KEBU7577-07

April 2015

Operation and
Maintenance
Manual
CP56B, CP68B, CP74B, CS56B, CS68B,
CS74B, CS78B and CS79B Vibratory
Soil Compactors
438 1-Up (CP56B)
M5P 1-Up (CP56B)
684 1-Up (CP68B)
SDT 1-Up (CP68B)
744 1-Up (CP74B)
M7B 1-Up (CP74B)
437 1-Up (CS56B)
M4M 1-Up (CS56B)
439 1-Up (CS68B)
MBF 1-Up (CS68B)
441 1-Up (CS74B)
E7E 1-Up (CS74B)
443 1-Up (CS78B)
M8M 1-Up (CS78B)
C79 1-Up (CS79B)

SAFETY.CAT.COM
 i05296198

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.
KEBU7577 3
Table of Contents

Table of Contents Identification Information ................ ................ 30

Foreword.............................. ............................. 4 Operation Section

Safety Section Before Operation ...................... ...................... 34

Machine Operation ..................... .................... 36

Safety Messages....................... ....................... 6
Engine Starting ........................ ....................... 81
Additional Messages ................... ....................11

General Hazard Information .............. ............. 12 Parking ............................. .............................. 83

Crushing Prevention and Cutting Prevention . 15 Transportation Information............... ............... 85

Burn Prevention....................... ....................... 15 Towing Information .................... ..................... 89

Fire Prevention and Explosion Prevention ... .. 16 Engine Starting (Alternate Methods) ....... ....... 94

Fire Safety ........................... ........................... 19 Maintenance Section

Fire Extinguisher Location ............... ............... 19 Maintenance Access ................... ................... 97

Tire Information........................ ....................... 20 Tire Inflation Information................. ................ 98

Electrical Storm Injury Prevention ......... ......... 21 Lubricant Viscosities and Refill Capacities... .. 99

Before Starting Engine ................. .................. 21 Maintenance Support .................. ................. 107

Engine Starting ........................ ....................... 21 Maintenance Interval Schedule .......... .......... 109

Before Operation ...................... ...................... 21 Warranty Section

Visibility Information.................... .................... 21 Warranty Information .................. .................. 159

Operation............................ ............................ 22 Reference Information Section

Engine Stopping ....................... ...................... 22 Reference Materials .................. ................... 160

Parking ............................. .............................. 23 Index Section

Slope Operation....................... ....................... 23 Index............................... .............................. 161

Equipment Lowering with Engine Stopped... .. 24

Sound Information and Vibration Information. 24

Operator Station ....................... ...................... 26

Guards (Operator Protection) ............. ............ 26

Product Information Section

General Information.................... .................... 28

4 KEBU7577
Foreword
Foreword
Literature Information
This manual should be stored in the operator's
compartment in the literature holder or seat back
literature storage area.
This manual contains safety information, operation
instructions, transportation information, lubrication
information and maintenance information.
Some photographs or illustrations in this publication
show details or attachments that can be different from
your machine. Guards and covers might have been
removed for illustrative purposes.
Continuing improvement and advancement of
product design might have caused changes to your
machine which are not included in this publication.
Read, study and keep this manual with the machine.
Whenever a question arises regarding your machine,
or this publication, please consult your 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.
Maintenance
The maintenance section is a guide to equipment
care. The Maintenance Interval Schedule (MIS) lists
the items to be maintained at a specific service
interval. Items without specific intervals are listed
under the "When Required" service interval. The
Maintenance Interval Schedule lists the page number
for the step-by-step instructions required to
accomplish the scheduled maintenance. Use the
Maintenance Interval Schedule as an index or "one
safe source" for all maintenance procedures.
Maintenance Intervals
Use the service hour meter to determine servicing
intervals. Calendar intervals shown (daily, weekly,
monthly, etc.) can be used instead of service hour
meter intervals if they provide more convenient
servicing schedules and approximate the indicated
service hour meter reading. Recommended service
should always be performed at the interval that
occurs first.
Under extremely severe, dusty or wet operating
conditions, more frequent lubrication than is specified
in the maintenance intervals chart might be
necessary.
Perform service on items at multiples of the original
requirement. For example, at every 500 service hours
or 3 months, also service those items listed under
every 250 service hours or monthly and every 10
service hours or daily.
California Proposition 65 Warning
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer,
birth defects, and other reproductive harm.
Battery posts, terminals and related accessories
contain lead and lead compounds. Wash hands after
handling.
Certified Engine Maintenance
Proper maintenance and repair is essential to keep
the engine and machine systems operating correctly.
As the heavy duty off-road diesel engine owner, you
are responsible for the performance of the required
maintenance listed in the Owner Manual, Operation
and Maintenance Manual, and Service Manual.
It is prohibited for any person engaged in the
business of repairing, servicing, selling, leasing, or
trading engines or machines to remove, alter, or
render inoperative any emission related device or
element of design installed on or in an engine or
machine that is in compliance with the regulations (40
CFR Part 89). Certain elements of the machine and
engine such as the exhaust system, fuel system,
electrical system, intake air system and cooling
system may be emission related and should not be
altered unless approved by Caterpillar.
Machine Capacity
Additional attachments or modifications may exceed
machine design capacity which can adversely affect
performance characteristics. Included would be
stability and system certifications such as brakes,
steering, and rollover protective structures (ROPS).
Contact your Cat dealer for further information.
KEBU7577 5
Foreword

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.
Machines and generator sets produced before First
Quarter 2001 will maintain their 8 character PIN
format.
Components such as engines, transmissions, axles,
etc. and work tools will continue to use an 8 character
Serial Number (S/N).
6 KEBU7577
Safety Section
Safety Messages

Safety Section

i04748493

Safety Messages
SMCS Code: 1000; 6700; 7000; 7405

Illustration 2 g02845368
KEBU7577 7
Safety Section
Safety Messages

Illustration 3 g02845377
8 KEBU7577
Safety Section
Safety Messages

There are several specific safety messages on your

machine. The exact location of the safety messages
and the description of the hazard are reviewed in this
section. Please take the time in order to become
familiar with the safety messages.
Make sure that all of the safety messages are legible.
Clean the safety messages or replace the safety
messages if you cannot read the words. Replace the
illustrations if the illustrations are not legible. When
you clean the safety messages, use a cloth, water,
and soap. Do not use solvent, gasoline, or other
harsh chemicals to clean the safety messages.
Solvents, gasoline, or harsh chemicals could loosen
the adhesive that secures the safety messages.
Loose adhesive will allow the safety message to fall.
Illustration 5 g01370908
Replace any safety messages that are 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. A seat belt should be worn at all times during ma-
chine operation to prevent serious injury or death
Do Not Operate (1) in the event of an accident or machine overturn.
Failure to wear a seat belt during machine opera-
This message is located on the operator console. tion may result in serious injury or death.

Product Link (3)

This message is located under the front of the canopy
for an open platform with two posts, on the left rear
post for an open platform with four posts and on the
right rear cab post for a closed platform.

Illustration 4 g01370904

Do not operate or work on this machine unless

you have read and understand the instructions
and warnings in the Operation and Maintenance
Manuals. Failure to follow the instructions or heed Illustration 6 g01370917
the warnings could result in injury or death. Con-
tact your Cat dealer for replacement manuals.
Proper care is your responsibility.

Seat Belt (2)

This message is located under the front of the canopy
for an open platform with two posts, on the left rear
post for an open platform with four posts and on the
right rear cab post for a closed platform. When a
machine is not equipped with a ROPS/FOPS guard,
the message is located on the base of the operator
seat.
KEBU7577 9
Safety Section
Safety Messages

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 Illustration 8 g01370909
that the device be disabled no less than 12 m
(40 ft) from the blast perimeter.

Do Not Weld or Drill (4)
If Equipped, this safety message is located on the
post for the ROPS (Rollover Protective Structure).
Explosion Hazard! Improper jumper cable con-
nections can cause an explosion resulting in seri-
ous injury or death. Batteries may be located in
separate compartments. Refer to the Operation
and Maintenance Manual for the correct jump
starting procedure.

Crushing Hazard (6)

This message is located on each side of the
articulation hitch.

Illustration 7 g01212098

Structural damage, an overturn, modification, al-

teration, or improper repair can impair this struc-
ture's protection capability thereby voiding this
certification. Do not weld on or drill holes in the Illustration 9 g01371644
structure. This will void the certification. Consult
your Cat dealer to determine this structure's limi-
tations without voiding its certification.
Stay back a safe distance. No clearance for a per-
Jumper Cables (5) son in this area when the machine turns. Severe
injury or death from crushing could occur.
This message is located behind the steps near the
auxiliary start receptacle and at the rear of the engine
compartment. Crushing Hazard (7)
This message is located on each side of the
articulation hitch.
10 KEBU7577
Safety Section
Safety Messages

No Ether (9)
This message is located on the end of the air cleaner.

Illustration 10 g01371647

Connect the steering frame lock between the front
and the rear frames before lifting, transporting, or
servicing the machine in the articulation area. Dis-
connect the steering frame lock and secure the
steering frame lock before resuming operation.
Severe injury or death could occur.
Hot Fluids (8)
Illustration 12 g01372254
Do not use ether. This machine is equipped with
glow plugs. Using ether can create explosions or
fires that can cause personal injury or death.
Read and follow the engine starting procedure in
the Operation and Maintenance Manual.

This message is located on the side of the radiator.

Illustration 11 g01371640

Pressurized system! Hot coolant can cause seri-

ous burns, injury or death. To open the cooling
system filler cap, stop the engine and wait until
the cooling system components are cool. Loosen
the cooling system pressure cap slowly in order
to relieve the pressure. Read and understand the
Operation and Maintenance Manual before per-
forming any cooling system maintenance.
KEBU7577 11
Safety Section
Additional Messages

i04876452

Additional Messages
SMCS Code: 1000; 6700; 7000; 7405

Illustration 14 g01418953

The Product Link System is a satellite communication

device that transmits information regarding the
machine back to Caterpillar and Cat 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.
Refer to Operation and Maintenance Manual,
Illustration 13 g03001398
“Product Link” for more information.

Make sure that all of the messages are legible. Clean Support Point (2)
the messages or replace the messages if you cannot
read the words. Replace the illustrations if the This message is located on both sides of the
illustrations are not legible. When you clean the machine.
messages, use a cloth, water, and soap. Do not use
solvent, gasoline, or other harsh chemicals to clean
the messages. Solvents, gasoline, or harsh
chemicals could loosen the adhesive that secures the
message. Loose adhesive will allow the message to
fall.
Replace any message that is damaged, or missing. If
a message is attached to a part that is replaced,
install a message on the replacement part. Any Cat
dealer can provide new messages.

Data Privacy (1)

This message is located under the front of the canopy
for an open platform with two posts, on the left rear
post for an open platform with four posts and on the Illustration 15 g01866913
right rear cab post for a closed platform.
This location is recommended for supporting the
machine or jacking up the machine.
12
Safety Section
General Hazard Information
i05218279
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. These
warning tags (Special Instruction, SEHS7332) are
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.
KEBU7577
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.
KEBU7577 13
Safety Section
General Hazard Information

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.
Illustration 18 g00687600
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 Always use a board or cardboard when you check for
effective chip deflector and personal protective a leak. Leaking fluid that is under pressure can
equipment. The maximum water pressure for penetrate body tissue. Fluid penetration can cause
cleaning purposes must be below 275 kPa (40 psi). serious injury and possible death. A pin hole leak can
cause severe injury. If fluid is injected into your skin,
Avoid direct spraying of water on electrical you must get treatment immediately. Seek treatment
connectors, connections, and components. When from a doctor that is familiar with this type of injury.
using air for cleaning, allow the machine to cool to
reduce the possibility of fine debris igniting when re- Containing Fluid Spillage
deposited on hot surfaces.
Care must be taken in order to ensure that fluids are
Trapped Pressure contained during performance of inspection,
maintenance, testing, adjusting, and repair of the
Pressure can be trapped in a hydraulic system. equipment. Prepare to collect the fluid with suitable
Releasing trapped pressure can cause sudden containers before opening any compartment or
machine movement or attachment movement. Use disassembling any component that contains fluids.
caution if you disconnect hydraulic lines or fittings.
High-pressure oil that is released can cause a hose to Refer to Special Publication, NENG2500, “Cat dealer
whip. High-pressure oil that is released can cause oil Service Tool Catalog” for the following items:
to spray. Fluid penetration can cause serious injury
and possible death. • Tools that are suitable for collecting fluids and
equipment that is suitable for collecting fluids
Fluid Penetration • Tools that are suitable for containing fluids and
Pressure can be trapped in the hydraulic circuit long equipment that is suitable for containing fluids
after the engine has been stopped. The pressure can
cause hydraulic fluid or items such as pipe plugs to Obey all local regulations for the disposal of liquids.
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.
14 KEBU7577
Safety Section
General Hazard Information

Inhalation • Never use compressed air for cleaning.

• Avoid brushing materials that contain asbestos.

• Avoid grinding materials that contain asbestos.

• Use a wet method in order to clean up asbestos
materials.

• A vacuum cleaner that is equipped with a high

efficiency particulate air filter (HEPA) can also be
used.
• Use exhaust ventilation on permanent machining
jobs.

• Wear an approved respirator if there is no other

way to control the dust.
Illustration 19 g02159053
• Comply with applicable rules and regulations for
Exhaust the work place. In the United States, use
Occupational Safety and Health Administration
Use caution. Exhaust fumes can be hazardous to (OSHA) requirements. These OSHA requirements
your health. If you operate the machine in an can be found in “29 CFR 1910.1001”. In Japan,
enclosed area, adequate ventilation is necessary. use the requirements found in the “Ordinance on
Prevention of Health Impairment due to Asbestos”
Asbestos Information in addition to the requirements of the Industrial
Safety and Health Act.
Cat equipment and replacement parts that are
shipped from Caterpillar are asbestos free. Caterpillar • Obey environmental regulations for the disposal of
recommends the use of only genuine Cat asbestos.
replacement parts. Use the following guidelines when
you handle any replacement parts that contain • Stay away from areas that might have asbestos
asbestos or when you handle asbestos debris. particles in the air.
Use caution. Avoid inhaling dust that might be Dispose of Waste Properly
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:

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.
KEBU7577
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.
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.
15
Safety Section
Crushing Prevention and Cutting Prevention
Coolant
When the engine is at operating temperature, the
engine coolant is hot. The coolant is also under
pressure. The radiator and all lines to the heaters or
to the engine contain hot coolant.
Any contact with hot coolant or with steam can cause
severe burns. Allow cooling system components to
cool before the cooling system is drained.
Check the coolant level only after the engine has
been stopped.
Ensure that the filler cap is cool before removing the
filler cap. The filler cap must be cool enough to touch
with a bare hand. Remove the filler cap slowly in
order to relieve pressure.
Cooling system conditioner contains alkali. Alkali can
cause personal injury. Do not allow alkali to contact
the skin, the eyes, or the mouth.
Oils
Hot oil and hot components can cause personal
injury. Do not allow hot oil to contact the skin. Also, do
not allow hot components to contact the skin.
Remove the hydraulic tank filler cap only after the
engine has been stopped. The filler cap must be cool
enough to touch with a bare hand. Follow the
standard procedure in this manual in order to remove
the hydraulic tank filler cap.
Batteries
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.
Always wear protective glasses when you work with
batteries. Wash hands after touching batteries. The
use of gloves is recommended.
16 KEBU7577
Safety Section
Fire Prevention and Explosion Prevention

i05948437 Keep shields in place. Exhaust shields (if equipped)

protect hot exhaust components from oil spray or fuel
Fire Prevention and Explosion spray in case of a break in a line, in a hose, or in a
seal. Exhaust shields must be installed correctly.
Prevention
Do not weld or flame cut on tanks or lines that contain
SMCS Code: 7000 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.
Illustration 21 g00704000
Store fuels and lubricants in properly marked
containers away from unauthorized personnel. Store
General oily rags and flammable materials in protective
containers. Do not smoke in areas that are used for
All fuels, most lubricants, and some coolant mixtures storing flammable materials.
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.
Illustration 22 g00704059
Keep the access doors to major machine
compartments closed and access doors in working
condition in order to permit the use of fire suppression Use caution when you are fueling a machine. Do not
equipment, in case a fire should occur. smoke while you are fueling a machine. Do not fuel a
machine near open flames or sparks. Always stop the
Clean all accumulations of flammable materials such engine before fueling. Fill the fuel tank outdoors.
as fuel, oil, and debris from the machine. Properly clean areas of spillage.
Do not operate the machine near any flame.
KEBU7577
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 g02298225
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.
Never check the battery charge by placing a metal
object across the terminal posts. Use a voltmeter in
order to check the battery charge.
17
Safety Section
Fire Prevention and Explosion Prevention
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 con-
tact 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.
18
Safety Section
Fire Prevention and Explosion Prevention
• Fraying
• Signs of abrasion or wear
• Cracking
• Discoloration
• Cuts on insulation
• Other damage
Make sure that all clamps, guards, clips, and straps
are reinstalled correctly. This will help to prevent
vibration, rubbing against other parts, and excessive
heat during machine operation.
Attaching electrical wiring to hoses and tubes that
contain flammable fluids or combustible fluids should
be avoided.
Consult your 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:
KEBU7577
• End fittings are damaged or leaking.
• Outer coverings are chafed or cut.
• Wires are exposed.
• Outer coverings are swelling or ballooning.
• Flexible parts of the hoses are kinked.
• Outer covers have exposed embedded armoring.
• End fittings are displaced.
Make sure that all clamps, guards, and heat shields
are installed correctly. During machine operation, this
will help to prevent vibration, rubbing against other
parts, excessive heat, and failure of lines, tubes, and
hoses.
Do not operate a machine when a fire hazard exists.
Repair any lines that are corroded, loose, or
damaged. Leaks may provide fuel for fires. Consult
your 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.
Consider installation of an aftermarket Fire
Suppression System, if the application and working
conditions warrant the installation.
KEBU7577 19
Safety Section
Fire Safety

i04025591 If the fire grows out of control, be aware of the

following risks:
Fire Safety • Tires on wheeled machines pose a risk of
SMCS Code: 7000 explosion as tires burn. Hot shrapnel and debris
can be thrown great distances in an explosion.
Note: Locate secondary exits and how to use the
secondary exits before you operate the machine. • Tanks, accumulators, hoses, and fittings can
rupture in a fire, spraying fuels and shrapnel over a
Note: Locate fire extinguishers and how to use a fire large area.
extinguisher before you operate the machine.
• Remember that nearly all of the fluids on the
If you find that you are involved in a machine fire, your machine are flammable, including coolant and oils.
safety and that of others on site is the top priority. The Additionally, plastics, rubbers, fabrics, and resins
following actions should only be performed if the in fiberglass panels are also flammable.
actions do not present a danger or risk to you and any
nearby people. At all times you should assess the risk
of personal injury and move away to a safe distance i04562000
as soon as you feel unsafe.
Move the machine away from nearby combustible
Fire Extinguisher Location
material such as fuel/oil stations, structures, trash, SMCS Code: 7000; 7419
mulch and timber.
Lower any implements and turn off the engine as
soon as possible. If you leave the engine running, the
engine will continue to feed a fire. The fire will be fed
from any damaged hoses that are attached to the
engine or pumps.
If possible, turn the battery disconnect switch to the
OFF position. Disconnecting the battery will remove
the ignition source in the event of an electrical short.
Disconnecting the battery will eliminate a second
ignition source if electrical wiring is damaged by the
fire, resulting in a short circuit.
Notify emergency personnel of the fire and your
location.
If your machine is equipped with a fire suppression Illustration 25 g02727662
system, follow the manufacturers procedure for
activating the system. There are two mounting bases located on the pillar for
the cab. Use these mounting bases in order to mount
Note: Fire suppression systems need to be regularly the fire extinguisher.
inspected by qualified personnel. You must be trained
to operate the fire suppression system.
Use the on-board fire extinguisher and use the
following procedure:

1. Pull the pin.

2. Aim the extinguisher or nozzle at the base of the

fire.
3. Squeeze the handle and release the extinguishing
agent.

4. Sweep the extinguisher from side to side across

the base of the fire until the fire is out.
Remember, if you are unable to do anything else,
shut off the machine before exiting. By shutting off the
machine, fuels will not continue to be pumped into the
fire.
20
Safety Section
Tire Information
Illustration 26 g02218893
The fire extinguisher should be mounted on the rear
leg for the canopy. Do not weld the ROPS in order to
install the fire extinguisher. Also, do not drill holes in
the ROPS in order to mount the fire extinguisher on
the ROPS.
If the fire extinguisher is mounted on the ROPS, strap
the mounting plate to a leg of the ROPS. If the weight
of the fire extinguisher is more than 4.5 kg (10 lb),
mount the fire extinguisher as low as possible on one
leg. Do not mount the fire extinguisher on the upper
one-third area of the leg.
i04160129
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.
KEBU7577
Illustration 27 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.
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.
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.
KEBU7577
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.
i00820587
Before Starting Engine
SMCS Code: 1000; 7000
Make sure that the steering frame lock link is stored in
the UNLOCKED position. The steering frame lock link
must be removed in order to steer the machine. 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.
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.
21
Safety Section
Electrical Storm Injury Prevention
i02676850
Engine Starting
SMCS Code: 1000; 7000
Illustration 28 g00104545
Do not start the engine or move any controls if there
is a “Do Not Operate” or similar warning tag attached
to the start switch or controls.
Before you start the engine, check for the presence of
bystanders or maintenance personnel. Ensure that all
personnel are clear of the machine. Briefly sound the
forward horn before you start the engine.
Move the parking brake switch to the “ON” position.
Start the engine and operate the engine in a well
ventilated area. In an enclosed area, vent the exhaust
to the outside.
i01361940
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.
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.
22
Safety Section
Operation
While the machine is in operation, constantly survey
the area around the machine in order to identify
potential hazards as hazards become visible around
the machine.
Your machine may be equipped with visual aids.
Some examples of visual aids are Closed Circuit
Television (CCTV) and mirrors. Before operating the
machine, ensure that the visual aids are in proper
working condition and that the visual aids are clean.
Adjust the visual aids using the procedures that are
located in this Operation and Maintenance Manual. If
equipped, the Work Area Vision System shall be
adjusted according to Operation and Maintenance
Manual, SEBU8157, “Work Area Vision System”. 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.
i03629772
Operation
SMCS Code: 7000
Machine Operating Temperature Range. The
machine must function satisfactorily in the anticipated
ambient temperature limits that are encountered
during operation. The minimum limits of items that will
effect the safe operation of the machine to be
considered are 0-100% relative humidity for −24 °C
(−11 °F) to 50 °C (122 °F) temperatures.
KEBU7577
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.
Make sure that no personnel will be endangered
before you move the machine.
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.
Note any needed repairs during machine operation.
Report any needed repairs.
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.
Never straddle a wire cable. Never allow other
personnel to straddle a wire cable.
Know the maximum dimensions of your machine.
i05426630
Engine Stopping
SMCS Code: 1000; 7000
Do not stop the engine immediately after the machine
has been operated under load. This can cause
overheating and accelerated wear of engine
components.
After the machine is parked and the parking brake is
engaged, allow the engine to run for five minutes
before shutdown. Running the engine allows hot
areas of the engine to cool gradually.
KEBU7577 23
Safety Section
Parking

i04725627 Compacting with drum beyond edge of surface –

Parking
SMCS Code: 7000
Park on a level surface. If you must park on a grade,
chock the wheels.
Move the propel control lever to the NEUTRAL
position.
Lower all attachments to the ground.
Engage the parking brake.
Stop the engine.
Turn the engine start switch to the OFF position and
remove the engine start switch key.
Always turn the battery disconnect switch to the OFF
position before leaving the machine.
If the machine will not be operated for a week or
more, remove the battery disconnect switch key.
Machines with solid drums can tip suddenly as the
center of balance of the machine moves beyond the
edge of the compacted surface. Slow down and pay
close attention when operating with the drum
extended beyond the edge of the compacted surface.
Minimize the amount of the drum that extends beyond
the edge.
Over compacting – When the material is fully
compacted, and the vibratory system is activated, the
drum may bounce on the compacted surface. If the
machine is on an incline, this can cause the machine
to move down the slope with the force of gravity.
Reduce the vibratory amplitude or shut off vibration if
the drum is bouncing on the compacted surface.

i03647047

Slope Operation
SMCS Code: 7000
Machines that are operating safely in various
Illustration 29 g01956702
applications depend on these criteria: the machine
model, configuration, machine maintenance, The appropriate method for driving off a compacted
operating speed of the machine, conditions of the surface
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.
Illustration 30 g01957405
Roughness of terrain or surface – The machine The improper method for driving off a compacted
may be less stable with uneven terrain. surface
Direction of travel – Avoid operating the machine Steering angle – The steering angle affects the
across the slope. When possible, operate the lateral balance of an articulated machine. When the
machine up the slopes and operate the machine machine is driven off the compacted mat, always exit
down the slopes. In order to achieve the best by turning the machine toward the edge. Refer to
compaction performance and steering control on a illustration 29 . Do not turn away from the edge when
slope, operate a vibratory soil compactor with the the machine is driven off the compacted mat. Refer to
drum end of the machine downhill. illustration 30 .
24
Safety Section
Equipment Lowering with Engine Stopped
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. The vibratory action of a vibratory
compactor can increase the tendency of material on
the edge of an incline to collapse.
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.
Operated equipment – Be aware of performance
features of the equipment in operation and the effects
on machine stability.
Operating techniques – Keep all attachments 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: Safe operation on steep slopes may require
special machine maintenance. Excellent skill of the
operator and proper equipment for specific
applications are also required. Consult the Operation
and Maintenance Manual for the proper fluid level
requirements and intended use for the machine.
i01329161
Equipment Lowering with
Engine Stopped
SMCS Code: 7000; 7000-II
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.
KEBU7577
i05977680
Sound Information and
Vibration Information
SMCS Code: 7000
Sound Level Information
Hearing protection may be needed when the machine
is operated with an open operator station for
extended periods or in a noisy environment. Hearing
protection may be needed when the machine is
operated with a cab that is not properly maintained or
when the doors and windows are open for extended
periods or in a noisy environment.
Sound Level Information for
Machines in European Union
Countries and in Countries that
Adopt the “EU Directives”
The operator sound pressure level is 75 dB(A). The
operator sound pressure level was measured
according to the static test procedures and conditions
that are specified in “ISO 6394”.
The exterior sound power level is 108 dB(A) for the
CS56B, CP56B, CS68B, and CP68B. The exterior
sound power level is 109 dB(A) for the CS74B,
CP74B, CS78B, and CS79B. The exterior sound
power level was measured according to the static test
procedures and conditions that are specified in “ISO
6393”.
“The European Union Physical
Agents (Vibration) Directive 2002/
44/EC”
Vibration Data for Single Drum Vibratory
Compactor
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 m/s2.
Information Concerning Whole Body
Vibration Level
This section provides vibration data and a method for
estimating the vibration level for a single drum
vibratory compactor.
KEBU7577 25
Safety Section
Sound Information and Vibration Information

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

Machine Vibration Levels Scenario Factors

Typical Operating Activity
Type X axis Y axis Z axis X axis Y axis Z axis
Single Drum Vi- compaction (boulder) 0,47 0,53 0,41 0,17 0,22 0,12
bratory
Compactor compaction (silt) 0,29 0,28 0,28 0,08 0,17 0,11

