work within 12 m (40 ft)
of a blast area, then Product Link PL321SR must be
disabled. In order to disable the Product Link
PL321SR install a Product Link Disconnect Switch in
the machine cab that will allow the Product Link
PL321SR module to be shut off. Refer to Special
Instruction, REHS2365, "An Installation Guide for the
Product Link PL321SR and for the PL300" for more
details and installation instructions. You may also
disconnect the Product Link PL321SR module from
the main power source by disconnecting the wiring
harness at the Product Link module.
This blast zone warning does not supersede the
published requirements or regulations found in "Title
30 of the Code of Federal Regulations (CFR)". This
warning does not allow deviation from the published
requirements or regulations found in "Title 30 of the
Code of Federal Regulations (CFR)". A hazard
assessment should be conducted by each
customer. Every customer should meet all of the
requirements of "Title 30 of the Code of Federal
Regulations (CFR)" in order to ensure the safe
storage, transportation, loading, and blasting of any
explosive.
The following Product Link PL321SR specifications
are provided in order to aid in conducting any
related hazard assessment and to ensure
compliance with all local regulations:
• The transmit power rating for the Product Link
PL321SR transmitter is five to ten watts
• The operating frequency range for the Product
Link PL321SR module is 148 MHz to 150 MHz.
Consult your Caterpillar dealer if there are any
questions.
Information for the initial installation of the Product
Link PL321SR is available in Special Instruction,
REHS2365, "Installation Guide for the Product Link
PL321SR".
Operation, configuration, and troubleshooting
information for the Product Link PL321SR can be
found in System Operation Troubleshooting Testing
and Adjusting, RENR7911.
Regulatory Compliance
Illustration 27
NOTICE
TransmissionofinformationusingProductLinkis
subjecttolegalrequirementsthatmayvaryfrom
locationtolocation,including,butnotlimitedto,radio
frequencyuseauthorization.TheuseofProductLink
mustbelimitedtothoselocationswherealllegal
requirementsfortheuseoftheProductLink
communicationnetworkhavebeensatisfied.
IntheeventthatamachineoutfittedwithProductLinkis
locatedinorrelocatedtoalocationwhere(i)legal
requirementsarenotsatisfiedor(ii)transmittingor
processingofsuchinformationacrossmultiple
locationswouldnotbelegal,Caterpillardisclaimsany
andallliabilityrelatedtosuchfailuretocomplyand
Caterpillarmaydiscontinuethetransmissionof
informationfromthatmachine.
Consult your Caterpillar dealer with any questions
that concern the operation of the Product Link in a
specific country.
ORBCOMM TYPE
APPROVAL: 801QWI
IC: 4650A-Q121415
XS1135AB

34. 34 QEBU2107-01
OperationSection
MachineOperation
Illustration 28
NOTE: Atranslatedextractoftheabovedocumentis
providedbelow.
We hereby declare that all essential radio test suites have been carriedout and that the above named
product is in conformity to all the essential requirements of Directive 1999/5/EC
declare under our sole responsibility that the product
BG L LO A
MONITORING REMOTE ASSETS WORLDWIDE
to which this declaration relates, is in conformity with the followingstandards and/or other normative
documents
The technical documentation relevant to the above equipment will be hel at:
We,
of
Identification mark:
The conformity assessment procedure referred to in Article 10 and detailed in Annex [IV] of Directive
1999/5/EC has been followed with the involvement of the following Notified Body:
The equipment will also carry the
Class 2 equipment identifier
BABT, Claremont House, 34 Molesey Road, Walton-on-Thames, KT12 4RQ, UK
Quake Global Inc (Previously Quake Wireless, Inc. up to January 2001)
9765 Clairemont Mesa Blvd, Suite A
San Diego, CA 92124, USA
EN 301 721 V1.2.1 (June 2001)
EN 300 489-20 V1.2.1 (November 2002)
EN 60950-1/A11:2004, 1st
Edition
Quake Global Inc (Previously Quake Wireless, Inc. up to January 2001)
9765 Clairemont Mesa Blvd, Suite A (Previously 5575 Ruffin Road, Suite 100 up to March
2002)
San Diego
CA 92124, USA (Previously 92123)
QHE2500, Q2000, Q1500, Q1400, Q1200S, Q1200SG, Q1200SH, Q1200SM and Q1200SV
DECLARATION OF CONFORMITY
0168
President
(name)
(title)
(signature of authorised person) (date)
Polina Braunstein
XS1136AB

