KEBU7583-01 (en-us)

September 2017

Operation and
Maintenance
Manual
Preliminary Information

RM500B Rotary Mixer

MB9 1-UP (Machine)
TAS 1-UP (Machine)

SAFETY.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.
KEBU7583-01 3
Table of Contents

Table of Contents Sound Information and Vibration Information . 29

Operator Station .............................................. 31

Foreword ........................................................... 5
Guards (Operator Protection) ......................... 31
Safety Section

Safety Messages............................................... 7
Product Information Section

General Information ........................................ 33

Additional Messages ....................................... 13
Identification Information ................................. 38
General Hazard Information............................ 15

Crushing Prevention and Cutting Prevention.. 18 Operation Section

Burn Prevention............................................... 18 Before Operation ............................................. 43

Fire Prevention and Explosion Prevention...... 19 Machine Operation .......................................... 45

Fire Extinguisher Location............................... 22 Engine Starting................................................ 81

Tire Information ............................................... 22 Machine Service.............................................. 83

Electrical Storm Injury Prevention ................... 23 Parking ............................................................ 88

High Pressure Fuel Lines ................................ 23 Machine Cleanup ............................................ 93

Before Starting Engine .................................... 24 Transportation Information .............................. 94

Engine Starting................................................ 24 Towing Information .......................................... 98

Before Operation ............................................. 25 Engine Starting (Alternate Methods)............... 99

Restricted Visibility .......................................... 25 Maintenance Section

Visibility Information ........................................ 25 Maintenance Access ..................................... 101

Operation......................................................... 26 Tire Inflation Information................................ 103

Operation......................................................... 27 Lubricant Viscosities and Refill Capacities ... 105

Engine Stopping .............................................. 27 Maintenance Support .................................... 121

Engine Stopping .............................................. 28 Maintenance Interval Schedule..................... 122

Parking ............................................................ 28 Maintenance Interval Schedule..................... 125

Parking ............................................................ 28 Warranty Section

Slope Operation .............................................. 28 Warranty Information..................................... 191

Equipment Lowering with Engine Stopped ..... 29 Reference Information Section

4 KEBU7583-01
Table of Contents

Reference Materials ...................................... 192

Index Section

Index.............................................................. 194
KEBU7583-01 5
Foreword

Foreword Maintenance Intervals

Literature Information
This manual should be stored in the operator's
compartment in the literature holder or seat back
literature storage area.
This manual contains safety information, operation
instructions, transportation information, lubrication
information and maintenance information.
Some photographs or illustrations in this publication
show details or attachments that can be different
from your machine. Guards and covers might have
been removed for illustrative purposes.
Continuing improvement and advancement of
product design might have caused changes to your
machine which are not included in this publication.
Read, study and keep this manual with the machine.
Whenever a question arises regarding your machine,
or this publication, please consult your Cat dealer for
the latest available information.
Safety
The safety section lists basic safety precautions. In
addition, this section identifies the text and locations
of warning signs and labels used on the machine.
Read and understand the basic precautions listed in
the safety section before operating or performing
lubrication, maintenance and repair on this machine.
Operation
The operation section is a reference for the new
operator and a refresher for the experienced
operator. This section includes a discussion of
gauges, switches, machine controls, attachment
controls, transportation and towing information.
Photographs and illustrations guide the operator
through correct procedures of checking, starting,
operating and stopping the machine.
Operating techniques outlined in this publication are
basic. Skill and techniques develop as the operator
gains knowledge of the machine and its capabilities.
Use the service hour meter to determine servicing
intervals. Calendar intervals shown (daily, weekly,
monthly, etc.) can be used instead of service hour
meter intervals if they provide more convenient
servicing schedules and approximate the indicated
service hour meter reading. Recommended service
should always be performed at the interval that
occurs first.
Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is specified
in the maintenance intervals chart might be
necessary.
Perform service on items at multiples of the original
requirement. For example, at every 500 service
hours or 3 months, also service those items listed
under every 250 service hours or monthly and every
10 service hours or daily.
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm.
Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands
after handling.
Certified Engine Maintenance
Proper maintenance and repair is essential to keep
the engine and machine systems operating correctly.
As the heavy duty off-road diesel engine owner, you
are responsible for the performance of the required
maintenance listed in the Owner Manual, Operation
and Maintenance Manual, and Service Manual.

Maintenance
The maintenance section is a guide to equipment
care. The Maintenance Interval Schedule (MIS) lists
the items to be maintained at a specific service
interval. Items without specific intervals are listed
under the "When Required" service interval. The
Maintenance Interval Schedule lists the page number
for the step-by-step instructions required to
accomplish the scheduled maintenance. Use the
Maintenance Interval Schedule as an index or "one
safe source" for all maintenance procedures.
6 KEBU7583-01
Foreword

It is prohibited for any person engaged in the Machines and generator sets produced before First
business of repairing, servicing, selling, leasing, or Quarter 2001 will maintain their 8 character PIN
trading engines or machines to remove, alter, or format.
render inoperative any emission related device or
element of design installed on or in an engine or Components such as engines, transmissions, axles,
machine that is in compliance with the regulations etc. and work tools will continue to use an 8 character
Serial Number (S/N).
(40 CFR Part 89). Certain elements of the machine
and engine such as the exhaust system, fuel system,
electrical system, intake air system and cooling
system may be emission related and should not be
altered unless approved by Caterpillar.

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

Cat Product Identification Number

Effective First Quarter 2001 the Cat Product
Identification Number (PIN) has changed from 8 to 17
characters. In an effort to provide uniform equipment
identification, Caterpillar and other construction
equipment manufacturers are moving to comply with
the latest version of the product identification
numbering standard. Non-road machine PINs are
defined by ISO 10261. The new PIN format will apply
to all Cat 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 g00751314

Where:
1. Caterpillar's World Manufacturing Code
(characters 1-3)
2. Machine Descriptor (characters 4-8)
3. Check Character (character 9)
4. Machine Indicator Section (MIS) or Product
Sequence Number (characters 10-17). These were
previously referred to as the Serial Number.
KEBU7583-01 7
Safety Section
Safety Messages

Safety Section
i05692389

Safety Messages
SMCS Code: 7000; 7405
There are several specific safety messages on this
machine. The exact location of the hazards and the
description of the hazards are reviewed in this
section. 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 Cat dealer can provide new
safety messages.
8 KEBU7583-01
Safety Section
Safety Messages

Illustration 2 g03615360

Do Not Operate (1)

This safety message is located on the operator
console.
KEBU7583-01
Illustration 3 g01370904
Do not operate or work on this machine unless
you have read and understand the instructions
and warnings in the Operation and Maintenance
Manual. Failure to follow the instructions or heed
the warnings could result in injury or death. Con-
tact any Caterpillar dealer for replacement man-
uals. Proper care is your responsibility.
Seat Belt (2)
This safety message is located in the cab.
Illustration 4 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.
Failure to wear a seat belt during machine opera-
tion may result in serious injury or death.
Product Link (3)
If equipped, this safety message is positioned in the
cab.
9
Safety Section
Safety Messages
Illustration 5 g01370917
This machine is equipped with a Caterpillar Prod-
uct Link communication device. When electric
detonators are used, this communication device
should be deactivated within 12 m (40 ft) of a
blast site for satellite-based systems and within
3 m (10 ft) of a blast site for cellular based sys-
tems, or within the distance mandated under ap-
plicable legal requirements. Failure to do so
could cause interference with blasting operations
and result in serious injury or death.
In cases where the type of Product Link module
cannot be identified, Caterpillar recommends that
the device be disabled no less than 12 m (40 ft)
from the blast perimeter.
Refer to Operation and Maintenance Manual ,
“Product Link” for further information.
Crush Hazard (4)
This safety message is located on the rear door
assembly.
10 KEBU7583-01
Safety Section
Safety Messages

Illustration 6 g01381178 Illustration 7 g01950122

No clearance for people with door closed. Always Rotor movement can cause injury or death. Stay
use door lock when working under hood. Door clear of the rotor when the engine is running.
closing on person can cause serious injury. Shut off the engine before performing any service
on the rotor or its housing.

Cutter Hazard and Rotor Movement

Hazard, Stay Back (5)
This safety message is located on both the left side
and the right side of the mixing chamber.
Flying Debris Hazard (Read the
Operation and Maintenance Manual
(6)
This safety message is located on both the left side
and the right side of the mixing chamber.
KEBU7583-01 11
Safety Section
Safety Messages

Illustration 8 g03615656 Illustration 9 g01953247

Flying debris may cause serious personal injury Do not operate this machine if the rotor service
or death. Maintain a minimum distance of 10 m panel door is not closed and secured.
(33 ft).

Improper Connections for Jump

Crush Hazard (Read the Operation
and Maintenance Manual (7)
This safety message is located on both the left side
and the right side of the mixing chamber.
Start Cables (8)
This safety message is located near the battery box
on the left side of the machine.
12 KEBU7583-01
Safety Section
Safety Messages

Illustration 11 g01372254

Do not use aerosol types of starting aids such as

ether. Such use could result in an explosion and
Illustration 10 g01409730 personal injury.

Hot Fluid Under Pressure (10)

IMPROPER JUMPER CABLE CONNECTIONS
CAN CAUSE EXPLOSION RESULTING IN PER- This safety message is located near the coolant
SONAL INJURY. pressure cap.

BATTERIES MAY BE LOCATED IN SEPARATE

COMPARTMENTS. WHEN USING JUMPER CA-
BLES, ALWAYS CONNECT POSITIVE (+) CABLE
TO POSITIVE (+) TERMINAL OF BATTERY CON-
NECTED TO STARTER SOLENOID AND NEGA-
TIVE (-) CABLE FROM EXTERNAL SOURCE TO
STARTER NEGATIVE (-) TERMINAL (IF MACHINE
NOT EQUIPPED WITH STARTER NEGATIVE TER-
MINAL, CONNECT TO ENGINE BLOCK.) FOLLOW
PROCEDURE IN THE OPERATION MANUAL.

Explosion Hazard (Ether) (9)

This safety message is located on the air cleaner
cover.
KEBU7583-01 13
Safety Section
Additional Messages

Illustration 12 g01371640

At operating temperature, the engine coolant is

hot and under pressure.
Steam can cause personal injury.
Check the coolant level only after the engine has
been stopped and the fill cap is cool enough to
touch with your bare hand.
Remove the fill cap slowly to relieve pressure.
Cooling system conditioner contains alkali. Avoid
contact with the skin and eyes to prevent person-
al injury.

i05696910

Additional Messages
SMCS Code: 1000; 7000; 7405
14 KEBU7583-01
Safety Section
Additional Messages

Illustration 13 g03617381

Wait to Disconnect Lamp (1)

Illustration 14 g03408962
Purge notice message

This notice is located next to the battery disconnect

switch.
KEBU7583-01
NOTICE
Do not turn the battery power disconnect switch off
until indicator lamp has turned off. If the switch is
turned off when the light is illuminated then the DEF
system will not purge and DEF could freeze and
cause damage to the pump and lines.
Data Privacy (2)
Illustration 15 g01418953
The Product Link System is a satellite communication
device that transmits information regarding the
machine back to Caterpillar and Caterpillar dealers
and customers. All logged events and diagnostic
codes that are available to the Caterpillar Electronic
Technician (ET) on the CAT data link can be sent to
the satellite. Information can also be sent to the
Product Link System. The information is used to
improve Caterpillar products and Caterpillar services.
15
Safety Section
General Hazard Information
Refer to Operation and Maintenance Manual,
“Product Link” for more information.
i07046904
General Hazard Information
SMCS Code: 7000
Illustration 16 g00104545
Typical example
Attach a “Do Not Operate” warning tag or a similar
warning tag to the start switch or to the controls.
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 in order to
maintain proper clearance when you operate the
equipment near fences or near boundary obstacles.
Be aware of high voltage power lines and power
cables that are buried. If the machine comes in
contact with these hazards, serious injury or death
may occur from electrocution.
16
Safety Section
General Hazard Information
Illustration 17 g00702020
Wear a hard hat, protective glasses, and other
protective equipment, as required.
Do not wear loose clothing or jewelry that can snag
on controls or on other parts of the equipment.
Make sure that all protective guards and all covers
are secured in place on the equipment.
Keep the equipment free from foreign material.
Remove debris, oil, tools, and other items from the
deck, from walkways, and from steps.
Secure all loose items such as lunch boxes, tools,
and other items that are not a part of the equipment.
Know the appropriate work site hand signals and the
personnel that are authorized to give the hand
signals. Accept hand signals from one person only.
Do not smoke when you service an air conditioner.
Also, do not smoke if refrigerant gas may be present.
Inhaling the fumes that are released from a flame that
contacts air conditioner refrigerant can cause bodily
harm or death. Inhaling gas from air conditioner
refrigerant through a lighted cigarette can cause
bodily harm or death.
Never put maintenance fluids into glass containers.
Drain all liquids into a suitable container.
Obey all local regulations for the disposal of liquids.
Use all cleaning solutions with care. Report all
necessary repairs.
Do not allow unauthorized personnel on the
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.
KEBU7583-01
When you perform maintenance above ground level,
use appropriate devices such as ladders or man lift
machines. If equipped, use the machine anchorage
points and use approved fall arrest harnesses and
lanyards.
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
effective chip deflector and personal protective
equipment. The maximum water pressure for
cleaning purposes must be below 275 kPa (40 psi).
Avoid direct spraying of water on electrical
connectors, connections, and components. When
using air for cleaning, allow the machine to cool to
reduce the possibility of fine debris igniting when re-
deposited on hot surfaces.
Trapped Pressure
Pressure can be trapped in a hydraulic system.
Releasing trapped pressure can cause sudden
machine movement or attachment movement. Use
caution if you disconnect hydraulic lines or fittings.
High-pressure oil that is released can cause a hose
to whip. High-pressure oil that is released can cause
oil to spray. Fluid penetration can cause serious
injury and possible death.
Fluid Penetration
Pressure can be trapped in the hydraulic circuit long
after the machine has been stopped. The pressure
can cause hydraulic fluid or items such as pipe plugs
to escape rapidly if the pressure is not relieved
correctly.
Do not remove any hydraulic components or parts
until pressure has been relieved or personal injury
may occur. Do not disassemble any hydraulic
components or parts until pressure has been relieved
or personal injury may occur. Refer to the Service
Manual for any procedures that are required to
relieve the hydraulic pressure.
KEBU7583-01
Illustration 18 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
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury.
Containing Fluid Spillage
Care must be taken in order to ensure that fluids are
contained during performance of inspection,
maintenance, testing, adjusting, and repair of the
equipment. Prepare to collect the fluid with suitable
containers before opening any compartment or
disassembling any component that contains fluids.
Refer to Special Publication, NENG2500, “Cat dealer
Service Tool Catalog” for the following items:
• Tools that are suitable for collecting fluids and
equipment that is suitable for collecting fluids
• Tools that are suitable for containing fluids and
equipment that is suitable for containing fluids
17
Safety Section
General Hazard Information
Obey all local regulations for the disposal of liquids.
Inhalation
Illustration 19 g02159053
Exhaust
Use caution. Exhaust fumes can be hazardous to
your health. If you operate the machine in an
enclosed area, adequate ventilation is necessary.
Asbestos Information
Cat equipment and replacement parts that are
shipped from Caterpillar are asbestos free.
Caterpillar recommends the use of only genuine Cat
replacement parts. Use the following guidelines when
you handle any replacement parts that contain
asbestos or when you handle asbestos debris.
Use caution. Avoid inhaling dust that might be
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is 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
Safety Section
Crushing Prevention and Cutting Prevention
• Use exhaust ventilation on permanent machining
jobs.
• Wear an approved respirator if there is no other
way to control the dust.
• Comply with applicable rules and regulations for
the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”. In Japan,
use the requirements found in the “Ordinance on
Prevention of Health Impairment due to Asbestos”
in addition to the requirements of the Industrial
Safety and Health Act.
• Obey environmental regulations for the disposal of
asbestos.
• Stay away from areas that might have asbestos
particles in the air.
Dispose of Waste Properly
Illustration 20 g00706404
Improperly disposing of waste can threaten the
environment. Potentially harmful fluids should be
disposed of according to local regulations.
Always use leakproof containers when you drain
fluids. Do not pour waste onto the ground, down a
drain, or into any source of water.
i01359664
Crushing Prevention and
Cutting Prevention
SMCS Code: 7000
Support the equipment properly before you perform
any work or maintenance beneath that equipment.
Do not depend on the hydraulic cylinders to hold up
the equipment. Equipment can fall if a control is
moved, or if a hydraulic line breaks.
KEBU7583-01
Do not work beneath the cab of the machine unless
the cab is properly supported.
Unless you are instructed otherwise, never attempt
adjustments while the machine is moving or while the
engine is running.
Never jump across the starter solenoid terminals in
order to start the engine. Unexpected machine
movement could result.
Whenever there are equipment control linkages the
clearance in the linkage area will change with the
movement of the equipment or the machine. Stay
clear of areas that may have a sudden change in
clearance with machine movement or equipment
movement.
Stay clear of all rotating and moving parts.
If it is necessary to remove guards in order to perform
maintenance, always install the guards after the
maintenance is performed.
Keep objects away from moving fan blades. The fan
blade will throw objects or cut objects.
Do not use a kinked wire cable or a frayed wire cable.
Wear gloves when you handle wire cable.
When you strike a retainer pin with force, the retainer
pin can fly out. The loose retainer pin can injure
personnel. Make sure that the area is clear of people
when you strike a retainer pin. To avoid injury to your
eyes, wear protective glasses when you strike a
retainer pin.
Chips or other debris can fly off an object when you
strike the object. Make sure that no one can be
injured by flying debris before striking any object.
i04760300
Burn Prevention
SMCS Code: 7000
Do not touch any part of an operating engine. Allow
the engine to cool before any maintenance is
performed on the engine. Relieve all pressure in the
air system, in the oil system, in the lubrication
system, in the fuel system, or in the cooling system
before any lines, fittings, or related items are
disconnected.
Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.
Any contact with hot coolant or with steam can cause
severe burns. Allow cooling system components to
cool before the cooling system is drained.
KEBU7583-01
Check the coolant level only after the engine has
been stopped.
Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to touch
with a bare hand. Remove the filler cap slowly in
order to relieve pressure.
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.
Oils
Hot oil and hot components can cause personal
injury. Do not allow hot oil to contact the skin. Also,
do not allow hot components to contact the skin.
Remove the hydraulic tank filler cap only after the
engine has been stopped. The filler cap must be cool
enough to touch with a bare hand. Follow the
standard procedure in this manual in order to remove
the hydraulic tank filler cap.
Batteries
The liquid in a battery is an electrolyte. Electrolyte is
an acid that can cause personal injury. Do not allow
electrolyte to contact the skin or the eyes.
Do not smoke while checking the battery electrolyte
levels. Batteries give off flammable fumes which can
explode.
19
Safety Section
Fire Prevention and Explosion Prevention
Always wear protective glasses when you work with
batteries. Wash hands after touching batteries. The
use of gloves is recommended.
i06180998
Fire Prevention and Explosion
Prevention
SMCS Code: 7000
Illustration 21 g00704000
General
All fuels, most lubricants, and some coolant mixtures
are flammable.
To minimize the risk of fire or explosion, Caterpillar
recommends the following actions.
Always perform a Walk-Around Inspection, which
may help you identify a fire hazard. Do not operate a
machine when a fire hazard exists. Contact your 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
Safety Section
Fire Prevention and Explosion Prevention
Do not operate the machine near any flame.
Keep shields in place. Exhaust shields (if equipped)
protect hot exhaust components from oil spray or fuel
spray in case of a break in a line, in a hose, or in a
seal. Exhaust shields must be installed correctly.
Do not weld or flame cut on tanks or lines that contain
flammable fluids or flammable material. Empty and
purge the lines and tanks. Then clean the lines and
tanks with a nonflammable solvent prior to welding or
flame cutting. Ensure that the components are
properly grounded in order to avoid unwanted arcs.
Dust that is generated from repairing nonmetallic
hoods or fenders may be flammable and/or
explosive. Repair such components in a well
ventilated area away from open flames or sparks.
Use suitable Personal Protection Equipment (PPE).
Inspect all lines and hoses for wear or deterioration.
Replace damaged lines and hoses. The lines and the
hoses should have adequate support and secure
clamps. Tighten all connections to the recommended
torque. Damage to the protective cover or insulation
may provide fuel for fires.
Store fuels and lubricants in properly marked
containers away from unauthorized personnel. Store
oily rags and flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials.
Illustration 22 g03839130
Use caution when you are fueling a machine. Do not
smoke while you are fueling a machine. Do not fuel a
machine near open flames or sparks. Do not use cell
phones or other electronic devices while you are
refueling. Always stop the engine before fueling. Fill
the fuel tank outdoors. Properly clean areas of
spillage.
KEBU7583-01
Avoid static electricity risk when fueling. Ultra low
sulfur diesel (ULSD) poses a greater static ignition
hazard than earlier diesel formulations with a higher
sulfur content. Avoid death or serious injury from fire
or explosion. Consult with your fuel or fuel system
supplier to ensure that the delivery system is in
compliance with fueling standards for proper
grounding and bonding practices.
Never store flammable fluids in the operator
compartment of the machine.
Battery and Battery Cables
Illustration 23 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
explosion.
Gases from a battery can explode. Keep any open
flames or sparks away from the top of a battery. Do
not smoke in battery charging areas. Do not use cell
phones or other electronic devices in battery
charging areas.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter in
order to check the battery charge.
KEBU7583-01
Daily inspect battery cables that are in areas that are
visible. Inspect cables, clips, straps, and other
restraints for damage. Replace any damaged parts.
Check for signs of the following, which can occur
over time due to use and environmental factors:
• Fraying
• Abrasion
• Cracking
• Discoloration
• Cuts on the insulation of the cable
• Fouling
• Corroded terminals, damaged terminals, and
loose terminals
Replace damaged battery cable(s) and replace any
related parts. Eliminate any fouling, which may have
caused insulation failure or related component
damage or wear. Ensure that all components are
reinstalled correctly.
An exposed wire on the battery cable may cause a
short to ground if the exposed area comes into
contact with a grounded surface. A battery cable
short produces heat from the battery current, which
may be a fire hazard.
An exposed wire on the ground cable between the
battery and the disconnect switch may cause the
disconnect switch to be bypassed if the exposed area
comes into contact with a grounded surface. This
may result in an unsafe condition for servicing the
machine. Repair components or replace components
before servicing the machine.
Fire on a machine can result in personal injury or
death. Exposed battery cables that come into
contact with a grounded connection can result in
fires. Replace cables and related parts that show
signs of wear or damage. Contact your Cat
dealer.
Wiring
Check electrical wires daily. If any of the following
conditions exist, replace parts before you operate the
machine.
• Fraying
• Signs of abrasion or wear
• Cracking
• Discoloration
21
Safety Section
Fire Prevention and Explosion Prevention
• Cuts on insulation
• Other damage
Make sure that all clamps, guards, clips, and straps
are reinstalled correctly. This will help to prevent
vibration, rubbing against other parts, and excessive
heat during machine operation.
Attaching electrical wiring to hoses and tubes that
contain flammable fluids or combustible fluids should
be avoided.
Consult your Cat dealer for repair or for replacement
parts.
Keep wiring and electrical connections free of debris.
Lines, Tubes, and Hoses
Do not bend high-pressure lines. Do not strike high-
pressure lines. Do not install any lines that are bent
or damaged. Use the appropriate backup wrenches
in order to tighten all connections to the
recommended torque.
Illustration 24 g00687600
Check lines, tubes, and hoses carefully. Wear
Personal Protection Equipment (PPE) in order to
check for leaks. Always use a board or cardboard
when you check for a leak. Leaking fluid that is under
pressure can penetrate body tissue. Fluid penetration
can cause serious injury and possible death. A pin
hole leak can cause severe injury. If fluid is injected
into your skin, you must get treatment immediately.
Seek treatment from a doctor that is familiar with this
type of injury.
Replace the affected parts if any of the following
conditions are present:
• End fittings are damaged or leaking.
• Outer coverings are chafed or cut.
• Wires are exposed.
• Outer coverings are swelling or ballooning.
• Flexible parts of the hoses are kinked.
22
Safety Section
Fire Extinguisher Location
• Outer covers have exposed embedded armoring.
• End fittings are displaced.
Make sure that all clamps, guards, and heat shields
are installed correctly. During machine operation, this
will help to prevent vibration, rubbing against other
parts, excessive heat, and failure of lines, tubes, and
hoses.
Do not operate a machine when a fire hazard exists.
Repair any lines that are corroded, loose, or
damaged. Leaks may provide fuel for fires. Consult
your Cat dealer for repair or for replacement parts.
Use genuine Cat parts or the equivalent, for
capabilities of both the pressure limit and
temperature limit.
Ether
Ether (if equipped) is commonly used in cold-weather
applications. Ether is flammable and poisonous.
Only use approved Ether canisters for the Ether
dispensing system fitted to your machine, do not
spray Ether manually into an engine, follow the
correct cold engine starting procedures. Refer to the
section in the Operation and Maintenance Manual
with the label “Engine Starting” .
Use ether in ventilated areas. Do not smoke while
you are replacing an ether cylinder.
Do not store ether cylinders in living areas or in the
operator compartment of a machine. Do not store
ether cylinders in direct sunlight or in temperatures
above 49° C (120.2° F). Keep ether cylinders away
from open flames or sparks.
Dispose of used ether cylinders properly. Do not
puncture an ether cylinder. Keep ether cylinders
away from unauthorized personnel.
Fire Extinguisher
As an additional safety measure, keep a fire
extinguisher on the machine.
Be familiar with the operation of the fire extinguisher.
Inspect the fire extinguisher and service the fire
extinguisher regularly. Follow the recommendations
on the instruction plate.
KEBU7583-01
Consider installation of an aftermarket Fire
Suppression System, if the application and working
conditions warrant the installation.
i05697573
Fire Extinguisher Location
SMCS Code: 7000; 7419
Any modifications to the inside of the operator station
should not project into the operator space. The
addition of a radio, fire extinguisher, and other
equipment must be installed so that the defined
operator space is maintained. Any item that is
brought into the cab should not project into the
defined operator space. A lunch box or other loose
items must be secured. Objects must not pose a
hazard in rough terrain or in the event of a rollover.
Illustration 25 g03617999
Mount the fire extinguisher to the left of the operator
seat at the base.
Note: Care should be taken in mounting the fire
extinguisher in order to prevent damage to wiring
under the seat base.
i06164462
Tire Information
SMCS Code: 7000
Explosions of air inflated tires have resulted from
heat-induced gas combustion inside the tires.
Explosions can be caused by heat that is generated
by welding, by heating rim components, by external
fire, or by excessive use of brakes.
A tire explosion is much more violent than a blowout.
The explosion can propel the tire, the rim
components, and the axle components from the
machine. Stay out of the trajectory path. Both the
force of the explosion and the flying debris can cause
property damage, personal injury, or death.
KEBU7583-01
Illustration 26 g02166933
Typical example of tire is shown
Do not approach a hot or an apparently damaged
tire.
Caterpillar recommends against using water or
calcium as a ballast for the tires except in machines
designed for this additional mass. For those
applicable machines, the maintenance section will
contain instructions on the correct tire inflation and
filling procedures. Ballast, such as fluid in the tires,
increases overall machine weight and may affect
braking, steering, power train components, or the
certification of the protective structure such as the
ROPS. The use of tire/rim rust preventatives or other
liquid additives is not required.
Proper nitrogen inflation equipment, and training
in using the equipment, are necessary to avoid
over inflation. A tire blowout or rim failure can re-
sult from improper or misused equipment and
personal injury or death can occur.
A tire blowout and/or rim failure can occur if the
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
are necessary. A tire blowout or a rim failure can
result from improper equipment or from misused
equipment.
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
Prevention
SMCS Code: 7000
When lightning is striking in the vicinity of the
machine, the operator should never attempt the
following procedures:
• Mount the machine.
• Dismount the machine.
If you are in the operator's station during an electrical
storm, stay in the operator's station. If you are on the
ground during an electrical storm, stay away from the
vicinity of the machine.
i02546320
High Pressure Fuel Lines
SMCS Code: 1000; 1252; 1274; 7000
S/N: MB91–Up
Contact with high pressure fuel may cause fluid
penetration and burn hazards. High pressure fuel
spray may cause a fire hazard. Failure to follow
these inspection, maintenance and service in-
structions may cause personal injury or death.
The high pressure fuel lines are the fuel lines that are
between the high pressure fuel pump and the high
pressure fuel manifold and the fuel lines that are
between the fuel manifold and cylinder head. These
fuel lines are different from fuel lines on other fuel
systems.
This is because of the following differences:
• The high pressure fuel lines are constantly
charged with high pressure.
• The internal pressures of the high pressure fuel
lines are higher than other types of fuel system.
24 KEBU7583-01
Safety Section
Before Starting Engine

• The high pressure fuel lines are formed to shape
and then strengthened by a special process.
Do not step on the high pressure fuel lines. Do not
deflect the high pressure fuel lines. Do not bend or
strike the high pressure fuel lines. Deformation or
damage of the high pressure fuel lines may cause a
point of weakness and potential failure.
Do not check the high pressure fuel lines with the
engine or the starting motor in operation. After the
engine has stopped allow 10 minutes to pass in order
to allow the pressure to be purged before any service
or repair is performed on the engine fuel lines.
Do not loosen the high pressure fuel lines in order to
remove air from the fuel system. This procedure is
not required.
Visually inspect the high pressure fuel lines before
the engine is started. This inspection should be each
day.
If you inspect the engine in operation, always use the
proper inspection procedure in order to avoid a fluid
penetration hazard. Refer to Operation and
Maintenance Manual, “General hazard Information”.
Inspect the condition of the seat belt and of the
mounting hardware. Replace any parts that are worn
or damaged. Regardless of appearance, replace the
seat belt after three years of use. Do not use a seat
belt extension on a retractable seat belt.
Make sure that the machine is equipped with a
lighting system that is adequate for the job
conditions. Make sure that all machine lights are
working properly.
Before you start the engine and before you move the
machine, make sure that no one is underneath the
machine, around the machine, or on the machine.
Make sure that the area is free of personnel.
i03709524
Engine Starting
SMCS Code: 1000; 7000

• Inspect the high pressure fuel lines for damage,

deformation, a nick, a cut, a crease, or a dent.

• Do not operate the engine with a fuel leak. If there

is a leak do not tighten the connection in order to
stop the leak. The connection must only be
tightened to the recommended torque. Refer to
Disassembly and Assembly for your engine.
• If the high pressure fuel lines are torqued correctly
and the high pressure fuel lines are leaking the Illustration 27 g00104545
high pressure fuel lines must be replaced.
Do not start the engine or move any controls if there
• Ensure that all clips on the high pressure fuel lines is a “Do Not Operate” or similar warning tag attached
are in place. Do not operate the engine with clips to the start switch or controls.
that are damaged, missing or loose. Push down on the upper part of the parking brake
switch in order to engage the parking brake.
• Do not attach any other item to the high pressure
fuel lines. Move the propel lever to the STOP position.
• Loosened high pressure fuel lines must be Disengage the rotor.
replaced. Also removed high pressure fuel lines
must be replaced. Refer to Disassembly and Place the rotor transmission and the propel
Assembly for your engine. transmission in the NEUTRAL position.
Briefly sound the horn before you start the engine.
i05871379
Start the engine and operate the engine in a well
Before Starting Engine ventilated area. In an enclosed area, vent the
exhaust to the outside.
SMCS Code: 1000; 7000
Start the engine only from the operator compartment.
Never short across the starter terminals or across the
batteries. Shorting could damage the electrical
system by bypassing the engine neutral start system.
KEBU7583-01 25
Safety Section
Before Operation

i03709542

Before Operation
SMCS Code: 7000
Clear all personnel from the machine and from the
area.
Clear all obstacles that are in the path of the
machine. Beware of hazards such as wires, ditches,
etc.
Make sure that the machine horn, the backup alarm
(if equipped) and all other warning devices are
working properly.
Fasten the seat belt securely.
Adjust the mirrors (if equipped).
Refer to Operation and Maintenance Manual, “Daily
Inspection” before you operate the machine.

i05697909

Restricted Visibility
SMCS Code: 7000
The size and the configuration of this machine may
result in areas that cannot be seen when the operator
is seated. Illustration 28 provides an approximate
visual indication of the areas of significant restricted
visibility. Illustration 28 indicates the restricted
visibility areas at ground level inside a radius of
12.00 m (39.37 ft) from the operator on a machine
without the use of optional visual aids. This
illustration does not provide areas of restricted
visibility for distances outside a radius of 12.00 m
(39.37 ft).
This machine may be equipped with optional visual
aids that may provide visibility to some of the
restricted visibility areas. For the areas that are not
covered by the optional visual aids, job site
organization must be utilized to minimize hazards of
this restricted visibility. Refer to Operation and
Maintenance Manual, “Visibility Information” for more
information on job site organization.
Illustration 28 g03719777
Top view of the machine
Note: The dark shaded areas of illustration 28
indicate the approximate locations with significant
restricted visibility when the operator station is moved
to the extreme left position on the machine. When the
operator station is moved to the extreme right
position on the machine the shaded areas are
reversed from left to right. When the operator station
is moved to other positions further adjustment of the
mirrors will be required.
i04862936
Visibility Information
SMCS Code: 7000
Before you start the machine, perform a walk-around
inspection in order to ensure that there are no
hazards around the machine.
While the machine is in operation, constantly survey
the area around the machine in order to identify
potential hazards as hazards become visible around
the machine.
26
Safety Section
Operation
Your machine may be equipped with visual aids.
Some examples of visual aids are Closed Circuit
Television (CCTV) and mirrors. Before operating the
machine, ensure that the visual aids are in proper
working condition and that the visual aids are clean.
Adjust the visual aids using the procedures that are
located in this Operation and Maintenance Manual. If
equipped, the Work Area Vision System shall be
adjusted according to Operation and Maintenance
Manual, SEBU8157, “Work Area Vision System”. If
equipped, the Cat Detect Object Detection shall be
adjusted according to the Operation and
Maintenance Manual, “Cat Detect Object Detection”
for your machine.
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
evaluated.
i05871388
Operation
SMCS Code: 7000
S/N: MB91–Up
The standard machine configuration is intended for
use within an ambient temperature range of 0 °C
(32 °F) to 46 °C (115 °F) temperatures unless
otherwise specified in marketing functional
specification.
Only operate the machine while you are in a seat.
The seat belt must be fastened while you operate the
machine. Only operate the controls while the engine
is running.
KEBU7583-01
While you operate the machine slowly in an open
area, check for proper operation of all controls and all
protective devices.
You must be sure that no one is in danger before the
machine is moved.
Do not allow riders on the machine unless the
machine has the following equipment:
• additional seat
• additional seat belt
Never use the work tool as a work platform.
To maintain proper machine control and effective
hydrostatic braking on downhill slopes over 6%,
this machine must be operated in Low Range (L).
Failure to follow these instructions could result in
an overspeed condition, loss of control and/or
sudden stopping by the secondary (emergency)
braking system which could cause serious injury
or death.
Note any needed repairs during machine operation.
Report any needed repairs.
Lower the rotor. Slowly propel the machine when you
start a cut. This operation prevents the machine from
riding up on the rotor and lunging backward. This
operation also prevents excessive bouncing.
Do not allow anyone to stand or walk behind the
machine while the machine is in operation. The
machine may lunge backward if the rotor hits an
obstruction.
Carry attachments approximately 40 cm (15 inches)
above ground level. Do not go close to the edge of a
cliff, an excavation, or an overhang.
If the machine begins to sideslip downward on a
grade, immediately remove the load and turn the
machine downhill.
Avoid any conditions that can lead to tipping the
machine. The machine can tip when you work on
hills, on banks and on slopes. Also, the machine can
tip when you cross ditches, ridges or other
unexpected obstructions.
Avoid operating the machine across the slope. When
possible, operate the machine up the slopes and
down the slopes.
Maintain control of the machine. Do not overload the
machine beyond the machine capacity.
Be sure that the hitches and the towing devices are
adequate.
Only connect the trailing equipment to a drawbar or
to a hitch.
KEBU7583-01
Never straddle a wire cable. Never allow other
personnel to straddle a wire cable.
Before you maneuver the machine, make sure that
no personnel are between the machine and the
trailing equipment. Block up the hitch of the trailing
equipment in order to align the hitch with the
drawbar. Maneuver the machine. Connect the
machine to the trailing equipment.
Know the maximum dimensions of your machine.
i05871396
Operation
SMCS Code: 7000
S/N: TAS1–Up
The standard machine configuration is intended for
use within an ambient temperature range of 0 °C
(32 °F) to 49 °C (120 °F) temperatures unless
otherwise specified in marketing functional
specification.
Only operate the machine while you are in a seat.
The seat belt must be fastened while you operate the
machine. Only operate the controls while the engine
is running.
While you operate the machine slowly in an open
area, check for proper operation of all controls and all
protective devices.
You must be sure that no one is in danger before the
machine is moved.
Do not allow riders on the machine unless the
machine has the following equipment:
• additional seat
• additional seat belt
Never use the work tool as a work platform.
To maintain proper machine control and effective
hydrostatic braking on downhill slopes over 6%,
this machine must be operated in Low Range (L).
Failure to follow these instructions could result in
an overspeed condition, loss of control and/or
sudden stopping by the secondary (emergency)
braking system which could cause serious injury
or death.
Note any needed repairs during machine operation.
Report any needed repairs.
Lower the rotor. Slowly propel the machine when you
start a cut. This operation prevents the machine from
riding up on the rotor and lunging backward. This
operation also prevents excessive bouncing.
27
Safety Section
Operation
Do not allow anyone to stand or walk behind the
machine while the machine is in operation. The
machine may lunge backward if the rotor hits an
obstruction.
Carry attachments approximately 40 cm (15 inches)
above ground level. Do not go close to the edge of a
cliff, an excavation, or an overhang.
If the machine begins to sideslip downward on a
grade, immediately remove the load and turn the
machine downhill.
Avoid any conditions that can lead to tipping the
machine. The machine can tip when you work on
hills, on banks and on slopes. Also, the machine can
tip when you cross ditches, ridges or other
unexpected obstructions.
Avoid operating the machine across the slope. When
possible, operate the machine up the slopes and
down the slopes.
Maintain control of the machine. Do not overload the
machine beyond the machine capacity.
Be sure that the hitches and the towing devices are
adequate.
Only connect the trailing equipment to a drawbar or
to a hitch.
Never straddle a wire cable. Never allow other
personnel to straddle a wire cable.
Before you maneuver the machine, make sure that
no personnel are between the machine and the
trailing equipment. Block up the hitch of the trailing
equipment in order to align the hitch with the
drawbar. Maneuver the machine. Connect the
machine to the trailing equipment.
Know the maximum dimensions of your machine.
i05356599
Engine Stopping
SMCS Code: 1000; 7000
S/N: MB91–Up
Do not stop the engine immediately after the machine
has been operated under load. Stopping the engine
immediately after machine being operated under a
load can cause overheating and accelerated wear of
engine components.
After the machine is parked and the parking brake is
engaged, allow the engine to run for 2 minutes before
shutdown. Allowing hot areas of the engine to cool
gradually.
Note: If the “Regen Active” indicator is illuminated,
do not shut off the engine. Refer to Operation and
Maintenance Manual, “Monitoring System” for more
information on indicators.
28 KEBU7583-01
Safety Section
Engine Stopping

i06299648 Engage the parking brake by pushing the parking

Engine Stopping
SMCS Code: 1000; 7000
S/N: TAS1–Up
Do not stop the engine immediately after the machine
has been operated under load. Stopping the engine
immediately can cause overheating and accelerated
wear of engine components.
After the machine is parked and the parking brake is
engaged, allow the engine to run at low idle for 5
minutes before shutdown. Running the engine allows
hot areas of the engine to cool gradually.
i01404607
Parking
SMCS Code: 7000
S/N: TAS1–Up
Park the machine on a level surface. If you must park
the machine on a grade, you must block the machine.
Move the propel lever to the NEUTRAL position in
order to stop the machine.
Place all controls in the NEUTRAL position.
Engage the parking brake by pushing the parking
brake control to the ON position. The parking brake
control will light.
Lower the rotor and the hood until the rotor rests on
the ground.
Stop the engine.
Turn the engine start switch to the OFF position and
remove the key.
Turn the battery disconnect switch to the OFF
position.
i05874186
Parking
SMCS Code: 7000
S/N: MB91–Up
Park the machine on a level surface. If you must park
the machine on a grade, you must block the machine.
Move the propel lever to the NEUTRAL position in
order to stop the machine.
Place all controls in the NEUTRAL position.
brake control to the ON position. The parking brake
control will light.
Lower the rotor and the hood until the rotor rests on
the ground.
Stop the engine.
Turn the engine start switch to the OFF position and
remove the key.
Do not turn the battery disconnect switch OFF until
the “Wait to Disconnect Lamp” has turned off. If the
battery disconnect switch is turned off before the
lamp has shut off, the DEF system will not purge.
DEF could freeze and damage the pump and lines.
Turn the battery disconnect switch to the OFF
position.
i07041547
Slope Operation
SMCS Code: 7000
Machines that are operating safely in various
applications depend on these criteria: the machine
model, configuration, machine maintenance,
operating speed of the machine, conditions of the
terrain, fluid levels, and tire inflation pressures. The
most important criteria are the skill and judgment of
the operator.
A well trained operator that follows the instructions in
the Operation and Maintenance Manual has the
greatest impact on stability. Operator training
provides a person with the following abilities:
observation of working and environmental conditions,
feel for the machine, identification of potential
hazards and operating the machine safely by making
appropriate decisions.
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.
Roughness of terrain or surface – The machine
may be less stable with uneven terrain.
Direction of travel – Avoid operating the machine
across the slope. When possible, operate the
machine up the slopes and operate the machine
down the slopes. Place the heaviest end of the
machine uphill when you are working on an incline.
Mounted equipment – Balance of the machine may
be impeded by the following components: equipment
that is mounted on the machine, machine
configuration, weights, and counterweights.
Nature of surface – Ground that has been newly
filled with earth may collapse from the weight of the
machine.
KEBU7583-01
Surface material – Rocks and moisture of the
surface material may drastically affect the machine's
traction and machine's stability. Rocky surfaces may
promote side slipping of the machine.
Slippage due to excessive loads – This may cause
downhill tracks or downhill tires to dig into the ground,
which will increase the angle of the machine.
Width of tracks or tires – Narrower tracks or
narrower tires further increase the digging into the
ground which causes the machine to be less stable.
Implements attached to the drawbar – This may
decrease the weight on the uphill tracks. This may
also decrease the weight on the uphill tires. The
decreased weight will cause the machine to be less
stable.
Height of the working load of the machine – When
the working loads are in higher positions, the stability
of the machine is reduced.
Operated equipment – Be aware of performance
features of the equipment in operation and the effects
on machine stability.
Operating techniques – Keep all attachments or
pulled loads low to the ground for optimum stability.
Machine systems have limitations on slopes –
Slopes can affect the proper function and operation
of the various machine systems. These machine
systems are needed for machine control.
Note: Operator's with lots of experience and proper
equipment for specific applications are also required.
Safe operation on steep slopes may also require
special machine maintenance. Refer to Lubricant
Viscosities and Refill Capacities in this manual for the
proper fluid level requirements and intended machine
use. Fluids must be at the correct levels to ensure
that systems will operate properly on a slope.
i01329161
Equipment Lowering with
Engine Stopped
SMCS Code: 7000
Before lowering any equipment with the engine
stopped, clear the area around the equipment of all
personnel. The procedure to use will vary with the
type of equipment to be lowered. Keep in mind most
systems use a high pressure fluid or air to raise or
lower equipment. The procedure will cause high
pressure air, hydraulic, or some other media to be
released in order to lower the equipment. Wear
appropriate personal protective equipment and follow
the established procedure in the Operation and
Maintenance Manual, “Equipment Lowering with
Engine Stopped” in the Operation Section of the
manual.
29
Safety Section
Equipment Lowering with Engine Stopped
i05697912
Sound Information and
Vibration Information
SMCS Code: 7000
Sound Level Information for
Machines in European Union
Countries and in Countries that
Adopt the “EU Directives”
The average operator sound pressure level that is
measured according to the test procedures and
conditions that are specified in “ISO 11204:1995” is
82 dB(A) for an enclosed cab. The cab was properly
installed and maintained. The test was conducted on
a stationary machine with the doors and the windows
closed. The engine was set to high idle. The cooling
fan was set at maximum fan speed. The heater/air
conditioner fan was set to the MID position. The rotor
speed was set to LOW position. The rotor was in the
raised up position. The swivel seat was in the straight
ahead position. The value is the maximum of the
readings that were obtained with the operator station
in the LEFT, CENTER, and RIGHT positions.
The A-weighted sound power level is 117 dB(A)
according to “ISO 3744:1995” and “EN500-3 Annex B
Noise Test Code” for soil stabilizing machines and
recycling machines (at maximum fan speed).
“The European Union Physical
Agents (Vibration) Directive 2002/
44/EC”
Vibration Data for Road Reclaimer/Soil
Stabilizer
Information Concerning Hand/Arm Vibration
Level
When the machine is operated according to the
intended use, the hand/arm vibration of this machine
is below 2.5 meter per second squared.
Information Concerning Whole Body Vibration
Level
This section provides vibration data and a method for
estimating the vibration level for the Road Reclaimer/
Soil Stabilizer.
Note: Vibration levels are influenced by many
different parameters. Many items are listed below.
• Operator training, behavior, mode and stress
• Job site organization, preparation, environment,
weather and material
30 KEBU7583-01
Safety Section
Sound Information and Vibration Information

• Machine type, quality of the seat, quality of the

suspension system, attachments and condition of
the equipment
It is not possible to get precise vibration levels for this
machine. The expected vibration levels can be
estimated with the information in Table 1 in order to
calculate the daily vibration exposure. A simple
evaluation of the machine application can be used.
Estimate the vibration levels for the three vibration
directions. For typical operating conditions, use the
average vibration levels as the estimated level. With
an experienced operator and smooth terrain, subtract
the Scenario Factors from the average vibration level
in order to obtain the estimated vibration level. For
aggressive operations and severe terrain, add the
Scenario Factors to the average vibration level in
order to obtain the estimated vibration level.
Note: All vibration levels are in meter per second
squared.