Note: Refer to “ISO/TR 25398 Mechanical Vibration -
Guideline for the assessment of exposure to whole
body vibration of ride on operated earthmoving
machines” for more information about vibration.
Guidelines for Reducing Vibration Levels
on Earthmoving Equipment
Vibration levels are influenced by many different
parameters, such as: operator training, operator
behavior, operator mode and stress, job site
organization, job site preparation, job site
environment, job site weather, job site material,
machine type, quality of the seat, quality of the
suspension system, attachments and condition of the
equipment.
Properly adjust machines. Properly maintain
machines. Operate machines smoothly. Maintain the
conditions of the terrain. The following guidelines can
help reduce the whole body vibration level:
1. Use the right type and size of machine, equipment,
and attachments.
2. Maintain machines according to the manufacturers
recommendations: tire pressures and brake and
steering systems, controls, hydraulic system, and
linkages.
3. Keep the terrain in good condition by performing
the following items: remove any large rocks or
obstacles, fill any ditches and holes and provide
machines and schedule time in order to maintain
the conditions of the terrain.
4. Keep the seat maintained and adjusted by doing
the following: adjust the seat and suspension for
the weight and the size of the operator and inspect
and maintain the seat suspension and adjustment
mechanisms.
5. Perform the following operations smoothly: steer,
brake, accelerate and shift the gears.
6. Move the attachments smoothly.
7. Adjust the machine speed and the route in order to
minimize the vibration level by doing the following:
drive around obstacles and rough terrain and slow
down when necessary to go over rough terrain.
8. Minimize vibrations for a long work cycle or a long
travel distance by doing the following: use
machines that are equipped with suspension
systems, if no ride control system is available,
reduce speed in order to prevent bounce and 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: adjust the
seat and adjust the controls in order to achieve
good posture, adjust the mirrors in order to
minimize twisted posture, provide breaks in order
to reduce long periods of sitting, avoid jumping
from the cab, minimize repeated handling of loads
and lifting of loads and minimize any shocks and
impacts during sports and leisure activities.
Consult your local Cat dealer for more information
about machine features that minimize vibration levels.
Consult your local Cat dealer about safe machine
operation.
26
Safety Section
Operator Station
Use the following web site in order to find your local
dealer:
Caterpillar, Inc.
www.cat.com
i03634321
Operator Station
SMCS Code: 7000; 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: 7150
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.
KEBU7577
Rollover Protective Structure
(ROPS), Falling Object Protective
Structure (FOPS) or Tip Over
Protection Structure (TOPS)
The ROPS/FOPS Structure (if equipped) on your
machine is specifically designed, tested and certified
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:
KEBU7577 27
Safety Section
Guards

• Demolition applications
• Rock quarries

• Forestry products
Additional guards may be required for specific
applications or work tools. The Operation and
Maintenance Manual for your machine or your work
tool will provide specific requirements for the guards.
Refer to Operation Maintenance manual, "Demolition"
for additional information. Consult your Caterpillar
dealer for additional information.
28 KEBU7577
Product Information Section
Specifications

Product Information (Table 3, contd)

Weight with Blade 12285 kg 12085 kg
Section (27084 lb) (26643 lb)

Height 312.6 cm (10.26 ft) 308.4 cm (10.12 ft)

General Information Width 229.5 cm (7.53 ft)

Length 585.5 cm (19.21 ft)

i05916589
Length with Blade 639.5 cm (20.98 ft)
Specifications
Table 4
SMCS Code: 7000
CS68B Vibratory Soil Compactor

Intended Use Weight 14325 kg (31581 lb)

This machine is classified as a roller as described in Weight with Blade 14980 kg (33025 lb)
“ISO 6165:2001”. This machine is used to level
material and compact material such as crushed rock, Weight with Shell Kit 15730 kg (34679 lb)
earth, and gravel.
Weight with Shell Kit and Blade 16380 kg (36112 lb)

Dimensions Height 310.9 cm (10.20 ft)

The specifications for your machine will vary Height with Shell Kit 320.8 cm (10.52 ft)
depending on the configuration of the machine and
work tools that may be added or removed. If your Width 233.5 cm (7.66 ft)
machine is equipped with a blade, the width of the Length 605.0 cm (19.85 ft)
machine will be 2.5 m (8.2 ft) for all machine models
that are covered in this Operation and Maintenance Length with Blade 654.5 cm (21.47 ft)
Manual.
Table 2
Table 5
CS56B Vibratory Soil Compactor
CP68B Vibratory Soil Compactor
Cab ROPS
Weight 14685 kg (32375 lb)
Weight 11500 kg 11290 kg
(25353 lb) (24890 lb) Weight with Blade 15345 kg (33830 lb)

Weight with Blade 12115 kg 11915 kg Height 311.7 cm (10.23 ft)

(26709 lb) (26268 lb)
Width 233.5 cm (7.66 ft)
Weight with Shell Kit 12900 kg 12700 kg
Length 605.0 cm (19.85 ft)
(28440 lb) (27999 lb)
Length with Blade 654.5 cm (21.47 ft)
Weight with Shell Kit 13525 kg 13325 kg
and Blade (29817 lb) (29377 lb)
Table 6
Height 311.4 cm (10.22 ft) 307.2 cm (10.07 ft)
CS74B Vibratory Soil Compactor
Height with Shell Kit 320.8 cm (10.52 ft) 317.6 cm (10.42 ft)
Weight 16000 kg (35274 lb)
Width 229.5 cm (7.53 ft)
Weight with Blade 16645 kg (36696 lb)
Length 585.5 cm (19.21 ft)
Weight with Shell Kit 17395 kg (38349 lb)
Length with Blade 639.5 cm (20.98 ft)
Weight with Shell Kit and Blade 18050 kg (39793 lb)

Table 3 Height 310.9 cm (10.20 ft)

CP56B Vibratory Soil Compactor Height with Shell Kit 320.8 cm (10.52 ft)
Cab ROPS Width 233.5 cm (7.66 ft)
Weight 11665 kg 11465 kg
Length 605.0 cm (19.85 ft)
(25717 lb) (25276 lb)
Length with Blade 654.5 cm (21.47 ft)

(continued)
KEBU7577 29
General Information
Specifications

Table 7
CP74B Vibratory Soil Compactor

Weight 16355 kg (36057 lb)

Weight with Blade 17015 kg (37512 lb)

Height 311.7 cm (10.23 ft)

Width 233.5 cm (7.66 ft)

Length 605.0 cm (19.85 ft)

Length with Blade 654.5 cm (21.47 ft)

Table 8
CS78B Vibratory Soil Compactor

Weight 18700 kg (41226 lb)

Weight with Shell Kit 18755 kg (41348 lb)

Height 310.9 cm (10.20 ft)

Height with Shell Kit 320.7 cm (10.52 ft)

Width 246.5 cm (8.09 ft)

Length 612.7 cm (20.10 ft)

Table 9
CS79B Vibratory Soil Compactor

Weight 20220 kg (44577 lb)

Weight with Shell Kit 20357 kg (44879 lb)

Height 310.9 cm (10.20 ft)

Height with Shell Kit 320.7 cm (10.52 ft)

Width 246.5 cm (8.09 ft)

Length 612.7 cm (20.10 ft)

30 KEBU7577
Identification Information
Plate Locations and Film Locations

Identification Information
i06128242

Plate Locations and Film

Locations
SMCS Code: 1000; 7000
The Product Information Number (PIN) will be 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 32 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. Product Identification Number (B)

For quick reference, record the identification numbers
in the spaces that are provided below the illustration.
Product Identification Number (PIN)
Service Information Plate (C)
Year of Manufacture Plate (If Required) (D)
CE Plate (If Required) (E)
Country of Origin Info Plate (If Required) (F)

European Union

Illustration 31 g02218954

The Product Identification Number (PIN) plate is

located at the rear of the machine on the left side. The
plate may have the following information:
Illustration 33 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.
KEBU7577 31
Identification Information
Plate Locations and Film Locations

• Engine Power Primary Engine (kW)

• Engine Power for Additional Engine (If Equipped)

• Typical Machine Operating Weight for European

Market (kg)

• Year of Construction
• Machine Type

China Pin Plate

Will be located next to the pin plate or on the pin
plate.
Illustration 36 g01212098

Structural damage, an overturn, modification, al-

teration, or improper repair can impair this struc-
ture's protection capability thereby voiding this
certification. Do not weld on or drill holes in the
structure. This will void the certification. Consult
your Cat dealer to determine this structure's limi-
tations without voiding its certification.

This machine has been certified to the standards that

are listed on the certification film. The maximum mass
of the machine, which includes the operator and the
Illustration 34 g03818462
attachments without a payload, should not exceed
the mass on the certification film.
Engine
Refer to Operation and Maintenance Manual,
“Guards (Operator Protection)” for more information.

Sound Certification

Illustration 35 g02842057

Engine Information and Serial Number Plate

Certification Illustration 37 g00933634

A typical example of this film is shown. Your machine
ROPS/FOPS Structure may have a different value.

This message is positioned on the ROPS on the left

side of the machine above the door.
32 KEBU7577
Identification Information
Emissions Certification Film

If equipped, the certification film is used to verify the i04019095

environmental sound certification of the machine. The
value that is listed on the film indicates the
guaranteed sound power level. The guaranteed
Emissions Certification Film
sound power level is measured at the time of SMCS Code: 1000; 7000; 7405
manufacture. The guaranteed sound power level is
measured according to the conditions that are Note: This information is pertinent in the United
specified in “ISO 6394:1998”. States, in Canada and in Europe.

Product Link Consult your Cat dealer for an Emission Control

Warranty Statement.
If equipped, this message is used to verify the
certification of the Product Link as an RF transmitter. This label is located on the engine.
The following specifications are provided to aid in
ensuring compliance with all local regulations:
Table 10
Operating frequency range 148 to 150 MHz

Transmitter power 5W

This message is located on the control group for the

Product Link. The control group is located on the top
of the cab.

Illustration 38 g01261742

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.
Consult your Cat dealer with any questions that
concern the operation of the Product Link in a specific
country.
KEBU7577 33
Identification Information
Declaration of Conformity

i05977686

Declaration of Conformity
SMCS Code: 1000; 7000

Table 11
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: Vibratory Soil Compactor

Model/Type: CS56B, CP56B, CS68B, CP68B, CS74B, CP74B, CS78B,

CS79B
Serial Number:
Commercial Name: Caterpillar

Fulfils all the relevant provisions of the following Directives

Directives Notified Body Document No.

2006/42/EC N/A
2000/14/EC amended by 2005/88/EC, Note (1)

2004/108/EC N/A

Note (1) Annex -_____ Guaranteed Sound Power Level -_____dB (A)
Representative Equipment Type Sound Power Level - _____dB (A)
Engine Power per ____-____ kW Rated engine speed - _____ 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 14, 2009, but may be subject to change, please refer to the individual declaration of conform-
ity issued with the machine for exact details.
34
Operation Section
Mounting and Dismounting
Operation Section
Before Operation
i05976221
Mounting and Dismounting
SMCS Code: 7000
Illustration 39 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.
KEBU7577
Machine Access System
Specifications
The machine access system has been designed to
meet the intent of the technical requirements in “ISO
2867:2011 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”.
i06067423
Daily Inspection
SMCS Code: 1000; 7000
For a maximum service life of the machine, complete
a thorough walk-around inspection before you mount
the machine and before you start the engine.
Inspect the area around the machine and under the
machine. Look for loose bolts, trash buildup, oil,
coolant leakage, broken parts, or worn parts.
Note: Watch closely for leaks. If you observe a leak,
find the source of the leak and correct the leak. If you
suspect a leak or you observe a leak, check the fluid
levels more frequently.
Inspect the condition of the equipment and of the
hydraulic components.
Check the condition of the tires. Adjust the inflation
pressure, if necessary.
Remove any mud that has accumulated between the
frame and the tires. The wheels may be interchanged
in order to prevent the accumulation of mud. For more
information refer to Operation and Maintenance
Manual, “Tire Spacing - Change”.
Check all of the oil levels, all of the coolant levels, and
all of the fuel levels.
Remove any trash buildup and debris. Make all
necessary repairs before you operate the machine.
Make sure that all covers and guards are securely
attached.
Adjust the mirrors for the correct rear view of the
machine.
Make sure that there is no air filter status fault on the
monitoring system.
Grease all of the fittings that must be serviced on a
daily basis.
KEBU7577
Cycle the auxiliary shutdown knob before starting the
engine at the beginning of every shift in order to verify
operation.
Daily, perform the procedures that are applicable to
your machine:
• Backup Alarm - Test
• Cooling System Coolant Level - Check
• Engine Oil Level - Check
• Hydraulic System Oil Level - Check
• Indicators and Gauges - Test
• Seat Belt - Inspect
i04711051
Steering Frame Lock
SMCS Code: 7506
No clearance for person in this area when ma-
chine turns. Severe injury or death from crushing
could occur.
Connect the steering frame lock between the front
and the rear frames before lifting, transporting, or
servicing the machine in the articulation area. Dis-
connect the steering frame lock and secure the
steering frame lock before resuming operation.
Severe injury or death could occur.
In order to install the steering frame lock pin, the
machine must be in the straight ahead position. The
lock pin will hold the front frame and the rear frame
rigid.
35
Before Operation
Steering Frame Lock
Illustration 40 g02219014
The steering frame lock is shown in the unlocked
position.
Engage the Steering Frame Lock
1. Move the machine into position. The machine must
be facing straight forward, not turned in either
direction.
2. Apply the parking brake.
3. Turn the engine start switch key to the OFF
position. Remove the key.
4. Remove the quick-release pin.
5. Use the handle on the lock pin in order to align the
upper hole in the lock pin with the hole in the lock
tube.
6. Insert the quick-release pin through the lock pin
and both sides of the lock tube. Make sure that the
quick-release pin extends fully through the lock
tube.
Disengage the Steering Frame Lock
1. Remove the quick-release pin.
2. Use the handle on the lock pin in order to align the
lower hole in the lock pin with the hole in the lock
tube.
3. Insert the quick-release pin through the lock pin
and both sides of the lock tube. Make sure that the
quick-release pin extends fully through the lock
tube.
36 KEBU7577
Machine Operation
Alternate Exit

Machine Operation i04711152

i04717210
Seat
SMCS Code: 7312; 7324
Alternate Exit
SMCS Code: 7308; 7310 Standard Seat

Illustration 41 g02821222

If necessary, open the cab window in order to exit the

cab. Unlatch the window, and swing the window open
in order to provide an exit.

Illustration 42 g02816377

In order to adjust the right side arm rest lift lever (1)
and hold lever (1) while adjusting the arm rest.
Release lever (1) in order to lock the arm rest in
position.
The seat can be moved in either the forward direction
or the rearward direction. Pull lever (2) upward and
hold lever (2) in order to move the seat to the desired
position. In order to lock the seat, release lever (2).
In order to adjust the suspension of the seat, turn
knob (4). Turn knob (4) clockwise in order to increase
the stiffness of the suspension of the seat. Turn knob
(4) counterclockwise in order to decrease the
stiffness of the suspension of the seat.
Adjust knob (4) until meter (3) shows the black line in
the middle of the yellow area.
In order to rotate the seat, use lever (5) and move the
seat to the desired position. Release lever (5) in order
to lock the seat in position.
In order to change the angle of the back rest, use
lever (6) and move the back rest to the desired
position. Release lever (6) in order to lock the back
rest.
In order to adjust the lumbar, turn knob (7). Turn knob
(7) clockwise in order to increase the lumbar. Turn
knob (7) counterclockwise in order to decrease the
lumbar.
KEBU7577 37
Machine Operation
Seat Belt

Air Ride Seat In order to adjust the suspension of the seat, pull
knob (11). Pull knob (11) outward in order to increase
the stiffness of the suspension of the seat. Push knob
(11) inward in order to decrease the stiffness of the
suspension of the seat.
Adjust knob (11) until meter (10) shows the black line
in the middle of the yellow area.
In order to rotate the seat, use lever (12) and move
the seat to the desired position. Release lever (12) in
order to lock the seat in position.
In order to change the angle of the back rest, use
lever (13) and move the back rest to the desired
position. Release lever (13) in order to lock the back
rest.
In order to adjust the lumbar, turn knob (14). Turn
knob (14) clockwise in order to increase the lumbar.
Turn knob (14) counterclockwise in order to decrease
the lumbar.
In order to adjust the height of the seat, turn knob
(15). Turn knob (15) clockwise in order to raise the
seat. Turn knob (15) counterclockwise in order to
Illustration 43 g02816116 lower the seat.

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.

Illustration 44 g02816117

In order to adjust the right side arm rest lift lever (8)
and hold lever (8) while adjusting the arm rest.
Release lever (8) in order to lock the arm rest in
position.
The seat can be moved in either the forward direction
or the rearward direction. Pull lever (9) upward and
hold lever (9) in order to move the seat to the desired
position. In order to lock the seat, release lever (9).
38 KEBU7577
Machine Operation
Mirror

Seat Belt Adjustment for Extension of the Seat Belt

Retractable Seat Belts
Fastening 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

Illustration 45 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.
Releasing The Seat Belt
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.
i04562015
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.

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.
Mirrors provide additional visibility around your
Illustration 46 g00039113 machine. Make sure that the mirrors are in proper
working condition and that the mirrors are clean.
Push the release button on the buckle in order to Adjust all mirrors at the beginning of each work period
release the seat belt. The seat belt will automatically and adjust the mirrors when you change operators.
retract into the retractor.
Modified Machines or machines that have additional
equipment or attachments may influence your
visibility.
KEBU7577 39
Machine Operation
Mirror

Mirror Adjustment Right Side Lower Rear View Mirror (1)

• Park the machine on a level surface.

• Stop the engine.

• Adjust rear view mirrors in order to provide visibility
behind the machine at a maximum distance of
30 m (98 ft) from the rear corners of the machine.
Note: Hand tools may be needed in order to adjust
the mirrors. Refer to Specifications, SENR3130,
“Torque Specifications” for the recommended torque.

Cab Mirrors

Illustration 48 g02277478

Adjust the right side rear view mirror (1) so that the
right side of the machine can be seen. Also adjust the
right side rear view mirror in order to see the
following:

• A view of at least 1 m (3.3 ft) from the side of the

machine can be seen from the operator seat.

• See an object on the ground at a distance of 30 m

(98 ft) from the rear corner of the compactor.

Right Side Upper Rear View Mirror (2)

Illustration 47 g02277476
(1) Right side lower rear view mirror
(2) Right side upper rear view mirror
(3) Left side lower rear view mirror
(4) Left side upper rear view mirror

Illustration 49 g02277479

Adjust the right side rear view mirror (2) so that the
right side of the machine can be seen. Also adjust the
right side rear view mirror in order to see the
following:
• A view of at least 1 m (3.3 ft) from the side of the
machine can be seen from the operator seat.
• See an object on the ground at a distance of 30 m
(98 ft) from the rear corner of the compactor.
40 KEBU7577
Machine Operation
Mirror

Left Side Lower Rear View Mirror (3) ROPS Mirrors

Illustration 50 g02277481

Adjust the left side rear view mirror (3) so that the left
side of the machine can be seen. Also adjust the left
side rear view mirror in order to see the following:
• A view of at least 1 m (3.3 ft) from the side of the
Illustration 52 g02727718
machine can be seen from the operator seat.
(5) Right side rear view mirror
• See an object on the ground at a distance of 30 m (6) Center rear view mirror
(7) Left side rear view mirror
(98 ft) from the rear corner of the compactor.

Left Side Upper Rear View Mirror (4) Right Side Rear View Mirror (5)

Illustration 51 g02277485 Illustration 53 g02727733

Adjust the left side rear view mirror (4) so that the left
side of the machine can be seen. Also adjust the left
side rear view mirror in order to see the following:
• A view of at least 1 m (3.3 ft) from the side of the
machine can be seen from the operator seat.
• See an object on the ground at a distance of 30 m
(98 ft) from the rear corner of the compactor.
Adjust the right side rear view mirror (5) so that the
right side of the machine can be seen. Also adjust the
right side rear view mirror in order to see the
following:
• A view of at least 1 m (3.3 ft) from the side of the
machine can be seen from the operator seat.
• See an object on the ground at a distance of 30 m
(98 ft) from the rear corner of the compactor.
KEBU7577 41
Machine Operation
Operator Controls

Center Rear View Mirror (6) i05841729

Operator Controls
SMCS Code: 7000; 7300; 7301; 7451

Note: Your machine may not be equipped with all of

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.
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
Illustration 54 g02727737
techniques develop as the operator gains knowledge
of the machine and the capabilities of the machine.
Adjust the center rear view mirror (6) so that the rear
of the machine can be seen. Also adjust the center
rear view mirror in order to see the following:
• A view of at least 1 m (3.3 ft) from the rear of the
machine can be seen from the operator seat.
• See an object on the ground at a distance of 30 m
(98 ft) from the rear of the compactor.

Left Side Rear View Mirror (7)

Illustration 56 g02841660
(1) Steering wheel
(2) Steering wheel position lock

Illustration 55 g02727740

Adjust the left side rear view mirror (7) so that the left
side of the machine can be seen. Also adjust the left
side rear view mirror in order to see the following:
• A view of at least 1 m (3.3 ft) from the side of the
machine can be seen from the operator seat.

• See an object on the ground at a distance of 30 m

(98 ft) from the rear corner of the compactor.
42 KEBU7577
Machine Operation
Operator Controls

Illustration 57 g02841663 Illustration 58 g02841698

Side Controls Type I (If Equipped) Side Controls Type II (If Equipped)
(3) Propel control (3) Propel control
(4) Vibratory button (4) Vibratory button
(5) Monitoring system (5) Monitoring system
(6) Emergency stop knob (6) Emergency stop knob
(7) Parking brake (7) Parking brake
(8) Horn (8) Horn
(9) Work lights (9) Work lights
(10) Beacon (10) Beacon
(11) Engine start switch (11) Engine start switch
(12) Keypad (12) Keypad
KEBU7577
Illustration 59
Keypad (12)
(13) Speed control increase
(14) Speed control decrease
(15) Propel speed range control
(16) Throttle control
(17) Vibratory frequency increase
(18) Vibratory frequency decrease
(19) Vibratory amplitude control
(20) Auto vibe activation control
Illustration 60
Cab controls (If Equipped)
(21) Fan speed control
(22) Temperature control
(23) Air conditioner switch
(24) Front window wiper switch
(25) Rear window wiper switch
43
Machine Operation
Operator Controls
Illustration 61 g02849027
(26) Leveling blade control (If Equipped)
g02726475
Illustration 62 g02932580
(27) 12V power receptacle
(28) Service connector
Steering Wheel (1)
The steering wheel controls the directional steering of
the machine. The machine will turn in the same
direction as the steering wheel.
Note: The steering frame lock must be unlocked in
order to steer the machine.
g02849023
Steering Wheel Position Lock (2)
Lift on the lock in order to release the steering wheel
position. Tilt the wheel to the desired position. Push
down on lock in order to lock the steering tilt position.
Monitoring System (3)
For more information refer to Operation and
Maintenance Manual, “Monitoring System”.
44
Machine Operation
Operator Controls
Propel Control (4)
When the ECM is cycled, the propel control will
default to the STOP position. This will happen
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. When
the propel lever is out of the neutral position, there will
be a warning displayed on the monitoring system. If
the warning is not displayed, test the propel control
for your machine.
Reference: For the correct procedure, refer to
Systems Operation, Testing and Adjusting, “Propel
Adjust - Test and Adjust” in order to test the propel
control.
FWD – Push the lever toward the front of the machine
in order to move the compactor forward. In order to
cause the machine to move faster, push the lever
farther.
STOP – Move the lever to the center STOP position
in order to stop the machine.
REV – Pull the lever toward the rear of the machine in
order to move the machine in reverse. In order to
cause the machine to move faster, pull the lever
farther.
Engine Start Switch (5)
Illustration 63 g01264219
OFF – In order to disconnect the
electrical power to the engine and to the
machine, turn the switch in a
counterclockwise direction to the OFF position
(A). Turn the switch to the OFF position (A) before
trying to restart the engine. Turn the switch to the
OFF position (A) in order to stop the engine.
KEBU7577
ON – In order to activate the cab circuits,
turn the switch to the ON position (B).
When the switch is released from the
START position (C), the switch will return to the
ON position (B).
START – Turn the engine start switch to
the START position (C) in order to crank
the engine. Release the key as soon as
the engine starts.
Note: If the engine does not start, return the switch to
the OFF position before returning to the START
position.
For more information, refer to the Operation and
Maintenance Manual, “Engine Starting” section.
Vibratory Button (6)
In order to turn on the vibration system, push the
button.
In order to stop the vibration system, push the button
again.
Note: A green indicator to the right of the monitor will
be illuminated when the vibratory system is activated.
Note: When the propel control is in the neutral
position, the vibratory system will only operate when
the auto vibe activation control is set to manual mode.
The throttle must be in ECO mode or High Idle and
the parking brake must not be set in order to activate
the vibratory system.
Horn (7)
Horn – Depress the horn button in order
to sound the horn. Use the horn for
alerting personnel or for Signaling
personnel.
Emergency Stop Knob (8)
Emergency Stop Knob – In order to stop
the machine and the engine, push the
knob downward. In order to release the
emergency stop knob, pull the knob upward.
Parking Brake (9)
Parking Brake Apply – In order to apply
the parking brake, push down on the
front of the rocker switch.
Parking Brake Release – In order to
release the parking brake, push down on
the back of the rocker switch.
Note: In order to propel the machine, the propel lever
must be in the STOP position before you release the
parking brake.
KEBU7577
Work Lights (10)
Work Lights – Push the bottom of the
switch down in order to turn on the front
work lights. Move the switch to the
center in order to turn off the work lights. Push
the top of the switch down in order to turn on the
front and the rear work lights.
Beacon (11)
Beacon – Push the top of the switch
down in order to turn on the beacon.
Push the bottom of the switch down in
order to turn off the beacon.
Keypad (12)
Indicator Lights
Illustration 64 g02155712
The indicator lights next to each button are described
in the following method:
(A) Top light
(B) Middle light
(C) Bottom light
Speed Control Increase (13)
Speed Control Increase – Push the
button in order to increase the speed. To
continue to increase the speed, push the
button again until the desired speed is achieved.
Hold the button down in order to increase the
speed faster.
45
Machine Operation
Operator Controls
Speed Control Decrease (14)
Speed Control Decrease – Push the
button in order to decrease the speed.
To continue to decrease the speed, push
the button again until the desired speed is
achieved. Hold the button down in order to
decrease the speed faster.
Propel Speed Range Control (15)
Propel Speed Range Control – Push the
propel speed range control button in
order to change the propel mode.
Low Mode – Push the propel speed range control
button once in order to select low mode. When low
mode is selected, indicator light (C) will be
illuminated. Low mode provides a lower travel speed.
Low mode does not travel as quick as travel mode or
High mode.
High Mode – Push the propel speed range control
button again in order to select high mode. When high
mode is selected, indicator lights (B) and (C) will be
illuminated. High mode has the highest travel speed.
Throttle Control (16)
Throttle Control – Push the button in
order to change the engine speed. Each
time the throttle control is changed the
new setting will be briefly displayed on the
monitoring system.
Low Idle – Push the throttle control button once in
order to select low idle. When low idle is selected,
indicator light (C) will be illuminated. When low idle is
selected, the engine will idle at 1200 RPM.
ECO mode – Push the throttle control button again in
order to select ECO mode. When ECO mode is
selected, indicator light (B) will be illuminated. When
eco mode is selected, the machine will use the
following RPM rules:
46
Machine Operation
Operator Controls
• When the parking brake is engaged, the engine
will idle at 800 RPM.
• When the parking brake is released, and the
propel control is in the neutral position, the engine
will idle at 1000 RPM.
• When the propel control is moved into the forward
or the reverse position, the engine will run at 1500
RPM.
• As additional speed is required, the engine speed
will increase up to 2000 RPM.
• When the vibratory system is activated, and the
machine is being propelled, the engine will run at
2000 RPM.
• If the vibratory system is turned off while the
machine is being propelled, the engine will run
between 1500 RPM and 2000 RPM depending on
the machine speed.
High Idle – Push and hold the throttle control button
for 2 seconds or more in order to select high idle.
When high idle is selected, indicator lights (A), (B),
and (C) will be illuminated. Push the button again in
order to return the machine to Eco mode. When high
idle is selected, the engine will idle at 2200 RPM.
Vibratory Frequency Increase (17)
Note: This button is only active when the machine is
equipped with the variable frequency vibe system.
Vibratory Frequency Increase – Push the
button in order to increase the vibratory
frequency. To continue to increase the
vibratory frequency, push the button again until
the desired vibratory frequency is achieved. Hold
the button down in order to increase the
frequency faster.
Vibratory Frequency Decrease (18)
Note: This button is only active when the machine is
equipped with the variable frequency vibe system.
Vibratory Frequency Decrease – Push
the button in order to decrease the
vibratory frequency. To continue to
decrease the vibratory frequency, push the button
again until the desired vibratory frequency is
achieved. Hold the button down in order to
decrease the frequency faster.
Vibratory Amplitude Control (19)
Vibratory Amplitude Control – Push the
vibratory amplitude control button in
order to change the vibratory amplitude.
KEBU7577
Low Amplitude – Push the button until indicator light
(C) is illuminated in order to select low amplitude.
High Amplitude – Push the button until indicator
lights (B) and (C) are illuminated in order to select
high amplitude.
Auto Vibe Activation Control (20)
Auto Vibe Activation Control – Push the
auto vibe activation control button once
in order to activate auto vibe. When auto
vibe is selected, indicator light (C) will be
illuminated.
Manual Mode – Push the button once in order to
select manual mode for the vibratory system. When
manual mode is selected, there will be no indicator
lights illuminated. In manual mode the vibratory
system may be activated at any time when the
machine is being propeled.
Automatic Mode – Push the button again in order to
select automatic mode. When automatic mode is
selected, indicator light (C) will be illuminated. In
automatic mode the vibratory system automatically
activates when you place the propel lever in either the
forward position or in the reverse position.
Fan Speed Control (21)
Fan Speed Control – Rotate the fan
speed control clockwise in order to
increase the speed of the fan. Rotate the
fan speed control counterclockwise in order to
decrease the speed of the fan.
Temperature Control (22)
Turn the temperature control clockwise in order to
increase the air temperature. Turn the temperature
control counterclockwise in order to decrease the air
temperature.
Air Conditioner Switch (23)
Air Conditioner Switch – Push down on
the top of the switch in order to activate
the air conditioner. Push down on the
bottom of the switch in order to turn off the air
conditioner.
Front Window Wiper Switch (24)
Front Window Wiper Switch – Push
down on the top of the switch in order to
turn on the front window wiper. Push
down the bottom of the switch in order to turn off
the front window wiper.
KEBU7577
Rear Window Wiper Switch (25)
Rear Window Wiper Switch – Push down
on the top of the switch in order to turn
on the rear window wiper. Push down
the bottom of the switch in order to turn off the
rear window wiper.
Leveling Blade Control (26) (If
Equipped)
The control for the leveling blade is used to adjust the
height of the leveling blade. The lever is a pedal that
is located on the floor.
FLOAT – Push the pedal forward into the
float detent. The leveling blade will
adjust to the contour of the ground when
the pedal is in the FLOAT position.
The pedal will remain in the FLOAT position until the
pedal is manually pulled out of the float detent. The
pedal will then return to the HOLD position.
LOWER – Push the pedal forward in
order to lower the leveling blade. The
pedal will return to the HOLD position
when you release the pedal. The leveling blade
will remain in the selected position.
HOLD – When you release the pedal
from the RAISE position or from the
LOWER position, the pedal will return to
the HOLD position.
RAISE – Push the pedal with your heel in
order to raise the leveling blade. The
pedal will return to the HOLD position
when you release the pedal. The leveling blade
will remain in the selected position.
12V Power Receptacle (27)
12V Power Receptacle – This power
receptacle can be used to power
automotive electrical equipment or
accessories. Remove the cap before use.
Service Connector (28)
Service Connector – This service port allows service
personnel to connect a laptop computer to the
machine electronics using the Cat Electronic
Technician tool. This connection will allow service
personnel to interrogate the machine systems and
engine systems.
47
Machine Operation
Battery Disconnect Switch
i04726611
Battery Disconnect Switch
SMCS Code: 1411
Illustration 65 g02220733
Battery Disconnect Switch – The battery
disconnect switch is located on the right
side of the engine compartment.
OFF – In order to deactivate the
electrical system, turn the switch to the
OFF position.
ON – To activate the electrical system,
insert the key and turn the switch in a
clockwise direction. The switch must be
in the ON position in order to start the engine.
The functions of the battery disconnect switch and the
engine start switch are different. When the battery
disconnect switch is turned to the OFF position, the
entire electrical system is disabled. When the engine
start switch is turned to the OFF position, the battery
remains connected to the electrical system.
Remove the key when you exit the machine for an
extended period of time. Also, remove the key when
you service the electrical system.
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.
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:
48
Machine Operation
Monitoring System
1. With the battery disconnect switch in the ON
position, verify that electrical components in the
operator compartment are functioning. 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.
i04805949
Monitoring System
SMCS Code: 1900; 5258; 7400; 7402; 7450; 7451;
7490
Indicator Lights
There are three indicator lights on each side of the
monitoring system display. There is one green
indicator, one amber indicator, and one red indicator.
The indicators will illuminate when certain machine
functions are activated, or when a fault occurs.
Right Side Green Indicator
The green indicator on the right side of the monitoring
system display will be illuminated when the vibratory
system is activated. When the vibratory activation
control is set to manual mode, the light will be
illuminated and the system will begin vibrating when
the system is activated. When the vibratory activation
control is set to automatic mode and the vibratory
system is activated, the light will illuminate but the
system will not begin vibrating until sufficient speed is
reached.
Left Side Green Indicator
The green indicator on the left side of the monitoring
system display will be illuminated when the blade
float function is activated.
Right Side Amber and Red Indicators
The amber and red indicators on the right side of the
monitoring system display are used to indicate the
following machine faults:
Level 1 Machine Fault – The right side amber
indicator will be illuminated. A level 1 machine fault is
a warning and does not act on any system.
Level 2 Machine Fault – The right side amber
indicator will flash. Systems may be derated or
disabled during a level 2 machine fault.
KEBU7577
Level 2+ Machine Fault – The right side amber
indicator will flash and an audible alarm will sound
continuously. Systems may be derated or disabled
during a level 2+ machine fault.
Level 3 Machine Fault – The right side amber
indicator will flash, the right side red indicator will be
illuminated, and an audible alarm will sound in sync
with the amber indicator. The propel and vibratory
systems will be disabled during a level 3 machine
fault.
Left Side Amber and Red Indicators
The amber and red indicators on the left side of the
monitoring system display are used to indicate the
following engine faults:
Level 1 Engine Fault – The left side amber indicator
will be illuminated. A level 1 engine fault is a warning
and does not act on any system.
Level 2 Engine Fault – The left side amber indicator
will flash. Systems may be derated or disabled during
a level 2 engine fault.
Level 2+ Engine Fault – The left side amber
indicator will flash and an audible alarm will sound
continuously. Systems may be derated or disabled
during a level 2+ engine fault.
Level 3 Engine Fault – The left side amber indicator
will flash, the left side red indicator will be illuminated,
and an audible alarm will sound in sync with the
amber indicator. The propel and vibratory systems will
be disabled during a level 3 engine fault.
Display Navigation
In order to navigate through the monitoring system
use the four soft keys that are located at the bottom of
the screen. Soft key selection options are displayed
above each key and are dependent on the current
screen that is being viewed within the monitoring
system. The soft key options are not displayed when
the keys are not in use. Press any key in order to
view the soft key options when the key options are
not displayed. The selection options will be displayed
for three seconds.
The following soft key options will be available
depending on the situation:
Brightness/Contrast – Press this key in
order to access brightness and contrast
settings.
Navigate Up – Press this key in order to
move up through the menu items.
Navigate Down – Press this key in order
to move down through the menu items.
KEBU7577 49
Machine Operation
Monitoring System

