SEBU7857-05 (en-us)

May 2019

Operation and
Maintenance
Manual
623G Wheel Tractor-Scraper
DBC 1-UP (623G)
DBY 1-UP (623G)

Language: Original Instructions

PUBLICATIONS.CAT.COM
 i06558969

Important Safety Information

Most accidents that involve product operation, maintenance and repair are caused by failure to observe
basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous
situations before an accident occurs. A person must be alert to potential hazards, including human factors
that can affect safety. This person should also have the necessary training, skills and tools to perform these
functions properly.
Improper operation, lubrication, maintenance or repair of this product can be dangerous and could
result in injury or death.
Do not operate or perform any lubrication, maintenance or repair on this product, until you verify
that you are authorized to perform this work, and have read and understood the operation,
lubrication, maintenance and repair information.
Safety precautions and warnings are provided in this manual and on the product. If these hazard warnings
are not heeded, bodily injury or death could occur to you or to other persons.
The hazards are identified by the “Safety Alert Symbol” and followed by a “Signal Word” such as
“DANGER”, “WARNING” or “CAUTION”. The Safety Alert “WARNING” label is shown below.

The meaning of this safety alert symbol is as follows:

Attention! Become Alert! Your Safety is Involved.
The message that appears under the warning explains the hazard and can be either written or pictorially
presented.
A non-exhaustive list of operations that may cause product damage are identified by “NOTICE” labels on
the product and in this publication.
Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.
The warnings in this publication and on the product are, therefore, not all inclusive. You must not
use this product in any manner different from that considered by this manual without first
satisfying yourself that you have considered all safety rules and precautions applicable to the
operation of the product in the location of use, including site-specific rules and precautions
applicable to the worksite. If a tool, procedure, work method or operating technique that is not
specifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for you
and for others. You should also ensure that you are authorized to perform this work, and that the
product will not be damaged or become unsafe by the operation, lubrication, maintenance or repair
procedures that you intend to use.
The information, specifications, and illustrations in this publication are on the basis of information that was
available at the time that the publication was written. The specifications, torques, pressures,
measurements, adjustments, illustrations, and other items can change at any time. These changes can
affect the service that is given to the product. Obtain the complete and most current information before you
start any job. Cat dealers have the most current information available.

When replacement parts are required for this

product Caterpillar recommends using Cat re-
placement parts.
Failure to follow this warning may lead to pre-
mature failures, product damage, personal in-
jury or death.

In the United States, the maintenance, replacement, or repair of the emission control devices and
systems may be performed by any repair establishment or individual of the owner's choosing.
SEBU7857-05 3
Table of Contents

Table of Contents General Information ........................................ 32

Identification Information ................................. 34

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

Safety Section Operation Section

Before Operation ............................................. 38

Safety Messages............................................... 6
Machine Operation .......................................... 40
Additional Messages ....................................... 12
Engine Starting................................................ 66
General Hazard Information............................ 15
Adjustments..................................................... 68
Crushing Prevention and Cutting Prevention.. 18
Parking ............................................................ 69
Burn Prevention............................................... 18
Transportation Information .............................. 72
Fire Prevention and Explosion Prevention...... 19
Jacking Location Information .......................... 74
Fire Extinguisher Location............................... 22
Towing Information .......................................... 76
Tire Information ............................................... 22
Engine Starting (Alternate Methods)............... 79
Electrical Storm Injury Prevention ................... 23

Before Starting Engine .................................... 23 Maintenance Section

Engine Starting................................................ 24 Tire Inflation Information.................................. 82

Before Operation ............................................. 24 Lubricant Viscosities and Refill Capacities ..... 84

Visibility Information ........................................ 24 Maintenance Support ...................................... 90

Restricted Visibility .......................................... 25 Maintenance Interval Schedule....................... 91

Operation......................................................... 26 Warranty Section

Engine Stopping .............................................. 26 Warranty Information..................................... 156

Parking ............................................................ 27 Reference Information Section

Slope Operation .............................................. 27 Reference Materials ...................................... 157

Equipment Lowering with Engine Stopped ..... 28 Index Section

Sound Information and Vibration Information . 28 Index.............................................................. 159

Operator Station .............................................. 30

Guards (Operator Protection) ......................... 30

Product Information Section

4 SEBU7857-05
Foreword

Foreword Whenever a question arises regarding your machine,

or this publication, please consult your Cat dealer for
the latest available information.
California Proposition 65 Warning
Safety
Diesel engine exhaust and some of its
constituents are known to the State of The safety section lists basic safety precautions. In
California to cause cancer, birth defects, addition, this section identifies the text and locations
of warning signs and labels used on the machine.
and other reproductive harm.
Read and understand the basic precautions listed in
WARNING – This product can the safety section before operating or performing
expose you to chemicals lubrication, maintenance, and repair on this machine.
including ethylene glycol, which
is known to the State of California to Operation
cause birth defects or other reproductive
harm. For more information go to: The operation section is a reference for the new
operator and a refresher for the experienced
www.P65Warnings.ca.gov operator. This section includes a discussion of
gauges, switches, machine controls, attachment
Do not ingest this chemical. Wash hands controls, transportation, and towing information.
after handling to avoid incidental Photographs and illustrations guide the operator
ingestion. through correct procedures of checking, starting,
operating, and stopping the machine.
WARNING – This product can
expose you to chemicals Operating techniques outlined in this publication are
basic. Skill and techniques develop as the operator
including lead and lead gains knowledge of the machine and its capabilities.
compounds, which are known to the
State of California to cause cancer, birth Maintenance
defects, or other reproductive harm. For
more information go to: The maintenance section is a guide to equipment
care. The Maintenance Interval Schedule (MIS) lists
www.P65Warnings.ca.gov the items to be maintained at a specific service
interval. Items without specific intervals are listed
Wash hands after handling components under the "When Required" service interval. The
that may contain lead. Maintenance Interval Schedule lists the page number
for the step-by-step instructions required to
accomplish the scheduled maintenance. Use the
Literature Information Maintenance Interval Schedule as an index or "one
safe source" for all maintenance procedures.
This manual should be stored in the operator's
compartment in the literature holder or seat back Maintenance Intervals
literature storage area.
Use the service hour meter to determine servicing
This manual contains safety information, operation
intervals. Calendar intervals shown (daily, weekly,
instructions, transportation information, lubrication
information, and maintenance information. monthly, etc.) can be used instead of service hour
meter intervals if the calendar intervals provide more
Some photographs or illustrations in this publication convenient servicing schedules and approximate the
show details or attachments that can be different indicated service hour meter reading. Perform the
from your machine. Guards and covers might have recommended service at the interval that occurs first.
been removed for illustrative purposes.
Under severe, dusty, or wet operating conditions,
Continuing improvement and advancement of more frequent lubrication than is specified in the
product design might have caused changes to your maintenance intervals chart might be necessary.
machine which are not included in this publication.
Read, study, and keep this manual with the machine.
SEBU7857-05 5
Foreword

Perform service on items at multiples of the original 2. Machine Descriptor (characters 4-8)
requirement. For example, at every 500 service
hours or 3 months, also service those items listed 3. Check Character (character 9)
under every 250 service hours or monthly and every
10 service hours or daily. 4. Machine Indicator Section (MIS) or Product
Sequence Number (characters 10-17). These were
previously referred to as the Serial Number.
Certified Engine Maintenance
Machines and generator sets produced before First
Proper maintenance and repair are essential to keep Quarter 2001 will maintain their 8 character PIN
the engine and machine systems operating correctly. format.
As the heavy-duty off-road diesel engine owner, you
are responsible for the performance of the required Components such as engines, transmissions, axles,
maintenance listed in the Owner Manual, Operation and work tools will continue to use an 8 character
and Maintenance Manual, and Service Manual. Serial Number (S/N).

It is prohibited for any person engaged in the

business of repairing, servicing, selling, leasing, or
trading engines or machines to remove, alter, or to
render inoperative, any emission-related device or
element of design installed on or in an engine or
machine that is in compliance with all applicable
regulations of the intended country to which it has
been shipped. Certain elements of the machine and
engine such as the exhaust system, fuel system,
electrical system, intake air system, and cooling
system may be emission-related and should not be
altered unless approved by Caterpillar.

Machine Capacity
Additional attachments or modifications may exceed
machine design capacity which can adversely affect
performance characteristics. Included would be
stability and system certifications such as brakes,
steering, and rollover protective structures (ROPS).
Contact your Cat dealer for further information.

Product Identification Number

Effective First Quarter 2001 the Product Identification
Number (PIN) has changed from 8 to 17 characters.
To provide uniform equipment identification,
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 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 g03891925

Where:
1. World Manufacturing Code (characters 1-3)
6 SEBU7857-05
Safety Section
Safety Messages

Safety Section
i03640970

Safety Messages
SMCS Code: 7000; 7405
There are several specific safety messages on this
machine. The exact location of the messages and the
description of the messages are reviewed in this
section. Please become familiarized with all safety
messages.
Make sure that all of the safety messages are legible.
Clean the safety messages or replace the safety
messages if you cannot read the words. Replace the
messages if the messages 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 messages. Loose
adhesive will allow the safety messages 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.
SEBU7857-05 7
Safety Section
Safety Messages

Illustration 2 g01953875

Illustration 3 g01627742

Do Not Operate (1)

8 SEBU7857-05
Safety Section
Safety Messages

This safety message is positioned on the right side of

the ROPS. This safety message is also positioned
inside the engine compartment.

Illustration 5 g01379133

Illustration 4 g01370904

Hitch and steering movement can reduce clearan-

ces suddenly and cause personal injury...

Do not operate or work on this machine unless Stop engine before servicing.
you have read and understand the instructions
and warnings in the Operation and Maintenance
Manuals. Failure to follow the instructions or
heed the warnings could result in injury or death.
No Clearance (3)
Contact your Caterpillar dealer for replacement This safety message is positioned on each side of the
manuals. Proper care is your responsibility. steering link.

Crushing Hazard (2)

This safety message is positioned on each side of the
hitch link.

Illustration 6 g01371644

Stay back a safe distance. No clearance for a per-

son in this area when the machine turns. Severe
injury or death from crushing could occur.

Do Not Weld On The ROPS/FOPS

Structure (4)
This safety message is positioned outside of the cab
to the left of the rear window.
SEBU7857-05 9
Safety Section
Safety Messages

Illustration 7 g01211895 Illustration 8 g01132602

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

This machine has been certified to the standards that Refer to Operation and Maintenance Manual,
are listed on the certification film. The maximum “Guards (Operator Protection)” for more information.
mass of the machine, which includes the operator
and the attachments without a payload, should not
exceed the mass on the certification film. Seat Belt (6)
Refer to Operation and Maintenance Manual, This safety message is positioned on the right side of
“Guards (Operator Protection)” for more information. the ROPS.

Do Not Weld On The ROPS/FOPS

Structure (5)
This safety message is positioned on the right side of
the ROPS.
10 SEBU7857-05
Safety Section
Safety Messages

Service Manual, RENR5885, “Product Link 151/201”

High Compressed Spring (8)

This safety message is positioned on each brake
actuator.

Illustration 9 g01370908

A seat belt should be worn at all times during ma-

chine operation to prevent serious injury or death
in the event of an accident or machine overturn. Illustration 11 g01379131
Failure to wear a seat belt during machine opera-
tion may result in serious injury or death.

Highly compressed spring inside this housing

Product Link (7) (If Equipped) can cause serious physical injury or death.
This safety message is positioned inside the cab on Do not service until you read and understand the
the rear surface of the front right ROPS post. information in the service manual when servicing
the parking/secondary brake actuator.

High Pressure Cylinder (9)

This safety message is positioned on the
accumulator cylinders.

Illustration 10 g01222611

This machine is equipped with a Caterpillar Prod-

uct 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.

Refer to the following topics:

Special Instruction, REHS1642, “Operation of the
Product Link System”. This replaces Operation and
Maintenance Manual, SEBU7351.
SEBU7857-05 11
Safety Section
Safety Messages

Refer to Operation and Maintenance Manual,

“Engine Starting with Jump Start Cables” for more
information.

Engine Coolant (11)

This safety message is positioned on the top of the
radiator tank.

Illustration 12 g01123184

High Pressure Cylinder.

Rapid discharging from disconnecting or disas-
sembly can result in personal injury or death. See
your Caterpillar dealer for tools and instructions Illustration 14 g01371640
for relieving pressure or charging. Precharge on-
ly with dry nitrogen gas.

The coolant is hot and the coolant is under pres-

Improper Connections For Jump sure. Do not touch the hot surfaces. Refer to the
Start Cables (10) Operation and Maintenance Manual for the proce-
dure to follow when you check the radiator.
This safety message is positioned inside the battery
compartment of the tractor. Refer to Operation and Maintenance Manual,
“Cooling System Coolant Level - Check” for more
information.

Relieve the Pressure (12)

This safety message is located near the floor cylinder
for the scraper. This safety message is positioned on
the frame of the scraper. This safety message is
located under the access cover which is near the rear
of the scraper.

Illustration 13 g01370909

Explosion Hazard! Improper jumper cable con-

nections can cause an explosion resulting in seri-
ous injury or death. Batteries may be located in
separate compartments. Refer to the Operation
and Maintenance Manual for the correct jump
starting procedure.
12 SEBU7857-05
Safety Section
Additional Messages

Refer to Operation and Maintenance Manual,

“Restricted Visibility” for more information.

i03200483

Illustration 15 g01371640

HYDRAULIC TANK
RELIEVE TANK PRESSURE WITH ENGINE OFF
BY REMOVING CAP SLOWLY TO PREVENT
BURNS FROM HOT OIL.

Crushing Hazard (13)

This safety message is located on the right rear
ROPS post.

Illustration 16 g01953898

There is restricted visibility to the area directly

behind the machine. Failure to make sure the area
is clear could result in injury or death. Use a sec-
ond person on the ground to make sure that the
area is clear before you operate the machine in
the REVERSE position. Refer to the Operation
and Maintenance Manual, “Operation Informa-
tion” for more information.

Additional Messages
SMCS Code: 7000; 7405
SEBU7857-05 13
Safety Section
Additional Messages

Illustration 17 g01633794

Illustration 18 g01250396
14 SEBU7857-05
Safety Section
Additional Messages

This message is located on the discharge line of the

air conditioner compressor.

Illustration 22 g00924082

Air Tank (3)

This message is located at the bottom of the left side
Illustration 19 g01633797 access door on the tractor. This message is also
located at the right rear of the scraper.

Illustration 20 g01633858 Illustration 23 g01119007

Alternate Exit (1) Data Privacy (4)

This message is located on the ROPS support This message is located in the cab.
assembly behind the operator and to the right of the
operator.

Illustration 24 g01418953

Illustration 21 g00907967 Hood Brace (5)

If the primary exit is blocked, use the hammer to This message is located on the right side of the
break the window. Exit the machine through the engine hood.
window.
Air Conditioner (2)
SEBU7857-05 15
Safety Section
General Hazard Information

Illustration 25 g01132878 Illustration 27 g01132883

Release the hood brace before attempting to lower i07746355

the engine hood.
Cat ELC (Extended Life Coolant) (6) General Hazard Information
SMCS Code: 7000
This message is located inside the engine
compartment on top of the coolant tank.

Illustration 28 g00104545
Illustration 26 g01132882
Typical example
Engine Coolant (7)
Attach a “Do Not Operate” warning tag or a similar
This message is located inside the engine warning tag to the start switch or to the controls.
compartment on top of the coolant tank. Attach the warning tag before you service the
equipment or before you repair the equipment.
Warning tag SEHS7332 is available from your Cat
dealer.

Operating the machine while distracted can result

in the loss of machine control. Use extreme cau-
tion when using any device while operating the
machine. Operating the machine while distracted
can result in personal injury or death.

Know the width of your equipment to maintain proper

clearance when you operate the equipment near
fences or near boundary obstacles.
16 SEBU7857-05
Safety Section
General Hazard Information

Be aware of high-voltage power lines and power When you perform maintenance above ground level,
cables that are buried. If the machine comes in use appropriate devices such as ladders or man lift
contact with these hazards, serious injury or death machines. If equipped, use the machine anchorage
may occur from electrocution. points and use approved fall arrest harnesses and
lanyards.

Pressurized Air and Water

Pressurized air and/or water can cause debris and/or
hot water to be blown out. The debris and/or hot
water could result in personal injury.
When pressurized air and/or pressurized water is
used for cleaning, wear protective clothing, protective
shoes, and eye protection. Eye protection includes
goggles or a protective face shield.
The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the
nozzle is deadheaded and the nozzle is used with an
Illustration 29 g00702020 effective chip deflector and personal protective
equipment. The maximum water pressure for
Wear a hard hat, protective glasses, and other cleaning purposes must be below 275 kPa (40 psi).
protective equipment, as required.
Avoid direct spraying of water on electrical
Do not wear loose clothing or jewelry that can snag connectors, connections, and components. When
on controls or on other parts of the equipment. using air for cleaning, allow the machine to cool to
reduce the possibility of fine debris igniting when re-
Make sure that all protective guards and all covers deposited on hot surfaces.
are secured in place on the equipment.
Keep the equipment free from foreign material. Trapped Pressure
Remove debris, oil, tools, and other items from the
deck, from walkways, and from steps. Pressure can be trapped in a hydraulic system.
Releasing trapped pressure can cause sudden
Secure all loose items such as lunch boxes, tools, machine movement or attachment movement. Use
and other items that are not a part of the equipment. caution if you disconnect hydraulic lines or fittings.
High-pressure oil that is released can cause a hose
Know the appropriate work site hand signals and the to whip. High-pressure oil that is released can cause
personnel that are authorized to give the hand oil to spray. Fluid penetration can cause serious
signals. Accept hand signals from one person only. injury and possible death.
Do not smoke when you service an air conditioner.
Also, do not smoke if refrigerant gas may be present. Fluid Penetration
Inhaling the fumes that are released from a flame that
contacts air conditioner refrigerant can cause bodily Pressure can be trapped in the hydraulic circuit long
harm or death. Inhaling gas from air conditioner after the machine has been stopped. The pressure
refrigerant through a lighted cigarette can cause can cause hydraulic fluid or items such as pipe plugs
bodily harm or death. to escape rapidly if the pressure is not relieved
correctly.
Never put maintenance fluids into glass containers.
Drain all liquids into a suitable container. Do not remove any hydraulic components or parts
until pressure has been relieved or personal injury
Obey all local regulations for the disposal of liquids. may occur. Do not disassemble any hydraulic
components or parts until pressure has been relieved
Use all cleaning solutions with care. Report all or personal injury may occur. Refer to the Service
necessary repairs. Manual for any procedures that are required to
relieve the hydraulic pressure.
Do not allow unauthorized personnel on the
equipment.
Unless you are instructed otherwise, perform
maintenance with the equipment in the servicing
position. Refer to Operation and Maintenance
Manual for the procedure for placing the equipment
in the servicing position.
SEBU7857-05 17
Safety Section
General Hazard Information

Obey all local regulations for the disposal of liquids.

Inhalation

Illustration 30 g00687600

Always use a board or cardboard when you check for

a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak can Illustration 31 g02159053
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment Exhaust
from a doctor that is familiar with this type of injury.
Use caution. Exhaust fumes can be hazardous to
your health. If you operate the machine in an
Containing Fluid Spillage enclosed area, adequate ventilation is necessary.
Care must be taken in order to ensure that fluids are
contained during performance of inspection, Asbestos Information
maintenance, testing, adjusting, and repair of the
equipment. Prepare to collect the fluid with suitable Cat equipment and replacement parts that are
containers before opening any compartment or shipped from Caterpillar are asbestos free.
disassembling any component that contains fluids. Caterpillar recommends the use of only genuine Cat
replacement parts. Use the following guidelines when
Refer to Special Publication, NENG2500, “Cat dealer you handle any replacement parts that contain
Service Tool Catalog” for the following items: asbestos or when you handle asbestos debris.

• Tools that are suitable for collecting fluids and Use caution. Avoid inhaling dust that might be
equipment that is suitable for collecting fluids generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
• Tools that are suitable for containing fluids and to your health. The components that may contain
equipment that is suitable for containing fluids asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is bound
in a resin or sealed in some way. Normal handling is
not hazardous unless airborne dust that contains
asbestos is generated.
If dust that may contain asbestos is present, there
are several guidelines that should be followed:

• Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos.

• Use a wet method in order to clean up asbestos
materials.
• A vacuum cleaner that is equipped with a high
efficiency particulate air filter (HEPA) can also be
used.
18 SEBU7857-05
Safety Section
Crushing Prevention and Cutting Prevention

• Use exhaust ventilation on permanent machining Do not work beneath the cab of the machine unless
jobs. the cab is properly supported.

• Wear an approved respirator if there is no other Unless you are instructed otherwise, never attempt
way to control the dust. adjustments while the machine is moving or while the
engine is running.
• Comply with applicable rules and regulations for
the work place. In the United States, use Never jump across the starter solenoid terminals in
order to start the engine. Unexpected machine
Occupational Safety and Health Administration movement could result.
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”. In Japan, Whenever there are equipment control linkages the
use the requirements found in the “Ordinance on clearance in the linkage area will change with the
Prevention of Health Impairment due to Asbestos” movement of the equipment or the machine. Stay
in addition to the requirements of the Industrial clear of areas that may have a sudden change in
Safety and Health Act. clearance with machine movement or equipment
movement.
• Obey environmental regulations for the disposal of Stay clear of all rotating and moving parts.
asbestos.
If it is necessary to remove guards in order to perform
• Stay away from areas that might have asbestos maintenance, always install the guards after the
particles in the air. maintenance is performed.

Dispose of Waste Properly Keep objects away from moving fan blades. The fan
blade will throw objects or cut objects.
Do not use a kinked wire cable or a frayed wire cable.
Wear gloves when you handle wire cable.
When you strike a retainer pin with force, the retainer
pin can fly out. The loose retainer pin can injure
personnel. Make sure that the area is clear of people
when you strike a retainer pin. To avoid injury to your
eyes, wear protective glasses when you strike a
retainer pin.
Chips or other debris can fly off an object when you
strike the object. Make sure that no one can be
injured by flying debris before striking any object.

i07746334

Illustration 32 g00706404
Burn Prevention
Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be SMCS Code: 7000
disposed of according to local regulations. Do not touch any part of an operating engine. Allow
the engine to cool before any maintenance is
Always use leakproof containers when you drain
performed on the engine. Relieve all pressure in the
fluids. Do not pour waste onto the ground, down a
air system, in the oil system, in the lubrication
drain, or into any source of water.
system, in the fuel system, or in the cooling system
before any lines, fittings, or related items are
i01359664 disconnected.

Crushing Prevention and Coolant

Cutting Prevention When the engine is at operating temperature, the
SMCS Code: 7000 engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
Support the equipment properly before you perform to the engine contain hot coolant.
any work or maintenance beneath that equipment.
Do not depend on the hydraulic cylinders to hold up Any contact with hot coolant or with steam can cause
the equipment. Equipment can fall if a control is severe burns. Allow cooling system components to
moved, or if a hydraulic line breaks. cool before the cooling system is drained.
SEBU7857-05 19
Safety Section
Fire Prevention and Explosion Prevention

Check the coolant level only after the engine has Always wear protective glasses when you work with
been stopped. batteries. Wash hands after touching batteries. The
use of gloves is recommended.
Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to touch
i07746336
with a bare hand. Remove the filler cap slowly to
relieve pressure.
Fire Prevention and Explosion
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
Prevention
the skin, the eyes, or the mouth. SMCS Code: 7000

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 to remove the
hydraulic tank filler cap.

Batteries
The liquid in a battery is an electrolyte. Electrolyte is
an acid that can cause personal injury. Do not allow
Illustration 33 g00704000
electrolyte to contact the skin or the eyes.
Do not smoke while checking the battery electrolyte General
levels. Batteries give off flammable fumes which can
explode. All fuels, most lubricants, and some coolant mixtures
are flammable.
To minimize the risk of fire or explosion, Caterpillar
recommends the following actions.
Always perform a Walk-Around Inspection, which
may help you identify a fire hazard. Do not operate a
machine when a fire hazard exists. Contact your Cat
dealer for service.
Understand the use of the primary exit and
alternative exit on the machine. Refer to Operation
and Maintenance Manual, “Alternative Exit”.
Do not operate a machine with a fluid leak. Repair
leaks and clean up fluids before resuming machine
operation. Fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause a
fire. A fire may cause personal injury or death.
Remove flammable material such as leaves, twigs,
papers, trash, and so on. These items may
accumulate in the engine compartment or around
other hot areas and hot parts on the machine.
Keep the access doors to major machine
compartments closed and access doors in working
condition in order to permit the use of fire
suppression equipment, in case a fire should occur.
Clean all accumulations of flammable materials such
as fuel, oil, and debris from the machine.
20 SEBU7857-05
Safety Section
Fire Prevention and Explosion Prevention

Do not operate the machine near any flame. Avoid static electricity risk when fueling. Ultra low
sulfur diesel (ULSD) poses a greater static ignition
Keep shields in place. Exhaust shields (if equipped) hazard than earlier diesel formulations with a higher
protect hot exhaust components from oil spray or fuel sulfur content. Avoid death or serious injury from fire
spray in case of a break in a line, in a hose, or in a or explosion. Consult with your fuel or fuel system
seal. Exhaust shields must be installed correctly. supplier to ensure that the delivery system is in
compliance with fueling standards for proper
Do not weld or flame cut on tanks or lines that contain grounding and bonding practices.
flammable fluids or flammable material. Empty and
purge the lines and tanks. Then clean the lines and Never store flammable fluids in the operator
tanks with a nonflammable solvent prior to welding or compartment of the machine.
flame cutting. Ensure that the components are
properly grounded in order to avoid unwanted arcs.
Battery and Battery Cables
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 35 g03839133

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
Cat 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
Illustration 34 g03839130 explosion.

Use caution when you are fueling a machine. Do not Gases from a battery can explode. Keep any open
smoke while you are fueling a machine. Do not fuel a flames or sparks away from the top of a battery. Do
machine near open flames or sparks. Do not use cell not smoke in battery charging areas. Do not use cell
phones or other electronic devices while you are phones or other electronic devices in battery
refueling. Always stop the engine before fueling. Fill charging areas.
the fuel tank outdoors. Properly clean areas of Never check the battery charge by placing a metal
spillage. object across the terminal posts. Use a voltmeter in
order to check the battery charge.
SEBU7857-05 21
Safety Section
Fire Prevention and Explosion Prevention

Daily inspect battery cables that are in areas that are • Cuts on insulation
visible. Inspect cables, clips, straps, and other
restraints for damage. Replace any damaged parts. • Other damage
Check for signs of the following, which can occur
over time due to use and environmental factors: Make sure that all clamps, guards, clips, and straps
are reinstalled correctly. This will help to prevent
• Fraying vibration, rubbing against other parts, and excessive
heat during machine operation.
• Abrasion
Attaching electrical wiring to hoses and tubes that
• Cracking contain flammable fluids or combustible fluids should
be avoided.
• Discoloration
Consult your Cat dealer for repair or for replacement
• Cuts on the insulation of the cable parts.
Keep wiring and electrical connections free of debris.
• Fouling

• Corroded terminals, damaged terminals, and Lines, Tubes, and Hoses

loose terminals
Do not bend high-pressure lines. Do not strike high-
Replace damaged battery cable(s) and replace any pressure lines. Do not install any lines that are bent
related parts. Eliminate any fouling, which may have or damaged. Use the appropriate backup wrenches
caused insulation failure or related component in order to tighten all connections to the
damage or wear. Ensure that all components are recommended torque.
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.

Illustration 36 g00687600

Fire on a machine can result in personal injury or Check lines, tubes, and hoses carefully. Wear
death. Exposed battery cables that come into Personal Protection Equipment (PPE) in order to
contact with a grounded connection can result in check for leaks. Always use a board or cardboard
fires. Replace cables and related parts that show when you check for a leak. Leaking fluid that is under
signs of wear or damage. Contact your Cat pressure can penetrate body tissue. Fluid penetration
dealer. 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
Wiring type of injury.
Check electrical wires daily. If any of the following Replace the affected parts if any of the following
conditions exist, replace parts before you operate the conditions are present:
machine.
• End fittings are damaged or leaking.
• Fraying
• Outer coverings are chafed or cut.
• Signs of abrasion or wear
• Wires are exposed.
• Cracking
• Outer coverings are swelling or ballooning.
• Discoloration
• Flexible parts of the hoses are kinked.
22 SEBU7857-05
Safety Section
Fire Extinguisher Location

• Outer covers have exposed embedded armoring. Consider installation of an aftermarket Fire
Suppression System, if the application and working
• End fittings are displaced. conditions warrant the installation.

Make sure that all clamps, guards, and heat shields i02370502
are installed correctly. During machine operation, this
will help to prevent vibration, rubbing against other
parts, excessive heat, and failure of lines, tubes, and Fire Extinguisher Location
hoses. SMCS Code: 7000
Do not operate a machine when a fire hazard exists. Make sure that a fire extinguisher is available. Be
Repair any lines that are corroded, loose, or familiar with the operation of the fire extinguisher.
damaged. Leaks may provide fuel for fires. Consult Inspect the fire extinguisher and service the fire
your Cat dealer for repair or for replacement parts. extinguisher regularly. Obey the recommendations
Use genuine Cat parts or the equivalent, for on the instruction plate.
capabilities of both the pressure limit and
temperature limit. The fire extinguisher may be mounted to the grab
handle that is located on the right platform near the
Ether front of the engine hood. Do not block access to the
following items:
Ether (if equipped) is commonly used in cold-weather
applications. Ether is flammable and poisonous. • handrails

Only use approved Ether canisters for the Ether • ladders

dispensing system fitted to your machine, do not
spray Ether manually into an engine, follow the • walkways
correct cold engine starting procedures. Refer to the
section in the Operation and Maintenance Manual • front side door of engine hood
with the label “Engine Starting” .
Do not weld a bracket on the Rollover Protective
Use ether in ventilated areas. Do not smoke while Structure (ROPS) in order to install the fire
you are replacing an ether cylinder. extinguisher. Also, do not drill holes in the ROPS in
order to mount the fire extinguisher on the ROPS.
Do not store ether cylinders in living areas or in the
operator compartment of a machine. Do not store i06164462
ether cylinders in direct sunlight or in temperatures
above 49° C (120.2° F). Keep ether cylinders away
from open flames or sparks.
Tire Information
SMCS Code: 7000
Dispose of used ether cylinders properly. Do not
puncture an ether cylinder. Keep ether cylinders Explosions of air inflated tires have resulted from
away from unauthorized personnel. heat-induced gas combustion inside the tires.
Explosions can be caused by heat that is generated
Fire Extinguisher by welding, by heating rim components, by external
fire, or by excessive use of brakes.
As an additional safety measure, keep a fire A tire explosion is much more violent than a blowout.
extinguisher on the machine. The explosion can propel the tire, the rim
components, and the axle components from the
Be familiar with the operation of the fire extinguisher. machine. Stay out of the trajectory path. Both the
Inspect the fire extinguisher and service the fire force of the explosion and the flying debris can cause
extinguisher regularly. Follow the recommendations property damage, personal injury, or death.
on the instruction plate.
SEBU7857-05 23
Safety Section
Electrical Storm Injury Prevention

When you inflate a tire, stand behind the tread and

use a self-attaching chuck.
Servicing tires and rims can be dangerous. Only
trained personnel that use proper tools and proper
procedures should perform this maintenance. If
correct procedures are not used for servicing tires
and rims, the assemblies could burst with explosive
force. This explosive force can cause serious
personal injury or death. Carefully obey the specific
instructions from your tire dealer.

i01122596

Electrical Storm Injury

Illustration 37 g02166933 Prevention
Typical example of tire is shown
SMCS Code: 7000
Do not approach a hot or an apparently damaged When lightning is striking in the vicinity of the
tire. machine, the operator should never attempt the
Caterpillar recommends against using water or following procedures:
calcium as a ballast for the tires except in machines
designed for this additional mass. For those • Mount the machine.
applicable machines, the maintenance section will
contain instructions on the correct tire inflation and • Dismount the machine.
filling procedures. Ballast, such as fluid in the tires, If you are in the operator's station during an electrical
increases overall machine weight and may affect storm, stay in the operator's station. If you are on the
braking, steering, power train components, or the ground during an electrical storm, stay away from the
certification of the protective structure such as the vicinity of the machine.
ROPS. The use of tire/rim rust preventatives or other
liquid additives is not required.
i03140043

Before Starting Engine

Proper nitrogen inflation equipment, and training SMCS Code: 1000; 7000
in using the equipment, are necessary to avoid
over inflation. A tire blowout or rim failure can re- Start the engine only from the operator's
sult from improper or misused equipment and compartment. Never short across the starter
personal injury or death can occur. terminals or across the batteries. Shorting could
bypass the engine neutral start system. Shorting
A tire blowout and/or rim failure can occur if the could also damage the electrical system.
inflation equipment is not used correctly, due to
the fact that a fully charged nitrogen cylinder's
pressure is approximately 15000 kPa (2200 psi).

Dry nitrogen gas is recommended for inflation of

tires. If the tires were originally inflated with air,
nitrogen is still preferred for adjusting the pressure.
Nitrogen mixes properly with air.
Nitrogen inflated tires reduce the potential of a tire
explosion because nitrogen does not aid combustion.
Nitrogen helps to prevent oxidation of the rubber,
deterioration of rubber, and corrosion of rim
components.
To avoid overinflation, proper nitrogen inflation
equipment and training in the usage of the equipment Illustration 38 g00927804
are necessary. A tire blowout or a rim failure can
result from improper equipment or from misused Depress the machine horn (1) in order to make sure
equipment. that the machine horn works properly.
24 SEBU7857-05
Safety Section
Engine Starting

Diesel engine exhaust contains products of

combustion which can be harmful to your health.
Always start the engine in a well ventilated area.
Always operate the engine in a well ventilated area. If
you are in an enclosed area, vent the exhaust to the
outside.
Briefly sound the horn before you start the engine.

i01349075

Before Operation
SMCS Code: 7000
Clear all personnel from the machine and from the
Illustration 39 g01120628 area.
Typical example Clear all obstacles from the path of the machine.
Beware of hazards such as wires, ditches, etc.
Adjust the mirrors (2) on your machine for the best
operator vision. Adjust both the inside mirror and the Make sure that all windows are clean. Secure the
outside mirror before you operate the machine. doors in the open position or in the shut position.
Secure the windows in the open position or in the
Inspect the condition of the seat belt and the shut position.
condition of mounting hardware. Replace any
damaged parts and any worn parts. Regardless of For the best vision of the area that is close to the
appearance, replace the seat belt after three years of machine, adjust the rear view mirrors (if equipped).
use. Do not use a seat belt extension on a retractable
seat belt. Make sure that the machine horn, the backup alarm
(if equipped) and all other warning devices are
Adjust the seat in order to achieve full pedal travel working properly.
when the operator's back is against the back of the
seat. Fasten the seat belt securely.

Make sure that the machine is equipped with a i07746368

lighting system that is adequate for the job
conditions. Make sure that all lights are working
properly. Visibility Information
SMCS Code: 7000
Before you start the engine or before you move the
machine, make sure that no one is on the machine, Before you start the machine, perform a walk-around
underneath the machine, or around the machine. inspection in order to ensure that there are no
Make sure that there are no personnel in the area.
hazards around the machine.
i03565626 While the machine is in operation, constantly survey
the area around the machine in order to identify
Engine Starting potential hazards as hazards become visible around
the machine.
SMCS Code: 1000; 7000
Your machine may be equipped with visual aids.
If a warning tag is attached to the engine start switch Some examples of visual aids are Closed Circuit
or to the machine controls, do not start the engine. Television (CCTV) and mirrors. Before operating the
Also, do not move any machine controls. machine, ensure that the visual aids are in proper
working condition and that the visual aids are clean.
Move all hydraulic controls to the HOLD position or to Adjust the visual aids using the procedures that are
the OFF position before you start the engine. located in this Operation and Maintenance Manual. If
equipped, the Work Area Vision System shall be
Move the transmission control (lever) to the adjusted according to Operation and Maintenance
NEUTRAL position. Manual, SEBU8157, “Work Area Vision System”. If
equipped, the Cat Detect Object Detection shall be
Engage the parking brake control. adjusted according to the Operation and
Maintenance Manual, “Cat Detect Object Detection”
for your machine.
SEBU7857-05 25
Safety Section
Restricted Visibility

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 safe movement of traffic

• 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 by the
user that result in a restriction of visibility shall be Illustration 40 g01635673
evaluated.
Top view of the machine
i03641204
Note: The shaded areas indicate the approximate
location of areas with significant restricted visibility.
Restricted Visibility
SMCS Code: 7000
The size and the configuration of this machine may There is restricted visibility to the area directly
result in areas that can not be seen when the behind the machine. Failure to make sure the area
operator is seated. Illustration 40 provides an is clear could result in injury or death. Use a sec-
approximate visual indication of areas of significant ond person on the ground to make sure that the
restricted visibility. Illustration 40 indicates restricted area is clear before you operate the machine in
visibility areas at ground level inside a radius of the REVERSE position. Refer to the Operation
12.00 m (40 ft) from the operator on a machine and Maintenance Manual, “Operation Informa-
without the use of optional visual aids. This tion” for more information.
illustration does not provide areas of restricted
visibility for distances outside a radius of 12.00 m
(40 ft).
This machine may be equipped with optional visual
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, the 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”.
26 SEBU7857-05
Safety Section
Operation

i07445037 Never use the work tool for a work platform.

Operation Note any needed repairs during machine operation.

Report any needed repairs.
SMCS Code: 7000
Do not operate the machine on ground conditions
that could result in the seat suspension travel stops
Machine Operating Temperature being contacted and do not operate the machine at
Range travel speeds that could result in the seat suspension
travel stops being contacted. Operating this machine
The standard machine configuration is intended for in rough ground conditions or at travels speeds not
use within an ambient temperature range of −40 °C suitable for the ground conditions may result in
(−40 °F) to 43 °C (110 °F). Special configurations for excessive seat vertical travel with impact of the
different ambient temperatures may be available. suspension against the travel stops, which may
Consult your Caterpillar dealer for additional cause injury. In order to minimize impact loading on
information on special configurations of your the operator, properly adjust the seat controls for the
machine. operator weight and height. Refer to Operation and
Maintenance Manual, “Seat” for more information.
Limiting Conditions and Criteria Carry attachments approximately 40 cm (15 inches)
above ground level. Do not go close to the edge of a
Limiting conditions are immediate issues with this cliff, an excavation, or an overhang.
machine that must be addressed prior to continuing
operation. If the machine begins to sideslip downward on a
grade, immediately remove the load and turn the
The Safety Section of the Operation and machine downhill.
Maintenance Manual describes limiting condition
Avoid any conditions that can lead to tipping the
criteria for replacing items such as safety messages,
machine. The machine can tip when you work on
seat belt and mounting hardware, lines, tubes, hoses,
hills, on banks and on slopes. Also, the machine can
battery cables and related parts, electrical wires, and
tip when you cross ditches, ridges, or other
repairing any fluid leak. unexpected obstructions.
The Maintenance Interval Schedule in the Operation Avoid operating the machine across the slope. When
and Maintenance Manual describes limiting condition possible, operate the machine up the slopes and
criteria that require repair or replacement for items (if down the slopes.
equipped) such as alarms, horns, braking system,
steering system, and rollover protective structures. Maintain control of the machine. Do not overload the
machine beyond the machine capacity.
The Monitoring System (if equipped) described in the
Operation Section of the Operation and Maintenance Never straddle a wire cable. Never allow other
Manual provides information on limiting condition personnel to straddle a wire cable.
criteria, including a warning level that requires
immediate shutdown of the machine. Before you maneuver the machine, make sure that
no personnel are between the machine and
attachments.
Machine Operation
Know the maximum dimensions of your machine.
Only operate the machine while you are in a seat.
The seat belt must be fastened while you operate the Always keep the Rollover Protective Structure
machine. Only operate the controls while the engine (ROPS) installed during machine operation.
is running.
i06299648
While you operate the machine slowly in an open
area, check for proper operation of all controls and all
protective devices. Engine Stopping
SMCS Code: 1000; 7000
Before you move the machine, make sure that no
one will be endangered. Do not stop the engine immediately after the machine
has been operated under load. Stopping the engine
Do not allow riders on the machine unless the immediately can cause overheating and accelerated
machine has the following equipment:
wear of engine components.
• additional seat
After the machine is parked and the parking brake is
• additional seat belt engaged, allow the engine to run at low idle for 5
minutes before shutdown. Running the engine allows
• Roll over Protective Structure (ROPS) hot areas of the engine to cool gradually.
SEBU7857-05 27
Safety Section
Parking

i03370980
Roughness of terrain or surface – The machine
Parking may be less stable with uneven terrain.

SMCS Code: 7000 Direction of travel – Avoid operating the machine

across the slope. When possible, operate the
Park the machine on a level surface. If you must park machine up the slopes and operate the machine
on a grade, chock the machine's wheels with suitable down the slopes. Place the heaviest end of the
chocks. Take into account the following: machine uphill when you are working on an incline.

