Operation and Maintenance Manual Motor Grader CAT 16M

SEBU7884-13November 2010

Operation andMaintenanceManual16M Motor GraderB9H1-Up (Machine)R9H1-Up (Machine)

SAFETY.CAT.COM

i03991620

Important Safety InformationMost accidents that involve product operation, maintenance and repair are caused by failure to observebasic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardoussituations before an accident occurs. A person must be alert to potential hazards. This person should alsohave the necessary training, skills and tools to perform these functions properly.

Improper operation, lubrication, maintenance or repair of this product can be dangerous andcould result in injury or death.Do not operate or perform any lubrication, maintenance or repair on this product, until you haveread 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 warningsare 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 asDANGER, 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 pictoriallypresented.

A non-exhaustive list of operations that may cause product damage are identified by NOTICE labelson 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 mustnot use this product in any manner different from that considered by this manual without firstsatisfying yourself that you have considered all safety rules and precautions applicable to theoperation of the product in the location of use, including site-specific rules and precautionsapplicable to the worksite. If a tool, procedure, work method or operating technique that is notspecifically recommended by Caterpillar is used, you must satisfy yourself that it is safe for youand for others. You should also ensure that the product will not be damaged or become unsafe bythe 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 thatwas 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 canaffect the service that is given to the product. Obtain the complete and most current information before youstart any job. Cat dealers have the most current information available.

When replacement parts are required for thisproduct Caterpillar recommends using Cat re-placement parts or parts with equivalent speci-fications including, but not limited to, physicaldimensions, type, strength and material.

Failure to heed this warning can lead to prema-ture failures, product damage, personal injury ordeath.

In the United States, the maintenance, replacement, or repair of the emission control devices andsystems may be performed by any repair establishment or individual of the owner's choosing.

SEBU7884-13 3Table of Contents

Table of Contents

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

Safety Section

Safety Messages .................................................... 6

Additional Messages ............................................. 14

General Hazard Information ................................. 18

Crushing Prevention and Cutting Prevention ........ 21

Burn Prevention .................................................... 21

Fire Prevention and Explosion Prevention ............ 22

Fire Safety ............................................................ 25

Fire Extinguisher Location .................................... 26

Tire Information ..................................................... 26

Electrical Storm Injury Prevention ......................... 26

Before Starting Engine .......................................... 27

Engine Starting ..................................................... 28

Before Operation .................................................. 28

Visibility Information .............................................. 29

Restricted Visibility ................................................ 29

Operation .............................................................. 30

Parking .................................................................. 31

Slope Operation .................................................... 32

Equipment Lowering with Engine Stopped ........... 33

Sound Information and Vibration Information ....... 33

Operator Station ................................................... 35

Guards (Operator Protection) ............................... 36

Product Information Section

General Information .............................................. 37

Identification Information ....................................... 39

Operation Section

Before Operation .................................................. 44

Machine Operation ............................................... 46

Engine Starting ..................................................... 96

Adjustments .......................................................... 99

Parking ................................................................ 100

Transportation Information .................................. 102

Jacking Location Information .............................. 106

Towing Information .............................................. 107

Engine Starting (Alternate Methods) ................... 109

Maintenance Section

Tire Inflation Information ...................................... 112

Lubricant Viscosities and Refill Capacities .......... 113

Maintenance Access ............................................ 119

Maintenance Support .......................................... 120

Maintenance Interval Schedule .......................... 123

Warranty Section

Warranty Information .......................................... 190

Reference Information Section

Reference Materials ............................................ 191

Index Section

Index ................................................................... 194

4 SEBU7884-13Foreword

ForewordLiterature InformationThis manual should be stored in the operator'scompartment in the literature holder or seat backliterature storage area.

This manual contains safety information, operationinstructions, transportation information, lubricationinformation and maintenance information.

Some photographs or illustrations in this publicationshow details or attachments that can be differentfrom your machine. Guards and covers might havebeen removed for illustrative purposes.

Continuing improvement and advancement ofproduct design might have caused changes to yourmachine 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 Caterpillardealer for the latest available information.

SafetyThe safety section lists basic safety precautions. Inaddition, this section identifies the text and locationsof warning signs and labels used on the machine.

Read and understand the basic precautions listedin the safety section before operating or performinglubrication, maintenance and repair on this machine.

OperationThe operation section is a reference for the newoperator and a refresher for the experiencedoperator. This section includes a discussion ofgauges, switches, machine controls, attachmentcontrols, transportation and towing information.

Photographs and illustrations guide the operatorthrough correct procedures of checking, starting,operating and stopping the machine.

Operating techniques outlined in this publication arebasic. Skill and techniques develop as the operatorgains knowledge of the machine and its capabilities.

MaintenanceThe maintenance section is a guide to equipmentcare. The Maintenance Interval Schedule (MIS) liststhe items to be maintained at a specific serviceinterval. Items without specific intervals are listedunder the "When Required" service interval. TheMaintenance Interval Schedule lists the pagenumber for the step-by-step instructions required toaccomplish the scheduled maintenance. Use theMaintenance Interval Schedule as an index or "onesafe source" for all maintenance procedures.

Maintenance Intervals

Use the service hour meter to determine servicingintervals. Calendar intervals shown (daily, weekly,monthly, etc.) can be used instead of service hourmeter intervals if they provide more convenientservicing schedules and approximate the indicatedservice hour meter reading. Recommended serviceshould always be performed at the interval thatoccurs first.

Under extremely severe, dusty or wet operatingconditions, more frequent lubrication than isspecified in the maintenance intervals chart mightbe necessary.

Perform service on items at multiples of the originalrequirement. For example, at every 500 servicehours or 3 months, also service those items listedunder every 250 service hours or monthly and every10 service hours or daily.

California Proposition 65 WarningDiesel engine exhaust and some of its constituentsare known to the State of California to cause cancer,birth defects, and other reproductive harm.

Battery posts, terminals and related accessoriescontain lead and lead compounds. Wash handsafter handling.

Certified Engine MaintenanceProper maintenance and repair is essential to keepthe engine and machine systems operating correctly.As the heavy duty off-road diesel engine owner, youare responsible for the performance of the requiredmaintenance listed in the Owner Manual, Operationand Maintenance Manual, and Service Manual.

SEBU7884-13 5Foreword

It is prohibited for any person engaged in thebusiness of repairing, servicing, selling, leasing, ortrading engines or machines to remove, alter, orrender inoperative any emission related device orelement of design installed on or in an engine ormachine that is in compliance with the regulations(40 CFR Part 89). Certain elements of the machineand engine such as the exhaust system, fuel system,electrical system, intake air system and coolingsystem may be emission related and should not bealtered unless approved by Caterpillar.

Machine CapacityAdditional attachments or modifications may exceedmachine design capacity which can adversely affectperformance characteristics. Included would bestability and system certifications such as brakes,steering, and rollover protective structures (ROPS).Contact your Caterpillar dealer for further information.

Caterpillar Product IdentificationNumberEffective First Quarter 2001 the Caterpillar ProductIdentification Number (PIN) has changed from 8 to 17characters. In an effort to provide uniform equipmentidentification, Caterpillar and other constructionequipment manufacturers are moving to complywith the latest version of the product identificationnumbering standard. Non-road machine PINs aredefined by ISO 10261. The new PIN format will applyto all Caterpillar machines and generator sets. ThePIN plates and frame marking will display the 17character PIN. The new format will look like thefollowing:

g00751314Illustration 1

Where:

1. Caterpillar's World Manufacturing Code (characters1-3)

2. Machine Descriptor (characters 4-8)

3. Check Character (character 9)

4. Machine Indicator Section (MIS) or ProductSequence Number (characters 10-17). These werepreviously referred to as the Serial Number.

Machines and generator sets produced before FirstQuarter 2001 will maintain their 8 character PINformat.

Components such as engines, transmissions, axles,etc. and work tools will continue to use an 8 characterSerial Number (S/N).

6 SEBU7884-13Safety SectionSafety Messages

Safety Sectioni03998218

Safety MessagesSMCS Code: 7000


SEBU7884-13 7Safety Section

Safety Messages



There are several specific safety messages on thismachine. The exact location of the hazards andthe description of the hazards are reviewed in thissection. Please become familiarized with all safetymessages.

Make sure that all of the safety messages are legible.Clean the safety messages or replace the safetymessages if you cannot read the words. Replacethe illustrations if the illustrations are not legible.When you clean the safety messages, use a cloth,water, and soap. Do not use solvent, gasoline, orother harsh chemicals to clean the safety messages.Solvents, gasoline, or harsh chemicals could loosenthe adhesive that secures the safety message. Looseadhesive will allow the safety message to fall.