Exit/Back One Screen – Press this key in • Basic Setup

order to go back one screen.
• Diagnostics
Select/Next – Press this key in order to • Machine Setup
make a selection or to navigate to the
next digit or screen element. • Screen Setup
Quick Data – Press this key in order to • System Setup
monitor the selected signals in a
scrollable single view display. Basic Setup
Brightness/Contrast

Illustration 68 g02795980

Illustration 66 g02616037 Use the Basic Setup screen to adjust the following
settings:
Press the Brightness/Contrast key in order to adjust
the brightness and contrast levels. Use the plus and • Language
minus keys on the left in order to adjust the
brightness. Use the plus and minus keys on the right • Units
in order to adjust the contrast. The Brightness/
Contrast screen will disappear after three seconds of Language
inactivity.

Main Menu

Illustration 69 g02795991

Illustration 67 g02795970
Use the Language screen to select the program
language.
The Main Menu screen is the starting point for
Use the up, down, and select keys in order to choose
configuring the monitoring system.
from the following languages:
The following options are available from the Main
Menu:
50 KEBU7577
Machine Operation
Monitoring System

• English The following options are available from the

Diagnostics screen:
• French
• Fault Log
• German
• Quick Data
• Italian

• Spanish Fault Log

Units

Illustration 72 g02796019

Fault information is saved and stored to the fault log.

Illustration 70 g02795997 Select either Active or Logged in order to monitor fault
activity.
Use the Units screen in order to change the units
displayed for the following options:
Active
• Ground Speed
• Pressure

• Temperature
• Fuel Rate

• Vibratory Speed

Diagnostics

Illustration 73 g02796028

The active fault menu displays all the active faults.

Use the up and down keys in order to scroll through
the active faults.

Illustration 71 g02796004

Use the Diagnostics screen to view fault logs and

access quick data.
KEBU7577 51
Machine Operation
Monitoring System

Logged

Illustration 76 g02796367

Illustration 74 g02796049 Scroll through the signal list using the up and down
keys. Use the select key to select or deselect the
The logged fault menu displays all the previous faults. signals that will be viewed on the Quick Data screen.
Use the up and down keys in order to scroll through The signals that are selected will show an asterisk to
the logged faults. the left of the signal name.
Refer to “Signals” for a list of available signals for
Quick Data monitoring.

Machine Setup

Illustration 75 g02796053

The Quick Data screen allows selected signals to be Illustration 77 g02796385

monitored in a scrollable single view display.
Use the Machine Setup menu to make changes to the
To select which signals are displayed, press the quick configuration of the machine.
data soft key.
52 KEBU7577
Machine Operation
Monitoring System

Configuration Number of Screens

Illustration 78 g02796391 Illustration 80 g02796403

Use the Configuration menu to choose from the Use the Number of Screens menu to set the number
following options: of screens that can be displayed.

• No Shell Select Screen

• Shell Installed Use the Select Screen menu to customize the screen
display. Use the following steps in order to customize
Screen Setup the screen:

Illustration 79 g02796401
Illustration 81 g02796406

Use the Screen Setup menu to change how

information is displayed on the screen. Use the 1. Use the up and down keys in order to select which
Screen Setup menu to adjust the following screen screen to customize. Then press the select button
settings: in order to customize the screen that is selected.
• Number of Screens
• Select Screen
KEBU7577 53
Machine Operation
Monitoring System

Illustration 82 g02796427 Illustration 84 g02802777

2. Use the up and down keys in order to select which 4. After a signal selection is made, press the next key
screen type to use. Then press the select button in in order to go to the next selection area. Use the
order to choose the selected screen type. The up, down, and next keys to select the signals.
following screen types are available:
Type 1 – Screen type 1 is a two-up screen view with
two signal capacity.
Type 2 – Screen type 2 is a three-up screen view with
one large signal capacity and two small signal
capacities.
Type 3 – Screen type 3 is a four-up display with four
small signal capacities.

Illustration 85 g02802797

5. Using the next key will rotate through the

selections in a clockwise rotation. After all signal
selections have been made, press the exit key in
order to return to the previous menu.

Illustration 83 g02802599

3. After the screen type is selected, select which

signals to monitor. Use the up and down keys to
cycle through the available signals.
54 KEBU7577
Machine Operation
Monitoring System

Reset Defaults

Illustration 86 g02802816

6. Navigate back for more screen selections, or press Illustration 88 g02796454

the exit key five times in order to display the

Use the Reset Defaults menu to reset all the
current selections. monitoring system settings to the original factory
default settings.
System Setup
System Info

Illustration 87 g02796437

Use the System Setup menu to monitor and control Illustration 89 g02796494
applications systems. Use this menu to access the
following setup menus: The System Info screen displays the part number, the
software revision number, and the serial number.
• Reset to Factory Screens Only information is displayed in the System Info
screen. No changes can be made.
• System Info
KEBU7577 55
Machine Operation
Product Link

Fault Pop-Up Alarms Engine Load –

Engine Oil Press –

Engine Speed SW –

Fuel Level –

Fuel Rate –

Illustration 90 g02625876
Hydraulic Temp –
When a fault is detected on the network, a flashing
red warning alarm will be activated and a fault
information pop-up window will be displayed listing
the current fault information. n/min –
Warning lights will flash when a popup alarm occurs
and will stay flashing until acknowledged. Warning
lights will remain lit until the fault is no longer on the Vehicle Speed –
network.
Press the exit button in order to clear the pop-up
alarm and return directly to the previous display Vibe Speed –
information. Press the up key in order to go to the
next fault. Press the down key in order to go to the
previous fault. Press the select key in order to clear
the pop-up and go directly to the current active fault i05956366
information screen.
Faults that have been acknowledged and are no Product Link
longer active will be shown in the Active Faults log in
italics. Logged faults will be displayed in the Previous SMCS Code: 7606
Faults log.
Note: Your machine may be equipped with the Cat
®
Product Link system.
Signals
The Caterpillar Product Link communication device
The following signals are available for monitoring: utilizes cellular and/or satellite technology to
communicate equipment information. This information
Ambient Temp – is communicated to Caterpillar, Cat dealers and
Caterpillar customers. The CaterpillarProduct Link
communication device contain Global Positioning
Battery Voltage – System (GPS) satellite receivers.
The capability of two-way communication between
the equipment and a remote user is available with the
CMV (If Equipped) – CaterpillarProduct Link communication device. The
remote user can be a dealer or a customer.

Coolant Temp –

DPF 1 Soot Percent –

56
Machine Operation
Product Link
Data Broadcasts
Data concerning this machine, the condition of the
machine, and the operation of the machine is being
transmitted by Product Link to Caterpillar and/or
Cat dealers. The data is used to serve the customer
better and to improve upon Caterpillar 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 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 Caterpillar products and
services
• Complying with legal requirements and valid court
orders
• Performing market research
• Offering the customer new products and services
Caterpillar may share some or all of the collected
information with Caterpillar affiliated companies,
dealers, and authorized representatives. Caterpillar
will not sell or rent collected information to any other
third party and will exercise reasonable efforts to
keep the information secure. Caterpillar recognizes
and respects customer privacy. For more information,
please contact your local Cat dealer.
KEBU7577
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.
Note: For older Product Link hardware (PL121SR,
321, 522, 523, 420, or 421), Caterpillar recommends
that the following minimum distances be maintained
from the site perimeter unless applicable legal
mandates require greater distances:
• 12 m (40 ft) for Product Link 121SR and 321SR
• 3 m (10 ft) for Product Link 522/523
If required, the following are suggested methods to
disable the CaterpillarProduct Link communication
device:
• Turn theProduct Link radio disable switch to the
OFF position.
• Disconnect the CaterpillarProduct Link
communication device from the main power
source. This action is performed by disconnecting
the wiring harness at the Product Link radio.
Note: If no radio disable switch is installed and the
equipment will be operating near a blast zone, a
Product Link radio disable switch may be installed on
the equipment. The switch will allow the
CaterpillarProduct Link communication device to be
shut off by the operator from the equipment control
panel. Refer to Special Instruction, REHS7339,
Special Instruction, REHS2365, Special Instruction,
REHS2368, Special Instruction, REHS5595, Special
Instruction, REHS5596, Special Instruction,
REHS8850, and Special Instruction, REHS9111 for
more details and installation instructions.
Note: For Product Link devices with an internal
battery back-up without a radio disable feature
including the PL420 system: Do not operate an asset
with this type of device within a blast site. Do not
operate within mandated or recommended distance
from a blast site perimeter.
KEBU7577 57
Machine Operation
Product Link

The following CaterpillarProduct Link communication Operation, configuration and troubleshooting

device specifications are provided in order to aid in information for the CaterpillarProduct Link
conducting any related hazard assessment and to communication device can be found in the Systems
ensure compliance with all local regulations: Operation, Troubleshooting, Testing and Adjusting,
Table 12 UENR3697, Systems Operation, Troubleshooting,
Testing and Adjusting, UENR5823, and Systems
Radio Transmitter Specifications Operation, Troubleshooting, Testing and Adjusting,
Radio Model Transmitter Fre- Transmitter Power
UENR5824, Special Instruction, REHS7911, and
(Maximum) quency Range Special Instruction, REHS8143.

PL121SR 148 MHz -150 MHz 5-10W Machine Security

824 MHz - 849 MHz
Machine Lock Icon –
880 MHz - 915 MHz

PL522/523 1710 MHz - 1785 1W

MHz De-rate – Some machines can have the machine
1850 MHz - 1910 engine de-rated remotely by the owner of the
MHz machine. The action causes the machine to operate
much slower than normal.
850 MHz - 900 MHz 2W for lower
PL420/421 1800 MHz - 1900 frequency,
1W for higher
A warning is given before this action occurs on the
MHz display with the machine lock icon and “Security
824 MHz - 849 MHz Pending” . When engine de-rate has happened, the
machine display shows the machine lock icon and
880 MHZ - 915 MHz “Security Enabled” . The operator should move the
1710 MHz - 1755
machine to a safe location, apply the parking brake,
PL640 MHz 0.5W typical, 2W power the machine down, notify the site supervisor,
G0100 max and contact your local Cat dealer.
1850 MHz - 1910
MHz Disable – Some machines can be prevented from
starting remotely by the owner of the machine. When
1920 MHz - 1980
disabling has happened, the machine display shows
MHz
the machine lock icon and “Security Enabled” .
824 MHz - 849 MHz Before the machine is disabled, the machine display
shows the machine lock icon and “Security Pending”
880 MHZ - 915 MHz
. The operator should notify the site supervisor.
1710 MHz - 1755
MHz 0.5W typical, 2W
PL641
max
Tampering – Tampering with the Product Link
1850 MHz - 1910 system to disable the Product Link can also result in
MHz engine de-rating of the machine. To avoid de-rating,
prevent tampering with the Product Link . If, machine
1920 MHz - 1980
diagnostics occur due to Product Link notify your
MHz
site supervisor immediately to prevent derating. An
1616 MHz - 1626.5 example of this situation is an antenna becoming
PL631 5.1W max
MHz damaged.

Consult your Cat dealer if there are any questions. Note: Leaving the blast site switch in the OFF
Information for the initial installation of the position for more than 48 machine hours can cause
CaterpillarProduct Link communication device is the machine to derate.
available in Special Instruction, REHS7339, Special
Instruction, REHS8850, Special Instruction,
REHS2365, Special Instruction, REHS2368, Special
Instruction, REHS5595, Special Instruction
REHS5596, andSpecial Instruction, REHS9111.
58 KEBU7577
Machine Operation
Product Link

Regulatory Compliance

Illustration 91 g01131982

NOTICE
Transmission of information using Product Link is
subject to legal requirements that may vary from loca-
tion to location, including, but not limited to, radio fre-
quency use authorization. The use of Product Link
must be limited to those locations where all legal re-
quirements for the use of the Product Link communi-
cation network have been satisfied.
If a machine outfitted with Product Link is located in
or relocated to a location where (i) legal requirements
are not satisfied or (ii) transmitting or processing of
such information across multiple locations would not
be legal, Caterpillar disclaims any liability related to
such failure to comply and Caterpillar may discon-
tinue the transmission of information from that
machine.

Consult your Cat dealer with any questions that

concern the operation of the Product Link in a
specific country.
Note: This equipment has been registered with the
Botswana Telecommunications Authority for use in
Botswana. BTA REGISTERED No: BTA/TA/2012/378
KEBU7577 59
Machine Operation
Product Link

Illustration 92 g02348438
60 KEBU7577
Machine Operation
Product Link

Illustration 93 g02657277
KEBU7577 61
Machine Operation
Product Link

Illustration 94 g02346204
62 KEBU7577
Machine Operation
Product Link

Illustration 95 g02346205
KEBU7577 63
Machine Operation
Product Link

Illustration 96 g02346208
64 KEBU7577
Machine Operation
Product Link

Illustration 97 g02727978
KEBU7577 65
Machine Operation
Product Link
66 KEBU7577
Machine Operation
Product Link

Illustration 98 g02727979
KEBU7577 67
Machine Operation
Product Link
68 KEBU7577
Machine Operation
Product Link

Illustration 99 g03341389
KEBU7577 69
Machine Operation
Product Link
70 KEBU7577
Machine Operation
Product Link

Illustration 100 g03341393

KEBU7577 71
Machine Operation
Product Link

Table 13
An EC Declaration of Conformity document was provided with the machine if it was manufactured to comply with specific requirements for the
European Union. In order to determine the details of the applicable Directives, review the complete EC Declaration of Conformity provided with
the machine. The extract shown below from an EC Declaration of Conformity for machines that are declared compliant to “2006/42/EC” applies
only to those machines originally “CE” marked by the manufacturer listed and which have not since been modified.

EC DECLARATION OF CONFORMITY OF MACHINERY

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

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

Standards & Regulations Manager,Caterpillar France S.A.S 40,

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

I, the undersigned, Geoffrey Ginzel, hereby certify that the construction equipment specified hereunder

Description: Generic Denomination: Radio and Telecommunications Terminal Equipment -

Function: Product Link -

Model/Type: G0100 Part Number:

417-4723
Serial Number: -

Commercial Name: Product Link -

Fulfills all the relevant provisions of the following Directives

- - -
Directives Notified Body Document No.

1999/5/EC N/A -

2006/95/EC - -

2004/108/EC N/A -

2011/65/EU - - -

2004/104/EC -

Harmonised Standards Taken Into Consideration: EN 60950-1 (ed.2), EN 301 511:v9.0.0, EN 300 440-2:V1.4.1:2010, EN
55022:2006 A1:2007, EN 63211:2008, EN 301 489-1:V1.8.1:2008, EN 61000-4-2:2008, EN 61000-4-3:2006, EN 61000-
4-6:2008, ISO 13309:2010, CISPR 25 (2nd Edition 2002)

Done at: Signature

Date: - - Name/Position -
-
72 KEBU7577
Machine Operation
Product Link

Illustration 101 g03724472

Table 14
An EC Declaration of Conformity document was provided with the machine if it was manufactured to comply with specific requirements for the
European Union. In order to determine the details of the applicable Directives, review the complete EC Declaration of Conformity provided with
the machine. The extract shown below from an EC Declaration of Conformity for machines that are declared compliant to “2006/42/EC” applies
only to those machines originally “CE” marked by the manufacturer listed and which have not since been modified.

EC DECLARATION OF CONFORMITY OF MACHINERY

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

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

Standards & Regulations Manager,Caterpillar France S.A.S 40,

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

I, the undersigned, Geoffrey Ginzel, hereby certify that the construction equipment specified hereunder

Description: Generic Denomination: Radio and Telecommunications Terminal Equipment -

Function: Product Link -

Model/Type: PL631 Part Number:

442-7199
Serial Number: -

Commercial Name: Product Link -

Fulfills all the relevant provisions of the following Directives

- - -
Directives Notified Body Document No.

1999/5/EC N/A -

2006/95/EC - -

2004/108/EC N/A -

2011/65/EU - - -

2004/104/EC -

Harmonised Standards Taken Into Consideration: EN 60950-1:2006+A12:2011, EN 300 440-2:V1.4.1, EN 301 441:
V1.1.1, EN301 489-1:V1.9.2, EN 301 489-20:V1.2.1, EN 63211:2008, ISO 13766:2006, ISO 14982:2009, ISO
13309:2010
Done at: Signature

Date: - - Name/Position -
-
KEBU7577 73
Machine Operation
Product Link

Illustration 102 g03724472

Table 15
An EC Declaration of Conformity document was provided with the machine if it was manufactured to comply with specific requirements for the
European Union. In order to determine the details of the applicable Directives, review the complete EC Declaration of Conformity provided with
the machine. The extract shown below from an EC Declaration of Conformity for machines that are declared compliant to “2006/42/EC” applies
only to those machines originally “CE” marked by the manufacturer listed and which have not since been modified.

EC DECLARATION OF CONFORMITY OF MACHINERY

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

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

Standards & Regulations Manager,Caterpillar France S.A.S 40,

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

I, the undersigned, Geoffrey Ginzel, hereby certify that the construction equipment specified hereunder

Description: Generic Denomination: Radio and Telecommunications Terminal Equipment -

Function: Product Link Part Number:

440-2104
Model/Type: PL641 Part Number:
440-2105
Serial Number: -

Commercial Name: Product Link -

Fulfills all the relevant provisions of the following Directives

- - -
Directives Notified Body Document No.

1999/5/EC N/A -

2006/95/EC - -

2004/108/EC N/A -

2011/65/EU - - -

2004/104/EC -

Harmonised Standards Taken Into Consideration: EN 60950-1:2006+A12:2011, EN301 489-1:V1.9.2: 2011, EN 301 511:
v9.0.2, EN 301 489-3:V1.4.1:2002, EN 300 440-2:V1.4.1:2010, EN 301 489-7:V1.3.1:2005, EN 301 908-1:V5.2.1 and
V6.2.1, EN 301489-24:V1.5.1:2010, EN 301 908-2:V5.2.1 and V6.2.1, EN 63211:2008, ISO 14982:2009, ISO
13309:2010, ISO 13766:2006

Done at: Signature

(continued)
74 KEBU7577
Machine Operation
Operation Information

(Table 15, contd)

Date: - - Name/Position -
-

Illustration 103 g03724472

i04756554 Vibratory Operation

Operation Information
SMCS Code: 1000; 7000

Operate the engine at full rpm for maximum brak-

ing, steering and propel control response. Opera-
tion below full throttle will adversely affect
response.
When climbing a steep grade, the propel control
lever must be moved SLOWLY in order to avoid
engine stall and possible loss of machine control.

Illustration 104 g02726479

Set the throttle control to the HIGH position. Attain the
(1) Vibratory button
desired travel speed before you engage the vibratory
system. In order to achieve optimum compaction, low
range should be used.
Stop the vibration system when you travel over
concrete or pavement that is hard.

NOTICE
The bearings in the vibratory reservoir for the weight
shaft are lubricated by rotating the drum assembly.
Turning the vibratory system on with the machine not
propelling may shorten the vibratory bearing life.

Begin the first pass of the compaction along the side

of the work. Gradually make subsequent passes
toward the center. Overlap the previous pass by
200 mm (8.0 inch) in order to eliminate uncompacted
areas.

NOTICE
Before changing the vibratory amplitude selection,
the system must be completely stopped.
KEBU7577 75
Machine Operation
Operation Information

(Table 17, contd)

2000 RPM (ECO 1400±50 VPM 1830±50 VPM
Mode)

2200 RPM (High 1400±50 VPM 1830±50 VPM

Idle)

Vibratory Frequency Increase

Vibratory Frequency Increase (2) – Push
the button in order to increase the
vibratory frequency. To continue to
increase the vibratory frequency, push the button
again until the desired vibratory frequency is
achieved. Hold the button down in order to
increase the frequency faster.

Vibratory Frequency Decrease

Illustration 105
Note: Until the vibratory system is warm, the vibration
frequency will be less than the standard frequency.
Run the vibration system for at least 15 minutes prior
to compaction work in order to warm the oil in the
vibratory system.
Vibratory System
Standard Vibration
When the machine is in the standard vibratory mode
and ECO mode, the vibratory frequency will be
reduced by 10%, the amplitude will remain the same
and the centrifical force will be reduced by 19%.
Table 16
Fixed Frequency Vibratory Specifications
Engine Speed Low and High Amplitude
Frequency
Vibratory Frequency Decrease (3) – Push
g02729610
the button in order to decrease the
vibratory frequency. To continue to
decrease the vibratory frequency, push the button
again until the desired vibratory frequency is
achieved. Hold the button down in order to
decrease the frequency faster.
Vibratory Amplitude Control
Vibratory Amplitude Control (4) – Push
the vibratory amplitude control button in
order to change the vibratory amplitude.
Auto Vibe
Auto Vibe Activation Control (5) – Push
the auto vibe activation control button
once in order to activate auto vibe. When
auto vibe is selected, the bottom light next to the
button will be illuminated.

2000 RPM (ECO Mode) 1664±50 VPM

High Amplitude
2200 RPM (High Idle) 1830±50 VPM In order to increase the height of the drum movement,
place the vibratory system in high amplitude.
High amplitude is used in the following situations:
Variable Frequency Vibe
• The job site requires higher compacting force in
When the variable frequency vibe system is utilized, order to meet the required density.
the full vibratory specifications are met in ECO mode.
Table 17 • In order to compact material with a depth of
Variable Frequency Vibratory Specifications 250 mm (10.0 inch) or more, use high amplitude.