• tire size Mounted equipment – Balance of the machine may

be impeded by the following components: equipment
• machine weight that is mounted on the machine, machine
configuration, weights, and counterweights.
• ground conditions Nature of surface – Ground that has been newly
Apply the service brake in order to stop the machine. filled with earth may collapse from the weight of the
Move the transmission control (lever) to the machine.
NEUTRAL position. Move the throttle control to the Surface material – Rocks and moisture of the
LOW IDLE position. surface material may drastically affect the machine's
traction and machine's stability. Rocky surfaces may
Engage the parking brake. promote side slipping of the machine.
Lower all equipment to the ground. Activate any Slippage due to excessive loads – This may cause
control locks. downhill tracks or downhill tires to dig into the ground,
which will increase the angle of the machine.
Stop the engine.
Width of tracks or tires – Narrower tracks or
Turn the engine start switch to the OFF position and narrower tires further increase the digging into the
remove the engine start switch key. ground which causes the machine to be less stable.
Turn the battery disconnect switch to the OFF Implements attached to the drawbar – This may
position. Remove the disconnect switch key if you do decrease the weight on the uphill tracks. This may
not operate the machine for an extended period of also decrease the weight on the uphill tires. The
time. This will prevent drainage of the battery. A decreased weight will cause the machine to be less
battery short circuit, any current draw from certain stable.
components, and vandalism can cause drainage of
the battery. Height of the working load of the machine – When
the working loads are in higher positions, the stability
of the machine is reduced.
i07746366
Operated equipment – Be aware of performance
Slope Operation features of the equipment in operation and the effects
on machine stability.
SMCS Code: 7000
Operating techniques – Keep all attachments or
Machines that are operating safely in various pulled loads low to the ground for optimum stability.
applications depend on these criteria: the machine
model, configuration, machine maintenance, Machine systems have limitations on slopes –
operating speed of the machine, conditions of the Slopes can affect the proper function and operation
terrain, fluid levels, and tire inflation pressures. The of the various machine systems. These machine
most important criteria are the skill and judgment of systems are needed for machine control.
the operator.
A well trained operator that follows the instructions in Note: Operators with lots of experience and proper
the Operation and Maintenance Manual has the equipment for specific applications are also required.
greatest impact on stability. Operator training Safe operation on steep slopes may also require
provides a person with the following abilities: special machine maintenance. Refer to Lubricant
observation of working and environmental conditions, Viscosities and Refill Capacities in this manual for the
feel for the machine, identification of potential proper fluid level requirements and intended machine
hazards and operating the machine safely by making use. Fluids must be at the correct levels to ensure
appropriate decisions. that systems will operate properly on a slope.
When you work on side hills and when you work on
slopes, consider the following important points:
Speed of travel – At higher speeds, forces of inertia
tend to make the machine less stable.
28 SEBU7857-05
Safety Section
Equipment Lowering with Engine Stopped

i01329161 The exterior sound power level is 111 dB(A) when the
value is measured according to the static pressure
Equipment Lowering with test procedures and the conditions that are specified
in “ISO 6393:2008”.
Engine Stopped
SMCS Code: 7000 Sound Level Information for
Before lowering any equipment with the engine Machines in European Union
stopped, clear the area around the equipment of all Countries and in Countries that
personnel. The procedure to use will vary with the
type of equipment to be lowered. Keep in mind most Adopt the “European Union
systems use a high pressure fluid or air to raise or Directives”
lower equipment. The procedure will cause high
pressure air, hydraulic, or some other media to be The static operator sound pressure level is 78 dB(A)
released in order to lower the equipment. Wear when “ISO 6394:2008” is used to measure the value
appropriate personal protective equipment and follow for an enclosed cab. The test was conducted with the
the established procedure in the Operation and cab doors and the cab windows closed. The cab was
Maintenance Manual, “Equipment Lowering with properly installed and maintained.
Engine Stopped” in the Operation Section of the
manual. “The European Union Physical
i03593425
Agents (Vibration) Directive 2002/
44/EC”
Sound Information and
Vibration Information Vibration Data for Wheel Scrapers
SMCS Code: 7000 Information Concerning Hand/Arm Vibration
Level
S/N: DBC1–Up
When the machine is operated according to the
Sound Level Information intended use, the hand/arm vibration of this machine
is below 2.5 meter per second squared.
The operator Equivalent Sound Pressure Level (Leq)
is 81 dB(A) when “ANSI/SAE J1166 OCT 98” is used Information Concerning Whole Body Vibration
to measure the value for an enclosed cab. This is a Level
work cycle sound exposure level. The cab was
properly installed and maintained. The test was This section provides vibration data and a method for
conducted with the cab doors and the cab windows estimating the vibration level for wheel scrapers.
closed.
Note: Vibration levels are influenced by many
Hearing protection may be needed when the different parameters. Many items are listed below.
machine is operated with an open operator station for
extended periods or in a noisy environment. Hearing • Operator training, behavior, mode and stress
protection may be needed when the machine is
operated with a cab that is not properly maintained or • Job site organization, preparation, environment,
when the doors and windows are open for extended weather and material
periods or in a noisy environment.
• Machine type, quality of the seat, quality of the
The average exterior sound pressure level is 86 dB suspension system, attachments and condition of
(A) when the “SAE J88Feb06 - Constant Speed the equipment
Moving Test” procedure is used to measure the value
for the standard machine. The measurement was It is not possible to get precise vibration levels for this
conducted under the following conditions: distance of machine. The expected vibration levels can be
15 m (49.2 ft) and “the machine moving forward in an estimated with the information in Table 1 in order to
intermediate gear ratio”. calculate the daily vibration exposure. A simple
evaluation of the machine application can be used.
SEBU7857-05 29
Safety Section
Sound Information and Vibration Information

Estimate the vibration levels for the three vibration

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

Note: All vibration levels are in meter per second

squared.

Table 1
“ISO Reference Table A - Equivalent vibration levels of whole body vibration emission for earthmoving equipment.”

Typical Operating Vibration Levels Scenario Factors

Machine Family Machine Type
Activity X axis Y axis Z axis X axis Y axis Z axis
Scraper Wheel Scraper work cycle 1,05 1,18 1,12 0,34 0,40 0,42

Note: Refer to “ISO/TR 25398 Mechanical Vibration - b. Brake and steering systems
Guideline for the assessment of exposure to whole
body vibration of ride on operated earthmoving c. Controls, hydraulic system and linkages
machines” for more information about vibration. This 3. Keep the terrain in good condition.
publication uses data that is measured by
international institutes, organizations and a. Remove any large rocks or obstacles.
manufacturers. This document provides information
b. Fill any ditches and holes.
about the whole body exposure of operators of
earthmoving equipment. Refer to Operation and c. Provide machines and schedule time in order to
Maintenance Manual, SEBU8257, “The European maintain the conditions of the terrain.
Union Physical Agents (Vibration) Directive 2002/44/
EC” for more information about machine vibration 4. Use a seat that meets “ISO 7096”. Keep the seat
levels. maintained and adjusted.
The Caterpillar suspension seat meets the criteria of a. Adjust the seat and suspension for the weight
“ISO 7096”. This represents vertical vibration level and the size of the operator.
under severe operating conditions. This seat is tested
with the input “spectral class EM2”. The seat has a b. Inspect and maintain the seat suspension and
transmissibility factor of “SEAT<1.0”. adjustment mechanisms.
The whole body vibration level of the machine varies. 5. Perform the following operations smoothly.
There is a range of values. The low value is 0.5 meter
per second squared. The machine meets the short a. Steer
term level for the design of the seat in “ISO 7096”. b. Brake
The value is 1.34 meter per second squared for this
machine. c. Accelerate.
Guidelines for Reducing Vibration Levels on d. Shift the gears.
Earthmoving Equipment
6. Move the attachments smoothly.
Properly adjust machines. Properly maintain 7. Adjust the machine speed and the route in order to
machines. Operate machines smoothly. Maintain the
conditions of the terrain. The following guidelines can minimize the vibration level.
help reduce the whole body vibration level: a. Drive around obstacles and rough terrain.
1. Use the right type and size of machine, equipment, b. Slow down when it is necessary to go over
and attachments. rough terrain.
2. Maintain machines according to the 8. Minimize vibrations for a long work cycle or a long
manufacturer's recommendations. travel distance.
a. Tire pressures
30 SEBU7857-05
Safety Section
Operator Station

a. Use machines that are equipped with Caterpillar, Inc.

suspension systems. www.cat.com
b. Use the ride control system on wheel scrapers. i07746362
c. If no ride control system is available, reduce
speed in order to prevent bounce. Operator Station
d. Haul the machines between workplaces. SMCS Code: 7000

9. Less operator comfort may be caused by other risk S/N: DBC1–Up

factors. The following guidelines can be effective Any modifications to the inside of the operator station
in order to provide better operator comfort: should not project into the operator space or into the
space for the companion seat (if equipped). The
a. Adjust the seat and adjust the controls in order
addition of a radio, fire extinguisher, and other
to achieve good posture. equipment must be installed so that the defined
b. Adjust the mirrors in order to minimize twisted operator space and the space for the companion seat
(if equipped) is maintained. Any item that is brought
posture. into the cab should not project into the defined
c. Provide breaks in order to reduce long periods operator space or the space for the companion seat
of sitting. (if equipped). A lunch box or other loose items must
be secured. Objects must not pose an impact hazard
d. Avoid jumping from the cab. in rough terrain or in the event of a rollover.
e. Minimize repeated handling of loads and lifting i07746359
of loads.
f. Minimize any shocks and impacts during sports Guards
and leisure activities. (Operator Protection)
Sources SMCS Code: 7000
There are different types of guards that are used to
The vibration information and the calculation protect the operator. The machine and the machine
procedure is based on “ISO/TR 25398 Mechanical
Vibration - Guideline for the assessment of exposure application determine the type of guard that should
to whole body vibration of ride on operated be used.
earthmoving machines”. Harmonized data is A daily inspection of the guards is required in order to
measured by international institutes, organizations check for structures that are bent, cracked, or loose.
and manufacturers. Never operate a machine with a damaged structure.
This literature provides information about assessing The operator becomes exposed to a hazardous
the whole body vibration exposure of operators of situation if the machine is used improperly or if poor
earthmoving equipment. The method is based on operating techniques are used. This situation can
measured vibration emission under real working occur even though a machine is equipped with an
conditions for all machines. appropriate protective guard. Follow the established
You should check the original directive. This operating procedures that are recommended for your
document summarizes part of the content of the machine.
applicable law. This document is not meant to
substitute the original sources. Other parts of these
documents are based on information from the United
Kingdom Health and Safety Executive.
Refer to Operation and Maintenance Manual,
SEBU8257, “The European Union Physical Agents
(Vibration) Directive 2002/44/EC” 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:
SEBU7857-05 31
Safety Section
Operator Protection

Rollover Protective Structure • Forestry products

(ROPS), Falling Object Protective Additional guards may be required for specific
Structure (FOPS) or Tip Over applications or work tools. The Operation and
Maintenance Manual for your machine or your work
Protection Structure (TOPS) tool will provide specific requirements for the guards.
Refer to Operation Maintenance manual,
The ROPS/FOPS Structure (if equipped) on your "Demolition" for additional information. Consult your
machine is specifically designed, tested and certified Cat dealer for additional information.
for that machine. Any alteration or any modification to
the ROPS/FOPS Structure could weaken the
structure. This places the operator into an
unprotected environment. Modifications or
attachments that cause the machine to exceed the
weight that is stamped on the certification plate also
place the operator into an unprotected environment.
Excessive weight may inhibit the brake performance,
the steering performance and the ROPS. The
protection that is offered by the ROPS/FOPS
Structure will be impaired if the ROPS/FOPS
Structure has structural damage. Damage to the
structure can be caused by an overturn, a falling
object, a collision, etc.
Do not mount items (fire extinguishers, first aid kits,
work lights, etc) by welding brackets to the ROPS/
FOPS Structure or by drilling holes in the ROPS/
FOPS Structure. Welding brackets or drilling holes in
the ROPS/FOPS Structures can weaken the
structures. Consult your Cat dealer for mounting
guidelines.
The Tip Over Protection Structure (TOPS) is another
type of guard that is used on mini hydraulic
excavators. This structure protects the operator in the
event of a tipover. The same guidelines for the
inspection, the maintenance and the modification of
the ROPS/FOPS Structure are required for the Tip
Over Protection Structure.

Other Guards (If Equipped)

Protection from flying objects and/or falling objects is
required for special applications. Logging
applications and demolition applications are two
examples that require special protection.
A front guard needs to be installed when a work tool
that creates flying objects is used. Mesh front guards
that are approved by Caterpillar or polycarbonate
front guards that are approved by Caterpillar are
available for machines with a cab or an open canopy.
On machines that are equipped with cabs, the
windows should also be closed. Safety glasses are
recommended when flying hazards exist for
machines with cabs and machines with open
canopies.
If the work material extends above the cab, top
guards and front guards should be used. Typical
examples of this type of application are listed below:
• Demolition applications

• Rock quarries
32 SEBU7857-05
Product Information Section
General Information

Product Information Table 3

Section 623G Wheel Tractor-Scraper

Engine C15 Acert Diesel Engine

LHX1–Up
General Information Transmission Eight speeds (forward)
One speed (reverse)
i03603783 M1R1–Up

Rated Load
SMCS Code: 7000
Intended Use
This Wheel Tractor-Scraper is an earthmoving
The empty weight of the machine will depend on the machine as described in ISO 6165:2001 and is
configuration of the machine and the options of the classified as a scraper. This machine is used to cut,
machine. Approximate weights are listed below. load, transport and discharge material through a
forward motion.
If the machine has a CE plate that is required for the
European Union, the weight on the CE plate is based
upon the sum of the empty machine weight and a Application/Configuration Restrictions
85 kg (187 lb) operator.
The operator station is ROPS certified to a tractor
Table 2
only mass of 17500 kg (38590 lb) as tractor portion
623G Wheel Tractor-Scraper of tractor-scrapers per Table 1 of ISO 3471:1994.
This excludes scraper weight and this weight
Empty Weight(1) 37510 kg (82695 lb) excludes payload.
Rated Load 25038 kg (55199 lb) For the maximum approved operating weight refer to
the loaded weight in Operation and Maintenance
Maximum Loaded Weight(1) 62548 kg (137894 lb) Manual, “Rated Load”.
Cubic Capacity 17.6 cubic meters heaped Maximum side grade operation without machine
(23 cubic yards heaped)
articulation is 51% grade.
(1) This weight includes a standard machine, a 75 kg (165 lb) op-
erator, and full fuel tanks. Note: The listed restriction assumes a machine
operating perpendicular to a side grade, graded
i03606684 ground surface, nominal payload, homogeneous
payload distribution in the bowl and operating on a
Specifications dry, firm underfooting. Refer to the Operation and
Maintenance Manual, “Slope Operation” for more
SMCS Code: 1000; 7000 information.
Maximum side grade operation with machine
articulation is 22% grade.
Note: The listed restriction assumes a machine
operating at a very slow ground speed on a graded
ground surface, nominal payload, homogeneous
payload distribution in the bowl and operating on a
dry, firm underfooting. Refer to the Operation and
Maintenance Manual, “Slope Operation” for more
information.
Service brake holding capability on a grade is 25%
grade.
Note: The listed restriction assumes the brake
components are within working specifications, a
Illustration 41 g01931573 graded ground surface and a dry, firm underfooting.
Approximate dimensions are shown. Dimensions will Evaluate the condition of the machine and the
vary depending on the configuration and the options. environment and use appropriate judgment to
(A) 3.58 m (11 ft 9 inch) maintain control of the machine.
(B) 3.71 m (12 ft 2 inch)
(C) 13.17 m (43 ft 3 inch)
SEBU7857-05 33
Product Information Section
Specifications

Parking brake holding capability on a grade is 15%

grade.

Note: The listed restriction assumes the brake

components are within working specifications, a
graded ground surface and a dry, firm underfooting.
Evaluate the condition of the machine and the
environment and use appropriate judgment to
maintain control of the machine.
While descending on a grade do not exceed 2600
RPM or damage to the engine may occur.
Use only in nonexplosive gas environments.
34 SEBU7857-05
Product Information Section
Identification Information

Identification Information
i03565637

Plate Locations and Film

Locations
SMCS Code: 1000; 6000; 7000
The Product Identification Number (PIN) will be used
to identify a machine.
Caterpillar products such as engines, transmissions
and major attachments are identified by Serial
Numbers (S/N).
Illustration 43 g00930241
For quick reference, record the identification
numbers in the spaces that are provided below the The Product Identification Number (PIN) for the
illustrations. scraper is located on the left side of the bowl. Plate
(2) is located above the draft arm. Plate (2) will have
the following information:
Model number
PIN

Illustration 42 g01117733

The Product Identification Number (PIN) for the

tractor is located on the right side of the tractor frame.
Plate (1) is below the operator compartment. Plate
(1) will have the following information:
Model number
PIN
Engine model number
Engine serial number Illustration 44 g00929722

Engine arrangement number Plate (3) for the transmission serial number is located
Transmission model number on the back side of the transmission.

Transmission serial number Transmission Serial Number

Transmission arrangement number

SEBU7857-05 35
Product Information Section
Plate Locations and Film Locations

Refer to Operation and Maintenance Manual,

“Guards (Operator Protection)” for more information.

European Union

Illustration 45 g01116553

Plate (4) for the engine serial number can be found

on the right side of the tractor frame. The serial
number for the engine can also be found on the right
side of the engine block.
Illustration 47 g01880193

Engine Serial Number

This plate is positioned on the bottom left side of
plate (1) for the PIN.
Certification
Note: The CE plate is on machines that are certified
ROPS/FOPS Structure to the European Union requirements that were
effective at that time.
This message is positioned on the ROPS.
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
Illustration 46 g01211895

Structural damage, an overturn, modification, al-

teration, or improper repair can impair this struc-
ture's protection capability thereby voiding this
certification. Do not weld on or drill holes in the
structure. Consult a Caterpillar dealer to deter-
mine this structure's limitations without voiding
its certification.

This machine has been certified to the standards that

are listed on the certification film. The maximum
mass of the machine, which includes the operator
and the attachments without a payload, should not
exceed the mass on the certification film.
36 SEBU7857-05
Product Information Section
Emissions Certification Film

Illustration 48 g01120192 Illustration 49 g01222547

This plate is positioned on the bottom left side of This message is located on the control group for the
plate (1) for the PIN. Product Link. The control group is located on the cab
rear wall to the right of the operator seat.
Note: The CE plate is on machines that are certified
to the European Union requirements that were If the machine is required to work within 6 m (20 ft) of
effective at that time. a blast area, power to the Product Link module must
be disconnected.
For machines compliant to 98/37/EC and 89/392/
EEC, the following information is stamped onto the Consult your Caterpillar dealer with any questions
CE plate. For quick reference, record this information that concern the operation of the Product Link in a
in the spaces that are provided below. specific country.

• Engine Power Primary Engine (kW) i07709181

• Typical Machine Operating Weight for European

Market (kg)
Emissions Certification Film
SMCS Code: 1000; 7000; 7405
• Year of Construction
Note: This information is pertinent in the United
For the name and address of the manufacturer, and
the country of origin of the machine, refer to the PIN States, in Canada and in Europe.
plate.
Consult your Cat dealer for an Emission Control
Warranty Statement.
Product Link
This label is located on the engine.
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:
Table 4
Operating frequency range 148 to 150 MHz

Transmitter power 5 Watts

SEBU7857-05 37
Product Information Section
Declaration of Conformity

Declaration of Conformity
SMCS Code: 1000; 7000

Table 5
An EC Declaration of Conformity document was provided with the machine if it was manufactured to comply with specific requirements for the
European Union. In order to determine the details of the applicable Directives, review the complete EC Declaration of Conformity provided with
the machine. The extract shown below from an EC Declaration of Conformity for machines that are declared compliant to “2006/42/EC” applies
only to those machines originally “CE” marked by the manufacturer listed and which have not since been modified.

EC DECLARATION OF CONFORMITY OF MACHINERY

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

Person authorized to compile the Technical File and to communicate relevant part (s) of the Technical File to the Authorities of Euro-
pean Union Member States on request:

Standards & Regulations Manager,Cat-

erpillar France S.A.S 40 , Avenue Leon-
Blum, B.P. 55, 38041 Grenoble Cedex
9, France

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

Description: Generic Denomination: Earth-moving Equipment

Function: Scraper

Model/Type: 623G

Serial Number:
Commercial Name: Caterpillar

Fulfils all the relevant provisions of the following Directives

Directives Notified Body Document No.

2006/42/EC N/A
2004/108/EC N/A

Done at: Signature

Date: Name/Position
Note: The above information was correct as of July 2009, but may be subject to change, please refer to the individual declaration of conformity
issued with the machine for exact details.
38 SEBU7857-05
Operation Section
Before Operation

Operation Section Machine Access System

Specifications
Before Operation The machine access system has been designed to
meet the intent of the technical requirements in “ISO
2867 Earth-moving Machinery – Access Systems”.
i04021647 The access system provides for operator access to
the operator station and to conduct the maintenance
Mounting and Dismounting procedures described in Maintenance section.
SMCS Code: 7000
Alternate Exit
Machines that are equipped with cabs have alternate
exits. For additional information, see Operation and
Maintenance Manual, “Alternate Exit”.

i02504712

Daily Inspection
SMCS Code: 1000; 7000

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact skin.
Illustration 50 g00037860
Typical example At operating temperature, the engine coolant is
hot and under pressure.
Mount the machine and dismount the machine only
at locations that have steps and/or handholds. Before Steam can cause personal injury.
you mount the machine, clean the steps and the Check the coolant level only after the engine has
handholds. Inspect the steps and handholds. Make been stopped and the cooling system pressure
all necessary repairs. cap is cool enough to touch with your bare hand.
Face the machine whenever you get on the machine Remove the cooling system pressure cap slowly
and whenever you get off the machine. to relieve pressure.
Maintain a three-point contact with the steps and with Cooling system conditioner contains alkali. Avoid
the handholds. contact with the skin and eyes to prevent person-
al injury.
Note: Three-point contact can be two feet and one
hand. Three-point contact can also be one foot and
two hands.
NOTICE
Do not mount a moving machine. Do not dismount a Accumulated grease and oil on a machine is a fire
moving machine. Never jump off the machine. Do not hazard. Remove this debris with steam cleaning or
carry tools or supplies when you try to mount the high pressure water, at least every 1000 hours or
machine or when you try to dismount the machine. each time any significant quantity of oil is spilled on a
Use a hand line to pull equipment onto the platform. machine.
Do not use any controls as handholds when you
enter the operator compartment or when you exit the For maximum service life of the machine, perform a
operator compartment. thorough walk-around inspection before you mount
the machine and before you start the engine.
Look around the machine and under the machine.
Look for trash buildup, dirt buildup, loose bolts, oil
leaks, coolant leaks, broken parts, cracked parts or
worn parts.
SEBU7857-05 39
Operation Section
Daily Inspection

Note: Watch closely for leaks. If you observe a leak, • Operation and Maintenance Manual, “Fuel Tank
find the source of the leak and correct the leak. If you Water and Sediment - Drain”
suspect a leak or you observe a leak, check the fluid
levels more frequently. • Operation and Maintenance Manual, “Hydraulic
Oil Cooler - Clean”
Inspect the condition of the equipment and of the
hydraulic components. • Operation and Maintenance Manual, “Hydraulic
System Oil Level - Check”
Check the condition of the tires. Adjust the inflation
pressure, if necessary. • Operation and Maintenance Manual, “Radiator
Core - Clean”
Check the oil levels, the coolant level, and the fuel
level. • Operation and Maintenance Manual, “Seat Belt -
Remove any trash buildup and debris. Make all Inspect”
necessary repairs before you operate the machine.
Make sure that all covers and guards are securely
attached.
The operator should be seated against the seat
backrest. Adjust the seat so that the operator is
allowed full travel of the pedals.
Adjust the mirrors for the correct rear view of the
machine.
Make sure that the engine air filter service indicator
for the tractor is not in the red zone.
Grease all of the fittings that need to be serviced on a
daily basis.
Daily, perform the procedures that are applicable to
your machine:
• Operation and Maintenance Manual, “Air Tank
Moisture and Sediment - Drain”

• Operation and Maintenance Manual, “Backup

Alarm - Test”

• Operation and Maintenance Manual, “Brakes,

Indicators and Gauges - Test”
• Operation and Maintenance Manual, “Cooling
System Coolant Level - Check”
• Operation and Maintenance Manual, “Elevator
Chain Idler - Lubricate”

• Operation and Maintenance Manual, “Engine Air

Filter Service Indicator - Inspect”

• Operation and Maintenance Manual, “Engine Air

Precleaner - Clean”
• Operation and Maintenance Manual, “Engine Oil
Level - Check”
• Operation and Maintenance Manual, “Floor
Rollers - Lubricate”
• Operation and Maintenance Manual, “Fuel System
Water Seperator - Drain”
40 SEBU7857-05
Operation Section
Machine Operation

Machine Operation i01809853

i02635783
Seat
SMCS Code: 7312
Alternate Exit S/N: DBC1–Up
SMCS Code: 7308; 7310
Note: Adjust the seat for a new operator or at the
S/N: DBC1–Up beginning of each shift.
The operator should be seated against the seat
backrest. Adjust the seat so that the operator is
allowed full travel of the pedals.

Illustration 53 g00927805

Swivel lever (1) – The seat is equipped

to rotate 30° in 10° increments. Pull up
Illustration 51 g01218193
on lever (1) for seat rotation. Rotate the
seat right or rotate the seat left until the desired
position is attained. Release the lever in order to
lock the seat into position.
Fore/Aft lever (2) – Move lever (2) to the
left. Move the seat forward or move the
seat backward until the desired position
is attained. Release the lever in order to lock the
seat into the desired position.
If the seat is loose on the suspension, tighten the set
screws. Refer to the topic that covers the seat in your
machine in Systems Operation, Testing and
Adjusting, Disassembly and Assembly, RENR2165
for the correct procedure.

Illustration 52 g01278721
Seat height and weight control knob (3)
– Pull out on knob (3) in order to move
This film is located above the hammer on the right the seat downward. Push in on the knob
rear post of the Rollover Protective Structure in order to move the seat upward. Release the
(ROPS). knob in order to lock the seat in the desired
position.
The rear cab window can be used as an alternate
exit. Use the hammer that is mounted on the ROPS Note: The operator must not change the height of the
in order to break the window. Push out the window. suspension so that the stroke is inadequate for the
particular application. The suspension height must be
changed if the seat bottoms out excessively or if the
seat bounces to the maximum height too much.
SEBU7857-05 41
Operation Section
Seat Belt

Damping lever (4) – Push forward on lever (4) in Lengthening the Seat Belt
order to decrease the rate of dampening for the seat
suspension. When you decrease the rate of
dampening for the seat suspension, the seat
suspension will move more freely. Pull backward on
lever (4) in order to increase the rate of dampening
for the seat suspension. When the rate of dampening
for the seat suspension is decreased, the seat
suspension will move less freely.

Seat recline lever (5) – Pull up on lever

(5). Move the back of the seat forward or
move the back of the seat backward
until the desired position is attained. Release the
lever in order to lock the back of the seat into
position.
Lumbar support knob (6) – Rotate knob Illustration 54 g00100709
(6) clockwise in order to increase back
support. Rotate the knob 1. Unfasten the seat belt.
counterclockwise in order to decrease back
support.
Seat armrest knobs (7) – Adjustment knobs (7) are
used to adjust the angle of the armrests when the
armrests are in the operating position. The knobs are
located on the bottom side of the armrests. Rotate
the knob clockwise in order to raise the angle of the
armrest. Rotate the knob counterclockwise in order to
lower the angle of the armrest.

i04200349

Seat Belt
SMCS Code: 7327
Illustration 55 g00932817
S/N: DBC1–Up
2. To remove the slack in outer loop (1), rotate buckle
Note: This machine was equipped with a seat belt
when the machine was shipped from Caterpillar. At (2). This will free the lock bar. This permits the
the time of installation, the seat belt and the seat belt to move through the buckle.
instructions for installation of the seat belt meet the 3. Remove the slack from the outer belt loop by
SAE J386 and ISO 6683 standards. Consult your Cat pulling on the buckle.
dealer for all replacement parts.
4. Loosen the other half of the seat belt in the same
Always check the condition of the seat belt and the manner. If the seat belt does not fit snugly with the
condition of the mounting hardware before you
operate the machine. buckle in the center, readjust the seat belt.

Seat Belt Adjustment for Non-

Retractable Seat Belts
Adjust both ends of the seat belt. The seat belt
should be snug but comfortable.
42 SEBU7857-05
Operation Section
Seat Belt

Shortening the Seat Belt Releasing The Seat Belt

Illustration 56 g00100713 Illustration 58 g00100717

1. Fasten the seat belt. Pull out on the outer belt loop Pull up on the release lever. This will release the seat
in order to tighten the seat belt. belt.

2. Adjust the other half of the seat belt in the same Seat Belt Adjustment for
manner.
Retractable Seat Belts
3. If the seat belt does not fit snugly with the buckle in
the center, readjust the seat belt. Fastening The Seat Belt
Fastening The Seat Belt

Illustration 59 g00867598

Illustration 57 g00932818 Pull seat belt (4) out of the retractor in a continuous
motion.
Fasten the seat belt catch (3) into the buckle (2).
Make sure that the seat belt is placed low across the Fasten seat belt catch (3) into buckle (2). Make sure
lap of the operator. that the seat belt is placed low across the lap of the
operator.
The retractor will adjust the belt length and the
retractor will lock in place. The comfort ride sleeve
will allow the operator to have limited movement.
SEBU7857-05 43
Operation Section
Mirror

Releasing The Seat Belt

Slips and falls can result in personal injury. Use

the machines access systems when adjusting the
mirrors. If the mirrors cannot be reached using
the machine access systems follow the instruc-
tions found within the Operation and Mainte-
nance Manual, “Mirror” in order to access the
mirrors.

Illustration 60 g00039113

Push the release button on the buckle in order to

release the seat belt. The seat belt will automatically
retract into the retractor.

Extension of the Seat Belt

When using retractable seat belts, do not use

seat belt extensions, or personal injury or death
can result.
The retractor system may or may not lock up de-
pending on the length of the extension and the Illustration 61 g01646673
size of the person. If the retractor does not lock (1) Right Side Mirror
up, the seat belt will not retain the person. (2) Cab Mirror

Longer, non-retractable seat belts and extensions for Mirrors provide additional visibility around your
the non-retractable seat belts are available. machine. Make sure that the mirrors are in proper
working condition and that the mirrors are clean.
Caterpillar requires only non-retractable seat belts to Adjust all mirrors at the beginning of each work
be used with a seat belt extension. period and adjust the mirrors when you change
operators.
Consult your Cat dealer for longer seat belts and for
information on extending the seat belts. Modified Machines or machines that have additional
equipment or attachments may influence your
i03235940 visibility.

Mirror Mirror Adjustment

SMCS Code: 7319 • Park the machine on a level surface.
• Stop the engine.

Adjust all mirrors as specified in the Operation Note: You may need to use hand tools in order to
and Maintenance Manual. Failure to heed this adjust certain types of mirrors.
warning can lead to personal injury or death.
44 SEBU7857-05
Operation Section
Operator Controls

Right Side Rear View Mirror

Illustration 62 g01646694

Adjust the right side rear view mirror (1) so 0.5 m

(1.5 ft)from the outer edge of the cross-tube of the
scraper bowl can be seen. Refer to illustration 62 .
Also adjust the right side rear view mirror in order to
see the following:
• a point on the ground 1 m (3.3 ft) to the right side
of the rear tire

Cab Mirror
The cab mirror (2) can be adjusted to a position in
order to allow the operator to see preferred areas on
the scraper portion of the machine during operations
such as loading and unloading.

i02460559

Operator Controls
SMCS Code: 7300; 7301; 7451

S/N: DBC1–Up

Note: Your machine may not be equipped with all of

the controls that are described in this topic.
SEBU7857-05 45
Operation Section
Operator Controls

Illustration 63 g01220138
Cab controls
(1) Heating and air conditioning switch (12) Warning hazard light switch (21) Throttle control (scraper)
(2) Temperature variable control (13) Bowl floodlight switch (22) Throttle control (tractor)
(3) Fan speed control (14) Scraper transmission neutral/run (23) Joystick control
(4) Rear window wiper/washer control control switch (24) Throttle lock control switch
(5) Side light switch (if equipped) (15) Mode select switch (25) Scraper power limiter control switch (if
(6) Interior dome light switch (16) Tractor-Scraper select switch equipped)
(7) Retarder control (17) Engine start switch (scraper) (26) Parking brake control switch
(8) Engine start switch (tractor) (18) Multifunction switch (27) Transmission control
(9) Cigar lighter (19) Steering column tilt and telescope (28) Differential lock control switch
(10) 12V Power receptacle control
(11) Headlight switch (20) Service brake control
46 SEBU7857-05
Operation Section
Operator Controls

Heating and Air Conditioning

Switch (1)
Heating and Air Conditioning
Switch – This switch is a three-
position switch. The CENTER
position of the switch is OFF. In order to activate
the air conditioner, push the switch to the TOP
position. In order to activate the heater, push the
switch to the BOTTOM position.

Temperature Variable Control (2)

Temperature Variable Control – This
Illustration 64 g01021436 knob will adjust the temperature of the
Scraper controls operator compartment. The knob has a
heating side and a cooling side. The heating side
(29) Panel light switch
(30) Remote throttle speed switch has a red marking. When you turn the knob all the
(31) Remote throttle switch way to the right, the heater will provide maximum
(32) Engine start switch heat. The cooling side has a blue marking. When
you turn the knob all the way to the left, the air
conditioner will provide maximum cooling.
Position the knob for your comfort.

Fan Speed Control (3)

Fan Speed Switch – The fan speed
switch controls the four-speed blower
fan motor for heating and for the air
conditioner. Turn fan speed switch (3) anywhere
between OFF position (left) and MAXIMUM
position (right).

Rear Window Wiper/Washer

Control (4)
Rear Window Wiper/Washer Control –
Turn knob (4) clockwise in order to turn
on the rear window wipers. Depress
knob (4) in order to wash the rear windows.

Side Light Switch (5)

Side Light Switch – For machines that
are equipped with the side light
attachment, push the switch upward in
order to turn on the side lights. Push the switch
downward in order to turn off the side lights. The
side lights will illuminate the work area. The side
lights will only work with the keyswitch in the ON
position.
SEBU7857-05 47
Operation Section
Operator Controls

Note: Do not turn on any lights without turning on the Note: If the engine fails to start, return the engine
running lights. Refer to “Headlight Switch (11)” for start switch key to the OFF position. This must be
more information. done before you attempt to start the engine again.

Interior Dome Light (6) Cigar Lighter (9)

Interior Dome Light – Push the switch upward in Cigar Lighter – The cigar lighter
order to turn on the dome light. Push the switch can be used as a 24V power
downward in order to turn off the dome light. receptacle. This power
receptacle can be used to power automotive
electrical equipment or accessories. Remove the
Retarder Control (7) cigar lighter before use.

The retarder (if equipped) provides continuous speed 12V Power Receptacle (10)
reduction during machine operation.
Retarder ON – Pull the lever toward you in order to 12V Power Receptacle – This power
engage the retarder. As the lever is pulled toward receptacle can be used to power
you, the braking action increases. automotive electrical equipment or
accessories. Remove the cap before use.
Retarder OFF – Push the lever away from you in
order to disengage the retarder. Headlight Switch (11)
Headlight Switch – This is a three-
Note: When the lever is moved, the retarder will position switch. Push the switch to the
engage after an interval of 3 or 4 seconds. Anticipate BOTTOM position in order to turn off the
this slight delay. following lights: headlights, dash lights, running
lights and tail lights. Push the switch to the
Engine Start Switch for the Tractor CENTER position in order to turn on only the
dash lights and the running lights. Push the
(8) switch to the TOP position in order to turn on the
headlights and the tail lights.
When you turn the key to the ON position, electrical
power is supplied to the systems.
Warning Hazard Light Switch (12)
OFF – When you insert the key and
when you remove the key, the engine Warning Hazard Light Switch – Push the
start switch must be in the OFF position. top of the switch in order to activate the
A running tractor engine and a running scraper hazard lights. Push the bottom of the
engine will stop running when the key is returned switch in order to deactivate the hazard lights.
to the OFF position.
Bowl Floodlight Switch (13)
ON – To activate the electrical circuits in
the cab, turn the key clockwise to the Bowl Floodlight Switch – Push the
ON position. switch upward in order to turn on the
bowl floodlights. Push the switch
START – To start the tractor engine, turn downward in order to turn off the bowl
the key clockwise to the START floodlights. The floodlights will illuminate the
position. After the engine starts, release work area. The floodlights will only work with the
the key. The key will return to the ON position. keyswitch in the ON position.
48 SEBU7857-05
Operation Section
Operator Controls

Note: Do not turn on any lights without turning on the Mode Select Switch (Scraper)
running lights. Refer to “Headlight Switch (11)” for
more information. The bottom of tractor-scraper select switch (16) must
be depressed in order to access the information
Scraper Transmission Neutral/Run about the scraper.

Control Switch (14) Tractor-Scraper Select Switch (16)

NOTICE Tractor-Scraper Select Switch –
Start the scraper engine before moving the machine. Switch (16) is used in order to
This is necessary to provide lubrication to the scraper display information for the
transmission. tractor or the scraper. Push the top of switch (16)
in order to view information about the tractor.
Transmission damage can result if the machine is
moved with the scraper engine stopped. Push the bottom of switch (16) in order to view
information about the scraper.

Scraper Transmission Neutral/Run Control Engine Start Switch for the Scraper
Switch – When the switch is used, the transmission
for the scraper will engage or the transmission will (17)
disengage.
Engine Start Switch for the
Scraper – Switch (17) is used to
DISENGAGE – Push the top of the start the scraper engine. Both
switch in order to disengage the scraper engine start switch (8) for the tractor and the
transmission. battery disconnect switch must be in the ON
ENGAGE – Push the bottom of the position in order to start the scraper engine.
Press the top of switch (17) in order to start the
switch in order to engage the scraper
transmission. scraper engine.

Note: During normal operation, the scraper Note: There are two engine start switches for the
transmission neutral/run control switch should be in scraper engine. Switch (17) is located in the operator
the ENGAGE position. compartment. Switch (32) is located on the scraper
control at the rear of the machine.
Mode Select Switch (15) Note: The electrical system of the scraper is
separate from the electrical system of the tractor. The
Mode Select Switch – Switch (15) is electrical system of the scraper is activated by a main
used to select the functions on the relay when engine start switch (8) for the tractor is
digital display window. Hold the switch turned to the ON position.
in order to scroll through the functions. Press the
switch momentarily in order to access the Note: If the engine fails to start, release the scraper
submodes. engine start switch. This must be done before you
attempt to start the engine again.
Mode Select Switch (Tractor)
Multifunction Switch (18)
The top of tractor-scraper select switch (16) must be
depressed in order to access the information about Windshield Wiper/Washer
the tractor.
Windshield Wipers – Rotate the handle
away from the operator in order to
activate the windshield wipers. There
are six positions for the windshield wipers.

OFF – When the handle is in the OFF

position, the wipers will be off.

INTERMITTENT POSITION 3 – The

wipers will operate intermittently. This is
the smallest interval of time between
cycles.
SEBU7857-05 49
Operation Section
Operator Controls

INTERMITTENT POSITION 2 – The position. When the lever is released, the steering
wipers will operate intermittently. column will remain in the desired position.

INTERMITTENT POSITION 1 – The Telescope – To telescope the steering column, push

wipers will operate intermittently. This is down on the lever. Then move the steering column to
the largest interval of time between the desired position. When the lever is released, the
cycles. steering column will remain in the desired position.

CONTINUOUS POSITION 1 – The wipers

will operate continuously. This is the Service Brake Control (20)
slow continuous speed.
Engage – Depress the service brake pedal in order
CONTINUOUS POSITION 2 – The wipers to engage the service brake. Use the service brake
will operate continuously. This is the for reducing ground speed or for stopping the
fast continuous speed. machine.
Windshield Washer – Push the button at
the end of the handle in order to activate Disengage – Release the service brake pedal in
the windshield washer. order to disengage the service brake.

Dimmer Switch
Throttle Control for the Scraper
Dimmer Switch – Push the (21)
dimmer switch away from the
steering wheel in order to Note: Throttle pedal (21) and throttle pedal (22) can
change the headlight beams from low beam to be operated at the same time with one foot.
high beam. Also, pull the dimmer switch toward
the steering wheel in order to change the Accelerate – Depress the throttle pedal in order to
headlight beams from high beam to low beam. increase the travel speed.