35. QEBU2107-01 35
OperationSection
MachineOperation
DECLARATION OF CONFORMITY
We, Quake Global, Inc (Previously Quake Wireless, Inc up to January 2001)
of 9765 Clairemont Mesa Blvd, Suite A (Previously 5575 Ruffin Road, Suite 100 up to March 2002)
San Diego
CA 92124, Usa (Previously 92123)
declareunderoursoleresponsibilitythattheproduct
QHE2500, Q2000, Q1500, Q1400, Q1200S, Q1200SG, Q1200SH, Q1200SM and Q1200SV
towhichthisdeclarationrelates,isinconformitywiththefollowingstandardsand/orothernormativedocuments.
EN 301 721 V1.2.1 (June 2001)
EN 300 489-20V1.2.1 (November 2002)
EN 60950-1/A11:2004, 1st Edition
Weherebydeclarethatallessentialradiotestsuiteshavebeencarriedoutandthattheabovenamedproductisin
conformitytoalltheessentialrequirementsofDirective“1999/5/EC”.
TheconformityassessmentprocedurereferredtoinArticle10anddetailedinAnnex[IV]ofDirective“1999/5/EC”has
beenfollowedwiththeinvolvementofthefollowingNotifiedBody:
BABT, Claremont House, 34 Molesey Foad, Walton-on-Thames, KT12 4RQ, UK
Identificationmark: 0168 Theequipmentwillalsocarrythe
Class2Equipmentidentifier.
Thetechnicaldocumentationrelevanttotheaboveequipmentwillbeheldat:
Quake Global Inc (Previously Quake Wireless, Inc. up to January 2001)
9765 Clairemont Mesa Blvd, Suite A
San Diego, CA 92124, USA
Polina Braunstein
President
(signatureofauthorizedperson) (date)

36. 36 QEBU2107-01
OperationSection
MachineOperation
Camera (if equipped)
The rear view camera system consists of a camera
that is located in the middle of the top of the rear of
the machine.
Illustration 29
Illustrationshowstherearviewcamera.
The rear view camera provides additional visibility to
the rear of the machine through the monitoring
system when the electrical circuits enable switch is
in the ENABLE position and the forward/reverse
propel lever is in the NEUTRAL or REVERSE
position.
In order to temporarily disable the rear view camera
press one of the monitoring system buttons.
For more information refer to Operation and
Maintenance Manual, ≈Monitoring System∆.
NOTE: The rear view camera system has been set
up by the factory or by a Caterpillar dealer in order
to provide views which comply with specified
guidelines. Consult your Caterpillar dealer before
any adjustments are made to the system.
The orientation of the camera is set during
installation. After installation, there should be no
need to make any physical adjustments under
normal operating conditions.
The camera lens and the monitoring system will
require periodic cleaning. Cleaning instructions for
the camera lens and the display are described in the
Maintenance section.
XS0106AC

37. QEBU2107-01 37
OperationSection
OperatorControls
Operator Controls
Machine and Engine Stop
Switches
Illustration 30
LocationofMachineandEngineStopSwitches
Machine and Engine Stop Switches √
There is a total of three machine and
engine stop switches on the machine.
ON √ Push the switch in to turn the switch ON and
disable the machine to operate.
OFF √ Pull the switch out to turn the switch OFF and
enable the machine to operate.
XS1248AB

38. 38 QEBU2107-01
OperationSection
OperatorControls
Illustration 31
There is one stop switch on the right rear ground
control panel.
Illustration 32
There is one stop switch on the left rear ground
control panel.
Illustration 33
There is a stop switch on the arm rest.
The engine will shut down when you depress any of
the machine and engine stop switches. The machine
will not operate, and the engine will not run until all
the machine and engine stop switches are pulled
up.
NOTE: The machine and engine stop switches
should only be used for stopping the machine when
rapid engine shutdown is necessary.
Reference: For the recommended engine stopping
procedure, refer to Operation and Maintenance
Manual, ≈Stopping the Engine∆.
XS1249AB
XS1250AB
XS1251AB

