KEBU7565-05

January 2014

Operation and
Maintenance
Manual
RM-300 Soil Stabilizer
BWR 487-Up (RM-300)

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.
KEBU7565 3
Table of Contents

Table of Contents Identification Information ................ ................ 42

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

Safety Section Before Operation ...................... ...................... 46

Machine Operation ..................... .................... 49

Safety Messages....................... ....................... 6
Engine Starting ....................... .......................110
Additional Messages ................... ................... 13

General Hazard Information .............. ............. 14 Machine Service ...................... ......................113

Crushing Prevention and Cutting Prevention . 17 Parking ............................. .............................119

Burn Prevention....................... ....................... 17 Machine Cleanup..................... ..................... 122

Fire Prevention and Explosion Prevention ... .. 18 Transportation Information.............. .............. 123

Towing Information ................... .................... 125

Fire Extinguisher Location ............... ............... 21
Engine Starting (Alternate Methods) ...... ...... 129
Tire Information........................ ....................... 22

Electrical Storm Injury Prevention ......... ......... 22 Maintenance Section

Before Starting Engine ................. .................. 23 Maintenance Access .................. .................. 131

Engine Starting ........................ ....................... 23 Tire Inflation Information................ ............... 133

Before Operation ...................... ...................... 23 Lubricant Viscosities and Refill Capacities.. . 135

Restricted Visibility .................... ..................... 23 Maintenance Support .................. ................. 145

Visibility Information.................... .................... 24 Maintenance Interval Schedule .......... .......... 146

Operation............................ ............................ 24 Reference Information Section

Engine Stopping ....................... ...................... 25 Reference Materials .................. ................... 221

Parking ............................. .............................. 25 Index Section

Slope Operation....................... ....................... 26 Index............................... .............................. 223

Equipment Lowering with Engine Stopped... .. 26

Sound Information and Vibration Information. 27

Operator Station ....................... ...................... 29

Guards (Operator Protection) ............. ............ 29

Product Information Section

General Information.................... .................... 31

4 KEBU7565
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.
KEBU7565 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 KEBU7565
Safety Section
Safety Messages

Safety Section
i03645872

Safety Messages
SMCS Code: 7000; 7405
There are several specific safety messages on this
machine. The exact location of the hazards and the
description of the hazards are reviewed in this
section. Please become familiarized with all safety
messages.
Make sure that all of the safety messages are legible.
Clean the safety messages or replace the safety
messages if you cannot read the words. Replace the
messages if the messages are not legible. When you
clean the safety messages, use a cloth, water and
soap. Do not use solvent, gasoline, or other harsh
chemicals to clean the safety messages. Solvents,
gasoline, or harsh chemicals could loosen the
adhesive that secures the safety messages. Loose
adhesive will allow the safety messages to fall.
Replace any safety message that is damaged, or
missing. If a safety message is attached to a part that
is replaced, install a safety message on the
replacement part. Any Caterpillar dealer can provide
new safety messages.
KEBU7565 7
Safety Section
Safety Messages

Illustration 2 g01956396
8 KEBU7565
Safety Section
Safety Messages

Do Not Operate (1)

This safety message is located on the operator's
console.

Illustration 4 g01370908

Illustration 3 g01370904
Do not operate or work on this machine unless
you have read and understand the instructions
and warnings in the Operation and Maintenance
Manual. Failure to follow the instructions or heed
the warnings could result in injury or death. Con-
tact any Caterpillar dealer for replacement man-
uals. Proper care is your responsibility.
A seat belt should be worn at all times during ma-
chine operation to prevent serious injury or death
in the event of an accident or machine overturn.
Failure to wear a seat belt during machine opera-
tion may result in serious injury or death.
Crush Hazard, Stay Back (3)
This safety message is located on the rear door
assembly.

Seat Belt (2)

This safety message is located on the operator's
console.

Illustration 5 g01412505

No clearance for people with door closed. Always

use door lock when working under hood. Door
closing on person can cause serious injury.
KEBU7565 9
Safety Section
Safety Messages

Cutter Hazard and Rotor Movement

Hazard, Stay Back (4)
This safety message is located on both the left side
and the right side of the mixing chamber.

Illustration 6 g01950122
Illustration 7 g01526717

Rotor movement can cause injury or death. Stay

clear of the rotor when the engine is running. Shut Flying debris may cause serious personal injury
off the engine before performing any service on or death. Maintain a minimum distance of 10 m
the rotor or its housing. (33 ft).

Flying Debris Hazard, Read the
Operation and Maintenance Manual
(5)
This safety message is located on both the left side
and the right side of the mixing chamber.
Crush Hazard, Read the Operation
and Maintenance Manual (6)
This safety message is located on both the left side
and the right side of the mixing chamber.
10 KEBU7565
Safety Section
Safety Messages

Illustration 9 g01370909

IMPROPER JUMPER CABLE CONNECTIONS CAN

Illustration 8
Do not operate this machine if the rotor service
panel door is not closed and secured.
Improper Connections for Jump
Start Cables (7)
CAUSE EXPLOSION RESULTING IN PERSONAL
g01953247 INJURY.
BATTERIES MAY BE LOCATED IN SEPARATE
COMPARTMENTS. WHEN USING JUMPER CA-
BLES, ALWAYS CONNECT POSITIVE (+) CABLE
TO POSITIVE (+) TERMINAL OF BATTERY CON-
NECTED TO STARTER SOLENOID AND NEGA-
TIVE (-) CABLE FROM EXTERNAL SOURCE TO
STARTER NEGATIVE (-) TERMINAL (IF MACHINE
NOT EQUIPPED WITH STARTER NEGATIVE TER-
MINAL, CONNECT TO ENGINE BLOCK.) FOLLOW
PROCEDURE IN THE OPERATION MANUAL.

This safety message is located near the battery box

on the left side of the machine. Explosion Hazard (Ether) (8)
This safety message is located on top of the engine
hood near the air intake.
KEBU7565 11
Safety Section
Safety Messages

Illustration 10 g01372254 Illustration 11 g01371640

Do not use aerosol types of starting aids such as
ether. Such use could result in an explosion and
personal injury.
Hot Fluid Under Pressure (9)
This safety message is located near the coolant
pressure cap.
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.

Product Link (10)

If equipped, this safety message is positioned on the
operator console.
12 KEBU7565
Safety Section
Safety Messages

Illustration 12 g01370917

This machine is equipped with a Caterpillar Prod-

uct Link communication device. When electric/
electronic detonators are used, this communica-
tion device should be deactivated within 12 m
(40 ft) of a blast site, or within the distance man-
dated under applicable legal requirements. Fail-
ure to do so could cause interference with
blasting operations and result in serious injury or
death.

Refer to Operation and Maintenance Manual,

“Product Link” for further information.
KEBU7565 13
Safety Section
Additional Messages

i02905327

Additional Messages
SMCS Code: 1000; 7000; 7405

Illustration 13 g01446071
14 KEBU7565
Safety Section
General Hazard Information

There are several specific messages on this i05218279

machine. The exact location of the messages and the
description of the information are reviewed in this
section. Please become familiar with all messages.
General Hazard Information
SMCS Code: 7000
Make sure that all of the messages are legible. Clean
the messages or replace the messages if you cannot
read the words. Replace the illustrations if the
illustrations are not legible. When you clean the
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
messages. Loose adhesive will allow the messages
to fall.
Data Privacy (1)
If equipped, additional message (1) is located in the
operator console.

Illustration 15 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.

Illustration 14 g01418953 Operating the machine while distracted can result

The Product Link System is a satellite communication
device that transmits information regarding the
machine back to Caterpillar and Caterpillar dealers
and customers. All logged events and diagnostic
codes that are available to the Caterpillar Electronic
Technician (ET) on the CAT data link can be sent to
the satellite. Information can also be sent to the
Product Link System. The information is used to
improve Caterpillar products and Caterpillar services.
Refer to Operation and Maintenance Manual,
“Product Link” for more information.
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.
KEBU7565
Illustration 16 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.
15
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.
The maximum air pressure for cleaning purposes
must be reduced to 205 kPa (30 psi) when the nozzle
is deadheaded and the nozzle is used with an
effective chip deflector and personal protective
equipment. The maximum water pressure for
cleaning purposes must be below 275 kPa (40 psi).
Avoid direct spraying of water on electrical
connectors, connections, and components. When
using air for cleaning, allow the machine to cool to
reduce the possibility of fine debris igniting when re-
deposited on hot surfaces.
Trapped Pressure
Pressure can be trapped in a hydraulic system.
Releasing trapped pressure can cause sudden
machine movement or attachment movement. Use
caution if you disconnect hydraulic lines or fittings.
High-pressure oil that is released can cause a hose to
whip. High-pressure oil that is released can cause oil
to spray. Fluid penetration can cause serious injury
and possible death.
Fluid Penetration
Pressure can be trapped in the hydraulic circuit long
after the engine has been stopped. The pressure can
cause hydraulic fluid or items such as pipe plugs to
escape rapidly if the pressure is not relieved correctly.
Do not remove any hydraulic components or parts
until pressure has been relieved or personal injury
may occur. Do not disassemble any hydraulic
components or parts until pressure has been relieved
or personal injury may occur. Refer to the Service
Manual for any procedures that are required to relieve
the hydraulic pressure.
16
Safety Section
General Hazard Information
Illustration 17 g00687600
Always use a board or cardboard when you check for
a leak. Leaking fluid that is under pressure can
penetrate body tissue. Fluid penetration can cause
serious injury and possible death. A pin hole leak can
cause severe injury. If fluid is injected into your skin,
you must get treatment immediately. Seek treatment
from a doctor that is familiar with this type of injury.
Containing Fluid Spillage
Care must be taken in order to ensure that fluids are
contained during performance of inspection,
maintenance, testing, adjusting, and repair of the
equipment. Prepare to collect the fluid with suitable
containers before opening any compartment or
disassembling any component that contains fluids.
Refer to Special Publication, NENG2500, “Cat dealer
Service Tool Catalog” for the following items:
• Tools that are suitable for collecting fluids and
equipment that is suitable for collecting fluids
• Tools that are suitable for containing fluids and
equipment that is suitable for containing fluids
Obey all local regulations for the disposal of liquids.
KEBU7565
Inhalation
Illustration 18 g02159053
Exhaust
Use caution. Exhaust fumes can be hazardous to
your health. If you operate the machine in an
enclosed area, adequate ventilation is necessary.
Asbestos Information
Cat equipment and replacement parts that are
shipped from Caterpillar are asbestos free. Caterpillar
recommends the use of only genuine Cat
replacement parts. Use the following guidelines when
you handle any replacement parts that contain
asbestos or when you handle asbestos debris.
Use caution. Avoid inhaling dust that might be
generated when you handle components that contain
asbestos fibers. Inhaling this dust can be hazardous
to your health. The components that may contain
asbestos fibers are brake pads, brake bands, lining
material, clutch plates, and some gaskets. The
asbestos that is used in these components is bound
in a resin or sealed in some way. Normal handling is
not hazardous unless airborne dust that contains
asbestos is generated.
If dust that may contain asbestos is present, there are
several guidelines that should be followed:
KEBU7565
• Never use compressed air for cleaning.
• Avoid brushing materials that contain asbestos.
• Avoid grinding materials that contain asbestos.
• Use a wet method in order to clean up asbestos
materials.
• A vacuum cleaner that is equipped with a high
efficiency particulate air filter (HEPA) can also be
used.
• Use exhaust ventilation on permanent machining
jobs.
• Wear an approved respirator if there is no other
way to control the dust.
• Comply with applicable rules and regulations for
the work place. In the United States, use
Occupational Safety and Health Administration
(OSHA) requirements. These OSHA requirements
can be found in “29 CFR 1910.1001”. In Japan,
use the requirements found in the “Ordinance on
Prevention of Health Impairment due to Asbestos”
in addition to the requirements of the Industrial
Safety and Health Act.
• Obey environmental regulations for the disposal of
asbestos.
• Stay away from areas that might have asbestos
particles in the air.
Dispose of Waste Properly
Illustration 19 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.
17
Safety Section
Crushing Prevention and Cutting Prevention
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.
18
Safety Section
Fire Prevention and Explosion 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.
KEBU7565
i05374405
Fire Prevention and Explosion
Prevention
SMCS Code: 7000
Illustration 20 g00704000
General
All fuels, most lubricants, and some coolant mixtures
are flammable.
To minimize the risk of fire or explosion, Caterpillar
recommends the following actions.
Always perform a Walk-Around Inspection, which
may help you identify a fire hazard. Do not operate a
machine when a fire hazard exists. Contact your Cat
dealer for service.
Understand the use of the primary exit and alternative
exit on the machine. Refer to Operation and
Maintenance Manual, “Alternative Exit”.
Do not operate a machine with a fluid leak. Repair
leaks and clean up fluids before resuming machine
operation. Fluids that are leaking or spilled onto hot
surfaces or onto electrical components can cause a
fire. A fire may cause personal injury or death.
Remove flammable material such as leaves, twigs,
papers, trash, and so on. These items may
accumulate in the engine compartment or around
other hot areas and hot parts on the machine.
Keep the access doors to major machine
compartments closed and access doors in working
condition in order to permit the use of fire suppression
equipment, in case a fire should occur.
Clean all accumulations of flammable materials such
as fuel, oil, and debris from the machine.
Do not operate the machine near any flame.
KEBU7565
Keep shields in place. Exhaust shields (if equipped)
protect hot exhaust components from oil spray or fuel
spray in case of a break in a line, in a hose, or in a
seal. Exhaust shields must be installed correctly.
Do not weld or flame cut on tanks or lines that contain
flammable fluids or flammable material. Empty and
purge the lines and tanks. Then clean the lines and
tanks with a nonflammable solvent prior to welding or
flame cutting. Ensure that the components are
properly grounded in order to avoid unwanted arcs.
Dust that is generated from repairing nonmetallic
hoods or fenders may be flammable and/or explosive.
Repair such components in a well ventilated area
away from open flames or sparks. Use suitable
Personal Protection Equipment (PPE).
Inspect all lines and hoses for wear or deterioration.
Replace damaged lines and hoses. The lines and the
hoses should have adequate support and secure
clamps. Tighten all connections to the recommended
torque. Damage to the protective cover or insulation
may provide fuel for fires.
Store fuels and lubricants in properly marked
containers away from unauthorized personnel. Store
oily rags and flammable materials in protective
containers. Do not smoke in areas that are used for
storing flammable materials.
Illustration 21 g00704059
Use caution when you are fueling a machine. Do not
smoke while you are fueling a machine. Do not fuel a
machine near open flames or sparks. Always stop the
engine before fueling. Fill the fuel tank outdoors.
Properly clean areas of spillage.
19
Safety Section
Fire Prevention and Explosion Prevention
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 22 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.
20
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.
KEBU7565
• 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 23 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:
KEBU7565 21
Safety Section
Fire Extinguisher Location

• End fittings are damaged or leaking. Consider installation of an aftermarket Fire

Suppression System, if the application and working
• Outer coverings are chafed or cut. conditions warrant the installation.

• Wires are exposed. i02203450

• Outer coverings are swelling or ballooning.

Fire Extinguisher Location
• Flexible parts of the hoses are kinked. SMCS Code: 7000; 7419
• Outer covers have exposed embedded armoring.
Open Platform
• End fittings are displaced.
Make sure that the fire extinguisher is on the
Make sure that all clamps, guards, and heat shields machine. Make sure that you are familiar with the
are installed correctly. During machine operation, this operation of the fire extinguisher. Inspect the fire
will help to prevent vibration, rubbing against other extinguisher and service the fire extinguisher. Obey
parts, excessive heat, and failure of lines, tubes, and the recommendations that are on the instruction
hoses. plate.
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.
Follow the correct cold engine starting procedures.
Refer to the section in the Operation and
Maintenance Manual with the label “Engine Starting”
. Illustration 24 g01225503

Do not spray ether manually into an engine if the
machine is equipped with a thermal starting aid for
cold weather starting.
Use ether in well ventilated areas. Do not smoke
while you are replacing an ether cylinder or while you
are using an ether spray.
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.
Mount the fire extinguisher to the left of the operator's
seat at the base.
Note: Care should be taken in mounting the fire
extinguisher in order to prevent damage to wiring
under the seat base.
Closed Platform
Any modifications to the inside of the operator station
should not project into the operator's space. The
addition of a radio, fire extinguisher, and other
equipment must be installed so that the defined
operator's space is maintained. Any item that is
brought into the cab should not project into the
defined operator's space. A lunch box or other loose
items must be secured. Objects must not pose a
hazard in rough terrain or in the event of a rollover.
22
Safety Section
Tire Information
Illustration 25 g01225005
Mount the fire extinguisher to the left of the operator's
seat at the base.
Note: Care should be taken in mounting the fire
extinguisher in order to prevent damage to wiring
under the seat base.
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.
Illustration 26 g02166933
Typical example of tire is shown
Do not approach a hot or an apparently damaged tire.
KEBU7565
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.
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.
KEBU7565
i00771840
Before Starting Engine
SMCS Code: 1000; 7000
Start the engine only from the operator compartment.
Never short across the starter terminals or across the
batteries. Shorting could damage the electrical
system by bypassing the engine neutral start system.
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.
Adjust the seat so that full pedal travel can be
achieved with the operator's back against the back of
the seat.
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.
i03646058
Engine Starting
SMCS Code: 1000; 7000
Illustration 27 g00102517
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.
Push down on the upper part of the parking brake
switch.
Move the propel lever to the STOP position.
Place the rotor control in the OFF position.
Briefly sound the horn before you start the engine.
23
Safety Section
Before Starting Engine
Start the engine and operate the engine in a well
ventilated area. In an enclosed area, vent the exhaust
to the outside.
i03709542
Before Operation
SMCS Code: 7000
Clear all personnel from the machine and from the
area.
Clear all obstacles that are in the path of the machine.
Beware of hazards such as wires, ditches, etc.
Make sure that the machine horn, the backup alarm
(if equipped) and all other warning devices are
working properly.
Fasten the seat belt securely.
Adjust the mirrors (if equipped).
Refer to Operation and Maintenance Manual, “Daily
Inspection” before you operate the machine.
i03720940
Restricted Visibility
SMCS Code: 7000
The size and the configuration of this machine may
result in areas that can not be seen when the
operator is seated. Illustration 28 provides an
approximate visual indication of the areas of
significant restricted visibility. Illustration 28 indicates
the restricted visibility areas at ground level inside a
radius of 12.00 m (39.37 ft) from the operator on a
machine without the use of optional visual aids. This
illustration does not provide areas of restricted
visibility for distances outside a radius of 12.00 m
(39.37 ft).
This machine may be equipped with optional visual
aids that may provide visibility to some of the
restricted visibility areas. For the areas that are not
covered by the optional visual aids, job site
organization must be utilized to minimize hazards of
this restricted visibility. Refer to Operation and
Maintenance Manual, “Visibility Information” for more
information on job site organization.
24
Safety Section
Visibility Information
Illustration 28 g02005356
Top view of the machine
Note: The shaded areas of illustration 28 indicate the
approximate locations with significant restricted
visibility when the operator station is moved to the
extreme left position on the machine. When the
operator station is moved to the extreme right position
on the machine the shaded areas are reversed from
left to right. When the operator station is moved to
other positions further adjustment of the mirrors will
be required.
i04862936
Visibility Information
SMCS Code: 7000
Before you start the machine, perform a walk-around
inspection in order to ensure that there are no
hazards around the machine.
While the machine is in operation, constantly survey
the area around the machine in order to identify
potential hazards as hazards become visible around
the machine.
KEBU7565
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.
i03709700
Operation
SMCS Code: 7000
The standard machine configuration is intended for
use within an ambient temperature range of 0 °C
(32 °F) to 50 °C (122 °F) temperatures unless
otherwise specified in marketing functional
specification.
Only operate the machine while you are in a seat.
The seat belt must be fastened while you operate the
machine. Only operate the controls while the engine
is running.
KEBU7565
While you operate the machine slowly in an open
area, check for proper operation of all controls and all
protective devices.
You must be sure that no one is in danger before the
machine is moved.
Do not allow riders on the machine unless the
machine has the following equipment:
• additional seat
• additional seat belt
Never use the work tool as a work platform.
To maintain proper machine control and effective
hydrostatic braking on downhill slopes over 6%,
this machine must be operated in Low Range (L).
Failure to follow these instructions could result in
an overspeed condition, loss of control and/or
sudden stopping by the secondary (emergency)
braking system which could cause serious injury
or death.
Note any needed repairs during machine operation.
Report any needed repairs.
Lower the rotor. Slowly propel the machine when you
start a cut. This operation prevents the machine from
riding up on the rotor and lunging backward. This
operation also prevents excessive bouncing.
Do not allow anyone to stand or walk behind the
machine while the machine is in operation. The
machine may lunge backward if the rotor hits an
obstruction.
Carry attachments approximately 40 cm (15 inches)
above ground level. Do not go close to the edge of a
cliff, an excavation, or an overhang.
If the machine begins to sideslip downward on a
grade, immediately remove the load and turn the
machine downhill.
Avoid any conditions that can lead to tipping the
machine. The machine can tip when you work on
hills, on banks and on slopes. Also, the machine can
tip when you cross ditches, ridges or other
unexpected obstructions.
Avoid operating the machine across the slope. When
possible, operate the machine up the slopes and
down the slopes.
Maintain control of the machine. Do not overload the
machine beyond the machine capacity.
Be sure that the hitches and the towing devices are
adequate.
Only connect the trailing equipment to a drawbar or to
a hitch.
25
Safety Section
Engine Stopping
Never straddle a wire cable. Never allow other
personnel to straddle a wire cable.
Before you maneuver the machine, make sure that no
personnel are between the machine and the trailing
equipment. Block up the hitch of the trailing
equipment in order to align the hitch with the drawbar.
Maneuver the machine. Connect the machine to the
trailing equipment.
Know the maximum dimensions of your machine.
i02298209
Engine Stopping
SMCS Code: 1000; 7000
Do not stop the engine of the machine immediately
after the machine has been operated under load. This
can cause overheating and accelerated wear of
engine components.
After the machine is parked and the parking brake is
engaged, allow the engine to run for five minutes
before shutdown. This allows hot areas of the engine
to cool gradually.
For more information, refer to the following topics in
the Operation Section of the Operation and
Maintenance Manual:
• “Stopping the Engine”
• “Stopping the Engine if an Electrical Malfunction
Occurs”
i01404607
Parking
SMCS Code: 7000
Park the machine on a level surface. If you must park
the machine on a grade, you must block the machine.
Move the propel lever to the NEUTRAL position in
order to stop the machine.
Place all controls in the NEUTRAL position.
Engage the parking brake by pushing the parking
brake control to the ON position. The parking brake
control will light.
Lower the rotor and the hood until the rotor rests on
the ground.
Stop the engine.
Turn the engine start switch to the OFF position and
remove the key.
Turn the battery disconnect switch to the OFF
position.
26 KEBU7565
Safety Section
Slope Operation

i03745198
Operated equipment – Be aware of performance
Slope Operation features of the equipment in operation and the effects
on machine stability.
SMCS Code: 7000
Operating techniques – Keep all attachments or
Machines that are operating safely in various pulled loads low to the ground for optimum stability.
applications depend on these criteria: the machine
model, configuration, machine maintenance, Machine systems have limitations on slopes –
operating speed of the machine, conditions of the Slopes can affect the proper function and operation of
terrain, fluid levels and tire inflation pressures. The the various machine systems. These machine
most important criteria are the skill and judgment of systems are needed for machine control.
the operator.
A well trained operator that follows the instructions in Note: Safe operation on steep slopes may require
the Operation and Maintenance Manual has the special machine maintenance. Excellent skill of the
greatest impact on stability. Operator training operator and proper equipment for specific
provides a person with the following abilities: applications are also required. Consult the Operation
observation of working and environmental conditions, and Maintenance Manual sections for the proper fluid
feel for the machine, identification of potential level requirements and intended machine use.
hazards and operating the machine safely by making
appropriate decisions.
i01329161
When you work on side hills and when you work on
slopes, consider the following important points: Equipment Lowering with
Speed of travel – At higher speeds, forces of inertia Engine Stopped
tend to make the machine less stable. SMCS Code: 7000
Roughness of terrain or surface – The machine Before lowering any equipment with the engine
may be less stable with uneven terrain. stopped, clear the area around the equipment of all
Direction of travel – Avoid operating the machine personnel. The procedure to use will vary with the
across the slope. When possible, operate the type of equipment to be lowered. Keep in mind most
machine up the slopes and operate the machine systems use a high pressure fluid or air to raise or
down the slopes. Place the heaviest end of the lower equipment. The procedure will cause high
machine uphill when you are working on an incline. pressure air, hydraulic, or some other media to be
released in order to lower the equipment. Wear
Mounted equipment – Balance of the machine may appropriate personal protective equipment and follow
be impeded by the following components: equipment the established procedure in the Operation and
that is mounted on the machine, machine Maintenance Manual, “Equipment Lowering with
configuration, weights and counterweights. Engine Stopped” in the Operation Section of the
manual.
Nature of surface – Ground that has been newly
filled with earth may collapse from the weight of the
machine.
Surface material – Rocks and moisture of the
surface material may drastically affect the machine's
traction and machine's stability. Rocky surfaces may
promote side slipping of the machine.
Slippage due to excessive loads – This may cause
downhill tracks or downhill tires to dig into the ground,
which will increase the angle of the machine.
Width of tracks or tires – Narrower tracks or
narrower tires further increase the digging into the
ground which causes the machine to be less stable.
Implements attached to the drawbar – This may
decrease the weight on the uphill tracks. This may
also decrease the weight on the uphill tires. The
decreased weight will cause the machine to be less
stable.
Height of the working load of the machine – When
the working loads are in higher positions, the stability
of the machine is reduced.
KEBU7565
i03721004
Sound Information and
Vibration Information
SMCS Code: 7000
Sound Level Information
The average operator sound pressure level that is
measured according to the test procedures and
conditions that are specified in “ISO 11204:1995” is
93 dB(A) for a machine that is equipped with an open
platform, ROPS, and a canopy. The test was
conducted on a stationary machine with the engine
set to high idle and the cooling fan was set at
maximum fan speed. The rotor speed was set to the
low position and the rotor was in the raised up
position. The swivel seat was in the straight ahead
position. The value is the average of the readings that
were obtained with the operator station in the LEFT,
CENTER, and RIGHT positions.
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 Performance for Machines
That Are Offered in European
Countries and in Countries that
Adopt the Directives of the
European Union
The average operator sound pressure level that is
measured according to the test procedures and
conditions that are specified in “ISO 11204:1995” is
75 dB(A) for an enclosed cab. The cab was properly
installed and maintained. The test was conducted on
a stationary machine with the doors and the windows
closed. The engine was set to high idle. The cooling
fan was set at maximum fan speed. The heater/air
conditioner fan was set to the MID position. The rotor
speed was set to LOW position. The rotor was in the
raised up position. The swivel seat was in the straight
ahead position. The value is an average of the
readings that were obtained with the operator station
in the LEFT, CENTER, and RIGHT positions.
Table 1
“ISO Reference Table A - Equivalent vibration levels of whole body vibration emission for earthmoving equipment.”
Machine Vibration Levels
Typical Operating Activity
Type X axis
Road Reclaim- cutting 0,15
er/Soil
Stabilizer roading 0,21
27
Safety Section
Sound Information and Vibration Information
“The European Union Physical
Agents (Vibration) Directive 2002/
44/EC”
Vibration Data for Road Reclaimer/Soil
Stabilizer
Information Concerning Hand/Arm
Vibration Level
When the machine is operated according to the
intended use, the hand/arm vibration of this machine
is below 2.5 meter per second squared.
Information Concerning Whole Body
Vibration Level
This section provides vibration data and a method for
estimating the vibration level for the Road Reclaimer/
Soil Stabilizer.
Note: Vibration levels are influenced by many
different parameters. Many items are listed below.
• Operator training, behavior, mode and stress
• Job site organization, preparation, environment,
weather and material
• Machine type, quality of the seat, quality of the
suspension system, attachments and condition of
the equipment
It is not possible to get precise vibration levels for this
machine. The expected vibration levels can be
estimated with the information in Table 1 in order to
calculate the daily vibration exposure. A simple
evaluation of the machine application can be used.
Estimate the vibration levels for the three vibration
directions. For typical operating conditions, use the
average vibration levels as the estimated level. With
an experienced operator and smooth terrain, subtract
the Scenario Factors from the average vibration level
in order to obtain the estimated vibration level. For
aggressive operations and severe terrain, add the
Scenario Factors to the average vibration level in
order to obtain the estimated vibration level.
Note: All vibration levels are in meter per second
squared.
Scenario Factors
Y axis Z axis X axis Y axis Z axis
0,10 0,17 0,06 0,03 0,02
0,34 0,25 0,03 0,07 0,04
28 KEBU7565
Safety Section
Sound Information and Vibration Information

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

Guideline for the assessment of exposure to whole
body vibration of ride on operated earthmoving
machines” for more information about vibration. This
publication uses data that is measured by
international institutes, organizations and
manufacturers. This document provides information
about the whole body exposure of operators of
earthmoving equipment. Refer to Operation and
Maintenance Manual Supplement, SEBU8257 for
more information about machine vibration levels.
The Caterpillar suspension seat meets the criteria of
“ISO 7096”. This represents vertical vibration level
under severe operating conditions.
Guidelines for Reducing Vibration Levels
on Earthmoving 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:
6. Move the attachments smoothly.
7. Adjust the machine speed and the route in order to
minimize the vibration level.
a. Drive around obstacles and rough terrain.
b. Slow down when it is necessary to go over
rough terrain.
8. Minimize vibrations for a long work cycle or a long
travel distance.
a. Use machines that are equipped with
suspension systems.
b. Use the ride control system.
c. If no ride control system is available, reduce
speed in order to prevent bounce.
d. Haul the machines between workplaces.

9. Less operator comfort may be caused by other risk

1. Use the right type and size of machine, equipment,
and attachments.
2. Maintain machines according to the manufacturer's
recommendations.
a. Tire pressures
b. Brake and steering systems
c. Controls, hydraulic system and linkages
3. Keep the terrain in good condition.
a. Remove any large rocks or obstacles.
b. Fill any ditches and holes.
c. Provide machines and schedule time in order
to maintain the conditions of the terrain.
4. Use a seat that meets “ISO 7096”. Keep the seat
maintained and adjusted.
factors. The following guidelines can be effective in
order to provide better operator comfort:
a. Adjust the seat and adjust the controls in order
to achieve good posture.
b. Adjust the mirrors in order to minimize twisted
posture.
c. Provide breaks in order to reduce long periods
of sitting.
d. Avoid jumping from the cab.
e. Minimize repeated handling of loads and lifting
of loads.
f. Minimize any shocks and impacts during
sports and leisure activities.

a. Adjust the seat and suspension for the weight

and the size of the operator.

b. Inspect and maintain the seat suspension and

adjustment mechanisms.

5. Perform the following operations smoothly.

a. Steer
b. Brake
c. Accelerate.
d. Shift the gears.
KEBU7565
i03634321
Operator Station
SMCS Code: 7000; 7300; 7301; 7325
Any modifications to the inside of the operator station
should not project into the operator space or into the
space for the companion seat (if equipped). The
addition of a radio, fire extinguisher, and other
equipment must be installed so that the defined
operator space and the space for the companion seat
(if equipped) is maintained. Any item that is brought
into the cab should not project into the defined
operator space or the space for the companion seat
(if equipped). A lunch box or other loose items must
be secured. Objects must not pose an impact hazard
in rough terrain or in the event of a rollover.
i03656846
Guards
(Operator Protection)
SMCS Code: 7000; 7150; 7325
There are different types of guards that are used to
protect the operator. The machine and the machine
application determines the type of guard that should
be used.
A daily inspection of the guards is required in order to
check for structures that are bent, cracked or loose.
Never operate a machine with a damaged structure.
The operator becomes exposed to a hazardous
situation if the machine is used improperly or if poor
operating techniques are used. This situation can
occur even though a machine is equipped with an
appropriate protective guard. Follow the established
operating procedures that are recommended for your
machine.
29
Safety Section
Operator Station
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:
30 KEBU7565
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.
Consult your Caterpillar dealer for additional
information.
KEBU7565 31
Product Information Section
Specifications

Product Information When the machine is equipped with a stabilization

rotor, the machine can blend additives with the base
Section material or the subgrade material, to a maximum
mixing depth of 508 mm (20 inch).
The RM-300 can be used to size the stabilized
General Information material to a specified maximum particle size.
The RM-300 can be used to aerate the soil in order to
i04905899 reduce the moisture content of the base material prior
to compaction.
Specifications
SMCS Code: 7000 Application and Configuration
Restrictions
The standard machine shipping specifications are
listed in the table below. The maximum approved operating weight of the RM-
Table 2 300 is 25855 kg (57000 lb).
RM-300 Rotary Mixer (with ROPS, cab and universal rotor)
Use the RM-300 only in non-explosive gas
Machine Weight environments.
S/N: BWR487–Up 23843 kg (52565 lb)
When reclaiming or stabilizing, front steer mode
should be used. Crab, coordinated, and rear steer
Length 10 m (32.9 ft) modes should not be used during reclaiming or
mixing to avoid side loading and potential damage to
Width 3 m (9.9 ft) the rotor and mixing chamber.
Height 3.37 m (11 ft) If stabilizing soil which contains large stones, stones
greater than 6 inches should be removed prior to
stabilizing. Attempting to process large stone during
Intended Use soil stabilization can result in damage to the rotor or
mixing chamber. The severity and rate at which any
The RM-300 is designed for full depth reclamation. damage occurs may increase based on the type,
Full depth reclamation is a pavement maintenance size, and frequency of the stone being encountered.
technique that is used to create improved base
material. Operation of the front and rear door of the mixing
chamber can affect machine performance. When
The full depth reclamation process involves the reclaiming or stabilizing, the front door should remain
pulverization of the entire thickness of the flexible open enough to allow some material to spill out in
pavement structure of a roadway. The full depth front of the chamber. The rear door should remain
reclamation process involves the pulverization of the open enough to allow material to escape the
chip seal layer. The pulverized material is blended chamber. Excess material being held in the chamber
with a specified portion of the road base. can increase wear rates to the rotor and mixing
chamber. If more mixing is required, subsequent
The maximum depth of the machine is 406 mm passes are recommended.
(16 inch).
Refer to Rotor Selection Guide, QEDQ1233 in order
In order to improve the strength of the road base, the to ensure that the correct rotor is being used for the
operator may blend the following materials into the application.
mix during the mixing process:
• asphalt emulsion i05118431

• stabilizing agents Application Guidelines

• aggregates
The RM-300 can be used on soil stabilization projects
in order to improve the mechanical load bearing
characteristics of the native subgrade soil or the
existing base material.
The RM-300 can be used on soil stabilization projects
in order to improve the chemical load bearing
characteristics of the native subgrade soil or the
existing base material.
(For the Spray Systems)
SMCS Code: 5612; 5615
The tables provided below use the following
equations to determine the application rate of water
or emulsion.
English Units – Application Rate (Gallons per
Square Yard) x Travel Speed (Feet per Minute) x
Spray Bar Width (Yards) = Gallons Sprayed in 1
Minute
32 KEBU7565
General Information
Application Guidelines

Metric Units – Application Rate (Liters per Square

Meter) x Travel Speed (Meters per Minute) x Spray
Bar Width (Meters) = Liters Sprayed in 1 Minute

Application Rate of Water (76.2 mm

(3 inch) Flow Meter)
• BWR387–Up

• ASW235–Up
The machines shown above are built with a 76.2 mm
(3 inch) flow meter and have a flow range of
113.5 L/min (30 US gpm) to 1836 L/min
(485 US gpm).

Note: Flow rates below 114 L/min (30 US gpm) will

result in a system fault, such as "Out of Range".
Table 3
Application Rate for Water Spray System
Values are provided in gallons per square yard and liters per square meter.

(Volume)

1.0 Gal 1.5 Gal 2.0 Gal 2.5 Gal 3.0 Gal 3.5 Gal 4.0 Gal 4.5 Gal 5.0 Gal 5.5 Gal
(Speed)
3.79 L 5.68 L 7.57 L 9.46 L 11.36 L 13.25 L 15.14 L 17.03 L 18.93 L 20.82 L
5 ft/min
1.52 m/min
10 ft/min 31.11 35.56 40.00 44.45 48.89
3.05 m/min 98.46 112.52 126.59 140.66 154.72
15 ft/min 33.33 40.00 46.67 53.33 60.00 66.67 73.33
4.57 m/min 105.49 126.59 147.69 168.79 189.88 210.98 232.08
20 ft/min 35.56 44.45 53.33 62.22 71.11 80.00 88.89 97.78
6.10 m/min 112.52 140.66 168.79 196.92 225.05 253.18 281.31 309.44
25 ft/min 33.33 44.45 55.56 66.67 77.78 88.89 100.00 111.11 122.22
7.62 m/min 105.49 140.66 175.82 210.98 246.15 281.31 316.47 351.64 386.80
30 ft/min 40.00 53.33 66.67 80.00 93.33 106.67 120.00 133.34 146.67
9.14 m/min 126.59 168.79 210.98 253.18 295.38 337.57 379.77 421.97 464.16
35 ft/min 31.11 46.67 62.22 77.78 93.33 108.89 124.45 140.00 155.56 171.11
10.67 m/min 98.46 147.69 196.92 246.15 295.38 344.61 393.83 443.06 492.29 541.52
40 ft/min 35.56 53.33 71.11 88.89 106.67 124.45 142.22 160.00 177.78 195.56
12.19 m/min 112.52 168.79 225.05 281.31 337.57 393.83 450.10 506.36 562.62 618.88
45 ft/min 40.00 60.00 80.00 100.00 120.00 140.00 160.00 180.00 200.00 220.00
13.72 m/min 126.59 189.88 253.13 316.47 379.77 443.06 506.36 569.65 632.95 696.24
50 ft/min 44.45 66.67 88.89 111.11 133.34 155.56 177.78 200.00 222.23 244.45
15.24 m/min 140.66 210.98 281.31 351.64 421.97 492.29 562.62 632.95 703.28 773.60
60 ft/min 53.33 80.00 106.67 133.34 160.00 186.67 213.34 240.00 266.67 293.34
18.29 m/min 168.79 253.18 337.57 421.97 506.36 590.75 675.14 759.54 843.93 928.32
70 ft/min 62.22 93.33 124.45 155.56 186.67 217.78 248.89 280.00 311.12 342.23
21.34 m/min 196.92 295.38 393.83 492.29 590.75 689.21 787.67 886.13 984.59 1083.05
80 ft/min 71.11 106.67 142.22 177.78 213.34 248.89 284.45 320.00 355.56 391.12
24.38 m/min 225.05 337.57 450.10 562.62 675.14 787.67 900.19 1012.72 1125.24 1237.77

(continued)
KEBU7565 33
General Information
Application Guidelines

(Table 3, contd)
90 ft/min 80.00 120.00 160.00 200.00 240.00 280.00 320.00 360.00 400.01 440.01
27.43 m/min 253.18 379.77 506.36 632.95 759.54 886.13 1012.72 1139.31 1265.90 1392.49
100 ft/min 88.89 133.34 177.78 222.23 266.67 311.12 355.56 400.01 444.45 488.90
30.48 m/min 281.31 421.97 562.62 703.28 843.93 984.59 1125.24 1265.90 1406.55 1547.21
110 ft/min 97.78 146.67 195.56 244.45 293.34 342.23 391.12 440.01 488.90
1701.93
33.53 m/min 309.44 464.16 618.88 773.60 928.32 1083.05 1237.77 1392.49 1547.21
120 ft/min 106.67 160.00 213.34 266.67 320.00 373.34 426.67 480.01
1687.86 1856.65
36.58 m/min 337.57 506.36 675.14 843.93 1012.72 1181.50 1350.29 1519.08
130 ft/min 115.56 173.34 231.11 288.89 346.67 404.45 462.23
1645.67 1828.52
39.62 m/min 365.70 548.56 731.41 914.26 1097.11 1279.96 1462.81
Application Rate for Water Spray System
Values are provided in gallons per square yard and liters per square meter.

(Volume)

6.0 Gal 7.0 Gal 8.0 Gal 9.0 Gal 10.0 Gal 11.0 Gal 12.0 Gal 13.0 Gal 14.0 Gal 15.0 Gal
(Speed)
22.71 L 26.50 L 30.28 L 34.07 L 37.85 L 41.64 L 45.42 L 49.21 L 52.99 L 56.78 L
5 ft/min 31.11 35.56 40.00 44.45 48.89 53.33 57.78 62.22 66.67
1.52 m/min 98.46 112.52 126.59 140.66 154.72 168.79 182.85 196.92 210.98
10 ft/min 53.33 62.22 71.11 80.00 88.89 97.78 106.67 115.56 124.45 133.34
3.05 m/min 168.79 196.92 225.05 253.18 281.31 309.44 337.57 365.70 393.83 421.97
15 ft/min 80.00 93.33 106.67 120.00 133.34 146.67 160.00 173.34 186.67 200.00
4.57 m/min 253.18 295.38 337.57 379.77 421.97 464.16 506.36 548.56 590.75 632.95
20 ft/min 106.67 124.45 142.22 160.00 177.78 195.56 213.34 231.11 248.89 266.67
6.10 m/min 337.57 393.83 450.10 506.36 562.62 618.88 675.14 731.41 787.67 843.93
25 ft/min 133.34 155.56 177.78 200.00 222.23 244.45 266.67 288.89 311.12 333.34
7.62 m/min 421.97 492.29 562.62 632.95 703.28 773.60 843.93 914.26 984.59 1054.91
30 ft/min 160.00 186.67 213.34 240.00 266.67 293.34 320.00 346.67 373.34 400.01
9.14 m/min 506.36 590.75 675.14 759.54 843.93 928.32 1012.72 1097.11 1181.50 1265.90
35 ft/min 186.67 217.78 248.89 280.00 311.12 342.23 373.34 404.45 435.56 466.67
10.67 m/min 590.75 689.21 787.67 886.13 984.59 1083.05 1181.50 1279.96 1378.42 1476.88
40 ft/min 213.34 248.89 284.45 320.00 355.56 391.12 426.67 462.23
1575.34 1687.86
12.19 m/min 675.14 787.67 900.19 1012.72 1125.24 1237.77 1350.29 1462.81
45 ft/min 240.00 280.00 320.00 360.00 400.01 440.01 480.01
1645.67 1772.26
13.72 m/min 759.54 886.13 1012.72 1139.31 1265.90 1392.49 1519.08
50 ft/min 266.67 311.12 355.56 400.01 444.45 488.90
1687.86 1828.52
15.24 m/min 843.93 984.59 1125.24 1265.90 1406.55 1547.21
60 ft/min 320.00 373.34 426.67 480.01
1687.86 1856.65
18.29 m/min 1012.72 1181.50 1350.29 1519.08
70 ft/min 373.34 435.56
1575.34 1772.26
21.34 m/min 1181.50 1378.42
80 ft/min 426.67
1575.34 1800.39
24.38 m/min 1350.29
90 ft/min 480.01
1772.26
27.43 m/min 1519.08
100 ft/min
1687.86
30.48 m/min
110 ft/min
1856.65
33.53 m/min

(continued)
34 KEBU7565
General Information
Application Guidelines

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

(Volume)

16.0 Gal 17.0 Gal 18.0 Gal 19.0 Gal 20.0 Gal 21.0 Gal 22.0 Gal 23.0 Gal 24.0 Gal 25.0 Gal
(Speed)
60.56 L 64.35 L 68.13 L 71.92 L 75.70 L 79.49 L 83.27 L 87.06 L 90.84 L 94.63 L
5 ft/min 71.11 75.56 80.00 84.45 88.89 93.33 97.78 102.22 106.67 111.11
1.52 m/min 225.05 239.11 253.18 267.25 281.31 295.38 309.44 323.51 337.57 351.64
10 ft/min 142.22 151.11 160.00 168.89 177.78 186.67 195.56 204.45 213.34 222.23
3.05 m/min 450.10 478.23 506.36 534.49 562.62 590.75 618.88 647.01 675.14 703.28
15 ft/min 213.34 226.67 240.00 253.34 266.67 280.00 293.34 306.67 320.00 333.34
4.57 m/min 675.14 717.34 759.54 801.73 843.93 886.13 928.32 970.52 1012.72 1054.91
20 ft/min 284.45 302.23 320.00 337.78 355.56 373.34 391.12 408.89 426.67 444.45
6.10 m/min 900.19 956.46 1012.72 1068.98 1125.24 1181.50 1237.77 1294.03 1350.29 1406.55
25 ft/min 355.56 377.78 400.01 422.23 444.45 466.67 488.90
1617.53 1687.86 1758.19
7.62 m/min 1125.24 1195.57 1265.90 1336.22 1406.55 1476.88 1547.21
30 ft/min 426.67 453.34 480.01
1603.47 1687.86 1772.26 1856.65
9.14 m/min 1350.29 1434.68 1519.08
35 ft/min
1575.34 1673.80 1772.26
10.67 m/min
40 ft/min
1800.39
12.19 m/min

Application Rate of Water (Standard

102 mm (4 inch) Flow Meter)
• BWR205–386
• ASW116–234
The machines shown above are built with a 102 mm
(4 inch) flow meter and have a flow range of
379 L/min (100 US gpm) to 1893 L/min
(500 US gpm). These machines can be converted to
a flow range of 189 L/min (50 US gpm) to 1079 L/min
(285 US gpm) per Service Magazine, SEPD0943.
Refer to “Application Rate of Water (Low Flow Rate
Conversion)” for machines that have been converted.

Note: Flow rates below 379 L/min (100 US gpm) will

result in a system fault, such as "Out of Range".
Table 4
Application Rate for Water Spray System
Values are provided in gallons per square yard and liters per square meter.