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

Machine Typical Operating Vibration Levels Scenario Factors

Type Activity X axis Y axis Z axis X axis Y axis Z axis
cutting 0,15 0,10 0,17 0,06 0,03 0,02
Road Reclaim-
er/Soil Stabilizer roading 0,21 0,34 0,25 0,03 0,07 0,04

Note: Refer to “ISO/TR 25398 Mechanical Vibration -

Guideline for the assessment of exposure to whole a. Tire pressures
body vibration of ride on operated earthmoving
machines” for more information about vibration. This b. Brake and steering systems
publication uses data that is measured by
international institutes, organizations and c. Controls, hydraulic system and linkages
manufacturers. This document provides information
about the whole body exposure of operators of 3. Keep the terrain in good condition.
earthmoving equipment. Refer to Operation and
a. Remove any large rocks or obstacles.
Maintenance Manual, SEBU8257, “The European
Union Physical Agents (Vibration) Directive 2002/44/ b. Fill any ditches and holes.
EC” for more information about machine vibration
levels. c. Provide machines and schedule time in order to
The Caterpillar suspension seat meets the criteria of maintain the conditions of the terrain.
“ISO 7096”. This represents vertical vibration level
4. Use a seat that meets “ISO 7096”. Keep the seat
under severe operating conditions.
maintained and adjusted.
Guidelines for Reducing Vibration Levels on
Earthmoving Equipment a. Adjust the seat and suspension for the weight
and the size of the operator.
Properly adjust machines. Properly maintain
machines. Operate machines smoothly. Maintain the b. Inspect and maintain the seat suspension and
conditions of the terrain. The following guidelines can adjustment mechanisms.
help reduce the whole body vibration level:
5. Perform the following operations smoothly.
1. Use the right type and size of machine, equipment,
and attachments. a. Steer
2. Maintain machines according to the b. Brake
manufacturer's recommendations.
KEBU7583-01
c. Accelerate.
d. Shift the gears.
6. Move the attachments smoothly.
7. Adjust the machine speed and the route in order to
minimize the vibration level.
a. Drive around obstacles and rough terrain.
b. Slow down when it is necessary to go over
rough terrain.
8. Minimize vibrations for a long work cycle or a long
travel distance.
a. Use machines that are equipped with
suspension systems.
b. Use the ride control system.
c. If no ride control system is available, reduce
speed in order to prevent bounce.
d. Haul the machines between workplaces.
9. Less operator comfort may be caused by other risk
factors. The following guidelines can be effective
in order to provide better operator comfort:
a. Adjust the seat and adjust the controls in order
to achieve good posture.
b. Adjust the mirrors in order to minimize twisted
posture.
c. Provide breaks in order to reduce long periods
of sitting.
d. Avoid jumping from the cab.
e. Minimize repeated handling of loads and lifting
of loads.
f. Minimize any shocks and impacts during sports
and leisure activities.
Sources
The vibration information and calculation procedure
is based on “ISO/TR 25398 Mechanical Vibration -
Guideline for the assessment of exposure to whole
body vibration of ride on operated earthmoving
machines”. Harmonized data is measured by
international institutes, organizations and
manufacturers.
This literature provides information about assessing
the whole body vibration exposure of operators of
earthmoving equipment. The method is based on
measured vibration emission under real working
conditions for all machines.
31
Safety Section
Operator Station
You should check the original directive. This
document summarizes part of the content of the
applicable law. This document is not meant to
substitute the original sources. Other parts of these
documents are based on information from the United
Kingdom Health and Safety Executive.
Refer to Operation and Maintenance Manual,
SEBU8257, “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:
Caterpillar, Inc.
www.cat.com
i03634321
Operator Station
SMCS Code: 7000; 7300; 7301; 7325
Any modifications to the inside of the operator station
should not project into the operator space or into the
space for the companion seat (if equipped). The
addition of a radio, fire extinguisher, and other
equipment must be installed so that the defined
operator space and the space for the companion seat
(if equipped) is maintained. Any item that is brought
into the cab should not project into the defined
operator space or the space for the companion seat
(if equipped). A lunch box or other loose items must
be secured. Objects must not pose an impact hazard
in rough terrain or in the event of a rollover.
i06146993
Guards
(Operator Protection)
SMCS Code: 7000; 7150; 7325
There are different types of guards that are used to
protect the operator. The machine and the machine
application determine the type of guard that should
be used.
A daily inspection of the guards is required in order to
check for structures that are bent, cracked or loose.
Never operate a machine with a damaged structure.
The operator becomes exposed to a hazardous
situation if the machine is used improperly or if poor
operating techniques are used. This situation can
occur even though a machine is equipped with an
appropriate protective guard. Follow the established
operating procedures that are recommended for your
machine.
32 KEBU7583-01
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 Caterpillar 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 Caterpillar 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
KEBU7583-01 33
Product Information Section
General Information

Product Information The RM-500B can be used on soil stabilization

projects in order to improve the chemical load
Section bearing characteristics of the native subgrade soil or
the existing base material.
When the machine is equipped with a stabilization
General Information rotor, the machine can blend additives with the base
material or the subgrade material, to a maximum
mixing depth of 508 mm (20 inch).
i05698149
The RM-500B can be used to size the stabilized
Specifications material to a specified maximum particle size.
SMCS Code: 7000 The RM-500B can be used to aerate the soil in order
to reduce the moisture content of the base material
The standard machine shipping specifications are prior to compaction.
listed in the table below.
Table 2 Application and Configuration
RM-500B Rotary Mixer Restrictions
Machine Weight 29120 kg (64199 lb) The maximum approved operating weight of the RM-
Length 10320 mm (33.9 ft)
500B is 34800 kg (76720 lb).

Width 2989 mm (9.8 ft)
Height 3605 mm (11.8 ft)
Note: Your machine may have different
specifications. Consult with your Caterpillar dealer in
order to determine the proper specifications for your
machine.
Intended Use
The RM-500B is designed for full depth reclamation.
Full depth reclamation is a pavement maintenance
technique that is used to create improved base
material.
The full depth reclamation process involves the
pulverization of the entire thickness of the flexible
pavement structure of a roadway. The full depth
reclamation process involves the pulverization of the
chip seal layer. The pulverized material is blended
with a specified portion of the road base.
The maximum depth of the machine is 406 mm
(16 inch).
In order to improve the strength of the road base, the
operator may blend the following materials into the
mix during the mixing process:
• asphalt emulsion
Use the RM-500B only in non-explosive gas
environments.
When reclaiming or stabilizing, front steer mode
should be used. Crab, coordinated, and rear steer
modes should not be used during reclaiming or
mixing to avoid side loading and potential damage to
the rotor and mixing chamber.
If stabilizing soil which contains large stones, stones
greater than 6 inches should be removed prior to
stabilizing. Attempting to process large stone during
soil stabilization can result in damage to the rotor or
mixing chamber. The severity and rate at which any
damage occurs may increase based on the type,
size, and frequency of the stone being encountered.
Operation of the front and rear door of the mixing
chamber can affect machine performance. When
reclaiming or stabilizing, the front door should remain
open enough to allow some material to spill out in
front of the chamber. The rear door should remain
open enough to allow material to escape the
chamber. Excess material being held in the chamber
can increase wear rates to the rotor and mixing
chamber. If more mixing is required, subsequent
passes are recommended.
Refer to Rotor Selection Guide, QEDQ1233 in order
to ensure that the correct rotor is being used for the
application.
i06751247

• stabilizing agents
Application Guidelines
• aggregates
(For the Spray Systems)
The RM-500B can be used on soil stabilization SMCS Code: 5612; 5615
projects in order to improve the mechanical load
bearing characteristics of the native subgrade soil or The tables provided below use the following
the existing base material. equations to determine the application rate of water
or emulsion.
34 KEBU7583-01
Product Information Section
For the Spray Systems

English Units – Application Rate (Gallons per

Square Yard) x Travel Speed (Feet per Minute) x
Spray Bar Width (feet) divide by 9= Gallons Sprayed
in 1 Minute
Metric Units – Application Rate (Liters per Square
Meter) x Travel Speed (Meters per Minute) x Spray
Bar Width (Meters) = Liters Sprayed in 1 Minute

Application Rate of Water

Standard water system 114 ± 1136 L/min
(30 ± 300 US gpm).
Low flow water system 60 ± 600 L/min
(16 ± 160 US gpm).

Note: The flow will turn off if the flow rate drops
below 114 L/min (30 US gpm) for the standard water
system and 60 L/min (16 US gpm) for the low flow
water system.

Table 3
Application Rate for Water Spray System
Values are provided in gallons per square yard and liters per square meter.

(Volume)

1.0 Gal 1.5 Gal 2.0 Gal 2.5 Gal 3.0 Gal 3.5 Gal 4.0 Gal 4.5 Gal 5.0 Gal 5.5 Gal
(Speed)
3.79 L 5.68 L 7.57 L 9.46 L 11.36 L 13.25 L 15.14 L 17.03 L 18.93 L 20.82 L
5 ft/min 15.5 17.8 20.0 22.2 22.4
1.52 m/min 58.7 67.4 75.7 84.0 92.4
10 ft/min 17.8 22.2 26.7 31.11 35.56 40.00 44.45 48.89
3.05 m/min 67.4 84.0 101.1 98.46 112.52 126.59 140.66 154.72
15 ft/min 20.0 26.7 33.33 40.00 46.67 53.33 60.00 66.67 73.33
4.57 m/min 75.7 101.1 105.49 126.59 147.69 168.79 189.88 210.98 232.08
20 ft/min 17.8 26.7 35.56 44.45 53.33 62.22 71.11 80.00 88.89 97.78
6.10 m/min 67.4 101.1 112.52 140.66 168.79 196.92 225.05 253.18 281.31 309.44
25 ft/min 22.2 33.33 44.45 55.56 66.67 77.78 88.89 100.00 111.11 122.22
7.62 m/min 84.0 105.49 140.66 175.82 210.98 246.15 281.31 316.47 351.64 386.80
30 ft/min 26.7 40.00 53.33 66.67 80.00 93.33 106.67 120.00 133.34 146.67
9.14 m/min 101.1 126.59 168.79 210.98 253.18 295.38 337.57 379.77 421.97 464.16
35 ft/min 31.11 46.67 62.22 77.78 93.33 108.89 124.45 140.00 155.56 171.11
10.67 m/min 98.46 147.69 196.92 246.15 295.38 344.61 393.83 443.06 492.29 541.52
40 ft/min 35.56 53.33 71.11 88.89 106.67 124.45 142.22 160.00 177.78 195.56
12.19 m/min 112.52 168.79 225.05 281.31 337.57 393.83 450.10 506.36 562.62 618.88
45 ft/min 40.00 60.00 80.00 100.00 120.00 140.00 160.00 180.00 200.00 220.00
13.72 m/min 126.59 189.88 253.13 316.47 379.77 443.06 506.36 569.65 632.95 696.24
50 ft/min 44.45 66.67 88.89 111.11 133.34 155.56 177.78 200.00 222.23 244.45
15.24 m/min 140.66 210.98 281.31 351.64 421.97 492.29 562.62 632.95 703.28 773.60
60 ft/min 53.33 80.00 106.67 133.34 160.00 186.67 213.34 240.00 266.67
18.29 m/min 168.79 253.18 337.57 421.97 506.36 590.75 675.14 759.54 843.93
70 ft/min 62.22 93.33 124.45 155.56 186.67 217.78 248.89
21.34 m/min 196.92 295.38 393.83 492.29 590.75 689.21 787.67

(continued)
KEBU7583-01 35
Product Information Section
For the Spray Systems

(Table 3, contd)
80 ft/min 71.11 106.67 142.22 177.78 213.34 248.89 284.45
24.38 m/min 225.05 337.57 450.10 562.62 675.14 787.67 900.19
90 ft/min 80.00 120.00 160.00 200.00 240.00 280.00
27.43 m/min 253.18 379.77 506.36 632.95 759.54 886.13
100 ft/min 88.89 133.34 177.78 222.23 266.67 311.12
30.48 m/min 281.31 421.97 562.62 703.28 843.93 984.59
110 ft/min 97.78 146.67 195.56 244.45 293.34
33.53 m/min 309.44 464.16 618.88 773.60 928.32
120 ft/min 106.67 160.00 213.34 266.67
36.58 m/min 337.57 506.36 675.14 843.93
130 ft/min 115.56 173.34 231.11 288.89
39.62 m/min 365.70 548.56 731.41 914.26
Application Rate for Water Spray System
Values are provided in gallons per square yard and liters per square meter.

(Volume)

6.0 Gal 7.0 Gal 8.0 Gal 9.0 Gal 10.0 Gal 11.0 Gal 12.0 Gal 13.0 Gal 14.0 Gal 15.0 Gal
(Speed)
22.71 L 26.50 L 30.28 L 34.07 L 37.85 L 41.64 L 45.42 L 49.21 L 52.99 L 56.78 L
5 ft/min 31.11 35.56 40.00 44.45 48.89 53.33 57.78 62.22 66.67
1.52 m/min 98.46 112.52 126.59 140.66 154.72 168.79 182.85 196.92 210.98
10 ft/min 53.33 62.22 71.11 80.00 88.89 97.78 106.67 115.56 124.45 133.34
3.05 m/min 168.79 196.92 225.05 253.18 281.31 309.44 337.57 365.70 393.83 421.97
15 ft/min 80.00 93.33 106.67 120.00 133.34 146.67 160.00 173.34 186.67 200.00
4.57 m/min 253.18 295.38 337.57 379.77 421.97 464.16 506.36 548.56 590.75 632.95
20 ft/min 106.67 124.45 142.22 160.00 177.78 195.56 213.34 231.11 248.89 266.67
6.10 m/min 337.57 393.83 450.10 506.36 562.62 618.88 675.14 731.41 787.67 843.93
25 ft/min 133.34 155.56 177.78 200.00 222.23 244.45 266.67 288.89
7.62 m/min 421.97 492.29 562.62 632.95 703.28 773.60 843.93 914.26
30 ft/min 160.00 186.67 213.34 240.00 266.67 293.34
9.14 m/min 506.36 590.75 675.14 759.54 843.93 928.32
35 ft/min 186.67 217.78 248.89 280.00
10.67 m/min 590.75 689.21 787.67 886.13
40 ft/min 213.34 248.89 284.45
12.19 m/min 675.14 787.67 900.19
45 ft/min 240.00 280.00
13.72 m/min 759.54 886.13
50 ft/min 266.67
15.24 m/min 843.93
Application Rate for Water Spray System
Values are provided in gallons per square yard and liters per square meter.

(Volume)

16.0 Gal 17.0 Gal 18.0 Gal 19.0 Gal 20.0 Gal 21.0 Gal 22.0 Gal 23.0 Gal 24.0 Gal 25.0 Gal
(Speed)
60.56 L 64.35 L 68.13 L 71.92 L 75.70 L 79.49 L 83.27 L 87.06 L 90.84 L 94.63 L
5 ft/min 71.11 75.56 80.00 84.45 88.89 93.33 97.78 102.22 106.67 111.11
1.52 m/min 225.05 239.11 253.18 267.25 281.31 295.38 309.44 323.51 337.57 351.64
10 ft/min 142.22 151.11 160.00 168.89 177.78 186.67 195.56 204.45 213.34 222.23
3.05 m/min 450.10 478.23 506.36 534.49 562.62 590.75 618.88 647.01 675.14 703.28
15 ft/min 213.34 226.67 240.00 253.34 266.67 280.00 293.34
4.57 m/min 675.14 717.34 759.54 801.73 843.93 886.13 928.32
20 ft/min 284.45
6.10 m/min 900.19
36 KEBU7583-01
Product Information Section
For the Spray Systems

Application Rate of Emulsion

The machine has a flow range of 114 L/min
(30 US gpm) to 1000 L/min (264 US gpm).
Note: The flow will turn off if the flow rate drops
below 114 L/min (30 US gpm).

Table 4
Application Rate for Emulsion Spray System
Values are provided in gallons per square yard and liters per square meter.

(Volume)

1.0 Gal 1.5 Gal 2.0 Gal 2.5 Gal 3.0 Gal 3.5 Gal 4.0 Gal 4.5 Gal 5.0 Gal 5.5 Gal
(Speed)
3.79 L 5.68 L 7.57 L 9.46 L 11.36 L 13.25 L 15.14 L 17.03 L 18.93 L 20.82 L
5 ft/min
1.52 m/min
10 ft/min 31.11 35.56 40.00 44.45 48.89
3.05 m/min 98.46 112.52 126.59 140.66 154.72
15 ft/min 33.33 40.00 46.67 53.33 60.00 66.67 73.33
4.57 m/min 105.49 126.59 147.69 168.79 189.88 210.98 232.08
20 ft/min 35.56 44.45 53.33 62.22 71.11 80.00 88.89 97.78
6.10 m/min 112.52 140.66 168.79 196.92 225.05 253.18 281.31 309.44
25 ft/min 33.33 44.45 55.56 66.67 77.78 88.89 100.00 111.11 122.22
7.62 m/min 105.49 140.66 175.82 210.98 246.15 281.31 316.47 351.64 386.80
30 ft/min 40.00 53.33 66.67 80.00 93.33 106.67 120.00 133.34 146.67
9.14 m/min 126.59 168.79 210.98 253.18 295.38 337.57 379.77 421.97 464.16
35 ft/min 31.11 46.67 62.22 77.78 93.33 108.89 124.45 140.00 155.56 171.11
10.67 m/min 98.46 147.69 196.92 246.15 295.38 344.61 393.83 443.06 492.29 541.52
40 ft/min 35.56 53.33 71.11 88.89 106.67 124.45 142.22 160.00 177.78 195.56
12.19 m/min 112.52 168.79 225.05 281.31 337.57 393.83 450.10 506.36 562.62 618.88
45 ft/min 40.00 60.00 80.00 100.00 120.00 140.00 160.00 180.00 200.00
696.24
13.72 m/min 126.59 189.88 253.18 316.47 379.77 443.06 506.36 569.65 632.95
50 ft/min 44.45 66.67 88.89 111.11 133.34 155.56 177.78 200.00
703.28 773.60
15.24 m/min 140.66 210.98 281.31 351.64 421.97 492.29 562.62 632.95
60 ft/min 53.33 80.00 106.67 133.34 160.00 186.67 213.34
759.54
18.29 m/min 168.79 253.18 337.57 421.97 506.36 590.75 675.14
70 ft/min 62.22 93.33 124.45 155.56 186.67 217.78
787.67
21.34 m/min 196.92 295.38 393.83 492.29 590.75 689.21
80 ft/min 71.11 106.67 142.22 177.78 213.34
787.67
24.38 m/min 225.05 337.57 450.10 562.62 675.14
90 ft/min 80.00 120.00 160.00 200.00
759.54
27.43 m/min 253.18 379.77 506.36 632.95
100 ft/min 88.89 133.34 177.78
703.28
30.48 m/min 281.31 421.97 562.62
110 ft/min 97.78 146.67 195.56
773.60
33.53 m/min 309.44 464.16 618.88
120 ft/min 106.67 160.00 213.34
36.58 m/min 337.57 506.36 675.14
130 ft/min 115.56 173.34
731.41
39.62 m/min 365.70 548.56

(continued)
KEBU7583-01 37
Product Information Section
For the Spray Systems

(Table 4, contd)
Application Rate for Emulsion Spray System
Values are provided in gallons per square yard and liters per square meter.

(Volume)

6.0 Gal 7.0 Gal 8.0 Gal 9.0 Gal 10.0 Gal 11.0 Gal 12.0 Gal 13.0 Gal 14.0 Gal 15.0 Gal
(Speed)
22.71 L 26.50 L 30.28 L 34.07 L 37.85 L 41.64 L 45.42 L 49.21 L 52.99 L 56.78 L
5 ft/min 31.11 35.56 40.00 44.45 48.89 53.33 57.78 62.22 66.67
1.52 m/min 98.46 112.52 126.59 140.66 154.72 168.79 182.85 196.92 210.98
10 ft/min 53.33 62.22 71.11 80.00 88.89 97.78 106.67 115.56 124.45 133.34
3.05 m/min 168.79 196.92 225.05 253.18 281.31 309.44 337.57 365.70 393.83 421.97
15 ft/min 80.00 93.33 106.67 120.00 133.34 146.67 160.00 173.34 186.67 200.00
4.57 m/min 253.18 295.38 337.57 379.77 421.97 464.16 506.36 548.56 590.75 632.95
20 ft/min 106.67 124.45 142.22 160.00 177.78 195.56 213.34
731.41 787.67
6.10 m/min 337.57 393.83 450.10 506.36 562.62 618.88 675.14
25 ft/min 133.34 155.56 177.78 200.00
703.28 773.60
7.62 m/min 421.97 492.29 562.62 632.95
30 ft/min 160.00 186.67 213.34
759.54
9.14 m/min 506.36 590.75 675.14
35 ft/min 186.67 217.78
787.67
10.67 m/min 590.75 689.21
40 ft/min 213.34
787.67
12.19 m/min 675.14
45 ft/min
759.54
13.72 m/min
Application Rate for Emulsion Spray System
Values are provided in gallons per square yard and liters per square meter.

(Volume)

16.0 Gal 17.0 Gal 18.0 Gal 19.0 Gal 20.0 Gal 21.0 Gal 22.0 Gal 23.0 Gal 24.0 Gal 25.0 Gal
(Speed)
60.56 L 64.35 L 68.13 L 71.92 L 75.70 L 79.49 L 83.27 L 87.06 L 90.84 L 94.63 L
5 ft/min 71.11 75.56 80.00 84.45 88.89 93.33 97.78 102.22 106.67 111.11
1.52 m/min 225.05 239.11 253.18 267.25 281.31 295.38 309.44 323.51 337.57 351.64
10 ft/min 142.22 151.11 160.00 168.89 177.78 186.67 195.56 204.45 213.34
703.28
3.05 m/min 450.10 478.23 506.36 534.49 562.62 590.75 618.88 647.01 675.14
15 ft/min 213.34
717.34 759.54 801.73
4.57 m/min 675.14
38 KEBU7583-01
Product Information Section
Identification Information

Identification Information
i06865873

Plate Locations and Film

Locations
SMCS Code: 1000; 7000
The Product Information Number (PIN) is used to
identify a powered machine that is designed for an
operator to ride.
Caterpillar products such as engines, transmissions
and major attachments that are not designed for an
operator to ride are identified by Serial Numbers. Illustration 30 g02436556

The Certification Plate (CE) is used to verify that the Manufacturer Name and Address
product conforms to all of the requirements that were
established by a country or a group of countries. The Model Number (A)
product is tested by a certified testing group in order
to verify conformance. PIN (B)

The emission certification film (if equipped) is used to Service Information Plate (If Required) (C)
verify that the engine meets the EPA emissions Year of Manufacture Plate (If Required) (D)
requirements.
CE Plate (If Required) (E)
For quick reference, record the identification
numbers in the spaces that are provided below the Country of Origin Info Plate (If Required) (F)
illustrations.

Illustration 31 g03618478
Illustration 29 g03618393
Location of the engine serial number plate.
Location of the Product Information Number (PIN)
plate The engine serial number plate is located on the right
side of the engine block, toward the back.
The Product Identification Number (PIN) is located on
the right side of the machine, near the ladder. This
plate will have the following information:
KEBU7583-01 39
Product Information Section
Plate Locations and Film Locations

Entity authorized to communicate on request as

required by Customs Union Technical Regulations of
the Eurasian Economic Union:
Caterpillar Eurasia LLC
75, Sadovnicheskaya Emb.
Moscow 115035, Russia

Certification
European Union

Illustration 32 g00123229
Serial number plate

The following information is stamped on the serial

number plate: engine serial number, engine model
and arrangement number.

Eurasian Economic Union

For machines compliant to the Eurasian Economic
Union requirements, the EAC mark plate is
positioned near the Product Identification Number
(PIN) plate (see Product Information Section of the
machine Operation and Maintenance Manual). The
EAC mark plate is placed on machines certified to the
Eurasian Economic Union requirements effective at
the time of market entry.
Illustration 34 g01880193
This plate is positioned on the bottom left side of the
plate for the PIN.
Note: The CE plate is on machines that are certified
to the European Union requirements that were
effective at that time.
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)
Illustration 33 g06094564
• Year of Construction
The Month and Year of Manufacture are on the PIN
plate. • Machine Type

Manufacturer Information
Manufacturer:
Caterpillar Paving Products Inc.,
9401 85 th Avenue North
Brooklyn park MN, 55445-2199
40 KEBU7583-01
Product Information Section
Plate Locations and Film Locations

If equipped, the certification film is used to verify the

environmental sound certification of the machine.
The value that is listed on the film indicates the
guaranteed sound power level. The guaranteed
sound power level is measured at the time of
manufacture. The guaranteed sound power level is
measured according to the conditions that are
specified in “ISO 6394:1998”.

Product Link
If equipped, this message is used to verify the
certification of the Product Link as a RF transmitter.
The following specifications are provided to aid in
ensuring compliance with all local regulations:
Table 5
Illustration 35 g01120192
Operating frequency range 148 to 150 MHz
This plate is positioned on the bottom left side of the Transmitter power 5 Watts
plate for the PIN.
Note: The CE plate is on machines that are certified This message is located on the control group for the
to the European Union requirements that were Product Link. The control group is located on the top
effective at that time. of the cab.
For machines compliant to 1998/42/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)

• Typical Machine Operating Weight for European
Market (kg)

• Year
For the name and address of the manufacturer, and
the country of origin of the machine, refer to the PIN
plate.
For manufacturer name and address and the country Illustration 37 g01261742
of origin, see the PIN plate.

Sound Certification
This machine is equipped with a Cat Product Link
radio communication device which must be deac-
tivated within 6.0 m (20 ft) of a blast zone. Failure
to do so could result in serious injury or death.

If the machine is required to work within 6 m (20 ft) of

a blast area, power to the Product Link module must
be disconnected.

Illustration 36 g00933634
A typical example of this film is shown. Your machine
may have a different value.
KEBU7583-01 41
Product Information Section
Emissions Certification Film

Consult your Caterpillar dealer with any questions

that concern the operation of the Product Link in a
specific country.

i05871485

Emissions Certification Film

SMCS Code: 1000; 7000; 7405

Note: This information is pertinent in the United

States, in Canada and in Europe.
Consult your Cat dealer for an Emission Control
Warranty Statement.
This label is located on the engine, and on the right
side of the machine to the right of the PIN plate.

i05698391

Declaration of Conformity
SMCS Code: 1000; 7000

Table 6
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 PAVING PRODUCTS INC. 9401 85th Ave. North Brooklyn Park, MN 55445 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,Caterpillar France S.A.S 40,

Avenue Leon-Blum, B.P. 55, 38041 Grenoble Cedex 9, France

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

Description: Generic Denomination: Paving Equipment

Function: Soil Stabilizer

Model/Type: RM500B

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

(continued)
42 KEBU7583-01
Product Information Section
Declaration of Conformity

(Table 6, contd)
Engine Power per ____-____ kW Rated engine speed - _____ rpm
Technical Documentation accessible through person listed above authorized to compile the Technical File

Done at: Signature

Date: Name/Position

Note: The above information was correct as of July 2014, but may be subject to change, please refer to the individual declaration of conformity
issued with the machine for exact details.
KEBU7583-01
Operation Section
Before Operation
i04021647
Mounting and Dismounting
SMCS Code: 7000
Illustration 38 g00037860
Typical example
Mount the machine and dismount the machine only
at locations that have steps and/or handholds. Before
you mount the machine, clean the steps and the
handholds. Inspect the steps and handholds. Make
all necessary repairs.
Face the machine whenever you get on the machine
and whenever you get off the machine.
Maintain a three-point contact with the steps and with
the handholds.
Note: Three-point contact can be two feet and one
hand. Three-point contact can also be one foot and
two hands.
Do not mount a moving machine. Do not dismount a
moving machine. Never jump off the machine. Do not
carry tools or supplies when you try to mount the
machine or when you try to dismount the machine.
Use a hand line to pull equipment onto the platform.
Do not use any controls as handholds when you
enter the operator compartment or when you exit the
operator compartment.
43
Operation Section
Before Operation
Machine Access System
Specifications
The machine access system has been designed to
meet the intent of the technical requirements in “ISO
2867 Earth-moving Machinery – Access Systems”.
The access system provides for operator access to
the operator station and to conduct the maintenance
procedures described in Maintenance section.
Alternate Exit
Machines that are equipped with cabs have alternate
exits. For additional information, see Operation and
Maintenance Manual, “Alternate Exit”.
i05698552
Daily Inspection
SMCS Code: 1000; 7000
Escaping fluid under pressure, even a pinhole
size leak, can penetrate body tissue, causing seri-
ous injury, and possible death. If fluid is injected
into your skin, it must be treated immediately by
a doctor familiar with this type of injury.
Always use a board or cardboard when checking
for a leak.
NOTICE
Accumulated grease and oil on a machine is a fire
hazard. Remove this debris with steam cleaning or
high pressure water, at least every 1000 hours or
each time any significant quantity of oil is spilled on
the machine.
Wipe all fittings, all caps, and all plugs, before you
service the machine.
Note: Keep a close watch for leaks. If any leaks are
observed, find the source of the leak. Repair the leak.
Check the fluid levels more frequently than the
recommended interval if you suspect a leak.
1. Inspect the precleaner for dirt buildup. Clean the
precleaner if dirt has accumulated.
2. Check the machine for loose wiring. Check the
machine for frayed wiring.
3. Inspect the lights for broken bulbs. Inspect the
lights for broken lenses. Replace the bulbs or the
lenses if the bulbs or the lenses are broken.
4. Open all access covers. Inspect the compartments
for any trash buildup. Remove any trash in the
compartments.
44 KEBU7583-01
Operation Section
Daily Inspection

5. Inspect the hydraulic system for leaks. Inspect the

hydraulic tank, the hoses, the tubes, the plugs,
and the fittings for leaks or damage. Repair any
damage. Repair any leaks.
6. All covers and guards must be securely in place.
Inspect all covers and guards for damage. Repair
any damage.
7. Inspect the steps, the walkways, and the
handholds for damage or wear. Repair the
components that are damaged or worn. Inspect
the steps, the walkways, and the handholds for
cleanliness. Clean the components.
8. Inspect the operator compartment for cleanliness.
Keep the operator compartment clean.
9. Daily, perform the maintenance procedures that
are applicable to your machine:

• Operation and Maintenance Manual, “Backup

Alarm - Test”

• Operation and Maintenance Manual, “Bolster

Oscillation Pin (Rear) - Lubricate”

• Operation and Maintenance Manual, “Cooling

System Coolant Level - Check”

• Operation and Maintenance Manual, “Engine

Oil Level - Check”

• Operation and Maintenance Manual, “Hydraulic

System Oil Level - Check”

• Operation and Maintenance Manual,

“Indicators and Gauges - Test”

• Operation and Maintenance Manual, “Rotor

Bearing Reservoir Oil Level - Check”

• Operation and Maintenance Manual, “Rotor

Cutter Bits - Inspect/Replace”

• Operation and Maintenance Manual, “Rotor

Cutter Bits (Side) - Inspect/Replace”

• Operation and Maintenance Manual, “Seat Belt

- Inspect”

• Operation and Maintenance Manual, “ Tire

Inflation - Check ”
KEBU7583-01
Machine Operation
i05700363
Seat
SMCS Code: 7312
Note: Adjust the seat for a new operator or at the
beginning of each shift.
The operator should sit in the seat in order to
determine the correct positioning. Adjust the seat so
that the operator is allowed full travel of all the
controls.
Lock the seat into position before you operate the
machine. Locking the seat will prevent unexpected
movement of the seat.
Illustration 39 g03620371
Arm Rest Adjustment (1) – Lift the arm rest
adjustment. Move the arm rest until the desired
position is attained. Release the handle in order to
lock the arm rest into position.
Heat (2) – If the machine is equipped with a heated
seat, push the switch in order to activate the heat.
Swivel Adjustment (3) – Lift the swivel adjustment.
Swivel the seat until the desired position is attained.
Release the handle in order to lock the seat into
position.
Weight Adjustment (4) – For seats with a
mechanical dial, rotate the dial in order to increase or
decrease the seat stiffness. For machines with an air
suspension seat, push in the button to increase the
stiffness, pull out the button to decrease the stiffness.
Back Angle Adjustment (5) – Lift the handle and
allow the seat back to tilt forward. Push the front of
the backrest, which will tilt the seat backward.
Release the handle at the desired position.
45
Operation Section
Machine Operation
Lumbar Adjustment (6) – Turn the knob clockwise
in order to increase the lumbar support. Turn the
knob counter-clockwise in order to decrease the
lumbar support.
i04575638
Seat Belt
SMCS Code: 7327
Note: This machine was equipped with a seat belt
when the machine was shipped from Caterpillar. At
the time of installation, the seat belt and the
instructions for installation of the seat belt meet the
SAE J386 and ISO 6683 standards. Consult your Cat
dealer for all replacement parts.
Always check the condition of the seat belt and the
condition of the mounting hardware before you
operate the machine.
Seat Belt Adjustment for
Retractable Seat Belts
Fastening The Seat Belt
Illustration 40 g00867598
Pull seat belt (4) out of the retractor in a continuous
motion.
Fasten seat belt catch (3) into buckle (2). Make sure
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.
46
Operation Section
Mirror
Releasing The Seat Belt
Illustration 41 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
size of the person. If the retractor does not lock
up, the seat belt will not retain the person.
Longer, non-retractable seat belts and extensions for
the non-retractable seat belts are available.
Caterpillar requires only non-retractable seat belts to
be used with a seat belt extension.
Consult your Cat dealer for longer seat belts and for
information on extending the seat belts.
i05701789
Mirror
SMCS Code: 7319
Adjust all mirrors as specified in the Operation
and Maintenance Manual. Failure to heed this
warning can lead to personal injury or death.
KEBU7583-01
Slips and falls can result in personal injury. Use
the machine's access systems when adjusting
the mirrors. If the mirrors cannot be reached us-
ing the machine access systems follow the in-
structions found within the Operation and
Maintenance Manual, “Mirror” in order to access
the mirrors.
Note: Your machine may not be equipped with all of
the mirrors that are described in this topic.
Illustration 42 g03621192
(1) Mirror on rear right side handrail
(2) Lower mirror on front right side handrail
(3) Upper mirror on front right side handrail
(4) Mirror on right side of hood
(5) Mirror on rear left side handrail
(6) Lower mirror on front left side handrail
(7) Upper mirror on front left side handrail
(8) Mirror on left side of hood
Mirrors provide additional visibility around your
machine. Make sure that the mirrors are in proper
working condition and that the mirrors are clean.
Adjust all mirrors at the beginning of each work
period and adjust the mirrors when you change
operators.
Modified Machines or machines that have additional
equipment or attachments may influence your
visibility.
KEBU7583-01 47
Operation Section
Mirror

The mirror adjustments that are discussed here are Lower Mirror on Front Right Side
for when the operator station is in the extreme left Handrail (2)
position. If the operator station is moved to the
extreme right position, the views for the mirrors will
be reversed from left to right. The mirrors will require
further adjustment when the operator station is
placed in an intermediate position. The operator is
responsible for adjusting the mirrors when the
position of the operator station is changed.

Mirror Adjustment
• Park the machine on a level surface.

• Lower the work tool to the ground.

• Stop the engine.

Note: Hand tools may be needed in order to adjust

the mirrors. Refer to Specifications, SENR3130,
“Torque Specifications” for the recommended torque.
Mirror on Rear Right Side Handrail (1)
Illustration 44 g03621259
When the lower mirror on the front right side handrail
is adjusted properly, no part of the machine will be
seen. A view of at least 1 m (3.3 ft) from the right
side of the machine, 1.5 m (4.9 ft) high, and 12 m
(39.4 ft) from the operator at the ground on the rear
side of the machine should be seen.

Upper Mirror on Front Right Side

Handrail (3)

Illustration 43 g03621257

Adjust the mirror on the rear right side handrail so

that a portion of the right side of the hood from the
screen to the front can be seen. A view of at least
2.5 m (8.2 ft) from the front center and right side of
the machine, 1.5 m (4.9 ft) high, and 12 m (39.4 ft)
from the operator at the ground in the front center of Illustration 45 g03621260
the machine should be seen.
Adjust the upper mirror on the front right handrail so
that the edge of the cutting chamber is visible.
48 KEBU7583-01
Operation Section
Mirror

Mirror on Right Side of Hood (4) Lower Mirror on Front Left Side Handrail
(6)

Illustration 46 g03621316
The mirror on the right side of the hood cannot be
seen when the cab is in the extreme left position.
Mirror on Rear Left Side Handrail (5)
Illustration 48 g03621264
Adjust the lower mirror on the front left side handrail
so that the left side of the machine, the left handrail,
and the left rotor lift cylinder can be seen. A view of at
least 1 m (3.3 ft) from the left side of the machine,
1.5 m (4.9 ft) high, and 12 m (39.4 ft) from the
operator at the ground on the rear left side of the
machine should be seen.

Upper Mirror on Front Left Side Handrail

(7)

Illustration 47 g03621262

Adjust the mirror on the rear left side handrail so that

a portion of the left side of the hood from the screen
to the front can be seen. A view of at least 2.5 m
(8.2 ft) from the front center of the machine, 1.5 m
(4.9 ft) high, and 12 m (39.4 ft) from the operator at
the ground in the front center of the machine should
be seen. Illustration 49 g03621265

Adjust the upper mirror on the front left handrail so

that the edge of the cutting chamber is visible.
KEBU7583-01
Mirror on Left Side of Hood (8)
Illustration 50 g03621267
Adjust the mirror on the left side of the hood so that
the left tire and the bottom corner of the operator
platform can be seen. A view of at least 12 m
(39.4 ft) from the operator at the ground on the rear
left side of the machine should be seen.
i05874246
Monitoring System
SMCS Code: 1900; 7000; 7400; 7490; 7600; 7601;
7603
Illustration 51 g03628828
Monitoring system
More detailed information about the use of
Information Display is available in a separate
publication. Refer to Systems Operation, UENR5497,
“RM500B Rotary Mixer Information Display System”.
49
Operation Section
Monitoring System
Performance Pages
Illustration 52 g03647571
The performance pages on the monitoring system
are the main introductory pages. Real-time machine
status information is displayed on the performance
page.
Categories for the navigation buttons are displayed
on each side of the performance page.
Top Level Navigation
Right Side Navigation Buttons
The Information Display has five buttons that act as
the principle navigation. The Display buttons have an
icon and are located on the right side of the Display.
The right side buttons are considered the categories
for navigation.
Display – Press the display button in
order to view the display menu.
Machine – Press the machine button in
order to view the machine menu.
Totals – Press the totals button in order
to view the totals menu.
Service – Press the service button in
order to view the service menu.
Left Side Navigation Buttons
The buttons on the left are considered hotkey buttons
and are application-specific for the rotary mixer.
Rotor – Press the rotor button in order
to access the main rotor page and view
the rotor settings.
50 KEBU7583-01
Operation Section
Monitoring System

Lights – Press the lights button in order
to activate and adjust the work lights.
Water Spray System – Press the water
spray system button in order to access
the main water spray system page and
adjust the water spray system settings.
Home – The “ Home”” button navigates to
the default screen from anywhere within
the Display.
Menu Buttons and Menu Button
Groups

Emulsion Spray System – Press the Navigation through menu lists and submenus is
possible by using the menu button groups. Menu
emulsion spray system button in order buttons do not show a pressed state. Instead, menu
to access the main emulsion spray buttons highlight in yellow when the operator selects
system page and adjust the emulsion spray an item. A menu button group is accessible by
system settings. directly touching a single button within the group, or
by using the navigation buttons along the right side.
Menu Navigation Buttons To select the highlighted item, press or touch the
“OK” button. On certain machines, if more than four
At the selection of a category, a menu appears and options are available and appear in a menu button
the right side buttons change to navigation buttons. group, a non-interactive scroll bar will appear.
While in the submenus, the right buttons are
displayed as the navigation keys for the category Scroll Bar
selected. In this state, the right side buttons are “Up” ,
“OK” , “Down” , “Back” , and “Home” .
Up – The “ Up”” navigation button
navigates lists and menus in the upward
direction.
OK – The “ OK”” button selects a
highlighted item, and confirms an
action.
Illustration 53 g03377932
Down – The “ Down”” navigation button A three page scroll bar on page 1.
navigates lists and menus in the
downward direction.
Back – The “ Back”” button navigates to
the previous screen, and cancels an
action.

Illustration 54 g03377990
A three page scroll bar on page 2.
KEBU7583-01 51
Operation Section
Monitoring System

The scroll bar object is used to navigate between the Pressing the “OK” button may not be necessary for
main performance pages. The scroll bar is all settings.
distinguished from the non-interactive scroll bar by
using an image to show the button characteristic in The newly set number appears in white text.
yellow. The scroll bar slider is also visually wider and
has an expanded activation zone to reduce activation Incremental Bar with Range
error. This scroll bar slider brings the next page into
view with either a touch above or below the slider or a
directional drag of the slider. Arrows appear on the
slider bar when more pages are available above or
below.

Incremental Bars
Incremental Bar

Illustration 57 g03378010

Increase a number by pressing the “+” button on the

Illustration 55 g03378002
Increase a number by pressing the “+” button on the
right end of the incremental bar.
Decrease a number by pressing the “-” button on the
left end of the incremental bar.
Incremental Bar with Value
right end of the incremental bar.
Decrease a number by pressing the “-” button on the
left end of the incremental bar.
When the desired number appears on the bar, press
the “OK” button to highlight that number in yellow and
set the number.
Pressing the “OK” button may not be necessary for
all settings.
When the number is set, a green status bar appears
with the new number in white.