39. QEBU2107-01 39
OperationSection
OperatorControls
Dashboard Controls (Main
Console)
Parking Brake Control
Illustration 34
Parking Brake Control √ The parking
brake switch is a two position switch. To
engage the brake, depress the switch.
When the parking brake is engaged, the propel
system is put into NEUTRAL. To disengage the
brake, pull the switch out.
The parking brake control should always be ON
under the following circumstances:
• Parking the machine
• Servicing the machine
• Starting the machine
• Exiting the operator's station
• Lowering the rotor into a cut
Engine Start Switch
Illustration 35
OFF √ In order to disconnect the electrical
power to the engine and to the machine,
turn the switch in a counterclockwise
direction to the OFF position. Turn the key to the OFF
position before you try to restart the engine. Turn the
key to the OFF position in order to stop the engine.
ON √ In order to activate the electrical
circuits, turn the switch to the ON position.
When the key is released from the START
position, the key will return to the ON position.
START √ Turn the engine start switch to
the START position in order to crank the
engine. Release the key as soon as the
engine starts.
NOTE: If the engine does not start, return the key to
the OFF position before returning to the START
position.
The following conditions must be met before you
start the engine:
• The battery disconnect switch must be in the ON
position.
• All machine control switches need to be turned
OFF.
• The parking brake should be ON.
• The rotor switch must be in the OFF position.
• The propel lever should be in the NEUTRAL
position.
XS0651AB
XS0651AB

40. 40 QEBU2107-01
OperationSection
OperatorControls
• All the machine and engine stop switches must be
pulled out.
• The grade and slope systems must be turned
OFF.
• All conveyors must be turned OFF
For more information, refer to the Operation and
Maintenance Manual, ≈Engine Starting∆ section.
Monitoring System
The monitoring system provides the operator with
continuous feedback on machine operation and on
system operation.
Illustration 36
(1)Numericfunctionselector
(2)Numericfunctionselector
(3)Escape
(4)Left/Rightscroll
(5)Confirm/Enter
(6)ScrollUporDown
Turn the ignition key switch to the ON ( I ) position.
The digital monitor will turn on. The monitor will
display an introduction for approximately 3 seconds.
After the introduction, the monitor will display the
default page for machine operation.
Illustration 37
(1)Machinespeed
(2)EngineRPM
(3)HourMeter
(4)RotorRPM
(5)DigitalMachineClock (hours:minutes:seconds)
(6)Fuelconsumption(gallons/hourorLiters/hour)
(7)Hydraulicoiltemperature
(8)Fuelpressure
(9)Turbochargerboostpressure
(10)Engineoilpressure
(11)Airintaketemperature
(12)Coolanttemperature
(13)Electricalsystemvoltage
GREEN OPERATING RANGE: When the indicator
bars (6), (7), (8), (9), (10), (11), (12) and (13) are in
the GREEN range, the system is operating in the
normal range.
YELLOW OPERATING RANGE: When one or more
indicator bars are in the YELLOW range, it is
necessary to make a change in machine operation.
A change in machine operation will reduce possible
machine damage to the indicated system. Make
repairs or adjustments at the next opportunity or at
the end of the shift.
RED OPERATING RANGE: If one or more indicator
bars are in the RED range, this condition requires an
immediate, safe shutdown in order to prevent severe
damage to the machine.
5 63
4
21
XS0191AA
9 8 7 6 13 12 11 10
1 2 3 45
XS0192AA

41. QEBU2107-01 41
OperationSection
OperatorControls
Fault Description List
Illustration 38
If the monitoring system detects a fault, the error
description will appear on the display and a caution
indicator will appear.
If there is more than one fault the monitoring system
automatically displays the errors using an auto-scroll
function.
Modes
Illustration 39
There are six modes of display. Press the numeric
selector to bring up the appropriate mode.
Mode 1 – Normal Mode
Illustration 40
Mode 1 is the normal mode used for monitoring the
machine status during operation.
XS0253AA
1 5
4 8
72
XS0194AA
XS0192AA