Replace any safety message that is damaged, ormissing. If a safety message is attached to a partthat is replaced, install a safety message on thereplacement part. Any Caterpillar dealer can providenew safety messages.


Do Not Operate (1)This safety message is located on the right side ofthe operator compartment.

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Do not operate or work on this machine unlessyou have read and understand the instructionsand warnings in the Operation and MaintenanceManuals. Failure to follow the instructions or heedthe warnings could result in injury or death. Con-tact any Caterpillar dealer for replacement manu-als. Proper care is your responsibility.

Unplanned Blade Movement (2)This safety message is positioned on the main switchpanel on the right side of the operator compartment.

g01379159

Personal injury could result from sudden move-ment of the blade when the centershift lockpin isreleased. To prevent unexpected blade movementand possible injury, lower the blade to the groundbefore you unlock the centershift linkage. See theOperation and Maintenance manual for completeinstructions before releasing the centershift lock-pin.

Refer to centershift lock switch inOperation andMaintenance Manual, Operator Controls for moreinformation.


Safety Messages

Improper Connections For JumpStart Cables (3)This safety message is positioned below the batteriesinside the service center.

g01370909

Explosion Hazard! Improper jumper cable connec-tions can cause an explosion resulting in seriousinjury or death. Batteries may be located in sep-arate compartments. Refer to the Operation andMaintenance Manual for the correct jump startingprocedure.

Refer to Operation and Maintenance Manual, EngineStarting with Jump Start Cables for more information.

No Clearance (4)This safety message is positioned at the front rightand the front left of the engine compartment.

g01371644

Stay back a safe distance. No clearance for a per-son in this area when the machine turns. Severeinjury or death from crushing could occur.

Product Link (5) (If Equipped)This safety message is attached to the dash or toanother area of the cab that is visible to the operator.

g01370917

This machine is equipped with a CaterpillarProduct Link communication device. When elec-tric/electronic detonators are used, this com-munication device should be deactivated within12 m (40 ft) of a blast site, or within the distancemandated under applicable legal requirements.Failure to do so could cause interference withblasting operations and result in serious injury ordeath.


Seat Belt (6)This safety message is located on the left side of theoperator compartment.

g01371636

A seat belt should be worn at all times during ma-chine operation to prevent serious injury or deathin 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.

Refer to Operation and Maintenance Manual, SeatBelt for more information.

Do Not Weld On The ROPS/FOPSStructure (7)This safety message is positioned on the ROPS.

g01211894

Structural damage, an overturn, modification, al-teration, or improper repair can impair this struc-ture's protection capability thereby voiding thiscertification. Do not weld on or drill holes in thestructure. This will void the certification. Consulta Caterpillar dealer to determine this structure'slimitations without voiding its certification.

This machine has been certified to the standardsthat are listed on the certification film. The maximummass of the machine, which includes the operatorand the attachments without a payload, should notexceed the mass on the certification film.

Refer to Operation and Maintenance Manual,Guards (Operator Protection) for more information.


Safety Messages

Engine Coolant (8)This safety message is positioned inside the coverfor the radiator cap.

g01371640

Pressurized system! Hot coolant can cause seri-ous burns, injury or death. To open the coolingsystem filler cap, stop the engine and wait untilthe cooling system components are cool. Loosenthe cooling system pressure cap slowly in order torelieve the pressure. Read and understand the Op-eration and Maintenance Manual before perform-ing any cooling system maintenance.

Refer to Operation and Maintenance Manual,Cooling System Coolant Level - Check for moreinformation.

Accumulator (9)This safety message is located on the blade cushionaccumulator which is located on the left-hand sideof the front frame.

g01325881

High Pressure Cylinder.

Rapid discharging from disconnecting or disas-sembly can result in personal injury or death. Seeyour Caterpillar dealer for tools and instructionsfor relieving pressure or charging. Precharge on-ly with dry nitrogen gas.

Refer to Operation and Maintenance Manual, BladeCushion Accumulator - Check for more information.


Accumulator (10)This safety message is positioned on the brakeaccumulators. The brake accumulators are located atthe rear of the cab.

g01371642

Hydraulic accumulator contains gas and oil underhigh pressure. Improper removal or repair proce-dures could cause severe injury. To remove or re-pair, instructions in the service manual must befollowed. Special equipment is required for test-ing and charging.

Refer to Operation and Maintenance Manual, BrakeAccumulator - Check for more information.

No Clearance (11)This safety message is positioned at the front left ofthe engine compartment.

g01371647

Connect the steering frame lock between the frontand the rear frames before lifting, transporting, orservicing the machine in the articulation area. Dis-connect the steering frame lock and secure thesteering frame lock before resuming operation.Severe injury or death could occur.


Safety Messages

Hydraulic System Oil (12)This safety message is positioned near the hydraulictank filler cap and this safety message is locatednear the hydraulic tank sight gauge.

g01637005

If the incorrect hydraulic oil viscosity is installedand themachine is operated in cold temperatures,the machine hydraulic system may not respond atnormal speeds. Sluggish machine control couldresult in injury or death. Use the correct oil vis-cosity for operating the machine in cold weath-er, and warm-up the machine before operating themachine in cold weather. See Operation and Main-tenance Manual, Engine and Machine Warm-Upfor more information on operation in cold tem-peratures. See Operation and Maintenance Man-ual, Lubricant Viscosities for the recommend-ed oil viscosity. If the hydraulic oil needs to bechanged, see Operation and Maintenance Manu-al, Hydraulic System Oil - Change for the proce-dure to change the hydraulic system oil.

Recoil Spring (13)This safety message is positioned at the bottom ofthe parking brake housing.

g01379131

This housing contains a highly compressedspring that can cause injury or death. Do notdisassemble this parking brake housing until youhave read and understand the correct procedurefor disassembly in the Service Manual.

14 SEBU7884-13Safety SectionAdditional Messages

i03827651

Additional MessagesSMCS Code: 7000



Additional Messages



There are several specific messages on this machine.The exact location of the hazards and the descriptionof the hazards are reviewed in this section. Pleasebecome familiarized with all messages.

Make sure that all of the messages are legible.Clean the messages or replace the messages ifyou cannot read the words. Replace the illustrationsif the illustrations are not legible. When you cleanthe messages, use a cloth, water and soap. Do notuse solvent, gasoline, or other harsh chemicals toclean the messages. Solvents, gasoline, or harshchemicals could loosen the adhesive that secures themessages. Loose adhesive will allow the messagesto fall.

Replace any message that is damaged, or missing.If a message is attached to a part that is replaced,install a message on the replacement part. AnyCaterpillar dealer can provide new messages.

Air Conditioner (1)

This message is located inside the enginecompartment near the hinges of the right front accessdoor.

16 SEBU7884-13Safety SectionAdditional Messages


Read the service manual before you perform anymaintenance on the air conditioner.

Alternate Exit (2)

This message is located on the door latch for theright door.


If the primary exit is blocked, exit the machinethrough the door on the right side of the machine.

Do Not Weld and Do Not Drill. (3)

This message is located on the left hand side of thefront frame.


Do not weld or drill the frame. Refer to Operation andMaintenance Manual, Guards (Operator Protection)for more information.

Alternate Exit (4)

If your machine is equipped with a snow wing, thismessage is located on the left ROPS support at therear of the operator's compartment.


If the primary exits are blocked, use the hammerto break the window. Exit the machine through thewindow.

Cat Extended Life Coolant (ELC) (5)

This message is located on the underside of theradiator cap access cover on top of the enginecompartment.


Refer to Operation and Maintenance Manual,Cooling System Coolant (ELC) - Change andOperation and Maintenance Manual, CoolingSystem Coolant Extender (ELC) - Add for moreinformation.

Data Privacy (6)


Additional Messages


This message is located in the cab on the left post.

Fuel Filler (7)

This message is located on the fuel tank near thefast fill fuel adapter.


NOTICEUse only a Caterpillar approved fast fill system to fuelmachines. Over pressurization may cause tank defor-mation and fuel spillage.

Contact your Cat dealer for fast fill system availability.

Refer to Operation and Maintenance Manual, FuelSystem - Fill for more information.

Articulation Bearing (8)

This message is located on the front left side of thetop hitch assembly near the grease points for thearticulation bearing.


Hydraulic System Oil (9)

This message is located near the hydraulic tank fillercap. A grease pen may be used on the left handside of this film to write down the current hydraulicoil viscosity.

Refer to Operation and Maintenance Manual,Monitoring System and Operation and MaintenanceManual, Hydraulic System Oil - Change for moreinformation to ensure that the correct oil type isselected in Messenger .