Upper Information Banner

Illustration 56 g03378008 Illustration 58 g03648107

Upper information banner in day mode.
Increase a number by pressing the “+” button on the
right end of the incremental bar.
Decrease a number by pressing the “-” button on the
left end of the incremental bar.
When the desired number appears on the bar, press
the “OK” button to highlight that number in yellow and
set the number.
52
Operation Section
Monitoring System
The upper information banner appears in the top
area of the screen. The upper information banner
shows the status and settings of the machine.
Navigation Path
Illustration 59 g03648113
The navigation patch consists of icons showing the
pages visited, or the path taken, to arrive at the
current page.
Pop-Up Messages
Illustration 60 g03383856
Pop-up messages within the monitoring system
inform the operator of a pending or immediate
machine condition. These messages are abbreviated
to relate the machine condition while the machine is
in operation. The messages are restricted to a
dedicated area of the display to minimize conflicts
with productivity and safety information.
The pop-up message box is formatted to provide
required information in a condensed, understandable
condition for the operator. Pop-up messages are
used for various information conditions and
severities.
KEBU7583-01
Information Pop-Ups
Information pop-ups provide non-safety critical
messages to the operator. Text within the messages
appears in complete words, allowing for greater
understanding. If multiple information pop-ups are
active, an arrow will appear and indicate so. Press
the arrow in order to scroll through all active pop-ups.
If the arrow is not pressed for five seconds, the
display automatically pages through active
information pop-ups, provided no warnings are
active. If any warnings are active, and not snoozed,
the information pop-ups will not display.
Warnings
Illustration 61 g03383856
There are three levels of warnings, and each level
appears as a different color. The following colors are
associated with each warning level:
Level 1 – Gray
Level 2 – Yellow
Level 3 – Red
Level 1 Warning
A Level 1 Warning supersedes any active information
pop-up.
If multiple warnings are active, an arrow will appear
and indicate so. Press the arrow in order to scroll
through all active pop-ups. The numbers above the
arrow indicate the index of the currently displayed
pop-up and the total number of active and unsnoozed
pop-ups that can be accessed using the arrow.
If the arrow is not pressed for five seconds, the
display automatically pages through the active Level
1 Warnings, provided no Level 2 or Level 3 Warnings
are active.
These warnings may be snoozed, after which time,
the warnings will reappear if the event generating the
warning remains active.
Level 2 Warning
A Level 2 Warning supersedes any active information
pop-up, and any Level 1 Warning.
KEBU7583-01 53
Operation Section
Monitoring System

If multiple warnings are active, an arrow will appear (Table 7, contd)

and indicate so. Press the arrow in order to scroll Emulsion Control (If Equipped)
through all active pop-ups. The numbers above the
arrow indicate the index of the currently displayed > Flow Rate
pop-up and the total number of active and unsnoozed
pop-ups that can be accessed using the arrow. > Application Rate

> Settings
If the arrow is not pressed for five seconds, the
display automatically pages through the active Level >> Spray Mode
2 Warnings, provided no Level 3 Warnings are active.
>> Nozzles
These warnings may be snoozed, depending on the
condition. If the warnings are an event, the warning >> Recirculation
will reappear if the event generating the warning
remains active.
Display
Level 3 Warning > Display Brightness

Level 3 Warnings are the highest priority. A Level 3 > Units

Warning always supersedes an active Level 2, or
> Software License Information
lower, pop-up.
If multiple warnings are active, an arrow will appear
and indicate so. Press the arrow in order to scroll Machine
through all active pop-ups. The numbers above the > Settings
arrow indicate the index of the currently displayed
pop-up and the total number of active and unsnoozed >> Load Control
pop-ups that can be accessed using the arrow.
>> Steering Adjustment
If the arrow is not pressed for five seconds, the >> Rotor Depth
display automatically pages through the active Level
3 Warnings only. >> Rotor Depth (Zero Depth Control)

>> Reversing Fan

Available Features
The features listed in the following table are available
for viewing in the Information Display on this Totals
machine. > Water
Table 7
> Emulsion
Menu Structure
Performance Pages
Service
> Diagnostics
Rotor Information
>> Diagnostics Details

>>> Forward Control Solenoid

Work Lights
>>> Reverse Control
> ECM Summary
Water Control (If Equipped)
>> Engine
> Flow Rate
>> Machine
> Application Rate
>> Transmission
> Settings
>> Product Link
>> Spray Mode
>> Aftertreatment
>> Nozzles
>> Display

(continued)
(continued)
54
Operation Section
Product Link
(Table 7, contd)
Pop-up Messages and Faults
i07103592
Product Link
SMCS Code: 7490; 7606
Note: Your machine may be equipped with the Cat ®
Product Link ™ system.
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
communication device uses Global Positioning
System (GPS) satellite receivers.
The capability of two-way communication between
the equipment and a remote user is available with the
Cat Product Link communication device. The remote
user can be a dealer or a customer.
Data Broadcasts
Data concerning this machine, the condition of the
machine, and the operation of the machine is being
transmitted by Cat Product Link to Caterpillar and/or
Cat dealers. The data is used to serve the customer
better and to improve upon Cat products and
services. The information transmitted may include:
machine serial number, machine location, and
operational data, including but not limited to: fault
codes, emissions data, fuel usage, service meter
hours, software, and hardware version numbers and
installed attachments.
Caterpillar and/or Cat dealers may use this
information for various purposes. Refer to the
following list for possible uses:
• 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
orders
• Performing market research
KEBU7583-01
• Offering the customer new products and services
Caterpillar may share some or all the collected
information with Caterpillar affiliated companies,
dealers, and authorized representatives. Caterpillar
will not sell or rent collected information to any other
third party and will exercise reasonable efforts to
keep the information secure. Caterpillar recognizes
and respects customer privacy. For more information,
please contact your local Cat dealer.
Operation in a Blast Site for
Product Link Radios
This equipment is equipped with a Cat® Product
Link communication device. When electric deto-
nators are being used for blasting operations, ra-
dio frequency devices can cause interference
with electric detonators for blasting operations
which can result in serious injury or death. The
Product Link communication device should be
deactivated within the distance mandated under
all applicable national or local regulatory require-
ments. In the absence of any regulatory require-
ments Caterpillar recommends the end user
perform their own risk assessment to determine
safe operating distance.
For information regarding the methods to disable the
Cat Product Link communication device, please refer
to your specific Cat Product Link manual listed below.
For more information regarding Cat Product Link
refer to Operation and Maintenance Manual,
SEBU8142, “Product Link - 121SR/321SR/420/421/
522/523” , Operation and Maintenance Manual,
SEBU8832, “Product Link PLE601, PL641, PL631,
PL542, PL240, PL241, PL141, PL131, PL161, and
G0100 Systems”, or Operation and Maintenance
Manual Supplement, “Regulatory Compliance
Information”.
i06750923
Operator Controls
SMCS Code: 7300; 7301; 7451
Note: Your machine may not be equipped with all the
controls that are discussed in this topic.
The operation section is a reference for the new
operator and a refresher for the experienced
operator. This section includes descriptions of
gauges, switches, machine controls, attachment
controls, transportation, and towing information.
KEBU7583-01 55
Operation Section
Operator Controls

Illustrations guide the operator through correct

procedures of checking, starting, operating, and
stopping the machine. Operating techniques that are
outlined in this publication are basic. Skill and
techniques develop as the operator gains knowledge
of the machine and the capabilities of the machine.

Illustration 62 g06105293

(1) Camera control (5) Turn signals (8) Horn

(2) Steering wheel (5A) Action lamp (9) Keypad
(3) Monitoring system (6) Auxiliary shutdown knob (10) Engine start switch
(4) Propel control (7) Parking brake
56 KEBU7583-01
Operation Section
Operator Controls

Illustration 63 g03621616
Propel Control (4)
(11) Rotor raise
(12) Rotor lower
(13) Rotor travel mode
(14) Rotor automatic depth setpoint
(15) Rear rotor door raise
(16) Rear rotor door lower
(17) Trigger

Illustration 64 g03621656
Keypad (9)
(18) Cruise control speed increase
(19) Cruise control speed decrease
(20) Travel mode
(21) Throttle control
(22) Steering mode select
(23) Spray system control
(24) Operator station slide left
(25) Rear steer left
(26) Front rotor door raise
(27) Front rotor door lower
(28) Chamber service mode / chamber float
(29) Chamber tilt back
(30) Rotor speed
(31) Rotor control
(32) Operator station slide right
(33) Rear steer right
KEBU7583-01 57
Operation Section
Operator Controls

Camera Control (1)

Camera Control – Push this switch to
toggle the images that are shown on the
monitor in the cab. For more
information, refer to Operation and Maintenance
Manual, “Monitoring System”.

Steering Wheel (2)

The steering wheel controls the directional steering of
the machine. The machine will turn in the same
direction as the steering wheel.

Illustration 65 g03623737
Monitoring System (3)
(34) 12V power receptacle For information concerning the monitoring system
(35) Lights
(36) Hazard lights
refer to Operation and Maintenance Manual,
(37) Regeneration switch “Monitoring System”.

Propel Control (4)

Illustration 66
(38) Temperature control
(39) Heater and air conditioner selector switch
(40) Fan speed control
(41) Front window wiper switch
(42) Rear window wiper switch
When the ECM is cycled, the propel control will
default to the STOP position. The propel control will
default to the STOP position regardless of the
position of the propel control. If the machine is started
with the propel lever out of the STOP position, the
lever must be placed in the STOP position before the
propel system will be active.
Refer to Systems Operation, Testing and Adjusting,
“Propel Adjust - Test and Adjust” to test the propel
control.
FWD – Press trigger (17) to move the lever out of the
neutral position. Push the lever away from the
g03623738 operator to move the machine forward. To cause the
machine to move faster, push the lever farther.
STOP – Move the lever to the center STOP position
to stop the machine.

REV – Press trigger (17) to move the lever out of the

neutral position. Pull the lever toward the operator to
move the machine in reverse. To cause the machine
to move faster, pull the lever farther.
58 KEBU7583-01
Operation Section
Operator Controls

Note: Shutting down the engine using this method is

Turn Signals (5)
Turn Signals – Push down on the left
side of the switch to activate the left turn
signal. Push down on the right side of
the switch to activate the right turn signal.
Action Lamp (5A)
Action Lamp (5A) – Action lamp will
flash for Level 2 alarms to warn the
operator that a change of machine
operation is required to avoid possible damage to
the indicated system, and flashes along with an
audible alarm for a Level 3 Alarm.
Auxiliary Shutdown Knob (6)
Auxiliary Shutdown Knob – To stop the
engine, push the knob downward. To
release the auxiliary shutdown knob,
pull the knob upward.
Parking Brake (7)
Parking Brake Apply – To apply the
parking brake, push the top of the
switch.
considered a hard shutdown which disables the DES.
Note: A warning message and/or Audible alarm will
be initiated. A fault code will be logged for improper
engine shutdown if exhaust temperature is above
limit.
Note: Overriding delayed engine shutdown may
reduce engine and machine system component life.
OFF – When you insert the engine start
switch key and when you remove the
engine start switch key, the engine start
switch must be in the OFF position. Also, turn the
engine start switch to the OFF position to stop
the engine.
ON – To activate the electrical circuits in
the cab, insert the engine start switch
key and turn the engine start switch
clockwise to the ON position.
START – To start the engine, insert the
engine start switch key and turn the
engine start switch clockwise to the
START position. When the engine start switch
key is released, the engine start switch will return
to the ON position.

Parking Brake Release – To release the

parking brake, push the bottom of the
switch. The parking brake will release
when the machine is propelled.
Note: If the propel control is not in the NEUTRAL
position when the parking brake is released, the
machine will not propel. The propel control must be
returned to the NEUTRAL position to propel the
machine.

Horn (8)
Horn – Push the top of the horn switch
to sound the horn. Use the horn for
alerting personnel or for signaling
personnel.

Engine Start Switch (10)

When you turn the switch to the ON position,
electrical power is supplied to the systems.
Engine Stop (Shutdown) – Turn the key
to this position to disable the delayed
engine shutdown (DES). The engine will
be shut down immediately.
KEBU7583-01
Note: If the engine fails to start, return the engine
start switch to the OFF position. This must be done
before you attempt to start the engine again.
Rotor Raise (11)
Rotor Raise – Push the button to raise
the rotor.
Rotor Lower (12)
Rotor Lower – Push the button to lower
the rotor.
Rotor Travel Mode (13)
Rotor Travel Mode – Push the button to
activate the rotor travel mode.
Rotor Automatic Depth Setpoint
(14)
Rotor Automatic Depth Setpoint – Press
the button twice to make the current
depth the setpoint. Press and hold the
button for 2 seconds to set the rotor depth to
automatic mode.
Rear Rotor Door Raise (15)
Rear Rotor Door Raise – Push the
button to raise the rear rotor door.
Rear Rotor Door Lower (16)
Rear Rotor Door Lower – Push the
button to lower the rear rotor door.
Cruise Control Speed Increase (18)
Cruise Control Speed Increase – Push
the button to increase the cruise control
speed. To continue to increase the
cruise control speed, push the button again until
the desired cruise control speed is achieved.
Hold the button down to increase the speed
faster.
59
Operation Section
Operator Controls
Cruise Control Speed Decrease
(19)
Cruise Control Speed Decrease – Push
the button to decrease the cruise
control speed. To continue to decrease
the cruise control speed, push the button again
until the desired cruise control speed is
achieved. Hold the button down to decrease the
speed faster.
Travel Mode (20)
Travel Mode – Push the button to
activate the propel travel mode. Push
the button again to turn off the propel
travel mode. When travel mode is activated, the
light next to the travel mode button will be
illuminated.
Throttle Control (21)
Throttle Control – Push the button to
change the engine speed.
Low Idle – The machine starts in low idle. If the
machine is in high idle, press the button to return to
low idle.
High Idle – Push the throttle control button to select
high idle. Push the button again to return the
machine to low idle.
Steering Mode Select (22)
Steering Mode Select – Push the button
to select the steering mode for the
machine.
Rear Steering Mode – When rear steering mode is
selected, the bottom indicator light will be illuminated.
The front wheels will turn in the direction commanded
by the steering wheel. The rear wheels will turn and
hold position using the rear steer right and rear steer
left keypad buttons.
Front Steering Mode – When front steering mode is
selected, the top indicator light will be illuminated. In
rear steering mode, only the front wheels will turn in
the direction commanded by the steering wheel. The
rear wheels will turn momentarily and return to center
using the rear steer right and rear steer left keypad
buttons.
Coordinated Steering Mode – When coordinated
steering mode is selected, the top and bottom
indicator lights will be illuminated. When machine is
operating in coordinated steering mode, rear wheels
turn in the opposite direction as front wheels.
60
Operation Section
Operator Controls
Crab Steering Mode – In crab steering mode the
rear wheels will pivot in the same direction as the
front wheels. The crab steer mode allows you to
move the machine sideways. With each actuation of
switch, steering mode cycles through rear steering,
front steering, coordinated steering, and crab
steering modes, in that order.
Note: When the engine is started, the steering mode
defaults to rear steering.
Spray System Control (23)
Spray System Control – Spray system
control switch is push-button type
switch. Switch controls three states of
spray bar operation, AUTO, ON, and OFF. 1st
depression of switch places spray system in
AUTO mode. When the spray system is set to
Auto, the spray bar will only spray when the
machine is moving. 2nd depression with two-
second hold turns spray system ON. Single
depression of switch with immediate release
while system is in either AUTO or ON turns
system OFF.
Operator Station Slide Left (24)
Operator Station Slide Left – Push the
button to slide the operator station to
the left. Ensure that the platform and the
access ladders are clear of objects and personnel
before you slide the operator station.
KEBU7583-01
Note: The operator must be seated in order for the
operator station slide to function.
Rear Steer Left (25)
Rear Steer Left – Push the button to turn
the rear wheels to the left.
Front Rotor Door Raise (26)
Front Rotor Door Raise – Push the
button to raise the front rotor door.
Front Rotor Door Lower (27)
Front Rotor Door Lower – Push the
button to lower the front rotor door.
Chamber Service Mode / Chamber
Float (28)
Chamber Service Mode – Push the
switch until the top light is illuminated to
tilt the rear of the rotor mixing chamber
upward. The chamber will maintain that position.
Chamber Float – Push the switch until
the lower light is illuminated to activate
the chamber float. When chamber float
is activated, the machine pressurizes both ends
of the cylinder. The pressure creates a slight
downward force on the rear door while the
machine is working. The cylinder can move in
this setting. Cylinder movement allows the rotor
to ride over irregularities on the ground.
Chamber Tilt (29)
Chamber Tilt – Push the switch in order
pressurize the base end of the cylinder.
The chamber will move downward to the
chamber lower position. The rotor will stay flat at
any depth of the rotor.
Rotor Speed (30)
Rotor Speed – Press the switch to
change the speed of the rotor.
Note: Upshifting or downshifting rotor speeds should
only be done when the engine speed is at low idle.
Note: Before shutting off the rotor, set the engine
throttle control to the SLOW position. Lower the rotor
to the LOW position and then stop the rotor.
KEBU7583-01
Note: Do not shut off the rotor at full throttle. Only
shut off the rotor if an emergency situation arises.
Rotor Control (31)
Rotor Control – Press and hold the
switch for 2 seconds to activate the
rotor. Push the switch again to turn off
the rotor.
Note: The rotor cannot be engaged with the engine
at high idle. Do not increase the engine idle speed
until the rotor is fully engaged.
Operator Station Slide Right (32)
Operator Station Slide Right – Push the
button to slide the operator station to
the right. Ensure that the platform and
the access ladders are clear of objects and
personnel before you slide the operator station.
Note: The operator must be seated in order for the
operator station slide to function.
Rear Steer Right (33)
Rear Steer Right – Push the button to
turn the rear wheels to the right.
12V Power Receptacle (34)
12V Power Receptacle – This power
receptacle can be used to power
automotive electrical equipment or
accessories. Remove the cap before use.
Lights (35)
Front Working Lights/Marker Lights/
Backlighting – Move the switch to the
top position to turn on the front working
lights, marker lights, and backlighting.
Off – Move the switch to the bottom position to turn
off the lights.
61
Operation Section
Operator Controls
Hazard Lights (36)
Hazard Lights – Push the top of the
switch to turn on the hazard lights. Push
the bottom of the switch to turn off the
hazard lights.
Regeneration Switch (37)
Note: The MIDDLE position of the regeneration
switch is the default position for automatic
regeneration.
Force Regeneration – The following
conditions must be met to force a
regeneration:
• The machine must be stopped with the parking
brake enabled
• The minimum coolant temperature must be
reached
• The DPF soot load must be achieved
Note: These conditions do not apply to automatic
regeneration, which may occur during regular
machine operation.
Press in the top of the switch for 2 seconds to begin
regeneration. The high exhaust temperature indicator
will become active showing that the regeneration is
active. The high exhaust temperature indicator will
deactivate after regeneration is completed or the
regeneration has been disabled. An indicator light on
the switch will illuminate showing that the
regeneration is active.
Disable Regeneration – Press in the
bottom of the switch for 2 seconds to
disable regeneration. An indicator light
on the switch will illuminate showing that the
regeneration is being disabled.
Note: To re-enable the regeneration, cycle the
engine start switch key or press and hold down the
force regeneration switch for 2 seconds.
Note: If the engine start switch key is cycled while
the regeneration system is disabled via the disable
regeneration switch, press and hold the disable
regeneration switch for 2 seconds to reinitiate the
disable regeneration.
62
Operation Section
Diesel Particulate Filter Regeneration
Refer to Operation and Maintenance Manual, “Diesel
Particulate Filter Regeneration” for more information.
Temperature Control (38)
Turn the temperature control clockwise to increase
the air temperature. Turn the temperature control
counterclockwise to decrease the air temperature.
Heater and Air Conditioner Control
(39)
The heater and air conditioner control is a three-
position switch.
Heater – Push the upper portion of the
switch to the HEATER position to turn
on the cab heater.
Move the switch to the middle OFF position to select
the ambient air temperature.
Air conditioner – Push the lower portion
of the switch to the AIR CONDITIONER
position to turn on the air conditioner.
Fan Speed Control (40)
The fan control is a three-position switch.
HIGH – Push the upper portion of the
switch to select the HIGH fan speed.
MEDIUM – Move the switch to the middle
position to select the MEDIUM fan
speed.
KEBU7583-01
LOW – Push the lower portion of the
switch to select the LOW fan speed.
Front Window Wiper Switch (41)
Front Window Wiper Switch – Push
down on the top of the switch to turn on
the front window wiper. Push down the
bottom of the switch to turn off the front window
wiper.
Rear Window Wiper Switch (42)
Rear Window Wiper Switch – Push down
on the top of the switch to turn on the
rear window wiper. Push down the
bottom of the switch to turn off the rear window
wiper.
i05813056
Diesel Particulate Filter
Regeneration
SMCS Code: 108F
S/N: MB91–Up
Regeneration
Regeneration is to increase the exhaust temperature
for a given time. The Caterpillar Regeneration
System (CRS) is used to remove soot from the DPF,
and warm up the Selective Catalyst Reduction (SCR)
system. The DPF traps both soot and ash. The ash is
removed through a manual cleaning process. Refer
to Operation and Maintenance Manual, “Diesel
Particulate Filter - Clean” for more information on the
service of the DPF.
Regeneration Indicators
Regeneration Active – When
illuminated, this indicator shows that
the system is active. This indicator
shows that elevated emission temperatures are
possible. This indicator will turn off when
regeneration is complete.
DPF – This indicator will illuminate in
order to show that a regeneration is
required. This indicator will illuminate
when “ Time to Regen”” is less than a pre-
determined amount of time.
KEBU7583-01
Regeneration Disabled – This indicator
will illuminate in order to show that a
regeneration has been disabled.
Regeneration Switch
Force Regeneration – Press in the top
switch for 2 seconds in order to begin
regeneration.
Disable Regeneration – Press in the
bottom switch for 2 seconds in order to
disable regeneration.
Note: If equipped with a rocker style switch, the
MIDDLE position of the regeneration switch is the
default position for automatic regeneration.
Note: If the engine start switch key is cycled or the
“Force Regeneration” switch is pressed for longer
than 2 seconds the system will no longer be disabled.
When the “Force Regeneration” switch is pressed
and “Time to Regen” is less than 8 hours,
regeneration will begin if the machine is at low idle
and is parked.
Note: If the engine start switch key is cycled while
the regeneration system is disabled via the “Disable
Regeneration” switch, press and hold the “Disable
Regeneration” switch for 2 seconds to reinitiate.
Modes of Regeneration
Automatic: The Electronic Control Module (ECM)
uses multiple inputs from the engine and the machine
to determine the best time to perform an automatic
regeneration. Automatic regenerations can take
place throughout the operating cycle of the engine.
The regeneration active indicator will be illuminated
when a regeneration is being performed.
Interruptions of the regeneration are acceptable. If a
regeneration is in progress and needs to be stopped,
it is permissible to press the “Disable Regeneration”
switch.
Note: Automatic adjustments of engine speed may
be noticed during regenerations. If a regeneration is
taking place and the engine is taken to low idle, the
engine speed may remain elevated in order to
maintain the regeneration.
Note: If the machine returns to work while an
automatic regeneration is active, the regeneration
may be stopped. The ECM will continue to monitor
inputs to determine the best time to restart the
regeneration.
63
Operation Section
Diesel Particulate Filter Regeneration
Manual: A manual regeneration is initiated by
pressing the “Force Regeneration” switch. A manual
regeneration will only be allowed if the “Time to
Regen” is less than 8 hours. If the “Force
Regeneration” switch is pressed before “Time to
Regen” is less than 8 hours, then “Regen not
Required” will be displayed. The machine must be
stationary, the parking brake must be applied, and
the engine must be at low idle in order to perform a
manual regeneration.
Disabled: When the regeneration system is in
disabled mode, automatic regenerations will not be
performed. The DPF indicator will illuminate if a
manual regeneration is required. The “Time to
Regen” displayed on the performance screen will
indicate the time until the next regeneration will be
required. However, the DPF indicator may illuminate
with time remaining on the display. When the DPF
indicator illuminates, the operator must perform a
manual regeneration.
Regeneration Triggers
A regeneration may be required for the following
reasons:
Soot: The DPF will collect soot produced by the
engine. An automatic regeneration will become
active to reduce soot level.
Start-Up Regeneration: A start-up regeneration is
initiated by the ECM after a cold engine start. This
regeneration is performed to heat the system to a
required temperature for Diesel Exhaust Fluid (DEF)
dosing to begin.
SCR Maintenance: A regeneration is performed to
maintain the SCR system.
ARD Maintenance: A regeneration is performed to
maintain the CRS system.
Regeneration System Warning
Indicators
Illustration 67 g02117258
The DPF Indicator will illuminate when a regeneration
is required. A regeneration should be performed as
soon as possible.
64
Operation Section
Selective Catalytic Reduction Warning System
Note: In some situations, the DPF indicator may stay
illuminated after a regeneration ends. The illuminated
DPF indicator indicates that a complete regeneration
has not been performed. A complete regeneration is
when the soot has been depleted or all of the criteria
for one of the other regeneration types have been
met. If the DPF indicator stays illuminated, perform a
regeneration without interruption. The DPF indicator
will shut off when a regeneration is complete.
Illustration 68 g02117259
If the soot load is above a threshold or “Time to
Regen” is 0 hours, then a regeneration is required.
The DPF indicator and an action indicator will be
illuminated. Engine power will be slightly derated. If
the machine continues to operate without a
regeneration, derate will eventually reach 100%.
Stop the machine and apply the parking brake. With
the engine at low idle, initiate a manual regeneration.
Illustration 69 g03676115
Once the amount of soot collected in the DPF has
reached a threshold or “Time to Regen” has been at
0 hours for a pre-determined time, the DPF indicator
and an action indicator will be illuminated and an
audible alarm will sound.
10 minutes after the illumination of the DPF indicator,
action indicator, and audible alarm, the engine will
shut down. The engine can be restarted by cycling
the engine start switch key. The engine will return to
the previous derate state before shutdown.
Once the amount of soot collected reaches a
threshold level or 6.4 hours of run time has passed
since the action indictor was illuminated without a
successful regeneration, the engine will have a 100%
derate.
KEBU7583-01
Once the amount of soot collected reaches a critical
threshold level, the regeneration will be locked out. At
this time, a regeneration can only be done through
Cat Electronic Technician (ET), by an authorized Cat
dealer. The engine may be restarted, but will only run
for 30 seconds before shutting down again.
i05771284
Selective Catalytic Reduction
Warning System
SMCS Code: 1091-WXX; 7400
S/N: MB91–Up
The selective catalytic reduction (SCR) system is a
system used to reduce NOx emissions from the
engine. Diesel exhaust fluid (DEF) is pumped from
the DEF tank and is sprayed into the exhaust stream.
The DEF reacts with the SCR catalyst to reduce NOx
and leaves a nitrogen and water vapor. The Exhaust
Gas Recirculation (EGR) system cools, measures,
and introduces recalculated exhaust gas into the
intake manifold to aid in NOx reduction.
NOTICE
Stopping the engine immediately after the engine has
been working under load can result in overheating of
SCR components.
Refer to the Operation and Maintenance Manual,
“Engine Stopping” procedure to allow the engine to
cool and to prevent excessive temperatures in the
turbocharger housing and the DEF injector.
NOTICE
Allow at least 2 minutes after shutting down the en-
gine before you turn the battery disconnect switch to
OFF. Disconnecting the battery power too soon will
prevent purging of the DEF lines after the engine is
shut down.
Definitions
Observe the following definitions.
Self-correct – Fault condition no longer exists. An
active fault code will no longer be active.
Notification – Action taken by the system to alert the
operator of pending Inducement.
Inducement – Engine derates, vehicle speed limits,
or other actions intended to prompt the operator to
repair or maintain the emission control system.
Inducement Trigger – Fault conditions that result in
activation of the inducement strategy. DEF level
inducement faults have a diagnostic fault code. DEF
quality fault, SCR tampering fault, SCR system fault,
and EGR system faults will all have a related
KEBU7583-01
diagnostic fault code along with an inducement
diagnostic fault code.
First occurrence – A DEF quality fault, SCR
tampering fault, SCR system fault, or an EGR system
fault becomes active for the first time.
Repeat occurrence – If any DEF quality fault, SCR
tampering fault, SCR system fault, or an EGR system
fault becomes active again within 40 hours of the first
occurrence.
Safe Harbor Mode – Safe harbor mode is a 20
minute engine run time period. The engine can be
operated with full power after reaching a level 3
inducement. Once in level 3 inducement, the
operator can perform a key cycle and the engine will
enter safe harbor mode. Safe harbor mode can only
be implemented once. Safe harbor mode is not
allowed for DEF level inducements.
Inducement Strategy for DEF Level
Illustration 70 g03661613
The DEF level percentage is shown on the
performance page of the monitoring system. For
more information refer to Operation and Maintenance
Manual, “Monitoring System”.
Illustration 71 g03661660
If the DEF level falls below 20%, an amber indicator
will illuminate next to the DEF level gauge on the
display. To avoid further inducements, turn the key to
the OFF position and add DEF to the DEF tank.
65
Operation Section
Selective Catalytic Reduction Warning System
Illustration 72 g03661630
If the DEF level falls below 13.5%, a level 1
inducement event will occur. The check engine lamp
and the emissions malfunction indicator lamp will
illuminate. The amber indicator next to the DEF level
gauge on the display will continue to remain lit.
Illustration 73 g03661648
If the DEF level is below 7.5%, a level 2 inducement
event will occur. The check engine lamp and the
emissions malfunction indicator lamp will illuminate
and a flashing action indicator will also illuminate.
The amber indicator next to the DEF level gauge on
the display will remain lit. If the ECM is configured to
“Reduced Performance” and the DEF level has
reached 1%, the machine will be limited to 75%
torque.
Illustration 74 g03661649
If the ECM is configured to “Reduced Performance”
and the DEF tank has been emptied of all DEF, the
engine will be in a level 3 final inducement. If the
ECM is configured to “Reduced Time” and the DEF
level is 3%, the engine will be in a level 3 final
inducement. Prior to final inducement the check
engine lamp and the emissions malfunction indicator
lamp will illuminate, the flashing action indicator will
illuminate, and an audible alarm will sound 20
seconds prior to the final inducement. The engine will
be taken to low idle or will be shut down. Once shut
down, the engine can be restarted for 5 minute
periods at reduced speed and torque. If set to idle,
the engine will idle indefinitely at reduced torque. The
amber indicator next to the DEF level gauge on the
display will remain lit.
66 KEBU7583-01
Operation Section
Battery Disconnect Switch

Note: Turn the key to the OFF position and add DEF
to the DEF tank to reset the DEF level inducement.

Inducement Strategy for DEF

Quality, Tampering, SCR System
Fault, and Impeded EGR
Illustration 77 g03623193

If a fault condition exists for the entire duration of

Illustration 75 g03623190
The emissions malfunction indicator lamp will
illuminate for a fault resulting from poor DEF quality,
SCR system tampering, SCR system fault, or an
EGR system fault. If the fault is the result of poor DEF
quality, SCR system tampering, or SCR system fault,
a first occurrence will result in a level 1 inducement
for a duration of 2.5 hours. The level 1 inducement
will also illuminate the check engine lamp. Repeat
occurrences will result in a level 1 inducement
duration of 5 minutes. If the fault is the result of an
EGR system fault, a first occurrence will result in a
level 1 inducement for a duration of 35 hours. Repeat
occurrences will result in a level 1 inducement
duration of 48 minutes.
inducement level 2, the strategy advances to
inducement level 3. The check engine lamp and the
emissions malfunction indicator lamp will illuminate,
flashing action indicator will illuminate, and an
audible alarm will sound 20 seconds prior to the level
3 inducement. The engine will be taken to low idle or
will be shut down. After the level 3 inducement you
may cycle the key, which will allow 20 minutes of
engine run time with full torque. After 20 minutes, the
engine will be in level 3 final inducement and will
allow idle only or be shut down until the issue has
been resolved. Once shut down, the engine can be
restarted for 5 minute periods at reduced speed and
torque. If set to idle, the engine will idle indefinitely at
reduced torque.
Note: Contact your Cat dealer for repairs if a fault
occurs.
i05710718
Battery Disconnect Switch
SMCS Code: 1411

S/N: MB91–Up

Illustration 76 g03623191

If a fault condition exists for the entire duration of

inducement level 1, the strategy advances to
inducement level 2. The check engine lamp and the
emissions malfunction indicator lamp will illuminate
and a flashing action indicator will also illuminate for
a fault resulting from poor DEF quality, SCR system
tampering, SCR system fault, or an EGR system
fault. For poor DEF quality, SCR system tampering,
and SCR system faults, the duration for a level 2
inducement is 70 minutes for the first occurrence. For
EGR system faults, the duration for a level 2
inducement is 60 minutes for the first occurrence.
Repeat occurrences for poor DEF quality, SCR
system tampering, and SCR system faults will result
in a level 2 inducement of 5 minutes. Repeat
occurrences for EGR system faults will result in a
level 2 inducement of 60 minutes.
KEBU7583-01
Illustration 78 g03628516
Illustration 79 g03408962
NOTICE
Do not turn off the battery disconnect switch until the
indicator lamp has turned off. If the switch is turned
off when the indicator lamp is illuminated the Diesel
Exhaust Fluid (DEF) system will not purge the DEF. If
the DEF does not purge, DEF could freeze and dam-
age the pump and lines.
NOTICE
Never move the battery disconnect switch to the OFF
position while the engine is operating. Serious dam-
age to the electrical system could result.
The battery disconnect switch is on the left side of the
machine above the front tire, near the ladder.
Battery Disconnect Switch – The battery
disconnect switch can be used in order
to disconnect the battery from the
engines electrical system. The key must be
inserted into the battery disconnect switch
before the battery disconnect switch can be
turned.
67
Operation Section
Battery Disconnect Switch
ON – To activate the electrical system,
insert the disconnect switch key and
turn the battery disconnect switch
clockwise. The battery disconnect switch must
be turned to the ON position before you start the
engine.
OFF – To deactivate the electrical
system, turn the battery disconnect
switch counterclockwise to the OFF
position.
Note: The battery disconnect switch and the engine
start switch serve different functions. When the
battery disconnect switch is turned off, the entire
electrical system is disabled. When only the engine
start switch is turned off, the battery remains
connected to the electrical system.
Turn the battery disconnect switch key to the OFF
position and remove the battery disconnect switch
key when you service the electrical system or you
service any other components of the machine.
Turn the battery disconnect switch key to the OFF
position and remove the battery disconnect switch
key when you exit the machine overnight or when the
machine is left for an extended period of one month
or longer. This procedure will prevent a short circuit
from draining the battery. This procedure will prevent
the components from draining the battery. This
procedure will also prevent the battery from being
drained by vandalism.
To ensure that no damage to the engine occurs,
verify that the engine is fully operational before
cranking the engine. Do not crank an engine that is
not fully operational.
Perform the following procedure in order to check the
battery disconnect switch for proper operation:
1. With the battery disconnect switch in the ON
position, verify that electrical components in the
operator compartment are functioning. Verify that
the hour meter is displaying information. Verify that
the engine will crank.
2. Turn the battery disconnect switch to the OFF
position.
3. Verify that the following items are not functioning:
electrical components in the operator
compartment, hour meter and engine cranking. If
any of the items continue to function with the
battery disconnect switch in the OFF position,
consult your Caterpillar dealer.
68
Operation Section
Battery Disconnect Switch
i05710874
Battery Disconnect Switch
SMCS Code: 1411
S/N: TAS1–Up
Illustration 80 g03628516
NOTICE
Never move the battery disconnect switch to the OFF
position while the engine is operating. Serious dam-
age to the electrical system could result.
The battery disconnect switch is on the left side of the
machine above the front tire, near the ladder.
Battery Disconnect Switch – The battery
disconnect switch can be used in order
to disconnect the battery from the
engines electrical system. The key must be
inserted into the battery disconnect switch
before the battery disconnect switch can be
turned.
ON – To activate the electrical system,
insert the disconnect switch key and
turn the battery disconnect switch
clockwise. The battery disconnect switch must
be turned to the ON position before you start the
engine.
OFF – To deactivate the electrical
system, turn the battery disconnect
switch counterclockwise to the OFF
position.
Note: The battery disconnect switch and the engine
start switch serve different functions. When the
battery disconnect switch is turned off, the entire
electrical system is disabled. When only the engine
start switch is turned off, the battery remains
connected to the electrical system.
KEBU7583-01
Turn the battery disconnect switch key to the OFF
position and remove the battery disconnect switch
key when you service the electrical system or you
service any other components of the machine.
Turn the battery disconnect switch key to the OFF
position and remove the battery disconnect switch
key when you exit the machine overnight or when the
machine is left for an extended period of one month
or longer. This procedure will prevent a short circuit
from draining the battery. This procedure will prevent
the components from draining the battery. This
procedure will also prevent the battery from being
drained by vandalism.
To ensure that no damage to the engine occurs,
verify that the engine is fully operational before
cranking the engine. Do not crank an engine that is
not fully operational.
Perform the following procedure in order to check the
battery disconnect switch for proper operation:
1. With the battery disconnect switch in the ON
position, verify that electrical components in the
operator compartment are functioning. Verify that
the hour meter is displaying information. Verify that
the engine will crank.
2. Turn the battery disconnect switch to the OFF
position.
3. Verify that the following items are not functioning:
electrical components in the operator
compartment, hour meter and engine cranking. If
any of the items continue to function with the
battery disconnect switch in the OFF position,
consult your Caterpillar dealer.
i05745676
Operator Interlocks
SMCS Code: 7451; 7490
Engine Start Interlock
After you start the engine, an incorrect operational
sequence will cause the function to be inoperable.
KEBU7583-01 69
Operation Section
Operator Interlocks

Illustration 81 g03628828

Note: The monitoring system will flash an icon in

order to indicate the appropriate operator error.
Refer to the following checklist for a description of the
engine start interlocks.
Table 8
Control Condition Indicator Remedy

The engine will not start if the aux- Pull the auxiliary shutdown knob
Engine Start Switch No indicator.
iliary shutdown knob is pressed. upward.

The engine is started with the Ro- The Rotor Service Switch must be
The Rotor Service Switch indicator
Rotor Service Switch tor Service Switch in the SERVICE set to OPERATE before the engine
will be illuminated.
position. is started.

The sequence error must be corrected before you

proceed with operation.

Propel Interlocks
The propel system may become nonfunctional if the
operator performs an incorrect operator sequence.
Table 9
Control Condition Indicator Response

The Parking Brake control must be

The machine is stopped. The park- turned OFF and the Propel control
Parking Brake ing brake is applied. The operator No indicator. returned to the NEUTRAL position
attempts to propel the machine. before the computer will respond
to the Propel control.

The machine is stopped and the

operator disengages the parking
Parking Brake brake while the Propel control is in
the FORWARD or REVERSE
position.
The Propel control must be re-
turned to the NEUTRAL position
No indicator.
before the computer will respond
to the Propel control.

The propel stops. The Propel con-

The machine is moving. The park- trol will remain inactive until the
Parking Brake No indicator.
ing brake is applied. Propel control is returned to the
NEUTRAL position.

The machine is working. The en-

Move the Propel control to the
gine speed is below 1600 RPM.
Propel Cutout Event on display. NEUTRAL position and move the
The rotor stops and the propel
Rotor control to the OFF position.
stops.
70 KEBU7583-01
Operation Section
Backup Alarm

Rotor Interlocks
The rotor system may become nonfunctional if the
operator performs an incorrect operator sequence.
Table 10
Control Condition Indicator Response

The operator attempts to engage

the rotor while the engine is at The engine will switch to low idle
Rotor Start HIGH idle. No indicator. automatically, and the rotor will be
The rotor depth must be greater engaged automatically.
than 75 mm (3 inch).

The engine speed drops below Reset the Propel control to NEU-
Rotor Cutout 1600 RPM. The rotor stops and Event on display. TRAL and wait 60 seconds then
the propel stops. engage the rotor again.

The operator attempts to shift the The rotor speed change will not be
Rotor Shifts rotor speed while the engine is at Event on display. accepted until the engine speed is
HIGH idle. lowered to LOW idle.

Note: If there is a fault, address the issue i05230610

immediately. Do not operate the machine when the
display screen shows an error. Camera
i05710989
(If Equipped)
SMCS Code: 7347; 7348
Backup Alarm The Work Area Vision System (WAVS) is a closed
SMCS Code: 7406 circuit television system that is designed to
supplement the view for the operator during machine
operation. The system may include one, two, or three
cameras, depending on the type of machine and the
application.
This system operates in the “automatic” mode by
design. The screen remains dark until the machine is
placed in the REVERSE gear for a one camera
system.

Illustration 82 g03628693

Backup Alarm – The backup alarm will

sound when the propel lever is in the
REVERSE position. The backup alarm
alerts any personnel that the machine is backing
up.
The backup alarm is on the rear of the machine. Illustration 83 g01223034
Display for WAVS
KEBU7583-01 71
Operation Section
Emulsion Spray System

• Impair access to any operator controls or impair

movement of any operator controls.
Prior to operating the machine, ensure that the
camera lens and the display are clean.
Refer to Operation and Maintenance Manual,
SEBU8157, “Work Area Vision System” for additional
information about WAVS. Also, see Special
Instruction, REHS3120, “WAVS Installation Guide for
Generic Applications” and Special Instruction,
REHS7242, “WAVS Generic Installation Guide for
Certain Cat® Products”.

i05722129

Illustration 84 g01223051 Emulsion Spray System

Camera for WAVS
SMCS Code: 5615
Prior to operating the machine, ensure proper For information on the emulsion spray application
orientation of images by the camera or cameras. The rate refer to Operation and Maintenance Manual,
cameras have been set up by the factory or by a Cat “Application Guidelines”.
dealer to provide views which comply with the
documented guidelines. Consult your Cat dealer
before any adjustments are made to the cameras. Emulsion System Nozzles
Note: Rear facing cameras should always be set to Use the correct nozzles for the flow rate. The use of
the mirror image configuration. incorrect nozzle sizes or plugged nozzles can result
in an inconsistent flow rate, the operating pressures
Upon power up of the monitor, the following will being too high, or damage to the pump vanes. Use
appear in the upper left-hand corner: “REAR1 M” . the following chart to determine the correct nozzle for
The monitor may switch from C1 to C2. The switch to the flow rate.
C2 can occur when the tractor is in reverse, Table 11
regardless of whether the tractor has either one or
two cameras. If the monitor switches from C1 to C2, Flow Rate Nozzle Part Number
the following will appear in the upper left-hand 1 L/min (0.3 US gpm) to
corner: “CHNL 2 M” . If “CHNL 2” is displayed instead 195 L/min (51.5 US gpm) 115-7573
of “CHNL 2 M” , contact the technical communicator
at the Cat dealership for proper adjustments to the 159 L/min (42 US gpm) to
115-7575
monitor. 665 L/min (176 US gpm)

Prior to operating the machine, ensure that the 285 L/min (75.3 US gpm) to
114-1189
features of the display are properly adjusted. Ensure 835 L/min (220.6 US gpm)
that the brightness and the contrast are adjusted
prior to operating the machine. Ensure that the
brightness and the contrast are adjusted after Emulsion System Pump
changes in the conditions for ambient light.
Air leaks on the suction side of the pump can result in
Prior to operating the machine, ensure that the erratic flow meter readings or damage to the pump
display is positioned in order to provide clear visibility vanes.
of the display from the operator seat. Do not position
the display in a way that will cause the following Pumping water or liquids with small particles, such as
conditions: sand or aggregates, can result in rapid wear or
damage to the pump vanes.
• Cover any safety messages or other important
information. The following actions can damage the vanes in the
emulsion system pump:
• Impede the entry to the cab or impede the exit
from the cab. • Foreign objects entering the pump

• Obstruct the visibility of the operator. • Running the pump dry for extended periods

• Obstruct the view of any indicators, gauges, or • Cavitation as a result of air leaks on the suction
monitoring system. side of the pump
• Viscosity too high for the vanes
72 KEBU7583-01
Operation Section
Push Bar

• Viscosity too high for the pump speed
• Incompatibility with the liquids pumped
• Excessive heat
• Worn or bent push rods, or worn push rod holes
• Settled or solidified material in the pump at startup
• Hydraulic hammer or pressure spikes
• Vanes installed incorrectly
i05656396
Push Bar
SMCS Code: 7121
2. Rotate the push bar from the storage position to
the forward position.
3. Using a spotter, position the water truck in front of
the soil stabilizer. The truck should be just in front
of the push bar.
4. Place the soil stabilizer and water truck in park.
5. Lift pin (1), and extend the push bar outward
toward the water truck.
6. Secure the eye of the push bar to the water truck
hitch. The push bar should be extended, and
between the inner and outer pin positions for pin
(1).
7. Clear the hitch area of personnel. Drive the water
truck slowly away from the soil stabilizer until pin
(1) falls into place.

i06809367

Operation Information
SMCS Code: 7000

Preparation for Operation

Rotor movement can cause injury or death. Stay

clear of the rotor when the engine is running.
Shut off the engine before performing any service
Illustration 85 g03586897 on the rotor or its housing.

The push bar is 1.98 m (6.5 ft) long and is mounted

to the front hitch. The push bar is used for pushing a
water truck.
Personal injury could result from the sudden stop
Storage of the machine. The parking brake is automati-
cally engaged when brake oil pressure drops be-
Perform the following steps in order to place the push low an adequate operating pressure.
bar in the storage position:
Make sure that no person is working on the machine
1. Lift pin (1). or that no person is near the machine when you
operate the machine. Maintain control of the machine
2. Slide the inner section of the bar into the outer at all times.
section.
Reduce the speed of the engine when you are
3. Insert pin (1) in the bar. operating the machine in a confined area.
4. Swing the bar to the side of the machine. In order to operate the machine properly, the
5. Lock the push bar in place with pin (2). following steps must be completed:
1. The rear door of the machine is equipped with a
Attaching to a Water Truck rear door service pin lock assembly.

Perform the following steps in order to attach the

push bar to a water truck:
1. Disconnect the push bar from pin (2).
KEBU7583-01 73
Operation Section
Operation Information

Illustration 86 g03654847 Illustration 89 g03655967

Retract the rear door service pin during operation.
2. See the rotor service lock (2) on the left side of the
rotor mixing chamber. Remove the retaining pin
(1). Move the rotor service lock (2) downward in
order to disengage the lock. Reinstall the retaining
pin (1).

Illustration 87 g03654839
To hold the rear door in the open position, the rear
door service pin should be extended to the LOCK
position.
Illustration 90 g03637697
The rotor service switch is located on the inside of
the circuit breaker box behind the access ladder on
the left side of the machine.

3. Unlock and open the circuit breaker box cover.

Illustration 88 g03654832
The rotor service lock is located on the left side of the
rotor mixing chamber.
74 KEBU7583-01
Operation Section
Operation Information

Illustration 91 g03655976 Illustration 93 g03656016

Location of the rotor service switch (3) (9) Rotor raise
(10) Rotor lower
(11) Rotor travel mode
4. Move the rotor service switch (3) downward to the (12) Rotor depth setpoint
OPERATE position.

Note: Make sure that service is completed. Do not

move the switch to the OPERATE position until
all personnel, tools, and debris are a safe
distance from the rotor.