Low and High Amplitude Frequency Note: Once you have achieved the desired density of
Engine Speed the material, continued operation at high amplitude
Minimum Maximum can crush the aggregate.

(continued)
76 KEBU7577
Machine Operation
Window (Side)

Note: Every job site is different due to the various i04952654

conditions of the soil. Moisture content and the type
of material vary from job site to job site. In order to Window (Side)
determine the amplitude that is needed, establishing
a test location at each job site is recommended. SMCS Code: 7310

1. In order to place the vibratory system in high

amplitude, press the vibratory amplitude control
button (4) until two lights are illuminated.

2. Move the propel lever to the FWD position or the

REV position.

3. Start the vibratory system by pressing vibratory on/

off control (1). The control is located on the top of
the propel lever.

4. In order to stop the vibratory system, press

vibratory on/off control (1).

5. Return the propel control to the STOP position. Illustration 106 g03138417

Low Amplitude
In order to decrease the height of the drum
movement, place the vibratory system in low
amplitude.
Low amplitude is used in the following situations:
• When operating the machine in high amplitude and
the drum separates from the soil, use low
amplitude in order to reach the desired soil density.
• The thickness of the material is less than 250 mm
(10.0 inch).
• Objects such as sewer systems or water systems
may be damaged due to high amplitude.
1. In order to place the vibratory system in high
amplitude, press the vibratory amplitude control
button (4) until the bottom light is lit.
In order to open the side window, rotate handles (1)
and push the window open. The window will latch to
the side of the cab.
In order to close the window, push button (2) to
release the window. After the window is released, pull
the window to the closed position. Rotate handles (1)
in order to lock the window in the closed position.
i01773138
Backup Alarm
SMCS Code: 7406
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.

2. Move the propel lever to the FWD position or the

REV position.

3. Start the vibratory system by pressing vibratory on/

off control (1). The control is located on the top of
the propel lever.

4. In order to stop the vibratory system, press

vibratory on/off control (1).

5. Return the propel control to the STOP position.

Illustration 107 g00930005

The backup alarm is located on the rear of the

machine.
KEBU7577
i06131930
Cat Compaction Control
SMCS Code: 1408; 1439; 5574-PXS; 7852
GPS Antenna (If Equipped)
In order to prevent personal injury during installa-
tion and removal of the GPS receivers, use an ap-
proved access system in order to reach the
mounting locations of the GPS receivers at the
top of the masts.
Use the following procedure in order to remove the
antenna:
Illustration 108 g03819276
1. Disconnect cable (2) from antenna (1).
2. Install cap (6) on the end of cable (2).
3. Turn handle (4) counterclockwise in order to loosen
the antenna assembly.
4. Use handle (3) in order to lift the antenna assembly
off mast (5).
Note: When installing the GPS antenna, fully
insert the quick release bracket onto the mast. If
the antenna is not fully installed, the
measurement from the drum tip to the antenna
will not be correct. This incorrect measurement
will result in incorrect elevation guidance and
construction.
77
Machine Operation
Cat Compaction Control
Machine Drive Power (If Equipped)
Illustration 109 g03692761
Refer to Specification Sheet, QEXQ1611, “Machine
Drive Power (MDP) Quick Start Guide” for more
information concerning the Machine Drive Power
system.
Machine Drive Power (MDP) is an exclusive
compaction measurement technology which collects
a measure of the energy necessary to overcome
rolling resistance. MDP derives a unit-less measure
indication of soil stiffness, or the ability for the
compacted surface to support a load. Readings are
scaled in a range between 0 - 150. A soil stiffness of
150 would be comparable to flat, smooth concrete.
The vibratory system can be On, or Off. The Drum
can be smooth, padded, or have a shell kit installed.
MDP technology has many advantages over
traditional measurement systems, but the system
must be used correctly in order to take full advantage.
Failure to use the MDP system properly will result in
false or misleading values. Use the following
procedure for the best results.
Note: The propel speed must be equal to or greater
than 1 km/h (0.6 mph), and the travel speed range
set to Low, in order for MDP to display a value,
otherwise a “Signal Not Available” message will be
displayed.
1. Set up the monitoring system to display the MDP
value. For information on changing which signals
are viewed on the monitoring system refer to
Operation and Maintenance Manual, “Monitoring
System”.
2. Establish a target compaction value. The target
value can be established using one of the following
methods:
Test Strip Comparison – Construct a test strip with a
representative material, layer thickness, and moisture
level. Establish a rolling pattern and compact the test
strip at production settings (frequency, amplitude, and
roller speed). The compactor has achieved maximum
compaction once MDP changes less than ±2 units
78 KEBU7577
Machine Operation
Cat Compaction Control

between passes for the given soil conditions. Note
the MDP value.
Point Comparison – Choose a properly compacted
area on the worksite that has been measured with a
traditional compaction measurement system. Run the
machine over this area, and note the MDP value.
3. Compact the worksite. During compaction of the
worksite, monitor the MDP value in order to get a
real-time indication of the compaction progress.
Areas of concern, such as unstable soils or
moisture levels, can be highlighted during this
step. Using production settings compact the
worksite by adding additional passes until the
noted MDP value from step 2 is achieved.
Be aware of the following situations:
• Operate the machine with a constant speed of
3 km/h (2 mph) in order to decrease the
variation in the MDP value. MDP values can
decrease slightly as speed is increased.
Automatic Speed Control (ASC) can be utilized
in order to maintain the proper speed. Use the
following steps in order to utilize ASC:
a. Set the monitoring system to indicate the
machine speed.
b. Push the propel lever all the way forward and
note the machine speed.
c. Increase or decrease the machine speed with
the speed control buttons to arrive at the
desired speed.

• If the soil type or conditions change with
respect to the target value conditions, a new
target value must be set. Repeat step 2 in order
to establish a new target value.
• For machines equipped with fixed frequency, if
the machine starts to decouple (bounce) while
in high amplitude, switch to low amplitude first,
then if needed, turn off the vibratory system. For
machines equipped with the variable frequency
attachment, change the frequency first, then if
needed, change the amplitude or turn off the
vibratory system. Changes in frequency,
amplitude, or vibration on/off will require
resetting the MDP target value.
4. Validate the compacted worksite. Proofing runs
require high accuracy. Establish a rolling pattern
and proof roll the worksite uniformly using the
same compactor. If desired, randomly check for
proper compaction of the worksite using traditional
compaction measurement methods.
Use the following guidelines during validation:
d. After the ASC is set up, pushing the propel
lever fully forward will result in a constant
speed.
Be aware of the following restrictions:
• MDP values between machines will be different
• MDP values are influenced by soil depths between
0.3 m (1 ft) - 0.6 m (2 ft)
Note: If the machine is equipped with Machine Drive
Power, then the system can be upgraded to include
mapping. For more information consult your Cat
dealer.
Note: MDP is calibrated at the factory and does not
require a field calibration unless the angle sensor is
replaced. Refer to Testing & Adjusting, UENR1815,
“Machine Drive Power Angle Sensor - Calibrate”.

• Operate in a forward direction. Measurements

in reverse give slightly higher, or false readings.

• Operate the machine in low propel mode. The

MDP system has been calibrated for low propel
mode.

• Operate the machine with the vibratory system

turned off. MDP values decrease as amplitude
is increased.
KEBU7577 79
Machine Operation
Cat Compaction Control

Compaction Meter Value (If

Equipped) 3. Compact the worksite. During compaction of the
worksite, monitor the CMV value in order to get a
real-time indication of the compaction progress.
Areas of concern, such as unstable soils or
change in moisture levels, can be highlighted
during this step. Using production settings,
compact the worksite by adding additional passes
until the noted CMV value from step 2 is achieved.
Be aware of the following situations:
• If the soil type or conditions change with respect to
the target value conditions, a new target value
must be set. Repeat step 2 in order to establish a
new target value.

Illustration 110 g03679492

Compaction Meter Value (CMV) is an accelerometer

based compaction measurement method. Values can
only be obtained when the vibration is activated. As
the stiffness of the ground being compacted
increases, more of the energy transmitted to the
ground by the vibrating drum is reflected back up and
is measured by the accelerometer. CMV derives a
unit-less measure indication of soil stiffness, readings
are scaled in a range between 0-150.
CMV must be used correctly in order to take full
advantage of the system. Failure to use the CMV
system properly will result in false or misleading Illustration 111 g03679607
values. Use the following procedure for the best
results.
• For machines equipped with the fixed frequency, if
Note: Always operate the propel speed range control the machine starts to decouple while compacting
in low mode when CMV is in use. in high amplitude a message will be shown on the
display. When the decoupling message is shown,
1. Set up the monitoring system to display the CMV switch to low amplitude. If the machine keeps
value. For information on changing which signals decoupling, the vibration will have to be turned off,
are viewed on the monitoring system refer to at which point CMV will be rendered inoperable.
Operation and Maintenance Manual, “Monitoring For machines equipped with variable frequency,
System”. change the frequency first, then change the
amplitude. Changes in amplitude and or frequency
2. Establish a target compaction value. The target will require resetting the CMV target value.
value can be established using one of the following
4. Validate the compacted worksite. Proofing runs
methods:
require high accuracy. Establish a rolling pattern
Test Strip Comparison – Construct a test strip with a and proof roll the worksite uniformly using the
representative material, layer thickness, and moisture same compactor. If desired, randomly check for
level. Establish a rolling pattern and compact the test proper compaction of the worksite using traditional
strip at production settings (frequency, amplitude, and
roller speed). When CMV changes less than ±5 units compaction measurement methods.
between passes, this change is an indication the Use the following guidelines during validation:
compactor has achieved the maximum compactive
effort under the given conditions. Note the CMV • Operate in a forward direction. Measurements
value.
in reverse will be different.
Point Comparison – Choose a properly compacted
area on the worksite that has been measured with a • Operate the machine in low propel mode.
traditional compaction measurement system. Run the
machine over this area, and note the CMV value.
80 KEBU7577
Machine Operation
Cat Compaction Control

• Operate the machine with a constant speed of

3 km/h (2 mph) in order to decrease the
variation in the CMV value. CMV values will
change as speed is increased or decreased.
Automatic Speed Control (ASC) can be utilized
in order to maintain the proper speed. Use the
following steps in order to utilize ASC:

a. Set the monitoring system to indicate the

machine speed.

b. Push the propel lever all the way forward and

note the machine speed.

c. Increase or decrease the machine speed with

the speed control buttons to arrive at the
desired speed.

d. After the ASC is set up, pushing the propel

lever fully forward will result in a constant
speed.
Be aware of the following restrictions:
• CMV cannot be used with a padded drum or a
padded shell kit. If the machine is equipped with a
shell kit, the kit will have to be removed prior to
using the CMV and the machine main controller
will have to be set up accordingly by using the
display and selecting the no shell option. For more
information refer to Operation and Maintenance
Manual, “Monitoring System”. See also Special
Instruction, REHS8033, “Shell Kit Attachment
Installation and Removal Procedure for certain B
Series Vibratory Soil Compactors”.
• CMV is less effective on cohesive materials

• Readings are influenced by soil up to a depth of

1-2 m (3-6 ft)

• Values between machines will be different

Note: If the machine is equipped with Compaction
Meter Value, then the system can be upgraded to
include mapping. For more information consult your
Cat dealer.

Note: CMV is calibrated at the factory and does not

require a different field calibration.
KEBU7577 81
Engine Starting
Engine Starting

Engine Starting 2. Push the bottom of parking brake switch (2)

downward.
i04560368 3. Push the switch for the throttle control (4) until the
LOW RPM position is selected.
Engine Starting
4. Check the indicator for the engine starting aid. The
SMCS Code: 1000; 7000
indicator must be off before you start the engine.

NOTICE
Do not crank the engine for more than 30 seconds. Al-
low the starter to cool for two minutes before cranking
again.
Turbocharger (if equipped) damage can result, if the
engine is not kept low until the engine oil light/gauge
verifies the oil pressure is sufficient.
5. Briefly sound the horn before you start the engine.
6. In order to crank the engine, turn key (3) to the
START position. When the engine starts, release
the key.
Cold Weather Starting
When the temperature is below −18°C (0°F), the use
of optional cold weather starting aids is
recommended. A coolant heater, a fuel heater, a
jacket water heater, or extra battery capacity may be
required.
Before you operate the machine in temperatures
below −23°C (−10°F), consult your Caterpillar dealer
or refer to Special Publication, SEBU5898, “Cold
Weather Recommendations for All Caterpillar
Machines”.

Illustration 114 g00680895

Glow plug icon
Illustration 112 g02726493

During cold weather the glow plugs will activate and

the glow plug icon will display on the display monitor
until the glow plugs are ready. Turn the key to the ON
position and wait until the glow plug icon is not
displayed before starting to crank the engine.

Note: Depending on the temperature, the glow plugs

may be ready before the display monitor completes
the start-up checks at key on start-up.
Rotate the key switch to the start position after
performing the start-up check list. Hold the key in the
start position until the engine starts.
Note: If the engine does not start after 30 seconds of
cranking time, the starter will disengage to allow
cooling of the starter.
If the engine did not start, turn the key off and rotate
the key switch to the on position. Wait for the start-up
checks and glow plug icon to turn off. Rotate to the
start position until the engine starts.

Illustration 113 g02816800

1. Move propel control (1) to the STOP position.

82 KEBU7577
Engine Starting
Engine and Machine Warm-Up

i04562319

Engine and Machine Warm-Up

SMCS Code: 1000; 7000

NOTICE
Keep the engine speed low until the engine oil indica-
tor light goes out.
If the light does not go out within ten seconds, stop
the engine and investigate the cause before starting
again. Failure to do so, can cause engine damage.

NOTICE
Steering the machine completely to the steering stops
while the hydraulic oil is below 0 °C (32 °F) can dam-
age the steering system.
In temperatures below 0 °C (32 °F) work warm oil into
the system by steering only a small amount at a time
in each direction. Slowly increase the amount of each
turn before steering completely to the steering stop.

1. Allow a cold engine to warm up at LOW IDLE for at

least 5 minutes.
2. Cycle all controls in order to allow warm oil to
circulate through all of the lines and the cylinders.
Observe the following recommendations during the
warm-up period for the engine:

• In temperatures above 0°C (32°F), the warm-up

period is 5 minutes.
• In temperatures below 0°C (32°F), the warm-up
period is 15 minutes or longer.
• In temperatures below −18°C (0°F), more time is
required if the hydraulic controls are sluggish.

• Do not use the machine if the filter indicator is ON.

KEBU7577 83
Parking
Stopping the Machine

Parking
i04560397

Stopping the Machine

SMCS Code: 7000

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

Illustration 116 g02816858

3. Push the switch for the throttle control (3) until Low
Idle or ECO Mode is selected.

i04560437

Stopping the Engine

SMCS Code: 1000; 7000
Illustration 115 g02726528

1. Move propel control (1) to the STOP position.
2. Push the top of the parking brake control switch (2)
downward.
NOTICE
Stopping the engine immediately after it has been
working under load, can result in overheating and ac-
celerated wear of the engine components.
Follow the stopping procedure outlined below, in or-
der to allow the engine to cool and prevent excessive
temperatures in the turbocharger center housing,
which could cause oil coking problems.

1. Before stopping the engine, allow the engine to run

at low idle with no load for 5 minutes. This
procedure allows the hot areas of the engine to
cool gradually and the procedure will extend the
life of the engine.
84 KEBU7577
Parking
Leaving the Machine

Illustration 117 g02726539

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

Remove the key.

3. Be sure that all of the controls are in the OFF

position. Be sure that all of the controls are in the
proper position for parking the machine.

i04562349

Leaving the Machine

SMCS Code: 7000

1. Use the steps and the handholds in order to

dismount the machine. Face the machine in order
to dismount the machine.
2. Always turn the battery disconnect switch to the
OFF position before leaving the machine.

3. If the machine will not be operated for a month or

more, remove the battery disconnect switch key.

4. Close all access covers and doors. If your machine

is equipped with a vandalism guard, install the
vandalism guard before you leave the machine.
KEBU7577
Transportation Information
i05319602
Shipping the Machine
SMCS Code: 7000; 7500
For the basic specifications of the machine, refer to
the Operation and Maintenance Manual,
“Specifications”.
Investigate the travel route for overpass clearances.
Make sure that there is adequate clearance for the
machine that is being transported.
Remove ice, snow, or other slippery material from the
loading dock and from the truck bed before you load
the machine onto the transport machine. Removing
ice, snow, or other slippery material will help to
prevent the machine from slipping in transit.
Note: Obey all laws that govern the characteristics of
a load (height, weight, width, and length). Observe all
regulations that govern wide loads.
When you move the machine to a colder climate,
make sure that the cooling system has the proper
antifreeze.
Illustration 118 g00303463
1. Before you load the machine, chock the trailer
wheels or the rail car wheels, as shown.
2. Rotate the antenna to the down position.
3. Move the machine into position.
4. Apply the parking brake for the machine.
5. Turn the engine start switch key to the OFF
position. Remove the key.
85
Transportation Information
Shipping the Machine
Illustration 119 g02219014
6. Install the steering frame lock pin. The pin will hold
the front frame and the rear frame rigid.
Refer to the Operation and Maintenance Manual,
“Steering Frame Lock” for further information.
7. Block the machine, and tie down the machine.
Refer to the Operation and Maintenance Manual,
“Lifting and Tying Down the Machine” for more
information.
8. Lock the doors and the access covers. Attach any
vandalism protection. Install the cover on the
console. Cover the operator seat.
9. To protect the cooling systems, mix a solution of
antifreeze and water. The solution should provide
protection to the lowest expected outside
temperature. Drain the excess coolant into a
suitable container.
10. Cover the exhaust opening. The turbocharger (if
equipped) should not rotate when the engine is not
operating. Damage to the turbocharger can result.
11. Perform a walk-around inspection and measure
the fluid levels in the various compartments.
Consult your Cat dealer for shipping instructions for
your machine.
i01954658
Roading the Machine
SMCS Code: 7000; 7500
Inflate the tires to the correct pressure. Refer to the
Operation and Maintenance Manual, “Tire Inflation
Pressure Adjustment”.
Perform a walk around inspection of the machine.
Measure the fluid levels in the various compartments.
86 KEBU7577
Transportation Information
Lifting and Tying Down the Machine

Check with the proper officials in order to obtain the Position the crane or the lifting device in order to lift
required licenses. the machine in a level position.
Install any required flags, signals, or lights.
Travel at a moderate speed. Observe all speed
limitations when you road the machine.

i06127121

Lifting and Tying Down the

Machine
SMCS Code: 7000; 7500

Improper lifting or tie-downs can allow load to

shift and cause injury and damage.

Illustration 121 g03817983

Preferred lifting method

Illustration 120 g03749746

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

the maximum weight of the machine
without any work tools.

Lifting Point – In order to lift the

machine, attach the lifting devices to the
lifting points.

Tie Down Point – In order to tie down the

machine, attach the tie-downs to the tie
down points.

Lifting the Machine

Use properly rated cables and properly rated slings in
order to lift the machine.
KEBU7577 87
Transportation Information
Lifting and Tying Down the Machine

Illustration 122 g03817985

Secondary lifting method

1. Move the machine into position.

2. Apply the parking brake.

Illustration 123 g03050357
3. Turn the engine start switch key to the OFF Preferred tie down method
position. Remove the key.

4. Install the steering frame lock pin.

5. 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.

6. 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

Do not tie down the machine over the operator
platform. Tying down the machine over the operator
platform will reduce the life of the drum mounts and Illustration 124 g03050459
the isolation mounts for the platform.
Front tie down points
Do not tie down the machine over the articulation
hitch. Tying down the machine over the articulation
hitch will reduce the life of the articulation bearings. 1. Move the machine into position.

2. Apply the parking brake.

88 KEBU7577
Transportation Information
Lifting and Tying Down the Machine

3. Turn the engine start switch key to the OFF

position. Remove the key.

4. Install the steering frame lock pin.

5. Chock the front drum and the rear tires.

6. Use the tie-down positions in order to secure the
machine. The tie-down positions are identified on
the machine by labels. There are two tie-down
positions on each side of the machine.
Refer to Operation and Maintenance Manual,
“Shipping the Machine” for shipping instructions.
KEBU7577
Towing Information
i04562363
Towing the Machine
SMCS Code: 7000
Improper hookup and towing is dangerous and
could result in injury or death to yourself or
others.
The towing connection must be rigid, or towing
must be done by two machines of the same size
as the towed machine. If two machines are used,
connect a machine on each end of the towed
machine.
If only one machine is used for towing, that ma-
chine must be larger than the towed machine.
Be sure that all necessary repairs and adjust-
ments have been made before a machine that has
been towed to a service area is put back into
operation.
These towing instructions are for moving a disabled
machine for a short distance at low speed. Move the
machine at a speed of 2 km/h (1.2 mph) or less to a
convenient location for repair. These instructions are
only for emergencies. Always haul the machine if long
distance moving is required.
Shielding must be provided on both machines. This
will protect the operator if the tow line or the tow bar
breaks.
Do not allow an operator to be on the machine that is
being towed unless the operator can control the
steering and/or the braking.
Before towing, make sure that the tow line or the tow
bar is in good condition. Make sure that the tow line or
the tow bar has enough strength for the towing
procedure that is involved. The strength of the towing
line or of the tow bar should be at least 150 percent of
the gross weight of the towing machine. This is true
for a disabled machine that is stuck in the mud and
for towing on a grade.
Keep the tow line angle to a minimum. Do not exceed
a 30 degree angle from the straight ahead position.
Quick machine movement could overload the tow line
or the tow bar. This could cause the tow line or the
tow bar to break. Gradual, steady machine movement
will be more effective.
89
Towing Information
Towing the Machine
Normally, the towing machine should be as large as
the disabled machine. Make sure that the towing
machine has enough brake capacity, enough weight,
and enough power. The towing machine must be able
to control both machines for the grade that is involved
and for the distance that is involved.
You must provide sufficient control and sufficient
braking when you are moving a disabled machine
downhill. This may require a larger towing machine or
additional machines that are connected to the rear.
This will prevent the machine from rolling away out of
control.
All situation requirements cannot be listed. Minimal
towing machine capacity is required on smooth, level
surfaces. On inclines in poor condition or on surfaces
in poor condition, maximum towing machine capacity
is required.
Attach the towing device and the machine before you
release the brakes.
Consult your Cat dealer for towing a disabled
machine.
Carefully follow all of the instructions in this section.
Running Engine
If the engine is running, the machine can be towed for
a short distance under certain conditions. The brakes
and the steering system must be operable.
Note: If there is a failure in the propel system, the
bypass valves will need to be disengaged before you
tow the machine. Refer to Operation and
Maintenance Manual, “Towing the Machine - Stopped
Engine” for information on disengaging the bypass
valves.
Illustration 125 g02223653
1. Block the drum and block the tires securely in order
to prevent movement of the machine. Do not
remove the blocking until the tow vehicle has been
positioned and the tow lines are in place.
90 KEBU7577
Towing Information
Towing the Machine

Stopped Engine

Shutting off the engine will result in the loss of

machine steering and the machines brakes will be
applied.

When the engine is stopped, additional steps may be

required before the machine is towed in order to avoid
damaging the power train, the steering system, and
the brakes.

Illustration 126 g02817359

2. Install a balance line between ports “ma” and

“mb” of the axle pump.

Illustration 128 g02223653

1. Block the drum and block the tires securely in order

to prevent the movement of the machine. Do not
remove the blocking until the tow vehicle has been
positioned and the tow lines are in place.

Illustration 127 g02817377 2. Install the steering frame lock pin. Refer to the
Operation and Maintenance Manual, “Steering
3. Install a balance line between ports “ma” and Frame Lock” for further information on the steering
“mb” of the drum pump. frame lock.
4. Attach the towing machine.

5. Remove the blocks.

6. Start the engine. Personal injury or death can result from a brake
malfunction.
7. Release the parking brake. Be sure all necessary repairs and adjustments
have been made before a machine that has been
8. Steer the machine that is towed in the direction of towed to a service area, is put back into
the tow line. operation.

9. When the disabled machine is in place, set the

parking brake.

10. Stop the engine and remove the key.

11. Block the machine.

12. Remove the tow lines.
13. Remove the balance lines.
KEBU7577 91
Towing Information
Towing the Machine

6. Connect the parking brake release pump. Refer to

the Operation and Maintenance Manual, “Parking
Brake Manual Release” for more information.
7. Attach the tow lines to the disabled machine.
8. Attach the tow line to the tow vehicle.
Note: Move the tow vehicle so that there is slight
tension on the tow line. This will maintain movement
of the disabled machine when the parking brake is
released.
9. Remove the steering lock pin.

Illustration 129 g01397806 10. Remove the blocks from the drum and the tires.

3. Disconnect the cylinders for steering from the hitch.

Secure the cylinders to the main frame of the NOTICE
Release the parking brake to prevent excessive wear
machine.
and damage to the braking system when towing.
The procedure for manual release of the parking
brake is outlined in the Operation and Maintenance
Manual, “Parking Brake Manual Release”.

11. Manually release the parking brake. Refer to the

Operation and Maintenance Manual, “Parking
Brake Manual Release” for more information.
12. Slowly tow the disabled machine to the desired
destination.
13. Block the drum and block the tires securely.

14. Disconnect the parking brake release pump.

Illustration 130 g02817359
15. Install the steering frame lock.
4. Install a balance line between ports “ma” and 16. Detach the towing machine and the tow lines.
“mb” of the axle pump.
17. Remove the balance lines
18. Connect the cylinders for the steering to the hitch.

19. Remove the steering lock pin.

Illustration 131 g02817377

5. Install a balance line between ports “ma” and

“mb” of the drum pump.
92 KEBU7577
Towing Information
Parking Brake Manual Release

i04562385

Parking Brake Manual Release

SMCS Code: 4267; 4354

Personal injury or death can result from a brake

malfunction. Do not operate the machine if the
brake was applied due to a malfunction of the
brake system.
Correct any problem before attempting to operate
the machine.
Illustration 133 g00040674

Note: The parking brake is located on the final drive
planetary (drum).
1. In order to prevent the machine from moving, block
the drum and block the tires securely.
4. In order to release the brakes, use the FT-1973
Adapter Group and the FT-1845 Pump Group.
5. Connect the brake release hose to the FT-1973
Adapter Group(5).

6. Turn the handle (4) of the bypass to the CLOSED

position.

7. Observe the opening pressure of the relief valve (2)

while you operate the pump handle (3).

NOTICE
Possible brake piston seal damage could result with-
out checking the relief valve. The opening pressure
must be checked and adjusted before making a
connection.

8. Adjust the opening pressure to 2413 ± 69 kPa

Illustration 132 g02219014
(350 ± 10 psi). Turn the handle (4) of the bypass to
the OPEN position.
2. In order to hold the front frame and the rear frame
rigid, install the steering frame lock pin.

3. The brakes can be released when you use the

following procedure.

Illustration 134 g02728101

9. Disconnect the brake line. In order to prevent the

loss of fluid, plug the brake line.
KEBU7577 93
Towing Information
Parking Brake Manual Release

Note: Depending on machine configuration there

may be two brake lines connected to the propel
pump. Remove the T junction from the pump that
both lines are connected to.
10. Connect the 8T-2857 Brake Release Adapter to
the brake line, or the T junction that connects to
both brake lines, depending on configuration.
Install the remainder of the FT-1973 Adapter
Group(5) to the pump pressure hose.

11. Place the pump near the operator.

12. Turn the handle (4) for the bypass to the CLOSED
position.

13. Operate the pump handle in order to produce a

pressure rise. The seal is seated when the
pressure rises to the maximum value.