24 V (10)

This message is located near the auxiliary startreceptacle.

18 SEBU7884-13Safety SectionGeneral Hazard Information


Engine Oil Drain (11)

This message is located at the left rear of themachine near the drain valve for the engine oil.


Hydraulic Tank Drain (12)

This message is located at the left rear of the machinenear the drain valve for the hydraulic system.


i04010649

General Hazard InformationSMCS Code: 7000


Attach a Do Not Operate warning tag or a similarwarning tag to the start switch or to the controls.Attach the warning tag before you service theequipment or before you repair the equipment. Thesewarning tags (Special Instruction, SEHS7332) areavailable from your Cat dealer.

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

Know the width of your equipment in order to maintainproper clearance when you operate the equipmentnear fences or near boundary obstacles.

Be aware of high voltage power lines and powercables that are buried. If the machine comes incontact with these hazards, serious injury or deathmay occur from electrocution.



General Hazard Information

Wear a hard hat, protective glasses, and otherprotective equipment, as required.

Do not wear loose clothing or jewelry that can snagon controls or on other parts of the equipment.

Make sure that all protective guards and all coversare secured in place on the equipment.

Keep the equipment free from foreign material.Remove debris, oil, tools, and other items from thedeck, 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 andthe personnel that are authorized to give the handsignals. 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 thatcontacts air conditioner refrigerant can cause bodilyharm or death. Inhaling gas from air conditionerrefrigerant through a lighted cigarette can causebodily 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 allnecessary repairs.

Do not allow unauthorized personnel on theequipment.

Unless you are instructed otherwise, performmaintenance with the equipment in the servicingposition. Refer to Operation and Maintenance Manualfor the procedure for placing the equipment in theservicing position.

When you perform maintenance above ground level,use appropriate devices such as ladders or man liftmachines. If equipped, use the machine anchoragepoints and use approved fall arrest harnesses andlanyards.

Pressurized Air and WaterPressurized air and/or water can cause debris and/orhot water to be blown out. The debris and/or hotwater could result in personal injury.

When pressurized air and/or pressurized water isused for cleaning, wear protective clothing, protectiveshoes, and eye protection. Eye protection includesgoggles or a protective face shield.

The maximum air pressure for cleaning purposesmust be reduced to 205 kPa (30 psi) when thenozzle is deadheaded and the nozzle is used withan effective chip deflector and personal protectiveequipment. The maximum water pressure forcleaning purposes must be below 275 kPa (40 psi).

Trapped PressurePressure can be trapped in a hydraulic system.Releasing trapped pressure can cause suddenmachine movement or attachment movement. Usecaution if you disconnect hydraulic lines or fittings.High-pressure oil that is released can cause a hoseto whip. High-pressure oil that is released can causeoil to spray. Fluid penetration can cause seriousinjury and possible death.

Fluid PenetrationPressure can be trapped in the hydraulic circuit longafter the engine has been stopped. The pressure cancause hydraulic fluid or items such as pipe plugs toescape rapidly if the pressure is not relieved correctly.

Do not remove any hydraulic components or partsuntil pressure has been relieved or personal injurymay occur. Do not disassemble any hydrauliccomponents or parts until pressure has been relievedor personal injury may occur. Refer to the ServiceManual for any procedures that are required torelieve the hydraulic pressure.


Always use a board or cardboard when you checkfor a leak. Leaking fluid that is under pressure canpenetrate body tissue. Fluid penetration can causeserious injury and possible death. A pin hole leak cancause severe injury. If fluid is injected into your skin,you must get treatment immediately. Seek treatmentfrom a doctor that is familiar with this type of injury.

20 SEBU7884-13Safety SectionGeneral Hazard Information

Containing Fluid SpillageCare must be taken in order to ensure that fluidsare contained during performance of inspection,maintenance, testing, adjusting, and repair of theequipment. Prepare to collect the fluid with suitablecontainers before opening any compartment ordisassembling any component that contains fluids.

Refer to Special Publication, NENG2500, CaterpillarDealer Service Tool Catalog for the following items:

Tools that are suitable for collecting fluids andequipment that is suitable for collecting fluids

Tools that are suitable for containing fluids andequipment that is suitable for containing fluids

Obey all local regulations for the disposal of liquids.

Inhalation


Exhaust

Use caution. Exhaust fumes can be hazardousto your health. If you operate the machine in anenclosed area, adequate ventilation is necessary.

Asbestos Information

Cat equipment and replacement parts that areshipped from Caterpillar are asbestos free.Caterpillar recommends the use of only genuineCat replacement parts. Use the following guidelineswhen you handle any replacement parts that containasbestos or when you handle asbestos debris.

Use caution. Avoid inhaling dust that might begenerated when you handle components that containasbestos fibers. Inhaling this dust can be hazardousto your health. The components that may containasbestos fibers are brake pads, brake bands, liningmaterial, clutch plates, and some gaskets. Theasbestos that is used in these components is boundin a resin or sealed in some way. Normal handlingis not hazardous unless airborne dust that containsasbestos is generated.

If dust that may contain asbestos is present, thereare several guidelines that should be followed:

Never use compressed air for cleaning.

Avoid brushing materials that contain asbestos.

Avoid grinding materials that contain asbestos.

Use a wet method in order to clean up asbestosmaterials.

A vacuum cleaner that is equipped with a highefficiency particulate air filter (HEPA) can also beused.

Use exhaust ventilation on permanent machiningjobs.

Wear an approved respirator if there is no otherway to control the dust.

Comply with applicable rules and regulationsfor the work place. In the United States, useOccupational Safety and Health Administration(OSHA) requirements. These OSHA requirementscan be found in 29 CFR 1910.1001.

Obey environmental regulations for the disposalof asbestos.

Stay away from areas that might have asbestosparticles in the air.


Crushing Prevention and Cutting Prevention

Dispose of Waste Properly


Improperly disposing of waste can threaten theenvironment. Potentially harmful fluids should bedisposed of according to local regulations.

Always use leakproof containers when you drainfluids. Do not pour waste onto the ground, down adrain, or into any source of water.

i01359664

Crushing Prevention andCutting PreventionSMCS Code: 7000

Support the equipment properly before you performany work or maintenance beneath that equipment.Do not depend on the hydraulic cylinders to holdup the equipment. Equipment can fall if a control ismoved, or if a hydraulic line breaks.

Do not work beneath the cab of the machine unlessthe cab is properly supported.

Unless you are instructed otherwise, never attemptadjustments while the machine is moving or whilethe engine is running.

Never jump across the starter solenoid terminalsin order to start the engine. Unexpected machinemovement could result.

Whenever there are equipment control linkages theclearance in the linkage area will change with themovement of the equipment or the machine. Stayclear of areas that may have a sudden change inclearance with machine movement or equipmentmovement.

Stay clear of all rotating and moving parts.

If it is necessary to remove guards in order to performmaintenance, always install the guards after themaintenance is performed.

Keep objects away from moving fan blades. The fanblade 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 retainerpin can fly out. The loose retainer pin can injurepersonnel. Make sure that the area is clear of peoplewhen you strike a retainer pin. To avoid injury toyour eyes, wear protective glasses when you strikea retainer pin.

Chips or other debris can fly off an object when youstrike the object. Make sure that no one can beinjured by flying debris before striking any object.

i01329099

Burn PreventionSMCS Code: 7000

Do not touch any part of an operating engine.Allow the engine to cool before any maintenance isperformed on the engine. Relieve all pressure in theair system, in the oil system, in the lubrication system,in the fuel system, or in the cooling system beforeany lines, fittings or related items are disconnected.

CoolantWhen the engine is at operating temperature, theengine coolant is hot. The coolant is also underpressure. The radiator and all lines to the heaters orto the engine contain hot coolant.

Any contact with hot coolant or with steam can causesevere burns. Allow cooling system components tocool before the cooling system is drained.

Check the coolant level only after the engine hasbeen stopped.

Ensure that the filler cap is cool before removing thefiller cap. The filler cap must be cool enough to touchwith a bare hand. Remove the filler cap slowly inorder to relieve pressure.

Cooling system conditioner contains alkali. Alkali cancause personal injury. Do not allow alkali to contactthe skin, the eyes, or the mouth.

22 SEBU7884-13Safety SectionFire Prevention and Explosion Prevention

OilsHot oil and hot components can cause personalinjury. 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 theengine has been stopped. The filler cap must becool enough to touch with a bare hand. Follow thestandard procedure in this manual in order to removethe hydraulic tank filler cap.