(Volume)

1.0 Gal 1.5 Gal 2.0 Gal 2.5 Gal 3.0 Gal 3.5 Gal 4.0 Gal 4.5 Gal 5.0 Gal 5.5 Gal
(Speed)
3.79 L 5.68 L 7.57 L 9.46 L 11.36 L 13.25 L 15.14 L 17.03 L 18.93 L 20.82 L
5 ft/min
1.52 m/min
10 ft/min
3.05 m/min

(continued)
KEBU7565 35
General Information
Application Guidelines

(Table 4, contd)
15 ft/min
4.57 m/min
20 ft/min
97.78
6.10 m/min
25 ft/min 111.11 122.22
100.00
7.62 m/min 351.64 386.80
30 ft/min 120.00 133.34 146.67
93.33 106.67
9.14 m/min 379.77 421.97 464.16
35 ft/min 124.45 140.00 155.56 171.11
93.33 108.89
10.67 m/min 393.83 443.06 492.29 541.52
40 ft/min 124.45 142.22 160.00 177.78 195.56
106.67
12.19 m/min 393.83 450.10 506.36 562.62 618.88
45 ft/min 120.00 140.00 160.00 180.00 200.00 220.00
100.00
13.72 m/min 379.77 443.06 506.36 569.65 632.95 696.24
50 ft/min 111.11 133.34 155.56 177.78 200.00 222.23 244.45
15.24 m/min 351.64 421.97 492.29 562.62 632.95 703.28 773.60
60 ft/min 133.34 160.00 186.67 213.34 240.00 266.67 293.34
106.67
18.29 m/min 421.97 506.36 590.75 675.14 759.54 843.93 928.32
70 ft/min 124.45 155.56 186.67 217.78 248.89 280.00 311.12 342.23
93.33
21.34 m/min 393.83 492.29 590.75 689.21 787.67 886.13 984.59 1083.05
80 ft/min 142.22 177.78 213.34 248.89 284.45 320.00 355.56 391.12
106.67
24.38 m/min 450.10 562.62 675.14 787.67 900.19 1012.72 1125.24 1237.77
90 ft/min 120.00 160.00 200.00 240.00 280.00 320.00 360.00 400.01 440.01
27.43 m/min 379.77 506.36 632.95 759.54 886.13 1012.72 1139.31 1265.90 1392.49
100 ft/min 133.34 177.78 222.23 266.67 311.12 355.56 400.01 444.45 488.90
30.48 m/min 421.97 562.62 703.28 843.93 984.59 1125.24 1265.90 1406.55 1547.21
110 ft/min 97.78 146.67 195.56 244.45 293.34 342.23 391.12 440.01 488.90
1701.93
33.53 m/min 309.44 464.16 618.88 773.60 928.32 1083.05 1237.77 1392.49 1547.21

(continued)
36 KEBU7565
General Information
Application Guidelines

(Table 4, contd)
120 ft/min 106.67 160.00 213.34 266.67 320.00 373.34 426.67 480.01
1687.86 1856.65
36.58 m/min 337.57 506.36 675.14 843.93 1012.72 1181.50 1350.29 1519.08
130 ft/min 115.56 173.34 231.11 288.89 346.67 404.45 462.23
1645.67 1828.52
39.62 m/min 365.70 548.56 731.41 914.26 1097.11 1279.96 1462.81
Application Rate for Water Spray System
Values are provided in gallons per square yard and liters per square meter.

(Volume)

6.0 Gal 7.0 Gal 8.0 Gal 9.0 Gal 10.0 Gal 11.0 Gal 12.0 Gal 13.0 Gal 14.0 Gal 15.0 Gal
(Speed)
22.71 L 26.50 L 30.28 L 34.07 L 37.85 L 41.64 L 45.42 L 49.21 L 52.99 L 56.78 L
5 ft/min
1.52 m/min
10 ft/min 115.56 124.45 133.34
97.78 106.67
3.05 m/min 365.70 393.83 421.97
15 ft/min 120.00 133.34 146.67 160.00 173.34 186.67 200.00
93.33 106.67
4.57 m/min 379.77 421.97 464.16 506.36 548.56 590.75 632.95
20 ft/min 124.45 142.22 160.00 177.78 195.56 213.34 231.11 248.89 266.67
106.67
6.10 m/min 393.83 450.10 506.36 562.62 618.88 675.14 731.41 787.67 843.93
25 ft/min 133.34 155.56 177.78 200.00 222.23 244.45 266.67 288.89 311.12 333.34
7.62 m/min 421.97 492.29 562.62 632.95 703.28 773.60 843.93 914.26 984.59 1054.91
30 ft/min 160.00 186.67 213.34 240.00 266.67 293.34 320.00 346.67 373.34 400.01
9.14 m/min 506.36 590.75 675.14 759.54 843.93 928.32 1012.72 1097.11 1181.50 1265.90
35 ft/min 186.67 217.78 248.89 280.00 311.12 342.23 373.34 404.45 435.56 466.67
10.67 m/min 590.75 689.21 787.67 886.13 984.59 1083.05 1181.50 1279.96 1378.42 1476.88
40 ft/min 213.34 248.89 284.45 320.00 355.56 391.12 426.67 462.23 497.78
1687.86
12.19 m/min 675.14 787.67 900.19 1012.72 1125.24 1237.77 1350.29 1462.81 1575.34
45 ft/min 240.00 280.00 320.00 360.00 400.01 440.01 480.01
1645.67 1772.26 1898.85
13.72 m/min 759.54 886.13 1012.72 1139.31 1265.90 1392.49 1519.08
50 ft/min 266.67 311.12 355.56 400.01 444.45 488.90
1687.86 1828.52
15.24 m/min 843.93 984.59 1125.24 1265.90 1406.55 1547.21
60 ft/min 320.00 373.34 426.67 480.01
1687.86 1856.65
18.29 m/min 1012.72 1181.50 1350.29 1519.08
70 ft/min 373.34 435.56 497.78
1772.26
21.34 m/min 1181.50 1378.42 1575.34
80 ft/min 426.67 497.78
1800.39
24.38 m/min 1350.29 1575.34
90 ft/min 480.01
1772.26
27.43 m/min 1519.08
100 ft/min
1687.86
30.48 m/min
110 ft/min
1856.65
33.53 m/min
Application Rate for Water Spray System
Values are provided in gallons per square yard and liters per square meter.

(Volume)

16.0 Gal 17.0 Gal 18.0 Gal 19.0 Gal 20.0 Gal 21.0 Gal 22.0 Gal 23.0 Gal 24.0 Gal 25.0 Gal
(Speed)
60.56 L 64.35 L 68.13 L 71.92 L 75.70 L 79.49 L 83.27 L 87.06 L 90.84 L 94.63 L

(continued)
KEBU7565 37
General Information
Application Guidelines

(Table 4, contd)
5 ft/min 111.11
93.33 97.78 102.22 106.67
1.52 m/min 351.64
10 ft/min 142.22 151.11 160.00 168.89 177.78 186.67 195.56 204.45 213.34 222.23
3.05 m/min 450.10 478.23 506.36 534.49 562.62 590.75 618.88 647.01 675.14 703.28
15 ft/min 213.34 226.67 240.00 253.34 266.67 280.00 293.34 306.67 320.00 333.34
4.57 m/min 675.14 717.34 759.54 801.73 843.93 886.13 928.32 970.52 1012.72 1054.91
20 ft/min 284.45 302.23 320.00 337.78 355.56 373.34 391.12 408.89 426.67 444.45
6.10 m/min 900.19 956.46 1012.72 1068.98 1125.24 1181.50 1237.77 1294.03 1350.29 1406.55
25 ft/min 355.56 377.78 400.01 422.23 444.45 466.67 488.90
1617.53 1687.86 1758.19
7.62 m/min 1125.24 1195.57 1265.90 1336.22 1406.55 1476.88 1547.21
30 ft/min 426.67 453.34 480.01 506.67
1687.86 1772.26 1856.65
9.14 m/min 1350.29 1434.68 1519.08 1603.47
35 ft/min 497.78
1673.80 1772.26 1870.71
10.67 m/min 1575.34
40 ft/min
1800.39 1912.91
12.19 m/min

Application Rate of Water (Low

Flow Rate Conversion)
• BWR205–386
• ASW116–234
The following table is for the machines shown above
that were built with a 102 mm (4 inch) flow meter, and
have been converted to a low flow range of 189 L/min
(50 US gpm) to 1079 L/min (285 US gpm) per
Service Magazine, SEPD0943.
Note: Flow rates below 379 L/min (100 US gpm) will
result in a system fault, such as "Out of Range".
Table 5
Application Rate for Water Spray System
Values are provided in gallons per square yard and liters per square meter.

(Volume)

1.0 Gal 1.5 Gal 2.0 Gal 2.5 Gal 3.0 Gal 3.5 Gal 4.0 Gal 4.5 Gal 5.0 Gal 5.5 Gal
(Speed)
3.79 L 5.68 L 7.57 L 9.46 L 11.36 L 13.25 L 15.14 L 17.03 L 18.93 L 20.82 L
5 ft/min
1.52 m/min
10 ft/min
44.45 48.89
3.05 m/min
15 ft/min 53.33 60.00 66.67 73.33
46.67
4.57 m/min 168.79 189.88 210.98 232.08
20 ft/min 53.33 62.22 71.11 80.00 88.89 97.78
44.45
6.10 m/min 168.79 196.92 225.05 253.18 281.31 309.44
25 ft/min 55.56 66.67 77.78 88.89 100.00 111.11 122.22
44.45
7.62 m/min 175.82 210.98 246.15 281.31 316.47 351.64 386.80
30 ft/min 53.33 66.67 80.00 93.33 106.67 120.00 133.34 146.67
9.14 m/min 168.79 210.98 253.18 295.38 337.57 379.77 421.97 464.16

(continued)
38 KEBU7565
General Information
Application Guidelines

(Table 5, contd)
35 ft/min 62.22 77.78 93.33 108.89 124.45 140.00 155.56 171.11
46.67
10.67 m/min 196.92 246.15 295.38 344.61 393.83 443.06 492.29 541.52
40 ft/min 53.33 71.11 88.89 106.67 124.45 142.22 160.00 177.78 195.56
12.19 m/min 168.79 225.05 281.31 337.57 393.83 450.10 506.36 562.62 618.88
45 ft/min 60.00 80.00 100.00 120.00 140.00 160.00 180.00 200.00 220.00
13.72 m/min 189.88 253.18 316.47 379.77 443.06 506.36 569.65 632.95 696.24
50 ft/min 44.45 66.67 88.89 111.11 133.34 155.56 177.78 200.00 222.23 244.45
15.24 m/min 140.66 210.98 281.31 351.64 421.97 492.29 562.62 632.95 703.28 773.60
60 ft/min 53.33 80.00 106.67 133.34 160.00 186.67 213.34 240.00 266.67
928.32
18.29 m/min 168.79 253.18 337.57 421.97 506.36 590.75 675.14 759.54 843.93
70 ft/min 62.22 93.33 124.45 155.56 186.67 217.78 248.89 280.00
984.59 1083.05
21.34 m/min 196.92 295.38 393.83 492.29 590.75 689.21 787.67 886.13
80 ft/min 71.11 106.67 142.22 177.78 213.34 248.89 284.45
1012.72
24.38 m/min 225.05 337.57 450.10 562.62 675.14 787.67 900.19
90 ft/min 80.00 120.00 160.00 200.00 240.00 280.00
1012.72
27.43 m/min 253.18 379.77 506.36 632.95 759.54 886.13
100 ft/min 88.89 133.34 177.78 222.23 266.67
984.59
30.48 m/min 281.31 421.97 562.62 703.28 843.93
110 ft/min 97.78 146.67 195.56 244.45
928.32 1083.05
33.53 m/min 309.44 464.16 618.88 773.60
120 ft/min 106.67 160.00 213.34 266.67
1012.72
36.58 m/min 337.57 506.36 675.14 843.93
130 ft/min 115.56 173.34 231.11 288.89
1097.11
39.62 m/min 365.70 548.56 731.41 914.26
Application Rate for Water Spray System
Values are provided in gallons per square yard and liters per square meter.

(Volume)

6.0 Gal 7.0 Gal 8.0 Gal 9.0 Gal 10.0 Gal 11.0 Gal 12.0 Gal 13.0 Gal 14.0 Gal 15.0 Gal
(Speed)
22.71 L 26.50 L 30.28 L 34.07 L 37.85 L 41.64 L 45.42 L 49.21 L 52.99 L 56.78 L
5 ft/min 53.33 57.78 62.22 66.67
44.45 48.89
1.52 m/min 168.79 182.85 196.92 210.98
10 ft/min 53.33 62.22 71.11 80.00 88.89 97.78 106.67 115.56 124.45 133.34
3.05 m/min 168.79 196.92 225.05 253.18 281.31 309.44 337.57 365.70 393.83 421.97
15 ft/min 80.00 93.33 106.67 120.00 133.34 146.67 160.00 173.34 186.67 200.00
4.57 m/min 253.18 295.38 337.57 379.77 421.97 464.16 506.36 548.56 590.75 632.95
20 ft/min 106.67 124.45 142.22 160.00 177.78 195.56 213.34 231.11 248.89 266.67
6.10 m/min 337.57 393.83 450.10 506.36 562.62 618.88 675.14 731.41 787.67 843.93
25 ft/min 133.34 155.56 177.78 200.00 222.23 244.45 266.67 288.89
984.59 1054.91
7.62 m/min 421.97 492.29 562.62 632.95 703.28 773.60 843.93 914.26
30 ft/min 160.00 186.67 213.34 240.00 266.67
928.32 1012.72 1097.11
9.14 m/min 506.36 590.75 675.14 759.54 843.93
35 ft/min 186.67 217.78 248.89 280.00
984.59 1083.05
10.67 m/min 590.75 689.21 787.67 886.13
40 ft/min 213.34 248.89 284.45
1012.72
12.19 m/min 675.14 787.67 900.19
45 ft/min 240.00 280.00
1012.72
13.72 m/min 759.54 886.13

(continued)
KEBU7565 39
General Information
Application Guidelines

(Table 5, contd)
50 ft/min 266.67
984.59
15.24 m/min 843.93
60 ft/min
1012.72
18.29 m/min
Application Rate for Water Spray System
Values are provided in gallons per square yard and liters per square meter.

(Volume)

16.0 Gal 17.0 Gal 18.0 Gal 19.0 Gal 20.0 Gal 21.0 Gal 22.0 Gal 23.0 Gal 24.0 Gal 25.0 Gal
(Speed)
60.56 L 64.35 L 68.13 L 71.92 L 75.70 L 79.49 L 83.27 L 87.06 L 90.84 L 94.63 L
5 ft/min 71.11 75.56 80.00 84.45 88.89 93.33 97.78 102.22 106.67 111.11
1.52 m/min 225.05 239.11 253.18 267.25 281.31 295.38 309.44 323.51 337.57 351.64
10 ft/min 142.22 151.11 160.00 168.89 177.78 186.67 195.56 204.45 213.34 222.23
3.05 m/min 450.10 478.23 506.36 534.49 562.62 590.75 618.88 647.01 675.14 703.28
15 ft/min 213.34 226.67 240.00 253.34 266.67 280.00
928.32 970.52 1012.72 1054.91
4.57 m/min 675.14 717.34 759.54 801.73 843.93 886.13
20 ft/min 284.45
956.46 1012.72 1068.98
6.10 m/min 900.19

Application Rate of Emulsion

• BWR292–Up

• ASW157–Up
The machines shown above have a flow range of
114 L/min (30 US gpm) to 757 L/min (200 US gpm).
Note: Flow rates below 114 L/min (30 US gpm) will
result in a system fault, such as "Out of Range".
Table 6
Application Rate for Emulsion Spray System
Values are provided in gallons per square yard and liters per square meter.

(Volume)

1.0 Gal 1.5 Gal 2.0 Gal 2.5 Gal 3.0 Gal 3.5 Gal 4.0 Gal 4.5 Gal 5.0 Gal 5.5 Gal
(Speed)
3.79 L 5.68 L 7.57 L 9.46 L 11.36 L 13.25 L 15.14 L 17.03 L 18.93 L 20.82 L
5 ft/min
1.52 m/min
10 ft/min 31.11 35.56 40.00 44.45 48.89
3.05 m/min 98.46 112.52 126.59 140.66 154.72
15 ft/min 33.33 40.00 46.67 53.33 60.00 66.67 73.33
4.57 m/min 105.49 126.59 147.69 168.79 189.88 210.98 232.08
20 ft/min 35.56 44.45 53.33 62.22 71.11 80.00 88.89 97.78
6.10 m/min 112.52 140.66 168.79 196.92 225.05 253.18 281.31 309.44
25 ft/min 33.33 44.45 55.56 66.67 77.78 88.89 100.00 111.11 122.22
7.62 m/min 105.49 140.66 175.82 210.98 246.15 281.31 316.47 351.64 386.80
30 ft/min 40.00 53.33 66.67 80.00 93.33 106.67 120.00 133.34 146.67
9.14 m/min 126.59 168.79 210.98 253.18 295.38 337.57 379.77 421.97 464.16
35 ft/min 31.11 46.67 62.22 77.78 93.33 108.89 124.45 140.00 155.56 171.11
10.67 m/min 98.46 147.69 196.92 246.15 295.38 344.61 393.83 443.06 492.29 541.52

(continued)
40 KEBU7565
General Information
Application Guidelines

(Table 6, contd)
40 ft/min 35.56 53.33 71.11 88.89 106.67 124.45 142.22 160.00 177.78 195.56
12.19 m/min 112.52 168.79 225.05 281.31 337.57 393.83 450.10 506.36 562.62 618.88
45 ft/min 40.00 60.00 80.00 100.00 120.00 140.00 160.00 180.00 200.00
696.24
13.72 m/min 126.59 189.88 253.18 316.47 379.77 443.06 506.36 569.65 632.95
50 ft/min 44.45 66.67 88.89 111.11 133.34 155.56 177.78 200.00
703.28 773.60
15.24 m/min 140.66 210.98 281.31 351.64 421.97 492.29 562.62 632.95
60 ft/min 53.33 80.00 106.67 133.34 160.00 186.67 213.34
759.54
18.29 m/min 168.79 253.18 337.57 421.97 506.36 590.75 675.14
70 ft/min 62.22 93.33 124.45 155.56 186.67 217.78
787.67
21.34 m/min 196.92 295.38 393.83 492.29 590.75 689.21
80 ft/min 71.11 106.67 142.22 177.78 213.34
787.67
24.38 m/min 225.05 337.57 450.10 562.62 675.14
90 ft/min 80.00 120.00 160.00 200.00
759.54
27.43 m/min 253.18 379.77 506.36 632.95
100 ft/min 88.89 133.34 177.78
703.28
30.48 m/min 281.31 421.97 562.62
110 ft/min 97.78 146.67 195.56
773.60
33.53 m/min 309.44 464.16 618.88
120 ft/min 106.67 160.00 213.34
36.58 m/min 337.57 506.36 675.14
130 ft/min 115.56 173.34
731.41
39.62 m/min 365.70 548.56
Application Rate for Emulsion Spray System
Values are provided in gallons per square yard and liters per square meter.

(Volume)

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

(continued)
KEBU7565 41
General Information
Application Guidelines

(Table 6, contd)
(Volume)

16.0 Gal 17.0 Gal 18.0 Gal 19.0 Gal 20.0 Gal 21.0 Gal 22.0 Gal 23.0 Gal 24.0 Gal 25.0 Gal
(Speed)
60.56 L 64.35 L 68.13 L 71.92 L 75.70 L 79.49 L 83.27 L 87.06 L 90.84 L 94.63 L
5 ft/min 71.11 75.56 80.00 84.45 88.89 93.33 97.78 102.22 106.67 111.11
1.52 m/min 225.05 239.11 253.18 267.25 281.31 295.38 309.44 323.51 337.57 351.64
10 ft/min 142.22 151.11 160.00 168.89 177.78 186.67 195.56 204.45 213.34
703.28
3.05 m/min 450.10 478.23 506.36 534.49 562.62 590.75 618.88 647.01 675.14
15 ft/min 213.34
717.34 759.54 801.73
4.57 m/min 675.14
42 KEBU7565
Identification Information
Plate Locations and Film Locations

Identification Information
i03646047

Plate Locations and Film

Locations
SMCS Code: 1000; 7000
The Product Information Number (PIN) is used to
identify a powered machine that is designed for an
operator to ride.
Caterpillar products such as engines, transmissions
and major attachments that are not designed for an
operator to ride are identified by Serial Numbers. Illustration 30 g01142511
Location of the Engine Serial Number plate
The Certification Plate (CE) is used to verify that the
product conforms to all of the requirements that were Engine Serial Number
established by a country or a group of countries. The
product is tested by a certified testing group in order
to verify conformance. Certification
The emission certification film (if equipped) is used to European Union
verify that the engine meets the EPA emissions
requirements.
For quick reference, record the identification numbers
in the spaces that are provided below the illustrations.

Illustration 31 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
Illustration 29 g01142512 reference, record this information in the spaces that
Location of the Product Information Number (PIN) are provided below.
plate

Machine PIN
KEBU7565 43
Identification Information
Plate Locations and Film Locations

• Engine Power Primary Engine (kW) Sound Certification

• Engine Power for Additional Engine (If Equipped)

• Typical Machine Operating Weight for European

Market (kg)

• Year of Construction
• Machine Type

Illustration 33 g00933634
A typical example of this film is shown. Your machine
may have a different value.

If equipped, the certification film is used to verify the

environmental sound certification of the machine. The
value that is listed on the film indicates the
guaranteed sound power level. The guaranteed
sound power level is measured at the time of
Illustration 32 g01120192 manufacture. The guaranteed sound power level is
measured according to the conditions that are
This plate is positioned on the bottom left side of the specified in “ISO 6394:1998”.
plate for the PIN.

Note: The CE plate is on machines that are certified Product Link

to the European Union requirements that were
effective at that time. If equipped, this message is used to verify the
certification of the Product Link as a RF transmitter.
For machines compliant to 1998/42/EC, the following The following specifications are provided to aid in
information is stamped onto the CE plate. For quick ensuring compliance with all local regulations:
reference, record this information in the spaces that Table 7
are provided below. Operating frequency range 148 to 150 MHz
• Engine Power Primary Engine (kW) Transmitter power 5 Watts

• Typical Machine Operating Weight for European

Market (kg) This message is located on the control group for the
Product Link. The control group is located on the top
• Year of the cab.
For the name and address of the manufacturer, and
the country of origin of the machine, refer to the PIN
plate.
For manufacturer name and address and the country
of origin, see the PIN plate.
44 KEBU7565
Identification Information
Emissions Certification Film

Illustration 34 g01261742

This machine is equipped with a Caterpillar Prod-

uct Link radio communication device which must
be deactivated within 6.0 m (20 ft) of a blast zone.
Failure to do so could result in serious injury or
death.

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

a blast area, power to the Product Link module must
be disconnected.
Consult your Caterpillar dealer with any questions
that concern the operation of the Product Link in a
specific country.

i04019095

Emissions Certification Film

SMCS Code: 1000; 7000; 7405

Note: This information is pertinent in the United

States, in Canada and in Europe.
Consult your Cat dealer for an Emission Control
Warranty Statement.
This label is located on the engine.
KEBU7565 45
Identification Information
Declaration of Conformity

i03646037

Declaration of Conformity
SMCS Code: 1000; 7000

Table 8
An EC Declaration of Conformity document was provided with the machine if it was manufactured to comply with specific requirements for the
European Union. In order to determine the details of the applicable Directives, review the complete EC Declaration of Conformity provided with
the machine. The extract shown below from an EC Declaration of Conformity for machines that are declared compliant to “2006/42/EC” applies
only to those machines originally “CE” marked by the manufacturer listed and which have not since been modified.

EC DECLARATION OF CONFORMITY OF MACHINERY

Manufacturer: CATERPILLAR PAVING PRODUCTS INC. 9401 85th Ave. North Brooklyn Park, MN 55445 USA

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

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

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

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

Description: Generic Denomination: Paving Equipment

Function: Soil Stabilizer

Model/Type: RM-300

Serial Number:
Commercial Name: Caterpillar

Fulfils all the relevant provisions of the following Directives

Directives Notified Body Document No.

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

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 October, 2009, but may be subject to change, please refer to the individual declaration of con-
formity issued with the machine for exact details.
46
Operation Section
Mounting and Dismounting
Operation Section
Before Operation
i04021647
Mounting and Dismounting
SMCS Code: 7000
Illustration 35 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.
KEBU7565
Machine Access System
Specifications
The machine access system has been designed to
meet the intent of the technical requirements in “ISO
2867 Earth-moving Machinery – Access Systems”.
The access system provides for operator access to
the operator station and to conduct the maintenance
procedures described in Maintenance section.
Alternate Exit
Machines that are equipped with cabs have alternate
exits. For additional information, see Operation and
Maintenance Manual, “Alternate Exit”.
i03721060
Daily Inspection
SMCS Code: 1000; 7000
Escaping fluid under pressure, even a pinhole
size leak, can penetrate body tissue, causing seri-
ous injury, and possible death. If fluid is injected
into your skin, it must be treated immediately by a
doctor familiar with this type of injury.
Always use a board or cardboard when checking
for a leak.
NOTICE
Accumulated grease and oil on a machine is a fire
hazard. Remove this debris with steam cleaning or
high pressure water, at least every 1000 hours or
each time any significant quantity of oil is spilled on
the machine.
Wipe all fittings, all caps, and all plugs, before you
service the machine.
Note: Keep a close watch for leaks. If any leaks are
observed, find the source of the leak. Repair the leak.
Check the fluid levels more frequently than the
recommended interval if you suspect a leak.
1. Inspect the precleaner for dirt buildup. Clean the
precleaner if dirt has accumulated.
KEBU7565
Illustration 36 g01151426
Location of the air cleaner service indicator
Illustration 37 g01151416
2. When the engine is at fast idle, note the position of
the indicator. Service the air cleaner when the
yellow piston is in the red zone.
Note: Stop the engine before you service the air
cleaner.
3. Check the machine for loose wiring. Check the
machine for frayed wiring.
4. Inspect the lights for broken bulbs. Inspect the
lights for broken lenses. Replace the bulbs or the
lenses if the bulbs or the lenses are broken.
5. Open all access covers. Inspect the compartments
for any trash buildup. Remove any trash in the
compartments.
47
Before Operation
Daily Inspection
6. Inspect the hydraulic system for leaks. Inspect the
hydraulic tank, the hoses, the tubes, the plugs, and
the fittings for leaks or damage. Repair any
damage. Repair any leaks.
7. All covers and guards must be securely in place.
Inspect all covers and guards for damage. Repair
any damage.
Illustration 38 g01151379
Typical example
Illustration 39 g01151399
Typical example
8. Inspect the steps, the walkways, and the
handholds for damage or wear. Repair the
components that are damaged or worn. Inspect the
steps, the walkways, and the handholds for
cleanliness. Clean the components.
9. Inspect the operator compartment for cleanliness.
Keep the operator compartment clean.
48 KEBU7565
Before Operation
Daily Inspection

10. Daily, perform the maintenance procedures that

are applicable to your machine:

• Operation and Maintenance Manual, “Backup

Alarm - Test”

• Operation and Maintenance Manual, “Bolster

Oscillation Pin (Rear) - Lubricate”

• Operation and Maintenance Manual, “Cooling

System Coolant Level - Check”

• Operation and Maintenance Manual, “Engine

Oil Level - Check”

• Operation and Maintenance Manual, “Hydraulic

System Oil Level - Check”

• Operation and Maintenance Manual, “Indicators

and Gauges - Test”

• Operation and Maintenance Manual, “Rotor

Bearing Reservoir Oil Level - Check”

• Operation and Maintenance Manual, “Rotor

Cutter Bits - Inspect/Replace”

• Operation and Maintenance Manual, “Rotor

Cutter Bits (Side) - Inspect/Replace”

• Operation and Maintenance Manual, “Seat Belt

- Inspect”

• Operation and Maintenance Manual, “Tire

Inflation - Check”
KEBU7565 49
Machine Operation
Seat

Machine Operation
i03743879

Seat
SMCS Code: 7312

Note: The operator's seat that is provided with this

machine is in compliance with the appropriate class
of ISO 7096.

Note: Not all features may be included on your

operator's seat.
Adjust the seat at the beginning of each work period
and adjust the seat when you change operators.
The seat and the operator side console move as one
unit.
Note: Do not contact any of the machine controls.
Unexpected movement of the machine may result. Illustration 41 g01162757
(1) Seat back tilt lever (if equipped)
Always use the seat belt when you operate the
machine. For further details on this procedure, refer to
Operation and Maintenance Manual, “Seat Belt”. To adjust the seat back tilt (if equipped), move lever
(1) and move the seat back to the desired position.

Illustration 40 g01166663
Illustration 42 g01162760

The operator can adjust the seat position forward or (2) Seat rotation lever
backward. The operator can rotate the seat to the left (3) Seat height indicator
or to the right. The operator can adjust the height of (4) Seat height control
(5) Seat position lever
the seat. The operator can adjust the angle of the (6) Armrest adjustment dial
armrests. If equipped, the operator can also adjust
the seat back tilt and the lumbar support. Pull up lever (2) in order to rotate the seat. Hold the
seat in the desired position. Release the lever.
Select the desired position in order to allow full pedal
travel and full lever travel.
50 KEBU7565
Machine Operation
Seat Belt

Use the seat height control (4) in order to adjust the
height of the seat. Place the handle in the operating
position. Turning the handle clockwise increases the
height of the seat. Turning the handle
counterclockwise decreases the height of the seat. If
the adjustment is correct, indicator (3) will turn green.
If the indicator shows red, further adjustment is
required.
To adjust the seat forward or backward, pull up lever
(5) and hold the lever. Move the seat to the desired
position. To lock the seat in the selected position,
release the lever.
A dial is on the bottom of each armrest. To adjust the
angle of the armrest, operate dial (6). Place the
armrests in the upright position when you enter the
machine or when you exit the machine.
i04200349
Seat Belt
SMCS Code: 7327
Note: This machine was equipped with a seat belt
when the machine was shipped from Caterpillar . At
the time of installation, the seat belt and the
instructions for installation of the seat belt meet the
SAE J386 and ISO 6683 standards. Consult your Cat
dealer for all replacement parts.
Always check the condition of the seat belt and the
condition of the mounting hardware before you
operate the machine.
Seat Belt Adjustment for Non-
Retractable Seat Belts
Adjust both ends of the seat belt. The seat belt should
be snug but comfortable.

Lengthening the Seat Belt

Illustration 43 g01162769
(7) Lumbar support knob (if equipped) Illustration 44 g00100709

The lumbar support (if equipped) is located in the

back of the seat. The lumbar support knob (7) is 1. Unfasten the seat belt.
located on the left side of the back of the seat. Turn
knob (7) counterclockwise in order to increase the
force of the lumbar support. In order to decrease the
lumbar support, continue to turn the knob
counterclockwise.
The operator can adjust the height of headrest (if
equipped). To adjust the headrest, hold the headrest
with both hands. Move the headrest up and down.
Release the headrest when the desired position is
attained. The headrest will remain in the desired
position.
KEBU7565 51
Machine Operation
Seat Belt

Fastening The Seat Belt

Illustration 45 g00932817

2. To remove the slack in outer loop (1), rotate buckle Illustration 47 g00932818

(2). This will free the lock bar. This permits the seat
Fasten the seat belt catch (3) into the buckle (2).
belt to move through the buckle. Make sure that the seat belt is placed low across the
lap of the operator.
3. Remove the slack from the outer belt loop by
pulling on the buckle.
Releasing The Seat Belt
4. Loosen the other half of the seat belt in the same
manner. If the seat belt does not fit snugly with the
buckle in the center, readjust the seat belt.

Shortening the Seat Belt

Illustration 48 g00100717

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

belt.

Illustration 46 g00100713

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

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

manner.
3. If the seat belt does not fit snugly with the buckle in
the center, readjust the seat belt.
52 KEBU7565
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 49 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.
i03721142
Mirror
(If Equipped)
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.
Illustration 50 g00039113

Push the release button on the buckle in order to

release the seat belt. The seat belt will automatically
retract into the retractor.
KEBU7565 53
Machine Operation
Mirror

Upper Mirror On Right Side Handrail (1)

Illustration 52 g02010858

Adjust the upper mirror on the right side handrail so

Illustration 51
(1) Upper mirror on right side handrail
(2) Lower mirror on right side handrail
(3) Upper mirror on right side of hood
(4) Lower mirror on right side of hood
(5) Upper mirror on left side handrail
(6) Lower mirror on left side handrail
(7) Upper mirror on left side of hood
(8) Lower mirror on left side of hood
that a portion of the right side of the hood from the
screen to the front can be seen. A view of at least
g02005588 2.5 m (8.2 ft) from the front center and right side of
the machine, 1.5 m (4.9 ft) high, and 12 m (39.4 ft)
from the operator at the ground in the front center of
the machine should be seen.
Lower Mirror On Right Side Handrail (2)

Mirrors provide additional visibility around your

machine. Make sure that the mirrors are in proper
working condition and that the mirrors are clean.
Adjust all mirrors at the beginning of each work period
and adjust the mirrors when you change operators.
Modified Machines or machines that have additional
equipment or attachments may influence your
visibility.
The mirror adjustments that are discussed here are
for when the operator station is in the extreme left
position. If the operator station is moved to the
extreme right position the views for the mirrors will be
reversed from left to right. The mirrors will require
further adjustment when the operator station is placed Illustration 53 g02005613
in an intermediate position. The operator is
responsible for adjusting the mirrors when the Adjust the lower mirror on the right side handrail so
position of the operator station is changed. that the right side of the machine, and the right
handrail can be seen. A view of at least 1 m (3.3 ft)
Mirror Adjustment from the right side of the machine, 1.5 m (4.9 ft) high,
and 12 m (39.4 ft) from the operator at the ground on
• Park the machine on a level surface. the rear side of the machine should be seen.

• Lower the work tool to the ground.

• Stop the engine.

Note: Hand tools may be needed in order to adjust
the mirrors. Refer to Specifications, SENR3130,
“Torque Specifications” for the recommended torque.
54
Machine Operation
Mirror
Upper Mirror On Right Side of Hood (3)
Illustration 54 g01998196
When the upper mirror on the right side of the hood is
adjusted properly no part of the machine will be seen.
A view of at least 1 m (3.3 ft) from the right side of the
front tire, 1.5 m (4.9 ft) high, and 12 m (39.4 ft) from
the operator at the ground on the right side of the
machine should be seen.
Lower Mirror On Right Side of Hood (4)
The lower mirror on the right side of the hood can not
be seen when the cab is in the extreme left position.
Upper Mirror On Left Side Handrail (5)
Illustration 55 g02010859
Adjust the upper mirror on the left side handrail so
that a portion of the left side of the hood from the
screen to the front can be seen. A view of at least
2.5 m (8.2 ft) from the front center of the machine,
1.5 m (4.9 ft) high, and 12 m (39.4 ft) from the
operator at the ground in the front center of the
machine should be seen.
KEBU7565
Lower Mirror On Left Side Handrail (6)
Illustration 56 g02010860
Adjust the lower mirror on the left side handrail so that
the left side of the machine, the left handrail, and the
left rotor lift cylinder can be seen. A view of at least
1 m (3.3 ft) from the left side of the machine, 1.5 m
(4.9 ft) high, and 12 m (39.4 ft) from the operator at
the ground on the rear side of the machine should be
seen.
Upper Mirror On Left Side of Hood (7)
Illustration 57 g02005633
When the upper mirror on the right side of the hood is
adjusted properly no part of the machine will be seen.
A view of at least 1 m (3.3 ft) from the left side of the
machine, 1.5 m (4.9 ft) high, and 12 m (39.4 ft) from
the operator at the ground on the rear side of the
machine should be seen.
KEBU7565
Lower Mirror On Left Side of Hood (8)
Illustration 58 g02005635
Adjust the lower mirror on the left side of the hood so
that the left tire and the bottom corner of the operator
platform can be seen. A view of at least 12 m (39.4 ft)
from the operator at the ground on the rear side of the
machine should be seen.
i05437872
Product Link
SMCS Code: 7490; 7606
Note: Your machine may be equipped with the Cat
®
Product Link system.
The Product Link 121SR/321SR system utilizes
satellite technology to communicate machine
information. The Product Link 420/421 and 522/523
are cellular based communication devices that
transmit machine information. This information is
communicated to Caterpillar , Cat dealers and
Caterpillar customers. Product Link systems
contain Global Positioning System (GPS) satellite
receivers.
The capability of two-way communication between
the machine and a remote user is available with the
Product Link 121SR/321SR, 420/421, and 522/523
system. The remote user can be a dealer or a
customer. At any time, a user can request updated
information from a machine such as hours of use or
the location of the machine. Also, the system
parameters for Product Link 121SR/321SR, 420/421,
and 522/523 systems can be changed.
55
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.
Operation in a Blast Site for
Product Link
The Product Link radio transmitter must be disabled
by the minimum distance mandated under all
applicable legal requirements, or the following
Caterpillar recommended distance from the site,
whichever is greater: 12 m (40 ft) for Product Link
121SR and 321SR and 3 m (10 ft) for Product Link
420/421 and 522/523.
56
Machine Operation
Product Link
The following are suggested methods to disable the
Product Link 121SR/321SR system or the Product
Link 522/523 system: (a) Install a Product Link
disconnect switch in the machine cab that will allow
the Product Link 121SR/321SR system or the
Product Link 522/523 system module to be shut off.
Refer to Special Instruction, REHS2365, “An
Installation Guide for the Product Link PL121SR and
for the PL300” and Special Instruction, REHS2368,
“Installation Procedure For Product Link PL522/523
(Cellular)” for more details and installation
instructions. Or, (b) Disconnect the Product Link
121SR/321SR system or the Product Link 522/523
module from the main power source by disconnecting
the wiring harness at the Product Link module.
For Product Link devices with an internal battery
back-up without a radio disable feature including the
PL420 and PL421 system: it is not recommended to
operate an asset with this type of device within a blast
site, nor should it be operated within the minimum
mandated or recommended distance from a blast site
perimeter.
The following Product Link system specifications are
provided in order to aid in conducting any related
hazard assessment and to ensure compliance with all
local regulations:
• The transmit power rating for the Product Link
121SR transmitter is 5 to 10 W.
• The operating frequency range for the Product
Link 121SR system is 148 to 150 MHz
• The transmit power rating for the Product Link
522/523 transmitter is approximately 1 W.
• The operating frequency range for the Product
Link 522/523 system is 824 to 849 MHz, 880 to
915 MHz, 1710 to 1785 MHz, and 1850 to 1910
MHz.
• The transmit power rating for the Product Link
420/421 system is 2 w for 850 MHz and 900 MHz
and 1 w for 1800 MHz and 1900 MHz.
Consult your Cat dealer if there are any questions.
Information for the initial installation of the Product
Link 121SR/321SR system is available in Special
Instruction, REHS2365, “An Installation Guide for the
Product Link PL121SR and for the PL300”.
Information for the initial installation of the Product
Link 522/523 system is available in Special
Instruction, REHS2368, “Installation Procedure For
Product Link PL522/523 (Cellular)”.
Operation, configuration and troubleshooting
information for the Product Link 121SR/321SR
system can be found in the Systems Operation,
Troubleshooting, Testing and Adjusting, RENR7911,
“Product Link 121/321”.
KEBU7565
Operation, configuration and troubleshooting
information for the Product Link 522/523 system can
be found in the Systems Operation, Troubleshooting,
Testing and Adjusting, RENR8143, “Product Link -
PL522/523”.
Information for the initial installation of the Product
Link 420 system is available in Special Instruction,
REHS5595, “Installation Procedure for Product Link
PL420 Retrofit”.
Information for the initial installation of the Product
Link 421 system is available in Special Instruction,
REHS5596, “Installation Procedure for Product Link
PL421 Retrofit”.
Machine Security
Machine Lock Icon –
De-rate – Some machines can have the machine
engine de-rated remotely by the owner of the
machine. The action causes the machine to operate
much slower than normal.
A warning is given before this action occurs on the
display with the machine lock icon and “Security
Pending” . When engine de-rate has happened, the
machine display shows the machine lock icon and
“Security Enabled” . The operator should move the
machine to a safe location, apply the parking brake,
power the machine down, notify the site supervisor,
and contact your local Cat dealer.
Disable – Some machines can be prevented from
starting remotely by the owner of the machine. When
disabling has happened, the machine display shows
the machine lock icon and “Security Enabled” .
Before the machine is disabled, the machine display
shows the machine lock icon and “Security Pending”
. The operator should notify the site supervisor.
Tampering – Tampering with the Product Link
system to disable the Product Link can also result in
engine de-rating of the machine. To avoid de-rating,
prevent tampering with the Product Link . If, machine
diagnostics occur due to Product Link notify your
site supervisor immediately to prevent derating. An
example of this situation is an antenna becoming
damaged.
Note: Leaving the blast site switch in the OFF
position for more than 48 machine hours can cause
the machine to derate.
KEBU7565 57
Machine Operation
Product Link

Regulatory Compliance

Illustration 59 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
58 KEBU7565
Machine Operation
Product Link

Illustration 60 g02348438
KEBU7565 59
Machine Operation
Product Link

Illustration 61 g02657277
60 KEBU7565
Machine Operation
Product Link

Illustration 62 g02346204
KEBU7565 61
Machine Operation
Product Link

Illustration 63 g02346205
62 KEBU7565
Machine Operation
Product Link

Illustration 64 g02346208
KEBU7565 63
Machine Operation
Product Link

Illustration 65 g02727978
64 KEBU7565
Machine Operation
Product Link
KEBU7565 65
Machine Operation
Product Link

Illustration 66 g02727979
66 KEBU7565
Machine Operation
Product Link
KEBU7565 67
Machine Operation
Product Link

Illustration 67 g03341389
68 KEBU7565
Machine Operation
Product Link
KEBU7565 69
Machine Operation
Product Link

Illustration 68 g03341393
70 KEBU7565
Machine Operation
Operator Controls

i03726601

Operator Controls
SMCS Code: 7300; 7301; 7451

Note: Your machine may not be equipped with all of

the controls that are described in this topic.