Directional Turn Signal Control Decelerate – Release the throttle pedal in order to
decrease the travel speed.
Right Directional Turn Signal – Push the
lever away from the operator in order to
activate the right turn signal. When the Note: Depressing throttle pedal (21) will not increase
lever is pushed forward away from the operator, the engine speed of the scraper unless the air
an indicator light will illuminate on the front dash. pressure is above 414 kPa (60 psi).
The right turn signal will flash until the lever is
manually returned to the OFF position. Throttle Control for the Tractor (22)
OFF – In the OFF position, the directional signal Note: Throttle pedal (22) and throttle pedal (21) can
lights will not flash. be operated at the same time with one foot.
Accelerate – Depress the throttle pedal in order to
Left Directional Turn Signal – Pull the
increase the travel speed.
lever toward the operator in order to
activate the left turn signal. When the
lever is pulled back toward the operator, an Decelerate – Release the throttle pedal in order to
indicator light will illuminate on the front dash. decrease the travel speed.
The left turn signal will flash until the lever is
manually returned to the OFF position.
Joystick Control (23)
Note: Refer to the “Indicators” topic in Operation and
Maintenance Manual, “Monitoring System” for more The joystick control is used to control the functions of
information about the indicator lights. the machine implements.

Steering Column Tilt and Note: After the engine is started, all implement
controls must be in the NEUTRAL position or the
Telescope Control (19) OFF position for two seconds before any of the
implements are allowed to operate.
Tilt – To tilt the steering column, pull up on the lever.
Then move the steering column to the desired
50 SEBU7857-05
Operation Section
Operator Controls

For specific information on the operation of the • Operation and Maintenance Manual, “Auger
implement controls that are affected, refer to the Control (Joystick)”
following topics (if equipped):
• Operation and Maintenance Manual, “Bowl Throttle Lock Control Switch (24)
Control (Joystick)”
Throttle Lock Control Switch – The
• Operation and Maintenance Manual, “Ejector switch maintains the engine rpm at a
Control (Joystick)” desired speed. Engage the switch in
order to keep the engine at the current rpm. When
• Operation and Maintenance Manual, “Apron the throttle lock is active, an indicator light will
Control (Joystick)” illuminate on the front dash. Refer to the
“Indicators” topic in Operation and Maintenance
• Operation and Maintenance Manual, “Bail Control Manual, “Monitoring System” for more
(Joystick)” information about the indicator light. Use the
throttle lock control on long hauls in order to
• Operation and Maintenance Manual, “Auger avoid driver fatigue. Fatigue may result from
Control (Joystick)” depressing the manual throttle control for an
extended period of time.
• Operation and Maintenance Manual, “Elevator
Control (Joystick)” ON – Push the top of the switch in order to turn on
the throttle lock control.
The joystick control will move forward and backward.
Also, the joystick control can move left or right. The
joystick control includes two push buttons, a thumb OFF – Push the bottom of the switch or slightly
lever, and an optional toggle switch. The joystick depress the service brake pedal in order to turn off
control has a left push button and a right push button. the throttle lock control.
The left push button is used to control the
transmission hold control. The right push button is
used for the cushion-hitch control. The thumb lever
can move left or right. The thumb lever is used for the
Scraper Power Limiter Control
apron control. If equipped, the toggle switch is used Switch (25)
for the bail control or for the auger control.
Scraper Power Limiter Control Switch –
For more information on the individual functions of If equipped, the switch reduces the
the joystick control, refer to the following topics (if power of the scraper engine. The switch
equipped):
is only for scrapers that are equipped with an
• Operation and Maintenance Manual, “Bowl auger. The switch should be engaged when the
Control (Joystick)” auger is engaged. The switch only needs to be
engaged at the beginning of the work day.
• Operation and Maintenance Manual, “Ejector
Control (Joystick)” ENGAGE – Push the top of the switch in order to
engage the scraper power limiter control.
• Operation and Maintenance Manual, “Apron
Control (Joystick)” DISENGAGE – Push the bottom of the switch in
order to disengage the scraper power limiter control.
• Operation and Maintenance Manual,
“Transmission Hold Control (Joystick)”
Note: The auger must be turning for loading and for
• Operation and Maintenance Manual, “Cushion- unloading of the scraper.
Hitch Control (Joystick)”
• Operation and Maintenance Manual, “Bail Control
Parking Brake Control Switch (26)
(Joystick)”
Parking Brake Control Switch – The switch must
• Operation and Maintenance Manual, “Elevator be used to engage the parking brake after the
machine has stopped.
Control (Joystick)”

ENGAGE – Push the top of the switch in

order to engage the parking brake.
SEBU7857-05 51
Operation Section
Operator Controls

DISENGAGE – Push the bottom of the

switch in order to disengage the parking
brake. The air pressure must be above Panel Light Switch (29)
621 kPa (90 psi) in order to disengage the
parking brake. Panel Light Switch – Push the switch
upward in order to turn on the panel
Note: The parking brake will engage automatically if
lights for the scraper. Push the switch
air pressure drops to 379 ± 34 kPa (55 ± 5 psi). If the
downward in order to turn off the panel lights for
parking brake automatically engages, the parking
the scraper.
brake control switch must be reset manually. When
the air pressure in the system has returned to the
normal operating pressure, the switch must be in the Remote Throttle Speed Switch (30)
ENGAGED position. Next, push the bottom of the
switch in order to disengage the brakes. Remote Throttle Speed Switch – Switch
(30) is a two-position momentary switch.
The switch is spring loaded in order to
Transmission Control (27) return to the MAINTAIN position when the switch
is released.
Refer to Operation and Maintenance Manual,
“Transmission Control” for more information. Accelerate – Push the switch upward in
order to increase the engine speed for
Differential Lock Control Switch the scraper. Momentary actuation of the
(28) switch increases the engine speed by 50 rpm/sec.

Decelerate – Push the switch downward

NOTICE in order to decrease the engine speed
To prevent damage to the differential, do not engage for the scraper. Momentary actuation of
the differential lock control at high speeds. the switch decreases the engine speed by 50
rpm/sec.
Do not turn machine with differential lock engaged.
Do not engage the differential lock control while one Remote Throttle Switch (31)
wheel is spinning. Decrease engine rpm until the
wheel stops spinning. Anticipate using the differential Remote Throttle Switch – Switch (31) is
lock before wheel slippage occurs. a two-position switch.
In areas of high resistance, it may be necessary to
turn the machine slightly in order to aid in unlocking The switch cannot be activated until the following
the differential lock. Decreasing the engine rpm may conditions have been met:
also be helpful.
• The parking brake must be ENGAGED.

Differential Lock Control Switch – There are two • The transmission control must be in the NEUTRAL
differential lock control switches in the operator position.
compartment. One switch is located to the left of the
foot pedals and the other switch is located to the right • The engine throttle for the scraper must be less
of the foot pedals. Both of the differential lock control than 5%.
switches will perform the same function. The
differential lock control switch on the right is used ON – Push the switch upward in order to
when the operator seat is rotated to the right. activate the remote throttle for the
scraper engine.
LOCK – Push down the switch and hold down the
switch in order to lock the differential. The differential OFF – Push the switch downward in
lock will help to prevent wheel slippage. Use the order to deactivate the remote throttle
differential lock when you are loading on soft ground for the scraper engine.
or on wet ground. Engage the differential lock only
when the wheels are not spinning. Engine Start Switch (32)
UNLOCK – Release the switch in order to unlock the Note: The keyswitch in the cab must be in the ON
differential. position in order to start the scraper engine.
52 SEBU7857-05
Operation Section
Engine Shutdown Switch

Engine Start Switch – The switch is

located on the scraper control at the
rear of the machine. Push the switch
upward in order to start the scraper engine. After
the switch is released, the switch will return to
the NEUTRAL position.

Note: If the engine fails to start, release engine start

switch (32). This must be done before you attempt to
start the engine again.

i02334166

Engine Shutdown Switch

SMCS Code: 1259; 7418-ZS; 7418 Illustration 66 g01116204

S/N: DBC1–Up Disconnect Switch ON – To activate the

electrical system, insert the key for the
battery disconnect switch and turn the
key clockwise. The battery disconnect switch
must be turned to the ON position before you
start the engine.
Disconnect Switch OFF – To deactivate
the electrical system, turn the key for
the battery disconnect switch
counterclockwise to the OFF position.
The battery disconnect switch and the engine start
switch perform different functions. To disable the
entire electrical system, turn off the battery
disconnect switch. When you only turn off the engine
start switch, the battery remains connected to the
Illustration 65 g01113459 electrical system.

The engine shutdown switch is located on the left Turn the battery disconnect switch to the OFF
front of the tractor. The switch is a two-position switch position and remove the key when you service the
with a red switch cover. electrical system or any other machine components
and when the machine will not be used for an
ENGINE RUN – The switch must be at extended period of a month or more. This will prevent
the ENGINE RUN position in order for the battery from being discharged.
the engine to be started.
NOTICE
ENGINE STOP – Move the switch to the Never move the battery disconnect switch to the OFF
top position in order to prevent engine position while the engine is operating. Serious dam-
operation. The engine will not operate age to the electrical system could result.
when the switch is in the ENGINE STOPPED
position.
i01804595
Note: The engine shutdown switch does not shut off
the machine's electrical system. Backup Alarm
SMCS Code: 7406
i02210527

S/N: DBY1–Up
Battery Disconnect Switch
SMCS Code: 1411

S/N: DBC1–Up
SEBU7857-05 53
Operation Section
Product Link

• Providing services to the customer and/or the

machine

• Checking or maintaining Cat Product Link

equipment
• Monitoring the health of the machine or
performance
• Helping maintain the machine and/or improve the
efficiency of the machine

• Evaluating or improving Cat products and

services

• Complying with legal requirements and valid court

Illustration 67 g00923208 orders
The backup alarm is located at the rear of the • Performing market research
machine.
• Offering the customer new products and services
The alarm sounds when the transmission control
lever is in the REVERSE position. The backup alarm Caterpillar may share some or all the collected
is used to alert people behind the machine. information with Caterpillar affiliated companies,
dealers, and authorized representatives. Caterpillar
i07742538 will not sell or rent collected information to any other
third party and will exercise reasonable efforts to
Product Link keep the information secure. Caterpillar recognizes
and respects customer privacy. For more information,
SMCS Code: 7490; 7606 please contact your local Cat dealer.
Note: Your machine may be equipped with the Cat ®
Product Link™ system. Operation in a Blast Site for
Product Link Radios
The Cat Product Link communication device utilizes
cellular and/or satellite technology to communicate
equipment information. This information is
communicated to Caterpillar, Cat dealers, and
Caterpillar customers. The Cat Product Link This equipment is equipped with a Cat® Product
communication device uses Global Positioning Link communication device. When electric deto-
System (GPS) satellite receivers. nators are being used for blasting operations, ra-
dio frequency devices can cause interference
The capability of two-way communication between with electric detonators for blasting operations
the equipment and a remote user is available with the which can result in serious injury or death. The
Cat Product Link communication device. The remote Product Link communication device should be
user can be a dealer or a customer. deactivated within the distance mandated under
all applicable national or local regulatory require-
ments. In the absence of any regulatory require-
Data Broadcasts ments Caterpillar recommends the end user
Data concerning this machine, the condition of the perform their own risk assessment to determine
machine, and the operation of the machine is being safe operating distance.
transmitted by Cat Product Link to Caterpillar and/or Refer to your products Operation and Maintenance
Cat dealers. The data is used to serve the customer Manual Supplement, “Regulatory Compliance
better and to improve upon Cat products and
services. The information transmitted may include: Information” for more information.
machine serial number, machine location, and For information regarding the methods to disable the
operational data, including but not limited to: fault Cat Product Link communication device, please refer
codes, emissions data, fuel usage, service meter to your specific Cat Product Link manual listed below:
hours, software, and hardware version numbers and
installed attachments.
• Operation and Maintenance Manual, SEBU8142,
Caterpillar and/or Cat dealers may use this “Product Link - PL121, PL321, PL522, and PL523”
information for various purposes. Refer to the
following list for possible uses:
54 SEBU7857-05
Operation Section
Heating and Air Conditioning Control

• Operation and Maintenance Manual, SEBU8832, Note: After the air conditioning system has been
“Product Link PLE702, PLE602, PLE601, PL641, activated, the refrigerant compressor will not engage
PL631, PL542, PL240, PL241, PL141, PL131, for 30 seconds. This 30 second delay is caused by
PL161, and PL042 Systems” the protection system for the refrigerant compressor.
Note: If no radio disable switch is installed and the Pressurizing – When heating or cooling is not
equipment will be operating near a blast zone, a desired, pressurize the cab in order to prevent dust
Product Link radio disable switch may be installed on from entering. Turn the temperature variable control
the equipment. The switch will allow the Cat Product all the way to the left for the most cooling. Select a
Link communication device to be shut off by the fan speed. Activate the heater control. The cab will
operator from the equipment control panel. For more be pressurized without being heated. The cab airflow
details and installation procedures, refer to the will be filtered.
following:
Defogging – Activate the air conditioning system.
• Special Instruction, REHS7339, “Installation Select a fan speed. Set the temperature control in the
Procedure for Product Link PLE640 Systems” warm area. This prevents moisture from forming on
the windshield and the windows. Adjust the
• Special Instruction, REHS8850, “Installation temperature control until the moisture level is
Procedure for the Elite Product Link PLE601, lowered. Adjust the temperature control until the
PLE641, and PLE631 Systems” temperature of the cab is comfortable.

• Special Instruction, SEHS0377, “Installation

Procedure for the Product Link PL131, PL141, and i02334335
PL161 Systems”

• Special Instruction, REHS9111, “Installation

Transmission Control
Procedure for the Pro Product Link PL641 and SMCS Code: 3065
PL631 Systems”
S/N: DBC1–Up
i02334334

Heating and Air Conditioning

Control
SMCS Code: 7320; 7337

S/N: DBC1–Up

Heating and Air Conditioning

System Operation
Refer to Operation and Maintenance Manual,
“Operator Controls” for information on the individual
controls.
Illustration 68 g01146622
The heating and air conditioning system can perform
four functions: Transmission Control – The transmission control is
to the right of the operator seat. When you want to
Heating – Activate the heating system. shift into gear, push in the black button on the left
Select your desired fan speed. Adjust side of the lever. The button is used to mechanically
the temperature variable control for the lock the control into the current gear. The top gear
function is set by top gear control (4).
desired temperature.

Air Conditioning – Activate the air DRIVE (1) – Move the lever to the desired forward
conditioning system. Select your speed. The transmission will shift automatically
desired fan speed. Adjust the between second speed and any higher speed that is
temperature variable control for the desired selected. Manual shifting is required when you shift
temperature. between first speed and second speed. Top gear
control (4) is used to set a limit for upshifts. The
engine must be running and the lever must be moved
to “D” in order for you to select a limit. “D” is the
DRIVE position. When the switch is held in the ON
SEBU7857-05 55
Operation Section
Bowl Control (Joystick)

position, the actual gear indicator will flash. Next, the

actual gear indicator will cycle through the available
gears. When the switch is released, the top drive
gear will be set to the value on the display. The
display will show the top gear for four seconds. After
the four seconds, the display will revert to the actual
gear. The maximum gear that is available to the
operator will never be greater than the maximum
gear that is set by the service personnel. The
minimum top gear that is available to the operator is
third gear in the forward direction. The transmission
will operate with a high gear limit until the machine is
turned off or until another gear is selected.

Note: When the engine experiences an overspeed

condition, the top gear control will allow the Illustration 69 g01250468
transmission to upshift one speed in order to correct
the overspeed condition. Bowl Control – The joystick control is located on the
right side of the operator compartment. The joystick
“ 2”” – SECOND SPEED position controls the movement of the scraper bowl. When the
engine is off and there is electrical power, the joystick
“ 1”” – FIRST SPEED position control will lower the scraper bowl. When there is no
electrical power to the machine, the joystick control
will not lower the bowl.
Note: This machine is equipped with an engine
neutral start system. The engine will not start unless
the lever is in the NEUTRAL position. Bowl QUICK DROP (1) – Push the
joystick control forward past the
NEUTRAL (2) – Move the lever to the “N” which is DETENT position in order to quickly
the NEUTRAL position when you park the machine lower the bowl. The joystick control will return to
or when you start the engine. The machine should the HOLD position when the joystick control is
not move when the lever is in the NEUTRAL position
and the parking brake is applied. released.

Bowl LOWER (2) – Push the joystick

REVERSE (3) – Move the lever to the “R” which is control partially forward in order to
the REVERSE position. The machine will move in lower the scraper bowl. The speed of the
reverse. scraper bowl will increase as the joystick control
is moved further from the HOLD position. The
joystick control will return to the HOLD position
i02500471 when the joystick control is released.

Bowl Control (Joystick) Bowl HOLD (3) – The joystick control will return to
the HOLD position when the joystick control is
SMCS Code: 5063; 5702 released. The bowl will remain in the position that is
selected.
S/N: DBC1–Up

Bowl RAISE (4) – Pull back the joystick

control partially in order to raise the
bowl. The speed of the scraper bowl will
increase as the joystick control is moved further
from the HOLD position. The joystick control will
return to the HOLD position when the joystick
control is released.

i02500484

Ejector Control (Joystick)

SMCS Code: 5063; 5702

S/N: DBC1–Up
56 SEBU7857-05
Operation Section
Elevator Control (Joystick)

Illustration 70 g01250476 Illustration 71 g01228118

Ejector Control – The joystick control is located on Elevator Control – The joystick is located to the right
the right side of the operator compartment. The of the operator's seat. The thumb lever is located on
joystick controls the movement of the ejector. the top of the joystick. The thumb lever controls the
direction and speed of the elevator.
Ejector FORWARD (1) – Push the
joystick control partially to the left in Elevator LOAD (1) – Push the thumb
order to move the ejector forward. The lever to the left in order to move the
speed of the ejector will increase as the joystick elevator in the forward direction. When
control is moved further from the HOLD position. the elevator is moving in the forward direction,
The joystick control will return to the HOLD the elevator will load the scraper bowl. The
position when the joystick control is released. elevator speed will increase as the thumb lever is
pushed further from the HOLD position.
Ejector HOLD (2) – The joystick control will return to
the HOLD position when the joystick control is HOLD (2) – The thumb lever will return to the HOLD
released. The ejector will remain in the position that position when the thumb lever is released. The
is selected. elevator will remain in the position that is selected.

Ejector RETURN (3) – Push the joystick Elevator UNLOAD (3) – Push the thumb
control partially to the right in order to lever to the right in order to move the
move the ejector backward. The speed elevator in the reverse direction. When
of the ejector will increase as the joystick control the elevator is moving in the reverse direction,
is moved further away from the HOLD position. the elevator will unload the scraper bowl. The
The joystick control will return to the HOLD elevator speed will increase as the thumb lever is
position when the joystick control is released. pushed further from the HOLD position.

Ejector AUTO RETURN (4) – Push the Note: The elevator does not need to be running
joystick control completely to the right when you are unloading fine material.
in order to turn on the auto return
function. Move the joystick to the left in order to Note: Under most conditions, you do not need to run
turn off the auto return function. When the the elevator in the UNLOAD position. Material with a
joystick is in the AUTO RETURN position, an high percentage of green plants may be a condition
indicator light will illuminate on the front dash. for unloading in the UNLOAD position. Running the
Refer to the “Indicators” topic in Operation and elevator in the UNLOAD position may cause faster
Maintenance Manual, “Monitoring System” for wear of the elevator chain.
more information.
i02500501

i02460715
Elevator Speed Control
Elevator Control (Joystick) (Joystick)
SMCS Code: 5063; 5702 SMCS Code: 5063; 5702
S/N: DBC1–Up S/N: DBC1–Up
SEBU7857-05 57
Operation Section
Transmission Hold Control (Joystick)

Illustration 72 g01228131 Illustration 73 g01250671

Elevator Speed Control – The joystick is located to Transmission Hold Control – The
the right side of the operator seat. The speed of the joystick control is located on the right
elevator is controlled by the thumb lever on the top of side of the operator compartment. Push
the joystick. The elevator speed control is set by
button (1) for the transmission hold is located on
toggle switch (1). Toggle switch (1) is located on the
front side of the joystick. the left side of the joystick control. The
transmission hold prevents the transmission
When the elevator is moving, push the toggle switch from shifting. Use the transmission hold for
in order to set the speed of the elevator. A new speed loading or approaching an upgrade. The
can be set for the elevator by cycling the toggle transmission hold may also be used for
switch OFF and ON again. unloading.
While the thumb lever is in the HOLD position, push ENGAGE – When the transmission hold is not
the toggle switch in order to release the elevator engaged, push in on push button (1) in order to
speed. engage the transmission hold. The transmission will
remain in the same gear. When the transmission hold
Note: If the engine is still running and you push the is engaged, an indicator light will illuminate on the
toggle switch again, the elevator speed will resume at front dash. Refer to the “Indicators” topic in Operation
the last speed that was set for the elevator. and Maintenance Manual, “Monitoring System” for
more information.
Refer to Operation and Maintenance Manual,
“Elevator Control (Joystick)” for more information on
controlling the elevator. DISENGAGE – When the transmission hold is
engaged, push in on push button (1) in order to
disengage the transmission hold. The transmission
i02500508 will shift automatically.

Transmission Hold Control

(Joystick) i02500746

SMCS Code: 3065 Cushion-Hitch Control

S/N: DBC1–Up (Joystick)
SMCS Code: 5063; 5702; 7107

S/N: DBC1–Up

Actuation of the cushion-hitch or steering control

can cause movement in the hitch area, reducing
clearances suddenly.
Personal injury or death can result from hitch
movement if a person is in the hitch area.
58 SEBU7857-05
Operation Section
Monitoring System

Illustration 74 g01250704 Illustration 75 g00928901

Cushion-Hitch Control – The joystick The Caterpillar Monitoring System includes the
control is located on the right side of the following components.
operator compartment. Push button (1) (1) Quad gauge module
for the cushion-hitch is located on the left side of
the joystick control. (2) Main display module (EMS) for the tractor
ON – When the cushion-hitch is not turned on, push (3) Speedometer, tachometer, and actual gear
in on push button (1) in order to turn on the cushion- indicator
hitch.
(4) Indicators
OFF – When the cushion-hitch is turned on, push in (5) Action lamp (tractor)
on push button (1) in order to turn off the cushion-
hitch. (6) Mode select switch (tractor)
Also, the monitoring system includes an action alarm
Note: The cushion-hitch should be turned on at all that is not shown.
times except when you are loading materials or when
you are dumping materials. When the cushion-hitch The monitoring system is designed to alert the
is turned off, the material will spread more smoothly. operator of a problem in one or more of the machine
This will help you to achieve faster cycle times. systems that are covered. The main display module
includes individual alert indicators for each machine
system. The action lamp and individual alert
i03644439 indicators will light when a problem occurs. Also, the
action alarm will sound when certain problems occur.
Monitoring System A self test of the monitoring system verifies that the
SMCS Code: 7000 main display module and the other display modules
are operating properly. The main display module
S/N: DBC1–Up performs an automatic self test when the key start
switch is turned from the OFF position to the ON
position. The operator must observe the outputs
(displays, action lamp, and action alarm) in order to
determine if the modules and the outputs are
operating properly.
Note: If a module is responsible for providing the
Warning Category 3 events and the module is not
functioning correctly, the machine requires an
immediate shutdown.
If the self test fails, wait for one minute before
performing the self test again. If the second self test
fails, consult your Caterpillar dealer or refer to
Systems Operation, Troubleshooting, Testing and
Adjusting, RENR7858 for further information.
SEBU7857-05 59
Operation Section
Monitoring System

Quad Gauge Module Fuel Level (10) – This gauge indicates

the amount of fuel that is remaining in
the fuel tank. When the fuel level is in
the red zone, a category 1 warning will occur. The
lights for the power train system will come on.

Main Display Module

Illustration 76 g00944179

Engine Coolant Temperature (7) – This

gauge indicates the engine coolant
temperature. When the temperature is
above 107 °C (225 °F), the needle will be in the
red zone. If the needle is in the red zone, stop the Illustration 77 g01132820
engine immediately and investigate the cause of
the problem. The main display module includes two rows of five
alert indicator lights and a digital display window. The
Do not operate the machine until the cause of the indicator lights monitor machine systems of the
problem has been corrected. tractor and scraper. Digital display window (19) will
display important numeric readouts for different
Note: If the temperature of the engine coolant machine systems. The default information that is
exceeds the maximum operating temperature, the displayed is for the tractor.
respective alert indicator will come on and the action
lamp will flash. Note: If a module is responsible for providing the
Warning Category 3 events and the module is not
Torque Converter Oil Temperature (8) – functioning correctly, the machine requires an
This gauge indicates the torque immediate shutdown.
converter oil temperature. When the
temperature is above 129 °C (264 °F), the needle Alert Indicators
will be in the red zone. If the needle is in the red
zone, reduce the load on the machine. If the Fuel Temperature (11) – This alert
needle stays in the red zone, stop the machine indicator shows that the fuel
and investigate the cause of the problem. temperature is too high.
Do not operate the machine until the cause of the Air Pressure (12) – This alert indicator
problem has been corrected.
shows that there is low air pressure in
Note: If the temperature of the torque converter oil the air system or that there is a failure in
exceeds the maximum operating temperature, the the air system.
respective alert indicator will come on and the action
Engine Oil Pressure (13) – This alert
lamp will flash.
indicator shows that there is low engine
Air Supply Pressure (9) – This gauge oil pressure for the selected engine.
indicates the air pressure in the air
Secondary Steering (14) (If Equipped) –
tanks. If the air pressure drops below
This alert indicator shows that the
517 ± 35 kPa (75 ± 5 psi), the needle will be in the
secondary steering system is engaged.
red zone. If the needle is in the red zone, stop the
When the secondary steering system is engaged,
machine and investigate the cause of the
the primary steering system has failed.
problem.
Engine Coolant Temperature (15) – This
alert indicator shows that the selected
engine coolant temperature is too high.
60 SEBU7857-05
Operation Section
Monitoring System

Hydraulic System Failure (16) – This Warning Category 2

alert indicator shows that the hydraulic
system is malfunctioning or that the In this category, the alert indicator and the action light
hydraulic system has failed. come on. This category requires a change in
machine operation in order to reduce excessive
Power Train System (17) – This alert temperature in one or more of the machine systems.
indicator shows that the engine control The following indicators can be illuminated with
system or the transmission control Warning Category 2:
system has a problem.
• Fuel Temperature (11)
Charging System (18) – This alert
indicator shows that the alternator for • Hydraulic System Failure (16)
the selected engine is malfunctioning. • Power Train System (17)
Parking Brake (20) – This alert indicator • Torque Converter Oil Temperature (21)
shows that the parking brake has been
engaged. The alert indicator should go Warning Category 3
out when the parking brake is disengaged.
In this category, the alert indicator and the action light
Torque Converter Oil Temperature (21) – come on and the action alarm sounds. This category
This alert indicator shows that the oil requires immediate shutdown of the machine in order
temperature for the selected torque to prevent injury to the operator and/or severe
converter is too high. damage to the machine. The following indicators can
be illuminated with Warning Category 3:
Digital Display Window
• Air Pressure (12)
Digital display window (19) is used to show different
sets of data for several machine systems. The default • Engine Oil Pressure (13)
readout of the display shows the tachometer for the
scraper engine. The mode select switch is used in • Secondary Steering (14)
order to select the functions on digital display window
(19). • Engine Coolant Temperature (15)
• Hydraulic System Failure (16)
Warning Categories
• Power Train System (17)
The Caterpillar Monitoring System provides three
warning categories. The first warning category • Charging System (18)
requires only operator awareness. The second
warning category requires an operator response. The
third warning category requires immediate shutdown
of machine systems.
Warning Category 1

In this category, only the alert indicator comes on.

This category alerts the operator that the machine
system needs attention. Failure of these systems will
not endanger the operator. Failure of these systems
will not cause serious damage to the machine
components. The following indicators can be
illuminated with Warning Category 1:
• Hydraulic System Failure (16)

• Power Train System (17)

• Charging System (18)
• Parking Brake (20)
SEBU7857-05 61
Operation Section
Operation Information

• Parking Brake (20) Left Turn (25) – This indicator shows

that the left turn signal is active.
Speedometer, Tachometer and
Actual Gear Indicator Right Turn (26) – This indicator shows
that the right turn signal is active.

High Beams (27) – This indicator shows

that the high beam headlights are on.

Transmission Hold (28) – This indicator

shows that the transmission hold
control is active.
Ejector Return (29) – This indicator
shows that the ejector is in the return
mode. The ejector is moving to the
return position.
Throttle Lock (30) – This indicator
shows that the throttle lock is active.
Illustration 78 g00944180

Analog Tachometer (22) – The tachometer will i04942669

display the engine rpm.
Operation Information
Digital Speedometer (23) – The speedometer
displays the machine ground speed during machine SMCS Code: 7000
operation. The speedometer is set to a default
reading in mph. Also, the digital speedometer can
display the optional reading of km/h.
Transmission Gear and Direction (24) – The digital
readout displays the direction of travel during
machine operation. Also, the digital readout will
display the transmission gear that is being used
during machine operation.

Indicators

Illustration 80 g01220360
(1) Retarder control
(2) Alert indicator for the secondary steering system
(3) Transmission hold control (joystick)
(4) Parking brake control switch
(5) Top gear control
(6) Transmission control
(7) Service brake control

Illustration 79 g01166026

Indicator Display – There are two indicator displays.

One indicator display is located in the operator
compartment on each side of the front dash.
62 SEBU7857-05
Operation Section
Operation Information

Do not operate the machine without normal air

pressure.
When you operate the machine in very rough Loading the machine in a straight line is preferred.
ground conditions or at travel speeds not suit-
able for the ground conditions, this may result in Do not overload the bowl.
excessive seat vertical travel with impact of the
suspension against the travel stops, which may
cause injury. Do not operate the machine on Operating The Machine
ground conditions and at travel speeds that could
result in the seat suspension travel stops being NOTICE
contacted. In order to minimize impact loading on Do not operate the machine when the scraper engine
the operator, properly adjust the seat controls (if equipped) is off.
based upon your weight and based upon your
height. Refer to the Operation and Maintenance Operating the machine with the scraper engine (if
Manual, “Seat” for more information. equipped) off will result in significant damage to the
scraper power train.

1. Check for adequate clearance around the

There is restricted visibility to the area directly machine.
behind the machine. Failure to make sure the area 2. Adjust the operator seat.
is clear could result in injury or death. Use a sec-
ond person on the ground to make sure that the 3. Adjust the mirrors.
area is clear before you operate the machine in
the REVERSE position. Refer to the Operation 4. Adjust the steering column.
and Maintenance Manual, “Operation Informa-
tion” for more information. 5. Fasten the seat belt.
6. Raise the bowl in order to pass over any obstacles.
Visibility behind the machine is restricted from the
operator station. Before you operate the machine in 7. Depress service brake control (7) in order to
the REVERSE position, a second person on the prevent the machine from moving.
ground is to be used to make sure that the area is
clear. The person that provides the direction must 8. Push the bottom of parking brake control switch (4)
remain in sight of the operator at all times. Stop the in order to release the parking brake.
machine if the person that provides the direction
cannot be seen or understood.
NOTICE
To prevent injury, make sure that no people are on For operator comfort and maximum service life of
the machine or near the machine. To prevent injury, power train components, deceleration and/or braking
keep the machine under control at all times. is recommended before any directional shifts are
made.
Reduce engine speed when you maneuver in tight
quarters or when you are going over a hill.
9. Move the transmission control to the desired
Select the appropriate travel speed before you begin direction and the appropriate gear speed.
to drive the machine downhill. Do not shift the
transmission control while you are going downhill. 10. Release the service brake control.

When you drive the machine downhill, use the same 11. Depress the throttle pedal until you achieve the
gear speed that would be used to drive the machine desired engine speed.
uphill.
12. Drive the machine forward in order to have the
Do not allow the engine to overspeed when you go best visibility and the best control.
downhill. Do not disengage the transmission while
you are traveling downhill. If equipped, use the Secondary Steering (If Equipped)
retarder control to reduce engine overspeed when
you are going downhill. If your machine is not
If alert indicator (2) flashes, steer the machine
equipped with a retarder control, use the service
immediately to a convenient location and stop the
brake control to reduce engine overspeed when you
machine.
are going downhill. Never coast the machine.
Make any necessary repairs before you return the
Adjust the operators seat. Fasten the seat belt. machine to operation.
Do not operate the machine when the parking brake The effort that is needed for steering may increase as
is applied. the machine slows down.
SEBU7857-05 63
Operation Section
Operation Information

Secondary steering only functions while the machine Downshifting

is moving forward.
If the ground speed is reduced or if the engine speed
Alert indicator (2) indicates that the secondary is reduced by an increased load, the transmission will
steering system is engaged. When the secondary automatically downshift in order to select the correct
steering system is engaged, the primary steering transmission speed.
system has failed.
NOTICE
Changing Direction and Speed The transmission is equipped with a downshift inhibi-
tor. The transmission will not necessarily downshift
Reverse speed, first speed forward, and second when the transmission control is moved. This pro-
speed forward must be manually selected. tects against engine overspeed.

The automatic range is third speed through eighth Do not downshift with the transmission hold control
speed. For each job condition, the transmission will applied. The ground speed could decrease suddenly,
automatically upshift and the transmission will or the engine could overspeed, when the transmis-
automatically downshift between second speed and sion hold control is released.
the highest speed that is being used. Move
transmission control (6) in one smooth motion. Accidental downshifting of the transmission control
During load cycles, haul cycles and dump cycles, does not mean immediate shifting of the
manual shifting is not recommended. transmission.
Use transmission hold control (3) to prevent If the machine continues to slow, or if the machine is
unwanted shifts. brought to a stop, the transmission will automatically
downshift one speed at a time. The transmission
Use top gear control (5) in order to set the top gear to always returns to second speed. Move transmission
be used. control (6) to the NEUTRAL position if the machine is
stopped.
NOTICE
The machine must be stopped and the engine at low
idle before changing direction. After moving the trans- Shift Inhibiting
mission control, do not accelerate until after hearing
or feeling the transmission clutches engage. A shift from any speed into NEUTRAL position is
inhibited.

Upshifting Normal Shifting

As the engine is accelerated and the ground speed An automatic downshift will occur when the engine
increases, the transmission will upshift. speed decreases to approximately 1280 rpm. An
automatic upshift will occur when the engine speed
As the ground speed continues to increase, the increases to approximately 1890 rpm. The shifting of
transmission will upshift one speed at a time. The the transmission is determined by the load that is put
transmission will upshift automatically between on the machine.
second speed and the highest speed that has been
selected. The transmission will stop upshifting at the If the ground speed is less than 5 km/h (3 mph) in
transmission speed that has been selected. any forward speed and the transmission control is
moved to the REVERSE position, the transmission
Moving transmission control (6) does not ensure immediately shifts into the REVERSE position.
immediate shifting of the transmission. The shifting of
the transmission is governed by the machine ground If the ground speed is more than 8 km/h (5 mph) in
speed. any forward speed and the transmission control is
moved to the REVERSE position, the transmission
Use transmission hold control (3) in order to prevent will not downshift until the ground speed of the
unwanted upshifts when the machine is approaching machine has been reduced to 5 km/h (3 mph). When
an upgrade. the ground speed is less than 5 km/h (3 mph) in the
NEUTRAL position and the transmission control has
Use transmission hold control (3) in order to prevent been moved to the REVERSE position, the
unwanted upshifts when the machine is loading transmission immediately shifts to the REVERSE
material and when the machine is dumping material position.
on rough terrain.
64 SEBU7857-05
Operation Section
Operation Information

Top Gear Control Parking Brake

Top gear control (5) is used to set a limit for upshifts. All four wheels of the Wheel Tractor-Scraper are
The engine must be running and the transmission equipped with parking brakes that are applied by
control must be moved to “D” in order for you to springs. The parking brakes and service brakes use
select a limit. “D” is the DRIVE position. When the the same brake actuator to activate the brakes.
switch is held in the ON position, the actual gear
indicator will flash. Next, the actual gear indicator will Push the top of parking brake control switch (4). This
cycle through the available gears. When the switch is will release the air pressure and the springs will be
released, the top drive gear will be set to the value on allowed to apply the parking brakes.
the display. The display will show the top gear for 4
seconds. After the 4 seconds, the display will revert If the brake air pressure drops below 517 ± 34 kPa
to the actual gear. The maximum gear that is (75 ± 5 psi), the action alarm will sound. If the brake
available to the operator will never be greater than air pressure drops below 379 ± 34 kPa (55 ± 5 psi),
the maximum gear that is set by the service the parking brakes will engage automatically.
personnel. The minimum top gear that is available to The action alarm will also sound if the transmission
the operator is third gear in the forward direction. The control is moved out of the NEUTRAL position during
transmission will operate with a high gear limit until engagement of the parking brake.
the machine is turned off or until another gear is
selected.
Retarder (If Equipped)
Note: When the engine experiences an overspeed
condition, the top gear control will allow the The retarder is a fluid coupling that is mounted at the
transmission to upshift one speed in order to correct engine flywheel housing. Engage retarder control (1)
the overspeed condition. in order to slow the machine ground speed. The
transmission must be in gear in order to drive the
retarder impeller.
Transmission Hold Control Activated
Use the retarder on a downgrade to prevent engine
When transmission hold control (3) is placed in the overspeed.
ENGAGED position, automatic shifts are inhibited.
Automatic downshifts are inhibited unless the engine Use the retarder to help to stop the machine. The
is in an underspeed condition. The transmission will retarder will not completely stop the machine and the
automatically downshift if the engine rpm drops too retarder will not hold the machine stationary.
low. Underspeed conditions will occur when the
engine rpm drops below 1000 rpm. Automatic Note: Use the retarder at least one time during each
upshifts are inhibited unless the engine is in an work day to keep the seals lubricated.
overspeed condition. If the engine speed reaches
2500 rpm, the transmission will automatically upshift. Retarding on a Downgrade

Braking Operation The speed selection is very important because a

lower speed increases the effective force of the
retarder. Generally, the speed that is used to
The braking system consists of three separate
negotiate an empty machine on an upgrade should
controls: service brake control (7), parking brake
be used to drive a loaded machine on a downgrade
control switch (4) and retarder control (1) (if
of the same slope. Readjust the speed after a trial
equipped). run.
Service Brake Before you approach a downgrade, slow the
machine. Anticipate the need to use the retarder.
All wheels of the Wheel Tractor-Scraper are Move retarder control (1) in order to engage the
equipped with air brakes. The air brakes are actuated retarder. The retarder will usually engage in less than
by air pressure when service brake control (7) is four seconds. Allow the transmission to downshift to
pushed by the operator. The braking force increases the necessary lower speed. Engage transmission
as the pedal pressure is increased. hold control (3).

The service brakes on Wheel Tractor-Scrapers are Select the proper transmission speed that will allow
designed to stop the machine. When you are using the retarder to maintain a safe ground speed with
the retarder, the service brakes should not be used little use of the service brakes.
repeatedly in order to slow the machine.
To ensure maximum cooling and the best retarding
affect, select the proper transmission speed that will
keep the engine speed above 1800 rpm. Do not allow
the engine speed to exceed 2300 rpm. Do not allow
the converter/retarder oil temperature to run in the
red zone. Select a lower speed, if necessary.
SEBU7857-05 65
Operation Section
Operation Information

Travel at the best average speed. Always reduce the

engine speed when applying the service brakes. Do
not attempt all of the braking at the bottom of a hill.
Keep braking steady while the ground speed is under
control.
Do not use the retarder in order to attempt to stay in a
lower speed on a long downgrade. Engine speed
may increase beyond the green operating range.
Use the service brakes until the speed is reduced.
Use the retarder when you are entering a cut or a
dump area. This will allow the transmission to
downshift.
Important Conditions During Retarding

The ground speed must be suitable for the operating

conditions. Operate the machine at a rate that will not
cause retarder overheating.
Braking should be steady. Do not try to brake in a
short distance while you operate at a fast speed.

NOTICE
Engine overspeed may cause serious damage. Keep
the tachometer indicator in the green operating
range.

Differential Lock
For the location of the differential lock control switch,
refer to Operation and Maintenance Manual,
“Operator Controls”.
Lock the differential when traction is poor. Both
wheels will turn at the same speed.
The differential lock will provide maximum traction at
all times. The differential lock can prevent wheel
slippage. Depress the differential lock control switch
when the machine is moving on soft ground or on wet
ground. Excessive wheel spin and uncontrolled
wheel spin can cause accelerated wear to certain
components of the drive train.
To prevent damage to the differential lock, do not
engage the differential lock control switch at high
speeds.
Do not turn the machine while the differential lock is
engaged.
Do not engage the differential lock control switch
while one wheel is spinning. Decrease the engine
rpm until the wheel stops spinning. Anticipate using
the differential lock before wheel slippage occurs.
The differential normally unlocks when the floor
switch is released. In areas of high resistance, it may
be necessary to turn the machine slightly in order to
unlock the differential. Decreasing the engine rpm
may also be helpful.
66 SEBU7857-05
Operation Section
Engine Starting

Engine Starting Note: Before any implements will operate, all

implement controls must be in the NEUTRAL
position or the OFF position for two seconds
i02460821 after the engine is started.