BatteriesElectrolyte is an acid. Electrolyte can cause personalinjury. Do not allow electrolyte to contact the skin orthe eyes. Always wear protective glasses for servicingbatteries. Wash hands after touching the batteriesand connectors. Use of gloves is recommended.

i04090611

Fire Prevention and ExplosionPreventionSMCS Code: 7000


GeneralAll fuels, most lubricants, and some coolant mixturesare flammable.

To minimize the risk of fire or explosion, Caterpillarrecommends the following actions.

Always perform a Walk-Around Inspection, whichmay help you identify a fire hazard. Do not operate amachine when a fire hazard exists. Contact your Catdealer for service.

Understand the use of the primary exit and alternativeexit on the machine. Refer to Operation andMaintenance Manual, Alternative Exit.

Do not operate a machine with a fluid leak. Repairleaks and clean up fluids before resuming machineoperation. Fluids that are leaking or spilled onto hotsurfaces or onto electrical components can cause afire. A fire may cause personal injury or death.

Remove flammable material such as leaves,twigs, papers, trash, and so on. These items mayaccumulate in the engine compartment or aroundother hot areas and hot parts on the machine.

Keep the access doors to major machinecompartments closed and access doors in workingcondition in order to permit the use of fire suppressionequipment, in case a fire should occur.

Clean all accumulations of flammable materials suchas fuel, oil, and debris from the machine.

Do not operate the machine near any flame.

Keep shields in place. Exhaust shields (if equipped)protect hot exhaust components from oil spray or fuelspray in case of a break in a line, in a hose, or in aseal. Exhaust shields must be installed correctly.

Do not weld or flame cut on tanks or lines that containflammable fluids or flammable material. Empty andpurge the lines and tanks. Then clean the lines andtanks with a nonflammable solvent prior to weldingor flame cutting. Ensure that the components areproperly grounded in order to avoid unwanted arcs.

Dust that is generated from repairing nonmetallichoods or fenders may be flammable and/or explosive.Repair such components in a well ventilated areaaway from open flames or sparks. Use suitablePersonal Protection Equipment (PPE).

Inspect all lines and hoses for wear or deterioration.Replace damaged lines and hoses. The lines andthe hoses should have adequate support and secureclamps. Tighten all connections to the recommendedtorque. Damage to the protective cover or insulationmay provide fuel for fires.

Store fuels and lubricants in properly markedcontainers away from unauthorized personnel. Storeoily rags and flammable materials in protectivecontainers. Do not smoke in areas that are used forstoring flammable materials.


Fire Prevention and Explosion Prevention


Use caution when you are fueling a machine. Do notsmoke while you are fueling a machine. Do not fuela machine near open flames or sparks. Always stopthe engine before fueling. Fill the fuel tank outdoors.Properly clean areas of spillage.

Follow practices for safe fueling that are describedin the Operation section of the Operation andMaintenance Manual section and follow localregulations. Never store flammable fluids in theoperator compartment of the machine.

Battery and Battery Cables


Caterpillar recommends the following in order tominimize the risk of fire or an explosion related tothe battery.

Do not operate a machine if battery cables or relatedparts show signs of wear or damage. Contact yourCat dealer for service.

Follow safe procedures for engine starting withjump-start cables. Improper jumper cable connectionscan cause an explosion that may result in injury.Refer to Operation and Maintenance Manual,Engine Starting with Jump Start Cables for specificinstructions.

Do not charge a frozen battery. This may cause anexplosion.

Gases from a battery can explode. Keep any openflames or sparks away from the top of a battery. Donot smoke in battery charging areas.

Never check the battery charge by placing a metalobject across the terminal posts. Use a voltmeter inorder to check the battery charge.

Daily inspect battery cables that are in areas thatare visible. Inspect cables, clips, straps, and otherrestraints for damage. Replace any damaged parts.Check for signs of the following, which can occurover time due to use and environmental factors:

Fraying

Abrasion

Cracking

Discoloration

Cuts on the insulation of the cable

Fouling

Corroded terminals, damaged terminals, and looseterminals

Replace damaged battery cable(s) and replaceany related parts. Eliminate any fouling, which mayhave caused insulation failure or related componentdamage or wear. Ensure that all components arereinstalled correctly.

An exposed wire on the battery cable may causea short to ground if the exposed area comes intocontact with a grounded surface. A battery cableshort produces heat from the battery current, whichmay be a fire hazard.

24 SEBU7884-13Safety SectionFire Prevention and Explosion Prevention

An exposed wire on the ground cable between thebattery and the disconnect switch may cause thedisconnect switch to be bypassed if the exposed areacomes into contact with a grounded surface. Thismay result in an unsafe condition for servicing themachine. Repair components or replace componentsbefore servicing the machine.

Fire on a machine can result in personal injuryor death. Exposed battery cables that come intocontact with a grounded connection can result infires. Replace cables and related parts that showsigns of wear or damage. Contact your Cat dealer.

WiringCheck electrical wires daily. If any of the followingconditions exist, replace parts before you operatethe machine.

Fraying

Signs of abrasion or wear

Cracking

Discoloration

Cuts on insulation

Other damage

Make sure that all clamps, guards, clips, and strapsare reinstalled correctly. This will help to preventvibration, rubbing against other parts, and excessiveheat during machine operation.

Attaching electrical wiring to hoses and tubes thatcontain flammable fluids or combustible fluids shouldbe avoided.

Consult your Cat dealer for repair or for replacementparts.

Keep wiring and electrical connections free of debris.

Lines, Tubes, and HosesDo not bend high-pressure lines. Do not strikehigh-pressure lines. Do not install any lines thatare bent or damaged. Use the appropriate backupwrenches in order to tighten all connections to therecommended torque.


Check lines, tubes, and hoses carefully. WearPersonal Protection Equipment (PPE) in order tocheck for leaks. Always use a board or cardboardwhen you check for a leak. Leaking fluid that is underpressure can penetrate body tissue. Fluid penetrationcan cause serious injury and possible death. A pinhole leak can cause severe injury. If fluid is injectedinto your skin, you must get treatment immediately.Seek treatment from a doctor that is familiar with thistype of injury.

Replace the affected parts if any of the followingconditions are present:

End fittings are damaged or leaking.

Outer coverings are chafed or cut.

Wires are exposed.

Outer coverings are swelling or ballooning.

Flexible parts of the hoses are kinked.

Outer covers have exposed embedded armoring.

End fittings are displaced.

Make sure that all clamps, guards, and heat shieldsare installed correctly. During machine operation, thiswill help to prevent vibration, rubbing against otherparts, excessive heat, and failure of lines, tubes, andhoses.

Do not operate a machine when a fire hazardexists. Repair any lines that are corroded, loose,or damaged. Leaks may provide fuel for fires.Consult your Cat dealer for repair or for replacementparts. Use genuine Cat parts or the equivalent, forcapabilities of both the pressure limit and temperaturelimit.


Fire Safety

EtherEther (if equipped) is commonly used in cold-weatherapplications. Ether is flammable and poisonous.

Follow the correct cold engine starting procedures.Refer to the section in the Operation and MaintenanceManual with the label Engine Starting.

Do not spray ether manually into an engine if themachine is equipped with a thermal starting aid forcold weather starting.

Use ether in well ventilated areas. Do not smokewhile you are replacing an ether cylinder or while youare using an ether spray.

Do not store ether cylinders in living areas or in theoperator compartment of a machine. Do not storeether cylinders in direct sunlight or in temperaturesabove 49 C (120.2 F). Keep ether cylinders awayfrom open flames or sparks.

Dispose of used ether cylinders properly. Do notpuncture an ether cylinder. Keep ether cylindersaway from unauthorized personnel.

Fire ExtinguisherAs an additional safety measure, keep a fireextinguisher on the machine.

Be familiar with the operation of the fire extinguisher.Inspect the fire extinguisher and service the fireextinguisher regularly. Follow the recommendationson the instruction plate.

Consider installation of an aftermarket FireSuppression System, if the application and workingconditions warrant the installation.

i04025591

Fire SafetySMCS Code: 7000

Note: Locate secondary exits and how to use thesecondary exits before you operate the machine.

Note: Locate fire extinguishers and how to use a fireextinguisher before you operate the machine.

If you find that you are involved in a machine fire, yoursafety and that of others on site is the top priority.The following actions should only be performed if theactions do not present a danger or risk to you andany nearby people. At all times you should assessthe risk of personal injury and move away to a safedistance as soon as you feel unsafe.

Move the machine away from nearby combustiblematerial such as fuel/oil stations, structures, trash,mulch, and timber.

Lower any implements and turn off the engine assoon as possible. If you leave the engine running,the engine will continue to feed a fire. The fire willbe fed from any damaged hoses that are attachedto the engine or pumps.