Illustration 69 g02009336

(1) Control for spray system
(2) Control for emulsion system
(3) Control for water system
(4) Temperature gauge for the engine
(5) Temperature gauge for the hydraulic oil
(6) Speedometer
(7) Warning light for the engine
(8) Tachometer
(9) Voltage gauge
(10) Engine oil pressure gauge
(11) Fuel gauge
(12) Hazard flasher control
(13) Emergency stop knob
(14) Headlight and work light switch
(15) Turn signal control
(16) Horn
(17) Load control
(18) Travel control
(19) Rotor control
(20) Engine throttle control
(21) Control for the rotor speed
(22) Rotor depth control
(23) Mixing chamber tilt control
(24) Differential lock switch
(25) Rear wheel drive switch
(26) Parking brake switch
(27) Control for the beacon and rear service
light
KEBU7565
Operator Console Controls
Control for the Spray System (1)
The control for the spray system is a two-position
switch.
Spray System (1) – Push the switch (1)
upward to the ON position in order to
turn on the spray system. Push the
switch (1) downward to the OFF position in order
to turn off the spray system.
Control for the Emulsion System (2)
The control for the emulsion system is a two-position
switch.
Emulsion (2) – Push the switch (2)
upward to the ON position in order to
turn on the emulsion. Push the switch (2)
downward to the OFF position in order to turn off
the emulsion.
Control for the Water System (3)
The control for the water system is a two-position
switch.
Water (3) – Push the switch (3) upward to
the ON position in order to turn on the
water. Push the switch (3) downward to
the OFF position in order to turn off the water.
Temperature Gauge for the Engine (4)
The temperature gauge for the engine (4) displays
the temperature of the engine. If the engine begins to
overheat, the warning light for the engine (6) will
flash. A fault indicator will then appear on the
operator's display. Shut off the engine immediately.
Temperature gauge for the hydraulic oil
(5)
The hydraulic oil temperature control (5) displays the
temperature of the hydraulic oil. If the hydraulic oil
has overheated, a fault message will be displayed on
the operator's display.
Speedometer (6)
The speedometer (6) displays the velocity of the
machine.
71
Machine Operation
Operator Controls
Warning Light for the Engine (7)
If there is a fault with the engine, the warning light for
the engine (7) will illuminate. Do not operate the
machine until the source of the warning has been
repaired.
Tachometer (8)
The tachometer (8) displays the engine speed in
revolutions per minute.
Voltage Gauge (9)
The voltage gauge (9) displays the available voltage
of the battery. If there is a problem with the battery,
the warning light for the engine (7) will illuminate and
the display screen will display a fault indicator.
Engine Oil Pressure Gauge (10)
The engine oil pressure gauge (10) displays the
engine oil pressure. If there is a problem with the
engine oil pressure, the warning light for the engine
(7) will illuminate and a warning horn will sound. The
display screen will also display a fault indicator.
Fuel Gauge (11)
The fuel gauge (11) displays the available fuel level
for the machine. If the fuel gauge (11) is approaching
0, stop the machine and refill the machine
immediately.
Hazard Flasher Control (12)
The hazard flasher control is a two-position switch.
Hazard – Push the switch (12) upward to
the ON position in order to activate the
hazard lights. Push the switch (12)
downward to the OFF position in order to turn off
the hazard lights.
Emergency Stop Knob (13)
Emergency Stop Knob – In the event of
an emergency, push the knob downward
in order to stop the engine and the
machine.
In order to release the emergency stop, pull the knob
upward.
Note: In order to propel the machine, the propel lever
must be in the NEUTRAL position before you release
the emergency stop.
72
Machine Operation
Operator Controls
Note: The stop switches should only be used
when rapid machine shutdown is necessary. For
the recommended engine stopping procedure, refer
to Operation and Maintenance Manual, “Stopping the
Machine”.
Headlight and Work Light Switch (14)
The headlight and the work light switch is a three-
position switch.
Headlights and Work Lights – Push the
switch (14) upward to the HEADLIGHTS
AND WORK LIGHTS position in order to
turn on the headlights and turn on the work lights.
Work Lights – Move switch (14) to the
WORK LIGHTS position in order to turn
on the work lights only. The work lights
are used to illuminate the rotor.
Note: Also see the Beacon and the Rear Service
Light Control.
Off – Push the switch (14) downward to
the OFF position in order to turn off the
headlights and turn off the work lights.
Turn Signal Control (15)
The turn signal control is a three-position switch.
LEFT – Push the switch (15) to the left in
order to activate the left turn signal.
When the switch for the turn signal is
pushed to the left, the left turn signal indicator
(39) will illuminate. The left turn signal will remain
on until the switch is manually returned to the
MIDDLE position.
Move switch (15) to the center OFF position in order
to turn off the turn signals.
RIGHT – Push the switch (15) to the right
in order to activate the right turn signal.
When the switch for the turn signal is
pushed to the right, the right turn signal indicator
(42) will illuminate. The right turn signal will
remain on until the switch is manually returned to
the MIDDLE position.
Horn (16)
The control for the horn is a two-position momentary
switch.
Horn – Depress button (16) in order to
sound the horn.
KEBU7565
Load Control (17)
The load control is a two-position switch.
Load control – Push the switch (17)
upward to the ON position in order to
activate the load control. Push the
switch (17) downward to the OFF position in order
to turn off the load control.
Travel Control (18)
The travel control is a two-position switch.
Travel mode – Push the switch (18)
upward to the TRAVEL MODE position in
order to activate the travel mode for the
propel system.
Work mode – Push the switch (18)
downward to the WORK MODE position
in order to activate the work mode for
the propel system.
Note: Do not change speeds while the machine is
moving.
Rotor Control (19)
The rotor control is a two-position switch.
Rotor control – Push the switch (19)
upward to the ON position in order to
activate the rotor. Push the switch (19)
downward to the OFF position in order to turn off
the rotor.
Note: The rotor can not be engaged with the engine
at high idle. Do not increase the engine idle speed
until the rotor is fully engaged. If the engagement of
the rotor fails an operator's error message will be
displayed on the operator's display screen.
Engine Throttle Control (20)
The throttle control is used to control the engine
speed. The throttle control is a two-position switch.
FAST – Push the switch (20) upward to
the FAST position in order to position
the engine speed at full speed.
SLOW – Push the switch (20) downward
to the SLOW position in order to position
the engine speed at idle.
Control for the Rotor Speed (21)
The control for the rotor speed is a three-position
switch.
KEBU7565
The control for the rotor speed (21) selects the speed
of the rotor. The speed of the rotor is measured in
revolutions per minute (RPM).
Note: Refer to Operation and Maintenance
Manual, “Operation Information” for proper
shifting of the rotor speeds.
Note: Before you shut off the rotor, set the engine
throttle control (20) to the SLOW position and
then stop the rotor.
Note: Do not shut off the rotor at full throttle. Only
shut off the rotor if an emergency situation arises.
Move the switch (21) to 115 RPM in order to select
the lowest speed of the rotor.
Move the switch (21) to 160 RPM in order to select
the medium speed of the rotor.
Move the switch (21) to 215 RPM in order to select
the highest speed of the rotor.
Rotor Depth Control (22)
The rotor depth control is a two-position momentary
switch.
The rotor depth control instructs the machine to
capture the existing depth of the rotor and the rotor
depth control instructs the machine to maintain the
depth of the rotor.
Rotor depth control – Hold switch (22) in
the down position while you watch the
rotor's depth on the display. The depth of
the rotor will be captured when the display
flashes.
Mixing Chamber Tilt Control (23)
The mixing chamber tilt control is a three-position
switch.
The mixing chamber tilt control is used to tilt the
mixing chamber. When the rear of the mixing
chamber is tilted upward, the chamber is in the
CHAMBER RAISE position.
CHAMBER RAISE – Push the switch (23)
upward to the CHAMBER RAISE position
in order to tilt the rear of the mixing
chamber upward. The chamber will maintain that
position.
73
Machine Operation
Operator Controls
CHAMBER FLOAT – Push the switch (23)
to the middle in order to place the switch
in the CHAMBER FLOAT position. When
you place the switch in the CHAMBER FLOAT
position, the machine pressurizes both ends of
the cylinder. The pressure creates a slight
downward force on the rear door while the
machine is working. The cylinder can move in this
setting. Cylinder movement allows the rotor to
ride over irregularities on the ground.
CHAMBER LOWER – Push the switch
(23) downward to the CHAMBER LOWER
position in order to pressurize the base
end of the cylinder. The chamber will move
downward to the CHAMBER LOWER position.
The rotor will stay flat at any depth of the rotor.
Differential Lock Control (24)
The differential lock control is a two-position switch.
The differential lock will increase the traction of the
machine.
Note: The differential lock is designed to disengage
at high speed.
Differential lock – Push the switch (24)
upward to the ON position in order to
engage the differential lock. Push the
switch (24) downward to the OFF position in order
to disengage the differential lock.
Note: The differential lock is designed to disengage
at high speeds and at speeds below 5 ft/min. The
differential lock is disengaged when the machine is
operated in reverse. The differential lock will also
disengage when the front wheels reach an angle of
13 degrees.
Rear Wheel Drive Control (25)
The rear wheel drive control is a two-position switch.
Note: In order to engage the rear wheel drive, the
machine must be stopped.
Rear wheel drive control – Push the
switch (25) upward to the ON position in
order to activate the rear wheel drive.
Push the switch (25) downward to the OFF
position in order to turn off the rear wheel drive.
74 KEBU7565
Machine Operation
Operator Controls

Parking Brake Switch (26) Display Function Controls

Parking Brake Switch – The parking
brake switch is a two-position rocker
switch. In order to engage the parking
brake, push down on the upper part of the rocker
switch. When the parking brake is engaged, the
propel system is put into NEUTRAL. In order to
disengage the parking brake, push down on the
lower part of the rocker switch.
Note: The parking brake must be engaged before
the machine operator leaves the operator station.

Control for the Beacon and Rear Service

Light (27)
The control for the beacon and rear service light is a
two-position switch.

Beacon and rear service light – Push the

switch (27) upward to the ON position in
order to turn on the beacon and turn on
the rear service light. Push the switch (27) Illustration 70 g01999615
downward to the OFF position in order to turn off (28) Preset menu key
the beacon and turn off the rear service light. (29) Preset menu key
(30) Preset menu key
(31) Preset menu key
(32) Fault indicator for the emulsion system
(33) Indicator for the emulsion system
(34) Fault indicator for the water system
(35) Indicator for the water system
(36) Escape key
(37) Enter key
(38) Scroll up key
(39) Scroll down key
KEBU7565
Illustration 71 g02009375
(40) Left turn signal
(41) Indicator for operator error
(42) Fault indicator for machine control
(43) Right turn signal
(44) Hydraulic system fault indicator
(45) Low air pressure indicator
(46) Indicator for hazard warning
(47) Indicator for the rotor service switch
(48) Indicator for the rotor lift lock
(49) Fault indicator for the engine
(50) Fault indicator for the battery
The display function controls are flat, momentary
keys.
Preset Menu Keys (28, 29, 30, 31)
Preset Menu Keys(28, 29, 30, 31) – Push
the preset menu keys (28, 29, 30, 31) in
order to view captured information about
the machine operation. Push the key and hold the
key for four seconds in order to assign the screen
display to the key.
Fault Indicator for the Emulsion System
(32)
Fault Indicator for the Emulsion System
– If there is a problem with the emulsion
system, the fault indicator for the
emulsion system (32) will be illuminated.
Indicator for the Emulsion System (33)
Indicator for the Emulsion System –
When the emulsion system is active, the
indicator for the emulsion system (33)
will be illuminated.
75
Machine Operation
Operator Controls
Fault Indicator for the Water System (34)
Fault Indicator for the Water System – If
there is a problem with the water system,
the fault indicator for the water system
(34) will illuminate.
Indicator for the Water System (35)
Indicator for the Water System – When
the water system is active, the indicator
for the water system (35) will illuminate.
Escape Key (36)
Escape – Push the escape key (36) in
order to escape from the present
function and return to the next higher
function.
Enter Key (37)
Enter – Push the enter key (37) in order
to execute the selected function.
Scroll Up Key (38)
Scroll Up Key – Push the scroll up key
(38) in order to scroll upward on the
display.
Scroll Down Key (39)
Scroll Down Key – Push the scroll down
key (39) in order to scroll downward on
the display.
Left Turn Signal (40)
Left Turn Signal – When the left turn
signal is activated, the left turn signal
indicator (40) will illuminate.
Indicator for Operator Error (41)
Indicator for Operator Error – If the
operator mode sequence is incorrect,
the indicator for operator error (41) will
illuminate.
Monitor the display for flashing icons that indicate the
operator error.
76 KEBU7565
Machine Operation
Operator Controls

Fault Indicator for Machine Control (42)
Fault Indicator for Machine Control – The
fault indicator for machine control (41)
will illuminate if there is a fault with the
machine control for the system. The fault
indicator for machine control (42) will also
illuminate if there is a fault with the sensors for
the system.
Right Turn Signal (43)
Right Turn Signal – When the right turn
signal is activated, the right turn signal
indicator (43) will illuminate.
Hydraulic System Fault Indicator (44)
Indicator for the Rotor Lift Lock (48)
Indicator for the Rotor Lift Lock – The
indicator for the rotor lift lock will
illuminate when there is a problem with
the rotor lift lock. The indicator for the rotor lift
lock (48) will also illuminate when the rotor lift
lock is in the UP position.
Fault Indicator for the Engine (49)
Fault Indicator for the Engine – The fault
indicator for the engine (49) will
illuminate if there is a fault with the
engine. The fault indicator for the engine (49) will
also be illuminated when the engine shutdown
switch is in the ON position.

Hydraulic System Fault Indicator – The
hydraulic system fault indicator (44) will
be illuminated for any of the following
conditions:
• The hydraulic oil is too hot.
• The hydraulic oil is bypassing the front propel filter.
• The hydraulic oil is bypassing the rear propel filter.
• The hydraulic oil is bypassing the fan filter.
• The hydraulic oil is bypassing the filter for the
water system.
Low Air Pressure Indicator (45)
Fault Indicator for the Battery (50)
Fault Indicator for the Battery – The fault
indicator for the battery (50) will be
illuminated when there is a fault with the
machine's charging system.
Display Information
The display screen will indicate when there is a fault
with the machine. Do not operate the machine if a
fault indicator is present. If a fault persists, contact
your Caterpillar dealer.
Note: Operator error fault codes can be identified by
a flashing icon on the display screen. The flashing
icon indicates the operator error.

Low Air Pressure Indicator – The low air

pressure indicator (45) is not used on
this model.

Indicator for Hazard Warning (46)

Indicator for Hazard Warning – The
indicator for hazard warning (46) will
illuminate when the hazard flasher
control (12) is in the ON position.

Indicator for the Rotor Service Switch (47)

Indicator for the Rotor Service Switch –
The indicator for the rotor service switch
(47) will illuminate when the rotor service
switch is in the SERVICE position.
KEBU7565
Display Screen
Illustration 72
(51) Indicator for the machine speed
(52) Operation mode and fault code indicator
(53) Left turn signal indicator
(54) Icon for the work light
(55) Icon for the warning beacon
(56) Icon for the headlights
(57) Right turn signal indicator
(58) Fast icon for the engine throttle control
(59) Indicator for the steering position
(60) Slow icon for the engine throttle control
(61) Alert indicator for the engine
(62) Icon for the hydraulic oil temperature
(63) Icon for the hydraulic oil filter
(64) Icon for the parking brake
(65) Rotor indicator
(66) High/Low icon for the rotor axle
(67) Automatic icon for the rotor mode
(68) Icon for the rotor chain drive case
(69) Up icon for the rotor mode
(70) Icon for the rear drive
(71) Icon for the propel differential lock
(72) Manual icon for the rotor mode
(73) Icon for the Rotor lift lock
(74) Water control
(75) Rotor depth indicator
(76) Icon for the emulsion system
(77) Indicator for the battery
(78) Low fuel level indicator
77
Machine Operation
Operator Controls
(79) Icon for operator error
(80) Icon for load control
(81) Icon for travel mode
(82) Icon for work mode
Indicator for the Machine Speed (51) – The
indicator for the machine speed (51) provides the
velocity of the machine while the machine is in
operation. The units of measurement are illuminated
to the right of the display screen. In order to change
units, refer to “Interaction With the Display Screen”.
Operation Mode and Fault Code Indicator (52) –
This display is used to communicate the operation
mode of the machine. If a fault occurs, the fault will
scroll across the display (52). Refer to “Fault Codes”
for more information on fault codes.
Left Turn Signal Indicator (53) – When
the left turn signal is activated, the left
turn signal indicator (53) will illuminate
on the display screen.
Icon for the Work Light (54) – When the
work lights have been turned on, the
icon for the work light (54) will illuminate
on the display screen.
Icon for the Warning Beacon (55) – When
the warning beacon has been activated,
the icon for the warning beacon (55) on
the display screen will illuminate.
Icon for the Headlights (56) – When the
headlights have been activated, the icon
for the headlights (56) will illuminate on
the display screen.
Icon for the Right Turn Signal (57) –
g02009394
When the right turn signal is activated,
the icon for the right turn signal (57) will
illuminate on the display screen.
Fast Icon for the Engine Throttle Control
(58) – When the engine throttle control is
in the FAST position, the fast icon for the
engine throttle control (58) is illuminated on the
display screen.
Indicator for the Steering Position (59) –
The indicator for the steering position
(59) communicates the four different
modes of steering. The four different modes of
steering are rear steer, front steer, crab steer, and
coordinated steer.
Slow Icon for the Engine Throttle Control
(60) – When the engine throttle control is
in the SLOW position, the slow icon for
the engine throttle control (60) is illuminated on
the display screen.
78
Machine Operation
Operator Controls
Alert Indicator for the Engine (61) – The
fault indicator for the engine (61) will
illuminate if there is a fault with the
engine. If this indicator is displayed on the
display screen, discontinue the use of the
machine immediately. Do not operate the machine
until the source of the fault is found and the
source of the fault is corrected.
Icon for the Hydraulic Oil Temperature
(62) – If the hydraulic oil temperature
reaches a dangerous level, the icon for
the hydraulic oil temperature (62) will illuminate.
Stop the machine and discontinue the use of the
rotor. Allow the machine to idle until the hydraulic
oil has been given sufficient time in order to cool.
Icon for the Hydraulic Oil Filter (63) – If
there is a problem with the hydraulic oil
filter, the icon for the hydraulic oil filter
(63) will illuminate. Discontinue operation and
replace the hydraulic filter. Refer to this Operation
and Maintenance Manual, “Hydraulic System Oil -
Change” for more information on the replacement
of a hydraulic oil filter.
Icon for the Parking Brake (64) – When
the parking brake is engaged, the icon
for the parking brake (64) will illuminate
on the display screen.
Rotor Indicator (65) – The rotor indicator
provides details regarding the rotor
speed, and the engagement of the rotor
clutch.
High/Low Icon for the Rotor Axle (66) –
The high/low icon for the rotor axle (66)
is only used on the RM-300 machines.
Automatic Icon for the Rotor Mode (67) –
When the rotor is in the automatic depth
control, the automatic icon for the rotor
mode (67) will illuminate on the display screen.
Icon for the Rotor Chain Drive Case (68)
– The icon for the rotor chain drive case
(68) will be solid when the rotor is ON.
The icon for the rotor chain drive case will blink
when the rotor is coasting to a stop. The symbol
is not present when the rotor is in the OFF
position.
Up Icon for the Rotor Mode (69) – When
the rotor is in the UP position, the up
icon for the rotor mode (68) will
illuminate.
Icon for the Rear Drive (70) – When the
rear drive is engaged, the icon for the
rear drive (70) will illuminate on the
display screen.
KEBU7565
Icon for the Propel Differential Lock (71)
– The icon for the propel differential lock
(71) indicates whether the propel
differential lock is engaged, the icon also
indicates if the propel differential lock is
disengaged. If the propel differential lock is
engaged, the icon for the propel differential lock
(71) will be illuminated.
Manual Icon for the Rotor Mode (72) –
When the rotor is in the manual mode,
the manual icon for the rotor mode (72)
will illuminate on the display screen.
Icon for the Rotor Lift Lock (73) – When
the rotor lift lock is engaged, the icon for
the rotor lift lock (73) is illuminated.
Perform maintenance on the machine only when
the rotor lift lock is engaged.
Water Control (74) – When the water
spray system is engaged, the water
control will be illuminated on the display
screen in one of the listed modes. The modes that
are available for the water control are ON, OFF,
MANUAL, and AUTO.
Rotor Depth Indicator (75) – These icons
are used to illustrate the depth of the
rotor cut. The number of illuminated
indicators increases with an increase in the depth
of the cut.
Icon for the Emulsion System (76) –
When the emulsion spray system is
engaged, the icon for the emulsion
system will be in one of the listed modes. The
modes that are available for the emulsion system
are ON, OFF, MANUAL, and AUTO.
Indicator for the Battery (77) – The
indicator for the battery (77) illuminates
when there is a problem with the battery
charging system.
Low Fuel Level Indicator (78) – When the
machine is low on fuel, the low fuel level
indicator (78) will illuminate. Fill the
machine with fuel. Refer to Operation and
Maintenance Manual, “Refill Capacities”.
Icon for Operator Error (79) – If an
operator error has occurred, the icon for
operator error (79) will illuminate on the
display screen and the appropriate icon will also
flash on the display screen in order to indicate the
error.
Icon for Load Control (80) – When the
device for load control is activated, the
icon for load control (80) will illuminate
on the display screen.
KEBU7565
Icon for Travel Mode (81) – When the
machine is in travel mode, the icon for
travel mode (81) will illuminate on the
display screen.
Note: Shifting of the travel mode switch is not allowed
while the machine is in motion.
Icon for Work Mode (82) – When the
machine is in work mode, the icon for
work mode (82) will illuminate on the
display screen.
Interaction With the Display Screen
Illustration 73 g01999615
Run Screen
When the run screen is displayed, pressing the enter
key (37) will bring up the setup screen.
When the run screen is displayed, pressing the scroll
up key (38) will bring up the diagnostic screen.
Setup Screen
When the setup screen is displayed, press the enter
key (37) in order to view the units screen.
When the setup screen is displayed, press the
escape key (36) in order to display the run screen.
Units Screen
When the units screen is displayed, use the scroll up
key (38) or the scroll down key (39) to select between
an English or a Metric display.
79
Machine Operation
Operator Controls
When the desired units have been selected, press
the enter key (37). Press the enter key (37) to save
the units setting and to return to the setup screen.
Diagnostic Screen
When the diagnostics screen is displayed, press the
scroll up key (38) or the scroll down key (39) to select
one of the listed display options.
• Hydraulic oil temperature (HYDTMP)
• Intake manifold (I TEMP)
• Load percent (LPRCNT)
• Battery (VOLTS)
• Fuel level (FLEVEL)
• Engine hours (ENGHRS)
• Fuel temp (F TEMP)
• Engine oil (PRESS)
• Engine RPM (ENGRPM)
• Coolant temperature (CTEMP)
Pressing the escape key (36) twice at any time while
you are in the diagnostic screen will return you to the
rotor depth screen.
Rotor Depth Screen
When the rotor depth screen is displayed, pressing
the escape key (36) will bring up the run screen.
When the rotor depth screen is displayed, press and
hold preset menu key (28) until the display flashes.
Preset menu key (28) has now been assigned as the
rotor depth.
Propel Screen
When in any screen, push the scroll up key (38)
repeatedly until the display reads “PROPEL HIGH
RES SPEED” . Press and hold preset menu key (29)
until the display flashes. Preset menu key (29) has
now been assigned as the “PROPEL HIGH RES
SPEED” . The displayed units will depend on the
operator's selected units. Refer to “Units Screen” in
order to change the displayed units.
When in any screen, push the scroll down key (39)
repeatedly until the display reads “PROPEL LOW
RES SPEED” . Press and hold preset menu key (30)
until the display flashes. Preset menu key (30) has
now been assigned as the “PROPEL LOW RES
SPEED” . The displayed units will depend on the
operator's selected units. Refer to “Units Screen” in
order to change the displayed units.
80 KEBU7565
Machine Operation
Operator Controls

Note: Pressing preset menu keys (28), (29), or (30)
will allow the operator to toggle between the three
functions during operation.
Note: Preset menu key (31) can be used to select the
water and emulsion functions if the machine is
equipped with these systems.
Water Spray Control (Manual Mode)
4. Once MD MAN has been selected, press the enter
key (37) to accept this mode.
Note: The operation mode/fault code display (52) will
read MANSET.
5. Use the scroll up key (38) to increase the rate of
the water spray. Use the scroll down key (39) to
decrease the rate of the water spray.

6. Press the enter key (37) to bring the water flow rate
screen up.

Note: The water spray bar should be turned ON and

Illustration 74 g01999615
Use the following instructions to use the water spray
control in the manual mode.
For further information regarding the water spray
system refer to Specifications, Systems Operation,
Testing and Adjusting, KENR3136, “Operator
Controls”
Note: Adjust the proper spray bar width by turning
OFF the appropriate spray bar nozzles.
the machine should be propelled forward. When the
machine is stopped, the water spray must be turned
OFF.
Note: Serial Number machine BWR404–Up have a
spray rate of 30 to 485 gallons per hour. In order to
spray at the lower rates a smaller nozzle must be
used.
Pressing the escape key will return you to the water
spray MANSET screen. You can adjust the water
spray rate from this screen. After the rate has been
set, press the enter key (36) in order to return to the
flow rate screen.
Pressing the enter key (37) while you are in the flow
display screen will display the WATER TOTAL
screen. The WATER TOTAL function is used to
calibrate the system at the factory.
To clear the water total, press the scroll up key (38) to
clear this information. If you press the enter key (37)
while you are in the water total screen, you will return
the water spray system to the OFF position.

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

start the engine.

2. Turn the water spray switch to the ON position.

Note: H2O water mode will scroll across the
operation mode/fault code display (52).

Note: Pressing the escape key (36) at any time will

return the system to the previously displayed screen.

Note: After H2O water mode has scrolled across the

operation mode/fault code display (52), the operation
mode/fault code display (52) will read MD OFF.

3. Use the scroll up key (38) to select the manual

mode of operation MD MAN.
KEBU7565
Water Spray Control (Automatic Mode)
Illustration 75 g01999615
Use the following instructions to use the water spray
control in the automatic mode.
For further information regarding the water spray
system refer to Specifications, Systems Operation,
Testing and Adjusting, KENR3136, “Operator
Controls”
Note: Adjust the proper spray bar width by turning
OFF the appropriate spray bar nozzles.
1. Turn the engine start switch to the ON position and
start the engine.
2. Turn the water spray switch to the ON position.
Note: H2O water mode will scroll across the
operation mode/fault code display (52).
Note: If you press the escape key (36) at any time,
you will return to the previously displayed screen.
Note: After H2O water mode has scrolled across the
operation mode/fault code display (52), the operation
mode/fault code display (52) will read MD OFF.
3. Use the scroll up key (38) to select the automatic
mode of operation (MD AUT) and press the enter
key.
4. Spray bar width (BWIDTH) appears in the display.
5. Use the scroll up key (38) to increase the width of
the spray bar. Use the scroll down key (39) to
decrease the width of the spray bar.
81
Machine Operation
Operator Controls
6. Press the enter key (37) to accept the selected
spray bar width and to advance to the total volume
(TOT VOL) screen.
Note: While the total volume screen (TOT VOL) is
displayed when you press the scroll up key (38) or
the scroll down key (39) you clear the total volume
(TOT VOL) value.
7. Press the enter key (37) to save the total volume
(TOT VOL) number and to advance to the total
distance (TOT DIS) screen.
Note: Pressing the scroll up key (38) or the scroll
down key (39) clears the total distance (TOT DIS)
value.
8. Press the enter key (37) to save the total distance
(TOT DIS) and to advance to the total area (AREA)
screen.
Note: While you are in the total area screen (AREA) if
you press the scroll up key (38) or the scroll down key
(39) you clear the total area (AREA) value
9. Press the enter key (37) to save the total area
(AREA) and to advance to the application rate
(RATE) screen.
10. Use the scroll up key (38) to increase the
application rate (RATE) or use the scroll down key
(39) to decrease the application rate (RATE).
11. Press the enter key (37) to save the application
rate (RATE) number and advance to the flow rate
(FLOW) screen.
12. Turn the switch for the water spray bar to the ON
position and start propelling the machine.
Note: As the machine speed increases the flow rate
of the water will increase. As the machine speed
decreases, the flow rate of the water decreases.
13. Press the escape key (36) to return to the
application rate (RATE) screen. From this screen
you can make any necessary changes to the
application rate (RATE).
To return the water spray system to the OFF position,
press the enter key (37) until the water mode off (MD
OFF) screen appears. You can also turn the water
spray switches to the OFF position.
Note: Serial number machines BWR404–Up have a
spray rate of 30 to 485 gallons per hour. In order to
spray at the lower rates a smaller nozzle must be
used.
Note: Serial number machines BWR1–403 the
minimum flow rate is 100 gallons per minute and the
maximum flow rate is 500 gallons per minute.
82
Machine Operation
Operator Controls
Emulsion Spray Control (Manual Mode)
Illustration 76 g01999615
Use the following instructions to use the emulsion
spray control in the manual mode.
For further information regarding the water spray
system refer to Specifications, Systems Operation,
Testing and Adjusting, KENR3136, “Operator
Controls”
Note: Adjust the proper spray bar width by turning
OFF the appropriate spray bar nozzles.
1. Turn the engine start switch to the ON position and
start the engine.
2. Turn the emulsion selector switch (2) to the ON
position.
Note: The emulsion mode message (EMUL) will
scroll across the operator mode/fault code display
(52).
Note: Pressing the escape key (36) at any time will
return the system to the previously displayed screen.
Note: After the emulsion mode message (EMUL) has
scrolled across the operator mode/fault code display
(52), the operation mode/fault code display (52) will
read EMUL OFF.
Note: The supply line should be connected and the
appropriate valves should be turned to the OPEN
position.
Note: Selecting the MD MAN position will place the
emulsion control in the recirculate mode. Prior to
operation you must purge all air from the system
using the provided drain valves.
KEBU7565
3. Use the scroll up key (38) to select the manual
mode of operation (MD MAN)
4. Once MD MAN has been selected, press the enter
key (37) in order to accept this mode.
Note: The operation mode/fault code display (52) will
read MANSET.
5. Use the scroll up key (38) in order to increase the
rate of the emulsion spray. Use the scroll down key
(37) in order to decrease the rate of the emulsion
spray.
Note: The supply line should be connected and the
appropriate valves should be turned to the OPEN
position.
Note: Selecting the MD MAN position will place the
emulsion control in the recirculate mode. Prior to
operation you must purge all air from the system
using the provided drain valves.
6. Press the enter key (37) in order to display the
emulsion flow rate screen.
Note: The emulsion spray bar should be ON and the
machine should be propelled forward. When the
machine is stopped, the emulsion spray must be
turned to the OFF position.
Pressing the escape key (36) will return you to the
emulsion spray manual set (MANSET) screen. You
can adjust the emulsion spray rate from this screen.
After the rate has been set, press the enter key (37) in
order to return to the flow rate screen.
Pressing the enter key (37) while you are in the flow
display screen will display the emulsion total (EMUL
TOTAL) screen. The EMUL TOTAL function is used to
calibrate the system at the factory.
In order to clear the emulsion total, press the scroll up
key (38). If you press the enter key (37) while you are
in the EMUL TOTAL screen, you will return the
emulsion spray system to the OFF position.
KEBU7565
Emulsion Spray Control (Automatic
Mode)
Illustration 77 g01999615
Use the following instructions to use the emulsion
spray control in the automatic mode.
For further information regarding the water spray
system refer to Specifications, Systems Operation,
Testing and Adjusting, KENR3136, “Operator
Controls”
Note: Adjust the proper spray bar width by turning
OFF the appropriate spray bar nozzles.
1. Turn the engine start switch to the ON position and
start the engine.
2. Turn the emulsion selector switch (2) to the ON
position.
Note: Emulsion mode (EMUL) will scroll across the
operation/mode fault code display (52).
Note: If you press the escape key (36) at any time,
you will return to the previously displayed screen.
Note: After EMUL has scrolled across the operation
mode/fault code display (51), the operation mode/
fault code display (52) will read MD OFF.
3. Use the scroll up key (38) in order to select the
automatic mode (MD AUT) of operation and press
the enter key (37).
4. Spray bar width (BWIDTH) will appear on the
display.
83
Machine Operation
Operator Controls
5. Use the scroll up key (38) in order to increase the
width of the spray bar. Use the scroll down key (39)
in order to decrease the width of the spray bar.
6. Press the enter key (37) in order to accept the
selected spray bar width and to advance to the
total volume (TOT VOL) screen.
Note: When the total volume (TOT VOL) is displayed
if you press the scroll up key (38) or the scroll down
key (39) you clear the total volume value.
7. Press the enter key (37) in order to save the total
volume (TOT VOL) and in order to advance ot the
total distance (TOT DIS) screen.
Note: Pressing the scroll up key (38) or the scroll
down key (39) clears the total distance (TOT DIS)
value.
8. Press the enter key (37) in order to save the total
distance (TOT DIS) and in order to advance to the
total area (AREA) screen.
Note: While you are in the total area (AREA) screen if
you press the scroll up key or the scroll down key the
total area value is cleared.
9. Press the enter key (37) in order to save the total
area (AREA) and in order to advance to the
application rate (RATE) screen.
10. Use the scroll up key (38) in order to increase the
application rate (RATE) or use the scroll down key
(39) in order to decrease the application rate
(RATE).
Note: The supply line should be connected and the
appropriate valves should be turned to the OPEN
position.
Note: Selecting the MD AUT position will place the
emulsion control in the recirculate mode. Prior to
operation you must purge all air from the system
using the provided drain valves.
11. Press the enter key (37) in order to save the
application rate (RATE) number and in order to
advace to the flow rate (FLOW) screen.
12. Turn the switch for the emulsion spray bar to the
ON position and start propelling the machine.
Note: As the machine speed increases, the flow rate
of the emulsion will increase. As the machine speed
decreases, the flow rate of the emulsion decreases.
84 KEBU7565
Machine Operation
Operator Controls

13. Press the escape key (36) in order to return to the
application rate (RATE) screen. From this screen
you can make any necessary changes to the
application rate (RATE) without stopping the
machine.
To return the emulsion spray system to the OFF
position, press the enter key (37) until the emulsion
mode off (MD OFF) screen appears. You can also
turn the emulsion spray switch (2) to the OFF
position.
Note: The minimum flow rate is 30 gallons per
minute. The maximum flow rate is 200 gallons per
minute.
Emulsion Spray Cleanout Mode
Note: After the emulsion mode message (EMUL) has
scrolled across the the operator's mode/fault code
display (52), the operator's mode/fault code display
(52) will read EMUL OFF.
4. Use the scroll up key (38) in order to select the
emulsion mode cleanout (CLNOUT)
5. Once CLNOUT has been selected, press the enter
key (37) in order to accept this mode.
6. Turn the spray bar switch to the ON position and
the spray pump will run in reverse at a rate of 50
gallons per minute. The emulsion will be pumped
back to the tanker.
Fault Codes
The following fault codes may be displayed during
operation. The fault codes listed below will scroll
across the display.
An example of this would be (SPEED DIAL VALUE
TO LOW), (FNRHANDLE NOT CALIBRATED).
Reference Specifications Systems Operation Testing
and Adjusting, KENR3134 and Specifications
Systems Operation Testing and Adjusting,
KENR3136 for further details and for troubleshooting
these fault codes.
Table 9
Item Possible Error Messages

Shorted to 5 volts
Value Too High
SPEEDDIAL = Speed Dial Value Too Low
Shorted to 0VDC
Not Calibrated
Illustration 78 g01999615 Shorted to 5 volts

Use the following instructions in order to use the Value Too High
emulsion spray control in the cleanout mode. FNRHANDLE = Fnr Handle Value Too Low
1. Turn the engine start switch to the ON position. Shorted to 0VDC
Not Calibrated
2. Insure the proper connections are made between
the transfer truck and the emulsion pump skid. PBRAKE SW = Park Brake Out of Range

Value Too High

3. Turn the emulsion selector switch (2) to the ON
F PROPVLV = Forward Propel
position. EDC Valve
Value Too Low

Note: The emulsion mode message (EMUL) will Not Calibrated

scroll across the operator's mode/fault code display Value Too High
(52). R PROPVLV = Reverse Propel
Value Too Low
EDC Valve
Note: Press the escape key (36) at any time in order Not Calibrated
to return the system to the previously displayed
screen.
(continued)
KEBU7565 85
Machine Operation
Operator Controls

(Table 9, contd) (Table 9, contd)

Value Too High Not Calibrated
DPTH SNSR = Rotor Depth
Value Too Low Value Too High
Sensor
RGHTVALVE = Right Steer
Not Calibrated Value Too Low
Valve
LFTLCK SW = Lift Lock Switch Out of Range Not Calibrated

RTRMOD SW = Rotor Mode Value Too High

Out of Range
Switch
FAN VALVE = Fan Valve Value Too Low
Value Too High
Not Calibrated
RTRDEPVLV = Rotor Depth
Value Too Low
Valve RTRTMPSNS = Rotor Tempera-
Value Too High
Not Calibrated ture Sensor

RTRON SW = Rotor On/Off HYDROSNSR = Hydraulic Oil

Out of Range Value Too High
Switch Temperature Sensor

HIIDLESW = High Idle Switch Out of Range PROPFILTR = Propel Filter Fault

RTRSPDSW = Rotor Speed RTR FILTR = Rotor Filter Fault

Out of Range
Switch
HYD FILTER = Hydraulic Filter Fault
RBRKGBXLO = Rotor Brake
Fault Value Too High
Axle Solenoid
BATTVOLTS = Battery Voltage
Value Too High Value Too Low
RGR1GBXHI = Rotor Gear 1
De-clutch Solenoid Value Too Low COOLNTTMP = Coolant
Value Too High
Temperature
RTRGEAR2 = Rotor Gear 2 Value Too High
OIL PRSSR = Oil Pressure Value Too Low
Clutch Solenoid Value Too Low
Fault
Value Too High CAN = Can Buss
RG3CLUTCH = Rotor Gear 3 No Data
Trans Solenoid Value Too Low
EMUL SNSR = Emulsion Flow Value Too High
ROTOR PPU = Rotor PPU Out of Range Sensor Value Too Low
RCLUTCHON = Rotor Clutch
Out of Range Value Too High
On/Off Switch
EMUL FVLV = Emulsion For-
STRMODESW = Steer Mode Value Too Low
Out of Range ward Valve
Switch Not Calibrated
Shorted to 5 Volts Value Too High
Value Too High EMUL RVLV = Emulsion Re-
Value Too Low
F STRSNSR = Front Steer verse Valve
Value Too Low Not Calibrated
Sensor
Shorted to 0VDC Value Too High
Not Calibrated H2O SNSR = Water Flow
Value Too Low
Sensor
Shorted to 5 Volts
Not Calibrated
Value Too High
FLEVEL = Fuel Level Sender Value Too Low
R STRSNSR = Rear Steer
Value Too Low
Sensor
Shorted to 0VDC
Not Calibrated
JOG SWITCH = Jog Switch Out of Range

Value Too High

LEFTVALVE = Left Steer Valve
Value Too Low

(continued)
86
Machine Operation
Operator Controls
Operator Side Console Controls
Illustration 79
(83) Control for the rotor mode
(84) Speed dial potentiometer
(85) Propel speed range control
(86) Control for the rear steer
(87) Control for the operator station slide
(88) Control for the front rotor door
(89) Control for the rear rotor door
(90) Control for the rotor elevation
(91) Rear steer
(92) Crab steer
(93) Coordinated steer
(94) Front steer
Control for the Rotor Mode (83)
The control for the rotor mode is a three-position
switch.
Note: Elevation of the rotor can be controlled
manually or the elevation can be changed
automatically.
Travel mode – Push the switch (83)
upward to the TRAVEL position in order
to raise the rotor to the travel position.
Manual mode – Move the switch (83) to
the MANUAL position in order to enable
manual control of the rotor elevation.
Use the elevation control (90) to raise the rotor or
lower the rotor.
KEBU7565
Auto mode – Push the switch (83)
downward to the AUTO position in order
to lower the rotor to the preset position.
Note: Use of the Auto Mode switch when starting to
cut in reclamation is not recommended. Lower the
rotor to the desired depth using the manual Mode and
then switch to the Auto Mode.
Speed Dial Potentiometer (84)
The speed dial potentiometer is a rotating variable
control.
The speed dial potentiometer (84) provides variable
control to the propel lever. This will allow the operator
to precisely adjust the maximum travel speed of the
machine.
Speed dial (84) – Turn the speed dial
potentiometer counterclockwise to the
lowest setting. Move the propel speed
range control (87) to the FULL stroke position.
Turn the speed dial potentiometer to the desired
travel speed. This will give the operator the ability
to maintain the repeatable set speed.
Propel Speed Range Control (85)
The propel speed range control is a linear variable
g02009461 control.
Move the lever away from the NEUTRAL position and
toward the FULL stroke position in order to increase
the speed.
Move the lever away from the FULL stroke position
and toward the NEUTRAL position in order to reduce
the speed.
Move the propel speed range control (85) downward
in order to propel the machine in a forward direction.
Move the propel speed range control (85) upward in
order to propel the machine in the reverse direction.
Control for the Rear Steer (86)
The control for the rear steer is a three-position
momentary switch. The control will return to the
center OFF position when the control is released.
The operator display screen will indicate what tires
are being used for steering.
Rear steer – To steer the rear of the
machine, push the toggle switch (86) in
the desired direction. As the machine
moves forward, the wheels will pivot in the
selected direction.
KEBU7565
Note: Rear steer is the default steering mode. When
the engine is started, the machine will be in the rear
steer mode regardless of the setting of the control for
the steer mode. The control for the steer mode must
be reset to rear steer first. The indicator light for
operator error will turn on. The indicator light for
operator error will turn off when the selector is cycled
out of the rear steer mode.
Control for the Operator Station Slide (87)
The control for the operator station slide is a three-
position momentary switch. The control will return to
the center OFF position when the control is released.
Note: The operator must be seated in order to slide
the operator station.
Note: The operator station slide control is used for
the following situations.
• To view the front chain guides
• To improve the operator's field of view
• To gain access to the platform covers
• To view the side of the machine
• To maneuver the machine around an obstacle
• To better view an obstacle in the path of the
machine
• To clear an overhead obstruction such as a tree
branch.
• To view the rear wheel position
• To view the front wheel position
• To view the front door position indicator
• To view the rear door position indicator
• To view the front mirrors (if equipped)
• To view the rear mirrors (if equipped)
Note: If a procedure, work method, or operating
technique is not specifically recommended by
Caterpillar, you must be certain that you are not
endangering yourself or others.
Note: Refer to Operation and Maintenance Manual,
“Mirror” for information on adjusting your mirrors.
Sliding the Operator Station – To slide
the operator station, push the toggle
switch (87) in the desired direction of
travel.
87
Machine Operation
Operator Controls
Note: Ensure that the platform and the access
ladders are clear of objects and personnel before you
slide the operator station. Proper care is your
responsibility.
Control for the Front Rotor Door (88)
The front rotor door control is a two-position switch.
Opening the Front Rotor Door – Push the
switch (88) upward to the OPEN position
in order to open the front rotor door.
Closing the Front Rotor Door – Push the
switch (88) downward to the CLOSED
position in order to close the front rotor
door.
Control for the Rear Rotor Door (89)
The rear rotor door control is a two-position switch.
Opening the Rear Rotor Door – Push the
switch (89) upward to the OPEN position
in order to open the rear rotor door.
Closing the Rear Rotor Door – Push the
switch (89) downward to the CLOSED
position in order to close the rear rotor
door.
Control for the Rotor Elevation (90)
The control for the rotor elevation is a two-position
switch.
Note: The control for the rotor mode (83) must be set
to the MANUAL position in order for you to manually
raise the rotor. The control for the rotor mode(83)
must be set to the MANUAL position in order for you
to manually lower the rotor.
Control for the Rotor Elevation – Push
the switch (90) upward to the RAISE
position in order to raise the rotor. Push
the switch (90) downward to the LOWER position
in order to lower the rotor.
Control for the Steer Mode (91, 92, 93, 94)
The control for the steer mode is a four-position rotary
switch.
Note: The rear wheels can turn automatically. Sound
the horn in order to clear personnel from the front and
rear wheels. Select the mode for steering after you
sound the horn. Proper care is your responsibility.
The rear wheels are controlled by the Electronic
Control Module. The direction of the rear wheels is
determined by the control for the steer mode. There
are four modes for steering.
88 KEBU7565
Machine Operation
Operator Controls

Note: Some modes of steering are limited to steer Overhead Console

angle when the machine is propelling in the reverse
direction.

Note: The coordinated steer mode will place the least

degree of load on the rotor during cutting on a radius.

Rear Steer (91) – Rotate the control for

the steer mode to the REAR STEER
position (91) in order to place the
machine in rear steer mode. You will have
independent control of the front steering and the
rear steering. Control the front steering with the
steering wheel (95). Control the rear steering with
the control for the rear steer (91).
Note: Rear steer is the default steering mode. When
the engine is started, the machine will be in the rear
steer mode regardless of the setting of the control for
the steer mode. In order to change the steer mode,
you must first reset the control for the steer mode to
the REAR STEER position.
Crab Steer (92) – Rotate the control for
the steer mode to the CRAB STEER
position (92) in order to place the
machine in crab steer mode. The rear wheels will
pivot in the same direction as the front wheels.
The rear wheels will follow the front wheels. This
crab steer mode allows you to move the machine
sideways.
Coordinated Steer (93) – Rotate the
control for the steer mode to the
COORDINATED STEER position (93) in
order to place the machine in coordinated steer
mode. The rear wheels will pivot in the opposite
direction of the front wheels. Coordinated steer
mode allows the machine to turn sharper corners.
Coordinated steer mode allows you to follow
turns with more accuracy. If you use the
coordinated steer mode, it is possible to reduce
the load on the ends of the rotor. Reduce the load
on the ends of the rotor in order to decrease the
wear on the bit holders.
Front Steer (94) – Rotate the control for
the steer mode to the FRONT STEER
position (94) in order to place the
machine in front steer mode. In front steer mode,
the rear wheels are locked in a position that is
parallel to the long axis of the machine. In front
steer mode, you can turn the front wheels in
either direction. Front steer mode enables you to
maintain a straight direction of travel.
Illustration 80 g02009463
(95) Control for cab temperature
(96) Control for the heater and the air conditioner
(97) Speed control for the cab fan
(98) Control for the window washer
(99) Control for the front window wiper
(100) Control for the rear window wiper
Control for Cab Temperature (95)
The temperature control is a rotating variable control.
Control for Cab Temperature (95) –
Rotate the temperature variable control
(95) counterclockwise in order to
decrease the air temperature. Rotate the
temperature variable control (95) clockwise in
order to increase the air temperature.
Control for the Heater and the Air
Conditioner (96)
The control for the heater and the air conditioner is a
three-position switch.
Heater – Push the upper portion of the
switch (96) to the HEATER position in
order to turn on the cab heater.
Move the switch (96) to the middle OFF position in
order to select the ambient air temperature.
Air conditioner – Push the lower portion
of the switch (96) to the AIR
CONDITIONER position in order to turn
on the air conditioner.
Speed Control for the Cab Fan (97)
The fan control is a three-position switch.
HIGH – Push the upper portion of the
switch (97) in order to select the HIGH
fan speed.
KEBU7565
MEDIUM – Move the switch (97) to the
middle position in order to select the
MEDIUM fan speed.
LOW – Push the lower portion of the
switch (97) in order to select the LOW
fan speed.
Pressurizing
When heating or cooling is not desired, pressurize the
cab in order to prevent dust from entering. Adjust
variable control (95) to a comfortable temperature.
Position fan control (97) to a speed that is needed to
keep out the dust.
Control for the Window Washer (98)
The control for the window washer is a three-position
momentary switch. The control will return to the
center OFF position when the control is released.
FRONT – Press the upper part of the
switch (98) in order to activate the front
window washer.
REAR – Press the lower part of the
switch (98) in order to activate the rear
window washer.
Control for the Front Window Wiper (99)
The control for the front window wiper is a three-
position switch.
FAST – Push the upper portion of the
switch (99) in order to select the FAST
speed for the front window wiper.
SLOW – Move the switch (99) to the
middle position in order to select the
SLOW speed for the front window wiper.
OFF – Press the lower part of the switch
(99) in order to turn off the front window
wiper.
Control for the Rear Window Wiper (100)
The control for the rear window wiper is a three-
position switch.
FAST – Push the upper portion of the
switch (100) in order to select the HIGH
speed for the rear window wiper.
SLOW – Move the switch (100) to the
middle position in order to select the
SLOW speed for the rear window wiper.
89
Machine Operation
Operator Controls
OFF – Press the lower part of the switch
(100) in order to turn off the rear window
wiper.
Engine Start Switch
Engine Start Switch
Note: When starting the machine it is recommended
that the engine start switch be turned to the ON
position. The operator should observe the display and
start the engine after the display has indicated RUN.
Failure to follow this sequence could generate faults
in the machine control during boot up of the machine
control. Do not operate the machine when there is a
display fault on the operator control panel.
The engine start switch is a three-position keyed
switch. The START position (103) is a momentary
position.
Illustration 81 g02009473
When you turn the engine start switch to the ON
position (102), electrical power is supplied to the
systems in the operator compartment.
OFF(101) – When you insert the engine
start switch key and when you remove
the engine start switch key, the engine
start switch must be in the OFF position (101). To
disconnect the power to the electrical circuits in
the operator station, turn the engine start switch
to the OFF position (101). Also, turn the engine
start switch to the OFF position (101) in order to
stop the engine.
ON(102) – To activate the electrical
circuits in the operator station, turn the
engine start switch key clockwise to the
ON position (102).
START(103) – To start the engine, turn
the engine start switch key clockwise to
the START position (103). When the
engine start switch key is released, the engine
start switch key will return to the ON position
(102).
90 KEBU7565
Machine Operation
Battery Disconnect Switch

Note: If the engine fails to start, return the engine
start switch key to the OFF position (100). This must
be done before you attempt to start the engine again.
Circuit Breaker Controls
Engine Shutdown Switch (105)
Note: The engine shutdown switch is used to stop the
engine in an emergency. Do not use the engine
shutdown switch during normal operation. Engine
damage may result.
The engine shutdown switch (105) is located on the
exterior of the circuit breaker box.
The engine shutdown switch (105) is a two-position
switch. Raise the cover and move the switch upward
in order to stop the engine in an emergency. After the
emergency conditions have been corrected, move the
switch downward in order to start the engine and run
the engine.