5. Close and lock the circuit breaker box cover.

Illustration 92 g03656011
(4) Monitoring system
(5) Propel control
(6) Auxiliary shutdown knob
(7) Parking brake
(8) Horn
KEBU7583-01
Illustration 94 g03656019
(13) Cruise control speed increase
(14) Cruise control speed decrease
(15) Throttle control
(16) Chamber raise / chamber float
(17) Rotor speed
(18) Rotor control
6. Press chamber float button (16) until the bottom
light next to the button is illuminated in order to
activate chamber float mode.
7. Press throttle control button (15) until FAST is
selected.
8. Press rotor travel mode button (11) in order to
activate the rotor travel mode.
9. Sound the horn (8) for several seconds in order to
alert personnel. Make sure that the personnel in
the area are clear of the machine. Make sure that
the personnel in the area are aware of the
movement of the machine.
10. Push down on the lower part of the parking brake
switch (7) in order to disengage the parking brake.
75
Operation Section
Operation Information
11. Move propel lever (5) to the proper direction.
Move the propel lever (5) to the proper speed for
travel.
Note: Move the propel lever (5) to the neutral
CENTER position in order to apply hydraulic braking
force to the machine.
Operator's Seat Adjustment
NOTICE
Use caution when moving the operators seat while
operating the machine.
Make sure that there are no obstacles in the path of
the machine.
You must be seated in order to move the operators
seat.
The operating position of the seat can be adjusted
during the operation of the machine. Refer to
Operation and Maintenance Manual, “Seat” for more
information on the adjustment of the operators seat
position.
Travel with the Rotor Locked
Illustration 95 g03654832
The rotor service lock is located on the left side of the
rotor mixing chamber.
Note: A lock for service to the rotor is provided on the
left side of the machine. Use the lock in order to
secure the rotor in the SERVICE position. The
SERVICE position is used during travel of the
machine. The SERVICE position is used for servicing
the rotor.
Perform the following steps in order to move the
machine without operating the rotor:
1. Make sure that the engine is warmed up.
2. Press throttle control button (15) until FAST is
selected.
76
Operation Section
Operation Information
3. Press rotor travel mode button (11) in order to
activate the rotor travel mode.
Illustration 96 g03655967
4. See the rotor service lock (2) on the left side of the
rotor mixing chamber. Remove the retaining pin
(1). Move the rotor service lock (2) upward in order
to engage the lock. Reinstall the retaining pin (1).
5. Push down on the lower part of the parking brake
switch (7) in order to disengage the parking brake.
To maintain proper machine control and effective
hydrostatic braking on downhill slopes over 6%,
this machine must be operated in Low Range (L).
Failure to follow these instructions could result in
an overspeed condition, loss of control and/or
sudden stopping by the secondary (emergency)
braking system which could cause serious injury
or death.
6. Use cruise control speed increase (13) and cruise
control speed decrease (14) in order to adjust the
cruise control speed.
7. Move the propel lever (5) to the proper direction.
Move the propel lever (5) to the proper speed for
travel.
8. In order to stop the travel of the machine, move the
propel lever (5) to the NEUTRAL position.
9. Press throttle control button (15) until SLOW is
selected.
10. Push down on the upper part of the parking brake
switch (7) in order to engage the parking brake.
KEBU7583-01
11. Stop the engine.
Operation of Rotor
Before engaging the rotor, be sure the rotor area
is clear of obstructions and personnel. Make sure
the rotor bits are clear of the grade or the ma-
chine may lunge backward when the rotor is
engaged.
Whenever starting a cut, lower the rotor slowly. If
the rotor is lowered too fast, the machine will ride
up onto the rotor and lunge backwards. The ma-
chine may also lunge backward a short distance
if the rotor hits some obstruction while cutting.
Never let anyone stand at the back of the machine
while it is in operation. Stand to the side of the
machine and stay clear of the machine.
Three different rotor speeds are available. Press
rotor speed button (17) in order to select the
appropriate setting. See this Operation and
Maintenance Manual, “Operator Controls”.
Starting Operation
Before engaging the rotor, be sure the rotor area
is clear of obstructions and personnel. Make sure
the rotor bits are clear of the grade or the ma-
chine may lunge backward when the rotor is
engaged.
Whenever starting a cut, lower the rotor slowly. If
the rotor is lowered too fast, the machine will ride
up onto the rotor and lunge backwards. The ma-
chine may also lunge backward a short distance
if the rotor hits some obstruction while cutting.
Never let anyone stand at the back of the machine
while it is in operation. Stand to the side of the
machine and stay clear of the machine.
Personal injury or death can result from sudden
machine movement.
Sudden movement of the machine can cause in-
jury to persons on or near the machine.
To prevent injury or death, make sure that the
area around the machine is clear of personnel
and obstructions before operating the machine.
Note: Cut one inch to two inches below the asphalt
surface in order to improve the wear of the teeth.
KEBU7583-01
Note: Overlap the cuts in order to ensure the
coverage of the roadway.
NOTICE
Hitting an obstruction during machine operation can
cause the engine to stall. If this occurs, restart the en-
gine within a minute. Failure to restart the engine can
result in turbocharger damage.
1. Plunge cutting may be required when you start the
operation. Propel the machine at a slow rate.
Slowly lower the rotor in order to start the plunge
cut. The slow, forward movement will help prevent
a bucking motion of the machine.
2. Cut deep enough to mix one or two inches of base
material with the material on the top surface.
Cutting at this depth will improve the life of the
teeth for the cutter. Cutting at this depth will allow
a greater forward speed and which will allow
machine stability.
3. When possible, making a transverse cut across
the roadway is always better. The transverse cut
should be done first. Making the transverse cut
first will allow the rotor to start cutting in the less
dense shoulder. The less dense shoulder will allow
the rotor to work into the roadway and across the
roadway. The transverse cut avoids the
undesirable, abrupt starting point for the
longitudinal cuts.
Illustration 97 g03656045
The chain guides are located at the front of the
machine.
77
Operation Section
Operation Information
4. Turn the handles on the chain guides
counterclockwise in order to loosen the chain
guides. Adjust the chain guides in order to align
the chains with the sides of the rotor. Tighten the
handles.
5. If your machine is equipped with a sliding operator
station, the first pass of operation should be made
with the operator station moved to the left side of
the machine or moved to the right side of the
machine. If you operate the machine in this
manner, you will have the best view of the guide
chain. If you make a return pass, move the
operator station to the opposite side of the
machine. Use the chain guide as a reference to
slightly overlap the previous cut. Proceed to step
6.
6. When you operate the machine in asphalt
reclamation, avoid lowering the rotor too fast.
Make sure that all personnel are 15 m (50 ft) in
back of the machine or 15 m (50 ft) in front of the
machine.
7. If you are performing a reclamation operation,
make sure that the front door on the mixing
chamber is partially open. For a reclamation
operation, make sure that the rear door for the
mixing chamber is adjusted properly. The rear
door will control the strike off height and the
material sizing. If the rear door is closed too far,
the propel system will not function properly. Open
the door in order to release some material.
Releasing the material will allow the propel to
recover.
8. The life of the teeth for the cutter will vary from one
location to another location. Periodically perform
the following procedure:
a. Stop the machine.
b. Press rotor control button (18) until the light next
to the button is not illuminated in order to turn off
the rotor.
c. Stop the engine.
d. Make sure that the rotor has stopped.
e. Perform the procedure that is listed in this
Operation and Maintenance Manual, “Servicing
the Rotor” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Note: Teeth holders can break if you operate a
cutter with worn cutter teeth. Teeth holders can
break if you operate a cutter that has broken cutter
teeth. Severe damage may result.
78 KEBU7583-01
Operation Section
Operation Information

f. Inspect the rotor. Check for any worn cutter

teeth. Check for any broken cutter teeth.
Replace any worn cutter teeth. Replace any
broken cutter teeth.

Note: If the teeth do not rotate freely, excessive

wear may result.

g. Inspect the teeth. Check the teeth for free

rotation. Replace any teeth that do not rotate.

Automatic Operation
Prepare the safety devices
Illustration 100 g03654832
1. The rear door of the machine is equipped with a The rotor service lock is located on the left side of the
rear door service pin lock assembly. rotor mixing chamber.

Illustration 98 g03654847
Illustration 101 g03655967
Retract the rear door service pin during operation.
2. See the rotor service lock (2) on the left side of the
rotor mixing chamber. Remove the retaining pin
(1). Move the rotor service lock (2) downward in
order to disengage the lock. Reinstall the retaining
pin (1).

Illustration 99 g03654839
To hold the rear door in the open position, the rear
door service pin should be extended to the LOCK
position.
KEBU7583-01
Illustration 102 g03637697
The rotor service switch is located on the inside of
the circuit breaker box behind the access ladder on
the left side of the machine.
3. Unlock and open the circuit breaker box cover.
Illustration 103 g03655976
Location of the rotor service switch (3)
Note: The rotor service switch (3) is a two-position
switch. When the switch is moved downward to the
OPERATE position, the machine can be started for
operation. When the switch is moved upward to the
SERVICE position, the machine is not allowed to
start.
4. Move the rotor service switch (3) downward to the
OPERATE position.
Note: Make sure that service is completed. Do not
move the switch to the OPERATE position until
all personnel, tools, and debris are a safe
distance from the rotor.
5. Close and lock the circuit breaker box cover.
Prepare the rotor for operation
1. Press rotor speed button (17) until the desired
working speed is selected.
79
Operation Section
Operation Information
2. Engage the rotor. Press rotor control button (18)
until the light next to the button is illuminated in
order to engage the rotor.
Note: The rotor will engage after a delay of a few
seconds. If the rotor does not turn, inspect the shear
bolt.
3. Press throttle control button (15) until FAST is
selected.
When reclaiming or stabilizing, front steer mode
should be used. Crab, coordinated, and rear steer
modes should not be used during reclaiming or
mixing to avoid side loading and potential damage to
the rotor and mixing chamber.
If stabilizing soil which contains large stones, stones
greater than 6 inches should be removed prior to
stabilizing. Attempting to process large stone during
soil stabilization can result in damage to the rotor or
mixing chamber. The severity and rate at which any
damage occurs may increase based on the type,
size, and frequency of the stone being encountered.
Operation of the front and rear door of the mixing
chamber can affect machine performance. When
reclaiming or stabilizing, the front door should remain
open enough to allow some material to spill out in
front of the chamber. The rear door should remain
open enough to allow material to escape the
chamber. Excess material being held in the chamber
can increase wear rates to the rotor and mixing
chamber. If more mixing is required, subsequent
passes are recommended.
Refer to Rotor Selection Guide, QEDQ1517 in order
to ensure that the correct rotor is being used for the
application.
Position the rotor for work
Note: Make sure that the rotor is operating at a
proper working speed before you attempt to lower the
rotor for work.
1. Press rotor raise button (9) in order to raise the
rotor. Press rotor lower button (10) in order to
lower the rotor. Lower the rotor into the cut until
the rotor is at the desired depth.
2. Double click the rotor automatic depth setpoint
button (12) in order to capture the depth of the
rotor.
3. Press and hold switch (12) for 2 seconds in order
to set the rotor mode to AUTO.
80 KEBU7583-01
Operation Section
Operation Information

Adjust the machine for work

Illustration 104 g03648352

1. Maintain an engine speed that is proper for doing

work. The load control is in automatic operation.
Automatic operation will keep engine rpm at
optimum working speed.
Refer to Operation and Maintenance Manual,
“Monitoring System” for additional information on
the load control.
2. Move the propel lever (5) to the proper direction.
Move the propel lever (5) to the proper speed for
travel. Use cruise control speed increase (13) and
cruise control speed decrease (14) in order to
adjust the cruise control speed.
3. Adjust the rear door opening in order to get the
desired sizing of material.
Note: If an obstruction is observed, stop the
machine. Press travel mode button (11) in order to
move the rotor to the travel position. After passing the
obstruction, press rotor lower button (12) in order to
return to AUTO MODE.
KEBU7583-01 81
Operation Section
Engine Starting

Engine Starting
i05711169

Engine Starting
SMCS Code: 1000; 7000

NOTICE
Do not crank the engine for more than 30 seconds.
Allow the starter to cool for 2 minutes before cranking
again.
Turbocharger damage can result, if the engine is not
kept at low idle until the engine oil light/gauge verifies
Illustration 106 g03628801
the oil pressure is sufficient.
The key must be in the RUN position with the engine Use the following procedure in order to start the
on in order to maintain electrical functions, maintain machine.
hydraulic functions and prevent serious machine
damage. 1. Lift auxiliary shutdown knob (2).
2. Push down parking brake switch (3) in order to
If the engine does not start, return the key to the OFF
position before you return the key to START. apply the parking brake.
3. Move the propel control lever (1) to the NEUTRAL
position.
NOTICE
Do not use ether starting fluid in diesel engines 4. Briefly sound the horn before you start the engine.
equipped with inlet manifold heater.
5. Turn key (4) clockwise to the START position.
When the engine starts release the key.

Illustration 105 g03628516

Turn the battery disconnect switch to the ON position.

82 KEBU7583-01
Operation Section
Engine and Machine Warm-Up

i05711231

Engine and Machine Warm-Up

SMCS Code: 1000; 7000

Illustration 107 g03628828

NOTICE
Keep the engine speed low until the engine oil pres-
sure registers on the gauge or until the engine oil indi-
cator light goes out.
If it does not register or the light does not go out with-
in ten seconds, stop the engine and investigate the
cause before starting again. Failure to do so, can
cause engine damage.

1. Warm up the engine at LOW IDLE.

2. Look at the monitoring system frequently during
operation.
If there is any indication of a problem, inspect the
machine for the cause of the problem. Before you
move the machine, repair all problems.
3. Cycle all controls in order to allow warm oil to
circulate through all of the lines and the cylinders.
Allow the engine to warm up until the cold oil warning
turns off. Using the machine before the cold oil
warning turns off will result in reduced response time,
KEBU7583-01 83
Operation Section
Machine Service

Machine Service
i05721489

Rotor Service Locks

SMCS Code: 6637

Rotor Service Switch Illustration 110 g03637780

Rotor service switch
(2) SERVICE position
(3) OPERATE position

2. Push the rotor service switch (1) upward in order to

Illustration 108 g03637697
1. The circuit breaker box is located behind the
access ladder on the left side of the machine.
Remove the padlock. Open the cover.
place the rotor in the SERVICE position (2). The
starter is locked out in the SERVICE position (2).
The SERVICE position (2) allows the rotor brake
to be released by energizing an electric pump. The
electric pump automatically maintains rotor brake
release pressure.
3. Push the rotor service switch downward in order to
place the rotor in the OPERATE position (3) for
machine operation.
4. After you change the position of the rotor service
switch, close the cover.
Note: When service is performed on the rotor, you
must lock the cover in order to prevent the rotor
service switch from being moved. Proper care is your
responsibility.

Rotor Service Lock

Illustration 109 g03637698

(1) Rotor service switch

Illustration 111 g00876195

The rotor service lock will lock the rotor in the highest
position for service of the rotor. The rotor service lock
will lock the rotor in the highest position for rotor
travel. Pull the lever upward. Place the lever in the
bracket groove for the cylinder lift lock.
84 KEBU7583-01
Operation Section
Servicing the Rotor

Note: When the lock for the rotor is engaged, there i05722150
will be no upward movement of the rotor. When the
lock for the rotor is engaged, there will be no Servicing the Rotor
downward movement of the rotor. The proximity
sensor by the lift lock handle disables automatic SMCS Code: 6637; 7000
movement of the rotor when the lock bar is in the
LOCK position.

Do not perform any cutter tooth replacement, and

do not perform service or maintenance on the ro-
tor, the rotor hood, or the chain cases until steps
1 to 10 are completed.
Failure to follow these instructions could allow
the rotor, chamber, or door to drop resulting in
serious personal injury or death.
1. Set the parking brake on the propel system.
2. Raise the rotor to the TRAVEL position to clear
any material that may be trapped between the cut-
ter bits and the paddles.
3. Tilt the rotor chamber forward, and raise the
rear door.
4. Reduce the engine speed to LOW idle.
5. Disengage the rotor drive.
6. Turn the ignition OFF in order to stop the
engine.
7. Remove the padlock from the circuit breaker
box, and open the cover for the circuit breaker
box. Place the rotor service switch in the SERV-
ICE position. Close the circuit breaker box cover
and install the padlock.
8. Engage the rotor service lock T bar that is lo-
cated on the left chain case on the lift cylinder.
9. Secure the rear door and mixing chamber in
position, by engaging the rear door service pin.
10. Do not start the engine again until all of the
services are completed and all personnel are
clear from the rotor area.
11. Remove the rotor lock and disengage the rear
door service pin.
12. Remove the padlock from the circuit breaker
box. Open the cover of the circuit breaker box.
Place the rotor service switch in OPERATE posi-
tion. Close the cover for the circuit breaker box
and install the padlock.
13. Sound the horn three times prior to starting
the engine.
KEBU7583-01 85
Operation Section
Servicing the Rotor

Perform steps 1 through 6 only after the service

has been completed.
Failure to follow these instructions could allow
the rotor, chamber, or door to drop resulting in
serious personal injury or death.
1. Complete the service.
2. Do not start the engine again until all services
are completed and all personnel are clear from
the rotor area.
3. Disengage the rear door service pin before low-
ering the rotor.
4. Disengage the rotor lock.
5. Remove the padlock from the circuit breaker
box, and open the circuit breaker box cover.
Place the rotor service switch in the OPERATE
position. Close the circuit breaker box cover and
install the padlock.
6. Sound the horn three times prior to starting the
engine in order to alert surrounding personnel.

NOTICE
Attach a "Do Not Operate" warning tag or a similar
warning tag to the start switch or to the controls be-
fore you service the equipment or before you repair
the equipment.
These warning tags are available from your Caterpil-
lar dealer. Refer to Special Instruction, SEHS7732 for
more information. Illustration 113 g03654755
(4) Engine throttle control
(5) Chamber raise
(6) Chamber lower
(7) Rotor control

Illustration 112 g03654751

(1) Propel lever
(2) Parking brake switch
(3) Engine start switch Illustration 114 g03654766
(8) Rotor travel mode
(9) Rear rotor door raise
(10) Rear rotor door lower
86 KEBU7583-01
Operation Section
Servicing the Rotor

1. Move the propel lever (1) to the NEUTRAL

position.
2. Push down on the upper part of the parking brake
switch (2) in order to engage the parking brake.
3. Press rotor travel mode button (8) in order to move
the rotor into the travel position. The travel position
will clear any material that may be trapped
between the cutter bits and the paddles.
4. Press chamber raise button (5) until the top light is
illuminated in order to tilt the rotor hood forward to
the maximum distance.
5. Press rear rotor door raise button (9) in order to
raise the rear rotor door. Illustration 116 g03654797
(11) Rotor service switch
6. Press engine throttle control button (4) until LOW
idle is selected.
7. Use rotor control button(7) in order to disengage
the rotor.
8. Turn the engine start switch (3) to the OFF
position. Make sure that the engine is not running.
Note: Once the rotor service switch is in SERVICE
position, the starting system for the machine is
disabled. Illustration 117 g03654809
Rotor service switch
Note: Do not start the engine. (12) SERVICE position
(13) OPERATE position

10. Move the rotor service switch (11) upward to the

SERVICE position (12).
11. Close the cover for the circuit breaker box.

Note: You must lock the cover in order to prevent the

rotor service switch from being moved to the
OPERATE position (14). Proper care is your
responsibility.

Illustration 115 g03637697

Location of the circuit breaker box

9. The circuit breaker box is located behind the

access ladder on the left side of the machine.
Open the cover for the circuit breaker box in order
to access the rotor service switch.

Illustration 118 g03654832

The rotor service lock is located on the left side of the
rotor mixing chamber.
KEBU7583-01 87
Operation Section
Servicing the Rotor

12. Engage the rotor service lock. See this Operation

and Maintenance Manual, “Rotor Service Locks”.

Illustration 119 g03654839

Rear door service pin in the extended position.

Note: Ensure that the rear door service pin is fully

extended to the lock position in order to hold the rear
door in the OPEN position.

13. Perform the necessary rotor service.

14. Once the service has been completed, move the
rotor service switch to the OPERATE position (13).

Illustration 120 g03654847

Rear door service pin in the retracted position.

Note: Ensure that the rear door service pin is fully

retracted in order to allow the rear door to close.

15. Disengage the rotor service locks. See this

Operation and Maintenance Manual, “Rotor
Service Locks”.
16. Do not start the engine until all services are
completed. Clear all personnel from the rotor area.
Sound the horn three times prior to starting the
engine.
88 KEBU7583-01
Operation Section
Parking

Parking Stopping the Engine from the

Operator Station
i05721390
1. Before you stop the engine, allow the engine to run
Stopping the Machine at low idle with no load for 5 minutes.
SMCS Code: 7000

Note: Use the propel lever to slow the machine.

Use the propel lever to stop the machine. Park on
a level surface. If parking on a grade is
necessary, block the machine securely.

Illustration 122 g03637156

2. Push down parking brake switch (1) in order to

apply the parking brake.
3. Be sure that all of the controls are in the OFF
position.
Illustration 121 g03637463
4. Turn engine start switch (2) to the OFF position.
1. Move the propel lever to the NEUTRAL position in Remove the key.
order to slow the machine and stop the machine.
2. After the machine has stopped, engage the
Auxiliary Shutdown Knob
parking brake by pushing down on the upper part
of the parking brake switch.
3. Move the switches for the lights to the OFF
position.
4. Lower the rotor to the ground.

i05720930

Stopping the Engine

SMCS Code: 1000; 7000

S/N: TAS1–Up

NOTICE Illustration 123 g03637190

Stopping the engine immediately after it has been
working under load can result in overheating and ac-
celerated wear of engine components.
Refer to the following procedure to allow the engine
to cool and to prevent excessive temperatures in the
turbocharger housing, which could cause oil coking
problems.
Auxiliary Shutdown Knob – In the event
of an emergency, push the knob
downward in order to stop the engine
and the machine.
In order to release the auxiliary shutdown knob, pull
the knob upward.
KEBU7583-01 89
Operation Section
Stopping the Engine

Note: In order to propel the machine, the propel lever Stopping the Engine from the
must be in the NEUTRAL position before you release
the auxiliary shutdown knob.
Operator Station
1. Before you stop the engine, allow the engine to run
Secondary Auxiliary Shutdown at low idle with no load for 5 minutes.
Knob

Illustration 125 g03637156

Illustration 124 g03637339
The secondary auxiliary shutdown knob is located on 2. Push down parking brake switch (1) in order to
the circuit breaker box on the left side of the machine. apply the parking brake.

The secondary auxiliary shutdown knob is used 3. Be sure that all of the controls are in the OFF
to stop the engine in an emergency. Do not use position.
the secondary auxiliary shutdown knob during
4. Turn engine start switch (2) to the OFF position.
normal operation. Engine damage may result.
Remove the key.
Secondary Auxiliary Shutdown Knob –
In the event of an emergency, push the Auxiliary Shutdown Knob
knob downward in order to stop the
engine and the machine.
In order to release the auxiliary shutdown knob, pull
the knob upward.

Note: In order to propel the machine, the propel lever

must be in the NEUTRAL position before you release
the auxiliary shutdown knob.

i05874211

Stopping the Engine

SMCS Code: 1000; 7000

S/N: MB91–Up
Illustration 126 g03637190

NOTICE
Stopping the engine immediately after it has been
working under load can result in overheating and ac-
celerated wear of engine components.
Refer to the following procedure to allow the engine
to cool and to prevent excessive temperatures in the
turbocharger housing, which could cause oil coking
problems.
Auxiliary Shutdown Knob – In the event
of an emergency, push the knob
downward in order to stop the engine
and the machine.
In order to release the auxiliary shutdown knob, pull
the knob upward.
90 KEBU7583-01
Operation Section
Stopping the Engine

Note: In order to propel the machine, the propel lever Note: There may be regulations that define the
must be in the NEUTRAL position before you release requirements for the operator and/or support
the auxiliary shutdown knob. personnel to be present when the engine is running.

Secondary Auxiliary Shutdown

Knob Leaving the machine unattended when the engine
is running may result in personal injury or death.
Before leaving the machine operator station, neu-
tralize the travel controls, lower the work tools to
the ground and deactivate all work tools.

Note: Leaving the engine unattended while running

Illustration 127 g03637339
The secondary auxiliary shutdown knob is located on
the circuit breaker box on the left side of the machine.
The secondary auxiliary shutdown knob is used
to stop the engine in an emergency. Do not use
the secondary auxiliary shutdown knob during
normal operation. Engine damage may result.
Secondary Auxiliary Shutdown Knob –
In the event of an emergency, push the
knob downward in order to stop the
engine and the machine.
In order to release the auxiliary shutdown knob, pull
the knob upward.
Note: In order to propel the machine, the propel lever
must be in the NEUTRAL position before you release
the auxiliary shutdown knob.
may result in property damage in the event of a
malfunction.
Turn the engine start switch to the OFF position.
Delayed Engine Shutdown – The
delayed engine shutdown indicator will
illuminate or the following text will be
displayed, ENGINE COOLDOWN ACTIVE.
Delayed engine shutdown will run whenever the
exhaust temperature is above a threshold at engine
shutdown. Delayed engine shutdown will run for a
minimum of 76 seconds and will continue to run until
the engine and system components are cooled. The
default maximum run time is 7 minutes.
Note: An authorized dealer can change the
maximum run time value up to 30 minutes, but the
default setting is 7 minutes.
Note: To override delayed engine shutdown and stop
the engine, turn the engine start switch to the STOP
position. Overriding delayed engine shutdown may
reduce engine and system component life. A warning
message and/or audible alarm will be initiated and a
fault code will be logged for improper engine
shutdown.

Delayed Engine Shutdown (If

Enabled)
The Delayed Engine Shutdown allows the engine to
run for a time after the engine start switch key is
turned to the OFF position to cool the engine and
system components. The engine start switch key
may be removed.
Note: The DEF purge process will run for 2 minutes
once the engine is shut down and must complete.
The purge process may occur during delayed engine
shutdown. Do not turn off battery disconnect switch
during the purge process. Do not turn off the battery
power disconnect switch until the battery disconnect
switch indicator lamp has turned off. If the purge
process does not complete, a diagnostic code will
become active.
KEBU7583-01 91
Operation Section
Stopping the Engine if an Electrical Malfunction Occurs

Illustration 128 g02362719 Illustration 130 g03634996

Note: At any time during a delayed engine shutdown, 2. Find the red fuel valve handle to the right of the
the engine start switch may be turned to the ON
fuel filters. Turn the fuel valve handle
position. The engine may be placed back into
counterclockwise in order to shut off the fuel to the
service.
engine.
i05718569
Note: Do not operate the machine until the cause of
the problem is corrected.
Stopping the Engine if an
Electrical Malfunction Occurs i05718410

SMCS Code: 1000; 7000

Equipment Lowering with
Turn the engine start key to the OFF position. If the
engine does not stop, perform the following
Engine Stopped
procedure. SMCS Code: 6000; 7000

Illustration 129 g03635016 Illustration 131 g03634856

Location of the manual rotor lowering valve
1. Open the left side lower engine access door.
The manual rotor lowering valve is located behind the
operator station. Use the valve to lower the rotor
when the engine is not running.
In order to lower the rotor, complete the following
procedure.
92 KEBU7583-01
Operation Section
Leaving the Machine

Illustration 132 g03634858 Illustration 134 g03628516

1. Turn the locking ring (1) counterclockwise in order
to unlock the valve control (2).
2. Rotate the valve control (2) counterclockwise in
order to lower the rotor.
3. After servicing, rotate the valve control (2)
clockwise and turn the locking ring (1) clockwise in
order to enable the rotor to be raised.
i05718269
Leaving the Machine
SMCS Code: 7000
Battery disconnect switch.
• Use the steps and use the handrails in order to
exit the machine.
• Maintain three points of contact when you
dismount the machine.
• Inspect the engine compartment for debris.
• When you park the machine overnight, turn the
key for the disconnect switch to the OFF position.
• Install the vandalism covers. Install the locks for
vandalism covers.

Illustration 133 g03634821

Steps and handrails.
KEBU7583-01 93
Operation Section
Machine Cleanup

Machine Cleanup
i05871911

Machine Cleanup Procedure

SMCS Code: 7000

Personal injury or death can result from sudden

machine movement.
Sudden movement of the machine can cause in-
jury to persons on or near the machine.
To prevent injury or death, make sure that the
area around the machine is clear of personnel
and obstructions before operating the machine.

The machine should be cleaned at the end of

operation each day. If the machine is not cleaned at
the end of each day, asphalt or debris could build up.
Cleaning the machine can help you find loose bolts,
loose hydraulic lines, or loose hydraulic fittings.
1. Clean the machine.
2. Clean the steps and the handholds that lead to the
operator station.
3. Clean the operator station.
During operation with cement, lime or lime slurry,
the following procedure may be necessary in
order to reduce the buildup of material between
the mixing chamber and the rotor.
1. After operation of the machine has been
completed for the day, move the machine to an
area that will allow the rotor to be lowered into the
ground without damage.
2. See the operator console. Place the rotor control in
the OFF position.
3. Move the rotor elevation control downward in order
to lower the rotor to the ground. Continue to lower
the rotor until the rear wheels of the machine are
off the ground.
4. Move the rotor elevation control upward until the
rotor is raised to maximum height.
The impact and the movement of the rotor will
dislodge excess material.
5. Repeat steps 3 through 4 until the material
between the mixing chamber and the rotor side
plates has been cleared.
94 KEBU7583-01
Operation Section
Transportation Information

Transportation Information • Cover the engine inlet. Cover the exhaust

opening.
i05871919
i02418921

Shipping the Machine Roading the Machine

SMCS Code: 7000; 7500
Check the route for shipping the machine. Make sure
that there will be clearance for the machine to travel
under the overpasses.
Prevent the machine from moving when you load the
machine on the truck. Prevent the machine from
sliding while the machine is in transit on the truck.
NOTICE
Obey all state and local laws governing the weight,
width and length of a load.
Make sure the cooling system has proper antifreeze
if moving machine to a colder climate.
Observe all regulations governing wide loads.
Loading the Machine
Note: You can transport the machine as a 3.00 m
(10 ft) load.
• Block the tires of the truck before you load the
machine on the truck. Block the wheels of the
railroad car before you load the machine on the
railroad car.
• Start the engine. Press the rotor travel button or
manually raise the rotor to the maximum UP.
Engage the rotor service lock.
SMCS Code: 7000; 7500
Moving the machine before all personnel are
clear of the machine could cause personal injury.
Sound the horn for several seconds before mov-
ing the machine.
Check with the proper officials in order to obtain the
required licenses.
Check all local traffic regulations. Obey all local traffic
regulations.
Investigate the travel route for overpass clearances.
There must be adequate clearance.
1. Perform a “Walk-Around Inspection”. Measure the
fluid levels in the various compartments.
2. Install the required flags, required signals, or
required lights.
3. Start the engine. See this Operation and
Maintenance Manual, “Engine Starting” for the
proper starting procedure.
4. Refer to this Operation and Maintenance Manual,
“Operation Information” topic, and this Operation
and Maintenance Manual, “Operator Controls”
topic, for information on moving the machine.

• Release the parking brake. i05711970

• Load the machine on the trailer. Lifting and Tying Down the
• Move the propel lever to the NEUTRAL position. Machine
• Engage the parking brake. SMCS Code: 7000; 7500

• Lower the rotor. The rotor must be on the floor of

the trailer. Open the rear door in order to prevent
the door from resting on the floor. Improper lifting or tie-downs can allow load to
shift and cause injury and damage.
• Move the throttle switch in order to reduce the
engine speed.

• Move the start switch for the engine to the OFF

position. Remove the key.
• Turn the disconnect switch to the OFF position.
Remove the key.
• Secure the machine with tie-downs before you
transport the machine .
KEBU7583-01 95
Operation Section
Lifting and Tying Down the Machine

Lifting the Machine

Illustration 135 g03705620

For the specifications of the machine, refer to

Operation and Maintenance Manual, “Specifications”.
For specifications of any work tools, refer to the
Operation and Maintenance Manual for the specific
work tool.
Lifting Mass – The lifting mass indicates
Illustration 136 g03629976
the maximum weight of the machine
without any work tools. Use properly rated cables and properly rated slings in
order to lift the machine.
Lifting Point – In order to lift the
machine, attach the lifting devices to the Position the crane or the lifting device in order to lift
lifting points. the machine in a level position.
Tie Down Point – In order to tie down the 1. Move the machine into position.
machine, attach the tie-downs to the tie
2. Apply the parking brake.
down points.
3. Turn the engine start switch key to the OFF
position. Remove the key.
4. Attach lifting cables to the lifting eyes. The lifting
eyes are identified on the machine by labels.
There are two lifting eyes on each side of the
machine.
96 KEBU7583-01
Operation Section
Lifting and Tying Down the Machine

5. Lift the machine slowly in order to make sure that

the machine stays level. Move the machine to the
desired position.

Tying Down the Machine

Illustration 137 g03630016

Left side tie down points.
KEBU7583-01 97
Operation Section
Lifting and Tying Down the Machine

Illustration 138 g03630018

Top view of tie down points.

1. Move the machine into position.

2. Apply the parking brake.
3. Turn the engine start switch key to the OFF
position. Remove the key.
4. Chock the front wheels and the rear wheels.
5. Use the tie-down positions in order to secure the
machine. The tie-down positions are identified on
the machine by labels. There are three tie-down
positions on each side of the machine.
Refer to Operation and Maintenance Manual,
“Shipping the Machine” for shipping instructions.
98 KEBU7583-01
Operation Section
Towing Information

Towing Information Quick movement of the machine could cause the tow
line or the tow bar to break.

i06809366
Normally, the towing machine should be as large as
the disabled machine. Make sure that the towing
machine has enough brake capacity. Make sure that
Towing the Machine there is enough weight and power in order to control
SMCS Code: 7000 both machines.
The towing machine should be as large as the
disabled machine. When you tow a machine down a
hill, use a larger machine in order to tow the disabled
Personal injury or death could result when towing machine down the hill. If that machine is not
a disabled machine incorrectly. sufficient, you might need additional machines. This
will prevent the disabled machine from uncontrolled
Make sure that all necessary repairs and adjust- rolling.
ments have been made before a machine that has
been towed to a service area is put back into Different situations cannot be given. Minimal towing
operation. machine capacity is required on a smooth level
surface. Maximum towing machine capacity is
Follow the recommendations below in order to required on inclines or poor surface conditions.
properly perform the towing procedure.
When you tow a machine, the machine that is towed
The hydraulic brakes for this machine are applied must be equipped with a brake system. The brake
with a spring. The hydraulic brakes for this machine system must operate from the operator compartment.
are released by pressure. If the engine is inoperable
or auxiliary system pressure drops below 2413 kPa Consult your Caterpillar dealer for towing a disabled
(350 psi), the brakes are applied and the machine machine.
cannot be moved.
The towing instructions are for moving a disabled Engine that is Running
machine. Tow the machine only for a few meters.
Tow the machine at a slow rate of speed. The speed If the ground drive system and the steering systems
should be no faster than 2 km/h (1.2 mph). These are operable, and the engine is running, the machine
instructions are only for emergencies. Always haul can be towed for a SHORT DISTANCE. The machine
the machine if long distance moving is required. can be pulled out of mud or the machine can be
pulled to the side of the road.
Shielding must be provided on the towing machine.
Shielding will protect the operator if the tow line The operator on the towed machine MUST steer the
breaks. Shielding will protect the operator if the tow machine in the direction of the tow line.
bar should break. Make sure that you perform all of the instructions in
Do not allow an operator to be on the machine that is the section for Towing Information.
being towed, unless the operator can control the
steering or the braking. Note: The engine must be running in order to steer
the machine.
Before the machine is towed, make sure that the line
that is used for towing the machine is in good
condition. Use a towing line that has the strength of
at least 1.5 times the weight of the towing machine. ,
Use a tow bar that has the strength of at least 1.5
times the weight of the towing machine.
When you tow a machine, attach the tow line only to
the tow eyes on the frame, if equipped.
Do not use a chain for pulling. A chain link can break
causing possible personal injury. Use a wire cable
that has a loop on the end or use a wire cable that
has a ring on the end. Use an observer to stop the
pulling procedure if the cable starts to break. Do not
tow the machine when that machine will not move.
Keep the tow line angle to a minimum. Do not exceed
a 30° angle. The machine should not be off-center
more than 30°.
KEBU7583-01
Engine Starting (Alternate
Methods)
i02421967
Engine Starting with Jump
Start Cables
SMCS Code: 1000; 7000
Failure to properly service the batteries may
cause peronal injury.
Prevent sparks near the batteries. They could
cause vapors to explode. Do not allow the jump
start cable ends to contact each other or the
machine.
Do not smoke when checking battery electrolyte
levels.
Electrolyte is an acid and can cause personal in-
jury if it contacts skin or eyes.
Always wear eye protection when starting a ma-
chine with jump start cables.
Improper jump start procedures can cause an ex-
plosion resulting in personal injury.
Always connect the battery positive (+) to battery
positive (+) and the battery negative (−) to battery
negative (−).
Jump start only with an energy source with the
same voltage as the stalled machine.
Turn off all lights and accessories on the stalled
machine. Otherwise, they will operate when the
energy source is connected.
NOTICE
When starting from another machine, make sure that
the machines do not touch. This could prevent dam-
age to engine bearings and electrical circuits.
Turn on (close) the battery disconnect switch prior to
the boost connection to prevent damage to electrical
components on the stalled machine.
Severely discharged maintenance free batteries do
not fully recharge from the alternator after jump start-
ing. The batteries must be charged to proper voltage
with a battery charger. Many batteries thought to be
unusable are still rechargeable.
This machine has a 24 volt starting system. Use only
the same voltage for jump starting. Use of a higher
voltage damages the electrical system.
99
Operation Section
Engine Starting (Alternate Methods)
Use of Jump Start Cables
When the auxiliary start receptacles are not
available, use the following procedure.
1. Determine the reason that the engine will not
crank. Refer to Special Instruction, SEHS7768,
“Use of 6V-2150 Starting Charging Analyzer
Group”. The procedure is applicable even if the
machine does not have a diagnostic connector.
2. On the stalled machine, place the propel control in
the NEUTRAL position. Engage the parking brake.
Lower all attachments to the ground. Move all
controls to the HOLD position.
3. Turn the engine start switch key to OFF on the
stalled machine. Turn off all accessories.
4. Turn on the battery disconnect switch on a stalled
machine.
5. Move the boost machine so that the cables can
reach the stalled machine. DO NOT ALLOW THE
MACHINES TO CONTACT EACH OTHER.
6. Stop the engine on the boost machine. If you are
using an auxiliary power source, turn off the
charging system.
7. Make sure that the batteries in the stalled machine
are not frozen.
8. Connect the positive jump start cable to the
positive cable terminal of the discharged battery.
Do not allow positive cable clamps to contact any
metal except for battery terminals.
Note: Batteries in series may be in separate
compartments. Use the terminal that is connected to
the starter solenoid. This battery is normally on the
same side of the machine as the starter.
9. Connect the positive jump start cable to the
positive terminal of the boost source. Use the
procedure from Step 8 in order to determine the
correct terminal.
10. Connect one end of the negative jump start cable
to the negative terminal of the electrical source.
11. Make the final connection. Connect the negative
cable to the frame of the stalled machine. Make
this connection away from the battery, the fuel, the
hydraulic lines, or moving parts.
12. Start the engine on the boost machine. If you are
using an auxiliary power source, energize the
charging system on the auxiliary power source.
13. Wait for a minimum of two minutes while the
batteries in the stalled machine partially charge.
100 KEBU7583-01
Operation Section
Engine Starting with Jump Start Cables

14. Attempt to start the stalled engine. Refer to

Operation and Maintenance Manual, “Engine
Starting”.
15. Immediately after you start the stalled engine,
disconnect the jump start cable from the BOOST
SOURCE.
16. Disconnect the other end of this cable from the
stalled machine.
17. When the engine is running and the charging
system is operating, determine the cause of the
failure of the charging system of the stalled
machine.
KEBU7583-01 101
Maintenance Section
Maintenance Access

Maintenance Section

Maintenance Access
i05714310

Access Doors and Covers

SMCS Code: 7251; 7263; 7273-572; 7273; 7273-573

Illustration 139 g03631658

(1) Left side radiator access door (5) Left side rotor access door (9) Circuit breaker and fuse box access door
(2) Left side engine access door (6) Front mixing chamber door (10) Left side lower engine access door
(3) Left side cab door (7) Storage compartment door
(4) Rear mixing chamber door (8) Battery access panel
102 KEBU7583-01
Maintenance Section
Access Doors and Covers

Illustration 140 g03631758

(11) Right side cab door (13) Right side radiator access door (15) DEF access door
(12) Right side engine access door (14) Right side lower engine access door (16) Right side rotor access door

Illustration 141 g03631865 Illustration 142 g03631936

(17) Right side upper access door (20) Transmission oil drain plug access panel
(18) Left side upper access door (21) Coolant drain valve access panel
(19) Cooling system pressure cap access door
KEBU7583-01
Tire Inflation Information
i02422711
Tire Inflation with Air
SMCS Code: 4203; 7500
Use a self-attaching inflation chuck and stand be-
hind the tread when inflating a tire.
Proper inflation equipment, and training in using
the equipment, are necessary to avoid overinfla-
tion. A tire blowout or rim failure can result from
improper or misused equipment.
Before inflating tire, install on the machine or put
tire in restraining device.
NOTICE
Set the tire inflation equipment regulator at no more
than 140 kPa (20 psi) over the recommended tire
pressure.
See this Operation and Maintenance Manual, “Tire
Inflation Pressure Adjustment”, for the proper tire
pressure.
i02422715
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.
Proper nitrogen inflation equipment, and training
in using the equipment, are necessary to avoid
over inflation. A tire blowout or rim failure can re-
sult from improper or misused equipment and
personal injury or death can occur.
A tire blowout and/or rim failure can occur if the
inflation equipment is not used correctly, due to
the fact that a fully charged nitrogen cylinder's
pressure is approximately 15000 kPa (2200 psi).
103
Maintenance Section
Tire Inflation Information
There are other benefits to using nitrogen in addition
to reducing the risk of an explosion. The use of
nitrogen for tire inflation lessens the slow oxidation of
the rubber. Use of nitrogen also slows gradual tire
deterioration. This is especially important for tires that
are expected to have a long service life of at least
four years. Nitrogen reduces the corrosion of rim
components. Nitrogen also reduces problems that
result from disassembly.
A tire blowout or a rim failure can cause personal
injury.
Use a self-attaching inflation chuck and stand be-
hind the tread when inflating a tire, to prevent
personal injury.
Note: Do not set the tire inflation equipment regulator
higher than 140 kPa (20 psi) over the recommended
tire pressure.
Use 6V-4040 Inflation Group or an equivalent
inflation group to inflate tires with a nitrogen gas
cylinder.
Reference: For tire inflation instructions, refer to
Special Instruction, SMHS7867, “Nitrogen Tire
Inflation Group”.
For nitrogen inflation, use the same tire pressures
that are used for air inflation. See this Operation and
Maintenance Manual, “Tire Inflation Pressure
Adjustment”, for the proper tire pressure.
i05772606
Tire Inflation Pressure
Adjustment
SMCS Code: 4203; 7500
The tire pressure in a warm shop area (18° to 21°C
(65° to 70°F) average temperature) 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.
When you operate the machine in freezing
temperatures, see Special Publication, SEBU5898,
“Cold Weather Recommendations”.
Tire Operating Pressures
For normal operating conditions, inflate the tires to
the following pressures:
104 KEBU7583-01
Maintenance Section
Tire Inflation Pressure Adjustment

Table 12
Tire Inflation Pressure

Front Tires 725/70-25 310.3 kPa (45 psi)

Rear Tires 23.1-26 310.3 kPa (45 psi)

KEBU7583-01
Lubricant Viscosities and
Refill Capacities
i05714889
Lubricant Viscosities
(Fluids Recommendations)
SMCS Code: 1000; 7000; 7581
S/N: MB91–Up
General Information for Lubricants
When you are operating the machine in temperatures
below −20°C (−4°F), refer to Special Publication,
SEBU5898, “Cold Weather Recommendations”. This
publication is available from your Cat dealer.
For cold-weather applications where transmission oil
SAE 0W-20 is recommended, Cat Cold Weather
TDTO is recommended.
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.
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 oil viscosity grade is determined by the
minimum ambient temperature (the air in the
immediate vicinity of the machine). Measure the
temperature when the machine is started and while
the machine is operated. In order to determine the
proper oil viscosity grade, refer to the “Min” column in
the table. This information reflects the coldest
ambient temperature condition for starting a cold
machine and for operating a cold machine. Refer to
the “Max” column in the table for operating the
machine at the highest temperature that is
anticipated. Unless specified otherwise in the
“Lubricant Viscosities for Ambient Temperatures”
tables, use the highest oil viscosity that is allowed for
the ambient temperature.
105
Maintenance Section
Lubricant Viscosities and Refill Capacities
Machines that are operated continuously should use
oils that have the higher oil viscosity in the final drives
and in the differentials. The oils that have the higher
oil viscosity will 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.
NOTICE
Not following the recommendations found in this
manual can lead to reduced performance and com-
partment failure.
Engine Oil
Cat oils have been developed and tested in order to
provide the full performance and life that has been
designed and built into Cat engines.
Cat DEO-ULS or oils that meet the Cat ECF-3
specification and the API CJ-4 are required for use in
the applications listed below. Cat DEO-ULS and oils
meeting Cat ECF-3 specification and the API CJ-4
and ACEA E9 oil categories have been developed
with limited sulfated ash, phosphorus, and sulfur.
These chemical limits are designed to maintain the
expected aftertreatment devices life, performance,
and service interval. If oils meeting the Cat ECF-3
specification and the API CJ-4 specifications are not
available, oils meeting ACEA E9 may be used. ACEA
E9 oils meet the chemical limits designed to maintain
aftertreatment device life. ACEA E9 oils are validated
using some but not all ECF-3 and API CJ-4 standard
engine performance tests. Consult your oil supplier
when considering use of an oil that is not Cat ECF-3
or API CJ-4 qualified.
Failure to meet the listed requirements will damage
aftertreatment-equipped engines and can negatively
impact the performance of the aftertreatment
devices. The Diesel Particulate Filter (DPF) will plug
sooner and require more frequent DPF ash service
intervals.
Typical aftertreatment systems include the following:
• Diesel Particulate Filters (DPF)
• Diesel Oxidation Catalysts (DOC)
• Selective Catalytic Reduction (SCR)
• Lean NOx Traps (LNT)
Other systems may apply.
106 KEBU7583-01
Maintenance Section
Fluids Recommendations

Table 13
Lubricant Viscosities for Ambient Temperatures

Oil Type and Performance °C °F

Compartment or System Oil Viscosities
Requirements Min Max Min Max
Cat DEO-ULS Cold Weather SAE 0W-40 −40 40 −40 104
Cat DEO-ULS SYN SAE 5W-40 −30 50 −22 122
Engine Crankcase
Cat DEO-ULS SAE 10W-30 −18 40 0 104
Cat DEO-ULS SAE 15W-40 −9.5 50 15 122

Hydraulic Systems
Refer to the “Lubricant Information” section in the
latest revision of the Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” for
detailed information. This manual may be found on
the Web at Safety.Cat.com.
The following are the preferred oils :

• Cat HYDO Advanced 10 SAE 10W

• Cat BIO HYDO Advanced
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%.
Second choice oils are listed below.