Engine Starting 6. Move all implement controls to the NEUTRAL

SMCS Code: 1000; 7000 position or the OFF position. For specific
information on the operation of the implement
S/N: DBC1–Up controls that are affected, refer to the following
topics (if equipped):

• Operation and Maintenance Manual, “Bowl

Diesel engine exhaust contains products of com- Control (Joystick)”
bustion which may cause personal injury.
• Operation and Maintenance Manual, “Ejector
Always start and operate the engine in a well ven- Control (Joystick)”
tilated area, and, if in an enclosed area, vent the
exhaust to the outside. • Operation and Maintenance Manual, “Apron
Control (Joystick)”

NOTICE • Operation and Maintenance Manual, “Bail

Do not crank the engine for more than 30 seconds. Control (Joystick)”
Allow the starting motor to cool for two minutes be-
fore cranking again. • Operation and Maintenance Manual, “Auger
Turbocharger (if equipped) damage can result, if the Control (Joystick)”
engine rpm is not kept low until the engine oil light/
gauge verifies the oil pressure is sufficient. • Operation and Maintenance Manual, “Elevator
Control (Joystick)”

7. Turn engine start switch (1) in order to start the

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

Note: If the temperature of the coolant is below 0 °C

(32 °F), the coolant temperature switch will cause
ether to be automatically injected into the engine.

i02395726

Engine and Machine Warm-Up

SMCS Code: 1000; 7000

NOTICE
Illustration 81 g01228185 Keep engine speed low until the engine oil pressure
registers on the gauge or the engine oil pressure indi-
1. Turn the battery disconnect switch to the ON cator light goes out. If it does not register or the light
position. does not go out within ten seconds, stop the engine
and investigate the cause before starting again. Fail-
2. Move transmission control (4) to the NEUTRAL ure to do so, can cause engine damage.
position.
3. Unlock the steering column. Move the steering 1. When the engine is cold, operate the engine at low
column to the desired position and lock the idle for at least five minutes.
steering column.
Cycle all controls in order to allow warm oil to
4. Engage parking brake control switch (3) . circulate through all hydraulic cylinders and
through all hydraulic lines.
5. Move joystick (2) to the HOLD position.
SEBU7857-05 67
Operation Section
Engine and Machine Warm-Up

Idle the engine. If the hydraulic functions are

sluggish, additional time may be required for
warm-up.
2. Release the brake. Move the equipment forward
and backward for several meters (yards). Exercise
the machine for several minutes.
In order to reduce the total warm up time, start
exercising the entire machine before you complete
the hydraulic warm up time.
3. Operate under a light load until the systems reach
normal operating temperatures.
4. During machine operation, frequently look at the
alert indicators and the gauges.
68 SEBU7857-05
Operation Section
Adjustments

Adjustments
i02500857

Blocking the Bowl

SMCS Code: 6201

Bowl or apron movement can cause serious in-

jury or death.
To prevent movement, block the bowl and apron
when performing maintenance in the bowl area.

Note: Any material that might fall on the worker

should be removed from the apron.

1. Park the machine on level ground.

2. Engage the parking brake.

Illustration 82 g00927653

3. Raise the bowl. Place a block under the bowl.

Blocks should be of material that is suitable for
carrying the weight of the bowl.
4. Lower the bowl to the block. Block the bowl only to
a height so that the bowl can be worked on.
5. Move the joystick control to the HOLD position.
6. Stop the engine. Turn the battery disconnect
switch to the OFF position.
SEBU7857-05 69
Operation Section
Parking

Parking
i01254854

Stopping the Machine

SMCS Code: 7000

NOTICE
Park on a level surface. If it is necessary to park on a
grade, block the wheels securely.
Do not engage the parking brake while the machine
is moving unless an emergency exists.

Illustration 83 g00916064
1. Apply the service brakes in order to stop the
machine. 3. Turn engine start switch (1) to the OFF position.
2. Move the transmission control to the NEUTRAL Remove the engine start switch key.
position.
Stopping The Engine From Outside
3. Engage the parking brake.
Of The Operator Compartment
4. Lower all implements to the ground. Apply a slight
downward pressure. Note: Use the engine shutdown switch only when
engine start switch (1) does not work or engine start
5. Turn off the cushion-hitch and lower the bail (if switch (1) can not be accessed.
equipped).
1. Run the engine at low idle for five minutes. Do not
i02335645 stop the engine immediately after the engine has
been working under load.
Stopping the Engine
SMCS Code: 1000; 7000

S/N: DBC1–Up

NOTICE
Stopping the engine immediately after it has been
working under load can result in overheating and ac-
celerated wear of the engine components.
Refer to the following stopping procedure, to allow
the engine to cool, and to prevent excessive temper-
atures in the turbocharger center housing, (if
equipped) which could cause oil coking problems.

Stopping The Engine From The Illustration 84 g01113459

Operator Compartment 2. Move the engine shutdown switch to the OFF

position. Refer to Operation and Maintenance
1. Use the procedure that is described in Operation Manual, “Engine Shutdown Switch” for further
and Maintenance Manual, “Stopping the Machine” information.
in order to stop the machine.
2. Run the engine at low idle for five minutes. Do not
stop the engine immediately after the engine has
been working under load.
70 SEBU7857-05
Operation Section
Stopping the Engine if an Electrical Malfunction Occurs

Note: The engine shutdown switch does not shut off Lowering The Equipment With
the machine's electrical system.
Electrical Power
i02449772

Stopping the Engine if an

Electrical Malfunction Occurs
SMCS Code: 1000; 7000
If the engine does not stop after turning the engine
start switch key to the OFF position, perform the
following procedure:
1. Apply the parking brake.
2. Lower the bowl to the ground.
3. Dismount the machine.
4. Locate the engine shutdown switch. Activate the Illustration 85 g01220462
engine shutdown switch in order to stop the
When the electrical system is operating properly, use
engine. Refer to Operation and Maintenance
joystick (2) to lower the implements. The joystick is
Manual, “Engine Shutdown Switch” for further located on the right side of the operator
information. compartment. Engine start switch (1), which is
located on the front dash, must be turned to the ON
Note: Do not operate the machine until the position. With the engine start switch in the ON
malfunction has been corrected. position, push the joystick forward in order to lower
the scraper bowl. Move the thumb lever left in order
i02500868 to lower the apron. When the implements have been
lowered to the ground, turn the engine start switch to
Equipment Lowering with the OFF position.

Engine Stopped
SMCS Code: 7000

Be sure all personnel are clear of equipment

while equipment is being lowered.
Failure to stay clear may result in personal injury.

Note: The implement controls must have electrical

power in order to move the implements.
SEBU7857-05 71
Operation Section
Leaving the Machine

Lowering The Equipment Without

Electrical Power

Illustration 86 g01114323

If the electrical system has malfunctioned or if the

electrical system has failed, use shutoff valve (3) to
lower the implements. The valve is located on the top
of the tractor transmission. The valve must be
opened in order to lower the bowl and the apron to
the ground. Turn the head of the valve clockwise in
order to open the valve. You must use a wrench or
pliers in order to turn the head of the valve. When the
implements have been lowered to the ground, turn
the head of the valve counterclockwise in order to
close the valve.

i00058524

Leaving the Machine

SMCS Code: 7000

1. Use the steps and the handholds when you

dismount. See the Operation and Maintenance
Manual, “Mounting and Dismounting” for further
information.
2. Inspect the engine compartment for debris. Clean
out any debris in order to avoid a fire hazard.
3. Remove all flammable debris from the front bottom
guard through the access doors in order to reduce
a fire hazard. Discard the debris properly.
4. Turn the key for the battery disconnect switch to
the OFF position. When the machine is left for an
extended period of one month or longer, you
should remove the key. This will help to prevent a
battery short circuit. Removing the key will also
help to protect the battery from vandalism and
from the current draw that is made by certain
components.
5. Lock all vandalism covers and all compartments.
72 SEBU7857-05
Operation Section
Transportation Information

Transportation Information 6. Turn the battery disconnect switch to the OFF

position. Remove the battery disconnect switch
key.
i01693803
7. Lock the door and the access covers. Attach any
Shipping the Machine vandalism protection.
SMCS Code: 7000; 7500 8. Block the tires. Secure the machine with tie-
downs.
Investigate the travel route for overpass clearances.
Make sure that there is adequate clearance for the 9. Cover the exhaust opening or secure the rain cap
machine that is being transported. This is especially in order to prevent the turbocharger from
important for machines that are equipped with a
ROPS, with a FOPS, with a cab, or with a canopy. windmilling in transit.

Remove ice, snow, or other slippery material from the To protect the cooling systems, mix the solution of
loading dock and from the truck bed before you load antifreeze and water. The solution should provide
the machine onto the transport machine. Removing protection to the lowest expected outside
temperature. Drain the coolant into a suitable
ice, snow, or other slippery material will help to
container.
prevent the machine from slipping in transit.
Perform a walk-around inspection and measure the
NOTICE fluid levels in the various compartments.
Obey all state and local laws governing the weight,
width and length of a load. Travel at a moderate speed. Observe all speed
limitations when you are roading the machine.
Remove the ether starting aid cylinder, if equipped.
Make sure the cooling system has proper antifreeze Consult your Caterpillar dealer for shipping
if moving machine to a colder climate. instructions for your machine.
Observe all regulations governing wide loads. i00058527

Roading the Machine

SMCS Code: 7000; 7500
Before you road a machine, consult your tire dealer
for recommended tire pressures and for speed
limitations.
Limitations for TON-kilometer per hour (TON-mile per
hour) must be obeyed. Consult your tire dealer for the
speed limit of the tires that are used.
When you travel for long distances, schedule stops in
order to allow the tires and the components to cool.
Stop for 30 minutes after every 40 km (25 miles) or
after every hour.
Illustration 87 g00100962 Inflate the tires to the correct pressure.

1. Before you load the machine, block the trailer Use a self-attaching inflation chuck and stand behind
the tire tread during the tire inflation. See the
wheels or the rail car wheels, as shown. Operation and Maintenance Manual for your machine
2. Lower all attachments to the floor of the transport for information on tire inflation.
machine. Move the transmission control (lever) to Perform a walk-around inspection and measure the
the NEUTRAL position. fluid levels in the various compartments.
3. Engage the parking brake. Check with the proper officials in order to obtain the
required licenses and authorization.
4. Stop the engine.
5. Turn the engine start switch to the OFF position. Travel at a moderate speed. Observe all speed
limitations when you road the machine.
Remove the engine start switch key.
SEBU7857-05 73
Operation Section
Lifting and Tying Down the Machine

i03650015 1. Shut off the engine. Engage the parking brake.

Leave the bowl in a RAISED position.
Lifting and Tying Down the 2. Place stops on the steering cylinders in order to
Machine prevent the tractor from turning.
SMCS Code: 7000; 7500 3. Place stops above the pivot stops in order to
prevent the tractor from pivoting.
NOTICE
Improper lifting or tie-downs can allow load to shift 4. Attach two lifting cables to the lifting eyes that are
and cause injury or damage. located above the bowl near the fuel tank.
5. Wrap a sling around the left steering arm. Wrap a
sling around the right steering arm. The slings
should be placed as close to the hitch as possible.
6. Connect the four lifting cables and center the
cables over the machine.
7. Lift the machine. Move the machine to the desired
position.

Tying down the Machine

Each machine is equipped with tie-down brackets.
Attach the tie down chains or attach the tie-down
straps to the tie-down brackets.
1. Lower the bowl before you install the tie-downs.
Illustration 88 g01953236
This message is located on the right side of the 2. Place blocks under the front wheels and place
hydraulic tank. blocks under the rear wheels. If the blocks can not
be placed under the wheels, place the blocks in a
Note: The shipping weight that is listed is the weight suitable location to prevent machine movement
of the most common configuration of the machine. If during transport.
attachments have been installed on your machine,
the weight of your machine and the center of gravity 3. Install tie-downs at several locations.
of your machine may vary.
4. Use the front machine retrieval pin to tie down the
See Operation and Maintenance Manual, “Rated front of the machine. If the machine is equipped
Load” for the weight of the machine. with a bail in the tractor, the bail can be used as a
tie-down from several angles.
Lifting Point – In order to lift the
machine, attach the lifting devices to the 5. Use the rear machine retrieval pins or use the rear
lifting points. machine retrieval hooks to tie down the rear of the
machine from several angles.
Tie Down Point – In order to tie down the
machine, attach the tie-downs to the tie 6. Use a bowl spreader tube, which is located in the
down points. scraper bowl, to tie down the middle of the
machine.
Lifting the Machine 7. Obey all of the laws that govern the actual load's
weight, the actual load's width, the actual load's
For lifting objects, use properly rated cables and
properly rated slings. Position the crane for a level lift. height, and the actual load's length. Additional
chains or straps may be required.
A tool such as a spreader bar may be used to lift the
machine. The width of the spreader bar should be See your Caterpillar dealer for shipping instructions
sufficient for preventing contact with the side of the for your machine. See the Operation and
machine. Maintenance Manual, “Shipping the Machine” for
further information.
Steering cylinder locks and hitch pivot locks are
required to lift the machine. Contact your local
Caterpillar dealer for more information on the hitch
pivot locks.
74 SEBU7857-05
Operation Section
Jacking Location Information

Jacking Location
Information
i07307663

Jacking/Blocking Locations
SMCS Code: 7000
Park the machine on level ground. Engage the
parking brake. Lower the bowl to the ground. Shut off
the engine.

Note: Empty the bowl before you jack up the

machine.
Illustration 90 g06278035

Raising the Machine Install the articulation stops on both steering

cylinders. Place the brace on the rod of the cylinder,
Do not raise the tractor and the scraper at the same then tighten the u-bolt around the rod to hold the
time without installing oscillation and articulation brace in place.
stops. Consult your Cat dealer for information on
oscillation and articulation stops for your machine. Raising with a Jack and Supporting
with Blocks
Place the jack in a location that will sustain the weight
of the machine such as a frame member. The frame
member should be parallel to the ground. The head
of the jack should be against a flat surface. Use a
jack which will support the weight of the machine.

Illustration 89 g06278030

Install the oscillation stops on the frame on both sides

of the oscillation joint. Adjust the bolt on top of each
stop until the machine cannot oscillate.

Illustration 91 g01114341

Location (1) is a suitable place for jacking up the

tractor. This location is part of the frame rail of the
tractor. After you have jacked up the machine to the
height that is required for you to perform the work
that is needed, place wood blocks for cribbing at
location (2). The wood blocks should be placed on
level ground.
Make sure that the machine is stable before you
proceed to work on the machine.
SEBU7857-05 75
Operation Section
Jacking/Blocking Locations

Place the lift stand in a location that will sustain the

weight of the machine such as a frame member. The
frame member should be parallel to the ground. The
head of the lift stand should be against a flat surface.
Use a lift stand which will support the weight of the
machine.
Make sure that the machine is stable before you
proceed to work on the machine.

Illustration 92 g00929652

A suitable place for jacking up the scraper is at

location (3). After you have raised the machine to the
height that is required for you to perform the work
that is needed, place wood blocks for cribbing at this
location. Once the wood blocks for cribbing are in
place, lower the jack until the machine is supported
by the blocks.
Make sure that the machine is stable before you
proceed to work on the machine.
Note: A stand is available from your Caterpillar
dealer which may be substituted for wood blocks that
are used for cribbing. Stands should only be used on
a concrete surface. Consult your Caterpillar dealer
for further information.

Raising and Supporting with a Lift

Stand

Illustration 93 g00929653
Typical example

Lift stand (B) is available from your Caterpillar dealer.

Consult your Caterpillar dealer for further information.
The lift stand combines lifting and supporting
functions. Two of these lift stands should be used if
you are lifting both sides of the machine. Lift stands
should only be used on concrete surfaces.
76 SEBU7857-05
Operation Section
Towing Information

Towing Information Shields must be provided on both machines. This will

protect the operator if the tow line or the tow bar
breaks.
i03649479
Do not allow an operator to be on the machine that is
being towed unless the operator can control the
Towing the Machine steering and/or the braking.
SMCS Code: 7000
Before you tow the machine, make sure that the tow
line or the tow bar is in good condition. Make sure
that the tow line or the tow bar has enough strength
for the towing procedure that is involved. The
Personal injury or death could result when towing strength of the tow line or of the tow bar should be at
a disabled machine incorrectly. least 150 percent of the gross weight of the towing
machine. This requirement is for a disabled machine
Block the machine to prevent movement before that is stuck in the mud and for towing on a grade.
releasing the brakes. The machine can roll free if
it is not blocked. Only attach the tow line to the towing eyes on the
frame, if equipped.
Follow the recommendations below, to properly
perform the towing procedure. Do not use a chain for pulling a disabled machine. A
chain link can break. This may cause personal injury.
Use a wire cable with ends that have loops or rings.
Put an observer in a safe position in order to watch
the pulling procedure. The observer can stop the
Personal injury or death can result from a brake procedure if the wire cable starts to break. Stop
malfunction. pulling whenever the towing machine moves without
moving the towed machine.
Make sure all necessary repairs and adjustments
have been made before a machine, that has been Keep the tow line angle to a minimum. Do not exceed
towed to a service area, is put back into a 30 degree angle from the straight ahead position.
operation.
Quick machine movement could overload the tow line
or the tow bar. This could cause the tow line or the
tow bar to break. Gradual, steady machine
movement will be more effective.
Personal injury or death can result from a ma- Normally, the towing machine should be as large as
chine moving during driveshaft removal and the disabled machine. Make sure that the towing
installation. machine has enough brake capacity, enough weight,
and enough power. The towing machine must be
Block the wheels securely so that the machine able to control both machines for the grade that is
cannot move. involved and for the distance that is involved.
The towing connection must be rigid, or towing You must provide sufficient control and sufficient
must be done by two machines of the same size braking when you are moving a disabled machine
or larger than the towed machine. Connect a ma- downhill. This may require a larger towing machine or
chine on each end of the towed machine. additional machines that are connected to the rear of
the disabled machine. This will prevent the machine
This machine is equipped with a parking brake that is from moving out of control downhill.
spring-applied and air pressure released. If the
engine or the system for pressure air is inoperable, All situation requirements cannot be listed. Minimal
the parking brake is applied and the machine cannot towing machine capacity is required on smooth, level
be moved. surfaces. Maximum towing machine capacity is
required on inclines or on surfaces in poor condition.
These towing instructions are for moving a disabled
machine for a short distance at low speed. Move the When any towed machine is loaded, the machine
machine at a speed of 2 km/h (1.2 mph) or less to a must be equipped with a brake system that is
convenient location for repair. Always haul the operable from the cab.
machine if long distance moving is required.
Consult your Caterpillar dealer for the equipment that
This machine can be towed by removing the drive is necessary for towing a disabled machine.
shaft from the machine. Refer to the machine's
Service Manual or consult your Caterpillar dealer for
the removal procedure for the drive shaft and for the
installation procedure for the drive shaft.
SEBU7857-05 77
Operation Section
Towing the Machine

Running Engine
If the engine is running, the machine can be towed
for a short distance under certain conditions. The
transmission and the steering system must be
operable. Tow the machine for a short distance
only. For example, pull the machine out of mud or
pull the machine to the side of the road.
The operator on the towed machine must steer the
machine in the direction of the tow line.
Carefully obey all of the instructions that are outlined
in this topic.
1. Move the transmission control (lever) to the
NEUTRAL position. Illustration 94 g01958744

2. Raise the attachments off the ground.

Stopped Engine
Perform the following steps before you tow the
machine:

Illustration 95 g01958745

1. Disconnect steering hose (1) and disconnect

steering hose (2). Cap the steering hose
connections. Connect steering hose (1) and
steering hose (2) with a union and two seal O-
rings.

NOTICE
Be sure the cylinder hoses are connected correctly
before operating the machine. With the hoses re-
versed, the steering system will not function.

2. If failure of the internal transmission or of the drive

line is suspected, remove the drive shaft.
For the removal procedures for the drive shaft and
the installation procedures for the drive shaft,
consult your Caterpillar dealer or refer to the
Service Manual.
3. Release the parking brake.
78 SEBU7857-05
Operation Section
Parking Brake Manual Release

NOTICE
Release the parking brake to prevent excessive wear
and damage to the parking brake system, when tow-
ing without brake air pressure.
The procedure for manual release of the parking
brake is outlined in the Operation and Maintenance
Manual, “Parking Brake Manual Release”.

4. Inspect the machine for power train damage. If

damage is suspected, remove the axle shafts.
5. Fasten the tow bar.
6. Remove the wheel blocks. Tow the machine
slowly. Do not exceed 2 km/h (1.2 mph). Illustration 96 g00916527

i02504274 3. Remove cotter pin (1) from link pin (2). Remove
the link pin.
Parking Brake Manual Release 4. Turn adjusting screw (3) counterclockwise. Turn
SMCS Code: 4267; 7000 adjusting shaft (4) counterclockwise until body (6)
of the slack adjuster does not contact brake rod
(5).

Personal injury or death can result from a brake 5. Disconnect the pressure air hose. The brake rod
malfunction. should not contact body (6). The brake should be
released now. If the brake rod still contacts the
Do not operate the machine if the brake was ap- body, loosen adjusting shaft (4) more.
plied due to a malfunction of the air system or the
brake. 6. Repeat Step 2 through Step 5 for each wheel.
Correct any problem before attempting to operate 7. If air pressure is not available to release the brake,
the machine. loosen adjusting screw (3). Turn adjusting screw
(3) counterclockwise.
1. Block the wheels. This will prevent the machine 8. Turn adjusting shaft (4) so that body (6) moves
from rolling away when the parking brake is downward.
disengaged.
9. Turn adjusting shaft (4) until pin (2) can be moved
Note: Proceed to Step 7 if air pressure is not freely. The brake should be released.
available.
10. Repeat Step 7 through Step 9 for each wheel.
2. Connect a pressure air hose from an operating
machine or from a portable air compressor to the
air inlet port of the rotochamber. Fill the
rotochamber with pressure air in order to release
the parking brake temporarily.
SEBU7857-05 79
Operation Section
Engine Starting (Alternate Methods)

Engine Starting (Alternate NOTICE

Ensure that the machine that is used as an electrical
Methods) source does not touch the stalled machine. This
could prevent damage to engine bearings and electri-
cal circuits.
i02504064
Turn on the disconnect switch on the electrical
Engine Starting with Jump source. This will help to prevent damage to electrical
components on the stalled machine.
Start Cables
This machine has a 24 volt starting system. Use only
SMCS Code: 1000; 1401; 7000 equal voltage for jump starting. Use of a higher volt-
age will damage the electrical system.
S/N: DBC1–Up
Severely discharged maintenance free batteries will
not fully recharge from the alternator alone after you
jump start the machine. The batteries must be
charged to the proper voltage with a battery charger.
Never "hotwire" or short across the starter termi- Many batteries that are considered to be unusable
nals! Hotwiring or shorting across the starter ter-
minals could bypass the engine neutral start can still be recharged.
system, damage the electrical system, and result Refer to Special Instruction, SEHS7633, “Battery Test
in unexpected machine motion or behavior. This Procedure” for complete information about testing
could cause personal injury or death.
and about charging. This document is available from
your Caterpillar dealer.

When auxiliary start receptacles are not available,

use the following procedure:
Failure to properly service the batteries may
cause personal injury. 1. Engage the parking brake on the stalled machine.
Place the transmission into NEUTRAL. Lower the
Prevent sparks near the batteries. They could equipment to the ground. Refer to Operation and
cause vapors to explode. Do not allow the jump Maintenance Manual, “Equipment Lowering with
start cable ends to contact each other or the
machine. Engine Stopped”. Move all controls to the HOLD
position.
Electrolyte is an acid and can cause personal in-
jury if it contacts the skin or eyes. 2. Turn the engine start switch on the stalled machine
to the OFF position. Turn off all accessories.
Always wear eye protection when starting a ma-
chine with jump start cables. 3. Turn the battery disconnect switch on the stalled
machine to the ON position.
Improper jump start procedures can cause an ex-
plosion resulting in personal injury. 4. Move the machine that is being used as an
electrical source near the stalled machine so that
When using jumper cables, always connect the the jump start cables reach the stalled machine.
positive (+) jumper cable to the positive (+) bat-
tery terminal first. Next, connect the negative (-) Do not allow the machines to contact each
jumper cable to the frame away from the bat- other.
teries. Follow the procedure in the Operation and 5. Stop the engine of the machine that is being used
Maintenance Manual.
as an electrical source. If you are using an
Jump start only with an energy source of the auxiliary power source, turn off the charging
same voltage as the stalled machine. system.
Turn off all lights and accessories on the stalled 6. Ensure that the battery caps on both machines are
machine. Otherwise, they will operate when the tight and correctly placed. Ensure that the
energy source is connected. batteries in the stalled machine are not frozen.
7. The positive ends of the jump start cable are red.
Connect one positive end of the jump start cable to
the positive cable terminal of the discharged
battery. Some machines have battery sets.
80 SEBU7857-05
Operation Section
Engine Starting with Auxiliary Start Receptacle

Note: Batteries that are in series may be in separate i02209504

compartments. Use the terminal that is connected to
the starter solenoid. This battery or battery set is Engine Starting with Auxiliary
normally on the same side of the machine as the
starting motor. Start Receptacle
SMCS Code: 1000; 7000
Note: Do not allow the positive cable clamps to
contact any metal except for the battery terminals.

8. Connect the other positive end of the jump start

cable to the positive cable terminal of the electrical
source.
9. Connect one negative end of the jump start cable
to the negative cable terminal of the electrical
source.
Note: In 24 volt battery systems, the negative cable
terminal of the electrical source is connected to the
battery disconnect switch in the same battery set that
is used in Step 8.

10. Connect the other negative end of the jump start

Illustration 97 g01115440
cable to the frame of the stalled machine. Do not
connect the jump start cable to a painted surface The auxiliary start receptacle for the tractor is located
on the machine or on the engine. Do not connect on the right side front of the machine.
the jump start cable to the battery post. Do not
allow the jump start cables to contact the battery Some Caterpillar products may be equipped with
auxiliary start receptacles as a standard part. All
cables, the fuel lines, the hydraulic lines, or any other machines can be equipped with a receptacle
moving parts. for parts service. Then, a permanent receptacle is
11. Start the engine of the machine that is being used always available for jump starting.
as an electrical source or energize the charging Two cable assemblies are also available in order to
system on the auxiliary power source. jump start the stalled machine from another machine
that is also equipped with this receptacle or with an
12. Wait at least two minutes before you attempt to auxiliary power pack. Your Caterpillar dealer can
start the stalled machine. This will allow the provide the correct cables for your application.
batteries in the stalled machine to partially charge.
1. Move the transmission control of the stalled
13. Attempt to start the stalled engine. Refer to machine into the NEUTRAL position. Engage the
Operation and Maintenance Manual, “Engine parking brake. Lower the attachment to the
Starting” in the Operation Section for the proper ground. Refer to Operation and Maintenance
starting procedure for your machine. Manual, “Equipment Lowering with Engine
Stopped”. Move all controls to the HOLD position.
14. Immediately after you start the stalled engine,
disconnect the jump start cables in the reverse 2. Turn the engine start switch on the stalled machine
order. to the OFF position. Turn off all accessories.
3. On the stalled machine, turn the battery disconnect
switch to the ON position.
4. Move the machine that is being used as a power
source so that the auxiliary starting cables can
reach the stalled machine. Do not allow the
machines to contact each other.
5. Stop the engine on the machine that is being used
as a power source. If you are using an auxiliary
power source, turn off the charging system.
6. Remove the dust covers on the auxiliary start
receptacles.
SEBU7857-05 81
Operation Section
Engine Starting with Auxiliary Start Receptacle

7. On the stalled machine, connect the appropriate

auxiliary cable to the auxiliary start receptacle.
8. Connect the other end of the auxiliary starting
cable to the auxiliary start receptacle that is on the
power source.
9. Start the engine on the machine that is being used
as a power source. If you are using an auxiliary
power source, energize the charging system on
the auxiliary power source.
10. Wait for a minimum of two minutes while the
batteries in the stalled machine partially charge.
11. Attempt to start the stalled engine. Refer to
Operation and Maintenance Manual, “Engine
Starting” in the Operation Section for the proper
starting procedure for your machine.
12. Immediately after you start the stalled engine,
disconnect the auxiliary starting cable from the
power source.
13. Disconnect the other end of the auxiliary starting
cable from the stalled machine.
14. Install the dust covers on the auxiliary start
receptacles.
15. When the engine is running and the charging
system is in operation, conclude the failure
analysis on the starting charging system of the
stalled machine, as required.
16. Severely discharged batteries will not fully
recharge from the alternator alone after you jump
start the machine. The batteries must be charged
to the proper voltage with a battery charger. Many
batteries that are considered to be unusable can
still be recharged.
82 SEBU7857-05
Maintenance Section
Tire Inflation Information

Maintenance Section

Tire Inflation Information

i00072696

Tire Inflation with Nitrogen

SMCS Code: 4203
Caterpillar recommends the use of dry nitrogen gas
for tire inflation and for tire pressure adjustments.
This includes all machines with rubber tires. Nitrogen
is an inert gas that will not aid combustion inside the
tire. Illustration 98 g00103698

Proper nitrogen inflation equipment, and training Personal injury or death could result with improp-
in using the equipment, are necessary to avoid er tire inflation techniques.
over inflation. A tire blowout or rim failure can re-
sult from improper or misused equipment and Use a self-attaching inflation chuck and stand be-
personal injury or death can occur. hind the tread when inflating a tire.
A tire blowout and/or rim failure can occur if the
inflation equipment is not used correctly, due to Note: Do not set the tire inflation equipment regulator
the fact that a fully charged nitrogen cylinder's higher than 140 kPa (20 psi) over the recommended
pressure is approximately 15000 kPa (2200 psi). tire pressure.

There are other benefits to using nitrogen in addition Use 6V-4040 Nitrogen Tire Inflation Group or an
to reducing the risk of an explosion. The use of equivalent part to inflate tires from a nitrogen gas
nitrogen for tire inflation lessens the slow oxidation of cylinder. Refer to Special Instruction, SMHS7867 for
the rubber. Use of nitrogen also slows gradual tire tire inflation instructions.
deterioration. This is especially important for tires that For nitrogen inflation, use the same tire pressures
are expected to have a long service life of at least that are used for air inflation. Consult your tire dealer
four years. Nitrogen reduces the corrosion of rim for operating pressures.
components. Nitrogen also reduces problems that
result from disassembly.
i01272051

Tire Shipping Pressure

SMCS Code: 4203; 7500
As shown, the tire inflation pressure is cold inflation
shipping pressure.
Table 6

Ply Rating or Shipping

Size Strength Pressure
Index kPa psi

623G Tractor
29.5R29 Michelin Two Star 485 70
29.5R29 Goodyear Two Star 517 75

29.5R29 Bridgestone Two Star 517 75

29.5R35 Michelin Two Star 450 65

(continued)
SEBU7857-05 83
Maintenance Section
Tire Inflation Pressure Adjustment

(Table 6, contd)
29.5R35 Bridgestone Two Star 517 75

29.5-29 34 450 65
29.5-35 28 414 60

Table 7

Ply Rating or Shipping

Size Strength Pressure
Index kPa psi

623G Scraper

29.5R29 Michelin Two Star 414 60

29.5R29 Goodyear Two Star 414 55

29.5R29 Bridgestone Two Star 414 55

29.5R35 Michelin Two Star 380 55

29.5R35 Bridgestone Two Star 450 65

29.5-29 34 345 50
29.5-35 28 310 45

The operating inflation pressure is based on the

weight of a ready-to-work machine without
attachments, at the rated payload, and in average
operating conditions. The inflation pressure for each
application may vary. Tire air pressure should always
be obtained from your tire supplier.
Refer to Operation and Maintenance Manual, “Tire
Inflation - Check” for further information.
Refer to Operation and Maintenance Manual, “Tire
Inflation with Nitrogen” for further information.
Refer to Operation and Maintenance Manual, “Tire
Inflation Pressure Adjustment” for further information.

i02610518

Tire Inflation Pressure

Adjustment
SMCS Code: 4203
Always obtain the proper tire inflation pressures and
maintenance recommendations for the tires on your
machine from your tire supplier. The tire pressure in a
warm shop area 18° to 21°C (65° to 70°F) will
significantly change when you move the machine into
freezing temperatures. If you inflate the tire to the
correct pressure in a warm shop, the tire will be
underinflated in freezing temperatures. Low pressure
shortens the life of a tire.

Reference: When you operate the machine in

freezing temperatures, refer to Special Publication,
SEBU5898, “Cold Weather Recommendations for All
Caterpillar Machines” in order to adjust tire inflation
pressures.
84 SEBU7857-05
Maintenance Section
Lubricant Viscosities and Refill Capacities

Lubricant Viscosities and NOTICE

Not following the recommendations found in this
Refill Capacities manual can lead to reduced performance and com-
partment failure.
i07444286

Lubricant Viscosities Engine Oil

SMCS Code: 1000; 7000; 7581 Caterpillar oils have been developed and tested in
order to provide the full performance and life that has
General Information for Lubricants been designed and built into Cat engines.

When you are operating the machine in temperatures Cat DEO-ULS multigrade and Cat DEO multigrade
below −20°C (−4°F), refer to Special Publication, oils are formulated with the correct amounts of
SEBU5898, “Cold Weather Recommendations”. This detergents, dispersants, and alkalinity in order to
publication is available from your Cat dealer. provide superior performance in Cat diesel engines
where recommended for use.
For cold-weather applications where transmission oil
SAE 0W-20 is recommended, Cat TDTO Cold Note: SAE 10W-30 is the preferred viscosity grade
Weather is recommended. for the 3116, 3126, C7, C-9, and C9 diesel engines
when the ambient temperature is between -18° C (0°
Refer to the “Lubricant Information” section in the F) and 40° C (104° F).
latest revision of the Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” for a
list of Cat engine oils and for detailed information.
This manual may be found on the Web at Safety.Cat.
com.
The footnotes are a key part of the tables. Read ALL
footnotes that pertain to the machine compartment in
question.

Selecting the Viscosity

In order to select the proper oil for each machine
compartment, refer to the "Lubricant Viscosity for
Ambient Temperature" table. Use the oil type AND oil
viscosity for the specific compartment at the proper
ambient temperature.
The proper lubricant viscosity grade is determined by
the minimum outside temperature when the machine
is started. The proper lubricant viscosity grade is also
determined by the maximum outside temperature
while the machine is operated. Use the column on
the table that is designated “Min” in order to
determine the lubricant viscosity grade that is
required when you start a cold machine and when
you operate a cold machine. Use the column on the
table that is designated “Max” to select the lubricant
viscosity grade when you operate the machine at the
highest temperature that is anticipated. When you
start the machine, use the oil with the highest
lubricant viscosity that is allowed for the temperature.
Machines that are continuously operated should use
the oils with a higher viscosity in the final drives and
differentials in order to maintain the highest possible
oil film thickness. Refer to “General Information for
Lubricants” article, “Lubricant Viscosities” tables, and
any associated footnotes. Consult your Cat dealer if
additional information is needed.
SEBU7857-05 85
Maintenance Section
Lubricant Viscosities

Table 8
Cat Diesel Engines Lubricant Viscosities for Ambient Temperatures

Oil Type and Performance °C °F

Compartment or System Oil Viscosities
Requirements Min Max Min Max
Cat DEO Cold Weather (API CK-4) SAE 0W-40 −40 40 −40 104

Engine Crankcase for all Direct In- Cat DEO-ULS SYN (API CK-4) SAE 5W-40 −30 50 −22 122
jection (DI) Engines
Cat DEO-ULS (API CK-4) SAE 10W-30 −18 40 0 104
Cat DEO (API CI-4/CI-4 PLUS) SAE 15W-40 −10 50 14 122

When fuels of sulfur level 0.1 percent (1000 ppm) or

higher are used, Cat DEO-ULS may be used if an oil
analysis program is followed. Base the oil change
interval on the oil analysis.

Other Oil Applications

Refer to the “Lubricant Information” section in the
latest revision of the Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” for a
list of Cat engine oils and for detailed information.
This manual may be found on the Web at Safety.Cat.
com.
Cat HYDO Advanced fluids are the preferred oils for
use in Cat machines hydraulic systems.
Cat HYDO Advanced fluids have a 50% increase
in the standard oil drain interval for machine
hydraulic systems (3000 hours versus 2000 hours)
over second and third choice oils when you follow the
maintenance interval schedule for oil filter changes
and for oil sampling that is stated in the Operation
and Maintenance Manual for your particular machine.
6000 hour oil drain intervals are possible when using
S·O·S Services oil analysis. Consult your Cat dealer
for details. When switching to Cat HYDO Advanced
fluids, cross contamination with the previous oil
should be kept to less than 10%.
86 SEBU7857-05
Maintenance Section
Lubricant Viscosities

Table 9
Wheel Tractor-Scrapers Lubricant Viscosities for Ambient Temperatures

Oil Type and Performance °C °F

Compartment or System Oil Viscosities
Requirements Min Max Min Max
SAE 0W-20 −40 40 −40 104
Cat HYDO Advanced 10
Cat HYDO Advanced 30 SAE 0W-40 −40 40 −40 104
Cat BIO HYDO Advanced SAE 0W-30 −40 40 −40 104
Cat MTO
Cat DEO-ULS SAE 5W-40 −30 40 −22 104
Cat DEO
SAE 10W −20 50 −4 122
Cat DEO-ULS SYN
Hydraulic System Cat DEO SYN SAE 30 10 50 50 122
Cat TDTO
Bio HYDO Advanced −40 40 −40 104
Cat TDTO-TMS
Cat Cold Weather DEO-ULS SAE10W-30 −20 40 −4 104
Cat Cold Weather TDTO
Cat ECF-1-a, Cat ECF-2, Cat SAE15W-40 −15 50 5 122
ECF-3, Cat TO-4, Cat TO-4M, Cat MTO −20 40 −4 104
Cat BF-2
Cat TDTO-TMS −15 50 5 122
SAE 0W-20 −40 10 −40 50

Cat TDTO SAE 10W −20 10 −4 50

Cat TDTO-TMS
Transmission SAE 30 0 35 32 95
Cat Cold Weather TDTO
Cat TO-4, Cat TO-4M SAE 50 10 50 50 122
Cat TDTO-TMS −20 43 −4 110
SAE 60 −7 50 19 122
Cat FDAO
Cat FDAO SYN SAE 50 −15 32 5 90
Nondriven Scraper Wheels Cat TDTO
SAE 30 −25 15 −13 59
except for 613G Cat TDTO-TMS
Cat FD-1, Cat TO-4, Cat TO- Cat TDTO-TMS −35 15 −31 59
4M
Cat FDAO SYN −15 50 5 122
Nondriven Scraper Wheels for
Cat Multipurpose Grease NLGI 2 −30 40 −22 104
613G
SAE 75W-90 −30 40 −22 104
SAE 75W-140 −30 45 −22 113
Cat GO (Gear Oil)
Nondriven Scraper Wheels
Cat Synthetic GO SAE 80W-90 −20 40 −4 104
(Towed Scrapers)
API GL-5 gear oil
SAE 85W-140 −10 50 14 122
SAE 90 0 40 32 104
SAE 75W-90 −30 40 −22 104

Differentials and Final Drives, SAE 75W-140 −30 45 −22 113

Cat GO (Gear Oil)
Auger Lower Bearings, Auger
Cat Synthetic GO SAE 80W-90 −20 40 −4 104
and Elevator Speed Reducers
API GL-5 gear oil
Elevator Lower Rollers SAE 85W-140 −10 50 14 122
SAE 90 0 40 32 104
SEBU7857-05 87
Maintenance Section
Lubricant Viscosities

Grease Applications
Table 10
Type of Cat Grease

Ambient Tempera-
Typical ture Range
Application Point Load and NLGI Grease Type
Load Factor
Speed °C °F Grade
Min Max Min Max
Continuous high total resist- −35 40 −31 104 1
High ance conditions with steady Cat Ultra 5Moly Grease
cycling. −30 50 −22 122 2
Brake Camshaft Bearings, Drive
Cat Advanced 3Moly
Shaft Slip Spline, Ejector Carrier Medium Typical road building use. −20 40 −4 104 2
Grease
and Support Rollers, Sprocket
Shaft Support Bearings Average use but with consid-
erable idling, favorable
Low −30 40 −22 104 2 Cat Multipurpose Grease
grades, low rolling resistance
and easy loading material.

Continuous high total resist- −35 40 −31 104 1

Structure Joints (Articulation, High ance conditions with steady Ultra 5Moly Grease
Cushion Hitch, Oscillation, cycling. −30 50 −22 122 2
Steering)
Medium Typical road building use. −20 40 −4 104 2 Advanced 3Moly Grease

Cat High Speed Ball Bear-

Fan Drive Bearings −20 40 −4 104 2
ing Grease

Reference: Refer to Special Publication, SEBU6250, • Increase the deposits.