Interior Dome Light

Illustration 82 g02009474
The circuit breaker panel is located behind the
access ladder on the left side of the machine. Unlock
the cover of the circuit breaker box in order to access
the control panel.
Interior Dome Light – This is a two
position rocker switch. Push in the rear
half of the switch in order to turn on the
interior dome light. Push in the front half of the
switch in order to turn off the interior dome light.
i03646648

Rotor Service Switch (104) Battery Disconnect Switch

SMCS Code: 1411
The rotor service switch (104) is a two-position
switch. The switch is located on the left side of the
circuit breaker panel.

Note: When the rotor service switch is engaged, the

rotor service indicator (47) will illuminate on the
display screen.

Note: In order to prevent activation of the rotor

during service, move the switch to the SERVICE
position and lock the cover. Do not allow anyone
to unlock the cover during service. Do not move
the switch to the OPERATE position until all
personnel, tools and debris are a safe distance
from the rotor. Proper care is your responsibility.
Note: Apply a service tag to the ignition in order
to further enforce that the machine should not be
started.
SERVICE – Push the rotor service switch
(104) upward in order to place the rotor
in the SERVICE position. The engine will
not be allowed to start.
Illustration 83 g01162775

OPERATE – Push the rotor service

switch (104) downward in order to place Battery Disconnect Switch – The battery
the rotor in the OPERATE position. The disconnect switch is on the left side of
machine can be started for operation. the machine behind the access door (1).
The access door is located behind the left front
tire on the side of the frame.
KEBU7565 91
Machine Operation
Operator Interlocks

To ensure that no damage to the engine occurs, verify

that the engine is fully operational before cranking the
engine. Do not crank an engine that is not fully
operational.
Perform the following procedure in order to check the
battery disconnect switch for proper operation:

1. With the battery disconnect switch in the ON

position, verify that electrical components in the
operator compartment are functioning. Verify that
the hour meter is displaying information. Verify that
the engine will crank.

2. Turn the battery disconnect switch to the OFF

position.

3. Verify that the following items are not functioning:

electrical components in the operator
compartment, hour meter and engine cranking. If
any of the items continue to function with the
Illustration 84 g01142527
battery disconnect switch in the OFF position,
consult your Caterpillar dealer.
ON Position (2) – Insert the key. Turn the
key clockwise to the ON position in i03339490
order to activate the electrical system.
The switch must be ON before you start the Operator Interlocks
engine.
SMCS Code: 7451; 7490
OFF Position (3) – Turn the key
counterclockwise in order to shut off the Engine Start Interlock
entire electrical system.
After you start the engine, an incorrect operational
Note: The battery disconnect switch and the engine sequence will cause the function to be inoperable.
start switch serve different functions. When the The operator sequence fault indicator will illuminate.
battery disconnect switch is turned off, the entire
electrical system is disabled. When only the engine
start switch is turned off, the battery remains
connected to the electrical system.
Turn the battery disconnect switch key to the OFF
position and remove the battery disconnect switch
key when you service the electrical system or you
service any other components of the machine.
Turn the battery disconnect switch key to the OFF
position and remove the battery disconnect switch
key when you exit the machine overnight or when the
machine is left for an extended period of one month
or longer. This procedure will prevent a short circuit
from draining the battery. This procedure will prevent
the components from draining the battery. This
procedure will also prevent the battery from being
drained by vandalism.

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. Illustration 85 g01676098
The location of the operator sequence fault indicator
(1) and the rotor service switch indicator (2) and the
display screen (3).
92 KEBU7565
Machine Operation
Operator Interlocks

Note: The display screen (3) will flash an icon in

order to indicate the appropriate operator error.
Refer to the following checklist for a description of the
engine start interlocks.
Table 10
Control Condition Indicator Remedy

The engine is started with the

To restore the functionality of the
Steer Mode switch set to “COOR-
The Operator Sequence Fault indi- steer modes, the Steer Mode
Steer Mode Switch DINATED STEER” , “CRAB
cator will be illuminated. switch must be set to the REAR
STEER” or “FRONT STEER”
STEER position.
mode.
The engine is started with the Pro- To make the propel functional, the
The Operator Sequence Fault indi-
Propel Control pel Control in the FORWARD posi- Propel control must be reset to the
cator will be illuminated.
tion or the REVERSE position. NEUTRAL position.

The Rotor control must be reset to

The engine is started with the Ro- The Operator Sequence Fault indi-
Rotor Control the OFF position before the rotor
tor control in the ON position. cator will be illuminated.
will become functional.
The Rotor Mode control is set to The Rotor Mode control must be
The Rotor Service Switch indicator
Rotor Mode Control WORK or TRAVEL when the en- set to the MANUAL position before
will be illuminated.
gine is started. the engine is started.

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

The sequence error must be corrected before you

proceed with operation.

Propel Interlocks
The propel system may become nonfunctional if the
operator performs an incorrect operator sequence.
Table 11
Control Condition Indicator Response

The Parking Brake control must be

The machine is stopped. The park- turned OFF and the Propel control
The Operator Sequence Fault indi-
Parking Brake ing brake is applied. The operator returned to the NEUTRAL position
cator will be illuminated.
attempts to propel the machine. before the machine's computer will
respond to the Propel control.

The machine is stopped and the

The Propel control must be re-
operator disengages the parking
The Operator Sequence Fault indi- turned to the NEUTRAL position
Parking Brake brake while the Propel control is in
cator will be illuminated. before the machine's computer will
the FORWARD or REVERSE
respond to the Propel control.
position.

The propel stops. The Propel con-

The machine is moving. The park- The Operator Sequence Fault indi- trol will remain inactive until the
Parking Brake
ing brake is applied. cator will be illuminated. Propel control is returned to the
NEUTRAL position.

The machine is working. The en-

gine speed is below 1000 RPM.
Propel Cutout
The rotor stops and the propel
stops.
Move the Propel control to the
The Operator Sequence Fault indi-
NEUTRAL position and move the
cator will be illuminated.
Rotor control to the OFF position.

Rotor Interlocks
The rotor system may become nonfunctional if the
operator performs an incorrect operator sequence.
KEBU7565 93
Machine Operation
Engine Hour Meter

Table 12
Control Condition Indicator Response

The Rotor control must be turned

“OFF” and the Throttle control
The operator attempts to engage
The Operator Sequence Fault indi- must be positioned to “LOW” idle.
Rotor Start the rotor while the engine is at
cator will be illuminated. Ensure that the low idle engine
HIGH idle.
speed is within 1000 to 1200 RPM.
Attempt to engage the rotor.

The operator activates a rotor

The rotor depth setpoint will not be
depth setpoint while the machine is The Operator Sequence Fault indi-
Rotor Depth Setpoint accepted until the Rotor Mode con-
in the work mode or the travel cator will be illuminated.
trol is in the MANUAL position.
mode.
The engine speed drops below Reset the Propel control to NEU-
The Operator Sequence Fault indi-
Rotor Cutout 1500 RPM. The rotor stops and the TRAL and turn the Rotor control to
cator will be illuminated.
propel stops. the OFF position.

The Rotor Mode control is set to The rotor height will not become
The Operator Sequence Fault indi-
Rotor Lift Lock Control WORK or TRAVEL while the lift adjustable until the Rotor Mode
cator will be illuminated.
lock pin is engaged. control is in the MANUAL position.

The operator attempts to shift the

The rotor speed change will not be
rotor speed while the engine is at The Operator Sequence Fault indi-
Rotor Shifts accepted until the engine speed is
HIGH idle, or while the rotor is still cator will be illuminated.
lowered to LOW idle.
turning.

i02328029 i02324936

Engine Hour Meter Service Light Power

SMCS Code: 7480 Receptacle
SMCS Code: 1408; 1429; 1436
One outlet is provided for the optional service light.

Illustration 86 g01162780
The service hour meter is located in the circuit
breaker box on the left side of the machine.

Service Hour Meter – The service hour

meter indicates the number of operating
hours for the engine.
94 KEBU7565
Machine Operation
Backup Alarm

i02325087

Backup Alarm
SMCS Code: 7406

Illustration 87 g01161272

Illustration 89 g01153130
The backup alarm is located on the rear bolster
behind the fuel tank drain at the pivot point of the
bolster.

Backup Alarm – The backup alarm will

sound when the direction switch is in the
REVERSE position. The backup alarm
alerts any personnel that the machine is backing
up.

i05230610

Illustration 88
The outlet (1) is located in the front of the engine
compartment on the lower left side.
Camera
(If Equipped)
SMCS Code: 7347; 7348
g01161267 The Work Area Vision System (WAVS) is a closed
circuit television system that is designed to
supplement the view for the operator during machine
operation. The system may include one, two, or three
cameras, depending on the type of machine and the
application.
This system operates in the “automatic” mode by
design. The screen remains dark until the machine is
placed in the REVERSE gear for a one camera
system.
KEBU7565 95
Machine Operation
Camera

Prior to operating the machine, ensure that the

features of the display are properly adjusted. Ensure
that the brightness and the contrast are adjusted prior
to operating the machine. Ensure that the brightness
and the contrast are adjusted after changes in the
conditions for ambient light.
Prior to operating the machine, ensure that the
display is positioned in order to provide clear visibility
of the display from the operator seat. Do not position
the display in a way that will cause the following
conditions:

• Cover any safety messages or other important

information.

Illustration 90 g01223034 • Impede the entry to the cab or impede the exit from
Display for WAVS the cab.
• Obstruct the visibility of the operator.

• Obstruct the view of any indicators, gauges, or

monitoring system.
• Impair access to any operator controls or impair
movement of any operator controls.
Prior to operating the machine, ensure that the
camera lens and the display are clean.
Refer to Operation and Maintenance Manual,
SEBU8157, “Work Area Vision System” for additional
information about WAVS. Also, see Special
Instruction, REHS3120, “WAVS Installation Guide for
Generic Applications” and Special Instruction,
REHS7242, “WAVS Generic Installation Guide for
Illustration 91 g01223051 Certain Cat® Products”.
Camera for WAVS
Prior to operating the machine, ensure proper
orientation of images by the camera or cameras. The
cameras have been set up by the factory or by a Cat
dealer to provide views which comply with the
documented guidelines. Consult your Cat dealer
before any adjustments are made to the cameras.
Note: Rear facing cameras should always be set to
the mirror image configuration.
Upon power up of the monitor, the following will
appear in the upper left-hand corner: “REAR1 M” .
The monitor may switch from C1 to C2. The switch to
C2 can occur when the tractor is in reverse,
regardless of whether the tractor has either one or
two cameras. If the monitor switches from C1 to C2,
the following will appear in the upper left-hand corner:
“CHNL 2 M” . If “CHNL 2” is displayed instead of
“CHNL 2 M” , contact the technical communicator at
the Cat dealership for proper adjustments to the
monitor.
96 KEBU7565
Machine Operation
Load Controller

i03726822

Load Controller
SMCS Code: 4457; 5258; 5631

Illustration 92 g02009516
Illustration 93 g01161338
Load control – Push the switch (1) The location of the rotor mode control (1) and the rotor
upward to the ON position in order to elevation control (2).
activate the load control. Push the
switch (1) downward to the OFF position in order
to turn off the load control.
ON – The load control is in automatic operation when
switch (1) is ON. This operation will keep engine RPM
at optimum working speed.

Note: The load control should be ON at all times.

Illustration 94 g01161345
OFF – The load control is in manual operation when
switch (1) is OFF. The three positions of the rotor mode control

The rotor depth setpoint control (6) is a two-position

Note: Do not allow engine RPM to drop below 1700 momentary switch. The rotor depth setpoint control is
RPM in manual mode. located on the operator console.

i03726827

Automatic/Manual Depth
Control
SMCS Code: 1435; 4457; 5258
The rotor mode control (1) is a three-position switch.
The rotor elevation control (2) is a two-position
switch. The rotor mode control and the rotor elevation
control are located on the operator side console.

Illustration 95 g02009533
The location of the rotor depth setpoint control (6) and
the display panel (7).

TRAVEL MODE(3) – This mode will move the rotor to

a height that is suitable for travel of the machine. This
KEBU7565 97
Machine Operation
Manual Propel Override Control

mode allows the operator to go over obstructions. i02460588

This mode allows the operator to travel between cuts.
Move the rotor mode control to the TRAVEL position
for engagement of the rotor service lock.
Manual Propel Override
Control
MANUAL MODE(4) – This mode is the default SMCS Code: 4815
position that will start the machine. If the machine is
started in any other mode, this switch must be reset
to the MANUAL position. The rotor elevation
control (2) is active when the rotor mode control
(1) is in the MANUAL position (4). Personal injury or death can result from sudden
machine movement.

Note: Starting the machine with the rotor mode Sudden movement of the machine can cause in-
control at the TRAVEL position or the AUTO position jury to persons on or near the machine.
will cause the display panel to indicate a fault code. To prevent injury or death, make sure that the area
No movement of the rotor will be allowed until the around the machine is clear of personnel and ob-
rotor mode control is reset to the MANUAL position. structions before operating the machine.
AUTO MODE(5) – This is the mode that is used for
doing work. This mode allows automatic movement of If the propel system fails, it is possible to override the
the rotor. The movement is to a predetermined machine interlocks in order to move the machine. Use
working depth. switches (1) and (2) in order to manually operate the
machine.
Note: The engine must be at high idle for proper
operation of the AUTO MODE.
Use the following commands in order to maintain the
working depth of the rotor when the machine is in
auto mode:
1. Move the rotor mode control (1) to the MANUAL
position (4).

2. Move the rotor elevation control (2) in order to

position the rotor at the desired working depth.

3. Move the rotor depth setpoint control (6) downward

to the SET position in order to capture the existing
depth of the rotor. The value on the display panel
(7) will be illuminated.

4. In order to maintain the set point, move the rotor

mode control (1) to the AUTO position (5).

5. When the machine is in auto mode, use the rotor

elevation control (2) to make temporary
adjustments to the height of the rotor. When the
rotor elevation control (2) is released, the rotor will
return to the set working depth.
98 KEBU7565
Machine Operation
Emulsion Spray System

3. Remove the cover in order to access the manual

propel override switches.

4. Place both manual propel override switches in the

UP position. This is also known as the BYPASS
position.

5. Start the engine.

6. Move the throttle control to the SLOW position.

7. Release the parking brake.

Note: When you move the propel lever, the machine
will move at a predetermined speed.

8. Move the propel lever to the forward position or to

the reverse position in order to move the machine.

9. Stop propelling the machine by placing the propel

lever in the NEUTRAL position.
Illustration 96 g01219059 10. Apply the parking brake and stop the engine.

11. Place both manual propel override switches in the

DOWN position and replace the access cover.

i04934682

Emulsion Spray System

SMCS Code: 5615
For information on the emulsion spray application rate
refer to Operation and Maintenance Manual,
“Application Guidelines”.

Emulsion System Nozzles

Illustration 97 g01219000
Use the correct nozzles for the flow rate. The use of
incorrect nozzle sizes or plugged nozzles can result
Switch (1) supplies a limited amount of voltage to the in an inconsistent flow rate, the operating pressures
propel lever. being too high, or damage to the pump vanes. Use
Switch (2) controls the parking brake. the following chart to determine the correct nozzle for
the flow rate.
Raising both switches will allow the machine to move. Table 13
The direction of the machine movement depends on Flow Rate Nozzle Part Number
the position of the propel lever. If the propel lever is in
the FORWARD position, the machine will travel 1 L/min (0.3 US gpm) to
115-7573
forward. If the propel lever is in the REVERSE 195 L/min (51.5 US gpm)
position, the machine will move in reverse.
115 L/min (30.4 US gpm) to
415 L/min (109.6 US gpm) 115-7575
Note: The manual propel override switches should be
used only when there is a fault with the machine 285 L/min (75.3 US gpm) to
control. The manual propel override switches should 835 L/min (220.6 US gpm) 114-1189
not be used to operate the machine. The manual
propel override switches should only be used to move
the machine to an area for repair. Emulsion System Pump
1. Engage the parking brake. Air leaks on the suction side of the pump can result in
erratic flow meter readings or damage to the pump
2. Move the propel lever to the NEUTRAL position. vanes.
KEBU7565
Pumping water or liquids with small particles, such as
sand or aggregates, can result in rapid wear or
damage to the pump vanes.
The following actions can damage the vanes in the
emulsion system pump:
• Foreign objects entering the pump
• Running the pump dry for extended periods
• Cavitation as a result of air leaks on the suction
side of the pump
• Viscosity too high for the vanes
• Viscosity too high for the pump speed
• Incompatibility with the liquids pumped
• Excessive heat
• Worn or bent push rods, or worn push rod holes
• Settled or solidified material in the pump at startup
• Hydraulic hammer or pressure spikes
• Vanes installed incorrectly
i05656396
Push Bar
SMCS Code: 7121
Illustration 98 g03586897
The push bar is 1.98 m (6.5 ft) long and is mounted
to the front hitch. The push bar is used for pushing a
water truck.
Storage
Perform the following steps in order to place the push
bar in the storage position:
1. Lift pin (1).
99
Machine Operation
Push Bar
2. Slide the inner section of the bar into the outer
section.
3. Insert pin (1) in the bar.
4. Swing the bar to the side of the machine.
5. Lock the push bar in place with pin (2).
Attaching to a Water Truck
Perform the following steps in order to attach the
push bar to a water truck:
1. Disconnect the push bar from pin (2).
2. Rotate the push bar from the storage position to
the forward position.
3. Using a spotter, position the water truck in front of
the soil stabilizer. The truck should be just in front
of the push bar.
4. Place the soil stabilizer and water truck in park.
5. Lift pin (1), and extend the push bar outward
toward the water truck.
6. Secure the eye of the push bar to the water truck
hitch. The push bar should be extended, and
between the inner and outer pin positions for pin
(1).
7. Clear the hitch area of personnel. Drive the water
truck slowly away from the soil stabilizer until pin
(1) falls into place.
i02608646
Operation Information
SMCS Code: 7000
Machine Control Reference
The following examples illustrate the proper operating
techniques for the RM-300. Refer to the following
instructions when you operate the machine in the
field.
The rotor is in first speed and the operator wants
to shift to third speed. Start the machine and
engage the rotor in first speed. Disengage the rotor
and set the rotor's speed switch to third speed. The
transmission will not shift and an operator error will be
displayed. When the rotor's transmission speed
sensor reads zero, the hydraulic cylinder will shift to
third speed. When this shift occurs, the rotor will be
rotating between ten and twenty revolutions per
minute. A small impact may be felt at this time.
100 KEBU7565
Machine Operation
Operation Information

The rotor is in third speed and the operator wants

to shift to first speed. Start the machine and engage
the rotor in third speed. Disengage the rotor and
move the rotor's speed switch to first speed. The Personal injury could result from the sudden stop
transmission will not shift and an operator error will be of the machine. The parking brake is automati-
displayed. When the rotor's transmission speed cally engaged when brake oil pressure drops be-
sensor reads zero, the hydraulic cylinder will shift to low an adequate operating pressure.
first speed. When this shift occurs, the rotor will be
rotating between ten and twenty revolutions per
minute. A small impact may be felt at this time. Make sure that no person is working on the machine
or that no person is near the machine when you
The rotor is in third speed and the operator wants operate the machine. Maintain control of the machine
to shift to second speed. Start the machine and at all times.
engage the rotor in third speed. Disengage the rotor
and move the rotor's speed switch to second speed. Reduce the speed of the engine when you are
The transmission will not shift and an operator error operating the machine in a confined area.
will be displayed. When the rotor's transmission
speed sensor reads zero, the hydraulic cylinder will In order to operate the machine properly, the following
shift to first speed and the axle will shift to HIGH. steps must be completed:
When this shift occurs, the rotor will be rotating
between ten and twenty revolutions per minute. A
small impact may be felt at this time.
The rotor is in first speed and the operator wants
to shift to second speed. Start the machine and
engage the rotor in first speed. Disengage the rotor
and move the rotor's speed switch to second speed.
The rotor axle will not shift and an operator error will
be displayed. When the rotor's transmission speed
sensor reads zero, the axle will shift to HIGH. When
this shift occurs, the rotor will be rotating between ten
and twenty revolutions per minute. A small impact
may be felt at this time.
The rotor is in second speed and the operator
wants to shift to first speed. Start the machine and
engage the rotor in second speed. Disengage the
Illustration 99 g01702554
rotor and move the rotor's speed switch to first speed.
The rotor axle will not shift and an operator error will Retract the rear door service pin during operation.
be displayed. When the rotor's transmission speed
sensor reads zero, the axle will shift to LOW. When
this shift occurs, the rotor will be rotating between ten
and twenty revolutions per minute. A small impact
may be felt at this time.
Note: It is important to remember that the
transmission must be turning in order to make a shift
in these situations.

i04905893

Operation Information
SMCS Code: 7000

Preparation for Operation Illustration 100 g01702563

To hold the rear door in the open position, the rear
door service pin should be extended to the LOCK
position.
Rotor movement can cause injury or death. Stay
clear of the rotor when the engine is running. Shut
off the engine before performing any service on
the rotor or its housing.
KEBU7565 101
Machine Operation
Operation Information

Illustration 101 g01162356 Illustration 103 g01161613

The rotor service lock is located on the left side of the The rotor service switch is located on the inside of the
rotor mixing chamber. circuit breaker box behind the access ladder on the
left side of the machine.

Illustration 102 g02009553

Illustration 104 g02009556

1. See the rotor service lock (2) on the left side of the
rotor mixing chamber. Remove the retaining pin
(1). Move the rotor service lock (2) downward in
order to disengage the lock. Reinstall the retaining
pin (1).
The padlock (3) and the circuit breaker box cover (4)
2. Remove the padlock (3). Open the circuit breaker
box cover (4).
102 KEBU7565
Machine Operation
Operation Information

Illustration 105 g02009558 Illustration 107 g02009582

Location of the rotor service switch (5)
3. Move the rotor service switch (5) downward to the
OPERATE position.
4. Close the circuit breaker box cover (4). Install the
padlock (3).
The operator side console is located to the immediate
right of the operator seat.
6. See the operator side console. Move the rotor
mode control (7) to the MANUAL MODE position.
7. Move the steer mode selector control (8) to the
REAR STEER position.

8. See the operator console. Move the rotor mixing

chamber tilt control (9) to the CHAMBER FLOAT
position.

9. Move the engine throttle control (10) upward to the

FAST position.

10. See the operator side console. Move the rotor

mode control (7) upward to the TRAVEL MODE
position.

11. See the operator console. Sound the horn (11) for
several seconds in order to alert personnel. Make
sure that the personnel in the area are clear of the
Illustration 106 g02009576 machine. Make sure that the personnel in the area
The operator console is located at the front of the are aware of the movement of the machine.
operator station.
12. Push down on the lower part of the parking brake
5. See the operator console. Move the rotor control switch (12) in order to disengage the parking
switch (6) downward to the OFF position. brake.
13. See the operator side console. Move the propel
speed lever (13) to the proper direction. Move the
propel speed lever (13) to the proper speed for
travel. Rotate the speed dial potentiometer (14) in
order to adjust the desired speed range.
KEBU7565
Note: Move the propel lever (13) to the neutral
CENTER position in order to apply hydraulic braking
force to the machine.
Travel with the Rotor Locked
Illustration 108 g01162356
The rotor service lock is located on the left side of the
rotor mixing chamber.
Note: A lock for service to the rotor is provided on the
left side of the machine. Use the lock in order to
secure the rotor in the SERVICE position. The
SERVICE position is used during travel of the
machine. The SERVICE position is used for servicing
the rotor.
Perform the following steps in order to move the
machine without operating the rotor:
1. Make sure that the engine is warmed up.
2. See the operator console. Move the engine throttle
control (10) upward to the FAST position.
3. See the operator side console. Move the rotor
mode control (7) upward to the TRAVEL MODE
position.
103
Machine Operation
Operation Information
Illustration 109 g02009653
4. See the rotor service lock (2) on the left side of the
rotor mixing chamber. Remove the retaining pin
(1). Move the rotor service lock (2) upward in order
to engage the lock. Reinstall the retaining pin (1).
5. See the operator console. Push down on the lower
part of the parking brake switch (12) in order to
disengage the parking brake.
6. See the operator side console. Rotate the speed
dial potentiometer (14) in order to select the
desired speed range.
Note: If the machine is on an incline, move the speed
dial potentiometer (14) to a slower initial setting.
7. Move the propel speed lever (13) to the proper
direction. Move the propel speed lever (13) to the
proper speed for travel. Rotate the speed dial
potentiometer (14) in order to adjust the desired
speed range.
8. In order to stop the travel of the machine, move the
propel speed lever (13) to the NEUTRAL position.
9. See the operator console. Move the engine throttle
control (10) downward to the SLOW position.
10. Push down on the upper part of the parking brake
switch (12) in order to engage the parking brake.
11. Stop the engine.
104
Machine Operation
Operation Information
Operation of Rotor
Before engaging the rotor, be sure the rotor area
is clear of obstructions and personnel. Make sure
the rotor bits are clear of the grade or the machine
may lunge backward when the rotor is engaged.
Whenever starting a cut, lower the rotor slowly. If
the rotor is lowered too fast, the machine will ride
up onto the rotor and lunge backwards. The ma-
chine may also lunge backward a short distance if
the rotor hits some obstruction while cutting.
Never let anyone stand at the back of the machine
while it is in operation. Stand to the side of the
machine and stay clear of the machine.
Illustration 110 g02009654
Location of the rotor speed range control (15)
Three different rotor speeds are available. Position
the rotor speed range control (15) to the appropriate
setting. See this Operation and Maintenance Manual,
“Operator Controls”Operation and Maintenance
Manual, Operator Controls.
Starting Operation
Before engaging the rotor, be sure the rotor area
is clear of obstructions and personnel. Make sure
the rotor bits are clear of the grade or the machine
may lunge backward when the rotor is engaged.
Whenever starting a cut, lower the rotor slowly. If
the rotor is lowered too fast, the machine will ride
up onto the rotor and lunge backwards. The ma-
chine may also lunge backward a short distance if
the rotor hits some obstruction while cutting.
Never let anyone stand at the back of the machine
while it is in operation. Stand to the side of the
machine and stay clear of the machine.
KEBU7565
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.
Note: Cut 1 inch to 2 inches below the asphalt
surface in order to improve the wear of the teeth.
Note: Overlap the cuts in order to ensure the
coverage of the roadway.
NOTICE
Hitting an obstruction during machine operation can
cause the engine to stall. If this occurs, restart the en-
gine within a minute. Failure to restart the engine can
result in turbocharger damage.
1. Plunge cutting may be required when you start the
operation. Propel the machine at a slow rate.
Slowly lower the rotor in order to start the plunge
cut. This will cause the rotor to work in an upcut
mode. The slow, forward movement will help
prevent a bucking motion of the machine.
2. Cut deep enough to mix one or two inches of base
material with the material on the top surface. This
will improve the life of the teeth for the cutter. This
will allow a greater forward speed and this will
allow machine stability.
3. When it is possible, it is always better to make a
transverse cut across the roadway. This should be
done first. This will allow the rotor to start cutting in
the less dense shoulder. This will allow the rotor to
work into the roadway and across the roadway.
The transverse cut avoids the undesirable, abrupt
starting point for the longitudinal cuts.
KEBU7565
Illustration 111 g01167701
The chain guides are located at the front of the
machine.
4. Turn the handles on the chain guides
counterclockwise in order to loosen the chain
guides. Adjust the chain guides in order to align
the chains with the sides of the rotor. Tighten the
handles.
5. If your machine is equipped with a standard fixed
station, proceed to step 6. If your machine is
equipped with a sliding operator station, proceed to
step 7.
6. If your machine is equipped with a standard fixed
station, the first pass should be a longitudinal cut
on the left side of the roadway. If you operate the
machine in this manner you will have the best view
of the guide chain on the edge of the roadway. If
you make a return pass you should move the
machine to the opposite side of the road. Keep the
shoulder of the road to the left side of the machine.
Make any remaining passes with the previous cuts
on the left side of the machine. Proceed to step 8.
105
Machine Operation
Operation Information
7. If your machine is equipped with a sliding operator
station, the first pass of operation should be made
with the operator station moved to the left side of
the machine or moved to the right side of the
machine. If you operate the machine in this
manner you will have the best view of the guide
chain. If you make a return pass, move the
operator station to the opposite side of the
machine. Use the chain guide as a reference to
slightly overlap the previous cut. Proceed to step 8.
8. When you operate the machine in asphalt
reclamation, avoid lowering the rotor too fast.
Make sure that all personnel are 15 m (50 ft) in
back of the machine or 15 m (50 ft) in front of the
machine.
9. If you are performing a reclamation operation, you
should make sure that the front door on the mixing
chamber is partially open. For a reclamation
operation, you should make sure that the rear door
for the mixing chamber is adjusted properly. The
rear door will control the strike off height and the
material sizing. If the rear door is closed too far, the
propel system will not function properly. Open the
door in order to release some material. This will
allow the propel to recover.
10. The life of the teeth for the cutter will vary from
one location to another location. Periodically
perform the following procedure:
a. Stop the machine.
Illustration 112 g02009656
Location of the rotor control switch (6)
b. Move the rotor control switch (6) downward to
the OFF position.
c. Stop the engine.
d. Make sure that the rotor has stopped.
106 KEBU7565
Machine Operation
Operation Information

e. Perform the procedure that is listed in this

Operation and Maintenance Manual,
“Servicing the Rotor”Operation and
Maintenance Manual, Servicing the Rotor.
Note: Teeth holders can break if you operate a
cutter with worn cutter teeth. Teeth holders can
break if you operate a cutter that has broken cutter
teeth. Severe damage may result.
f. Inspect the rotor. Check for any worn cutter
teeth. Check for any broken cutter teeth.
Replace any worn cutter teeth. Replace any
broken cutter teeth.
Note: If the teeth do not rotate freely, excessive Illustration 114 g01702563
wear may result. To hold the rear door in the open position, the rear
g. Inspect the teeth. Check the teeth for free door service pin should be extended to the LOCK
rotation. Replace any teeth that do not rotate. position.

Automatic Operation
Prepare the safety devices

Illustration 115 g01162356

The rotor service lock is located on the left side of the
rotor mixing chamber.

Illustration 113 g01702569

Retract the rear door service pin during operation.
KEBU7565 107
Machine Operation
Operation Information

2. Remove the padlock (3). Open the circuit breaker

box cover (4).

Illustration 116 g02009553

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

Illustration 119 g02009558

Location of the rotor service switch (5)

Note: The rotor service switch (5) is a two-position

switch. When the switch is moved downward to the
OPERATE position, the machine can be started for
operation. When the switch is moved upward to the
SERVICE position, the machine is not allowed to
start.
3. Move the rotor service switch (5) downward to the
OPERATE position.

4. Close the circuit breaker box cover (7). Install the

padlock (3).
Illustration 117 g01161613
The rotor service switch is located on the inside of the
circuit breaker box behind the access ladder on the Prepare the engine for operation of the
left side of the machine. rotor

Illustration 118 g02009556

The padlock (3) and the circuit breaker box cover (4)
108 KEBU7565
Machine Operation
Operation Information

Operation of the front and rear door of the mixing

chamber can affect machine performance. When
reclaiming or stabilizing, the front door should remain
open enough to allow some material to spill out in
front of the chamber. The rear door should remain
open enough to allow material to escape the
chamber. Excess material being held in the chamber
can increase wear rates to the rotor and mixing
chamber. If more mixing is required, subsequent
passes are recommended.
Refer to Rotor Selection Guide, QEDQ1233 in order
to ensure that the correct rotor is being used for the
application.

Position the rotor for work

Illustration 120 g02009576
The operator console is located at the front of the Note: Make sure that the rotor is operating at a
operator station. proper working speed before you attempt to lower the
rotor for work.
1. See the operator console. Move the engine throttle
control (10) downward to the SLOW position.

Prepare the rotor for operation

1. Select the proper rotor speed that is required for

work.
2. Engage the rotor. Move the rotor control (6) upward
to the ON position.

Note: The rotor will engage after a delay of a few

seconds. Do not advance the engine to high throttle
setting before the rotor is fully engaged. This will
result in an operator error and the rotor will not
engage.

3. Move the engine throttle control (12) upward to the

FAST position in order to accelerate the rotor to the
speed that is required for work.
When reclaiming or stabilizing, front steer mode
should be used. Crab, coordinated, and rear steer
modes should not be used during reclaiming or
mixing to avoid side loading and potential damage to
the rotor and mixing chamber.
If stabilizing soil which contains large stones, stones
greater than 6 inches should be removed prior to
stabilizing. Attempting to process large stone during
soil stabilization can result in damage to the rotor or
mixing chamber. The severity and rate at which any
damage occurs may increase based on the type,
size, and frequency of the stone being encountered.
Illustration 121 g02009582
The operator side console is located to the immediate
right of the operator seat.
1. If the rotor is in the SERVICE position, lower the
rotor. See the operator side console. Move the
rotor mode control (7) to the MANUAL position.
2. Move the rotor elevation control (19) upward in
order to raise the rotor. Move the rotor elevation
control (19) downward in order to lower the rotor.
Lower the rotor into the cut until the rotor is at the
desired depth.
KEBU7565 109
Machine Operation
Operation Information

3. See the operator console. Move the rotor depth

setpoint control (16) upward for 3 seconds in order
to capture the depth of the rotor. Hold the control
until the display (17) flashes. The display will
indicate the value that is accepted. Release the
control.
4. Move the rotor mode control (7) downward to the
AUTO position.

Adjust the machine for work

1. Maintain an engine speed that is proper for doing

work. Move the load control (18) upward to the ON
position. The load control is in automatic operation.
Automatic operation will keep engine rpm at
optimum working speed.

2. See the operator side console. Move the propel

speed lever (13) to the proper direction. Move the
propel speed lever (13) to the proper speed for
travel. Rotate the speed dial potentiometer (14) in
order to adjust the desired speed range.

3. Adjust the rear door opening in order to get the

desired sizing of material.
Note: If an obstruction is observed, stop the machine.
move the rotor mode control (7) upward to the
TRAVEL MODE position. After passing the
obstruction, move the rotor mode control (7)
downward to the AUTO MODE position.
110 KEBU7565
Engine Starting
Engine Starting

Engine Starting
4. Verify that all of the switches on the operator side
console are in the OFF position.
i03727042

Engine Starting
SMCS Code: 1000; 7000

Illustration 124 g02009693

(2) Engine throttle control
(3) Engine start switch
(4) Display panel
(5) Horn
Illustration 122 g02009678
The location of the parking brake (1) on the operator 5. Move the engine throttle control (2) to the LOW
console IDLE position.

1. Verify that the parking brake (1) is engaged. 6. Turn the engine start switch (3) to the ON position.
Observe the display panel (4) for error messages.
Correct any faults.

7. Sound the horn (5) twice. Wait for several seconds

to alert nearby personnel.

8. Turn the engine start switch (3) to the START

position. Release the engine start switch (3) when
the engine starts. If the engine does not start after
30 seconds, release the switch. Allow the starter to
cool for two minutes before cranking again.
Note: Do not engage the starter until the starter motor
and the flywheel have stopped rotating.

NOTICE
Illustration 123 g01161211 Do not crank the engine for more than 30 seconds. Al-
The location of the propel speed lever on the operator low the starter to cool for two minutes before cranking
side console again. Turbocharger damage can result if the engine
rpm is not kept low until the oil gauge display verifies
2. Move the propel speed lever to the NEUTRAL that the oil pressure is sufficient.
position.

3. Verify that all of the switches on the operator

console are in the OFF position.
KEBU7565
Illustration 125 g01161927
The location of the rotor service switch (6)
Illustration 126 g01162786
(7) SERVICE position
Note: The engine will not start if the rotor service
switch (6) is in the SERVICE position (7).
You should use starting aids for cold weather starting
if the temperature is below −18 °C (−0 °F). A heater
for the coolant may be required for cold weather
starting. A heater for the fuel may be required for cold
weather starting. A jacket for the water may be
required for cold weather starting. More capacity for
the battery may be required for cold weather starting.
At temperatures below −23 °C (−10 °F), you should
consult your Caterpillar dealer. You can use Special
Publication, SEBU5898 for the recommended starting
procedure. The Operation and Maintenance Manual
is available at your Caterpillar dealer.
111
Engine Starting
Engine and Machine Warm-Up
i03727065
Engine and Machine Warm-Up
SMCS Code: 1000; 7000
NOTICE
Keep engine speed low until the engine oil pressure
registers on the gauge. If it does not register within 15
seconds, stop the engine and investigate the cause
before starting the engine again. Failure to do so can
cause engine damage.
Illustration 127 g02009699
1. Move the engine throttle control (1) to the LOW
IDLE position.
2. Observe the display panel (2) for error messages.
Correct any faults. If there are any level 3
warnings, stop the engine immediately.
3. Allow a cold engine to warm up at low idle for at
least five minutes.
4. Look at the operator's panels frequently during the
operation of the machine. If any of the gauges do
not function properly, stop the engine. Inspect the
electrical system or the machine system in order to
find the cause of the malfunctioning gauge.
Perform necessary repairs prior to starting the
machine again.
5. Test all the controls. Check the controls for proper
operation.
112 KEBU7565
Engine Starting
Engine and Machine Warm-Up

6. Cycle all of the hydraulic controls in order to help

speed the warm-up of the hydraulic components.
Allow warm oil to circulate through all cylinders and
lines.

Note: Observe the following recommendations:

• Allow the engine to run for 15 minutes at

temperatures above 0 °C (32 °F).

• Allow the engine to run for 30 minutes at

temperatures below 0 °C (32 °F).

• Allow the engine to run for more than 30

minutes at temperatures below −18 °C (−0 °F).

• Allow the engine to run for more than 30

minutes if hydraulic functions are sluggish.
KEBU7565 113
Machine Service
Servicing the Rotor

Machine Service
i03727073 Perform steps 1 through 6 only after the service
has been completed.
Servicing the Rotor Failure to follow these instructions could allow
SMCS Code: 6637; 7000 the rotor, chamber, or door to drop resulting in
serious personal injury or death.
1. Complete the service.

Do not perform any cutter tooth replacement, and 2. Do not start the engine again until all services
do not perform service or maintenance on the ro- are completed and all personnel are clear from
the rotor area.
tor, the rotor hood, or the chain cases until steps
1 to 10 are completed. 3. Disengage the rear door service pin before low-
ering the rotor.
Failure to follow these instructions could allow
the rotor, chamber, or door to drop resulting in 4. Disengage the rotor lock.
serious personal injury or death.
5. Remove the padlock from the circuit breaker
1. Set the parking brake on the propel system. box, and open the circuit breaker box cover. Place
the rotor service switch in the OPERATE position.
2. Raise the rotor to the TRAVEL position to clear Close the circuit breaker box cover and install the
any material that may be trapped between the cut- padlock.
ter bits and the paddles.
6. Sound the horn three times prior to starting the
3. Tilt the rotor chamber forward, and raise the engine in order to alert surrounding personnel.
rear door.
4. Reduce the engine speed to LOW idle.
NOTICE
5. Disengage the rotor drive. Attach a "Do Not Operate" warning tag or a similar
warning tag to the start switch or to the controls be-
6. Turn the ignition OFF in order to stop the fore you service the equipment or before you repair
engine,
the equipment.
7. Turn the ignition key to the ON position. Do not These warning tags are avaliable from your Caterpil-
start the engine.
lar dealer. Refer to Special Instruction, SEHS7732 for
8. Remove the padlock from the circuit breaker more information.
box, and open the cover for the circuit breaker
box. Place the rotor service switch in the SERV-
ICE position. Close the circuit breaker box cover
and install the padlock.
9. Engage the rotor service lock T bar that is lo-
cated on the left chain case on the lift cylinder.
10. Secure the rear door and mixing chamber in
position, by engaging the rear door service pin.
11. Do not start the engine again until all of the
services are completed and all personnel are
clear from the rotor area.
12. Remove the rotor lock and disengage the rear
door service pin.
13. Remove the padlock from the circuit breaker
box. Open the cover of the circuit breaker box. Illustration 128 g01309496
Place the rotor service switch in OPERATE posi-
tion. Close the cover for the circuit breaker box 1. Move the propel lever (1) to the NEUTRAL
and install the padlock. position.
14. Sound the horn three times prior to starting
the engine.
114 KEBU7565
Machine Service
Servicing the Rotor

7. Move the rotor control (3) to the OFF position in

order to disengage the rotor.

Illustration 129 g02009706

Operator console
(2) Parking brake switch
(3) Rotor control Illustration 131 g01309486
(4) Engine throttle control
(5) Rotor mixing chamber tilt control 8. Turn the engine start switch (8) to the OFF position.
Make sure that the engine is not running.

Note: Once the rotor service switch is in SERVICE

position, the starting system for the machine is
disabled.
9. Turn the ignition key to the ON position. This will
allow the rotor brake release pump to function.
Note: Do not start the engine.

Illustration 130 g01309485

Operator side console
(6) Rotor mode control
(7) Rear rotor door control

2. Push down on the upper part of the parking brake

switch (2) in order to engage the parking brake.

3. Move the rotor mode control (6) to the TRAVEL

MODE position in order to clear any material that Illustration 132 g01161613
may be trapped between the cutter bits and the Location of the circuit breaker box
paddles.

4. Use the rotor mixing chamber tilt control (5) in order

to tilt the rotor hood forward to the maximum
distance.
5. Move the rear rotor door control (7) to the RAISE
position.

6. Move the engine throttle control (4) to the LOW idle

position.
KEBU7565 115
Machine Service
Servicing the Rotor

11. Move the rotor service switch (12) upward to the

SERVICE position (13).

12. Close the cover (11). Install the padlock (10) in

order to lock the rotor service switch in the
SERVICE position (13).
Note: You must lock the cover in order to prevent the
rotor service switch from being moved to the
OPERATE position (14). Proper care is your
responsibility.

Illustration 133 g01309487

10. The circuit breaker box (9) is located behind the

access ladder on the left side of the machine.
Remove the padlock (10). Open the cover (11).

Illustration 136 g01208301

The rotor service lock is located on the left side of the
rotor's mixing chamber.

13. Engage the rotor service lock. See Operation and

Maintenance Manual, “Rotor Service
Locks”Operation and Maintenance Manual, Rotor
Service Locks.

Illustration 134 g01309491

Location of the rotor service switch (12)

Illustration 137 g01702563

Rear door service pin

Illustration 135 g01309493 14. If your machine is equipped with a rear door
Rotor service switch service pin for the rear door, ensure that the
locking pin is fully extended to the lock position in
(13) SERVICE position
(14) OPERATE position order to hold the rear door in the OPEN position.
See illustration 137 .
116 KEBU7565
Machine Service
Rotor Service Locks

15. Perform the necessary rotor service. i02343176

16. Once the service has been completed, remove Rotor Service Locks
the padlock (10) from the circuit breaker box (9).
SMCS Code: 6637
Open the cover (11).

17. Move the rotor service switch downward to the Rotor Service Switch
OPERATE position (14).

18. Close the cover (11) and install the padlock (10).

Illustration 139 g01161613

Location of the circuit breaker box

Illustration 138 g01702569

19. If your machine is equipped with a rear door

service pin for the rear door lock, ensure that the
locking pin is fully retracted in order to allow the
rear door to close. See illustration 138 .
20. Disengage the rotor service lock. See this
Operation and Maintenance Manual, “Rotor
Service Locks”Operation and Maintenance
Manual, Rotor Service Locks.

21. Do not start the engine until all services are

completed. Clear all personnel from the rotor area.
Sound the horn three times prior to starting the
Illustration 140 g01161798
engine.
1. The circuit breaker box (1) is located behind the
access ladder on the left side of the machine.
Remove the padlock (2). Open the cover (3).
KEBU7565 117
Machine Service
Rotor Service Locks

Rotor Service Lock

Illustration 143 g00876195

The rotor service lock will lock the rotor in the

Illustration 141
Location of the rotor service switch (4)
HIGHEST position for service of the rotor. The rotor
service lock will lock the rotor in the HIGHEST
position for rotor travel. Pull the lever upward. Place
g01161801 the lever in the bracket groove for the cylinder lift lock.
Note: When the lock for the rotor is engaged, there
will be no upward movement of the rotor. When the
lock for the rotor is engaged, there will be no
downward movement of the rotor. The proximity
sensor by the lift lock handle disables automatic
movement of the rotor when the lock bar is in the
LOCK position.