• Cat MTO
• Cat DEO

• Cat DEO-ULS
• Cat TDTO
• Cat TDTO Cold Weather

• Cat TDTO-TMS
• Cat DEO-ULS SYN

• Cat DEO SYN

• Cat DEO-ULS Cold Weather
KEBU7583-01 107
Maintenance Section
Fluids Recommendations

Table 14
Lubricant Viscosities for Ambient Temperatures

Oil Type and Performance °C °F

Compartment or System Oil Viscosities
Requirements Min Max Min Max
Cat HYDO Advanced 10
SAE 10W −20 50 −4 122
Cat TDTO
Hydraulic System
Cat DEO-ULS
SAE15W-40 −15 50 5 122
Cat DEO

Soil Stabilizers
Where recommended for use, Cat TDTO SAE 50 or
TO-4 SAE 50 is preferred in most applications,
particularly continuous operation. If the ambient
temperature is below −15 °C (5 °F), warm up the oil
prior to operation. The oil must be maintained to a
temperature above −15 °C (5 °F) during operation. If
the ambient temperature is below −15 °C (5 °F),
perform the procedures in the Operation and
Maintenance Manual , “Engine and Machine Warm-
Up” prior to operation. If the ambient temperature is
below −25 °C (−13 °F), consult your Caterpillar
dealer for instructions. Failure to warm up the oil prior
to operation will cause damage to the machine.
Table 15
Lubricant Viscosities for Ambient Temperatures

Oil Type and Performance °C °F

Compartment or System Oil Viscosities
Requirements Min Max Min Max
Cat TDTO SAE 50 -10 50 14 122
Front Propel Planetary Drives Cat TDTO-TMS
Rear Propel Planetary Drives Cat Cold Weather TDTO TDTO-TMS -20 50 -4 122
Cat TO-4, Cat TO-4M

Rotor Drive Planetary Cat FDAO SAE 60 -7 50 19 122

Rotor Chain Drive Case and Rotor

Cat TDTO SAE 30 0 50 32 122
Bearing Reservoir

Rotor Transmission Cat TDTO SAE 10W -20 50 -4 122

CAT GO (Gear Oil)
Rotor Differential SAE 85W-140 -10 50 14 122
API GL-5 gear oil

Special Lubricants
Grease
In order to use a non-Cat grease, the supplier must
certify that the lubricant is compatible with Cat
grease.
Each pin joint should be flushed with the new grease.
Ensure that all old grease is removed. Failure to meet
this requirement may lead to failure of a pin joint.
108 KEBU7583-01
Maintenance Section
Fluids Recommendations

Table 16
Recommended Grease
°C °F
Compartment or System GreaseType NLGI Grade
Min Max Min Max
Cat Prime Application
NLGI Grade 2 −20 40 −4 104
Grease
NLGI Grade 2 −30 50 −22 122
Cat Extreme Application
NLGI Grade 1 −35 40 −31 104
Grease
External Lubrication Points NLGI Grade 0 −40 35 −40 95
Cat Extreme Application
NLGI Grade 0 −50 20 −58 68
Grease - Arctic
Cat Extreme Application
NLGI Grade 2 −20 60 −4 140
Grease - Desert

Diesel Fuel Recommendations Diesel fuel must meet “Cat Specification for Distillate
Fuel” and the latest versions of “ASTM D975” or “EN
590” in order to ensure optimum engine performance.
Refer to Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” for the latest fuel
information and for Cat fuel specification. This
manual may be found on the Web at Safety.Cat.com.

NOTICE
Ultra Low Sulfur Diesel (ULSD) fuel 0.0015 percent
(≤15 ppm (mg/kg)) sulfur is required by regulation for
use in engines certified to nonroad Tier 4 standards
(U.S. EPA Tier 4 certified) and that are equipped with
exhaust aftertreatment systems.
European ULSD 0.0010 percent (≤10ppm (mg/kg))
sulfur fuel is required by regulation for use in engines
certified to European nonroad Stage IIIB and newer
Illustration 143 g02157153 standards and are equipped with exhaust aftertreat-
ment systems.
NACD Film

Misfueling with fuels of higher sulfur level will

invalidate the warranty and have the following
negative effects:

• Shorten the time interval between

aftertreatment device service intervals (cause
the need for more frequent service intervals)

• Adversely impact the performance and life of

aftertreatment devices (cause loss of
performance)

• Reduce regeneration intervals of

aftertreatment devices

• Reduce engine efficiency and durability.

Illustration 144 g02052934
EAME Film • Increase the wear.

• Increase the corrosion.

• Increase the deposits.

• Lower fuel economy

KEBU7583-01
• Shorten the time period between oil drain intervals
(more frequent oil drain intervals).
• Increase overall operating costs.
Failures that result from the use of improper fuels
are not Cat factory defects. Therefore the cost of
repairs would not be covered by a Cat warranty.
Caterpillar does not require the use of ULSD in off
road and machine applications that are not Tier 4/
Stage IIIB certified engines. ULSD is not required in
engines that are not equipped with after treatment
devices. For Tier 4/Stage IIIB/Stage IV certified
engines always follow operating instructions. Fuel
tank inlet labels are installed in order to ensure that
the correct fuels are used.
Refer to Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” for more details
about fuels, lubricants, and Tier 4 requirements. This
manual may be found on the Web at Safety.Cat.com.
Diesel Exhaust Fluid
General Information
Diesel Exhaust Fluid (DEF) is a liquid that is injected
into the exhaust system of engines equipped with
Selective Catalytic Reduction (SCR) systems. SCR
reduces emissions of nitrogen oxides (NOx) in diesel
engine exhaust.
Diesel Exhaust Fluid (DEF) is also known under
other names including Aqueous Urea Solution (AUS)
32, AdBlue, or generically referred to as urea.
In engines equipped with SCR emissions reduction
system, DEF is injected in controlled amounts into
the engine exhaust stream. At the elevated exhaust
temperature, urea in DEF is converted to ammonia.
The ammonia chemically reacts with NOx in diesel
exhaust in the presence of the SCR catalyst. The
reaction converts NOx into harmless nitrogen (N2)
and water (H2O).
DEF Recommendations
For use in Cat engines, DEF must meet all the
requirements defined by “ISO 22241-1”
Requirements.
Caterpillar recommends the use of DEF available
through the Cat parts ordering system for use in Cat
engines equipped with SCR systems. Refer to Table
17 for part number information:
Table 17
Cat Part Number Container Size
350-8733 2.5 gal bottle
350-8734 1000-L tote
109
Maintenance Section
Fluids Recommendations
In North America, commercial DEF that is API
approved and meets all the requirements defined in
“ISO 22241-1” may be used in Cat engines that are
equipped with SCR systems.
Outside of North America, commercial DEF that
meets all requirements defined in “ISO 22241-1” may
be used in Cat engines that are equipped with SCR
systems.
The supplier should provide documentation to prove
the DEF is compliant with the requirements of “ISO
22241-1”.
NOTICE
Cat does not warrant the quality or performance of
non-Cat fluids.
NOTICE
Do not use agriculture grade urea solutions. Do
not use any fluids that do not meet “ISO 22241-1” Re-
quirements in SCR emissions reduction systems.
Use of these fluids can result in numerous problems
including damage to SCR equipment and a reduction
in NOx conversion efficiency.
DEF is a solution of solid urea that is dissolved in
demineralized water to produce a final concentration
of 32.5% urea. DEF concentration of 32.5% is
optimal for use in SCR systems. DEF solution of
32.5% urea has the lowest attainable freeze point of
−11.5° C (11.3° F). DEF concentrations that are
higher or lower than 32.5% have higher freeze
points. DEF dosing systems and “ISO 22241-1”
specifications are designed for a solution that is
approximately 32.5%.
Caterpillar offers a refractometer, Cat part number
360-0774, that can be used to measure DEF
concentration. Follow the instructions provided with
the instrument. Appropriate commercial portable
refractometers can be used to determine urea
concentration. Follow the instructions from the
manufacturer.
DEF Guidelines
DEF solution is typically colorless and clear. Changes
to color or clarity are indicators of quality issues.
Quality of DEF can degrade when stored and
handled inappropriately or if DEF is not protected
from contamination. Details are provided below.
If quality issues are suspected, testing of DEF should
focus on urea percentage, alkalinity as NH3 and
biuret content. DEF that does not pass all these tests
or that is no longer clear should not be used.
Materials compatibility
DEF is corrosive. Due to the corrosion caused, DEF
must be stored in tanks constructed of approved
materials. Recommended storage materials:
110
Maintenance Section
Fluids Recommendations
Stainless Steels:
• 304 (S30400)
• 304L (S30403)
• 316 (S31600)
• 316L (S31603)
Alloys and metals:
• Chromium Nickel (CrNi)
• Chromium Nickel Molybdenum (CrNiMo)
• Titanium
Non-metallic materials:
• Polyethylene
• Polypropylene
• Polyisobutylene
• Teflon (PFA)
• Polyfluoroethylene (PFE)
• Polyvinylidene fluoride (PVDF)
• Polytetrafluoroethylene (PTFE)
Materials NOT compatible with DEF solutions include
Aluminum, Magnesium, Zinc, Nickel coatings, Silver
and Carbon steel and Solders containing any of the
above. Unexpected reactions may occur if DEF
solutions come in contact with any non-compatible
material or unknown materials.
Bulk storage
Follow all local regulations covering bulk storage
tanks. Follow proper tank construction guidelines.
Tank volume typically should be 110% of planned
capacity. Appropriately vent indoor tanks. Plan for
control of overflow of the tank. Heat tanks that
dispense DEF in cold climates.
Bulk tank breathers should be fitted with filtration to
keep airborne debris from entering the tank.
Desiccant breathers should not be used because
water will be absorbed, which potentially can alter
DEF concentration.
Handling
Follow all local regulations covering transport and
handling. DEF transport temperature is
recommended to be −5° C (23° F) to 25° C (77° F).
All transfer equipment and intermediate containers
should be used exclusively for DEF. Containers
should not be reused for any other fluids. Ensure that
transfer equipment is made from DEF-compatible
materials. Recommended material for hoses and
other non-metallic transfer equipment include:
KEBU7583-01
• Nitrile Rubber (NBR)
• Fluoroelastomer (FKM)
• Ethylene Propylene Diene Monomer (EPDM)
The condition of hoses and other nonmetallics that
are used with DEF should be monitored for signs of
degradation. DEF leaks are easily recognizable by
white urea crystals that accumulate at the site of the
leak. Solid urea can be corrosive to galvanized or
unalloyed steel, aluminum, copper, and brass. Leaks
should be repaired immediately to avoid damage to
surrounding hardware.
Cleanliness
Contaminants can degrade the quality and life of
DEF. Filtering DEF is recommended when dispensed
into the DEF tank. Filters should be compatible with
DEF and should be used exclusively with DEF.
Check with the filter supplier to confirm compatibility
with DEF before using. Mesh-type filters using
compatible metals, such as stainless steel, are
recommended. Paper (cellulose) media and some
synthetic filter media are not recommended because
of degradation during use.
Care should be taken when dispensing DEF. Spills
should be cleaned immediately. Machine or engine
surfaces should be wiped clean and rinsed with
water. Caution should be used when dispensing DEF
near an engine that has recently been running.
Spilling DEF onto hot components will cause harmful
vapors.
Stability
DEF fluid is stable when stored and handled properly.
The quality of DEF rapidly degrades when stored at
high temperatures. The ideal storage temperature for
DEF is between −9° C (15.8° F) and 25° C (77° F).
DEF that is stored above 35° C (95° F) for longer
than 1 month must be tested before use. Testing
should evaluate Urea Percentage, Alkalinity as NH3
and Biuret content.
The length of storage of DEF is listed in the following
table:
Table 18
Storage Temperature Expected DEF Life
Below 25° C (77° F) 18 months
25° C (77° F) to 30° C (86° F) 12 months
30° C (86° F) to 35° C (95° F) 6 months
Above 35° C (95° F) test quality before use
Refer to “ISO 22241” document series for more
information about DEF quality control.
KEBU7583-01 111
Maintenance Section
Fluids Recommendations

Note: Dispose of all fluids according to applicable The following two types of coolants may be used in
regulations and mandates. Cat diesel engines:
Preferred – Cat ELC (Extended Life Coolant)
Fuel Additives
Acceptable – Cat DEAC (Diesel Engine Antifreeze/
Cat Diesel Fuel Conditioner and Cat Fuel System Coolant)
Cleaner are available for use when needed. These
products are applicable to diesel and biodiesel fuels.
Consult your Cat dealer for availability.

Biodiesel
Biodiesel is a fuel that can be made from various
renewable resources that include vegetable oils,
animal fat, and waste cooking oil. Soybean oil and
rapeseed oil are the primary vegetable oil sources. In
order to use any of these oils or fats as fuel, the oils
or fats are chemically processed (esterified). The
water and contaminants are removed.
U.S. distillate diesel fuel specification “ASTM D975-
09a” includes up to B5 (5 percent) biodiesel.
Currently, any diesel fuel in the U.S. may contain up
to B5 biodiesel fuel.
European distillate diesel fuel specification “EN 590”
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
biodiesel fuel.
Note: The diesel portion used in the biodiesel blend
must be Ultra Low Sulfur Diesel (15 ppm sulfur or
less, per “ASTM D975”). In Europe the diesel fuel
portion used in the biodiesel blend must be sulfur free
diesel (10 ppm sulfur or less, per “EN 590”). The final
blend must have 15 ppm sulfur or less.
When biodiesel fuel is used, certain guidelines must
be followed. Biodiesel fuel can influence the engine
oil, aftertreatment devices, non-metallic, fuel system
components, and others. Biodiesel fuel has limited
storage life and has limited oxidation stability. Follow
the guidelines and requirements for engines that are
seasonally operated and for standby power
generation engines.
In order to reduce the risks associated with the use of
biodiesel, the final biodiesel blend and the biodiesel
fuel used must meet specific blending requirements.
All the guidelines and requirements are provided in
the latest revision of Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations”. This
manual may be found on the Web at Safety.Cat.com.

Coolant Information
The information provided in this “Coolant
Recommendation” section should be used with the
“Lubricants Information” provided in the latest
revision of Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations”. This
manual may be found on the Web at Safety.Cat.com.
112 KEBU7583-01
Maintenance Section
Lubricant Viscosities

NOTICE
Never use water alone as a coolant. Water alone is
corrosive at engine operating temperatures. In addi-
tion, water alone does not provide adequate protec-
tion against boiling or freezing.

Standard Factory Fill Fluids

Table 19
Standard Factory Fill Fluids(1)

°C °F
Compartment or System Oil Viscosities
Min Max Min Max
Engine Crankcase SAE 15W-40 -9.5 50 15 122

Hydraulic Systems Cat HYDO Advanced 10 -20 50 -4 122

Front Propel Planetary Drives Cat TDTO

-10 50 14 122
Rear Propel Planetary Drives SAE 50

Rotor Drive Planetary SAE 60 -7 50 19 122

Rotor Chain Drive Case and Rotor Bearing

SAE 30 0 50 32 122
Reservoir
Rotor Transmission SAE 10W -20 50 -4 122
Rotor Differential SAE 85W-140 -10 50 14 122
(1) The machine is delivered from the factory with the designated fluids.

i05714893 The footnotes are a key part of the tables. Read ALL
footnotes that pertain to the machine compartment in
Lubricant Viscosities question.

(Fluids Recommendations) Selecting the Viscosity

SMCS Code: 1000; 7000; 7581
S/N: TAS1–Up
General Information for Lubricants
When you are operating the machine in temperatures
below −20°C (−4°F), refer to Special Publication,
SEBU5898, “Cold Weather Recommendations”. This
publication is available from your Cat dealer.
For cold-weather applications where transmission oil
SAE 0W-20 is recommended, Cat Cold Weather
TDTO is recommended.
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.
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 oil viscosity grade is determined by the
minimum ambient temperature (the air in the
immediate vicinity of the machine). Measure the
temperature when the machine is started and while
the machine is operated. In order to determine the
proper oil viscosity grade, refer to the “Min” column in
the table. This information reflects the coldest
ambient temperature condition for starting a cold
machine and for operating a cold machine. Refer to
the “Max” column in the table for operating the
machine at the highest temperature that is
anticipated. Unless specified otherwise in the
“Lubricant Viscosities for Ambient Temperatures”
tables, use the highest oil viscosity that is allowed for
the ambient temperature.
KEBU7583-01 113
Maintenance Section
Fluids Recommendations

Machines that are operated continuously should use

oils that have the higher oil viscosity in the final drives
and in the differentials. The oils that have the higher
oil viscosity will 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.

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

Engine Oil
Cat oils have been developed and tested in order to
provide the full performance and life that has been
designed and built into Cat engines.
Cat DEO-ULS multigrade and Cat DEO multigrade
oils are formulated with the correct amounts of
detergents, dispersants, and alkalinity in order to
provide superior performance in Cat diesel engines
where recommended for use.

Note: SAE 10W-30 is the preferred viscosity grade

for the 3116, 3126, C7, C-9, and C9 diesel engines
when the ambient temperature is between -18° C (0°
F) and 40° C (104° F).
Note: C175 Series diesel engines require the use of
multigrade SAE 40 oil. For example: SAE 0W-40,
SAE 5W-40, SAE 10W-40, or SAE 15W-40. In
ambient temperatures of −9.5° C (15° F) or above,
SAE 15W-40 is the preferred oil viscosity grade

Table 20
Lubricant Viscosities for Ambient Temperatures

Oil Type and Performance °C °F

Compartment or System Oil Viscosities
Requirements Min Max Min Max
Cat DEO-ULS Cold Weather SAE 0W-40 −40 40 −40 104
Cat DEO-ULS SYN
SAE 5W-40 −30 50 −22 122
Cat DEO SYN
Engine Crankcase Cat DEO-ULS
SAE 10W-30 −18 40 0 104
Cat DEO
Cat DEO-ULS
SAE 15W-40 −9.5 50 15 122
Cat DEO
114 KEBU7583-01
Maintenance Section
Fluids Recommendations

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

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

Hydraulic Systems
Refer to the “Lubricant Information” section in the
latest revision of the Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” for
detailed information. This manual may be found on
the Web at Safety.Cat.com.
The following are the preferred oils for use in most
Cat machine hydraulic systems:
• Cat HYDO Advanced 10 SAE 10W

• Cat BIO HYDO Advanced

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%.
Second choice oils are listed below.
• Cat HYDO Advanced 30 SAE 30W

• Cat MTO
• Cat DEO

• Cat DEO-ULS
• Cat TDTO

• Cat TDTO Cold Weather

• Cat TDTO-TMS

• Cat DEO-ULS SYN

• Cat DEO SYN
• Cat DEO-ULS Cold Weather
KEBU7583-01 115
Maintenance Section
Fluids Recommendations

Table 21
Lubricant Viscosities for Ambient Temperatures

Oil Type and Performance °C °F

Compartment or System Oil Viscosities
Requirements Min Max Min Max
Cat HYDO Advanced 10
SAE 10W −20 50 −4 122
Cat TDTO
Cat HYDO Advanced 30
SAE 30 0 50 32 122
Cat TDTO
Cat BIO HYDO Advanced “ISO 46” Multi-Grade −30 50 −22 122
Cat MTO
Cat DEO-ULS SAE10W-30 −20 40 −4 104
Cat DEO
Hydraulic System
Cat DEO-ULS
SAE15W-40 −15 50 5 122
Cat DEO
Cat TDTO-TMS Multi-Grade −15 50 5 122
Cat DEO-ULS SYN
SAE 5W-40 −25 40 −13 104
Cat DEO SYN
Cat DEO-ULS Cold Weather SAE0W-40 −40 40 −40 104
Cat TDTO Cold Weather SAE 0W-20 −40 40 −40 104

Soil Stabilizers
Where recommended for use, Cat TDTO SAE 50 or
TO-4 SAE 50 is preferred in most applications,
particularly continuous operation. If the ambient
temperature is below −15 °C (5 °F), warm up the oil
prior to operation. The oil must be maintained to a
temperature above −15 °C (5 °F) during operation. If
the ambient temperature is below −15 °C (5 °F),
perform the procedures in the Operation and
Maintenance Manual , “Engine and Machine Warm-
Up” prior to operation. If the ambient temperature is
below −25 °C (−13 °F), consult your Caterpillar
dealer for instructions. Failure to warm up the oil prior
to operation will cause damage to the machine.
Table 22
Lubricant Viscosities for Ambient Temperatures

Oil Type and Performance °C °F

Compartment or System Oil Viscosities
Requirements Min Max Min Max
Cat TDTO SAE 50 10 50 50 122
Front Propel Planetary Drives Cat TDTO-TMS
Rear Propel Planetary Drives Cat Cold Weather TDTO TDTO-TMS -20 50 -4 122
Cat TO-4, Cat TO-4M

Rotor Drive Planetary Cat FDAO SAE 60 -7 50 19 122

Rotor Chain Drive Case and Rotor

Cat TDTO SAE 30 0 50 32 122
Bearing Reservoir

Rotor Transmission Cat TDTO SAE 10W -20 50 -4 122

CAT GO (Gear Oil)
Rotor Differential SAE 85W-140 -10 50 14 122
API GL-5 gear oil
116 KEBU7583-01
Maintenance Section
Fluids Recommendations

Special Lubricants
Grease
In order to use a non-Cat grease, the supplier must
certify that the lubricant is compatible with Cat
grease.
Each pin joint should be flushed with the new grease.
Ensure that all old grease is removed. Failure to meet
this requirement may lead to failure of a pin joint.
Table 23
Recommended Grease
°C °F
Compartment or System GreaseType NLGI Grade
Min Max Min Max
Cat Prime Application
NLGI Grade 2 −20 40 −4 104
Grease
NLGI Grade 2 −30 50 −22 122
Cat Extreme Application
NLGI Grade 1 −35 40 −31 104
Grease
External Lubrication Points NLGI Grade 0 −40 35 −40 95
Cat Extreme Application
NLGI Grade 0 −50 20 −58 68
Grease - Arctic
Cat Extreme Application
NLGI Grade 2 −20 60 −4 140
Grease - Desert

Diesel Fuel Recommendations • Increase overall operating costs

Diesel fuel must meet “Caterpillar Specification for
Distillate Fuel” and the latest versions of “ASTM
D975” or “EN 590” in order to ensure optimum engine
performance. Refer to Special Publication,
SEBU6250, “Caterpillar Machine Fluids
Recommendations” for the latest fuel information and
for Cat fuel specification. This manual may be found
on the Web at Safety.Cat.com.
The preferred fuels are distillate fuels. These fuels
are commonly called diesel fuel, furnace oil, gas oil,
or kerosene. These fuels must meet the “Caterpillar
Specification for Distillate Diesel Fuel for Off-
Highway Diesel Engines”. Diesel Fuels that meet the
Caterpillar specification will help provide maximum
engine service life and performance.
• Negatively impact engine emissions
Failures that result from the use of improper fuels are
not Caterpillar factory defects. Therefore the cost of
repairs would not be covered by a Caterpillar
warranty.
Caterpillar does not require the use of ULSD in off
road and machine applications that are not Tier 4/
Stage IIIB certified engines. ULSD is not required in
engines that are not equipped with after treatment
devices.
Follow operating instructions and fuel tank inlet
labels, if available, in order to ensure that the correct
fuels are used.

Misfueling with fuels of high sulfur level can have

the following negative effects:
• Reduce engine efficiency and durability
• Increase the wear

• Increase the corrosion

• Increase the deposits

• Lower fuel economy

• Shorten the time period between oil drain intervals
(more frequent oil drain intervals)
KEBU7583-01 117
Maintenance Section
Fluids Recommendations

Refer to Special Publication, SEBU6250, “Caterpillar Acceptable – Cat DEAC (Diesel Engine Antifreeze/
Machine Fluids Recommendations” for more details Coolant)
about fuels and lubricants. This manual may be
found on the Web at Safety.Cat.com.

Fuel Additives
Cat Diesel Fuel Conditioner and Cat Fuel System
Cleaner are available for use when needed. These
products are applicable to diesel and biodiesel fuels.
Consult your Cat dealer for availability.

Biodiesel
Biodiesel is a fuel that can be made from various
renewable resources that include vegetable oils,
animal fat, and waste cooking oil. Soybean oil and
rapeseed oil are the primary vegetable oil sources. In
order to use any of these oils or fats as fuel, the oils
or fats are chemically processed (esterified). The
water and contaminants are removed.
U.S. distillate diesel fuel specification “ASTM D975-
09a” includes up to B5 (5 percent) biodiesel.
Currently, any diesel fuel in the U.S. may contain up
to B5 biodiesel fuel.
European distillate diesel fuel specification “EN 590”
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
biodiesel fuel.
When biodiesel fuel is used, certain guidelines must
be followed. Biodiesel fuel can influence the engine
oil, aftertreatment devices, non-metallic, fuel system
components, and others. Biodiesel fuel has limited
storage life and has limited oxidation stability. Follow
the guidelines and requirements for engines that are
seasonally operated and for standby power
generation engines.
In order to reduce the risks associated with the use of
biodiesel, the final biodiesel blend and the biodiesel
fuel used must meet specific blending requirements.
All the guidelines and requirements are provided in
the latest revision of Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations”. This
manual may be found on the Web at Safety.Cat.com.

Coolant Information
The information provided in this “Coolant
Recommendation” section should be used with the
“Lubricants Information” provided in the latest
revision of Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations”. This
manual may be found on the Web at Safety.Cat.com.
The following two types of coolants may be used in
Cat diesel engines:
Preferred – Cat ELC (Extended Life Coolant)
118 KEBU7583-01
Maintenance Section
Capacities (Refill)

NOTICE
Never use water alone as a coolant. Water alone is
corrosive at engine operating temperatures. In addi-
tion, water alone does not provide adequate protec-
tion against boiling or freezing.

Standard Factory Fill Fluids

Table 24
Standard Factory Fill Fluids(1)

°C °F
Compartment or System Oil Viscosities
Min Max Min Max
Engine Crankcase SAE 15W-40 -9.5 50 15 122

Hydraulic Systems Cat HYDO Advanced 10 -20 50 -4 122

Front Propel Planetary Drives Cat TDTO

-10 50 14 122
Rear Propel Planetary Drives SAE 50

Rotor Drive Planetary SAE 60 -7 50 19 122

Rotor Chain Drive Case and Rotor Bearing

SAE 30 0 50 32 122
Reservoir
Rotor Transmission SAE 10W -20 50 -4 122
Rotor Differential SAE 85W-140 -10 50 14 122
(1) The machine is delivered from the factory with the designated fluids.

i06751297

Capacities (Refill)
SMCS Code: 1000; 7000; 7560

S/N: MB91–Up
Table 25
Approximate Refill Capacities

Compartment or System Liters US Gallons Imp Gallons Recommended Type

Fuel Tank (usable) 1056 279 232

Cooling System 80 21.13 15.4

Engine Oil with a Filter 52 13.74 11.44

Propel Planetary Gear Reducer (front each) 8.4 2.22 1.85

Hydraulic Tank 224 59.17 49.27

Refer to Operation and Maintenance Manual,
Rotor Drive Axle 17 4.5 3.7
“Lubricant Viscosities”.
Rotor Axle Hub (each) 3.8 1 0.8

Rotor Bearing Reservoir 12 3.17 2.64

Chain Case (each) 25.6 6.8 5.6

Rotor Transmission 50 13.2 11

Propel Planetary Gear Reducer (each) 5.9 1.56 1.3

(continued)
KEBU7583-01 119
Maintenance Section
Capacities (Refill)

(Table 25, contd)

DEF Tank 46 12.15 10.12
kg lbs

Refrigerant(1) 1.9 4.2 R-134a

ml oz

Refrigerant Oil 180 6 Polyalkylene Glycol (PAG) Oil

Refrigerant Lines 90 3 Polyalkylene Glycol (PAG) Oil

(1) Refer to Service Manual, “Air Conditioning and Heating R-134a for All Caterpillar Machines” for additional information

i06751348

Capacities (Refill)
SMCS Code: 1000; 7000; 7560

S/N: TAS1–Up
Table 26
Approximate Refill Capacities

Compartment or System Liters US Gallons Imp Gallons Recommended Type

Fuel Tank (usable) 1056 279 232

Cooling System 70 18.5 15.4

Engine Oil with a Filter 52 13.74 11.44

Propel Planetary Gear Reducer (front each) 8.4 2.22 1.85

Hydraulic Tank 224 59.17 49.27

Refer to Operation and Maintenance Manual,
Rotor Drive Differential Oil 17 4.5 3.7 “Lubricant Viscosities”.
Rotor Drive Planetary Oil 3.8 1 0.8

Rotor Bearing Reservoir 3.79 1 0.83

Rotor Chain Drive Case Oil 25.6 6.8 5.6

Rotor Transmission 34.1 9 7.5
Propel Planetary Gear Reducer (each) 5.9 1.56 1.3

kg lbs

Refrigerant(1) 1.9 4.2 R-134a

ml oz

Refrigerant Oil 180 6 Polyalkylene Glycol (PAG) Oil

Refrigerant Lines 90 3 Polyalkylene Glycol (PAG) Oil

(1) Refer to Service Manual, “Air Conditioning and Heating R-134a for All Caterpillar Machines” for additional information
120 KEBU7583-01
Maintenance Section
S·O·S Information

i04311449

S·O·S Information
SMCS Code: 1000; 1348; 3080; 4070; 4300; 5050;
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.
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.
KEBU7583-01
Maintenance Support
i06066971
System Pressure Release
SMCS Code: 1250-553-PX; 1300-553-PX; 1350-
553-PX; 3000-553-PX; 4250-553-PX; 4300-553-PX;
5050-553-PX; 5612-553-PX; 5615-553-PX; 7540-
553-PX
Personal injury or death can result from sudden
machine movement.
Sudden movement of the machine can cause in-
jury to persons on or near the machine.
To prevent injury or death, make sure that the
area around the machine is clear of personnel
and obstructions before operating the machine.
Coolant System
Pressurized system: Hot coolant can cause seri-
ous burn. To open cap, stop engine, wait until ra-
diator is cool. Then loosen cap slowly to relieve
the pressure.
To relieve the pressure from the coolant system, turn
off the machine. Allow the cooling system pressure
cap to cool. Remove the cooling system pressure
cap slowly in order to relieve pressure.
Hydraulic System
Personal injury can result from hydraulic oil pres-
sure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Seri-
ous injury can be caused if this pressure is not
released before any service is done on the hy-
draulic system.
Make sure all of the attachments have been low-
ered, oil is cool before removing any components
or lines. Remove the oil filler cap only when the
engine is stopped, and the filler cap is cool
enough to touch with your bare hand.
1. Shut off the engine.
2. Slowly loosen the filler cap in order to release the
pressure in the hydraulic tank.
121
Maintenance Section
Maintenance Support
3. Tighten the filler cap.
4. The pressure in the hydraulic system has been
released. Lines and components can be removed.
i01821998
Welding on Machines and
Engines with Electronic
Controls
SMCS Code: 1000; 7000
Proper welding procedures are necessary in order to
avoid damage to the electronic controls and to the
bearings. The following steps should be followed in
order to weld on a machine or an engine with
electronic controls.
1. Turn off the engine.
2. Turn the battery disconnect switch to the OFF
position. If there is no battery disconnect switch,
remove the negative battery cable at the battery.
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 in order to reduce the possibility of
damage to the following components:
• Bearings of the drive train
• Hydraulic components
• Electrical components
• Other components of the machine
NOTICE
Do NOT use electrical components (ECM or sensors)
or electronic component grounding points for ground-
ing the welder.
4. Protect any wiring harnesses from the debris
which is created from welding. Protect any wiring
harnesses from the splatter which is created from
welding.
5. Use standard welding procedures in order to weld
the materials together.
122
Maintenance Section
Maintenance Interval Schedule
i06731936
Maintenance Interval Schedule
SMCS Code: 1000; 7000
S/N: MB91–Up
Ensure that all safety information, warnings, and
instructions are read and understood before any
operation or any maintenance procedures are
performed.
The user is responsible for the performance of
maintenance. All adjustments, the use of proper
lubricants, fluids, filters, and the replacement of
components due to normal wear and aging are
included. Failure to adhere to proper maintenance
intervals and procedures may result in diminished
performance of the product and/or accelerated wear
of components.
Use mileage, fuel consumption, service hours, or
calendar time, WHICH EVER OCCURS FIRST, in
order to determine the maintenance intervals.
Products that operate in severe operating conditions
may require more frequent maintenance. Refer to the
maintenance procedure for any other exceptions that
may change the maintenance intervals.
Note: The aftertreatment system can be expected to
function properly for the useful life of the engine
(emissions durability period), as defined by
regulation. All prescribed maintenance requirements
must be followed.
Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be
performed.
When Required
“ Battery - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . 130
“ Battery - Recycle” . . . . . . . . . . . . . . . . . . . . . . . . 131
“ Battery or Battery Cable - Inspect/Replace”. . . . 131
“ Camera - Clean/Adjust”. . . . . . . . . . . . . . . . . . . . 133
“ Circuit Breakers - Reset” . . . . . . . . . . . . . . . . . . . 134
“ DEF Filler Screen - Clean” . . . . . . . . . . . . . . . . . 141
“ Diesel Exhaust Fluid - Fill”. . . . . . . . . . . . . . . . . . 143
“ Emulsion Spray Nozzles - Clean” . . . . . . . . . . . . 146
“ Emulsion Spray System Strainer - Clean” . . . . . 148
“ Engine Air Filter Primary Element - Clean/
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
“ Engine Air Filter Secondary Element -
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
“ Engine Air Precleaner - Clean” . . . . . . . . . . . . . . 152
KEBU7583-01
“ Film (Product Identification) - Clean” . . . . . . . . . 156
“ Fuel System - Prime” . . . . . . . . . . . . . . . . . . . . . . 157
“ Fuses - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 160
“ Oil Filter - Inspect” . . . . . . . . . . . . . . . . . . . . . . . . 168
“ Radiator and Hydraulic Oil Cooler - Clean” . . . . 170
“Refrigerant Dryer - Replace” . . . . . . . . . . . . . . . . 171
“ Rotor Cutter Bits (Side) - Inspect/Replace” . . . . 176
“ Rotor Cutter Bits - Inspect/Replace”. . . . . . . . . . 177
“ Tool Holder - Inspect/Replace” . . . . . . . . . . . . . . 186
“ Water Spray System Nozzles - Clean” . . . . . . . . 189
“ Water Spray System Strainer - Clean” . . . . . . . . 190
Initial 20 Service Hours
“ Tool Holder - Inspect/Replace” . . . . . . . . . . . . . . 186
Every 10 Service Hours or Daily
“ Backup Alarm - Test” . . . . . . . . . . . . . . . . . . . . . . 130
“ Bolster Oscillation Pin (Rear) - Lubricate” . . . . . 131
“ Cooling System Coolant Level - Check”. . . . . . . 139
“ Emulsion Spray System - Clean” . . . . . . . . . . . . 147
“ Engine Crankcase Breather Tube - Inspect/
Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
“ Engine Oil Level - Check” . . . . . . . . . . . . . . . . . . 152
“ Hydraulic System Oil Level - Check ” . . . . . . . . . 164
“ Rotor Bearing Reservoir Oil Level - Check” . . . . 173
“ Seat Belt - Inspect” . . . . . . . . . . . . . . . . . . . . . . . 184
“ Tire Inflation - Check” . . . . . . . . . . . . . . . . . . . . . 186
Every 50 Service Hours
“ Mixing Chamber Disc Hub - Lubricate”. . . . . . . . 166
Every 50 Service Hours or Weekly
“ Emulsion Pump - Lubricate” . . . . . . . . . . . . . . . . 146
“ Fuel Tank Water and Sediment - Drain” . . . . . . . 160
“ Mixing Chamber Door Cylinder Ends (Front) -
Lubricate” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
“ Mixing Chamber Door Cylinder Ends (Rear) -
Lubricate” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
KEBU7583-01
“ Mixing Chamber Door Hinges (Front) -
Lubricate” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
“ Mixing Chamber Door Hinges (Rear) -
Lubricate” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
“ Mixing Chamber Linkage - Lubricate”. . . . . . . . . 167
“ Mixing Chamber Tilt Cylinder Ends -
Lubricate” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
“ Propel Planetary Oil - Check” . . . . . . . . . . . . . . . 169
“ Rotor Chain Drive Case Oil Level - Check” . . . . 175
“ Rotor Drive Differential Oil Level - Check” . . . . . 179
“ Rotor Drive Planetary Oil - Check” . . . . . . . . . . . 180
“ Rotor Lift Cylinder Ends - Lubricate”. . . . . . . . . . 180
“ Rotor Shear Disc - Lubricate” . . . . . . . . . . . . . . . 180
“ Rotor Torque Limiter Coupling - Inspect” . . . . . . 181
“ Rotor Transmission Oil - Check”. . . . . . . . . . . . . 183
“ Steering Cylinder Ends - Lubricate” . . . . . . . . . . 185
“ Steering Knuckle - Lubricate” . . . . . . . . . . . . . . . 185
“ Steering Linkage - Lubricate” . . . . . . . . . . . . . . . 186
“ Water Spray System Pump Oil Level -
Check” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Initial 250 Service Hours
“ Auxiliary Hydraulic System Charge Filter -
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
“ Engine Valve Rotators - Inspect” . . . . . . . . . . . . 155
“ Hydraulic System Return Filter - Replace”. . . . . 165
“ Rotor Transmission Oil Filter - Replace” . . . . . . 183
Every 250 Service Hours
“ Engine Oil Sample - Obtain” . . . . . . . . . . . . . . . . 153
Every 250 Service Hours or 3
Months
“ Belts - Inspect/Adjust/Replace”. . . . . . . . . . . . . . 131
“ Cab Air Filter - Clean/Replace” . . . . . . . . . . . . . . 132
“ Hydraulic System Oil Sample - Obtain” . . . . . . . 165
“ Parking Brake - Check” . . . . . . . . . . . . . . . . . . . . 168
“ Propel Planetary Oil - Change” . . . . . . . . . . . . . . 169
“ Propel Planetary Oil Sample - Obtain” . . . . . . . . 170
“ Rotor Bearing Reservoir Oil - Change”. . . . . . . . 172
123
Maintenance Section
Maintenance Interval Schedule
“ Rotor Bearing Reservoir Oil Sample - Obtain”. . 173
“ Rotor Brake - Adjust” . . . . . . . . . . . . . . . . . . . . . . 173
“ Rotor Chain Drive Case Oil - Change” . . . . . . . . 175
“ Rotor Drive Differential Oil - Change” . . . . . . . . . 178
“ Rotor Drive Differential Oil Sample - Obtain” . . . 179
“ Rotor Drive Planetary Oil - Change” . . . . . . . . . . 179
“ Rotor Drive Planetary Oil Sample - Obtain” . . . . 180
“ Rotor Shear Disc Bolts - Inspect/Replace”. . . . . 181
“ Rotor Transmission Oil - Change” . . . . . . . . . . . 182
“ Rotor Transmission Oil Sample - Obtain”. . . . . . 183
“ Water Spray System Pump Oil - Change” . . . . . 189
Initial 500 Hours (for New Systems,
Refilled Systems, and Converted
Systems)
“Cooling System Coolant Sample (Level 2) -
Obtain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Every 500 Service Hours
“ Engine Oil and Filter - Change”. . . . . . . . . . . . . . 153
“ Fuel System Primary Filter - Clean/Inspect/
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
“ Fuel System Secondary Filter - Replace”. . . . . . 158
“ Fuel Tank Strainer - Clean” . . . . . . . . . . . . . . . . . 159
Every 500 Service Hours or 6
Months
“Cooling System Coolant Sample (Level 1) -
Obtain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
“ Rotor Bearing Reservoir Breather - Replace” . . 172
“ Rotor Drive Differential Breather - Replace” . . . 178
“ Rotor Transmission Breather - Replace” . . . . . . 182
Every 1000 Service Hours or 1 Year
“ Auxiliary Hydraulic System Charge Filter -
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
“ Braking System - Test” . . . . . . . . . . . . . . . . . . . . 132
“ Cooling System Pressure Cap - Clean/
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
“ Hydraulic System Oil - Change” . . . . . . . . . . . . . 162
124 KEBU7583-01
Maintenance Section
Maintenance Interval Schedule

“ Hydraulic System Oil Filter - Replace” . . . . . . . . 163 “ Diesel Particulate Filter - Clean” . . . . . . . . . . . . . 146
“ Hydraulic System Return Filter - Replace”. . . . . 165
Every 6000 Service Hours or 3
“ Hydraulic Tank Breather - Replace” . . . . . . . . . . 165 Years
“ Hydraulic Tank Screen - Clean” . . . . . . . . . . . . . 166 “ Cooling System Coolant Extender (ELC) -
Add” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
“ Rollover Protective Structure (ROPS) -
Inspect” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Every 10 000 Service Hours
“ Rotor Transmission Oil Filter - Replace” . . . . . . 183
“ DEF Manifold Filters - Replace” . . . . . . . . . . . . . 141
Every 2000 Service Hours
Every 12 000 Service Hours or 6
“ Fuel Tank Cap Filter - Replace” . . . . . . . . . . . . . 159
Years
“ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . 155
“ Cooling System Coolant (ELC) - Change” . . . . . 136
Every 2000 Service Hours or 1 Year
“ Engine Mounts - Inspect” . . . . . . . . . . . . . . . . . . 152

Every Year
“Cooling System Coolant Sample (Level 2) -
Obtain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Every 2500 Service Hours

“ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . 155

Every 3000 Service Hours or 2

Years
“ Cooling System Water Temperature Regulator -
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
“ Engine Water Pump - Inspect” . . . . . . . . . . . . . . 156