42. 42 QEBU2107-01
OperationSection
OperatorControls
Mode 2 – Simplified mode
Illustration 41
Mode 2 is a simplified version of Mode 1. The fuel
level, air intake temperature, turbo boost pressure
and alternator charging voltage do not appear in this
mode.
Mode 3 – Not Used
Mode 4 – Input/output signal mode
Illustration 42
Mode 4 is for monitoring the various input and output
signals of the electronic control system.
To navigate within mode 4, press the corresponding
numeric button on the display and follow the
instructions provided on the display.
Mode 5 – Camera selection mode
Illustration 43
Mode 5 is for selecting which video camera (if
equipped) signal to display.
Mode 6 – Not Used
Mode 7 – Configuration mode
Illustration 44
Mode 7 is for setting the language, measurement
units, and date and hour format.
To navigate within mode 7, press the corresponding
numeric button on the display and follow the
instructions provided on the display.
Mode 8 – Service mode
Mode 8 is for use by Caterpillar dealer personnel to
configure, diagnose and repair the machine.
Contact your Caterpillar dealer for more information.
XS0254AA
XS0196AA
XS0197AA
XS0198AA

43. QEBU2107-01 43
OperationSection
OperatorControls
Brightness/Contrast Adjust
Illustration 45
Press left or right scroll buttons (1) during menu
popup in order ti increase or decrease the display
contrast.
Press up or down scroll buttons (2) during menu
popup in order ti increase or decrease the display
brightness.
NOTE: Features available on monocromatic
displays only.
Indicators
Illustration 46
Charging System (1) √ The indicator will
illuminate when the alternator is
malfunctioning. If the indicator illuminates,
move the machine to a safe area and stop the
machine. Investigate the problem. Do not operate
the machine until all of the repairs have been made.
Parking Brake (2) √ The indicator will
illuminate when the parking brake is applied.
Hydraulic Oil Low Level (3) √ The
indicator will illuminate when the hydraulic
oil level in the hydraulic oil tank is too low.
Hydraulic Oil Filter (4) √ The indicator for
the hydraulic oil filter will illuminate when
the hydraulic oil pressure drops below the
normal operating pressure. Service the
hydraulic oil filter as soon as possible when this
indicator illuminates.
Engine Air Filter (5) √ The indicator will
illuminate when the engine air filters are
excessively restricted or plugged. Replace
or clean the air filters as soon as possible when this
indicator illuminates.
Right Rear Leg (6) √ The indicator will
illuminate when the right rear leg is not
locked.
NOTE: The traction control system is disabled when
the right rear leg unlocked indicator is on.
1
XS0111AC
2
15
14
98
32 10 4 126115
13
16
17
1
7
XS0161AA
+-

44. 44 QEBU2107-01
OperationSection
OperatorControls
Engine Fault Indicator (7) √ The indicator
(red) indicates faults in the engine electrical
system. When starting the machine, the
indicator should come on for approximately two
seconds (self-test of the engine electronic system) and
turn off. During these two seconds, do not move the
machine. The number of times the light flashes
indicates the type and cause of the fault detected.
NOTE: The faults indicated are described in the
table below.
Engine Fault Indicator (8) √ The indicator
(orange) indicates mechanical faults in the
engine. When starting the machine, the
indicator should come on for approximately two
seconds (self-test of the engine's electronic system)
and turn off. During these two seconds, do not move
the machine. The number of times the light flashes
indicates the type and cause of the fault detected.
NOTE: The faults indicated are described in the
table below.
Table4
Engine Fault Indications
Indicatorstatusbeforeenginestarts:Check
Enginefaultindicator(7) Enginefaultindicator(8) FaultDescription
ON ON Warninglighttest
OFF OFF Warninglightok
Indicatorstatusbeforeenginestarts:Coldstarting
Enginefaultindicator(7) Enginefaultindicator(8) FaultDescription
ON OFF Coldstartmode(preheat)
OFF OFF Coldstartmode(preheat)complete
Indicatorstatusstartingtheengine
Enginefaultindicator(7) Enginefaultindicator(8) FaultDescription
OFF OFF Noerror
OFF ON Engineoilpressurelow
Indicatorstatuswhenstartingtheengine:Failuretostart
Enginefaultindicator(7) Enginefaultindicator(8) FaultDescription
OFF OFF Noerror
ON OFF Electricalfault
OFF FLASHING Enginefailstostartbecausemechanicalfaulthas
beendetected
Indicatorstatuswhileengineisrunning:Check
Enginefaultindicator(7) Enginefaultindicator(8) FaultDescription
OFF OFF Noerror
ON ON Engineoilpressurelow
FLASHING OFF Enginecoolanttemperaturetoohigh
OFF FLASHING Enginestoppedduetoexcessivepowerdrop
ON OFF Electricalfault
ON ON Engineoilpressurelowandelectricalfault
ON FLASHING Stoppingtheengine
FLASHING ON Engineoilpressurelowandenginecoolant
temperaturehigh