Manual Rotor Lowering Valve

Illustration 142 g01162798
Rotor service switch
(5) SERVICE position
(6) OPERATE position

2. Push the rotor service switch (4) upward in order to

place the rotor in the SERVICE position (5). The
starter is locked out in the SERVICE position (5).
The SERVICE position (5) allows the rotor brake to
be released by energizing an electric pump. The
electric pump automatically maintains rotor brake
release pressure.

3. Push the rotor service switch downward in order to

place the rotor in the OPERATE position (6) for
machine operation.

4. After you change the position of the rotor service

switch, close the cover (3). Install the padlock (2).

Note: When service is performed on the rotor, you

must lock the cover in order to prevent the rotor Illustration 144 g01161826
service switch from being moved. Proper care is your Location of the manual rotor lowering valve
responsibility.
118 KEBU7565
Machine Service
Rotor Service Locks

The manual rotor lowering valve is located behind the

operator station on the left side of the machine. Use
the valve to lower the rotor when the engine is not
running.
In order to lower the rotor, complete the following
procedure.

1. Turn the locking ring counterclockwise in order to

unlock the valve control.
2. Rotate the valve control counterclockwise in order
to lower the rotor.
3. After servicing, rotate the valve control clockwise
and turn the locking ring clockwise in order to
enable the rotor to be raised.
KEBU7565 119
Parking
Stopping the Machine

Parking Stopping the Engine from the

Operator Station
i03727082

Stopping the Machine

SMCS Code: 7000

Note: Use the propel lever to slow the machine.

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

Illustration 146 g02009715

Illustration 145 g01161211

1. When the machine is stopped, move the throttle
switch (1) downward to the SLOW position in order
The propel lever in the NEUTRAL position
to reduce the engine speed.
1. Move the propel lever to the NEUTRAL position in 2. Run the engine for five minutes at low idle.
order to slow the machine and stop the machine.
3. Turn the key for engine start switch (2) to the OFF
2. After the machine has stopped, push down on the position. Remove the key.
upper part of the parking brake switch in order to
engage the parking brake. Emergency Stop Knob
3. Move the switches for the lights to the OFF
position.

4. Lower the rotor to the ground.

i03727100

Stopping the Engine

SMCS Code: 1000; 7000

NOTICE
Stopping the engine immediately after it has been
working under load can result in overheating and ac-
celerated wear of engine components. Illustration 147 g02009717

Refer to the following procedure to allow the engine to Emergency Stop Knob – In the event of
cool and to prevent excessive temperatures in the tur- an emergency, push the knob downward
bocharger housing, which could cause oil coking
problems. in order to stop the engine and the
machine.
In order to release the emergency stop, pull the knob
upward.
120 KEBU7565
Parking
Stopping the Engine if an Electrical Malfunction Occurs

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

must be in the NEUTRAL position before you release
the emergency stop.

Secondary Emergency Stop

Illustration 148 g01163613

The engine shutdown switch is located on the circuit Illustration 149 g01158384
breaker box on the left side of the machine.
1. Open the access door (1) for the engine
The engine shutdown switch is used to stop the
compartment. The door is located on the left side
engine in an emergency. Do not use the engine
shutdown switch during normal operation. Engine of the machine.
damage may result.

1. Lift the cover.

2. Move the engine shutdown switch upward in order
to stop the engine. Make sure that the machine is
secured.

i02343255

Stopping the Engine if an

Electrical Malfunction Occurs
SMCS Code: 1000; 7000
Turn the engine start key to the OFF position. If the
engine does not stop, perform the following Illustration 150 g01169045
procedure.
2. See the red fuel valve handle to the right of the fuel
filters. Turn the fuel valve handle counterclockwise
in order to shut off the fuel to the engine.
Note: Do not operate the machine until the cause of
the problem is corrected.
KEBU7565 121
Parking
Equipment Lowering with Engine Stopped

i02345318 i02323402

Equipment Lowering with Leaving the Machine

Engine Stopped SMCS Code: 7000
SMCS Code: 6000; 7000

Illustration 152 g01151399

Illustration 151 g01161826

Location of the manual rotor lowering valve

The manual rotor lowering valve is located behind the

operator station on the left side of the machine. Use
the valve to lower the rotor when the engine is not
running.
In order to lower the rotor, complete the following
procedure.

1. Turn the locking ring counterclockwise in order to

unlock the valve control.
2. Rotate the valve control counterclockwise in order
to lower the rotor.
Illustration 153 g01161205
3. After servicing, rotate the valve control clockwise
and turn the locking ring clockwise in order to • Use the steps and use the handholds in order to
enable the rotor to be raised. exit the machine.
• Inspect the engine compartment for debris.

• When you park the machine overnight, you should

turn the key for the disconnect switch (1) to the
OFF position.

• Install the vandalism covers. Install the locks for

vandalism covers.
122 KEBU7565
Machine Cleanup
Machine Cleanup Procedure

Machine Cleanup
i02358697

Machine Cleanup Procedure

SMCS Code: 7000

Personal injury or death can result from sudden

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

The machine should be cleaned at the end of each

day's operation. If the machine is not cleaned at the
end of each day, asphalt or debris could build up.
Cleaning the machine can help you find loose bolts,
loose hydraulic lines or loose hydraulic fittings.

1. Clean the machine.

2. Clean the steps and the handholds that lead to the
operator station.

3. Clean the operator station.

During operation with cement, lime or lime slurry,
the following procedure may be necessary in
order to reduce the buildup of material between
the mixing chamber and the rotor side plates.

1. After operation of the machine has been completed

for the day, move the machine to an area that will
allow the rotor to be lowered into the ground
without damage.

2. See the operator console. Place the rotor control in

the OFF position.

3. See the operator side console. Place the rotor

mode control in the MANUAL position.

4. Move the rotor elevation control downward in order

to lower the rotor to the ground. Continue to lower
the rotor until the rear wheels of the machine are
off of the ground.

5. Move the rotor elevation control upward until the

rotor is raised to maximum height.

6. Repeat steps 4 through 5 until the material

between the mixing chamber and the rotor side
plates has been cleared.
KEBU7565
Transportation Information
i01700114
Shipping the Machine
SMCS Code: 7000; 7500
Check the route for shipping the machine. Make sure
that there will be clearance for the machine to travel
under the overpasses.
Prevent the machine from moving when you load the
machine on the truck. Prevent the machine from
sliding while the machine is in transit on the truck.
NOTICE
Obey all state and local laws governing the weight,
width and length of a load.
Make sure the cooling system has proper antifreeze if
moving machine to a colder climate.
Observe all regulations governing wide loads.
Loading the Machine
Note: You can transport the machine as a 3.00 m
(10 ft) load.
123
Transportation Information
Shipping the Machine
• Block the tires of the truck before you load the
machine on the truck. Block the wheels of the
railroad car before you load the machine on the
railroad car.
• Start the engine. Set the rotor mode switch to
TRAVEL or manually raise the rotor to the
maximum UP. Engage the rotor service lock.
• Release the parking brake.
• Load the machine on the trailer.
• Move the propel lever to the NEUTRAL position.
• Engage the parking brake.
• Lower the rotor. The rotor must be on the floor of
the trailer. Open the rear door in order to prevent
the door from resting on the floor.
• Move the throttle switch in order to reduce the
engine speed.
• Move the start switch for the engine to the OFF
position. Remove the key.
• Turn the disconnect switch to the OFF position.
Remove the key.
• Secure the machine with tie-downs when you
transport the machine .
• Cover the engine inlet. Cover the exhaust opening.
i02363758
Roading the Machine
SMCS Code: 7000; 7500
Moving the machine before all personnel are clear
of the machine could cause personal injury.
Sound the horn for several seconds before mov-
ing the machine.
Check with the proper officials in order to obtain the
required licenses.
Check all local traffic regulations. Obey all local traffic
regulations.
Investigate the travel route for overpass clearances.
There must be adequate clearance.
1. Perform a “Walk-Around Inspection”. Measure the
fluid levels in the various compartments.
2. Install the required flags, required signals, or
required lights.
124 KEBU7565
Transportation Information
Lifting and Tying Down the Machine

3. Start the engine. See this Operation and
Maintenance Manual, “Engine Starting” for the
proper starting procedure.
4. Refer to this Operation and Maintenance Manual,
“Operation Information” topic, and this Operation
and Maintenance Manual, “Operator Controls”
topic, for information on moving the machine.
Position the crane or the lifting device in order to lift
the machine in a level position.
1. Move the machine into position.
2. Apply the parking brake.
3. Turn the engine start switch key to the OFF
position. Remove the key.

i03714829 4. Attach lifting cables to the lifting eyes. The lifting

eyes are identified on the machine by labels. There
Lifting and Tying Down the are two lifting eyes on each side of the machine.
Machine 5. Lift the machine slowly in order to make sure that
SMCS Code: 7000; 7500 the machine stays level. Move the machine to the
desired position.

Tying Down the Machine

Improper lifting or tie-downs can allow load to
1. Move the machine into position.
shift and cause injury and damage.
2. Apply the parking brake.

3. Turn the engine start switch key to the OFF

position. Remove the key.

4. Chock the front wheels and the rear wheels.

5. Use the tie-down positions in order to secure the
machine. The tie-down positions are identified on
the machine by labels. There are three tie-down
positions on each side of the machine.
Refer to Operation and Maintenance Manual,
“Shipping the Machine” for shipping instructions.

Illustration 154 g02001296

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.
KEBU7565
Towing Information
i02345684
Towing the Machine
SMCS Code: 7000
Personal injury or death could result when towing
a disabled machine incorrectly.
Make 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.
Follow the recommendations below in order to
properly perform the towing procedure.
The hydraulic brakes for this machine are applied
with a spring. The hydraulic brakes for this machine
are released by pressure. If the engine is inoperable
or auxiliary system pressure drops below 8613 kPa
(1250 psi), the brakes are applied and the machine
cannot be moved.
The towing instructions are for moving a disabled
machine. You should tow the machine only for a few
meters. You should tow the machine at a slow rate of
speed. The speed should be no faster than 2 km/h
(1.2 mph). These instructions are only for
emergencies. Always haul the machine if long
distance moving is required.
Shielding must be provided on the towing machine.
Shielding will protect the operator if the tow line
breaks. Shielding will protect the operator if the tow
bar should break.
Do not allow an operator to be on the machine that is
being towed, unless the operator can control the
steering or the braking.
Before the machine is towed, you should make sure
that the line that is used for towing the machine is in
good condition. Use a towing line that has the
strength of at least 1.5 times the weight of the towing
machine. , Use a tow bar that has the strength of at
least 1.5 times the weight of the towing machine.
When you tow a machine, attach the tow line only to
the tow eyes on the frame, if equipped.
Do not use a chain for pulling. A chain link can break
causing possible personal injury. Use a wire cable
that has a loop on the end or use a wire cable that
has a ring on the end. Use an observer to stop the
pulling procedure if the cable starts to break. You
should not tow the machine when that machine will
not move.
125
Towing Information
Towing the Machine
Keep the tow line angle to a minimum. Do not
exceed a 30° angle. The machine should not be off-
center more than 30°.
Quick movement of the machine could cause the tow
line or the tow bar to break.
Normally, the towing machine should be as large as
the disabled machine. Make sure that the towing
machine has enough brake capacity. , Make sure that
there is enough weight and power in order to control
both machines.
The towing machine should be as large as the
disabled machine. When you tow a machine down a
hill, you should use a larger machine in order to tow
the disabled machine down the hill. If that machine is
not sufficient, you might need additional machines.
This will prevent the disabled machine from
uncontrolled rolling.
Different situations cannot be given. Minimal towing
machine capacity is required on a smooth level
surface. Maximum towing machine capacity is
required on inclines or poor surface conditions.
When you tow a machine, the machine that is towed
must be equipped with a brake system. The brake
system must operate from the operator compartment.
Consult your Caterpillar dealer for towing a disabled
machine.
Engine that is Running
If the ground drive system and the steering systems
are operable, and the engine is running, the machine
can be towed for a SHORT DISTANCE. The machine
can be pulled out of mud or the machine can be
pulled to the side of the road.
The operator on the towed machine MUST steer the
machine in the direction of the tow line.
Make sure that you perform all of the instructions in
the section for Towing Information.
Note: The engine must be running in order to steer
the machine.
Use the following procedure if the propel system is
not functioning.
126 KEBU7565
Towing Information
Towing the Machine

Illustration 157 g00875610

2. Turn bypass actuator nut (1) counterclockwise by

Illustration 155 g01171846
The propel pump is located at the rear of the engine
compartment on the left side of the machine
three full turns.
3. After the machine is towed, tighten bypass actuator
nut (1) to a torque of 71 N·m (52 lb ft).
Engine that is Stopped
1. Block the tires on the machine in order to prevent
the machine from moving.

Illustration 158 g01163615

(1) Lock ring
(2) Hand pump

Illustration 156 g01171838 2. The manual control for the parking brake is located
next to the battery box on the left side of the
1. Locate two (2) multifunction valves on the propel machine. The parking brake must be manually
pump. released before any movement of the machine.
See this Operation and Maintenance Manual,
“Parking Brake Manual Release” for the proper
procedure.
KEBU7565 127
Towing Information
Parking Brake Manual Release

Illustration 161 g00875610

4. Turn bypass actuator nut (1) counterclockwise by

three full turns.
5. After the machine is towed, tighten bypass actuator
nut (1) to a torque of 71 N·m (52 lb ft).
Illustration 159 g01171846
The propel pump is located at the rear of the engine
compartment on the left side of the machine i05221824

Parking Brake Manual Release

SMCS Code: 4267
The manual control for the parking brake is located
next to the battery box on the left side of the machine.

Illustration 162 g03337970

Illustration 160 g01171838 Perform the following steps in order to release the
parking brakes manually:
3. Locate two (2) multifunction valves on the propel
pump. 1. Rotate locking ring (3) counterclockwise.

2. Rotate needle valve knob (2) clockwise.

3. Pump hand pump (1) until resistance is felt.

128 KEBU7565
Towing Information
Parking Brake Manual Release

Operating Condition
NOTICE
Do not operate the machine while the needle valve
knob is rotated clockwise. Operating the machine in
this condition can damage the braking system.

Perform the following steps in order to return the

machine to operating condition:

1. Rotate needle valve knob (2) counterclockwise

until the knob stops.

2. Rotate locking ring (3) clockwise until the locking

ring is snug.
KEBU7565
Engine Starting (Alternate
Methods)
i02159214
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.
129
Engine Starting (Alternate Methods)
Engine Starting with Jump Start Cables
NOTICE
When starting from another machine, make sure that
the machines do not touch. This could prevent dam-
age to engine bearings and electrical circuits.
Turn on (close) the battery disconnect switch prior to
the boost connection to prevent damage to electrical
components on the stalled machine.
Severely discharged maintenance free batteries do
not fully recharge from the alternator after jump start-
ing. The batteries must be charged to proper voltage
with a battery charger. Many batteries thought to be
unusable are still rechargeable.
This machine has a 24 volt starting system. Use only
the same voltage for jump starting. Use of a higher
voltage damages the electrical system.
Refer to Special Instruction, Battery Test Procedure,
SEHS7633, available from your Caterpillar dealer, for
complete testing and charging information.
Use of Jump Start Cables
When the auxiliary start receptacles are not available,
use the following procedure.
1. Determine the reason that the engine will not
crank. Refer to Special Instruction, SEHS7768,
“Use of 6V-2150 Starting Charging Analyzer
Group”. The procedure is applicable even if the
machine does not have a diagnostic connector.
2. On the stalled machine, place the propel control in
the NEUTRAL position. Engage the parking brake.
Lower all attachments to the ground. Move all
controls to the HOLD position.
3. Turn the engine start switch key to OFF on the
stalled machine. Turn off all accessories.
4. Turn on the battery disconnect switch on a stalled
machine.
5. Move the boost machine so that the cables can
reach the stalled machine. DO NOT ALLOW THE
MACHINES TO CONTACT EACH OTHER.
6. Stop the engine on the boost machine. If you are
using an auxiliary power source, turn off the
charging system.
7. Make sure that the batteries in the stalled machine
are not frozen.
8. Connect the positive jump start cable to the
positive cable terminal of the discharged battery.
Do not allow positive cable clamps to contact any
metal except for battery terminals.
130 KEBU7565
Engine Starting (Alternate Methods)
Engine Starting with Jump Start Cables

Note: Batteries in series may be in separate

compartments. Use the terminal that is connected to
the starter solenoid. This battery is normally on the
same side of the machine as the starter.
9. Connect the positive jump start cable to the
positive terminal of the boost source. Use the
procedure from Step 8 in order to determine the
correct terminal.
10. Connect one end of the negative jump start cable
to the negative terminal of the electrical source.

11. Make the final connection. Connect the negative

cable to the frame of the stalled machine. Make
this connection away from the battery, the fuel, the
hydraulic lines, or moving parts.

12. Start the engine on the boost machine. If you are

using an auxiliary power source, energize the
charging system on the auxiliary power source.

13. Wait for a minimum of two minutes while the

batteries in the stalled machine partially charge.

14. Attempt to start the stalled engine. Refer to

Operation and Maintenance Manual, “Engine
Starting”.

15. Immediately after you start the stalled engine,

disconnect the jump start cable from the BOOST
SOURCE.
16. Disconnect the other end of this cable from the
stalled machine.
17. When the engine is running and the charging
system is operating, determine the cause of the
failure of the charging system of the stalled
machine.
KEBU7565
Maintenance Section
Access Doors and Covers
SMCS Code: 7251; 7263; 7273-572; 7273-573;
7273
Illustration 163
Side view
(1) Engine access doors
(2) Coolant tank access door
(3) Vandalism covers
(4) Rear mixing chamber door
Maintenance Access
i02369414
(5) Side rotor access door
(6) Front mixing chamber door
(7) Battery box cover
(8) Circuit breaker box cover
131
Maintenance Section
Access Doors and Covers
g01163893
(9) Battery disconnect switch door
(10) Grill door
132 KEBU7565
Maintenance Access
Access Doors and Covers

Illustration 164 g01163658

Bottom view
(11) Coolant drain valve cover
(12) Crankcase drain valve cover
(13) Front pan shield
(14) Rear pan shield

Illustration 165 g01163916

Top view
(2) Coolant tank access door
(3) Vandalism covers
(15) Access doors
(16) Access panels
(17) Rotor case
KEBU7565
Tire Inflation Information
i02358678
Tire Inflation with Air
SMCS Code: 4203; 7500
Use a self-attaching inflation chuck and stand be-
hind the tread when inflating a tire.
Proper inflation equipment, and training in using
the equipment, are necessary to avoid overinfla-
tion. A tire blowout or rim failure can result from
improper or misused equipment.
Before inflating tire, install on the machine or put
tire in restraining device.
NOTICE
Set the tire inflation equipment regulator at no more
than 140 kPa (20 psi) over the recommended tire
pressure.
See this Operation and Maintenance Manual, “Tire
Inflation Pressure Adjustment”, for the proper tire
pressure.
i02358690
Tire Inflation with Nitrogen
SMCS Code: 4203
Caterpillar recommends the use of dry nitrogen gas
for tire inflation and for tire pressure adjustments. This
includes all machines with rubber tires. Nitrogen is an
inert gas that will not aid combustion inside the tire.
Proper nitrogen inflation equipment, and training
in using the equipment, are necessary to avoid
over inflation. A tire blowout or rim failure can re-
sult from improper or misused equipment and
personal injury or death can occur.
A tire blowout and/or rim failure can occur if the
inflation equipment is not used correctly, due to
the fact that a fully charged nitrogen cylinder's
pressure is approximately 15000 kPa (2200 psi).
133
Tire Inflation Information
Tire Inflation with Air
There are other benefits to using nitrogen in addition
to reducing the risk of an explosion. The use of
nitrogen for tire inflation lessens the slow oxidation of
the rubber. Use of nitrogen also slows gradual tire
deterioration. This is especially important for tires that
are expected to have a long service life of at least
four years. Nitrogen reduces the corrosion of rim
components. Nitrogen also reduces problems that
result from disassembly.
A tire blowout or a rim failure can cause personal
injury.
Use a self-attaching inflation chuck and stand be-
hind the tread when inflating a tire, to prevent per-
sonal injury.
Note: Do not set the tire inflation equipment regulator
higher than 140 kPa (20 psi) over the recommended
tire pressure.
Use 6V-4040 Inflation Group or an equivalent
inflation group to inflate tires with a nitrogen gas
cylinder.
Reference: For tire inflation instructions, refer to
Special Instruction, SMHS7867, “Nitrogen Tire
Inflation Group”.
For nitrogen inflation, use the same tire pressures
that are used for air inflation. See this Operation and
Maintenance Manual, “Tire Inflation Pressure
Adjustment”, for the proper tire pressure.
i02346404
Tire Inflation Pressure
Adjustment
SMCS Code: 4203; 7500
The tire pressure in a warm shop area (18° to 21°C
(65° to 70°F) average temperature) will significantly
change when you move the machine into freezing
temperatures. If you inflate the tire to the correct
pressure in a warm shop, the tire will be underinflated
in freezing temperatures. Low pressure shortens the
life of a tire.
When you operate the machine in freezing
temperatures, see Special Publication, SEBU5898,
“Cold Weather Recommendations”.
Tire Operating Pressures
For normal operating conditions, inflate the tires to the
following pressures:
134 KEBU7565
Tire Inflation Information
Tire Inflation Pressure Adjustment

Table 14
Tire Inflation Pressure

Front Tires 28.1-26 269 kPa (39 psi)

Rear Tires 18.4-30 221 kPa (32 psi)

KEBU7565
Lubricant Viscosities and
Refill Capacities
i03900759
Lubricant Viscosities
SMCS Code: 1000; 7000; 7581
Selecting the Viscosity
Ambient temperature is the temperature of the air in
the immediate vicinity of the machine. This may differ
due to the machine application from the generic
ambient temperature for a geographic region. When
selecting the proper oil viscosity for use, review
both the regional ambient temperature and the
potential ambient temperature for a given
machine application. Generally, use the higher
temperature as the criterion for the selection of the oil
viscosity. Generally, use the highest oil viscosity that
is allowed for the ambient temperature when you start
the machine. Refer to the “Lubricant Viscosities for
Ambient Temperatures” tables for guidance. In cold
weather applications, the preferred method is to use
properly sized machine compartment heaters and a
higher viscosity grade oil. Thermostatically controlled
heaters that circulate the oil are preferred.
The proper oil viscosity grade is determined by the
minimum ambient temperature (the air in the
immediate vicinity of the machine). This is 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 in order to select the oil
viscosity grade 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
when you start the machine.
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 Caterpillar
dealer if additional information is needed.
135
Lubricant Viscosities and Refill Capacities
Lubricant Viscosities
Note: SAE 0W and SAE 5W oils, where allowed for
use in non-hydraulic system compartments, are
generally not recommended for use in machines that
are operated continuously and/or are heavily loaded.
Refer to the “Lubricant Viscosities for Ambient
Temperatures” tables for guidance. The oils that have
the higher oil viscosity will maintain the highest
possible oil film thickness. Consult your Caterpillar
dealer if additional information is needed.
Note: Oil viscosity grade selection is also machine
compartment specific. For guidance on selecting oil
viscosity, refer to the “Lubricant Viscosities for
Ambient Temperatures” tables.
Note: Generally, use the highest oil viscosity that is
available to meet the requirement for the temperature
at start-up.
NOTICE
Proper oil viscosity AND oil type/specification are re-
quired to maximize machine compartment perform-
ance and life. Do NOT use only oil viscosity, or only
oil type to determine the machine compartment oil se-
lection. Using only the oil viscosity or only the oil type
to determine a machine compartment oil selection
can lead to reduced performance and compartment
failure. Refer to the “Lubricant Viscosities for Ambient
Temperatures” tables and to ALL of the associated
footnotes.
NOTICE
Not following the recommendations found in the “Lu-
bricant Viscosities for Ambient Temperatures” tables
and associated footnotes can lead to reduced per-
formance and compartment failure.
General Information for Lubricants
The information provided in this “Lubricant Viscosities
for Ambient Temperatures” article and Tables should
be used in conjunction with the information provided
in the Special Publication, SEBU6250, “Caterpillar
Machine Fluids Recommendations”.
NOTICE
Caterpillar does not warrant the quality or perform-
ance of non-Caterpillar fluids and greases.
NOTICE
Do NOT use only the oil viscosities when determining
the recommended oil for an engine compartment. The
oil type (performance requirements) MUST also be
used.
Note: Only use the oil type and the specification that
is recommended for the various machine
compartments.
136 KEBU7565
Lubricant Viscosities and Refill Capacities
Lubricant Viscosities

Note: Some machine compartments allow the use of

more than one oil type. For the best results, do not
mix oil types.

Note: Different brand oils may use different additive

packages to meet the various machine compartment
performance specification recommendations. For the
best results, do not mix oil brands.
Note: The availability of the various Caterpillar oils
will vary by region.
Note: SAE 10W viscosity grade oil used in most
Caterpillar machine compartments must have a
minimum viscosity of 5.8 cSt at 100 °C (212 °F) (
“ASTM D445”).
Note: The minimum acceptable viscosity for
commercial alternative oils in most Caterpillar
machine hydraulic and hydrostatic transmission
systems is 6.6 cSt at 100 °C (212 °F) ( “ASTM
D445”).
Note: Caterpillar oils are the preferred oils.
Table 15
Recommendations for powertrain, transmissions, and hydraulics Fluids and Caterpillar Performance Requirements

Minimum acceptable Performance Re-

Preferred Application
quirements for commercial oils
Hydraulic systems and Hydrostatic
Cat HYDO Advanced Per Product Data Sheet requirements
Transmissions
Hydraulic systems and Hydrostatic transmis-
Cat Bio HYDO Advanced Cat BF-2
sions requiring biodegradable fluids

Cat TDTO Cat TO-4 Powershift transmissions, some direct drive

transmissions, final drives, differentials and
Cat TDTO-TMS Cat TO-4M transfer drives of many machines

Cat ATF Cat AT-1 On-Highway truck Automatic transmissions

Highly loaded final drives and axles that do

Cat FDAO, Cat FDAO SYN Cat FD-1
not have friction materials
Gears and roller bearings where extreme
Cat GO API GL-5
pressure additives are required.

When you are operating the machine in temperatures
below −20°C (−4°F), refer to Special Publication,
SEBU5898, “Cold Weather Recommendations”. This
is available from your Caterpillar dealer.
For cold weather applications where transmission oil
SAE 0W-20 is recommended, Cat Cold Weather
TDTO is the first choice oil. Second choice for cold
weather transmission applications are commercial
oils of full synthetic basestock that do not have
viscosity index improvers and do meet the
performance requirements of the Cat TO-4
specification. Typical lubricant viscosity grades are
SAE 0W-20, SAE 0W-30, and SAE 5W-30.
Commercial oils that contain a Cat TO-4 additive
package and a lubricant viscosity grade of SAE 0W-
20, SAE 0W-30, or SAE 5W-30 are a last choice.
Caterpillar has determined that Medium Wheel
Loaders equipped with the High Ambient Cooling
Attachment can operate with Cat HYDO Advanced
10 Hydraulic System Oil in ambient temperatures
from −20° C (−4° F) to 50° C (122° F).
The footnotes are a key part of the tables. Read ALL
footnotes that pertain to the machine compartment in
question.
Cat Engines
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.
KEBU7565 137
Lubricant Viscosities and Refill Capacities
Lubricant Viscosities

Supplemental heat is recommended for cold-soaked
starts below the minimum ambient temperature. The
parasitic load and other factors will determine if
supplemental heat is required for cold-soaked starts
that are above the minimum temperature that is
stated. Cold-soaked starts occur when the engine
has not been operated for a period of time. The oil
becomes more viscous due to cooler ambient
temperatures.
Cat DEO-ULS and Cat DEO multigrade oils are the
preferred oils for use in ALLCat diesel engines.
Commercial alternative diesel engine oils are, as a
group, second choice oils.
Cat DEO-ULS or oils that meet the Cat ECF-3
specification and the API CJ-4 oil category are
required for use in nonroad Tier 4 United States
Environmental Protection Agency (U.S. EPA) certified
engines that are equipped with aftertreatment
devices.
Cat DEO-ULS or oils that meet the Cat ECF-3
specification and the API CJ-4 are required for use in
the applications listed below. If oils meeting the Cat
ECF-3 specification and the API CJ-4 specifications
are not available, oils meeting ACEA E9 may be
used. ACEA E9 oils meet the chemical limits
designed to maintain aftertreatment device life. ACEA
E9 oils are validated using some but not all ECF-3
and API CJ-4 standard engine performance tests.
Consult your oil supplier when considering use of an
oil that is not Cat ECF-3 or API CJ-4 qualified.
• Nonroad EU Stage IIIB and IV type-approved
engines that are equipped with aftertreatment
devices
Typical aftertreatment systems include the following:
• Diesel Particulate Filters (DPF)
• Diesel Oxidation Catalysts (DOC)
• Selective Catalytic Reduction (SCR)
• Lean NOx Traps (LNT)
Other systems may apply.
Cat DEO-ULS and Cat DEO are recommended for
all pre-Tier 4 engines that use Ultra Low Sulfur Diesel
(ULSD) or Low Sulfur Diesel (LSD) fuels.
Cat DEO is recommended for engines using fuels of
sulfur levels that exceed 0.1 percent (1000 ppm). Cat
DEO-ULS may be used in these applications if an oil
analysis program is followed. The oil change interval
may be affected by the fuel sulfur level.
Cat DEO-ULS SYN and Cat DEO SYN are SAE
5W-40 viscosity grade oils.
Cat Cold Weather DEO-ULS is an SAE 5W-40
viscosity grade oil.
Cat ECF refers to Engine Crankcase Fluid
specifications. Commercial alternative diesel engine
oils must meet one or more of these Cat ECF
specifications.
If ambient temperature conditions at engine start-up
require the use of multigrade SAE 0W oil, SAE 0W-40
viscosity grade is generally preferred over SAE 0W-
30.

• Nonroad Japan Step 4 approved engines that are

equipped with aftertreatment devices
Cat DEO-ULS and oils meeting the Cat ECF-3
specification and the API CJ-4 and ACEA E9 oil
categories have the following chemical limits:
• 1 percent maximum sulfated ash

• 0.12 percent maximum phosphorous

• 0.4 percent maximum sulfur
The chemical limits were developed in order to
maintain the expected aftertreatment devices life,
performance and service intervals. Use of oils other
than Cat DEO-ULS or oils that do not meet the Cat
ECF-3 specification and the API CJ-4 oil category
(and/or ACEA E9 category for EU and Japan specific
applications listed above) in aftertreatment-equipped
engines can negatively impact performance of the
aftertreatment devices, can contribute to Diesel
Particulate Filter (DPF) plugging and/or can cause the
need for more frequent DPF ash service intervals.
Refer to your engine specific Operation and
Maintenance Manual, and refer to your aftertreatment
device documentation, if available, for additional
guidance.
138 KEBU7565
Lubricant Viscosities and Refill Capacities
Lubricant Viscosities

Table 16
Lubricant Viscosities for Ambient Temperatures

Oil Type and Performance °C °F

Compartment or System Oil Viscosities
Requirements Min Max Min Max
SAE 0W-40 −40 40 −40 104

Cat DEO-ULS SAE 5W-30 −30 30 −22 86

Cat DEO
SAE 0W-30 −40 30 −40 86
Cat DEO-ULS SYN
Engine Crankcase for all Machines Cat DEO SYN SAE 5W-40 −30 50 −22 122
Cat Cold Weather DEO-ULS
SAE 10W-30 −18 40 0 104
Cat ECF-1-a, Cat ECF-2, Cat
ECF-3 SAE 10W-40 −18 50 0 122
SAE 15W-40 −9.5 50 15 122

Cat Hydraulic Systems and

Hydrostatic Transmissions
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.
Cat HYDO Advanced 10 SAE 10W, Cat HYDO
Advanced 30 SAE 30W, or Cat BIO HYDO
Advanced are the preferred oils for use in most
Caterpillar machine hydraulic and hydrostatic
transmission systems. Cat HYDO Advanced fluids
have a 50% increase in the standard oil drain
interval for machine hydraulic systems (3000 hours
versus 2000 hours) over second and third choice oils
- when following 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 Caterpillar dealer for details. In order to
gain the most benefit from the improved performance
designed into Cat HYDO Advanced fluids, when
switching to Cat HYDO Advanced fluids, cross
contamination with the previous oil should be kept to
less than 10%.
Second choice oils are Cat MTO, Cat DEO, Cat
DEO-ULS, Cat TDTO, Cat Cold Weather TDTO, Cat
TDTO-TMS, Cat DEO-ULS SYN, Cat DEO SYN,
Cat Cold Weather DEO-ULS. Third choice oils are
commercial oils that meet Cat ECF-1-a, Cat ECF-2,
Cat ECF-3, Cat TO-4, or the Cat TO-4M
performance requirements, and that have a minimum
zinc additive level of 0.09 percent (900 ppm).
Commercial biodegradable hydraulic oil must meet
the Cat BF-2 specification.
The minimum viscosity for commercial alternative oils
used in most Cat machine hydraulic and hydrostatic
transmission systems is 6.6 cSt at 100 °C (212 °F) (
“ASTM D445”).
KEBU7565 139
Lubricant Viscosities and Refill Capacities
Lubricant Viscosities

Table 17
Lubricant Viscosities for Ambient Temperatures

Oil Type and Performance °C °F

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

Reclaimer Mixers
Where recommended for use, Cat TDTO SAE 50 or
TO-4 SAE 50 is preferred in most applications,
particularly continuous operation. If the ambient
temperature is below −15 °C (5 °F), warm up the oil
prior to operation. The oil must be maintained to a
temperature above −15 °C (5 °F) during operation. If
the ambient temperature is below −15 °C (5 °F),
perform the procedures in the Operation and
Maintenance Manual, “Engine and Machine Warm-
Up” prior to operation. If the ambient temperature is
below −25 °C (−13 °F), consult your Caterpillar
dealer for instructions. Failure to warm up the oil prior
to operation will cause damage to the machine.
Table 18
Lubricant Viscosities for Ambient Temperatures

Oil Type and Performance °C °F

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

Rotor Chain Drive Case and Rotor

Cat TDTO SAE 30 0 35 32 122
Bearing Reservoir

Cat TDTO SAE 50 10 50 50 122

Cat TDTO-TMS
Rotor Transmission
Cat Cold Weather TDTO TDTO-TMS -20 50 -4 122
Cat TO-4, Cat TO-4M

SAE 80W-90 -20 40 -4 104

CAT GO (Gear Oil)
Rotor Differential SAE 85W-140 -10 50 14 122
API GL-5 gear oil
SAE 90 0 40 32 104
140 KEBU7565
Lubricant Viscosities and Refill Capacities
Lubricant Viscosities

Lubricating Grease Cat Ultra 5Moly Grease

Cat Multipurpose Grease
Cat Multipurpose Grease is a National Lubricating
Grease Institute (NLGI) grade 2 grease. This grease
is made with petroleum base oil and a lithium
complex thickener. Cat Multipurpose Grease is
formulated for use in applications that have a low
severity to a medium severity and moderate
temperatures.
Cat Multipurpose Grease meets the NLGI
certification of “GC-LB”. (This certification relates to
extended service intervals in automotive chassis
points and in wheel bearings with disc brakes in
automobiles, vans and light trucks.)
Cat Ultra 5Moly Greases are available in NLGI
grades 0, 1, and 2. Cat Ultra 5Moly Greases are
made with special blends of petroleum base oils and
a Calcium Sulfonate Complex thickener. These
greases also have 5% Molybdenum diSulfide (MoS2
or “Moly”) and added tackifier. Cat Ultra 5Moly
Greases are specially formulated in order to protect
all of the most heavily loaded joints in any Caterpillar
machine against galling, wear, and corrosion. This
protection is sustained while work is being done in
moderate temperatures and with wet working
conditions or dry working conditions.
Cat Ultra 5Moly Grease exceeds the NLGI
certification of “GC-LB”.

Note: If the application calls for a multipurpose Note: If the application calls for Cat Ultra 5Moly
grease and Cat Multipurpose Grease is not Grease and Cat Ultra 5Moly Grease is not available,
available, consult the grease data sheets. Use a consult the data sheets for the grease. From these
substitute that meets or exceeds the performance data sheets, use a substitute that meets the
characteristics of Cat Multipurpose Grease. performance characteristics of Cat Ultra 5Moly
Grease.
Cat Advanced 3Moly Grease
Cat Advanced 3Moly Grease is an NLGI grade 2
grease. This grease is made with petroleum base oil
and a lithium complex thickener. This grease also has
3% Molybdenum diSulfide (MoS2 or “Moly”). Cat
Advanced 3Moly Grease is formulated for use in
applications with low severity to high severity at
moderate temperatures. In addition, the molybdenum
in Cat Advanced 3Moly Grease is a special grade
that has a median particle size of 3 microns in order
to meet the special requirements of some rolling
element bearings. Cat Advanced 3Moly Grease is
recommended for heavily loaded pin joints, and high
impact applications in machines.
Cat Advanced 3Moly Grease meets the NLGI
certification of “GC-LB”.
Note: If the application calls for a multipurpose
grease with molybdenum and Cat Advanced 3Moly
Grease is not available, consult the data sheets for
the greases. Use a substitute that meets or exceeds
the performance characteristics of Cat Advanced
3Moly Grease.
KEBU7565 141
Lubricant Viscosities and Refill Capacities
Lubricant Viscosities

Grease Application Chart

Table 19
Ambient Temperature Range
Typical Load and
Application Point Load Factor °C °F NLGI Grade Grease Type
Speed
Min Max Min Max

457 mm (18) soil/305 −35 40 −31 104 1 Ultra 5Moly

High
mm (12) asphalt. −30 50 −22 122 2 Grease

Lubrication Points 305 mm (12) soil/150 Advanced 3Mo-

Medium −20 40 −4 104 2
mm (6) asphalt. ly Grease

150 mm (6) soil/100 Multipurpose

Low −30 40 −22 104 2
mm (4) asphalt. Grease

Ultra-Low Sulfur Diesel (ULSD) Low Sulfur Diesel (LSD)

The United States (U.S.) Environmental Protection
Agency (EPA) defines Ultra-Low Sulfur Diesel (ULSD
- S15) as a U.S. diesel fuel with a sulfur content not to
exceed 15 parts per million (ppm(mg/kg)) or 0.0015
percent by weight. ULSD was introduced for the U.S.
on-highway diesel engine market in October 2006.
ULSD will be available in December 2010 for off-
highway diesel engines and machines and for the on-
highway diesel engine markets. Engines certified to
nonroad Tier 4 standards (Stage IV in Europe) and
are equipped with exhaust aftertreatment systems
are designed to run on ULSD only. Use of LSD or
fuels higher than 15 ppm (mg/kg) sulfur in these
engines will reduce engine efficiency and engine
durability and will damage emissions control systems
and/or shorten their service interval. Failures that
result from the use of fuels are not Caterpillar factory
defects. Therefore the cost of repairs would not be
covered by a Caterpillar warranty.
Caterpillar does not require the use of ULSD in non-
road and machine applications that are not Tier 4/
Stage IIIB/ Stage IV certified engines and are not
equipped with aftertreatment devices. For Tier 4/
Stage IIIB/Stage IV certified engines, always follow
operating instructions and fuel tank inlet labels to
insure the correct fuels are used.
Note: ULSD has less electrical conductivity than
LSD. Follow all industry standard grounding and
safety practices.
Sulfur-free Diesel Fuel
In Europe, ultra low sulfur diesel fuel will have a
maximum of 0.0010 percent (10 ppm(mg/kg)) sulfur
and is typically referred to as “sulfur-free”. This sulfur
level is defined in European Standard “EN
590:2004”.
Note: Another available diesel fuel in Europe has a
maximum sulfur content of 0.005 percent (50 ppm).
This sulfur level is defined in European Standard “EN
590:2004”.
Low Sulfur Diesel (LSD - S500) is defined by the U.S.
EPA as a U.S. diesel fuel with sulfur content not to
exceed 500 ppm or 0.05 percent by weight.
Note: Both ULSD and LSD must meet the fuel
requirements outlined in the most current revision
level of “ASTM D975”.
Biodiesel
Biodiesel is a fuel that can be made from a variety of
renewable resources that include vegetable oils,
animal fat, and waste cooking oil. Soybean oil and
rapeseed oil are the primary vegetable oil sources. In
order to use any of these oils or fats as fuel, the oils or
fats are chemically processed (esterified) and the
water and contaminants removed.
Fuel made of 100 percent renewable resource is
generally referred to as B100 biodiesel or neat
biodiesel.
Biodiesel can be blended with distillate diesel fuel.
The blends can be used as fuel. The most commonly
available biodiesel blends are B5, which is 5 percent
biodiesel and 95 percent distillate diesel fuel, and
B20, which is 20 percent biodiesel and 80 percent
distillate diesel fuel. Note that the percentages are
volume based.
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.
Cat engines can run on B5 biodiesel blend. Most Cat
engines can run on B20 biodiesel blend. The
biodiesel and biodiesel final blend must conform to
the quality recommendations provided in Table 20 .
142 KEBU7565
Lubricant Viscosities and Refill Capacities
Lubricant Viscosities

Table 20
Biodiesel Fuel Recommendations for Caterpillar Off-Highway Engines

Biodiesel Blend Stock Final Blend Distillate Diesel Fuel used for blending(1)

B5: Caterpillar distillate diesel fuel specification.

(3) Caterpillar distillate diesel fuel specification,
Caterpillar biodiesel specification.(2)
“ASTM D975” or “EN590”
B20: “ASTM D7467” and “API” gravity 30-45
(1) For Tier 4 applications in the U.S., the diesel fuel portion of the final blend must meet the requirements of S15 fuels (15 ppm sulfur) designa-
tions in the latest edition of “ASTM D975” specification. For Stage IIIB and later applications in EU, the diesel fuel portion of the final blend
must meet the requirements for sulfur free (10 ppm sulfur) designation in the latest edition of “EN590”. The final blend must have 15 ppm sulfur
or less.
(2) Refer to the “Biodiesel” section of the latest revision of Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations”.
(3) Refer to the “Fuel” section of the latest revision of Special Publication, SEBU6250, “Caterpillar Machine Fluids Recommendations”.