“Caterpillar Machine Fluids Recommendations” for
additional information about grease. This manual • Lower fuel economy
may be found on the Web at Safety.Cat.com.
• Shorten the time period between oil drain intervals
(more frequent oil drain intervals).
Diesel Fuel Recommendations
• Increase overall operating costs.
Diesel fuel must meet Caterpillar Specification for
Distillate Fuel and the latest revisions of “ASTM • Negatively impact engine emissions
D975-09a” and “EN 590” in order to ensure optimum
engine performance. Refer to Special Publication, Failures that result for the use of improper fuels are
SEBU6250, “Caterpillar Machine Fluids not Caterpillar factory defects. Therefore, the cost of
Recommendations” for the latest fuel information and repairs would not be covered by a Caterpillar
for Caterpillar fuel specification. This manual may be warranty.
found on the Web at Safety.Cat.com.
Caterpillar does not require the use of ULSD in non-
The preferred fuels are distillate fuels. These fuels road and machine applications that are not Tier 4/
are commonly called diesel fuels, furnace oil, gas oil, Stage IIIB/ Stage IV certified engines and are not
or kerosene. These fuels must meet the Caterpillar equipped with aftertreatment devices. Follow
Specification for Distillate Fuel For Off-Highway operating instructions and fuel tank inlet labels, if
Diesel Engines. Diesel fuels that meet the Caterpillar available in order to ensure that the correct fuels are
will help provide maximum engine service life and used..
performance. This manual may be found on the Web
at Safety.Cat.com.
Misfueling with fuels of high sulfur level can have
the following negative effects:
• Reduce engine efficiency and durability.

• Increase the wear.

• Increase the corrosion.
88 SEBU7857-05
Maintenance Section
Capacities (Refill)

Refer to Special Publication, SEBU6250, “Caterpillar All of the guidelines and requirements are provided in
Machine Fluids Recommendations” for more details the latest revision of Special Publication, SEBU6250,
about fuels, lubricants. This manual may be found on “Caterpillar Machine Fluids Recommendations”. This
the Web at Safety.Cat.com. manual may be found on the Web at Safety.Cat.com

Fuel Additives Coolant Information

Cat Diesel Fuel Conditioner and Cat Fuel System The information provided in this “Coolant
Cleaner are available for use when needed. These Recommendation” section should be used with the
products are applicable to diesel and biodiesel fuels. “Lubricants Information” provided in the latest
Consult your Cat dealer for availability. revision of Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations”. This
Biodiesel manual may be found on the Web at Safety.Cat.com.

Biodiesel is a fuel that can be made from various The following two types of coolants may be used in
renewable resources that include vegetable oils, Cat diesel engines:
animal fat, and waste cooking oil. Soybean oil and
rapeseed oil are the primary vegetable oil sources. In Preferred – Cat ELC (Extended Life Coolant)
order to use any of these oils or fats as fuel, the oils Acceptable – Cat DEAC (Diesel Engine Antifreeze/
or fats are chemically processed (esterified). The Coolant)
water and contaminants are removed.
U.S. distillate diesel fuel specification “ASTM D975-
09a” includes up to B5 (5 percent) biodiesel. NOTICE
Currently, any diesel fuel in the U.S. may contain up Never use water alone as a coolant. Water alone is
corrosive at engine operating temperatures. In addi-
to B5 biodiesel fuel. tion, water alone does not provide adequate protec-
European distillate diesel fuel specification “EN 590” tion against boiling or freezing.
includes up to B5 (5 percent) and in some regions up
to B7 (7 percent) biodiesel. Any diesel fuel in Europe
may contain up to B5 or in some regions up to B7 i03638947
biodiesel fuel.
Note: Up to B20 biodiesel blend level is acceptable
Capacities (Refill)
for use in Motor Grader engines. SMCS Code: 1000; 7000; 7560

Note: The diesel portion used in the biodiesel blend Table 11

must be Ultra Low Sulfur Diesel (ULSD) fuel 0.0015 APPROXIMATE REFILL CAPACITIES
percent (≤15 ppm (mg/kg)) or less per “ASTM D975-
09a”. In Europe the diesel fuel portion used in the Compartment or Liter US gal Imp gal
biodiesel blend must be sulfur free diesel ULSD System
0.0010 percent (≤10ppm (mg/kg) or less per “EN Engine Crankcase 38 10.0 8.4
590”. The final blend must have (≤15 ppm (mg/kg))
sulfur or less. Transmission and Retarder 68 18.0 15.0
Hydraulic System 125 33.0 27.5
When biodiesel fuel is used, certain guidelines
should be followed. Biodiesel fuel can influence the Cooling System 73 19.3 16.1
engine oil, aftertreatment devices, non-metallic
components, fuel system components, and others. Fuel Tank 606 160.1 133.3
Biodiesel fuel has limited storage life and has limited
oxidation stability. Follow the guidelines and Differential 121 32.0 26.6
requirements for engines that are seasonally Each Final Drive 20 5.3 4.4
operated and for standby power generation engines.
Coolant for Each Wheel 45 11.9 9.9
In order to reduce the risks associated with the use of Windshield Washer 6 1.6 1.3
biodiesel, the final biodiesel blend and the biodiesel Reservoir
fuel must meet specific blending requirements.
Elevator Gear Box 10 2.6 2.2
Rear Wheel Bearings 4 1.1 0.9
(Each Side)
SEBU7857-05 89
Maintenance Section
S·O·S Information

i07445339

S·O·S Information
SMCS Code: 1000; 7000; 7542
S·O·S Services is a highly recommended process for
Cat customers to use in order to minimize owning
and operating cost. Customers provide oil samples,
coolant samples, and other machine information. The
dealer uses the data in order to provide the customer
with recommendations for management of the
equipment. In addition, S·O·S Services can help
determine the cause of an existing product problem.
Refer to Special Publication, SEBU6250, “Caterpillar
Machine Fluid Recommendations” for detailed
information concerning S·O·S Services.
The effectiveness of S·O·S Services is dependent on
timely submission of the sample to the laboratory at
recommended intervals.
Refer to the Operation and Maintenance Manual,
“Maintenance Interval Schedule” for a specific
sampling location and a service hour maintenance
interval.
Consult your Cat dealer for complete information and
assistance in establishing an S·O·S program for your
equipment.
90 SEBU7857-05
Maintenance Section
Maintenance Support

Maintenance Support
i07746333

Welding on Machines and

Engines with Electronic
Controls
SMCS Code: 1000; 7000
Do not weld on any protective structure. If it is
necessary to repair a protective structure, contact
your Cat dealer.
Proper welding procedures are necessary to avoid
damage to the electronic controls and to the
bearings. When possible, remove the component
that must be welded from the machine or the engine
and then weld the component. If you must weld near
an electronic control on the machine or the engine,
temporarily remove the electronic control to prevent
heat related damage. The following steps should be
followed to weld on a machine or an engine with
electronic controls.
1. Turn off the engine. Place the engine start switch
in the OFF position.
2. If equipped, turn the battery disconnect switch to
the OFF position. If there is no battery disconnect
switch, remove the negative battery cable at the
battery.

NOTICE
Do NOT use electrical components (ECM or sensors)
or electronic component grounding points for ground-
ing the welder.

3. Clamp the ground cable from the welder to the

component that will be welded. Place the clamp as
close as possible to the weld. Make sure that the
electrical path from the ground cable to the
component does not go through any bearing. Use
this procedure to reduce the possibility of damage
to the following components:

• Bearings of the drive train

• Hydraulic components

• Electrical components

• Other components of the machine

4. Protect any wiring harnesses and components

from the debris and the spatter which is created
from welding.
5. Use standard welding procedures to weld the
materials together.
SEBU7857-05 91
Maintenance Section
Maintenance Interval Schedule

i07742209 “ Oil Filter - Inspect” . . . . . . . . . . . . . . . . . . . . . . . . 144

Maintenance Interval Schedule “ Secondary Steering - Test” . . . . . . . . . . . . . . . . . 146

SMCS Code: 1000; 7000; 7500; 7519 “ Steering Pump Outlet Screen - Clean” . . . . . . . . 147

Ensure that all safety information, warnings and “ Window Washer Reservoir - Fill” . . . . . . . . . . . . 154
instructions are read and understood before any
operation or any maintenance procedures are “ Window Wiper - Inspect/Replace” . . . . . . . . . . . 154
performed.
“ Windows - Clean”. . . . . . . . . . . . . . . . . . . . . . . . . 155
The user is responsible for the performance of
maintenance, including all adjustments, the use of Every 10 Service Hours or Daily
proper lubricants, fluids, filters, and the replacement
of components due to normal wear and aging. Failure “ Air Tank Moisture and Sediment - Drain” . . . . . . . 95
to adhere to proper maintenance intervals and
procedures may result in diminished performance of “ Backup Alarm - Test” . . . . . . . . . . . . . . . . . . . . . . . 96
the product and/or accelerated wear of components.
“ Brakes, Indicators and Gauges - Test” . . . . . . . . . 99
Use mileage, fuel consumption, service hours, or
calendar time, WHICH EVER OCCURS FIRST, in “ Cooling System Coolant Level - Check”. . . . . . . 106
order to determine the maintenance intervals.
Products that operate in severe operating conditions “ Elevator Chain Idler - Lubricate” . . . . . . . . . . . . . 119
may require more frequent maintenance.
“ Engine Air Filter Service Indicator - Inspect” . . . 124
Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be “ Engine Air Precleaner - Clean” . . . . . . . . . . . . . . 125
performed. “ Engine Oil Level - Check” . . . . . . . . . . . . . . . . . . 126

When Required “ Floor Rollers - Lubricate”. . . . . . . . . . . . . . . . . . . 131

“ Fuel System Water Separator - Drain” . . . . . . . . 134
“ Battery - Recycle” . . . . . . . . . . . . . . . . . . . . . . . . . 96
“ Fuel Tank Water and Sediment - Drain” . . . . . . . 135
“ Battery or Battery Cable - Inspect/Replace”. . . . . 97
“ Hydraulic Oil Cooler - Clean” . . . . . . . . . . . . . . . 138
“ Circuit Breakers - Reset” . . . . . . . . . . . . . . . . . . . 102
“ Hydraulic System Oil Level - Check ” . . . . . . . . . 142
“ Clearance between Elevator Flight and Cutting
Edge - Check/Adjust”. . . . . . . . . . . . . . . . . . . . . . . 103 “ Radiator Core - Clean” . . . . . . . . . . . . . . . . . . . . 144
“ Cutting Edges and End Bits - Inspect/ “ Seat Belt - Inspect” . . . . . . . . . . . . . . . . . . . . . . . 145
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
“ Draft Arm Wear Plates - Check/Adjust” . . . . . . . 113 Initial 50 Service Hours
“ Ejector Carrier Rollers - Check/Adjust” . . . . . . . 114 “ Transmission Oil Filter and Magnetic Screen -
Replace/Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
“ Ejector Guide Rollers - Check/Adjust” . . . . . . . . 115
“ Ejector Support Rollers - Check/Adjust”. . . . . . . 116
Every 50 Service Hours or Weekly
“ Elevator Chain - Inspect/Adjust” . . . . . . . . . . . . . 117 “ Cab Air Filter - Clean/Replace” . . . . . . . . . . . . . . 101

“ Engine Air Filter Primary Element - Clean/ “ Elevator Chain Adjustment Cylinder -
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Lubricate” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

“ Engine Air Filter Secondary Element - “ Hitch - Lubricate” . . . . . . . . . . . . . . . . . . . . . . . . . 137

Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 “ Tire Inflation - Check” . . . . . . . . . . . . . . . . . . . . . 148
“ Engine Air Filter Service Indicator - Inspect/
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124 Initial 250 Service Hours (or at first
“ Ether Starting Aid Cylinder - Replace” . . . . . . . . 129 oil change)
“ Fuel System - Prime” . . . . . . . . . . . . . . . . . . . . . . 131 “ Electronic Unit Injector - Inspect/Adjust” . . . . . . 117

“ Fuses - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 136 “ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . 129

92 SEBU7857-05
Maintenance Section
Maintenance Interval Schedule

“ Evaporator Coil and Heater Coil - Clean”. . . . . . 130 “ Hydraulic System Oil Filter (Gear Pump and Case
Drain) - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Every 250 Service Hours “ Hydraulic System Oil Filter (Pilot) - Replace”. . . 140
“Cooling System Coolant Sample (Level 1) - “ Hydraulic System Oil Filter - Replace” . . . . . . . . 141
Obtain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
“ Hydraulic Tank Breaker Relief Valve - Clean” . . 143
Every 250 Service Hours or “ Transmission Oil Filter and Magnetic Screen -
Monthly Replace/Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

“ Air Dryer - Check” . . . . . . . . . . . . . . . . . . . . . . . . . 94 Every 1000 Service Hours or 6

“ Belts - Inspect/Replace” . . . . . . . . . . . . . . . . . . . . 97 Months
“ Brake Air System Pressure - Test” . . . . . . . . . . . . 98 “ Air Dryer Desiccant - Replace” . . . . . . . . . . . . . . . 95
“ Braking System - Test” . . . . . . . . . . . . . . . . . . . . . 99 “ Battery - Clean/Check” . . . . . . . . . . . . . . . . . . . . . 96
“ Differential and Final Drive Oil Level - Check” . . 113 “ Brake Air System Warning Horn - Test” . . . . . . . . 98
“ Elevator Chain Roller - Check/Lubricate”. . . . . . 120 “ Differential and Final Drive Breather - Clean” . . .111
“ Elevator Speed Reducer - Check/Lubricate” . . . 120 “ Rollover Protective Structure (ROPS) -
Inspect” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
“ Engine Oil Sample - Obtain” . . . . . . . . . . . . . . . . 127
“ Suction Screen (Transmission Scavenge) -
“ Hydraulic System Oil Sample - Obtain” . . . . . . . 143 Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
“ Transmission Oil Level - Check” . . . . . . . . . . . . . 152 “ Transmission Breather - Clean” . . . . . . . . . . . . . 149
“ Transmission Oil Sample - Obtain” . . . . . . . . . . . 152 “ Transmission Oil - Change”. . . . . . . . . . . . . . . . . 149
“ Wheel Bearing Oil Level - Check”. . . . . . . . . . . . 153 “ Wheel Coolant Level - Check” . . . . . . . . . . . . . . 153

Initial 500 Hours (for New Systems, Every 2000 Service Hours
Refilled Systems, and Converted
“ Elevator Speed Reducer Oil - Change” . . . . . . . 121
Systems)
“Cooling System Coolant Sample (Level 2) -
Every 2000 Service Hours or 1 Year
Obtain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
“ Brake Shoes and Drums - Inspect/Replace” . . . . 99
Every 500 Service Hours or 3 “ Condenser (Refrigerant) - Clean” . . . . . . . . . . . . 104
Months “ Differential Thrust Pin Clearance - Check”. . . . . .111
“ Accumulator (Cushion Hitch) - Check” . . . . . . . . . 94 “ Differential and Final Drive Oil - Change”. . . . . . .111
“ Brake Camshaft Bearing - Lubricate” . . . . . . . . . . 98 “ Ejector Carrier Rollers - Inspect/Pack/
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
“ Differential and Final Drive Oil Sample -
Obtain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 “ Ejector Guide Rollers - Inspect/Pack/
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
“ Engine Oil (High Speed) and Oil Filter -
Change” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 “ Ejector Support Rollers - Inspect/Pack/
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
“ Engine Oil and Filter - Change”. . . . . . . . . . . . . . 128
“ Electronic Unit Injector - Inspect/Adjust” . . . . . . 117
“ Fuel System Primary Filter (Water Separator)
Element - Replace” . . . . . . . . . . . . . . . . . . . . . . . . 132 “ Elevator Drive Tube Roller Bearing -
Lubricate” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
“ Fuel System Secondary Filter - Replace”. . . . . . 133
“ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . 129
“ Fuel Tank Cap and Strainer - Clean” . . . . . . . . . 135
“ Evaporator Coil and Heater Coil - Clean”. . . . . . 130
SEBU7857-05 93
Maintenance Section
Maintenance Interval Schedule

“ Hitch - Inspect” . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

“ Hydraulic System Oil - Change” . . . . . . . . . . . . . 138
“ Wheel Bearing Oil - Change” . . . . . . . . . . . . . . . 152

Every Year
“Cooling System Coolant Sample (Level 2) -
Obtain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
“ Engine Air Filter Service Indicator - Inspect/
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
“Refrigerant Dryer - Replace” . . . . . . . . . . . . . . . . 144

Every 3000 Service Hours or 2

Years
“ Cooling System Pressure Cap - Clean/
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
“ Cooling System Water Temperature Regulator -
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
“ Crankshaft Vibration Damper - Inspect” . . . . . . . 109

Every 3 Years
“ Seat Belt - Replace”. . . . . . . . . . . . . . . . . . . . . . . 146

Every 6000 Service Hours or 3

Years
“ Cooling System Coolant Extender (ELC) -
Add” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Every 12 000 Service Hours or 6

Years
“ Cooling System Coolant (ELC) - Change” . . . . . 104
94 SEBU7857-05
Maintenance Section
Accumulator (Cushion Hitch) - Check

i02228281

Accumulator (Cushion Hitch) -

Check
SMCS Code: 5077-535

S/N: DBC1–Up

Illustration 100 g00910985

Illustration 99 g01124228 1. Open drain valves (1) for the air tanks on the
tractor. The air tanks should have air pressure.
The cushion-hitch accumulator is located on the right There are three valves on the tractor.
side of the machine near the center hitch.
2. Check for moisture in the air tank. Moisture will
Check the precharge pressure in the cushion-hitch spray from drain valves (1) if moisture is present.
accumulator. Add nitrogen, if necessary. Refer to
Specifications, Systems Operation, Testing and Close drain valves (1).
Adjusting, “Accumulator (Cushion-Hitch) - Test and 3. Open access door (2).
Charge”. You may need to consult your Caterpillar
dealer for the checking procedure.

i01778508

Air Dryer - Check

SMCS Code: 4285-535

S/N: DBC1–Up
SEBU7857-05 95
Maintenance Section
Air Dryer Desiccant - Replace

Illustration 101 g00909446 Illustration 102 g00909536

Replace the air dryer desiccant cartridge or rebuild

4. If there is moisture in the air tank, replace air dryer the air dryer desiccant cartridge if water cannot be
desiccant cartridge (3) or rebuild air dryer absorbed. Consult your Caterpillar dealer for service
desiccant cartridge (3). Consult your Caterpillar or for replacement parts.
dealer for information about replacing air dryer
desiccant cartridge (3) and for instructions for i01778832
rebuilding air dryer desiccant cartridge (3).
Note: Small amounts of moisture may be in the
Air Tank Moisture and
system due to condensation in the system. Moisture Sediment - Drain
may also be in the system if an air dryer is installed SMCS Code: 4272-543-M&S
on a machine that has been operating without an air
dryer. Several weeks may be required in order to The air tanks should have some air pressure.
completely dry the system.
Check the air tanks at the end of the shift for moisture
and for sediment.
i01778591
Moisture and sediment can accumulate in the air
Air Dryer Desiccant - Replace tank. This can lead to a low reserve of air. The air
dryer may need to be serviced. Refer to Operation
SMCS Code: 4285-510-DSS and Maintenance Manual, “Air Dryer - Check” for
further information.
S/N: DBC1–Up
If oil is draining from the tanks, consult your
Caterpillar dealer.

Air lines to and from the air dryer must be at at-

mospheric pressure. Release the air pressure
from the air system completely before performing
maintenance.
96 SEBU7857-05
Maintenance Section
Backup Alarm - Test

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

order to perform the test.
2. Apply the service brakes.
3. Move the transmission control lever to the
REVERSE position. The backup alarm should
start to sound immediately.
The backup alarm should sound immediately. The
alarm alerts the personnel behind the machine
that the machine is backing up. The backup alarm
should continue to sound until the transmission
control lever is moved to the NEUTRAL position or
to the FORWARD position.

i01851167

Battery - Clean/Check
SMCS Code: 1401-070; 1401-535; 1402-535; 1402-
070
Illustration 103 g00909442
S/N: DBC1–Up
Three valves (1) are on the left side of the tractor.
The valves are located in the recess for the step. 1. Turn the engine start switch to the OFF position.
Turn all switches to the OFF position.
Open the valves. Allow the moisture and the
sediment to drain into a suitable container. Close the 2. Turn the battery disconnect switch to the OFF
valves. position. Remove the key.
3. At the battery disconnect switch, disconnect the
negative battery cable that is connected to the
frame.

Note: Do not allow the disconnected battery cable to

contact the disconnect switch.

4. Check the battery terminals for corrosion. If

corrosion is present, clean the battery terminals
with a wire brush.
5. Coat the battery terminals with petroleum jelly, if
necessary.
6. Connect the negative battery cable at the battery
Illustration 104 g00909637
disconnect switch.
The air tank for the scraper is on the right rear side of 7. Install the key for the battery disconnect switch.
the scraper. Turn the key to the ON position.
Open drain valve (2). Allow the moisture and the
sediment to drain into a suitable container. Close i07746330
valve (2).
Battery - Recycle
i03639910
SMCS Code: 1401-561
Backup Alarm - Test Always recycle a battery. Never discard a battery.
SMCS Code: 7406-081 Always return used batteries to one of the following
The backup alarm is on the rear of the machine. locations:

• A battery supplier
SEBU7857-05 97
Maintenance Section
Battery or Battery Cable - Inspect/Replace

• An authorized battery collection facility Inspect

• Recycling facility

i01851175

Battery or Battery Cable -

Inspect/Replace
SMCS Code: 1401-040; 1401-510; 1402-040; 1402-
510

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

Turn all switches to the OFF position.
2. Turn the battery disconnect switch to the OFF
position. Remove the key.
Illustration 105 g01117288
3. At the battery disconnect switch, disconnect the
(1) Fan drive belt
negative battery cable that is connected to the (2) Air conditioning compressor and alternator drive belt
frame.
1. Park the machine on level ground. Move the
Note: Do not allow the disconnected battery cable to
transmission control to the NEUTRAL position and
contact the disconnect switch.
engage the parking brake. Shut off the engine.
4. Disconnect the negative battery cable from the 2. Open the engine access cover that is on the right
terminals of the battery. side of the tractor.
5. Perform the necessary repairs. Replace the cable 3. Inspect the condition of the fan drive belt (1).
or the battery, as needed. Inspect the condition of the air conditioning
6. Connect the negative battery cable to the terminals compressor and alternator drive belt (2). Inspect
of the battery. the belts for the following conditions:

7. Connect the negative battery cable at the battery • excessive cracking

disconnect switch.
• excessive wear
8. Install the key for the battery disconnect switch.
Turn the key to the ON position. • excessive stretching

i03639915 • excessive damage

Belts - Inspect/Replace • missing pieces

SMCS Code: 1397-040; 1397-510 • frayed areas

S/N: DBC1–Up
98 SEBU7857-05
Maintenance Section
Brake Air System Pressure - Test

4. Close the engine access cover. i01401548

Replace Brake Air System Warning

If the belts need replacement, refer to the Service
Horn - Test
Manual or contact your local Caterpillar dealer. SMCS Code: 7402-081; 7408-081
The warning horn for the air brake system should
i02443636
sound when the air pressure gauge shows a reading
below 517 ± 35 kPa (75 ± 5 psi).
Brake Air System Pressure -
1. The parking brake should be in the ENGAGED
Test position.
SMCS Code: 4250-081-PX
2. The transmission control should be in the
NEUTRAL position.
3. Start the engine.
4. Watch the air pressure gauge. The air pressure
must be above 517 ± 35 kPa (75 ± 5 psi).
5. Purge air from the air tanks by doing the following
procedure:

• Engage and disengage the service brake until

the air pressure drops below 517 ± 35 kPa
(75 ± 5 psi).

The warning horn should sound and the action

lamp should flash. Make repairs if the warning
horn is not sounding or the action lamp is not
flashing.

i02556186

Brake Camshaft Bearing -

Illustration 106 g01220965 Lubricate
1. Start the engine and look at air pressure gauge (2). SMCS Code: 4251-086-BD
Allow the brake system air pressure to reach
850 ± 50 kPa (125 ± 10 psi).
2. Apply the service brake by holding down service
brake pedal (1).
3. Stop the engine.
4. The reading on the air pressure gauge should not
drop by more than 35 kPa (5 psi) after the engine
is stopped for 10 minutes. Repair the brakes, if
necessary.

Illustration 107 g00919030

Tractor wheel
SEBU7857-05 99
Maintenance Section
Brake Shoes and Drums - Inspect/Replace

2. Check the brake shoes for wear or for damage.

Measure the thickness of the brake linings. If the
thickness of the brake linings is less than 7.2 mm
(0.28 inch), replace the brake linings.
3. Check the brake drum for wear or for damage.
Repair the brake drum or replace the brake drum,
if necessary.
4. Install the wheel brake dust cover.

i02444593

Brakes, Indicators and Gauges

Illustration 108 g01152437
- Test
Scraper wheel SMCS Code: 4251-081; 4267-081; 7000; 7450-081;
7490-081
The grease fittings for the brake camshaft bearings
can be reached from the back side of each wheel. Before you operate the machine, perform the
following checks and make any necessary repairs:
1. Remove the covers that are on the fittings.
1. Look for broken lenses on the gauges, broken
2. Wipe the fittings before you apply lubricant through indicator lights, broken switches, and other broken
the fittings. components in the cab.
3. Apply the appropriate lubricant through the fittings 2. Start the engine.
for the tractor wheels and for the scraper wheels in
3. Look for inoperative gauges.
order to lubricate the brake camshaft bearings.
4. Turn on all machine lights. Check for proper
4. Replace the covers for the fittings.
operation.
i01792845 5. Sound the forward horn.

Brake Shoes and Drums - 6. Move the machine forward and test the service
brakes. If the service brakes malfunction, consult
Inspect/Replace your Caterpillar dealer for proper repair.
SMCS Code: 4252-040; 4252-510; 4253-510; 4253- 7. Engage the parking brake.
040
8. Move the machine forward in order to test the
parking brake. If the parking brake malfunctions,
consult your Caterpillar dealer for proper repair.
9. Stop the engine.

i02243155

Braking System - Test

SMCS Code: 4251-081; 4267-081

S/N: DBC1–Up

Illustration 109 g00920131

Front Wheel

Note: Check the brakes on all four wheels. Rear

wheels are similar to the front wheels.

1. Remove the wheel brake dust covers.

100 SEBU7857-05
Maintenance Section
Braking System - Test

Service Brake Holding Ability Test If the machine moves with the engine rpm less
than 1200 rpm, consult your Caterpillar dealer for
an inspection of the machine.
7. Reduce the engine speed to low idle and move the
Personal injury can result if the machine moves transmission control to the NEUTRAL position.
while testing.
Engage the parking brake. Lower the bowl to the
If the machine begins to move during test, reduce ground and stop the engine.
the engine speed immediately and engage the
parking brake. NOTICE
If the machine moved while testing the brakes, con-
Make sure that the area around the machine is clear tact your Caterpillar Dealer. Have the dealer inspect
of personnel and of obstacles. and, if necessary, repair the service brakes before re-
turning the machine to operation.
Test the brakes on a dry, level surface.
Fasten the seat belt before you test the brakes. Note: If the friction material for the brakes needs to
This test determines whether the service brake is be replaced, the new friction material may require
functional. This test is not intended to measure the conditioning for maximum performance. Consult your
maximum brake holding effort. Caterpillar dealer or see Special Instruction,
SEHS9187 for the procedure for conditioning.

Parking And Secondary Brake

Holding Ability Test
Make sure that no people or obstacles are in the area
around the machine.
Test the brakes on a dry, level surface.
Fasten the seat belt before you test the brakes.
This test determines whether the parking brake is
functional. This test is not intended to measure the
maximum brake holding effort.
1. Start the tractor engine and the scraper engine.
Illustration 110 g01132855
Scroll to Numeric Readout Mode on display area
(1). Look at the air pressure on display area (1).
1. Start the tractor engine and the scraper engine.
Allow the brake system air pressure to reach the
Scroll to Numeric Readout Mode on display area
cut out pressure for the throttle.
(1). Look at the air pressure on display area (1).
Allow the brake system air pressure to reach the 2. Disengage the scraper transmission by moving the
cut out pressure for the throttle. scraper transmission neutral/run switch to the
DISENGAGE position.
2. Disengage the scraper transmission by moving the
scraper transmission neutral/run switch to the 3. Raise the bowl.
DISENGAGE position.
4. Apply the parking brake.
3. Raise the bowl.
5. While the engine is at an idle and the parking
4. Apply the service brake and release the parking brake is applied, move the transmission control to
brake. the SECOND SPEED position.
5. While the engine is at an idle and the service brake
is applied, move the transmission control to the
SECOND SPEED position.
If the machine begins to move, reduce the engine
6. Gradually increase the engine rpm. The service speed immediately and apply the service brake
brake should prevent machine movement when pedal.
the engine is running at 1200 rpm or less.
SEBU7857-05 101
Maintenance Section
Cab Air Filter - Clean/Replace

6. Gradually increase the engine rpm. The parking

brake should prevent machine movement when
the engine is running at 1000 rpm or less.
If the machine moves with the engine rpm less
than 1000 rpm, consult your Caterpillar dealer for
an inspection of the machine.
7. Reduce the engine speed and move the
transmission control to the NEUTRAL position.
Lower the bowl to the ground and stop the engine.

NOTICE
If the machine moved while testing the brakes, con-
tact your Caterpillar Dealer. Have the dealer inspect
and, if necessary, repair the service brakes before re-
turning the machine to operation.

Note: If the friction material for the brakes needs to

be replaced, the new friction material may require
conditioning for maximum performance. Consult your
Caterpillar dealer or see Special Instruction, Illustration 111 g01166341
SEHS9187 for the procedure for conditioning.
1. Open access door (1). Install rod (2) in order to
i02301254
secure the access door.
Cab Air Filter - Clean/Replace Note: Use the appropriate equipment in order to
SMCS Code: 7342-510; 7342-070 open the access door and install the rod from the
ground.
S/N: DBC1–Up

Cleaning the Filters

Outside Filters
Note: Clean the air filters more often during dusty
conditions.

Illustration 112 g01166347

2. Remove latches (3) which hold the filter element in

place.
3. Remove the filter element. Clean the filter element
with pressure air or wash the filter element in
warm water. Use a nonsudsing household
detergent. Rinse the filter element in clean water
and air dry the filter element thoroughly.
4. After you clean the filter element, inspect the filter
element. Do not use a filter element with damaged
pleats or a damaged seal. If the filter element is
damaged, replace the filter element.
102 SEBU7857-05
Maintenance Section
Circuit Breakers - Reset

5. Install the filter element. Replace latches (3). Circuit Breakers

Reinstall the access cover.

Inside Filter

Illustration 114 g01229770

The circuit breakers for the tractor are located at the

left side of the operator's seat.
Illustration 113 g01152478
Circuit Breaker/Reset – Push in the
1. Remove latches (4) which hold the filter element in button in order to reset the circuit
place. Remove access cover (5). breaker. If the electrical system is
working properly, the button will remain
2. Remove the filter element. Clean the filter element depressed. If the button does not remain
with pressure air or wash the filter element in depressed, check the appropriate electrical
warm water. Use a nonsudsing household circuit. Repair the electrical circuit, if necessary.
detergent. Rinse the filter element in clean water
and air dry the filter element thoroughly. Blower Motor (1) – 20 AMP

3. After you clean the filter element, inspect the filter

element. Do not use a filter element with damaged
Keyswitch (2) – 10 AMP
pleats or a damaged seal. If the filter element is
damaged, replace the filter element.
4. Install the filter element. Reinstall access cover (5). Headlamp (3) (If Equipped) – 15 AMP
Replace latches (4).

i02500897
Stop/Tail/Turn Lamp (4) (If Equipped) –
10 AMP
Circuit Breakers - Reset
SMCS Code: 1420-529

S/N: DBC1–Up
SEBU7857-05 103
Maintenance Section
Clearance between Elevator Flight and Cutting Edge - Check/Adjust

Circuit Breaker Panel

Illustration 115 g01221006

The circuit breaker panel is located below the cab on

the left side of the tractor. Access to the circuit
breakers is through an opening on the left side of the
front frame. Illustration 116 g03645081

Alternator (5) – 80 AMP The clearance between the elevator flights and the
top of the cutting edge may be adjusted. The
distance between the top of the cutting edge and the
elevator flights is set at the factory at approximately
Main Power (6) – 80 AMP 61 mm (2.4 inch). Two shims (5) are located on top
of the welded bracket when the machine is shipped
from the factory. The welded brackets are located on
24 V Electrical Socket (7) each side of the bowl. Place the shims equally on
each of the brackets. Special plates (3) and (4) are
located above the removable shims (5). Plates (3)
and (4) must remain in the top position. The top two
Advanced Diesel Engine Management plates prevent damage to the attaching bolts (2).
(8) – 15 AMP Four shims (5) are located on the bottom of the
welded bracket when the machine is shipped from
the factory.
i05736498
Shims may need to be added to the top of the bracket
Clearance between Elevator when you are working in material which is
compacted. The space that is between the cutting
Flight and Cutting Edge - edge and the elevator flight will become wider. Shims
may also need to be added to the top of the bracket
Check/Adjust when the components of the elevator become worn.
SMCS Code: 6232-535; 6232-025
Shims may need to be removed from the top of the
S/N: DBY1–Up bracket when you are working in loose material. The
space that is between the cutting edge and the
elevator flight will become narrower.
1. Park the machine on level ground. Lower the bowl.
Apply the parking brake.
2. Raise the front of the elevator with a jack or a
hoist. Place blocks or stands under the front of the
elevator once the elevator has been raised. Lower
the elevator until the elevator is resting on the
blocks or stands.
Note: The front of the elevator must not be resting on
the top plate.
104 SEBU7857-05
Maintenance Section
Condenser (Refrigerant) - Clean

3. Remove bolts (1) that hold plate (3) in place. 3. Use clean water in order to wash off all dust and
Remove plate (3). dirt from the condenser.
4. Remove bolts (2). Remove plate (4). 4. Replace the radiator grill.
5. Reposition shims (5) in order to achieve the proper
i02500932
distance.
6. Replace plate (4). Replace bolts (2). Cooling System Coolant (ELC)
7. Replace plate (3). Replace bolts (1). - Change
Note: Bolts (1) have a special torque requirement. SMCS Code: 1350-044-NL
Refer to Specifications, SENR3130, “Torque
S/N: DBC1–Up
Specifications” “Ground Engaging Tool (G.E.T.)
Fasteners” for the correct information.

8. Follow Steps 3 through 5 in order to position the

shims on the other side of the bowl. Personal injury can result from hot coolant,
steam and alkali.
9. Lower the front of the elevator.
At operating temperature, engine coolant is hot
i02207380
and under pressure. The radiator and all lines to
heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Condenser (Refrigerant) -
Remove filler cap slowly to relieve pressure only
Clean when engine is stopped and radiator cap is cool
SMCS Code: 1805-070 enough to touch with your bare hand.

S/N: DBC1–Up Do not attempt to tighten hose connections when

the coolant is hot, the hose can come off causing
burns.
NOTICE
If excessively dirty, clean condenser with a brush. To Cooling System Conditioner contains alkali.
prevent damage or bending of the fins, do not use a Avoid contact with skin and eyes.
stiff brush.
Repair the fins if found defective.
NOTICE
Do not change the coolant until you read and under-
stand the cooling system information in Special Publi-
cation, SEBU6250, “Caterpillar Machine Fluids
Recommendations”.
Failure to do so could result in damage to the cooling
system components.

NOTICE
Mixing ELC with other products reduces the effective-
ness of the coolant and shortens coolant life. Use on-
ly Caterpillar products or commercial products that
have passed the Caterpillar EC-1 specifications for
premixed or concentrate coolants. Use only Caterpil-
lar Extender with Caterpillar ELC. Failure to follow
these recommendations could result in the damage
Illustration 117 g01114468 to cooling systems components.

The refrigerant condenser is located behind the front If ELC cooling system contamination occurs see the
radiator grill. topic Extended Life Coolant (ELC) in the Special
Publication, SEBU6250, “Caterpillar Machine Fluids
1. Remove the radiator grill. Recommendations”.
2. Inspect the condenser for debris. If necessary,
clean the condenser.
SEBU7857-05 105
Maintenance Section
Cooling System Coolant Extender (ELC) - Add

• Special Publication, SEBU6250, “Caterpillar

NOTICE
Care must be taken to ensure that fluids are con- Machine Fluids Recommendations” “Cooling
tained during performance of inspection, mainte- System Specifications”
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain- • Operation and Maintenance Manual,
ers before opening any compartment or disassem- “Capacities (Refill)”
bling any component containing fluids.
8. Start the engine. Operate the engine without the
Refer to Special Publication, NENG2500, “Dealer
cooling system pressure cap until the water
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products. temperature regulator opens and the coolant level
stabilizes.
Dispose of all fluids according to local regulations
and mandates. 9. Check the coolant level. The radiator is full when
the sight glass is completely covered. Also, the
If the coolant in the machine is changed to Extended radiator is full when the coolant level reaches the
Life Coolant (ELC) from another type of coolant, refer top of the angled cut on the filler tube. Refer to
to Special Publication, SEBU6250, “Caterpillar Operation and Maintenance Manual, “Cooling
Machine Fluids Recommendations” “Cat Extended
Life Coolant (ELC)”. System Coolant Level - Check”.

If the coolant is dirty or if you observe any foaming in 10. Inspect the gasket of the cooling system pressure
the cooling system, drain the coolant before the cap. If the gasket is damaged, replace the gasket.
recommended interval.
11. Install the cooling system pressure cap.
1. Park the machine on a level surface and engage
12. Stop the engine.
the parking brake. Stop the engine. Allow the
engine to cool.
i02336986
2. Loosen the cooling system pressure cap slowly in
order to release the pressure. Remove the cooling Cooling System Coolant
system pressure cap. Extender (ELC) - Add
SMCS Code: 1352-544-NL

S/N: DBC1–Up

Personal injury can result from hot coolant,

steam and alkali.
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines to
heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove filler cap slowly to relieve pressure only
when engine is stopped and radiator cap is cool
Illustration 118 g01115071 enough to touch with your bare hand.

3. The coolant drain valve is located behind guard Do not attempt to tighten hose connections when
(2). Remove access cover (1) for the coolant drain the coolant is hot, the hose can come off causing
valve. burns.

4. Open the coolant drain valve. Drain the coolant Cooling System Conditioner contains alkali.
Avoid contact with skin and eyes.
into a suitable container.
5. Flush the cooling system with clean water until the When Caterpillar Extended Life Coolant (ELC) is
used, an extender must be added to the cooling
draining water is transparent. system. See Operation and Maintenance Manual,
6. Close the coolant drain valve. Install the access “Maintenance Interval Schedule” for the proper
cover. service interval. The amount of extender is
determined by the cooling system capacity.
7. Add ELC. Refer to the following topics:
106 SEBU7857-05
Maintenance Section
Cooling System Coolant Level - Check

Table 12
Amount of Caterpillar Extender (ELC)

Cooling System Capacity Recommended Amount of

Caterpillar Extender Personal injury can result from hot coolant,
steam and alkali.
22 to 30 L (6 to 8 US gal) 0.57 L (20 oz)
At operating temperature, engine coolant is hot
31 to 38 L (8 to 10 US gal) 0.71 L (24 oz)
and under pressure. The radiator and all lines to
39 to 49 L (10 to 13 US gal) 0.95 L (32 oz) heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
50 to 64 L (13 to 17 US gal) 1.18 L (40 oz)
Remove filler cap slowly to relieve pressure only
65 to 83 L (17 to 22 US gal) 1.60 L (54 oz) when engine is stopped and radiator cap is cool
enough to touch with your bare hand.
84 to 114 L (22 to 30 US gal) 2.15 L (72 oz)

115 to 163 L (30 to 43 US gal) 3.00 L (100 oz) Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
164 to 242 L (43 to 64 US gal) 4.40 L (148 oz) burns.
Cooling System Conditioner contains alkali.
Note: For cooling systems with larger capacities, use Avoid contact with skin and eyes.
the formula in Table 13 in order to determine the
correct amount of extender. The coolant level sight gauge is located on top of the
radiator on the right side of the coolant tank.
Table 13
Calculation of ELC Extender
V(1) × 0.02 = X(2)
(1) V is the total volume of the cooling system.
(2) X is the amount of ELC Extender that is required.

For additional information about adding an extender,

see Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” “Extended Life
Coolant (ELC)” or consult your Caterpillar dealer.

i02500944

Cooling System Coolant Level

- Check Illustration 119 g01114916
SMCS Code: 1350-535-FLV
1. Park the machine on level ground. Engage the
S/N: DBC1–Up parking brake.
2. Stop the engine.
3. Check the coolant level in the sight gauge. If the
coolant level is at the bottom of the sight gauge,
more coolant is needed.

Note: The filler tube has an angled cut inside of the

coolant tank that can also be used to check the
coolant level. Add coolant when the coolant level
reaches the bottom of the angled cut on the filler
tube.