45. QEBU2107-01 45
OperationSection
OperatorControls
Machine General Fault (9) √ The indicator
will illuminate when a fault occurs.
NOTE: A text message on monitoring system shows
the fault description; read the message and take the
appropriate action.
Electrical System Disabled (10) √ The
indicator will illuminate when the electrical
system is disabled.
Electrical System Enabled (11) √ The
indicator will illuminate when the electrical
system is enabled.
Rotor Engaged (12) √ The indicator will
illuminate when the rotor is engaged.
Water Spray (13) √ The indicator for the
water spray will illuminate when the water
spray system is activated.
Electronic Management Manual Bypass
(14) √ The indicator will illuminate when
the electronic management of the machine
is manually bypassed.
Work Light (15) √ The indicator for the
work light will illuminate when the work
lights are on.
Water Tank Low Level (16) √ The indicator
will illuminate when the water level in the
tank is low.
Turn Signals (17) (If Equipped) √ The
indicator will illuminate when the turn
signals are activated.
Fuel Level Gauge
Illustration 47
Fuel Level Gauge √ This gauge indicates the fuel
level.
Hydraulic Circuit Pressure Gauge
Illustration 48
Hydraulic Circuit Pressure Gauge √
This gauge indicates the hydraulic
operating pressure in the propel
system.
XS0650AB
XS0208AA

46. 46 QEBU2107-01
OperationSection
OperatorControls
Moldboard Pressure Gauge
Illustration 49
Moldboard Pressure Gauge √ This
gauge indicates the hydraulic operating
pressure of the moldboard.
Selector for the Lights and the
Horn
Illustration 50
OFF √ Turn the knob counterclockwise in order to
turn off all of the lights.
Parking Lights √ Turn the knob clockwise
to the first position in order to turn on the
parking lights and the dashboard lights.
Roading Lights √ Turn the knob clockwise
to the second position in order to turn on
the roading lights.
Work Lights √ Turn the knob clockwise to
the third position in order to turn on the
work lights.
Horn √ Push the knob in order to activate
the horn.
XS0208AA
XS0651AB

47. QEBU2107-01 47
OperationSection
OperatorControls
Turn Signal Switch (If Equipped)
Illustration 51
Turn Signal √ Move the switch for the turn
signal to the left in order to activate the left
turn signal lights. Move the switch for the
turn signal to the right in order to activate
the right turn signal lights.
Hazard Lights Switch (If Equipped)
Illustration 52
Hazard Lights √ Push the switch in order
to activate the hazard lights. Push the
switch again in order to deactivate the
hazard lights. The switch will illuminate
when the hazard lights are on.
XS0651AB XS0651AB

48. 48 QEBU2107-01
OperationSection
OperatorControls
Steering Wheel
Illustration 53
Steering wheel √ Controls the steering angle of the
tracks. Turn the steering wheel clockwise to turn the
machine to the right. Turn the steering wheel
counterclockwise to turn the machine to the left.
Dashboard Lights
Illustration 54
The dashboard lights illuminate when the parking
lights, the roading lights and the working lights are
turned ON.
Levelling System Selector
Illustration 55
Levelling System Selector √ Controls the
operating mode of the levelling system
installed on the machine.
AUTOMATIC √ Move the selector upward
for automatic operation of the levelling
system. In AUTOMATIC, the left and right
milling depth will be controlled by the automatic
levelling system and the levelling system will turn on
and off with the ON/STANDBY switch.
OFF √ Move the selector to the center
position to turn the levelling system OFF.
MANUAL √ Move the selector downward
for manual operation of the levelling system.
In MANUAL, the left and right milling depth
will be controlled by the automatic levelling system.
The levelling system is always on regardless of the
position of the ON/STANDBY switch.
XS0616AB
XS0651AB
XS0651AB