If possible, turn the battery disconnect switch to theOFF position. Disconnecting the battery will removethe ignition source in the event of an electrical short.Disconnecting the battery will eliminate a secondignition source if electrical wiring is damaged by thefire, resulting in a short circuit.

Notify emergency personnel of the fire and yourlocation.

If your machine is equipped with a fire suppressionsystem, follow the manufacturers procedure foractivating the system.

Note: Fire suppression systems need to be regularlyinspected by qualified personnel. You must be trainedto operate the fire suppression system.

Use the on-board fire extinguisher and use thefollowing procedure:

1. Pull the pin.

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

3. Squeeze the handle and release the extinguishingagent.

4. Sweep the extinguisher from side to side acrossthe base of the fire until the fire is out.

Remember, if you are unable to do anything else,shut off the machine before exiting. By shutting offthe machine, fuels will not continue to be pumpedinto the fire.

If the fire grows out of control, be aware of thefollowing risks:

Tires on wheeled machines pose a risk of explosionas tires burn. Hot shrapnel and debris can bethrown great distances in an explosion.

Tanks, accumulators, hoses, and fittings canrupture in a fire, spraying fuels and shrapnel over alarge area.

26 SEBU7884-13Safety SectionFire Extinguisher Location

Remember that nearly all of the fluids on themachine are flammable, including coolant and oils.Additionally, plastics, rubbers, fabrics, and resinsin fiberglass panels are also flammable.

i03755313

Fire Extinguisher LocationSMCS Code: 7000

Do not weld a bracket on the Rollover ProtectiveStructure (ROPS) in order to install the fireextinguisher. Also, do not drill holes in the ROPS inorder to mount the fire extinguisher on the ROPS.

i04123892

Tire InformationSMCS Code: 7000

Explosions of air inflated tires have resulted fromheat-induced gas combustion inside the tires.Explosions can be caused by heat that is generatedby welding, by heating rim components, by externalfire, or by excessive use of brakes.

A tire explosion is much more violent than ablowout. The explosion can propel the tire, the rimcomponents, and the axle components from themachine. Stay out of the trajectory path. Both theforce of the explosion and the flying debris can causeproperty damage, personal injury, or death.

g02166933Illustration 29Typical example of tire is shown

Do not approach a hot or an apparently damaged tire.

Caterpillar recommends against using water orcalcium as a ballast for the tires. Ballast, such as fluidin the tires, increases overall machine weight andmay affect braking, steering, power train components,or the certification of the protective structure such asthe ROPS. The use of tire/rim rust preventatives orother liquid additives is not required.

Dry nitrogen gas is recommended for inflation of tires.If the tires were originally inflated with air, nitrogenis still preferred for adjusting the pressure. Nitrogenmixes properly with air.

Nitrogen inflated tires reduce the potential ofa tire explosion because nitrogen does not aidcombustion. Nitrogen helps to prevent oxidation ofthe rubber, deterioration of rubber, and corrosion ofrim components.

To avoid overinflation, proper nitrogen inflationequipment and training in the usage of the equipmentare necessary. A tire blowout or a rim failure canresult from improper equipment or from misusedequipment.

When you inflate a tire, stand behind the tread anduse a self-attaching chuck.

Servicing tires and rims can be dangerous. Onlytrained personnel that use proper tools and properprocedures should perform this maintenance. Ifcorrect procedures are not used for servicing tiresand rims, the assemblies could burst with explosiveforce. This explosive force can cause seriouspersonal injury or death. Carefully obey the specificinstructions from your tire dealer.

i01122596

Electrical Storm InjuryPreventionSMCS Code: 7000

When lightning is striking in the vicinity of themachine, the operator should never attempt thefollowing procedures:

Mount the machine.

Dismount the machine.

If you are in the operator's station during an electricalstorm, stay in the operator's station. If you are on theground during an electrical storm, stay away fromthe vicinity of the machine.


Before Starting Engine

i03756097

Before Starting EngineSMCS Code: 1000; 7000


Remove pin (1). Remove the frame lock pin (2) fromthe frame. Store frame lock pin in storage bracket (3).Replace pin (1). Frame lock pin (2) must be removedin order to articulate the machine. Refer to Operationand Maintenance Manual, Steering Frame Lock formore information.


Remove wheel lean locking bolt (4) from the lockedposition.

NOTICEDo not operate the machine with the wheel lean boltin the locked position. Machine damage may occur.

Start the engine only from the operator'scompartment. Never short across the starterterminals or across the batteries. Shorting couldbypass the engine neutral start system. Shortingcould also damage the electrical system.


Depress the horn button (5) in order to make surethat the machine horn works properly.


The mirrors on your machine may be different. Adjustthe mirrors for the best operator vision. Adjust theinside mirror or the inside mirrors before you operatethe machine. If the machine is equipped with outsidemirrors, adjust the outside mirrors before you operatethe machine. Refer to Operation and MaintenanceManual, Mirror for more information on the mirroradjustment.

Inspect the condition of the seat belt and the conditionof mounting hardware. Replace any damaged partsand any worn parts. Regardless of appearance,replace the seat belt after three years of use. Do notuse a seat belt extension on a retractable seat belt.

Adjust the seat in order to achieve full pedal travelwhen the operator's back is against the back of theseat.

28 SEBU7884-13Safety SectionEngine Starting

Adjust the seat in order to achieve good posture.

Adjust the control pod height and adjust the controlpod fore/aft position. Your elbow should be slightlyahead of your shoulder. Your wrist should be slightlybelow your elbow.

Make sure that the machine is equipped with alighting system that is adequate for the job conditions.Make sure that all lights are working properly.

Before you start the engine or before you move themachine, make sure that no one is on the machine,underneath the machine, or around the machine.Make sure that there are no personnel in the area.

i03830016

Engine StartingSMCS Code: 1000; 7000

If a warning tag is attached to the engine start switchor to the machine controls, do not start the engine.Also, do not move any machine controls.

1. Adjust the operator seat.

2. Fasten the seat belt.

3. Before you start the engine, check for the presenceof bystanders or maintenance personnel. Ensurethat all personnel are clear of the machine. Brieflysound the forward horn before you start theengine.

4. Engage the parking brake.

5. Place the transmission control switch inNEUTRAL.

6. Align the left hand joystick in relative to theposition of the front wheels. Refer to Operationand Maintenance Manual, Operator Controls -Joystick Steering Alignment for more information.

7. Turn the engine start switch key in order to startthe engine.

8. Release the engine start switch key when theengine starts.

9. Confirm steering control by actuating the steeringcontrol with the left joystick. If the steering isnot engaged the primary steering indicator andthe secondary steering indicators will illuminate.Refer to Operation and Maintenance Manual,Monitoring System for more information. Realignthe left joystick if necessary.

10.Disengage the parking brake.

11.Select your desired FORWARD or REVERSEdirection and select your requested gear.

Diesel engine exhaust contains products ofcombustion which can be harmful to your health.Always start the engine in a well ventilated area.Always operate the engine in a well ventilated area.If you are in an enclosed area, vent the exhaust tothe outside.

Briefly sound the horn before you start the engine.

Check for the presence of personnel. Ensure that allpersonnel are clear of the machine.

i02795956

Before OperationSMCS Code: 7000; 7600

Cold ambient temperatures could result in the lossof secondary braking capability due to inadequatehydraulic accumulator nitrogen pre-charge. Theloss of the secondary braking system as well asthe main hydraulic pressure will result in little orno braking capability and a potential for injury ordeath.

It is recommended to perform a brake accumula-tor check anytime the machine has been idle forlonger than two hours below 25 C (13 F). Referto Operation and Maintenance Manual beforeperforming any check of the brake accumulator.

Clear all personnel from the machine and from thearea.

Clear all obstacles from the path of the machine.Beware of hazards such as wires, ditches, etc.

Make sure that all windows are clean. Secure thedoors in the open position or in the shut position.Secure the windows in the open position or in theshut position.

For the best vision of the area that is close to themachine, adjust the rear view mirrors (if equipped).

Make sure that the machine horn, the backup alarm(if equipped) and all other warning devices areworking properly.

Fasten the seat belt securely.


Visibility Information

i03162317

Visibility InformationSMCS Code: 7000

Before you start the machine, perform a walk-aroundinspection in order to ensure that there are nohazards around the machine.

While the machine is in operation, constantly surveythe area around the machine in order to identifypotential hazards as hazards become visible aroundthe machine.