14. When the engine is stopped, additional steps are

required before the machine is towed. Refer to the
Operation and Maintenance Manual, “Towing the
Machine” for more information.
15. The machine can be towed.
Tow the machine for short distances only. Tow the
machine at a slow speed of less than 2 km/h
(1.2 mph).
94
Engine Starting (Alternate Methods)
Engine Starting with Jump Start Cables
Engine Starting (Alternate
Methods)
i04032490
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 can prevent damage
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.
KEBU7577
Use of Jump Start Cables
When the auxiliary start receptacle is not available,
use the following procedure.
1. Make the initial determination of the machine's
failure to crank. Refer to Special Instruction,
REHS0354, “Use of 6V-2150 Starting Charging
Analyzer Group”. The procedure is applicable even
if the machine does not have a diagnostic
connector.
2. Move the transmission of the stalled machine into
the STOP position. Engage the parking brake.
Lower all attachments to the ground. Move all
controls to the HOLD position.
3. Turn the engine start switch on the stalled machine
to the OFF position. Turn off all accessories.
4. Turn on the battery disconnect switch on a stalled
machine.
5. Move the machine that is being used as a power
source so that the jump-start cables can reach the
stalled machine. DO NOT ALLOW THE
MACHINES TO CONTACT EACH OTHER.
6. Stop the engine on the machine that is being used
as a power source. If you are using an auxiliary
power source, turn off the charging system.
7. Check the battery caps for correct placement and
for correct tightness. Make these checks on both
machines. Make sure that the batteries in the
stalled machine are not frozen. Check the batteries
for low electrolyte.
Illustration 135 g02223817
8. Open the battery access cover.
KEBU7577
Illustration 136 g02223837
9. Connect the positive jump-start cable to the
positive battery terminal.
Do not allow positive cable clamps to contact any
metal except for the positive battery terminal.
10. Connect the positive jump-start cable to the
positive terminal of the boost source. Use the
procedure from Step 9 in order to determine the
correct terminal.
11. Connect one end of the negative jump-start cable
to the negative terminal of the electrical source.
Illustration 137 g02223854
12. Make the final connection. Connect the negative
cable to the negative battery terminal.
13. Start the engine on the machine that is being
used as a power source. If you are using an
auxiliary power source, energize the charging
system on the auxiliary power source.
14. Wait for a minimum of two minutes while the
batteries in the stalled machine partially charge.
95
Engine Starting (Alternate Methods)
Engine Starting with Auxiliary Start Receptacle
15. Attempt to start the stalled engine. Refer to
Operation and Maintenance Manual, “Engine
Starting”.
16. Immediately after you start the stalled engine,
disconnect the jump-start cable from the machine
that is being used as a power source.
17. Disconnect the other end of the jump-start cable
from the stalled machine.
18. When the engine is running and the charging
system is in operation, conclude the failure
analysis on the starting charging system of the
stalled machine, as required.
i04562397
Engine Starting with Auxiliary
Start Receptacle
SMCS Code: 1450; 1463
NOTICE
To prevent damage to engine bearings and to electri-
cal circuits when you jump-start a machine, do not al-
low the stalled machine to touch the machine that is
used as the electrical source.
Turn on (close) the battery disconnect switch prior to
the boost connection to prevent damage to electrical
components on the stalled machine.
Use only equal voltage for starting. Check the battery
and starter voltage rating of your machine. Use only
the same voltage for jump starting. Use of a welder or
higher voltage will damage the electrical system.
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.
Refer to Special Instruction, SEHS7633, “Battery Test
Procedure” for complete testing and charging infor-
mation. This publication is available from your Cat
dealer.
96 KEBU7577
Engine Starting (Alternate Methods)
Engine Starting with Auxiliary Start Receptacle

10. Wait for a minimum of 2 minutes while the

batteries in the stalled machine partially charge.

11. Attempt to start the stalled engine. Refer to

Operation and Maintenance Manual, “Engine
Starting”.

12. Immediately after you start the stalled engine,

disconnect the jump-start cable from the machine
that is being used as a power source.

13. Disconnect the other end of the jump-start cable

from the stalled machine.
Illustration 138 g02728152
14. When the engine is running and the charging
Some products may be equipped with auxiliary start system is in operation, conclude the failure
receptacles as a standard part. All other machines analysis on the starting charging system of the
can be equipped with a receptacle from parts service. stalled machine, as required.
Then, a permanent receptacle is always available for
jump starting.
Two cable assemblies are also available in order to
jump-start the stalled machine from another machine
that is also equipped with this receptacle or with an
auxiliary power pack. Your Cat dealer can provide
the correct cables for your application.

1. Make the initial determination of the machine's

failure to crank.
2. Move the transmission of the stalled machine into
the STOP position. Engage the parking brake.
Lower all attachments to the ground.

3. Turn the engine start switch on the stalled machine

to the OFF position. Turn off all accessories.

4. Turn on the battery disconnect switch on the stalled

machine.
5. Move the machine that is being used as a power
source so that the jump-start cables can reach the
stalled machine. DO NOT ALLOW THE
MACHINES TO CONTACT EACH OTHER.
6. Stop the engine on the machine that is being used
as a power source. If you are using an auxiliary
power source, turn off the charging system.

7. On the stalled machine, connect the appropriate

jump-start cable to the auxiliary start receptacle.

8. Connect the other end of the jump-start cable to

the auxiliary start receptacle that is on the power
source.
9. Start the engine on the machine that is being used
as a power source. If you are using an auxiliary
power source, energize the charging system on
the auxiliary power source.
KEBU7577 97
Maintenance Section
Access Doors and Covers

Maintenance Section

Maintenance Access
i04032476

Access Doors and Covers

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

Engine Hood

Illustration 139 g02223696

Use the handle in order to unlatch the hood for the

engine. Opening the engine hood will allow access to
the engine and major components.
98 KEBU7577
Tire Inflation Information
Tire Shipping Pressure

Tire Inflation Information

i02828698

Tire Shipping Pressure

SMCS Code: 4203; 7500
The tire inflation pressures that are shown in the
following table are the shipping pressures. The
shipping pressures will vary from the operating
pressures for the machine. Adjust the tire pressures
before operating the machine.
Table 18
Ply Rating Maximum Shipping Pressure

8 200 kPa (30 psi)

10 200 kPa (30 psi)

12 200 kPa (30 psi)

14 200 kPa (30 psi)

KEBU7577 99
Lubricant Viscosities and Refill Capacities
Lubricant Viscosities

Lubricant Viscosities and NOTICE

Refill Capacities Not following the recommendations found in this man-
ual can lead to reduced performance and compart-
ment failure.
i05193070

Lubricant Viscosities Engine Oil

(Fluids Recommendations) Cat oils have been developed and tested in order to
SMCS Code: 1000; 7000; 7581 provide the full performance and life that has been
designed and built into Cat engines.

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.
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

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.
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.
100 KEBU7577
Lubricant Viscosities and Refill Capacities
Lubricant Viscosities

Table 19
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

When fuels of sulfur level of 0.1 percent (1000 ppm) • Cat MTO
or higher are used, Cat DEO-ULS may be used if
S·O·S oil analysis program is followed. Base the oil • Cat DEO
change interval on the oil analysis.
• Cat DEO-ULS
Hydraulic Systems
• Cat TDTO
Refer to the “Lubricant Information” section in the
latest revision of the Special Publication, SEBU6250, • Cat TDTO Cold Weather
“Caterpillar Machine Fluids Recommendations” for
detailed information. This manual may be found on • Cat TDTO-TMS
the Web at Safety.Cat.com.
• Cat DEO-ULS SYN
The following are the preferred oils for use in most
Cat machine hydraulic systems: • Cat DEO SYN

• Cat HYDO Advanced 10 SAE 10W • Cat DEO-ULS Cold Weather

• Cat HYDO Advanced 30 SAE 30W

• 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.
Table 20
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
Hydraulic System SAE 10W −20 40 −4 104
Cat TDTO

(continued)
KEBU7577 101
Lubricant Viscosities and Refill Capacities
Lubricant Viscosities

(Table 20, contd)

Lubricant Viscosities for Ambient Temperatures

Oil Type and Performance °C °F

Compartment or System Oil Viscosities
Requirements Min Max Min Max
Cat HYDO Advanced 30
SAE 30 0 50 32 122
Cat TDTO
Cat BIO HYDO Advanced “ISO 46” Multi-Grade −30 45 −22 113
Cat MTO
Cat DEO-ULS SAE10W-30 −20 40 −4 104
Cat DEO
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 Compactors For low temperatures, do not use API GL-5 or API
GL-4 Gear Oils for the Vibratory support, the Final
Refer to the “Lubricant Information” section in the Drive Planetary (Drum), or the Eccentric Weight
latest revision of the Special Publication, SEBU6250, Housing. Select a commercial full synthetic gear and
“Caterpillar Machine Fluids Recommendations” for bearing lubricant with no viscosity improvers and with
detailed information. This manual may be found on ISO 68 viscosity grade. This lubricant should have a
the Web at Safety.Cat.com. minimum viscosity index of 145, and have a minimum
pour point of −47 °C (−53 °F).
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.
Do not use SAE 50 viscosity grade oil in ICM
controlled transmissions. Do not use SAE 50
viscosity grade oil for the hydraulic drive winch case.
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.
Do not use API GL-5 or API GL-4 Gear Oils for the
Vibratory support, the Final Drive Planetary (Drum),
or the Eccentric Weight Housing. 4C-6767 Synthetic
Oil is a premium PAO (Polyalpaolefin) synthetic gear
and bearing lubricant with no viscosity improvers.
This lubricant has an ISO viscosity grade of 220, and
a minimum viscosity index of 152. Commercial oil
selected for this application should have a full
synthetic base stock with no viscosity improvers, an
ISO viscosity grade of 220, and a minimum viscosity
index of 150.
102 KEBU7577
Lubricant Viscosities and Refill Capacities
Lubricant Viscosities

Table 21
Lubricant Viscosities for Ambient Temperatures

°C °F
Compartment or System Oil Type and Category Oil Viscosities
Min Max Min Max
Cat HYDO Advanced 10
SAE 10W −20 40 −4 104
Cat TDTO
Cat HYDO Advanced 30
SAE 30 0 50 32 122
Cat TDTO
Cat BIO HYDO Advanced “ISO 46” Multi-Grade −30 45 −22 113
Cat MTO
Cat DEO-ULS SAE10W-30 −20 40 −4 104
Cat DEO
Drum Cooling Oil
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
SAE 30 -20 43 -4 110
Axle - Differential and Cat TDTO
SAE 50 10 50 50 122
Planetaries commercial TO-4
Cat TDTO - TMS -30 43 -22 110

Cat 4C-6767 synthetic ISO 220 -20 50 -4 122

Cat TDTO
Vibratory Support SAE 50 -11 50 12 122
commercial TO-4
commercial synthetic synthetic ISO 68 -47 21 -53 70

Cat 4C-6767 synthetic ISO 220 -20 50 -4 122

Cat TDTO
Final Drive Planetary (Drum) SAE 50 -11 50 12 122
commercial TO-4
commercial synthetic synthetic ISO 68 -47 21 -53 70

Cat 4C-6767 synthetic ISO 220 -20 50 -4 122

Eccentric Weight Housing
commercial synthetic synthetic ISO 68 -47 21 -53 70

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.
KEBU7577 103
Lubricant Viscosities and Refill Capacities
Lubricant Viscosities

Table 22
Recommended Grease
°C °F
Compartment or System GreaseType NLGI Grade
Min Max Min Max
Cat Advanced 3Moly NLGI Grade 2 −20 40 −4 104

NLGI Grade 2 −30 50 −22 122

Cat Ultra 5Moly NLGI Grade 1 −35 40 −31 104
External Lubrication Points
NLGI Grade 0 −40 35 −40 95
Cat Arctic Platinum NLGI Grade 0 −50 20 −58 68
Cat Desert Gold NLGI Grade 2 −20 60 −4 140
Steering Column(1) Cat Multipurpose Grease NLGI Grade 2 −30 40 −22 104
(1) HMU Steering

Diesel Fuel Recommendations
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.
Misfueling with fuels of high sulfur level can have
the following negative effects:
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.
Refer to Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” for more details
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.

• Reduce engine efficiency and durability Biodiesel

• Increase the wear Biodiesel is a fuel that can be made from various
renewable resources that include vegetable oils,
• Increase the corrosion animal fat, and waste cooking oil. Soybean oil and
rapeseed oil are the primary vegetable oil sources. In
• Increase the deposits order to use any of these oils or fats as fuel, the oils or
fats are chemically processed (esterified). The water
• Lower fuel economy and contaminants are removed.

• Shorten the time period between oil drain intervals
(more frequent oil drain intervals)
• Increase overall operating costs
• 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.
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.
104 KEBU7577
Lubricant Viscosities and Refill Capacities
Lubricant Viscosities

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)
Acceptable – Cat DEAC (Diesel Engine Antifreeze/
Coolant)

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.
KEBU7577 105
Lubricant Viscosities and Refill Capacities
Capacities (Refill)

Standard Factory Fill Fluids

Table 23
Standard Factory Fill Fluids(1)

°C °F
Compartment or System Oil Viscosities
Min Max Min Max
Engine Crankcase SAE 10W-30 -9.5 50 15 122

Hydraulic Systems Cat HYDO Advanced 10 -20 40 -4 104

Axle - Differential and Planetaries SAE 30 -20 43 -4 110

Vibratory Support synthetic ISO 220(2) -20 50 -4 122

Final Drive Planetary (Drum) synthetic ISO 220(2) -20 50 -4 122

Eccentric Weight Housing synthetic ISO 220(2) -20 50 -4 122

(1) The machine is delivered from the factory with the designated fluids.
(2) Do not use API GL-5 or API GL-4 Gear Oils for the Vibratory support, the Final Drive Planetary (Drum), or the Eccentric Weight Housing. 4C-
6767 (185-4759) Synthetic Oil is a premium PAO (Polyalpaolefin) synthetic gear and bearing lubricant with no viscosity improvers. This lubri-
cant has an ISO viscosity grade of 220, and a minimum viscosity index of 152. Commercial oil selected for this application should have a full
synthetic base stock with no viscosity improvers, an ISO viscosity grade of 220, and a minimum viscosity index of 150.

i05918698 (Table 24, contd)

Eccentric Weight Housing 13 3.2 2.6
Capacities (Refill)
Drum Cooling Oil(2) 21 5.6 4.6
SMCS Code: 1000; 6320; 7000; 7560
Vibratory Support Housing 0.85 0.22 0.19
S/N: 6841–Up
Final Drive Planetary (Drum) 4.3 1.14 0.95
S/N: 4371–Up Final Drive Planetary (Axle) 1.75 0.5 0.4
S/N: 4381–Up (1) Add 0.5 L (0.5 qt) of 197-0017Axle and Brake Oil Additive
when you change the oil in the axle center housing.
S/N: 4391–Up (2) The drum cooling oil is for cooling purposes only. The mainte-
nance interval does not require the drum cooling oil to be
S/N: MBF1–Up changed.
S/N: M4M1–Up
i05916581
S/N: M5P1–Up
S/N: SDT1–Up Capacities (Refill)
Table 24 SMCS Code: 1000; 6320; 7000; 7560
REFILL CAPACITIES S/N: 4411–Up
Approximate
CS56B / CP56B / CS68B / CP68B S/N: 4431–Up
US Imperial S/N: 7441–Up
Compartment or System Liters
Gallons Gallons
Cooling System 27.8 7.3 6.1
S/N: C791–Up

Heater System 1.2 0.32 0.26 S/N: M7B1–Up

Fuel Tank Capacity 242 64.0 53.2 S/N: E7E1–Up

Engine Oil with Filter 16.5 4.36 3.63 S/N: M8M1–Up

Hydraulic Tank (only) 50 13.2 11.0

Differential and Axle Gear 14.5 3.8 3.2

Reducer (1)

(continued)
106 KEBU7577
Lubricant Viscosities and Refill Capacities
S·O·S Information

Table 25
REFILL CAPACITIES
Approximate
CS74B / CP74B / CS78B / CS79B
US Imperial
Compartment or System Liters
Gallons Gallons
Cooling System 28.2 7.4 6.2

Heater System 1.2 0.32 0.26

Fuel Tank Capacity 332 87.7 73.0

Engine Oil with Filter 16.5 4.36 3.63

Hydraulic Tank (only) 50 13.2 11.0

Differential and Axle Gear 14.5 3.8 3.2

Reducer (1)

Eccentric Weight Housing 13 3.2 2.6

Drum Cooling Oil(2) 21 5.6 4.6

Vibratory Support Housing 0.85 0.22 0.19

Final Drive Planetary (Drum) 4.3 1.14 0.95

Final Drive Planetary (Axle) 1.75 0.5 0.4

(1) Add 0.5 L (0.5 qt) of 197-0017Axle and Brake Oil Additive
when you change the oil in the axle center housing.
(2) The drum cooling oil is for cooling purposes only. The mainte-
nance interval does not require the drum cooling oil to be
changed.

i04311449

S·O·S Information
SMCS Code: 1348; 3080; 4070; 4250; 4300; 5050;
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.
KEBU7577
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; 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 ob-
structions 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 re-
leased before any service is done on the
hydraulic 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.
107
Maintenance Support
System Pressure Release
3. Tighten the filler cap.
4. The pressure in the hydraulic system has been
released. Lines and components can be removed.
i03636245
Welding on Machines and
Engines with Electronic
Controls
SMCS Code: 1000; 7000
Do not weld on any protective structure. If it is
necessary to repair a protective structure, contact
your Caterpillar dealer.
Proper welding procedures are necessary in order to
avoid damage to the electronic controls and to the
bearings. When possible, remove the component that
must be welded from the machine or the engine and
then weld the component. If you must weld near an
electronic control on the machine or the engine,
temporarily remove the electronic control in order to
prevent heat related damage. The following steps
should be followed in order to weld on a machine or
an engine with electronic controls.
1. Turn off the engine. Place the engine start switch in
the OFF position.
2. If equipped, turn the battery disconnect switch to
the OFF position. If there is no battery disconnect
switch, remove the negative battery cable at the
battery.
NOTICE
Do NOT use electrical components (ECM or sensors)
or electronic component grounding points for ground-
ing the welder.
3. Clamp the ground cable from the welder to the
component that will be welded. Place the clamp as
close as possible to the weld. Make sure that the
electrical path from the ground cable to the
component does not go through any bearing. Use
this procedure 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
108 KEBU7577
Maintenance Support
Welding on Machines and Engines with Electronic Controls

4. Protect any wiring harnesses and components

from the debris and the spatter which is created
from welding.

5. Use standard welding procedures in order to weld

the materials together.
KEBU7577 109
Maintenance Support
Maintenance Interval Schedule

i06123158 “Wheel Nuts - Tighten”.......................................... 157

Maintenance Interval Schedule “Window Washer Reservoir - Fill”......................... 157

SMCS Code: 1000; 7000 “Window Wiper - Inspect/Replace”....................... 157

Ensure that all safety information, warnings, and “Windows - Clean” ................................................ 158
instructions are read and understood before any
operation or any maintenance procedures are Initial 10 Service Hours
performed.
“Shell Kit Bolt Torque - Check”.............................. 151
The user is responsible for the performance of
maintenance. All adjustments, the use of proper Every 10 Service Hours or Daily
lubricants, fluids, filters, and the replacement of
components due to normal wear and aging are “Backup Alarm - Test” ............................................111
included. Failure to adhere to proper maintenance
intervals and procedures may result in diminished “Cooling System Coolant Level - Check” ..............116
performance of the product and/or accelerated wear
of components. “Engine Oil Level - Check”.................................... 129

Use mileage, fuel consumption, service hours, or “Hydraulic System Oil Level - Check ”.................. 146
calendar time, WHICH EVER OCCURS FIRST, in
order to determine the maintenance intervals. “Seat Belt - Inspect” .............................................. 150
Products that operate in severe operating conditions
may require more frequent maintenance. Refer to the Every 50 Service Hours or Weekly
maintenance procedure for any other exceptions that
may change the maintenance intervals. “Fuel Tank Water and Sediment - Drain” .............. 143

Note: Before each consecutive interval is performed, “Leveling Blade - Lubricate”.................................. 148
all maintenance from the previous interval must be
“Steering Cylinder Ends - Lubricate” .................... 153
performed.
“Tire Inflation - Check” .......................................... 153
When Required
“Battery - Clean/Check” ......................................... 111
Initial 250 Service Hours
“Axle Oil (Rear) - Change” .....................................110
“Battery - Recycle” .................................................112
“Final Drive Planetary (Axle) Oil - Change” .......... 133
“Battery or Battery Cable - Inspect/Replace”.........112
“Final Drive Planetary (Drum) Oil - Change” ........ 135
“Cab Air Filter - Clean/Replace” ............................113
“Vibratory Support Oil - Change” .......................... 155
“Cutting Edges (Leveling Blade) - Inspect/
Replace” ............................................................... 121 Every 250 Service Hours
“Door Latches - Lubricate”.................................... 121
“Cooling System Coolant Sample (Level 1) -
“Drum Cooling Oil - Change” ................................ 122 Obtain” ...................................................................117

“Drum Scrapers - Inspect/Adjust/Replace”........... 122 Every 250 Service Hours or 3

“Engine Air Filter Primary Element - Clean/ Months
Replace” ............................................................... 127
“Axle Oil Level (Rear) - Check”..............................111
“Engine Air Filter Secondary Element - Replace”. 128
“Belts - Inspect/Adjust/Replace”............................112
“Film (Product Identification) - Clean”................... 132
“Engine Oil Sample - Obtain”................................ 130
“Fuel System - Prime”........................................... 136
“Final Drive Planetary (Axle) Oil Level - Check”... 134
“Fuses - Replace” ................................................. 143
“Final Drive Planetary (Drum) Oil - Check”........... 136
“Oil Filter - Inspect” ............................................... 148
“Isolation Mounts - Inspect/Replace”.................... 147
“Radiator Core - Clean” ........................................ 149
“Vibratory Support Oil Level - Check”................... 156
“Tire Spacing - Change” ....................................... 154
110 KEBU7577
Maintenance Support
Axle Oil (Rear) - Change

Every 500 Service Hours Every 3000 Service Hours

“Fuel Tank Strainer - Clean”.................................. 142 “Steering Column Spline (HMU Steering) -
Lubricate”.............................................................. 151
“Hood Latch - Adjust ”........................................... 145
Every 3000 Service Hours or 2
Every 500 Service Hours or 6
Years
Months
“Cooling System Water Temperature Regulator -
“Axle Oil Sample - Obtain” .....................................111 Replace” ................................................................119
“Engine Oil and Filter - Change”........................... 130
Every 3 Years
“Fuel System Filter (In-Line) - Replace” ............... 137
“Seat Belt - Replace” ............................................151
“Fuel System Primary Filter (Water Separator) -
Replace” ............................................................... 138 Every 3000 Service Hours or 3
“Fuel System Secondary Filter - Replace” ........... 139 Years
“Eccentric Weight Housing Oil - Change”............. 124
“Fuel System Third Filter - Replace”..................... 140
“Hydraulic System Oil Sample - Obtain”............... 147 Every 6000 Service Hours or 3
“Parking Brake - Check” ....................................... 149
Years
“Cooling System Coolant Extender (ELC) - Add” ..115
“Shell Kit Bolt Torque - Check”.............................. 151
“Vibratory Support Oil Sample - Obtain”............... 157 Every 12 000 Service Hours or 6
Years
Every 1000 Service Hours or 1 Year
“Cooling System Coolant (ELC) - Change” ...........113
“Axle Oil (Rear) - Change” .....................................110
i04201614
“Cooling System Pressure Cap - Clean/Replace”.118
“Engine Valve Lash - Check/Adjust”..................... 131 Axle Oil (Rear) - Change
“Final Drive Planetary (Axle) Oil - Change” .......... 133 SMCS Code: 3260-044; 3278-044; 3278

“Final Drive Planetary (Axle) Oil Sample - Obtain”134

“Final Drive Planetary (Drum) Oil - Change” ........ 135
“Final Drive Planetary (Drum) Oil Sample -
Obtain” .................................................................. 136
“Hydraulic System Oil Filter - Replace” ................ 145
“Hydraulic Tank Breather - Replace” .................... 147
“Rollover Protective Structure (ROPS) - Inspect”. 150
“Vibratory Support Oil - Change” .......................... 155

Every 2000 Service Hours

Illustration 140 g02391056
“Fuel Tank Cap Filter - Replace”........................... 142

Every Year 1. Remove differential drain plug (1). The plug is

located on the back side of the differential case at
“Cooling System Coolant Sample (Level 2) - the bottom.
Obtain” ...................................................................118
Note: Drain the oil into a suitable container. Dispose
of the used oil in an appropriate manner.
KEBU7577 111
Maintenance Support
Axle Oil Level (Rear) - Check

2. Remove differential level/fill plug (2). Differential Start the engine in order to perform the test. The
level/fill plug (2) is located on the back side of the backup alarm will not function when the engine is not
differential case. running.

3. Clean drain plug (1) and install drain plug (1). Add
the proper oil to the differential. Maintain the level
of the oil to the bottom of the hole for differential
level/fill plug (2). Refer to the Operation and
Maintenance Manual, “Lubricant Viscosities and
Capacities (Refill)” section for more information.
Move the propel control lever to the REVERSE
position.
The backup alarm should start to sound immediately.
The backup alarm will continue to sound until the
transmission control lever is moved to the STOP
position or to the FORWARD position.

4. Clean the filler plug. Install the filler plug.

i01849999

Axle Oil Level (Rear) - Check

SMCS Code: 3260-535-FLV; 3278-535; 3278

Note: Always check the oil level when the machine is

parked on a level surface.

Note: The differential level/fill plug is located on the

back side of the rear axle.
1. Remove the level/fill plug. Maintain the oil level to Illustration 141 g00930005
the bottom of the level/fill plug opening. If
necessary, add oil. If the backup alarm does not sound, make the
necessary repairs immediately. Do not operate a
Note: When you add oil, allow the oil to settle in order machine without a backup alarm.
to verify the oil level.
i04032515
2. Clean the level/fill plug. Install the plug.
Battery - Clean/Check
i06123213
SMCS Code: 1401-070; 1401-535; 1402-070; 1402-
535
Axle Oil Sample - Obtain
SMCS Code: 3260-008; 3278-008; 7542
Obtain an oil sample of the differential oil through the
oil level/fill plug. The oil level/fill plug is located on the
back side of the rear axle.
Refer to the Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” and
refer to the Operation and Maintenance Manual,
“Sampling Interval and Location of Sampling Valve”
for more information. Refer to Special Publication,
PEGJ0047, “How To Take A Good Oil Sample” for
more information about obtaining an oil sample.

i04712302

Backup Alarm - Test Illustration 142 g02223877

SMCS Code: 7406-081 Note: The batteries that are supplied with the
machines are maintenance free batteries. You do not
The backup alarm is located at the rear of the need to check the level of the electrolyte in the
machine. maintenance free batteries.
Tighten the battery retainer (2). Tighten the battery
retainers at every 1000 hours.
112 KEBU7577
Maintenance Support
Battery - Recycle

Check the following items at every 1000 hours. If
necessary, check the following items more often.
• Clean the top of the batteries with a clean cloth.
• Clean the battery terminals (1). As needed, coat
the battery terminals with petroleum jelly.
i00993589
8. Remove the cable from the positive terminal on the
second battery. The cable connects the positive
terminal of the second battery to the starter.
9. Remove the cable from the negative terminal of the
first battery. The cable connects the first battery
negative terminal to the disconnect switch.
10. Remove the cable from the starter.

Battery - Recycle 11. Perform the necessary repairs. Replace the

cables or the batteries, as needed.
SMCS Code: 1401-561
Always recycle a battery. Never discard a battery. 12. Reverse the above steps in order to reconnect the
batteries.
Always return used batteries to one of the following
locations: 13. Connect the battery cable at the battery
disconnect switch.
• A battery supplier
14. Install the battery disconnect switch key. Turn the
• An authorized battery collection facility battery disconnect switch to the ON position.
• Recycling facility 15. Install the battery compartment cover.

i03629796 i02539415

Battery or Battery Cable - Belts - Inspect/Adjust/Replace

Inspect/Replace SMCS Code: 1357-025; 1357-040; 1357-510
SMCS Code: 1401-040; 1401-510; 1402-040; 1402- Your engine is equipped with one belt to run the
510 alternator and the A/C compressor (if equipped).

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

Turn all switches to the OFF position.

2. Turn the battery disconnect switch to the OFF

position. Remove the battery disconnect switch
key.

3. Open the battery compartments. There is one

compartment at the rear of the machine.