4. If additional coolant is needed, remove the

pressure cap slowly in order to relieve the
pressure.
5. Add more coolant.
SEBU7857-05 107
Maintenance Section
Cooling System Coolant Sample (Level 1) - Obtain

Note: The radiator is full when the sight gauge is

completely covered. Also, the radiator is full when the
coolant level reaches the top of the angled cut on the
filler tube.

i02500922

Cooling System Coolant

Sample (Level 1) - Obtain
SMCS Code: 1350-008

S/N: DBC1–Up
Note: Obtaining a Coolant Sample (Level 1) is
optional if the cooling system is filled with Cat Illustration 120 g01116606
ELC (Extended Life Coolant). Cooling systems that
are filled with Cat ELC should have a Coolant Obtain the sample of the coolant as close as possible
Sample (Level 2) that is obtained at the to the recommended sampling interval. In order to
recommended interval that is stated in the receive the full effect of S·O·S coolant analysis, you
must establish a consistent trend of data. In order to
Maintenance Interval Schedule. establish a pertinent history of data, perform
consistent samplings that are evenly spaced.
Note: Obtain a Coolant Sample (Level 1) if the Supplies for collecting samples can be obtained from
cooling system is filled with any other coolant your Caterpillar dealer.
instead of Cat ELC. This includes the following
types of coolants: Use the following guidelines for proper sampling of
the coolant:
• Commercial long life coolants that meet the
Caterpillar Engine Coolant Specification -1 • Complete the information on the label for the
(Caterpillar EC-1) sampling bottle before you begin to take the
samples.
• Cat Diesel Engine Antifreeze/Coolant (DEAC)
• Keep the unused sampling bottles stored in plastic
• Commercial heavy-duty antifreeze/coolant bags.

NOTICE • Obtain coolant samples directly from the coolant

Care must be taken to ensure that fluids are con- sample port. You should not obtain the samples
tained during performance of inspection, mainte- from any other location.
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain- • Keep the lids on empty sampling bottles until you
ers before opening any compartment or disassem- are ready to collect the sample.
bling any component containing fluids.
• Place the sample in the mailing tube immediately
Refer to Special Publication, NENG2500, “Dealer after obtaining the sample in order to avoid
Service Tool Catalog” for tools and supplies suitable contamination.
to collect and contain fluids on Cat products.
• Never collect samples from expansion bottles.
Dispose of all fluids according to local regulations
and mandates. • Never collect samples from the drain for a system.
Submit the sample for Level 1 analysis.
Note: Level 1 results may indicate a need for
Level 2 Analysis. For additional information about coolant analysis,
refer to Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” or consult your
Caterpillar dealer.
108 SEBU7857-05
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain

i04054030 Reference: For additional information about coolant

analysis, refer to Special Publication, SEBU6250,
Cooling System Coolant “Caterpillar Machine Fluids Recommendations” or
consult your Cat dealer.
Sample (Level 2) - Obtain
SMCS Code: 1350-008 i02500949

S/N: DBC1–Up Cooling System Pressure Cap

NOTICE - Clean/Replace
Care must be taken to ensure that fluids are con- SMCS Code: 1382-070; 1382-510
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product. S/N: DBC1–Up
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Dealer Personal injury can result from hot coolant,
Service Tool Catalog” for tools and supplies suitable steam and alkali.
to collect and contain fluids on Cat products.
At operating temperature, engine coolant is hot
Dispose of all fluids according to local regulations and under pressure. The radiator and all lines to
and mandates. heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove filler cap slowly to relieve pressure only
when engine is stopped and radiator cap is cool
enough to touch with your bare hand.
Personal injury can result from hot coolant,
steam and alkali. Do not attempt to tighten hose connections when
At operating temperature, engine coolant is hot the coolant is hot, the hose can come off causing
and under pressure. The radiator and all lines to burns.
heaters or the engine contain hot coolant or Cooling System Conditioner contains alkali.
steam. Any contact can cause severe burns. Avoid contact with skin and eyes.
Remove filler cap slowly to relieve pressure only The cooling system pressure cap is located on the
when engine is stopped and radiator cap is cool top of the radiator underneath the hood cover.
enough to touch with your bare hand.
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns.
Cooling System Conditioner contains alkali.
Avoid contact with skin and eyes.

Note: Ensure that the engine is warmed up to

operating temperature and running in order to obtain
the sample.
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. Supplies for
collecting samples can be obtained from your Cat
dealer.
Illustration 121 g01114644
Refer to Operation and Maintenance Manual,
“Cooling System Coolant Sample (Level 1) - Obtain” 1. Remove the cooling system pressure cap slowly in
for the guidelines for proper sampling of the coolant. order to relieve the pressure.
Submit the sample for Level 2 analysis. 2. Inspect the cap for damage, for foreign material,
and for deposits.
3. Clean the cap with a clean cloth or replace the cap,
if necessary.
SEBU7857-05 109
Maintenance Section
Cooling System Water Temperature Regulator - Replace

4. Inspect the condition of the gasket in the cap. 3. Remove the turbocharger water line from the cover
Replace the gasket, if necessary. assembly.
5. Install the pressure cap. 4. Clean the area around the water temperature
regulator housing.
i02558927
5. Remove the bolts from the water temperature
regulator housing and remove the water
Cooling System Water temperature regulator housing.
Temperature Regulator - 6. Remove the water temperature regulator from the
Replace water temperature regulator housing. Remove the
SMCS Code: 1355-510 gasket from the water temperature regulator
housing. Remove the seal from the water
S/N: DBC1–Up temperature regulator housing.

NOTICE
The water temperature regulators may be reused if
Personal injury can result from hot coolant, the water temperature regulators are within test spec-
steam and alkali. ifications, are not damaged, and do not have exces-
sive buildup of deposits.
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines to
heaters or the engine contain hot coolant or NOTICE
steam. Any contact can cause severe burns. It is mandatory to always operate the engine with a
water temperature regulator. Depending on load, fail-
Remove filler cap slowly to relieve pressure only ure to operate with a water temperature regulator
when engine is stopped and radiator cap is cool could result in either an overheating or an overcool-
enough to touch with your bare hand. ing condition.
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns. NOTICE
If the water temperature regulator is installed incor-
Cooling System Conditioner contains alkali. rectly, it will cause the engine to overheat.
Avoid contact with skin and eyes.
Replace the water temperature regulator for the 7. Install a new seal in the water temperature
cooling system on a regular basis in order to reduce regulator housing. Install a new water temperature
the chance of unscheduled downtime. Replace the regulator and a new gasket. Install the water
water temperature regulator for the cooling system temperature regulator. Install the water
on a regular basis in order to reduce the chance of temperature regulator housing.
problems with the cooling system.
8. Install the turbocharger water line and the hose.
The water temperature regulator should be replaced Tighten the hose clamp.
after the cooling system has been cleaned. Replace
the water temperature regulator while the cooling 9. Add the cooling system coolant.
system is completely drained or while the cooling
system coolant is drained to a level that is below the Note: The radiator is full when the sight gauge is
housing assembly of the water temperature regulator. completely covered. Also, the radiator is full when the
coolant level reaches the top of the angled cut on the
NOTICE filler tube. Refer to Operation and Maintenance
Failure to replace the engine's water temperature Manual, “Cooling System Coolant Level - Check”.
regulator on a regularly scheduled basis could cause
severe engine damage.
i02469814

1. Drain the cooling system coolant to a level that is Crankshaft Vibration Damper -
below the housing assembly of the water
temperature regulator.
Inspect
SMCS Code: 1205-040
2. Loosen the hose clamp and remove the hose from
the water temperature regulator housing. S/N: DBC1–Up
110 SEBU7857-05
Maintenance Section
Cutting Edges and End Bits - Inspect/Replace

Damage to the crankshaft vibration damper or failure Note: Any material that might fall on the worker
of the crankshaft vibration damper will increase should be removed from the apron and from the
torsional vibrations. These vibrations will result in sides of the bowl.
damage to the crankshaft and to other engine
components. A deteriorating vibration damper will 1. Park the machine on level ground.
cause excessive gear train noise at variable points in
the speed range. 2. Engage the parking brake.
The damper is mounted to the crankshaft which is
located behind the belt guard on the front of the
engine.
Caterpillar recommends replacing the vibration
damper for any of the following reasons:

• The engine has had a failure because of a broken

crankshaft.
• The S·O·S oil analysis detected a worn crankshaft
front bearing.
• The S·O·S oil analysis detected a large amount of
gear train wear that is not caused by a lack of oil.
• Fluid leakage is detected during inspection. Illustration 122 g00915980

• The housing is damaged.

3. Raise the bowl and block up the bowl. Block the
Refer to Disassembly and Assembly, “Crankshaft bowl on both sides. Blocks should be of material
Vibration Damper and Pulley - Remove and Install” that is suitable for carrying the weight of the bowl.
for the procedure to remove the damper and for the Only block up the bowl to a sufficient height for the
procedure to install the damper. removal of the cutting edges. Refer to Operation
The vibration damper can be used again if none of and Maintenance Manual, “Blocking the Bowl”.
the above conditions are found or if the vibration
damper is not damaged.
Consult your Caterpillar dealer for more information
about damper replacement.

i02216604

Cutting Edges and End Bits -

Inspect/Replace
SMCS Code: 6801-040; 6801-510; 6804-510; 6804-
040

S/N: DBY1–Up
Illustration 123 g01118723

4. If the cutting edges (1) are worn, remove the bolts

Personal injury or death can result, if the bowl is
for the cutting edges (1). If the opposite sides of
not blocked up. Block the bowl before changing
cutting edge. the cutting edges are not worn, rotate the cutting
edges and install the opposite sides of the cutting
edges outward. Clean the contact surfaces before
NOTICE installing.
Do not attempt to increase wear life by welding on
cutting edges. This may result in premature failures. 5. Install new cutting edge sections if the cutting
edges are worn on both sides.
Change or rotate the cutting edges or router bits, be-
fore the mounting surfaces become worn.
SEBU7857-05 111
Maintenance Section
Differential Thrust Pin Clearance - Check

6. If the end bits (2) are worn, remove the bolts for i01796700
the end bits (2). If the opposite sides of the end
bits are not worn, rotate the end bits and install the Differential and Final Drive
opposite sides of the end bits outward. Clean the
contact surfaces before installing.
Breather - Clean
SMCS Code: 3258-070-BRE; 4050-070-BRE
7. Install new end bits if the end bits are worn on both
sides. S/N: DBC1–Up
8. Install the bolts and tighten the bolts to the
specified torque. See Service Manual, SENR3130,
“Torque Specifications” “Ground Engaging Tool (G.
E.T.) Fasteners”.
9. Raise the bowl and remove the blocking. Lower
the bowl to the ground.
10. After a few hours of operation, check the bolts for
proper torque. Tighten the bolts, if necessary.

i02444371

Differential Thrust Pin

Clearance - Check Illustration 125 g00919944
SMCS Code: 3258-535-T9
The differential and final drive breather for the tractor
S/N: DBC1–Up is located on the top of the transmission and at the
right rear of the tractor.
Use the following procedure to clean the breather.
1. Remove the breather.
2. Wash the breather in clean, nonflammable solvent.
3. Allow the breather to dry.
4. Install the breather.

i02500962

Differential and Final Drive Oil

- Change
SMCS Code: 3258-044; 4050-044
Illustration 124 g00919942

The differential thrust pin is located at the front of the S/N: DBC1–Up
differential housing behind the left front wheel.
For the correct procedure to adjust the differential
thrust pin, refer to the Power Train Systems Hot oil and hot components can cause personal
Operation, Testing and Adjusting, “Differential and injury. Do not allow hot oil or hot components to
Bevel Gear - Adjust” for your machine or consult your contact skin.
Caterpillar dealer.
112 SEBU7857-05
Maintenance Section
Differential and Final Drive Oil - Change

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products.
Dispose of all fluids according to local regulations
and mandates.

Illustration 127 g01221454

(3) Final drive filler plug
(4) Final drive drain plug

Note: Final drive drain plug (4) is located on the hub

of the wheel. The final drive drain plug must be at the
lowest point in order to drain the final drive. Refer to
Illustration 127 .

7. Clean the area around final drive drain plug (4).

8. Remove the final drive drain plug. Drain the oil into
a suitable container.
9. Clean the final drive drain plug. Install the final
Illustration 126 g01250922
drive drain plug.
(1) Differential drain plug 10. Repeat this procedure for the other wheel.
(2) Transmission drain plug

Differential drain plug (1) is located under the

transmission of the tractor. Transmission drain plug
(2) is located behind the differential drain plug. The
differential drain plug is located closer to the front of
the machine.
Operate the machine until the differential oil is warm.
1. Park the machine on a level surface.
2. Lower the bowl to the ground.
3. Engage the parking brake. Stop the engine.
4. Clean the area around differential drain plug (1).
5. Remove the differential drain plug. Drain the oil
Illustration 128 g00920188
into a suitable container.
(5) Oil filler tube for the differential
6. Clean the differential drain plug. Install the (6) Sight gauge
differential drain plug.
Note: Oil filler tube (5) is located at the right rear of
the tractor.

11. Clean the area around the oil filler tube. Remove
the oil filler cap.
SEBU7857-05 113
Maintenance Section
Differential and Final Drive Oil Level - Check

12. Fill the differential with oil through the oil filler 3. Clean sight gauge (2) and oil filler cap (1).
tube. Fill the differential to the “FULL” mark in sight
4. Maintain the oil level between the “FULL” and the
gauge (6). Refer to Operation and Maintenance
“ADD” marks on the sight gauge.
Manual, “Capacities (Refill)” and Operation and
Maintenance Manual, “Lubricant Viscosities” for 5. Remove oil filler cap (1). Add oil, if necessary.
further information.
6. Clean oil filler cap (1) and install oil filler cap (1).
13. Clean the oil filler cap. Install the oil filler cap.
i01816090
Note: The differential and the final drives share a
common reservoir. However, the oil level of the final
drives should be checked. Final drive filler plug (3)
Differential and Final Drive Oil
must be horizontal with the center of the final drive in Sample - Obtain
order to check the oil level of the final drive. Final
SMCS Code: 3258-008; 4050-008; 7542-008
drive drain plug (4) will be at the bottom of the wheel.
Refer to Illustration 127 . S/N: DBC1–Up
14. Clean the area around the final drive filler plug.
Remove the final drive filler plug.
15. Oil should be dripping out of the filler plug hole
when the final drive is full of oil. If necessary, add
oil through the filler plug hole.
16. Clean the final drive filler plug. Install the final
drive filler plug.
17. Repeat this procedure for the other wheel.

i01797381

Differential and Final Drive Oil

Level - Check Illustration 130 g00927182

SMCS Code: 3258-535-FLV; 4050-535-FLV A sample of the differential and the final drive oil can
be obtained by pulling a sample through the filler
S/N: DBC1–Up tube. The filler tube for the differential and final drive
oil is located on the back right side of the
transmission on the tractor. Refer to Special
Publication, PEHP6001, “How To Take A Good Oil
Sample” for more information about obtaining a
sample of the differential and final drive oil.

i02238423

Draft Arm Wear Plates - Check/

Adjust
SMCS Code: 6204-025-WK; 6204-535-WK

S/N: DBY1–Up

Illustration 129 g00923735

The sight gauge for the differential and final drive oil
is located on the back right side of the transmission
on the tractor.
1. Park the machine on level ground.
2. Lower the bowl. Shut off the engine.
114 SEBU7857-05
Maintenance Section
Ejector Carrier Rollers - Check/Adjust

i05939904

Ejector Carrier Rollers - Check/

Adjust
SMCS Code: 6229-025; 6229-535

S/N: DBY1–Up
Two ejector carrier rollers are located at the base of
the ejector. These rollers prevent the ejector from
contacting the floor of the bowl.
Check the adjustment for the ejector carrier rollers.
The ejector carrier rollers are correctly adjusted if the
ejector does not contact the bottom of the bowl.
Illustration 131 g01128904
1. Park the machine on level ground. Engage the
1. Check the clearance between the draft arm wear parking brake.
plate (1) and the shoe (2). Refer to Specifications, 2. Lower the bowl and the apron to the ground.
“Draft Frame” for the necessary clearance. Add
shims, if necessary.
2. Chock the wheels.

Illustration 133 g01221477

3. Loosen roller shaft clamping bolt (1).

Illustration 132 g01128905 4. Move eccentric roller shaft (2) to a position that
allows the ejector to pass over the bottom of the
3. Use a suitable lifting device in order to lift the rear bowl. The ejector carrier rollers must be adjusted
of the scraper. Lift the rear of the scraper in order so that the clearance between the bottom of the
to place the bowl in the lowest possible position. ejector and the bottom of the bowl is between
Support the rear of the scraper for safety. 2.0 to 4.0 mm (0.08 to 0.16 inch).
4. Remove the upper bolts for the wear plate. 5. Tighten roller shaft clamping bolt (1). Tighten the
5. Remove cribbing and raise the bowl as far as bolt to 370 ± 50 N·m (273 ± 37 lb ft).
possible. 6. Repeat Step 3 through Step 5 in order to adjust the
6. Remove lower bolts for the wear plate. other ejector carrier roller.

7. Replace shims or replace the wear plate. 7. Start the engine.

Repeat the procedure for the other side of the bowl. 8. Move the ejector forward and backward.
9. Stop the engine.
10. Check for drag between the ejector and the
bottom of the bowl. Repeat the adjustment
procedure, if necessary.
SEBU7857-05 115
Maintenance Section
Ejector Carrier Rollers - Inspect/Pack/Replace

For more information refer to Testing and Adjusting,

“Ejector Clearance - Adjust”.

i02444688

Ejector Carrier Rollers -

Inspect/Pack/Replace
SMCS Code: 6229-086; 6229-040; 6229-510

S/N: DBY1–Up

Illustration 135 g00920596

The ejector guide rollers are at the middle of the

ejector. There are two ejector guide rollers. These
rollers prevent the ejector from contacting the sides
of the bowl. These rollers prevent the ejector from
cocking.
1. Park the machine on level ground. Engage the
parking brake.
2. Lower the bowl to the ground and close the apron.

Illustration 134 g00920884

3. Take the measurement between the ejector guide
rails to determine the narrowest point.
Two ejector carrier rollers are located at the base of
the ejector. 4. Move the ejector to the narrowest point inside the
bowl.
1. Park the machine on level ground. Engage the
parking brake. 5. Loosen roller shaft clamping bolt (1).

2. Lower the bowl and the apron to the ground. 6. Move eccentric roller shaft (2) to a clearance of
2.0 to 4.0 mm (0.08 to 0.16 inch) between the
3. Remove the debris from each roller in order to ejector rollers and the ejector guide rails.
inspect the rollers.
7. Tighten roller shaft clamping bolt (1). Tighten the
4. Pack the bearings of the rollers. bolt to 370 ± 50 N·m (273 ± 37 lb ft).
Reference: Machine Systems Disassembly and 8. Repeat Step 4 through Step 7 to adjust the other
Assembly, “Roller (Ejector Carrier)” ejector guide roller.
Reference: Hydraulic System Specifications, 9. Start the engine.
“Ejector”
10. Move the ejector forward and backward.
i06561520 11. Stop the engine.
12. Check for drag between the ejector guide rollers
Ejector Guide Rollers - Check/ and the sides of the bowl. Repeat the adjustment
Adjust procedure, if necessary.
SMCS Code: 6230-025; 6230-535 For more information refer to Testing and Adjusting,
“Ejector Clearance - Adjust”.
S/N: DBY1–Up
116 SEBU7857-05
Maintenance Section
Ejector Guide Rollers - Inspect/Pack/Replace

i02501076

Ejector Guide Rollers -

Inspect/Pack/Replace
SMCS Code: 6230-086; 6230-510; 6230-040

S/N: DBY1–Up

Illustration 137 g00920605

The ejector support rollers are located at the rear of

the ejector. There are two ejector support rollers.
These rollers support the rear portion of the ejector.
1. Park the machine on level ground. Engage the
parking brake.
2. Lower the bowl to the ground and close the apron.
Illustration 136 g00920902
3. Check the adjustment for the ejector support
The ejector guide rollers are located at the middle of rollers. The ejector support rollers are correctly
the ejector. There are two ejector guide rollers. These adjusted if the ejector support rollers run fully in
rollers prevent the ejector from contacting the sides the track.
of the bowl. These rollers prevent the ejector from
cocking. 4. Loosen roller shaft clamping bolt (1).
1. Park the machine on level ground. Engage the 5. Move eccentric roller shaft (2) to a position that
parking brake. allows the roller to fully contact the track.
2. Lower the bowl to the ground and close the apron. 6. Tighten roller shaft clamping bolt (1).
3. Remove any debris from each ejector guide roller. 7. Repeat Step 4 through Step 6 in order to adjust the
4. Inspect the ejector guide rollers for damage. other ejector support roller.
Replace the ejector guide rollers, if necessary. 8. Start the engine.
5. Pack the ejector guide rollers. Consult your 9. Move the ejector forward and backward.
Caterpillar dealer for further information on this
procedure. 10. Stop the engine.
11. Check for drag between the ejector and the sides
i02501091 of the frame. Repeat the adjustment procedure, if
necessary.
Ejector Support Rollers -
Check/Adjust i02501093

SMCS Code: 6230-025; 6230-535 Ejector Support Rollers -

S/N: DBY1–Up Inspect/Pack/Replace
SMCS Code: 6230-510; 6230-086; 6230-040

S/N: DBY1–Up
SEBU7857-05 117
Maintenance Section
Electronic Unit Injector - Inspect/Adjust

Only qualified service personnel should perform this

maintenance. Refer to the following topics for your
machine for the correct checking procedure and for
the correct adjustment procedure.

• Engine Systems Operation, Testing and

Adjusting, “Electronic Unit Injector - Test”
• Engine Systems Operation, Testing and Adjusting,
“Electronic Unit Injector - Adjust”
The operation of Caterpillar engines with improper
adjustments of the electronic unit injector can reduce
engine efficiency. This reduced efficiency could result
in excessive fuel usage and/or shortened engine
component life.
Illustration 138 g00921939

i02501115
Two ejector support rollers are located at the rear of
the ejector.
Elevator Chain - Inspect/
1. Park the machine on level ground. Engage the
parking brake.
Adjust
SMCS Code: 6231-040; 6231-025
2. Lower the bowl to the ground and close the apron.
3. Remove any debris from each ejector support S/N: DBY1–Up
roller.
Inspect the Elevator Chain
4. Inspect the ejector support rollers for damage.
Replace the ejector support rollers, if necessary.
5. Pack the ejector support rollers. Consult your
Caterpillar dealer for further information on this
procedure.

i01798044

Electronic Unit Injector -

Inspect/Adjust
SMCS Code: 1251-025; 1251-040; 1290-025; 1290-
040

S/N: DBC1–Up
Illustration 139 g00671063

1. Park the machine on level ground. Engage the

Be sure the engine cannot be started while this parking brake.
maintenance is being performed. To prevent pos-
sible injury, do not use the starting motor to turn 2. Lower the bowl to the ground. Shut off the engine.
the flywheel. 3. Inspect the slack of the elevator chain at the widest
Hot engine components can cause burns. Allow space that is between the arrows. The widest
additional time for the engine to cool before space will be halfway between the upper sprocket
measuring/adjusting the unit injectors. and the lower idler. The upper arrow is located at
the lower edge of the frame assembly for the
The electronic unit injectors use high voltage. elevator. The lower arrow is on the upper side of
Disconnect the unit injector enable circuit con-
nector in order to prevent personal injury. Do not the elevator chain. The slack in the elevator chain
come in contact with the injector terminals while should be 254 to 356 mm (10 to 14 inches).
the engine is running.
Note: Adjust the elevator chain when the distance
between the arrows exceeds 356 mm (14 inches).
118 SEBU7857-05
Maintenance Section
Elevator Chain - Inspect/Adjust

4. Inspect the elevator chain for wear. 1. Remove the plate which covers the mechanism for
adjusting the chain.
5. Measure the length of 10 chain links. Replace the
elevator chain if the 10 links measure more than NOTICE
1079 mm (42.5 inches). Refer to Disassembly and Care must be taken to ensure that fluids are con-
Assembly, “Flight (Elevator) - Remove and Install” tained during performance of inspection, mainte-
for further information. nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
Note: Failure to replace a worn elevator chain will ers before opening any compartment or disassem-
result in excessive wear to the drive sprockets. bling any component containing fluids.
Refer to Special Publication, NENG2500, “Dealer
Adjust the Elevator Chain Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products.
Dispose of all fluids according to local regulations
and mandates.

2. Clean the area around lower grease fitting (5) and

upper grease fitting (6).
3. Open upper grease fitting (6) by turning the fitting
counterclockwise for one half turn.
4. Attach a grease gun to lower grease fitting (5).
Apply grease to the fitting until drive assembly (4)
moves upward. Grease will flow from vent (7).
5. Insert shims (2) or remove shims (2) in order to
Illustration 140 g00923405 achieve the proper chain adjustment.

Note: Chain links may be removed from the elevator

chain in order to obtain more adjustment for the
elevator chain. A half link may need to be removed. A
whole link may need to be removed. Always remove
the same number of links from each side of the
elevator chain.

6. Install bolt (3). Install locking nuts (1).

Note: Do not tighten the nuts at this time.

7. Close upper grease fitting (6) by turning the fitting

in a clockwise direction until the fitting is tight.
8. Open lower grease fitting (5) by turning the fitting
counterclockwise for one half turn.
Illustration 141 g00923117
9. Attach a grease gun to upper grease fitting (6).
The mechanism for adjusting the elevator chain is Apply grease to upper grease fitting (6) until drive
located near the top of the elevator. The chain assembly (4) moves downward against the shims
tension for the elevator is controlled by extending and grease stops flowing from vent (7).
drive assembly (4) for the elevator. The drive
assembly is extended by pumping grease into a filler 10. Close lower grease fitting (5) by turning in a
valve. The grease is pumped into a cylinder. The clockwise direction until the fitting is tight.
cylinder will push drive assembly (4) outward. Shims
are then placed in the gap which is created when 11. Install locking nut (1) on bolt (3). Tighten the
drive assembly (4) is extended. The grease pressure locking nut.
is then relieved. The cylinder retracts. Drive
assembly (4) will then rest against the shims. Bolt (3) Note: The bolt should not be tightened all the way.
holds the shims in place. Allow some space in the bolt to allow the drive
assembly to flex.
Note: Spare shims are bolted to the top of the
scraper push frame.
SEBU7857-05 119
Maintenance Section
Elevator Chain Adjustment Cylinder - Lubricate

12. Remove the mechanism for adjusting the chain 1. Clean the area around grease fitting (1).
from the elevator frame.
2. Apply grease to the fitting.
13. Remove the cover plate from the opposite side of
3. Repeat Step 1 and Step 2 in order to lubricate the
the machine and install the mechanism for
other pin.
adjusting the chain.
14. Install the cover plate. i02501213

15. Repeat Steps 2 through 11 for the other chain

tension adjuster.
Elevator Chain Idler - Lubricate
SMCS Code: 6248-086
i02501191
S/N: DBY1–Up
Elevator Chain Adjustment
Cylinder - Lubricate
SMCS Code: 5320-086

S/N: DBY1–Up

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable Illustration 143 g00486735
to collect and contain fluids on Cat products.
Dispose of all fluids according to local regulations
and mandates.

Illustration 144 g00495552

Elevator chain idlers (1) are located on the elevator

frame. Two idlers are located on each side of the
elevator frame.
Illustration 142 g00496695
1. Park the machine on level ground. Engage the
Two grease fittings are located near the top of the parking brake.
assembly for the elevator. One fitting is on the left
side. One fitting is on the right side. The fittings 2. Lower the bowl to the ground.
lubricate the pin for the adjustment of the elevator
chain. 3. Clean the area around grease fittings (2).

A relief valve is located on the inside of each of the 4. Apply grease through the fittings.
pins. The relief valve will prevent the O-rings of the
pin from being pushed out of place. Do not try to 5. Follow Step 3 and Step 4 for the other idlers.
apply grease to the relief valve.
120 SEBU7857-05
Maintenance Section
Elevator Chain Roller - Check/Lubricate

i02501241

Elevator Chain Roller - Check/

Lubricate
SMCS Code: 6260-086; 6260-535

S/N: DBY1–Up

Illustration 146 g00929898

The roller bearing for the elevator drive tube (1) is

located on the right side of the elevator drive tube.
Refer to Disassembly and Assembly, “Elevator Drive
- Assemble” for further information on repacking the
bearings.
Consult your Caterpillar dealer for further information.
Illustration 145 g01250801

Elevator chain rollers (2) are located at the lower end i00968135
of the elevator frame. One roller is located on each
side of the elevator frame. Elevator Speed Reducer -
1. Park the machine on level ground. Engage the Check/Lubricate
parking brake. SMCS Code: 6236-086-ELV; 6236-535-ELV
2. Lower the bowl to the ground.
S/N: DBY1–Up
3. Position filler plug (1) so that the plug is near the
top center of the roller. Refer to Illustration 145 .
4. Clean the area around the filler plug. Remove the
filler plug.
5. Maintain the oil level to the bottom of the filler hole.
If necessary, add oil.
6. Clean the filler plug. Install the filler plug.
7. Repeat Step 1 through Step 6 for the other
elevator chain roller.

i02216611

Elevator Drive Tube Roller Illustration 147 g00493201

Bearing - Lubricate
The elevator speed reducer (1) is located at the top
SMCS Code: 7551-086-ELV of the elevator. The elevator speed reducer is on the
left side of the elevator.
S/N: DBY1–Up
1. Park the machine on level ground. Lower the bowl.
Apply the parking brake.
2. Clean the area around the filler plug (2).
SEBU7857-05 121
Maintenance Section
Elevator Speed Reducer Oil - Change

3. Remove the filler plug. Oil should drip out of the 6. Clean the drain plug. Install the drain plug.
filler hole. Add oil if oil is needed. Refer to
7. Remove the filler plug. Fill the gear case with oil.
Operation and Maintenance Manual, “Lubricant
Refer to the following topics:
Viscosities” for further information.
4. Clean the filler plug. Install the filler plug. • Operation and Maintenance Manual, “Lubricant
Viscosities”
i02501275
• Operation and Maintenance Manual,
“Capacities (Refill)”
Elevator Speed Reducer Oil -
Change Note: Oil should drip out of the filler hole when the
gear case is full of oil.
SMCS Code: 6236-044-ELV
8. Clean the filler plug. Install the filler plug.
S/N: DBY1–Up
i02467304
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- Engine Air Filter Primary
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
Element - Clean/Replace
ers before opening any compartment or disassem- SMCS Code: 1054-510-PY; 1054-070-PY
bling any component containing fluids.
S/N: DBC1–Up
Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable NOTICE
to collect and contain fluids on Cat products. Service the air cleaner only with the engine stopped.
Engine damage could result.
Dispose of all fluids according to local regulations
and mandates. Service the air cleaner filter element when the
yellow piston on the engine air filter service
indicator enters the red zone or the indicator
reads 63.5 cm (25 inch) of water. Refer to
Operation and Maintenance Manual, “Engine Air
Filter Service Indicator - Inspect”.

Illustration 148 g00493240

Elevator speed reducer (1) is located at the top of the

elevator. The elevator speed reducer is on the left
side of the elevator. Illustration 149 g00102316
1. Park the machine on level ground. Engage the
parking brake. 1. Remove cover (1) for the air filter housing.

2. Lower the bowl to the ground. 2. Remove primary filter element (2) from the air filter
housing.
3. Clean the area around filler plug (2).
3. Clean the inside of the air filter housing.
4. Clean the area around drain plug (3).
4. If the machine is equipped with a vacuator valve,
5. Remove the drain plug. Allow the oil to drain into a clean the vacuator valve on the cover for the air
suitable container. filter housing.
122 SEBU7857-05
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace

5. Install a clean primary air filter element. Install the There are two common methods that are used to
cover for the air filter housing. clean primary air filter elements:

Note: Refer to “Cleaning Primary Air Filter • Pressurized air

Elements”.
• Vacuum cleaning
6. Reset the engine air filter service indicator.
Pressurized Air
If the yellow piston in the indicator moves into the red
zone after starting the engine or the exhaust smoke Pressurized air can be used to clean primary air filter
is still black after installation of a clean primary filter elements that have not been cleaned more than two
element, install a new primary filter element. If the times. Pressurized air will not remove deposits of
piston remains in the red zone replace the secondary carbon and oil. Use filtered, dry air with a maximum
element. pressure of 207 kPa (30 psi).

Cleaning Primary Air Filter

Elements

NOTICE
Caterpillar recommends certified air filter cleaning
services available at participating Caterpillar dealers.
The Caterpillar cleaning process uses proven proce-
dures to assure consistent quality and sufficient filter
life.
Observe the following guidelines if you attempt to
clean the filter element:
Do not tap or strike the filter element in order to re-
Illustration 150 g00281692
move dust.
Do not wash the filter element. Note: When the primary air filter elements are
cleaned, always begin with the clean side (inside) in
Use low pressure compressed air in order to remove order to force dirt particles toward the dirty side
the dust from the filter element. Air pressure must not
(outside).
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter Aim the hose so that the air flows inside the element
element. Take extreme care in order to avoid damage along the length of the filter in order to help prevent
to the pleats. damage to the paper pleats. Do not aim the stream of
air directly at the primary air filter element. Dirt could
Do not use air filters with damaged pleats, gaskets, be forced further into the pleats.
or seals. Dirt entering the engine will cause damage
to engine components.

The primary air filter element can be used up to six

times if the element is properly cleaned and
inspected. When the primary air filter element is
cleaned, check for rips or tears in the filter material.
The primary air filter element should be replaced at
least one time per year. This replacement should be
performed regardless of the number of cleanings.

NOTICE
Do not clean the air filter elements by bumping or tap-
ping. This could damage the seals. Do not use ele-
ments with damaged pleats, gaskets, or seals.
Damaged elements will allow dirt to pass through.
Engine damage could result.

Visually inspect the primary air filter elements before

cleaning. Inspect the air filter elements for damage to
the seal, the gaskets, and the outer cover. Discard
any damaged air filter elements.
SEBU7857-05 123
Maintenance Section
Engine Air Filter Secondary Element - Replace

Vacuum Cleaning
Vacuum cleaning is another method for cleaning
primary air filter elements which require daily
cleaning because of a dry, dusty environment.
Cleaning with pressurized air is recommended prior
to vacuum cleaning. Vacuum cleaning will not
remove deposits of carbon and oil.

Inspecting the Primary Air Filter

Elements

Illustration 152 g00281694

Do not use paint, a waterproof cover, or plastic as a

protective covering for storage. An air flow restriction
may result. To protect against dirt and damage, wrap
the primary air filter elements in Volatile Corrosion
Inhibited (VCI) paper.
Place the primary air filter element into a box for
storage. For identification, mark the outside of the
box and mark the primary air filter element. Include
the following information:
• Date of cleaning
Illustration 151 g00281693

• Number of cleanings
Inspect the clean, dry primary air filter element. Use a
60 watt blue light in a dark room or in a similar facility. Store the box in a dry location.
Place the blue light in the primary air filter element.
Rotate the primary air filter element. Inspect the
i01854719
primary air filter element for tears and/or holes.
Inspect the primary air filter element for light that may
show through the filter material. If it is necessary in Engine Air Filter Secondary
order to confirm the result, compare the primary air
filter element to a new primary air filter element that
Element - Replace
has the same part number. SMCS Code: 1054-510-SE
Do not use a primary air filter element that has any S/N: DBC1–Up
tears and/or holes in the filter material. Do not use a
primary air filter element with damaged pleats,
gaskets or seals. Discard damaged primary air filter NOTICE
elements. Always replace the secondary element. Do not at-
tempt to reuse it by cleaning. Engine damage could
result.
Storing Primary Air Filter Elements
If a primary air filter element that passes inspection Note: Replace the engine air filter secondary
will not be used, the primary air filter element can be element when you service the engine air filter primary
stored for future use. element for the third time. Replace the secondary
element if the exhaust smoke remains black and a
clean primary element has been installed. Also,
replace the secondary element if the element has
been in service for one year.

1. Remove the air cleaner cover and the primary

element.
124 SEBU7857-05
Maintenance Section
Engine Air Filter Service Indicator - Inspect

1. Use a towel to remove the dust which has

collected on indicator (1).
2. Examine the indicator. The machine may be
operated when the indicator is yellow.
Note: The machine should not be operated when the
indicator is red. If the indicator is red, the air filter will
need to be cleaned or the air filter will need to be
replaced.

3. Once the air filter has been checked, the indicator

should be reset. Push in reset button (2) on the
indicator. The indicator will return to the yellow
color.
Illustration 153 g00039214
Note: Refer to Operation and Maintenance Manual,
“Engine Air Filter Service Indicator - Inspect/Replace”
2. Remove the secondary element. in order to check an engine air filter service indicator
3. Cover the air inlet opening. Clean the inside of the that is faulty.
air cleaner housing.
Reference: Operation and Maintenance Manual,
4. Uncover the air inlet opening. Install a new “Engine Air Filter Primary Element - Clean/Replace”
secondary element.
Reference: Operation and Maintenance Manual,
5. Install the primary element and the air cleaner “Engine Air Filter Secondary Element - Replace”
cover.
i03195601
i02501327
Engine Air Filter Service
Engine Air Filter Service Indicator - Inspect/Replace
Indicator - Inspect (If Equipped)
SMCS Code: 7452-040
SMCS Code: 7452-040; 7452-510
S/N: DBC1–Up
S/N: DBC1–Up
NOTICE
Service the air cleaner only with the engine stopped.
Engine damage could result.

Illustration 155 g01156530

Note: If equipped, the air filter indicator should be

replaced during engine overhauls. If equipped, the air
Illustration 154 g01116656 filter indicator should be replaced during replacement
of any major engine component. If equipped, replace
The engine air filter service indicator is located on the the air filter indicator at least one time per year.
right side of the tractor in the engine compartment.
1. Open the access door.
SEBU7857-05 125
Maintenance Section
Engine Air Precleaner - Clean

2. Stop the engine. Check the operation of service 4. Install engine air precleaner (2). Tighten clamp (1).
indicator (1) by pressing in reset button (2) on the
service indicator. This should require no more than i02501545
three presses of the reset button.
3. Next, check the movement of the yellow piston in
Engine Oil (High Speed) and
the service indicator. Start the engine and Oil Filter - Change
accelerate the engine to high idle for a few SMCS Code: 1318-510-HZ
seconds. After the accelerator control (pedal) is
released, the yellow piston should remain at the S/N: DBC1–Up
highest position that was achieved during
acceleration.
4. If the indicator will not reset easily, replace the
Hot oil and hot components can cause personal
service indicator. If the yellow piston of the injury. Do not allow hot oil or hot components to
indicator will not latch at the highest vacuum that is contact skin.
attained, replace the service indicator.
5. Close the access door.
NOTICE
Care must be taken to ensure that fluids are con-
i01550089 tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Engine Air Precleaner - Clean Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
SMCS Code: 1055-070 bling any component containing fluids.
S/N: DBC1–Up Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable
NOTICE to collect and contain fluids on Cat products.
Service the engine air precleaner only with the en-
gine stopped. Engine damage could result. Dispose of all fluids according to local regulations
and mandates.
The engine air precleaner is positioned on top of the
engine compartment. Your machine may be equipped with a high speed
arrangement for changing the engine oil. The high
speed arrangement allows the oil to be quickly
withdrawn. The high speed arrangement allows the
oil to be quickly replaced.
The high speed arrangement has a hose which is
attached to the oil pan at the drain hole. The other
end of the hose has a quick coupler.
Note: Drain the crankcase while the oil is warm. This
allows waste particles that are suspended in the oil to
drain. As the oil cools, the waste particles will settle
to the bottom of the crankcase. The particles will not
be removed by draining the oil and the particles will
recirculate in the engine lubrication system with the
new oil.

Illustration 156 g00805907 1. Park the machine on a level surface. Engage the
parking brake.
1. Loosen clamp (1) at the bottom of engine air
precleaner (2). 2. Shut off the engine.

2. Remove engine air precleaner (2) and inspect the

opening for dirt and debris. Clean the tubes, if
necessary.
3. Clean engine air precleaner (2) with pressure air or
wash the engine air precleaner (2) in clean warm
water.
126 SEBU7857-05
Maintenance Section
Engine Oil Level - Check

Note: There are rotation index marks on the filter that

are spaced 90 degrees or 1/4 of a turn away from
each other. When you tighten the filter, use the
rotation index marks as a guide.

11. Tighten the filter according to the instructions that

are printed on the filter. Use the index marks as a
guide for tightening the filter. For non-Caterpillar
filters, refer to the installation instructions that are
provided by the supplier of the filter.

Note: You may need to use a Caterpillar strap

wrench, or another suitable tool, in order to turn the
filter to the amount that is required for final
installation. Make sure that the installation tool does
Illustration 157 g01115011 not damage the filter.