Your machine may be equipped with visual aids.Some examples of visual aids are Closed CircuitTelevision (CCTV) and mirrors. Before operating themachine, ensure that the visual aids are in properworking condition and that the visual aids are clean.Adjust the visual aids using the procedures that arelocated in this Operation and Maintenance Manual.If equipped, the Work Area Vision System shall beadjusted according to Operation and MaintenanceManual, SEBU8157, Work Area Vision System.

It may not be possible to provide direct visibility onlarge machines to all areas around the machine.Appropriate job site organization is required in orderto minimize hazards that are caused by restrictedvisibility. Job site organization is a collection of rulesand procedures that coordinates machines andpeople that work together in the same area. Examplesof job site organization include the following:

Safety instructions

Controlled patterns of machine movement andvehicle movement

Workers that direct traffic to move when it is safe

Restricted areas

Operator training

Warning symbols or warning signs on machinesor on vehicles

A system of communication

Communication between workers and operatorsprior to approaching the machine

Modifications of the machine configuration by theuser that result in a restriction of visibility shall beevaluated.

i03340444

Restricted VisibilitySMCS Code: 7000

The size and the configuration of this machine mayresult in areas that can not be seen when the operatoris seated. Illustration 34 provides an approximatevisual indication of areas of significant restrictedvisibility. Illustration 34 indicates restricted visibilityareas at ground level inside a radius of 12.00 m(39.37 ft) from the operator on a machine withoutthe use of optional visual aids. This illustration doesnot provide areas of restricted visibility for distancesoutside a radius of 12.00 m (39.37 ft).

This machine may be equipped with optional visualaids that may provide visibility to some of therestricted visibility areas. Refer to this Operation andMaintenance Manual, Mirror for more information onadditional visibility. If your machine is equipped withcameras, refer to this Operation and MaintenanceManual, Camera for more information on additionalvisibility. For areas that are not covered by theoptional visual aids, the job site organization mustbe utilized to minimize hazards of this restrictedvisibility. For more information regarding job siteorganization refer to Operation and MaintenanceManual, Visibility Information.


Note: The shaded areas indicate the approximatelocation of areas with significant restricted visibility.

30 SEBU7884-13Safety SectionOperation

i03858115

OperationSMCS Code: 7000; 7600

Machine Operating TemperatureRangeThe standard machine configuration is intended foruse within an ambient temperature range of 15 C(5 F) to 40 C (104 F). Special configurations fordifferent ambient temperatures may be required.Consult your Caterpillar dealer for additionalinformation on special configurations of yourmachine.

Machine Operation



Note: For information on steering alignment referto Operation and Maintenance Manual, OperatorControls - Joystick Steering Alignment.

Only operate the machine while you are in the seat.The seat belt must be fastened while you operate themachine. Only operate the controls while the engineis running.

Before you operate the machine, remove the wheellean locking bolt from the wheel lean lock bracket.Make sure that the frame lock pin is stored in theunlocked position. Articulate the machine. The framelock link must be removed in order to articulate themachine.

Note: With joystick steering, the position sensors forthe steering cylinders limit the steering angle of theaxle. This causes the axle stops to not make contact.

Do not use the wheel lean locking bolt and the wheellean lock bracket in order to center the wheel leanof the machine.

While the ground is being graded, do not operate themachine with the doors open.

While you operate the machine slowly in an openarea, check for proper operation of all controls and allprotective devices.

Before you maneuver the machine, make surethat no personnel are between the machine andattachments.

Before you move the machine, you must make surethat no one will be endangered.

When you operate the machine and when youoperate the worktool in an open area, check forproper operation of the controls and check foroperation of the protective devices.

Do not allow riders on the machine while the machineis being operated.

Never use the work tool for a work platform.

Reduce engine speed when you maneuver in tightquarters or when you are going over a hill.

Do not operate the machine close to a cliff. Do notoperate the machine near an excavation. Do notoperate the machine near an overhang.

When you operate the machine downhill, use twotransmission gears less than the transmission gearthat is used when you operate the machine up thesame hill.

Note: Caterpillar does not recommend that youshift to the NEUTRAL position when you operatethe machine downhill. If you shift to the NEUTRALposition the machine may require additional brakingeffort that could accelerate wear of the service brakecomponents.


Parking

Do not allow the engine to overspeed when youoperate the machine downhill. If overspeed exists,use the service brake control to decrease the speedto a level that will allow you to downshift. Repeat thisprocess until a stable speed is obtained. Before theengine is pushed beyond a dangerous speed level,the transmission will automatically upshift in order tokeep the engine speed within a safe speed range.However, when the maximum gear is reached, theservice brakes must be used to control the machinespeed and the service brakes must be used toprevent the engine from overspeeding.

Carry attachments approximately 40 cm (15 inches)above ground level. Do not go close to the edge of acliff, an excavation, or an overhang.

If the machine begins to sideslip downward on agrade, immediately remove the load and turn themachine downhill.

Avoid any conditions that can lead to tipping themachine. The machine can tip when you work onhills, on banks and on slopes. Also, the machinecan tip when you cross ditches, ridges or otherunexpected obstructions.

Avoid operating the machine across the slope. Whenpossible, operate the machine up the slopes anddown the slopes.

When you operate the machine on a slope usea low ground speed for maximum control of themachine. When you release the accelerator there willbe immediate reduction in engine rpm and groundspeed.

When you operate on a slope engage the differentiallock control. When you operate on a slope use thethrottle lock and use the accelerator control.

On steeper slopes, shift the blade drawbar uphilltoward the toe of the moldboard. Articulate the rearframe so the heavy engine frame is on the downhillside of the slope for added stability.

When you operate on a slope less than 2.5:1 startat the top of the slope. Cast the withdrawn materialoutside of the rear tandem tires to prevent the reartires from sliding.

Maintain control of the machine. Do not overload themachine beyond the machine capacity.

Never straddle a wire cable. Never allow otherpersonnel to straddle a wire cable.

Know the maximum dimensions of your machine.

Always keep the Rollover Protective Structure(ROPS) installed during machine operation.

Note any needed repairs during machine operation.Report any needed repairs.

Park Brake Override

You have the ability to override the steering alignmentand you have the ability to override the parking brakeinterlocks in order to move the machine out of danger.

Note: A Warning Category 2S will occur during a parkbrake override. The alarm will deactivate once thetransmission is returned to the NEUTRAL positionor machine speed has been detected and the frontwheels have been aligned to the left hand joystickand the steering has become active.

In order to activate the park brake override, followthese steps:

Push in the bottom of the parking brake switch inorder to disengage the parking brake.

Depress the transmission modulator control(inching pedal). If the left hand joystick has notbeen aligned with the front wheels the steering willnot activate. The park brake will not release.

Bring the machine to high idle by depressing theaccelerator control.

Position the left hand joystick in the position youwant the front wheels to align.

Select the preferred direction on the transmissioncontrol switch.

Slowly release the transmission modulator control(inching pedal). The park brake will now disengageand the machine will move in the direction that hasbeen selected.

The front wheels will automatically align to thesame angle as the left hand joystick when machinespeed is detected. The steering will then becomeactive.

Note: 1F and 1R are the only gears that areavailable to override the parking brake. Upshifting willnot change the selected gear until the front wheelshave been aligned to the left hand joystick and thesteering has become active.

i03859335

ParkingSMCS Code: 7000

Park the machine on a level surface. If you must parkon a grade, chock the machine's wheels.

32 SEBU7884-13Safety SectionSlope Operation

Apply the transmission modulator control (inchingpedal) in order to stop the machine. Apply theservice brake in order to stop the machine. Move thetransmission control switch to the NEUTRAL position.Move the throttle control to the LOW IDLE position.

Engage the parking brake.

Lower all equipment to the ground. Activate anycontrol locks.

Turn the engine start switch to the OFF position andremove the engine start switch key.

Always turn the battery disconnect switch to the OFFposition before leaving the machine.

If the machine will not be operated for a month ormore, remove the battery disconnect switch key.

i03745198

Slope OperationSMCS Code: 7000

Machines that are operating safely in variousapplications depend on these criteria: the machinemodel, configuration, machine maintenance,operating speed of the machine, conditions of theterrain, fluid levels, and tire inflation pressures. Themost important criteria are the skill and judgment ofthe operator.

A well trained operator that follows the instructionsin the Operation and Maintenance Manual hasthe greatest impact on stability. Operator trainingprovides a person with the following abilities:observation of working and environmental conditions,feel for the machine, identification of potentialhazards, and operating the machine safely by makingappropriate decisions.

When you work on side hills and when you work onslopes, consider the following important points:

Speed of travel At higher speeds, forces of inertiatend to make the machine less stable.

Roughness of terrain or surface The machinemay be less stable with uneven terrain.