4. At the battery disconnect switch, disconnect the

negative battery cable that is connected to the
frame.
Note: Do not allow the disconnected battery cables to Illustration 143 g01272591
contact the disconnect switch. Do not allow the Alternator Belt with A/C
disconnected battery cables to contact the other
cables. Do not allow the disconnected battery cables
to contact the opposite terminal of either battery.

5. Disconnect the negative battery cable at the

battery.

6. Disconnect the positive terminal of the cable that

connects the batteries from the first battery.

7. Remove the negative terminal of the cable that

connects the two batteries from the second battery.
KEBU7577 113
Maintenance Support
Cab Air Filter - Clean/Replace

4. After you clean the air filters, inspect the air filters.
If the air filters are damaged or badly
contaminated, use new air filters.

5. Install the filters in the reverse order of the above

steps.

i04745759

Cooling System Coolant (ELC)

- Change
SMCS Code: 1395-044-NL

Illustration 144 g01272592 Note: In order to access the areas required to

Alternator Belt without A/C
Inspect the condition of the belt for wear and damage.
The belt is self-adjusting for proper tension. No
measuring or adjustment is required.
If installation of a new belt is required, refer to
Disassembly and Assembly, KENR6004, “CP/CS-56,
CP/CS-64, CP/CS-74 Vibratory Compactors” or
Disassembly and Assembly, KENR6413, “CP/CS-76
Vibratory Compactors”.
i06067007
perform this procedure, a portable access system
(ladder, stair assembly, man lift, or other portable
access system) that is suitable and compliant to local
regulations may be necessary.
Drain the coolant whenever the coolant is dirty. Drain
the coolant when foam is observed.
1. Stop the engine. Allow the cooling system to cool
completely.
2. Open the engine compartment.

Cab Air Filter - Clean/Replace

SMCS Code: 7311-040; 7311-070; 7311-070-FI;
7311-510-FI; 7311; 7342-070; 7342-070-FI; 7342-
510-FI; 7342-510; 7342; 7521
The cab air filter is located to the left of the seat.

Illustration 145 g02827917

1. Remove the two hand knobs.

2. Pull up on the filter cover in order to remove the
filters.
3. Clean the air filters using compressed air with a
maximum of 200 kPa (30 psi).
114
Maintenance Support
Cooling System Coolant (ELC) - Change
Illustration 146 g02842998
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.
3. Slowly loosen cooling system cap (1) on the shunt
tank. Slowly remove cooling system cap (1).
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.
4. The cooling system drain valve is located on the
bottom corner of the radiator. Open the drain valve
. Allow the coolant to drain into a suitable
container.
KEBU7577
5. Close the drain valve . Fill the radiator with a
solution which consists of clean water and of
cooling system cleaner. Once the radiator is filled,
fill the cooling system expansion tank to the full
line. The concentration of the cooling system
cleaner in the solution should be between 6
percent and 10 percent.
6. Start the engine. Run the engine for 90 minutes.
7. Stop the engine. Allow the cooling system to cool
completely. Open the drain valve. Drain the
cleaning solution into a suitable container.
8. While the engine is stopped, flush the system with
water. Flush the system until the draining water is
transparent.
9. Close the drain valve.
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 Cater-
pillar EC-1 specifications for premixed or concentrate
coolants. Use only Caterpillar Extender with Caterpil-
lar 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.
10. Add the coolant solution. See the following topics:
• Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations”, “Cooling
System Specifications”
• Operation and Maintenance Manual,
“Capacities (Refill)”
Note: If you are using Caterpillar antifreeze, do not
add the supplemental coolant additive at this time
and/or change the element at this time.
KEBU7577
Illustration 147 g02843176
11. Add coolant to the cooling system expansion tank
until the coolant reaches the full line.
12. Start the engine. Run the engine without cooling
system cap (1) until the thermostat opens and the
coolant level stabilizes.
Note: If the machine is equipped with a cab heater,
the temperature control must be turned to the hot
position when the engine is running. Turning the
temperature control to the hot position will ensure that
the lines and the core are full of coolant.
13. Maintain the level of the coolant to the top of the
radiator and to the full line on the expansion tank.
14. Replace cooling system cap (1) if the gasket is
damaged. Install cooling system cap (1).
15. Stop the engine.
16. Close the engine compartment.
115
Maintenance Support
Cooling System Coolant Extender (ELC) - Add
i04745795
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.
Note: In order to access the areas required to
perform this procedure, a portable access system
(ladder, stair assembly, man lift, or other portable
access system) that is suitable and compliant to local
regulations may be necessary.
When a Caterpillar Extended Life Coolant (ELC) is
used, an Extender must be added to the cooling
system.
Use a 8T-526 Coolant Test Kit to check the
concentration of the coolant.
Refer to the Special Publication, SEBU6250,
“Caterpillar Machines Fluids Recommendations”,
“Cooling System Specifications” for more information
about the addition of Extender.
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, shortens cool-
ant service life, and may cause premature wear to
components.
Use only Caterpillar products or commercial prod-
ucts that have passed the Caterpillar EC-1 specifica-
tion for pre-mixed or concentrate coolants. Use only
Extender 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 compartment.
116
Maintenance Support
Cooling System Coolant Level - Check
Illustration 148 g02842998
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
radiator 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, “Caterpillar Machines Fluids
Recommendations”, “Cooling System
Specifications” for the proper amount.
Illustration 149 g02843176
6. Maintain the level of the coolant to the full line on
the expansion tank.
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 compartment.
KEBU7577
i04745809
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.
Note: In order to access the areas required to
perform this procedure, a portable access system
(ladder, stair assembly, man lift, or other portable
access system) that is suitable and compliant to local
regulations may be necessary.
Illustration 150 g02842998
1. Slowly loosen the filler cap on the shunt tank in
order to release any pressure in the system.
Slowly remove the filler cap on the shunt tank.
KEBU7577 117
Maintenance Support
Cooling System Coolant Sample (Level 1) - Obtain

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 samples
may contaminate the samples that are being drawn.
This contaminate may cause a false analysis and an
incorrect interpretation that could lead to concerns by
both dealers and customers.

Note: Level 1 results may indicate a need for

Level 2 Analysis.

Illustration 151 g02843116

2. Maintain the coolant level between the indicated

lines. If coolant must be added daily, check the
cooling system for leaks. Repair the leaks as the
leaks are found.
3. Inspect the gasket. Inspect the filler cap on the
shunt tank. Clean the filler cap on the shunt tank
with a clean cloth. Replace the cap if the gasket or
the cap are damaged.

4. Install the filler cap on the shunt tank. Illustration 152 g02842296

The coolant sample port is located on the right side of

i04745092
Cooling System Coolant
Sample (Level 1) - Obtain
SMCS Code: 1350-008; 1395-008; 1395-554; 7542-
008; 7542
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.
the machine near the engine oil filler plug.
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:

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

118 KEBU7577
Maintenance Support
Cooling System Coolant Sample (Level 2) - Obtain

• 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
Illustration 153 g02842296
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.
i04745571
The coolant sample port is located on the right side of
the machine near the engine oil filler plug.
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.
Refer to Operation and Maintenance Manual,
“Cooling System Coolant Sample (Level 1) - Obtain”
for the guidelines for proper sampling of the coolant.
Submit the sample for Level 2 analysis.

Cooling System Coolant For additional information about coolant analysis, see
Special Publication, SEBU6250, “Caterpillar Machine
Sample (Level 2) - Obtain Fluids Recommendations” or consult your Caterpillar
dealer.
SMCS Code: 1350-008; 1395-008; 1395-554; 7542-
008; 7542
i04730383

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 samples
may contaminate the samples that are being drawn.
This contaminate may cause a false analysis and an
incorrect interpretation that could lead to concerns by
both dealers and customers.
Cooling System Pressure Cap -
Clean/Replace
SMCS Code: 1382-070; 1382-510
Note: In order to access the areas required to
perform this procedure, a portable access system
(ladder, stair assembly, man lift, or other portable
access system) that is suitable and compliant to local
regulations may be necessary.

1. Open the engine compartment.

KEBU7577
Cooling System Water Temperature Regulator - Replace
Illustration 154 g02224021
2. The cooling system pressure cap is on the top of
the shunt tank.
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.
3. Remove the cooling system pressure cap slowly in
order to relieve pressure.
4. 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.
5. Install the cooling system pressure cap.
6. Close the engine compartment.
119
Maintenance Support
i04745628
Cooling System Water
Temperature Regulator -
Replace
SMCS Code: 1355-510; 1393-010
Note: In order to access the areas required to
perform this procedure, a portable access system
(ladder, stair assembly, man lift, or other portable
access system) that is suitable and compliant to local
regulations may be necessary.
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 reg-
ulator on a regularly scheduled basis could cause se-
vere 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. Open the engine compartment.
120
Maintenance Support
Cooling System Water Temperature Regulator - Replace
Illustration 155 g02842998
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.
2. Remove the cooling system pressure cap in order
to relieve the pressure in the cooling system.
Illustration 156 g02842999
3. Loosen hose clamp (3) and remove hose (4) from
water temperature regulator housing (1).
4. Remove bolts (2) from water temperature regulator
housing (1) and remove water temperature
regulator housing (1).
KEBU7577
5. Remove the gasket and remove the water
temperature regulator from the water temperature
regulator housing. Make a note of the orientation of
the old regulator.
NOTICE
The water temperature regulators may be reused if
the water temperature regulators are within test speci-
fications, 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.
6. Install a new water temperature regulator. Orient
the regulator in the same manner as the old
regulator. Install a new gasket. Install the water
temperature regulator housing.
7. Install the water temperature regulator housing and
the hose. Tighten the hose clamp.
Illustration 157 g02843176
8. Add the cooling system coolant. Maintain the level
of the coolant to the top of the radiator and to the
full line on the expansion tank.
9. Inspect cooling system pressure cap and the
gasket for damage. Replace the pressure cap if
the pressure cap or the gasket are damaged.
KEBU7577 121
Maintenance Support
Cutting Edges (Leveling Blade) - Inspect/Replace

10. Install the cooling system pressure cap.

7. Raise the leveling blade. Remove the blocks.
11. Close the engine compartment.
8. Lower the leveling blade to the ground.
i01735234
9. Check the bolts for proper torque after a few hours
Cutting Edges (Leveling Blade) of operation.

- Inspect/Replace i05429521
SMCS Code: 6801-040; 6801-510
Door Latches - Lubricate
SMCS Code: 7308-086-LX

Personal injury or death can result if the levelling
blade is not blocked up. Block the levelling blade
before changing the cutting edge.
The latches are coated with dry film lubricant and the
use of wet type lubricant is not recommended. Wet
type lubricant is not recommended due to the dust
build-up the lubricant will cause. When necessary,
use a dry-type lubricant to maintain smooth operation.

Illustration 158 g00646073

Illustration 159 g03426711

There are two cutting edges on the front of the blade Lubricate the door latch with a dry film lubricant.
(1). There are two skid plates on the bottom of the
blade (2).
Replace the cutting edge if the cutting edge is
damaged. Replace the cutting edge if the cutting
edge is excessively worn.

1. Raise the leveling blade. Block the leveling blade

securely. Place the blocks under the arms (3) of
the blade.
2. Remove the bolts. Remove the cutting edge.

3. Clean the contact surfaces.

4. If the opposite edge of the cutting edge is not worn,
use the opposite edge. If the opposite edge is
worn, replace the cutting edge.

5. Install the bolts. Tighten the bolts to the torques

that are specified in the Operation and
Maintenance Manual, “Torques for Ground
Engaging Tool Bolts”.

6. Inspect the skid plates. Replace the skid plates if

the skid plates are damaged or worn.
122 KEBU7577
Maintenance Support
Drum Cooling Oil - Change

In order to check the level of the oil, rotate the drum

so the plug is at the bottom of the drum. Remove the
plug. Maintain the oil to the bottom of the opening.
Refer to the Operation and Maintenance Manual,
“Lubricant Viscosities” and the Operation and
Maintenance Manual, “Capacities (Refill)”.

i05130412

Drum Scrapers - Inspect/

Adjust/Replace
SMCS Code: 6607-025; 6607-040; 6607-510

Smooth Drum Steel Scrapers (If

Equipped)
There is one scraper that is located on the front
bumper. There is an optional steel scraper for the rear
of the drum.
Illustration 160 g02223696
Adjust
Lubricate the engine hood latch with a dry film
lubricant.
Loosen the two bolts.
i02527775 Adjust the steel scraper to 20 mm (0.79 inch) from
the drum surface.
Drum Cooling Oil - Change Smooth Drum Flexible Scrapers (If
SMCS Code: 6605-044-OC
Equipped)

Illustration 161 g01264633 Illustration 162 g02830059

Note: Clean the area around the fill/drain plug before

servicing the drum. Adjust
The drum cooling oil requires service when the 1. Inspect flexible scraper (3). Clean the flexible
disassembly of the drum or the assembly of the drum
is needed. scraper of dirt and debris.

Rotate the fill/drain plug to the bottom of the drum.
Remove the drain plug. Pump the oil out of the drum.
Use the drain plug opening in order to fill the cavity.
Install the plug after adding the correct amount of oil.
The oil will be near the bottom of the opening.
2. Loosen bolts (4) that are holding the rear flexible
scraper blade and the backing plate to the bracket.
3. Loosen nuts (1) that hold the front flexible scraper
blade and the backing plate to the bracket.
KEBU7577 123
Maintenance Support
Drum Scrapers - Inspect/Adjust/Replace

Note: When you adjust flexible scraper (3), the steel Padded Drum Scrapers (If
backing plate (2) must not come into contact with the
surface of the drum.
Equipped)
4. Adjust flexible scraper blades (3) to 7 mm
(0.25 inch) away from the surface of the drum. Adjust
Backing plate (2) must be set back 35 mm
(1.375 inch) from the end of the scraper. Adjust
flexible scraper blade (3) and backing plate (2)
together.

5. Tighten the nuts.

Replace

1. Replace the flexible scrapers if excessive wear or

damage is evident.

2. Loosen the bolts and nuts (1) that are holding

flexible scraper blades (3).
Illustration 163 g03289756
3. Remove the flexible scraper blades (3). Install the
new flexible scraper blades. There is one set of scrapers on the front of the drum,
and one set of scrapers on the rear of the drum.
Note: When you adjust flexible scraper blade (3), the
1. Inspect the scrapers. Clean the dirt and the debris
steel backing plate (2) must not come into contact
with the surface of the drum. from the scrapers.
4. Adjust the flexible scraper blades (3) to 7 mm
(0.25 inch) away from the surface of the drum. The
backing plate (2) must be set back 35 mm
(1.375 inch) from the end of the scraper. Adjust the
flexible scraper blades (3) and the backing plate
together.

5. Tighten the bolts and tighten the nuts.

Illustration 164 g03289757

2. There are two bolts (2) for each scraper (1). Each
scraper is individually adjustable.

3. Slide the scraper (1) toward the drum. Adjust each

scraper so the tip is 20 ± 10 mm (0.8 ± 0.4 inch)
from the surface of the drum.
4. Tighten bolts (2) to 240 ± 40 N·m (177 ± 30 lb ft).
124 KEBU7577
Maintenance Support
Eccentric Weight Housing Oil - Change

i01850129
4. Clean the plug. Install the plug.
Eccentric Weight Housing Oil -
5. Rotate the drum until indicator bar (1) is at the
Change bottom of the drum.
SMCS Code: 6606-044-OC

Change the Oil

1. Take an oil sample from each eccentric weight
housing. There is one eccentric weight housing on
each side of the drum. No flushing is necessary, if
the oil sample cleanliness rating is equal or lower
than ISO 23/21. The flushing procedure should be
performed if an oil sample cleanliness rating is
higher than ISO 23/21.

Illustration 167 g00907477

6. Remove the filler plug.

Illustration 165 g00946226

(1) Indicator bar

Illustration 168 g00907478

7. Remove the level check plug. Fill the housing with

oil. Refer to the Operation and Maintenance
Manual, “Lubrication Viscosities” and Operation
and Maintenance Manual, “Capacities (Refill)”.
Maintain the level of the oil to the bottom of the
level check opening.

8. Clean the plugs. Install the plugs.

Illustration 166 g00907476 9. Repeat this procedure for the other eccentric
weight housing.
2. Rotate the drum until indicator bar (1) is at the top
of the drum. The drain plug is at the bottom of the Flush the Housing
housing.

3. Place a suitable container under the drain plug.

Remove the drain plug. Drain the housing
completely. Repeat this step for both housings.
KEBU7577 125
Maintenance Support
Eccentric Weight Housing Oil - Change

Illustration 169 g00661129

1. There are two eccentric weight housings. The

housings are on each side of the drum. Perform
the following procedure on each housing.

2. Drain the oil from the eccentric weight housings. Illustration 171 g00684344
(1) 8C-6875 Connector
(2) 8B-5774 Reducer Bushing
(3) 9U-6989 Head
(4) 9U-6983 Filter Element
(5) 6V-3965 Nipple Assembly
(6) 8T-4834 Swivel Orifice Tee
(7) 127-8781 Filter Cart
(8) 2.4 m (8 ft) of 25 mm (1 inch) hose
(9) 3B-6498 Elbow
(10) 3L-7024 Street Elbow
(11) 127-0593 Connector
(12) 3B-7728 Elbow
(13) 3B-7265 Pipe Nipple
(14) 940 mm (37 inch) of 25 mm (1 inch) pipe

4. Use the 127-8781 Transfer Cart Group in order to

flush the oil in the 208 L (55 US gal) drum. Filter
the oil for 30 minutes. The particle count of the
Illustration 170 g00411939
clean oil must be a maximum of ISO 18/13.
3. Pump 151 L (40 US gal) of a suitable hydraulic oil
into a 208 L (55 US gal) drum.

Illustration 172 g00411939

5. Raise the machine. The drum and tires must not be

in contact with the ground or the floor. Support the
machine on stands.
126 KEBU7577
Maintenance Support
Eccentric Weight Housing Oil - Change

Illustration 175 g00907480

Illustration 173 g00412139
8. Rotate the drum until the fill/drain plug is at the
6. Start the engine. Release the parking brake and bottom and the indicator bar is at the top.
rotate the drum until the fill/drain plug is at the top
of the housing. Remove the plug. Install the valve
and fitting assembly that is appropriate for your
machine.

Illustration 176 g00412139

9. Remove the level check plug. Connect the quick

coupler (16). Fill the housing with 22 L (6 US gal)
Illustration 174 g00698763 gallons of clean oil. Install the plug.

7. Assemble the 126-7187 Adapter(17) into the 10. Run the first flush cycle.
male end of the 5R-3796 Quick Coupling
Assembly(16). Install the adapter into the hole for a. Start the engine. Release the brake.
the oil fill/drain plug. Assemble the 8T-0198 Seal
b. Set the travel speed control to low speed. In
Connector(15) onto the female end of the quick
order to rotate the drum, move the propel
coupler. Attach the female end of the quick coupler
control.
to the suction hose of the transfer cart in order to
drain the flushing oil from the housing. c. Set the vibratory amplitude control to the LOW
position.

d. Turn on the vibratory system. Run the vibratory

system for 5 seconds. Turn off the vibratory
system. Repeat the cycle for three minutes.
Note: For each cycle, do not run the vibratory
system more than 5 seconds.
KEBU7577 127
Maintenance Support
Engine Air Filter Primary Element - Clean/Replace

e. Stop the drum. Position the drum in order to

drain the housings.

11. Install the transfer cart. Pump the oil out of the
housings. Cycle the oil through the filter for 30
minutes. Cycle the oil until the oil is cleaned to a
rating of ISO 18/13 or better.

12. Install the transfer cart to the housings. Pump the

oil into the housings. For the second cycle, repeat
steps 6 through 9. After the second cycle, take an
oil sample before filtering the oil. No further
flushing is necessary, if the oil sample cleanliness
rating is equal or lower than ISO 19/16. Another Illustration 177 g00537958
flushing is necessary, if the oil sample cleanliness
rating is higher than ISO 19/16. 2. Squeeze the outlet tube slightly in order to purge
the dirt from the outlet tube.
13. When the flushing is complete, rotate the drum to
the position in order to drain the housings. Remove
the valve and fitting assembly. Drain as much of
the oil as possible.

14. Rotate the drum until the fill/drain plug is at the

top. Remove the level check plug. Fill the drum to
the correct level. Refer to the Operation and
Maintenance Manual, “Capacities (Refill)”. Refer to
the Special Publication, SEBU6250, “Lubrication
Specifications”.

Note: The new oil must have a oil sample cleanliness

rating that is equal or lower than ISO 18/13.

i04729275
Illustration 178 g00101413

Engine Air Filter Primary 3. Loosen the four cover latches and remove the air
Element - Clean/Replace cleaner cover.
SMCS Code: 1054-070-PY; 1054-510-PY

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

Service the air cleaner filter element when the air

filter status fault is displayed on the monitoring
system.

Note: In order to access the areas required to

perform this procedure, a portable access system
(ladder, stair assembly, man lift, or other portable
access system) that is suitable and compliant to local
regulations may be necessary.
Illustration 179 g00101415
1. Open the engine compartment.
4. Remove the primary filter element from the air
cleaner housing.
128 KEBU7577
Maintenance Support
Engine Air Filter Secondary Element - Replace

5. Clean the air cleaner cover and the inside of the air 12. Install the air cleaner cover and close the latches
cleaner housing. securely.

6. Inspect the O-ring seal on the air cleaner cover.

Replace the O-ring seal if the O-ring seal is worn
or damaged.

NOTICE
Do not clean the filter elements by bumping or tapping
them. Do not use filter elements with damaged pleats,
gaskets or seals. Engine damage can result.
Make sure the cleaned filter elements are completely
dry before installing into the filter housing. Water re-
maining in the elements can cause false indications
of contamination in Scheduled Oil Sampling test
results.
Illustration 181 g00101416
7. Clean the primary filter. Inspect the primary filter.
Note: Install the air cleaner cover properly. The
Primary filter elements can be cleaned with low- arrows must point upward.
pressure air. Caterpillar does not recommend 13. Change the filter if the exhaust smoke is still
cleaning the air filter.
black.
Refer to Operation and Maintenance, “General
Hazard Information” before you use pressure air in Note: Replace the primary filter if the primary filter
order to clean the primary filter element. has been in service for one year.

14. Close the engine compartment.

i04730717

Engine Air Filter Secondary

Element - Replace
SMCS Code: 1054-510-SE

Illustration 180 g00102970
8. Direct air along the pleats inside the primary filter
element and outside the primary filter element. Do
not touch pleats with the air nozzle.
NOTICE
Always replace the secondary filter element. Never
attempt to reuse the secondary filter element by
cleaning the element.
When the primary filter element is replaced, the sec-
ondary filter element should be replaced.
The secondary filter element should also be replaced
if the exhaust smoke is still black.

9. Inspect the primary filter element after the element
is clean. Do not use a primary filter element with
damaged pleats, damaged gaskets, or damaged
seals.
10. Encase the clean primary filter element and store
the clean primary filter element in a clean, dry
place.
Note: In order to access the areas required to
perform this procedure, a portable access system
(ladder, stair assembly, man lift, or other portable
access system) that is suitable and compliant to local
regulations may be necessary.
1. Open the engine compartment.

11. Install the clean primary filter.

KEBU7577
2. See Operation and Maintenance Manual, “Engine
Air Filter Primary Element - Clean/Replace”.
Remove the air cleaner cover from the air cleaner
housing. Remove the primary filter element from
the air cleaner housing.
Illustration 182 g00101451
3. Remove the secondary filter element.
4. Cover the air inlet opening. Clean the inside of the
air cleaner housing.
5. Remove the cover from the air inlet opening.
6. Install the new secondary filter element.
7. Install the primary filter element.
8. Install the air cleaner cover and close the latches
securely.
9. Close the engine compartment.
i04745977
Engine Oil Level - Check
SMCS Code: 1348-535-FLV
NOTICE
Do not under fill or overfill engine crankcase with oil.
Either condition can cause engine damage.
Stop the engine in order to check the oil level. DO
NOT check the oil level when the engine is running.
Park the machine on a level surface.
1. Open the engine compartment.
129
Maintenance Support
Engine Oil Level - Check
Illustration 183 g02843318
2. Remove oil level gauge (1). Wipe the oil level
gauge with a clean cloth. Insert the oil level gauge.
Remove the oil level gauge and note the oil level.
Insert the oil level gauge.
Note: Refer to the Operation and Maintenance
Manual, “Lubricant Viscosities and Capacities (Refill)”
for the correct amount of oil that is used when the oil
is changed. The correct amount of oil determines the
correct level of the oil in the FULL range on the oil
level gauge.
NOTICE
Do not overfill the crankcase. The oil level must not
reach the top of the FULL range mark or above the
FULL range mark.
3. Maintain the oil level on the oil level gauge
between the FULL RANGE mark and the ADD OIL
mark . Add oil if the oil level is too low.
Note: Operating your engine with the oil level above
the FULL mark in the FULL Range could cause the
crankshaft to dip into the oil. Operating above the
FULL mark could result in excessively high operating
temperatures. The high operating temperatures could
result in reduced lubricating characteristics of the oil,
which could cause damage to the bearings and loss
of engine power.
Add The Engine Oil
1. Open the engine compartment.
130
Maintenance Support
Engine Oil Sample - Obtain
Illustration 184
2. Remove oil filler plug (2).
3. Add the oil.
4. Clean the oil filler plug. Install the oil filler plug.
5. Close the engine compartment.
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.
Each oil sample should be taken when the oil is warm
and when the oil is mixed. The sample should be
taken at this time in order to ensure that the sample is
representative of the oil in the crankcase.
Obtain the S·O·S Sample
Use the oil sampling valve in order to obtain an S·O·S
sample.
To avoid contamination of the oil samples, the tools
and the supplies that are used for obtaining oil
samples must be clean.
KEBU7577
Refer to Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” for additional
information. Refer to Special Publication, PEGJ0047,
“How To Take A Good Oil Sample” for more
information about obtaining an oil sample. Consult
your Cat dealer for complete information and
assistance in establishing an S·O·S program for your
engine.
1. Open the engine compartment.
g02843320
i06124724 Illustration 185 g02843416
2. The oil sampling valve is on the right side of the
machine. The oil sampling valve is located above
the oil filter.
3. Open the sampling valve. Obtain an oil sample in a
suitable container and close the sampling valve.
Refer to the Operation and Maintenance Manual,
“General Hazard Information” for information that
pertains to containing fluid spillage.
4. Seal the container and label the container. Send
the sample to your Cat dealer for analysis.
5. Close the engine compartment.
i04746118
Engine Oil and Filter - Change
SMCS Code: 1318-510
Run the engine in order to warm up the oil. Stop the
engine before you drain the oil. When the oil is warm,
the waste particles are suspended in the oil. The
waste particles will be removed when the oil is
drained.
As the oil cools, the waste particles settle to the
bottom of the oil pan. The waste particles will not be
removed if the oil is too cool.
The waste particles can recirculate through the
engine lubrication system if the recommended
procedure is not followed.
KEBU7577
1. Open the engine compartment.
2. Remove the access panel under the machine.
Illustration 186 g02843461
3. Place a suitable container under drain valve (1).
Refer to the Operation and Maintenance Manual,
“General Hazard Information” for information that
pertains to containing fluid spillage.
4. Open drain valve (1) in order to drain the oil.
5. Allow the oil to completely drain.
6. Close the drain valve.
Illustration 187 g02843456
7. Remove filter element (2). Discard the used filter
element.
8. Clean the filter housing base. All of the old filter
seal must be removed from the filter housing base.
9. Apply a thin coat of engine oil to the seal of the new
filter elements.
131
Maintenance Support
Engine Valve Lash - Check/Adjust
10. Install the new filters by hand. When the seal
contacts the base, tighten the filter element for an
additional 3/4 turn. This will tighten the filter
sufficiently.
Every new oil filter has rotation index marks that
are spaced at 90 degree increments. Use the
rotation index marks as a guide for tightening the
oil filter.
Illustration 188 g02843463
11. Remove the oil filler plug (3). Fill the crankcase
with new oil. See Operation and Maintenance
Manual, “Capacities (Refill)”. See Operation and
Maintenance Manual, “Lubricant Viscosities”.
Clean the oil filler cap and install the oil filler cap.
12. Before you start the engine, check the oil level on
oil level gauge (4). The oil level must be within the
FULL RANGE on the oil level gauge.
13. Start the engine. Run the engine for 2 minutes.
Inspect the machine for leaks. Stop the machine.
14. Wait for 10 minutes in order to allow the oil to
drain back into the crankcase. Check the oil level.
Maintain the oil level within the FULL RANGE on
the oil level gauge.
15. Close the engine compartment.
i03363188
Engine Valve Lash - Check/
Adjust
SMCS Code: 1105-025; 1105-535
This maintenance is recommended by Caterpillar as
part of a lubrication and preventive maintenance
schedule in order to help provide maximum engine
life.
132 KEBU7577
Maintenance Support
Film (Product Identification) - Clean

i03997106

Ensure that the engine can not be started while Film (Product Identification) -
this maintenance is being performed. To help pre- Clean
vent possible injury, do not use the starting motor
to turn the flywheel. SMCS Code: 7405-070; 7557-070

Hot engine components can cause burns. Allow

additional time for the engine to cool before meas-
uring/adjusting valve lash clearance.