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

Every 5000 Service Hours

“ ARD Spark Plug - Clean”. . . . . . . . . . . . . . . . . . . 129
“ Diesel Exhaust Fluid Filter - Replace” . . . . . . . . . . . .
“ Diesel Exhaust Fluid Injector - Replace” . . . . . . 145
KEBU7583-01
i06731937
Maintenance Interval Schedule
SMCS Code: 1000; 7000
S/N: TAS1–Up
Ensure that all safety information, warnings, and
instructions are read and understood before any
operation or any maintenance procedures are
performed.
The user is responsible for the performance of
maintenance. All adjustments, the use of proper
lubricants, fluids, filters, and the replacement of
components due to normal wear and aging are
included. Failure to adhere to proper maintenance
intervals and procedures may result in diminished
performance of the product and/or accelerated wear
of components.
Use mileage, fuel consumption, service hours, or
calendar time, WHICH EVER OCCURS FIRST, in
order to determine the maintenance intervals.
Products that operate in severe operating conditions
may require more frequent maintenance. Refer to the
maintenance procedure for any other exceptions that
may change the maintenance intervals.
Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be
performed.
When Required
“ Battery - Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . 130
“ Battery - Recycle” . . . . . . . . . . . . . . . . . . . . . . . . 131
“ Battery or Battery Cable - Inspect/Replace”. . . . 131
“ Camera - Clean/Adjust”. . . . . . . . . . . . . . . . . . . . 133
“ Circuit Breakers - Reset” . . . . . . . . . . . . . . . . . . . 134
“ Emulsion Spray Nozzles - Clean” . . . . . . . . . . . . 146
“ Emulsion Spray System - Clean” . . . . . . . . . . . . 147
“ Engine Air Filter Primary Element - Clean/
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
“ Engine Air Filter Secondary Element -
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
“ Engine Air Precleaner - Clean” . . . . . . . . . . . . . . 152
“ Film (Product Identification) - Clean” . . . . . . . . . 156
“ Fuses - Replace” . . . . . . . . . . . . . . . . . . . . . . . . . 160
“ Oil Filter - Inspect” . . . . . . . . . . . . . . . . . . . . . . . . 168
“ Radiator and Hydraulic Oil Cooler - Clean” . . . . 170
“Refrigerant Dryer - Replace” . . . . . . . . . . . . . . . . 171
125
Maintenance Section
Maintenance Interval Schedule
“ Rotor Cutter Bits (Side) - Inspect/Replace” . . . . 176
“ Rotor Cutter Bits - Inspect/Replace”. . . . . . . . . . 177
“ Tool Holder - Inspect/Replace” . . . . . . . . . . . . . . 186
“ Water Spray System Nozzles - Clean” . . . . . . . . 189
“ Water Spray System Strainer - Clean” . . . . . . . . 190
Initial 20 Service Hours
“ Tool Holder - Inspect/Replace” . . . . . . . . . . . . . . 186
Every 10 Service Hours or Daily
“ Backup Alarm - Test” . . . . . . . . . . . . . . . . . . . . . . 130
“ Bolster Oscillation Pin (Rear) - Lubricate” . . . . . 131
“ Cooling System Coolant Level - Check”. . . . . . . 139
“ Emulsion Spray System - Clean” . . . . . . . . . . . . 147
“ Engine Crankcase Breather Tube - Inspect/
Clean” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
“ Engine Oil Level - Check” . . . . . . . . . . . . . . . . . . 152
“ Hydraulic System Oil Level - Check ” . . . . . . . . . 164
“ Rotor Bearing Reservoir Oil Level - Check” . . . . 173
“ Seat Belt - Inspect” . . . . . . . . . . . . . . . . . . . . . . . 184
“ Tire Inflation - Check” . . . . . . . . . . . . . . . . . . . . . 186
Every 50 Service Hours
“ Mixing Chamber Disc Hub - Lubricate”. . . . . . . . 166
Every 50 Service Hours or Weekly
“ Emulsion Pump - Lubricate” . . . . . . . . . . . . . . . . 146
“ Fuel Tank Water and Sediment - Drain” . . . . . . . 160
“ Mixing Chamber Door Cylinder Ends (Front) -
Lubricate” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
“ Mixing Chamber Door Cylinder Ends (Rear) -
Lubricate” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
“ Mixing Chamber Door Hinges (Front) -
Lubricate” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
“ Mixing Chamber Door Hinges (Rear) -
Lubricate” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
“ Mixing Chamber Linkage - Lubricate”. . . . . . . . . 167
“ Mixing Chamber Tilt Cylinder Ends -
Lubricate” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
“ Propel Planetary Oil - Check” . . . . . . . . . . . . . . . 169
126 KEBU7583-01
Maintenance Section
Maintenance Interval Schedule

“ Rotor Chain Drive Case Oil Level - Check” . . . . 175
“ Rotor Drive Differential Oil Level - Check” . . . . . 179
“ Rotor Drive Planetary Oil - Check” . . . . . . . . . . . 180
“ Rotor Lift Cylinder Ends - Lubricate”. . . . . . . . . . 180
“ Rotor Shear Disc - Lubricate” . . . . . . . . . . . . . . . 180
“ Rotor Torque Limiter Coupling - Inspect” . . . . . . 181
“ Rotor Transmission Oil - Check”. . . . . . . . . . . . . 183
“ Steering Cylinder Ends - Lubricate” . . . . . . . . . . 185
“ Steering Knuckle - Lubricate” . . . . . . . . . . . . . . . 185
“ Steering Linkage - Lubricate” . . . . . . . . . . . . . . . 186
“ Water Spray System Pump Oil Level -
Check” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Initial 250 Service Hours
“ Auxiliary Hydraulic System Charge Filter -
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
“ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . 155
“ Engine Valve Rotators - Inspect” . . . . . . . . . . . . 155
“ Hydraulic System Return Filter - Replace”. . . . . 165
“ Rotor Transmission Oil Filter - Replace” . . . . . . 183
Every 250 Service Hours
“ Engine Oil Sample - Obtain” . . . . . . . . . . . . . . . . 153
Every 250 Service Hours or 3
Months
“ Belts - Inspect/Adjust/Replace”. . . . . . . . . . . . . . 131
“ Cab Air Filter - Clean/Replace” . . . . . . . . . . . . . . 132
“ Hydraulic System Oil Sample - Obtain” . . . . . . . 165
“ Parking Brake - Check” . . . . . . . . . . . . . . . . . . . . 168
“ Propel Planetary Oil - Change” . . . . . . . . . . . . . . 169
“ Propel Planetary Oil Sample - Obtain” . . . . . . . . 170
“ Rotor Bearing Reservoir Oil - Change”. . . . . . . . 172
“ Rotor Bearing Reservoir Oil Sample - Obtain”. . 173
“ Rotor Brake - Adjust” . . . . . . . . . . . . . . . . . . . . . . 173
“ Rotor Chain Drive Case Oil - Change” . . . . . . . . 175
“ Rotor Drive Differential Oil - Change” . . . . . . . . . 178
“ Rotor Drive Differential Oil Sample - Obtain” . . . 179
“ Rotor Drive Planetary Oil - Change” . . . . . . . . . . 179
“ Rotor Drive Planetary Oil Sample - Obtain” . . . . 180
“ Rotor Shear Disc Bolts - Inspect/Replace”. . . . . 181
“ Rotor Transmission Oil - Change” . . . . . . . . . . . 182
“ Rotor Transmission Oil Sample - Obtain”. . . . . . 183
“ Water Spray System Pump Oil - Change” . . . . . 189
Initial 500 Hours (for New Systems,
Refilled Systems, and Converted
Systems)
“Cooling System Coolant Sample (Level 2) -
Obtain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Every 500 Service Hours
“ Engine Oil and Filter - Change”. . . . . . . . . . . . . . 153
“ Fuel System Primary Filter - Clean/Inspect/
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
“ Fuel System Secondary Filter - Replace”. . . . . . 158
“ Fuel Tank Strainer - Clean” . . . . . . . . . . . . . . . . . 159
Every 500 Service Hours or 6
Months
Every 1000 Service Hours or 1 Year
“ Auxiliary Hydraulic System Charge Filter -
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
“ Braking System - Test” . . . . . . . . . . . . . . . . . . . . 132
“ Cooling System Pressure Cap - Clean/
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
“ Hydraulic System Oil - Change” . . . . . . . . . . . . . 162
“ Hydraulic System Oil Filter - Replace” . . . . . . . . 163
“ Hydraulic System Return Filter - Replace”. . . . . 165
“ Hydraulic Tank Breather - Replace” . . . . . . . . . . 165
“ Hydraulic Tank Screen - Clean” . . . . . . . . . . . . . 166
“ Rollover Protective Structure (ROPS) -
Inspect” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
KEBU7583-01 127
Maintenance Section
Maintenance Interval Schedule

“ Rotor Transmission Oil Filter - Replace” . . . . . . 183

Every 2000 Service Hours

“ Fuel Tank Cap Filter - Replace” . . . . . . . . . . . . . 159

Every 2000 Service Hours or 1 Year

“ Engine Mounts - Inspect” . . . . . . . . . . . . . . . . . . 152

Every Year
“Cooling System Coolant Sample (Level 2) -
Obtain” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Every 2500 Service Hours

“ Engine Valve Lash - Check” . . . . . . . . . . . . . . . . 155

Every 3000 Service Hours or 2

Years
“ Cooling System Water Temperature Regulator -
Replace” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
“ Engine Water Pump - Inspect” . . . . . . . . . . . . . . 156

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

Every 5000 Service Hours

“ Diesel Exhaust Fluid Filter - Replace” . . . . . . . . . . . .
“ Diesel Exhaust Fluid Injector - Replace” . . . . . . 145
“ Diesel Particulate Filter - Clean” . . . . . . . . . . . . . 146

Every 6000 Service Hours or 3

Years
“ Cooling System Coolant Extender (ELC) -
Add” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Every 12 000 Service Hours or 6

Years
“ Cooling System Coolant (ELC) - Change” . . . . . 136
128
Maintenance Section
Auxiliary Hydraulic System Charge Filter - Replace
i05738326
Auxiliary Hydraulic System
Charge Filter - Replace
SMCS Code: 5068-510
Note: Cleanliness must be a priority when you
drain the hydraulic oil and when you fill the
hydraulic oil. Cleanliness must be a priority when
you change the filters. Drain the oil and fill the oil
in a clean work area. Use clean tools. Make sure
that you have clean hands. Clean the outside of
the hydraulic tank before you start to operate the
machine.
Drain the hydraulic tank before you change the filter.
Illustration 145 g03646464
1. The hydraulic tank drain valve is located beneath
the access steps on the right side of the machine.
2. Connect a temporary drain hose to the drain valve.
Place the other end of the drain hose in a suitable
container.
Illustration 146 g03646480
3. Clean the area around the filler cap.
KEBU7583-01
4. Loosen the filler cap in order to equalize the
pressure in the hydraulic tank.
5. Open the drain valve. Drain the oil to a suitable
container. Allow the oil to drain until the hydraulic
tank is empty.
6. Close the drain valve.
7. Remove the temporary drain hose from the drain
valve.
8. Remove the container.
Illustration 147 g03646485
Auxiliary hydraulic system filter.
9. Place a suitable container under the filter.
10. Remove the filter from the filter base.
11. Clean the filter base.
12. Install the new filter by hand.
Instructions for the installation of the filter are
printed on the side of each Caterpillar spin-on
filter. For non-Caterpillar filters, refer to the
installation instructions that are provided by the
supplier of the filter.
13. Open the filler cap.
14. Fill the hydraulic tank with clean hydraulic oil.
Refer to Operation and Maintenance Manual,
“Lubricant Viscosities” when you select a hydraulic
oil.
15. Close the filler cap.
16. Start the machine.
17. Allow the engine to run for several minutes.
18. Check for leaks.
19. Stop the machine.
20. Repair any leaks.
KEBU7583-01
21. Remove the container. Dispose of all fluids
according to local regulations. Dispose of the old
filter according to local regulations. Proper care is
your responsibility.
22. Continue to check for leaks after you place the
machine in operation.
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information that
pertains to containing fluid spillage.
i05873298
ARD Spark Plug - Clean
SMCS Code: 1555-070
S/N: MB91–Up
NOTICE
If the engine is running or the key is in the ON posi-
tion, the ARD plug will continue to fire. Turn the key
to the OFF position before servicing the ARD plug.
Illustration 148 g03705298
1. Remove top screen (1) on the hood .
129
Maintenance Section
ARD Spark Plug - Clean
Illustration 149 g03705301
2. Remove spark pug access cover (3).
Illustration 150 g03705302
3. Remove wire harness (3) from spark plug (4).
4. Use a deep well socket and a breaker bar to
loosen the spark plug. If necessary, see your Cat
dealer for the part number of the socket. After the
spark plug has been loosened, use the socket to
remove the spark plug by hand in order to detect
problems with the threads.
NOTICE
Do not overtighten the spark plug. The shell can be
cracked and the gasket can be deformed. The metal
can deform and the gasket can be damaged. The
shell can be stretched. This will loosen the seal that
is between the shell and the insulator, allowing com-
bustion pressure to blow past the seal. Serious dam-
age to the engine can occur.
Use the proper torque.
5. Install the spark plug by hand until the spark plug
contacts the ARD. Torque the spark plug to the
proper specification. Refer to Specifications,
“Spark Plug” for the proper torque specification.
130 KEBU7583-01
Maintenance Section
Backup Alarm - Test

6. Connect the wiring harness. i05728136

7. Install the access panel and hood screen.

Battery - Clean
i05727980 SMCS Code: 1401-070

Backup Alarm - Test

SMCS Code: 7406-081 Batteries give off flammable fumes which can
explode.
1. Start the engine.
To avoid injury or death, do not strike a match,
cause a spark, or smoke in the vicinity of a
battery.

Note: Maintenance free batteries are included with a

new machine. You do not need to check the
electrolyte level in the maintenance free batteries.

Illustration 151 g03641919

2. Engage parking brake (1).

3. Slowly move the propel lever (2) toward the
REVERSE position. Do not move the propel lever
to the FULL REVERSE. Do not move the
machine.
The backup alarm should sound. The backup alarm Illustration 153 g03641958
will sound until the propel lever is moved to the
CENTER position or until the propel lever is moved to The battery box is located behind the operator
the FORWARD position. access ladder on the right side of the machine.

Note: The CENTER position is the neutral position.

Illustration 154 g03641962

1. Turn the battery disconnect switch to the OFF

Illustration 152 g03628693
position. Refer to this Operation and Maintenance
The backup alarm is located on the rear bolster Manual, “Battery Disconnect Switch” topic, for the
behind the fuel tank drain at the pivot point of the
bolster. proper procedure.
KEBU7583-01
Note: There is limited clearance between the battery
box and the battery terminals. Use care when you
disconnect the battery terminals. Do not allow the
battery terminals or the battery posts to come in
contact with the battery box. Do not allow the battery
terminals or the battery posts to come in contact with
the battery box cover.
2. Remove the battery box cover.
3. Remove the battery terminal covers (1).
4. Clean the battery terminals. Coat the battery
terminals with petroleum jelly.
5. Replace the battery terminal covers.
6. Tighten the battery retainers (2).
7. Clean the top of the batteries (3) with a clean cloth.
8. Replace the battery box cover.
i06543763
Battery - Recycle
SMCS Code: 1401-561
Always recycle a battery. Never discard a battery.
Always return used batteries to one of the following
locations:
• A battery supplier
• An authorized battery collection facility
• Recycling facility
i05728588
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. Open the engine compartment. Refer to Operation
and Maintenance Manual, “Access Doors and
Covers”. The batteries are located on the left side
of the machine, behind the ladder.
3. Disconnect the negative battery cable at the
battery.
4. Disconnect the positive battery cable from the
battery.
5. Remove the cable from the engine starter.
131
Maintenance Section
Battery - Recycle
6. Perform the necessary repairs. Replace the cables
or the battery, as needed.
7. Reverse the above steps in order to reconnect the
battery.
8. Close the engine compartment.
i02422916
Belts - Inspect/Adjust/Replace
SMCS Code: 1357-040; 1357-025; 1357-510
Inspect Belts
You should inspect the belts in your engine in order to
get the maximum performance out of your engine.
The belts should be inspected for wear and for
cracks. Check the belt tension. If the belts are loose,
the belts will slip. Belts that slip will cause poor
performance of the alternator.
1. Turn off the engine.
2. Turn the battery disconnect switch to the OFF
position.
3. Inspect the belts.
4. Inspect the tension of the alternator belt.
To check the belt tension, apply 110 N (25 lb) of
force to the belt. The force must be applied midway
between the pulleys. If the belts are properly
adjusted, the belts will deflect 10 to 15 mm
(.4 to .6 inch).
Check the adjustment on new belts after the new
belts have operated for 30 minutes. For multiple belt
drive applications, replace the belts in matched sets.
If only one belt of a matched set is replaced, the new
belt will carry more load than the old belts. The old
belts will be stretched. The additional load on the new
belt could cause the new belt to break.
i05728658
Bolster Oscillation Pin (Rear) -
Lubricate
SMCS Code: 7051-086; 7223-086
Lubricate two fittings.
132 KEBU7583-01
Maintenance Section
Braking System - Test

5. While the machine is moving, move the propel

lever to the CENTER neutral position. The
machine should smoothly come to a quick stop.
Note: If the propel lever fails to stop the machine,
apply the parking brake in order to stop the
machine. Block the machine securely on a level
surface. Contact your Caterpillar dealer. Do not
operate the machine until the machine has been
repaired.

6. Check the parking brake. See this Operation and

Maintenance Manual, “Parking Brake - Check”
topic, for the proper procedure.

Illustration 155 g03641991 i05873369

1. Lubricate the front fitting (1). Cab Air Filter - Clean/Replace

SMCS Code: 7342-510; 7342-070

Note: Clean the cab air filters more often if the

machine is being operated in dusty conditions. If
there is a noticeable reduction in the flow of air from
the air vents, check the filters.

Internal Cab Filter

Illustration 156 g03641992

2. Lubricate the rear fitting (2).

i02423657

Braking System - Test

SMCS Code: 4250-081; 4267-081
Illustration 157 g03705327
Check the area around the machine. Make sure that
the machine is clear of personnel and clear of The internal cab filter (1) is positioned beneath the
obstacles. operator seat.

Test the brakes on a dry, level surface. Clean the Filter

Fasten the seat belt before you test the brakes.
Note: The following test is used to determine if the
braking function of the propel system is effective.
1. Start the engine.
2. Move the propel travel control to the TRAVEL
MODE position.
3. Release the parking brake.
4. Propel the machine forward at full travel speed.
1. Slide the internal cab filter (1) toward the right side
of the machine in order to remove the filter.
2. Clean the filter with pressure air.
3. Install the filter.
4. Slide the cover for the internal cab filter to the left
in order to cover the new filter.
KEBU7583-01 133
Maintenance Section
Camera - Clean/Adjust

Replace the Filter 5. Replace the cover for the external cab filter and
secure the cover with two screws.
Note: Replace the internal cab filter, as required.
i03714913
1. Slide the internal cab filter (1) toward the right side
of the machine in order to remove the filter. Camera - Clean/Adjust
2. Discard the filter. (WAVS (If Equipped))
3. Install the new filter. SMCS Code: 7348
4. Slide the cover for the internal cab filter to the left In order to maintain sufficient vision, keep the Work
in order to cover the new filter. Area Vision System (WAVS) camera lens and the
display clean.
External Cab Filter

Illustration 159 g01223034

The WAVS display is located in the operator station.
Illustration 158 g03705350
The external cab filter (2) is located on the rear of the Use a soft, damp cloth in order to clean the display.
cab. The external filter filters the fresh air that enters The display has a soft plastic surface that can be
the cab. easily damaged by an abrasive material. The display
is not sealed. Do not immerse the display with
liquid.
Clean the filter
1. Remove the two screws from the cover for the
external cab filter (2) and remove the cover.
2. Remove the filter.
3. Clean the filter with pressure air.
4. Install the filter.
5. Replace the cover for the external cab filter and
secure the cover with two screws.

Replace the filter

Note: Replace the external cab filter, as required.
Illustration 160 g01223051

1. Remove the two screws from the cover for the
external cab filter (2) and then remove the cover.
2. Remove the filter.
3. Discard the filter.
A WAVS camera is located on the rear of the
machine.
Use a damp cloth or water spray in order to clean the
camera lens. The camera is a sealed unit. The
camera is not affected by high pressure spray.

4. Install the new filter. Note: The camera is equipped with an internal heater
to help counteract the effects of condensation, snow,
or ice.
134 KEBU7583-01
Maintenance Section
Circuit Breakers - Reset

For more information on WAVS, refer to Operation

and Maintenance Manual, SEBU8157, “Work Area
Vision System”.

i05728711

Circuit Breakers - Reset

SMCS Code: 1420-529

Note: Your machine may not be equipped with all of

the components that are described in this topic.
Consult your Caterpillar dealer for the specific
information for your machine.

Illustration 162 g03642043

(1) Empty – 20A

(2) Empty – 20A
(3) Emissions 1 – 20A
(4) Emissions 2 – 20A
Illustration 161 g03637697
(5) Cab – 60A
The circuit breaker box is located behind the access
ladder on the left side of the machine. (6) Pump – 105A

1. Open the circuit breaker box cover. (7) Main – 105A

2. Push in the reset button. Pushing in the button will

reset the circuit breaker. If the system is operating i05728745
properly, the button will stay depressed. If the
button does not stay depressed, check the Cooling System Coolant
electrical circuits. Sample (Level 1) - Obtain
Note: Some circuit breakers are self-resetting. SMCS Code: 1395-008

Note: The amperage for the circuit is printed on

the circuit breaker button.
At operating temperature, the engine coolant is
hot and under pressure.
Steam can cause personal injury.
Check the coolant level only after the engine has
been stopped and the fill cap is cool enough to
touch with your bare hand.
Remove the fill cap slowly to relieve pressure.
Cooling system conditioner contains alkali. Avoid
contact with the skin and eyes to prevent person-
al injury.
KEBU7583-01
Note: It is not necessary to obtain a Coolant
Sample (Level 1) if the cooling system is filled
with Cat ELC (Extended Life Coolant). Cooling
systems that are filled with Cat ELC should have a
Coolant Sample (Level 2) that is obtained at the
recommended interval that is stated in the
Maintenance Interval Schedule.
Note: Obtain a Coolant Sample (Level 1) if the
cooling system is filled with any other coolant
instead of Cat ELC. This includes the following
types of coolants.
• Commercial long life coolants that meet the
Caterpillar Engine Coolant Specification-1
(Caterpillar EC-1)
• Cat Diesel Engine Antifreeze/Coolant (DEAC)
• Commercial heavy-duty antifreeze/coolant
Note: Level 1 results may indicate a need for
Level 2 Analysis.
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 163 g03642077
Coolant sample port
135
Maintenance Section
Cooling System Coolant Sample (Level 2) - Obtain
Obtain the sample of the coolant as close as possible
to the recommended sampling interval. In order to
receive the full effect of S·O·S analysis, a consistent
trend of data must be established. In order to
establish a pertinent history of data, perform
consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from
your Caterpillar dealer.
Use the following guidelines for proper sampling of
the coolant:
• Complete the information on the label for the
sampling bottle before you begin to take the
samples.
• Keep the unused sampling bottles stored in plastic
bags.
• Obtain coolant samples directly from the coolant
sample port. You should not obtain the samples
from any other location.
• Keep the lids on empty sampling bottles until you
are ready to collect the sample.
• Place the sample in the mailing tube immediately
after obtaining the sample in order to avoid
contamination.
• Never collect samples from expansion bottles.
• Never collect samples from the drain for a system.
Submit the sample for Level 1 analysis.
For additional information about coolant analysis, see
Special Publication, SEBU6250, “Caterpillar Machine
Fluids Recommendations” or consult your Caterpillar
dealer.
i05728767
Cooling System Coolant
Sample (Level 2) - Obtain
SMCS Code: 1395-008; 1395-554
NOTICE
Always use a designated pump for oil sampling, and
use a separate designated pump for coolant sam-
pling. Using the same pump for both types of sam-
ples may contaminate the samples that are being
drawn. This contaminate may cause a false analysis
and an incorrect interpretation that could lead to con-
cerns by both dealers and customers.
136
Maintenance Section
Cooling System Coolant (ELC) - Change
Illustration 164 g03642077
Coolant sample port.
1. Obtain the sample of the coolant as close as
possible to the recommended sampling interval.
Supplies for collecting samples can be obtained
from your Caterpillar dealer.
Reference: Refer to Operation and Maintenance
Manual, “Cooling System Coolant Sample (Level 1) -
Obtain” for the guidelines for proper sampling of the
coolant.
2. Submit the sample for Level 2 analysis.
Reference: For additional information about coolant
analysis, refer to Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” or
consult your Caterpillar dealer.
KEBU7583-01
i05873411
Cooling System Coolant (ELC)
- Change
SMCS Code: 1395-044-NL
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 cooling system pressure cap slowly to
relieve pressure only when engine is stopped and
cooling system pressure cap is cool 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 Coolant Additive contains alkali.
Avoid contact with skin and eyes.
NOTICE
Mixing Extended Life Coolant (ELC) with other prod-
ucts reduces the effectiveness of the coolant and
shortens coolant life. Use only Caterpillar products or
commercial products that have passed the Caterpillar
EC-1 specifications for premixed or concentrate cool-
ants. Use only Caterpillar Extender with Caterpillar
ELC. Failure to follow these recommendations could
result in the damage to cooling systems components.
If ELC cooling system contamination occurs, refer to
Operation and Maintenance, “Extended Life Coolant
(ELC)” under the topic ELC Cooling System
Contamination.
Drain the coolant whenever the coolant is dirty or
whenever foaming is observed.
1. Make sure that the engine has cooled.
KEBU7583-01 137
Maintenance Section
Cooling System Coolant (ELC) - Change

12. Fill the system with clean water.

13. Start the engine. Operate the engine until the
engine reaches operating temperature.
14. Stop the engine.
15. Drain the system.
16. Close drain valve (3).
17. Repeat steps 12 to 16 until the water that drains
from the system is clear. Make sure that all of the
cleaner is flushed from the system.
18. Add the coolant solution. See Special
Publication, SEBU6250, “Cooling System
Illustration 165 g03642213 Specifications” for specific information about
coolant.
2. Turn pressure cap (1) counterclockwise in order to
loosen the cap. Slowly loosen the pressure cap in Note: Do not add the supplemental coolant additive
order to relieve the pressure. Slowly remove the at this time unless you are using Caterpillar Coolant.
pressure cap. Consult your Caterpillar dealer for specific
information.
3. Open the right side radiator access panel.
19. Start the engine. Operate the engine. Make sure
that pressure cap (1) is removed. The thermostat
must open and the coolant level must stabilize.
20. Maintain the level of the coolant to the proper
mark on sight glass (2).
21. Install pressure cap (1).
22. Stop the engine.
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information that
pertains to containing fluid spillage.
Note: Dispose of drained fluids according to local
regulations. Proper care is your responsibility.
Illustration 166 g03705364

4. Place a suitable container under coolant drain

valve (3).
5. Open the drain valve by turning the valve
counterclockwise. Allow the coolant to drain into a
suitable container.
6. Close drain valve (3) by turning the valve bolt
clockwise.
7. Fill the system with a mixture of clean water and a
6% to 10% concentration of cleaner.
8. Start the engine. Operate the engine for 90
minutes.
9. Stop the engine.
10. Drain the cleaning solution.
11. Close drain valve (3).
138
Maintenance Section
Cooling System Coolant Extender (ELC) - Add
i02423775
Cooling System Coolant
Extender (ELC) - Add
SMCS Code: 1352-544-NL
At operating temperature, the engine coolant is
hot and under pressure.
Steam can cause personal injury.
Check the coolant level only after the engine has
been stopped and the fill cap is cool enough to
touch with your bare hand.
Remove the fill cap slowly to relieve pressure.
Cooling system conditioner contains alkali. Avoid
contact with the skin and eyes to prevent person-
al injury.
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.
When a Caterpillar Extended Life Coolant (ELC) is
used, an Extender must be added to the cooling
system. See Special Publication, SEBU6250,
“Cooling System Specifications” for all cooling
system requirements.
Use a 8T-5296 Coolant Test Kit to check the
concentration of the coolant.
For additional information about the addition of
Extender, see the Special Publication, SEBU6250,
“Cooling System Specifications” or consult your
Caterpillar dealer.
KEBU7583-01
NOTICE
Topping off or mixing Cat ELC with other products
that do not meet Caterpillar EC-1 specifications re-
duces the effectiveness of the coolant and shortens
coolant service life.
Use only Caterpillar products or commercial products
that have passed the Caterpillar EC-1 specification
for pre-mixed or concentrate coolants. Use only Ex-
tender with Cat ELC.
Failure to follow these recommendations can result in
shortened cooling system component life.
1. Stop the engine. Allow the cooling system to
completely cool.
2. Open the engine hood .
3. Slowly loosen the cooling system pressure cap in
order to relieve system pressure. Remove the
cooling system pressure cap.
4. If necessary, drain enough coolant from the
system in order to allow the addition of the
Extender.
5. Add the recommended amount of extender to the
coolant system. Refer to the Special Publication,
SEBU6250, “Extended Life Coolant (ELC)” for the
proper amount.
6. Maintain the coolant level to 1 cm of the bottom of
the fill pipe.
7. Inspect the gasket on the cooling system pressure
cap. Replace the cooling system pressure cap if
the gasket is damaged.
8. Install the cooling system pressure cap.
9. Close the engine hood.
For additional information on the addition of extender,
see Special Publication, SEBU6250, “Coolant
Recommendations” or consult your Caterpillar dealer.
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information that
pertains to containing fluid spillage.
Note: Dispose of drained fluids according to local
regulations.
KEBU7583-01
i05728791
Cooling System Coolant Level
- Check
SMCS Code: 1350-535-FLV
At operating temperature, the engine coolant is
hot and under pressure.
Steam can cause personal injury.
Check the coolant level only after the engine has
been stopped and the fill cap is cool enough to
touch with your bare hand.
Remove the fill cap slowly to relieve pressure.
Cooling system conditioner contains alkali. Avoid
contact with the skin and eyes to prevent person-
al injury.
Illustration 167 g03642213
1. Turn pressure cap (1) counterclockwise in order to
loosen the cap. Slowly loosen the pressure cap in
order to relieve the pressure. Slowly remove the
pressure cap.
2. Maintain the level of the coolant to the middle of
sight glass (2).
3. Inspect the system pressure cap and the system
pressure cap seal for damage. Clean the cap with
a clean cloth or replace the pressure cap.
4. Install pressure cap (1).
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information that
pertains to containing fluid spillage.
Note: Dispose of spilled fluids according to local
regulations. Proper care is your responsibility.
139
Maintenance Section
Cooling System Coolant Level - Check
i02424360
Cooling System Pressure Cap
- Clean/Replace
SMCS Code: 1382-070; 1382-510
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 cooling system pressure cap slowly to
relieve pressure only when engine is stopped and
cooling system pressure cap is cool 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 Coolant Additive contains alkali.
Avoid contact with skin and eyes.
1. Open the engine hood.
2. Remove the cooling system pressure cap slowly in
order to relieve pressure.
3. Inspect the cooling system pressure cap for
foreign material, for deposits, and for damage.
Clean the cooling system pressure cap with a
clean cloth. If the cooling system pressure cap is
damaged, replace the cooling system pressure
cap.
4. Install the cooling system pressure cap.
5. Close the engine hood.
140
Maintenance Section
Cooling System Water Temperature Regulator - Replace
i05873450
Cooling System Water
Temperature Regulator -
Replace
SMCS Code: 1355-510; 1393-010
At operating temperature, the engine coolant is
hot and under pressure.
Steam can cause personal injury.
Check the coolant level only after the engine has
been stopped and the fill cap is cool enough to
touch with your bare hand.
Remove the fill cap slowly to relieve pressure.
Cooling system conditioner contains alkali. Avoid
contact with the skin and eyes to prevent person-
al injury.
Replace the water temperature regulator on a regular
basis in order to reduce the chance of unscheduled
downtime and of problems with the cooling system.
The water temperature regulator should be replaced
after the cooling system has been cleaned. Replace
the water temperature regulator while the cooling
system is completely drained. Replace the water
temperature regulator while the cooling system
coolant is drained to a level below the water
temperature regulator housing.
NOTICE
Failure to replace the engine's water temperature
regulator on a regularly scheduled basis could cause
severe engine damage.
Note: If you are only replacing the water temperature
regulator, drain the cooling system coolant to a level
that is below the water temperature regulator
housing.
1. Remove the cooling system pressure cap in order
to relieve the pressure in the cooling system.
KEBU7583-01
Illustration 168 g03705382
The water temperature regulator is located on the
inside of a housing that is on the right side of the
engine.
2. Remove the water temperature regulator housing.
3. Remove the gasket and remove the water
temperature regulator.
NOTICE
The water temperature regulators may be reused if
the water temperature regulators are within test spec-
ifications, are not damaged, and do not have exces-
sive buildup of deposits.
NOTICE
Since Caterpillar engines incorporate a shunt design
cooling system, it is mandatory to always operate the
engine with a water temperature regulator.
Depending on load, failure to operate with a water
temperature regulator could result in either an over-
heating or an overcooling condition.
NOTICE
If the water temperature regulator is installed incor-
rectly, it will cause the engine to overheat.
4. Install a new water temperature regulator.
5. Reinstall the housing.
6. Add the cooling system coolant. Maintain the level
of the coolant to the proper line on the sight glass.
7. Inspect cooling system pressure cap and the
gasket for damage. Replace the pressure cap if
the pressure cap or the gasket are damaged.
8. Install the cooling system pressure cap.
9. Check for leaks.
KEBU7583-01
i05698174
DEF Filler Screen - Clean
SMCS Code: 108K-070-Z3
S/N: MB91–Up
NOTICE
Ensure that the engine is stopped before any servic-
ing or repair is performed.
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, “Cat Dealer
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
fluids on Cat products.
Dispose of all fluids according to local regulations
and mandates.
The filler neck adapter filter screen in the diesel
exhaust fluid tank will need to be cleaned or replaced
if contaminated.
Illustration 169 g03618438
1. Use a screwdriver or pick to press the tabs (1).
2. Pull the screen assembly (2) upward from both
sides and remove from the fill neck adapter
141
Maintenance Section
DEF Filler Screen - Clean
3. Use water or compressed air to clean out the filter
screen (3). If there is any debris inside, let dry and
remove the debris by turning the screen upside
down and dumping debris out. If the debris cannot
be removed or the filter screen is damaged,
replace the filler neck adapter filter screen.
i05830613
DEF Manifold Filters - Replace
SMCS Code: 108K-510-FI
S/N: MB91–Up
NOTICE
Ensure that the engine is stopped before any servic-
ing or repair is performed.
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, “Cat Dealer
Service Tool Catalog” or refer to Special Publication,
PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
fluids on Cat products.
Dispose of all fluids according to local regulations
and mandates.
Note: Refer to Special Instruction, REHS8231,
“Removal Procedures for Diesel Exhaust Fluid (DEF)
Connectors” for the correct removal procedure of
hose assemblies (1) and (5).
142 KEBU7583-01
Maintenance Section
DEF Manifold Filters - Replace

Illustration 170 g03662693 Illustration 172 g03665737

1. Clamp off hoses (1). 4. Unscrew the band clamp (9) and remove the band
clamp from the filter base (10).
2. Remove clips (2) and (3). Disconnect harness
assemblies (4). Remove hose assemblies (1) and
(5).

Illustration 171 g03665701

3. Remove bolts (6), plate (7), tank manifold (8), and

gasket (not shown).
KEBU7583-01 143
Maintenance Section
Diesel Exhaust Fluid - Fill

7. Install new filter by pulling filter over the manifold

coils up to the bottom of the assembled filter base.

Illustration 175 g03665754

8. Tighten the band clamp 4.5 ± 0.7 N·m

(40 ± 6 lb in), ensuring that the band clamp is
aligned, as shown in illustration 175 , to the flat
spot on the base. Ensure that the filter does not
bunch when tightening the band clamp.
9. Install the tank manifold following steps 3 through
5 in reverse order with a new gasket.
10. Tighten bolts (6) in an alternating sequence to
5 ± 1 N·m (44 ± 9 lb in). Tighten bolts (6) a second
time in an alternating sequence to 5 ± 1 N·m
(44 ± 9 lb in). Apply rubber lubricant to the o-ring
seal inside of hose assemblies (1).
Illustration 173 g03664911
i05738378

5. Remove the filter (11) from the filter base. Diesel Exhaust Fluid - Fill
SMCS Code: 108K-544

S/N: MB91–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 machine.
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Dispose of all fluids according to local regulations
and mandates.

Illustration 174 g03666075 Reference: See Operation and Maintenance

Manual, “Capacities (Refill)” for the capacity of the
6. Remove the suction filter (12) at the bottom of the fuel tank for your machine.
header coils by pulling tabs (13). Replace with a
new suction filter.
144 KEBU7583-01
Maintenance Section
Diesel Exhaust Fluid Filter - Replace

i06892580

Diesel Exhaust Fluid Filter -

Replace
SMCS Code: 108K-510-FI; 108K-544

Illustration 176 g03379943

DEF Tank Filler Cap

Illustration 178 g03332612

Typical Example

Illustration 177 g03646517

Location of the DEF tank filler cap.
1. Clean the blue DEF tank filler cap and the
surrounding area.
2. Remove the blue DEF tank filler cap.
3. Fill the tank with diesel exhaust fluid (DEF).
Note: Do not fill the DEF tank from a
contaminated container or funnel.
Note: Do not over fill the tank. DEF can freeze and
needs room for expansion.
Personal injury can result from improper han-
dling of chemicals.
Make sure you use all the necessary protective
equipment required to do the job.
Make sure that you read and understand all direc-
tions and hazards described on the labels and
material safety data sheet of any chemical that is
used.
Observe all safety precautions recommended by
the chemical manufacturer for handling, storage,
and disposal of chemicals.

4. Install the blue DEF tank filler cap. NOTICE

Refer to Operation and Maintenance Manual, Ensure that the engine is stopped before any servic-
“Lubricant Viscosities” for more information on diesel ing or repair is performed.
exhaust fluid (DEF) guidelines.
KEBU7583-01 145
Maintenance Section
Diesel Exhaust Fluid Injector - Replace

Note: Avoid twisting the DEF filter (1) upon

NOTICE
Care must be taken to ensure that fluids are con- installation. Twisting may cause a tear.
tained during performance of inspection, mainte-
nance, testing, adjusting, and repair of the product. i05296597
Be prepared to collect the fluid with suitable contain-
ers before opening any compartment or disassem-
bling any component containing fluids.
Diesel Exhaust Fluid Injector -
Replace
Refer to Special Publication, NENG2500, “Cat Dealer
Service Tool Catalog” or refer to Special Publication, SMCS Code: 108I-510
PECJ0003, “Cat Shop Supplies and Tools Catalog”
for tools and supplies suitable to collect and contain
fluids on Cat products.
Dispose of all fluids according to local regulations
and mandates.

1. Remove the diesel exhaust fluid (DEF) filter cap

(3) with a 27 mm (1.06 inch) wrench.
2. Remove the rubber cone insert (2) from the DEF
filter (1).

Illustration 180 g03363165

Typical example shown

1. Remove the diesel exhaust fluid (DEF) line (1)

Illustration 179 g03332637
Typical Example
3. Insert the DEF filter removal tool (4) into the DEF
filter (1) and remove the DEF filter (1).
Note: Avoid twisting the DEF filter (1) upon removal.
Twisting may cause a tear.
4. Clean the area around the filter housing.
5. Lubricate the seals of the new DEF filter (1) with
diesel exhaust fluid or distilled water.
6. Install new DEF filter (1) and rubber cone insert.
Torque the filter to 20 ± 5 N·m (14.8 ± 3.7 lb ft)
with a 27 mm (1.06 inch) wrench.
from the injector (4).
2. Remove the coolant lines (2) from the injector.
3. Remove the electrical connector (3) from the
injector.
4. Remove the bolts from the injector and remove the
injector.
5. Replace gasket. The steel side of the gasket
should face towards diesel particulate filter (DPF)
outlet.
6. Replace the injector.
7. Apply anti-seize to bolt threads.
8. Torque the bolts of the injector to 5 N·m (3.7 lb ft).
Retighten all bolts to 5 N·m (3.7 lb ft), then turn
90°.
9. Connect the electrical connector.
10. Connect the coolant lines.
11. Connect the DEF line.
146 KEBU7583-01
Maintenance Section
Diesel Particulate Filter - Clean

i05425848 i05729359

Diesel Particulate Filter - Clean Emulsion Spray Nozzles -

SMCS Code: 108F-070; 1091-070 Clean
Consult your Cat dealer when the DPF needs to be SMCS Code: 5615-070
cleaned.
The approved Caterpillar DPF maintenance
procedure requires that one of the following actions
be taken when the DPF needs to be cleaned:
• The DPF from your machine can be replaced with
a new DPF
• The DPF from your machine can be replaced with
a remanufactured DPF
• The DPF from your machine can be cleaned by
your local authorized Cat dealer, or a Caterpillar
approved DPF cleaning machine, and reinstalled
Note: In order to maintain emissions documentation,
the DPF that is removed from the machine when the Illustration 182 g03642282
DPF is cleaned must be reinstalled on the same
machine. 1. Loosen bolts (1). There are two bolts on each end
Note: A specific ash service regeneration must be of the spray bar. Raise the spray bar completely.
performed before removing a DPF that will be Tighten bolts (1).
cleaned. All three scenarios listed above require a
reset of the ash monitoring system in the engine
ECM.

i05729340

Emulsion Pump - Lubricate

SMCS Code: 5616-086

Illustration 183 g03642284

2. Remove nozzle (2). There are 16 nozzles on the

spray bar.
3. Soak the nozzles (2) in clean diesel fuel or clean
solvent.
4. Replace the nozzles (2) after the nozzles are
clean.
Illustration 181 g03642254
5. Loosen bolts (1). Move the spray bar back into the
Identify one lubrication fitting (1) on each end of the original position.
emulsion pump. Lubricate the two fittings.
6. Tighten bolts (1) to the proper torque value.
KEBU7583-01
i05729385
Emulsion Spray System -
Clean
SMCS Code: 5615-070
Clean the Emulsion Spray System
Clean the emulsion spray system after every use.
Note: The procedure to clean the emulsion spray
system requires the use of one barrel of clean
asphalt release agent.
The rotor and the hood must be lifted away from the
ground. The rotor and the hood must be clear of all
obstacles. All chains and locking devices must be
installed before you start the procedure.
Note: The following parts must be drained of all of
the emulsion: pump, spray bar, strainer and lines.
1. Ensure that the proper connections are made
between the transfer truck and the emulsion pump
skid.
Illustration 184 g03662243
2. Turn the emulsion system clean out switch to the
ON position.
3. The spray pump will run in reverse. Operate the
system for 30 seconds in order to purge the
emulsion from the emulsion spray system. The
emulsion is pumped back into the source.
147
Maintenance Section
Emulsion Spray System - Clean
Illustration 185 g03642301
4. Close inlet valve (2).
5. Turn the emulsion system clean out to OFF in the
display.
6. Remove the cap and attach a hose to recirculate
connection (3).
7. Place the hose from the recirculate connection and
the suction hose from valve (2) into a barrel of
asphalt release agent.
8. Open valve (2).
9. Set recirculate valve (1) to the dump position. In
the dump position the flow going into the strainer is
blocked and the flow coming out of connection (3)
is open.
10. Turn the emulsion system ON in the display. The
spray bar control on the keypad is OFF.
11. Operate the system for 5 to 10 minutes with the
engine at idle. Observe the discharge hose
connected to port (3) for particles. If particles are
present continue to operate the system.
12. Turn the emulsion system OFF in the display.
13. Turn valve (1) to the recirculate position.
14. Close valve (2).
Note: In order to store the machine for extended
periods, do not drain the asphalt release agent from
the emulsion spray system. Leaving the asphalt
relese agent will prevent the pump from corroding
inside and prevent any remaining emulsion from
hardening and damaging the internal pump
components. Before the machine is returned to
service, the asphalt release agent should be drained
from the system.
148 KEBU7583-01
Maintenance Section
Emulsion Spray System Strainer - Clean

Note: When the emulsion pump is used to pump

water or corrosive liquid, precautions must be taken
in order to extend the wear rate of the pump vanes.
The water or corrosive liquid must be drained
completely from the pump, and the pump should be
preserved with a rust inhibiting solution.

Flush the Pump

NOTICE
If flushing fluid is to be left in the pump for an ex-
tended time, the fluid must be a lubricating, non-cor-
rosive fluid. If a corrosive, non-lubricating fluid is
used, the fluid must be flushed from the pump imme-
diately. Leaving water or corrosive material in the
Illustration 186 g03642315
pump can damage the pump. In this case flush and
preserve the pump with a lubricating, non-corrosive
fluid. Check with your additive supplier for the proper 1. Remove the eight bolts from the front of the
solvent to use. emulsion spray system.

Note: Refer to Operation and Maintenance Manual,

NOTICE
After flushing the pump some residual fluid will re-
main in the pump and piping. Not properly flushing
the pump can result in damage to the pump.
Use the following procedure in order to flush the
pump:
1. Allow the pump to evacuate as much fluid as
possible.
2. Run cleaning fluid through the pump intake. The
cleaning fluid should be compatible with the pump
o-rings and vane material. Use a fluid that will
prevent solidification of the fluid being transferred
and facilitate flushing.
3. Operate the pump against a closed discharge for
15 seconds to allow the cleaning fluid to
recirculate through the internal relief valve.
“General Hazard Information” for information that
pertains to containing fluid spillage.
2. Remove the emulsion spray system strainer and
rinse the strainer with water.
NOTICE
Dispose of all fluids according to local regulations
and mandates.
3. Remove the plug and drain any remaining fluid
from the strainer into a suitable container.
4. Reinstall the plug and the strainer.
5. Tighten the eight bolts to a torque of 47 ± 9 N·m
(35 ± 7 lb ft).
i05729410

i05729395 Engine Air Filter Primary

Element - Clean/Replace
Emulsion Spray System
SMCS Code: 1054-510-PY; 1054-070-PY
Strainer - Clean
SMCS Code: 5615-070 Remove the Primary Element
In order to clean the emulsion spray system strainer,
complete the following steps. NOTICE
Service the air cleaner only with the engine stopped.
Engine damage could result.