Direction of travel Avoid operating the machineacross the slope. When possible, operate themachine up the slopes and operate the machinedown the slopes. Place the heaviest end of themachine uphill when you are working on an incline.

Mounted equipment Balance of the machinemay be impeded by the following components:equipment that is mounted on the machine, machineconfiguration, weights, and counterweights.

Nature of surface Ground that has been newlyfilled with earth may collapse from the weight of themachine.

Surface material Rocks and moisture of thesurface material may drastically affect the machine'straction and machine's stability. Rocky surfaces maypromote side slipping of the machine.

Slippage due to excessive loads This may causedownhill tracks or downhill tires to dig into the ground,which will increase the angle of the machine.

Width of tracks or tires Narrower tracks ornarrower tires further increase the digging into theground which causes the machine to be less stable.

Implements attached to the drawbar This maydecrease the weight on the uphill tracks. This mayalso decrease the weight on the uphill tires. Thedecreased weight will cause the machine to be lessstable.

Height of the working load of the machine When the working loads are in higher positions, thestability of the machine is reduced.

Operated equipment Be aware of performancefeatures of the equipment in operation and the effectson machine stability.

Operating techniques Keep all attachments orpulled loads low to the ground for optimum stability.

Machine systems have limitations on slopes Slopes can affect the proper function and operationof the various machine systems. These machinesystems are needed for machine control.

Note: Safe operation on steep slopes may requirespecial machine maintenance. Excellent skill ofthe operator and proper equipment for specificapplications are also required. Consult the Operationand Maintenance Manual sections for the proper fluidlevel requirements and intended machine use.


Equipment Lowering with Engine Stopped

i01329161

Equipment Lowering withEngine StoppedSMCS Code: 7000

Before lowering any equipment with the enginestopped, clear the area around the equipment ofall personnel. The procedure to use will vary withthe type of equipment to be lowered. Keep in mindmost systems use a high pressure fluid or air toraise or lower equipment. The procedure will causehigh pressure air, hydraulic, or some other mediato be released in order to lower the equipment.Wear appropriate personal protective equipment andfollow the established procedure in the Operationand Maintenance Manual, Equipment Lowering withEngine Stopped in the Operation Section of themanual.

i03649889

Sound Information andVibration InformationSMCS Code: 7000

Sound Level InformationThe operator Equivalent Sound Pressure Level(Leq) is 72 dB(A) when ANSI/SAE J1166 OCT 98is used to measure the value for an enclosed cab.This is a work cycle sound exposure level. The cabwas properly installed and maintained. The test wasconducted with the cab doors and the cab windowsclosed. The engine cooling fan speed varied duringthe test.

Hearing protection may be needed when themachine is operated with an open operator station forextended periods or in a noisy environment. Hearingprotection may be needed when the machine isoperated with a cab that is not properly maintained orwhen the doors and windows are open for extendedperiods or in a noisy environment.

The average exterior sound pressure level is 78dB(A) when the SAE J88Apr95 - Constant SpeedMoving Test procedure is used to measure the valuefor the standard machine. The measurement wasconducted under the following conditions: distance of15 m (49.2 ft) and the machine moving forward inan intermediate gear ratio. The engine cooling fanspeed varied during the test.

Sound Level Information forMachines in European UnionCountries and in Countries thatAdopt the European UnionDirectivesNote: The information below applies only tomachines that have the CE mark on the PIN plate.

The static operator sound pressure level is 70dB(A) when ISO 6396:2008 is used to measurethe value for an enclosed cab. The measurementwas conducted with the cab doors and the cabwindows closed. The cab was properly installed andmaintained.

The dynamic operator sound pressure level is 73dB(A) when ISO 6396:2008 is used to measure thevalue for an enclosed cab. The measurement wasconducted at 70% of the maximum engine coolingfan speed. The sound level may vary at differentengine cooling fan speeds. The measurementwas conducted with the cab doors and the cabwindows closed. The cab was properly installed andmaintained.

The European Union PhysicalAgents (Vibration) Directive2002/44/EC

Vibration Data for Motor Graders

Information Concerning Hand/Arm VibrationLevel

When the machine is operated according to theintended use, the hand/arm vibration of this machineis below 2.5 meter per second squared.

Information Concerning Whole Body VibrationLevel

This section provides vibration data and a method forestimating the vibration level for motor graders.

Note: Vibration levels are influenced by manydifferent 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 thesuspension system, attachments, and condition ofthe equipment

34 SEBU7884-13Safety SectionSound Information and Vibration Information

It is not possible to get precise vibration levels forthis machine. The expected vibration levels can beestimated with the information in Table 1 in orderto calculate the daily vibration exposure. A simpleevaluation of the machine application can be used.

Estimate the vibration levels for the three vibrationdirections. For typical operating conditions, use theaverage vibration levels as the estimated level. Withan experienced operator and smooth terrain, subtractthe Scenario Factors from the average vibration levelin order to obtain the estimated vibration level. Foraggressive operations and severe terrain, add theScenario Factors to the average vibration level inorder to obtain the estimated vibration level.

Note: All vibration levels are in meter per secondsquared.

Table 1

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

Vibration Levels Scenario FactorsMachineType

Typical OperatingActivity X axis Y axis Z axis X axis Y axis Z axis

finish grading 0,41 0,48 0,38 0,22 0,26 0,14

hard grading 0,61 0,64 0,78 0,21 0,21 0,30MotorGraderstransfer 0,39 0,36 0,58 0,25 0,25 0,34

Note: Refer to ISO/TR 25398 Mechanical Vibration -Guideline for the assessment of exposure to wholebody vibration of ride on operated earthmovingmachines for more information about vibration.This publication uses data that is measuredby international institutes, organizations andmanufacturers. This document provides informationabout the whole body exposure of operators ofearthmoving equipment. Refer to Operation andMaintenance Manual, SEBU8257, The EuropeanUnion Physical Agents (Vibration) Directive2002/44/EC for more information about machinevibration levels.

The Caterpillar suspension seat meets the criteria ofISO 7096. This represents vertical vibration levelunder severe operating conditions. This seat is testedwith the input spectral class EM4. The seat has atransmissibility factor of SEAT


Operator Station

a. Adjust the seat and suspension for the weightand the size of the operator.

b. Inspect and maintain the seat suspension andadjustment mechanisms.

5. Perform the following operations smoothly.

a. Steer

b. Brake

c. Accelerate.

d. Shift the gears.

6. Move the attachments smoothly.

7. Adjust the machine speed and the route in orderto minimize the vibration level.

a. Drive around obstacles and rough terrain.

b. Slow down when it is necessary to go overrough terrain.

8. Minimize vibrations for a long work cycle or a longtravel distance.

a. Use machines that are equipped withsuspension systems.

b. Use the ride control system on motor graders.

c. If no ride control system is available, reducespeed in order to prevent bounce.

d. Haul the machines between workplaces.

9. Less operator comfort may be caused by other riskfactors. The following guidelines can be effectivein order to provide better operator comfort:

a. Adjust the seat and adjust the controls in orderto achieve good posture.

b. Adjust the mirrors in order to minimize twistedposture.

c. Provide breaks in order to reduce long periodsof sitting.

d. Avoid jumping from the cab.

e. Minimize repeated handling of loads and liftingof loads.

f. Minimize any shocks and impacts during sportsand leisure activities.

SourcesThe vibration information and calculation procedureis based on ISO/TR 25398 Mechanical Vibration- Guideline for the assessment of exposureto whole body vibration of ride on operatedearthmoving machines. Harmonized data ismeasured by international institutes, organizationsand manufacturers.

This literature provides information about assessingthe whole body vibration exposure of operators ofearthmoving equipment. The method is based onmeasured vibration emission under real workingconditions for all machines.

You should check the original directive. Thisdocument summarizes part of the content of theapplicable law. This document is not meant tosubstitute the original sources. Other parts of thesedocuments are based on information from the UnitedKingdom Health and Safety Executive.

Refer to Operation and Maintenance Manual,SEBU8257, The European Union PhysicalAgents (Vibration) Directive 2002/44/EC for moreinformation about vibration.

Consult your local Caterpillar dealer for moreinformation about machine features that minimizevibration levels. Consult your local Caterpillar dealerabout safe machine operation.

Use the following web site in order to find your localdealer:

Caterpillar, Inc.www.cat.com

i03634321

Operator StationSMCS Code: 7000

Any modifications to the inside of the operator stationshould not project into the operator space or intothe space for the companion seat (if equipped).The addition of a radio, fire extinguisher, and otherequipment must be installed so that the definedoperator space and the space for the companion seat(if equipped) is maintained. Any item that is broughtinto the cab should not project into the definedoperator space or the space for the companion seat(if equipped). A lunch box or other loose items mustbe secured. Objects must not pose an impact hazardin rough terrain or in the event of a rollover.