NOTICE
Only qualified service personnel should perform this
maintenance. Refer to the Service Manual or your
Caterpillar dealer for the complete valve lash adjust-
ment procedure.
Operation of Caterpillar engines with improper valve
adjustments can reduce engine efficiency. This re-
duced efficiency could result in excessive fuel usage
and/or shortened engine component life.
Illustration 189 g02174985

Note: Any air lines that are disconnected during a

valve lash adjustment must be plugged in order to
protect the engine. Prevent the entry of airborne dirt,
debris and abrasive particles. Keep all parts clean
from contamination. Contaminants may cause rapid
wear. This shortens the component life.

Illustration 190 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.
KEBU7577
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
Power washing or washing with pressure may be
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)
• 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.
133
Maintenance Support
Final Drive Planetary (Axle) Oil - Change
i04205092
Final Drive Planetary (Axle) Oil
- Change
SMCS Code: 4050-044-OC
Illustration 191 g02392656
1. Position one final drive so that the oil fill/drain plug
is at the bottom.
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information on
Containing Fluid Spillage.
2. Remove the oil fill/drain plug. Allow the oil to drain
into a suitable container.
3. Clean the plug and inspect the O-ring seal. If wear
or damage is evident, replace the oil fill/drain plug
and/or the O-ring seal.
4. Install the oil fill/drain plug.
5. Rotate the final drive so that the oil fill/drain plug is
horizontal.
6. Fill the final drive to the bottom of the opening on
the oil fill/drain plug. See Operation and
Maintenance Manual, “Lubricant Viscosities” and
Operation and Maintenance Manual, “Capacities
(Refill)”.
7. Install the oil fill/drain plug.
8. Perform Step 1 to Step 7 on the other final drive.
Use a different container for the oil so that the oil
samples from the final drives will be separate.
9. Completely remove the oil that has spilled onto
surfaces.
10. Start the engine. Operate the machine in the
FORWARD direction and in the REVERSE
direction.
134 KEBU7577
Maintenance Support
Final Drive Planetary (Axle) Oil Level - Check

i06123231
11. Apply the parking brake.
Final Drive Planetary (Axle) Oil
12. Stop the engine. Check the oil level.
Sample - Obtain
13. Check the drained oil for metal chips or for SMCS Code: 4050-008
particles. If there are any chips or particles, consult
your Caterpillar dealer.

14. Properly dispose of the drained material. Obey

local regulations for the disposal of the material.

i04033079

Final Drive Planetary (Axle) Oil

Level - Check
SMCS Code: 4050-535-FLV

Illustration 193 g02226373

Obtain the oil sample when you change the oil.

Refer to the Operation and Maintenance Manual,
“General Hazard Information” for information that
pertains to fluid spillage.
Refer to Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” and refer to
Special Publication, PEGJ0047, “How To Take A
Good Oil Sample” for more information about
obtaining an oil sample. Consult your Caterpillar
dealer for complete information.
Illustration 192 g02226373

1. Position the machine so that the oil fill/drain plug is

horizontal.

Note: Refer to Operation and Maintenance Manual,

“General Hazard Information” for information on
Containing Fluid Spillage.
2. Remove the oil fill/drain plug.

3. Check the oil level. The oil should be near the

bottom of the oil fill/drain plug.

4. Add oil through the oil fill/drain plug, if necessary.

Note: Do not overfill the final drive.
5. Clean the oil fill/drain plug. Inspect the O-ring seal.
Replace the O-ring seal if the O-ring seal is worn
or damaged.

6. Install the oil fill/drain plug.

7. Repeat the procedure for the other final drive.

KEBU7577 135
Maintenance Support
Final Drive Planetary (Drum) Oil - Change

i04205150 4. After the oil is drained, install drain plug (3).

Final Drive Planetary (Drum)

Oil - Change
SMCS Code: 4050-044-OC; 5655-044-OC

Illustration 196 g02227756

5. Filler plug (1) is located at the top of the planetary

and level check plug (2) is located at the middle.
Illustration 194 g02227755 6. Remove level check plug (2) and filler plug (1).
The final drive planetary is located on the left side of 7. Refer to the Operation and Maintenance Manual,
the drum. “Lubricant Viscosities and Capacities (Refill)”.

8. Fill the planetary until the oil is at the bottom of

level check plug (2).
Note: Check the oil again after 5 minutes. This allows
time for the oil to travel through the planetary.
Continue to fill and wait until the oil level remains at
the bottom of level check plug (2).

9. Clean plugs (1) and (2). Install plugs (1) and (2).

Illustration 195 g02392718

1. Drain plug (3) is located at the bottom of the final

drive planetary.

2. Remove drain plug (3). Drain the oil into a suitable

container. Dispose of the oil in an acceptable
manner. Refer to the Operation and Maintenance
Manual, “General Hazard Information” for
information that pertains to containing fluid
spillage.

3. Inspect drain plug (3) for metal debris. If the size of

the metal debris is 3 mm (0.12 inch) or more, there
may be damage to the planetary.

Note: Consult your Caterpillar dealer for further

information.
136 KEBU7577
Maintenance Support
Final Drive Planetary (Drum) Oil - Check

i04034511 i06123237

Final Drive Planetary (Drum) Final Drive Planetary (Drum)

Oil - Check Oil Sample - Obtain
SMCS Code: 4050-535-FLV; 5655-535-FLV SMCS Code: 4050-008; 5655-008

Illustration 197 g02227755 Illustration 199 g02393276

The final drive planetary is located on the left side of
the drum.
Obtain the oil sample according to the Operation and
Maintenance Manual, “Maintenance Interval
Schedule”.
Refer to the Operation and Maintenance Manual,
“General Hazard Information” for information that
pertains to containing fluid spillage.
Refer to Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” and refer to
Special Publication, PEGJ0047, “How To Take A
Good Oil Sample” for more information about
obtaining an oil sample. Consult your Caterpillar
dealer for complete information.

i04747869

Fuel System - Prime

Illustration 198 g02227756
SMCS Code: 1250-548

1. Remove level check plug (2). Check the level of NOTICE

the oil in the planetary. Maintain the level of the oil
at the bottom of the opening for level check plug
(2).
2. Clean plug(2). Install plug (2).
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.
KEBU7577 137
Maintenance Support
Fuel System Filter (In-Line) - Replace

• The filter screen is more than half obstructed.

• Engine performance is poor.

1. Open the engine compartment.

Illustration 200 g02844657

1. Operate the fuel priming pump plunger in order to

fill the new filter element with fuel. Continue to
pump until a resistance is felt. This resistance will
indicate that the filter element is full of fuel. Illustration 201 g02844936

2. Start the engine. If the engine will not start, further

priming is necessary. If the engine starts but the 2. The in-line filter is located on the right side of the
engine continues to misfire, further priming is machine next to the primary fuel filter.
necessary. If the engine starts but the engine 3. Loosen the clamps.
continues to emit smoke, further priming is
necessary. 4. Remove the fuel filter and discard the fuel filter.
Allow the fuel to drain into a suitable container.
3. If the engine starts but the engine runs rough,
continue to run the engine at low idle. Continue to 5. Install a new in-line filter.
run the engine at low idle until the engine runs
6. Tighten the clamps.
smoothly.
7. Prime the fuel system. Refer to the Operation and
i04748074 Maintenance Manual, “Fuel System - Prime”
section for the correct procedure.
Fuel System Filter (In-Line) -
8. Start the engine.
Replace
SMCS Code: 1261-510 9. Check for leaks.
10. Fully close the engine hood.
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.

Note: Replace the fuel filter before the scheduled

interval if any of the following occur:
138
Maintenance Support
Fuel System Primary Filter (Water Separator) - Replace
i04747909
Fuel System Primary Filter
(Water Separator) - Replace
SMCS Code: 1261-510; 1263-510
Personal injury can result from air pressure.
Personal injury can result without following prop-
er procedure. When using pressure air, wear a
protective face shield and protective clothing.
Maximum air pressure at the nozzle must be less
than 205 kPa (30 psi) for cleaning purposes.
Personal injury can result when using cleaner
solvents.
To help prevent personal injury, follow the instruc-
tions and warnings on the cleaner solvent con-
tainer before using.
Personal injury or death can result from a fire.
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire.
Clean up all leaked or spilled fuel. Do not smoke
while working on the fuel system.
Turn the disconnect switch OFF or disconnect the
battery when changing fuel filters.
NOTICE
Do not pre-fill the fuel filter with fuel before you install
the fuel filter. Contaminated fuel WILL DAMAGE the
fuel system components.
NOTICE
Caterpillar STRONGLY recommends the use of
advanced efficiency (high efficiency) primary fuel
filters. Advanced efficiency fuel filters are de-
signed in order to better protect diesel engines
that have higher injection pressures and closer
tolerances. Use of primary fuel filters that are NOT
advanced efficiency fuel filters will result in short-
ened fuel system component life. Caterpillar ad-
vanced efficiency fuel filters are the preferred
primary filters for Caterpillar engines.
KEBU7577
NOTICE
Severe working conditions can shorten the life of the
fuel system. Severe conditions refer to a dusty envi-
ronment and/or dirty fuel. Under severe conditions,
reduce the maintenance interval to 250 service hours.
In order to keep the engine in optimum condition, it is
important to keep the fuel free from contamination. As
fuel system contamination usually occurs during
refueling, the following points should be observed:
• Only use clean fuel of the correct grade from a
reliable source.
• Do not refuel from contaminated containers or
containers that are not suitable for fuel
storage.
• Do not use contaminated equipment.
• Regularly clean the outside of the fuel filler cap
and the area around the fuel filler cap.
• Only use Caterpillar approved fuel filters. The
use of Caterpillar filters is essential in order to
protect the fuel system.
• Do not service the fuel filters ahead of the
suggested maintenance interval, unless you
are instructed by the monitoring system. This
will increase the risk of contamination in the
fuel system.
Note: In order to reduce the risk of contamination in
the system, do not remove the primary fuel filter and
the secondary fuel filters simultaneously. Perform
these operations separately.
Note: After the engine has stopped, you must wait
for 60 seconds in order to allow the fuel pressure
to be purged from the high-pressure fuel lines
before any service or repair is performed on the
engine fuel lines.
1. Open the engine compartment. The fuel filter
element is located on the right side of the machine
toward the rear of the engine compartment.
2. Turn the fuel supply valve (if equipped) 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.
KEBU7577
Illustration 202 g02844679
4. Open the drain (3). Allow the fluid to drain into the
container.
5. Tighten the drain by hand pressure only.
6. Remove wiring harness (4) from the sensor on the
bottom of the clear bowl (2).
7. Remove the clear bowl from the filter (1).
8. Use a Caterpillar strap wrench in order to remove
the filter. Discard the old seals and the canister in a
safe place.
9. Clean the clear bowl.
10. Install a new filter.
Note: Do not pre-fill the fuel filter before you
install the fuel filter.
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 90 degrees or 1/4 of a turn away
from each other. When you tighten the filter, use the
rotation index marks as a guide.
b. Tighten the filter according to the instructions
that are printed on the filter. Use the index
marks as a guide.
11. Install the clear bowl on the filter. Ensure that the
sensor (if equipped) is in the correct position.
12. Install the wiring harness to the sensor.
13. Be sure to dispose of the fuel in a safe place.
14. Prime the fuel system. Refer to Operation and
Maintenance Manual, “Fuel System - Prime” for
more information.
139
Maintenance Support
Fuel System Secondary Filter - Replace
15. Close the engine compartment.
Replace the Secondary Fuel Filter
Replace the secondary fuel filter immediately after
you change the primary fuel filter. Refer to Operation
and Maintenance Manual, “Fuel System Secondary
Filter - Replace”for more information.
i04747969
Fuel System Secondary Filter -
Replace
SMCS Code: 1261-510-SE
Personal injury or death can result from a fire.
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire.
Clean up all leaked or spilled fuel. Do not smoke
while working on the fuel system.
Turn the disconnect switch OFF or disconnect the
battery when changing fuel filters.
NOTICE
Do not pre-fill the fuel filter with fuel before you install
the fuel filter. Contaminated fuel WILL DAMAGE the
fuel system components.
NOTICE
Caterpillar STRONGLY recommends the use of ul-
tra-high efficiency secondary fuel filters for this
machine model. Ultra-high efficiency fuel filters
are designed in order to better protect diesel en-
gines that have higher injection pressures and
closer tolerances. Use of secondary fuel filters
that are NOT ultra-high efficiency fuel filters will
result in shortened fuel system component life.
Caterpillar ultra-high efficiency fuel filters are the
preferred secondary filters for this machine
model.
NOTICE
Severe working conditions can shorten the life of the
fuel system. Severe conditions refer to a dusty envi-
ronment and/or dirty fuel. Under severe conditions,
reduce the maintenance interval to 250 service hours.
In order to keep the engine in optimum condition, it is
important to keep the fuel free from contamination. As
fuel system contamination usually occurs during
refueling, the following points should be observed:
140
Maintenance Support
Fuel System Third Filter - Replace
• Only use clean fuel of the correct grade from a
reliable source.
• Do not refuel from contaminated containers or
containers that are not suitable for fuel
storage.
• Do not use contaminated equipment.
• Regularly clean the outside of the fuel filler cap
and the area around the fuel filler cap.
• Only use Caterpillar approved fuel filters. The
use of Caterpillar filters is essential in order to
protect the fuel system.
• Do not service the fuel filters ahead of the
suggested maintenance interval, unless you
are instructed by the monitoring system.
Changing the fuel filters ahead of the
suggested maintenance interval will increase
the risk of contamination in the fuel system.
Note: In order to reduce the risk of contamination in
the system, do not remove the primary fuel filter and
the secondary fuel filter simultaneously. Perform
these operations separately.
Note: After the engine has stopped, you must wait
for 60 seconds in order to allow the fuel pressure
to be purged from the high-pressure fuel lines
before any service or repair is performed on the
engine fuel lines.
Illustration 203 g02844776
1. Open the engine compartment. The secondary fuel
filter is located on the right side of the machine.
2. Place a suitable container under the fuel filter in
order to catch any fuel that might spill. Clean up
any spilled fuel.
3. Clean the outside of the fuel filter. Use a Caterpillar
strap wrench in order to remove the filter from the
engine and dispose of the filter in a safe place.
KEBU7577
4. Install a new filter.
Note: Do not fill the new filter before you install
the new filter.
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 90 degrees or 1/4 of a turn away from each
other. When you tighten the filter, use the rotation
index marks as a guide.
b. Tighten the filter according to the instructions
that are printed on the filter. Use the index
marks as a guide.
5. Before you start the engine, make sure that the
drain valves are closed.
6. Check for leaks.
7. Start the engine.
8. Check for leaks.
9. Close the engine compartment.
i04748029
Fuel System Third Filter -
Replace
SMCS Code: 1261-510; 1261-510-SE
Personal injury or death can result from a fire.
Fuel leaked or spilled onto hot surfaces or electri-
cal components can cause a fire.
Clean up all leaked or spilled fuel. Do not smoke
while working on the fuel system.
Turn the disconnect switch OFF or disconnect the
battery when changing fuel filters.
NOTICE
Do not pre-fill the fuel filter with fuel before you install
the fuel filter. Contaminated fuel WILL DAMAGE the
fuel system components.
KEBU7577 141
Maintenance Support
Fuel System Third Filter - Replace

NOTICE
Caterpillar STRONGLY recommends the use of ul-
tra-high efficiency secondary fuel filters for this
machine model. Ultra-high efficiency fuel filters
are designed in order to better protect diesel en-
gines that have higher injection pressures and
closer tolerances. Use of secondary fuel filters
that are NOT ultra-high efficiency fuel filters will
result in shortened fuel system component life.
Caterpillar ultra-high efficiency fuel filters are the
preferred secondary filters for this machine
model.

NOTICE
Illustration 204 g02844817
Severe working conditions can shorten the life of the
fuel system. Severe conditions refer to a dusty envi-
ronment and/or dirty fuel. Under severe conditions, 1. Open the engine compartment. The third fuel filter
reduce the maintenance interval to 250 service hours. is located on the right side of the machine.

2. Place a suitable container under the fuel filter in

In order to keep the engine in optimum condition, it is
important to keep the fuel free from contamination. As
fuel system contamination usually occurs during
refueling, the following points should be observed:
• Only use clean fuel of the correct grade from a
reliable source.
order to catch any fuel that might spill. Clean up
any spilled fuel.
3. Clean the outside of the fuel filter. Use a Caterpillar
strap wrench in order to remove the filter from the
engine and dispose of the filter in a safe place.

• Do not refuel from contaminated containers or 4. Install a new filter.

containers that are not suitable for fuel
storage.
• Do not use contaminated equipment.
• Regularly clean the outside of the fuel filler cap
and the area around the fuel filler cap.
• Only use Caterpillar approved fuel filters. The
use of Caterpillar filters is essential in order to
protect the fuel system.
• Do not service the fuel filters ahead of the
suggested maintenance interval, unless you
are instructed by the monitoring system.
Changing the fuel filters ahead of the
suggested maintenance interval will increase
the risk of contamination in the fuel system.
Note: In order to reduce the risk of contamination in
the system, do not remove the primary fuel filter and
the third fuel filter simultaneously. Perform these
operations separately.
Note: After the engine has stopped, you must wait
for 60 seconds in order to allow the fuel pressure
to be purged from the high-pressure fuel lines
before any service or repair is performed on the
engine fuel lines.
Note: Do not fill the new filter before you install
the new filter.
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 90 degrees or 1/4 of a turn away from each
other. When you tighten the filter, use the rotation
index marks as a guide.
b. Tighten the filter according to the instructions
that are printed on the filter. Use the index
marks as a guide.
5. Before you start the engine, make sure that the
drain valves are closed.
6. Check for leaks.
7. Start the engine.
8. Check for leaks.
9. Close the engine compartment.
142 KEBU7577
Maintenance Support
Fuel Tank Cap Filter - Replace

i04445353 i04415238

Fuel Tank Cap Filter - Replace Fuel Tank Strainer - Clean

SMCS Code: 1273-510-Z2; 1273-510-FI SMCS Code: 1273-070-STR

Illustration 205 g02612539 Illustration 206 g02609604

1. Remove the fuel tank cap. 1. Remove fuel tank cap (1).

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.
2. Remove strainer (2) from the filler opening.
3. Wash the strainer in a clean, nonflammable
solvent.
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
Manual, “Fuel Cap Filter - Replace”.
4. Install the strainer into the filler opening.

6. Install the fuel tank cap 5. Install the fuel tank cap.
KEBU7577 143
Maintenance Support
Fuel Tank Water and Sediment - Drain

i04035261 Primary Fuse Panel

Fuel Tank Water and Sediment
- Drain
SMCS Code: 1273-543-M&S

Illustration 208 g02845136

The compartment for the primary fuse panel is

located on the right side of the operator station, next
to the seat.

Illustration 207 g02229633

The drain valve is located on the bottom of the fuel

tank.
Drain the water and the sediment into a suitable
container. Refer to the Operation and Maintenance
Manual, “General Hazard Information” for information
that pertains to containing fluid spillage.
Close the drain valve. Install the access plate.
Note: Dispose of all fluids according to local
regulations.

i04748274

Fuses - Replace
SMCS Code: 1417-510

Fuse – The fuses protect the electrical

system from damage that is caused by Illustration 209 g02845156
overloaded circuits. Change the fuse if
Primary fuse panel 1
the element separates. If the element of the new
fuse separates, check the circuit. Repair the
problem before you operate the machine.
144 KEBU7577
Maintenance Support
Fuses - Replace

Controls Power (11) – 10 amp

Front Work Lights (12) – 10 amp

Rear Work Lights (13) – 10 amp

Shutdown Status (14) – 10 amp

Electric Fuel Pump (15) – 7.5 amp

Window Wiper/Washer (16) – 20 amp

HVAC Cab (17) – 20 amp

Illustration 210 g02845157
Primary fuse panel 2

Ignition System (1) – 7.5 amp Cat Grade Control (18) – 15 amp

Machine ECM (2) – 15 amp Spare Fuse (19) – 7.5 amp

12V Converter (3) – 15 amp Spare Fuse (20) – 10 amp

Horn (4) – 7.5 amp Spare Fuse (21) – 15 amp

Cab Accessory (5) – 10 amp Spare Fuse (22) – 20 amp

Cat Grade Control (6) – 10 amp

Backup Alarm (7) – Relay

Spare (8) – Relay

Switched Power (9) – Relay

Main Machine (10) – 7.5 amp

KEBU7577
Secondary Fuse Panel
Illustration 211
The secondary fuse panel is located behind the
panel, next to the battery disconnect switch.
Illustration 212
Engine ECM (23) – 30 amp
Engine Preheater (24) – 30 amp
Electrical System (25) – 30 amp
Electrical System (26) – 50 amp
145
Maintenance Support
Hood Latch - Adjust
i04567317
Hood Latch - Adjust
SMCS Code: 7251
Adjusting the Bumpers
g02845362
Illustration 213 g02730830
Adjust the bumpers on the hood in order to prevent
wear on the latch and striker. Use the following steps
in order to adjust the bumpers:
1. Loosen the jam nut on both bumpers.
2. Rotate the bumper so that the bumper touches the
frame rail.
Proper adjustment of the bumper is achieved when
the hood cannot be moved up or down while the
hood is in the closed position.
g02845356
3. Tighten the jam nut on both bumpers.
i04714129
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.
146
Maintenance Support
Hydraulic System Oil Level - Check
Illustration 214 g02407798
1. The filter is on the right side of the machine. The
filter is located above the hydraulic tank.
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.
4. Remove the filter housing with a 1.25 inch socket
or box end wrench. Do not use an air wrench,
open-end wrench, or adjustable wrench.
5. Remove the filter element from the filter housing,
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).
KEBU7577
Illustration 215 g02229677
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”.
i04035269
Hydraulic System Oil Level -
Check
SMCS Code: 5056-535-FLV; 5095-535-FLV
Note: Always check the hydraulic oil level when the
machine is parked on a level surface.
Illustration 216 g02229677
1. 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.
KEBU7577 147
Maintenance Support
Hydraulic System Oil Sample - Obtain

2. If necessary, add oil. i04748183

Refer to the Operation and Maintenance Manual,

“Capacities (Refill)”. Refer to the Operation and
Hydraulic Tank Breather -
Maintenance Manual, “Lubricant Viscosities”. Replace
SMCS Code: 5050-510-BRE; 5056-510-BRE; 5118-
510

Illustration 217 g02229676

3. In order to add the oil, remove the filler cap. Add

Illustration 219 g02845022
the oil through the filler tube. Clean the oil filler cap
and install the filler cap.
1. Open the engine compartment.
i06123239 2. Remove the breather.

Hydraulic System Oil Sample - 3. Replace the breather.

Obtain 4. Close the engine compartment.
SMCS Code: 5050-008; 5056-008; 5095-008
i05320666

Isolation Mounts - Inspect/

Replace
SMCS Code: 5654-040; 5654-510

Illustration 218 g02229773

The sampling port for the hydraulic oil is located next

to the hydraulic oil filters. Refer to Special Publication,
SEBU6250, “Caterpillar Machine Fluids
Recommendations” and refer to Special Publication,
PEGJ0047, “How To Take A Good Oil Sample” for
more information about obtaining an oil sample. Illustration 220 g02394584
Consult your Caterpillar dealer for complete
information.
148
Maintenance Support
Leveling Blade - Lubricate
1. Check the mounts for cracks which exceed 25 mm
(1.0 inch). If two or more mounts on a side have
cracks which exceed 25 mm (1.0 inch), replace all
the mounts on that side of the machine.
2. Check for broken mounts. If any mounts are
completely broken through, replace all the mounts
on that side of the machine.
3. Check for a split in the middle of the mount. If any
mounts are split in the middle, replace all of the
mounts on that side of the machine.
Refer to the Disassembly and Assembly for further
information on removing and installing the isolation
mounts.
i04035288
Leveling Blade - Lubricate
(If Equipped)
SMCS Code: 5102-086; 5103-086; 6060-086
Note: Clean the fittings before you lubricate the
fittings.
Illustration 221 g02229861
Lubricate grease fitting (1) that is located at the top of
the leveling blade cylinder.
Lubricate grease fitting (2) that is located at the
bottom of the leveling blade cylinder.
There are two grease fittings (3) for the blade pivot
pins that must be lubricated. The fittings are located
at the bottom of the pivot. There is one fitting on each
side of the machine.
KEBU7577
i02106227
Oil Filter - Inspect
SMCS Code: 1308-507; 3004-507; 3067-507; 5068-
507
Inspect a Used Filter for Debris
Illustration 222 g00100013
The element is shown with debris.
Use a filter cutter to cut the filter element open.
Spread apart the pleats and inspect the element for
metal and for other debris. An excessive amount of
debris in the filter element can indicate a possible
failure.
If metals are found in the filter element, a magnet can
be used to differentiate between ferrous metals and
nonferrous metals.
Ferrous metals can indicate wear on steel parts and
on cast iron parts.
Nonferrous metals can indicate wear on the
aluminum parts of the engine such as main bearings,
rod bearings, or turbocharger bearings.
Small amounts of debris may be found in the filter
element. This could be caused by friction and by
normal wear. Consult your Caterpillar dealer in order
to arrange for further analysis if an excessive amount
of debris is found.
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.
KEBU7577 149
Maintenance Support
Parking Brake - Check

i04035299 • The propel lever is in the NEUTRAL position.

Parking Brake - Check • The parking brake is engaged.

SMCS Code: 4267-535
Note: If the machine configuration changes, the
parking brakes must be tested.
Check the area around the machine. Make sure that
the machine is clear of personnel and clear of
obstacles.
Put the steering frame lock in the UNLOCKED
position.
Fasten the seat belt before checking the parking
brake.
The following tests are used to determine if the
parking brake is functional on a specified grade or a
specified slope. These tests are not intended to
measure the maximum brake holding effort. Read all
of the steps before you perform the following
procedure.
• The machine is positioned on the specified
slope.
Personal injury can result if the machine moves
while testing.
If the machine begins to move, release the park-
ing brake and use the propel lever in order to
move the machine to a level surface.
5. Park the machine on a level surface. If your
machine is equipped with a leveling blade, lower
the leveling blade to the ground.
6. Stop the engine.
NOTICE
If the machine moved during the brake test, consult
your Caterpillar dealer.
The dealer must inspect the brake system and make
any necessary repairs before the machine is returned
to operation.

i04729854

Radiator Core - Clean

SMCS Code: 1353-070-KO

Illustration 223 g02229913

Open the engine compartment. The radiator core is
located at the rear of the machine.
Position the machine on the incline of the slope, but
near the base of the slope in order to check the
parking brake. The test position should be 40 percent
or a 22 degree slope.

1. Start the engine. Refer to the Operation and

Maintenance Manual, “Engine Starting” for
information on starting the engine.

2. If your machine is equipped with a leveling blade,

raise the leveling blade. Move the machine into the
test position.