3. Clean the area around dust cover (1) for the male 12. Pump new oil into the engine. Refer to the
quick coupler that is on the hose. following topics:

4. Remove the dust cover. Clean the male fitting. • Operation and Maintenance Manual, “Lubricant
Viscosities”
5. Remove the dust cover from the female fitting of
the suction hose. Clean the female fitting. • Operation and Maintenance Manual,
6. Attach the suction hose to the male fitting. Remove “Capacities (Refill)”
the oil from the engine.
• Operation and Maintenance Manual, “Engine
Oil Level - Check”

13. Remove the hose from the male coupler. Install

the dust cover.
14. Start the engine and allow the oil to warm.
15. Check the following items for leaks: engine, male
fitting and engine oil filter.
16. Shut off the engine.
17. Run the engine for ten minutes.
18. Check oil level gauge (3). Maintain the oil level
between the marks on the “LOW IDLE” side of the
oil level gauge. If necessary, add oil.
Illustration 158 g01115015

i02501551
7. Remove engine oil filter (2) with a strap type
wrench. Refer to Operation and Maintenance
Manual, “Oil Filter - Inspect”.
Engine Oil Level - Check
SMCS Code: 1000-535-FLV
8. Clean the filter mounting base with a clean towel.
Make sure that the old filter seal has been S/N: DBC1–Up
removed.
9. Apply a thin film of clean engine oil to the seal of
the new filter.
Hot oil and hot components can cause personal
10. Install the new filter hand tight until the seal of the injury. Do not allow hot oil or hot components to
filter contacts the filter mounting base. Note the contact skin.
position of the index marks on the filter in relation
to a fixed point on the filter mounting base.
SEBU7857-05 127
Maintenance Section
Engine Oil Sample - Obtain

NOTICE
Do not under fill or overfill engine crankcase with oil.
Either condition can cause engine damage.

Illustration 160 g01116258

5. Clean the area around oil filler cap (2).

6. If necessary, add oil by removing the oil filler cap.
Illustration 159 g01115060
7. Clean the oil filler cap and install the oil filler cap.
Oil level gauge (1) is located on the right side of the
tractor. 8. Close the engine access cover.

1. Park the machine on level ground. Engage the i02501555

parking brake.
2. Lower the bowl to the ground.
Engine Oil Sample - Obtain
SMCS Code: 1000-008; 7542-008
3. Open the engine access cover that is on the right
side of the machine. S/N: DBC1–Up
4. Check the “LOW IDLE” side of the oil level gauge
while the engine is running. Maintain the oil level
between the “ADD” mark and the “FULL” mark.
Check the “ENGINE STOPPED” side of the oil
level gauge while the engine is stopped. Maintain
the oil level between the “LOW” mark and the
“FULL” mark.
Note: When you operate the machine on severe
slopes, the oil level in the engine crankcase must be
at the “FULL” mark on the “ENGINE STOPPED” side
of the oil level gauge.

Illustration 161 g01115066

The sampling valve for the engine oil is located on

the filter base. The engine oil filter is located on the
right side of the engine in the engine compartment.
Refer to Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” “S·O·S Oil
Analysis” for information that pertains to obtaining a
sample of the engine oil. Refer to Special Publication,
PEHP6001, “How To Take A Good Oil Sample” for
more information about obtaining a sample of the
engine oil.
128 SEBU7857-05
Maintenance Section
Engine Oil and Filter - Change

i02501558

Engine Oil and Filter - Change

SMCS Code: 1318-510

S/N: DBC1–Up

Hot oil and hot components can cause personal

injury. Do not allow hot oil or hot components to
contact skin.

NOTICE Illustration 163 g01115253

Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- Oil filter (3) is on the right side of the engine.
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain- Note: Drain the crankcase while the oil is warm. This
ers before opening any compartment or disassem- allows waste particles that are suspended in the oil to
bling any component containing fluids. drain. As the oil cools, the waste particles will settle
to the bottom of the crankcase. The particles will not
Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable be removed by draining the oil and the particles will
to collect and contain fluids on Cat products. recirculate in the engine lubrication system with the
new oil.
Dispose of all fluids according to local regulations
and mandates. 1. Park the machine on a level surface and engage
the parking brake. Stop the engine.

Note: API CH-4, API CI-4, and API CI-4 PLUS oils 2. Remove crankcase drain valve access cover (1)
are acceptable in the C15 Acert Diesel Engine if from guard (2).
the requirements of Caterpillar's ECF-1 (Engine
3. Use a wrench to open the crankcase drain valve.
Crankcase Fluid specification - 1) are met. The oil
change interval should not exceed 500 hours. Allow the oil to drain into a suitable container.
4. Close the crankcase drain valve. Install the
crankcase drain valve access cover.
5. Open the access door on the right side of the
engine.
6. Remove engine oil filter (3) with a strap type
wrench. Refer to Operation and Maintenance
Manual, “Oil Filter - Inspect”. Discard the used oil
filter properly.
7. Clean the filter mounting base with a clean towel.
Make sure that all of the old filter seal has been
removed.
8. Apply a thin film of clean engine oil to the seal of
Illustration 162 g01115071 the new filter.

The oil drain is located on the engine oil pan. Guard 9. Install the new filter hand tight until the seal of the
(2) covers the engine oil pan. filter contacts the filter mounting base. Note the
position of the index marks on the filter in relation
to a fixed point on the filter mounting base.

Note: There are rotation index marks on the filter that

are spaced 90 degrees or 1/4 of a turn away from
each other. When you tighten the filter, use the
rotation index marks as a guide.
SEBU7857-05 129
Maintenance Section
Engine Valve Lash - Check

10. Tighten the filter according to the instructions that i02243110

are printed on the filter. Use the index marks as a
guide for tightening the filter. For non-Caterpillar Engine Valve Lash - Check
filters, refer to the installation instructions that are SMCS Code: 1105-535
provided by the supplier of the filter.
S/N: DBC1–Up
Note: You may need to use a Caterpillar strap
wrench, or another suitable tool, in order to turn the
filter to the amount that is required for final
installation. Make sure that the installation tool does
not damage the filter. Ensure that the engine can not be started while
this maintenance is being performed. To help pre-
vent possible injury, do not use the starting motor
to turn the flywheel.
Hot engine components can cause burns. Allow
additional time for the engine to cool before
measuring/adjusting valve lash clearance.

NOTICE
Only qualified service personnel should perform this
maintenance. Refer to the Service Manual or your
Caterpillar dealer for the complete valve lash adjust-
ment procedure.
Operation of Caterpillar engines with improper valve
adjustments can reduce engine efficiency. This re-
duced efficiency could result in excessive fuel usage
Illustration 164 g01116290
and/or shortened engine component life.
11. Clean the area around oil filler cap (5). The initial valve lash adjustment is recommended at
the first scheduled oil change. The valve lash
12. Remove the oil filler cap. Fill the crankcase with adjustment should then be made at every 2000 hour
new oil. Refer to the following topics: interval. The adjustment is necessary due to the
initial wear of the valve train components and to the
• Operation and Maintenance Manual, “Lubricant seating of the valve train components.
Viscosities”
This maintenance is recommended by Caterpillar as
• Operation and Maintenance Manual, part of a lubrication and preventive maintenance
“Capacities (Refill)” schedule in order to help provide maximum engine
life.
• Operation and Maintenance Manual, “Engine Ensure that the engine is stopped before measuring
Oil Level - Check” the valve lash. To obtain an accurate measurement,
allow the valves to cool before this maintenance is
13. Clean the oil filler cap and install the oil filler cap. performed.
14. Start the engine and allow the oil to warm. Note: In order to check the valve lash on the tractor
engine, use the right hand timing calibration port.
15. Check the engine for leaks. Check the filter for
leaks. Refer to the Service Manual for more information.
16. Run the engine for ten minutes.
i02501572
17. Check oil level gauge (4). Maintain the oil level
between the marks on the “LOW IDLE” side of the Ether Starting Aid Cylinder -
oil level gauge. If necessary, add oil. Replace
18. Stop the engine. SMCS Code: 1456-510-CD
19. Close the engine access door.
S/N: DBC1–Up
130 SEBU7857-05
Maintenance Section
Evaporator Coil and Heater Coil - Clean

i02229995

Breathing ether vapors or repeated contact of Evaporator Coil and Heater

ether with skin can cause personal injury. Per-
sonal injury may occur from failure to adhere to
Coil - Clean
the following procedures. SMCS Code: 7309-070; 7343-070
Use ether only in well ventilated areas. S/N: DBC1–Up
Do not smoke while changing ether cylinders.
Use ether with care to avoid fires.
Do not store replacement ether cylinders in living
areas or in the operator's compartment.
Do not store ether cylinders in direct sunlight or
at temperatures above 49 °C (120 °F).
Discard cylinders in a safe place. Do not puncture
or burn cylinders.
Keep ether cylinders out of the reach of unauthor-
ized personnel.
To avoid possible injury, be sure the brakes are
applied and all controls are in HOLD or NEUTRAL Illustration 166 g01124894
when starting the engine.

Illustration 167 g01124895

Illustration 165 g01117134
Heater coil (3) and evaporator coil (4) are located in
The ether starting aid cylinder is mounted on the right front of the operator compartment on the left side of
side of the engine compartment underneath the the machine. The coils are located on the top of the
engine hood. heating and air conditioning unit. The coils are
protected by cover (1) and cover (2).
1. Loosen ether cylinder retaining clamp (1). Unscrew
the ether cylinder. 1. Remove cover (1). Next, remove cover (2).

2. Remove used gasket (2). Install the new gasket. A 2. Clean heater coil (3) and evaporator coil (4).
new gasket is provided with each new ether 3. Replace cover (2). Next, replace cover (1).
cylinder.
Note: If you are operating the machine under harsh
3. Install the new ether cylinder. Tighten the ether conditions or with the cab door open, it may be
cylinder hand tight. Tighten the cylinder retaining necessary to clean the coils more often.
clamp with your fingers.
SEBU7857-05 131
Maintenance Section
Floor Rollers - Lubricate

i02501593

Floor Rollers - Lubricate

SMCS Code: 6228-086

S/N: DBY1–Up

Illustration 169 g01117169

The switch is located on the right side of the engine

compartment underneath the hood. The fuel priming
pump is on the right side of the engine compartment
underneath the hood.

Note: The engine start switch must be in the OFF

Illustration 168 g00754904 position in order to prime the fuel system. Do not
attempt to start the engine until the fuel system is
The elevator floor rollers are located on the door purged of air.
assembly. Two rollers are located on each side of the
assembly. The pump is used when any of the following
1. Park the machine on level ground. Engage the procedures are performed:
parking brake. • Changing the fuel filters
2. Lower the bowl to the ground.
• Priming the fuel system
3. Clean the area around the grease fittings for the
rollers. • Changing the fuel lines

4. Apply grease to the fittings on both sides of the • Purging air from the fuel system
machine.

i02501597

Fuel System - Prime

SMCS Code: 1250-548

S/N: DBC1–Up

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products.
Dispose of all fluids according to local regulations
and mandates.
132 SEBU7857-05
Maintenance Section
Fuel System Primary Filter (Water Separator) Element - Replace

• The engine starts but the engine continues to

misfire.

• The engine starts but the engine continues to

emit smoke.

7. If the engine starts but the engine runs rough,

continue to run the engine at low idle until the
engine runs smoothly.

i02502044

Fuel System Primary Filter

(Water Separator) Element -
Replace
SMCS Code: 1260-510; 1263-070

S/N: DBC1–Up

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Illustration 170 g01128777 Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable
1. Open the purge valve. Hold the drain hose to the to collect and contain fluids on Cat products.
container in order to catch the fuel.
Dispose of all fluids according to local regulations
Note: Use a 4 L (1 US gal) container in order to and mandates.
capture the fuel that will pass through the purge
valve. For capturing the fuel, a drain hose is routed
through the bottom of the mounting plate for the NOTICE
hydraulic tank. Do not fill fuel filters with fuel before installing them.
Contaminated fuel will cause accelerated wear to fuel
system parts. Fuel system should be primed prior to
2. Push the switch upward to the ON position in order starting the engine.
to pump the fuel.
Note: If the pump will not pump fuel, the pump may
be faulty or an air leak may occur on the suction side
of the fuel system.

3. Continue to prime the fuel system until the flow of

fuel is free of air bubbles. Fuel should flow
continuously from the hose.
4. After air has been purged from the fuel system,
close the purge valve.
5. Push the switch upward to the ON position for
approximately 30 seconds in order to pressurize
the fuel system.
6. Start the engine. Further priming may be
necessary if any of the following conditions exist:

• The engine will not start.

SEBU7857-05 133
Maintenance Section
Fuel System Secondary Filter - Replace

9. Install water separator bowl (3) onto new primary

fuel filter (2) by hand.
10. Apply clean diesel fuel to the seal of the new
filter.
11. Install the new filter hand tight until the seal of the
filter contacts the filter mounting base. Note the
position of the index marks on the filter in relation
to a fixed point on the filter mounting base.
Note: There are rotation index marks on the filter that
are spaced 90 degrees or 1/4 of a turn away from
each other. When you tighten the filter, use the
rotation index marks as a guide.

12. Tighten the filter according to the instructions that

are printed on the filter. Use the index marks as a
guide for tightening the filter. For non-Caterpillar
filters, refer to the installation instructions that are
provided by the supplier of the filter.
Note: You may need to use a Caterpillar strap
wrench, or another suitable tool, in order to turn the
filter to the amount that is required for final
installation. Make sure that the installation tool does
not damage the filter.

13. Return the fuel shutoff valve to the OPEN

Illustration 171 g01115383
position.
The primary fuel filter is on the right side of the 14. Purge the air from the fuel system. Refer to
engine compartment underneath the hood.
Operation and Maintenance Manual, “Fuel System
1. Park the machine on a level surface. Engage the - Prime” for further instructions.
parking brake.
Note: The secondary fuel filter should also be
2. Lower the bowl to the ground. Shut off the engine. changed at this time. Refer to Operation and
Maintenance Manual, “Fuel System Secondary Filter
3. Move fuel shutoff valve (4) to the CLOSED
- Replace” for further instructions.
position.
4. Clean primary fuel filter (2). Clean filter mounting 15. Start the engine and check for leaks.
base (1), which is located above the filter.
i02502074
5. Turn the filter to the left in order to loosen the filter.
Loosen the filter with a strap type wrench. Fuel System Secondary Filter -
6. Remove the filter. Clean the bottom of the filter Replace
mounting base. Make sure that all of the old filter
SMCS Code: 1261-510-SE
seal is removed.
7. Remove water separator bowl (3) from primary fuel S/N: DBC1–Up
filter (2). Clean the water separator bowl and clean
the groove for the O-ring.
Note: Check the water separator bowl for damage. If
no damage is present, reuse the water separator
bowl.

8. Lubricate the O-ring with clean diesel fuel or

lubricate the O-ring with clean motor oil. Place the
O-ring in the groove on the water separator bowl.
134 SEBU7857-05
Maintenance Section
Fuel System Water Separator - Drain

8. Install the new filter hand tight until the seal of the
NOTICE
Care must be taken to ensure that fluids are con- filter contacts the filter mounting base. Note the
tained during performance of inspection, mainte- position of the index marks on the filter in relation
nance, testing, adjusting, and repair of the product. to a fixed point on the filter mounting base.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem- Note: There are rotation index marks on the filter that
bling any component containing fluids. are spaced 90 degrees or 1/4 of a turn away from
each other. When you tighten the filter, use the
Refer to Special Publication, NENG2500, “Dealer rotation index marks as a guide.
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products. 9. Tighten the filter according to the instructions that
Dispose of all fluids according to local regulations are printed on the filter. Use the index marks as a
and mandates. guide for tightening the filter. For non-Caterpillar
filters, refer to the installation instructions that are
provided by the supplier of the filter.

Note: You may need to use a Caterpillar strap

wrench, or another suitable tool, in order to turn the
filter to the amount that is required for final
installation. Make sure that the installation tool does
not damage the filter.

10. Return the fuel shutoff valve to the OPEN

position.
11. Purge the air from the fuel system. Refer to
Operation and Maintenance Manual, “Fuel System
- Prime” for further instructions.
Note: The primary fuel filter should also be changed
at this time. Refer to Operation and Maintenance
Manual, “Fuel System Primary Filter (Water
Separator) Element - Replace” for further
instructions.

12. Start the engine and check for leaks.

Illustration 172 g01115396
i02502138
The secondary fuel filter is on the right side of the
engine compartment above the primary fuel filter. Fuel System Water Separator -
1. Park the machine on a level surface. Engage the Drain
parking brake. SMCS Code: 1263-543
2. Lower the bowl to the ground. Shut off the engine.
S/N: DBC1–Up
3. Move fuel shutoff valve (3) to the CLOSED
position. NOTICE
Care must be taken to ensure that fluids are con-
4. Clean secondary fuel filter (2). Clean filter tained during performance of inspection, mainte-
mounting base (1), which is located above the nance, testing, adjusting, and repair of the product.
filter. Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
5. Turn the filter to the left in order to loosen the filter. bling any component containing fluids.
Loosen the filter with a strap type wrench.
Refer to Special Publication, NENG2500, “Dealer
6. Remove the filter. Clean the bottom of the filter Service Tool Catalog” for tools and supplies suitable
mounting base. Make sure that all of the old filter to collect and contain fluids on Cat products.
seal is removed. Dispose of all fluids according to local regulations
7. Apply clean diesel fuel to the seal of the new filter. and mandates.
SEBU7857-05 135
Maintenance Section
Fuel Tank Cap and Strainer - Clean

6. Install the gasket.

7. Remove the strainer. Clean the strainer in clean,
nonflammable solvent.
8. Install the strainer.
9. Clean the fuel tank cap. Install the fuel tank cap.

i02502146

Fuel Tank Water and Sediment

- Drain
SMCS Code: 1273-543-M&S
Illustration 173 g01115402
S/N: DBY1–Up
Typical example
NOTICE
Fuel system water separator (1) is mounted below Care must be taken to ensure that fluids are con-
the primary fuel filter. Refer to Operation and tained during performance of inspection, mainte-
Maintenance Manual, “Fuel System Primary Filter nance, testing, adjusting, and repair of the product.
(Water Separator) Element - Replace” for the location Be prepared to collect the fluid with suitable contain-
of the primary fuel filter. ers before opening any compartment or disassem-
bling any component containing fluids.
1. Open drain (2) on water separator bowl (1).
2. Drain the water from the water separator bowl. Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable
3. Close the drain. to collect and contain fluids on Cat products.
Dispose of all fluids according to local regulations
i02556412
and mandates.
Fuel Tank Cap and Strainer -
Clean
SMCS Code: 1273-070-STR; 1273-070-Z2

S/N: DBY1–Up
The fuel tank cap is located on the top of the fuel
tank.
The fuel tank cap has a filter element that is located
within the cap. The filter element filters the air that
enters the fuel tank as the fuel level changes.
The strainer is located under the fuel tank cap. The
strainer will strain the fuel as the fuel enters the fuel
tank.
Illustration 174 g01122503
1. Clean the area around the fuel tank cap.
2. Remove the fuel tank cap. The drain valve for the fuel system is located behind
the right scraper wheel. The drain valve is located
3. Remove the gasket that is part of the fuel tank cap. inside the rear frame. This drain valve is used for
Inspect the gasket for damage. If the gasket is draining diesel fuel from the fuel tank.
damaged, replace the gasket. 1. Move the drain valve to the OPEN position.
4. Disassemble the fuel tank cap. Remove the filter 2. Collect the fuel in a clear container that is suitable.
elements. Clean the filter elements in clean,
nonflammable solvent. 3. Move the drain valve to the CLOSED position in
order to examine the fuel that is collected.
5. Apply a thin coat of oil to the filter elements.
Assemble the fuel tank cap. 4. Examine the fuel that is collected for water and for
sediment. Water collects below the diesel fuel.
136 SEBU7857-05
Maintenance Section
Fuses - Replace

5. If water or sediment is in the fuel, repeat Step 1

through Step 4 until no water or no sediment is
found in the fuel.

i05215204

Fuses - Replace
SMCS Code: 1417-510

S/N: DBC1–Up

NOTICE
Replace fuses with the same type and size only. Oth-
erwise, electrical damage can result.
Illustration 176 g01122717
If it is necessary to replace fuses frequently, an elec-
trical problem may exist. Contact your Caterpillar A film with pictographs is located on the inside of the
dealer. fuse box cover. The location of a fuse matches the
location of the pictograph.
Front and Rear Wiper/Washer (1) – 10
AMP

Rear Work Lights (2) – 15 AMP

Machine Sensors (3) – 10 AMP

Air Dryer (4) – 10 AMP

Differential Lock (5) – 10 AMP

Illustration 175 g01229743

The fuse box is located on the left side of the

operator's seat. Latch (1) holds the cover on the fuse Lighter (6) – 10 AMP
box. Turn the latch clockwise in order to expose the
fuses.
Note: The front headlights, the instrument lights, the Defrost Fan (7) – 10 AMP
dome light, and the red lights on the rear of the
scraper are on an automatic breaker. The automatic
breaker is located inside the fuse box. Ether Starting Aid (8) – 10 AMP
Note: Your machine may not utilize all of the fuses
that are listed below.
Vertical Seat Adjustment (9) – 15 AMP
Fuses – The fuses protect the electrical
system from damage that is caused by
overloaded circuits. If the element inside
Caterpillar Monitoring System (10) – 15
the fuse separates, replace the fuse. Check the
AMP
circuit if the element is separated in the new fuse.
Repair the circuit, if necessary.
Converter (11) – 10 AMP

Spare (12)
SEBU7857-05 137
Maintenance Section
Hitch - Inspect

Product Link (13) – 10 AMP Note: Only one of the horizontal hitch pins is shown.

Spare (14)

Implement Control and Transmission

Control (15) – 20 AMP

Horn and Backup Alarm (16) – 10 AMP

i01306523

Hitch - Inspect
Illustration 179 g00438643
SMCS Code: 4305-040; 7107-040; 7113-040
There are six pins (4), (5), (6), (7), (8) and (9) in the
Consult your Caterpillar Dealer for the allowable links for the steering. Inspect the pins for wear or for
tolerance of all the pins. damage. Replace the pins in the links for the steering
if it is necessary.
Note: Refer to the Disassembly and Assembly for
further information.

i02237644

Hitch - Lubricate
SMCS Code: 7107-086; 7113-086

Illustration 177 g00692116

Inspect the upper hitch pin (1) for wear. Inspect the
lower hitch pin (2) for wear. Replace the pins if it is
necessary.

Illustration 180 g01128529

Note: Clean all of the fittings before you apply

grease.
Twenty-four grease fittings are located near the
cushion-hitch accumulator.

Illustration 178 g00692133

Inspect the two horizontal hitch pins (3) for wear or

for damage. Replace the horizontal hitch pins, if
necessary.
138 SEBU7857-05
Maintenance Section
Hydraulic Oil Cooler - Clean

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products.
Dispose of all fluids according to local regulations
and mandates.

Illustration 181 g01128531 Note: The normal hydraulic oil change interval is
at every 2000 Service Hours or 1 Year. By
Five grease fittings are located on the draft frame. performing S·O·S oil analysis, the hydraulic oil
These fittings are accessible from the back of the
change interval may be extended to 4000 Service
tractor.
Hours or 2 Years. S·O·S oil analysis must be
Note: If any of the remote lines are damaged, performed at every 500 Service Hours or 3
replace the damaged lines. Fill the new lines with Months in order to extend the hydraulic oil
grease. change interval. The results from the S·O·S oil
analysis will determine if the hydraulic oil change
interval may be extended. If S·O·S oil analysis is
i01276876
not available, the hydraulic oil change interval
must remain at every 2000 Service Hours or 1
Hydraulic Oil Cooler - Clean Year . Refer to the Operation and Maintenance
SMCS Code: 1374-070 Manual, “S·O·S Information”.

S/N: DBC1–Up Note: Cat HYDO Advanced 10 has a 50% increase

in the standard oil drain interval for machine
The hydraulic oil cooler (if equipped) is located in hydraulic systems (3000 hours versus 2000
front of the radiator for the tractor. hours) over second and third choice oils - when
Clean the oil cooler and clean the radiator at the following the maintenance interval schedule for
same time. Clean the oil cooler in the same manner oil filter changes and for oil sampling that is
as you clean the radiator. stated in the Operation and Maintenance Manual
for your particular machine. 6000 hour oil drain
You can use compressed air, high pressure water, or intervals are possible when using S·O·S Services
steam to remove dust and other debris from the oil analysis. Contact your Cat dealer for details.
radiator core. However, the use of compressed air is
preferred.

Note: Care must be taken when you are using high

pressure water. High pressure water can cause
damage to the radiator. Use of a water spray nozzle
on the pressure washer which will disperse the water
pressure is preferred.

Note: At the same interval, clean the air conditioner

condenser.

i03210861

Hydraulic System Oil - Change

SMCS Code: 5056-044
Illustration 182 g01124541
S/N: DBC1–Up
Hydraulic tank drain valve (1) is located on the
bottom of the hydraulic tank in front of the right tractor
wheel.
SEBU7857-05 139
Maintenance Section
Hydraulic System Oil Filter (Gear Pump and Case Drain) - Replace

Note: Before you change the hydraulic tank oil, the 8. Clean the hydraulic tank drain plug. Install the
machine must meet the following conditions: hydraulic tank drain plug.
• The machine must be level. 9. A screen is located under hydraulic oil filler cap (3).
Remove the screen.
• The parking brake must be applied.
10. Wash the screen in clean, nonflammable solvent.
• The hydraulic oil must be warm. Inspect the screen for damage. If the screen is
damaged, replace the screen.
• The transmission control must be in NEUTRAL.
11. Install the screen.
• The bowl must be lowered.
12. Fill the hydraulic tank to the proper level. Refer to
the following topics:

• Operation and Maintenance Manual, “Lubricant

Viscosities”

• Operation and Maintenance Manual,

“Capacities (Refill)”

• Operation and Maintenance Manual, “Hydraulic

System Oil Level - Check”

13. Inspect the cap seal for damage. If the seal is

damaged, replace the seal.
14. Install the hydraulic oil filler cap.
Illustration 183 g01124542
15. Start the machine. Run the machine at a low idle.
Hydraulic oil filler cap (3) is located on top of the 16. Check the hydraulic oil level. The oil level should
hydraulic tank. be above the “ADD” level in the sight gauge. Add
1. Clean the hydraulic oil filler cap. oil, if necessary.
2. The hydraulic oil filler cap is a locking cap. If a Note: The oil must be free from bubbles. If there are
padlock is on the cap, remove the padlock. Raise bubbles in the oil, then air is entering the hydraulic
lever (4) in order to engage the lug. system. Inspect the suction hoses and the clamps. If
necessary, tighten any loose clamps and any loose
3. Turn the hydraulic oil filler cap counterclockwise in connections. Replace any damaged hoses.
order to remove the cap. Slowly remove the cap in
order to relieve pressure in the hydraulic tank. 17. Stop the engine.
4. Slowly remove hydraulic tank drain plug (2).
i02503059
5. Open hydraulic tank drain valve (1). Allow the oil to
drain into a suitable container. Hydraulic System Oil Filter
6. Change the hydraulic system filters. Refer to the (Gear Pump and Case Drain) -
following topics that apply to your machine: Replace
• Operation and Maintenance Manual, “Hydraulic SMCS Code: 5068-510; 5091-510
System Oil Filter (Gear Pump and Case Drain)
- Replace” S/N: DBY1–Up

• Operation and Maintenance Manual, “Hydraulic

System Oil Filter (Pilot) - Replace”

• Operation and Maintenance Manual, “Hydraulic

System Oil Filter - Replace”

7. Close the hydraulic tank drain valve.

140 SEBU7857-05
Maintenance Section
Hydraulic System Oil Filter (Pilot) - Replace

8. Tighten the filter according to the instructions that

NOTICE
Care must be taken to ensure that fluids are con- are printed on the filter. Use the index marks as a
tained during performance of inspection, mainte- guide for tightening the filter. For non-Caterpillar
nance, testing, adjusting, and repair of the product. filters, refer to the installation instructions that are
Be prepared to collect the fluid with suitable contain- provided by the supplier of the filter.
ers before opening any compartment or disassem-
bling any component containing fluids. Note: You may need to use a Caterpillar strap
wrench, or another suitable tool, in order to turn the
Refer to Special Publication, NENG2500, “Dealer
filter to the amount that is required for final
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products. installation. Make sure that the installation tool does
not damage the filter.
Dispose of all fluids according to local regulations
and mandates. 9. Start the engine. Check for leaks.
10. Check the hydraulic oil level. Add oil to the
hydraulic tank, if necessary. Refer to Operation
and Maintenance Manual, “Hydraulic System Oil
Level - Check” for more information.

i02503089

Hydraulic System Oil Filter

(Pilot) - Replace
SMCS Code: 5068-510-PS

S/N: DBC1–Up

Illustration 184 g00669655

Hot oil and hot components can cause personal
The filter for the gear pump and the case drain is on injury. Do not allow hot oil or hot components to
the right side of the transmission. contact skin.

1. Park the machine on a level surface. Apply the

parking brake. NOTICE
Care must be taken to ensure that fluids are con-
2. Lower the bowl to the ground. Shut off the engine tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
3. Clean the area around the filter. Be prepared to collect the fluid with suitable contain-
4. Remove the filter with a strap type wrench. Refer ers before opening any compartment or disassem-
to Operation and Maintenance Manual, “Oil Filter - bling any component containing fluids.
Inspect”. Discard the used oil filter properly. Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable
5. Clean the filter mounting base. Make sure that all
to collect and contain fluids on Cat products.
of the old filter seal has been removed.
Dispose of all fluids according to local regulations
6. Apply a thin coat of clean hydraulic oil to the seal and mandates.
of the new filter.
7. Install the new filter hand tight until the seal of the
filter contacts the filter mounting base. Note the
position of the index marks on the filter in relation
to a fixed point on the filter mounting base.
Note: There are rotation index marks on the filter that
are spaced 90 degrees or 1/4 of a turn away from
each other. When you tighten the filter, use the
rotation index marks as a guide.
SEBU7857-05 141
Maintenance Section
Hydraulic System Oil Filter - Replace

10. Check the hydraulic oil level. Add oil to the

hydraulic tank, if necessary. Refer to Operation
and Maintenance Manual, “Hydraulic System Oil
Level - Check” for more information.

i02503105

Hydraulic System Oil Filter -

Replace
SMCS Code: 5068-510

S/N: DBC1–Up

Illustration 185 g01124877 NOTICE

Care must be taken to ensure that fluids are con-
The pilot oil filter is located at the left rear of the tained during performance of inspection, mainte-
tractor behind the transmission filter. nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
1. Park the machine on a level surface and apply the ers before opening any compartment or disassem-
parking brake. bling any component containing fluids.

2. Stop the engine. Lower the bowl to the ground. Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable
3. Clean the area around the pilot oil filter. to collect and contain fluids on Cat products.
4. Remove the filter with a strap type wrench. Refer Dispose of all fluids according to local regulations
to Operation and Maintenance Manual, “Oil Filter - and mandates.
Inspect”. Discard the used oil filter properly.
5. Clean the filter mounting base. Make sure that all
of the old filter seal has been removed.
6. Apply a thin film of clean hydraulic oil to the seal of
the new filter.
7. Install the new filter hand tight until the seal of the
filter contacts the filter mounting base. Note the
position of the index marks on the filter in relation
to a fixed point on the filter mounting base.
Note: There are rotation index marks on the filter that
are spaced 90 degrees or 1/4 of a turn away from
each other. When you tighten the filter, use the
rotation index marks as a guide.
Illustration 186 g01124630
8. Tighten the filter according to the instructions that
are printed on the filter. Use the index marks as a Oil filter cover (3) is located on top of the hydraulic
guide for tightening the filter. For non-Caterpillar tank. Two oil filters and a screen are located under
filters, refer to the installation instructions that are the oil filter cover. The hydraulic tank is located in
front of the right tractor wheel.
provided by the supplier of the filter.
1. Park the machine on level ground. Apply the
Note: You may need to use a Caterpillar strap parking brake.
wrench, or another suitable tool, in order to turn the
filter to the amount that is required for final 2. Lower the bowl to the ground. Shut off the engine.
installation. Make sure that the installation tool does
not damage the filter. 3. Clean hydraulic oil filler cap (1). The hydraulic oil
filler cap is located on top of the hydraulic tank.
9. Start the engine. Check for leaks at the pilot oil
4. The hydraulic oil filler cap is a locking cap. If a
filter.
padlock is on the cap, remove the padlock. Raise
lever (2) in order to engage the lug.
142 SEBU7857-05
Maintenance Section
Hydraulic System Oil Level - Check

5. Turn the hydraulic oil filler cap counterclockwise in

order to remove the cap. Slowly remove the cap in
order to relieve pressure in the hydraulic tank.
Replace the cap after you have relieved pressure
in the hydraulic tank.
6. Clean oil filter cover (3). Remove four bolts (4) that
hold the oil filter cover in place.
7. Remove the two filters. Discard the filters properly.
8. Remove the screen.
9. Wash the screen in clean, nonflammable solvent.
Inspect the screen for damage. Replace the
screen if the screen is damaged.
Illustration 187 g01124663
10. Install the screen. Install two new filters.
The hydraulic tank is located in front of the right
11. Inspect the O-ring seal for the oil filter cover. tractor wheel. Hydraulic oil filler cap (2) is located on
Replace the O-ring seal if the O-ring is damaged. top of the hydraulic tank.
12. Install the oil filter cover. 1. Clean sight gauge (1) in order to view the hydraulic
tank oil level.
13. Refer to Operation and Maintenance Manual,
“Hydraulic System Oil Level - Check” for further
information.

i02503111

Hydraulic System Oil Level -

Check
SMCS Code: 5050-535-FLV

S/N: DBC1–Up
Note: Before you check the hydraulic tank oil level,
the machine must meet the following conditions:
• The machine must be level. Illustration 188 g01124666

• The parking brake must be applied.

2. If necessary, add oil to the hydraulic tank.
• The hydraulic oil must be warm.
Note: Clean hydraulic oil filler cap (2) before adding
• The engine must be running at low idle. oil to the hydraulic tank.

• The transmission control must be in NEUTRAL. 3. The hydraulic oil filler cap is a locking cap. If a
padlock is on the cap, remove the padlock. Raise
• The cushion-hitch must be in the OFF position. lever (3) in order to engage the lug.
• The ejector must be moved forward. 4. Turn the hydraulic oil filler cap counterclockwise in
order to remove the cap. Slowly remove the cap in
• Slight downward pressure must be applied on the order to relieve pressure in the hydraulic tank.
bowl.
1. Add hydraulic oil until the oil level in the sight
gauge is at the “FULL” level.
2. Inspect the hydraulic oil filler cap for damage to the
seal. If the seal is damaged, replace the seal.
3. Install the hydraulic oil filler cap.
SEBU7857-05 143
Maintenance Section
Hydraulic System Oil Sample - Obtain

i03429784 Refer to Special Publication, PEHP6001, “How To

Take A Good Oil Sample” for more information about
Hydraulic System Oil Sample - obtaining a sample of hydraulic oil.
Obtain i02503169
SMCS Code: 5050-008; 7542-008
Hydraulic Tank Breaker Relief
S/N: DBC1–Up
Valve - Clean
Note: Your machine may be equipped with a “Type 1” SMCS Code: 5118-070
location of the sampling valve or a “Type 2” location
of the sampling valve. S/N: DBC1–Up

Type 1

Illustration 191 g01124743

The hydraulic tank breaker relief valve is located on

Illustration 189 g01124705 the top of the hydraulic tank near the hydraulic oil
filler cap. The hydraulic tank breaker relief valve
The hydraulic oil sampling valve is located on top of controls the pressure in the tank and the vacuum in
the return tube near the hydraulic tank. the tank.

Type 2 1. Clean debris from the breaker relief valve.

2. Turn the breaker relief valve counterclockwise in
order to remove the breaker relief valve. Slowly
remove the breaker relief valve in order to relieve
pressure in the hydraulic tank.
3. Remove the retaining ring from the top of the
breaker relief valve.
4. Remove the metal cover that is under the retaining
ring. A filter is under the metal cover.
5. Wash the breaker relief valve and wash the filter in
a clean nonflammable solvent.
6. Dry the breaker relief valve. Dry the filter. Use
compressed air in order to speed the drying.
Illustration 190 g01781733 7. Inspect the filter for damage. If the filter is
damaged, replace the filter.
The hydraulic oil sampling valve is located on right
side of the hitch near the grease block. 8. Inspect the O-ring that is between the filter and the
housing of the hydraulic tank breaker relief valve.
Refer to Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” “S·O·S Oil If the O-ring is damaged, replace the O-ring.
Analysis” for information that pertains to obtaining a
sample of hydraulic oil.
144 SEBU7857-05
Maintenance Section
Oil Filter - Inspect

9. Inspect the breaker relief valve for damage. If the Using an oil filter element that is not recommended
breaker relief valve is damaged, replace the by Caterpillar can result in severe engine damage to
breaker relief valve. engine bearings, to the crankshaft, and to other
parts. This can result in larger particles in unfiltered
10. Apply a thin film of clean hydraulic oil to the O- oil. The particles could enter the lubricating system
ring. Assemble the filter on the breaker relief and the particles could cause damage.
valve.
i01696128
11. Install the breaker relief valve on the hydraulic
tank. Radiator Core - Clean
i02106227 SMCS Code: 1353-070-KO

S/N: DBC1–Up
Oil Filter - Inspect
You can use compressed air, high pressure water, or
SMCS Code: 1308-507; 3004-507; 3067-507; 5068-
steam to remove dust and other debris from the
507 radiator core. However, the use of compressed air is
preferred.
S/N: DBC1–Up
Note: Care must be taken when you are using high
Inspect a Used Filter for Debris pressure water. High pressure water can cause
damage to the radiator. If you use high pressure
water, use a water spray nozzle on the pressure
washer which will disperse the water pressure.
See Special Publication, SEBD0518, “Know Your
Cooling System” for the complete procedure for
cleaning the radiator core.

i02318448

Refrigerant Dryer - Replace

SMCS Code: 7322-710

S/N: DBC1–Up

Illustration 192 g00100013

The element is shown with debris.

Use a filter cutter to cut the filter element open.

Spread apart the pleats and inspect the element for
metal and for other debris. An excessive amount of
debris in the filter element can indicate a possible
failure.
If metals are found in the filter element, a magnet can
be used to differentiate between ferrous metals and
nonferrous metals.
Ferrous metals can indicate wear on steel parts and
on cast iron parts.
Nonferrous metals can indicate wear on the
aluminum parts of the engine such as main bearings,
rod bearings, or turbocharger bearings.
Small amounts of debris may be found in the filter
element. This could be caused by friction and by
normal wear. Consult your Caterpillar dealer in order
to arrange for further analysis if an excessive amount
of debris is found.
SEBU7857-05 145
Maintenance Section
Rollover Protective Structure (ROPS) - Inspect

i01696168

Personal injury can result from contact with Rollover Protective Structure
refrigerant. (ROPS) - Inspect
Contact with refrigerant can cause frost bite. SMCS Code: 7323-040; 7325-040
Keep face and hands away to help prevent injury.
S/N: DBC1–Up
Protective goggles must always be worn when re-
frigerant lines are opened, even if the gauges in-
dicate the system is empty of refrigerant. NOTICE
Do not attempt to straighten the ROPS structure. Do
Always use precaution when a fitting is removed. not repair the ROPS by welding reinforcement plates
Slowly loosen the fitting. If the system is still to the structure.
under pressure, release it slowly in a well venti- If there are any cracks in the welds, in the castings,
lated area. or in any metal section of the ROPS, consult your
Personal injury or death can result from inhaling Caterpillar dealer for repairs.
refrigerant through a lit cigarette.
Inhaling air conditioner refrigerant gas through a 1. Inspect the ROPS for loose bolts. Inspect the
lit cigarette or other smoking method or inhaling ROPS for damaged bolts. Replace the damaged
fumes released from a flame contacting air condi- bolts and the missing bolts with original equipment
tioner refrigerant gas, can cause bodily harm or parts only. Torque the bolts to 1050 ± 150 N·m
death. (775 ± 110 lb ft).
Do not smoke when servicing air conditioners or Note: Apply oil to all ROPS bolt threads before you
wherever refrigerant gas may be present.
install the bolt. Failure to apply oil can result in
Use a certified recovery and recycling cart to improper bolt torque.
properly remove the refrigerant from the air con-
ditioning system. 2. Operate the machine on a rough surface. Replace
the ROPS mounting supports if the ROPS makes
a noise or if the ROPS rattles.
NOTICE
If the refrigerant system has been open to the outside If there are any cracks in the welds, in the castings,
air (without being plugged) for more than 30 minutes, or in any metal section of the ROPS, consult your
the receiver-dryer must be replaced. Moisture will en- Caterpillar dealer for repairs.
ter an open refrigerant system and cause corrosion
which will lead to component failure. i04423622

Seat Belt - Inspect

SMCS Code: 7327-040

S/N: DBC1–Up
Always inspect the condition of the seat belt and the
condition of the seat belt mounting hardware before
you operate the machine. Replace any parts that are
damaged or worn before you operate the machine.