When biodiesel fuel is used, certain guidelines need Coolant is normally composed of three elements:
to be followed. Biodiesel fuel can influence the engine water, additives, and glycol. Additionally, coolants
oil, aftertreatment devices, non metallics, fuel system containing ethylene glycol may also use embittering
components, etc. Follow the guidelines provided in agents to make the coolant taste bad.
the latest revision of Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations”. Caterpillar recommends a 1:1 mixture of properly
inhibited distilled or deionized water and glycol. This
Biodiesel fuel has limited storage life and has limited mixture will provide optimum heavy-duty performance
oxidation stability. Follow the guidelines provided in as a coolant/antifreeze.
the latest revision of Special Publication, SEBU6250, Table 21
“Caterpillar Machine Fluids Recommendations” for
Coolant Service Life
storage and handling. Follow these guidelines for
engines that are seasonally operated and for standby Coolant Type Service Life (1) (2)
generation engines.
12000 Service Hours or Six Years
Cat ELC
Coolant Recommendations (3)

Commercial coolant that meets

The information provided in this “Coolant 6000 Service Hours or Six Years
the Caterpillar EC-1
Recommendation” section should be used in (4) (5)
conjunction with the “Lubricants Information” provided Specification
in the latest revision of Special Publication, 3000 Service Hours or Three
SEBU6250, “Caterpillar Machine Fluids Cat DEAC
Years
Recommendations”.
Commercial Heavy-Duty Cool-
The following two types of coolants may be used in ant/Antifreeze that meets 3000 Service Hours or Two Years
Caterpillar diesel engines : “ASTM D6210”

Preferred – Cat ELC (Extended Life Coolant) Commercial Heavy-Duty Cool-

Acceptable – (listed in order of most recommended
to least recommended)
• Cat DEAC (Diesel Engine Antifreeze/Coolant)
• a commercial extended life coolant that meets the
Caterpillar EC-1 (Engine Coolant -1) specification
and the additional requirements for EC-1
specification coolants as stated in the coolant
section of Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations”.
• a commercial heavy-duty antifreeze/coolant that
meets the “ASTM D6210-06” specifications
• a commercial heavy-duty antifreeze/coolant that
meets “ASTM D4985-05” specifications
ant/Antifreeze that meets 3000 Service Hours or One Year
“ASTM D4985”
(1) Use the interval that occurs first.
(2) Refer to the engine's Operation and Maintenance Manuals,
“Maintenance Interval Schedule” for the correct interval for re-
placement of the cooling system water temperature regulator.
(3) Cat ELC Extender must be added at 6000 service hours or one
half of the service life of the Cat ELC.
(4) An extender must be added at 3000 service hours or one half of
the service life of the coolant.
(5) In order to be used in Caterpillar diesel engines in accordance
with the service interval for EC-1 coolants that is listed in this
Special Publication, commercial EC-1 coolants must also pass/
conform to the additional requirements for EC-1 specification
coolants as stated in the coolant section of this Special Publica-
tion. Cat EC-1 coolants must also meet the requirements of the
“ASTM D6210” specification.
KEBU7565 143
Lubricant Viscosities and Refill Capacities
Lubricant Viscosities

Water (Table 22, contd)

Caterpillar Minimum Acceptable Water Requirements
NOTICE
Never use water alone without Supplemental Coolant Property Maximum Limit ASTM Test
Additives (SCA) or without inhibited coolant. Water
“D1888”
alone is corrosive at engine operating temperatures. 340 mg/L “Federal
In addition, water alone does not provide adequate Total Solids (20 grains/US gal) Method
protection against boiling or freezing. 2504B”(1)

Acidity pH of 5.5 to 9.0 “D1293”

Note: Caterpillar strongly recommends a minimum of
30 percent glycol in diesel engine cooling systems,
with a minimum of 50 percent glycol very strongly
recommended. Use only glycol based coolants that
meet one or more of the coolant specifications that
are defined as preferred or acceptable in this Special
Publication and that also comply with any additional
requirements that are stated in this Special
Publication (i.e. chemical composition, the use of
SCA, the use of Extender, etc.). Refer to the
Operation and Maintenance Manual for your engine
for any exceptions.
(1) Total dissolved solids dried at 103° C (217° F) - 105° C
(221° F), “Standard Method for the Examination of Water and
Wastewater”, “American Public Health Association”, “www.
apha.org”, “www.aphabookstore.org”, (888) 320-APHA.
For a water analysis, consult one of the following
sources:
• Caterpillar dealer
• Local water utility company
• Agricultural agent

NOTICE • Independent laboratory

All Cat diesel engines equipped with air-to-air after-
Note: Periodic analysis of water that is used in the
cooling (ATAAC) require a minimum of 30 percent gly-
coolant is recommended. Water quality can be
col in order to help prevent water pump cavitation.
affected by a variety of factors including
malfunctioning purification equipment, earthquakes,
Water in the water/glycol coolants is more effective and droughts.
than glycol alone in transferring heat.
Cat ELC Extender
Distilled water or deionized water is
recommended for use in engine cooling systems. Cat ELC Extender is added to the cooling system
halfway through the Cat ELC Extender service life.
DO NOT use the following types of water in cooling Treat the cooling system with Cat ELC Extender at
systems: hard water, softened water that has been 6000 hours or one half of the coolant service life.
conditioned with salt and sea water.
If distilled water or deionized water is not available,
SCA
use water that meets or exceeds the minimum SCA (supplemental coolant additive) is a general
acceptable water requirements that are listed in Table
term for an inhibitor package that is added to a
22 .
cooling system. In glycol-based coolant applications,
Table 22
SCA is added to pre-charge a new coolant that is not
Caterpillar Minimum Acceptable Water Requirements fully formulated and/or to recharge an in-service
conventional coolant on a maintenance basis to
Property Maximum Limit ASTM Test maintain proper inhibitor levels.
“D512”,
Chloride (Cl) 40 mg/L (2.4 grains/US gal)
“D4327”
100 mg/L “D516”
Sulfate (SO4)
(5.9 grains/US gal) “D4327”
170 mg/L
Total Hardness (10 grains/US gal) “D1126”

(continued)
144 KEBU7565
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 15W-40 -9.5 50 15 122

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

Cat TDTO
Front Propel Planetary Drives -10 50 50 122
SAE 50
Rotor Chain Drive Case and Rotor Bearing Cat TDTO
0 35 32 122
Reservoir SAE 30
Cat TDTO
Rotor Transmission -10 50 50 122
SAE 50
Rotor Differential SAE 80W-90 -20 40 -4 104
(1) The machine is delivered from the factory with the designated fluids.

i02615184 i04311449

Capacities (Refill) S·O·S Information

SMCS Code: 1000; 7000; 7560
Table 24
Approximate Refill Capacities
Compartment or
Liters
System
Fuel tank (usable)
Cooling system
Engine oil with a filter
Propel planetary
gear reducer (each)
SMCS Code: 1000; 1348; 3080; 4070; 4300; 5050;
7000; 7542
S·O·S Services is a highly recommended process for
Cat customers to use in order to minimize owning
and operating cost. Customers provide oil samples,
US Gallons
coolant samples, and other machine information. The
dealer uses the data in order to provide the customer
1056 (279) with recommendations for management of the
(16.5)
equipment. In addition, S·O·S Services can help
62.5
determine the cause of an existing product problem.
32 (8.5)
Refer to Special Publication, SEBU6250, “Caterpillar
(1.3)
Machine Fluid Recommendations” for detailed
5 information concerning S·O·S Services.

Hydraulic tank 233 (61.5) Refer to the Operation and Maintenance Manual,
“Maintenance Interval Schedule” for a specific
Rotor drive axle 17 (4.5)
sampling location and a service hour maintenance
Rotor axle hub interval.
3.8 (1)
(each)
Consult your Cat dealer for complete information
Rotor bearing and assistance in establishing an S·O·S program for
2 (0.5)
reservoir your equipment.
Chain case (each) 25.6 (6.8)

Rotor transmission 12.3 (3.25)

Refrigerant Ait
1.7 kg (3.8 lbs)
Conditioning
KEBU7565 145
Maintenance Support
Welding on Machines and Engines with Electronic Controls

Maintenance Support
i01821998

Welding on Machines and

Engines with Electronic
Controls
SMCS Code: 1000; 7000
Proper welding procedures are necessary in order to
avoid damage to the electronic controls and to the
bearings. The following steps should be followed in
order to weld on a machine or an engine with
electronic controls.
1. Turn off the engine.

2. Turn the battery disconnect switch to the OFF

position. If there is no battery disconnect switch,
remove the negative battery cable at the battery.

3. Clamp the ground cable from the welder to the

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

• Bearings of the drive train

• Hydraulic components

• Electrical components

• Other components of the machine

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

4. Protect any wiring harnesses from the debris which

is created from welding. Protect any wiring
harnesses from the splatter which is created from
welding.

5. Use standard welding procedures in order to weld

the materials together.
146
Maintenance Support
Maintenance Interval Schedule
i05654511
Maintenance Interval Schedule
SMCS Code: 1000; 7000
Ensure that all safety information, warnings, and
instructions are read and understood before any
operation or any maintenance procedures are
performed.
The user is responsible for the performance of
maintenance. All adjustments, the use of proper
lubricants, fluids, filters, and the replacement of
components due to normal wear and aging are
included. Failure to adhere to proper maintenance
intervals and procedures may result in diminished
performance of the product and/or accelerated wear
of components.
Use mileage, fuel consumption, service hours, or
calendar time, WHICH EVER OCCURS FIRST, in
order to determine the maintenance intervals.
Products that operate in severe operating conditions
may require more frequent maintenance. Refer to the
maintenance procedure for any other exceptions that
may change the maintenance intervals.
Note: Before each consecutive interval is performed,
all maintenance from the previous interval must be
performed.
Note: If Cat HYDO Advanced hydraulic oils are
used, the hydraulic oil change interval may be
extended substantially. S·O·S services may extend
the oil change even longer. Consult your Cat dealer
for details.
When Required
“Battery - Clean” ................................................... 151
“Battery - Recycle” ................................................ 151
“Battery or Battery Cable - Inspect/Replace”........ 151
“Camera - Clean/Adjust”....................................... 154
“Circuit Breakers - Reset” ..................................... 155
“Emulsion Spray Nozzles - Clean” ....................... 165
“Emulsion Spray System Strainer - Clean”........... 169
“Engine Air Filter Primary Element - Clean/
Replace” ............................................................... 169
“Engine Air Filter Secondary Element - Replace”. 172
“Engine Air Filter Service Indicator - Inspect”....... 173
“Engine Air Precleaner - Clean”............................ 174
“Fuel System - Prime”........................................... 181
“Oil Filter - Inspect” ............................................... 194
KEBU7565
“Radiator and Hydraulic Oil Cooler - Clean”......... 196
“Refrigerant Dryer - Replace” ............................... 201
“Rotor Cutter Bits (Side) - Inspect/Replace”......... 204
“Rotor Cutter Bits - Inspect/Replace”.................... 205
“Tool Holder - Inspect/Replace” ............................ 215
“Water Spray System Nozzles - Clean”................ 219
“Water Spray System Strainer - Clean” ................ 220
Initial 20 Service Hours
“Tool Holder - Inspect/Replace” ............................ 215
Every 10 Service Hours or Daily
“Backup Alarm - Test” ........................................... 150
“Bolster Oscillation Pin (Rear) - Lubricate”........... 152
“Cooling System Coolant Level - Check” ............. 162
“Emulsion Spray System - Clean” ........................165
“Engine Crankcase Breather Tube - Inspect/
Clean” ................................................................... 175
“Engine Oil Level - Check”.................................... 175
“Hydraulic System Oil Level - Check ”.................. 189
“Indicators and Gauges - Test” ............................. 190
“Rotor Bearing Reservoir Oil Level - Check” ........ 203
“Rotor Drive Differential Oil Level - Check” .......... 207
“Rotor Transmission Oil - Check” ..........................211
“Seat Belt - Inspect” .............................................. 212
“Tire Inflation - Check” .......................................... 215
Initial 50 Service Hours
“Rotor Clutch - Test/Adjust” .................................. 204
Every 50 Service Hours
“Mixing Chamber Disc Hub - Lubricate” ............... 191
Every 50 Service Hours or Weekly
“Automatic Lubrication System Grease - Add” ..... 148
“Drive Shaft Support Bearing - Lubricate” ............ 164
“Emulsion Pump - Lubricate” ................................ 165
“Fuel Tank Water and Sediment - Drain” .............. 187
“Mixing Chamber Door Cylinder Ends (Front) -
Lubricate”.............................................................. 191
KEBU7565
“Mixing Chamber Door Cylinder Ends (Rear) -
Lubricate”.............................................................. 192
“Mixing Chamber Door Hinges (Front) - Lubricate”192
“Mixing Chamber Door Hinges (Rear) - Lubricate”192
“Mixing Chamber Linkage - Lubricate” ................. 193
“Mixing Chamber Tilt Cylinder Ends - Lubricate”.. 194
“Propel Planetary Oil - Check”.............................. 195
“Rotor Clutch - Lubricate” ..................................... 204
“Rotor Drive Bearings - Lubricate”........................ 206
“Rotor Lift Cylinder Ends - Lubricate” ................... 209
“Rotor Shear Disc - Lubricate”.............................. 209
“Rotor Torque Limiter Coupling - Inspect”............. 209
“Steering Cylinder Ends - Lubricate” .................... 213
“Steering Knuckle - Lubricate”.............................. 214
“Steering Legs (Rear) - Lubricate”........................ 214
“Steering Linkage - Lubricate” .............................. 215
“Water Spray System Pump Oil Level - Check” ... 220
Every 100 Service Hours
“Rotor Clutch - Test/Adjust” .................................. 204
Initial 250 Service Hours
“Auxiliary Hydraulic System Filter - Replace” ....... 148
“Emulsion Spray System Charge Filter - Replace”167
“Engine Valve Lash - Check” ................................ 178
“Engine Valve Rotators - Inspect”......................... 178
“Front Propel Pump Charge Filter - Replace”....... 180
“Hydraulic System Return Filter - Replace”.......... 189
“Rear Propel Pump Charge Filter - Replace” ....... 199
“Water Spray System Charge Filter - Replace” .... 218
Every 250 Service Hours or 3
Months
“Belts - Inspect/Adjust/Replace” ........................... 152
“Cab Air Filter - Clean/Replace” ........................... 153
“Engine Oil Sample - Obtain”................................ 176
“Engine Oil and Filter - Change”........................... 176
“Hydraulic System Oil Sample - Obtain”............... 189
147
Maintenance Support
Maintenance Interval Schedule
“Parking Brake - Check” .......................................194
“Propel Planetary Oil - Change” ........................... 195
“Propel Planetary Oil Sample - Obtain” ................ 196
“Rotor Drive Differential Oil - Change”.................. 207
“Rotor Drive Differential Oil Sample - Obtain” ...... 207
“Rotor Drive Shaft Universal Joints - Lubricate” ... 208
“Rotor Shear Disc Bolts - Inspect/Replace”.......... 209
“Rotor Transmission Oil - Change”....................... 210
“Rotor Transmission Oil Sample - Obtain”.............211
“Water Spray System Pump Oil - Change”........... 219
Initial 500 Hours (for New Systems,
Refilled Systems, and Converted
Systems)
“Cooling System Coolant Sample (Level 2) -
Obtain” .................................................................. 158
Every 500 Service Hours or 6
Months
“Cooling System Coolant Sample (Level 1) -
Obtain” .................................................................. 157
“Fuel System Primary Filter - Clean/Inspect/
Replace” ............................................................... 183
“Fuel System Secondary Filter - Replace” ........... 184
“Fuel Tank Cap Filter and Strainer - Replace/
Clean” ................................................................... 186
“Rotor Bearing Reservoir Breather - Replace” ..... 202
“Rotor Bearing Reservoir Oil - Change” ............... 202
“Rotor Bearing Reservoir Oil Sample - Obtain” .... 203
“Rotor Chain Drive Case Oil - Change” ................ 203
“Rotor Drive Differential Breather - Replace”........ 207
“Rotor Drive Differential Sump Screen - Replace” 208
“Rotor Transmission Breather - Replace”............. 210
“Rotor Transmission Sump Screen - Replace”......211
Every 1000 Service Hours or 1 Year
“Auxiliary Hydraulic System Filter - Replace” ....... 148
“Braking System - Test” ........................................ 153
“Cooling System Pressure Cap - Clean/Replace” 163
“Emulsion Spray System Charge Filter - Replace”167
148 KEBU7565
Maintenance Support
Automatic Lubrication System Grease - Add

“Engine Crankcase Breather - Clean” .................. 174 SMCS Code: 7540-538; 7540
“Front Propel Pump Charge Filter - Replace”....... 180
“Hydraulic System Oil - Change” .......................... 188
“Hydraulic System Return Filter - Replace”.......... 189
“Hydraulic Tank Breather - Replace” .................... 190
“Hydraulic Tank Screen - Clean”........................... 190
“Rear Propel Pump Charge Filter - Replace” ....... 199
“Rollover Protective Structure (ROPS) - Inspect”. 202
“Water Spray System Charge Filter - Replace” .... 218

Every 2000 Service Hours or 1 Year

Illustration 166 g01237048
“Engine Mounts - Inspect” .................................... 175
Fill the grease reservoir that is located on the water
“Engine Valve Lash - Check” ................................ 178 spray system pump.
“Engine Valve Rotators - Inspect”......................... 178
i02347571

Every Year
“Cooling System Coolant Sample (Level 2) -
Obtain” .................................................................. 158
Every 3000 Service Hours or 2
Years
“Cooling System Water Temperature Regulator -
Replace” ............................................................... 163
“Engine Water Pump - Inspect” ............................ 179
Every 3 Years
“Seat Belt - Replace” ............................................ 212
Auxiliary Hydraulic System
Filter - Replace
SMCS Code: 5068-510
Note: Cleanliness must be a priority when you
drain the hydraulic oil and when you fill the
hydraulic oil. Cleanliness must be a priority when
you change the filters. Drain the oil and fill the oil
in a clean work area. Use clean tools. Make sure
that you have clean hands. Clean the outside of
the hydraulic tank before you start to operate the
machine.
Drain the hydraulic tank before you change the filter.

Every 6000 Service Hours or 3

Years
“Cooling System Coolant Extender (ELC) - Add” . 161

Every 12 000 Service Hours or 6

Years
“Cooling System Coolant (ELC) - Change” .......... 159

i02477236

Automatic Lubrication System

Grease - Add
Illustration 167 g01163215
(Water Spray System Pump)
1. See the hydraulic tank drain valve beneath the
access steps on the right side of the machine.
KEBU7565 149
Maintenance Support
Auxiliary Hydraulic System Filter - Replace

Illustration 168 g01163193

Top view of the hydraulic tank drain valve

2. Connect a temporary drain hose to the drain valve.

Place the other end of the drain hose in a suitable
container.
Illustration 170 g01156020
The hydraulic filters are located behind the access
ladder on the right side of the machine.

Illustration 169 g01163184

3. Clean the area around the filler cap.

4. Loosen the filler cap in order to equalize the

pressure in the hydraulic tank.

5. Open the drain valve. Drain the oil to a suitable

container. Allow the oil to drain until the hydraulic
tank is empty.
Illustration 171 g01162824
6. Close the drain valve. The auxiliary hydraulic system filter
7. Remove the temporary drain hose from the drain
9. Place a suitable container under the filter.
valve.
10. Remove the filter from the filter base.
8. Remove the container.
11. Clean the filter base.
12. Install the new filter.
13. Open the filler cap.
150 KEBU7565
Maintenance Support
Backup Alarm - Test

14. Fill the hydraulic tank with clean, approved

hydraulic oil.

15. Close the filler cap.

16. Start the machine.

17. Allow the engine to run for several minutes.

18. Check for leaks.

19. Stop the machine.

20. Repair any leaks.

21. Remove the container. Dispose of all fluids

according to local regulations. Dispose of the old
filter according to local regulations. Proper care is
your responsibility.
22. Continue to check for leaks after you place the
machine in operation.
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information that
pertains to containing fluid spillage.
Illustration 173 g01153034
3. Slowly move propel lever (2) toward the REVERSE
position. Do not move the propel lever to the FULL
REVERSE. Do not move the machine.
The back up alarm should sound. The back up alarm
will sound until the propel lever is moved to the
CENTER position or until the propel lever is moved to
the FORWARD position.

Note: The CENTER position is the neutral position.

i03727988

Backup Alarm - Test

SMCS Code: 7406-081

1. Start the engine.

Illustration 174 g01153130

The backup alarm is located on the rear bolster
behind the fuel tank drain at the pivot point of the
bolster.

Illustration 172 g02010595

2. Engage parking brake (1).

KEBU7565 151
Maintenance Support
Battery - Clean

i02360573 2. Remove the battery box cover.

Battery - Clean 3. Remove the battery terminal covers (1).

SMCS Code: 1401-070 4. Clean the battery terminals. Coat the battery
terminals with petroleum jelly.

5. Replace the battery terminal covers.

Batteries give off flammable fumes which can
explode. 6. Tighten the battery retainers (2).

To avoid injury or death, do not strike a match, 7. Clean the top of the batteries (3) with a clean cloth.
cause a spark, or smoke in the vicinity of a
battery. 8. Replace the battery box cover.

i00993589
Note: Maintenance free batteries are included with a
new machine. You do not need to check the
electrolyte level in the maintenance free batteries. Battery - Recycle
SMCS Code: 1401-561
The battery box is located behind the operator access
ladder on the right side of the machine. Always recycle a battery. Never discard a battery.
Always return used batteries to one of the following
locations:

• A battery supplier
• An authorized battery collection facility

• Recycling facility

i03728041

Battery or Battery Cable -

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

Illustration 175 g01153189

1. Disconnect the battery. Refer to this Operation and

Maintenance Manual, “Battery Disconnect Switch”
topic, for the proper procedure.

Note: There is limited clearance between the battery

box and the battery terminals. Use care when you Illustration 176 g01153243
disconnect the battery terminals. Do not allow the
battery terminals or the battery posts to come in 1. Turn the engine start switch (1) to the OFF position.
contact with the battery box. Do not allow the battery Remove the key.
terminals or the battery posts to come in contact with
the battery box cover.
152
Maintenance Support
Belts - Inspect/Adjust/Replace
Illustration 177 g02010616
Note: Do not disengage the parking brake.
2. Turn all of the switches on the operators console
(2) and (3) to the OFF position.
3. Turn all of the switches on the operators side
console (4) to the OFF position.
4. Turn the key for the battery disconnect switch to
the OFF position. Remove the key.
5. Disconnect the negative battery cable at the
battery disconnect switch. The negative battery
cable is connected to the frame of the machine.
Note: Do not allow the battery cable that is
disconnected to touch the disconnect switch.
6. Disconnect the negative battery cable at the
battery.
7. Make any repairs that are required. Replace the
battery.
8. Connect the negative battery cable to the battery.
KEBU7565
9. Connect the battery to the battery disconnect
switch.
10. Install the key. Turn the battery disconnect switch
to the ON position.
i02422916
Belts - Inspect/Adjust/Replace
SMCS Code: 1357-025; 1357-040; 1357-510
Inspect Belts
You should inspect the belts in your engine in order to
get the maximum performance out of your engine.
The belts should be inspected for wear and for
cracks. Check the belt tension. If the belts are loose,
the belts will slip. Belts that slip will cause poor
performance of the alternator.
1. Turn off the engine.
2. Turn the battery disconnect switch to the OFF
position.
3. Inspect the belts.
4. Inspect the tension of the alternator belt.
To check the belt tension, apply 110 N (25 lb) of force
to the belt. The force must be applied midway
between the pulleys. If the belts are properly
adjusted, the belts will deflect 10 to 15 mm
(.4 to .6 inch).
Check the adjustment on new belts after the new
belts have operated for 30 minutes. For multiple belt
drive applications, replace the belts in matched sets.
If only one belt of a matched set is replaced, the new
belt will carry more load than the old belts. The old
belts will be stretched. The additional load on the new
belt could cause the new belt to break.
i02330861
Bolster Oscillation Pin (Rear) -
Lubricate
SMCS Code: 7051-086; 7223-086
Lubricate two fittings.
KEBU7565 153
Maintenance Support
Braking System - Test

1. Start the engine.

2. Move the propel travel control to the TRAVEL

MODE position.

3. Release the parking brake.

4. Propel the machine forward at full travel speed.

5. While the machine is moving, move the propel

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

6. Check the parking brake. See this Operation and

Maintenance Manual, “Parking Brake - Check”
Illustration 178 g01163472 topic, for the proper procedure.

1. Lubricate the front fitting (1). i03342202

Cab Air Filter - Clean/Replace

SMCS Code: 7342-070; 7342-510

Note: Clean the cab air filters more often if the

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

Internal Cab Filter

Illustration 179 g01163495

2. Lubricate the rear fitting (2).

i02362246

Braking System - Test

SMCS Code: 4250-081; 4267-081
Check the area around the machine. Make sure that
the machine is clear of personnel and clear of
obstacles.
Test the brakes on a dry, level surface.
Fasten the seat belt before you test the brakes.
Note: The following test is used to determine if the Illustration 180 g01681653
braking function of the propel system is effective. The internal cab filter (1) is positioned beneath the
operator's seat at the front of the seat platform.
154 KEBU7565
Maintenance Support
Camera - Clean/Adjust

Clean the Filter 5. Replace the cover for the external cab filter and
secure the cover with two screws.
1. Slide the cover for internal cab filter (1) toward the
right side of the machine. Replace the Filter
2. Remove the filter. Note: Replace the external cab filter, as required.
3. Clean the filter with pressure air. 1. Remove the two screws from the cover for the
external cab filter (2) and then remove the cover.
4. Install the filter.
5. Slide the cover for the internal cab filter to the left in 2. Remove the filter.
order to cover the new filter. 3. Discard the filter.

Replace the Filter 4. Install the new filter.

5. Replace the cover for the external cab filter and
Note: Replace the internal cab filter, as required.
secure the cover with two screws.
1. Slide the cover for internal cab filter (1) toward the
right side of the machine. i03714913

2. Remove the filter. Camera - Clean/Adjust

3. Discard the filter. (WAVS (If Equipped))
4. Install the new filter. SMCS Code: 7348

5. Slide the cover for the internal cab filter to the left in In order to maintain sufficient vision, keep the Work
Area Vision System (WAVS) camera lens and the
order to cover the new filter. display clean.
External Cab Filter

Illustration 182 g01223034

The WAVS display is located in the operator station.
Illustration 181 g01680558
The external cab filter (2) is located on the rear of the Use a soft, damp cloth in order to clean the display.
cab. This filters the fresh air that enters the cab. The display has a soft plastic surface that can be
easily damaged by an abrasive material. The display
is not sealed. Do not immerse the display with
Clean the Filter liquid.

1. Remove the two screws from the cover for the

external cab filter (2) and remove the cover.

2. Remove the filter.

3. Clean the filter with pressure air.

4. Install the filter.

KEBU7565 155
Maintenance Support
Circuit Breakers - Reset

Illustration 183 g01223051 Illustration 185 g01163420

A WAVS camera is located on the rear of the
machine.
Use a damp cloth or water spray in order to clean the
camera lens. The camera is a sealed unit. The
camera is not affected by high pressure spray.
Note: The camera is equipped with an internal heater
to help counteract the effects of condensation, snow,
or ice.
For more information on WAVS, refer to Operation
and Maintenance Manual, SEBU8157, “Work Area
Vision System”.
i03728280
1. Remove the padlock. Open the circuit breaker box
cover.
2. Push in the reset button. This will reset the circuit
breaker. If the system is operating properly, the
button will stay depressed. If the button does not
stay depressed, you must check the electrical
circuits.
Note: Some circuit breakers are self-resetting.
Note: The amperage for the circuit is printed on
the circuit breaker button.

Circuit Breakers - Reset

SMCS Code: 1420-529

Note: Your machine may not be equipped with all of

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

Illustration 184 g01161613

The circuit breaker box is located behind the access
ladder on the left side of the machine.
156 KEBU7565
Maintenance Support
Circuit Breakers - Reset

Illustration 186 g01163424

(1) Rotor service switch (14) Rear door, front door, rear steer valves and cab
pressure fan control
(2) Optional
(15) Operator console controls
(3) Optional
(16) Machine control
(4) Optional
(17) Cab main breaker
(5) Roading lights
(18) Alternator circuit breaker
(6) Horn
(19) Main breaker
(7) Unswitched control power
(20) Secondary engine shutdown switch
(8) Engine control
(9) Engine ignition
(10) Work lights and flood lights
(11) Additive spray system
(12) Beacon light and rear service light
(13) 4 wheel steer and fan control
KEBU7565 157
Maintenance Support
Cooling System Coolant Sample (Level 1) - Obtain

i02331181
NOTICE
Care must be taken to ensure that fluids are con-
Cooling System Coolant tained during performance of inspection, mainte-
Sample (Level 1) - Obtain nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
SMCS Code: 1395-008 before opening any compartment or disassembling
any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
At operating temperature, the engine coolant is Tools and Shop Products Guide” for tools and sup-
hot and under pressure. plies suitable to collect and contain fluids on Caterpil-
lar products.
Steam can cause personal injury.
Dispose of all fluids according to local regulations and
Check the coolant level only after the engine has mandates.
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: 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.
Illustration 187 g01163965
Note: Obtain a Coolant Sample (Level 1) if the
Coolant sample port
cooling system is filled with any other coolant
instead of Cat ELC .This includes the following Obtain the sample of the coolant as close as possible
types of coolants. to the recommended sampling interval. In order to
receive the full effect of S·O·S analysis, you must
• Commercial long life coolants that meet the establish a consistent trend of data. In order to
Caterpillar Engine Coolant Specification -1 establish a pertinent history of data, perform
(Caterpillar EC-1) consistent samplings that are evenly spaced.
Supplies for collecting samples can be obtained from
• Cat Diesel Engine Antifreeze/Coolant (DEAC) your Caterpillar dealer.
• Commercial heavy-duty coolant/antifreeze Use the following guidelines for proper sampling of
the coolant:
Note: Level 1 results may indicate a need for
Level 2 Analysis.
158 KEBU7565
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
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.
i02331811
Cooling System Coolant
Sample (Level 2) - Obtain
SMCS Code: 1395-008; 1395-554
Illustration 188 g01163965
Coolant sample port
1. Obtain the sample of the coolant as close as
possible to the recommended sampling interval.
Supplies for collecting samples can be obtained
from your Caterpillar dealer.
Reference: Refer to Operation and Maintenance
Manual, “Cooling System Coolant Sample (Level 1) -
Obtain” for the guidelines for proper sampling of the
coolant.
2. Submit the sample for Level 2 analysis.
Reference: For additional information about coolant
analysis, refer to Special Publication, SEBU6250,
“Caterpillar Machine Fluids Recommendations” or
consult your Caterpillar dealer.

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.
KEBU7565 159
Maintenance Support
Cooling System Coolant (ELC) - Change

i02330978

Cooling System Coolant (ELC)

- Change
SMCS Code: 1395-044-NL

Personal injury can result from hot coolant, steam

and alkali.
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines to
heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove cooling system pressure cap slowly to
relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
touch with your bare hand.
Do not attempt to tighten hose connections when
Illustration 189 g01163533
the coolant is hot, the hose can come off causing
burns.
2. Open the access panel on the top of the hood (1).
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.

NOTICE
Mixing Extended Life Coolant (ELC) with other prod-
ucts reduces the effectiveness of the coolant and
shortens coolant life. Use only Caterpillar products
or commercial products that have passed the 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.

Drain the coolant whenever the coolant is dirty or

whenever foaming is observed.

1. Make sure that the engine has cooled. Illustration 190 g01163536

3. Turn the pressure cap (2) counterclockwise in

order to loosen the cap. Slowly loosen the
pressure cap in order to relieve the pressure.
Slowly remove the pressure cap.
160 KEBU7565
Maintenance Support
Cooling System Coolant (ELC) - Change

11. Drain the cleaning solution.

12. Close the drain valve (4).

13. Fill the system with clean water.

14. Start the engine. Operate the engine until the

engine reaches operating temperature.

15. Stop the engine.

16. Drain the system.

17. Close the drain valve (4).

18. Repeat steps 13 to 17 until the water that drains

from the system is clear. Make sure that all of the
cleaner is flushed from the system.

19. Add the coolant solution. See Special Publication,

SEBU6250, “Cooling System Specifications” for
specific information about coolant.
Illustration 191 g01163558
Note: Do not add the supplemental coolant additive
4. Loosen two bolts in order to open the coolant drain at this time unless you are using Caterpillar Coolant.
valve cover (3). Consult your Caterpillar dealer for specific
information.
20. Start the engine. Operate the engine. Make sure
that the pressure cap (2) is removed. The
thermostat must open and the coolant level must
stabilize.
21. Maintain the level of the coolant to the proper
mark on the sight glass (5).

22. Install the pressure cap (2).

23. Stop the engine.

24. Close the access panel (1).

Note: Refer to Operation and Maintenance Manual,
Illustration 192 g01163563 “General Hazard Information” for information that
pertains to containing fluid spillage.
5. Place a suitable container under the coolant drain
valve (4). Note: Dispose of drained fluids according to local
regulations. Proper care is your responsibility.
6. Open the drain valve (4) by turning the valve bolt
counterclockwise. Allow the coolant to drain into a
suitable container.
7. Close the drain valve (4) by turning the valve bolt
clockwise.
8. Fill the system with a mixture of clean water and a
6% to 10% concentration of cleaner.
9. Start the engine. Operate the engine for 90
minutes.
10. Stop the engine.
KEBU7565
i02331164
Cooling System Coolant
Extender (ELC) - Add
SMCS Code: 1352-544-NL
At operating temperature, the engine coolant is
hot and under pressure.
Steam can cause personal injury.
Check the coolant level only after the engine has
been stopped and the fill cap is cool enough to
touch with your bare hand.
Remove the fill cap slowly to relieve pressure.
Cooling system conditioner contains alkali. Avoid
contact with the skin and eyes to prevent person-
al injury.
NOTICE
Care must be taken to ensure that fluids are con-
tained during performance of inspection, mainte-
nance, testing, adjusting and repair of the product. Be
prepared to collect the fluid with suitable containers
before opening any compartment or disassembling
any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and sup-
plies suitable to collect and contain fluids on Caterpil-
lar products.
Dispose of all fluids according to local regulations and
mandates.
When a Caterpillar Extended Life Coolant (ELC) is
used, an Extender must be added to the cooling
system. See Special Publication, SEBU6250,
“Cooling System Specifications” for all cooling system
requirements.
Use a 8T-5296 Coolant Test Kit to check the
concentration of the coolant.
For additional information about the addition of
Extender, see the Special Publication, SEBU6250,
“Cooling System Specifications” or consult your
Caterpillar dealer.
161
Maintenance Support
Cooling System Coolant Extender (ELC) - Add
NOTICE
Topping off or mixing Cat ELC with other products
that do not meet Caterpillar EC-1 specifications re-
duces the effectiveness of the coolant and shortens
coolant service life.
Use only Caterpillar products or commercial 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 access panel on the top of the hood.
3. Slowly loosen the cooling system pressure cap in
order to relieve system pressure. Remove the
cooling system pressure cap.
4. If necessary, drain enough coolant from the system
in order to allow the addition of the Extender.
5. Add the recommended amount of extender to the
coolant system. Refer to the Special Publication,
SEBU6250, “Extended Life Coolant (ELC)” for the
proper amount.
6. Maintain the coolant level to 1 cm of the bottom of
the fill pipe.
7. Inspect the gasket on the cooling system pressure
cap. Replace the cooling system pressure cap if
the gasket is damaged.
8. Install the cooling system pressure cap.
9. Close the access panel.
For additional information on the addition of extender,
see Special Publication, SEBU6250, “Coolant
Recommendations” or consult your Caterpillar dealer.
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information that
pertains to containing fluid spillage.
Note: Dispose of drained fluids according to local
regulations.
162 KEBU7565
Maintenance Support
Cooling System Coolant Level - Check

i02331170

Cooling System Coolant Level

- Check
SMCS Code: 1350-535-FLV

At operating temperature, the engine coolant is

hot and under pressure.
Steam can cause personal injury.
Check the coolant level only after the engine has
been stopped and the fill cap is cool enough to
touch with your bare hand.
Remove the fill cap slowly to relieve pressure.
Cooling system conditioner contains alkali. Avoid
contact with the skin and eyes to prevent person-
al injury. Illustration 194 g01163602

2. Turn the pressure cap (2) counterclockwise in

order to loosen the cap. Slowly loosen the
pressure cap in order to relieve the pressure.
Slowly remove the pressure cap.

3. Maintain the level of the coolant to the proper mark

on the sight glass (3).

4. Inspect the system pressure cap and the system

pressure cap seal for damage. Clean the cap with
a clean cloth or replace the pressure cap.

5. Install the pressure cap (2).

6. Close the access panel (1).

Note: Refer to Operation and Maintenance Manual,

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

Note: Dispose of spilled fluids according to local

regulations. Proper care is your responsibility.
Illustration 193 g01163533

1. Open the access panel on the top of the hood (1).

KEBU7565
i02331172
Cooling System Pressure Cap -
Clean/Replace
SMCS Code: 1382-070; 1382-510
Personal injury can result from hot coolant, steam
and alkali.
At operating temperature, engine coolant is hot
and under pressure. The radiator and all lines to
heaters or the engine contain hot coolant or
steam. Any contact can cause severe burns.
Remove cooling system pressure cap slowly to
relieve pressure only when engine is stopped and
cooling system pressure cap is cool enough to
touch with your bare hand.
Do not attempt to tighten hose connections when
the coolant is hot, the hose can come off causing
burns.
Cooling System Coolant Additive contains alkali.
Avoid contact with skin and eyes.
1. Open the access panel on the top of the hood.
2. Remove the cooling system pressure cap slowly in
order to relieve pressure.
3. Inspect the cooling system pressure cap for foreign
material, for deposits, and for damage. Clean the
cooling system pressure cap with a clean cloth. If
the cooling system pressure cap is damaged,
replace the cooling system pressure cap.
4. Install the cooling system pressure cap.
5. Close the access panel.
163
Maintenance Support
Cooling System Pressure Cap - Clean/Replace
i02331886
Cooling System Water
Temperature Regulator -
Replace
SMCS Code: 1355-510; 1393-010
At operating temperature, the engine coolant is
hot and under pressure.
Steam can cause personal injury.
Check the coolant level only after the engine has
been stopped and the fill cap is cool enough to
touch with your bare hand.
Remove the fill cap slowly to relieve pressure.
Cooling system conditioner contains alkali. Avoid
contact with the skin and eyes to prevent person-
al injury.
Replace the water temperature regulator on a regular
basis in order to reduce the chance of unscheduled
downtime and of problems with the cooling system.
The water temperature regulator should be replaced
after the cooling system has been cleaned. Replace
the water temperature regulator while the cooling
system is completely drained. Replace the water
temperature regulator while the cooling system
coolant is drained to a level below the water
temperature regulator housing.
NOTICE
Failure to replace the engine's water temperature 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. Remove the cooling system pressure cap in order
to relieve the pressure in the cooling system.
164 KEBU7565
Maintenance Support
Drive Shaft Support Bearing - Lubricate

NOTICE
If the water temperature regulator is installed incor-
rectly, it will cause the engine to overheat.

4. Install a new water temperature regulator.

5. Reinstall the housing.

6. Add the cooling system coolant. Maintain the level

of the coolant to the proper line on the sight glass.

7. Inspect cooling system pressure cap and the

Illustration 195 g01163997
The water temperature regulator is located on the
inside of a housing that is on top of the engine block
toward the front of the machine.
gasket for damage. Replace the pressure cap if
the pressure cap or the gasket are damaged.
8. Install the cooling system pressure cap.
i02479727

2. Remove the water temperature regulator housing. Drive Shaft Support Bearing -
Lubricate
SMCS Code: 3267-086-BD

Illustration 196 g01163998

3. Remove the gasket and remove the water

temperature regulator. Illustration 197 g01238439

1. Move the operator station to the left side of the

NOTICE
machine and open the access cover.
The water temperature regulators may be reused if
the water temperature regulators are within test speci- 2. Locate the support bearing for the rotor drive shaft
fications, are not damaged, and do not have exces-
and apply three pumps of grease to the grease
sive buildup of deposits.
fitting.

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.
KEBU7565 165
Maintenance Support
Emulsion Pump - Lubricate

i02615792

Emulsion Pump - Lubricate

SMCS Code: 5616-086

Illustration 200 g00893853

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

spray bar.

Illustration 198 g01309731 3. Soak the nozzles (2) in clean diesel fuel or clean
solvent.
Identify one lubrication fitting (1) on each end of the
emulsion pump. Lubricate the two fittings. 4. Replace the nozzles (2) after the nozzles are
clean.
i04934653 5. Loosen bolts (1). Move the spray bar back into the
original position.
Emulsion Spray Nozzles -
Clean 6. Tighten bolts (1) to the proper torque value.

SMCS Code: 5615-070

i04926841

Emulsion Spray System -

Clean
SMCS Code: 5615-070

Clean the Emulsion Spray System

Clean the emulsion spray system after every use.

Note: The procedure to clean the emulsion spray

system requires the use of one barrel of clean asphalt
release agent.
The rotor and the hood must be lifted away from the
ground. The rotor and the hood must be clear of all
Illustration 199 g00893851 obstacles. All chains and locking devices must be
installed before you start the procedure.
1. Loosen bolt (1). There are two bolts on each end of
the spray bar. Raise the spray bar completely. Note: The following parts must be drained of all of the
emulsion: pump, spray bar, strainer and lines.
Tighten bolts (1).
166
Maintenance Support
Emulsion Spray System - Clean
Illustration 201 g03095636
1. Ensure that the proper connections are made
between the transfer truck and the emulsion pump
skid.
2. Turn the emulsion system switch (2) to the ON
position.
Note: The emulsion mode message (EMUL) will
scroll across the operator mode/fault code display.
Note: Press the escape key (3) at any time in order to
return the system to the previously displayed screen.
Note: After the emulsion mode message (EMUL) has
scrolled across the operator mode/fault code display,
the operator mode/fault code display will read EMUL
OFF.
3. Use the scroll up key (5) in order to select the
emulsion mode cleanout (CLNOUT)
4. Once CLNOUT has been selected, press enter key
(4) in order to accept this mode.
5. The spray pump will run in reverse at a rate of 50
gallons per minute. Operate the system for 30
seconds in order to purge the emulsion from the
emulsion spray system. The emulsion is pumped
back into the source.
KEBU7565
Illustration 202 g03095936
6. Close inlet valve (7).
7. Turn emulsion system switch (2) to the OFF
position.
8. Remove the cap and attach a hose to recirculate
connection (8).
9. Place the hose from the recirculate connection and
the suction hose from valve (7) into a barrel of
asphalt release agent.
10. Open valve (7).
11. Set recirculate valve (6) to the dump position. In
the dump position the flow going into the strainer is
blocked and the flow coming out of connection (8)
is open.
12. Turn emulsion system switch (2) to the ON
position. Spray system control switch (1) should be
in the OFF position.
13. Operate the system for 5 to 10 minutes with the
engine at idle. Observe the discharge hose
connected to port (8) for particles. If particles are
present continue to operate the system.
14. Turn emulsion system switch (2) to the OFF
position.
15. Turn valve (6) to the recirculate position.
16. Close valve (7).
KEBU7565 167
Maintenance Support
Emulsion Spray System Charge Filter - Replace

Note: In order to store the machine for extended i02616130

periods, do not drain the asphalt release agent from
the emulsion spray system. Leaving the asphalt Emulsion Spray System
relese agent will prevent the pump from corroding
inside and prevent any remaining emulsion from Charge Filter - Replace
hardening and damaging the internal pump SMCS Code: 5615-510-FI
components. Before the machine is returned to
service, the asphalt release agent should be drained Note: Cleanliness must be a priority when you
from the system. drain the hydraulic oil and when you fill the
hydraulic oil. Cleanliness must be a priority when
Note: When the emulsion pump is used to pump you change the filters. Drain the oil and fill the oil
water or corrosive liquid, precautions must be taken in a clean work area. Use clean tools. Make sure
in order to extend the wear rate of the pump vanes. that you have clean hands. Clean the outside of
The water or corrosive liquid must be drained the hydraulic tank before you start to operate the
completely from the pump, and the pump should be machine.
preserved with a rust inhibiting solution.
Note: A vacuum system may be used as an
Flush the Pump alternative method in order to drain the oil from the
system. Use a suitable container to prevent spilling
NOTICE the oil. Consult your Caterpillar dealer for the proper
If flushing fluid is to be left in the pump for an ex- procedure.
tended time, the fluid must be a lubricating, non-corro-
sive fluid. If a corrosive, non-lubricating fluid is used,
the fluid must be flushed from the pump immediately.
Leaving water or corrosive material in the pump can
damage the pump. In this case flush and preserve the
pump with a lubricating, non-corrosive fluid. Check
with your additive supplier for the proper solvent to
use.

NOTICE
After flushing the pump some residual fluid will remain
in the pump and piping. Not properly flushing the
pump can result in damage to the pump.

Use the following procedure in order to flush the Illustration 203 g01163215
pump:

1. Allow the pump to evacuate as much fluid as 1. See the hydraulic tank drain valve beneath the
possible. access steps on the right side of the machine.

2. Run cleaning fluid through the pump intake. The

cleaning fluid should be compatible with the pump
o-rings and vane material. Use a fluid that will
prevent solidification of the fluid being transferred
and facilitate flushing.

3. Operate the pump against a closed discharge for

15 seconds to allow the cleaning fluid to recirculate
through the internal relief valve.

Illustration 204 g01163193

Top view of the hydraulic tank drain valve
168 KEBU7565
Maintenance Support
Emulsion Spray System Charge Filter - Replace

2. Connect a temporary drain hose to the drain valve.

Place the other end of the drain hose in a suitable
container.

Illustration 205 g01163184

3. Clean the area around the filler cap.

Illustration 206 g01156020

4. Loosen the filler cap in order to equalize the The hydraulic filters are located behind the access
pressure in the hydraulic tank. ladder on the right side of the machine.

5. Open the drain valve. Drain the oil to a suitable

container. Allow the oil to drain until the hydraulic
tank is empty.

6. Close the drain valve.

7. Remove the temporary drain hose from the drain
valve.
8. Remove the container.

Illustration 207 g01178436

The emulsion spray system charge filter

9. Place a suitable container under the filter.

10. Remove the filter from the filter base.
11. Clean the filter base.
12. Install the new filter.
13. Open the filler cap.
KEBU7565 169
Maintenance Support
Emulsion Spray System Strainer - Clean

14. Fill the hydraulic tank with clean, approved 2. Remove the emulsion spray system's strainer and
hydraulic oil. rinse the strainer with water.

15. Close the filler cap.

NOTICE
16. Start the machine. Dispose of all fluids according to local regulations and
mandates.
17. Allow the engine to run for several minutes.

18. Check for leaks. 3. Remove the plug and drain any remaining fluid
from the strainer into a suitable container.
19. Stop the machine.
4. Reinstall the plug and the strainer.
20. Repair any leaks.
5. Tighten the eight bolts to a torque of 47 ± 9 N·m
21. Remove the container. Dispose of all fluids (35 ± 7 lb ft).
according to local regulations. Dispose of the old
filter according to local regulations. Proper care is i02320364
your responsibility.

22. Continue to check for leaks after you place the

Engine Air Filter Primary
machine in operation. Element - Clean/Replace
Note: Refer to Operation and Maintenance Manual, SMCS Code: 1054-070-PY; 1054-510-PY
“General Hazard Information” for information that
pertains to containing fluid spillage. Remove the Primary Element
i02605119 NOTICE
Service the air cleaner only with the engine stopped.
Emulsion Spray System Engine damage could result.

Strainer - Clean Service the air cleaner filter element when the
SMCS Code: 5615-070 yellow piston on the engine air filter service
indicator enters the red zone or the indicator
In order to clean the emulsion spray system's strainer, reads 63.5 cm (25 inch) of water. Refer to
complete the following steps. Operation and Maintenance Manual, “Engine Air
Filter Service Indicator - Inspect”.