Service the air cleaner filter element when the

monitoring system indicates the filter must be
changed. Refer to Operation and Maintenance
Manual, “Monitoring System” for more
information.
1. Open the left side engine access door.
KEBU7583-01
Illustration 187
2. Locate the air filter housing.
3. Open the air filter housing.
Illustration 188
Primary filter element.
4. Remove the primary filter element.
149
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
5. Reverse the steps in order to install the primary
filter element.
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:
g03642340
Do not tap or strike the filter element in order to re-
move dust.
Do not wash the filter element.
Use low pressure compressed air in order to remove
the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage
to the pleats.
Do not use air filters with damaged pleats, gaskets,
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
g03642341
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.
There are two common methods that are used to
clean primary air filter elements:
• Pressurized air
• Vacuum cleaning
150
Maintenance Section
Engine Air Filter Primary Element - Clean/Replace
Pressurized Air
Pressurized air can be used to clean primary air filter
elements that have not been cleaned more than two
times. Pressurized air will not remove deposits of
carbon and oil. Use filtered, dry air with a maximum
pressure of 207 kPa (30 psi).
Illustration 189 g00281692
Note: When the primary air filter elements are
cleaned, always begin with the clean side (inside) in
order to force dirt particles toward the dirty side
(outside).
Aim the hose so that the air flows inside the element
along the length of the filter in order to help prevent
damage to the paper pleats. Do not aim the stream of
air directly at the primary air filter element. Dirt could
be forced further into the pleats.
KEBU7583-01
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 190 g00281693
Inspect the clean, dry primary air filter element. Use a
60 watt blue light in a dark room or in a similar facility.
Place the blue light in the primary air filter element.
Rotate the primary air filter element. Inspect the
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
order to confirm the result, compare the primary air
filter element to a new primary air filter element that
has the same part number.
Do not use a primary air filter element that has any
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
elements.
Storing Primary Air Filter Elements
If a primary air filter element that passes inspection
will not be used, the primary air filter element can be
stored for future use.
KEBU7583-01 151
Maintenance Section
Engine Air Filter Secondary Element - Replace

Illustration 191 g00281694 Illustration 192 g03642340

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

protective covering for storage. An air flow restriction 2. Locate the air filter housing.
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

• Number of cleanings
Store the box in a dry location.

i05729415

Illustration 193 g03642352

Engine Air Filter Secondary
Element - Replace 3. Remove the cover. Remove primary element (1).
SMCS Code: 1054-510-SE 4. Remove secondary element (2).
5. Cover the opening for the air inlet. Clean the inside
NOTICE of the housing for the air cleaner.
Service the air cleaner only with the engine stopped.
Engine damage could result. 6. Remove any dust in the filter outlet. Remove any
debris from the filter outlet.

NOTICE 7. Uncover the opening for the air inlet. Install a new
Always replace the secondary filter element. Never secondary element.
attempt to reuse the element by cleaning.
8. Install the primary element. Install the cover for the
The secondary filter element should be replaced at primary element.
the time the primary element is serviced for the third
time. 9. Close the engine hood.

The secondary filter element should also be replaced

if the yellow piston in the filter element indicator en-
ters the red zone after installation of a clean primary
element, or if the exhaust smoke is still black.

1. Open the left side engine access door.

152 KEBU7583-01
Maintenance Section
Engine Air Precleaner - Clean

i05729430 i05738406

Engine Air Precleaner - Clean Engine Crankcase Breather

SMCS Code: 1055-070 Tube - Inspect/Clean
SMCS Code: 1317-571-TU
NOTICE
Service the air cleaner only with the engine stopped.
Engine damage could result.

NOTICE
Service the air precleaner only with the engine
stopped. Engine damage could result.

Illustration 195 g03646550

Inspect the engine crankcase breather tube for dirt

and debris. If necessary, clean the engine crankcase
breather tube.

i05873722

Illustration 194 g03642360 Engine Mounts - Inspect

1. Check the air inlet screen for trash. Check the air
inlet screen for dirt.
2. Remove the screen if the screen is dirty. Clean the
screen with air pressure. Install the screen.
SMCS Code: 1152-040
There are four engine mounts that must be checked.
Engine vibration can be caused by improper
mounting of the engine. Engine vibration can be
caused by loose engine mounts or deteriorated
engine mounts.
Inspect the engine mounts for deterioration.
Replace any engine mount that is deteriorated.
Inspect the engine mounts for correct bolt torque.
Tighten the mounts if the mounts are loose.
See your Caterpillar dealer for further information and
instructions for your machine.

i05732628

Engine Oil Level - Check

SMCS Code: 1348-535-FLV

1. To check the oil level, stop the engine.

KEBU7583-01
Illustration 196 g03643437
2. Check the engine oil level with oil level gauge (1).
NOTICE
Do not overfill crankcase. The oil level must not be
above the FULL RANGE on the dipstick.
3. Maintain the engine oil level on the oil level gauge
between the “FULL” mark and the “ADD” mark .
4. Clean oil filler cap (2). Remove the oil filler cap. If
necessary, add oil.
5. Install the oil filler cap (2).
i05732796
Engine Oil Sample - Obtain
SMCS Code: 1000-008
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact the skin.
Obtain the Sample and the
Analysis
In addition to a good preventive maintenance
program, Caterpillar recommends using S·O·S oil
analysis at regular scheduled intervals in order to
monitor the condition of the engine and the
maintenance requirements of the engine.
153
Maintenance Section
Engine Oil Sample - Obtain
Each oil sample should be taken when the oil is warm
and when the oil is well mixed. The sample should be
taken at this time in order to ensure that the sample is
representative of the oil in the crankcase. Refer to
Special Publication, SEBU6250, “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.
Obtain the S·O·S Sample
Illustration 197 g03643465
Obtain the engine oil sample when the oil is changed.
Obtain the engine oil sample at the regular
maintenance interval.
i05732836
Engine Oil and Filter - Change
SMCS Code: 1318-510
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.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact skin.
154
Maintenance Section
Engine Oil and Filter - Change
Illustration 198 g03643503
Location of the crankcase drain valve cover.
The crankcase drain valve is located behind an
access cover underneath the front of the machine.
1. Park the machine on a level surface and engage
the parking brake. Stop the engine.
Note: Drain the crankcase while the oil is warm.
Draining the oil while warm 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 199 g03643506
2. Remove the crankcase drain valve cover (1).
KEBU7583-01
Illustration 200 g03643507
Crankcase drain valve (2).
3. Place a suitable container underneath the
crankcase drain valve (2). If necessary, attach a
drain hose to the drain valve.
4. Turn the handle on the valve counterclockwise in
order to open the valve. Allow the oil to drain into
the container.
5. Once the oil has drained, close the valve.
Illustration 201 g03643511
The engine oil filter (3) is located on the right side of
the machine
6. Place a suitable container under the filter.
7. Remove the engine oil filter (3) with a strap type
wrench. See Operation and Maintenance Manual,
“Oil Filter - Inspect”. Discard the used oil filter
properly.
8. Clean the filter mounting base with a clean towel.
Make sure that all of the old filter seal has been
removed.
9. Apply a thin film of clean engine oil to the seal of
the new engine oil filter.
10. Install the new engine oil filter by hand.
KEBU7583-01 155
Maintenance Section
Engine Valve Lash - Check

Instructions for the installation of the filter are
printed on the side of each Caterpillar spin-on
filter. For non-Caterpillar filters, refer to the
installation instructions that are provided by the
supplier of the filter.
Note: There are rotation index marks on the engine
oil filter that are spaced 90 degrees or 1/4 of a turn
away from each other. When you tighten the engine
oil filter, use the rotation index marks as a guide.
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.
15. Install both padlocks (if equipped).
16. Stop the engine.
Note: Dispose of the oil according to local
regulations. Dispose of the oil filter according to local
regulations. Proper care is your responsibility.
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information that
pertains to containing fluid spillage.
i01897328
Engine Valve Lash - Check
SMCS Code: 1105-535

Note: A qualified service person should perform the

valve lash check and/or the valve lash adjustment.
Special tools and training are required.
Refer to your machine's Service Manual for complete
instructions.

i01430256

Engine Valve Rotators -

Inspect
SMCS Code: 1109-040

Illustration 202 g03643514

S/N: TAS1–Up
(4) Oil filler cap
(5) Oil level gauge

11. Clean the area around the oil filler cap (4).
Remove the padlock from the oil filler cap (if
equipped). Remove the oil filler cap. Fill the
crankcase with new oil. See the following topics:
When inspecting the valve rotators, protective
glasses or face shield and protective clothing
must be worn, to prevent being burned by hot oil
or spray.

• Operation and Maintenance Manual, “Lubricant 1. Start the engine.

Viscosities”
2. Operate the engine at low idle.
• Operation and Maintenance Manual,
“Capacities (Refill)”

• Operation and Maintenance Manual, “Engine

Oil Level - Check”

12. Clean the oil filler cap and install the oil filler cap.
13. Start the engine and allow the oil to warm. Check
the engine for leaks. Check the filter for leaks.
14. Remove the padlock from the oil level gauge (if
equipped). Run the engine and check the oil level
gauge (5) after the engine has been running for
ten minutes. Maintain the oil between the marks
on the “LOW IDLE” side of the oil level gauge. If
necessary, add oil.
156 KEBU7583-01
Maintenance Section
Engine Water Pump - Inspect

i03997106

Film (Product Identification) -

Clean
SMCS Code: 7405-070; 7557-070

Illustration 203 g00755444

3. Watch the top surface of each valve rotator. Each

valve rotator should turn slightly when the valve
closes.
4. If a valve fails to rotate, contact your Caterpillar
dealer. Illustration 205 g02174985

i05873728

Engine Water Pump - Inspect

SMCS Code: 1361-040
A water pump that has failed might cause severe
engine overheating. Severe engine overheating
could result in the following problems:

• Cracks in the cylinder head

• Piston seizure

• Other potential engine damage

Illustration 206 g02175297

Typical example of the Product Identification Films.

Cleaning of the Films

Make sure that all of the product identification films
are legible. Make sure that the recommended
procedures are used in order to clean the product
identification films. Ensure that all the product
identification films are not damaged or missing.
Clean the product identification films or replace the
films.

Illustration 204 g03705564

The water pump is located on the right side of the

engine.
Visually inspect the water pump for leaks. If leaks are
found, all the seals must be replaced.
KEBU7583-01 157
Maintenance Section
Fuel System - Prime

Hand Washing
Use a wet solution with no abrasive material that
contains no solvents and no alcohol. Use a wet
solution with a “pH” value between 3 and 11. Use a
soft brush, a rag, or a sponge in order to clean the
product identification films. Avoid wearing down the
surface of the product identification films with
unnecessary scrubbing. Ensure that the surface of
the product identification films is flushed with clean
water and allow the product identification films to air
dry.
Power Washing
2. Start the engine. If the engine will not start, further
priming is necessary. If the engine starts but the
engine continues to misfire, further priming is
necessary.
3. If the engine starts but the engine runs rough,
continue to run the engine at low idle. Continue to
run the engine at low idle until the engine runs
smoothly.
Note: If the engine cannot be primed or the fuel
pressure is low, check the in-tank fuel inlet tube
screen.

Power washing or washing with pressure may be i05733290

used in order to clean product identification films.
However, aggressive washing can damage the
product identification films.
Excessive pressure during power washing can
damage the product identification films by forcing
water underneath the product identification films.
Water lessens the adhesion of the product
identification film to the product, allowing the product
identification film to lift or curl. These problems are
magnified by wind. These problems are critical for the
perforated film on windows.
To avoid lifting of the edge or other damage to the
product identification films, follow these important
steps:
• Use a spray nozzle with a wide spray pattern.
• A maximum pressure of 83 bar (1200 psi)
• A maximum water temperature of 50° C (120° F)
Fuel System Primary Filter -
Clean/Inspect/Replace
SMCS Code: 1260-510; 1260-070; 1260-040
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire. To help prevent
possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
NOTICE
Do not allow dirt to enter the fuel system. Thoroughly
clean the area around a fuel system component that
will be disconnected. Fit a suitable cover over discon-
nected fuel system component.

• Hold the nozzle perpendicular to the product

identification film at a minimum distance of
305 mm (12 inch).
• Do not direct a stream of water at a sharp angle to
the edge of the product identification film.
NOTICE
Do not use a tool in order to remove the fuel filter. At-
tempting to remove the fuel filter with a filter wrench
or a filter strap could damage the locking ring.

i04372845

Fuel System - Prime

SMCS Code: 1250-548

S/N: MB91–Up
1. The fuel transfer pump is electrically controlled
when the key is on. Turning the key to the on
position will automatically prime the system after
the filters have been changed.

Note: The transfer pump will continue to pump for 60

seconds after the key is placed in the on position and
the engine is not started. Illustration 207 g03635016

1. Open the lower left side engine access door.

158
Maintenance Section
Fuel System Secondary Filter - Replace
Illustration 208 g03643667
2. Turn the fuel supply valve (1) to the OFF position
before performing this maintenance.
3. Place a suitable container under the water
separator in order to catch any fuel that might spill.
Clean up any spilled fuel. Clean the outside of the
water separator and the fuel filter.
Illustration 209 g03643679
4. Open the drain (4). Allow the fluid to drain into the
container.
5. Tighten the drain by hand pressure only.
6. If equipped, remove the wiring harness from the
sensor on the bottom of the clear bowl.
7. Use a strap wrench to remove the filter housing
from the filter head base. The clear bowl stays with
the filter housing and is not removable.
8. Clean clear bowl (3).
9. Install a new filter (2).
Note: Do not pre-fill the fuel filter before you
install the fuel filter.
KEBU7583-01
a. Install a new filter hand tight until the seal of the
filter contacts the base. Note the position of the
index marks on the filter in relation to a fixed
point on the filter base.
Note: There are rotation index marks on the filter
that are spaced 180 degrees or 1/2 of a turn away
from each other. When you tighten the filter, use
the rotation index marks as a guide.
b. Tighten the filter according to the instructions
that are printed on the filter. Use the index
marks as a guide.
10. Ensure that the sensor (if equipped) is in the
correct position.
11. If equipped, install the wiring harness to the
sensor.
12. Be sure to dispose of the fuel in a safe place.
13. Prime the fuel system. Refer to Operation and
Maintenance Manual, “Fuel System - Prime” for
more information.
14. Close the engine compartment.
Replace the Secondary Fuel Filters
Replace the secondary fuel filters immediately after
you change the primary fuel filter. Refer to Operation
and Maintenance Manual, “Fuel System Secondary
Filter - Replace”for more information.
i05733312
Fuel System Secondary Filter -
Replace
SMCS Code: 1261-510-SE
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire. To help prevent
possible injury, turn the start switch off when
changing fuel filters or water separator elements.
Clean up fuel spills immediately.
KEBU7583-01 159
Maintenance Section
Fuel Tank Cap Filter - Replace

i04445353
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte- Fuel Tank Cap Filter - Replace
nance, testing, adjusting, and repair of the product.
Be prepared to collect the fluid with suitable contain- SMCS Code: 1273-070-FI; 1273-070-Z2
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 211 g02612539

1. Remove the fuel tank cap.

Illustration 210 g03643701
1. Open the left side engine access door.
2. Remove both secondary fuel filters. Discard the
filters properly.
3. Clean the mounting base of the fuel filters.
Remove any part of the old seal that remains on
2. Remove filter element screws (2) from the
underside of the fuel tank cap and remove old filter
element (1).
3. Wash the fuel tank cap in a clean, nonflammable
solvent.
4. Install a new fuel cap filter element.
5. Install filter element screws (2) in order to secure
filter element (1) to the fuel tank cap.
6. Install the fuel tank cap
i04415238

the mounting base of the fuel filters.

Fuel Tank Strainer - Clean
4. Install the new filters by hand.
SMCS Code: 1273-070-STR
Note: Rotational index marks are positioned on the
filter at 90 degree intervals. Use these rotation index
marks as a guide when you tighten the filter.

5. Clean up any spills immediately.

6. Start the engine and check for leaks.

Illustration 212 g02609604

1. Remove fuel tank cap (1).

160 KEBU7583-01
Maintenance Section
Fuel Tank Water and Sediment - Drain

2. Remove strainer (2) from the filler opening. Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information that
3. Wash the strainer in a clean, nonflammable pertains to containing fluid spillage.
solvent.
i05873737
Note: Do not clean the fuel tank cap. Cleaning the
cap could damage the filter. For more information on
the fuel cap filter, refer to Operation and Maintenance Fuses - Replace
Manual, “Fuel Cap Filter - Replace”. SMCS Code: 1417-510
4. Install the strainer into the filler opening.
5. Install the fuel tank cap.

i05733324

Fuel Tank Water and Sediment

- Drain
SMCS Code: 1273-543-M&S

Illustration 214 g03637697

The fuse boxes are located behind the access ladder

on the left side of the machine.

Fuses – Fuses protect the electrical

system from damage that is caused by
overloaded circuits. Change a fuse if the
element separates. If the element of a new fuse
separates, check the circuit and/or repair the
circuit.
Illustration 213 g03643714
NOTICE
1. The fuel tank drain valve is located at the rear of Always replace fuses with the same type and ca-
the machine. The valve is located under the fuel pacity fuse that was removed. Otherwise, electrical
tank. damage could result.

2. Place a suitable container under the drain valve in

order to catch spilled fuel. NOTICE
If it is necessary to replace fuses frequently, an elec-
Note: Attach a temporary hose to the drain valve in trical problem may exist.
order to reduce splashing the fuel.
Contact your Cat dealer.
3. Open the drain valve for the fuel. Allow the water to
drain into the container. Allow the sediment to To replace a fuse, use the puller that is stored in the
drain into the container. fuse panel.
4. Close the drain valve for the fuel. The following list identifies the circuits that are
5. Check for leaks. Repair any leaks. Continue to protected by each fuse. The amperage for each fuse
is included with each circuit.
check for leaks after you place the machine in
operation.
Note: Dispose of drained material according to local
regulations.
KEBU7583-01 161
Maintenance Section
Fuses - Replace

(9) Spare – 15 Amp

(10) Cab – 15 Amp
(11) Horn – 15 Amp
(12) Aftertreatment ECM – 15 Amp
(13) Engine ECM – 15 Amp

Illustration 215 g03705573

Illustration 217 g03705581

Fuse box (2)

(14) Fuel Pump – Relay

(15) Rotor Service Switch – Relay
(16) Spare – 7.5 Amp
(17) Operator Controls – 7.5 Amp
(18) Rear Lights 2 – 7.5 Amp
(19) Spare – 10 Amp
(20) Rotor Service Switch – 10 Amp
(21) Product Link – 10 Amp
Illustration 216 g03705578
Fuse box (1) (22) Cab Lights / 12V Power Outlet – 10 Amp

(1) HVAC Fan – Relay (23) Spare – 15 Amp

(2) Horn – Relay (24) Machine ECM – 15 Amp

(3) Starter – Relay (25) Transmission ECM – 15 Amp

(4) Spare – 7.5 Amp

(5) Horn / Turn Signals – 7.5 Amp
(6) Fuel Pump – 7.5 Amp
(7) Aftertreatment System – 7.5 Amp
(8) Spare – 10 Amp
162 KEBU7583-01
Maintenance Section
Hydraulic System Oil - Change

Illustration 218 g03705582 Illustration 219 g03705583

Fuse box (3) Fuse box (4)

(26) Front Lights 1 – Relay (39) Front Rotor Door Open – Relay
(27) Rear Lights 1 – Relay (40) Front Rotor Door Close – Relay
(28) Front Lights 2 – Relay (41) Rear Rotor Door Open – Relay
(29) Beacon – Relay (42) Rear Rotor Door Close – Relay
(30) Lights – Relay (43) Radio – Relay
(31) Starter – 7.5 Amp (44) Rotor Doors Open/Close – 7.5 Amp
(32) Dynamic Pick Up – 7.5 Amp (45) Beacon – 7.5 Amp
(33) Radio – 7.5 Amp (46) Front Lights 2 – 7.5 Amp
(34) Camera – 7.5 Amp (47) Sensors – 7.5 Amp
(35) Emulsion Pump – 10 Amp (48) 12V Power Outlet – 10 Amp
(36) Gauges – 10 Amp (49) Rear Lights 1 – 10 Amp
(37) Heated Seat – 10 Amp (50) Front Lights 1 – 15 Amp
(38) Battery – 15 Amp (51) Lights – 15 Amp

i05874100

Hydraulic System Oil - Change

SMCS Code: 5056-044; 5095-044

Note: Cleanliness must be a priority when you

change the hydraulic oil. Change the oil in a clean
work area. Use clean tools. Make sure that you
have clean hands. Clean the outside of the
hydraulic tank before you start to operate the
machine.
KEBU7583-01
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact skin.
Illustration 220 g03705832
The hydraulic tank drain valve is located beneath the
access steps on the right side of the machine.
1. Connect a temporary drain hose to the drain valve.
Place the other end of the drain hose in a suitable
container.
Illustration 221 g03705839
2. Clean the area around the filler cap.
3. Loosen the filler cap in order to equalize the
pressure in the hydraulic tank.
4. Open the drain valve. Drain the oil to a suitable
container. Allow the oil to drain until the hydraulic
tank is empty.
5. Close the drain valve.
6. Open the filler cap.
7. Pour a small amount of hydraulic oil in the tank.
Clean the bottom of the tank.
163
Maintenance Section
Hydraulic System Oil Filter - Replace
8. Open the drain valve. Drain the oil to a suitable
container. Allow the oil to drain until the hydraulic
tank is empty.
9. Close the drain valve.
10. Remove the temporary drain hose from the drain
valve.
11. Remove the container.
12. Fill the hydraulic tank with clean hydraulic oil.
Refer to Operation and Maintenance Manual,
“Lubricant Viscosities” when you select a hydraulic
oil.
13. Close the filler cap.
14. Check for leaks. Repair any leaks. Continue to
check for leaks after you place the machine in
operation.
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information that
pertains to containing fluid spillage.
i05874126
Hydraulic System Oil Filter -
Replace
SMCS Code: 5068-510
Replace the hydraulic system oil filter every 1000
service hours or 1 year. If S·O·S analysis is
performed, then the hydraulic system oil filter can be
replaced every 2000 service hours or 2 years.
NOTICE
Take extreme care to insure the cleanliness of the hy-
draulic oil. Keep the hydraulic oil clean in order to ex-
tend the component life and assure the maximum
performance.
164 KEBU7583-01
Maintenance Section
Hydraulic System Oil Level - Check

Illustration 222 g03705850 Illustration 223 g03643747

1. The filter is on the right side of the machine next to
the ladder.
2. In order to catch any oil that spills, place a suitable
container under the filter. Refer to the Operation
and Maintenance Manual, “General Hazard
Information” for information that pertains to fluid
spillage.
3. Remove the plug in the bottom of the filter housing
in order to pre-drain the filter housing.
10. Observe the level of the hydraulic oil in the sight
glass. Maintain the oil level within the sight glass.
When the oil is at ambient temperature, the oil
should be visible within the bottom of the sight
glass.
Refer to the Operation and Maintenance Manual,
“Capacities (Refill)”. Refer to the Operation and
Maintenance Manual, “Lubricant Viscosities”.
i05733330

4. Remove the filter housing with a 1.25 inch socket

or box end wrench. Do not use an air wrench, Hydraulic System Oil Level -
open-end wrench, or adjustable wrench. Check
5. Remove the filter element from the filter housing, SMCS Code: 5050-535-FLV; 5095-535-FLV
and discard the filter in a proper manner.
6. Clean the filter housing. Install the plug in the
bottom of the filter housing.
7. Coat the new gasket with clean oil.
8. Install the new filter element and gasket in the filter
housing.
9. Install the filter housing. Tighten the filter housing
to a torque of 40 ± 5 N·m (30 ± 4 lb ft).

Illustration 224 g03643747

Maintain the proper oil level in the sight gauge.

Note: Allow space for the hydraulic oil to expand. Do
not overfill the hydraulic tank.
KEBU7583-01 165
Maintenance Section
Hydraulic System Oil Sample - Obtain

i05733351

Hydraulic System Oil Sample -

Obtain
SMCS Code: 5095-008; 7542-008

Illustration 226 g03646495

1. Remove the cover for the Hydraulic System Return

Filter.
2. Replace the Hydraulic System Return Filter.
3. Install the cover for the Hydraulic System Return
Illustration 225 g03643769
Filter.
1. Start the engine. Allow the engine to warm up for i05874137
at least 10 minutes.
2. Stop the engine. Hydraulic Tank Breather -
3. Use the sampling valve that is located on the Replace
auxiliary return filter to obtain the sample of the SMCS Code: 5056-510-BRE
hydraulic oil.
Refer to Special Publication, SEBU6250, “S·O·S Oil
Analysis” for information that pertains to obtaining a
sample of the hydraulic oil. Refer to Special
Publication, PEHP6001, “How To Take A Good Oil
Sample” for more information about obtaining a
sample of the hydraulic oil.

i05738365

Hydraulic System Return Filter

- Replace
SMCS Code: 5068-510
The hydraulic tank is located on top of the machine.
The cover for the Hydraulic System Return Filter is Illustration 227 g03705882
located on the top side of the hydraulic tank.
The breather is located on the top of the hydraulic
tank.
1. Remove the breather.
2. Install the new breather.
166 KEBU7583-01
Maintenance Section
Hydraulic Tank Screen - Clean

i05874147 i05735445

Hydraulic Tank Screen - Clean Mixing Chamber Door Cylinder

SMCS Code: 5056-070-Z3 Ends (Front) - Lubricate
SMCS Code: 5102-086

Illustration 228 g03705909

Illustration 230 g03644335

1. Remove the hydraulic oil filler cap and pull the
screen outward. Lubricate four fittings.
2. Clean the screen in clean, nonflammable solvent. The upper fitting on the left cylinder is oriented
Dry the screen with pressure air. toward the rear of the machine.
3. Install the screen and install the cap.
i05735467

i05735403
Mixing Chamber Door Cylinder
Mixing Chamber Disc Hub - Ends (Rear) - Lubricate
Lubricate SMCS Code: 5102-086
SMCS Code: 4184-086; 536H-RX

Illustration 231 g03644347

Illustration 229 g03644314 Lubricate two fittings.

Apply lubricant to the grease fitting for the hub. The
hub is located behind the rotor chain drive case.
There is one hub located on each side of the
machine.
KEBU7583-01 167
Maintenance Section
Mixing Chamber Door Hinges (Front) - Lubricate

i05735539 i05735580

Mixing Chamber Door Hinges Mixing Chamber Linkage -

(Front) - Lubricate Lubricate
SMCS Code: 6635-086-HNG SMCS Code: 6635-086-KL

Illustration 232 g03644400 Illustration 234 g03644421

Lubricate the four hinges on the front mixing chamber Lubricate four fittings on the top of the machine.
door.

i05735560

Mixing Chamber Door Hinges

(Rear) - Lubricate
SMCS Code: 6635-086-HNG

Illustration 235 g03644425

One fitting is located on the bottom of each linkage.

Lubricate two fittings.

Illustration 233 g03644411

Lubricate the four hinges on the rear mixing chamber

door.
168 KEBU7583-01
Maintenance Section
Mixing Chamber Tilt Cylinder Ends - Lubricate

i05735651 If metals are found in the filter element, a magnet can

be used to differentiate between ferrous metals and
Mixing Chamber Tilt Cylinder nonferrous metals.

Ends - Lubricate Ferrous metals can indicate wear on steel parts and
on cast iron parts.
SMCS Code: 5102-086
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.
Using an oil filter element that is not recommended
by Caterpillar can result in severe engine damage to
engine bearings, to the crankshaft, and to other
parts. This can result in larger particles in unfiltered
oil. The particles could enter the lubricating system
and the particles could cause damage.

Illustration 236 g03644469 i02425547

Lubricate the two fittings on the mixing chamber tilt
cylinder.
i02106227
Oil Filter - Inspect
SMCS Code: 1308-507; 3004-507; 3067-507; 5068-
507
Inspect a Used Filter for Debris
Illustration 237 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.
Parking Brake - Check
SMCS Code: 4267-535
Check the area around the machine. Make sure that
the machine is clear of personnel and clear of
obstacles.
Test the parking brake on a dry, level surface.
Fasten the seat belt before you test the parking
brake.
The following tests are used to determine if the
parking brake is functional. These tests are not
intended to measure the maximum brake holding
effort. The brake holding effort that is required to
sustain a machine at a specific engine rpm will vary
depending on the machine. The variations are the
differences in the engine setting, and in the power
train efficiency, etc.
1. Start the engine.
2. Move the propel travel control to the TRAVEL
MODE position.
3. Release the parking brake.
4. Propel the machine forward at full travel speed.
5. While the machine is moving, apply the parking
brake. The machine should stop within 5.78 m
(18.96 ft).
6. Reduce the engine speed to low idle.
7. Move the propel control lever to the NEUTRAL
position.
8. Stop the engine.
KEBU7583-01 169
Maintenance Section
Propel Planetary Oil - Change

Note: If the machine did not stop within 5.78 m
(18.96 ft), block the machine securely on a level
surface. Contact your Caterpillar dealer. Do not
operate the machine until the machine has been
repaired.
9. Install oil filler plug (2).
Note: The planetary is composed of two
compartments. Allow the oil level to fill both
compartments and recheck the oil level after 30 min.

i05735673 i05735713

Propel Planetary Oil - Change Propel Planetary Oil - Check

SMCS Code: 4051-044-OC SMCS Code: 4051-535-FLV

Note: Refer to this Operation and Maintenance There are four propel planetary drives on the
Manual, “General Hazard Information” topic, for machine, perform the following steps on each drive.
information that pertains to containing fluid spillage.

Note: Dispose of drained fluids according to local

regulations.
There are four propel planetary drives on the
machine, perform the following steps on each drive.

Illustration 239 g03644479

(1) Oil drain plug.
(2) Oil filler plug.

1. Position the machine on a level surface so that the

oil drain plug (1) is at the lowest level.
Illustration 238 g03644479 Note: Make sure that the line for the oil level is
(1) Oil drain plug. parallel with the ground.
(2) Oil filler plug.
2. Remove oil filler plug (2).
1. Position the machine on a level surface so that oil
3. Add oil until the oil level is at the bottom of the hole
drain plug (1) is at the lowest level. This position
for the oil filler plug. Refer to Operation and
will allow the oil to drain.
Maintenance Manual, “Lubricant Viscosities” when
Note: Make sure that the line for the oil level is you select an oil.
parallel with the ground. 4. Install oil filler plug (2).
2. Place a suitable container under drain plug (1). Note: Refer to this Operation and Maintenance
3. Loosen oil filler plug (2). Manual, “General Hazard Information” topic, for
information that pertains to containing fluid spillage.
4. Remove oil drain plug (1).
Note: Dispose of spilled fluids according to local
5. Drain the oil into a suitable container. regulations.
6. Install oil drain plug (1).
7. Remove oil filler plug (2).
8. Add oil until the oil level is at the bottom of the hole
for the oil filler plug. Refer to Operation and
Maintenance Manual, “Lubricant Viscosities” when
you select an oil.
170 KEBU7583-01
Maintenance Section
Propel Planetary Oil Sample - Obtain

i05735715 1. The grill assembly (1) does not open. The louvers
for the radiator can be removed in order to gain
Propel Planetary Oil Sample - access to the fan group.
Obtain 2. Inspect the grill assembly (1) for debris. If
SMCS Code: 4051-008 necessary, clean the grill assembly.

Note: Refer to this Operation and Maintenance

Manual, “Propel Planetary Oil - Change” topic, for
information on changing the oil in the propel
planetaries.
Obtain oil samples for the front propel axle planetary
and for the rear propel axle planetary when you
change the oil.
Send the oil sample to your dealer for analysis.
Note: Refer to Special Publication, SEBU6250,
“S·O·S Oil Analysis” and Special Publication,
PEHP6001, “How To Take A Good Oil Sample” for
more information.
Illustration 241 g03647084
i05739140
(2) Fan group
(3) Cooling group
Radiator and Hydraulic Oil (4) Fan guard

Cooler - Clean
SMCS Code: 1353-070-KO; 1374-070
Compressed air is preferred to remove dust and
general debris from the cooling group. Clean the
cooling group according to the condition of the
components. Clean both sides of the components.
Note: The cooling group may require cleaning more
often when lime or cement are mixed. Water should
not be used to clean the cooling group if lime or
cement has contaminated the cooling group.
3. Inspect the fan group (2) for debris that is located
in front of the fan group. If necessary, clean the
area in front of the fan group.
4. Inspect the fan group for debris that is located
between the fan guard (4) and the fan blades.
Inspect the fan group (2) for debris that is located
between the fan group and the cooling group (3). If
necessary, clean components with compressed air
only.

Note: High engine coolant temperature or high

hydraulic oil temperature indicate that the cooling
group needs to be cleaned.

Illustration 242 g03647096

The following components are part of the cooling
group (3):
(5) Air-to-air aftercooler core (ATAAC)
(6) Radiator core
Illustration 240 g03647078
(7) Hydraulic oil cooler core
(8) A/C core
(1) Grill assembly
KEBU7583-01
5. Inspect the front of the cooling group (3) for debris.
If necessary, clean the front of the cooling group.
Illustration 243 g03647106
6. Open the radiator access doors (9) that are located
on both sides of the machine.
7. Inspect the back of the cooling group for debris. If
necessary, clean the back of the cooling group.
8. Close the radiator access doors.
9. Install any louvers for the radiator that were
removed.
171
Maintenance Section
Refrigerant Dryer - Replace
i01879009
Refrigerant Dryer - Replace
(If Equipped)
SMCS Code: 7322-510
Personal injury can result from contact with
refrigerant.
Contact with refrigerant can cause frost bite.
Keep face and hands away to help prevent injury.
Protective goggles must always be worn when re-
frigerant lines are opened, even if the gauges in-
dicate the system is empty of refrigerant.
Always use precaution when a fitting is removed.
Slowly loosen the fitting. If the system is still
under pressure, release it slowly in a well venti-
lated area.
Personal injury or death can result from inhaling
refrigerant through a lit cigarette.
Inhaling air conditioner refrigerant gas through a
lit cigarette or other smoking method or inhaling
fumes released from a flame contacting air condi-
tioner refrigerant gas, can cause bodily harm or
death.
Do not smoke when servicing air conditioners or
wherever refrigerant gas may be present.
Use a certified recovery and recycling cart to
properly remove the refrigerant from the air con-
ditioning system.
NOTICE
If the refrigerant system has been open to the outside
air (without being plugged) for more than 30 minutes,
the receiver-dryer must be replaced. Moisture will en-
ter an open refrigerant system and cause corrosion
which will lead to component failure.
Note: 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.
172 KEBU7583-01
Maintenance Section
Rollover Protective Structure (ROPS) - Inspect

i05253356 i05737045

Rollover Protective Structure Rotor Bearing Reservoir Oil -

(ROPS) - Inspect Change
SMCS Code: 7323-040; 7325-040 SMCS Code: 751T-044
Inspect the rollover protective structure (ROPS) for 1. Park the machine on a level surface.
any loose bolts or damaged bolts. Replace the
damaged bolts with original equipment parts only.
Replace the ROPS mounting support if the ROPS
rattles. Replace the ROPS mounting support if the
ROPS makes noise.
Do not straighten the ROPS or repair the ROPS by
welding reinforcement plates to the ROPS.
Consult your Cat dealer for inspection of any
potential damage or repair of any damage to any
Operator Protective structure, including ROPS,
FOPS, TOPS, OPS and OPG. Refer to Special
Instruction, SEHS6929, “Inspection, Maintenance,
and Repair of Operator Protective Structures (OPS)
and Attachment Installation Guidelines for All
Earthmoving Machinery” for more information.
Illustration 245 g03645546

i05737026 The rotor bearing reservoir is located on top of the

machine.
Rotor Bearing Reservoir 2. Remove the rotor bearing reservoir filler cap.
Breather - Replace
SMCS Code: 751T-510-BRE

Illustration 246 g03645558

Illustration 244 g03645530

3. There are two hoses the rotor drives on each side
of the machine. Place a suitable container under
1. Remove the old breather. each pair of hoses.

2. Install the new breather. 4. Disconnect the hoses from the adapter
assemblies.
5. Allow the oil to drain from the hoses into the
suitable containers.
6. Attach the hoses to the adapter assemblies.
7. Fill the rotor bearing reservoir with oil until the oil is
slightly above the center divider.
KEBU7583-01
Note: Make sure that an equal amount of oil is
present on both sides of the divider.
8. Replace the filler cap.
9. Remove the containers. Dispose of the oil
according to local regulations.
Note: Dispose of spilled fluids according to local
regulations. Refer to this Operation and Maintenance
Manual, “General Hazard Information” topic, for
information that pertains to containing fluid spillage.
i05737065
Rotor Bearing Reservoir Oil
Level - Check
SMCS Code: 751T-535-FLV
1. In order to ensure an accurate reading, park
the machine on a level surface.
Illustration 247 g03645546
The rotor bearing reservoir is located on top of the
machine.
2. Inspect the rotor bearing reservoir. The oil level
should be slightly above the center divider. The oil
level should be equal on both sides of the center
divider. A low oil level on one side of the center
divider may be an indication of leakage or
excessive use of oil on that side of the system. If
the oil level is lower on one side of the center
divider, consult your Caterpillar dealer.
3. If the oil level is low, remove the filler cap. Fill the
rotor bearing reservoir with oil until the oil is
slightly above the center divider. Replace the filler
cap.
Note: When you fill the system, make sure that an
equal amount of oil is present on both sides of the
divider.
173
Maintenance Section
Rotor Bearing Reservoir Oil Level - Check
i02358298
Rotor Bearing Reservoir Oil
Sample - Obtain
SMCS Code: 751T-008
Note: Refer to this Operation and Maintenance
Manual, “Rotor Bearing Reservoir Oil - Change”
topic, for information on changing the oil in the rotor
bearing reservoir system.
Obtain a sample of the oil when you change the oil.
Send the oil sample to your dealer for analysis.
Note: Refer to Special Publication, SEBU6250,
“S·O·S Oil Analysis” and Special Publication,
PEHP6001, “How To Take A Good Oil Sample” for
more information.
i05737073
Rotor Brake - Adjust
SMCS Code: 3275-025; 5631-025-BRK
Personal injury or death can result from sudden
machine movement.
Sudden movement of the machine can cause in-
jury to persons on or near the machine.
To prevent injury or death, make sure that the
area around the machine is clear of personnel
and obstructions before operating the machine.
Personal injury can result from hydraulic oil pres-
sure and hot oil.
Hydraulic oil pressure can remain in the hydraulic
system after the engine has been stopped. Seri-
ous injury can be caused if this pressure is not
released before any service is done on the hy-
draulic system.
Make sure all of the attachments have been low-
ered, and the oil is cool before removing any
components or lines. Remove the oil filler cap on-
ly when the engine is stopped, and the filler cap
is cool enough to touch with your bare hand.
1. Park the machine on a smooth, horizontal surface.
174 KEBU7583-01
Maintenance Section
Rotor Brake - Adjust

Illustration 248 g03641919

2. Move propulsion lever (1) to the NEUTRAL

position.
3. Push down on the upper part of parking brake
switch (2) in order to engage the parking brake.
Illustration 250 g03645596
4. Stop the engine.
8. Rotate the adjustment screw (4) clockwise until the
5. Remove the rear belly plate.
brake is clamped onto the disc.
6. Move the key to the ON position.
9. Rotate the adjustment screw (4) counter clockwise
by 1/3 to 1/2 of a turn.
10. Move rotor service switch (3) to the OFF position.

Note: When the rotor service switch (3) is placed in

the OFF position, the hydraulic pressure is released
from the brake.

11. Move the key to the OFF position.

12. Reinstall the rear belly guard.

Illustration 249 g03645593

7. Move the rotor service switch (3) to the SERVICE

position.
Note: When the rotor service switch (3) is placed in
the SERVICE position, hydraulic pressure is supplied
to the brake.
KEBU7583-01 175
Maintenance Section
Rotor Chain Drive Case Oil - Change

i05737116 i05737141

Rotor Chain Drive Case Oil - Rotor Chain Drive Case Oil
Change Level - Check
SMCS Code: 5634-044 SMCS Code: 5634-535-FLV

Illustration 251 g03645625 Illustration 252 g03645648

1. Start the engine. 1. Raise the rotor to the upper limit.

2. Raise the rotor to the upper limit. 2. Place a suitable container below the oil filler plug.
3. Remove breather (1) from the top of the rotor chain 3. Remove the oil filler plug.
drive case.
4. If oil does not flow from the port for the plug, fill the
4. Place a suitable container below plug (2) on the chain case to the level of the oil filler plug.
bottom of the rotor chain drive case.
5. Clean the oil filler plug.
5. Remove plug (2). Drain the oil to a suitable
6. Install the oil filler plug.
container.
7. Repeat steps 2 through 6 on the other side of the
6. Install plug (2) on the bottom of the rotor drive
machine.
chain case.
8. Remove the containers. Dispose of all fluids
7. Remove filler plug (3). Fill the chain drive case with
according to local regulations. Proper care is your
oil to the filler plug (3).
responsibility.
8. Install breather (1).
Note: Refer to this Operation and Maintenance
9. Repeat 3 through 8 on the other side of the Manual, “General Hazard Information” for information
machine. that pertains to containing fluid spillage.
10. Remove the containers. Dispose of all fluids
according to local regulations. Proper care is your
responsibility.
Note: Refer to this Operation and Maintenance
Manual, “General Hazard Information” for information
that pertains to containing fluid spillage.
176 KEBU7583-01
Maintenance Section
Rotor Cutter Bits (Side) - Inspect/Replace

i05737151

Rotor Cutter Bits (Side) -

Inspect/Replace
SMCS Code: 6637-510-KT; 6637-040-KT; 6819-510;
6819-040

Do not perform any cutter tooth replacement, and

do not perform service or maintenance on the ro-
tor, the rotor hood, or the chain cases until steps
1 to 10 are completed.
Failure to follow these instructions could allow Illustration 253 g03645658
the rotor, chamber, or door to drop resulting in Side rotor access door (1).
serious personal injury or death.
1. Set the parking brake on the propel system. 1. Use a hammer to disengage the pin in order to
open access door (1).
2. Raise the rotor to the TRAVEL position to clear
any material that may be trapped between the cut-
ter bits and the paddles.
3. Tilt the rotor chamber forward, and raise the
rear door.
4. Reduce the engine speed to LOW idle.
5. Disengage the rotor drive.
6. Turn the ignition OFF in order to stop the
engine,
7. Turn the ignition key to the ON position. Do not
start the engine.
8. Remove the padlock from the circuit breaker
box, and open the cover for the circuit breaker Illustration 254 g03645662
box. Place the rotor service switch in the SERV-
ICE position. Close the circuit breaker box cover 2. Inspect side cutter bits (2).
and install the padlock.
Wear a hard hat and protective glasses. Additional
9. Engage the rotor service lock T bar that is lo- protective equipment may also be required. Use a
cated on the left chain case on the lift cylinder. hammer and a punch to remove a worn holder or a
damaged holder.
10. Secure the rear door and mixing chamber in
position, by engaging the rear door service pin. The bits for the rotor should be checked for wear.
The bits for the rotor should be replaced if the
11. Do not start the engine again until all of the distance from the holders of the rotor bits to the tip
services are completed and all personnel are of the bits for the rotor is 32 mm (1.26 inch) or
clear from the rotor area. less. The bits for the rotor should be replaced if the
distance from the exposed carbide tip is 32 mm
12. Remove the rotor lock and disengage the rear
(1.26 inch) or less.
door service pin.
Check the holders for the bits for cracks. Check
13. Remove the padlock from the circuit breaker the holders for the bits for breaks. Check the
box. Open the cover of the circuit breaker box. holders when you check the bits.
Place the rotor service switch in OPERATE posi-
tion. Close the cover for the circuit breaker box
and install the padlock.
14. Sound the horn three times prior to starting
the engine.
KEBU7583-01
When the bits for the rotor need to be changed,
the bits should be changed as a group. You should
change the bits as a group so that all of the bits
will be the same length. When the bits for the rotor
are not the same length, the long bits will wear
faster. When the bits for the rotor are not the same
length, the long bits will break. Save bits that are
worn in order to replace bits that are broken.
Replace a bit that is broken with a bit that is the
same length as the other bits in the rotor.
3. Close access door (1). Use a hammer in order to
engage the pin and secure the pin in place.
i05737173
Rotor Cutter Bits - Inspect/
Replace
SMCS Code: 6637-040-KT; 6637-510-KT; 6819-510;
6819-040
Illustration 255 g03645682
Check and Inspect the Rotor Bits
The rotor bits should be checked for excessive wear.
Replace the rotor bits when the following problems
occur:
• Uneven wear
• Carbide is missing from the tip.
• The shoulder of the bit is severely eroded.
• The neck that supports the carbide is significantly
thinner.
Replacing a Rotor Bit
Individual bits may have excessive wear. Individual
bits may have carbide damage. Replace these bits
with new bits or with bits that are worn to the same
level as the majority of the remaining bits. When all
the bits have significant wear, replace all the bits at
the same time.
177
Maintenance Section
Rotor Cutter Bits - Inspect/Replace
Do not perform any cutter tooth replacement, and
do not perform service or maintenance on the ro-
tor, the rotor hood, or the chain cases until steps
1 to 10 are completed.
Failure to follow these instructions could allow
the rotor, chamber, or door to drop resulting in
serious personal injury or death.
1. Set the parking brake on the propel system.
2. Raise the rotor to the TRAVEL position to clear
any material that may be trapped between the cut-
ter bits and the paddles.
3. Tilt the rotor chamber forward, and raise the
rear door.
4. Reduce the engine speed to LOW idle.
5. Disengage the rotor drive.
6. Turn the ignition OFF in order to stop the
engine,
7. Turn the ignition key to the ON position. Do not
start the engine.
8. Remove the padlock from the circuit breaker
box, and open the cover for the circuit breaker
box. Place the rotor service switch in the SERV-
ICE position. Close the circuit breaker box cover
and install the padlock.
9. Engage the rotor service lock T bar that is lo-
cated on the left chain case on the lift cylinder.
10. Secure the rear door and mixing chamber in
position, by engaging the rear door service pin.
11. Do not start the engine again until all of the
services are completed and all personnel are
clear from the rotor area.
12. Remove the rotor lock and disengage the rear
door service pin.
13. Remove the padlock from the circuit breaker
box. Open the cover of the circuit breaker box.
Place the rotor service switch in OPERATE posi-
tion. Close the cover for the circuit breaker box
and install the padlock.
14. Sound the horn three times prior to starting
the engine.
Removing a Rotor Bit
1. Put the rotor in the service position.
Wear a hard hat and protective glasses. Additional
protective equipment may also be required. Use a
hammer and a punch to remove the worn bits.
178 KEBU7583-01
Maintenance Section
Rotor Drive Differential Breather - Replace

Note: Refer to the Operation and Maintenance i02426160

Manual, “Servicing the Rotor”.
Rotor Drive Differential Oil -
2. Rotate the rotor until the bit is accessible.
Change
3. Insert the tip of a drive pin into the back opening of
SMCS Code: 5633-044
the bit holder. Use a hammer in order to drive the
bit out of the holder.
4. Place the new bit in the holder. Use a hammer to
drive the bit into position. Keep the keeper spring
engaged with the holder.

i02426152

Rotor Drive Differential

Breather - Replace
SMCS Code: 5633-510-BRE

Illustration 257 g00871977

1. Remove drain plug (1).

2. Allow the oil to drain to a suitable container.
3. Install drain plug (1).

Illustration 256 g01212683

1. Remove the old breather.

2. Install the new breather.

Illustration 258 g01005271

4. Remove filler plug (2).

5. Use filler plug (2) to fill the axle. Fill the axle until oil
drains out.
6. Install the filler plug.
KEBU7583-01 179
Maintenance Section
Rotor Drive Differential Oil Level - Check

i02426180 i02436514

Rotor Drive Differential Oil Rotor Drive Planetary Oil -

Level - Check Change
SMCS Code: 5633-535-FLV SMCS Code: 4050-044-OC; 5630-044-OC

1. Orient the rotor so that the filler plug is at the top of

the cylindrical surface. The drain plug should be at
the bottom of the cylindrical surface.
2. Place a suitable container under the planetary in
order to catch spilled oil.