Illustration 193 g01159180

Refer to Service Manual, SENR5664, “Air

Conditioning and Heating R-134a for All Caterpillar
Machines” for the proper procedure to change the
receiver-dryer assembly and for the procedure to
reclaim the refrigerant gas.
146 SEBU7857-05
Maintenance Section
Seat Belt - Replace

Illustration 195 g01152685

Illustration 194 g02620101

Typical Example
(1) Date of installation (retractor)
Typical example (2) Date of installation (buckle)
(3) Year of manufacture (tag) (fully extended web)
Inspect buckle (1) for wear or for damage. If the (4) Year of manufacture (underside) (buckle)
buckle is worn or damaged, replace the seat belt.
Consult your Cat dealer for the replacement of the
Inspect seat belt (2) for webbing that is worn or seat belt and the mounting hardware.
frayed. Replace the seat belt if the webbing is worn
or frayed. Determine age of new seat belt before installing on
seat. A manufacture label is on belt webbing and
Inspect all seat belt mounting hardware for wear or imprinted on belt buckle. Do not exceed install by
for damage. Replace any mounting hardware that is date on label.
worn or damaged. Make sure that the mounting bolts
are tight. Complete seat belt system should be installed with
new mounting hardware.
If your machine is equipped with a seat belt
extension, also perform this inspection procedure for Date of installation labels should be marked and
the seat belt extension. affixed to the seat belt retractor and buckle.

Contact your Cat dealer for the replacement of the Note: Date of installation labels should be
seat belt and the mounting hardware. permanently marked by punch (retractable belt) or
stamp (non-retractable belt).
Note: The seat belt should be replaced within 3 years
of the date of installation. A date of installation label If your machine is equipped with a seat belt
is attached to the seat belt retractor and buckle. If the extension, also perform this replacement procedure
date of installation label is missing, replace belt within for the seat belt extension.
3 years from the year of manufacture as indicated on
belt webbing label, buckle housing, or installation i03641375
tags (non-retractable belts).
Secondary Steering - Test
i06891605
(If Equipped)
Seat Belt - Replace SMCS Code: 4300-081-SST
SMCS Code: 7327-510 S/N: DBC1–Up
S/N: DBC1–Up Check the secondary steering system by using the
following procedure:
The seat belt should be replaced within 3 years of the
date of installation. A date of installation label is 1. Install a pressure gauge, and a hose in the
attached to the seat belt retractor and buckle. If the secondary steering system. Install the
date of installation label is missing, replace belt within
3 years from the year of manufacture as indicated on components between the ground driven
belt webbing label, buckle housing, or installation secondary steering pump and the check valve.
tags (non-retractable belts).
SEBU7857-05 147
Maintenance Section
Steering Pump Outlet Screen - Clean

Illustration 196 g00100829 Illustration 197 g01116121

2. Route the pressure gauge to a location that allows

the operator to see the gauge and safely drive the
machine.
3. Start the engine. Operate the machine at
approximately 16 km/h (10 mph).
4. Drive the machine in a straight line.
5. Observe the gauge.
6. If the gauge shows pressure, the secondary
steering pump is working.
7. If the gauge does not show pressure repair the
secondary steering pump or replace the
secondary steering pump. Illustration 198 g00922722

The steering pump outlet screen is located inside the

i02503829
left frame rail of the tractor.
Steering Pump Outlet Screen - Note: Clean the steering pump outlet screen when
Clean there is pump failure or when the pump is changed in
the hydraulic system.
SMCS Code: 4306-070-Z3
1. Remove bolts (1) and elbow (2).
S/N: DBC1–Up
2. Inspect seal (3). If the seal is damaged, replace
seal (3).
3. Remove steering pump outlet screen (4). Clean
the screen and the elbow in a nonflammable
solvent.
4. Install the steering pump outlet screen, the seal,
the elbow, and the bolts.

i02503841

Suction Screen (Transmission

Scavenge) - Clean
SMCS Code: 3030-070-Z3

S/N: DBC1–Up
148 SEBU7857-05
Maintenance Section
Tire Inflation - Check

12. Clean the drain plug. Install the drain plug.

NOTICE
Care must be taken to ensure that fluids are con- 13. Start the engine.
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product. 14. Check the area around the screen housing for
Be prepared to collect the fluid with suitable contain- leaks.
ers before opening any compartment or disassem-
bling any component containing fluids. 15. Check the transmission oil level. Add oil, if
necessary. Refer to Operation and Maintenance
Refer to Special Publication, NENG2500, “Dealer
Manual, “Transmission Oil Level - Check” for the
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products. proper procedure.

Dispose of all fluids according to local regulations 16. Stop the engine.
and mandates.
i02449833

Tire Inflation - Check

SMCS Code: 4203-535-AI

Personal injury can result from improper tire

inflation.
A tire blowout or rim failure can result from im-
proper or misused equipment.
Use a self-inflating chuck and stand behind the
tread when inflating a tire.
Proper inflating equipment, and training in using
Illustration 199 g01124806 the equipment, are necessary to avoid
overinflating.
The suction screen for the transmission is located at
the rear of the transmission. Before inflating tire, put the tire in a restraining
device.
1. Park the machine on level ground. Apply the
parking brake.
2. Lower the bowl to the ground. Shut off the engine.
3. Clean the area around the housing for the suction
screen.
4. Remove drain plug (3). Allow the oil to drain into a
suitable container.
5. Remove bolts (1) for the cover of the suction
screen.
6. Remove cover (2).
7. Remove the suction screen. Clean the suction
screen in nonflammable solvent.
8. Inspect the suction screen for damage. If the
suction screen is damaged, replace the suction
screen.
9. Install the suction screen.
10. Inspect the seal for the cover. Replace the seal if
the seal is damaged.
11. Clean the cover. Install the cover.
SEBU7857-05 149
Maintenance Section
Transmission Breather - Clean

i02503846

Transmission Breather - Clean

SMCS Code: 3030-070-BRE

S/N: DBC1–Up

Illustration 200 g01222964

Illustration 201 g00923124
Measure the pressure of each tire with a tire gauge.
A regular tire gauge will work on tires that are inflated The transmission breather is located on the top of the
with nitrogen. transmission at the right rear of the tractor.

Note: Scraper tires should be inflated with nitrogen Use the following procedure to clean the breather:
gas in order to prevent the tires from exploding. 1. Clean the area around the breather.
1. Park the machine on level ground. Apply the 2. Remove the breather.
parking brake.
3. Wash the breather in clean, nonflammable solvent.
2. Lower the bowl to the ground. Shut off the engine.
4. Allow the breather to dry.
3. Clean the area around the valve stem for the tire.
5. Install the breather.
4. Remove valve stem cap (1).
i02503848
5. Measure the pressure of each tire with a tire
gauge. Add nitrogen gas if the pressure is low. Transmission Oil - Change
6. Install the valve stem cap on the valve stem. SMCS Code: 3030-044
Refer to the following additional information about tire
inflation: S/N: DBC1–Up

• Operation and Maintenance Manual, “Tire Inflation

with Nitrogen”
Hot oil and hot components can cause personal
• Operation and Maintenance Manual, “Tire injury. Do not allow hot oil or hot components to
Shipping Pressure” contact skin.
• Operation and Maintenance Manual, “Tire Inflation
Pressure Adjustment”
Consult your Caterpillar dealer for further information
on the correct operating pressures and the correct
load ratings.
150 SEBU7857-05
Maintenance Section
Transmission Oil Filter and Magnetic Screen - Replace/Clean

NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products.
Dispose of all fluids according to local regulations
and mandates.

Illustration 203 g01253204

(3) Transmission oil filler tube
(4) Transmission sight gauge

6. Clean the area around transmission oil filler tube

(3). Remove the oil filler cap.
7. Fill the transmission with oil through the
transmission oil filler tube to the “FULL” mark in
transmission sight gauge (4). Refer to the
following topics:

• Operation and Maintenance Manual, “Lubricant

Viscosities”
Illustration 202 g01250922 • Operation and Maintenance Manual,
(1) Differential drain plug “Capacities (Refill)”
(2) Transmission drain plug
8. Clean the oil filler cap. Install the oil filler cap.
Transmission drain plug (2) is located under the
tractor. Differential drain plug (1) is closer to the front 9. Start the engine. Run the engine at low idle.
of the machine.
10. Inspect the transmission for leaks.
Note: Operate the machine until the transmission oil
is warm. 11. Slowly operate the transmission control in order
to circulate the oil.
1. Park the machine on a level surface. Apply the
12. Maintain the oil level between the “FULL” and
parking brake.
“ADD” marks on transmission sight gauge (4). Add
2. Lower the bowl to the ground. Stop the engine. oil through the oil filler tube, if necessary.
3. Clean the area around transmission drain plug (2). 13. Stop the engine.
4. Remove the transmission drain plug. Drain the oil
i02503871
into a suitable container.
Note: Clean the suction screen at this time. Refer to Transmission Oil Filter and
Operation and Maintenance Manual, “Suction Screen Magnetic Screen - Replace/
(Transmission Scavenge) - Clean” for the proper
procedure. Clean
SMCS Code: 3030-070-MGS; 3067-510
5. Clean the transmission drain plug and install the
transmission drain plug. S/N: DBC1–Up
SEBU7857-05 151
Maintenance Section
Transmission Oil Filter and Magnetic Screen - Replace/Clean

8. Insert a new filter element into the transmission oil

filter housing.
Hot oil and hot components can cause personal 9. Inspect the seal for the transmission oil filter
injury. Do not allow hot oil or hot components to
contact skin. housing. Replace the seal if the seal is damaged.
10. Install the cover on the transmission oil filter
housing. Install the bolts on the transmission oil
NOTICE filter housing.
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- 11. Install the drain plug in the transmission oil filter
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain- housing.
ers before opening any compartment or disassem-
bling any component containing fluids.
Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable
to collect and contain fluids on Cat products.
Dispose of all fluids according to local regulations
and mandates.

Illustration 205 g01124854

The magnetic screen is located below the

transmission oil filter at the rear of the transmission
housing.
1. Remove drain plug (6). Drain the oil into a suitable
container.
2. Remove bolts (4).
Illustration 204 g01124853 3. Remove cover (5).

Transmission oil filter housing (2) is located on the 4. Remove the magnetic screen.
top left side of the transmission case at the left rear of
the tractor. 5. Separate the magnets from the magnetic screen.
Wash the magnetic screen and the magnets in a
1. Park the machine on level ground. Apply the nonflammable solvent.
parking brake.
Note: Do not rap the magnets on hard objects. The
2. Lower the bowl to the ground. Stop the engine. magnets may be damaged. Replace any damaged
3. Clean the transmission oil filter housing. magnets.

4. Remove drain plug (3). Allow the oil to drain into a 6. Allow the cleaned parts to dry. Use compressed air
suitable container. in order to speed the drying of the parts.
5. Remove bolts (1) from the transmission oil filter 7. Clean the magnets with a towel or clean the
housing. Remove the cover from the transmission magnets with a stiff bristle brush.
oil filter housing. 8. Install the magnets into the magnetic screen.
6. Remove the used filter element and discard the 9. Install the magnetic screen into the transmission
used filter element. housing.
7. Clean the inside of the transmission oil filter 10. Install the cover and the bolts.
housing with a clean towel.
11. Install the drain plug.
152 SEBU7857-05
Maintenance Section
Transmission Oil Level - Check

12. Add transmission oil. Maintain the oil level i02503913

between the “FULL” mark and the “ADD” mark on
the transmission sight gauge. Refer to Operation Transmission Oil Sample -
and Maintenance Manual, “Transmission Oil Level
- Check” for the proper procedure.
Obtain
SMCS Code: 3030-008; 7542-008
13. Start the engine. Run the engine at low idle.
S/N: DBC1–Up
14. Check the transmission oil filter for leaks. Check
the magnetic screen for leaks.
15. Check the oil level of the transmission. Add oil, if
necessary.
16. Stop the engine.

i02503889

Transmission Oil Level - Check

SMCS Code: 3030-535-FLV

S/N: DBC1–Up

Illustration 207 g01124873

The sampling valve for the transmission is located at

the left rear of the tractor.
Refer to Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” “S·O·S Oil
Analysis” for information that pertains to obtaining a
sample of the transmission oil.
Refer to Special Publication, PEHP6001, “How To
Take A Good Oil Sample” for more information about
obtaining a sample of the transmission oil.

i02503917
Illustration 206 g01253192
(1) Transmission oil filler tube Wheel Bearing Oil - Change
(2) Transmission sight gauge
SMCS Code: 4234-044-OC
Transmission sight gauge (2) is located on the back
right side of the transmission. S/N: DBY1–Up
1. Park the machine on level ground. Place the
NOTICE
transmission in NEUTRAL and apply the parking Care must be taken to ensure that fluids are con-
brake. tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product.
2. Lower the bowl to the ground. Run the engine at Be prepared to collect the fluid with suitable contain-
low idle. ers before opening any compartment or disassem-
bling any component containing fluids.
3. Clean the area around transmission sight gauge
(2) and transmission oil filler tube (1). Refer to Special Publication, NENG2500, “Dealer
Service Tool Catalog” for tools and supplies suitable
4. Maintain the oil level between the “FULL” mark and to collect and contain fluids on Cat products.
the “ADD” mark on the transmission sight gauge.
Dispose of all fluids according to local regulations
5. Remove the oil filler cap and add oil, if necessary. and mandates.
6. Clean the oil filler cap and install the oil filler cap.
7. Stop the engine.
SEBU7857-05 153
Maintenance Section
Wheel Bearing Oil Level - Check

Illustration 208 g01128800 Illustration 209 g01128618

The wheel bearings are located on the rear wheels of The wheel bearings are located on the rear wheels of
the scraper. the scraper.
1. Clean the area around cover (1). 1. Clean the surface around the oil filler plug.
Remove the oil filler plug.
2. Loosen bolts (2). Allow the oil to drain into a
suitable container. 2. Ensure that the oil level is maintained at the
bottom of the opening for the oil filler plug.
3. Remove the bolts. Clean the cover. Clean the
wheel. 3. Clean the oil filler plug and install the oil filler plug.
4. Inspect the gasket that is between the cover and Repeat the procedure for the wheel.
the wheel for damage. Replace the gasket, if
necessary. i02446418

5. Install the cover. Install the bolts.

Wheel Coolant Level - Check
6. Remove oil filler plug (3). Fill the wheel bearing
SMCS Code: 4207-535-FLV
with oil. Maintain the oil level at the bottom of the
opening for the oil filler plug. Refer to the following
topics:
With a lack of wheel coolant, personal injury or
• Operation and Maintenance Manual, “Lubricant
death can result. The brakes can generate
Viscosities” enough heat to burn the tire bead. A burning bead
produces gases inside the tire that can explode,
• Operation and Maintenance Manual, endangering personnel within 500 meters (1500
“Capacities (Refill)” feet).
7. Clean the oil filler plug and install the oil filler plug.
Repeat the procedure for the other wheel.

i02503939

Wheel Bearing Oil Level -

Check
SMCS Code: 4234-535-FLV

S/N: DBY1–Up
154 SEBU7857-05
Maintenance Section
Window Washer Reservoir - Fill

NOTICE
Use Caterpillar nonfreezing window washer solvent
or a commercially available windshield washer fluid in
order to prevent freezing of the windshield washer
system.

Illustration 210 g01222390 Illustration 211 g01116175

Check/fill plug (1) for the wheel coolant is located on The window washer reservoir (1) is located inside the
the outer edge of the wheel. engine compartment on the right side of the machine.
Note: The check/fill plug is easily confused with final 1. Remove cap (2).
drive drain plug (2). Refer to Operation and
Maintenance Manual, “Differential and Final Drive Oil 2. Fill the window washer reservoir through the filler
- Change” for the location of the final drive drain plug. tube.
3. Replace cap (2).
1. Check/fill plug (1) must be horizontal with the
center line of the axle in order to check the coolant
i01774940
level. Refer to Illustration 210 .
2. Clean the area around the check/fill plug. Window Wiper - Inspect/
3. Remove the check/fill plug. Antifreeze should be Replace
dripping from the plug hole. SMCS Code: 7305-040; 7305-510
4. Add antifreeze, if necessary. A solution of 50
S/N: DBC1–Up
percent water and 50 percent Caterpillar
antifreeze is preferable. If Caterpillar antifreeze is
not used, commercially available ethylene glycol-
type antifreeze can be used as a substitute.
5. Clean the check/fill plug. Install the check/fill plug.
6. Perform Step 1 through Step 5 for the other
wheels.

i02210505

Window Washer Reservoir -

Fill
SMCS Code: 7306-544
Illustration 212 g00907308
S/N: DBC1–Up
One window wiper is located at the cab front window.
One window wiper is located at the cab rear window.
The window wipers have replaceable wiper blades.
SEBU7857-05 155
Maintenance Section
Windows - Clean

Replace the wiper blades when the following Clean the front, right side, and rear windows from the
conditions occur: top of the engine enclosure. Access this area by
using the ladders and the walkways that are located
• The wiper blades streak the windows of the cab. on the right hand side of the machine. Be sure to use
the areas of the walkways that are covered with a slip
• The wiper blades are damaged. resistant surface. Use the provided handholds on the
cab to maintain a secure position. If necessary, use a
• The wiper blades are worn. squeegee with an extension handle to fully reach
across the front and rear windows.
Note: Damaged wiper blades may cause permanent
damage to the glass of the cab windows. Use commercially available window cleaning
solutions to clean the windows.
i02853227

Windows - Clean
SMCS Code: 7310-070

S/N: DBC1–Up

When cleaning the windows, use the recom-

mended procedure in this manual. Serious injury
or death could result from falling if the appropri-
ate procedure and equipment is not used.

Illustration 213 g01421075

Clean the left side windows of the cab while you are
standing on the ground or on a stable work platform.
Use the appropriate equipment in order to reach the
left side windows. If you are standing on the ground,
use a squeegee with an extension handle.
156 SEBU7857-05
Warranty Section
Warranty Information

Warranty Section 3. New non-road diesel engines installed in

construction machines conforming to the South
Korean regulations for construction machines
Warranty Information manufactured after January 1, 2015, and operated
and serviced in South Korea, including all parts of
their emission control systems (“emission related
i06044323 components”), are:
Emissions Warranty a. Designed, built, and equipped so as to conform,
at the time of sale, with applicable emission
Information standards prescribed in the Enforcement Rule
SMCS Code: 1000 of the Clean Air Conservation Act promulgated
by South Korea MOE.
The certifying engine manufacturer warrants to the
ultimate purchaser and each subsequent purchaser b. Free from defects in materials and
that: workmanship in emission-related components
1. New non-road diesel engines and stationary diesel that can cause the engine to fail to conform to
engines less than 10 liters per cylinder (including applicable emission standards for the warranty
Tier 1 and Tier 2 marine engines < 37 kW, but period.
excluding locomotive and other marine engines) The aftertreatment system can be expected to
operated and serviced in the United States and function properly for the lifetime of the engine
Canada, including all parts of their emission (emissions durability period) subject to prescribed
control systems (“emission related components”), maintenance requirements being followed.
are:
A detailed explanation of the Emission Control
a. Designed, built, and equipped so as to conform, Warranty that is applicable to new non-road and
at the time of sale, with applicable emission stationary diesel engines, including the components
standards prescribed by the United States covered and the warranty period, is found in a
supplemental Special Publication. Consult your
Environmental Protection Agency (EPA) by way authorized Cat dealer to determine if your engine is
of regulation. subject to an Emission Control Warranty and to
b. Free from defects in materials and obtain a copy of the applicable Special Publication.
workmanship in emission-related components
that can cause the engine to fail to conform to
applicable emission standards for the warranty
period.
2. New non-road diesel engines (including Tier 1 and
Tier 2 marine propulsion engines < 37 kW and Tier
1 through Tier 4 marine auxiliary engines < 37 kW,
but excluding locomotive and other marine
engines) operated and serviced in the state of
California, including all parts of their emission
control systems (“emission related components”),
are:
a. Designed, built, and equipped so as to conform,
at the time of sale, to all applicable regulations
adopted by the California Air Resources Board
(ARB).
b. Free from defects in materials and
workmanship which cause the failure of an
emission-related component to be identical in
all material respects to the component as
described in the engine manufacturer's
application for certification for the warranty
period.
SEBU7857-05 157
Reference Information Section
Reference Materials

Reference Information Special Publication, SEBU5898, “Cold Weather

Recommendations for all Caterpillar Machines”
Section Special Publication, SEBU6250, “Caterpillar Machine
Fluids Recommendations”

Reference Materials Special Publication, SELF9001, “Federal Emission

Control Warranty”
i04024587 Specifications, SENR3130, “Torque Specifications”

Reference Material Systems Operation, Testing and Adjusting, and

Disassembly and Assembly, RENR2165, “Comfort
SMCS Code: 1000; 7000 Series Seat for Caterpillar Machines”
The following literature can be obtained from any Cat Video Tape, AEVN5227, “Conventional and Push-
dealer: Pull Scrapers G-Series Operating Tips”
Service Manual, RENR7911, “Product Link 121SR/ Video Tape, PEVN1736, “Caterpillar Air Filter Service
321SR” Indicator”
Service Manual, SENR5664, “Air Conditioning and Parts Manual, SEBP4234, “623G Wheel-Tractor
Heating R-134a for All Caterpillar Machines”
S/N: DBC1–Up
Service Parts, PECP9067, “One Safe Source” ”

Special Instruction, REHS0354, “Charging System Parts Manual, SEBP4235, “623G Scraper
Troubleshooting” S/N: DBY1–Up
”
Special Instruction, REHS1642, “Operation of the
Product Link System” Service Manual, RENR5760, “Specifications,
Systems Operation, Testing and Adjusting,
Special Instruction, SEHS6929, “Inspection, Schematics”
Maintenance, and Repair of ROPS and Attachment Systems Operation, Troubleshooting, and Testing
Installation Guidelines” and Adjusting, RENR7858, “Wheel Tractor-Scrapers
Special Instruction, SEHS7332, “Warning Tag - Caterpillar Monitoring System”
Danger Do Not Operate”
Operation and Maintenance Manuals are available in
Special Instruction, SEHS7633, “Battery Test other languages. Consult your Caterpillar dealer for
Procedure” information about obtaining these Operation and
Maintenance Manuals.
Special Instruction, SEHS9031, “Storage Procedure
for Caterpillar Products” Additional Reference Material
Special Instruction, SEHS9187, “Brake Linings ASTM D2896, “TBN Measurements” The document
Require Conditioning On Machines With Drum can normally be obtained from your local
Brakes” technological society, from your local library, or from
Special Instruction, SMHS7867, “6V-4040 Nitrogen your local college.
Tire Inflation Group” SAE J313, “Diesel Fuels” This can be found in the
SAE handbook. Also, this publication can be
Special Publication, NENG2500, “Caterpillar Dealer obtained from your local technological society, from
Service Tool Catalog” your local library, or from your local college.
Special Publication, PEHP6001, “How to Take a SAE J754, “Nomenclature” This can normally be
Good Oil Sample” found in the SAE handbook.
Special Publication, PEHP7076, “Understanding SAE J183, “Classification” This can normally be
S·O·S Services Test” found in the SAE handbook.
Special Publication, PEWJ0074, “Caterpillar Filter Engine Manufacturers Association, “ Engine Fluids
and Fluid Application Guide” Data Book”
Special Publication, SEBD0518, “Know Your Cooling
System”
Special Publication, SEBD1587, “What ROPS/FOPS
Certification Means”
158 SEBU7857-05
Reference Information Section
Decommissioning and Disposal

Engine Manufacturers Association

Two North LaSalle Street, Suite 2200
Chicago, IL USA 60602
E-mail: [email protected]
(312) 827-8700
Facsimile (312) 827-8737

i07743978

Decommissioning and
Disposal
SMCS Code: 1000; 7000
When the product is removed from service, local
regulations for the product decommissioning will
vary. Disposal of the product will vary with local
regulations.
Improperly disposing of waste can threaten the
environment. Obey all local regulations for the
decommissioning and disposal of materials.
Utilize appropriate personal protective equipment
when decommissioning and disposing product.
Consult the nearest Cat dealer for additional
information. Including information for component
remanufacturing and recycling options.
SEBU7857-05 159
Index Section

Index
A Cooling System Coolant Extender (ELC) -
Add .............................................................. 105
Accumulator (Cushion Hitch) - Check............. 94
Cooling System Coolant Level - Check......... 106
Additional Messages ....................................... 12
Cooling System Coolant Sample (Level 1) -
Adjustments..................................................... 68
Obtain .......................................................... 107
Air Dryer - Check ............................................. 94
Cooling System Coolant Sample (Level 2) -
Air Dryer Desiccant - Replace ......................... 95
Obtain .......................................................... 108
Air Tank Moisture and Sediment - Drain ......... 95
Cooling System Pressure Cap - Clean/
Alternate Exit ................................................... 40
Replace ....................................................... 108
Cooling System Water Temperature
B Regulator - Replace..................................... 109
Backup Alarm .................................................. 52 Crankshaft Vibration Damper - Inspect......... 109
Backup Alarm - Test ........................................ 96 Crushing Prevention and Cutting Prevention.. 18
Battery - Clean/Check ..................................... 96 Cushion-Hitch Control (Joystick)..................... 57
Battery - Recycle ............................................. 96 Cutting Edges and End Bits - Inspect/
Battery Disconnect Switch .............................. 52 Replace ........................................................110
Battery or Battery Cable - Inspect/Replace..... 97
Before Operation ....................................... 24, 38 D
Before Starting Engine .................................... 23
Daily Inspection ............................................... 38
Belts - Inspect/Replace ................................... 97
Declaration of Conformity................................ 37
Inspect ......................................................... 97
Decommissioning and Disposal.................... 158
Replace........................................................ 98
Differential and Final Drive Breather -
Blocking the Bowl ............................................ 68
Clean ............................................................ 111
Bowl Control (Joystick).................................... 55
Differential and Final Drive Oil - Change........ 111
Brake Air System Pressure - Test ................... 98
Differential and Final Drive Oil Level -
Brake Air System Warning Horn - Test............ 98
Check............................................................113
Brake Camshaft Bearing - Lubricate ............... 98
Differential and Final Drive Oil Sample -
Brake Shoes and Drums - Inspect/Replace.... 99
Obtain ...........................................................113
Brakes, Indicators and Gauges - Test ............. 99
Differential Thrust Pin Clearance - Check...... 111
Braking System - Test ..................................... 99
Draft Arm Wear Plates - Check/Adjust...........113
Parking And Secondary Brake Holding Ability
Test........................................................... 100
Service Brake Holding Ability Test............. 100 E
Burn Prevention............................................... 18 Ejector Carrier Rollers - Check/Adjust ...........114
Batteries....................................................... 19 Ejector Carrier Rollers - Inspect/Pack/
Coolant ........................................................ 18 Replace ........................................................115
Oils............................................................... 19 Ejector Control (Joystick) ................................ 55
Ejector Guide Rollers - Check/Adjust.............115
C Ejector Guide Rollers - Inspect/Pack/
Replace ........................................................116
Cab Air Filter - Clean/Replace ...................... 101
Ejector Support Rollers - Check/Adjust..........116
Cleaning the Filters.................................... 101
Ejector Support Rollers - Inspect/Pack/
Capacities (Refill) ............................................ 88
Replace ........................................................116
Circuit Breakers - Reset ................................ 102
Electrical Storm Injury Prevention ................... 23
Circuit Breakers ......................................... 102
Electronic Unit Injector - Inspect/Adjust .........117
Clearance between Elevator Flight and
Elevator Chain - Inspect/Adjust......................117
Cutting Edge - Check/Adjust ....................... 103
Adjust the Elevator Chain ...........................118
Condenser (Refrigerant) - Clean................... 104
Inspect the Elevator Chain .........................117
Cooling System Coolant (ELC) - Change ..... 104
160 SEBU7857-05
Index Section

Elevator Chain Adjustment Cylinder - Battery and Battery Cables.......................... 20

Lubricate.......................................................119 Ether ............................................................ 22
Elevator Chain Idler - Lubricate......................119 Fire Extinguisher.......................................... 22
Elevator Chain Roller - Check/Lubricate....... 120 General ........................................................ 19
Elevator Control (Joystick) .............................. 56 Lines, Tubes, and Hoses ............................. 21
Elevator Drive Tube Roller Bearing - Wiring........................................................... 21
Lubricate...................................................... 120 Floor Rollers - Lubricate ................................ 131
Elevator Speed Control (Joystick)................... 56 Foreword ........................................................... 4
Elevator Speed Reducer - Check/Lubricate . 120 California Proposition 65 Warning ................. 4
Elevator Speed Reducer Oil - Change.......... 121 Certified Engine Maintenance ....................... 5
Emissions Certification Film ............................ 36 Literature Information .................................... 4
Emissions Warranty Information ................... 156 Machine Capacity .......................................... 5
Engine Air Filter Primary Element - Clean/ Maintenance .................................................. 4
Replace ....................................................... 121 Operation ....................................................... 4
Cleaning Primary Air Filter Elements ........ 122 Product Identification Number ....................... 5
Inspecting the Primary Air Filter Safety............................................................. 4
Elements .................................................. 123 Fuel System - Prime...................................... 131
Storing Primary Air Filter Elements ........... 123 Fuel System Primary Filter (Water
Engine Air Filter Secondary Element - Separator) Element - Replace..................... 132
Replace ....................................................... 123 Fuel System Secondary Filter - Replace ...... 133
Engine Air Filter Service Indicator - Inspect .. 124 Fuel System Water Separator - Drain ........... 134
Engine Air Filter Service Indicator - Inspect/ Fuel Tank Cap and Strainer - Clean .............. 135
Replace (If Equipped).................................. 124 Fuel Tank Water and Sediment - Drain ......... 135
Engine Air Precleaner - Clean....................... 125 Fuses - Replace ............................................ 136
Engine and Machine Warm-Up ....................... 66
Engine Oil (High Speed) and Oil Filter - G
Change ........................................................ 125
Engine Oil and Filter - Change ...................... 128 General Hazard Information............................ 15
Engine Oil Level - Check............................... 126 Containing Fluid Spillage............................. 17
Engine Oil Sample - Obtain........................... 127 Dispose of Waste Properly .......................... 18
Engine Shutdown Switch ................................ 52 Fluid Penetration ......................................... 16
Engine Starting.......................................... 24, 66 Inhalation ..................................................... 17
Engine Starting (Alternate Methods)............... 79 Pressurized Air and Water........................... 16
Engine Starting with Auxiliary Start Trapped Pressure ........................................ 16
Receptacle..................................................... 80 General Information ........................................ 32
Engine Starting with Jump Start Cables ......... 79 Guards............................................................. 30
Engine Stopping .............................................. 26 Guards (Operator Protection)
Engine Valve Lash - Check ........................... 129 Other Guards (If Equipped) ......................... 31
Equipment Lowering with Engine Stopped .... 28, Rollover Protective Structure (ROPS), Falling
70 Object Protective Structure (FOPS) or Tip
Lowering The Equipment With Electrical Over Protection Structure (TOPS)............. 31
Power ......................................................... 70
Lowering The Equipment Without Electrical H
Power ......................................................... 71
Heating and Air Conditioning Control.............. 54
Ether Starting Aid Cylinder - Replace ........... 129
Heating and Air Conditioning System
Evaporator Coil and Heater Coil - Clean....... 130
Operation ................................................... 54
Hitch - Inspect................................................ 137
F Hitch - Lubricate ............................................ 137
Fire Extinguisher Location............................... 22 Hydraulic Oil Cooler - Clean.......................... 138
Fire Prevention and Explosion Prevention...... 19 Hydraulic System Oil - Change ..................... 138
Hydraulic System Oil Filter - Replace ........... 141
SEBU7857-05 161
Index Section

Hydraulic System Oil Filter (Gear Pump Every 250 Service Hours ............................. 92
and Case Drain) - Replace .......................... 139 Every 250 Service Hours or Monthly ........... 92
Hydraulic System Oil Filter (Pilot) - Every 3 Years............................................... 93
Replace ....................................................... 140 Every 3000 Service Hours or 2 Years ......... 93
Hydraulic System Oil Level - Check.............. 142 Every 50 Service Hours or Weekly.............. 91
Hydraulic System Oil Sample - Obtain.......... 143 Every 500 Service Hours or 3 Months......... 92
Type 1 ........................................................ 143 Every 6000 Service Hours or 3 Years ......... 93
Type 2 ........................................................ 143 Every Year ................................................... 93
Hydraulic Tank Breaker Relief Valve - Initial 250 Service Hours (or at first oil
Clean ........................................................... 143 change) ...................................................... 91
Initial 50 Service Hours................................ 91
I Initial 500 Hours (for New Systems, Refilled
Systems, and Converted Systems) ........... 92
Identification Information ................................. 34 When Required............................................ 91
Important Safety Information............................. 2 Maintenance Section....................................... 82
Maintenance Support ...................................... 90
J Mirror ............................................................... 43
Mirror Adjustment ........................................ 43
Jacking Location Information .......................... 74
Monitoring System........................................... 58
Jacking/Blocking Locations............................. 74
Indicators ..................................................... 61
Raising and Supporting with a Lift Stand .... 75
Main Display Module ................................... 59
Raising the Machine .................................... 74
Quad Gauge Module ................................... 59
Raising with a Jack and Supporting with
Speedometer, Tachometer and Actual Gear
Blocks ........................................................ 74
Indicator ..................................................... 61
Mounting and Dismounting ............................. 38
L Alternate Exit ............................................... 38
Leaving the Machine ....................................... 71 Machine Access System Specifications...... 38
Lifting and Tying Down the Machine ............... 73
Lifting the Machine....................................... 73 O
Tying down the Machine .............................. 73
Oil Filter - Inspect .......................................... 144
Lubricant Viscosities ....................................... 84
Inspect a Used Filter for Debris ................. 144
Biodiesel ...................................................... 88
Operation......................................................... 26
Coolant Information ..................................... 88
Limiting Conditions and Criteria .................. 26
Diesel Fuel Recommendations ................... 87
Machine Operating Temperature Range ..... 26
Engine Oil .................................................... 84
Machine Operation ...................................... 26
Fuel Additives .............................................. 88
Operation Information ..................................... 61
General Information for Lubricants.............. 84
Braking Operation........................................ 64
Grease Applications .................................... 87
Changing Direction and Speed ................... 63
Other Oil Applications.................................. 85
Differential Lock ........................................... 65
Selecting the Viscosity................................. 84
Operating The Machine ............................... 62
Lubricant Viscosities and Refill Capacities ..... 84
Secondary Steering (If Equipped) ............... 62
Shift Inhibiting .............................................. 63
M Operation Section............................................ 38
Machine Operation .......................................... 40 Operator Controls............................................ 44
Maintenance Interval Schedule....................... 91 12V Power Receptacle (10)......................... 47
Every 10 Service Hours or Daily.................. 91 Bowl Floodlight Switch (13) ......................... 47
Every 1000 Service Hours or 6 Months....... 92 Cigar Lighter (9)........................................... 47
Every 12 000 Service Hours or 6 Years....... 93 Differential Lock Control Switch (28) ........... 51
Every 2000 Service Hours........................... 92 Engine Start Switch (32).............................. 51
Every 2000 Service Hours or 1 Year ........... 92 Engine Start Switch for the Scraper (17) ..... 48
162 SEBU7857-05
Index Section

Engine Start Switch for the Tractor (8) ........ 47 Restricted Visibility .......................................... 25
Fan Speed Control (3) ................................. 46 Roading the Machine ...................................... 72
Headlight Switch (11)................................... 47 Rollover Protective Structure (ROPS) -
Heating and Air Conditioning Switch (1)...... 46 Inspect ......................................................... 145
Interior Dome Light (6)................................. 47
Joystick Control (23) .................................... 49 S
Mode Select Switch (15).............................. 48
Multifunction Switch (18) ............................. 48 S·O·S Information ........................................... 89
Panel Light Switch (29)................................ 51 Safety Messages............................................... 6
Parking Brake Control Switch (26) .............. 50 Crushing Hazard (13) .................................. 12
Rear Window Wiper/Washer Control (4) ..... 46 Crushing Hazard (2) ...................................... 8
Remote Throttle Speed Switch (30) ............ 51 Do Not Operate (1) ........................................ 7
Remote Throttle Switch (31)........................ 51 Do Not Weld On The ROPS/FOPS Structure
Retarder Control (7)..................................... 47 (4)................................................................. 8
Scraper Power Limiter Control Switch Do Not Weld On The ROPS/FOPS Structure
(25)............................................................. 50 (5)................................................................. 9
Scraper Transmission Neutral/Run Control Engine Coolant (11) ......................................11
Switch (14) ................................................. 48 High Compressed Spring (8) ....................... 10
Service Brake Control (20) .......................... 49 High Pressure Cylinder (9) .......................... 10
Side Light Switch (5).................................... 46 Improper Connections For Jump Start Cables
Steering Column Tilt and Telescope Control (10)..............................................................11
(19)............................................................. 49 No Clearance (3) ........................................... 8
Temperature Variable Control (2) ................ 46 Product Link (7) (If Equipped)...................... 10
Throttle Control for the Scraper (21)............ 49 Relieve the Pressure (12).............................11
Throttle Control for the Tractor (22) ............. 49 Seat Belt (6) ................................................... 9
Throttle Lock Control Switch (24) ................ 50 Safety Section ................................................... 6
Tractor-Scraper Select Switch (16) ............. 48 Seat ................................................................. 40
Transmission Control (27) ........................... 51 Seat Belt .......................................................... 41
Warning Hazard Light Switch (12)............... 47 Extension of the Seat Belt ........................... 43
Operator Station .............................................. 30 Seat Belt Adjustment for Non-Retractable
Seat Belts................................................... 41
Seat Belt Adjustment for Retractable Seat
P
Belts ........................................................... 42
Parking ...................................................... 27, 69 Seat Belt - Inspect ......................................... 145
Parking Brake Manual Release....................... 78 Seat Belt - Replace ....................................... 146
Plate Locations and Film Locations ................ 34 Secondary Steering - Test (If Equipped) ....... 146
Certification.................................................. 35 Shipping the Machine...................................... 72
Product Information Section............................ 32 Slope Operation .............................................. 27
Product Link .................................................... 53 Sound Information and Vibration
Data Broadcasts .......................................... 53 Information..................................................... 28
Operation in a Blast Site for Product Link Sound Level Information.............................. 28
Radios ........................................................ 53 Sound Level Information for Machines in
European Union Countries and in Countries
R that Adopt the “European Union
Directives” .................................................. 28
Radiator Core - Clean ................................... 144 Sources........................................................ 30
Rated Load ...................................................... 32 “The European Union Physical Agents
Reference Information Section ..................... 157 (Vibration) Directive 2002/44/EC”.............. 28
Reference Material ........................................ 157 Specifications .................................................. 32
Additional Reference Material ................... 157 Intended Use ............................................... 32
Reference Materials ...................................... 157 Steering Pump Outlet Screen - Clean........... 147
Refrigerant Dryer - Replace .......................... 144
SEBU7857-05 163
Index Section

Stopping the Engine ........................................ 69

Stopping The Engine From Outside Of The
Operator Compartment.............................. 69
Stopping The Engine From The Operator
Compartment ............................................. 69
Stopping the Engine if an Electrical
Malfunction Occurs........................................ 70
Stopping the Machine...................................... 69
Suction Screen (Transmission Scavenge) -
Clean ........................................................... 147

T
Table of Contents .............................................. 3
Tire Inflation - Check ..................................... 148
Tire Inflation Information.................................. 82
Tire Inflation Pressure Adjustment .................. 83
Tire Inflation with Nitrogen............................... 82
Tire Information ............................................... 22
Tire Shipping Pressure.................................... 82
Towing Information .......................................... 76
Towing the Machine......................................... 76
Running Engine ........................................... 77
Stopped Engine ........................................... 77
Transmission Breather - Clean ..................... 149
Transmission Control ...................................... 54
Transmission Hold Control (Joystick) ............. 57
Transmission Oil - Change............................ 149
Transmission Oil Filter and Magnetic
Screen - Replace/Clean .............................. 150
Transmission Oil Level - Check..................... 152
Transmission Oil Sample - Obtain ................ 152
Transportation Information .............................. 72

V
Visibility Information ........................................ 24

W
Warranty Information..................................... 156
Warranty Section ........................................... 156
Welding on Machines and Engines with
Electronic Controls ........................................ 90
Wheel Bearing Oil - Change.......................... 152
Wheel Bearing Oil Level - Check .................. 153
Wheel Coolant Level - Check........................ 153
Window Washer Reservoir - Fill .................... 154
Window Wiper - Inspect/Replace .................. 154
Windows - Clean ........................................... 155
Product and Dealer Information
Note: For product identification plate locations, see the section “Product Identification Information” in the Operation
and Maintenance Manual.

Delivery Date:

Product Information
Model:

Product Identification Number:

Engine Serial Number:

Transmission Serial Number:

Generator Serial Number:

Attachment Serial Numbers:

Attachment Information:

Customer Equipment Number:

Dealer Equipment Number:

Dealer Information
Name: Branch:

Address:

Dealer Contact Phone Number Hours

Sales:

Parts:

Service:
SEBU7857 CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade
©2019 Caterpillar dress as well as corporate and product identity used herein, are trademarks of Caterpillar and
All Rights Reserved may not be used without permission.

166 May 2019