Illustration 208 g01303989

1. Remove the eight bolts from the front of the

emulsion spray system.
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information that
pertains to containing fluid spillage.
170
Maintenance Support
Engine Air Filter Primary Element - Clean/Replace
Illustration 209 g01158384
1. Open the access door (1) for the engine
compartment. The door is located on the left side
of the machine.
Illustration 210 g01160157
2. Locate the air filter housing (2). The air filter
housing is located on the left side of the engine
compartment underneath the hood.
3. Open the air filter housing.
4. Remove the primary filter element.
KEBU7565
5. Reverse the steps in order to install the primary
filter element.
Cleaning Primary Air Filter
Elements
NOTICE
Caterpillar recommends certified air filter cleaning
services available at participating Caterpillar dealers.
The Caterpillar cleaning process uses proven proce-
dures to assure consistent quality and sufficient filter
life.
Observe the following guidelines if you attempt to
clean the filter element:
Do not tap or strike the filter element in order to re-
move dust.
Do not wash the filter element.
Use low pressure compressed air in order to remove
the dust from the filter element. Air pressure must not
exceed 207 kPa (30 psi). Direct the air flow up the
pleats and down the pleats from the inside of the filter
element. Take extreme care in order to avoid damage
to the pleats.
Do not use air filters with damaged pleats, gaskets, or
seals. Dirt entering the engine will cause damage to
engine components.
The primary air filter element can be used up to six
times if the element is properly cleaned and
inspected. When the primary air filter element is
cleaned, check for rips or tears in the filter material.
The primary air filter element should be replaced at
least one time per year. This replacement should be
performed regardless of the number of cleanings.
NOTICE
Do not clean the air filter elements by bumping or tap-
ping. This could damage the seals. Do not use ele-
ments with damaged pleats, gaskets, or seals.
Damaged elements will allow dirt to pass through. En-
gine damage could result.
Visually inspect the primary air filter elements before
cleaning. Inspect the air filter elements for damage to
the seal, the gaskets, and the outer cover. Discard
any damaged air filter elements.
There are two common methods that are used to
clean primary air filter elements:
• Pressurized air
• Vacuum cleaning
KEBU7565
Pressurized Air
Pressurized air can be used to clean primary air filter
elements that have not been cleaned more than two
times. Pressurized air will not remove deposits of
carbon and oil. Use filtered, dry air with a maximum
pressure of 207 kPa (30 psi).
Illustration 211 g00281692
Note: When the primary air filter elements are
cleaned, always begin with the clean side (inside) in
order to force dirt particles toward the dirty side
(outside).
Aim the hose so that the air flows inside the element
along the length of the filter in order to help prevent
damage to the paper pleats. Do not aim the stream of
air directly at the primary air filter element. Dirt could
be forced further into the pleats.
Vacuum Cleaning
Vacuum cleaning is another method for cleaning
primary air filter elements which require daily cleaning
because of a dry, dusty environment. Cleaning with
pressurized air is recommended prior to vacuum
cleaning. Vacuum cleaning will not remove deposits
of carbon and oil.
171
Maintenance Support
Engine Air Filter Primary Element - Clean/Replace
Inspecting the Primary Air Filter
Elements
Illustration 212 g00281693
Inspect the clean, dry primary air filter element. Use a
60 watt blue light in a dark room or in a similar facility.
Place the blue light in the primary air filter element.
Rotate the primary air filter element. Inspect the
primary air filter element for tears and/or holes.
Inspect the primary air filter element for light that may
show through the filter material. If it is necessary in
order to confirm the result, compare the primary air
filter element to a new primary air filter element that
has the same part number.
Do not use a primary air filter element that has any
tears and/or holes in the filter material. Do not use a
primary air filter element with damaged pleats,
gaskets or seals. Discard damaged primary air filter
elements.
Storing Primary Air Filter Elements
If a primary air filter element that passes inspection
will not be used, the primary air filter element can be
stored for future use.
172 KEBU7565
Maintenance Support
Engine Air Filter Secondary Element - Replace

Illustration 213 g00281694

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

protective covering for storage. An airflow restriction
may result. To protect against dirt and damage, wrap
the primary air filter elements in Volatile Corrosion
Inhibited (VCI) paper.
Illustration 214 g01158384
Place the primary air filter element into a box for
storage. For identification, mark the outside of the box
and mark the primary air filter element. Include the 1. Open the access door (1) for the engine
following information: compartment. The door is located on the left side
of the machine.
• Date of cleaning
• Number of cleanings
Store the box in a dry location.

i02320455

Engine Air Filter Secondary

Element - Replace
SMCS Code: 1054-510-SE

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

NOTICE
Always replace the secondary filter element. Never
attempt to reuse it by cleaning.
The secondary filter element should be replaced at Illustration 215 g01160157
the time the primary element is serviced for the third
time.
2. Locate the air filter housing (2). The air filter
The secondary filter element should also be replaced housing is located on the left side of the engine
if the yellow piston in the filter element indicator enters compartment underneath the hood.
the red zone after installation of a clean primary ele-
ment, or if the exhaust smoke is still black. 3. Remove the cover. Remove the primary element.

4. Remove the secondary element.

KEBU7565 173
Maintenance Support
Engine Air Filter Service Indicator - Inspect

5. Cover the opening for the air inlet. Clean the inside
of the housing for the air cleaner.

6. Remove any dust in the filter outlet. Remove any

debris from the filter outlet.
7. Uncover the opening for the air inlet. Install a new
secondary element.

8. Install the primary element. Install the cover for the

primary element.

9. Close the access door.

i02320459
Illustration 217 g01160187
Engine Air Filter Service
2. Locate the air filter service indicator (2). The air
Indicator - Inspect filter service indicator is located on the left side of
SMCS Code: 7452-040 the engine compartment underneath the hood.

NOTICE 3. Start the engine. Ensure that the engine is running

Service the air cleaner only with the engine stopped. at high idle.
Engine damage could result.

Illustration 218 g01151416

Illustration 216 g01158384 4. Observe the yellow piston that is inside the
indicator. Service the air cleaner when the yellow
1. Open the access door (1) for the engine piston moves to the red zone.
compartment. The door is located on the left side
of the machine. 5. Stop the engine.

6. Close the access door.

174 KEBU7565
Maintenance Support
Engine Air Precleaner - Clean

i02369418 i03343344

Engine Air Precleaner - Clean Engine Crankcase Breather -

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

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

Illustration 220 g01718814

(1) Hose
(2) Hose clamp
(3) Crankcase breather
(4) Mounting bolt

1. Loosen the hose clamp (2). Remove the hose (1)

Illustration 219 g01162827
1. Check the air inlet screen for trash. Check the air
inlet screen for dirt.
2. Remove the screen if the screen is dirty. Clean the
screen with air pressure. Install the screen.
from the crankcase breather (3).
2. Remove the four mounting bolts (4) and remove
the crankcase breather from the engine.
3. Wash the breather element in clean nonflammable
solvent. Dry the breather with pressure air.
4. Replace the gasket for the crankcase breather if
the gasket is damaged. .

5. Install the crankcase breather. Secure the

crankcase breather with the four mounting bolts.

6. Install the breather hose and tighten the clamp.

KEBU7565 175
Maintenance Support
Engine Crankcase Breather Tube - Inspect/Clean

i03715480 Engine vibration can be caused by improper

mounting of the engine. Engine vibration can be
Engine Crankcase Breather caused by loose engine mounts or deteriorated
engine mounts.
Tube - Inspect/Clean
Inspect the engine mounts for deterioration.
SMCS Code: 1317-571-TU
Replace any engine mount that is deteriorated.
Inspect the engine mounts for correct bolt torque.
Tighten the mounts if the mounts are loose.
See your Caterpillar dealer for further information and
instructions for your machine.

i02328341

Engine Oil Level - Check

SMCS Code: 1348-535-FLV

NOTICE
Do not overfill the crankcase. Engine damage can
result.

Illustration 221 g02001998

The engine crankcase breather tube is located
underneath the front of the machine.

Inspect the engine crankcase breather tube for dirt

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

i01687969

Engine Mounts - Inspect

SMCS Code: 1152-040 Illustration 223 g01162828

1. When the engine is stopped, maintain the oil level

between the “L” and the “F” on the side of
dipstick (1) that reads “ENGINE STOPPED” .

2. When the engine is running, maintain the oil level

between the “L” and the “F” on the side of
dipstick (1) that reads “LOW IDLE” .

3. Remove oil filler cap (2). Add oil if it is necessary.

4. Clean filler cap (2). Install filler cap (2).

Illustration 222 g00869811

There are four engine mounts that need to be

checked.
176 KEBU7565
Maintenance Support
Engine Oil Sample - Obtain

i01881039

Engine Oil Sample - Obtain Hot oil and hot components can cause personal
SMCS Code: 1000-008 injury. Do not allow hot oil or hot components to
contact skin.

Note: API CH-4, API CI-4, and API CI-4 PLUS oils
Hot oil and hot components can cause personal are acceptable in the C11 Acert Diesel Engine if
injury. Do not allow hot oil or hot components to the requirements of Caterpillar's ECF-1 (Engine
contact the skin. Crankcase Fluid specification - 1) are met. Do not
allow the oil change interval to exceed 250 hours.
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 well mixed. The sample should be
taken at this time in order to ensure that the sample is
representative of the oil in the crankcase. Refer to
Special Publication, SEBU6250, “S·O·S Oil Analysis”
for information that pertains to obtaining a sample of
the engine oil. Refer to Special Publication,
PEHP6001, “How To Take A Good Oil Sample” for
more information about obtaining a sample of the
engine oil.

Obtain the S·O·S Sample

Obtain the engine oil sample when the oil is changed.
Obtain the engine oil sample at the regular Illustration 224 g01160666
maintenance interval. Location of the crankcase drain valve cover

i02369423 The crankcase drain valve is located behind an

access cover underneath the front of the machine.
Engine Oil and Filter - Change 1. Park the machine on a level surface and engage
SMCS Code: 1318-510 the parking brake. Stop the engine.

NOTICE Note: Drain the crankcase while the oil is warm. This
Care must be taken to ensure that fluids are con- allows waste particles that are suspended in the oil to
tained during performance of inspection, mainte- drain. As the oil cools, the waste particles will settle to
nance, testing, adjusting and repair of the product. Be the bottom of the crankcase. The particles will not be
prepared to collect the fluid with suitable containers removed by draining the oil and the particles will
before opening any compartment or disassembling recirculate in the engine lubrication system with the
any component containing fluids. new oil.
Refer to Special Publication, NENG2500, “Caterpillar
Dealer Service Tool Catalog” for tools and supplies
suitable to collect and contain fluids on Caterpillar
products.
Dispose of all fluids according to local regulations and
mandates.
KEBU7565
Illustration 225
2. Remove the crankcase drain valve cover (1).
Illustration 226
The location of the crankcase drain valve (2)
3. Place a suitable container underneath the
crankcase drain valve (2).
4. Turn the handle on the valve counterclockwise in
order to open the valve. Allow the oil to drain into
the container.
5. Once the oil has drained, close the valve.
177
Maintenance Support
Engine Oil and Filter - Change
g01160520 Illustration 227 g01160705
The location of the engine oil filter (3) on the right side
of the machine
6. Remove the engine oil filter (3) with a strap type
wrench. See Operation and Maintenance Manual,
“Oil Filter - Inspect”. Discard the used oil filter
properly.
7. Clean the filter mounting base with a clean towel.
Make sure that all of the old filter seal has been
removed.
8. Apply a thin film of clean engine oil to the seal of
the new engine oil filter.
9. Install the new engine oil filter hand tight until the
seal of the engine oil filter contacts the filter
mounting base. Note the position of the index
g01160540
marks on the filter in relation to a fixed point on the
filter mounting base.
Note: There are rotation index marks on the engine
oil filter that are spaced 90 degrees or 1/4 of a turn
away from each other. When you tighten the engine
oil filter, use the rotation index marks as a guide.
10. Tighten the oil filter according to the instructions
that are printed on the filter. Use the index marks
as a guide for tightening the oil filter.
Note: You may need to use a Caterpillar strap
wrench, or another suitable tool, in order to turn the
filter to the amount that is required for final
installation. Make sure that the installation tool does
not damage the filter.
178 KEBU7565
Maintenance Support
Engine Valve Lash - Check

i01442024

Engine Valve Lash - Check

SMCS Code: 1105-535

Illustration 228 g01160715

The location of the oil filler cap (4) and the dipstick (5)
on the left side of the machine

11. Clean the area around the oil filler cap (4).
Remove the padlock from the oil filler cap (if Illustration 229 g00755446
equipped). Remove the oil filler cap. Fill the
crankcase with new oil. See the following topics: Adjust the clearance within 0.08 mm (0.003 inch) of
the setting that is in the chart.
• Operation and Maintenance Manual, “Lubricant Table 25
Viscositites” Valve Clearance Setting

• Operation and Maintenance Manual, Intake 0.38 mm (0.015 inch)

“Capacities (Refill)” Exhaust 0.76 mm (0.030 inch)

• Operation and Maintenance Manual, “Engine

Oil Level - Check” Refer to the Service Manual or refer to your
Caterpillar dealer in order to perform the procedure
12. Clean the oil filler cap and install the oil filler cap. for the valve adjustment.

13. Start the engine and allow the oil to warm. Check Note: After you set the valve clearance and before
the engine for leaks. Check the filter for leaks. you install the valve covers, check the valve rotators.

14. Remove the padlock from the dipstick (if i01430256

equipped). Run the engine and check the dipstick
(5) after the engine has been running for ten Engine Valve Rotators - Inspect
minutes. Maintain the oil between the marks on the
SMCS Code: 1109-040
“LOW IDLE” side of the dipstick. If necessary, add
oil.
15. Install both padlocks (if equipped).
When inspecting the valve rotators, protective
16. Stop the engine. glasses or face shield and protective clothing
must be worn, to prevent being burned by hot oil
Note: Dispose of the oil according to local or spray.
regulations. Dispose of the oil filter according to local
regulations. Proper care is your responsibility.
1. Start the engine.
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information that 2. Operate the engine at low idle.
pertains to containing fluid spillage.
KEBU7565 179
Maintenance Support
Engine Water Pump - Inspect

Illustration 230 g00755444

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

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

i02328343

Engine Water Pump - Inspect

SMCS Code: 1361-040 Illustration 231 g01162830

A water pump that has failed might cause severe 1. Open the access door (1) on the right side of the
engine overheating. Severe engine overheating could
result in the following problems: machine.

• Cracks in the cylinder head

• Piston seizure
• Other potential engine damage

Illustration 232 g01162832

2. Visually inspect the water pump (2) for leaks. If

leaks are found, all the seals must be replaced.

3. Close the engine compartment.

180 KEBU7565
Maintenance Support
Front Propel Pump Charge Filter - Replace

i02348232

Front Propel Pump Charge

Filter - Replace
SMCS Code: 5068-510

Note: Cleanliness must be a priority when you

drain the hydraulic oil and when you fill the
hydraulic oil. Cleanliness must be a priority when
you change the filters. Drain the oil and fill the oil
in a clean work area. Use clean tools. Make sure
that you have clean hands. Clean the outside of
the hydraulic tank before you start to operate the
machine.
Illustration 235 g01163184

3. Clean the area around the filler cap.

4. Loosen the filler cap in order to equalize the

pressure in the hydraulic tank.

5. Open the drain valve. Drain the oil to a suitable

container. Allow the oil to drain until the hydraulic
tank is empty.

6. Close the drain valve.

7. Remove the temporary drain hose from the drain
valve.

Illustration 233 g01163215 8. Remove the container.

1. See the hydraulic tank drain valve beneath the

access steps on the right side of the machine.

Illustration 234 g01163193

Top view of the hydraulic tank drain valve
Illustration 236 g01156020
2. Connect a temporary drain hose to the drain valve.
The hydraulic filters are located behind the access
Place the other end of the drain hose in a suitable ladder on the right side of the machine.
container.
KEBU7565 181
Maintenance Support
Fuel System - Prime

i02314677

Fuel System - Prime

SMCS Code: 1250-548

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 containers
before opening any compartment or disassembling
any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and sup-
plies suitable to collect and contain fluids on Caterpil-
lar products.
Dispose of all fluids according to local regulations and
mandates.

Illustration 237 g01163051

The front propel pump charge filter

1. Place a suitable container under the filter.

2. Remove the filter from the filter base.
3. Clean the filter base.
4. Install the new filter.
5. Open the filler cap.

6. Fill the hydraulic tank with clean, approved

hydraulic oil.

7. Close the filler cap.

8. Start the machine.

9. Allow the engine to run for several minutes.

10. Check for leaks.

Illustration 238 g01158384
11. Stop the machine.

12. Repair any leaks. 1. Open the access door (1) for the engine
compartment. The door is located on the left side
13. Remove the container. Dispose of all fluids of the machine.
according to local regulations. Dispose of the old
filter according to local regulations. Proper care is
your responsibility.

14. Continue to check for leaks after you place the

machine in operation.

Note: Refer to Operation and Maintenance Manual,

“General Hazard Information” for information that
pertains to containing fluid spillage.
182 KEBU7565
Maintenance Support
Fuel System - Prime

• Changing the fuel lines

• Purging air from the fuel system

Note: The engine start switch must be in the OFF

position in order to prime the fuel system. Do not
attempt to start the engine until the fuel system is
purged of air.
Note: Use a suitable 4 L (1 US gal) container in order
to capture the fuel that will pass through the purge
valve.
4. Open the purge valve (4) by turning the valve
counterclockwise. Do not remove the valve. Hold
the drain hose to the container in order to catch the
fuel.
5. Push the switch upward to the ON position in order
to pump the fuel.
Note: If the pump will not pump fuel, the pump may
Illustration 239 g01158493
be faulty or an air leak may exist on the suction side
of the fuel system.
2. Locate the primary fuel filter (2). The fuel filters are
6. Continue to prime the fuel system until the flow of
located on the left side of the engine compartment
fuel is free of air bubbles. Fuel should flow
underneath the hood.
continuously from the drain hose.

7. After air has been purged from the fuel system,

close the purge valve.

8. Push the switch upward to the ON position for

approximately 30 seconds in order to pressurize
the fuel system. Continue to pump until the fuel
filters are full. When the system is pressurized and
the fuel filters become full, move the switch
downward to the OFF position.

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

priming is necessary. If the engine starts but the
engine continues to misfire, further priming is
necessary. If the engine starts but the engine
continues to emit smoke, further priming is
necessary.

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

continue to run the engine at low idle until the
engine runs smoothly.
Illustration 240 g01159085
11. Inspect the components for fuel leaks. If fuel leaks
3. Locate the fuel priming pump switch (3). The fuel are found, identify the source of the leaks and
priming pump switch is a component of the primary make repairs.
fuel filter assembly.
12. When you have completed the procedures,
The pump is used when the following operations retrieve the containers. Clean up any spilled fluid.
occur: Dispose of the fluids according to local regulations.
Dispose of the cleaning materials according to
• Changing the fuel filters
local regulations. Proper care is your responsibility.
• Priming the fuel system
KEBU7565 183
Maintenance Support
Fuel System Primary Filter - Clean/Inspect/Replace

13. Close the access door (1) for the engine

compartment.

i02348329

Fuel System Primary Filter -

Clean/Inspect/Replace
SMCS Code: 1260-040; 1260-070; 1260-510

Personal injury or death may result from failure to

adhere to the following procedures.
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
Illustration 241 g01158384
battery when changing fuel filters.
2. Open the access door (1) for the engine
NOTICE compartment. The door is located on the left side
Do not fill the fuel filters with fuel before installing the of the machine.
fuel filters. The fuel will not be filtered and could be
contaminated. Contaminated fuel will cause acceler-
ated wear to fuel system parts.

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 containers
before opening any compartment or disassembling
any component containing fluids.
Refer to Special Publication, NENG2500, “Caterpillar
Tools and Shop Products Guide” for tools and sup-
plies suitable to collect and contain fluids on Caterpil-
lar products.
Dispose of all fluids according to local regulations and
mandates.

1. Turn the start switch to the OFF position or

disconnect the battery when maintenance is
performed on the fuel filter. See this Operation and
Maintenance Manual, “Battery Disconnect Switch”
for the proper procedure to disconnect the battery.
Illustration 242 g01158493
3. Locate the primary fuel filter assembly (2). The fuel
filters are located on the left side of the engine
compartment underneath the hood.

4. Place a suitable container under the filter in order

to catch spilled fluids.
184 KEBU7565
Maintenance Support
Fuel System Secondary Filter - Replace

18. Install the new filter onto the base. Tighten the
filter by hand until the seal contacts the filter base.
Additionally tighten the filter by 3/4 rotation.

19. Turn the fuel valve handle (3) 90 degrees in order

to turn on the fuel.
20. Reconnect the battery, if necessary.

21. Prime the fuel system. See this Operation and

Maintenance Manual, “Fuel System - Prime” for
the proper procedure.

22. Check for leaks. Repair any leaks. Continue to

check for leaks after you place the machine in
Illustration 243 g01177023 operation.

5. See the red fuel valve handle (3) that is located to Note: Refer to Operation and Maintenance Manual,
the right of the primary fuel filter base (7). Turn the “General Hazard Information” for information that
pertains to containing fluid spillage.
fuel valve handle upward 90 degrees in order to
shut off the fuel.
i02356632
6. Turn drain valve (4) counterclockwise in order to
open the valve. The drain valve is located on the Fuel System Secondary Filter -
bottom of the water separator bowl (5).
Replace
7. Drain the filter (6) into a suitable container. Make SMCS Code: 1261-510-SE
sure that the filter is empty.

8. Close the drain valve (4).

9. Hold the bottom of the filter (6) while you loosen the
bowl (5). Remove the bowl.

10. Turn the filter (6) counterclockwise in order to

loosen the filter. If the filter will not turn, use a strap
wrench to loosen the filter.
11. Remove filter (6) from the filter base (7).

12. Dispose of the old filter according to local

regulations.

13. Clean the bottom of the filter base (7). Make sure
that all of the old filter seal is removed from the
bottom groove of the opening in the base.

14. Clean the water separator bowl (5). Clean the

groove for the seal. Inspect the seal. If the seal is
worn or damaged, replace the seal.
Illustration 244 g01158384
15. Lubricate the seal with clean diesel fuel or
lubricate the seal with clean motor oil. Place the 1. Open the access door (1) for the engine
seal in the groove on the water separator bowl. compartment. The door is located on the left side
of the machine.
16. Install the water separator bowl onto the new filter
by hand. Tighten the bowl assembly to 15 N·m
(11 lb ft).

17. Apply clean diesel fuel to the seal of the new filter.
KEBU7565
Illustration 245 g01163105
2. Locate the secondary fuel filter (2). The fuel filters
are located on the left side of the engine
compartment underneath the hood. The secondary
fuel filter is located toward the front of the machine.
3. Place a suitable container under the filter in order
to catch spilled fuel.
Illustration 246 g01177087
4. See the red fuel valve handle (3) that is located to
the right of the primary fuel filter. Turn the fuel valve
handle 90 degrees in order to shut off the fuel.
185
Maintenance Support
Fuel System Secondary Filter - Replace
Illustration 247 g01177095
5. Loosen the secondary fuel filter (4).
6. Clean the base for the filter.
7. Use your hand to install the new filter.
There are rotation index marks that are 90° on the
filter. Use the rotation index marks as a guide to
tighten the filter.
8. Turn the fuel valve handle (3) 90 degrees in order
to open the shutoff valve for the fuel .
9. Prime the fuel system. Refer to Operation and
Maintenance Manual, “Fuel System - Prime” for
the proper procedure.
10. Check for leaks. Repair any leaks. Continue to
check for leaks after you place the machine in
operation.
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information that
pertains to containing fluid spillage.
186 KEBU7565
Maintenance Support
Fuel Tank Cap Filter and Strainer - Replace/Clean

i02434612

Fuel Tank Cap Filter and

Strainer - Replace/Clean
SMCS Code: 1273-070-STR; 1273-070-Z2; 1273-
510-FI

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 Illustration 249 g00100213
while working on the fuel system.
1. Lift the lever (5) and turn the lever (5)
Turn the disconnect switch OFF or disconnect the
battery when changing fuel filters. counterclockwise until the lever stops. Remove the
cap.

2. Inspect seal (4) for damage. Replace the seal, if

necessary.

3. Remove screws (1), filter assembly (2), drain valve

(3) and gaskets.

4. Remove the strainer that is located in the filler

opening.

5. Wash the strainer and the fuel tank cap in a clean,

nonflammable solvent.
6. Install a new cap filter kit. Install the gaskets, drain
valve (3), filter assembly (2), and screws (1).

7. Apply a thin film of fuel to the gasket of the fuel tank

cap.

8. Install the fuel tank cap.

Note: Refer to Operation and Maintenance Manual,
Illustration 248 g01158311 “General Hazard Information” for information that
This is the location of the fuel tank cap. pertains to containing fluid spillage.
KEBU7565 187
Maintenance Support
Fuel Tank Water and Sediment - Drain

i02329892

Fuel Tank Water and Sediment

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

Illustration 251 g01163140

The drain valve in the OPEN position

3. Open the drain valve for the fuel. Allow the water to
drain into the container. Allow the sediment to
drain into the container.
Illustration 250 g01163154

1. Identify the drain valve for the fuel (1). The valve is
located at the rear of the machine. The valve is
located under the fuel tank.
2. Place a suitable container under the drain valve in
order to catch spilled fuel.

Note: Attach a temporary hose to the drain valve in

order to reduce splashing the fuel.

Illustration 252 g01163135

The drain valve in the CLOSED position

4. Close the drain valve for the fuel.

5. Check for leaks. Repair any leaks. Continue to
check for leaks after you place the machine in
operation.
188 KEBU7565
Maintenance Support
Hydraulic System Oil - Change

Note: Dispose of drained material according to local

regulations.

Note: Refer to Operation and Maintenance Manual,

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

i02329965

Hydraulic System Oil - Change

SMCS Code: 5056-044; 5095-044

Note: Cleanliness must be a priority when you

change the hydraulic oil. Change the oil in a clean
work area. Use clean tools. Make sure that you Illustration 254 g01163193
have clean hands. Clean the outside of the
hydraulic tank before you start to operate the Top view
machine.
1. Connect a temporary drain hose to the drain valve.
Place the other end of the drain hose in a suitable
container.
Hot oil and hot components can cause personal
injury. Do not allow hot oil or hot components to
contact skin.

Illustration 255 g01163184

2. Clean the area around the filler cap.

Illustration 253 g01163215
3. Loosen the filler cap in order to equalize the
The hydraulic tank drain valve is located beneath the pressure in the hydraulic tank.
access steps on the right side of the machine.
4. Open the drain valve. Drain the oil to a suitable
container. Allow the oil to drain until the hydraulic
tank is empty.

5. Close the drain valve.

6. Open the filler cap.

7. Pour a small amount of hydraulic oil in the tank.

Clean the bottom of the tank.
8. Open the drain valve. Drain the oil to a suitable
container. Allow the oil to drain until the hydraulic
tank is empty.

9. Close the drain valve.

KEBU7565 189
Maintenance Support
Hydraulic System Oil Level - Check

10. Remove the temporary drain hose from the drain i02434627
valve.
Hydraulic System Oil Sample -
11. Remove the container.
Obtain
12. Fill the hydraulic tank with clean, approved
SMCS Code: 5095-008; 7542-008
hydraulic oil.

13. Close the filler cap.

14. Check for leaks. Repair any leaks. Continue to

check for leaks after you place the machine in
operation.
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information that
pertains to containing fluid spillage.

i02329948

Hydraulic System Oil Level -

Check Illustration 257 g01216314
SMCS Code: 5050-535-FLV; 5095-535-FLV
1. Start the engine. Allow the engine to warm-up for at
least ten minutes.
2. Stop the engine.

3. Use the sampling valve that is located on the

auxiliary return filter to obtain the sample of the
hydraulic oil.
Refer to Special Publication, SEBU6250, “S·O·S Oil
Analysis” for information that pertains to obtaining a
sample of the hydraulic oil. Refer to Special
Publication, PEHP6001, “How To Take A Good Oil
Sample” for more information about obtaining a
sample of the hydraulic oil.

Illustration 256 g01163178 i02320298

Maintain the proper oil level in the sight gauge.
Note: Allow space for the hydraulic oil to expand. Do
not overfill the hydraulic tank.
Hydraulic System Return Filter
- Replace
SMCS Code: 5068-510
The hydraulic tank is located on top of the machine.
The cover for the Hydraulic System Return Filter is
located on the top side of the hydraulic tank.
190 KEBU7565
Maintenance Support
Hydraulic Tank Breather - Replace

i02330106

Hydraulic Tank Screen - Clean

SMCS Code: 5056-070-Z3

Illustration 258 g01160065

1. Remove the cover for the Hydraulic System Return

Filter.
2. Replace the Hydraulic System Return Filter.
Illustration 260 g01163228

3. Replace the cover for the Hydraulic System Return

Filter. 1. Remove the hydraulic oil filler cap and pull the
screen outward.
i02320272
2. Clean the screen in clean, nonflammable solvent.
Dry the screen with pressure air.
Hydraulic Tank Breather -
Replace 3. Install the screen and install the cap.
SMCS Code: 5056-510-BRE
i03728080

Indicators and Gauges - Test

SMCS Code: 7450-081

Illustration 259 g01160045

The breather is located on the top of the hydraulic

tank.
1. Remove the breather. Illustration 261 g02010639

2. Install the new breather. 1. Check for broken lenses in the gauges.

2. Check for broken indicator lights.

3. Check for broken switches.

4. Start the engine.
KEBU7565 191
Maintenance Support
Mixing Chamber Disc Hub - Lubricate

5. Check for gauges that do not operate. SMCS Code: 5102-086

6. Turn on all of the lights for the machine (1).

7. Check for the proper operation of the lights.

8. Push in on the horn button (2) in order to check the

horn.
9. Stop the engine.

10. Make any repairs before you operate the

machine.

i05252151

Mixing Chamber Disc Hub -

Illustration 263 g01177160
Lubricate
(If Equipped)
SMCS Code: 4184-086; 536H-RX

Illustration 264 g01177193

The upper fitting on the left cylinder is oriented toward
the rear of the machine.
Illustration 262 g03345411 Lubricate four fittings.
Apply lubricant to the grease fitting for the hub.

i02356750

Mixing Chamber Door Cylinder

Ends (Front) - Lubricate
(If Equipped)
192 KEBU7565
Maintenance Support
Mixing Chamber Door Cylinder Ends (Rear) - Lubricate

i02356676 i02357057

Mixing Chamber Door Cylinder Mixing Chamber Door Hinges

Ends (Rear) - Lubricate (Rear) - Lubricate
SMCS Code: 5102-086 SMCS Code: 6635-086-HNG

Illustration 265 g01177114 Illustration 267 g01177347

Lubricate two fittings. Lubricate four hinges.

i02356878

Mixing Chamber Door Hinges

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

Illustration 266 g01177198

Lubricate four hinges.

KEBU7565 193
Maintenance Support
Mixing Chamber Linkage - Lubricate

i02357159

Mixing Chamber Linkage -

Lubricate
SMCS Code: 6635-086-KL

Illustration 270 g01177503

Illustration 268 g01177393

Illustration 271 g01177513

One fitting is located on the bottom of each linkage.

Lubricate two fittings.

Illustration 269 g01177451

Lubricate four fittings on the top of the machine.

194 KEBU7565
Maintenance Support
Mixing Chamber Tilt Cylinder Ends - Lubricate

i02358731 Ferrous metals can indicate wear on steel parts and

on cast iron parts.
Mixing Chamber Tilt Cylinder Nonferrous metals can indicate wear on the
Ends - Lubricate aluminum parts of the engine such as main bearings,
rod bearings, or turbocharger bearings.
SMCS Code: 5102-086
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.

i02425547

Parking Brake - Check

Illustration 272 g01178451 SMCS Code: 4267-535
Lubricate two fittings. Check the area around the machine. Make sure that
the machine is clear of personnel and clear of
obstacles.
i02106227
Test the parking brake on a dry, level surface.
Oil Filter - Inspect Fasten the seat belt before you test the parking
SMCS Code: 1308-507; 3004-507; 3067-507; 5068- brake.
507
The following tests are used to determine if the
parking brake is functional. These tests are not
Inspect a Used Filter for Debris intended to measure the maximum brake holding
effort. The brake holding effort that is required to
sustain a machine at a specific engine rpm will vary
depending on the machine. The variations are the
differences in the engine setting, and in the power
train efficiency, etc.

1. Start the engine.

2. Move the propel travel control to the TRAVEL

MODE position.

3. Release the parking brake.

4. Propel the machine forward at full travel speed.

5. While the machine is moving, apply the parking

Illustration 273 g00100013 brake. The machine should stop within 5.78 m
The element is shown with debris. (18.96 ft).
Use a filter cutter to cut the filter element open. 6. Reduce the engine speed to low idle.
Spread apart the pleats and inspect the element for
metal and for other debris. An excessive amount of 7. Move the propel control lever to the NEUTRAL
debris in the filter element can indicate a possible position.
failure.
If metals are found in the filter element, a magnet can 8. Stop the engine.
be used to differentiate between ferrous metals and
nonferrous metals.
KEBU7565 195
Maintenance Support
Propel Planetary Oil - Change

Note: If the machine did not stop within 5.78 m Note: Dispose of drained fluids according to local
(18.96 ft), block the machine securely on a level regulations.
surface. Contact your Caterpillar dealer. Do not
operate the machine until the machine has been i02358222
repaired.
Propel Planetary Oil - Check
i02358161
SMCS Code: 4051-535-FLV
Propel Planetary Oil - Change
SMCS Code: 4051-044-OC

Illustration 275 g01178009

Illustration 274 g01178009
(1) Oil drain plug
(2) Oil filler plug
1. Position the machine on a level surface so that the
oil drain plug (1) is at the lowest level. This position
will allow the oil to drain.
Note: Make sure that the line for the oil level is
parallel with the ground.
2. Place a suitable container under the drain plug (1).
3. Loosen the oil filler plug (2).
4. Remove the oil drain plug (1).
5. Drain the oil into a suitable container.
6. Replace the oil drain plug (1).
7. Remove the oil filler plug (2).
8. Add oil until the oil level is at the bottom of the hole
for the oil filler plug.
(1) Oil drain plug
(2) Oil filler plug
1. Position the machine on a level surface so that the
oil drain plug (1) is at the lowest level.
Note: Make sure that the line for the oil level is
parallel with the ground.
2. Remove the oil filler plug (2).
3. Add oil until the oil level is at the bottom of the hole
for the oil filler plug.
4. Replace the oil filler plug (2).
5. Repeat steps1 through 4 for the other planetary
drives.
Note: Refer to this Operation and Maintenance
Manual, “General Hazard Information” topic, for
information that pertains to containing fluid spillage.
Note: Dispose of spilled fluids according to local
regulations.

9. Replace the oil filler plug (2).

10. Repeat steps 2 through 9 for the other planetary

drives.
Note: Refer to this Operation and Maintenance
Manual, “General Hazard Information” topic, for
information that pertains to containing fluid spillage.
196 KEBU7565
Maintenance Support
Propel Planetary Oil Sample - Obtain

i02358241

Propel Planetary Oil Sample -

Obtain
SMCS Code: 4051-008

Note: Refer to this Operation and Maintenance

Manual, “Propel Planetary Oil - Change” topic, for
information on changing the oil in the propel
planetaries.
Obtain a sample of the oil when you change the oil.
Send the oil sample to your dealer for analysis.
Note: Refer to Special Publication, SEBU6250,
“S·O·S Oil Analysis” and Special Publication,
PEHP6001, “How To Take A Good Oil Sample” for
more information.

i03728102

Radiator and Hydraulic Oil

Cooler - Clean
SMCS Code: 1353-070-KO; 1374-070
Compressed air is preferred to remove dust and Illustration 276 g01157701
general debris from the cooling group. Clean the
(1) Grill assembly
cooling group according to the condition of the (3) Fan group
components. Clean both sides of the components. (5) Cooling group
(12) Access panel
Note: The cooling group may require cleaning more (14) Air conditioning condenser core (if equipped)
often when lime or cement are mixed. Water should
not be used to clean the cooling group if lime or
cement has contaminated the cooling group.
Note: High engine coolant temperature or high
hydraulic oil temperature indicate that the cooling
group needs to be cleaned.

Illustration 277 g01156663

(1) Grill assembly
(2) Grill assembly handle
KEBU7565 197
Maintenance Support
Radiator and Hydraulic Oil Cooler - Clean

1. Open the grill assembly (1) by pulling outward on

the grill assembly handle (2).

Illustration 279 g01157222

(3) Fan group
(4) Fan guard
Illustration 278 g01156617 (5) Cooling group
(1) Grill assembly
(3) Fan group 4. Inspect the fan group for debris that is located
between the fan guard (4) and the fan blades.
2. Inspect the grill assembly (1) for debris. If Inspect the fan group (3) for debris that is located
necessary, clean the grill assembly. between the fan group and the cooling group (4). If
necessary, clean components with compressed air
3. Inspect the fan group (3) for debris that is located in only.
front of the fan group. If necessary, clean the area
in front of the fan group.
198 KEBU7565
Maintenance Support
Radiator and Hydraulic Oil Cooler - Clean

Illustration 280 g01157065

The following components are part of the cooling
group (5):
(6) Air-to-air aftercooler (ATAAC) core
(7) Radiator core
(8) Hydraulic oil cooler core
(9) Rotor transmission cooler core
(10) Rotor axle cooler core Illustration 281 g01157903

5. Inspect the front of the cooling group (5) for debris. 6. Open the access doors (11) on each side of the
If necessary, clean the front of the cooling group. machine.
See figure 280 for the location of the radiator core
(7) and the location of the hydraulic oil cooler core
(8). If necessary, clean components with
compressed air only.
KEBU7565
Illustration 282 g01157646
7. See the inner access panels (12). The inner
access panels are located at the front of the
engine compartment on each side of the machine.
Turn the three fasteners (13) on each inner access
panel counterclockwise in order to loosen the
panel. Remove both panels.
Illustration 283 g01157666
8. Inspect the back of the cooling group (5) for debris.
If necessary, clean the back of the cooling group.
See figure 280 for the location of the radiator core
(7) and the location of the hydraulic oil cooler core
(8).
199
Maintenance Support
Rear Propel Pump Charge Filter - Replace
Illustration 284 g01156491
9. If your machine is equipped with an A/C condenser
core (14), clean the core according to the condition
of the core.
10. Reinstall the inner access panel on each side of
the machine.
11. Close the access doors on each side of the
machine.
12. Close the grill assembly.
See Special Publication, SEBD0518, “Know Your
Cooling System” for more detailed information about
cleaning radiator fins.
i02358662
Rear Propel Pump Charge
Filter - Replace
SMCS Code: 5068-510
Note: Cleanliness must be a priority when you
drain the hydraulic oil and when you fill the
hydraulic oil. Cleanliness must be a priority when
you change the filters. Drain the oil and fill the oil
in a clean work area. Use clean tools. Make sure
that you have clean hands. Clean the outside of
the hydraulic tank before you start to operate the
machine.
Note: A vacuum system may be used as an
alternative method in order to drain the oil from the
system. Use a suitable container to prevent spilling
the oil. Consult your Caterpillar dealer for the proper
procedure.
200 KEBU7565
Maintenance Support
Rear Propel Pump Charge Filter - Replace

4. Loosen the filler cap in order to equalize the

pressure in the hydraulic tank.

5. Open the drain valve. Drain the oil to a suitable

container. Allow the oil to drain until the hydraulic
tank is empty.

6. Close the drain valve.

7. Remove the temporary drain hose from the drain
valve.
8. Remove the container.

Illustration 285 g01163215

1. See the hydraulic tank drain valve beneath the

access steps on the right side of the machine.

Illustration 286 g01163193

Illustration 288 g01156020
Top view of the hydraulic tank drain valve
The hydraulic filters are located behind the access
2. Connect a temporary drain hose to the drain valve. ladder on the right side of the machine.
Place the other end of the drain hose in a suitable
container.

Illustration 287 g01163184

3. Clean the area around the filler cap.

KEBU7565
Illustration 289
Location of the rear propel pump charge filter
9. Place a suitable container under the filter.
10. Remove the filter from the filter base.
11. Clean the filter base.
12. Install the new filter.
13. Open the filler cap.
14. Fill the hydraulic tank with clean, approved
hydraulic oil.
15. Close the filler cap.
16. Start the machine.
17. Allow the engine to run for several minutes.
18. Check for leaks.
19. Stop the machine.
20. Repair any leaks.
21. Remove the container. Dispose of all fluids
according to local regulations. Dispose of the old
filter according to local regulations. Proper care is
your responsibility.
22. Continue to check for leaks after you place the
machine in operation.
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information that
pertains to containing fluid spillage.
201
Maintenance Support
Refrigerant Dryer - Replace
i01879009
Refrigerant Dryer - Replace
(If Equipped)
SMCS Code: 7322-510
Personal injury can result from contact with
refrigerant.
Contact with refrigerant can cause frost bite. Keep
face and hands away to help prevent injury.
Protective goggles must always be worn when re-
frigerant lines are opened, even if the gauges indi-
cate the system is empty of refrigerant.
Always use precaution when a fitting is removed.
Slowly loosen the fitting. If the system is still
under pressure, release it slowly in a well venti-
g01163048 lated area.
Personal injury or death can result from inhaling
refrigerant through a lit cigarette.
Inhaling air conditioner refrigerant gas through a
lit cigarette or other smoking method or inhaling
fumes released from a flame contacting air condi-
tioner refrigerant gas, can cause bodily harm or
death.
Do not smoke when servicing air conditioners or
wherever refrigerant gas may be present.
Use a certified recovery and recycling cart to
properly remove the refrigerant from the air condi-
tioning system.
NOTICE
If the refrigerant system has been open to the outside
air (without being plugged) for more than 30 minutes,
the receiver-dryer must be replaced. Moisture will en-
ter an open refrigerant system and cause corrosion
which will lead to component failure.
Note: Refer to Service Manual, SENR5664, “Air
Conditioning and Heating R-134a For All Caterpillar
Machines” for the proper procedure to change the
receiver-dryer assembly and for the procedure to
reclaim the refrigerant gas.
202 KEBU7565
Maintenance Support
Rollover Protective Structure (ROPS) - Inspect

i05253356 1. Park the machine on a level surface.

Rollover Protective Structure

(ROPS) - Inspect
SMCS Code: 7323-040; 7325-040
Inspect the rollover protective structure (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. Replace the ROPS mounting support if the
ROPS makes noise.
Do not straighten the ROPS or repair the ROPS by
welding reinforcement plates to the ROPS.
Consult your Cat dealer for inspection of any Illustration 291 g01178103
potential damage or repair of any damage to any The rotor bearing reservoir is located on top of the
Operator Protective structure, including ROPS, machine.
FOPS, TOPS, OPS and OPG. Refer to Special
Instruction, SEHS6929, “Inspection, Maintenance,
and Repair of Operator Protective Structures (OPS) 2. See the rotor bearing reservoir. Remove the filler
and Attachment Installation Guidelines for All cap.
Earthmoving Machinery” for more information.

i02358268

Rotor Bearing Reservoir

Breather - Replace
SMCS Code: 751T-510-BRE

Illustration 292 g01178096

3. See the rotor drives. There are two hoses on each

side of the machine. Place a suitable container
under each pair of hoses.

4. Disconnect the hoses from the adapter

Illustration 290
1. Remove the old breather.
2. Install the new breather.
assemblies.
g01178089
5. Allow the oil to drain from the hoses into the
suitable containers.
6. Attach the hoses to the adapter assemblies.
7. Fill the rotor bearing reservoir with oil until the oil is
i02358280 slightly above the center divider.

Rotor Bearing Reservoir Oil - Note: Make sure that an equal amount of oil is
present on both sides of the divider.
Change
SMCS Code: 751T-044 8. Replace the filler cap.
KEBU7565 203
Maintenance Support
Rotor Bearing Reservoir Oil Level - Check

9. Remove the containers. Dispose of the oil i02358298

according to local regulations.
Rotor Bearing Reservoir Oil
Note: Dispose of spilled fluids according to local
regulations. Refer to this Operation and Maintenance Sample - Obtain
Manual, “General Hazard Information” topic, for SMCS Code: 751T-008
information that pertains to containing fluid spillage.
Note: Refer to this Operation and Maintenance
i02358293 Manual, “Rotor Bearing Reservoir Oil - Change” topic,
for information on changing the oil in the rotor bearing
Rotor Bearing Reservoir Oil reservoir system.

Level - Check Obtain a sample of the oil when you change the oil.
SMCS Code: 751T-535-FLV Send the oil sample to your dealer for analysis.

1. In order to ensure an accurate reading, park the Note: Refer to Special Publication, SEBU6250,
machine on a level surface. “S·O·S Oil Analysis” and Special Publication,
PEHP6001, “How To Take A Good Oil Sample” for
more information.

i02363175

Rotor Chain Drive Case Oil -

Change
SMCS Code: 5634-044

Illustration 293 g01178103

The rotor bearing reservoir is located on top of the
machine.

2. Inspect the rotor bearing reservoir. The oil level

should be slightly above the center divider. The oil
level should be equal on both sides of the center
divider. A low oil level on one side of the center
divider may be an indication of leakage or
Illustration 294 g01180301
excessive use of oil on that side of the system. If
the oil level is lower on one side of the center
divider, consult your Caterpillar dealer. 1. Start the engine.