Illustration 259 g00871996

Maintain the oil level in the tube to the centerline of

the axle.

i01884088

Rotor Drive Differential Oil Illustration 260 g01212692

Sample - Obtain 3. Remove drain plug (1).

SMCS Code: 5633-008
In addition to a good preventive maintenance
program, Caterpillar recommends using S·O·S oil
analysis at regular scheduled intervals in order to
monitor the condition of the engine and the
maintenance requirements of the engine.
Note: Refer to the Operation and Maintenance
Manual, “Rotor Drive Differential Oil - Change” for
information on changing the oil in the final drive
planetary.
Refer to Special Publication, SEBU6250, “S·O·S Oil
Analysis” for information that pertains to obtaining a
sample from the final drive planetary. Refer to
Special Publication, PEHP6001, “How To Take A
Good Oil Sample” for more information about
obtaining a sample from the final drive planetary.
Obtain a sample of the oil when you change the oil.
Send the oil sample to your dealer for analysis.
4. Allow the oil to drain to a suitable container.
5. Install drain plug (1).
6. Remove filler plug (3).
7. Remove plug (2).
8. Use filler plug (3) to fill the axle. Fill the planetary
until oil drains out of plug (2). Refer to Operation
and Maintenance Manual, “Lubricant Viscosities”
for selecting a lubricant.
9. Install filler plug (3).
10. Install plug (2).
11. Check for leaks. Repair any leaks. Continue to
check for leaks after you place the machine in
operation.
Refer to Operation and Maintenance Manual,
“General Hazard Information” for information that
pertains to containing fluid spillage.
180 KEBU7583-01
Maintenance Section
Rotor Drive Planetary Oil - Check

i02436519 i05737382

Rotor Drive Planetary Oil - Rotor Lift Cylinder Ends -

Check Lubricate
SMCS Code: 4050-535-FLV; 5630-535-FLV SMCS Code: 5102-086

Illustration 261 g01212708 Illustration 262 g03645802

Maintain the oil level at the centerline of the There are two rotor lift cylinders on the machine.
planetary. The rotor drive planetary should be filled Each cylinder has one fitting. Lubricate the fitting on
with oil to plug (1). the lower end of each cylinder.

i01884055 i05908060

Rotor Drive Planetary Oil Rotor Shear Disc - Lubricate

Sample - Obtain (If Equipped)
SMCS Code: 4050-008; 5630-008 SMCS Code: 5631-086
In addition to a good preventive maintenance
program, Caterpillar recommends using S·O·S oil
analysis at regular scheduled intervals in order to
monitor the condition of the engine and the
maintenance requirements of the engine.

Note: Refer to the Operation and Maintenance

Manual, “Rotor Drive Planetary Oil - Change” for
information on changing the oil in the final drive
planetary.
Refer to Special Publication, SEBU6250, “S·O·S Oil
Analysis” for information that pertains to obtaining a
sample from the final drive planetary. Refer to
Special Publication, PEHP6001, “How To Take A
Good Oil Sample” for more information about
obtaining a sample from the final drive planetary. Illustration 263 g00881639

Obtain a sample of the oil when you change the oil. Lubricate one fitting.
Send the oil sample to your dealer for analysis.
KEBU7583-01
i05908062
Rotor Shear Disc Bolts -
Inspect/Replace
(If Equipped)
SMCS Code: 5635-040-BC; 5635-510-BC
Illustration 264 g00881652
Make sure that the bolt is loose. Do not tighten the
bolt if the bolt is loose. Replace the bolt if the bolt is
broken.
Note: Use only the 7X-0319 Bolt. This bolt has a
shank length that is not threaded. The shank length
that is not threaded will not allow the bolt to be
tightened against the shear disc plates. If you tighten
the plates, a higher torque load will result and you
could damage the rotor drive components. The
7X-0319 Bolt is designed to shear in order to
protect the drive components.
Note: If the bolt has failed, find the source of the
failure. If necessary, consult with your Caterpillar
dealer.
For information on releasing the rotor brake in order
to align the shear bolt holes, refer to Operation and
Maintenance Manual, “Servicing the Rotor”.
181
Maintenance Section
Rotor Shear Disc Bolts - Inspect/Replace
i02436320
Rotor Torque Limiter Coupling
- Inspect
(If Equipped)
SMCS Code: 5632-040-QC
Illustration 265 g01002606
(1) Flush Indicators.
(2) This is the index mark.
Use a black marker or a permanent mark for the
index mark.
Note: Place an index mark across the back side of
the torque limiter and spring plate. Use this method to
determine if the torque limiter shows an indexing
point or if the torque limiter does not show an
indexing point after some use. Disassemble the
torque limiter and clean the torque limiter if the torque
limiter does not show an indexing point in tough
applications. Disassemble the torque limiter and
clean the torque limiter if the machine has not been in
operation for three months or more.
When the indicators are flush with the machined
recess of the plate, you must rebuild the clutch.
Note: Refer to Special Instruction REHS2768,
“Maintenance Procedure for the Torque Limiting
Coupling on the Road Reclaimer” for additional
information.
182 KEBU7583-01
Maintenance Section
Rotor Transmission Breather - Replace

i05737423

Rotor Transmission Breather -

Replace
SMCS Code: 5635-510-BRE

Illustration 267 g03645856

3. Remove drain plug (1). Allow the oil to drain into

the container.
4. Install drain plug (1).
5. Remove the container.
Illustration 266 g03645841
6. Install the shield.
1. Remove the old breather.
2. Install the new breather.

i05737426

Rotor Transmission Oil -

Change
SMCS Code: 5635-044
The drain plug is located beneath the rotor
transmission.
1. Remove the shield that is beneath the rotor
transmission.
Illustration 268 g03645869
2. Place a suitable container underneath the rotor
transmission. The filler cap for the rotor transmission is located
under the access cover on the right side of the deck.

Note: The oil level gauge is part of the filler cap.

7. Fill the rotor transmission to the mark on the oil

level gauge. Refer to Operation and Maintenance
Manual, “Lubricant Viscosities” when you select a
transmission oil.
Note: Dispose of the oil according to local
regulations. Proper care is your responsibility.

Note: Refer to Operation and Maintenance Manual,

“General Hazard Information” for information that
pertains to containing fluid spillage.
KEBU7583-01 183
Maintenance Section
Rotor Transmission Oil - Check

i05737452 i05738062

Rotor Transmission Oil - Rotor Transmission Oil Filter -

Check Replace
SMCS Code: 5635-535 SMCS Code: 5635-510-FI

1. Remove the filler cap.

Illustration 270 g03646184

Illustration 269 g03645869
The filler cap for the rotor transmission is located
under the access cover on the right side of the deck.
Note: The oil level gauge is part of the filler cap.
The oil filter is located near the access ladder on the
right side of the machine.
1. Turn off the engine.
2. Place a suitable container under the old oil filter.

2. Use the oil level gauge to check the oil level. 3. Remove the old oil filter.

3. The oil level should be at the FULL mark on the oil
level gauge.
4. Add oil if the oil level is low. Refer to Operation and
Maintenance Manual, “Lubricant Viscosities” when
you select an oil.
4. Install the new oil filter by hand.
Instructions for the installation of the filter are
printed on the side of each Caterpillar spin-on
filter.
5. Turn on the machine. Check for oil leaks.

Note: Refer to Operation and Maintenance Manual, i02428153

“General Hazard Information” for information that
pertains to containing fluid spillage. Rotor Transmission Oil
Sample - Obtain
SMCS Code: 5635-008

Note: Refer to this Operation and Maintenance

Manual, “Rotor Transmission Oil - Change” topic for
information on changing the oil in the rotor
transmission.
Obtain a sample of the oil when you change the oil.
Note: Refer to Special Publication, SEBU6250,
“S·O·S Oil Analysis” and Special Publication,
PEHP6001, “How To Take A Good Oil Sample” for
more information.
184
Maintenance Section
Seat Belt - Inspect
i04423622
Seat Belt - Inspect
SMCS Code: 7327-040
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 271 g02620101
Typical example
Inspect buckle (1) for wear or for damage. If the
buckle is worn or damaged, replace the seat belt.
Inspect seat belt (2) for webbing that is worn or
frayed. Replace the seat belt if the webbing is worn
or frayed.
Inspect all seat belt mounting hardware for wear or
for damage. Replace any mounting hardware that is
worn or damaged. Make sure that the mounting bolts
are tight.
If your machine is equipped with a seat belt
extension, also perform this inspection procedure for
the seat belt extension.
Contact your Cat dealer for the replacement of the
seat belt and the mounting hardware.
Note: The seat belt should be replaced within 3 years
of the date of installation. A date of installation label
is attached to the seat belt retractor and buckle. If the
date of installation label is missing, replace belt within
3 years from the year of manufacture as indicated on
belt webbing label, buckle housing, or installation
tags (non-retractable belts).
KEBU7583-01
i06891605
Seat Belt - Replace
SMCS Code: 7327-510
The seat belt should be replaced within 3 years of the
date of installation. A date of installation label is
attached to the seat belt retractor and buckle. If the
date of installation label is missing, replace belt within
3 years from the year of manufacture as indicated on
belt webbing label, buckle housing, or installation
tags (non-retractable belts).
Illustration 272 g01152685
Typical Example
(1) Date of installation (retractor)
(2) Date of installation (buckle)
(3) Year of manufacture (tag) (fully extended web)
(4) Year of manufacture (underside) (buckle)
Consult your Cat dealer for the replacement of the
seat belt and the mounting hardware.
Determine age of new seat belt before installing on
seat. A manufacture label is on belt webbing and
imprinted on belt buckle. Do not exceed install by
date on label.
Complete seat belt system should be installed with
new mounting hardware.
Date of installation labels should be marked and
affixed to the seat belt retractor and buckle.
Note: Date of installation labels should be
permanently marked by punch (retractable belt) or
stamp (non-retractable belt).
If your machine is equipped with a seat belt
extension, also perform this replacement procedure
for the seat belt extension.
KEBU7583-01 185
Maintenance Section
Steering Cylinder Ends - Lubricate

i05874159 i05738136

Steering Cylinder Ends - Steering Knuckle - Lubricate

Lubricate SMCS Code: 3020-086-QZ; 4321-086
SMCS Code: 4303-086-BD

Front Steering Cylinder Ends

Illustration 275 g03646236

Illustration 273 g03705919

There are two fittings on each side of the machine.

Lubricate the fittings.

Rear Steering Cylinder Ends

Illustration 276 g03646238

The steering knuckle lubrication fittings are located

Illustration 274
Find the fittings on each end of the rear steering
cylinders. Lubricate the four fittings.
forward of the front axle. Lubrication lines connect
the fittings to the steering knuckle kingpins. There are
four steering knuckle lubrication fittings on the
machine. There are two fittings on each side of the
machine. The upper fitting is connected to the upper
steering knuckle kingpin. The lower fitting is
connected to the lower steering knuckle kingpin.
g03705918
Use the fittings to lubricate the upper and the lower
steering knuckle kingpin on each side of the
machine.
186 KEBU7583-01
Maintenance Section
Steering Linkage - Lubricate

i05738151 i05738168

Steering Linkage - Lubricate Tire Inflation - Check

SMCS Code: 4318-086 SMCS Code: 4203-535-PX

Front Steering Linkage

Illustration 279 g03646284

Check the tires daily for the proper inflation and for
Illustration 277 g03646270 wear. Check the lug nuts for the wheel . Tighten the
lug nuts if the lug nuts are loose.
Identify one fitting on each end of the steering
linkage. Lubricate the two fittings. Check the tires for leaks if the tire pressure is low.

Rear Steering Linkage Refer to Operation and Maintenance Manual, “Tire

Inflation Pressure Adjustment”, for the proper tire
pressure.

i05738195

Tool Holder - Inspect/Replace

SMCS Code: 6637-510; 6637-040

Illustration 278 g03646274

Identify one fitting on each end of the rear steering

linkage. Lubricate the two fittings.

Illustration 280 g03645682

Check and Inspect the Tool

Holders
The tool holders should be checked for the following
problems:
KEBU7583-01 187
Maintenance Section
Tool Holder - Inspect/Replace

• Breaks Replace the holders if any of the above problems

occur.
• Cracks

• Excessive erosion
Replacing a Damaged Tool Holder

Do not perform any cutter tooth replacement, and

do not perform service or maintenance on the ro-
tor, the rotor hood, or the chain cases until steps
1 to 10 are completed.
Failure to follow these instructions could allow
the rotor, chamber, or door to drop resulting in
serious personal injury or death.
1. Set the parking brake on the propel system.
2. Raise the rotor to the TRAVEL position to clear
any material that may be trapped between the cut-
ter bits and the paddles.
3. Tilt the rotor chamber forward, and raise the
rear door.
4. Reduce the engine speed to LOW idle.
5. Disengage the rotor drive.
6. Turn the ignition OFF in order to stop the
engine,
7. Turn the ignition key to the ON position. Do not
start the engine.
8. Remove the padlock from the circuit breaker
box, and open the cover for the circuit breaker
box. Place the rotor service switch in the SERV-
ICE position. Close the circuit breaker box cover
and install the padlock.
9. Engage the rotor service lock T bar that is lo-
cated on the left chain case on the lift cylinder.
10. Secure the rear door and mixing chamber in
position, by engaging the rear door service pin.
11. Do not start the engine again until all of the
services are completed and all personnel are
clear from the rotor area.
12. Remove the rotor lock and disengage the rear
door service pin.
13. Remove the padlock from the circuit breaker
box. Open the cover of the circuit breaker box.
Place the rotor service switch in OPERATE posi-
tion. Close the cover for the circuit breaker box
and install the padlock.
14. Sound the horn three times prior to starting
the engine.
188 KEBU7583-01
Maintenance Section
Tool Holder - Inspect/Replace

Personal injury could result when striking an
object. Keep personnel away when striking an
object. Always wear protective glasses when
striking an object.
1. Put the rotor in the service position.
Wear a hard hat and protective glasses. Additional
protective equipment may also be required. Use a
hammer and a punch to remove the worn bits.
Note: Refer to the Operation and Maintenance
Manual, “Servicing the Rotor”.
2. Remove the bolt from the holder or knock off the
head of the bolt.
3. Use a hammer in order to remove the holder. To
remove a worn tool holder from the base, hit the
back of the tool holder as close as possible to the
top of the base with a steel hammer that weighs
1.8 kg (4 lb) to 2.25 kg (5 lb).
Note: Do not hit the base with the hammer.
4. Remove the tool holder and clean any debris from
the base.
Note: Refer to Installation of the Tool Holder for
information on installing the new tool holder.
Installation of the Tool Holder
1. Place tool holder (1) in base (2).
2. Hit tool holder (1) on the front of T section (4) four
to five times with a steel hammer that weighs
1.8 kg (4 lb) to 2.25 kg (5 lb). This will drive tool
holder (1) into base (2). At this point, tool holder
(1) and base (2) will be locked together by the
tapers.
3. Striking the tool holder with the hammer will cause
a dull heavy sound. When the tool holder has been
seated in the base, striking the tool holder with the
hammer will cause the tone to change to a high
pitch. The change of tone signifies that the tool
holder and the base have locked together.
4. Once tool holder (1) has seated in base (2) install
bolt (3). Tighten bolt (3) to a torque of 88 ± 7 N·m
(65 ± 5 lb ft).
Note: Do not use only the torque on the bolt to seat
the tool holder. The strength of the bolt is insufficient
to apply the required load for assembly.
5. Operate the machine for four to six hours.
6. Check the tool holders and bolts. Reseat any loose
tool holders and tighten any loose bolts. Refer to
Step 2.
7. Operate the machine for 10 to 12 hours. All tool
holders should be tight. If any tool holders are
loose disassemble the tool holders. Reassemble
the tool holders. Refer to Step 2.

Personal injury could result when striking an

object. Keep personnel away when striking an
object. Always wear protective glasses when
striking an object.

Illustration 281 g01435570

(1) Tool holder
(2) Base
(3) Bolt
(4) T section
KEBU7583-01 189
Maintenance Section
Water Spray System Nozzles - Clean

8. Tool holders and bases that have been tightened 4. Replace the nozzles (2) after the nozzles are
twice are locked together by the tapers. The tool clean.
holders and bases should remain locked under
5. Loosen bolts (1). Move the spray bar back into the
normal working conditions. Loss of bolts from a
original position.
properly assembled unit is not detrimental. The
tool holder and the base are locked together by 6. Tighten bolts (1) to the proper torque value.
the tapers.
i05874356
i05738222
Water Spray System Pump Oil
Water Spray System Nozzles - - Change
Clean (If Equipped)
(If Equipped) SMCS Code: 5614-044; 5616-044
SMCS Code: 5612-070; 5615-070

Illustration 284 g03706130

Illustration 282 g03719926

1. Loosen bolts (1). There are two bolts on each end
of the spray bar. Raise the spray bar completely.
Tighten bolts (1).
Fill the automatic greaser as required (1).
Change the oil pump for the water spray system (2).
Allow the oil to drain into a suitable container.
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information that
pertains to containing fluid spillage.
Note: Dispose of drained fluids according to local
regulations.

Illustration 283 g03719928

2. Remove nozzle (2). There are 16 nozzles on the

spray bar.
3. Clean the nozzles (2) with soap and water or clean
solvent.
190 KEBU7583-01
Maintenance Section
Water Spray System Pump Oil Level - Check

i05874361 3. Rinse the strainer with water in order to remove

any debris.
Water Spray System Pump Oil 4. Reinstall the clean strainer assembly.
Level - Check 5. Hand tighten the top fastener.
(If Equipped)
SMCS Code: 5614-535-FLV

Illustration 285 g03706138

Use the sight glass for the oil level in order to check
the oil level in the oil pump for the water spray
system.

i05738299

Water Spray System Strainer -

Clean
SMCS Code: 5612-070-STR

Illustration 286 g03646450

In order to clean the strainer, follow the listed

procedure.
1. Unscrew the top fastener.
2. Pull out the strainer assembly.
KEBU7583-01 191
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,
Information at the time of sale, with applicable emission
standards prescribed in the Enforcement Rule
SMCS Code: 1000 of the Clean Air Conservation Act promulgated
The certifying engine manufacturer warrants to the by South Korea MOE.
ultimate purchaser and each subsequent purchaser
that: b. Free from defects in materials and workmanship
in emission-related components that can cause
1. New non-road diesel engines and stationary diesel the engine to fail to conform to applicable
engines less than 10 liters per cylinder (including emission standards for the warranty period.
Tier 1 and Tier 2 marine engines < 37 kW, but
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
maintenance requirements being followed.
control systems (“emission related components”),
are: A detailed explanation of the Emission Control
Warranty that is applicable to new non-road and
a. Designed, built, and equipped so as to conform, stationary diesel engines, including the components
at the time of sale, with applicable emission covered and the warranty period, is found in a
standards prescribed by the United States 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
obtain a copy of the applicable Special Publication.
b. Free from defects in materials and 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.
192 KEBU7583-01
Reference Information Section
Reference Materials

Reference Information Specifications, SENR3130, “Torque Specifications”

Section System Operation, Troubleshooting, Testing and

Adjusting, RENR7911, “Product Link 121SR/321SR”
Special Instruction, REHS2365, “An Installation
Reference Materials Guide for the Product Link PL121SR and for the
PL300”
i05656953 Service Parts, PECP9067, “One Safe Source”

Reference Material Special Instruction, SEHS7332, “Warning Tag -

Danger Do Not Operate”
SMCS Code: 1000; 7000
Special Instruction, SEHS7633, “Battery Test
The following literature can be obtained from any Procedure”
Caterpillar dealer:
Special Publication, PEGJ0047, “How to Take a
Special Instruction, PEHJ0192, “Optimizing Oil Good Oil Sample”
Change Intervals”
Special Publication, PEGJ0046, “S·O·S Services:
Special Instruction, PEHJ0191, “S·O·S Fluid Understanding Your Results”
Analysis”
Special Publication, PEWJ0074, “Caterpillar Filter
Special Publication, SEBD0518, “Know Your Cooling and Fluid Application Guide”
System”
Special Publication, PMEP5027, “Extended Life
Special Publication, SEBD0970, “Coolant and Your Coolant/Antifreeze Label”
Engine”
Operation and Maintenance Manual, SEBU8157,
Special Publication, SEBD0717, “Diesel Fuels and “Work Area Vision System”
Your Engine”
Operation and Maintenance Manuals are available in
Special Instruction, SEHS9031, “Storage Procedure other languages. Consult your Caterpillar dealer for
for Caterpillar Products” information about obtaining these Operation and
Maintenance Manuals.
Special Publication, SEBU5898, “Cold Weather
Recommendations” Additional Reference Material
Special Publication, SEBD0640, “Oil and Your ASTM D2896, “TBN Measurements” This publication
Engine” can normally be obtained from your local
Special Publication, SEBU6250, “Caterpillar Machine technological society, from your local library, or from
Fluids Recommendations” your local college.

Special Publication, SEBF8029, “Guideline For SAE J313, “Diesel Fuels” This publication can be
Reusable Parts and Salvage Operations” found in the SAE handbook. Also, this publication
can be obtained from your local technological society,
Operation and Maintenance Manual, SEBU8257, from your local library, or from your local college.
“The European Union Physical Agents (Vibration)
Directive “2002/44/EC” ” SAE J754, “Nomenclature” This publication can
normally be found in the SAE handbook.
Service Manual, SENR5664, “Air Conditioning and
Heating with R-134A (All Caterpillar Machines)” SAE J183, “Classification” This publication can
normally be found in the SAE handbook.
Special Instruction, REHS0354, “Charging System
Troubleshooting” Engine Manufacturers Association, “Engine Fluids
Data Book”
Special Instruction, REHS1642, “Operation of the
Product Link System”
Special Publication, NENG2500, “Caterpillar Dealer
Service Tool Catalog”
Service Magazine, SEHS6929, “Inspection,
Maintenance, and Repair of ROPS and Attachment
Installation Guidelines”
KEBU7583-01 193
Reference Information Section
Decommissioning and Disposal

Engine Manufacturers Association

333 West Wacker Drive, Suite 810
Chicago, IL USA 60606
E-mail: ema@emamail.org
(312) 929-1970
Facsimile (312) 929-1975

i03989612

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. Consult the nearest Cat dealer for
additional information.
194 KEBU7583-01
Index Section

Index
A Cooling System Coolant Sample (Level 2) -
Obtain .......................................................... 135
Access Doors and Covers............................. 101
Cooling System Pressure Cap - Clean/
Additional Messages ....................................... 13
Replace ....................................................... 139
Data Privacy (2) ........................................... 15
Cooling System Water Temperature
Wait to Disconnect Lamp (1) ....................... 14
Regulator - Replace..................................... 140
Application Guidelines (For the Spray
Crushing Prevention and Cutting Prevention.. 18
Systems)........................................................ 33
Application Rate of Emulsion....................... 36
Application Rate of Water ............................ 34 D
ARD Spark Plug - Clean................................ 129 Daily Inspection ............................................... 43
Auxiliary Hydraulic System Charge Filter - Declaration of Conformity................................ 41
Replace ....................................................... 128 Decommissioning and Disposal.................... 193
DEF Filler Screen - Clean ............................. 141
B DEF Manifold Filters - Replace ..................... 141
Diesel Exhaust Fluid - Fill.............................. 143
Backup Alarm .................................................. 70
Diesel Exhaust Fluid Filter - Replace ............ 144
Backup Alarm - Test ...................................... 130
Diesel Exhaust Fluid Injector - Replace ........ 145
Battery - Clean............................................... 130
Diesel Particulate Filter - Clean..................... 146
Battery - Recycle ........................................... 131
Diesel Particulate Filter Regeneration ............ 62
Battery Disconnect Switch ........................ 66, 68
Modes of Regeneration ............................... 63
Battery or Battery Cable - Inspect/Replace... 131
Regeneration ............................................... 62
Before Operation ....................................... 25, 43
Regeneration Indicators .............................. 62
Before Starting Engine .................................... 24
Regeneration Switch ................................... 63
Belts - Inspect/Adjust/Replace ...................... 131
Regeneration System Warning Indicators... 63
Inspect Belts .............................................. 131
Regeneration Triggers................................. 63
Bolster Oscillation Pin (Rear) - Lubricate ...... 131
Braking System - Test ................................... 132
Burn Prevention............................................... 18 E
Batteries....................................................... 19 Electrical Storm Injury Prevention ................... 23
Coolant ........................................................ 18 Emissions Certification Film ............................ 41
Oils............................................................... 19 Emissions Warranty Information ................... 191
Emulsion Pump - Lubricate ........................... 146
C Emulsion Spray Nozzles - Clean................... 146
Emulsion Spray System .................................. 71
Cab Air Filter - Clean/Replace ...................... 132
Emulsion System Nozzles ........................... 71
External Cab Filter ..................................... 133
Emulsion System Pump .............................. 71
Internal Cab Filter ...................................... 132
Emulsion Spray System - Clean ................... 147
Camera - Clean/Adjust (WAVS (If
Clean the Emulsion Spray System ............ 147
Equipped)) ................................................... 133
Flush the Pump.......................................... 148
Camera (If Equipped) ...................................... 70
Emulsion Spray System Strainer - Clean...... 148
Capacities (Refill) ...................................118–119
Engine Air Filter Primary Element - Clean/
Circuit Breakers - Reset ................................ 134
Replace ....................................................... 148
Cooling System Coolant (ELC) - Change ..... 136
Cleaning Primary Air Filter Elements ........ 149
Cooling System Coolant Extender (ELC) -
Inspecting the Primary Air Filter
Add .............................................................. 138
Elements .................................................. 150
Cooling System Coolant Level - Check......... 139
Remove the Primary Element.................... 148
Cooling System Coolant Sample (Level 1) -
Engine Air Filter Secondary Element -
Obtain .......................................................... 134
Replace ....................................................... 151
KEBU7583-01
Engine Air Precleaner - Clean....................... 152
Engine and Machine Warm-Up ....................... 82
Engine Crankcase Breather Tube - Inspect/
Clean ........................................................... 152
Engine Mounts - Inspect................................ 152
Engine Oil and Filter - Change ...................... 153
Engine Oil Level - Check............................... 152
Engine Oil Sample - Obtain........................... 153
Obtain the Sample and the Analysis ......... 153
Engine Starting.......................................... 24, 81
Engine Starting (Alternate Methods)............... 99
Engine Starting with Jump Start Cables ......... 99
Use of Jump Start Cables............................ 99
Engine Stopping ........................................ 27–28
Engine Valve Lash - Check ........................... 155
Engine Valve Rotators - Inspect .................... 155
Engine Water Pump - Inspect ....................... 156
Equipment Lowering with Engine Stopped .... 29,
91
F Hydraulic System Oil Filter - Replace ........... 163
Film (Product Identification) - Clean.............. 156
Cleaning of the Films ................................. 156
Fire Extinguisher Location............................... 22
Fire Prevention and Explosion Prevention...... 19
Battery and Battery Cables.......................... 20
Ether ............................................................ 22
Fire Extinguisher.......................................... 22
General ........................................................ 19
Lines, Tubes, and Hoses ............................. 21
Wiring........................................................... 21
Foreword ........................................................... 5
California Proposition 65 Warning ................. 5
Cat Product Identification Number ................ 6
Certified Engine Maintenance ....................... 5
Literature Information .................................... 5
Machine Capacity .......................................... 6
Maintenance .................................................. 5
Operation ....................................................... 5
Safety............................................................. 5
Fuel System - Prime ...................................... 157
Fuel System Primary Filter - Clean/Inspect/
Replace ....................................................... 157
Replace the Secondary Fuel Filters .......... 158
Fuel System Secondary Filter - Replace ...... 158
Fuel Tank Cap Filter - Replace...................... 159
Fuel Tank Strainer - Clean............................. 159
Fuel Tank Water and Sediment - Drain ......... 160
Fuses - Replace ............................................ 160
195
Index Section
G
General Hazard Information............................ 15
Containing Fluid Spillage............................. 17
Dispose of Waste Properly .......................... 18
Fluid Penetration ......................................... 16
Inhalation ..................................................... 17
Pressurized Air and Water........................... 16
Trapped Pressure ........................................ 16
General Information ........................................ 33
Guards............................................................. 31
Guards (Operator Protection)
Other Guards (If Equipped) ......................... 32
Rollover Protective Structure (ROPS), Falling
Object Protective Structure (FOPS) or Tip
Over Protection Structure (TOPS)............. 32
H
High Pressure Fuel Lines ................................ 23
Hydraulic System Oil - Change ..................... 162
Hydraulic System Oil Level - Check.............. 164
Hydraulic System Oil Sample - Obtain.......... 165
Hydraulic System Return Filter - Replace..... 165
Hydraulic Tank Breather - Replace ............... 165
Hydraulic Tank Screen - Clean...................... 166
I
Identification Information ................................. 38
Important Safety Information............................. 2
L
Leaving the Machine ....................................... 92
Lifting and Tying Down the Machine ............... 94
Lifting the Machine....................................... 95
Tying Down the Machine ............................. 96
Lubricant Viscosities (Fluids
Recommendations) ..............................105, 112
Biodiesel ............................................. 111, 117
Coolant Information ............................ 111, 117
Diesel Exhaust Fluid .................................. 109
Diesel Fuel Recommendations ..........108, 116
Engine Oil ...........................................105, 113
Fuel Additives ..................................... 111, 117
General Information for Lubricants.....105, 112
Hydraulic Systems..............................106, 114
Selecting the Viscosity........................105, 112
Soil Stabilizers ....................................107, 115
Special Lubricants ..............................107, 116
Standard Factory Fill Fluids................112, 118
196
Index Section
Lubricant Viscosities and Refill Capacities ... 105
M Mixing Chamber Linkage - Lubricate ............ 167
Machine Cleanup ............................................ 93
Machine Cleanup Procedure........................... 93
Machine Operation .......................................... 45
Machine Service.............................................. 83
Maintenance Access ..................................... 101
Maintenance Interval Schedule............. 122, 125
Every 10 000 Service Hours ...................... 124
Every 10 Service Hours or Daily........ 122, 125
Every 1000 Service Hours or 1 Year ........ 123,
126
Every 12 000 Service Hours or 6 Years.... 124,
127
Every 2000 Service Hours................. 124, 127
Every 2000 Service Hours or 1 Year ........ 124,
127
Every 250 Service Hours ................... 123, 126
Every 250 Service Hours or 3 Months...... 123,
126
Every 2500 Service Hours................. 124, 127
Every 3 Years..................................... 124, 127
Every 3000 Service Hours or 2 Years ...... 124,
127
Every 50 Service Hours ..................... 122, 125
Every 50 Service Hours or Weekly.... 122, 125
Every 500 Service Hours ................... 123, 126
Every 500 Service Hours or 6 Months...... 123,
126
Every 5000 Service Hours................. 124, 127
Every 6000 Service Hours or 3 Years ...... 124,
127
Every Year ......................................... 124, 127
Initial 20 Service Hours...................... 122, 125
Initial 250 Service Hours.................... 123, 126
Initial 500 Hours (for New Systems, Refilled
Systems, and Converted Systems) ........ 123,
126
When Required.................................. 122, 125
Maintenance Section..................................... 101
Maintenance Support .................................... 121
Mirror ............................................................... 46
Mirror Adjustment ........................................ 47
Mixing Chamber Disc Hub - Lubricate .......... 166
Mixing Chamber Door Cylinder Ends
(Front) - Lubricate........................................ 166
Mixing Chamber Door Cylinder Ends
(Rear) - Lubricate ........................................ 166
Mixing Chamber Door Hinges (Front) -
Lubricate...................................................... 167
KEBU7583-01
Mixing Chamber Door Hinges (Rear) -
Lubricate...................................................... 167
Mixing Chamber Tilt Cylinder Ends -
Lubricate...................................................... 168
Monitoring System........................................... 49
Available Features ....................................... 53
Incremental Bars ......................................... 51
Menu Buttons and Menu Button Groups ..... 50
Navigation Path ........................................... 52
Performance Pages..................................... 49
Pop-Up Messages ....................................... 52
Scroll Bar ..................................................... 50
Top Level Navigation ................................... 49
Upper Information Banner ........................... 51
Mounting and Dismounting ............................. 43
Alternate Exit ............................................... 43
Machine Access System Specifications...... 43
O
Oil Filter - Inspect .......................................... 168
Inspect a Used Filter for Debris ................. 168
Operation................................................... 26–27
Operation Information ..................................... 72
Automatic Operation.................................... 78
Operation of Rotor ....................................... 76
Operator's Seat Adjustment ........................ 75
Preparation for Operation ............................ 72
Starting Operation ....................................... 76
Travel with the Rotor Locked ....................... 75
Operation Section............................................ 43
Operator Controls............................................ 54
12V Power Receptacle (34)......................... 61
Action Lamp (5A) ......................................... 58
Auxiliary Shutdown Knob (6) ....................... 58
Camera Control (1) ...................................... 57
Chamber Service Mode / Chamber Float
(28)............................................................. 60
Chamber Tilt (29) ......................................... 60
Cruise Control Speed Decrease (19) .......... 59
Cruise Control Speed Increase (18)............ 59
Engine Start Switch (10).............................. 58
Fan Speed Control (40) ............................... 62
Front Rotor Door Lower (27) ....................... 60
Front Rotor Door Raise (26) ........................ 60
Front Window Wiper Switch (41) ................. 62
Hazard Lights (36) ....................................... 61
Heater and Air Conditioner Control (39)...... 62
Horn (8)........................................................ 58
Lights (35) .................................................... 61
KEBU7583-01
Monitoring System (3) ................................. 57
Operator Station Slide Left (24)................... 60
Operator Station Slide Right (32) ................ 61
Parking Brake (7)......................................... 58
Propel Control (4) ........................................ 57
Rear Rotor Door Lower (16) ........................ 59
Rear Rotor Door Raise (15)......................... 59
Rear Steer Left (25) ..................................... 60
Rear Steer Right (33)................................... 61
Rear Window Wiper Switch (42).................. 62
Regeneration Switch (37) ............................ 61
Rotor Automatic Depth Setpoint (14) .......... 59
Rotor Control (31) ........................................ 61
Rotor Lower (12).......................................... 59
Rotor Raise (11)........................................... 59
Rotor Speed (30) ......................................... 60
Rotor Travel Mode (13)................................ 59
Spray System Control (23) .......................... 60
Steering Mode Select (22)........................... 59
Steering Wheel (2)....................................... 57
Temperature Control (38) ............................ 62
Throttle Control (21)..................................... 59
Travel Mode (20).......................................... 59
Turn Signals (5) ........................................... 58
Operator Interlocks.......................................... 68
Engine Start Interlock .................................. 68
Propel Interlocks .......................................... 69
Rotor Interlocks............................................ 70
Operator Station .............................................. 31
P Rotor Drive Planetary Oil Sample - Obtain ... 180
Parking ...................................................... 28, 88
Parking Brake - Check .................................. 168
Plate Locations and Film Locations ................ 38
Certification.................................................. 39
Eurasian Economic Union ........................... 39
Product Information Section............................ 33
Product Link .................................................... 54
Data Broadcasts .......................................... 54
Operation in a Blast Site for Product Link
Radios ........................................................ 54
Propel Planetary Oil - Change ...................... 169
Propel Planetary Oil - Check ......................... 169
Propel Planetary Oil Sample - Obtain ........... 170
Push Bar.......................................................... 72
Attaching to a Water Truck .......................... 72
Storage ........................................................ 72
R Safety Messages............................................... 7
Radiator and Hydraulic Oil Cooler - Clean .... 170
197
Index Section
Reference Information Section ..................... 192
Reference Material ........................................ 192
Additional Reference Material ................... 192
Reference Materials ...................................... 192
Refrigerant Dryer - Replace (If Equipped) .... 171
Restricted Visibility .......................................... 25
Roading the Machine ...................................... 94
Rollover Protective Structure (ROPS) -
Inspect ......................................................... 172
Rotor Bearing Reservoir Breather -
Replace ....................................................... 172
Rotor Bearing Reservoir Oil - Change .......... 172
Rotor Bearing Reservoir Oil Level - Check ... 173
Rotor Bearing Reservoir Oil Sample -
Obtain .......................................................... 173
Rotor Brake - Adjust ...................................... 173
Rotor Chain Drive Case Oil - Change ........... 175
Rotor Chain Drive Case Oil Level - Check.... 175
Rotor Cutter Bits - Inspect/Replace............... 177
Check and Inspect the Rotor Bits .............. 177
Removing a Rotor Bit................................. 177
Replacing a Rotor Bit................................. 177
Rotor Cutter Bits (Side) - Inspect/Replace.... 176
Rotor Drive Differential Breather - Replace .. 178
Rotor Drive Differential Oil - Change............. 178
Rotor Drive Differential Oil Level - Check ..... 179
Rotor Drive Differential Oil Sample -
Obtain .......................................................... 179
Rotor Drive Planetary Oil - Change............... 179
Rotor Drive Planetary Oil - Check ................. 180
Rotor Lift Cylinder Ends - Lubricate .............. 180
Rotor Service Locks ........................................ 83
Rotor Service Lock ...................................... 83
Rotor Service Switch ................................... 83
Rotor Shear Disc - Lubricate (If Equipped) ... 180
Rotor Shear Disc Bolts - Inspect/Replace
(If Equipped) ................................................ 181
Rotor Torque Limiter Coupling - Inspect (If
Equipped) .................................................... 181
Rotor Transmission Breather - Replace........ 182
Rotor Transmission Oil - Change .................. 182
Rotor Transmission Oil - Check .................... 183
Rotor Transmission Oil Filter - Replace ........ 183
Rotor Transmission Oil Sample - Obtain....... 183
S
S·O·S Information ......................................... 120
Crush Hazard (4) ........................................... 9
198
Index Section
Crush Hazard (Read the Operation and
Maintenance Manual (7) .............................11
Cutter Hazard and Rotor Movement Hazard,
Stay Back (5) ............................................. 10
Do Not Operate (1) ........................................ 8
Explosion Hazard (Ether) (9) ....................... 12
Flying Debris Hazard (Read the Operation
and Maintenance Manual (6) ..................... 10
Hot Fluid Under Pressure (10)..................... 12
Improper Connections for Jump Start Cables
(8)................................................................11
Product Link (3) ............................................. 9
Seat Belt (2) ................................................... 9
Safety Section ................................................... 7
Seat ................................................................. 45
Seat Belt .......................................................... 45
Extension of the Seat Belt ........................... 46
Seat Belt Adjustment for Retractable Seat
Belts ........................................................... 45
Seat Belt - Inspect ......................................... 184
Seat Belt - Replace ....................................... 184
Selective Catalytic Reduction Warning
System........................................................... 64
Definitions .................................................... 64
Inducement Strategy for DEF Level ............ 65
Inducement Strategy for DEF Quality,
Tampering, SCR System Fault, and Impeded
EGR ........................................................... 66
Servicing the Rotor.......................................... 84
Shipping the Machine...................................... 94
Loading the Machine ................................... 94
Slope Operation .............................................. 28
Sound Information and Vibration
Information..................................................... 29
Sound Level Information for Machines in
European Union Countries and in Countries
that Adopt the “EU Directives” ................... 29
Sources........................................................ 31
“The European Union Physical Agents
(Vibration) Directive 2002/44/EC”.............. 29
Specifications .................................................. 33
Intended Use ............................................... 33
Steering Cylinder Ends - Lubricate ............... 185
Front Steering Cylinder Ends .................... 185
Rear Steering Cylinder Ends ..................... 185
Steering Knuckle - Lubricate ......................... 185
Steering Linkage - Lubricate ......................... 186
Front Steering Linkage .............................. 186
Rear Steering Linkage............................... 186
Stopping the Engine .................................. 88–89
Auxiliary Shutdown Knob....................... 88–89
KEBU7583-01
Delayed Engine Shutdown (If Enabled) ...... 90
Secondary Auxiliary Shutdown Knob .... 89–90
Stopping the Engine from the Operator
Station.................................................. 88–89
Stopping the Engine if an Electrical
Malfunction Occurs........................................ 91
Stopping the Machine...................................... 88
System Pressure Release............................. 121
Coolant System ......................................... 121
Hydraulic System....................................... 121
T
Table of Contents .............................................. 3
Tire Inflation - Check ..................................... 186
Tire Inflation Information................................ 103
Tire Inflation Pressure Adjustment ................ 103
Tire Operating Pressures .......................... 103
Tire Inflation with Air ...................................... 103
Tire Inflation with Nitrogen............................. 103
Tire Information ............................................... 22
Tool Holder - Inspect/Replace ....................... 186
Check and Inspect the Tool Holders.......... 186
Installation of the Tool Holder .................... 188
Replacing a Damaged Tool Holder............ 187
Towing Information .......................................... 98
Towing the Machine......................................... 98
Engine that is Running................................. 98
Transportation Information .............................. 94
V
Visibility Information ........................................ 25
W
Warranty Information..................................... 191
Warranty Section ........................................... 191
Water Spray System Nozzles - Clean (If
Equipped) .................................................... 189
Water Spray System Pump Oil - Change (If
Equipped) .................................................... 189
Water Spray System Pump Oil Level -
Check (If Equipped)..................................... 190
Water Spray System Strainer - Clean ........... 190
Welding on Machines and Engines with
Electronic Controls ...................................... 121
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:
KEBU7583 CAT, CATERPILLAR, their respective logos, “Caterpillar Yellow”, and the POWER EDGE trade
©2017 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.

200 September 2017