3. Place the throttle control into the LOW IDLE

position.
Illustration 224 g02830600
4. Engage the parking brake.
Remove bolts (1) in order to rotate the oil cooler away
The machine should not move under the following from the radiator.
conditions.
Inspect the radiator and oil cooler for debris. If
• The engine is at low idle. necessary, clean the radiator and oil cooler.
150 KEBU7577
Maintenance Support
Rollover Protective Structure (ROPS) - Inspect

Compressed air is preferred, but high-pressure water i04423622

or steam can be used to remove dust and general
debris. Clean the radiator according to the condition
of the radiator.
Seat Belt - Inspect
SMCS Code: 7327-040
Note: High-pressure water can bend the oil cooler
and the radiator fins. Always inspect the condition of the seat belt and the
condition of the seat belt mounting hardware before
See Special Publication, SEBD0518, “Know Your you operate the machine. Replace any parts that are
Cooling System” for more information about cleaning damaged or worn before you operate the machine.
radiator fins.
Rotate the oil cooler back to the original position and
install bolts (1).
Close the engine compartment.

i05418093

Rollover Protective Structure

(ROPS) - Inspect
SMCS Code: 7323-040

Illustration 226 g02620101

Typical example

Inspect buckle (1) for wear or for damage. If the

Illustration 225 g02394577
Inspect the rollover protective structure (ROPS) for
cracks. Inspect the ROPS for any loose bolts or
damaged bolts. Replace the damaged bolts with
original equipment parts only.
Replace the ROPS mounting support if the ROPS
rattles.
Do not straighten the ROPS or repair the ROPS by
welding reinforcement plates to the ROPS.
Consult your Caterpillar dealer for the repair of the
ROPS.
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).
KEBU7577 151
Maintenance Support
Seat Belt - Replace

i04421974 SMCS Code: 6605-535-PA

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 228 g02453319

There are eight bolts (1) that hold the two shell halves
together. Tighten the bolts in a sequential pattern in
order to maintain a uniform gap between the two shell
halves. Tighten the bolts to a torque of 460 N·m
(340 lb ft).
Refer to Special Instruction, REHS0712, “Shell Kit
Illustration 227 g01152685 Installation and Removal Procedure” for information
Typical Example on the installation and removal of the shell kit.
(1) Date of installation (retractor)
(2) Date of installation (buckle) i04730072
(3) Year of manufacture (tag) (fully extended Web)
(4) Year of manufacture (underside) (buckle) Steering Column Spline (HMU
Consult your Cat dealer for the replacement of the Steering) - Lubricate
seat belt and the mounting hardware.
SMCS Code: 4310-086-SN; 4310-086-JF; 4338-
Determine age of new seat belt before installing on 086-SN; 4343-086-SN; 4343-086-JF
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.
Illustration 229 g02831199
i04286150
The metering pump is located under the front of the
Shell Kit Bolt Torque - Check operator station.
(If Equipped)
152 KEBU7577
Maintenance Support
Steering Column Spline (HMU Steering) - Lubricate

Crushing Hazard. Connect the steering frame lock

between front and rear frames before servicing
the machine in the articulation area. Disconnect
the steering frame lock and secure it in the stored
position before resuming operation. Failure to do
so could result in serious injury or death.

Refer to Operation and Maintenance Manual“Steering

Frame Lock”....... before entering the articulation joint.
Note: Do not disconnect any hydraulic lines from the
metering pump.
Use the following steps to lubricate the splines on the
Illustration 232 g01560274
steering column:
(4) Rubber Boot

3. Inspect the rubber boot (4) that is located on the

steering column for wear. If necessary, replace the
boot.
4. Clean the male splines on the steering column.
Clean the female splines in the pump.

5. Apply a small amount of 186-1531 Molykote to

the male splines and to the female splines.

6. Apply a small amount of 186-1531 Molykote

between the bottom of boot (4) and the seal for the
pump.

Illustration 230 g02394319 7. Push the pump into position.

(1) Metering Pump
(2) Bolts 8. Tighten the four bolts that hold the pump.

1. Support the metering pump (1). Loosen the four 9. Test the steering system.
bolts (2) that hold the pump. Do not loosen the
hose couplings.

Illustration 231 g02394320

(3) Splines

2. Lower the pump in order to expose the splines (3).

KEBU7577 153
Maintenance Support
Steering Cylinder Ends - Lubricate

i04035313 i02977178

Steering Cylinder Ends - Tire Inflation - Check

Lubricate SMCS Code: 4203-535-PX
SMCS Code: 4303-086-BD 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 Operation and Maintenance
Manual, SEBU5898, “Cold Weather
Recommendations”.

Tire Inflation Pressure

Illustration 233 g02219014

The liquid ballast in tires is an irritant. Protect the
eyes and face from the spray that comes out of
Lower the steering frame lock pin into the LOCKED the valve stem when checking the ballast level in
position. the tires or when checking the tires air pressure.
Failure to protect the eyes and face could result in
Note: Wipe all of the fittings before you lubricate the personal injury.
fittings.
The tires are filled with liquid ballast from the factory.
When you check the tire pressure, move the machine
so that the valve stem for the tire is in the twelve
o'clock position in order to prevent the liquid ballast
from spraying out of the valve stem. Use 1P-0545
Pressure Gauge for tires that are equipped with a
liquid ballast.
Note: There will be a slight amount of liquid ballast in
the valve stem after moving the machine into position.
Depress the valve stem in order to allow the liquid
ballast to be blown out of the valve stem before
attaching the pressure gauge. Only use a pressure
gauge that is capable of handling liquid.

Tire Operating Pressures

Illustration 234 g02229974
1. There are two steering cylinders. One steering
cylinder is on the right side of the machine and one
steering cylinder is on the left side of the machine.
Lubricate the front lube fitting (1) on each side of
the machine.
2. Lubricate the rear lube fitting (2) on each side of
the machine.
3. Raise the steering frame lock pin into the
UNLOCKED position.
Since operating conditions can vary, inflate the tires
to the following pressures:
Low Pressure Limit – Adjust the tire pressure to the
low pressure limit in order to improve traction.
Lowering the tire pressure will also provide a
smoother ride.
Normal Operating Pressure – Adjust the tire
pressure to the normal operating pressure when
special conditions do not exist.
High Pressure Limit – Adjust the tire pressure to the
high pressure limit in order to improve stability.
154 KEBU7577
Maintenance Support
Tire Spacing - Change

Raising the tire pressure will also reduce the flex in
the sidewall.
Maximum Shipping Pressure – Adjust the tire
pressure to the maximum shipping pressure when
you ship the machine.
Note: After shipping the machine, return the tire
pressure to the correct operating pressure before
operating the machine.
Table 26
i04035331
Tire Spacing - Change
SMCS Code: 4200-018; 4202-018; 4203-018
When the wheels are installed in the standard
configuration, mud may accumulate between the
frame and tires. The wheels may be interchanged in
order to prevent the accumulation of mud.
Perform the following steps in order to interchange
the tires:

Ply Low Pres-

Normal Op-
High Pres-
Maximum 1. Engage the parking brake.
erating Shipping
Rating sure Limit sure Limit
Pressure Pressure 2. Block the drum.
80 kPa 110 kPa 110 kPa 200 kPa
8 (12 psi) (16 psi) (16 psi) (30 psi)
3. Jack up the rear of the machine until the tires are
off the ground. Refer to Operation and
80 kPa 110 kPa 140 kPa 200 kPa Maintenance Manual, “Additional Messages” for
10 (12 psi) (16 psi) (20 psi) (30 psi)
the jacking up locations.
80 kPa 110 kPa 165 kPa 200 kPa
12 (12 psi) (16 psi) (24 psi) (30 psi)

80 kPa 110 kPa 195 kPa 200 kPa

14 (12 psi) (16 psi) (28 psi) (30 psi)

Tire Ballast
The liquid ballast for tires is a solution of water and
calcium chloride powder CaCl. Calcium chloride
powder CaCl is an additive which will provide an
antifreeze protection and additional weight. If a tire is
repaired or replaced, the tire must be filled with the
correct amount of liquid ballast before the machine
returns to operation. The correct mixture for the liquid
ballast is 300 grams (0.66 lb) of calcium chloride
powder CaCl2 per 1 L (0.26 US gal) of water. Fill each
tire with 430 L (114 US gal) of thirty percent calcium
chloride and seventy percent water. The level of the
liquid ballast can be checked by using the following
procedure:

1. Move the machine to a flat surface and park the

machine with the valve stem in the 9 o'clock Illustration 235 g02230055
position.
4. Remove the wheel nuts that hold wheel (1) and the
2. Remove the cap for the valve stem.
wheel nuts that hold wheel (2) and remove the
3. Check for fluid by depressing the stem in the valve wheels.
stem. The liquid ballast should spray from the
stem.
4. Move the machine so that the valve stem is in the
12 o'clock position.

5. Depress the stem in the valve stem. A light mist

should spray from the valve stem.
KEBU7577 155
Maintenance Support
Vibratory Support Oil - Change

i04208854

Vibratory Support Oil - Change

SMCS Code: 5656-044-OC

Illustration 237 g02231833

Illustration 236 g02230056
The vibratory support is located on the right side of
the drum.
5. Move wheel (1) from the left side of the machine to
the right side of the machine. Install wheel (1) so
that the inside of the wheel is now the outside.
Install the wheel nuts, refer to Operation and
Maintenance Manual, “Wheel Nuts - Tighten” for
the correct torque.

6. Move wheel (2) from the right side of the machine

to the left side of the machine. Install wheel (2) so
that the inside of the wheel is now the outside.
Install the wheel nuts, refer to Operation and
Maintenance Manual, “Wheel Nuts - Tighten” for
the correct torque.

Note: When the wheels are installed in the alternate

configuration, the valve stem will be facing toward the
machine. Illustration 238 g02394239

Note: When the wheels are installed in the alternate
configuration, the width of the machine at the wheels
becomes greater than the width at the drum. Consult
with local regulations in order to address any
problems with operation or transportation.
1. Drain plug (3) is located at the bottom.
2. Remove drain plug (3). Drain the oil into a suitable
container. Dispose of the oil in an acceptable
manner.

Note: Refer to Operation and Maintenance Manual,

“General Hazard Information” for information that
pertains to containing fluid spillage.

3. After the oil is drained, clean the drain plug. Install

drain plug (3).
156 KEBU7577
Maintenance Support
Vibratory Support Oil Level - Check

Illustration 239 g02231834 Illustration 241 g02231834

4. Filler plug (1) is located at the top of the support.
Note: When a machine is equipped with a sensor for
the VPM gauge, there is a guard over the fill port hole.
The level check plug can be used as a filler plug in
this case.
5. Remove filler plug(1) and the level check plug (2).
6. Refer to the Operation and Maintenance Manual,
“Lubricant Viscosities and Capacities (Refill)”.
7. Fill the support until the oil is at the bottom of the
level check plug opening (2).
8. Clean plugs (1) and (2). Install plugs (1) and (2).
i04035843
1. The level check plug (2) is located at the three
o'clock position.
2. Remove level check plug (2). Check the level of
the oil. Maintain the level of the oil at the bottom of
the level check plug opening.
Note: When a machine is equipped with a sensor for
the VPM gauge, there is a guard over the fill port hole.
The level check plug can be used as a filler plug in
this case.
3. If the oil level is low, remove filler plug (1).
4. In order to maintain the proper oil level, add oil.
5. Refer to the Operation and Maintenance Manual,
“Lubricant Viscosities and Capacities (Refill)”.

Vibratory Support Oil Level - 6. Clean the plugs and install the plugs.
Check
SMCS Code: 5656-535-FLV

Illustration 240 g02231833

The vibratory support is located on the right side of

the drum.
KEBU7577 157
Maintenance Support
Vibratory Support Oil Sample - Obtain

i06123344 i04035855

Vibratory Support Oil Sample - Window Washer Reservoir - Fill

Obtain SMCS Code: 7306-544; 7306-544-KE; 7306
SMCS Code: 5656-008

Illustration 244 g02231897

Illustration 242 g02231833 The window washer reservoir is located on the right
side of the cab.
Refer to Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations” and refer to If the level of the cleaning solution is low, refill the
Special Publication, PEGJ0047, “How To Take A reservoir.
Good Oil Sample” for more information about
obtaining an oil sample. Consult your Caterpillar
i04035857
dealer for complete information.

Note: After you obtain an oil sample, add oil in order Window Wiper - Inspect/
to maintain the proper level. Replace
i06068178
SMCS Code: 7305-040; 7305-510

Wheel Nuts - Tighten

SMCS Code: 4201-527-NT; 4210-527

Illustration 243 g02231874

Machines equipped with 20 wheel nuts require a

torque of 460 ± 60 N·m (340 ± 45 lb ft). Illustration 245 g02231914

Machines equipped with 24 wheel nuts require a Inspect the front window wiper blade and the rear
torque of 630 ± 80 N·m (465 ± 59 lb ft). window wiper blade. If necessary, replace the window
wiper blades.
158 KEBU7577
Maintenance Support
Windows - Clean

i00851568

Windows - Clean
SMCS Code: 7310-070; 7340-070
Use commercially available window cleaning
solutions in order to clean the windows. Clean the
outside of the cab windows from the ground unless
handholds are available.
KEBU7577 159
Warranty Section
Emissions Warranty Information

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

Warranty Information
i06044323
Emissions Warranty
Information
SMCS Code: 1000
The certifying engine manufacturer warrants to the
ultimate purchaser and each subsequent purchaser
that:
1. New non-road diesel engines and stationary diesel
engines less than 10 liters per cylinder (including
Tier 1 and Tier 2 marine engines < 37 kW, but
excluding locomotive and other marine engines)
operated and serviced in the United States and
Canada, 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, with applicable
emission standards prescribed by the United
States Environmental Protection Agency
(EPA) by way of regulation.
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.
construction machines conforming to the South
Korean regulations for construction machines
manufactured after January 1, 2015, and operated
and serviced in South Korea, 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, with applicable
emission standards prescribed in the
Enforcement Rule of the Clean Air
Conservation Act promulgated by South Korea
MOE.
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.
The aftertreatment system can be expected to
function properly for the lifetime of the engine
(emissions durability period) subject to prescribed
maintenance requirements being followed.
A detailed explanation of the Emission Control
Warranty that is applicable to new non-road and
stationary diesel engines, including the components
covered and the warranty period, is found in a
supplemental Special Publication. Consult your
authorized Cat dealer to determine if your engine is
subject to an Emission Control Warranty and to
obtain a copy of the applicable Special Publication.

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.
160 KEBU7577
Reference Information Section
Reference Material

Reference Information
Section

Reference Materials
i05975063

Reference Material
SMCS Code: 1000; 7000
Additional literature regarding your product may be
purchased from your local Cat dealer or by visiting
www.cat.com. Use the product name, sales model,
and serial number in order to obtain the correct
information for your product.

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.
KEBU7577 161
Index Section

Index
A Crushing Prevention and Cutting Prevention .. 15
Cutting Edges (Leveling Blade) - Inspect/
Access Doors and Covers ............................... 97
Replace........................................................ 121
Engine Hood ................................................ 97
Additional Messages ........................................11
Data Privacy (1) ............................................11 D
Support Point (2)...........................................11
Alternate Exit ................................................... 36 Daily Inspection ............................................... 34
Axle Oil (Rear) - Change ................................110 Declaration of Conformity ................................ 33
Axle Oil Level (Rear) - Check .........................111 Decommissioning and Disposal .................... 160
Axle Oil Sample - Obtain ................................111 Door Latches - Lubricate ............................... 121
Drum Cooling Oil - Change............................ 122
Drum Scrapers - Inspect/Adjust/Replace ...... 122
B Padded Drum Scrapers (If Equipped)........ 123
Smooth Drum Flexible Scrapers (If Equipped)
Backup Alarm .................................................. 76
................................................................. 122
Backup Alarm - Test........................................ 111
Smooth Drum Steel Scrapers (If Equipped)
Battery - Clean/Check ....................................111
................................................................. 122
Battery - Recycle ............................................112
Battery Disconnect Switch............................... 47
Battery or Battery Cable - Inspect/Replace ....112 E
Before Operation ........................................21, 34
Before Starting Engine .................................... 21 Eccentric Weight Housing Oil - Change ........ 124
Belts - Inspect/Adjust/Replace........................112 Change the Oil ........................................... 124
Burn Prevention............................................... 15 Flush the Housing ...................................... 124
Batteries....................................................... 15 Electrical Storm Injury Prevention ................... 21
Coolant......................................................... 15 Emissions Certification Film ............................ 32
Oils............................................................... 15 Emissions Warranty Information.................... 159
Engine Air Filter Primary Element - Clean/
Replace........................................................ 127
C Engine Air Filter Secondary Element -
Replace........................................................ 128
Cab Air Filter - Clean/Replace ........................113
Engine and Machine Warm-Up........................ 82
Capacities (Refill) .......................................... 105
Engine Oil and Filter - Change ...................... 130
Cat Compaction Control .................................. 77
Engine Oil Level - Check ............................... 129
Compaction Meter Value (If Equipped) ........ 79
Add The Engine Oil.................................... 129
GPS Antenna (If Equipped) ......................... 77
Engine Oil Sample - Obtain ........................... 130
Machine Drive Power (If Equipped) ............. 77
Obtain the Sample and the Analysis.......... 130
Cooling System Coolant (ELC) - Change.......113
Engine Starting ...........................................21, 81
Cooling System Coolant Extender (ELC) -
Cold Weather Starting.................................. 81
Add ...............................................................115
Engine Starting (Alternate Methods) ............... 94
Cooling System Coolant Level - Check ..........116
Engine Starting with Auxiliary Start
Cooling System Coolant Sample (Level 1) -
Receptacle..................................................... 95
Obtain ...........................................................117
Engine Starting with Jump Start Cables .......... 94
Cooling System Coolant Sample (Level 2) -
Use of Jump Start Cables ............................ 94
Obtain ...........................................................118
Engine Stopping .............................................. 22
Cooling System Pressure Cap - Clean/
Engine Valve Lash - Check/Adjust ................ 131
Replace.........................................................118
Equipment Lowering with Engine Stopped...... 24
Cooling System Water Temperature
Regulator - Replace......................................119
162
Index Section
F Inhalation ..................................................... 14
Film (Product Identification) - Clean .............. 132
Cleaning of the Films ................................. 132
Final Drive Planetary (Axle) Oil - Change...... 133
Final Drive Planetary (Axle) Oil Level -
Check........................................................... 134
Final Drive Planetary (Axle) Oil Sample -
Obtain .......................................................... 134
Final Drive Planetary (Drum) Oil - Change .... 135
Final Drive Planetary (Drum) Oil - Check ...... 136
Final Drive Planetary (Drum) Oil Sample -
Obtain .......................................................... 136
Fire Extinguisher Location ............................... 19
Fire Prevention and Explosion Prevention ...... 16
Battery and Battery Cables .......................... 17
Ether ............................................................ 18
Fire Extinguisher.......................................... 18
General ........................................................ 16
Lines, Tubes, and Hoses ............................. 18
Wiring........................................................... 17
Fire Safety ....................................................... 19
Foreword............................................................ 4
California Proposition 65 Warning ................. 4
Cat Product Identification Number................. 5
Certified Engine Maintenance........................ 4
Literature Information..................................... 4
Machine Capacity .......................................... 4
Maintenance .................................................. 4
Operation ....................................................... 4
Safety............................................................. 4
Fuel System - Prime ...................................... 136
Fuel System Filter (In-Line) - Replace ........... 137
Fuel System Primary Filter (Water
Separator) - Replace.................................... 138
Replace the Secondary Fuel Filter............. 139
Fuel System Secondary Filter - Replace ....... 139
Fuel System Third Filter - Replace ................ 140
Fuel Tank Cap Filter - Replace ...................... 142
Fuel Tank Strainer - Clean ............................. 142
Fuel Tank Water and Sediment - Drain.......... 143
Fuses - Replace............................................. 143
Primary Fuse Panel ................................... 143
Secondary Fuse Panel............................... 145
G Lubricant Viscosities and Refill Capacities...... 99
General Hazard Information ............................ 12
Containing Fluid Spillage ............................. 13
Dispose of Waste Properly........................... 14
Fluid Penetration.......................................... 13
KEBU7577
Pressurized Air and Water ........................... 13
Trapped Pressure ........................................ 13
General Information......................................... 28
Guards (Operator Protection) .......................... 26
Other Guards (If Equipped).......................... 26
Rollover Protective Structure (ROPS), Falling
Object Protective Structure (FOPS) or Tip
Over Protection Structure (TOPS) ............. 26
H
Hood Latch - Adjust ....................................... 145
Adjusting the Bumpers............................... 145
Hydraulic System Oil Filter - Replace ............ 145
Hydraulic System Oil Level - Check .............. 146
Hydraulic System Oil Sample - Obtain .......... 147
Hydraulic Tank Breather - Replace................ 147
I
Identification Information ................................. 30
Important Safety Information ............................. 2
Isolation Mounts - Inspect/Replace ............... 147
L
Leaving the Machine ....................................... 84
Leveling Blade - Lubricate (If Equipped)........ 148
Lifting and Tying Down the Machine................ 86
Lifting the Machine....................................... 86
Tying Down the Machine.............................. 87
Lubricant Viscosities (Fluids
Recommendations) ....................................... 99
Biodiesel .................................................... 103
Coolant Information.................................... 104
Diesel Fuel Recommendations.................. 103
Engine Oil .................................................... 99
Fuel Additives ............................................ 103
General Information for Lubricants .............. 99
Hydraulic Systems ..................................... 100
Selecting the Viscosity ................................. 99
Soil Compactors......................................... 101
Special Lubricants...................................... 102
Standard Factory Fill Fluids ....................... 105
M
Machine Operation .......................................... 36
KEBU7577
Maintenance Access ....................................... 97
Maintenance Interval Schedule ..................... 109
Every 10 Service Hours or Daily ................ 109
Every 1000 Service Hours or 1 Year...........110
Every 12 000 Service Hours or 6 Years ......110
Every 2000 Service Hours ..........................110
Every 250 Service Hours ........................... 109
Every 250 Service Hours or 3 Months ....... 109
Every 3 Years..............................................110
Every 3000 Service Hours ..........................110
Every 3000 Service Hours or 2 Years .........110
Every 3000 Service Hours or 3 Years .........110
Every 50 Service Hours or Weekly ............ 109
Every 500 Service Hours ............................110
Every 500 Service Hours or 6 Months ........110
Every 6000 Service Hours or 3 Years .........110
Every Year...................................................110
Initial 10 Service Hours .............................. 109
Initial 250 Service Hours ............................ 109
When Required.......................................... 109
Maintenance Section....................................... 97
Maintenance Support .................................... 107
Mirror ............................................................... 38
Cab Mirrors .................................................. 39
Mirror Adjustment......................................... 39
ROPS Mirrors............................................... 40
Monitoring System........................................... 48
Basic Setup.................................................. 49
Brightness/Contrast ..................................... 49
Diagnostics .................................................. 50
Display Navigation ....................................... 48
Fault Pop-Up Alarms.................................... 55
Indicator Lights............................................. 48
Machine Setup ............................................. 51
Main Menu ................................................... 49
Screen Setup ............................................... 52
Signals ......................................................... 55
System Setup............................................... 54
Mounting and Dismounting.............................. 34
Alternate Exit................................................ 34
Machine Access System Specifications ...... 34
O Data Broadcasts .......................................... 56
Oil Filter - Inspect........................................... 148
Inspect a Used Filter for Debris.................. 148
Operation......................................................... 22
Operation Information...................................... 74
High Amplitude............................................. 75
Low Amplitude ............................................. 76
Vibratory Operation...................................... 74
163
Index Section
Vibratory System.......................................... 75
Operation Section............................................ 34
Operator Controls ............................................ 41
12V Power Receptacle (27) ......................... 47
Air Conditioner Switch (23) .......................... 46
Auto Vibe Activation Control (20)................. 46
Beacon (11).................................................. 45
Emergency Stop Knob (8)............................ 44
Engine Start Switch (5) ................................ 44
Fan Speed Control (21)................................ 46
Front Window Wiper Switch (24).................. 46
Horn (7) ........................................................ 44
Keypad (12) ................................................. 45
Leveling Blade Control (26) (If Equipped).... 47
Monitoring System (3).................................. 43
Parking Brake (9) ......................................... 44
Propel Control (4)......................................... 44
Propel Speed Range Control (15)................ 45
Rear Window Wiper Switch (25) .................. 47
Service Connector (28) ................................ 47
Speed Control Decrease (14) ...................... 45
Speed Control Increase (13)........................ 45
Steering Wheel (1) ....................................... 43
Steering Wheel Position Lock (2)................. 43
Temperature Control (22)............................. 46
Throttle Control (16)..................................... 45
Vibratory Amplitude Control (19).................. 46
Vibratory Button (6) ...................................... 44
Vibratory Frequency Decrease (18)............. 46
Vibratory Frequency Increase (17) .............. 46
Work Lights (10)........................................... 45
Operator Station .............................................. 26
P
Parking .......................................................23, 83
Parking Brake - Check................................... 149
Parking Brake Manual Release ....................... 92
Plate Locations and Film Locations................. 30
Certification.................................................. 31
Product Identification Number (PIN) ............ 30
Product Information Section ............................ 28
Product Link..................................................... 55
Machine Security ......................................... 57
Operation in a Blast Site for Product Link
Radios ........................................................ 56
Regulatory Compliance ............................... 58
164 KEBU7577
Index Section

R Engage the Steering Frame Lock ................ 35

Stopping the Engine ........................................ 83
Radiator Core - Clean.................................... 149
Stopping the Machine...................................... 83
Reference Information Section ...................... 160
System Pressure Release............................. 107
Reference Material ........................................ 160
Coolant System.......................................... 107
Reference Materials ...................................... 160
Hydraulic System....................................... 107
Roading the Machine....................................... 85
Rollover Protective Structure (ROPS) -
Inspect ......................................................... 150 T
Table of Contents............................................... 3
S Tire Inflation - Check...................................... 153
Tire Ballast ................................................. 154
S·O·S Information.......................................... 106
Tire Inflation Pressure ................................ 153
Safety Messages............................................... 6
Tire Inflation Information.................................. 98
Crushing Hazard (6)....................................... 9
Tire Information................................................ 20
Crushing Hazard (7)....................................... 9
Tire Shipping Pressure .................................... 98
Do Not Operate (1)......................................... 8
Tire Spacing - Change................................... 154
Do Not Weld or Drill (4) .................................. 9
Towing Information .......................................... 89
Hot Fluids (8)................................................ 10
Towing the Machine......................................... 89
Jumper Cables (5) ......................................... 9
Running Engine ........................................... 89
No Ether (9).................................................. 10
Stopped Engine ........................................... 90
Product Link (3).............................................. 8
Transportation Information............................... 85
Seat Belt (2) ................................................... 8
Safety Section ................................................... 6
Seat ................................................................. 36 V
Air Ride Seat................................................ 37
Standard Seat .............................................. 36 Vibratory Support Oil - Change...................... 155
Seat Belt .......................................................... 37 Vibratory Support Oil Level - Check .............. 156
Extension of the Seat Belt............................ 38 Vibratory Support Oil Sample - Obtain .......... 157
Seat Belt Adjustment for Retractable Seat Visibility Information......................................... 21
Belts ........................................................... 38
Seat Belt - Inspect ......................................... 150 W
Seat Belt - Replace........................................ 151
Shell Kit Bolt Torque - Check (If Equipped) ... 151 Warranty Information ..................................... 159
Shipping the Machine ...................................... 85 Warranty Section ........................................... 159
Slope Operation............................................... 23 Welding on Machines and Engines with
Sound Information and Vibration Information.. 24 Electronic Controls....................................... 107
Sound Level Information.............................. 24 Wheel Nuts - Tighten ..................................... 157
Sound Level Information for Machines in Window (Side) ................................................. 76
European Union Countries and in Countries Window Washer Reservoir - Fill .................... 157
that Adopt the “EU Directives”................... 24 Window Wiper - Inspect/Replace .................. 157
“The European Union Physical Agents Windows - Clean............................................ 158
(Vibration) Directive 2002/44/EC” .............. 24
Specifications .................................................. 28
Dimensions .................................................. 28
Intended Use................................................ 28
Steering Column Spline (HMU Steering) -
Lubricate ...................................................... 151
Steering Cylinder Ends - Lubricate................ 153
Steering Frame Lock ....................................... 35
Disengage the Steering Frame Lock ........... 35
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 Phone Hours

Contact Number

Sales:

Parts:

Service:
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All Rights Reserved dress as well as corporate and product identity used herein, are trademarks of Caterpillar and
may not be used without permission.