3. If the oil level is low, remove the filler cap. Fill the
rotor bearing reservoir with oil until the oil is slightly
above the center divider. Replace the filler cap.
Note: When you fill the system, make sure that an
equal amount of oil is present on both sides of the
divider.
2. Raise the rotor to the upper limit.
3. Remove breather (1) from the top of the rotor chain
drive case.
4. Place a suitable container below plug (2) on the
bottom of the rotor chain drive case.
5. Remove plug (2). Drain the oil to a suitable
container.
6. Install plug (2) on the bottom of the rotor drive
chain case.
204 KEBU7565
Maintenance Support
Rotor Clutch - Lubricate

7. Remove filler plug (3). Fill the chain drive case with
oil to the filler plug (3).
8. Install breather (1).
9. Repeat 3 through 8 on the other side of the
machine.
10. Remove the containers. Dispose of all fluids
according to local regulations. Proper care is your
responsibility.
Note: Refer to this Operation and Maintenance
Manual, “General Hazard Information” for information
that pertains to containing fluid spillage.
i02360758
Rotor Clutch - Lubricate
SMCS Code: 5631-086-CL
The lubrication fittings for the rotor clutch are located
behind the access ladder on the right side of the
machine.
Illustration 295 g01177930
Apply one pump of grease to each fitting. Lubricate
four fittings.
i02357994
Rotor Clutch - Test/Adjust
SMCS Code: 5631-025-CL; 5631-081-CL
Test and adjust the rotor clutch. Refer to
Specifications, Systems Operation/Testing and
Adjusting, KENR3146, “Rotor Clutch - Test and
Adjust” for the proper procedure.
i03728182
Rotor Cutter Bits (Side) -
Inspect/Replace
SMCS Code: 6637-040-KT; 6637-510-KT; 6819-040;
6819-510
Do not perform any cutter tooth replacement, and
do not perform service or maintenance on the ro-
tor, the rotor hood, or the chain cases until steps
1 to 10 are completed.
Failure to follow these instructions could allow
the rotor, chamber, or door to drop resulting in
serious personal injury or death.
1. Set the parking brake on the propel system.
2. Raise the rotor to the TRAVEL position to clear
any material that may be trapped between the cut-
ter bits and the paddles.
3. Tilt the rotor chamber forward, and raise the
rear door.
4. Reduce the engine speed to LOW idle.
5. Disengage the rotor drive.
6. Turn the ignition OFF in order to stop the
engine,
7. Turn the ignition key to the ON position. Do not
start the engine.
8. Remove the padlock from the circuit breaker
box, and open the cover for the circuit breaker
box. Place the rotor service switch in the SERV-
ICE position. Close the circuit breaker box cover
and install the padlock.
9. Engage the rotor service lock T bar that is lo-
cated on the left chain case on the lift cylinder.
10. Secure the rear door and mixing chamber in
position, by engaging the rear door service pin.
11. Do not start the engine again until all of the
services are completed and all personnel are
clear from the rotor area.
12. Remove the rotor lock and disengage the rear
door service pin.
13. Remove the padlock from the circuit breaker
box. Open the cover of the circuit breaker box.
Place the rotor service switch in OPERATE posi-
tion. Close the cover for the circuit breaker box
and install the padlock.
14. Sound the horn three times prior to starting
the engine.
KEBU7565
Illustration 296 g01238378
1. Use a hammer to disengage the pin in order to
open access door (1).
Illustration 297 g01238379
2. Inspect cutter bits (2).
Wear a hard hat and protective glasses. Additional
protective equipment may also be required. Use a
hammer and a punch to remove a worn holder or a
damaged holder.
The bits for the rotor should be checked for wear.
The bits for the rotor should be replaced if the
distance from the holders of the rotor bits to the tip
of the bits for the rotor is 32 mm (1.26 inch) or
less. The bits for the rotor should be replaced if the
distance from the exposed carbide tip is 32 mm
(1.26 inch) or less.
You should check the holders for the bits for
cracks. You should check the holders for the bits
for breaks. You should check the holders when you
check the bits.
205
Maintenance Support
Rotor Cutter Bits - Inspect/Replace
When the bits for the rotor need to be changed, the
bits should be changed as a group. You should
change the bits as a group so that all of the bits will
be the same length. When the bits for the rotor are
not the same length, the long bits will wear faster.
When the bits for the rotor are not the same length,
the long bits will break. You should save bits that
are worn in order to replace bits that are broken.
You should replace a bit that is broken with a bit
that is the same length as the other bits in the rotor.
3. Close access door (1). Use a hammer in order to
engage the pin and secure the pin in place.
i05157051
Rotor Cutter Bits - Inspect/
Replace
SMCS Code: 6637-040-KT; 6637-510-KT; 6819-040;
6819-510
Illustration 298 g00880791
Check and Inspect the Rotor Bits
The rotor bits should be checked for excessive wear.
Replace the rotor bits when the following problems
occur:
• Uneven wear
• Carbide is missing from the tip.
• The shoulder of the bit is severely eroded.
• The neck that supports the carbide is significantly
thinner.
Replacing a Rotor Bit
Individual bits may have excessive wear. Individual
bits may have carbide damage. Replace these bits
with new bits or with bits that are worn to the same
level as the majority of the remaining bits. When all
the bits have significant wear, replace all the bits at
the same time.
206 KEBU7565
Maintenance Support
Rotor Drive Bearings - Lubricate

Note: Refer to the Operation and Maintenance

Manual, “Servicing the Rotor”.
Do not perform any cutter tooth replacement, and 2. Rotate the rotor until the bit is accessible.
do not perform service or maintenance on the ro-
tor, the rotor hood, or the chain cases until steps 3. Insert the tip of a drive pin into the back opening of
1 to 10 are completed. the bit holder. Use a hammer in order to drive the
Failure to follow these instructions could allow bit out of the holder.
the rotor, chamber, or door to drop resulting in
serious personal injury or death. 4. Place the new bit in the holder. Use a hammer to
drive the bit into position. Keep the keeper spring
1. Set the parking brake on the propel system. engaged with the holder.
2. Raise the rotor to the TRAVEL position to clear
any material that may be trapped between the cut- i02463124
ter bits and the paddles.
Rotor Drive Bearings -
3. Tilt the rotor chamber forward, and raise the
rear door. Lubricate
4. Reduce the engine speed to LOW idle. SMCS Code: 5631-086-BD

5. Disengage the rotor drive.

Rotor Drive Differential
6. Turn the ignition OFF in order to stop the There are four lubrication points on the rotor drive
engine, differential.
7. Turn the ignition key to the ON position. Do not
start the engine.
8. Remove the padlock from the circuit breaker
box, and open the cover for the circuit breaker
box. Place the rotor service switch in the SERV-
ICE position. Close the circuit breaker box cover
and install the padlock.
9. Engage the rotor service lock T bar that is lo-
cated on the left chain case on the lift cylinder.
10. Secure the rear door and mixing chamber in
position, by engaging the rear door service pin.
11. Do not start the engine again until all of the
services are completed and all personnel are
Illustration 299 g01229005
clear from the rotor area.
12. Remove the rotor lock and disengage the rear Lubricate one fitting on each side of the differential.
door service pin.
13. Remove the padlock from the circuit breaker
box. Open the cover of the circuit breaker box.
Place the rotor service switch in OPERATE posi-
tion. Close the cover for the circuit breaker box
and install the padlock.
14. Sound the horn three times prior to starting
the engine.

Removing a Rotor Bit

1. Put the rotor in the service position.
Wear a hard hat and protective glasses. Additional Illustration 300 g01229006
protective equipment may also be required. Use a
hammer and a punch to remove the worn bits. Lubricate one fitting on each side of the differential
housing.
KEBU7565 207
Maintenance Support
Rotor Drive Differential Breather - Replace

i02330111 5. Remove filler plug (2).

Rotor Drive Differential 6. Use filler plug (2) to fill the axle. Fill the axle until oil
drains out.
Breather - Replace
SMCS Code: 5633-510-BRE 7. Install the filler plug.

8. Check for leaks. Repair any leaks. Continue to

check for leaks after you place the machine in
operation.
Refer to Operation and Maintenance Manual,
“General Hazard Information” for information that
pertains to containing fluid spillage.

i02330113

Rotor Drive Differential Oil

Level - Check
SMCS Code: 5633-535-FLV

Illustration 301 g01163236

1. Remove the old breather.

2. Install the new breather.

i02330112

Rotor Drive Differential Oil -

Change
SMCS Code: 5633-044

1. Place a suitable container under the differential in

order to catch spilled oil. Illustration 303 g01163239

Maintain the oil level in the tube to the centerline of

the axle.

i01884088

Rotor Drive Differential Oil

Sample - Obtain
SMCS Code: 5633-008
In addition to a good preventive maintenance
program, Caterpillar recommends using S·O·S oil
analysis at regular scheduled intervals in order to
monitor the condition of the engine and the
maintenance requirements of the engine.
Illustration 302 g01163237
Note: Refer to the Operation and Maintenance
Manual, “Rotor Drive Differential Oil - Change” for
2. Remove drain plug (1). information on changing the oil in the final drive
planetary.
3. Allow the oil to drain to a suitable container.
4. Install drain plug (1).
208 KEBU7565
Maintenance Support
Rotor Drive Differential Sump Screen - Replace

Refer to Special Publication, SEBU6250, “S·O·S Oil
Analysis” for information that pertains to obtaining a
sample from the final drive planetary. Refer to Special
Publication, PEHP6001, “How To Take A Good Oil
Sample” for more information about obtaining a
sample from the final drive planetary.
Obtain a sample of the oil when you change the oil.
Send the oil sample to your dealer for analysis.
i03728226
10. Reinstall the bracket.
11. Reinstall the shield.
Note: Dispose of spilled fluids according to local
regulations. Dispose of the old parts according to
local regulations. Proper care is your responsibility.
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information that
pertains to containing fluid spillage.

i03347315
Rotor Drive Differential Sump
Screen - Replace Rotor Drive Shaft Universal
SMCS Code: 5633-510-Z3 Joints - Lubricate
SMCS Code: 5631-086-UJ
1. Remove the shield from the bottom of the machine.
2. Drain the oil from the system into a suitable
container.
3. Note the direction of flow that is indicated on the
old sump screen.

4. Place a suitable container underneath the old

sump screen.

Illustration 305 g01722092

(1) Rear drive shaft universal joint lubrication point

Illustration 304 g01163996

Location of the sump screen for the rotor drive
differential

5. Loosen the hose connectors on each side of the

old sump screen.

6. Remove the bracket. Remove the sump screen.

Illustration 306 g01722102
7. The sump screen is disposable. Discard the old
(2) Front drive shaft universal joint lubrication point
sump screen.

8. Install the new sump screen. Make sure that the

arrow that is printed on the part is pointing in the
direction of flow.
9. Remove the container.
KEBU7565 209
Maintenance Support
Rotor Lift Cylinder Ends - Lubricate

This machine is equipped with a front rotor drive shaft i02462909

and a rear rotor drive shaft. Each drive shaft has two
universal joints. Lubricate the four fittings on the
universal joints. This will provide grease to the
Rotor Shear Disc Bolts -
universal joint. When you use a standard grease gun, Inspect/Replace
pump the grease gun four times per fitting. The
grease should purge the bearings of the universal SMCS Code: 5635-040-BC; 5635-510-BC
joint.

i02436312

Rotor Lift Cylinder Ends -

Lubricate
SMCS Code: 5102-086

Illustration 309 g00881652

Make sure that the bolt is loose. Do not tighten the

bolt if the bolt is loose. Replace the bolt if the bolt is
broken.
Note: Use only the 8T-9378 Bolt. This bolt has a
shank length that is not threaded. The shank length
that is not threaded will not allow the bolt to be
Illustration 307 g01155653 tightened against the shear disc plates. If you tighten
the plates, a higher torque load will result and you
There are two rotor lift cylinder on the machine. Each could damage the rotor drive components. The
cylinder has one fitting. Lubricate the fitting on the 8T-9378 Bolt is designed to shear in order to protect
lower end of each cylinder. the drive components.

Note: If the bolt has failed, find the source of the

i01694195
failure. If necessary, consult with your Caterpillar
dealer.
Rotor Shear Disc - Lubricate
SMCS Code: 5631-086 i02436320

Rotor Torque Limiter Coupling

- Inspect
(If Equipped)

Illustration 308 g00881639

Lubricate one fitting.

210 KEBU7565
Maintenance Support
Rotor Transmission Breather - Replace

SMCS Code: 5632-040-QC

Illustration 311 g01163994

Illustration 310 g01002606

1. Remove the old breather.
(1) Flush Indicators.
(2) This is the index mark. 2. Install the new breather.
Use a black marker or a permanent mark for the
i03728242
index mark.

Note: Place an index mark across the back side of Rotor Transmission Oil -
the torque limiter and spring plate. Use this method to
determine if the torque limiter shows an indexing
Change
point or if the torque limiter does not show an SMCS Code: 5635-044
indexing point after some use. Disassemble the
torque limiter and clean the torque limiter if the torque The drain plug is located beneath the rotor
limiter does not show an indexing point in tough transmission.
applications. Disassemble the torque limiter and 1. Remove the shield that is beneath the rotor
clean the torque limiter if the machine has not been in
transmission.
operation for three months or more.
When the indicators are flush with the machined
recess of the plate, you must rebuild the clutch.

Note: Refer to Special Instruction REHS2768,

“Maintenance Procedure for the Torque Limiting
Coupling on the Road Reclaimer” for additional
information.

i02331889

Rotor Transmission Breather -

Replace
SMCS Code: 5635-510-BRE
Illustration 312 g01178272
(1) Rotor transmission sump screen filter
(2) Hose

2. Place a suitable container underneath the sump

screen filter (1) for the rotor transmission.

3. Remove the hose (2) from the sump screen filter

(1). Allow the oil to drain into the container.

4. Install the hose.

KEBU7565 211
Maintenance Support
Rotor Transmission Oil - Check

5. Remove the container.

3. The oil level should be at the FULL mark on the
6. Install the shield. dipstick.

4. Add oil if the oil level is low.

Note: Refer to Operation and Maintenance Manual,

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

i02479716

Rotor Transmission Oil Sample

- Obtain
SMCS Code: 5635-008

1. Start the engine. Allow the engine to warm-up for at

Illustration 313 g01163988 least ten minutes.
The filler cap for the rotor transmission is located
under the access cover on the right side of the deck. 2. Engage the rotor and allow the rotor to run for a few
minutes.
7. Fill the rotor transmission to the mark on the 3. Stop the rotor.
dipstick. The dipstick is welded to the filler cap.
4. Move the operator station to the left side of the
Note: Dispose of the oil according to local
machine.
regulations. Proper care is your responsibility.
5. Stop the engine.
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information that 6. Raise the right access panel on the deck and
pertains to containing fluid spillage. remove the dipstick.

i02331860 7. Use the proper S·O·S tooling to obtain a sample

from the transmission.
Rotor Transmission Oil - Check Refer to Special Publication, SEBU6250, “S·O·S Oil
SMCS Code: 5635-535 Analysis” for information that pertains to obtaining a
sample of the oil. Refer to Special Publication,
1. Remove the filler cap. PEHP6001, “How To Take A Good Oil Sample” for
more information about obtaining a sample of the oil.

i03728244

Rotor Transmission Sump

Screen - Replace
SMCS Code: 5635-510-Z3

1. Remove the shield from the bottom of the machine.

Illustration 314 g01163988
The filler cap for the rotor transmission is located
under the access cover on the right side of the deck.
2. Drain the oil from the system into a suitable
container.
3. Note the direction of flow that is indicated on the
old sump screen.
4. Place a suitable container underneath the old
sump screen.

2. Use the dipstick to check the oil level.

212
Maintenance Support
Seat Belt - Inspect
Illustration 315 g01163995
Location of the sump screen for the rotor
transmission
5. Loosen the hose connectors on each side of the
old sump screen.
6. Remove the bracket. Remove the sump screen.
7. The sump screen is disposable. Discard the old
sump screen.
8. Install the new sump screen. Make sure that the
arrow that is printed on the part is pointing in the
direction of flow.
9. Remove the container.
10. Reinstall the bracket.
11. Reinstall the shield.
Note: Dispose of spilled fluids according to local
regulations. Dispose of the old parts according to
local regulations. Proper care is your responsibility.
Note: Refer to Operation and Maintenance Manual,
“General Hazard Information” for information that
pertains to containing fluid spillage.
i02301933
Seat Belt - Inspect
SMCS Code: 7327-040
Always check the condition of the seat belt and the
condition of the seat belt mounting hardware before
you operate the machine. Replace any parts that are
damaged or worn before you operate the machine.
KEBU7565
Illustration 316 g00932801
Typical example
Check the seat belt mounting hardware (1) for wear
or for damage. Replace any mounting hardware that
is worn or damaged. Make sure that the mounting
bolts are tight.
Check buckle (2) for wear or for damage. If the buckle
is worn or damaged, replace the seat belt.
Inspect the seat belt (3) for webbing that is worn or
frayed. Replace the seat belt if the seat belt is worn or
frayed.
Note: A date label for determining the age of the seat
belt is attached to each seat belt. See this Operation
and Maintenance Manual, “Seat Belt - Replace” topic,
for the proper replacement intervals.
If your machine is equipped with a seat belt
extension, also perform this inspection procedure for
the seat belt extension.
Contact your authorized dealer for the replacement of
the seat belt and the seat belt mounting hardware.
i04421974
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).
KEBU7565 213
Maintenance Support
Steering Cylinder Ends - Lubricate

i02461935

Steering Cylinder Ends -

Lubricate
SMCS Code: 4303-086-BD

Front Steering Cylinder Ends

Illustration 317 g01152685

Typical Example
(1) Date of installation (retractor)
(2) Date of installation (buckle)
(3) Year of manufacture (tag) (fully extended Web)
(4) Year of manufacture (underside) (buckle)

Consult your Cat dealer for the replacement of the

seat belt and the mounting hardware.
Determine age of new seat belt before installing on
seat. A manufacture label is on belt webbing and
Illustration 318 g01216959
imprinted on belt buckle. Do not exceed install by
date on label. Lubricate one fitting on each side of the machine.
Complete seat belt system should be installed with
new mounting hardware. Rear Steering Cylinder Ends
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 319 g01156086

Find the fitting on each end of the rear steering

cylinder. Lubricate the two fittings.
214 KEBU7565
Maintenance Support
Steering Knuckle - Lubricate

i02308899 Use the fittings (1) to lubricate the upper and the
lower steering knuckle kingpin on each side of the
Steering Knuckle - Lubricate machine.
SMCS Code: 3020-086-QZ; 4321-086
i02308444

Steering Legs (Rear) -

Lubricate
SMCS Code: 4345-086

Illustration 322 g01156222

Illustration 320 g01156382
Identify one fitting at the top of the steering leg on
each side of the machine. Lubricate the two fittings.

Illustration 321 g01156442

The steering knuckle lubrication fittings (1) are

located forward of the front axle. Lubrication lines
connect the fittings to the steering knuckle kingpins.
There are four steering knuckle lubrication fittings on
the machine. There are two fittings on each side of
the machine. The upper fitting is connected to the
upper steering knuckle kingpin. The lower fitting is
connected to the lower steering knuckle kingpin.
KEBU7565 215
Maintenance Support
Steering Linkage - Lubricate

i02461946 i02358676

Steering Linkage - Lubricate Tire Inflation - Check

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

Front Steering Linkage

Illustration 325 g01163240

Illustration 323
Identify one fitting on each end of the front steering
linkage. Lubricate the two fittings.
Check the tires daily for the proper inflation and for
wear. Check the lug nuts for the wheel . Tighten the
lug nuts if the lug nuts are loose.
Check the tires for leaks if the tire pressure is low.
See this Operation and Maintenance Manual, “Tire
Inflation Pressure Adjustment”, for the proper tire
g01156168
pressure.
i05157032

Rear Steering Linkage Tool Holder - Inspect/Replace

SMCS Code: 6637-040; 6637-510

Illustration 324 g01156183

Identify one fitting on each end of the rear steering Illustration 326 g00880791
linkage. Lubricate the two fittings.
Check and Inspect the Tool Holders
The tool holders should be checked for the following
problems:
216 KEBU7565
Maintenance Support
Tool Holder - Inspect/Replace

• Breaks Replacing a Damaged Tool Holder

• Cracks

• Excessive erosion
Do not perform any cutter tooth replacement, and
Replace the holders if any of the above problems do not perform service or maintenance on the ro-
occur.
tor, the rotor hood, or the chain cases until steps
1 to 10 are completed.
Failure to follow these instructions could allow
the rotor, chamber, or door to drop resulting in
serious personal injury or death.
1. Set the parking brake on the propel system.
2. Raise the rotor to the TRAVEL position to clear
any material that may be trapped between the cut-
ter bits and the paddles.
3. Tilt the rotor chamber forward, and raise the
rear door.
4. Reduce the engine speed to LOW idle.
5. Disengage the rotor drive.
6. Turn the ignition OFF in order to stop the
engine,
7. Turn the ignition key to the ON position. Do not
start the engine.
8. Remove the padlock from the circuit breaker
box, and open the cover for the circuit breaker
box. Place the rotor service switch in the SERV-
ICE position. Close the circuit breaker box cover
and install the padlock.
9. Engage the rotor service lock T bar that is lo-
cated on the left chain case on the lift cylinder.
10. Secure the rear door and mixing chamber in
position, by engaging the rear door service pin.
11. Do not start the engine again until all of the
services are completed and all personnel are
clear from the rotor area.
12. Remove the rotor lock and disengage the rear
door service pin.
13. Remove the padlock from the circuit breaker
box. Open the cover of the circuit breaker box.
Place the rotor service switch in OPERATE posi-
tion. Close the cover for the circuit breaker box
and install the padlock.
14. Sound the horn three times prior to starting
the engine.
KEBU7565
Personal injury could result when striking an
object. Keep personnel away when striking an
object. Always wear protective glasses when
striking an object.
1. Put the rotor in the service position.
Wear a hard hat and protective glasses. Additional
protective equipment may also be required. Use a
hammer and a punch to remove the worn bits.
Note: Refer to the Operation and Maintenance
Manual, “Servicing the Rotor”.
Illustration 327 g00880791
2. Remove the bolt from the holder or knock off the
head of the bolt.
3. Use a hammer in order to remove the holder. To
remove a worn tool holder from the base, hit the
back of the tool holder as close as possible to the
top of the base with a steel hammer that weighs
1.8 kg (4 lb) to 2.25 kg (5 lb).
Note: Do not hit the base with the hammer.
4. Remove the tool holder and clean any debris from
the base.
Note: Refer to Installation of the Tool Holder for
information on installing the new tool holder.
Installation of the Tool Holder
Personal injury could result when striking an
object. Keep personnel away when striking an
object. Always wear protective glasses when
striking an object.
217
Maintenance Support
Tool Holder - Inspect/Replace
Illustration 328 g01435570
(1) Tool holder
(2) Base
(3) Bolt
(4) T section
1. Place tool holder (1) in base (2).
2. Hit tool holder (1) on the front of T section (4) four
to five times with a steel hammer that weighs
1.8 kg (4 lb) to 2.25 kg (5 lb). This will drive tool
holder (1) into base (2). At this point, tool holder (1)
and base (2) will be locked together by the tapers.
3. Striking the tool holder with the hammer will cause
a dull heavy sound. When the tool holder has been
seated in the base, striking the tool holder with the
hammer will cause the tone to change to a high
pitch. The change of tone signifies that the tool
holder and the base have locked together.
4. Once tool holder (1) has seated in base (2) install
bolt (3). Tighten bolt (3) to a torque of 88 ± 7 N·m
(65 ± 5 lb ft).
Note: Do not use only the torque on the bolt to seat
the tool holder. The strength of the bolt is insufficient
to apply the required load for assembly.
5. Operate the machine for four to six hours.
6. Check the tool holders and bolts. Reseat any loose
tool holders and tighten any loose bolts. Refer to
Step 2.
7. Operate the machine for 10 to 12 hours. All tool
holders should be tight. If any tool holders are
loose disassemble the tool holders. Reassemble
the tool holders. Refer to Step 2.
218 KEBU7565
Maintenance Support
Water Spray System Charge Filter - Replace

8. Tool holders and bases that have been tightened

twice are locked together by the tapers. The tool
holders and bases should remain locked under
normal working conditions. Loss of bolts from a
properly assembled unit is not detrimental. The
tool holder and the base are locked together by the
tapers.

i02358642

Water Spray System Charge

Filter - Replace
(If Equipped)
Illustration 330 g01163193
SMCS Code: 5068-510
Top view of the hydraulic tank drain valve
Note: Cleanliness must be a priority when you
drain the hydraulic oil and when you fill the 2. Connect a temporary drain hose to the drain valve.
hydraulic oil. Cleanliness must be a priority when Place the other end of the drain hose in a suitable
you change the filters. Drain the oil and fill the oil container.
in a clean work area. Use clean tools. Make sure
that you have clean hands. Clean the outside of
the hydraulic tank before you start to operate the
machine.
Note: A vacuum system may be used as an
alternative method in order to drain the oil from the
system. Use a suitable container to prevent spilling
the oil. Consult your Caterpillar dealer for the proper
procedure.

Illustration 331 g01163184

3. Clean the area around the filler cap.

4. Loosen the filler cap in order to equalize the

pressure in the hydraulic tank.

5. Open the drain valve. Drain the oil to a suitable

container. Allow the oil to drain until the hydraulic
tank is empty.
Illustration 329 g01163215
6. Close the drain valve.
1. See the hydraulic tank drain valve beneath the
access steps on the right side of the machine. 7. Remove the temporary drain hose from the drain
valve.
8. Remove the container.
KEBU7565 219
Maintenance Support
Water Spray System Nozzles - Clean

14. Fill the hydraulic tank with clean, approved

hydraulic oil.

15. Close the filler cap.

16. Start the machine.

17. Allow the engine to run for several minutes.

18. Check for leaks.

19. Stop the machine.

20. Repair any leaks.

21. Remove the container. Dispose of all fluids

according to local regulations. Dispose of the old
filter according to local regulations. Proper care is
your responsibility.

22. Continue to check for leaks after you place the

machine in operation.
Illustration 332 g01156020
Note: Refer to Operation and Maintenance Manual,
The hydraulic filters are located behind the access “General Hazard Information” for information that
ladder on the right side of the machine. pertains to containing fluid spillage.

i01695032

Water Spray System Nozzles -

Clean
(If Equipped)
SMCS Code: 5612-070; 5615-070

Illustration 333 g01178436

The water spray system charge filter
Illustration 334 g00872773
9. Place a suitable container under the filter.
Clean the water spray nozzles.
10. Remove the filter from the filter base.
11. Clean the filter base. i02477216

12. Install the new filter. Water Spray System Pump Oil -
13. Open the filler cap. Change
(If Equipped)
220 KEBU7565
Maintenance Support
Water Spray System Pump Oil Level - Check

SMCS Code: 5614-044; 5616-044 i02463042

Water Spray System Strainer -

Clean
SMCS Code: 5612-070-STR

Illustration 335 g01237036

Change the oil for the water spray system pump.

Allow the oil to drain into a suitable container.

Note: Refer to Operation and Maintenance Manual, Illustration 337 g01228976

“General Hazard Information” for information that
pertains to containing fluid spillage. In order to clean the strainer, follow the listed
procedure.
Note: Dispose of drained fluids according to local
1. Unscrew the top fastener.
regulations.
2. Pull out the strainer assembly.
i01695136
3. Rinse the strainer with water in order to remove
Water Spray System Pump Oil any debris.
Level - Check 4. Reinstall the clean strainer assembly.
(If Equipped) 5. Hand tighten the top fastener.
SMCS Code: 5614-535-FLV

Illustration 336 g00872839

Use the sight glass for the oil level in order to check
the oil level in the oil pump for the water spray
system.
KEBU7565
Reference Information
Section
Reference Materials
i05656953
Reference Material
SMCS Code: 1000; 7000
The following literature can be obtained from any
Caterpillar dealer:
Special Instruction, PEHJ0192, “Optimizing Oil
Change Intervals”
Special Instruction, PEHJ0191, “S·O·S Fluid
Analysis”
Special Publication, SEBD0518, “Know Your Cooling
System”
Special Publication, SEBD0970, “Coolant and Your
Engine”
Special Publication, SEBD0717, “Diesel Fuels and
Your Engine”
Special Instruction, SEHS9031, “Storage Procedure
for Caterpillar Products”
Special Publication, SEBU5898, “Cold Weather
Recommendations”
Special Publication, SEBD0640, “Oil and Your
Engine”
Special Publication, SEBU6250, “Caterpillar Machine
Fluids Recommendations”
Special Publication, SEBF8029, “Guideline For
Reusable Parts and Salvage Operations”
Operation and Maintenance Manual, SEBU8257,
“The European Union Physical Agents (Vibration)
Directive “2002/44/EC” ”
Service Manual, SENR5664, “Air Conditioning and
Heating with R-134A (All Caterpillar Machines)”
Special Instruction, REHS0354, “Charging System
Troubleshooting”
Special Instruction, REHS1642, “Operation of the
Product Link System”
Special Publication, NENG2500, “Caterpillar Dealer
Service Tool Catalog”
Service Magazine, SEHS6929, “Inspection,
Maintenance, and Repair of ROPS and Attachment
Installation Guidelines”
Specifications, SENR3130, “Torque Specifications”
221
Reference Information Section
Reference Material
System Operation, Troubleshooting, Testing and
Adjusting, RENR7911, “Product Link 121SR/321SR”
Special Instruction, REHS2365, “An Installation
Guide for the Product Link PL121SR and for the
PL300”
Service Parts, PECP9067, “One Safe Source”
Special Instruction, SEHS7332, “Warning Tag -
Danger Do Not Operate”
Special Instruction, SEHS7633, “Battery Test
Procedure”
Special Publication, PEGJ0047, “How to Take a Good
Oil Sample”
Special Publication, PEGJ0046, “S·O·S Services:
Understanding Your Results”
Special Publication, PEWJ0074, “Caterpillar Filter
and Fluid Application Guide”
Special Publication, PMEP5027, “Extended Life
Coolant/Antifreeze Label”
Operation and Maintenance Manual, SEBU8157,
“Work Area Vision System”
Operation and Maintenance Manuals are available in
other languages. Consult your Caterpillar dealer for
information about obtaining these Operation and
Maintenance Manuals.
Additional Reference Material
ASTM D2896, “TBN Measurements” This publication
can normally be obtained from your local
technological society, from your local library, or from
your local college.
SAE J313, “Diesel Fuels” This publication can be
found in the SAE handbook. Also, this publication can
be obtained from your local technological society,
from your local library, or from your local college.
SAE J754, “Nomenclature” This publication can
normally be found in the SAE handbook.
SAE J183, “Classification” This publication can
normally be found in the SAE handbook.
Engine Manufacturers Association, “Engine Fluids
Data Book”
Engine Manufacturers Association
333 West Wacker Drive, Suite 810
Chicago, IL USA 60606
E-mail: ema@emamail.org
(312) 929-1970
Facsimile (312) 929-1975
222 KEBU7565
Reference Materials
Decommissioning and Disposal

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.
KEBU7565 223
Index Section

Index
A Cooling System Coolant Extender (ELC) - Add
..................................................................... 161
Access Doors and Covers ............................. 131
Cooling System Coolant Level - Check ......... 162
Additional Messages ....................................... 13
Cooling System Coolant Sample (Level 1) -
Application Guidelines (For the Spray
Obtain .......................................................... 157
Systems)........................................................ 31
Cooling System Coolant Sample (Level 2) -
Application Rate of Emulsion....................... 39
Obtain .......................................................... 158
Application Rate of Water (76.2 mm (3 inch)
Cooling System Pressure Cap - Clean/
Flow Meter) ................................................ 32
Replace........................................................ 163
Application Rate of Water (Low Flow Rate
Cooling System Water Temperature
Conversion)................................................ 37
Regulator - Replace..................................... 163
Application Rate of Water (Standard 102 mm
Crushing Prevention and Cutting Prevention .. 17
(4 inch) Flow Meter) ................................... 34
Automatic Lubrication System Grease - Add
(Water Spray System Pump) ....................... 148 D
Automatic/Manual Depth Control..................... 96
Auxiliary Hydraulic System Filter - Replace... 148 Daily Inspection ............................................... 46
Declaration of Conformity ................................ 45
Decommissioning and Disposal .................... 222
B Drive Shaft Support Bearing - Lubricate........ 164
Backup Alarm .................................................. 94
Backup Alarm - Test....................................... 150 E
Battery - Clean............................................... 151
Battery - Recycle ........................................... 151 Electrical Storm Injury Prevention ................... 22
Battery Disconnect Switch............................... 90 Emissions Certification Film ............................ 44
Battery or Battery Cable - Inspect/Replace ... 151 Emulsion Pump - Lubricate............................ 165
Before Operation ........................................23, 46 Emulsion Spray Nozzles - Clean ................... 165
Before Starting Engine .................................... 23 Emulsion Spray System .................................. 98
Belts - Inspect/Adjust/Replace....................... 152 Emulsion System Nozzles ........................... 98
Inspect Belts .............................................. 152 Emulsion System Pump............................... 98
Bolster Oscillation Pin (Rear) - Lubricate....... 152 Emulsion Spray System - Clean.................... 165
Braking System - Test.................................... 153 Clean the Emulsion Spray System ............ 165
Burn Prevention............................................... 17 Flush the Pump.......................................... 167
Batteries....................................................... 18 Emulsion Spray System Charge Filter -
Coolant......................................................... 18 Replace........................................................ 167
Oils............................................................... 18 Emulsion Spray System Strainer - Clean ...... 169
Engine Air Filter Primary Element - Clean/
Replace........................................................ 169
C Cleaning Primary Air Filter Elements ......... 170
Inspecting the Primary Air Filter Elements
Cab Air Filter - Clean/Replace ....................... 153
................................................................. 171
External Cab Filter ..................................... 154
Remove the Primary Element .................... 169
Internal Cab Filter....................................... 153
Engine Air Filter Secondary Element -
Camera - Clean/Adjust (WAVS (If
Replace........................................................ 172
Equipped)) ................................................... 154
Engine Air Filter Service Indicator - Inspect... 173
Camera (If Equipped) ...................................... 94
Engine Air Precleaner - Clean ....................... 174
Capacities (Refill) .......................................... 144
Engine and Machine Warm-Up....................... 111
Circuit Breakers - Reset................................. 155
Engine Crankcase Breather - Clean.............. 174
Cooling System Coolant (ELC) - Change...... 159
224
Index Section
Engine Crankcase Breather Tube - Inspect/
Clean ........................................................... 175
Engine Hour Meter........................................... 93
Engine Mounts - Inspect................................ 175
Engine Oil and Filter - Change ...................... 176
Engine Oil Level - Check ............................... 175
Engine Oil Sample - Obtain ........................... 176
Obtain the Sample and the Analysis.......... 176
Engine Starting .........................................23, 110
Engine Starting (Alternate Methods) ............. 129
Engine Starting with Jump Start Cables ........ 129
Use of Jump Start Cables .......................... 129
Engine Stopping .............................................. 25
Engine Valve Lash - Check............................ 178
Engine Valve Rotators - Inspect .................... 178
Engine Water Pump - Inspect........................ 179
Equipment Lowering with Engine Stopped..... 26,
121
F Hydraulic System Oil Sample - Obtain .......... 189
Fire Extinguisher Location ............................... 21
Closed Platform ........................................... 21
Open Platform.............................................. 21
Fire Prevention and Explosion Prevention ...... 18
Battery and Battery Cables .......................... 19
Ether ............................................................ 21
Fire Extinguisher.......................................... 21
General ........................................................ 18
Lines, Tubes, and Hoses ............................. 20
Wiring........................................................... 20
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
Front Propel Pump Charge Filter - Replace .. 180
Fuel System - Prime ...................................... 181
Fuel System Primary Filter - Clean/Inspect/
Replace........................................................ 183
Fuel System Secondary Filter - Replace ....... 184
Fuel Tank Cap Filter and Strainer - Replace/
Clean ........................................................... 186
Fuel Tank Water and Sediment - Drain.......... 187
KEBU7565
G
General Hazard Information ............................ 14
Containing Fluid Spillage ............................. 16
Dispose of Waste Properly........................... 17
Fluid Penetration.......................................... 15
Inhalation ..................................................... 16
Pressurized Air and Water ........................... 15
Trapped Pressure ........................................ 15
General Information......................................... 31
Guards (Operator Protection) .......................... 29
Other Guards (If Equipped).......................... 29
Rollover Protective Structure (ROPS), Falling
Object Protective Structure (FOPS) or Tip
Over Protection Structure (TOPS) ............. 29
H
Hydraulic System Oil - Change...................... 188
Hydraulic System Oil Level - Check .............. 189
Hydraulic System Return Filter - Replace...... 189
Hydraulic Tank Breather - Replace................ 190
Hydraulic Tank Screen - Clean ...................... 190
I
Identification Information ................................. 42
Important Safety Information ............................. 2
Indicators and Gauges - Test......................... 190
L
Leaving the Machine ..................................... 121
Lifting and Tying Down the Machine.............. 124
Lifting the Machine..................................... 124
Tying Down the Machine............................ 124
Load Controller ................................................ 96
Lubricant Viscosities...................................... 135
Biodiesel .................................................... 141
Cat Engines .............................................. 136
Cat Hydraulic Systems and Hydrostatic
Transmissions.......................................... 138
Cat ELC Extender .................................... 143
Coolant Recommendations ....................... 142
General Information for Lubricants ............ 135
Low Sulfur Diesel (LSD)............................. 141
Lubricating Grease..................................... 140
Reclaimer Mixers ....................................... 139
SCA............................................................ 143
Selecting the Viscosity ............................... 135
KEBU7565
Standard Factory Fill Fluids ....................... 144
Sulfur-free Diesel Fuel ............................... 141
Ultra-Low Sulfur Diesel (ULSD) ................. 141
Water.......................................................... 143
Lubricant Viscosities and Refill Capacities.... 135
M Inspect a Used Filter for Debris.................. 194
Machine Cleanup........................................... 122
Machine Cleanup Procedure......................... 122
Machine Operation .......................................... 49
Machine Service .............................................113
Maintenance Access ..................................... 131
Maintenance Interval Schedule ..................... 146
Every 10 Service Hours or Daily ................ 146
Every 100 Service Hours ........................... 147
Every 1000 Service Hours or 1 Year.......... 147
Every 12 000 Service Hours or 6 Years ..... 148
Every 2000 Service Hours or 1 Year.......... 148
Every 250 Service Hours or 3 Months ....... 147
Every 3 Years............................................. 148
Every 3000 Service Hours or 2 Years ........ 148
Every 50 Service Hours ............................. 146
Every 50 Service Hours or Weekly ............ 146
Every 500 Service Hours or 6 Months ....... 147
Every 6000 Service Hours or 3 Years ........ 148
Every Year.................................................. 148
Initial 20 Service Hours .............................. 146
Initial 250 Service Hours ............................ 147
Initial 50 Service Hours .............................. 146
Initial 500 Hours (for New Systems, Refilled
Systems, and Converted Systems).......... 147
When Required.......................................... 146
Maintenance Section..................................... 131
Maintenance Support .................................... 145
Manual Propel Override Control ...................... 97
Mirror (If Equipped).......................................... 52
Mirror Adjustment......................................... 53
Mixing Chamber Disc Hub - Lubricate (If
Equipped) .................................................... 191
Mixing Chamber Door Cylinder Ends (Front)
- Lubricate (If Equipped) .............................. 191
Mixing Chamber Door Cylinder Ends (Rear)
- Lubricate.................................................... 192
Mixing Chamber Door Hinges (Front) -
Lubricate ...................................................... 192
Mixing Chamber Door Hinges (Rear) -
Lubricate ...................................................... 192
Mixing Chamber Linkage - Lubricate............. 193
Mixing Chamber Tilt Cylinder Ends -
Lubricate ...................................................... 194
225
Index Section
Mounting and Dismounting.............................. 46
Alternate Exit................................................ 46
Machine Access System Specifications ...... 46
O
Oil Filter - Inspect........................................... 194
Operation......................................................... 24
Operation Information.............................. 99–100
Automatic Operation .................................. 106
Machine Control Reference ......................... 99
Operation of Rotor...................................... 104
Preparation for Operation .......................... 100
Starting Operation...................................... 104
Travel with the Rotor Locked ..................... 103
Operation Section............................................ 46
Operator Controls ............................................ 70
Circuit Breaker Controls............................... 90
Display Function Controls............................ 74
Display Information ...................................... 76
Engine Start Switch...................................... 89
Interior Dome Light....................................... 90
Operator Console Controls .......................... 71
Operator Side Console Controls.................. 86
Overhead Console....................................... 88
Operator Interlocks .......................................... 91
Engine Start Interlock................................... 91
Propel Interlocks .......................................... 92
Rotor Interlocks............................................ 92
Operator Station .............................................. 29
P
Parking .....................................................25, 119
Parking Brake - Check................................... 194
Parking Brake Manual Release ..................... 127
Operating Condition................................... 128
Plate Locations and Film Locations................. 42
Certification.................................................. 42
Product Information Section ............................ 31
Product Link..................................................... 55
Data Broadcasts .......................................... 55
Machine Security ......................................... 56
Operation in a Blast Site for Product Link ... 55
Regulatory Compliance ............................... 57
Propel Planetary Oil - Change....................... 195
Propel Planetary Oil - Check ......................... 195
Propel Planetary Oil Sample - Obtain............ 196
Push Bar.......................................................... 99
226
Index Section
Attaching to a Water Truck........................... 99
Storage ........................................................ 99
R
Radiator and Hydraulic Oil Cooler - Clean..... 196
Rear Propel Pump Charge Filter - Replace ... 199
Reference Information Section ...................... 221
Reference Material ........................................ 221
Additional Reference Material.................... 221
Reference Materials ...................................... 221
Refrigerant Dryer - Replace (If Equipped) ..... 201
Restricted Visibility .......................................... 23
Roading the Machine..................................... 123
Rollover Protective Structure (ROPS) -
Inspect ......................................................... 202
Rotor Bearing Reservoir Breather - Replace
..................................................................... 202
Rotor Bearing Reservoir Oil - Change ........... 202
Rotor Bearing Reservoir Oil Level - Check.... 203
Rotor Bearing Reservoir Oil Sample -
Obtain .......................................................... 203
Rotor Chain Drive Case Oil - Change............ 203
Rotor Clutch - Lubricate................................. 204
Rotor Clutch - Test/Adjust.............................. 204
Rotor Cutter Bits - Inspect/Replace ............... 205
Check and Inspect the Rotor Bits .............. 205
Removing a Rotor Bit ................................. 206
Replacing a Rotor Bit ................................. 205
Rotor Cutter Bits (Side) - Inspect/Replace..... 204
Rotor Drive Bearings - Lubricate ................... 206
Rotor Drive Differential............................... 206
Rotor Drive Differential Breather - Replace ... 207
Rotor Drive Differential Oil - Change ............. 207
Rotor Drive Differential Oil Level - Check ...... 207
Rotor Drive Differential Oil Sample - Obtain .. 207
Rotor Drive Differential Sump Screen -
Replace........................................................ 208
Rotor Drive Shaft Universal Joints -
Lubricate ...................................................... 208
Rotor Lift Cylinder Ends - Lubricate............... 209
Rotor Service Locks .......................................116
Rotor Service Lock......................................117
Rotor Service Switch...................................116
Rotor Shear Disc - Lubricate ......................... 209
Rotor Shear Disc Bolts - Inspect/Replace ..... 209
Rotor Torque Limiter Coupling - Inspect (If
Equipped) .................................................... 209
Rotor Transmission Breather - Replace ........ 210
Rotor Transmission Oil - Change .................. 210
Rotor Transmission Oil - Check......................211
KEBU7565
Rotor Transmission Oil Sample - Obtain ........211
Rotor Transmission Sump Screen -
Replace.........................................................211
S
S·O·S Information.......................................... 144
Safety Messages ............................................... 6
Crush Hazard, Read the Operation and
Maintenance Manual (6) .............................. 9
Crush Hazard, Stay Back (3) ......................... 8
Cutter Hazard and Rotor Movement Hazard,
Stay Back (4)................................................ 9
Do Not Operate (1)......................................... 8
Explosion Hazard (Ether) (8) ....................... 10
Flying Debris Hazard, Read the Operation and
Maintenance Manual (5) .............................. 9
Hot Fluid Under Pressure (9) ........................11
Improper Connections for Jump Start Cables
(7)............................................................... 10
Product Link (10)...........................................11
Seat Belt (2) ................................................... 8
Safety Section ................................................... 6
Seat ................................................................. 49
Seat Belt .......................................................... 50
Extension of the Seat Belt............................ 52
Seat Belt Adjustment for Non-Retractable Seat
Belts ........................................................... 50
Seat Belt Adjustment for Retractable Seat
Belts ........................................................... 52
Seat Belt - Inspect ......................................... 212
Seat Belt - Replace........................................ 212
Service Light Power Receptacle...................... 93
Servicing the Rotor .........................................113
Shipping the Machine .................................... 123
Loading the Machine.................................. 123
Slope Operation............................................... 26
Sound Information and Vibration Information.. 27
Sound Level Information.............................. 27
Sound Performance for Machines That Are
Offered in European Countries and in
Countries that Adopt the Directives of the
European Union ......................................... 27
“The European Union Physical Agents
(Vibration) Directive 2002/44/EC” .............. 27
Specifications .................................................. 31
Intended Use................................................ 31
Steering Cylinder Ends - Lubricate................ 213
Front Steering Cylinder Ends..................... 213
Rear Steering Cylinder Ends ..................... 213
Steering Knuckle - Lubricate ......................... 214
KEBU7565 227
Index Section

Steering Legs (Rear) - Lubricate ................... 214

Steering Linkage - Lubricate.......................... 215
Front Steering Linkage............................... 215
Rear Steering Linkage ............................... 215
Stopping the Engine .......................................119
Emergency Stop Knob ................................119
Secondary Emergency Stop ...................... 120
Stopping the Engine from the Operator Station
..................................................................119
Stopping the Engine if an Electrical
Malfunction Occurs ...................................... 120
Stopping the Machine.....................................119

T
Table of Contents............................................... 3
Tire Inflation - Check...................................... 215
Tire Inflation Information................................ 133
Tire Inflation Pressure Adjustment................. 133
Tire Operating Pressures........................... 133
Tire Inflation with Air ...................................... 133
Tire Inflation with Nitrogen ............................. 133
Tire Information................................................ 22
Tool Holder - Inspect/Replace ....................... 215
Check and Inspect the Tool Holders .......... 215
Installation of the Tool Holder..................... 217
Replacing a Damaged Tool Holder ............ 216
Towing Information ........................................ 125
Towing the Machine....................................... 125
Engine that is Running............................... 125
Engine that is Stopped............................... 126
Transportation Information............................. 123

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

W
Water Spray System Charge Filter -
Replace (If Equipped) .................................. 218
Water Spray System Nozzles - Clean (If
Equipped) .................................................... 219
Water Spray System Pump Oil - Change (If
Equipped) .................................................... 219
Water Spray System Pump Oil Level -
Check (If Equipped) ..................................... 220
Water Spray System Strainer - Clean............ 220
Welding on Machines and Engines with
Electronic Controls....................................... 145
228 KEBU7565
Index Section
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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