49. QEBU2107-01 49
OperationSection
OperatorControls
Automatic Engine Speed Selector
Illustration 56
Automatic Engine Speed Selector √
Enables operation of the automatic engine
speed control system.
AUTOMATIC √ Move the selector up to
enable the automatic engine speed control
function. When the control is in
AUTOMATIC, the engine speed will increase to the
maximum rpm when the ON/STANDBY switch on the
side control console is ON. The engine speed will
decrease to low idle when the ON/STANDBY switch
on the side control console is OFF.
OFF √ Move the selector to the center
position to turn the automatic engine speed
control OFF and control the engine with the engine
RPM control.
MANUAL √ Move the selector down to
raise the engine speed to the maximum,
regardless of the engine rpm control position.
Engine RPM Control
Illustration 57
Engine RPM Control √ Used to regulate engine
rpm. The engine rpm control is enabled only when
automatic engine speed selector is in the OFF
position. To increase engine RPM, rotate the Engine
RPM Control clockwise. To decrease engine RPM,
rotate the Engine RPM Control Counterclockwise.
XS0651AB XS0651AB

50. 50 QEBU2107-01
OperationSection
OperatorControls
Canopy Raise/Lower Control
(If Equipped)
Illustration 58
Canopy Raise/Lower Control √ Lowers
the canopy to reduce machine height
during transportation.
Move the switch UP to raise the canopy.
Move the switch DOWN to lower the canopy.
NOTE: When the selector is released, the switch
will return to the center position and the canopy will
stop moving.
NOTE: Before lowering the canopy, raise and lock
the windscreen.
Reference: Refer to Operation and Maintenance
Manual, ≈Windscreen∆ for the proper procedure to
raise the windscreen.
Front Columns Manual Raise
Switch
Illustration 59
Front Columns Manual Raise Switch √
Disables the front legs of the machine to
float freely up or down with contour of the
ground and raise the machine to the
service height position.
OFF √ Move the Front Columns Manual
Raise Switch to the OFF position in order to
allow the front legs to float when the front of
the machine is raised to maximum height. Enables
the front legs to float up and down with the contour
of the road. This is the normal operation position.
ON √ Move the Front Columns Manual
Raise Switch to the ON position in order to
enable the front of the machine to be raised to
Service Height Position. With the machine in the
Service Height Position, maintenance can be
performed on the machine.
NOTE: To maximize machine stability, keep the
Front Columns Manual Raise Switch in the OFF
position. This is the normal operating position.
NOTE: Front Columns Manual Raise Switch can be
set to OFF when it is necessary to load the machine
on a steep trailer ramp or when the machine comes
out from a deep tranch. For transporting, it is
recommended to keep the Front Columns Manual
Raise Switch in the OFF position to ensure all tracks/
tires are firmly on the trailer for maximum stability.
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51. QEBU2107-01 51
OperationSection
OperatorControls
Indicator Test Switch
Illustration 60
Indicator Test Switch √ Press the switch to
test the indicators. The switch illuminates the
hydraulic oil low level indicator, the
hydraulic oil filter indicator and the engine air filter
indicator. Repair or replace any indicators which do
not illuminate.
Electric Circuits Enable Switch
Illustration 61
Electric Circuits Enable Switch √ Press the
electric circuits enable switch to enable all
electrical circuits. The inside of the Electric
Circuits Enable Switch will illuminate and the
Electrical System Enabled Indicator will illuminate,
when the machine electrical circuits are enabled.
Main Machine Height Control Lever
Illustration 62
Main Machine Height Control Lever √ Raises and
lowers the rear and front legs together to determine
the machine height and rotor cutting depth.
FRONT UP √ Move the lever upward to
extend both front legs and raise the front of
the machine.
FRONT DOWN √ Move the lever downward
to retract both front legs and lower the front
of the machine.
REAR UP √ Move the lever to the left to
extend both rear legs and raise the rear of
the machine.
MACHINE UP √ Move the lever to the right
to extend all four legs and raise the
machine.
NOTE: To maximize machine stability, keep the
front columns manual raise switch in the OFF
position.
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52. 52 QEBU2107-01
OperationSection
OperatorControls
Moldboard Control Switch
Illustration 63
Moldboard Control Switch √ Used to Raise,
Lock and Float the Moldboard.
RAISE √ Move the Moldboard Control
Switch UP to RAISE the Moldboard. Release
the moldboard control switch and the