36 SEBU7884-13Safety SectionGuards

i03656846

Guards(Operator Protection)SMCS Code: 7000

There are different types of guards that are used toprotect the operator. The machine and the machineapplication determines the type of guard that shouldbe used.

A daily inspection of the guards is required in order tocheck for structures that are bent, cracked or loose.Never operate a machine with a damaged structure.

The operator becomes exposed to a hazardoussituation if the machine is used improperly or if pooroperating techniques are used. This situation canoccur even though a machine is equipped with anappropriate protective guard. Follow the establishedoperating procedures that are recommended for yourmachine.

Rollover Protective Structure(ROPS), Falling Object ProtectiveStructure (FOPS) or Tip OverProtection Structure (TOPS)The ROPS/FOPS Structure (if equipped) on yourmachine is specifically designed, tested andcertified for that machine. Any alteration or anymodification to the ROPS/FOPS Structure couldweaken the structure. This places the operatorinto an unprotected environment. Modifications orattachments that cause the machine to exceed theweight that is stamped on the certification plate alsoplace the operator into an unprotected environment.Excessive weight may inhibit the brake performance,the steering performance and the ROPS. Theprotection that is offered by the ROPS/FOPSStructure will be impaired if the ROPS/FOPSStructure has structural damage. Damage to thestructure can be caused by an overturn, a fallingobject, a collision, etc.

Do not mount items (fire extinguishers, first aidkits, work lights, etc) by welding brackets to theROPS/FOPS Structure or by drilling holes in theROPS/FOPS Structure. Welding brackets or drillingholes in the ROPS/FOPS Structures can weakenthe structures. Consult your Caterpillar dealer formounting guidelines.

The Tip Over Protection Structure (TOPS) isanother type of guard that is used on mini hydraulicexcavators. This structure protects the operator inthe event of a tipover. The same guidelines for theinspection, the maintenance and the modification ofthe ROPS/FOPS Structure are required for the TipOver Protection Structure.

Other Guards (If Equipped)Protection from flying objects and/or falling objects isrequired for special applications. Logging applicationsand demolition applications are two examples thatrequire special protection.

A front guard needs to be installed when a work toolthat creates flying objects is used. Mesh front guardsthat are approved by Caterpillar or polycarbonatefront guards that are approved by Caterpillar areavailable for machines with a cab or an open canopy.On machines that are equipped with cabs, thewindows should also be closed. Safety glasses arerecommended when flying hazards exist for machineswith cabs and machines with open canopies.

If the work material extends above the cab, topguards and front guards should be used. Typicalexamples of this type of application are listed below:

Demolition applications

Rock quarries

Forestry products

Additional guards may be required for specificapplications or work tools. The Operation andMaintenance Manual for your machine or yourwork tool will provide specific requirements for theguards. Consult your Caterpillar dealer for additionalinformation.

SEBU7884-13 37Product Information Section

General Information

Product InformationSection

General Informationi03765285

SpecificationsSMCS Code: 7000

g01944693Illustration 37Approximate dimenisons are shown. Dimensions will vary depending on the configuration and the options.

(1) 3703 mm (12 ft 2 inch)(2) 688 mm (2 ft 3 inch)(3) 1841 mm (6 ft 1 inch)(4) 3069 mm (10 ft 1 inch)(5) 6985 mm (22 ft 11 inch)

(6) 9963 mm (32 ft 7 inch)(7) 11672 mm (38 ft 2 inch)(8) 407 mm (1 ft 4 inch)(9) 3088 mm (10 ft 2 inch)(10) 3405 mm (11 ft 2 inch)

(11) 2509 mm (8 ft 3 inch)(12) 3096 mm (10 ft 2 inch)(13) 3096 mm (10 ft 2 inch)

The basic shipping specifications are listed in thefollowing table:

38 SEBU7884-13Product Information SectionGeneral Information

Table 2

16M Motor Grader

Engine C13 Acert Diesel EngineMHX1-Up

TransmissionEight Forward SpeedsSix Reverse SpeedsDGY1-Up

Approximate operatingweight(1) 26060 kg (57452 lb)

Approximate CE plateweight (2) 30371 kg (66956 lb)

Turning Radius, OutsideFront Tires 8.9 m (29 ft 2inch)

Front Axle - TotalOscillation Per Side 32

0

1F 4.5 km/h (2.8 mph)

2F 6.3km/h (3.9 mph)

3F 9 km/h (5.6 mph)

4F 12.4 km/h (7.7 mph)

5F 19.3 km/h (12 mph)

6F 26.8 km/h (16.7 mph)

7F 37 km/h (23 mph)

8F 53.9km/h (33.5 mph)

1R 3.6 km/h (2.2 mph)

2R 6.8 km/h (4.2 mph)

3R 9.8 km/h (6.1 mph)

4R 15.2 km/h (9.5 mph)

5R 29.3 km/h (18.2 mph)

Travel Speeds

6R 42.6 km/h (26.5 mph)

Ripping Depth, Maximum 452 mm (1 ft 6 inch)

No engine deratingrequired up to 4572 m (15000 ft)

Maximum Blade PositionAngle 65

0

(1) This weight includes a full fuel tank, an operator, a ripper, apush plate, and a 16 foot blade.

(2) This weight includes the base weight, a 90 kg (200 lb) operator,a full fuel tank, a ripper, a push plate, a belly guard, a HDbattery, work lights, high bar lamps, HVAC, sound suppression,rear fenders, and the roading arrangement.

Table 3

16M Motor GraderWeights

Base Weight 26060 kg (57452 lb)

Push Plate, Counterweight 835 kg (1841 lb)

Ripper (Mount) 318 kg (701 lb)

Rear Ripper 2177 kg (4799 lb)

Ripper Tooth 65 kg (143 lb)

Sound Guard 124 kg (273 lb)

Transmission Guard 159 kg (350 lb)

High Bar Lamps 23 kg (51 lb)

Sound Suppression Group 11 kg (24 lb)

Rear Fenders 522 kg (1151 lb)

Right or Left BladeExtension 141 kg (311 lb)

European UnionArrangement 136 kg (300 lb)

Intended UseThe 16M Motor Grader is an earthmoving machine.The 16M is classified as a grader described in ISO6165:2001. This is a self-propelled wheeled machinewhich has an adjustable blade positioned betweenthe front and rear axles. This Motor Grader can alsobe fitted with a front mounted blade or a rear mountedripper. This Motor Grader is intended for the followingapplications: use in grading, sloping, ditching andscarifying of materials through a forward motion.

Application/ConfigurationRestrictionsMaximum approved operating weight is 35974 kg(79309 lb).

The cab structure is ROPS certified to ISO 3471:1994for up to 35974 kg (79309 lb).

Maximum drawbar pull is 231307 N (52000 lb)

Parking brake holding capability on a grade is 20%grade.

Service brake holding capability on a grade is 25%grade.

Use only in environments with nonexplosive gases.

SEBU7884-13 39Product Information SectionIdentification Information

Identification Informationi03940133

Plate Locations and FilmLocationsSMCS Code: 1000; 7000

The Product Identification Number (PIN) will be usedto identify a powered machine that is designed foran operator to ride.

Cat products such as engines, transmissions, andmajor attachments that are not designed for anoperator to ride are identified by Serial Numbers.

For quick reference, record the identification numbersin the spaces that are provided below the illustrations.


The Product Identification Number (PIN) is locatedon the left side of the main frame in front of the liftcylinder bracket. This plate will have the followinginformation:

Model number_______________________________________________

PIN_____________________________________________________________

Engine model number_____________________________________

Engine serial number______________________________________

Engine arrangement number_____________________________

Transmission model number_____________________________

Transmission serial number______________________________

Transmission arrangement number____________________


Transmission Serial Number_____________________________


Serial Number ______________________________________________

Engine Serial Number_____________________________________

Arrangement Number _____________________________________

Certification

ROPS/FOPS Structure

This message is positioned on the ROPS on the leftside of the machine above the door.

40 SEBU7884-13Product Information SectionIdentification Information


Structural damage, an overturn, modification, al-teration, or improper repair can impair this struc-ture's protection capability thereby voiding thiscertification. Do not weld on or drill holes in thestructure. This will void the certification. Consulta Caterpillar dealer to determine this structure'slimitations without voiding its certification.

This machine has been certified to the standardsthat are

Operation and Maintenance Manual Motor Grader CAT 16M

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