moldboard will lock to position. In the LOCKED
position, the moldboard Indicator light will NOT be
illuminated.
Reference: Refer to Operation and Maintenance
Manual, ≈Open and Close the Rotor Service Door∆
for the proper procedure to open the rotor service
door and access the rotor for service.
LOCKED √ When the moldboard control
Switch is released from the RAISE position,
the switch will self-return to the center
position. The moldboard will remain locked. When
the moldboard control switch is released from the
FLOAT position, the switch will self-return to the
center position. The moldboard will remain in the
FLOAT mode and the moldboard float indicator light
will be illuminated.
FLOAT √ Move the moldboard control
switch down to the FLOAT position. Release
the moldboard control switch and the moldboard will
unlock and float downward. The moldboard
indicator light will illuminate.
NOTE: The FLOAT position is the normal operating
position for cutting operation.
Right Rear Leg Rotation Enable
Switch
Illustration 64
Right Rear Leg Rotation Enable Switch √ Enables
the electrical circuits for rotating the right rear leg to
the inboard position and to the outboard position.
OFF √ Move the switch to the left to disable
the right rear leg rotation system.
ON √ Move the switch to the right to enable
the right rear leg rotation system.
Reference: Refer to Operation and Maintenance
Manual, ≈Extend and Retract the Right Rear Leg∆ for
the proper procedure to swing the right rear leg.
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53. QEBU2107-01 53
OperationSection
OperatorControls
Right Rear Leg Rotation Control
Illustration 65
IN √ With the right rear leg rotation enable
switch ON, move the Right Rear Leg
Rotation Enable Switch to the left to retract
the right rear leg IN.
OUT √ With the right rear leg rotation
enable switch ON, move the Right Rear Leg
Rotation Enable Switch to the right to extend
the right rear leg OUT.
Reference: Refer to Operation and Maintenance
Manual, ≈Extend and Retract the Right Rear Leg∆ for
the proper procedure to swing the right rear leg.
Propel Speed Selector
Illustration 66
Propel Speed Selector √ Selects machine travel
speed.
Rabbit √ Move the selector to the rabbit
position to operate the machine in the high
travel speed range.
Turtle √ Move the selector to the turtle
position to operate the machine in the low
working speed range.
Differential Lock √ Move the selector to the
differential lock position to operate the
machine at low working speed with the
hydraulic differential lock function activated. The
hydraulic differential lock function minimizes track/
wheel slippage on loose or slippery ground and
when milling hard, high density material.
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54. 54 QEBU2107-01
OperationSection
OperatorControls
Antislab Device Control Switch
Illustration 67
Antislab Device Control Switch √ Used to
raise, lock and float the antislab device. The
antislab device reduces the possibility of
large chunks of milled surface breaking off and
entering the rotor chamber.
NOTE: The Antislab Device Control Switch is a
spring loaded switch and will return to the center
position.
RAISE √ Move the antislab device control
switch to the RAISE position to raise antislab
device. Move the Antislab Control Switch UP
to RAISE the antislab device. Release the antislab
device control switch and the antislab device will
lock to position.
LOCKED √ When the antislab device
control switch is released from the RAISE
position, the switch will self-return to the
center position. The antislab device will remain
locked. When the antislab device control switch is
released from the FLOAT position, the antislab
device control switch will self-return to the center
position. The antislab device will remain in the
FLOAT mode.
FLOAT √ Move the antislab device control
Switch down to the FLOAT position. Release
the antislab device control switch. The antislab
device will unlock and float downward.
NOTE: The FLOAT position is the normal operating
position for cutting operation.
Conveyor Mode Switch
Illustration 68
Conveyor Mode Switch √ Used to select
the operating mode of the primary and
secondary conveyors.
OFF √ Move the conveyor mode control
Switch to the center position to turn the
conveyors OFF.
MANUAL √ Move the control down to
operate the conveyors in MANUAL mode. In
manual mode the conveyors are always ON.
AUTOMATIC √ Move the conveyor mode
control switch up to the automatic position to
operate the conveyors in Automatic mode.
When the conveyors are in AUTOMATIC, the
conveyor system will turn on and off when the ON/
STAND-BY Switch is turned ON and OFF.
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